Exsulite Kooltherm Specification & Installation Manual
Contents
1. 0120 5341430 09 LY 0115 TANVd WaSHLIOOY WWOS OS UYSONSY YAWAIOd 30 1909 1643 GA0GSaW3 SONINAdO JO SYINYO9 OL SdIHLS 9NIOHOJNI3H TWNOSVIG WAWINIW 106 SONINAdO 3O4 JDIACV LNO LAS Refer to the Exsulite Kooltherm Construction Drawings Manual for above roof details 2 2 4 Cavity Spacer Vertically install 1 kiln dried treated pine H2 timber batten to each stud for residential housing construction or project specific designed metal hat amp cleat system for multiresidential construction Fix the cavity spacer onto all studs and around all windows amp doors and ensure that it is finished hard down on the inside edge of the Exsulite starter channel Once all cavity spacers are installed on each elevation or wall side check with a straight edge to ensure the wall is level to within a 5mm tolerance over a 3 metre span The panel is fixed to the vertical batten covity spacer to allow for drainage to the cavity closer starter channel at the base of the wall 2 2 5 Exsulite Kooltherm Panel Fixing Measure and cut Exsulite Kooltherm panels using a masonry diamond blade in a standard power saw or sharp knife The panel is to be installed oriented horizontally with a staggered brick joint layout fixed at 275mm centres on stud lines Exsulite fixings to be used in all cases with no subs2. Finisher sign off Name Installer No Signature Date of completion Project Specific Checklist Description Comments By Who Other Comments On completion of this form it is the responsibility of the Exsulite Trained Installer to forward it to Dulux AcraTex by email to sales exsulite com au or by fax to 61 8 8347 1963 as part of job registration process Dulux is a division of DuluxGroup Australia Pty Ltd ABN 67 000 049 427 Dulux AcraTex and Exsulite are registered trade marks and Matrix Basecoat is a trade mark of DuluxGroup Australia Pty Lid Kooltherm is a registered trade mark of Kingspan Holdings IRL Limited Page 3 of 3 ana 4 2 d E anda MJ LL Exsulite Thermal Facade System by
3. ONIONOINISY Y NMOHS HSIN d XY30NIY 38V SNOISN3MWIG 310 IVNH3LDG SNOILISOd GALS S3lBVA 0027 LHOISH TANVd 00 00 LHOISH T3NVd ooz S3MLN3O WNANIXYN 09 LY SGNLS YIANIL TANVd WaFHLIOOY WWOS OS SLNIOP TANVd TVOLLS3A TVLNOZINOH OL S39v3uns JO 3HLN39 LY NOILONYLSNOO 3 8vaNvaxa 30 0 3 31 ATIVOLLYSA S381N3O 93903 T3Nvd LY SONIXIJ H19N31 T3NVd f TANVd WOLLYSA LY 539319 9NIM90 18 WM GALS C331 N32 009 4 4 JDIAGV INO 135 27 O1 February 2015 Exsulite Kooltherm Specification amp Installation Manual Version 1 AINO 9 V SV NMOHS HSA HLIM QV38 0061 SNOISNAWIG ALON TIY TANWd SNOILISOd 15 YANYOO NYNLIY 5 LH9I3H 9NIN3dO 0012 S mico 2 No x 2 218 co HI9N3T I3NVd SSNIN3dO 8 SLNIOP TANWd TWOILYSA LV SNOLLVYLANAd TIVM 539319 9NDI2O 18 IVNOLLIQOV ONY SONINAdO OL 39 1 ONIHSW14
4. Checked windows and doors installed with correct reveal size to suit cavity Damp proof course installed to slab rebate e Exsulite breathable absorbent wall wrap installed e If not state alternative breathable wrap installed e Exsulite Cavity spacer installed Cavity spacer thickness mm If not type of cavity spacer installed and by who Type mm Panel Type Exsulite EPS Raw Panel 40mm 60mm 75mm 80mm 100mm Other Exsulite Composite Panel 60mm 75mm 80mm 100mm Other Exsulite Kooltherm Panel C SOmm Other Exsulite screws and washers installed at maximum 275mm vertically and maximum 600mm horizontally Approved aluminium flashing tape installed around windows doors meter box openings and all penetrations Exsulite panels glued fully along abutting edges with approved foam adhesive All exposed panel edges fully enclosed with PVC channel Exsulite cavity closer with weep holes Exsulite PVC external angles fixed with approved adhesive Control Joints to masonry with 10mm gap and backing rod strip Exsulite panel to window sills cut at minimum 10 degrees Detail
5. Site Access and Scaffolding Checklist Yes No Comments Who ls all access scaffolding set up to install the specified system ls all scaffolding and access equipment checked and approved Installer Checklist Yes No Comments Who All Exsulite components supplied by Dulux with no substitution Checked frame with straight edge up to 5mm tolerance Was rectification required and if so by whom Checked frame for additional back blocking to ensure double studs at vertical butt joints to panels Page 1 of 3 5412 0714 Installer Checklist continued Back blocking required and if so by who Comments By Who Checked expansion joint locations and ensured double studs Vertical expansions joints installed at max 6 0m centres Refer to Exsulite Construction Drawings manual for details Horizontal expansions joints installed at max 3 0m centres Refer to Exsulite Construction Drawings manual for details Checked gable area framing at 600mm max centres Backing plates for fixing of down pipe brackets before panel installation Backing plates to clothes lines pergolas and other external fixtures Checked flashing over roof areas parapets and balconies
6. Primer Coat Dulux AcraPrime XPS Size 151 120m Base Coat Exsulite Matrix Basecoat Size 20kg Approximately 3m 5mm thick plus wastage Exsulite 165gsm Alkali Resistant Mesh Size 50m x 1m 50m Primer Coat Dulux Green Render Sealer optional Texture Coat Exsulite Texture Size 151 12m Protective Membrane Topcoat Exsulite Membrane Size 151 Approximately 70m NOTE The above calculations are a guide only For project specific requirements please talk to your Dulux AcraTex representative 2 1 7 Tool Requirements Electric saw Safety gloves Hammer Floats plastic amp foam with diamond tip blade fitted with amp safety glasses a vacuum extraction appliance where possible y A E m ui Dust mask Hawk amp trowel Empty pails m jl Cordless drill Lr E L EL Staple Gun Roller Scaffold Sharp blade knife Caulking gun Spatula Exsulite Kooltherm Specification amp Installation Manual Version 1 O1 February 2015 E 2 1 8 Before Commencing Installation Read the Exsulite Kooltherm Thermal Facade System Installation Manual in conjunction with the project consultant project specific specification and drawing details to familiarise yourself with the relevant project specific requirements including Fire Rated Level FRL Bush Fire Attack Level
7. 54055 Thickness per stud Spacings Thickness per stud Spacings NI 5 275mm 50mm 5 275mm N2 50mm 275mm 50mm 5 275mm N3 5 275mm 50mm 275mm N4 50mm 3 275mm 50mm 5 2 5mm 5 5 275mm 50mm 5 275mm 3 2 5mm 50mm 5 275mm el 50mm 5 275mm 50mm 275mm 2 5 275mm 50mm 5 275mm 3 2 5mm 50mm 5 2 5mm CA 50mm 5 2 5mm 50mm P 214 Assumption is based on a panel size of 2270mm x 1200mm panel size is acceptable to use a panel thickness equal to or greater than the minimum requirement to satisty the wind classification and meet thermal and acoustic requirements Increased peak pressures occur near the edges of side walls on buildings Using AS4055 the size of the building has been assumed and hence the size of these high pressure zones is specified as 1 200mm from wall corners NOTE The fixings per stud indicate the number of fixings required at each stud support along each sheet Table Two For Wind Classification to 54055 Minimum Panel Thickness and Fixings Walls Located Within 1200mm from Corners Wind Stud Centres 450mm Stud Centres 600mm Classification Min Panel Fixings Fixing Min Panel Fixings Fixing 54055 Thickness per stud Spacings Thickness per stud Spacings 1 D 2 5mm 50mm 5 2 5mm N2 50mm 5 275mm 50mm 5 275mm N3 50mm 3 275mm 50mm 5 275mm N4 50mm 5 2 5mm 50mm 3 2 5mm 5 5 2
8. Certificate of Installation and Exsulite Warranty Job Registration forms are required for warranty purposes and forms part of the Exsulite warranty procedure The Exsulite Trained Installer and Exsulite Trained Finisher can either be the same or separate entities who have attended the Exsulite Training Course System Used Please tick one Exsulite Thermal Facade Cavity System Exsulite Composite Thermal Facade Cavity System Exsulite Thermal Facade Non Cavity System Exsulite Composite Thermal Facade Non Cavity System ExsuliteKooltherm Thermal Facade System Project Information Project Start Date Timber Frame Steel Frame Site Address C Within 1km of Coastal Area Wind pressures confirmed by engineer Project Builder Contact Number Contact Name AAC Brick Other Ground Level Construction Exsulite AAC Brick Other L Dulux Specification Number Upper Level Construction Exsulite Exsulite Panel Wall Area Exsulite Trained Installer Entity Company Name Installer Name Exsulite Installer No Mobile Nominated Installer Nominated Installer No Exsulite Trained Finisher Entity Company Name Installer Name Exsulite Installer No Nominated Installer Mobile Nominated Installer No
9. amp builders This Specification amp Installation Manual is designed to provide fixing guidelines to both timber and steel frame construction as total integrated light weight self draining cavity walling system This Technical Specification amp Installation Manual is intended for use by Dulux Exsulite Trained amp Registered Installers builders specifiers and designers who are involved with the specification amp installation of the Exsulite Kooltherm Facade System Providing more design flexibility options and faster build process than conventional masonry construction 1 0 Overview Dulux AcraTex is a pioneer in the use of External Insulation Facade Systems EIFS designing and installing coating systems specifically for wall applications EIFS walling systems have been used in Europe for over 50 years In recent years the use of Lightweight Cladding Systems as alternate solutions in the building and construction industry has grown rapidly but proper system design and installation has not been considered The Building Code of Australia BCA or National Construction Code INCC requires appropriate design and installation controls to quality any alternate solution and ultimate success requires a total system approach integrating design componentry installation and performance requirements The Exsulite Kooltherm Thermal Facade System by Dulux AcraTex protects specifiers surveyors builders and their clients from
