ROCKCOTE SOLID WALLING SYSTEMS...Rockcote Solid Walling Systems are built on over 20 years experience, and each component has been specifically designed or selected to meet strict

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ROCKCOTE SOLID WALLING SYSTEMS THERMAL: FACE FIXED

THERMAL: CAVITY

IMPACT: FACE FIXED

IMPACT: CAVITY

FIRE ZONE

IMPORTANT INFORMATION The Rockcote Solid Walling Systems are complete systems and must be installed as such:

• Strictly in accordance with the relevant Rockcote Solid Walling System Specifications

• By experienced installers who have the relevant skills and trade qualifications, and after proper detailing and integration with the

other components of construction by a qualified design and construction professional

All components, including the Rockcote Solid EPS Base Board, EPS Batten, ROCKCOTE PM100, ROCKCOTE reinforcing mesh, ROCKCOTE

texture coatings, paint and all ancillaries form part of and are critical to the performance of the system. Any substitution of non-compliant parts or

materials could compromise the performance of the system and would nullify the warranty.

All components for the Rockcote Solid Walling System, except for the EPS Wall Panels, Fix n Foam and SikaFlex can be obtained from Rockcote.

For full particulars of the Rockcote Solid Warranty and Stockists of the Rockcote on 1300 736 668.

BEFORE INSTALLATION PLEASE READ THE FOLLOWING DISCLAIMER CAREFULLY DISCLAIMER

This manual provides, in good faith, information on the correct procedures and materials to be used for the installation of the Rockcote Solid

Walling System over framed and solid structures. The drawings and details are to assist design and construction professionals (Specifiers,

Architects, Building Designers & Engineers, Builders, Applicators and Installers) in the correct design, detailing and installation of the System. It is

impossible to cover every possible application of the Rockcote Solid Walling Systems within this manual. Specific design, detailing and installation

must be undertaken by the appropriately qualified and experienced design and construction professionals, who will be responsible for ensuring

that the Rockcote Solid Walling System and the information and details in this manual are suitable for any intended design and application. Used

in that context, the Rockcote Solid Walling Systems are a complete system. ROCKCOTE Enterprises Pty Ltd will not accept responsibility for its

Systems where they are misused or not installed and maintained in complete accordance with ROCKCOTE’s installation, maintenance and

technical recommendations.

No part of this manual may be reproduced, transmitted or translated in any language in any form, by any means, without the prior written permission

of ROCKCOTE Enterprises Pty Ltd.

Copyright (c) 2012 ROCKCOTE Enterprises Pty Ltd. All rights reserved.

Information provided in this booklet was correct at the

time of printing (13/06/12). For the latest Rockcote System

Guide and product information, visit the Rockcote website

WWW.ROCKCOTE.COM.AU

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GLOSSARY OF TERMS

Installer

Meaning the qualified, experienced and licensed tradesperson who installs and/or supervises the installation of the EPS panels and the application

of the RRR System, as described in the ROCKCOTE Solid Installation Manual and information brochure.

Cladding Installer

Meaning the qualified, experienced and licensed tradesperson who installs the EPS panels, as described in the ROCKCOTE Solid Installation

Manual and information brochure.

Applicator

Meaning the qualified, experienced and licensed tradesperson who applies the PM100, reinforcing mesh and ROCKCOTE’s range of Acrylic

Coloured Renders, as described in the ROCKCOTE Solid Installation Manual and information brochure.

ROCKCOTE Solid Top Coats

Meaning ROCKCOTE’s Armour Flex, Armour Plus, Clearcote and Repel range of membranes and sealers applied as per ROCKCOTE’s

specifications.

Building Designer/Construction Professional

Meaning a suitably qualified, registered building designer licensed to carry out the design and specification of building work.

EPS Wall Panels

Meaning expanded polystyrene panels made from M grade polystyrene manufactured to AS 1366.3-1992, containing both an insect repellent and

flame retardant.

EPS Battens

Meaning expanded polystyrene battens made from H grade polystyrene manufactured to AS 1366.3-1992, containing both an insect repellent and

flame retardant.

ROCKCOTE

Meaning ROCKCOTE Enterprises Pty Ltd ABN 42 066 227 174

ROCKCOTE SOLID WALLING SYSTEM

Meaning the walling system comprising of the specified panels installed and coated with the RRR System, as described in the relevant manual and

information brochure.

RRR System

Meaning the ROCKCOTE Reinforced Render System as described in the relevant manual and information brochure.

Specifier

Meaning a person trained, qualified and licensed to carry out the design and specification of building work.

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Table of Contents GLOSSARY OF TERMS ........................................................................................................................................................ 2

INTRODUCTION ................................................................................................................................................................. 5

1.0 ONE SYSTEM—MANY BENEFITS ............................................................................................................................ 7

1.01 Components ................................................................................................................................................ 7

1.02 User benefits ............................................................................................................................................. 12

2.0 RRR COATING SYSTEM ........................................................................................................................................ 14

2.01 General ...................................................................................................................................................... 14

2.02 Critical factors ........................................................................................................................................... 14

2.03 Applicator ................................................................................................................................................... 14

2.04 Pre-coating system inspection ............................................................................................................... 14

2.06 Fitting PVC angle beads .......................................................................................................................... 15

2.07 Reinforced render installation ................................................................................................................. 15

2.08 Curing ......................................................................................................................................................... 15

2.09 Fibreglass mesh ....................................................................................................................................... 15

2.10 ROCKCOTE flexible acrylic-based texture coating ............................................................................. 16

2.11 Health and safety ...................................................................................................................................... 16

3.0 REPAIR AND MAINTENANCE ............................................................................................................................... 17

3.01 Cleaning ..................................................................................................................................................... 17

3.02 Maintenance inspection ........................................................................................................................... 17

