masonry design guide

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Masonry Design GuideSTRUCTURAL, FIRE AND ACOUSTICS VICTORIA BOOK 1

www.boral.com.au/masonry

Updated February 2009

Victoria Book 1 A

PAGE

A B

Introduction

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2 Fast Find Product & Application Guide . . . . . . . . . . . . . . . . . A3

Products @ a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4 About This Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6

Structural DesignMovement (Control Joints) . . . . . . . . . . . . . . . . . . . . . . . . . . B6 Energy Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7 Reinforced Masonry Lintels. . . . . . . . . . . . . . . . . . . . . . . . . . B8 Design of Core Filled & Steel Reinforced Masonry Retaining Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . B9 Structural Design Guidelines for Core Filled & Steel Reinforced Masonry Retaining Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . B11

Introduction to the Structural Design of Masonry . . . . . . . . B2Robustness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2

Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5 Bending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5 Shear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6 Durability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6

C

Fire DesignEffect of Chases on Fire Rated Masonry . . . . . . . . . . . . . . . C4 How to Select Boral Masonry Units for Fire Rated Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5 Structural Adequacy Selection Graphs & Tables . . . . . . . . . . C8

Masonry Design for Fire Resistance (FRL) . . . . . . . . . . . . . . C2 Masonry Design for Structural Adequacy FRL . . . . . . . . . . . C2 Masonry Design for Integrity FRL . . . . . . . . . . . . . . . . . . . . . C3 Masonry Design for Insulation FRL . . . . . . . . . . . . . . . . . . . . C4

Index to Structural Adequacy Selection Graphs . . . . . . . . . . C8

D

Acoustic DesignGuidelines for Optimum Performance. . . . . . . . . . . . . . . . . . D4 Acoustic Performance On-site. . . . . . . . . . . . . . . . . . . . . . . . D5 Home Cinema Rooms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6

Acoustic Performance Ratings (STC & Rw) . . . . . . . . . . . . . . D2 Designing Masonry Walls for Acoustic Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3

E

Fire & Acoustic SystemsScoria Quick Brick (SB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . E10 FireLight Quick Brick (FL). . . . . . . . . . . . . . . . . . . . . . . . . . . E12

Finding Acoustic Systems & Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2 Fire Rated Block - Scoria Blend (SB) . . . . . . . . . . . . . . . . . . . E4

Acousticell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E14 Standard Ash Grey Block (AG) . . . . . . . . . . . . . . . . . . . . . . . . E6 Concrete-Basalt Bricks (B) . . . . . . . . . . . . . . . . . . . . . . . . . . E8

The information presented herein is supplied in good faith and to the best of our knowledge was accurate at the time of preparation. No responsibility can be accepted by Boral or its staff for any errors or omissions. Users are advised to make their own determination as to the suitability of this information in relation to their particular purpose and specific circumstances. Since the information contained in this document may be applied under conditions beyond our control, no responsibility can be accepted by us for any loss or damage caused by any person acting or refraining from action as a result of this information.

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Victoria Book 1 A

The quickest way to find a Boral Masonry Structural, Fire or Acoustic Wall Solution. Simply follow the FAST FIND GUIDE on the right hand side of the table.

BORAL MASONRY BLOCK & BRICK PRODUCTSNLB = Non-loadbearing LB = Loadbearing

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Scoria Blend (SB) Standard Ash Grey Block (AG) Core Filled Block Acousticell Designer Block Concrete-Basalt Brick (B) Scoria & FireLight Bricks

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1

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Best performance is achievedwith plasterboard lining

Please refer to MDG Book 2, BoralMasonry Block & Brick Guide

For technical support and sales office details please refer to the outside back cover

BORAL MASONRY DESIGN GUIDE

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Fast Find a Boral SolutionSelect your application criteria from the top of the table Go straight to the section letter and page number indicated at the intersection of product rows and application columns (e.g. Section E, Page E6 in this example)

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Victoria oo Victoria Book Victoria Book 1 A t

Boral Engineered Blocksfor Structural, Fire & Acoustic Wall Systems

Standard Ash Grey Block (AG)Hollow Concrete Block suitable for loadbearing and non-loadbearing applications. Basalt content is >45% allowing the higher slenderness ratios of AS3700, table 6.1 to be used.

Scoria Blend High Fire Rated BlockManufactured in a unique Scoria Blend material offering High Fire Performance, ideal for high rise buildings with reinforced concrete frames or portal frame buildings. Suitable for non-loadbearing walls. If used for light load construction, the lower slenderness ratios of Designer Block apply.

Back-up BlockAsh Grey Concrete Block in 162mm height (equivalent to 2 courses of standard brick). Designed for cost effective construction of the back-up leaf in face brick veneer walls.

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Victoria Book Victoria B ok Victoria Book 1 A Bo

Boral Engineered Bricksfor Structural, Fire & Acoustic Wall Systems

Core Fill BlockAsh Grey Concrete Block or Designer Block coloured and textured finishes for reinforced retaining walls and loadbearing walls requiring increased robustness.

FireLight Quick Brick (FL)FireLight Quick Brick for non-loadbearing fire and/or acoustic systems where weight saving is important. Quick Brick format (162mm height) for faster, more cost effective construction.

AcousticellEngineered block for premium sound absorption and attenuation of industrial and commercial noise.

Scoria Quick Brick (SB)Medium weight Scoria Quick Brick for nonloadbearing fire and/or acoustic systems. Quick Brick format (162mm height) for faster, more cost effective construction.

Concrete-Basalt Brick (B)Standard Size and Quick Brick (162mm height) in Concrete-Basalt material for good fire performance and loadbearing characteristics.


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Victoria Book 1 A

Boral Masonry Commercial Construction SolutionsBoral Masonry Victoria offers a comprehensive range of proven products and systems including Masonry Blocks, Masonry Bricks, Fire and Acoustic Wall Systems, Segmental Block Retaining Walls and Segmental Paving Products.

Whats in this GuideThe Boral Masonry Structural, Fire & Acoustic guide (this book), provides a summary of important design information for structural, fire and acoustic masonry applications and an extensive range of fire and/or acoustic systems to cater for many design scenarios.

This guide has been prepared as a comprehensive Boral Product Reference Guide. It does not attempt to cover all the requirements of the Codes and Standards which apply to masonry construction for structural, fire or acoustic applications. All structural, fire and acoustic detailing should be checked and approved by appropriately qualified engineers before construction. Boral reserves the right to change the contents of this guide without notice. Please note that this guide is based on products available at the time of publication from the Boral Masonry Victorian sales region. Different products and specifications may apply to Boral products sourced from other regions.

Additional Assistance & Information Contact Details: Please refer to the outside back cover of this publication for Boral Masonry contact details. Colour and Texture Variation: The supply of raw materials can vary over time. In addition, variation can occur between product types and production batches. Also please recognise the printed colours in this brochure are only a guide. Please, always ask to see a sample of your colour/texture choice before specifying or ordering. Terms and Conditions of Sale: For a full set of Terms and Conditions of Sale please contact your nearest Boral Masonry sales office.

Section B Structural DesignSection B discusses design issues relevant to the selection of Boral Masonry products for structural adequacy, based on appropriate wall design criteria.

Section C Fire DesignSection C discusses the relevant design processes for the selection of Boral Masonry Products for fire rated applications. This section includes a step-by-step selection guide and a series of selection graphs which can greatly speed up the preliminary selection and comparison of suitable designs and products.

Section D Acoustic DesignSection D provides a brief overview of acoustic rating methods, relevant considerations for acoustic design and guidelines for good acoustic design and detailing methods.

Section E Fire & Acoustic SystemsSection E of this guide provides an extensive range of fire and acoustic wall system solutions supported by test results and acoustic performance estimates.

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BORAL MASONRY


Masonry Design GuideSTRUCTURAL, FIRE AND ACOUSTICS VICTORIA BOOK 1 B STRUCTURAL DESIGN

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B

Victoria Book 1 B

Introduction to the Structural Design of MasonryThe following design information is based on Australian Standard AS3700:2001 Masonry structures. Reference to Clauses and Formulae are those used in AS3700. This information is provided as a guide only to the processes involved in designing masonry. All masonry should be designed by a suitably qualified structural engineer.

Legend to Symbols used in Robustness Calculations: H = the clear height of a member between horizontal lateral supports, in metres; for a member without top horizontal support, the overall height from the bottom lateral support, in metres the minimum thickness of the member, in metres in cavity-wall construction, the minimum thickness of the thicker leaf

=

tr

= =

RobustnessAS3700, Clause 4.6.1 requires walls to have an adequate degree of Robustness. Robustness is a minimum design requirement, and may be overridden by Fire, Wind, Snow, Earthquake, Live and Dead Load requirements. kt In robustness calculations, there are height, length, and panel action formulae. By reworking the standard formulae provided and inserting known data, it is possible to determine whether a chosen design and Boral masonry product will provide adequate robustness. Should the initial product/design chosen not provide a suitable solution, then a thicker Boral masonry product more suited to the application should be evaluated, or alternatively, add extra restraints or reinforcement. The following section is laid out with AS3700 formulae and explanation in the left hand column, while worked examples can be found in the adjacent right hand column.

or two thirds the sum or thicknesses of the two leaves, whichever is greater, in metres or in diaphragm wall construction, the overall thickness of the wall, in metres = a thickness coefficient, values as given in AS3700 Table 7.2 (see the end of this section) robustness coefficient, values as given in AS3700 Table 4.2 (see end of this section) for edge restraints at top, bottom and vertical sides (either separately or in combination) the clear length of the wall between vertical lateral supports, in metres; or for a wall without a vertical support at one end or at a control joint or for walls containing openings, the length to that unsupported end or control joint or edge of opening, in metres.

