no1 technical manual - firecrunch australia · 2020. 1. 23. · as/1530.4 -2014 iso/iec 17025 nata...

TECHNICAL MANUALINSTALLATION : F i re Tested FRL Systems

FIRECRUNCH IS A

FIRE TESTED BUILDING CLADDING & FLOORING

PRODUCT FIRE TESTED IN

AUSTRALIA BY NATA ACCREDITED

TEST LABS CSIRO UNDER

AS/1530.4 -2014 ISO/IEC 17025NATA IS THE AUSTRALIAN INTERNATIONAL MEMBER OF ILAC , WHICH IS

THE INTERNATIONAL LABORATORY ASSOCIATION CO-OPERATION,

COMPLYING WITH ISO / IEC 17025 AND OTHER INTERNATIONALLY

RECOGNIZED STANDARDS IN 160 MEMBER COUNTRIES.

FIRE TESTED BYNATA / CSIRO

& OTHERS

NO METAL CORROSIVE CHLORIDE

NATA CERTIFIED

NO METAL CORROSIVE CHLORIDE

NATA CERTIFIED

MgSO4Sulphate Board

firecrunch.com.au

UPDATE JAN 2020

No1

02 No1 2020

CONTENTS 2

FIRECRUNCH OVERVIEW 3

KEY FEATURES 3

PRODUCT APPLICATIONS 3

ENVIRONMENTAL PROPERTIES 4

FIRE PROTECTION 4

AUSTRALIAN CERTIFICATION 5

FIRE PROPERTIES 5

AUSTRALIAN TESTS 5

AUSTRALIAN & NEW ZEALAND STANDARDS 6

INTERNATIONAL STANDARDS 7

BOARD THICKNESS, SIZES AND EDGES • FRL 30/30/30 • 60/60/60 • 90/90/90 /...120/120 8

STEEL FRAME CONSTRUCTION 10

STEEL FRAME CONSTRUCTION FIRE RATED WALL : LOAD BEARING FRL 90/90/90 11

FIRE TESTED FIRE SEPARATION WALL AND BOUNDARY WALL: FRL 120/120/120 STEEL FRAMED CONSTRUCTION 1.15 BMT 12

FIRE RATED FIRE SEPARATION WALL FRL 120/120/120: STEEL FRAMED CONSTRUCTION 1.15 BMT BOUNDARY WALLS, STEEL AND TIMBER FRAMING 13

TIMBER AND STEEL FRAMING UP TO FRL 90/90/90 (LOAD BEARING): BOUNDARY WALLS STEEL AND TIMBER FRAMING 14

FIRE RATED WALL : STEEL FRAME CONSTRUCTION FRL RATED INTERNAL & EXTERNAL WALLS GENERAL INSTALLATION 15

FIRE RATED WALL : STEEL FRAME CONSTRUCTION FRL RATED INTERNAL & EXTERNAL WALLS GENERAL INSTALLATION - INTERNAL & EXTERNAL FIRE WALLS 16

FIRE RATED WALL - INTERNAL COLD ROLLED FORM, STEEL FRAME CONSTRUCTION NON LOAD BEARING FRL -/120/120 17

FIRE RATED WALL - EXTERNAL COLD FORMED SECTION INSTALLATION: STEEL FRAME CONSTRUCTION EXTERNAL FIRE WALLS - INSTALLATION FRL 90/90/90 AND FRL --/90/90 18

FIRE RATED WALL -EXTERNAL FIRE WALLS - INSTALLATION: FRL 60/60/60 AND FRL ---/60/60 STEEL FRAME FRL 60/60/60 (LOAD BEARING) 19

TIMBER FRAME CONSTRUCTION 20

FIRE RATED WALL - LOAD BEARING TIMBER FRAME CONSTRUCTION FRL 60/60/60**** 21

TIMBER FRAME WALLS FRL 60/60/60 (LOAD BEARING) 22

FIRE RATED WALL TIMBER FRAME CONSTRUCTION: (NCC) FIRE WALL SYSTEM INSTALLATION - INTERNAL & EXTERNAL FIRE WALLS TIMBER 23