3.03 Repair ......................................................................................................................................................... 17

4.0 PRODUCT INFORMATION .................................................................................................................................... 18

4.01 Product support ........................................................................................................................................ 18

4.02 Warranty .................................................................................................................................................... 18

5.0 DESIGN CONSIDERATIONS .................................................................................................................................. 19

5.01 General ...................................................................................................................................................... 19

5.02 Structure .................................................................................................................................................... 19

5.03 Rockcote Solid-EPS Cavity walling panel and batten sizes .............................................................. 19

5.04 Curved walls .............................................................................................................................................. 19

5.05 Wind zones ................................................................................................................................................ 19

5.06 Limitations.................................................................................................................................................. 19

5.07 Insulation values ....................................................................................................................................... 20

5.08 Acoustic values ......................................................................................................................................... 20

5.09 Impact resistance ..................................................................................................................................... 20

5.10 Serviceable life.......................................................................................................................................... 20

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5.11 Maintenance .............................................................................................................................................. 20

5.12 Moisture ..................................................................................................................................................... 20

5.14 Fire .............................................................................................................................................................. 21

5.15 Non-hazardous material .......................................................................................................................... 21

6.0 INSTALLATION AND FIXING ................................................................................................................................. 22

6.01 Timber and steel wall framing ................................................................................................................ 22

6.02 Cutting and drilling .................................................................................................................................... 22

6.03 Beads ......................................................................................................................................................... 22

6.04 Expansion joints........................................................................................................................................ 23

6.05 Concrete and masonry walls .................................................................................................................. 23

6.06 Handling and storage ............................................................................................................................... 23

6.07 Health and safety ...................................................................................................................................... 23

7.0 CONSTRUCTION DETAILS .................................................................................................................................... 25

7.01 Panel fixing ................................................................................................................................................ 25

7.04 Termites ..................................................................................................................................................... 25

7.05 Slab on ground.......................................................................................................................................... 25

7.06 Timber floor First floor / Horizontal Control Joint Details .................................................................... 26

7.7 Wall to roof ................................................................................................................................................ 26

7.8 Parapets ..................................................................................................................................................... 26

7.9 Soffit and eaves ........................................................................................................................................ 26

7.10 Doors .......................................................................................................................................................... 26

7.11 Windows .................................................................................................................................................... 26

7.16 Decorative mouldings .............................................................................................................................. 26

8.0 FINISHING ............................................................................................................................................................ 28

8.01 Sleeve ........................................................................................................................................................ 28

8.02 Penetrations .............................................................................................................................................. 28

8.03 Fixtures ...................................................................................................................................................... 28

8.04 Sealants ..................................................................................................................................................... 28

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INTRODUCTION The information in this manual is compiled for use by the building designer/construction professional and any user

of the Rockcote Solid Walling System – EPS Cavity, to assist in developing project specifications and to provide

guidance on the correct installation of the Rockcote Solid Walling System – EPS Cavity in domestic applications.

The Rockcote Solid Walling System – EPS Cavity consists of specified EPS panels, EPS battens polymer modified

cement render, reinforcing mesh, flexible, acrylic-based texture coating and high film build acrylic top coat. This

system forms a barrier wall with cavity, which is intended to resist the ingress of water from the exterior surface

of the building. The cavity is present to provide a back-up to drain any water from leaks or condensation from

behind the wall.

Correct detailing and integration with the other components of the building by a qualified building designer is

essential. All details and flashings must prevent moisture accumulating behind the wall and direct water to the

outside of the system.

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From being named UDIA Champion Project for Sustainable Development in 2002 to finalist in the prestigious

international FIABCI Prix D’Excellence Awards in 2008, The ROCKCOTE Design Centre has been winning acclaim since

it was first sketched out on the drawing board.

At ROCKCOTE we believe the honour is not in winning awards but in deserving them.

The protruding office area features 60mm polystyrene on timber studs. Main wall areas are tilt up reinforced

concrete with 40mm polystyrene exterior facing bonded to the wall when poured. The excellent insulation of the

RRR system and high thermal mass of the masonry allows this building to remain comfortable year-round without

artificial heating or air conditioning.

Energy efficient design and construction delivers houses and buildings that are more comfortable to live in and

cheaper to run. Insulation acts to keep out heat in summer and to keep heat in during winter. See section 5.07.

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1.0 ONE SYSTEM—MANY BENEFITS Rockcote Solid Walling Systems offer insulative systems that delivers the look and feel of masonry—a

genuinely seamless rendered finish for lightweight energy efficient walls. Offering design freedom, flexibility

and long-term durability, the system’s performance has been proven in conditions ranging from the extreme

cold of alpine regions, to the humidity of the tropics.

The EPS Cavity system can be fitted over standard timber and steel stud walls, and is also suitable for use over

concrete or masonry walls, where they provide an insulating barrier, allowing the thermal mass of the masonry

to help moderate indoor temperatures.

The EPS Cavity system incorporates the installation of a 25mm drainage cavity. This gives additional moisture

protection and a higher Insulative rating over the Face Fix system.

1.01 Components

1.01.01 EPS Battens

H grade polystyrene conforming to AS 1366.3-1992, containing flame retardant additives. The

standard thickness of the batten is 25mm and is supplied in lengths of 1.2m.

1.01.02 Expanded Polystyrene (EPS) board

M grade polystyrene conforming to AS 1366.3-1992, containing both flame retardant and insect

repellent additives. The standard thicknesses are 60 and 75mm, supplied in standard sheet sizes of

1.2 x 2.5m and 1.2 x 5.0m.

1.01.03 Fixings

See relevant Wind Loadings in Section 5.05 for fixing centres.

Timber Framing

NOTE: All timber screws must have at least 25mm of screw shaft screwed into the timber frame.