10. AcraTex and installed by a Dulux AcraTex Exsulite Trained amp Registered Installer 1 1 1 If you a Specifier Dulux AcraTex ensures the Exsulite Kooltherm Thermal Facade System is fit for its specified purpose provided it is installed in strict accordance with the specification amp installation manual and the agreed specification by a Dulux AcraTex Exsulite Trained amp Registered Installer 1 1 2 If you are a Dulux AcraTex Exsulite Trained amp Registered Installer Ensure you follow the design amp installation guidelines provided in conjunction with the Exsulite Construction Drawing details Exsulite system components can only be supplied by Dulux AcraTex or other Dulux AcraTex approved suppliers 1 1 3 If you are a Builder To ensure your build meets the design specification make sure all work is completed by a Dulux AcraTex Exsulite Trained amp Registered Installer An Exsulite Kooltherm Certificate of Completion amp Project Warranty will only be issued when the installation is completed by a Dulux AcraTex Exsulite Trained amp Registered Installer 1 1 4 Design amp Installation Any alternative Exsulite Kooltherm Thermal Facade System project specific specification outside the standard system must be pre sanctioned by Dulux Acralex The alternative Exsulite Kooltherm project specific specification must be secured prior to job commencement Where an Exsulite Kooltherm System project specific specificat
11. Slab amp Footings Slab and footings on which the building is situated must be designed and certified by a qualitied structural engineer This should comply in accordance with AS2870 Residential Slabs amp Footings and or AS 3600 Concrete Structures as appropriate 1 3 5 Ground Clearance amp Pest Control Install Exsulite Kooltherm Thermal Facade System with a minimum 75mm clearance refer to Exsulite construction drawings for details or in accordance with local building codes Adjacent finished grade must slope away from the building in accordance with local building codes typically a minimum slope of 50mm over the first metre Do not install external cladding in areas where it may remain in contact with standing water or debris Do not back fill All BCA and local council requirements must be complied with by the builder of the project to ensure adequate protection against pest attack such as termites The requirements vary across different states in Australia Refer to the BCA code and AS 3660 1 2000 1 3 6 Coastal Areas In coastal areas located within 1km of the shoreline or large exposure to salt air a protective weatherproof membrane topcoat must be used in all cases Recommendation is that the facade should be regularly inspected for contamination amp pollutants and washed down accordingly 1 3 7 Colour Selection Avoid the use of dark colours these will raise the surface temperature and can damage the clad
12. at all building weak points or where potential cracking may occur e g in line with openings windows doors horizontally between floor levels and at all interfaces of different building construction materials and or as defined by a responsible Building Project Engineer The placement and correct installation of control joints is the responsibility of the Building Engineer Builder to determine if the joints are sufficient to accommodate the movement of the specific project building Typical vertical control joints are 10mm 1 2mm wide and horizontal joints are 15mm 20mm wide and filled with an approved paintable flexible sealant Alternatively a U PVC control joint bead is inserted in position prior to render application After the texture coat application the bead is cut through and filled with Selleys Flexiseal Refer to the Selleys specification data sheet Placement of Expansion Control Joints Horizontal Wall Areas Wall length 6 Metres Metres Vertically Construction joints between floor levels and gable ends where 3 Metres the total wall height including gable exceeds maximum distance Scribed control joints Above large window and door openings Note Internal Corner When rendering mesh up to but not across corner then later scribe a control joint into the render cutting nick the mesh intermittently to relieve the tension within the mesh Fill with sealant prior to texture coating Exs
13. at concrete slab rebate in accordance with Exsulite Construction details All components have been installed fully in accordance with Exsulite Installation Manual and Construction Details Collected all off cuts and placed in clear plastic bags for recycling collection Installer sign off Name Installer No Signature Date of completion Page 2 of 3 5412 0714 Applied PU sealant to expansion joints control joints Comments and around windows meter box and other penetrations L 1s NO Do not overcoat sealant with Basecoat or Texture Overcoat only with membrane External PVC angles installed and by who Yes No By Who Protective drop sheets to roof and adjacent areas Vas No Date Batch No Quantity bags Exsulite Matrix Basecoat applied a omments Exsulite mesh embedded into basecoat overlapped C min 100mm diagonal strips at corners of openings Yes No f Green Render Sealer when texture coating within C Date Comments 5 days of base coat application Yes No Date Batch No Quantity buckets Exsulite Texture coat applied Fad E roduct olour omments Date Batch No Quantity buckets Exsulite Membrane top coat applied e roduct olour omments Applied in accordance with Dulux AcraTex Exsulite Commens es o product data sheets and product specifications
14. bottom Refer to the Exsulite Kooltherm Construction Drawings Manual for over roof or slab edge details This may vary subject to individual project requirements When installing the Exsulite starter channel above a deck flat or pitched roof ensure a gap of a minimum 25mm is left between the bottom of the Exsulite starter channel and the finished level Finally ensure that the deck flat or pitched roof has had the correct flashing installed is fit for purpose and is sloping away from the wall cladding Exsulite Kooltherm Specification amp Installation Manual Version 1 February 2015 SLNIOP TANVd TWOILYSA ONIONOSNISY TVINOZIOH TIY OL S39vans HSIN WHOSINI LY NINO V SV NMOHS Qv38 AOTIY HLIM SINVHISYN NOLLONYLSNOD 38V SNOISNAINIG 3 LON IVNH3LX3 TIV 40 aL vnoaav HI9N31 T3NVd 1 042 f SNOILISOd GALS LHOISH TANVd 00 w 0027 00 LHOISH T3NVd ooz m Sle SZZ Sle d 4 5 SIYLNIO IWDIWIXVIN ATIVOLLH3A SJYLNIO WIAGZC 3Nvd TWOILYSA LV wuuosr LY SGNLS YIANIL 3903 TANVd LV SONIXIJ 5302314 9NDI9078 IVNOLLIQOV HNVd WaFHLIOOY WWOS 9 OS CS OSV 4 4 JOIAQV INO 135
15. cleaned with a low pressure water blast less than 45Opsi using a fanjet of cold water at 45 degree angle from the wall not perpendicular The fan of the water blaster should be kept minimum of 30cm from the surface of the Dulux AcraTex Texture coating in order to avoid damage Localised grime or ingrained dirt should be removed by cleaning with a scrubbing brush along with a solution of detergent and warm water Under no circumstances should you attempt to remove heavy staining using a high pressure water blaster Check for cracked loose or missing sealant as part of your regular maintenance inspections You will find sealant in most areas where different substrates meet ie Above door openings windows pipes where walls meet the soffit line and where electrical fittings and handrails have been attached to walls Control joints should also be inspected as part of maintenance inspections All deteriorated or damaged sealant should be removed and replaced as soon as it is apparent We recommend that a paintable polyurethane sealant be used It is important to monitor areas that are heavily exposed to the elements such as parapets and balcony handrail tops Due to the minimal slope on these areas it will tend to hold dirt amp grime which can potentially lead to mould over time if not regularly washed These building sections should also be checked for any movement over time due to the extremes of thermal movement so it is critical that they ar
16. measuring down from the soffits eaves 1200mm and flicking another chalk line then fix the top row of panels Once the two runs of sheets have been fixed you will be required to cut a piece to fit in between the panels and complete the cladding side of your first wall Using a Dulux AcraTex approved construction PU foam adhesive spray onto all panel edges where the panel is to be joined 2 2 6 Exsulite Fixing Disks amp Screws In accordance with tables 1 2 and 3 re Wind Design For 600mm stud centres The required fixings are 5 per stud fixed at 275mm ctrs and 50mm from the top and 50mm from the bottom edge 25 fixings per panel including sheet ends subject to project requirements amp wind design For 450mm stud centres The required fixings is a minimum of per stud fixed at 275mm ctrs and 5 from the top and 50mm from the bottom edge Minimum is 25 fixings per panel including sheet ends subject fo project requirements amp wind design NOTE Fixings are to be applied in accordance with Tables 1 2 and 3 on pages 10 and 11 2 2 7 Adhesives Once the wall panels have been fixed spray adhesive PU foam approved amp supplied only by Dulux AcraTex Exsulite Kooltherm Specification amp Installation Manual Version 1 February 2015 29 into all panel joints Once dry cut off excess with a knife and then all joins flush When the total thickness is greater than 50mm apply in multiple layers moisturising