TIMBER FRAME CONSTRUCTION: INSTALLATION : INTERNAL FIRE RATED WALL 24

FIRE TESTED DOUBLE FRAME, PARTY WALL SYSTEM : INSTALLATION - TIMBER FRAME CONSTRUCTION: FRL 90/90/90 **** 25

FIRE TESTED DOUBLE FRAME, PARTY WALL SYSTEM : INSTALLATION - TIMBER AND STEEL FRAME CONSTRUCTION • FRL 90/90/90 **** 26

FIRECRUNCH (NCC) ALTERNATIVE SYSTEM: FIRE SEPARATION WALL TIMBER AND STEEL FRAMING• FRL 90/90/90 27

FIRE TESTED DOUBLE FRAME , PARTY WALL SYSTEM • STEEL FRAME CONSTRUCTION FRL 90/90/90 28

FIRE RATED : CEILINGS & FLOORS 29

FIRE RATED CEILINGS AND FLOORS : FRL 90/90/90 30

FLOOR CEILING CSIRO FIRE TESTED SYSTEM: AS/1530.4-2014/20 DTS/ BCA FRL ----/90/90 LOAD BEARING FRL 90/90/90 31

STORAGE & HANDLING • OCCUPATIONAL HEALTH AND SAFETY • WHAT TOOLS ARE NEEDED? • CUTTING & MACHINING • UNDERCOAT & SEAL 32

GENERAL FIXING & INSTALLATION: • INTERNAL AND EXTERNAL FIRE JOINT SEALING • FASTENING • RECOMMENDED SCREW SIZES 33

PLASTER JOINT SETTING AND PAINTING 34

SINGLE TIMBER FRAMED FIRE WALLS FRL 60/60/60 35

STEEL FRAMED FIRE WALLS FRL 90/90/90 36

SINGLE TIMBER FRAMED FIRE WALLS FRL 90/90/90 37

Read the Content to find the right FRL for your projest/Building for /Timber or Steel

firecrunch.com.au FIRE TESTED BY NATA / CSIRO & OTHERS

03 No1 2020

FireCrunch CLADDING OVERVIEW Is a newly developed and extensively tested modern building board used in construction. It is made from a mixture of non organic minerals, bonders and fibre mesh composites. FireCrunch contains no formaldehyde, no asbestos and no toxic chemicals, NO VOC and most important no steel corrosive magnesium chloride as do most MgO products from China FireCrunch uses magnesium sulphate as the bonder and eliminates any steel corrosion. Australian NON ASBESTOS test certification by Clear safe NSW a NATA accredited testing laboratory to Australian Standards AS/4964 and Sharp and Howells Melb NATA test labs Non chloride (MgChl2). see Certification this web site.

KEY FEATURES ( NO METAL CORROSIVE (Mgchl2) CHLORIDE)

FCA is a smooth cut, densely bonded, 1.15 g/cm3 mineral fibre structure of FireCrunch ensures excellent machining and working properties using normal woodworking equipment or hand tools. In addition, the smooth face surface provides an ideal base for paint finishing with most industrial and domestic coatings. The back surface of FireCrunch is characterised by a coarse, wire screen texture which makes it ideal for rendering and tiling (although tile fixings can be applied to either side). FireCrunch is available in a range of accurately dimensioned sheet sizes and in thicknesses of 10mm interior exterior cladding boards available with square edge and tapered (recessed) edge for plaster set on long sides. 19mm TG flooring and 16mm TG decking interior / exterior use is available in TG size 2700 x 600.. Whilst all FireCrunch in any thickness is (NATA LABS Fire Tested) as Non Combustible AS/1530.1 .(Ask for test certificate) Only 10mm and above is "system Fire tested" ( CSIRO) in FRL from 30/30/30 to 90/90/90 and NCC solutions for FRL120/120/120 and above. FireCrunch is Certified and assessed for use in fire penetration walls, FIRE COLLARS (Snap Fire Systems) assessed by NATA CSIRO for use with FireCrunch 10mm sheets to FRL.../90/90.