Fix 60mm EPS Wall Panels with 10-8 x 115mm Buildex Climacoat 3 CSK Ribbed Head Class 3 screws.

Fix 75mm EPS Wall Panels with 10-8 x 125mm Buildex Climacoat 3 CSK Ribbed Head Class 3

screws .

Washers for both are 10 x 40mm grey nylon.

Steel Framing

Fix 60mm RRR-EPS Wall Panels with Buildex 115mm Countersunk Steel Self Drilling 6-311-0621-

1MP screws.

Fix 75mm RRR-EPS Wall Panels with Buildex 125mm Countersunk Steel Self Drilling 6-311-0622-

2MP screws.

Washers for both are 10 x 40mm grey nylon.

1.01.04 Render Trims

ROCKCOTE has developed a range of trims designed specifically for each ROCKCOTE Solid Walling

System.

ROCKCOTE Solid Starter Trims: Use on foundations and roof awning apron.

• 75mm Starter Trim Code: 2641

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• 100mm Starter Trim Code: 2772

Figure 1.01.03a ROCKCOTE Solid Starter Trims.

ROCKCOTE Solid Control Joint Trims: Used for all control joints and internal corners

• 60mm Control Joint Trim Code: 2211

• 75mm Control Joint Trim Code: 1799

Figure 1.01.03b ROCKCOTE Solid Control Joint Trims.

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ROCKCOTE Solid Pre-Meshed Trim Code: 4049

• Pre-Meshed Trim for reveals and external corners

Figure 1.01.03c - ROCKCOTE Pre-meshed Trims.

Rockcote Solid Walling Systems are built on over 20 years experience, and each component has been

specifically designed or selected to meet strict criteria.

All components, including the EPS base board, EPS Batten, ROCKCOTE PM100, ROCKCOTE

reinforcing mesh, ROCKCOTE texture coatings, paint and all ancillaries form part of and are critical to the

performance of the system. Any substitution of non-compliant parts or materials could compromise the

performance of the system and would nullify the warranty.

1.01.04 ROCKCOTE Patch n Prep

Cement based Adhesive with a high Polymer addition. Rockcote Patch n Prep must be used to

fasten both Control Joint and Pre-meshed Trims. Figure 1.01.02d ROCKCOTE Solid Pre-Meshed Trim.

1.01.05 ROCKCOTE PM100

Polymer modified cement renders specifically designed to be applied easily and adhere to EPS

base board.

1.01.06 Reinforcing mesh

Alkali resistant fibreglass mesh, 4.5mm weave, 160 g/m2. This is a critical component and

cannot be substituted without affecting the performance of the system. Only ROCKCOTE

fibreglass mesh may be used under the system warranty.

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Figure 1.01.05a - ROCKCOTE MESH.

1.01.07 Coloured Render, Textures, Protective Finishes

All Rockcote Solid walling Systems are designed to be finished with at least 1mm of dry film

thickness of ROCKCOTE acrylic-based coloured render or texture, plus an optional acrylic

ROCKCOTE paint or sealer.

1.01.08 Colour

Rockcote acrylic textures and paints are available in a wide range of colours and textures.

However, the selection of dark colours on external walls exposed to direct sunlight can lead to

excessive heat build-up in the wall, as the heat is trapped by the insulation underneath and

could possibly cause a breakdown of the coating system. Only colours with a Light Reflectance

Value [LRV] over 40% can be used on the standard ROCKCOTE SOLID EPS Systems.

If a colour darker than 40% is required then contact Rockcote for a specific coating system

specification to meet requirements.

1.01.09 Specialised tools and plastering machines

ROCKCOTE has continually improved application efficiencies and finish standards through its

introduction of specialist tools, mixing apparatus and plastering machines.

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Other components required are:

Fix N Foam

SikaFlex

Vapour permeable building wrap

These can be bought from your local distributor. Please contact Rockcote on 1300 736 668 if

you would like further information.

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1.02 User benefits

1.02.01 Excellent thermal insulation

The external location of the RRR- EPS Walling places the insulation in the best position, as far

towards the outside of the building as possible, where the temperature fluctuates. This reduces

the amount of energy required to maintain a constant temperature inside. Furthermore, the

insulation performance of EPS does not deteriorate during its lifetime.

The incorporation of a cavity further improves the overall insulation (R-Value) of the wall.

1.02.02 Biologically inert

EPS is an inert organic material that will not rot and is highly resistant to mildew. It does not

degrade into harmful substances, is not water soluble and does not give off any water soluble

substances, which contaminate ground water.

1.02.03 Insect resistant

EPS provides no nutritive value to ants, termites or rodents. Only suitably treated EPS Boards

must be used.

1.02.04 Flame retardant

EPS panels are manufactured to AS 1366.3-1992, containing fire retardant additives.

1.02.05 Cost effective

The EPS System offers an attractive, cost efficient, insulative walling system.

1.02.06 Production

EPS Walling uses far less energy in its manufacture than conventional building materials.

1.02.07 Easy to install

EPS Walling is light, practical, safe, easy to handle and install.

1.02.08 Level 5 Finish

Due to a number of factors the Rockcote Solid Walling system can achieve a level 5 finish, with

the look and feel of masonry. Visible board joints and wavy walls under critical light are a thing

of the past.

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Levels of finish for light

weight claddings to

external walls

System Characteristics

and finish

LEVEL 1:

CEMENT SHEET

Expressed joints.

Standard paint finish.

Visible PVC sheet

joiners.

Painted flat finish.

Will follow the frame

straightness.

LEVEL 2:

CEMENT SHEET

Joints taped and patched.

Roll-on texture coating.

Joints may be visible

under side-light

conditions.

Not recommended for

broad wall installation on

quality projects.

LEVEL 3:

CEMENT SHEET

Joints taped and patched.

2mm trowel-on texture

coating or polymer render.

