ROCKCOTE SOLID WALLING SYSTEMS SOLID... · membrane top coat. This system forms a lightweight but impact resistant cavity wall, which is intended to both resist the ingress of water

ROCKCOTE SOLID WALLING SYSTEMS

IMPACT CAVITY

INTRODUCTIONThe information in this manual is compiled for use by the building designer/construction professional

and any user of the ROCKCOTE Solid Walling System: Impact Cavity to assist in developing project

specifications and to provide guidance on the correct installation of the ROCKCOTE Solid Walling

System: Impact in domestic applications.

The ROCKCOTE Solid Walling System: Impact Cavity consists of suitable Fibre Cement Sheet

panels, Kingspan Insulative Wrap, EPS Battens, ROCKCOTE Acrybond, Polymer Modified Cement

Render, and Reinforcing Mesh, flexible acrylic-based Coloured Render and/or high performance

membrane top coat. This system forms a lightweight but impact resistant cavity wall, which is

intended to both resist the ingress of water from the exterior surface plus allow any water that builds

up behind the wall to escape.

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.

GLOSSARY OF TERMS _________________________________________________________________________________

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.

Cladding Installer

Meaning the qualified, experienced and licensed tradesperson who installs the FCS, as described in

the ROCKCOTE Solid Installation Manual and information brochure.

Installer

Meaning the qualified, experienced and licensed tradesperson who installs and/or supervises the

installation of the FCS and the application of the RRR System, 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.

FCS

Meaning fibre cement sheet 6mm thick manufactured to AS2908.2.

ROCKCOTE

Meaning ROCKCOTE Enterprises Pty Ltd ABN 42 066 227 174

ROCKCOTE Solid Walling System or “ROCKCOTE Solid”

Meaning the walling system comprising of the specified EPS, FC or AAC sheets or 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 RRR manual and

information brochure.

Specifier

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

work.

1.0 ONE SYSTEM—MANY BENEFITS

The ROCKCOTE Solid Walling Systems offer insulative walling systems delivering the look

and feel of masonry—a genuinely seamless rendered finish for lightweight energy efficient

walls in either EPS panels, FCS or AAC panels. Offering design freedom, flexibility and long-

term durability, the systems’ performance have been proven in conditions ranging from the

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

The ROCKCOTE Solid Walling System: Impact: Cavity system can be fitted over standard

timber and steel stud walls, where it provides a lightweight impact resistant walling finish with a

seamless rendered finish.

1.01 Components

The ROCKCOTE Solid Walling Systems are built on over 30 years experience and each

component has been specifically designed or selected to meet strict criteria.

All components, including FCS base board, EPS Battens, Kingspan Air-CeLL

Permishield®, ROCKCOTE Acrybond, ROCKCOTE Patch & Prep, ROCKCOTE PM100,

ROCKCOTE mesh, ROCKCOTE Coloured Render, ROCKCOTE Armour membrane,

and ROCKCOTE Trims 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.

1.01.01 Permisheild Insulative Building Wrap

Kingspan Air-CeLL Permishield® (Patent No. 2006203389), a revolutionary breathable

vapour barrier and insulation wrapped up in a single product. Kingspan AIr-CeLL

Permishield® is designed specifically for use behind lightweight cladding materials that

require vapour permeance. Manufactured with a patented closed-cell structure

sandwiched by highly reflective foil surfaces and pierced with tiny, evenly-spaced

breather holes, Kingspan AIr-CeLL Permishield® allows building professionals to do

away with the traditional sarking-plus-batts combination in order to achieve thermal

compliance as well as satisfy vapour permeance. Compliant with Australian Standards

AS/NZS 4859.1.

When installed correctly the Insulative wrap also provides additional compression shock

resistance for the walling system. This further protects the rendered finish from

delamination and damage.

1.01.02 Fibre Cement Sheet (FCS)

Fibre Cement Sheet is manufactured from Portland cement, finely ground silica, cellulose

fibres and water. It is cured in a high-pressure steam autoclave to create a durable,

dimensionally stable product.

One of the benefits of the ROCKCOTE Solid Walling System: Impact: Cavity system is

that any 6mm Fibre Cement Sheet (FCS) that complies with AS2908.2 can be used. It is

important to note that the board is installed rough side out for better adhesion of the

render to the surface.