Cv,Ch =

Lr

=

=

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Victoria Book 1 B

Formulae and ExplanationIsolated Piers Formula 4.6.2 (1) is used for isolated piers. Masonry with a length less than one fifth of its height and free ends, is considered to be an isolated pier. Formula (1) is: H tr Cv

Worked ExamplesAim: To determine the Maximum Wall Height of an Isolated Pier

Example 1: Minimum wall thickness tr = 230mm A single leaf structure, unreinforced, then Cv = 13.5 H 0.23 x 13.5 H 3.105m (maximum wall height) Example 2: Minimum wall thickness, tr = 140mm A single leaf structure, reinforced, then Cv = 30 H 0.14 x 30 H 4.200m (maximum wall height)

By re-working formula (1), the maximum height for an isolated pier can be determined: H tr x Cv Where Cv is obtained from AS3700 Table 4.2 (Refer to Page B5).

Formulae and Explanation

Worked Examples

Wall with Free Ends Formula 4.6.2 (2) is used for walls spanning vertically (i.e. wall with free ends). Formula (2) is: H Cv kt x tr

Aim: Criteria:

To determine the Maximum Height of a Wall with Free Ends Minimum wall thickness, tr = 110mm kt = 1 (wall without piers)

By re-working formula (2), the maximum wall height is: H kt x tr x Cv. Where kt is obtained from AS3700 Table 7.2 (Refer to Page B5) or By re-working formula (2), the minimum wall thickness is: kt x tr H Cv

Example 1: If wall is freestanding, then Cv=6 (must be checked by an engineer for wind loads etc.) H 1.0 x 0.11 x 6 H 0.660m Example 2: If wall is laterally restrained along its top, then Cv=27 H 1.0 x 0.11 x 27 H 2.970m Example 3: If wall is laterally restrained along its top and supports a slab, then Cv=36 H 1.0 x 0.11 x 36 H 3.960m


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Formulae and ExplanationWall with Restraint at End or Ends Formula 4.6.2 (3) is for walls spanning horizontally [i.e. restrained end(s)]. Walls that have one or both ends laterally restrained and L Ch tr i.e. L tr x Ch Where Ch is obtained from AS3700 Table 4.2. (Refer to Page B5) H tr = no limit

Worked ExamplesAim: To determine the Maximum Length of a Wall with Restraint at End or Ends Wall thickness tr = 110mm

Criteria:

Example 1: If wall is restrained along one end, then Ch = 12 L 0.11 x 12 L 1.320m Example 2: If wall is restrained along both ends, then Ch = 36 L 0.11 x 36 L 3.960m NOTE: If the wall exceeds the permitted length, then a thicker wall is required or formula 4.6.2 (4) governs and H will be limited. (See below).

NOTE: This means that although the wall height is not limited by its thickness, the wall length is limited. Stair wells and chimneys work to this formula.

Formulae and ExplanationWall with Restraint at Top and End or Ends Formula 4.6.2 (4) is for walls spanning vertically and horizontally (i.e. with restraint along the top and one or two ends) and length L tr x Ch. Where Ch is obtained from AS3700 Table 4.2. (Refer to Page B5) Formula (4) is: H tr Cv + Ch Lr Chtr

Worked ExamplesAim: To determine the Maximum Height of a Wall with Restraint at Top and End or Ends Wall thickness tr = 110mm Wall length = 2m

Criteria:

Example 1: If wall supports a slab, then Cv = 36, and if restrained along one end, then Ch = 12 H 12 ( 36 + 2 12 x 0.11 ) 0.11

By re-working formula (4), the maximum wall height is: H

( C + L CC t ) t v h r hr

r

H 5.9m

NOTE: Control joints, and openings greater than one fifth of wall height are treated as free ends unless specific measures are taken to provide adequate lateral support.

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Victoria Book 1 B

Table B1 (Extract from AS3700 : Table 4.2) Cv Top and bottom edge restraints to wall panelsFree

StrengthCompressive strength is resistance to load, measured by the amount of pressure to crush a masonry unit. The pressure, usually measured in megapascals (MPa), is the force in kilonewtons (kN) x 1000, divided by the loaded area in square mm. Unconfined compressive strength is compressive strength, multiplied by an aspect ratio, Ka (see AS4456.4, Table 1). The unit height divided by its thickness is used to determine the aspect ratio. A solid brick will give a lower compressive strength if crushed on its end rather than on its flat, as normally laid. In theory, the aspect ratio will convert both tests to the same unconfined compressive strength. The strength of hollow blocks is calculated by dividing the force by the face shells only. A 90mm hollow and 90mm solid block are both 10MPa, but since the area of the face shells on the hollow block is about half the area of the solid block, the hollow will only carry half the load of the solid. Characteristic Unconfined Compressive Strength of masonry UNITS is uc. uc is the average of crushing forces divided by loaded areas, multiplied by the aspect ratio, minus the standard deviation x 1.65. Characteristic Compressive Strength of a masonry WALL is m. m is the square root of uc, multiplied by Km (a mortar strength factor), multiplied by Kh (a factor for the amount of mortar joints) as per AS3700, 3.3.2. The Km factor is 1.4 for M3 mortar on solid and cored units and is 1.6 for the face shells of hollow units. For the richer M4 mortar it is 1.5 (Table 3.1). The Kh factor is 1 for 76mm high units with 10mm mortar beds and is 1.3 for 190mm units with 10mm mortar beds. In other words, a wall of 190mm high units is 30% stronger than a wall of 76mm high units of the same uc.

Vertically unreinforced

Vertically reinforced or prestressed 12 with reinforcement continuous into support. Otherwise 6.

6SUPPORT

Load other than concrete slab or no load Lateral SupportSUPPORT

27

36

Concrete Slab Lateral SupportSUPPORT

36

48

ISOLATED PIERSLateral SupportSUPPORT

13.5

30

Edge restraints on vertical sides of wall panelsSUPPORT

Ch Horizontally unreinforced Horizontally reinforced or prestressed 24 with reinforcement continuous past support. Otherwise 16

12

SUPPORT

SUPPORT

36

48

Table B2 (Extract from AS3700 : Table 7.2) Thickness Coefficient (kt) for Walls Stiffened by Monolithically Engaged Piers Pier Spacing/Pier Width (Refer to Note 1) 6 8 10 15 20 or more Thickness Coefficient (kt) Pier Thickness Ratio (twp/t) 1 2 3 1.0 1.4 2.0 1.0 1.3 1.7 1.0 1.2 1.4 1.0 1.1 1.2 1.0 1.0 1.0

BendingCharacteristic Flexural Tensile Strength is mt. Masonry is good in compression but poor in tension. Mortar joint strength is generally zero or 0.2MPa for loads from wind, earthquake etc. Higher bending forces may require masonry to be partially reinforced.

NOTES: 1. Pier spacing is taken as the distance between centrelines of piers. 2. Linear interpolation may be used.twp tWall Leaf

Pier Width Pier Spacing


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Victoria Book 1 B

ShearCharacteristic Shear Strength is ms. At damp course, it is zero unless tested. Elsewhere, mortar joints have ms values of between 0.15 and 0.35MPa. As with tension, high shear loads may require partially reinforced masonry.

Even if they are well away from the coast, they may be subjected to acidic or alkaline soils. In any case, moisture in the ground is absorbed into the masonry, creating an environment ideal for bacteria, which feeds lichens and algae which can eventually be detrimental. AS/NZS4456.10 gives methods of testing and definitions for durability (salt tests). An alternative to testing is a history of survival in a marine environment. Concrete masonry has been used for Surf Club construction around Australia for decades.

DurabilityMasonry designed for Durability is deemed to satisfy when it meets the requirements of AS3700 Section 5, which details what areas require Exposure, General Purpose and Protected grades. Assessment of these grades is defined in AS/NZS4456.10 Resistance to Salt Attack. AS3700 defines the usage of each of these grades as: Protected Grade (PRO) Elements above the damp-proof course in non-marine exterior environments. Elements above the damp-proof course in other exterior environments, with a waterproof coating, properly flashed junctions with other building elements and a top covering (roof or coping) protecting the masonry. General Purpose Grade (GP) Suitable for use in an external wall excluding severe marine environment. Exposure Grade (EXP) Suitable for use in external walls exposed to severe marine environments, i.e. up to 100m from a surf coast or up to 1km from a non surf coast. The distances are specified from mean high water mark. Mortar mix requirements for durability are detailed in AS3700 Table 10.1. Mortar joints must be ironed. Salt attack is the most common durability problem. The salt in salt water is in solution. It can be absorbed into masonry or at least, its mortar joints. When the water evaporates, it migrates towards the outside face taking the salt with it until the amount of water left is saturated. It can no longer hold all the salt in solution and salt crystals begin to form. The salt crystals then take up space, sometimes more than the texture of the masonry will allow. The crystal then pops a piece of the outer surface off to make room and salt attack begins. Walls below damp course also require greater durability.