Joints may be visible

under side-light

conditions (critical light).

Not recommended for

broad wall installation on

quality projects.

LEVEL 4:

CEMENT SHEET

Joint taped and set.

Polymer render over entire

wall.

Joints may be visible

under side-light

conditions (critical light).

Not recommended for

broad wall installation on

quality projects.

LEVEL 4:

POLYSTYRENE RRR40

ROCKCOTE Reinforced

Render System for

lightweight claddings.

RRR EPS 40mm

Finished with

ROCKCOTE Reinforced

Render System.

Continuous render finish.

Joints not visible under

normal lighting

conditions.

May be some evidence of

studs or panel joints

under severe side light.

LEVEL 5:

POLYSTYRENE RRR60 and

POLYSTYRENE RRR75

ROCKCOTE Reinforced

Render System for

lightweight claddings.

RRR EPS 60mm–100mm

No visible joint sunder

any light conditions.

Look and feel of rendered

masonry.

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2.0 RRR COATING SYSTEM

2.01 General

All Rockcote Solid Walling Systems utilise a variation of the Rockcote Reinforced Render (RRR) System

to coat each different base sheet. Each walling system is a complete system in which each component

has been specifically designed or selected to meet strict criteria and is critical to the performance of the

system. The panels and flashing details must be installed in accordance with the project plans and

specifications.

All work must be carried out by suitably qualified tradespeople with experience in this area.

The RRR coating system consists of:

• ROCKCOTE PVC angle beads, starter and edge strips

• ROCKCOTE PM100

• ROCKCOTE 160g/m2 alkali resistant fibreglass reinforcing mesh

• ROCKCOTE flexible acrylic-based texture coating

• ROCKCOTE acrylic paints/sealers.

2.02 Critical factors

• The thickness of the full RRR coating system including the render should not exceed 8mm unless

otherwise specified.

• The ROCKCOTE PM100 must be properly cured.

• The correct grade and quality of fibreglass reinforcing mesh must be used.

• The reinforcing mesh must be correctly installed just below the exterior surface of the render.

• The top coat must include at least 1mm dry film thickness of ROCKCOTE acrylic-based Coloured

Render coating or polymer render, plus an optional membrane or sealer dependant on selected finish.

• The colour chosen shall have a LRV (Light Reflectance Value) greater than 40% for the standard RRR

coating system. For colours with a lower LRV a specialised coating system can be recommended by

Rockcote.

2.03 Applicator

Application of the ROCKCOTE Reinforced Render (RRR) System is a specialist procedure and

should only be carried out by an applicator with the relevant trade qualifications and experience.

2.04 Pre-coating system inspection

Ensure that the panels have been fitted in accordance with the project plans and specifications, and that

the substrate is suitable for the application of the RRR System.

• Walls must be clean and dry before rendering can commence

• Check that the walls are straight and all joints are flush

• Check the fixings

• Check that all internal and external corners have been formed correctly and have true lines

• Sand back any irregularities and dust down the wall with a broom or compressed air to remove all dust

and loose material

• Seal around any extrusions through the walls and around windows with a flexible joint filling compound,

as referred to in Sections 8.02 and 8.04.

2.05 Preparation

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Before commencing any rendering work, ensure that the work area is clean and tidy, with a well set up

mixing area, all tools and equipment are clean and any mechanical equipment in good working order with

current safety certification.

Check that all scaffolding is safe, complete and correctly set up for the job.

Ensure that all windows, joinery and finished work adjacent to the work areas are suitably masked and/or

protected, prior to commencing any rendering.

2.06 Fitting PVC angle beads

Beads must be installed straight and true using ROCKCOTE Patch & Prep, allowing for the correct

thickness of finished render.

2.07 Reinforced render installation

Before commencing application, ensure all angles and base beads are correctly fitted, all windows and

adjacent surfaces are masked and the correct scaffolding is in place. Measure and pre-cut reinforcing

mesh.

Install extra 200mm x 400mm reinforcement strips across the resurgent corners of all openings at an

angle of 45º.

Machine application is the preferred method of applying ROCKCOTE PM100, using a plastering machine

capable of mixing and applying between 12–25 litres/minute.

For hand application, mix the render in a suitable container, firstly adding approximately 4 litres of

clean water per 20kg bag of ROCKCOTE PM100. Slowly add the ROCKCOTE PM100 to the water,

while stirring with a mechanical stirrer.

More water or powder may be added to achieve the desired trowelable consistency. Refer to the

ROCKCOTE PM100 Technical Specifications for mixing details.

Using a suitable plastering machine or a hawk and trowel, apply the ROCKCOTE PM100 RENDER to an

area of wall and screed or level the wet render using an H section straight edge or Darby. Avoid

overworking the render, as this can cause moisture build-up on the surface of the substrate, causing the

render to slump or slide.

Using the angle beads as a guide, the render is screeded to the level of the beads to achieve a straight,

flat surface. After allowing the render to ‘firm up’, the ROCKCOTE fibreglass mesh is trowelled into the

surface of the wet render, keeping it just below the surface of the render. When applying the mesh, start

at the top of the wall and work down. Ensure that the mesh overlaps all joints by at least 50mm and

overlaps the outside edge of all beading.

As the wall dries, trowel or float the wall to achieve a straight flat finish suitable for the subsequent

application of the acrylic-based texture coating.

2.08 Curing

ROCKCOTE PM100 is a cement-based product and correct curing procedures must be followed. In hot,

dry, windy conditions, it will be necessary to wet the finished wall down regularly for up to three days.

Render cannot be applied in freezing conditions and uncured material must not be allowed to freeze.

2.09 Fibreglass mesh

The fibreglass mesh (160 gram) is a critical component of the RRR-EPS System and must be correctly

installed.