ROCKCOTE recommends the following 6mm FCS

BGC – Durasheet

James Hardie – HardiFlex

CSR - Cemintel Cladding Sheet

1.01.03 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.

1.01.04 Render Trims

ROCKCOTE has developed a range of trims designed specifically for each

ROCKCOTE Solid Walling System.

Starter Trims: Use on foundations and roof awning apron.

40mm Starter Trim Code: 2640

Control Joint Bead: Used for Flashing and Backing Rod at Horizontal Control

Joints.

Expansion Joint Trim Code: 4034

Pre-Meshed Trim: Used for reveals and external corners

Pre-Meshed Trim Code: 4049

1.01.05 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.

1.01.06 ROCKCOTE Acrybond

Primer specifically designed to aid adhesion of PM100 to the FCS sheet. Must

be diluted to 1 part Acrybond with 2 parts water.

1.01.06 ROCKCOTE PM100

Polymer modified cement render with excellent adhesion to the base board.

1.01.07 Reinforcing mesh

Alkali resistant fibreglass mesh, 6.0mm 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.

1.01.06 Acrylic-base Coloured Render and Armour membrane 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, plus

an acrylic ROCKCOTE paint or sealer.

1.01.07 Colour

ROCKCOTE acrylic-based Coloured Renders and Armour high performance

membranes are available in a wide range of colours. However the selection of

dark colours on external walls exposed to direct sunlight can lead to excessive

heat build-up within the wall. The heat can led to expansion of the FCS and

subsequent failure of the coating system. Only colours with a Light Reflectance

Value (LRV) over 40% can be used on the standard ROCKCOTE Solid Walling

System: Impact. If a colour darker than 40% LRV is required then please

contact ROCKCOTE for a coating system specification customised to meet

your requirements.

1.01.08 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.

1.02 User benefits

1.02.01 Excellent Impact Resistance

The ROCKCOTE Solid Walling System: Impact is designed for greater Impact

resistance over that of EPS (Expanded Polystyrene). Typically EPS systems

will suffer some damage even with low level impacts.

Testing at the ROCKCOTE has shown that impacts of 0.5kg steel ball from

1.5m onto ROCKCOTE Solid: Impact systems have resulted in NO impact or

delamination damage. The equivalent test onto EPS system suffered damage

up to 3mm deep.

1.02.02 Fully Rendered Seamless Finish

Unlike other FCS systems that have patched joints and are finished over with

2mm of acrylic textures; ROCKCOTE Solid Walling Systems offer a fully

rendered screeded finish. This is because 4 to 6mm of PM100 cement render

is used and hence levelling can occur.

So no more joints visible under different lighting!

1.02.03 Insect resistant

FCS and EPS provide no nutritive value to ants, termites or rodents.

1.02.04 Flame retardant

All FCS panels specified in Section 1.01.02 have Early Fire

Hazard Properties of

- Ignition Index 0

- Spread of Flame Index 0

- Heat Evolved Index 0

- Smoke Developed Index 0-1

A 6mm FCS system automatically qualify to BAL 29 requirements as a 6mm

FCS sheet is used in construction.

1.02.05 Cost effective

The ROCKCOTE Solid Walling System: Impact offers an attractive, cost

efficient, insulative walling system.

1.02.06 Production

ROCKCOTE Solid Walling System: Impact uses far less energy in the

manufacture of it’s components over that of conventional building materials.

1.02.07 Easy to install

ROCKCOTE Solid Walling System: Impact is light, practical, safe, easy to

handle and install.

2.0 RRR COATING SYSTEM

2.01 General

All ROCKCOTE Solid Walling Systems use variations of the original ROCKCOTE

Reinforced Render (RRR) Coating System. 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, strictly in accordance with ROCKCOTE’s written instructions

and specifications.

The RRR Coating system consists of:

• ROCKCOTE PVC angle trims, starter and edge strips

• ROCKCOTE PM100

• ROCKCOTE 160g/m2 alkali resistant fibreglass

reinforcing mesh

• ROCKCOTE flexible acrylic-based Coloured Render and/or ROCKCOTE Armour high

performance membrane.

2.02 Critical factors

• The board must be installed rough side out for better adhesion of the cement render.

• The board must be primed with 1 part Acrybond to 2 parts water for better adhesion of

the cement render.