MovementIn general, concrete units contract as they cure while clay units will expand. They both expand as they take up water and contract as they dry. They both expand as they get hot and contract as they cool.

Curing Movement in Concrete UnitsAS/NZS4456.12 gives methods for determining coefficients of curing contraction and coefficients of drying contraction for concrete units. Drying Contraction The drying contraction test on masonry units is an indication of their maximum amount of movement from totally saturated to ambient dry. A typical result is 0.5mm/m but can be as high as 1mm/m for lightweight units that are more absorptive. For example, a drying contraction of 0.5mm/m, in an 8m panel of masonry, has the potential to shrink 4mm from saturated condition to dry.

External Control JointsAS3700, Clause 4.8 requires control joint spacing to limit panel movement to: 10mm maximum for opening of control joints, 15mm maximum for closing of control joints, and 5mm minimum when closed. The Australian Masonry Manual recommends control joints at 8m centres for concrete units, 6m centres for lightweight ( 1500 2200 Spacing S(mm) 600 400

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BORAL MASONRY


Masonry Design GuideSTRUCTURAL, FIRE AND ACOUSTICS VICTORIA BOOK 1 C FIRE DESIGN

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Victoria Book 1 C

Masonry Design for Fire ResistanceFire Resistance Levels (FRL)FRL come from the Building Code of Australias (BCA) tables for Type A, B or C construction. The Type of construction depends on the Class of building and the number of stories or floors. There are 3 figures in the Fire Resistance Level. eg: FRL 60/120/120 meaning Structural Adequacy for 60 minutes / Integrity for 120 minutes / Insulation for 120 minutes.

Masonry Design for Structural Adequacy FRLLegend for the following formulae Srf = the slenderness ratio in design for fire resistance for structural adequacy. See table C2 on page C7 for maximum Srf. avf = 0.75 if the member is laterally supported along its top edge. = 2.0 if the member is not laterally supported along its top edge. H = the clear height of a member between horizontal lateral supports; or = for a member without top horizontal support, the overall height from the bottom lateral support. t = the overall thickness of the member cross-section perpendicular to the principal axis under consideration; for members of cavity wall construction, the wall thickness assessed is in accordance with Clause 6.3.2.1(a) and (b).

Structural AdequacyThis governs the wall height, length, thickness and restraints. Masonry unit suppliers do not control the wall height, length or restraints, therefore do not control Structural Adequacy. However, information that is useful in the design of masonry walls is the maximum Slenderness ratio (Srf). Boral Masonry provides Srf information for all of its masonry units, and its use is discussed in more detail later.

IntegrityThis is the resistance to the passage of flame or gas. To provide integrity, masonry walls must be structurally adequate because cracks that form when it bows can allow flame through the wall. Since the masonry unit supplier does not control Structural Adequacy, they cannot control integrity either.

ah = 1.0 if the member is laterally supported along both its vertical edges. = 2.5 if the member is laterally supported along one vertical edge. L = The clear length of a wall between vertical lateral supports; or = for a wall without vertical support at one end or at a control joint or for walls containing openings, the length to that unsupported end or control joint or edge of opening. NOTE: A control joint in a wall, or an edge to an opening in a wall, shall be regarded as an unsupported edge to the wall unless specific measures are taken to provide adequate lateral support at the edge. Structural Adequacy may be overridden by design for robustness; wind; live or earthquake loads. A fire on one side of a wall will heat that side, making it expand and lean towards the fire. When the lean or bow reaches half the thickness of the original wall, the wall becomes structurally inadequate. The formulae in AS3700, Clause 6.3.2.2 limits masonry panel size, depending on its restraints and thickness.

InsulationThis is resistance to the passage of heat. Insulation is governed by the type and thickness of the material used to produce the masonry unit. This is controlled by the masonry unit manufacturer. In relation to FRL, masonry must always provide Insulation to an equal or better level than is required for Integrity.

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Victoria Book 1 C

The Slenderness ratio (Srf) of the proposed wall is calculated as per Clause 6.3.2.2. If this value is less than the maximum Srf in Table 6.1 [or the Srf calculated from Fire Tests and Clause 6.3.3(b)(ii)], then the wall complies. If the Srf of the wall is greater than the maximum permissible, it is recalculated for an increased thickness and/or extra restraints. There are 4 formulae for calculating Srf: 6.3.2.2 (1) and (2) are the HEIGHT formulae. FORMULA 1 and 2 is: Srf = avf H t

For cavity walls, two thirds of the total thickness can be used for t, provided that BOTH leaves are restrained in the same positions (eg: external leaf stops at slab also). If the external leaf is a veneer to the slab edge, the internal leaf must provide the Structural Adequacy FRL on its own. For reinforced masonry, the Srf of 36, from Table 6.1 may be used. Reinforcement can be horizontal, as bond beams when spanning between columns. Reinforcement can be vertical, as filled cores when spanning between slabs. In either case, reinforcement can be spaced up to 2m apart, depending on span. This reinforcement stiffens the masonry and resists bowing. Reinforced walls with Srf < 36 have a 240 minute FRL for Structural Adequacy. All calculations should be checked by an engineer. Other loads may supersede Structural Adequacy requirements.

6.3.2.2 (3) is the PANEL ACTION formula. FORMULA 3 is: Srf = 0.7 t

L t

avf H ah L

6.3.2.2 (4) is the LENGTH formula. FORMULA 4 is: Srf = ah

Masonry Design for Integrity FRL(The resistance to the passage of flame or gas). It is impractical to provide test results for all possible masonry wall designs, and therefore Integrity must be proved in some other way. With masonry wall design, the most practical way to prove Integrity is to prove Structural Adequacy and Insulation equal to or better than the Integrity requirement. (Logically, if the wall is designed to minimise bowing it will not crack and therefore resist the passage of flame and gas for the specified time). This method is also the best way to prove integrity even when a wall may not be required to comply with a structural adequacy FRL value, such as is the case with non loadbearing walls. eg: if the BCA requires an FRL of -/90/90, the wall has no actual structural adequacy requirement, but to prove integrity of 90 minutes, the wall must be structurally adequate for 90 minutes.

The actual Srf is the lesser of the resulting figures. Formula (1) and (2) always govern where there is no end restraint, and often govern where walls are long, relative to their height. Projects with multiple wall lengths (eg: home units) can use this formula as a one size fits all method of calculating the masonry thickness. Formula (3) allows a wall to exceed the height given by formula (1) and (2) provided at least one end is restrained as well as the top. Formula (4) governs the wall length, often where there is no top restraint (eg: portal frame factories) and where walls are short, relative to their height (eg: a lift well or vent shaft). From a suppliers perspective, it is helpful to be able to calculate the maximum height* for a given thickness (masonry unit), eg: H = Srf x t Avf

and calculate the thickness from a given wall size. t = Avf x H Srf

where t is the OVERALL thickness, whether the units are solid or hollow. NOTE:* Refer to the Structural Adequacy Selection Graphs on pages C9 to C15 for maximum height values.


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Victoria Book 1 C

Masonry Design for Insulation FRLInsulation is the one FRL component that a masonry unit manufacturer does control. It is governed by the type of material and the material thickness. Material thickness is defined in AS3700, Clause 6.5.2 as the overall thickness for solid and grouted units and units with cores not more than 30% of the units overall volume. For hollow units (cores > 30%), the material thickness is the net volume divided by the face area. For cavity walls, t = the sum of material thicknesses in both leaves. (not two thirds as for the Structural Adequacy FRL).

Effect of Chases on Fire Rated MasonryStructural Adequacy FRL To assess the effect of chases on Structural Adequacy FRLs, the direction in which the wall spans must be taken into account. Walls spanning vertically may be chased vertically. The horizontal chase is limited to 4 times the wall thickness. Walls spanning vertically and horizontally may be chased horizontally up to half the wall length. Horizontal chases should be kept to a bare minimum. Walls spanning vertically and horizontally may be chased vertically up to half the wall height. If these limits are exceeded, the masonry design thickness must be reduced by the depth of the recess or, in the case of vertical chases, designed as 2 walls with unsupported ends at the chase. Integrity and Insulation FRLs Maximum depth of recess is 30mm. Maximum area is 1,000mm2. Total maximum area on both sides of any 5m2 of wall is 100,000mm2 If these limits are exceeded, the masonry design thickness must be reduced by the depth of the recess. Refer to the Boral Masonry Design Guide, (MDG Book 1) for more details.

Options for Increasing FRLsThe Structural Adequacy FRL can be increased by adding wall stiffeners, by increasing the overall thickness, by adding reinforcement or by protecting the wall with Boral Plasterboard FireStop board, fixed to furring channels (on both sides of the wall if a fire rating is required from both sides). Integrity FRLs are increased by increasing the other two FRL values to the required Integrity FRL. Insulation FRLs can be increased by core filling, by adding another leaf of masonry, by rendering both sides of the wall if the fire can come from either side. NOTE: Only ONE thickness of render is added to the material thickness and that must be on the cold side because the render on the exposed face will drop off early in a fire). Boral FireStop plasterboard on furring channels can increase the Insulation FRL from either side. Unlike render, the Boral FireStop and furring system does not drop off the hot side so quickly due to the boards fire resistance, the mechanical fixing of the board to furring and the furring to the wall.