The mesh is to be trowelled into the surface of the wet render, positioned just below the surface. Under

no circumstances should the mesh be fixed to the walls and render applied over it. Overlap all sheets a

minimum of 50mm and overlap the inside edge of all beading. Install extra reinforcement strips across the

resurgent corners of all openings at an angle of 45º prior to rendering.

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2.10 ROCKCOTE flexible acrylic-based texture coating

The ROCKCOTE flexible texture coating is an integral component of the RRR-EPS System and must be

applied to the specified dry film thickness of at least 1mm.

Application of the texture coating can commence once the render has been cured and is dry.

The texture coating is applied using a stainless steel trowel or suitable spray machine and finished with a

plastic or polystyrene float to the required finish.

The texture coating may be tinted to the required finish colour.

Suitable ROCKCOTE Systems include:

• Santa Fe

• Polyfine

• Sandcote

• Quicksand / Quicksand Coarse

• Acrylic Texture Range (Medium / Coarse)

• 1mm, 2mm or 3mm Trowel-On over-coated with ROCKCOTE Armour

• Polymer Render over-coated with ROCKCOTE Armour

• Polymer Render HB. over-coated with ROCKCOTE Armour

Acrylic top coats from the ROCKCOTE Armour range or the ROCKCOTE Roll-On Texture range can then

be applied to provide added flexibility and durability. This is recommended in areas exposed to severe

weather conditions (i.e. beachfront locations).

2.11 Health and safety

When working with ROCKCOTE Renders, observe the usual precautions for handling cement and water-

based products. Ensure compliance with all Workplace Health and Safety regulations and Industry Codes

of Practice.

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3.0 REPAIR AND MAINTENANCE

3.01 Cleaning

Exterior walls should be cleaned down every twelve months, or as required. Use a biodegradable

detergent to remove any built-up dirt or grime. Wash with a low pressure water cleaner and

environmentally-sensitive cleaning solution, when a major clean is required. Mould or fungus must be

treated with a residual fungicide, Rockcote recommends the use of Rockcote Fungicidal wash which has

been specifically designed for this purpose.

Refer to the ROCKCOTE SOLID WALLING System Maintenance Guide for further cleaning and

maintenance information.

3.02 Maintenance inspection

Annual inspection of the exterior walls must be made to ensure they remain in good condition. Checks

must be made of the exterior coating system, sealants, flashings, control joints and any waterproofing

systems. Pay particular attention when inspecting for sealant deterioration.

3.03 Repair

Immediately repair damaged areas or cracks to prevent water penetration. Repair damaged areas with

ROCKCOTE Reinforced Render (if required). Fill cracks with flexible, external, paintable patching

compound. Repaint the repaired area.

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4.0 PRODUCT INFORMATION

4.01 Product support

ROCKCOTE regularly updates its literature to keep pace with product developments and design trends,

and therefore reserves the right to revise and change its technical information without notice.

4.02 Warranty

4.02.01

The ROCKCOTE SOLID Walling System carries a complete system warranty provided that it is:

• installed as a complete system by experienced installers who have the relevant skills and

trade qualifications

• installed after proper detailing and integration with the other components of construction, by

an appropriately qualified and experienced design and construction professional

• maintained strictly in accordance with the ROCKCOTE SOLID Walling System specifications.

4.02.02

This warranty covers loss arising from defects in the components of the ROCKCOTE SOLID

Walling System (excluding accessories and components manufactured or supplied by an

unrelated third party). Except to the extent imposed by any mandatory Australian law, liability

under this warranty is limited to replacement and/or repair by ROCKCOTE of any defect solely

attributable to defective ROCKCOTE SOLID Walling System components that do not meet

ROCKCOTE’s standards.

4.02.03

ROCKCOTE will not accept responsibility for its systems where they are misused or not

installed and maintained in complete accordance with ROCKCOTE’s installation, maintenance

and technical specifications.

4.02.04

All specified components (including the Wall Panel, ROCKCOTE PM100, ROCKCOTE

reinforcing mesh, ROCKCOTE texture coatings, ROCKCOTE paint or sealers and all specified

ancillaries) form part of, and are critical to the performance of the system.

Any substitution with non-conforming parts or materials could compromise the performance of

the System and will nullify the warranty.

All components for the ROCKCOTE SOLID, except Wall Panels, can be obtained from

ROCKCOTE.

RRR-EPS Wall Panels can be obtained from ROCKCOTE’s nominated suppliers.

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5.0 DESIGN CONSIDERATIONS

5.01 General

The ROCKCOTE SOLID Walling System forms an integrated, seam-free render finish and weather-

resistant thermal envelope to the exterior walls of a building. A properly designed and insulated building can

reduce energy costs by up to 80%. The external location of the EPS puts the insulation in the best position,

as far towards the outside of the building as possible, where temperature fluctuates. This reduces the

amount of energy required to maintain a constant temperature inside and provides higher levels of comfort.

5.02 Structure

All timber and steel framing is required to be framed, braced, trimmed and finished in accordance with best

trade practice and to comply with the requirements of all relevant Australian Standards and Statutory

Authority requirements.

RRR-EPS-60mm and 75mm have sufficient strength and rigidity to be supported by wall framing spaced

at 600mm maximum centres.

When RRR-EPS-40 is used over a timber frame, 450mm stud centres are recommended.

RRR-EPS-40mm can be installed directly over concrete/masonry walls.

5.03 Rockcote Solid-EPS Cavity walling panel and batten sizes

RRR-EPS Standard Wall Panels

2500mm x 1200mm x 60mm

2500mm x 1200mm x 75mm

Wall panels are available in 5.0m lengths upon request.

25mm thick * 40mm wide * 1.2m long H grade EPS battens are available from National Polystyrene.