PRODUCT APPLICATIONS

FireCrunch has a very wide range of uses for residential, commercial and industrial buildings, schools, hospitals, Government & social housing, utility buildings etc. The board has additional applications in fire safety, electrical switchboard backing blocks, electrical wiring channels and internal electrical risers and lift wells in multi-story and commercial buildings. Fire tests by NATA/CSIRO cover FireCrunch single 10mm sheets using Snap Fire Collars and internal wall electrics and plumbing protection for to FRL ...../90/90 and beyond.

(See web site for the full plans and instructional installations for building classification BCA classes 1 to 10.)

Internal applications: Internal walls, ceilings, floor sub base, bush fire building and roofing, wet areas tile backer, counter tops, kitchen furniture, built in wardrobes, hot areas and Fire surrounds.

Wet area applications: bathrooms, shower recess, kitchen, LAMINATED SURFACES - suitable for any wet areas or humidity prone areas. FireCrunch is mould resistant and once sealed correctly, will not degrade in standing water or flood conditions it remains inert and can simply be dried out in 48 HOURS , WITH NO LOSS OF MATERIAL INTEGRITY , re plaster set and repainted. Exterior applications: weatherboarding, soffits, lining or decking (meets AS/3959 and can be painted, papered, tiled, rendered or veneered.


04 No1 2020

ENVIRONMENTAL PROPERTIES Planet friendly, tree friendly

During the manufacturing process, in carbonation, FireCrunch draws back 90% of the Co2 created and makes it a virtually carbon neutral product generating 90% less Co2 than cement and plaster board products while eliminating the destruction of millions of oxygen producing, life sustaining trees.FireCrunch is 100% RECYCLABLE, and 45% waste recovery. FireCrunch (10mm, and 19mm) has been tested to ensure the highest fire protection offered and all in one board without compromising on quality or price. FireCrunch provides solutions in single and double stud fire separation wall systems without the use of complex expensive shaft liner and expensive space robbing Hebel sytems methods. The primary FRL tests in FRL 30/30/30 to FRL90/90/90 tests have been have been fire tested in systems, by the NATA Labs and CSIRO.see CERTIFICATION web site. Acoustic third party tests certified to Rw62 plus ctr, NET 52 and above . A double frameparty wall alternative is also available from X-Fire FRL 90/90/90 timber framing.The very high Fire Resistance Level (FRL) of FireCrunch means it can be used in all BAL areas including FZ in Bush FireAreas under AS/NZS 1530.8.2. (See separate Bush fire manual web site) Load Bearing Timber Frame FRL 90/90/90 Steel Frame FRL 90/90/90 tests have been fire tested in systems, assessed and certified by the CSIRO. see Accreditation web site. AS/1530.4- 2014/20 AND Acoustic third party tests certified to Rw62 plus ctr net 52 and above.*****Timber Frame FRL 90/90/90 Load bearing assessments are for the structural engineer to determine. Steel Frame FRL 120/120/120

FIRE PROTECTION

FireCrunch (10mm ) has been tested to ensure the highest fire protection PROVIDED and all in one 10mm board without compromising on quality or price. FireCrunch provides solutions in single and double stud fire separation wall systems without the use of complex expensive shaft liner OR EXPENSIVE HEBEL methods. The primary FRL tests in 30/30/30 to 90/90/90 tests have been fire tested in systems, assessed by the CSIRO. see Accreditation web site. Acoustic third party tests certified to Rw62 etc..show Rw52 net ctr . A double stud party wall alternative is also available from FireCrunch. The very high Fire Resistance Level (FRL 90/90/90 ) for FireCrunch means it can be used in all BAL areas including FZ in Bush Fire Areas under AS/NZS 1530.8.2. and AS 1530.4-2005/19).