Recesses for ServicesRecesses that are less than half of the masonry thickness and are less than 10,000mm2 for both sides within any 5m2 of the masonry, do not have an effect on fire ratings. If these limits are exceeded, the masonry design thickness must be reduced by the depth of the recess.

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Victoria Book 1 C

How to Select Boral Masonry Units for Fire Rated WallsAll design information, table data and graphs in this guide are derived from formulae in AS3700 : 2001 Masonry Structures, Part 6.3 for Structural Adequacy Fire Resistance Levels (FRL) and Part 4.6 for Robustness. Tables and graphs assume all walls are built on concrete slabs or broad footings and have adequate restraints. Piers, cavity walls, freestanding walls, earthquake, wind and other loads are not addressed in this guide. All fire rated walls should be designed by a suitably qualified engineer.

Step 1Determine required wall FRL from the Building Code of Australia (BCA). The Building Code of Australia (BCA), Section C defines the CLASS and TYPE of building and designates the required Fire Resistant Level (FRL) in terms of three criteria. See adjacent example.

Example

eg: 120/60/60 Insulation Integrity Structural Adequacy

NOTE: For masonry wall design, the FRL for any given wall must comply with: Structural Adequacy Integrity Insulation Refer to the section Design for Integrity on page C3 for additional explanation.

eg. If the BCA required FRL is: /120/60 Then the chosen wall design must have an actual FRL of: 120/120/120 or better.

Worked Example A 6m high, 6m long fire rated, non-loadbearing wall in a 3 storey warehouse. BCA specifies Class 7, Type b Construction. BCA Section C1.1, Table 4 specifies an FRL 240/240/240.


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Victoria Book 1 C

Step 2Select an appropriate Boral Masonry Unit based on the FRL Insulation Requirement. The third figure in an FRL rating is the Insulation. Table C1 provides the Insulation values for the various Boral units. Check the Materials Attributes (see notes below the table) to ensure the selection is fit for its purpose.

Worked Example From Table C1, the following units all achieve 240 minutes FRL for Insulation: Fire Rated Block 12.401, 15.401, 15.483 and 20.401 Grout Filled Masonry (190mm) 20.42 and 20.48. (However, the use of Scoria Blend may be more cost effective).

Table C1 FRL Insulation Values for Boral Masonry Units (Victoria)Fire Test 30 60 INSULATION FRL (minutes) 90 120 180 240 Material Product Code/Type* 15.01SC 15.301; 10.331; 10.383 12.401; 15.401; 15.483; 20.401 Scoria Quick Brick FireLight Quick Brick 10.01; 10.201 15.01; 15.201 20.01; Brick B1, Quick Brick Solid or Cored 15.01; 15.42; 15.48 20.01; 20.42; 20.48 30.48

Yes Scoria Blend (SB) Yes Scoria Blend (SB) Yes Scoria Blend (SB) Yes Scoria Blend (SB) Yes FireLight (FL) d.t.s.. +render Ash Grey (AG) & Designer Block d.t.s.. Ash Grey (AG) & Designer Block d.t.s.. Ash Grey (AG) & Designer Block d.t.s.. +render Ash Grey (AG) & Designer Block d.t.s.. +render Grout Filled Masonry 140mm d.t.s. Grout Filled Masonry 190mm d.t.s. Grout Filled Masonry 290mm d.t.s. deemed to satisfy. +render = 10mm render both faces * Product Codes listed are for the Full Size Unit. Fractional size blocks in the same range have the same FRL rating.

Material Attributes (Victoria)Scoria Blend High Fire Rated Block uc = 8 MPa. Offers excellent Insulation and Structural Adequacy FRLs for NONLOADBEARING fire rated walls. 10% lighter than Standard Ash Grey units. Scoria Blend is hard, durable and suitable for paint or render. Acoustic performance with plasterboard linings is excellent. Acoustic performance with render is medium range. Scoria Quick Brick (SB) uc = 5 MPa Insulation FRL of 240 minutes. High slenderness ratio (Srf) for Structural Adequacy FRL. Suitable for NON LOADBEARING fire rated walls. Light weight, 20% lighter than Standard Ash Grey units. Acoustic performance with plasterboard linings is excellent. FireLight Quick Brick (FL) uc = 3 MPa Insulation FRL of 120 minutes. High slenderness ratio (Srf) for Structural Adequacy FRL. Suitable for NON LOADBEARING fire rated walls. Light weight, 35% lighter than Standard Ash Grey units. Acoustic performance with plasterboard linings is excellent.

Designer Block. uc = 10MPa. Blocks provide a 60 or 90 minute Insulation FRL. Suitable for LOADBEARING applications. Standard Ash Grey (AG) uc = 10MPa. Basalt 45% Offers excellent Srf values for Structural Adequacy FRL. Suitable for LOADBEARING walls. Acoustic performance with plasterboard is excellent. Acoustic performance with render is excellent. Reinforced Grout Filled Masonry. uc = 15MPa. AS3700 allows an Srf value of 36 for reinforced masonry. This in turn allows for the largest walls to be built using the thinnest masonry option. Suitable for LOADBEARING applications. Grout strength to be 20MPa.

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Victoria Book 1 C

Step 3Check the Structural Adequacy of the selected units. The Slenderness ratio (Srf) of a fire rated wall is calculated as per AS3700 : 2001, Clause 6.3.2.2, and must not exceed the Srf values given in AS3700 or calculated from Fire Tests. Table C2 provides the maximum Srf values for Boral masonry units.

Worked Example The calculated Srf value for your wall design MUST NOT EXCEED the value from the accompanying table. See following page for an explanation on using the Boral Srf graphs to assist preliminary selection. eg. Fire Rated Block - Scoria Blend (SB) required to provide Structural Adequacy for 240 minutes has an Srf = 19.7. (refer to page C11). Also refer to the previous explanation and AS3700 for Srf calculation methods. In this example, the 6 x 6m wall, with lateral restraint on 4 sides, 190mm thick has an Srf = 19.2. as per formula 6.3.2.2 (3). Alternatives are 20.401 (SB) and 20.48 with reinforcement and core filling. As the wall in this example is non-loadbearing, the Scoria Blend 20.401 is the more economical solution.

Table C2 Maximum Srf Values for Boral Masonry UnitsSrf Values Fire FRL (minutes) for Structural Adequacy Test 30 60 90 120 180 240 Yes 22.6 22.6 22.6 22.6 21.5 19.7 Yes 22.6 22.6 22.6 22.6 21.5 19.7 Yes 29 29 26.9 24.9 22.2 20.3 d.t.s. 25 22.5 21 20 18 17 d.t.s. 19.5 18 17 16 15.5 15 d.t.s. 36 36 36 36 36 36 d.t.s.= deemed to satisfy, as per AS3700 : 2001, Table 6.1.

Material Scoria Blend (SB) Scoria Quick Brick FireLight Standard Ash Grey (AG) and Basalt Quick Brick Designer Block Reinforced & Grout Filled Masonry

Condition of use Non loadbearing ONLY Non loadbearing ONLY Non loadbearing ONLY Any Any Any


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Boral Structural Adequacy Selection Graphs & TablesTo assist with the preliminary selection of Boral masonry units for fire rated walls, a graphical selection method based on Srf values has been developed. The following pages provide graphs and tables for a selection of Boral masonry units where at least one end of the wall has lateral restraint. Additional tables are provided for walls with no end restraint and for reinforced/grout filled masonry, following these graphs. IMPORTANT The following selection graphs are based on Specific Products manufactured at Victorian Boral Plants. Should these units be sourced from other plants, the specification should be checked with the respective supply plant.

How to Use the Boral Structural Adequacy FRL GraphsFire Rated Block - Scoria-Blend (SB)Worked Example 1. Select the appropriate page and graph for the chosen masonry unit material.SUPPORT SUPPORT

Structural Adequacy 180 minutes FRLLaterally supported both ends and top9 8 7 Height of wall between supports (m) 6

SUPPORT

SUPPORT

2. Select the appropriate graph with Structural Adequacy for the required minutes. (180 minutes for this example).Leaf Thickness

3. Select the appropriate graph for the chosen wall restraint (support) criteria. (Support on both sides, top and bottom for this example). 4. Plot the intersection of the Wall Height and the Wall Length on the graph. (For this example 6m height x 6m length). 5. The result MUST FALL BELOW the coloured line indicated for the chosen masonry unit thickness. In this example, the result is above the line for 140mm units but below the line for 190mm units. Therefore 190mm units would be suitable. (140mm units would not be suitable for this example).