5.04 Curved walls

40mm and 60mm Wall Panels can be curved to a radius greater than 2.5 metres. Where a tighter radius

is required, multiple layers of specially ordered 20mm thick panels can be used, with the joints offset

between layers. However, special consideration should be given to detailing flashings, angle beads and

the like.

5.05 Wind zones

Properly installed, the RRR-EPS System is suitable for use in the following building wind zones:

Wind Zone/Classification Maximum Fixing Centres

N1 and N2 300mm

N3, C1 200mm

5.06 Limitations

The ROCKCOTE SOLID-EPS Cavity Walling System is not designed to provide structural bracing. If

structural bracing is required, use internal linings or other specifically designed wall bracing.

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ROCKCOTE SOLID-EPS Cavity Walling is not suitable for use in and must be separated from chimneys,

flues or fireplaces.

ROCKCOTE SOLID-EPS Cavity Walling must not come in contact with the ground for extended periods of

time. It cannot be used for retaining walls.

THIS MANUAL IS LIMITED TO DOMESTIC CONSTRUCTION.

Designers and Installers must check that the details in this manual meet their own specific requirements.

5.07 Insulation values

All insulation materials are rated for their performance in restricting heat transfer. This rating is expressed

as an R-value which is the measure of the material’s resistance to heat transfer (thermal resistance). The

higher the R-value, the greater the insulating effect.

60mm EPS Walling 1.6 2.7

75mm EPS Walling 2.0 3.1

** - R-values have been calculated with 10mm plasterboard, 90mm air gap (stud), antiglare foil, 25mm air gap (batten), M-grade EPS and Rockcote

Reinforced Render System (RRR).

5.08 Acoustic values

60mm Rockcote Solid-EPS Cavity System fixed to a 75mm stud frame, lined internally with standard

10mm Gyprock and with either Rockwool or glass fibre wool cavity insulation, will achieve an STC rating

of greater than 50.

5.09 Impact resistance

Properly installed, the Rockcote Solid-EPS Cavity System has sufficient impact resistance for most

domestic situations. In situations where high impacts may occur, then a double layer of ROCKCOTE

Reinforced Render, with double layers of mesh is recommended.

Additional impact resistance can be obtained by using a VH grade EPS board, instead of M grade.

Ensure that the board does contain insect and fire resistant additives.

5.10 Serviceable life

The Rockcote Solid-EPS Cavity System, properly installed and maintained, has an expected serviceable

life of at least 30 years under typical (rather than extreme) Australian conditions.

5.11 Maintenance

Exterior walls should be cleaned down every twelve months. Regular inspection of the exterior walls must

be made to ensure they remain in good condition.

For further information see the Rockcote Solid Walling Maintenance Guide.

5.12 Moisture

Rockcote Solid Walling systems must not be installed in contact with the ground. It must be installed in strict

accordance with the manual inclusive of exterior coating system, sealants, flashings, control joints and any

waterproofing systems to prevent the ingress of water, either by condensation or leakage through the wall or

adjacent construction components.

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5.14 Fire

Fully installed, the Rockcote Solid Walling-EPS System does not provide a fire rated wall. Rockcote Solid

Walling--EPS Walling is however manufactured from fire retardant polystyrene and will not support

combustion. RRR- EPS Walling must be separated from heat sources such as fireplaces, chimneys and

flues.

Rockcote has certification for BAL-29 for a Thermal Cavity system, please contact Rockcote for further

details.

5.15 Non-hazardous material

Fully installed, the RRR System is non-hazardous.

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6.0 INSTALLATION AND FIXING

6.01 Timber and steel wall framing

New framing

All timber and steel framing is required to be framed, braced, trimmed and finished in accordance with best

trade practice and to comply with the requirements of all relevant Australian Standards and Statutory

Authority requirements.

Maximum stud centres is 600mm apart.

Existing framing

Inspect existing framing and replace unsound timber.

Prime all exposed timber.

Maximum stud centres is 600mm apart.

Back blocking

Where EPS panels join off framing, back block the joint by fitting a piece of stud/noggin behind the joint

and fixing with glue, screws and washers. Refer to Section 7.01.

Solid backing

Solid timber backing is required for fixing taps, down pipes, lights, balustrading, pull-out or fold-down clothes

lines, etc.

Fitting

Before commencing to fit the EPS Battens & Wall Panels, check that the wall framing is straight and

within acceptable tolerances, all windows, doors and flashings are installed and solid back blocks are in

place. Fit starter strips to the base of the wall allowing at least 50mm overlap of the slab below floor level.

Refer to Drawing 7.01.02 - Batten Layout. EPS Walling can be installed either vertically or horizontally.

Battens and Panels are fitted into the starter strips, with panels glued and butted together at all joints,

apart from control/expansion joints. Screw off panels from the centre out to the edges at the required

centres along studs and around all edges (see Wind Loadings information in section 5.05). Overlap the

full thickness of the panel at internal corners. External panel joints are to be mitred. Fit the Rockcote Pre-

Meshed Trims to all external corners using ROCKCOTE Patch n Prep. Ensure that all the mesh is then

trowelled into the Patch n Prep. THIS ENSURES THE MESHED BEAD IS SECURED TO PROVIDE A

STRAIGHT AND TRUE CORNER. Ensure that panels and angle beads are straight and plumb, and allow

for the correct thickness of render and finish coating.

Bracing

EPS Walling is not a bracing board. Use EPS Walling ‘Over Bracing’ panels for fixing over plywood or

fibre cement wall braces.

Panels are easier to install if bracing is fitted to the inside of walls.

Gluing and sealing

Adhesives

Current testing indicates that Bostik ‘No More Nails’, HBFuller Toolbox & Maxbond, Bears ‘Stronghold’

and Fix-Tech Fixit Mate & Fix’N’Foam are suitable.

Sealants

Bostik ‘Seal n Flex’, Sika ‘Pro2 hp’, HB Fuller Superseal 101 and FixTech Fixseal MSP 15 are suitable.