17. the wet freshly applied Exsulite Matrix Basecoat layer The Exsulite reinforcing mesh 165gsm 5mm x 5mm aperture Once Exsulite mesh is installed and overlapped by min of 100mm on all edges immediately apply additional Exsulite Matrix Basecoat mixture to completely cover and encapsulate the mesh with minimum of 2mm cover and an overall minimum total thickness of 5mm Do not push the mesh to the surface of the cladding Finish the Exsulite Matrix Basecoat layer by lightly scratching the surface to provide a surface key for subsequent levelling coats Additional impact resistance can be provided by installing an additional layer of Exsulite mesh and Exsulite Matrix Basecoat NOTE Where texture coating application is to occur within 7 days of Exsulite Matrix Basecoat completion Dulux AcraTex recommends that one coat of Dulux AcraTex Green Render Sealer a high alkali resistant primer is applied in accordance with relevant product data sheets It will help consolidate the surface and enhance subsequent coating application and provide total system durobility Exsulite Texture Coating Apply one coat of Exsulite Texture 0 8 in accordance with the relevant product data amp application data sheets PU Sealant Application Install Selleys Flexiseal PU sealant or other approved sealant around all window amp door frames all openings penetrations electrical meter boxes ducting floor amp joist penetrations fixings an
18. 5 Benefits of Installing a Drainage Cavity System The Drainage Cavity separates the Exsulite Kooltherm Panel from the frame creating a second layer of defence that allows air flow to dry out any condensation moisture water ingress that may form in the wall or behind the Exsulite Kooltherm Panel as a second line of defence The cavity is created by installing a vertical cavity spacer batten to each wall stud This allows any moisture water ingress to drain down the back of the panel and out through the bottom of the wall via weep holes that are located within the cavity closer Any remaining condensation or moisture within the cavity can then dry along the bottom of the cavity and the Exsulite vapour permeable wall wrap The Drainage Cavity System will allow for moisture management as follows A Deflection This first line of defence against moisture water ingress A well designed and constructed Drainage Cavity system will deflect any potential water ingress or condensation away from the vapour permeable wall wrap and frame B Drainage A Drainage Cavity provides a second line of defence against condensation and or moisture water ingress allowing any build up behind the facade system to drain to the bottom of the wall section and out via the weep holes located in the cavity closer at the base of the wall Drying A Drainage Cavity allows air flow through the bottom of the cavity so any remaining moisture or condensatio
19. 75mm 50mm 220mm N 50mm 275mm 50mm 7 180mm el 50mm 5 2 5mm 50mm 3 2 5mm C2 3 2 5mm 50mm 275mm C3 2 5mm 50mm 1 80mm C4 180mm Minimum number of fixings per stud is based on the assumption of a 2270mm x 1 200mm panel size laid with the short edge up the stud To meet thermal amp acoustic requirements it is acceptable to use thicker panels than the minimum requirement and still satisfy the wind classification As described in the tables increased peak pressure occurs within 1200mm of the edges of walls NCC Volume One Class 2 to 9 Multi Residential Construction Design ultimate wind pressures calculated in accordance with AS NZS1170 2 structural Design Actions Part 2 Wind Actions where design net wind pressures do not exceed 7 6kPa for framing at 600mm maximum spacing or 7 99kPa for framing at 450mm maximum spacing This result is applicable to buildings less than or equal to 200m in height Wind pressures must account for such factors as site wind speed direction terrain height shielding and topography Table Three AS1170 2 Wind Loads For Buildings That Fall Outside AS4055 Maximum fixing spacings to satisfy design ultimate wind pressures kPa for stud spacing of 450mm amp 600mm are provided below Design Ultimate Stud Centres 450mm Stud Centres 600mm Wind Pressure AS1170 2 Min Panel Min Fixings Fixing Min Panel Min Fixings Fixing Not to
20. Cavity Timber Spacer Timber MGP10 Treated Pine H2 kiln dried or Metal Top Hat amp Cleat system to meet project specitic requirements Job size m2 of wall area to be installed Calculate total wall area including openings total m Calculate all openings doors amp windows total m Take total wall area minus all openings 2 total area to be installed Take m of area to be installed plus 10 divide by 2 72 to give you the number of Exsulite Kooltherm panels needed for the job ExsuliteKooltherm System Screws amp Disks Allow 9 of each per m or 25 of each per Exsulite Kooltherm Panel Exsulite Kooltherm System Screws 10G Class 3 sizes 105mm screws for 50mm panel with 20mm or 25mm Cavity Timber Spacer minimum 130mm screws for 80mm panel with 20mm Cavity Timber Spacer minimum 75mm screws for 50mm panel with Metal Top Hat Cavity Spacer minimum 100mm screws for 80mm panel with Metal Top Hat Cavity Spacer minimum Exsulite Breathable Wall Wrap Size 2 7m x 30m 82m Exsulite Starter Channel amp Angles Size 3 metre lengths measure lineal metres to where they are to be installed 5 for wastage Damp Course Size 300mm x 30m Foam Adhesive 1 x 750ml per 30m Flashing Tape for openings size 25m roll Selleys Nails Fast size 300ml allow 1 tube per 12 lineal metres of angles Selleys Flexi Seal Sealant size 600ml
21. Exsulite Thermal Facade System by amp x INSTAL v MAN UAL Ja ir it he sound buildin 5 applied c E J ule ing fdal Fm n is PECIFICATION 1 4 5 Water Japour Resena Weatherproofing amp Water Resistance Window Rev 4 Placement j Expansion Joints innel ith Weep Holes n accordance with tables 1 2 and 3 re Wind 29 5 S 5 4 e il 1 jf 16 17 17 29 30 30 30 30 30 31 31 31 31 33 ngo 34 36 Exsulite membrane topcoat Exsulite Texture coating Dulux AcraTex Green Render Sealer optional Exsulite Matrix Basecoat 165gsm Alkali Resistant Mesh Exsulite Matrix Basecoat Dulux Acralex AcraPrime XPS Primer Fixings Exsulite Kooltherm panel PU expanding foam adhesive External angle beads Starter channel with weep holes Cavity Spacers Breathable Wall wrap Timber or Steel frame Internal Plasterboard Exsulite Kooltherm Specification amp Installation Manual Version 1 February 2015 3 Section 1 Exsulite Kooltherm Thermal Facade System Specification Light weight wall cladding solutions for specifiers surveyors
22. Exsulite Matrix levelling coat with 165gsm alkali resistant mesh Exsulite Acrylic Texture coating to selected colour with a LRV gt 35 Selleys Flexiseal Joint Sealant or as approved by Dulux AcraTex Exsulite Membrane or Dulux AcraTex AcraShield Advance or AcraSkin weatherproof membrane top coat to selected colour with a LRV gt 35 1 4 2 Moisture Management Cavity System Exsulite Kooltherm Thermal Facade System helps moisture management through its cavity spacer amp non reflective Exsulite breathable water barrier wall wrap If condensation occurs moisture can efficiently drain from the cavity through the specially designed starter channels with weep holes that also provide airflow throughout the entire cavity Panels are fixed to the vertical cavity spacer battens top hats and the cavity drains vertically to the bottom starter channel with weep holes The cavity spacers battens top hats separate the cladding material from the timber framing It protects the timber frame from any occasional leaking by providing a gap allowing moisture to drain down the outside face of the wall wrap amp cladding and out through the base of the cavity Any remaining moisture within the cavity is able to dry due to the ventilation provided along the bottom of the cavity closer starter channel with weep holes Exsulite Kooltherm Specification amp Installation Manual Version 1 February 2015 1 4 3 Exsulite Kooltherm Panel Compo
23. Facade System K5 panel strength is greater than 150kPa at 10 deformation 1 4 5 Water Vapour Resistance Exsulite Kooltherm panel has been tested in accordance with AS 2498 5 1993 Methods of testing rigid cellular plastics Determination of water vapour transmission rate results being 34 34 g m 1 4 6 Weatherproofing amp Water Resistance The Kingspan Insulation Kooltherm Panel is tested to AS4284 2008 Testing of Building Facades It is ideal for use in areas of high humidity and does not contain nutrients that support the growth of mould amp mildew Exsulite Kooltherm Thermal Facade weatherproof finishing Exsulite Membrane AcraTex AcraShield and AcraSkin top coat by Dulux has been tested to AS4548 5 1999 Guide to Long Life coatings for concrete amp masonry Testing shows water transmission results of lt 19 m 24hr kPa and a vapour transmission rate of 51 9g m 24hr Refer to Dulux AcraTex product data sheets 1 4 7 Penetrations Normal industry standards should be followed for the installation of services into the building In order to avoid disrupting the layout services should be installed through the frame All penetrations through the ExsuliteKooltherm Thermal Facade System must allow for differential movement between the installed system and the services All penetrations a potential source of water ingress and spread of fire and are required be sealed with a Dulux Acralex or hea