• 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 with water.

• 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

ROCKCOTE QRender PM100

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

based Coloured Render coating.

• The colour chosen shall have a Light Reflectance Value greater than 40% for the

standard RRR Coating system.

2.03 Applicator

Application of the ROCKCOTE Reinforced Render (RRR) Coating 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 rough side out and in accordance with the

project plans and specifications, and that the substrate is suitable for the application of

the RRR Coating System.

• FCS must be installed rough side out. If the FCS is installed smooth side out

ROCKCOTE Keycote must be used instead of ROCKCOTE Acrybond on first coat.

• 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.

2.06 Preparation

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 Priming

Before rendering can commence all FCS surfaces must be primed with Acrybond

solution. This solution is obtained by diluting 1 part Acrybond with 2 parts water (33%

solution).

2.07 Fitting trims

Trims must be installed straight and true, allowing for the correct thickness of finished

render. ROCKCOTE Patch & Prep must be used to fit trims. In all cases apply

ROCKCOTE Patch n Prep either onto trim or onto FCS surface and then overlay trim.

2.08 Reinforced render installation

Before commencing application, ensure all windows and adjacent surfaces are masked

and the correct scaffolding is in place.

Ensure all angle and base trims are correctly fitted using ROCKCOTE Patch n Prep.

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 using ROCKCOTE Patch n Prep.

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

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 trims as a guide, the render is screeded to the level of the trims 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 Coloured Render.

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 24 hours, then let the walls dry. Render cannot be applied in freezing

conditions and uncured material must not be allowed to freeze.

2.09 Fibreglass mesh

Alkali resistant fibreglass mesh, 6.0mm weave, 160 g/m2 is a critical component of the

ROCKCOTE Solid Walling System: Impact cavity and must be correctly installed.

Overlap all mesh sheets and the mesh from the pre-meshed trims to a minimum of

50mm.

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

surface of the render.

IMPORTANT: Under no circumstances should the mesh be fixed directly to the

substrate before the render is applied.

2.10 ROCKCOTE flexible Acrylic-based Coloured Render

The ROCKCOTE flexible Coloured Render is an integral component of the ROCKCOTE

Solid Walling Systems and must be applied to the specified dry film thickness of at least

1mm.

Application of the Coloured Render can commence once the render has cured and is

dry.

The Coloured Render is applied using a stainless steel trowel or suitable spray machine

and finished with a plastic or poly float to the desired finish.

ROCKCOTE Coloured Renders can be tinted to the required colour. Please ensure LRV of

colour is greater than 40%.

Suitable ROCKCOTE Coloured Renders include:

Quicksand Coarse

Sandcote

Pearlcote

Finecote

Santa Fe

Santini

Acrylic top coats from the ROCKCOTE Armour range can then be applied to provide a

and added flexibility and durability.

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.

3.0 REPAIR AND MAINTENANCE

3.01 Cleaning

Exterior walls should be kept clean. 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. We recommend ROCKCOTE Fungicidal Wash which has been

specifically developed 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 (RRR) Coating System if required.

Fill cracks with flexible, external, paintable patching compound and recoat the surface.

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 correct grade of FCS panel, Insulative

Wrap, ROCKCOTE Acrybond, ROCKCOTE Patch & Prep, ROCKCOTE

PM100, ROCKCOTE reinforcing mesh, ROCKCOTE Coloured Renders,

ROCKCOTE Armour membrane, ROCKCOTE Trims 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 Walling System, except FCS panels,

can be obtained from ROCKCOTE.

FCS wall panels can be obtained from manufacturers of panels that meet

ROCKCOTE’s Solid Walling System: Impact specifications.

5.0 DESIGN CONSIDERATIONS

5.01 General

The ROCKCOTE Solid Walling Impact 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 location of the Permishield Building Wrap allows it to provide

3 critical benefits

Insulation

Vapour permeable moisture barrier

Shock Absorbency for outer render coating.

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. Specified FCS Panels have sufficient strength and rigidity to be

supported by wall framing spaced at 600mm maximum centers. Timber framing

must comply with AS 1684.2 & .3 National Timber Framing Code.

FCS must not be fixed to wet framing. It is strongly recommended that kiln

dried timber is used for framing. If sheets are fixed to ‘wet’ framing problems

may occur at a later date due to excessive timber shrinkage.