Refer to adhesives and EPS panel manufacturers for current recommendation for use with EPS panels.

6.02 Cutting and drilling

A standard diamond masonry blade in a power saw is recommended to ensure an accurate and straight

cut. Set blade to thickness of panel. EPS Battens and Wall Panels can also be cut using a handsaw or

knife. Return unused off cuts to your local EPS recycling collection point or use them in the wall cavity for

extra insulation.

6.03 Beads

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ROCKCOTE Solid Walling System includes a range of suitable UV stabilised PVC trims. Starter trims to

suit 40mm, 60mm, 75mm and 100mm panels are available in external grade PVC. Reveals and external

corners should be finished with ROCKCOTE Solid Pre-Meshed Trim.

ENSURE REVEAL FLANGE IS FULLY GLUED TO EPS.

Window flashings are to be external grade PVC. Before applying sealant, clean and prime PVC. To

clean, apply acetone with a clean, dry cloth in one direction, and allow to flash off for 4 minutes before

priming. Alternatively Bostik N40 Primer may be used.

6.04 Expansion joints

Expansion joints are to be provided to allow for movement. Vertical control joints are required every 6

metres, and horizontal control joints are required every 3 metres or where timber or steel floor joists

occur. All control joints must utilise the ROCKCOTE Solid Walling System: Thermal Control Joint Trims.

Control joints must also be provided where ROCKCOTE Solid Walling System: Thermal meets other

cladding materials and where specified by a building design professional. Where control joints are to be

installed, the EPS panels must be independently fixed to studs/fixing points. Refer to Section 7.04.

6.05 Concrete and masonry walls

General

EPS System battens and panels are fixed to concrete and masonry walls by mechanical fixing.

Adhesive

ROCKCOTE Patch n Prep and FixTech ‘Fix’N’Foam foam adhesive have been used with success.

Mechanical fixings

Hilti IDP polypropylene anchors.

Fitting

Walls are required to be clean and free from dirt, oil, vegetation, crumbling or loose material.

Position the EPS battens & panels and drill (8mm bit) through into the masonry at each corner (offset in

by 100mm).

Use a minimum of 9 x IDP anchors per square metre.

When installing with render, apply fully to the back of the panel with a coarse notched trowel.

Panels are to be fitted into the starter strips and butted together.

All gaps are to be filled with EPS off cuts before fitting subsequent panels.

Overlap the full thickness of the panel at internal corners. External corners are to be mitred.

Mechanical fixings are to be installed at the rate of 9 fixings per m2.

6.06 Handling and storage

Care should be taken when handling EPS panels to avoid any damage to edges, corners and faces.

Panels must be stacked flat, off the ground and supported on a level platform. Goods stored in the

open are to be protected from prolonged exposure to direct sunlight and kept away from extreme heat

and organic solvents. Panels must be dry prior to fixing. Panels must always be carried on edge. Any

minor damage should be repaired with joint compounds or foamed polyurethane glue. Fixings and

other accessories must be stored so that they are kept clean, dry and undamaged.

6.07 Health and safety

Fully and properly installed, the ROCKCOTE SOLID-EPS System are non-hazardous. However, as with

all composite materials, general safety clothing and gloves are to be worn when handling or cutting EPS

battens & panels. It is recommended that a facemask and protective glasses be worn when cutting or

drilling the board. ROCKCOTE recommends that a qualified and authorised work place health and safety

officer (or equivalent) be consulted for specific advice.

ROCKCOTE is committed to maintaining a healthy and safe working environment, to ensure a project is

completed successfully and effectively, without compromising the health of any individual. To help

achieve this:

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• Provide a safe work place, including plant and equipment

• Actively encourage and insist that safe work methods are practised

• Provide supervision and appropriate training when required

• Ensure that all employees and other site visitors/workers understand and accept their responsibilities to

promote a safe workplace.

• Ensure that clients’ health and safety requirements and obligations are strictly adhered to.

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7.0 CONSTRUCTION DETAILS See relevant drawings in our website to illustrate each of the following details:

7.01 Panel fixing

See relevant Wind Loadings in Section 5.05 for fixing centres.

Timber Framing

NOTE: All timber screws must have at least 25mm of screw shaft screwed into the timber frame.

Fix 60mm EPS Wall Panels with 10-8 x 115mm Buildex Climacoat 3 CSK Ribbed Head Class 3 screws.

Fix 75mm EPS Wall Panels with 10-8 x 125mm Buildex Climacoat 3 CSK Ribbed Head Class 3 screws .

Washers for both are 10 x 40mm grey nylon.

Steel Framing

Fix 60mm RRR-EPS Wall Panels with Buildex 115mm Countersunk Steel Self Drilling 6-311-0621-1MP

screws.

Fix 75mm RRR-EPS Wall Panels with Buildex 125mm Countersunk Steel Self Drilling 6-311-0622-2MP

screws.

Washers for both are 10 x 40mm grey nylon.

Refer to 7.01.01 Panel Fixing and 7.01.02 Batten Spacing drawings.

7.02 Internal & External corners

It is important when forming internal and external corners that the drawings are followed correctly. In all

cases, the abutting corner panels should be bonded with suitable adhesive and sealed with polyurethane

sealants. Rockcote recommends mitring the corners as it creates a stronger joint with less risk of

cracking.

Refer to 7.02.01 External Corner and 7.02.02 Internal Corner drawings.