24. ace mask safety goggles amp safety shoes Fine dust cuttings can be hazardous and personal protection equipment is recommended at all times All cutting should be conducted in well ventilated spaces Power tools should be up to date with test amp tagged label in accordance with state OH amp S regulations and should be fitted with dust extraction systems Refer to your local WorkCover or WorkSafe authority websites for your local OH amp S regulations prior to commencing work For all product handling procedures refer to the relevant product MSDS prior to commencing work alternatively contact Dulux on 13 23 77 or Kingspan 1300 247 235 Safety Information Cutting Outdoors Position the cutting area so that the wind will blow the dust away from workers Use a dust reducing circular saw equipped with vacuum extraction Drilling Machining Sanding Cutting Always wear a P2 mask when performing any activity which produces dust Keep other workers at least 3 metres from the operation Safety Tips Avoid using power saws indoors Only use saws fitted with vacuum extraction Always damp dust with water when sweeping Do not use grinders on this product Follow tool manufacturers instructions at all times P2 Respirator When performing any activity that produces dust always wear a P2 respirator mask If you have any concerns please contact a qualified industrial hygienist Manual Handling In order to pre
25. cted correctly to allow the fitting of the panels so that a true and accurate outside face is achieved the frame is out of tolerance it should be checked and straightened prior to fitting the panels 2 1 10 Timber Framing must comply with AS1684 National Timber Framing Code 2 1 11 Structural Bracing is to be of the Integral Wall Frame Exsulite Kooltherm Thermal Facade System does not contribute to the structural integrity of the frame All studs and noggings must be checked with a long straight edge for line and face accuracy to ensure the stud wall has a true and accurate outside face wall frames must be straight plumb amp level with a tolerance not more than 3mm to 4mm across a 3 metre span both vertically amp horizontally and be laterally restrained The panel will not straighten any warped frames and any warping may be visible at job completion 2 1 12 Metal Framing must comply with AS3623 Domestic Metal Framing A cold formed steel frame constructed in accordance with NASH Standard for Residential and Low rise Steel Framing Part 1 Design Criteria 2 1 13 Window Reveals Details Exsulite Kooltherm Panel Exsulite Cavity Spacer Window Reveal 50mm 25mm 65mm 80mm 20mm 90mm Be sure that the window reveals are sitting 25mm proud of the studs 2 1 14 Placement of Expansion Joints Good building practice provides for expansion joints at 3m height amp 6m max wide intervals and
26. d any gap that appears where different substrates meet and all other penetrations including plumbing and electrical conduit NOTE Joint Sealant can only be applied once the Exsulite Texture coating has been completed and before the Exsulite weatherproof membrane topcoat Exsulite Membrane Weatherproof protective top coat s Apply Exsulite Membrane or AcraShield Advance or AcraSkin in accordance with the relevant product data amp application data sheets NOTE Material consumption will vary depending on surface porosity and application technique allowance is to be made when estimating material quantities Spread rates nominated are theoretical maximum rates required to achieve the specified film builds for technical performance 2 3 1 Standards Of Finish Permissible Variation Design samples approved by the Contractor Builder are provided as indicative examples only and are not intended as final examples of onsite application The appearance of the finished system shall as near as practicable match the approved onsite sample in terms of installation details texture colour and uniformity Permissible variation and due regard shall be given for textural variation owing to multiple applicators onsite restraints scaffold limitations and angle side light or illumination accentuating surface irregularities 2 3 2 Care Precaution The manutacturers recommendations for installation and application as specified in the installati
27. d contractor approved flexible sealant Back blocking should occur for items such as downpipes brackets outside taps light fittings and other building services to the appropriate locations and apply flashing tape before panel installation Exsulite Kooltherm Specification amp Installation Manual Version 1 February 2015 Section 2 Exsulite Kooltherm Thermal Facade System Installation 2 1 0 Dulux Acralex Exsulite Trained amp Registered Installer The Building Code Australia BCA requires appropriate design and installation controls to quality any alternate solution and ultimate success requires a total systems approach integrating Design Componentry amp Installation Using Dulux AcraTex Exsulite Trained amp Registered Installer not only provides peace of mind but also ensures that the final build meets the design specification All Dulux AcraTex Exsulite Trained amp Registered Installer accreditation can be verified by their Exsulite Identification Card and Registration Number Project QA Process is a critical element of the Exsulite total system approach and the Exsulite installer network ensures total facade system compliance from start fo finish 2 1 1 Quality Control Dulux Acralex Exsulite Trained amp Registered Installers are required to participate in on going refresher training from Dulux AcraTex to maintain their installer accreditation and only a Dulux AcraTex Exsulite Trained amp Registered I
28. ding system Use only colours with LRV greater than 35 or consult Dulux AcraTex on the potential to use InfraCOOL Heat Reflective Coatings that can assist in keeping the surface cooler depending on your colour choice Consult your Dulux AcraTex Exsulite Representative for project specific requirements 1 3 8 Control Joints During the life of a building the building and materials that it is constructed from will move This movement is due to many factors such as structure movement thermal expansion amp contraction and differential movement between materials This movement unless relieved or accommodated for will impart stress on the building and construction materials and lead to cracking To accommodate for building movement relieve stresses and reduce the risk of cracking movement joints must be installed Articulation Joints make the walls more flexible by breaking it into a series of small areas Differential movement between the facade and adjacent structural elements need to be accommodated for via an A J joint Control Joints C J is an expansion joint to relieve thermal expansion or contraction between the Exsulite Kooltherm Thermal Facade System and other adjacent materials or structures Good building practice provides for expansion joints at 3m height amp wide intervals and at all building weak points or where potential cracking may occur e g in line with openings windows doo
29. e rating Rw Exsulite Kooltherm System 50mm Cavity System no wall batt Rw 37 2 dB Exsulite Kooltherm System 80mm Cavity System no wall batt 4 6 4 6 Rw 37z 2 dB Exsulite Kooltherm System 50mm Cavity System 2 0 Batt 5 0 4 8 Rw 41 2 dB Exsulite Kooltherm System 8Omm Cavity System 2 0 Batt 6 5 6 3 Rw 41 2 dB Exsulite Kooltherm System 50mm Cavity System 2 5 Batt 219 N A Exsulite Kooltherm System 80mm Cavity System 2 5 Batt 7 0 6 8 N A Smart Rate amp Acoustic Assessment Report can be provided upon request Note This report must account for variation of material R Value with mean temperature which will reduce summer total R Values and increase winter total R Values state that it is in compliance with AS NZS 4859 1 1 4 4 Impact Resistance Exsulite Kooltherm Thermal Facade System provides impact resistance to levels similar to that of other common materials Minor damage can be repaired by recoating with Dulux AcraTex coating system Additional impact resistance can be achieved with the additional layers of Exsulite alkali resistant mesh and Exsulite Matrix Basecoat Exsulite Kooltherm Thermal Facade System has been tested to AS NZS4040 5 1996 Methods of testing sheet roof and wall cladding resistance to impact sandbag for wall boards where the MGrade Styrene 1O5kPa compressive stress at 10 deformation Exsulite Kooltherm Thermal
30. e Two Class 1 and 10 buildings with wind loads to either AS NZS 1170 2 or AS 4055 Wind loads for housing for Wind Classifications N1 N2 N3 N4 N5 N6 and Cyclonic Regions C1 C2 C3 and CA within the AS4055 limitations less than 8 5m in height less than 16m in width and where the length does not exceed five times the width and roof pitch does not exceed 35 degrees fixed to either steel or timber frames Integration of System Design Components and Installation is delivered by a Dulux AcraTex Exsulite amp Registered Installer to ensure the build meets the design specification System installation and job quality control documentation is project managed by a Dulux Exsulite Trained amp Registered Installer to ensure all jobs are installed in accordance with Exsulite Kooltherm Thermal Facade System specifications The CodeMark Certificate of Conformity can be provided upon request 1 3 0 Design Considerations Compliance All design and construction must comply with the appropriate requirements of the current Building Code of Australia regulations The BCA is comprised of two volumes The volumes divide the types of building into two groups being Volume 1 Class 2 to Class 9 Buildings and Volume 2 Class 1 amp Class 10 Buildings Housing Provisions All the regulations for construction of buildings are contained in these volumes The ExsuliteKooltherm Thermal Facade System is CodeMark certified as a total int