190mm 5 4 3 2 1 0 0 1 2 3 4 5 6 7 8 9 Length of wall between supports (m) 140mm 110mm 90mm

Index to Structural Adequacy FRL Graphs & TablesProduct Group FRL Minutes (Structural Adequacy) Page

Scoria Blend (SB) & Scoria Quick Brick Scoria Blend (SB) & Scoria Quick Brick Scoria Blend (SB) & Scoria Quick Brick FireLight Quick Brick (FL) FireLight Quick Brick (FL) Standard Ash Grey (AG) Standard Ash Grey (AG) Designer Block Designer Block Walls Restrained at Top (Unrestrained Ends) Reinforced & Grout Filled Masonry Walls

60 120 180 240 90 120 60 90 60 90 60 240 60 240

C9 C10 C11 C12 C13 C14 C15 C16 C17 C18 C18

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Victoria Book 1 C

Scoria Blend (SB) High Fire Rated Block -

Srf = 22.6

Structural Adequacy for 60-120 minutes Fire Resistant Level (FRL)

SUPPORT

SUPPORT

SUPPORT

Laterally supported both ends and top9 8 7 Height of wall between supports (m)

SUPPORT

Laterally supported both ends, top freeLeaf Thickness 9 8 7 Height of wall between supports (m) 6 5 4 3 2 1 0 0 1 2 3 4 5

SUPPORT

SUPPORT

Structural Adequacy 60 120 minutes FRL

SUPPORT


Leaf Thickness

6 5 4 3 2 1 0 0 1 2 3 4 5 6 7 8 9 Length of wall between supports (m)

190mm

140mm 110mm 90mm

190mm 140mm 110mm 90mm

6

7

8

9

Length of wall between supports (m)

SUPPORT

Laterally supported one end and top9 8 7 Height of wall between supports (m)

SUPPORT

Laterally supported one end top freeLeaf Thickness 9 8 7 Height of wall between supports (m) 6 5 4 3 2 1 0 0 1 2 3 4 5

SUPPORT


SUPPORT


SUPPORT

Leaf Thickness

6 190mm 5 4 3 2 1 0 0 1 2 3 4 5 6 7 8 9 Length of wall between supports (m) 140mm 110mm 90mm

190mm 140mm 110mm 90mm 6 7 8 9



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Srf = 21.5

Structural Adequacy for 180 minutes Fire Resistant Level (FRL)

SUPPORT

SUPPORT

SUPPORT


SUPPORT

Laterally supported both ends, top freeLeaf Thickness 9 8 7 Height of wall between supports (m) 6 5 4 3

SUPPORT

SUPPORT

Structural Adequacy 180 minutes FRL

SUPPORT


Leaf Thickness


190mm 2 1 0 0 1 2 3 4 5 6 7 8 9 Length of wall between supports (m) 140mm 110mm 90mm

SUPPORT


SUPPORT


SUPPORT


SUPPORT


SUPPORT

Leaf Thickness


190mm 140mm 110mm 90mm 6 7 8 9


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Victoria Book 1 C


Srf = 19.7


SUPPORT

SUPPORT

SUPPORT


SUPPORT


SUPPORT

SUPPORT


SUPPORT


Leaf Thickness

6 5 4 3 2 1 0 0 1 2 3 4 5 6 7 8 9 Length of wall between supports (m) 190mm 140mm 110mm 90mm

190mm 2 1 0 0 1 2 3 4 5 6 7 8 9 Length of wall between supports (m) 140mm 110mm 90mm

SUPPORT


SUPPORT


SUPPORT


SUPPORT


SUPPORT

Leaf Thickness

6 5 4 3 2 1 0 0 1 2 3 4 5 6 7 8 9 Length of wall between supports (m) 190mm

140mm 110mm 90mm

190mm 140mm 110mm 90mm 6 7 8 9



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FireLight Quick Bricks (FL) -

Srf = 26.9


SUPPORT

SUPPORT

SUPPORT


SUPPORT

Laterally supported both ends, top freeLeaf Thickness 190mm 9 8 7 Height of wall between supports (m) 6 5 4 3 2 1 0 0 1 2 3 4 5

SUPPORT

SUPPORT


SUPPORT


Leaf Thickness


190mm 140mm 110mm 100mm 90mm

6

7

8

9


SUPPORT


SUPPORT

Laterally supported one end, top freeLeaf Thickness 9 8 7 Height of wall between supports (m) 6 5 4 3 2 1 0 0 1 2 3 4 5

SUPPORT


SUPPORT


SUPPORT

Leaf Thickness


140mm 110mm 100mm 90mm

190mm 140mm 110mm 90/100mm 6 7 8 9


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Victoria Book 1 C

FireLight Quick Bricks (FL) -

Srf = 24.9


SUPPORT

SUPPORT

SUPPORT

Laterally supported both ends and top9 8 7 Height of wall between supports (m) 6 5 4 3 2 1 0 0 1 2 3 4 5

SUPPORT


SUPPORT

SUPPORT


SUPPORT


Leaf Thickness

190mm

140mm 110mm 100mm 90mm

190mm 2 1 0 0 1 2 3 4 5 6 7 8 9 Length of wall between supports (m) 140mm 110mm 100mm 90mm

6

7

8

9


SUPPORT


SUPPORT


SUPPORT


SUPPORT


SUPPORT

Leaf Thickness

6 190mm 5 4 3 2 1 0 0 1 2 3 4 5 6 7 8 9 Length of wall between supports (m) 140mm 110mm 100mm 90mm

190mm 140mm 110mm 90/100mm 6 7 8 9



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Ash Grey (AG)

Srf = 22.5

(Basalt 45%)


SUPPORT

SUPPORT

SUPPORT


SUPPORT


SUPPORT

SUPPORT


SUPPORT


Leaf Thickness

6 5 4 3 2 1 0 0 1 2 3 4 5 6 7 8 9 Length of wall between supports (m)

190mm

140mm 110mm 90mm

190mm 140mm 110mm 90mm

6

7

8

9


SUPPORT


SUPPORT


SUPPORT


SUPPORT


SUPPORT

Leaf Thickness


190mm 140mm 110mm 90mm 6 7 8 9


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Victoria Book 1 C

Ash Grey (AG)

Srf = 21.0

(Basalt 45%)


SUPPORT

SUPPORT

SUPPORT


SUPPORT


SUPPORT

SUPPORT


SUPPORT


Leaf Thickness


190mm 140mm 110mm 90mm

6

7

8

9


SUPPORT


SUPPORT


SUPPORT


SUPPORT


SUPPORT

Leaf Thickness


140mm 110mm 90mm

190mm 140mm 110mm 90mm 6 7 8 9



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Designer Block

Srf = 18.0


SUPPORT

SUPPORT

SUPPORT


SUPPORT


SUPPORT

SUPPORT


SUPPORT


Leaf Thickness

6 5 190mm 4 140mm 3 2 1 0 0 1 2 3 4 5 6 7 8 9 Length of wall between supports (m) 110mm 90mm

190mm 140mm 110mm 90mm

6

7

8

9


SUPPORT


SUPPORT


SUPPORT


SUPPORT


SUPPORT

Leaf Thickness

6 5 190mm 4 140mm 3 2 1 0 0 1 2 3 4 5 6 7 8 9 Length of wall between supports (m) 110mm 90mm

190mm 140mm 110mm 90mm 6 7 8 9


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Victoria Book 1 C

Designer Block

Srf = 17.0


SUPPORT

SUPPORT

SUPPORT


SUPPORT


SUPPORT

SUPPORT


SUPPORT


Leaf Thickness


190mm 140mm 110mm 90mm

6

7

8

9


SUPPORT


SUPPORT


SUPPORT


SUPPORT


SUPPORT

Leaf Thickness


190mm 140mm 110mm 90mm 6 7 8 9



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Victoria Book 1 C

Walls Restrained at Top (Unrestrained Ends)Walls without restraint to the ends, but with lateral restraint along their top have maximum heights irrespective of their length as detailed in the following table. (Most doorways and windows create free ends).

SUPPORT

SUPPORTMaterial Thickness 60 90mm Fire Rated Block - Scoria Blend (SB) & Scoria Quick Brick (SB) 110mm 140mm 190mm FireLight Quick Brick (FL) 110mm 90mm Ash Grey (AG) 110mm 140mm 190mm 90mm Designer Block 140mm 190mm Reinforced & Grout Filled* 140mm 190mm 2.430 2.970 3.780 5.130 2.970 2.430 2.970 3.780 5.130 2.160 3.360 4.560 5.040 6.840 Maximum Wall Height (metres) Structural Adequacy (FRL minutes) 90 120 180 2.430 2.970 3.780 5.130 2.970 2.430 2.970 3.780 5.130 2.040 3.173 4.307 5.040 6.840 2.430 2.970 3.780 5.130 2.970 2.400 2.933 3.733 5.067 1.920 2.987 4.053 5.040 6.840 2.430 2.970 3.780 5.130 2.970 2.160 2.640 3.360 4.560 1.860 2.893 3.927 5.040 6.840

240 2.364 2.889 3.677 4.991 2.970 2.040 2.493 3.173 4.307 1.800 2.800 3.800 5.040 6.840

*Governed by Robustness. Can be higher if supporting a slab. These heights can be exceeded when one or both ends are restrained as well as the top.

Reinforced Masonry WallsReinforced cores spanning vertically, ie. restraint top and bottomStructural Adequacy 60 240 minutes FRLLateral support along top Single Steel reinforced and fully grouted cores Core fill spacing

Reinforced bond beams spanning horizontally, ie. restraint bottom and both endsStructural Adequacy 60 240 minutes FRL

SUPPORT

Lateral support at both ends

SUPPORT

Single Steel reinforced and fully grouted bond beams

Bond beam spacing

Slab or broad footing

SUPPORTCore Fill Spacing (metres) Every 10th core (2m) Every 10th core (2m) Every 10th core (2m) Every 10th core (2m) Every 8th core (1.6m) Leaf Thickness (mm) 140 140 190 190 190

Slab or broad footing

SUPPORT

Maximum Wall Height (metres) 4.000 5.040 4.800 6.400 6.840

Steel N12 N16 N12 N16 N16

Maximum Wall Length (metres) 4.000 5.040 4.800 6.400 6.840

Steel N12 N16 N12 N16 N16

Bond Beam Spacing (metres) Every 10th course (2m) Every 10th course (2m) Every 10th course (2m) Every 10th course (2m) Every 8th course (1.6m)

Leaf Thickness (mm) 140 140 190 190 190

Maximum vertical load on wall = 11.25 H kN/m where H is in metres.