7.03 Control joints Control joints are required where specified by building design professional, and are designed to relieve structural movement between the wall cladding and building frame. Vertical control joints are required no further than every 6 metres. Double studs are required at all vertical control joints, ensuring polystyrene panels are independently fixed to studs or fixing points. Vertical joints are best aligned with windows, doors, openings, or internal corners. Horizontal control joints are required every 3 metres, or where timber or steel floor joists occur. Control joints must also occur where the ROCKCOTE Solid Walling System: Thermal meets other cladding materials. Rockcote recommends “V notching” the paintable flexible sealant in a control joint. Coatings can then be applied over the sealant. This allows for a clean straight control joint, any future minor movements within the joint results in the angle of “V notch” changing. If any cracking in the coating occurs it does so in a straight line. Refer to 7.03.01 Vertical Control Joint, 7.06.01 First Floor Detail and 7.03.02 EPS to Masonry Block drawings.

7.04 Termites

The Building Code of Australia, in conjunction with AS 3660, specifies the requirement for termite risk management. The edge of a slab-on-ground can be used as a visual perimeter barrier, provided that the slab edge is left exposed not less than 75mm above finished ground level, and provided that the face is not concealed by flashing, render, tiling, cladding or landscaping.

7.05 Slab on ground

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All foundations must comply with the relevant standards and local authority requirements. ROCKCOTE Solid Walling System: Thermal is suitable for construction on concrete slabs or suspended floors. Concrete slabs can either be rebated or non-rebated. The slab rebate needs to be a minimum 50mm below floor level and 100mm above paved level or 150mm above ground level (subject of course to compliance with statutory requirements). To ensure a flush finish, the width of the rebate needs to allow for the thickness of the ROCKCOTE Solid Walling System: Thermal, inclusive of the applied render and coating system. Minimum ground clearances must be maintained at all times during the life of the building.

Refer to 7.05.01 Rebated Slab Edge and 7.05.02 Slab Edge drawings.

7.06 Timber floor First floor / Horizontal Control Joint Details

It is important that a horizontal control joint is incorporated at the level of the flooring.

Refer to 7.06.01 First Floor Details

7.7 Wall to roof

It is important that a minimum 10mm gap is incorporated in-between the wall and roofing. This ensures

any wall or roof movement does not put pressure on the render system.

Refer to 7.07.01 Wall to Roof drawing.

7.8 Parapets

The correct detailing on Parapets is important to ensure that water ingress does not occur. Rockcote

recommends metal capping is placed over Parapets. The top of the parapet should be constructed to

shed water away from the visible wall face.

Refer to 7.08.01 Parapet drawings.

7.9 Soffit and eaves

The eaves or roof overhang play a significant role in the thermal performance of a building. Eaves or

overhangs are used to shade the walls in summer and to capture the sun’s heat in winter. It is important

that a gap is incorporated in-between the render system and the eaves. If a timber quad is not used then

this gap needs to be filled with a paintable polyurethane sealant.

Refer to 7.09.01 Soffit drawing.

7.10 Doors

Door framing must be fixed in position prior to installation of ROCKCOTE EPS wall panels. Cut

ROCKCOTE EPS wall panels neatly around but independently of door frames. There must be a minimum

3mm gap between the door frame and render system. This gap must be sealed with a suitable paintable

polyurethane sealant.

7.11 Windows

Windows and associated flashing should be installed prior to the installation of ROCKCOTE EPS wall

panels wherever possible. Rockcote has two different window sill profiles. One allows for the drainage of

any water ingress via weep holes. If a window sill is used it is important that these weep holes are not

rendered over.

Refer to Window Drawings 7.11.01 Window Sill Cavity Drained, 7.11.02 Window Sill Weep Hole, 7.11.03

Window Head and 7.11.04 Window Jamb

7.16 Decorative mouldings

To provide added design flexibility, decorative mouldings or features can be made by cutting the EPS

Wall Panels into bands or by laminating multiple layers and shaping to the desired profile. Once

installed, the full RRR coating system needs to be applied over the entire surface of the moulding.

Alternatively, a wide range of decorative mouldings are available from different manufacturers.

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7.17 Sunhoods

Sunhoods provide a simple, stylish, cost-effective shading option for window and door openings. The EPS

sunhoods are attached to engineered galvanized dipped steel brackets that are mechanically fixed to the

timber or steel frame.

Refer to 7.17.01 Sunhood Diagram

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8.0 FINISHING

8.01 Sleeve

Sleeve all copper, PVC products and electrical cabling that are required to penetrate the completed

ROCKCOTE SOLID - EPS System.

8.02 Penetrations

Weatherproof and/or waterproof voids or gaps created by service penetrations through the completed

ROCKCOTE SOLID- EPS System. Inject with expandable polyurethane foam and seal with a long lasting,

approved, paintable polyurethane sealant to make weather tight. Where practical, add a flange or decorative

feature over the hole or penetration.

8.03 Fixtures

Heavy items are not to be fitted directly to the ROCKCOTE SOLID- EPS System Wall Panels. Heavy

items require their own stand-alone supports or should be tied to the supporting wall frame (e.g. clothes

lines). Lightweight items subject to frequent handling (e.g. flood lights and sensors) also require a

mounting plate fixed to the frame to give long-term fixing support. The mounting plate must be installed

prior to fitting of the EPS Panels.

8.04 Sealants

Use an approved, paintable and flexible exterior grade weatherproof sealant as general purpose gap

filler. Apply sealant in accordance with the manufacturer’s recommendations. For a sealant to work

effectively, it must be applied so that the depth of sealant is twice the width of the opening.

Use a backing rod as required. Ensure surfaces are in good condition, clean and free from oil, dust, loose

materials and release agents. Apply masking tape to surfaces where contact with sealant is not required.

Tape should be removed before the sealant cures. Smooth the surface of the sealant to ensure excess

sealant is removed. Comply with sealant manufacturer’s directions for curing or drying times, before

painting.

8.05 Electrical Electrical wires must be separated from the EPS substrate to avoid plasticiser migration from the plastic coating around the electrical wires into the EPS, leaving them brittle and susceptible to cracking.