31. e inspected and maintained Any damage to the texture coating needs to be recoated from edge to edge of the effected wall area to ensure texture and colour consistency accidental damage occurs please feel free to contact your local Dulux Acralex representative or phone Dulux AcraTex Customer Service on 1300 662 841 and they will provide the support or technical expertise required to help solve the problem Visual cracks may indicate underlying structural problems a professional should always inspect them Temporary repairs can be made to cracks by filling them with polyurethane paintable sealant until the inspection has been completed and permanent repairs undertaken During your inspections don t forget to check areas that are cold and dark such as behind heavy foliage Dirt provides the perfect nutrient for mould and algae growth The tiny roots that these organisms use cling to your walls will cause your texture coating to deteriorate very quickly if not regularly cleaned Recoating is recommended after a minimum of 10 years to rejuvenate the surface appearance This can be done by using Dulux AcraSkin protective membrane coating to a selected Dulux AcraTex colour which will protect from air pollutants water ingress and dirt accumulation to provide a new low maintenance surface 2 4 1 Health amp Safety Dulux Acralex recommends safe work practices at all times including the use of personal protective equipment f
32. e slightly countersunk in a concave recess on the outer surface of the panel and located so as it retains its original shape NOTE Care should be taken to not overdrive the fixing as this will strip the plastic disc and the fixing will be ineffective General fixings spacing of 275mm apart per stud at 25 per sheet with 50mm end distance at panel corner adds up to 1200mm panel width with stud spacings at 600mm maximum subject to panel span and thickness NOTE Where FRL wall is specified please refer to Dulux AcraTex for a FRL Project Specific Specification in accordance Exova Warrington Fire Certificate of Assessment prior to commencement of system installation 2 2 0 Installation Procedure 2 2 1 Exsulite Wall Wrap Install the Exsulite Breathable Wall Wrap with a staple gun to a properly prepared frame Appropriate head flashings over the top of the building wrap must be fitted before a compatible building wrap tape is used to seal the junction of the head flashing and building wrap If head flashings cannot be used an acceptable alternative flashing must be provided NOTE Wall Wrap is to have neither tears nor break points Followed by installation of the Exsulite Cavity Spacer fixed to each stud 2 2 2 Weatherproof Flashing Tape Install Dulux AcraTex supplied Flashing Tape aluminium bituminous selFadhesive flashing tape for weatherproofing around all windows frames including sills doors openings penetrations intersections con
33. each layer 2 2 8 Control Joints Good building practice provides for expansion joints at maximum 3m in height amp 6m wide intervals and at all building weak points or where potential cracking may occur e g in line with openings windows doors horizontally between floor levels and at all interfaces of different building construction materials and or as defined by the responsible Building Engineer The placement and correct installation of control joints is the responsibility of the Building Engineer Builder relative to the construction design Refer to Exsulite Kooltherm Construction Drawings Manual for control joint details 2 2 9 Corner Details Corners are butt joined and glued together with a suitable construction adhesive approved amp supplied by Dulux Acralex being Expanding PU foam adhesive Refer to Exsulite Kooltherm Construction Drawings Manual for corner details 2 2 10 Window Details The panel is fixed to the window head and sill as per section details with the reveals finished Exsulite angles should be fixed on all panel edges of doors and window reveals and thoroughly glued with construction adhesive and suitably covered with mesh and or reinforced Underneath all window sills leave a 12mm gap and fit external trims around window Fill the gap with an approved Dulux AcraTex construction foam adhesive and when dry cut off flush with the bottom of the window This will allow adequate fall on the window sill
34. eads and jambs All of which must be flashed prior to panel installation Cavity Spacer for Residential Application Timber MGP10 Treated Pine H2 Kiln Dried Dulux AcraTex approved PU expanding foam adhesive Cavity Spacer for Multi Residential Application Hat project specific designed system Damp Proof Course Dulux AcraTex XPS Primer for maximum adhesion to the Exsulite Kooltherm panel surface Exsulite Matrix levelling coat with 165gsm alkali resistant mesh Kooltherm K5 50mm or 80mm Panel Exsulite or Dulux AcraTex Acrylic Texture coating to selected colour with LRV gt 35 Exsulite Fixing Disk amp Class 3 10 Gauge Bugle Head Screws further than 1km of coastal areas Selleys Flexiseal Joint PU Sealant or as approved by Dulux Exsulite Starter Channel with weep holes Placed at the base of the cavity these function as a cavity closer to drain to the exterior at the bottom of the cavity Exsulite Membrane or Dulux Acralex AcraShield Advance or AcraSkin weatherproof membrane top coat to selected colour with a LRV gt 35 Corner angles and expansion beads installed prior to render application Exsulite Kooltherm Specification amp Installation Manual Version 1 February 2015 2 1 6 Exsulite Kooltherm Thermal Facade System Material Estimate Guide Exsulite Kooltherm Panel size 2270mm x 1200mm 2 72m
35. eck with plumbers and electricians and backblock for any wall mounted services as it is imperative that this is done prior to panel installation e Check that all eaves and flashings have been completed by the builder to the requirements of the projec specitication prior to commencement e Check that the wall wrap installed by the builder is of breathable type and if not advise the builder that the wrap is does not conform and will be required to be replaced with Exsulite wall wrap Check that correct windows with reveal sizes are fitted in accordance with the project specification Check that the outside of the reveal is flush with the external frame and 10mm proud on the inside allowing for the internal plasterboard Make sure that they have been fixed off correctly level and plumb e Check to ensure that the correct damp course has been installed to slab edge and termite treatment has been completed Where no damp course has been installed by others then it must be installed by the Dulux Acralex Exsulite Trained amp Registered Installer prior to the Exsulite wall wrap being installed 2 1 9 Framing ExsuliteKooltherm Thermal Facade System can be fixed to either timber of steel framing All frames should comply with the relevant building code and or Australian Standard for the type of construction Studs should be positioned to a maximum of 600mm centres with noggins at maximum of 1 350mm centres The frame must be constru
36. egrated facade system in compliance with the Building Code of Australia s performance criteria for 1 Structural performance wind resistance 2 Thermal performance 3 Damp and weatherproofing CodeMark certification provides building certifiers with the confidence that the system performs against these criteria and together with an Exsulite Kooltherm Certificate of Installation from a Dulux AcraTex Exsulite Trained amp Registered Installer confirms that the build meets the design specification at job completion System design should consider factors such as Purpose of structure Residential or Wall wrap vapour permeable for Multi Residential location similar to coastal or inland e Identify BCA performance requirements and any additional project specific needs Wind design actions subject local wind pressures Self draining cavity to allow drainage of any moisture ingress or condensation hat design for MultiResidential based on wind design actions condensation control amp weatherproofing Thermal R Value energy efficiency Fire Resistance Level FRL Acoustics Rw Ctr values Frame design and stud spacings timber or steel Minimum panel thickness based on wind design pressure Colour selection Light Reflective Value LRV gt 35 Additional wall insulation Control joint installation Exsulite Kooltherm Specification amp Installation Manual Version 1 February 201
37. exceed Thickness per stud Spacings Thickness per stud Spacings 7 99kPa 50mm 5 27 5mm 50mm 5 275mm equal to 4 0 5 0 50mm 275mm 50mm 6 220mm 6 0 50mm 6 220mm 50mm 7 180mm ZQ 50mm 7 180mm 50mm 8 160mm 7 0 50mm 7 180mm 50mm 9 50mm 7 99 50mm 7 180mm 1 3 2 Framing amp Substructure Timber framing must comply with AS 1684 National Timber Framing Code NOTE The timber used in the project must be of sufficient standard in terms of durability to meet the local conditions to which the timber will be exposed such as moisture or insect attack The force applied to the panels by the wind loading is transferred into the stud frame The frame must meet the requirements of the relevant Australian Standard The bracing and hold down requirements should be met by the frame design The allowance of shrinkage in timber framing in BCA 2006 Vol 2 Section 3 3 1 10 by providing gaps between frame and masonry should be adopted as a minimum 1 3 3 Metal framing must comply with AS 3623 Domestic Metal Framing cold formed steel frame constructed in accordance with NASH Standard for Residential and Lowrise Steel Framing Part 1 Design Criteria NOTE Structural bracing is to be part of the integral wall frame The Exsulite Kooltherm Thermal Facade System doesn t contribute to the structural integrity of the frame Exsulite Kooltherm Specification amp Installation Manual Version 1 February 2015 1 3 4