C18


SUPPORT

BORAL MASONRY


Masonry Design GuideSTRUCTURAL, FIRE AND ACOUSTICS VICTORIA BOOK 1 D ACOUSTIC DESIGN

1

D

Victoria Book 1 D

Acoustic Performance RatingsSTC and Rw.STC (Sound Transmission Class) and Rw (Weighted Sound Reduction Index) are similar in that they are a single number evaluation of STL (Sound Transmission Loss) measurements over 16 frequencies. The use of STC was changed to Rw in BCA Amendment 6, issued in January 2000. The lowest frequency measured in Rw is 100Hz. (STC started at 125Hz). The highest frequency measured in Rw is 3150Hz. (STC finished at 4000 Hz). AS1276 gives a set contour that is positioned over the STL results so that the total of points above the results and below the contour (deficiencies) does not exceed 32. Rw is then read off where the contour crosses the 500Hz line. The maximum 8dB deficiency, which pulled the STC contour down, is not used for Rw. Instead, there are two numbers after Rw, eg: Rw45 (-1; -5). The first figure in the brackets is an indication of deterioration due to high frequency noise (eg. a blender). The second figure indicates deterioration due to low frequency noise (eg. low speed trucks, bass guitar, or home cinema speakers).

Masonry with Plasterboard SystemsDaub-fixed Plasterboard The cornice cement daubs, used to fix plasterboard to masonry, create a small cavity in which resonances can occur. The more dense, smooth and impervious the masonry is the more it will bounce or resonate the sound, allowing the plasterboard to re-radiate the sound. Tests on linings with extra daubs (spacing was halved) gave lower performances, presumably due to extra bridges through the daubs. Concrete masonry has a coarser texture and is more porous than clay. The noise energy that gets through the wall and bounces off the plasterboard is re-absorbed into the concrete, where it dissipates, as a tiny amount of heat. Lightweight concrete masonry performs relatively poorly when bare. When lined, it gives a vast improvement. Higher density concrete units improve the Rw of the bare wall, but when plasterboard is daub fixed, the amount of improvement decreases as the concrete units begin to behave similarly to clay.

Masonry with Plasterboard on Furring ChannelsFurring channels are rollformed galvanised metal battens to which plasterboard can be fixed, using self tapping screws. Popular products include Rondo rollformed steel furring channel (N 129 which is 28mm deep) or (N 308 which is 16mm deep). Furring channels increase the gap between masonry and plasterboard, making it harder for resonating energy to build up pressure on the board. Plumbing and electrical services can be fitted into this gap, avoiding the need to chase recesses into the masonry. A further increase of 3 or 4dB can be achieved with Tontine TSB3 polyester (or equivalent) insulation in the cavity between the plasterboard and masonry. Another increase of 3 to 5dB can be achieved with a second layer of plasterboard, fixed with grab screws to the first layer, (and no gaps). Boral Plasterboard now make SoundStop, a higher density board.

Impact Sound ResistanceFrom May 2004, the BCA requires impact rated walls to be of discontinuous construction. An impact rating is required for walls where a wet area (including a kitchen) is opposite a habitable room in an adjoining apartment.

Masonry with RenderAcoustic performance with single leaf rendered masonry follows the Mass Law. The acoustic performance of these walls depends on their mass. More mass gives better performance. The relationship is logarithmic: If a 110mm wall gives Rw45, a 230mm wall of the same brick may give Rw57, and a 450mm wall may give Rw63. Cavity walls behave differently. Sound waves can resonate in cavities. The narrower the cavity becomes, the more resonance occurs. Insulation in the cavity helps absorb resonating sound. Narrow cavities should have bond breaker board to prevent mortar from providing a bridge for sound to travel between leaves.

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Victoria Book 1 D

Masonry with Plasterboard on Stud FramingIn this system, vibrations are isolated by the gap between the masonry and the stud frame. Plasterboard is screw fixed to the outside of a stud wall, which is positioned 20mm from one face of the masonry. An extra 6dB can be gained by placing Tontine TSB5 insulation between the studs. The other side of the masonry can be lined with daub fixed plasterboard or rendered. 13mm render can add an extra 1dB more than daub fixed board. This system complies with the BCA requirement of discontinuous construction for impact rated walls.

How loud is noise?

Designing Masonry Walls for Acoustic PerformanceBuilding acoustics is the science of controlling noise in buildings, including the minimisation of noise transmission from one space to another and the control of noise levels and characteristics within a space. The term building acoustics embraces sound insulation and sound absorption. The two functions are quite distinct and should not be confused. Noise has been defined as sound which is undesired by the recipient, but it is very subjective and it depends on the reactions of the individual. However, when a noise is troublesome it can reduce comfort and efficiency and, if a person is subjected to it for long enough periods, it can result in physical discomfort or mental distress. In the domestic situation, a noisy neighbour can be one of the main problems experienced in attached dwellings. The best defence against noise must be to ensure that proper precautions are taken at the design stage and during construction of a building. This means that the correct acoustic climate must be provided in each space and that noise transmission levels are compatible with the usage. Remedial measures, after occupation, can be expensive and inconvenient. Ideally, the sound insulation requirements for a building should take into account both internal and external sound transmission.

Sound InsulationAny wall system that separates one dwelling from another, or that separates one room from another, should be selected to provide a sufficient level of insulation against noise. There are two types of noise transfer through partitions, airborne transfer, and structure-borne transfer. Both may need to be considered in order to achieve the desired result. Noise sources, such as voices, televisions and musical instruments, generate noise in the air in one room, and this noise passes through the partition and into the room on the other side. This is known as airborne noise. As we know, some partitions are better than others at isolating airborne noise. In order to simply compare the isolating performance of partitions Rw rating was developed. A partition with a high Rw rating isolates sound better than a partition with a low Rw rating. If we compare two partitions, and one has an Rw which is 10 rating points higher, then the noise passing through the wall with the higher Rw will be about half the loudness when compared with the noise passing through the wall with the lower Rw. The Rw ratings are obtained from tests carried out in certified laboratories, under controlled conditions. When identical partitions are part of buildings and tested insitu, it is often found that the actual Rw rating obtained, usually called the Weighted Standardised Level Difference


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Victoria Book 1 D

(Dnt,w), is lower than the laboratory Rw. This reduction in performance can be due to flanking paths (that is to say that noise also passes through other parts of the building) or may be due to poor detailing such as incorrect installation of pipes, power points etc.

Boral Acousticell blocks have extremely high absorption rates (90%) at low frequency. Refer to Acousticell product page in this guide and the Boral Masonry Block Guide. The porous surface and lightweight aggregates in lightweight masonry give it high sound absorption values (> 50%) across all frequencies. Refer to the Lightweight product page in the Fire Rated Walls section of this guide.

Structure-borne Noise & Weighted Normalised Impact Sound Pressure Level (Ln,w)When a building element is directly, or indirectly, impacted or vibrated then some of the energy passes through the partition and is re-radiated as noise to the room on the other side. This is called structure-borne noise or impact noise. For walls, the most common sources of structure-borne noise are: Cupboard doors, fixed to party walls, being closed Kitchen appliances being used on benches touching walls Plumbing fittings, particularly taps, being connected to walls Light switches being turned on and off, and Dishwashers, washing machines, clothes dryers etc. touching walls Walls satisfy impact or structure-borne noise isolation either by conforming to the deemed to satisfy provisions of the Building Code of Australia Impact Sound or Test of Equivalence, using a single number description for impact insulation or the Opinion of a suitably qualified acoustic engineer. The generally accepted test for impact is Weighted Normalised Impact Sound Pressure Level or Ln,w. In this method of interpreting impact sound resistance, lower values represent better impact insulation. Another single number description used for impact is the Impact Insulation Class or IIC. When used for walls it may be called WIIC for laboratory testing or WFIIC for field testing. Unfortunately, as there are different test methods used to obtain the impact rating for walls, results cannot always be directly compared. The larger the value of the WIIC the better the impact insulation.

Sound Isolation CriteriaFrom May 2004, the Building Code of Australia (BCA) specifications for minimum levels of sound isolation have been increased. These increased specifications are: Unit to corridor or stairs Unit to unit Rw 50 50

Rw + Ctr

Where a wet area of one unit adjoins a habitable room in another unit, the wall construction must be of a discontinuous type.

Guidelines for Optimum PerformanceTo achieve the optimum performance for a wall system, the exact construction as specified including perimeter sealing must be adopted. Any variations from the systems detailed in this guide should be approved by the project acoustic consultant as it can increase or decrease the acoustical isolation of wall systems.

InstallationUnless careful attention to installation detail is followed, significant reductions in sound isolation can occur, particularly with high performance walls. The following need to be taken into account.