Timber Frame FRL 90/90/90 Load Bearing Steel Frame FRL 90/90/90


05 No1 2020

Australian Certification

FireCrunch is certified and complies with the Building Code of Australia (BCA):

1. BCA Volume One 2014: C1.8 Lightweight Construction, C1.10 Fire hazard properties and C1.12 non-combustible components, including state variations for NSW.2. BCA Volume Two 2014: Part 3.5.3.3, Fibre Cement Planks and Weatherboard Cladding.3. BCA Volume Two 2014: Part 3.5.3.4, Fibre Cements Sheet Wall Cladding.4. BCA Volume Two 2014: Part 3.5.3.5, Eaves and Soffit Linings.5. BCA Volume Two 2014: Part 3.7.1, Fire separation for FRL, including state variations for SA.6. BCA Volume Two 2014: Part 3.7.4, Bushfire areas to Part: 3.7.4.0 and 3.7.4.1, including state variations NSW, QLD, SA,TAS.7. BCA Volume Two 2014: Part 3.8.6, Sound Insulation, including state and territory for NT. For more information on FireCrunch certification go to the company website: firecrunch.com.au

FIRE PROPERTIESFireCrunch is 100% fire resistant. It will not burn in a fire.FireCrunch complies with the Building Code of Australia (BCA) Material Group Number Classification and Deemed to Satisfy Provisions, as determined by AS/NZS 3837, AS/NZS 3959, AS1530.8.2 ) AS/1530.4 FRL TO 60/60/60 and 90/90/90 (Fire Tested and Scientific Assessment by CSIRO). The FireCrunch building product has been fire tested by the CSIRO to the Certification level standards of AS/3837 (Group 1 - Smoke release tests and non combustible materials test AS1530.1 and SYSTEMS TESTS UNDER AS/1530.4(2019) .FireCrunch (min. 10mm thickness) is certified for Bushfire Attack Levels (BAL) low, 12.5,19, 29, 40 and FZ (Flame Zone over 50Kw m2 irradiation, 1200ºc) regulation areas. FireCrunch meets the AS 3959 requirements, when used to protect timber - framing, under AS/NZ 3837 Group 1 materials and AS1530.1 and AS1530.4, and meets AS/3959 and AS/1530.8.2BLUE MNTNS CITY COUNCIL (BMCC Surveyors / Certifiers NOV 2019DEC 2017 Horizontal and vertical element FURNACE TESTS1000 degc BCA Compliance time and temperature curve. *******

Floors ceilings and bush fire roofing BMCC Surveyors and certifiers approved Bush Fire BAL FZ for Roofing, Eaves Walls and Floors ( NOV 2019) (Blue Mountains City Council : BMCC)

AUSTRALIAN TESTS:CSIRO carried out Non Combustible material tests for AS/1530.1 in 2019 see web site certifications and manuals.In progress special additional testing under AS/5637.

AS/NZS 3837:1998 Method of test for heat and smoke release rates for materials and calorimeter (Cone calorimeter test) - Walls & Ceilings.

AS/1530.4/2005-2014CSIRO FIRE REPORT March 2016 NO 2674 REPORT NO FSV 1708 Compliance ISO/IEC/17025CSIRO FIRE REPORT March 2016 NO 2707 REPORT NO FSV 1711 Compliance ISO/IEC/17025Methods for fire tests on building materials, components and structures,Part 4: Fire-resistance test of elements of construction covering fire resistance .

AS/NZS 1530.8.2 Applicable and covered under (AS/1530.4-2005/19)Bushfire Attack Levels (BAL) from BAL 12.5 to BAL 40 and Flame Zone (FZ) - over 50Kw m2 irradiation, 1200ºC SIMULATEDREAL TIME LIVE BUSH FIRE TEST CSIRO FEBRUARY 2012 MOGO NSW J LEONARD CSIRO PROJECT LEADER REPORT TESTDATE 15/02/2012 REF EP12179/FILE FE 2508 REPORT DATE JULY 2012 plus YGL GROUP Registered Fire Engineers SYD.Assessment under performance solutions NCC wall and roofing fire tests to meet AS1530.8.2 NATA LABS, RESOLUTELABORATORIES BRISBANE 2018.

Specimen (10mm) All FireCrunch CSIRO fire tests under AS/ 1530.4-2016 were exposed in the 1000 deg c furnace in "mandatory vertical orientation". Failure to orient the sheets vertical and to the exact fixing process with support elements specified as shown in the FireCrunch fire manuals will void the FCA Warranties.