38. ficates amp Project Specific Specification can be supplied upon request Exsulite Kooltherm Specification amp Installation Manual Version 1 February 2015 1 4 0 System Performance Criteria Exsulite Kooltherm Thermal Facade System is a fully integrated system designed amp supplied by Dulux AcraTex and installed by an Dulux AcraTex Exsulite Trained amp Registered Installer in accordance with this Exsulite Kooltherm Specitication and Installation Manual Construction Drawings and in conjunction with individual product and application data sheets to all building code and Australian standard requirements The system integrates Kingspan Kooltherm K5 panel which has many decades of facade installation history in the Northern Hemisphere The Kingspan panel has a high performance fibretree rigid thermoset insulation core sandwiched between two layers of tissue autohesively bonded to the insulation core during manufacture The Exsulite Kooltherm Thermal Facade System comprises of Exsulite breathable wall wrap wall cavity spacers consisting of either a timber batten for residential application or project designed Top Hat fixing system for multi residential applications flashing tape to all openings amp penetrations Exsulite starter piece cavity closer with weep holes Exsulite fixing components Dulux AcraTex XPS Primer Exsulite Matrix Basecoat with alkali resistant mesh Exsulite Texture and Exsulite Membrane is the finishing wea
39. ion outside the standard approved system is used performance and or appearance of the system may be compromised As a consequence any warranties or guarantees whether express or implied may also be compromised Dulux AcraTex does not approve nor endorse the use of any non standard or non approved Dulux AcraTex Exsulite Kooltherm Thermal Facade System components Dulux AcraTex will not be responsible for the performance of a system with non standard or non approved components The use of any non standard or non approved components will compromise the system and no product warranty will be issued for the system Exsulite Kooltherm Specification amp Installation Manual Version 1 February 2015 5 1 2 0 Uses Exsulite Kooltherm Thermal Facade System by Dulux AcraTex provides a weatherproof cladding and insulation system for various Residential and Multi Residential applications It can also be installed to masonry amp concrete substrates in accordance with Dulux AcraTex project specific design fixing specification The Exsulite Kooltherm Thermal Facade is used as a light weight integrated facade system as an alternative to masonry systems in the Multi Residential and Residential Sector Multi Residential External Walls to NCC Volume One Class 2 to 9 buildings with wind loads calculated in accordance with AS NZS 1170 2 Fixed amp finished to either steel or timber frame construction Residential External Walls to NCC Volum
40. lant Install Selleys Flexiseal PU sealant around all window amp door frames all openings penetrations electrical meter boxes ducting floor amp joist penetrations the gap that appears between where different substrates meet and all other penetrations including plumbing and electrical conduit NOTE Joint sealant can only be applied once the Exsulite Texture coating has been completed and before the Exsulite Membrane weatherproof topcoat Refer to the Selleys Flexiseal Product Data Sheet for installation guidelines and to the Exsulite Construction Drawings for details 2 2 15 Quality Control During the installation works as per above the Dulux AcraTex Exsulite Trained amp Registered Installer will complete the Exsulite Certificate of Installation Installer Checklist to ensure job quality control This then forms part of the project QC documentation confirming that the Dulux AcraTex Exsulite Trained amp Registered Installer has installed in accordance with the Exsulite Kooltherm Thermal Facade System Specification amp Installation Manual and is handed over to the project principal 2 2 16 Weather amp Temperature Weather conditions can affect application and drying time Hot or dry conditions and limited working time can accelerate drying times and may require adjustments in the scheduling of work to achieve desired results different to working times in the shade Cool or damp conditions extend working amp drying
41. n can be absorbed by the vapour permeable wall wrap and allowed to dry out This drainage cavity is not ventilated to the outside air to an extent that would compromise the thermal performance of the systems 1 3 1 Design Ultimate Wind Pressures A qualified engineer is to be involved to determine wind pressures based on a buildings geographic location in accordance with the Australian Standard AS4055 for residential housing and AS NZS1170 2 for Multi Residential The effects of wind load around corners is considered in the design and information provided in this manual Refer to the wind load tables for recommended fixing requirements Design ultimate wind pressures must account for factors such as site wind speed direction terrain height shielding and topography These project specific considerations should be conducted amp approved by a qualified engineer at design stage prior to job commencement to ensure that the final system design is fit for purpose specific to the project and is designed to Australian Standards AS4055 or AS NZS1170 2 for wind loading requirements The wind load will determine the system specifications Torres Strait Islands Nhulunbuy C gine B Christmas Island Region B Region C Region aw 11 2 Cocos Islands 2 5 Region BORING x Moreton Region 2 Mareeba D 50 km 100 2 j ur Region C 190 8 Kununurra A fih Smo
42. nections heads amp jambs and must be flashed prior to panel installation It must cover both wall wrap amp substrate to ensure a closed weatherproof seal is achieved 2 2 3 Exsulite Starter Channel with Weep Holes The starter channel must be installed 10 15mm above flashings and 25mm above the base of the wall frame and needs to be set to a 1 in 12 fall to allow drainage of any moisture that may occur from the top Contact with the ground is not permitted and a 75mm gap must be maintained Exsulite Starter Channel _ e Aluminium Stainless Steel Clouts 30mm Timber Frame PVC Galvanised Clouts 30mm Aluminium Stainless Steel Screw With Twin Seal 25mm Steel Frame PVC Self Drilling 12 Gauge Metal Screw 20mm m 27mm install with a Aluminium Collated Drive Pin Powers Tarh tool Concrete T Round Head Nylon Nail Drive Anchor pe un knock NOTE No back filling Therefore there will be no capillary provided that the starter channel and coating are correctly installed The starter channel must be butt joined and sealed on the junction with an approved PU sealant Apply Selleys Liquid Nails Fast Grab to the inside base of the starter channel prior to installing the Exsulite Kooltherm panel to assist with adhesion of the panel to the starter channel Once tacked into position the screwing of the Exsulite Kooltherm Panels will secure the starter channel into its finishing position at the
43. nstaller can provide an Exsulite Certificate of Installation for job sign off 2 1 2 Handling and Storage Exsulite Kooltherm Thermal Facade System panels and fixing components should be stored elevated under cover and laid flat Edges and corners are to be protected at all times Standard panels 50mm and 80mm thick are manufactured with dimensions of 2270mm x 1200mm 2 72m per panel Dulux and Kingspan recommend that the specified Dulux finishing system be applied to the panels as soon as possible according to this specification However if installation is interrupted for any extended periods of time with the possibility of inclement weather the surface of all panels should be covered in order to provide them with protection If the panels are exposed to inclement weather they will need to dry prior to any AcraTex XPS Primer coat being applied Any panels exposed to an extended period of inclement weather should be replaced prior to installation 2 1 3 Resistance to Solvents Fungi amp Rodents The insulation core is resistant to short term contact with petrol and with most dilute acids alkalis and mineral oils However it is recommended that any spills be cleaned off fully before the panels are installed Damaged panels or panels that have been in contact with harsh solvents or acids should not be used The insulation core and facings used in the manufacture of Kingspan Kooltherm K5 EWB help resist mould and microbial gr
44. on amp application guidelines must be observed at all times The coating system must not be applied when rain is anticipated Adequate protection against rain and dust must be provided for the coating during application During periods of high temperature above 30 C work needs to be scheduled during the coolest part of the day and away from direct sunlight During periods of cooler temperatures 10 18 C work needs to be scheduled during the morning and completed with adequate time to allow the coating to form a coherent film before the temperature falls below 10 C this is particularly important on exposed southern elevations and may require assistance to dry Refer to individual product data sheets for each component for additional precautions Exsulite Kooltherm Specification amp Installation Manual Version 1 February 2015 2 4 amp The exterior coating should be cleaned regular basis This will help maintain your coatings aesthetic appearance and preserve your Dulux AcraTex Texture coating system Cleaning an annual basis will remove light soil as well as grime and airborne pollutants Coastal exposure will have a build up of salt contamination and a six month wash down is recommended All joint sealants should be regularly checked to ensure no cracking is evident to allow water ingress Where cracking is evident sealant will need to be replaced immediately The exterior can be