The metal framing must not exceed 1.6 mm in thickness and comply with any

relevant Australian Domestic Construction Standards..

EPS battens must have a maximum thickness of 25 mm to allow adequate nail

penetration. Battens supporting sheet joints must have a minimum actual face

width of 45 mm

5.03 Typical FCS walling panel sizes

5.04 Wind zones

As the FCS is not located on the framing due to EPS battens it cannot be used

to increase bracing. The Australian Standard for “Residential timber - framed

construction” must be adhered

: AS 1684.2 (Non cyclonic areas)

: AS 1684.3 (Cyclonic areas)

Racking forces due to wind loading shall be calculated as per these Australian

Standards. For bracing data on other construction methods and applications,

contact your relevant Fibre Cement Sales Office.

5.05 Limitations

The ROCKCOTE Solid Walling System: Impact: Cavity FCS sheets are not

directly attached to the structural framing therefore cannot be designed to

provide structural bracing. It is not suitable for use in and must be separated

from chimneys, flues or fireplaces. ROCKCOTE Solid Walling: Impact 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.

LENGTH WIDTH WIDTH

900 1200

1800

2400

2700

3000

5.07 Thermal Performance (Air-Cell Permishield)

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.

Cladded Stud Framed Walls Heat Flow In Heat Flow Out

Permishield® 65 RT1.6 RT1.8

Permishield® 80 RT1.7 RT1.9

The R-values shown are Total R-values for the building element as required by

the Energy Provisions of the Building Code of Australia.

AIR-CELL® products are manufactured, tested and packaged in conformance

with AS/NZS 4859.1:2002 - Amdt 1. The contribution of the product Total R-

values depends on installation and environmental conditions. The R-value will

be reduced in the event of the accumulation of dust on the upward facing

surfaces and in those cavities that are ventilated.

Refer to the Kingspan website for further information.

5.09 Impact resistance

Properly installed, the ROCKCOTE Solid Walling System: Impact has good

impact resistance for most domestic situations. ROCKCOTE recommends the

Impact system over that of EPS systems where greater Impact resistance is

required.

5.10 Serviceable life

The ROCKCOTE Solid 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 Maintenance Guide.

5.12 Moisture

ROCKCOTE Solid Walling System: Impact 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.

5.14 Fire

The ROCKCOTE Solid Walling System: Impact does not provide a fire rated

wall. However it is manufactured from non-combustible material. Fully installed,

the ROCKCOTE Solid Walling System: Impact will provide a bush fire attack

level of 29 (BAL 29).

5.15 Non-hazardous material

Fully installed, the ROCKCOTE Solid Impact: Cavity is non-hazardous

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.

Solid backing

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

fold-down clothes lines, etc.

Insulative Wrap

Refer to Kingspan guidelines for correct fitting of the Permisheild wrap.

Fitting

Before commencing to fit Permisheild Insulative Wrap and FCS 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. FCS should be installed either vertically. Panels are fitted into the starter strips,

butted together at all joints, apart from control/expansion joints. Screw or nail off panels

from the centre out to the edges at 200mm centres or as otherwise specified along studs

and around all edges (see Wind Loadings information in section 5.05). Fit approved 4.5mm

external angle beads to all external corners using ROCKCOTE Patch & Prep. Ensure that

panels and angle beads are straight and plumb, and allow for the correct thickness of

render and finish coating.

Batten Fixing

H grade battens can be initially glued into place over the Insulative wrap, located over the

wall studs.

Bracing

ROCKCOTE Solid Walling System: Impact: Cavity is not a bracing system.

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 for attaching

battens. ROCKCOTE recommends Patch n Prep in fixing all trims.

Sealants

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

15 are suitable. Refer to adhesives and FCS panel manufacturers for current

recommendation for use with FCS panels.

6.02 Cutting and drilling

FCS may be cut to size on site. If using power tools for cutting, drilling or sanding they

must be fitted with appropriate dust collection devices or alternatively an approved (P1 or

P2) dust mask and safety glasses should be worn. It is recommended that work always

be carried out in a well-ventilated location.

The most suitable cutting methods are:

Score the sheet face 4 or 5 times with a ‘score and snap’ knife. Support the scored edge

and snap the sheet upward for a clean break.