Perimeter Acoustical SealingIt should be noted that as the sound isolation performance of a partition increases, then the control of flanking paths becomes more critical. Consequently, the perimeter sealing requirements for a low sound rating wall, such as Rw30, are much less than for a high sound rating wall, such as Rw60. However, it is neither necessary, nor is it cost effective, to provide very high perimeter acoustic sealing for a low rating Rw wall. The perimeter isolation for each leaf must be commensurate with the acoustic isolation of the leaf. It cannot be over emphasised, however, that for high performance walls, the sealing of each leaf must be virtually airtight.

Noise Reduction Coefficient (NRC)Designers of theatres, music rooms and power transformer enclosures etc may often choose materials which have an efficient sound absorption value and incorporate them within the building design. The level of sound absorption for material is stated as the NRC (Noise Reduction Coefficient). This value is derived as a result of acoustic testing on the material, and determined by calculation from the average amount of sound energy absorbed over a range of frequencies between 250Hz and 2000Hz.

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Victoria Book 1 D

For a sealant to be effective at controlling noise passing through gaps, it must have the following properties. Good flexibility, elastic set Low hardness Excellent adhesion, usually to concrete, timber, plaster and galvanised steel Minimal shrinkage (less than 5%) Moderate density (greater than 800kg/m3), and Fire rated where required (All walls required by the BCA to be sound rated also have fire ratings) All of the above properties must be maintained over the useful life of the building, that is, greater than 20 years. Examples of a suitable sealant include: Bostik Findley Fireban One Boral Plasterboard Fyreflex Boral Plasterboard WR Sealant Tremco synthetic rubber acoustical sealant Some silicone sealants and Some acrylic latex sealants

IMPORTANT: The use of expanding foam sealants is not acceptable. Reference should be made to the manufacturer to ensure the particular type or grade of sealant is suitable for the purpose.

Noise FlankingIt is beyond the scope of this manual to provide full details for control of all flanking paths. However, flanking can significantly reduce the perceived isolation of a wall system and should therefore be given careful consideration. Typical flanking paths are shown in the Fig D1.

Acoustic Performance On-SiteLaboratory Test results are achieved under ideal controlled conditions, and estimates are calculated from known performance, experience and computer simulation programs. To repeat the performance in the field, attention to detail in the design and construction of the partition and its adjoining floor/ ceiling and associated structure is of prime importance. Even the most basic principles, if ignored, can seriously downgrade the sound insulation performance of a building element.

Through ventilation and service ducts Through ceilings and the above ceiling cavity

Through windows, doors, gaps and air leaks

Through perimeter joints between the wall and floor, or the wall and ceiling (or underside of the floor slab) or wall junctions

Through back to back cupboards Through light switches, or GPO's, located in the wall, poor sealing at penetrations

Through floors and the below floor crawl space Through shared building elements such as floor boards, floor joists, continuous plasterboard walls, continuous plasterboard ceilings, and even continuous concrete walls and floors

Fig D1 Flanking Paths


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Victoria Book 1 D

Boral Masonry cannot guarantee that field performance ratings will match laboratory or estimated opinions. However, with careful attention during erection of the wall, correct installation to specification and proper caulking/sealing, the assembly should produce a field performance close to and comparable with tested or estimated values. Apart from installation procedures, workmanship and caulking, the following items can also affect the acoustic performance on site.

AppliancesIn cases where sound insulation is important, noise producing fixtures or appliances such as water closets, cisterns, water storage tanks, sluices, dishwashers, washing machines and pumps should be repositioned or isolated from the structure with resilient mountings and flexible service leads and connections. Where fittings are duplicated on opposite sides of partitions, they should be offset.

DoorsHollow, cored and even solid doors generally provide unsatisfactory sound insulation between rooms. Doors can also provide direct air leaks between rooms thus having a bad effect on the overall sound insulation of the partition in which they are inserted. The higher the insulation of the partition, the worse is the effect of doors. Where sound insulation is important, specialised heavyweight doors or, preferably, two doors separated by an absorbent lined airspace or lobby should be used.

Electrical Outlets & Service PipesElectrical outlets, switch boxes and similar penetrations should not be placed back to back. If power outlets are installed back-to-back, they will create a flanking path or sound leak. Seal backs and sides of boxes and the perimeter of all penetrations with acoustic sealant. Penetrations should be avoided where sound insulation is important. This includes recessed fittings or ducts such as skirting heating, electrical or telephone wiring trunking, light fittings, inter-communication systems and alarms, medical and laboratory gas outlets. Plumbing connections between fittings or appliances on opposite sides of a partition offer a path for transmission of sound and should be sealed. If possible introduce discontinuity in the pipework between fittings, such as a flexible connection within or on the line of a partition.

Lightweight Panels Above DoorsThese are often incorporated for aesthetic reasons, however, the performance of a partition with good sound insulation can be considerably degraded by lightweight panels.

Air Paths Through Gaps, Cracks or HolesGaps, cracks or openings, however small, readily conduct airborne sounds and can considerably reduce the sound insulation of a construction.

Home Cinema RoomsBoral Masonry and Plasterboard divisions have a number of high performance wall systems which have been specifically developed for home cinema applications. Please contact Boral Masonry for additional assistance and information on the available solutions, or visit the website: www.boral.com.au/cinemazone for solutions using Boral masonry products.

Noise paths through vents or lightweight decorative panels

Noise paths through lightweight panel doors

Noise paths through vents

Noise paths through gaps

Fig D2 Flanking Paths Fig D3 Acoustic Performance Overview

D6


BORAL MASONRY


Masonry Design GuideSTRUCTURAL, FIRE AND ACOUSTICS VICTORIA BOOK 1 E FIRE AND ACOUSTIC SYSTEMS

1

E

Victoria Book 1 E

Boral Fire & Acoustic Masonry Wall SystemsThis section of the Boral Masonry Design Guide contains detailed information on the fire and acoustic performance of Boral masonry products, and provides System Solutions for fire and acoustic wall designs. The following illustration details typical page layouts and the type and location of information you may need to complete your product selection and wall design.

Finding Acoustic Systems & Technical SpecificationsProduct Name Product Icons with dimensions for products available in your region/state Product Introduction and Application Information

Product Specific Acoustic Test Results and Wall Lining System Information Product Identification

Fire & Acoustic Systems


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Victoria Book 1 E

BOOK

1

E12FireLight Quick Brick (FL)INTRODUCTION INTRODUCTION Boral Masonry Victoria is constantly Boral Masonry Victoria is constantly developing new and innovative developing new and innovative products.FireLight Quick Brick (FL) products. FireLight Quick Brick (FL) utilises a unique low-density utilises a unique low-density blended blended concrete material which concrete material which provides provides high fire rated performance high fire rated performance together together with minimum weight. with minimum weight. FireLight Quick Brick is ideal for FireLight Quick Brick is ideal for non-loadbearing applications such non-loadbearing applications such as walls in concrete framed office as walls in concrete framed office buildings and high-rise home buildings and high-rise home units. units. FireLight Quick Brick is 230mm long FireLight Quick Brick 2 courses of by 162mm high, equal to is 230mm long by 162mm high, equal to 2 standard brick with mortar, making courses highly efficient and with them a of standard brick costmortar, construction component. effective making them a highly efficient and cost-effective construction component. FIRE DESIGN FIRE DESIGN CONSIDERATIONS CONSIDERATIONS FireLight Quick Brick is a fire tested FireLight Quick Brick is a fire tested lightweight concrete which is unique lightweight concrete which is unique to Boral, and provides excellent fire to Boral, and provides excellent fire rating characteristics. rating characteristics. ACOUSTIC DESIGN ACOUSTIC DESIGN CONSIDERATIONS CONSIDERATIONS FireLight Quick Brick is not FireLight Quick Brick is not recommended for cement rendered recommended for cement rendered acoustic walls, but gives excellent acoustic walls, but gives excellent sound resistance with a wide variety sound resistance with a wide variety of tested board-lining systems. of tested board-lining systems. The 1st test on page E13 qualifies The 1st test on page E13 qualifies for walls enclosing vent shafts in a for walls enclosing vent shafts in a 40. habitable room: Rw ++CCtr 40. habitable room: Rw tr The 3rd test qualifies for unit-toThe 3rd test qualifies for unit-to50. corridor walls: R w 50. corridor walls: Rw

Victoria Book 1 E

1

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E13

162 162

Acoustic Systems - 110mm Quickbrick FireLight (FL) Quickbrick FireLight (FL)ACOUSTIC ACOUSTIC RATING RATING Rw (c, ctr) Rw (c, ctr)Boral Test N Boral Test N

110 110

230 230

FireLight Quick Brick (FL) FireLight Quick Brick (FL)

WALL LINING WALL LINING

110mm 110mm LIGHTWEIGHT LIGHTWEIGHT QUICK BRICK (FL) QUICK BRICK (FL)

WALL LINING WALL LINING

(-1, -5) (-1, -5) T621-05s33 T621-05s33

45 45

1 x 13mm Boral Plasterboard daub fixed 1 x 13mm Boral Plasterboard daub fixed at 500mm centres. at 500mm centres. Suits vents in habitable rooms. Suits vents in habitable rooms. Rw + ctr = 40 Rw + ctr = 40

126mm 126mm

(-1, -6) (-1, -6) T621-05s32 T621-05s32

47 47

1 x 13mm Boral Plasterboard daub fixed 1 x 13mm Boral Plasterboard daub fixed at 500mm centres at 500mm centres142mm 142mm