45. othed gt Ivanhoe imagon coasting B Derby Burketown Q ownsville C X J Broome Sk Port Hedland 0 Normanton C Se 0 Karratha D Collinsville Ww 222 Rockhampton 20 2 Marble Bar B e un PU Mos Onslow 0 Marble B 1A Alice Springs issa 4 Millstream SY Bundaberg C Region D 7 Exmouth Region 3 25 Carnarvon S VA Region B H Gascoyne Junction Region A4 5 pyCallytharra Springs Toowoomba ASE Kyogle 1B Corindi Norfolk island Mullewa e B our 6 MAL Morawa A Region A1 A 9 Woomera ad Howe Island Geraldton B 5 po iib 7 Region A is green Ceduna astle Head PERTH CANBERRA Esperance ADEL AIDE Region A2 Region B Wagga Wagga 35 35 c SOO SKM a Wollongong Albany Mount Gambier 70 km S 50 km R Region A5 e Ei State border Regions are marked with the letters within 70 km Sale A A1 to A5 B C and D of Melbourne GP O Geelong 40 Coastal Region boundaries A5 smooth lines set in from a smoothed Launceston coastline by 50 100 150 and 200 km Region A3 Islands within 50 km of the coast HOBART are the same Region as the adjacent coast a Australia 45 NCC Volume Two Class 1 amp 10 Residential Housing Construction AS4055 has a more simplified method of determining wind loads for domestic housing and a
46. owth and do not provide any food value to vermin The polythene packaging of Kingspan Insulation products should not at any stage be used for long term outdoor protection Panels should be stored inside a building If however outside storage cannot be avoided then the panels should be stacked elevated from the ground and covered with a polythene sheet or weatherproof tarpaulin It is the responsibility of the Dulux AcraTex Exsulite Trained amp Registered Installer to conduct a stringent quality check of Exsulite Kooltherm components prior to commencement of work to ensure the correct product items quantities and colours have been delivered to site in good order and are ready for use Dulux AcraTex will not be responsible for rectifying potential claims where no evidence of the above following installation and job completion is provided 2 1 4 No Component Substitution Design amp installations of any non standard or non approved Dulux AcraTex Exsulite Kooltherm system components will not be the responsibility of Dulux AcraTex and will void any product warranty or claims in relation to product performance 2 1 5 Exsulite Kooltherm Thermal Facade System Components Description Exsulite Breathable Vapor Permeable Wall Wrap Product Description Flashing Tape aluminium bituminous selFadhesive flashing tape for weatherproofing around all window frames including sills doors openings penetrations intersections connections h
47. rs horizontally between floor levels and at all interfaces of different building construction materials and or as defined by a responsible Building Project Engineer The placement and correct installation of control joints is the responsibility of the Building Engineer Builder in determining the placement and number of control joints to accommodate any anticipated movement Typical vertical control joints 1Omm 12mm wide and horizontal joints 1 2 wide filled with a suitable backing rod and approved flexible polyurethane sealant The project engineer has responsibility for determining where control joins are to be located 1 3 9 Bushfire Attack Levels BAL The NCC Vol 2 Part 3 7 4 covers the fire requirements for Bushfire Areas the AS3959 Construction of Buildings in Bushfire Prone Areas products tested to the requirements of 30 30 30 OR 30 30 tested to AS1530 4 can be used in all areas The Exsulite Kooltherm Facade System can be used in all BAL areas NOTE Test Certificates amp Project Specific Specification can be supplied on request 1 3 10 Fire Resistant Levels FRL The Exsulite Kooltherm Facade System has been tested to NCC requirements of C1 1 FireResisting Construction The Australian testing procedure for the Fire Resistance Levels FRL is AS1530 4 for 30 30 30 60 60 60 90 90 90 to which the Exsulite Kooltherm Facade System has been tested to by Exova Warrington Fire and i
48. s BAL wall details Acoustic Thermal colour It is the responsibility of the Dulux AcraTex Exsulite Trained amp Registered Installer to ensure that the substrate framework to which the Exsulite Kooltherm Thermal Facade System is to be installed is properly prepared in strict accordance with the relevant Australian Standards Building Code of Australia regulations and project specitic requirements Ensure that all preparation work prior to commencement of system installation has been completed by the relevant trades and that the substrate onto which the Exsulite Kooltherm Thermal Facade System is to be fixed to is ready for installation work to commence This includes installation of flashings to brickwork window amp door openings and penetrations Ensure wall levels have been checked amp signed off by a project site supervisor Where the installer is not satisfied with the substrate standard they are to advise the head contractor prior to commencement of work of these concerns Once the substrate has been rectified to a standard that meets the site agreed sample works only then can the work commence Some checks may include Check that the frame conforms to the relevant BCA regulations and Australian Standards as well as local standards for structural requirements including wind loadings and bracing Refer to the relevant Exsulite wind design criteria for panel amp fixing based on project specitic wind pressures e Ch
49. s at render stage Refer to Exsulite Kooltherm Construction Drawings Manual for window details 2 2 11 Parapet Detail Metal flashing is the preferred method for waterproofing and should be approved by the project consultant refer to drawings for preferred parapet detail 2 2 12 Balcony amp Terraces Where waterproofing is required this should be in accordance with the project specification and project principal Where alternative waterproofing detail is required please refer to the Exsulite Kooltherm Construction Drawings Manual for balcony details 2 2 13 Exsulite External Beads amp Angles Once all of the wall area has been installed it is important to go around with a straight edge and make sure that all external corners are plumb and true Rasp off using sandpaper to make sure that all edges are perfectly straight ready for installation for corner angles amp beading Install 3 5mm Exsulite external bead with Selleys Liquid Nails Fast down the centre of both sides and one run of glue in the junction of the bead Cut a 45 degree angle on both ends of the bead so it finishes flush with the soffit at the top and flush with the starter bead at the bottom Once fitted check it using a straight edge for straightness and wipe off excess glue protruding through slots in the bead NOTE External beads must be installed where the panels are installed adjacent to another substrate ie brick amp timber 2 2 14 Joint Sea
50. s suitable for use as a FRL Walling System The NCC Vol 2 Part 3 7 1 details the requirements in residential buildings for fire resistance for external walls where the external wall is less than 0 9m from an allotment boundary or less than 1 8m from a building on the same allotment In these circumstances a Fire Resistance Levels FRL wall is required from the outside of not less than 60 60 60 The Exsulite Kooltherm Facade System has been tested and is suitable for use as a FRL Walling System NOTE System installation requires that it is to be installed in accordance with the relevant Exova Warrington Certificate Of Assessment and Exsulite Koolterm Facade System Installation Manual amp Construction Drawings Dulux AcraTex does not approve nor endorse the use of any non standard or non approved FRL system components as outlined in the Exova Warrington Certificate Of Assesmet Where a Fire Rated Level FRL wall is specified please refer to Dulux AcraTex for a Project Specific FRL Specification in accordance Exova Warrington Fire Certificate of Assessment at project specification stage or alternative prior to commencement system installation Dulux AcraTex will not be responsible for the FRL system performance with non standard or non approved components are substituted with alternative components The use of any non standard or non approved components will compromise the FRL system performance criteria and void all warranty claims Test Certi
51. sition Exsulite Kooltherm panel is manufactured without the use of CFC HCFCs and has Zero Ozone Depletion Potential Zero ODP Test data is as stated by Kingspan Kooltherm K5 data sheet Product Testing Thermal Conductivity value BS EN 13166 2008 0 020 W m K Insulant thickness gt 45mm Compressive Strength BS 1 5 EN 826 1996 Typically exceeds 120kPa at 10 compression Water Vapour Resistance BS EN 12086 1997 gt 300 MN s g S EN 12086 1998 Fire Performance lgnitability AS 1530 3 Spread of Flame Flame Spread Index O Heat Release Smoke Smoke Release Development 4 Group Classification AS NZS 3837 Group 1 Surface Spread of Flame BS 476 Parts 6 amp 7 Class O NOTE Where Fire Rated Level FRL wall is specified please refer to Dulux AcraTex for a FRL Project Specific Specification in accordance Exova Warrington Fire Certificate of Assessment prior to commencement of system installation Exsulite Kooltherm Panel Product Data Thermal Conductivity at 23 C in accordance with 0 020 W m K for panel thicknesses gt 45mm AS NZS 4859 1 Product Material R Value at 23 C in accordance with AS NZS 4859 1 50mm R 2 5 80mm R 4 0 Exsulite Kooltherm Thermal Facade System Thermal R Value amp Acoustic Rating Smart Rate Assessment as a Total Walling System from Plasterboard to Coating Winter Summer Airborne sound R Value R Valu