Hand Guillotine

Cut on the off-cut side of the line to allow for the blade thickness. Notches can be made

by cutting the two sides of the notch. Score along the back edge then snap upwards to

remove the notch.

Drilling

Use normal high-speed drill bits. Do not use the drill’s hammer function. For small round

holes, the use of a hole-saw is recommended.

For small rectangular or circular penetrations, drill a series of small holes around the

perimeter of the cut out. Tap out the waste piece from the sheet face while supporting

the underside of the opening to avoid damage. Clean rough edges with a rasp. Large

rectangular openings are formed by deeply scoring the perimeter of the opening. Next,

form a hole in the centre of the opening (refer method above) then saw cut from the hole

to the corners of the opening. Snap out the four triangular segments. Clean rough edges

with a rasp..

6.03 Trims

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

Starter trims to suit a 40mm FCS cavity are available in external grade PVC. Reveals

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

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 4.8 metres, and horizontal control joints are

required every 3 metres or where timber and steel floor joists occur. Control joints must

also be provided where ROCKCOTE Solid Walling Systems meet other cladding

materials.

Where control joints are to be installed, the FCS panels must be independently fixed to

studs/fixing points. Refer to Section 7.04.

6.06 Handling and storage

Care should be taken when handling FCS to avoid any damage to edges, corners and

faces. FCS 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. FCS must be dry prior

to fixing. FCS must always be carried on edge. Any minor damage should be repaired

with joint compounds. 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 Walling System: Impact is non-

hazardous. However, as with all composite materials, general safety clothing and

gloves are to be worn when handling or cutting FCS 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.

Specified FCS as manufactured will not release airborne dust, but during drilling,

cutting and sanding operations cellulose fibres, silica and calcium silicate dust may be

released. Breathing in fine silica dust is hazardous, prolonged exposure (usually over

several years) may cause bronchitis, silicosis or cancer.

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:

• 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.

7.0 CONSTRUCTION DETAILS

7.01 Panel fixing

See relevant Wind Loadings in Section 5.05 for fixing centres.

Timber Framing

Fix 6mm FCS sheets with the following

- Hot Dipped Galvanised Flat Head Nails

Hand Driven – 3.75 * 75mm

Machine Driven – 3.2 * 88mm

Nail head must be driven flush with sheet surface.

- Class 3 wood screws 8-10 * 57mm

Exposed costal areas use stainless steel nails and screws to minimise any future

corrosion.

Steel Framing

Fix 6mm FCS sheets with the following

- Class 3 Wing TeksTM

6-20 * 50mm rib head screws

H Grade Batten

Framework

Fig 7.01.01

75mm x 25mm Horizontal Batten Fixing Blocks to befitted on an angle to avoid moisture entrapment

Batten Layout Detail

Do not join sheets adjacent toWindow or door openingsunless they are a Control Joint

200 x 400 Mesh at all angles of openings

Figure 7.01.02 Panel Fixing

Sheets to be f itted v ertically with smooth sideto the batten with f ixings at 200mm centres

7.02 Internal and external corners

It is important when forming internal and external corners that the following drawings are

installed correctly. In all cases, the abutting corner panels should be bonded with suitable

adhesive and sealed with polyurethane sealants.

Permishield 6.5 Building Wrap

25mm H Grade batten

Rockcote 160Gsm Mesh

Rockcote Reinforced Render System

6mm Fibre Cement Sheet

Paintable Polyurethane Sealant

Figure 7.02.01 Internal corner

Internal Control Joint with



25mm H Grade batten


Figure 7.02.02 External corner

Rockcote Meshed External Bead

7.03 Junctions

Paintable Polyeurethane Sealant


25mm H Grade batten




Air Seal Backer Rod

Flashing By Main Contractor

Figure 7.03 Junction to Other Substrate

Other Substrate

7.04 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 4.8 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: Impact meets other

cladding materials.


25mm H Grade batten




Paintable Poly urethane Sealant


6-10mm

Figure 7.04.01 Vertical Control Joint


25mm H Grade batten




Paintable Polyurethane Flexible Sealant


PVC Expansion Bead Flashing

10mm Joint

Figure 7.04.02 Horizontal Control Joint

7.05 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 or cladding.