1 x 13mm Boral Plasterboard daub fixed 1 x 13mm Boral Plasterboard daub fixed at 500mm centres at 500mm centres

(-2, -8) (-2, -8) T621-05s31 T621-05s31

51 51


169mm Standard Clips 169mm Tontine TSB3 insulation in cavity

1 x 13mm Boral Plasterboard screw fixed 1 x 13mm Boral Plasterboard screw fixed 28mm furring channel at 600mm centres 28mm furring channel at 600mm centres Standard Clips

Tontine TSB3 insulation in cavity 1 x 13mm Boral Plasterboard 1 x 13mm Boral Plasterboard 70mm pine studs 70mm pine studs 20mm clear of masonry

(-3, -9) (-3, -9) T621-05s30 T621-05s30 IIC IIC (-4, -12) (-4, -12) Option based Option based on Test T621on Test T62105s25 05s25 IIC IIC

60 60


Wall Cross section Icon and Overall System Thickness

229mm 20mm clear of masonry 229mm Tontine TSB6 insulation in cavity

Tontine TSB6 insulation in cavity1 x 13mm Boral Plasterboard 1 x 13mm Boral Plasterboard 64mm metal studs 64mm metal studs 20mm clear of masonry 20mm clear of masonry Tontine TSB6 in cavity Tontine TSB6 in cavity

Availability information for your region/stateAvailability Availability

The 4th, 5th and 6th tests qualify The 4th, 5th and 6th tests qualify for unit-to-unit walls where for unit-to-unit walls where Rw + Ctr 50 and impact ratings Rw + Ctr 50 and impact ratings are required and can also be used are required and can also be used in dry-to-dry, wet-to-dry and wet-toin dry-to-dry, wet-to-dry and wetto-wet areas. wet areas.

62 62

1 x 13mm Boral Plasterboard 1 x 13mm Boral Plasterboard 28mm furring channel 28mm furring channel Standard clips Standard clips Tontine TSB3 in cavity Tontine TSB3 in cavity 1 x 13mm Boral Plasterboard 1 x 13mm Boral Plasterboard 16mm furring channel 16mm furring channel Standard Clips Standard Clips TSB2 insulation in cavity TSB2 insulation in cavity

250mm 250mm

(-4, -11) (-4, -11) T621-05s29 T621-05s29 IIC IIC

63 63

244mm 20mm clear of masonry 244mm Tontine TSB6 insulation in cavity

1 x 13mm Boral Plasterboard 1 x 13mm Boral Plasterboard 70mm pine studs 70mm pine studs 20mm clear of masonry

Tontine TSB6 insulation in cavity

No minimum order quantities apply. No minimum order quantities apply. Lead time 0-2 weeks. Lead time 0-2 weeks.

Specifications SpecificationsRw (Estimate or *Tested) Maximum Slenderness Ratio (Srf) Rw (Estimate or *Tested) Maximum Slenderness Ratio (Srf) With Lining System N N Insulation (minutes) With Lining System N N Insulation (minutes) FRL (minutes) per per FRL (minutes) per per m22 Pallet 60 90 120 180 240 IIC m Pallet 60 90 120 180 240 IIC 24.2 250 29 26.9 24.9 22.2 20.3 47 54 58 56 60 24.2 250 29 26.9 24.9 22.2 20.3 47 54 58 56 60 120 120 Refer toto Lining Systems on Page E3.IIC = = Complies with BCA requirement for Impact Sound Resistance. Lining Systems on Page E3. Complies with BCA requirement for Impact Sound Resistance. IIC Refer = Quantity may vary from plant to plant. = Quantity may vary from plant to plant. Product Product Code TxLxH (mm) Code TxLxH (mm) FireLight 110x230x162 FireLight 110x230x162 Quick Brick (FL) Quick Brick (FL) uc uc MPa MPa 3 3 Unit Unit Wt Wt kg kg 4.5 4.5

IMPACT SOUND RESISTANCE IIC = Systems comply with BCA requirements for IMPACT SOUND RESISTANCE. IMPACT SOUND RESISTANCE IIC = Systems comply with BCA requirements for IMPACT SOUND RESISTANCE.

E12



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E13

Fire Performance Data Product Specifications

Acoustic Performance Data

Acoustic Test Result (Rw) and Impact Isolation Information (IIC)

Lining, Framing and Insulation Description for each side of the wall

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Victoria Book 1 E

Acoustic Systems DataAcoustic performance information for six of the most popular wall lining systems may be provided within the Product Specification Tables on the following product pages. Alternatively, you may be referred to more detailed test information and alternative lining systems. LINING SYSTEMRefer to product pages

When information is provided in the table, it is tabulated, under the System Headings of , , , , and . The following Table details the wall lining and insulation information for these six systems, and provides thickness information to assist wall thickness calculation. Acoustic performance estimates have been calculated by Wilkinson Murray (Acoustic Consultants).

WALL LINING

BORAL MASONRY BRICK OR BLOCKAs per product pages

WALL LINING

BOOK

13mm Render

Masonry Thickness +26mm

13mm Render

1 x 13mm Boral Plasterboard daub fixed




Masonry Thickness +71mm Masonry Thickness +84mm or +77mm

1 x 13mm Boral Plasterboard screw fixed 28mm furring channel at 600mm centres Boral Impact Clips at 1200mm centres Tontine TSB3 insulation in cavity


1 x 13mm Boral Plasterboard screw fixed or 1 x 6mm Villaboard screw fixed over 1 x 13mm Boral Plasterboard screw fixed 28mm furring channel at 600mm centres Boral Impact Clips at 1200mm centres Tontine TSB3 insulation in cavity 1 x 13mm Boral Plasterboard screw fixed 28mm furring channel at 600mm centres Boral Impact Clips at 1200mm centres Tontine TSB3 insulation in cavity 1 x 13mm Boral Plasterboard screw fixed 51mm steel studs at 600mm centres 20mm gap Tontine TSB5 insulation in cavity

1 x 13mm Boral Plasterboard screw fixed 28mm furring channel at 600mm centres Standard Clips at 1200mm centres Tontine TSB2 insulation in cavity 1 x 13mm Boral Plasterboard screw fixed 28mm furring channel at 600mm centres Standard Clips at 1200mm cts Tontine TSB2 insulation in cavityAcousti c Estim ate



s with these L ining

System

s


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Victoria Book 1 E

E4

Fire Rated Block - Scoria Blend (SB) Fire Rated Block - Scoria Blend (SB) Series 100, 120, 150 & 200 Series 100, 120, 150 & 200INTRODUCTION INTRODUCTION Fire Rated Block (SB) is manufactured Fire Rated Block (SB) is manufactured from a scoria-blend material which from a scoria-blend material which reduces the block weight and increases reduces the block weight and increases the fire performance characteristics. the fire performance characteristics. Fire Rated Block (SB) is ideal for nonFire Rated Block (SB) is ideal for nonloadbearing walls of commercial, loadbearing walls of commercial, industrial and high-rise buildings industrial and high-rise buildings with concrete and portal framed with concrete and portal framed structures. structures. Fire Rated Block (SB) is also suitable Fire Rated Block (SB) is also suitable for loadbearing walls, however the Srf for loadbearing walls, however the Srf values from Designer Block masonry values from Designer Block masonry units apply. Refer to Section C of this units apply. Refer to Section C of this guide for more information. guide for more information.Availability Availability No minimum order quantities apply. No minimum order quantities apply. Lead time 0-2 weeks. Lead time 0-2 weeks.

Fire Rated Block (SB) is manufactured Fire Rated Block (SB) is manufactured in 90, 110, 140 and 190mm thicknesses in 90, 110, 140 and 190mm thicknesses to suit most types of fire and/or acoustic to suit most types of fire and/or acoustic wall construction. wall construction. FIRE DESIGN CONSIDERATIONS FIRE DESIGN CONSIDERATIONS Fire Rated Block (SB) utilises a Fire Rated Block (SB) utilises a unique scoria-blend material, which unique scoria-blend material, which has been shown through fire testing has been shown through fire testing to provide excellent fire insulation to provide excellent fire insulation characteristics. characteristics. Please refer to the fire performance Please refer to the fire performance characteristics in the specifications characteristics in the specifications table. table.

ACOUSTIC DESIGN ACOUSTIC DESIGN CONSIDERATIONS CONSIDERATIONS Fire Rated Block (SB) provides excellent Fire Rated Block (SB) provides excellent sound resistance with a wide variety of sound resistance with a wide variety of board-lining systems. board-lining systems. Please refer to the acoustic performance Please refer to the acoustic performance characteristics in the specifications characteristics in the specifications table. table. FRACTIONAL SIZE BLOCKS FRACTIONAL SIZE BLOCKS Boral Masonry Victoria manufactures Boral Masonry Victoria manufactures an extensive range of special purpose an extensive range of special purpose blocks and fractional size blocks to blocks and fractional size blocks to complement the products detailed on complement the products detailed on this page. Please refer to the Boral this page. Please refer to the Boral Block & Brick Guide (MDG Book 2) for Block & Brick Guide (MDG Book 2) for additional information. additional information.

Specifications SpecificationsProduct Product Code Code 10.331 10.331 10.383 10.383 12.401 12.401 15.01SC 15.01SC 15.301 15.301

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