52. ssists in determining the minimum panel thickness amp fixings requirements Design ultimate wind pressures calculated in accordance with AS 4055 Wind loads for housing wind classifications N1 N2 N3 N4 N5 N6 and for Cyclonic Regions C1 C2 C3 and CA where design net wind pressures do not exceed 7 6kPa for framing at 600mm maximum stud spacing or 7 99kPa for framing at 450mm maximum stud spacing AS4055 limitations require buildings designed to this standard to be less than 8 5m in height less than 16m in width where the length does not exceed five times the width the roof pitch does not exceed 35 degrees Exsulite Kooltherm Thermal Facade System shall be fixed to either steel or timber frames Class 1 and 10 buildings that fall outside this scope require wind pressures to be calculated from AS1170 2 including regions of high pressures at corners General vertical fixing spacing is 275mm 5 fixings at 275mm spacings and 50mm edge distance top amp bottom for a 1200mm wide panel for most common applications in low wind suburban locations Exsulite Kooltherm Specification amp Installation Manual Version 1 February 2015 Table For Wind Classification AS4055 Minimum Panel Thickness and Fixings Wall Areas Over 1200mm Away From Corners Wind Stud Centres 450mm Stud Centres 600mm Classification Min Panel Fixings Fixing Min Panel Fixings Fixing
53. the risks of mixed componentry being used with uncontrolled installation Exsulite Kooltherm Thermal Facade System by Dulux AcraTex offers a single supply source for the Total Facade System from wall wrap fo the weatherproofing coating Exsulite Kooltherm Thermal Facade System is a light weight exterior walling system that provides both weatherproofing amp insulation of the building envelope and helps to eliminate thermal bridging that can occur through the wall frame Exsulite Kooltherm Thermal Facade System is designed as a total integrated lightweight nondoad bearing facade system to deliver a weatherproof external building envelope with a self draining cavity for moisture management whilst providing high thermal performance R value The Exsulite Kooltherm Thermal Facade System is CodeMark certified as a total integrated facade system Comprising of Exsulite breathable wall wrap wall cavity spacers with timber battens for residential applications or a project designed Top Hot fixing system for Multi Residential applications Kooltherm K5 Phenolic Panel flashing tape to all openings amp penetrations Exsulite starter piece covity closer with weep holes Exsulite fixing components Dulux AcraTex XPS Primer Exsulite Matrix Basecoat with alkali resistant mesh Exsulite Texture and Exsulite Membrane weatherproof protective coating or an approved Dulux Acralex texture and AcraTex membrane topcoat system designed amp supplied by Dulux
54. therproof coating system Unless otherwise specitied or approved all Exsulite system components amp coating materials used must be Dulux Exsulite products as listed in the next section All system components amp coating products are to be delivered to the job in unbroken containers bearing the brand name and name of the manufacturer and must be subject to the installers inspection amp contirmation of correct materials received in good order 1 4 1 Exsulite Kooltherm Thermal Facade System consists of Exsulite BreathableVapour Permeable Wall Wrap Cavity Spacer for Residential Application Timber MGP10 Treated Pine H2 Kiln Dried Cavity Spacer for Multi Residential Application Top Hat project specific designed system Damp proof course e Kooltherm K5 50mm or 80mm Panel Exsulite fixing disk amp Class 3 10 gauge bugle head screws further than 1km of coastal areas Exsulite Starter Channel with weep holes Corner angles and expansion beads installed prior to render application Flashing Tape aluminium bituminous self adhesive flashing tape for weatherproofing around all window frames including sills doors openings penetrations intersections connections heads and jambs All of which must be flashed prior to panel installation Dulux approved PU expanding foam adhesive Dulux Acralex XPS Primer for maximum adhesion to the Exsulite Kooltherm panel surface
55. times and may require added measures of protection against wind dust dirt and rain Refer to product data sheets for application conditions amp guidelines prior to work commencing Exsulite Kooltherm Specification amp Installation Manual Version 1 February 2015 2 3 0 Dulux Acralex Finishing System Application Dulux AcraTex XPS Primer All surfaces must be cured clean sound and free of all contaminates such as dust form oils release agents mortar splashes mould and algae Metal and tie wire on surfaces must be removed or treated against corrosion Apply AcraPrime XPS by roller or brush at 8 10 m to give a minimum DFT of 15 20 microns Applications must form a continuous Adhesive Key Coat film to maximise adhesion Exsulite Matrix Basecoat with Exsulite Mesh In a clean 15 litre pail add 3 5 4 0 litres of clean water slowly add Exsulite Matrix Basecoat while stirring until a cream trowelable paste is formed Apply the basecoat layer of Exsulite Matrix Basecoat by stainless steel trowel to fully cover the panel surface with 2 3 mm cover Refer to the Exsulite Matrix Basecoat data sheet amp application data sheet for full details Approximate material usage of 1 7kg m mm will vary with application technique The first pass of Exsulite Matrix Basecoat over XPS primer requires the addition of Dulux Acra Bond to promote additional adhesion Embed Exsulite Reinforcement Mesh into
56. titution allowed of non approved alternative fixings Fixings should be started at 50 mm from the bottom of the first sheet at ground level Typically 5 fixings are used per stud line subject to wind classification The panel is required to be fixed to the stud Extra supporting back blocking members will be required at panel joints so each panel is individually fixed Panels must not protrude beyond the cavity spacer stud by more than 150mm Back blocking requires full stud width NOTE Adhesive fixed back blocking amp merchant grade timber is not allowed On a single story frame measure 1210mm up from the rebate at both ends of the wall and flick a chalk line Starting from the corner fit your sheet horizontally and work to your starting line On a double story frame first of all you must complete points 2 2 3 amp 2 2 4 above relevant to the project by measuring 121 up from the rebate and fixing off the bottom row of panels Measure up from the top of the flooring 1 200mm from both ends and chalk a line Fix the first run of panels along this line Work upwards to the soffit then from the bottom of the first run of sheets measure down 1205mm and chalk a line and fix that run of sheets fo the line leaving a 5mm gap between the two runs of sheets for expansion Then work down towards the bottom row of sheets that have been fitted to the starter channel Once the first run of panels have been fitted start the second run by
57. ulite Kooltherm Specification amp Installation Manual Version 1 February 2015 2 1 15 Fixing Guide Exsulite Kooltherm Thermal Facade System Residential Housing Vol 2 Class 1 amp 10 Frame Panel Cavity Starter Channel Minimum Thickness Spacer weepholes Screw Length alee eee 5 20mm 7 105 3 10 Bugle Needle Point Timber 50mm 25mm 5mm 105mm 3 10 Bugle Needle Point 80mm 20mm 100mm 130mm 3 10 Bugle Needle Point Hose 25am sua ee eats Poner use up to O 55mm steel n Bugle Needle Point f 80mm 25mm 105mm 130mm 3 jp eese a use up to O 55mm steel NOTE Needle point screws used for timber frame fixing applications can be used in light gauge steel frame fixing depending on the length of the screw A minimum of 3 full threads need to be screwed through the steel The needle points can pierce through 0 55mm steel Where heavier gauge steel is used and exceeds 0 55mm a self drilling metal screw is required to be used Within 1km of a coastal environment Class 4 screws must be used This is deemed as medium to severe marine exposure in accordance with AS 3566 Exsulite fixings Class non coastal areas 10 Gauge screws with an Exsulite 40mm fixing disk is driven into the middle of the stud until the disk just penetrates the panel face When fastened correctly the screw head and the 40mm fixing disk should b
58. vent musculoskeletal injuries manual handling of heavy panels should be kept to a minimum and where possible mechanical lifting devices should be employed Where mechanical assistance is not possible more than one person should assist lifting when necessary Weights lifted by individuals should be kept to a minimum Employees should be trained in manual handling techniques A clean work site and good planning will assist in good general safety on site Protective Clothing The wearing of suitable clothing such as long sleeves and trousers and appropriate gloves is recommended Exsulite Kooltherm Specification amp Installation Manual Version 1 February 2015 35 5412 0714 Exsulite Thermal Facade System by Certificate of Installation The Exsulite Certificate of Installation is for use by a Exsulite Trained amp Registered Installer as a Quality Control Document to certify that the specified Exsulite system has been installed in accordance with the Exsulite Installation procedures as set out in the Exsulite Specification amp Installation manual Exsulite Construction Drawings manual amp Dulux specification The Certificate of Installation is used to record on site work procedures amp substrate standards for the Installation of the Exsulite Thermal Facade System and the Application of Dulux AcraTex finishing system signed off amp handed over at job completion The Exsulite
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