7.06 Slab on ground

All foundations must comply with the relevant standards and local authority

requirements. ROCKCOTE Solid Walling System: Impact Cavity 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: Impact Cavity,

inclusive of the applied render and coating system. Minimum ground clearances must be

maintained at all times during the life of the building.

25mm H Grade batten




Rockcote Starter Tr im


Dampcourse/Termite Barrier

Figure 7.06 Slab Detail

Ground Clearance as per Local Building Regulations

7.07 Timber floor

Rockcote Starter Trim

Rockcote Reinf orced Render System



25mm H Grade batten


Sub Floor Timbers

Pier & Ant Capping50mm Min

Figure 7.07 Timber Floor

7.08 First floor detail

Flashing by Main contractor


Rockcote Reinf orced Render Sy stem



25mm H Grade batten


Rockcote Render Sy stem

Masonry Block

Figure 7.08 First Floor detail

7.09 Veranda detail


25mm H Grade batten





Flashing by Main contractor


Air Seal Backer Rod

7.09 Verandah Detail

7.10 Wall to roof




25mm H Grade batten

Apron Flashing by Others

Minumum 10mm Space



Figure 7.10 Wall to Roof

7.11 Parapets

The top of the parapet should be constructed to shed water away from the visible wall

face.

Rockcote 160 GSM Mesh

Rockcote Reinforced Render Sys tem

25 mm H Grade EPS B atten

Rockcote Meshed External T rim

Metal Capping Des igned & Fitted by Main Contrac tor

Roof Flashing Des igned & Fitted by Main Contrac tor

Rockcote S tarter T rim



10mm Space

Figure 7.11 Parapet

7.12 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.


25mm H Grade batten





3-4mm Gap Between Soffi t & Cladding

Optional Quad by Main Contrac tor

Figure 7.12 Soffit

7.13 Doors

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

wall panels neatly around but independently of door frames.


25mm H Grade batten






Flashing by Main Contractor

Figure 7.13.01





25mm H Grade batten



Figure 7.13.02 Door Jamb

7.14 Windows

Windows and associated flashing should be installed

prior to the installation of ROCKCOTE FCS wall panels wherever possible.

Permishield 6.5 Bui lding Wrap

25mm H Grade batten






Flashing by Main Contractor

Figure 7.14.01 Window Head





25mm H Grade batten



Figure 7.14.02 Window Jamb

7.15 Window sill



25mm H Grade batten


Window Flashing

Paintable Polyeurethane Sealant

Rubber Weather Strip

Figure 7.15 Window Sill

7.16 Decorative mouldings

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

using FC (Fibre Cement) or EPS (Expanded Polystyrene) moulds . Once installed, the

RRR Coating System needs to be fully applied over these features. Note Keycote or

Acrybond 33% solution will need to be used over FC before applying the RRR system.

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

manufacturers can be used.

NOTE: Anywhere water can sit, a 30 degree fall away from the walling system is

required.

7.17 Sunhoods

Sunhoods provide a simple, stylish, cost-effective shading option for window and door

openings. The sunhoods are attached to engineered galvanized dipped steel brackets that

are mechanically fixed to the timber or steel frame. EPS and FC sunhoods need to be coated

in the RRR system once installed.



Paintable Flexible Sealant

Sunhood Bracket at 600 centres

Drip Bead Around Perimeter

20mm

25mm H Grade batten

6mm Thick Plate

440mm

Fig No. 7.17SunHood detai l

Permishield 6.5 Bui lding Wrap


Waterproof Membrane over Rockcote P M100 & Mesh

Mesh overlay at internal angle

8.0 FINISHING

8.01 Sleeve

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

the completed RRR-FCS Walling System.





25mm H Grade batten


Figure 8.01 Sleeves

8.02 Penetrations

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

completed RRR- FCS Walling 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.


25mm H Grade batten





Meter Box

Figure 8.02 Penetrations

8.03 Fixtures

Heavy items are not to be fitted directly to the RRR- FCS System Wall Panels. Heavy

items require their own stand-alone supports or should be tied to the supporting wall

frame (eg clothes lines). Lightweight items subject to frequent handling (eg 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 FCS 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.

ROCKCOTE SOLID WALLING SYSTEMS SOLID... · membrane top coat. This system forms a lightweight but impact resistant cavity wall, which is intended to both resist the ingress of water

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