TEST RESULTSIgnition No combustion at 1100ºCflame propagation No flame out at 1100ºCHeat release NominalSmoke release 1.5MJ/m2


06 No1 2020

AUSTRALIAN AND NEW ZEALAND STANDARDS

AS/ 1530.4/2014/20 CSIRO FIRE TEST REPORTS 24/08/2015 NO 2674 REPORT NO FSV 1708 Compliance ISO/IEC/1702521/09/2015 NO 2707 REPORT NO FSV 1711 Compliance ISO/IEC/17025

AS/NZS 3837 -Method of test for heat and smoke release rates for materials and products using an oxygen consumption calorimeter (Cone calorimeter test) - Walls & Ceilings (AS/NZS 3837) complies with Group 1 specification A 2.4 BCA).Properties are determined as follows:(a) Rate of heat release, by measurement of the oxygen consumption, as determined by the oxygen concentration and the flow rate in the exhaust product stream.(b) Effective heat of combustion from a concomitant measurement of specimen mass loss rate, in combination with the heat release rate.(c) Smoke release, by obscuration of light by the combustion product stream.(d) Ignitability, as a measurement of time from initial exposure to time of sustained flaming. (No Flaming recorded)

AS/NZS 1530.8 - Methods for fire tests exclusively for materials and elements of construction in bushfire-prone areas, namely:

AS/1530.8.1 - Tests on elements of construction for buildings exposed to simulated bushfire attack; Part 8.1 - Radiant heat and small flaming source, which covers BAL12.5 to BAL 40 *********

AS 1530.8.2 - Tests on elements of construction for buildings exposed to simulated bushfire attack.Part 8.2: Large flaming sources, which covers BAL FZ.

ISO 9239.1 - Reaction to fire tests for floor coverings (Floor radiant panel test). The main outcome from the test is a material’s critical radiant flux. The critical radiant flux is an indication of the amount of heat flux that needs to be applied to a material, to cause a small flame to ignite the material. The higher the material’s critical radiant flux, the better performing a material is. NO FLAME OUT RECORDED FOR TEST PERIOD.

AS/3959-2009 - Construction of buildings in bush-fire prone areas The objective of this Standard is to prescribe particular construction details for buildings to reduce the risk of ignition from a bush fire.Properties are determined as follows:(a) Potential for ignition caused by burning embers, radiant heat or flame generated by a bush fire; and (b) Intensity of the bush fire attack on the building.

BUSH FIRE ATTACK LEVELS (BAL) AND CORRESPONDING SECTIONS FOR SPECIFIC CONSTRUCTION REQUIREMENTS

Bush fire Attack Level (BAL) Description of predicted bush fire attack and levels of exposure.BAL-LOW There is insufficient risk to warrant specific construction requirements.BAL-12.5 Ember attack.BAL-19 Increasing levels of ember attack and burning debris ignited by wind borne embers together with increasing heat flux.BAL-29 Increasing levels of ember attack and burning debris ignited by wind borne embers together with increasing heat flux.BAL-40 Increasing levels of ember attack and burning debris ignited by wind borne embers together with increasing heat flux with the increased likelihood of exposure to flames.BAL-FZ Direct exposure to flames from fire front in addition to heat flux and ember attack.


07 No1 2020

INTERNATIONAL STANDARDS

FireCrunch has a class A fire rating internationally relates to AS/1530.1 NATA CSIRO TESTED 2019• European Standards UNI EN ISO 1182 (non-combustible)• European Standards UNI EN ISO 1716 (heat resistance)• European Standards UNI EN ISO 13501-1 (smoke and flame)• United States & Canada US ASTM E136 (non-combustible)• British Standard 476 part 4 1970 (non-combustible)

(ILAC) THE INTERNATIONAL LABORATORY ACCREDITATION ASSOCIATION has world wide complying laboratory testing with worldwide membership over 100 countries In Australia NATA is the complying member and in China ,The Chinese National Academyof Science (CNAS) . Testing approved by either of these 2 entities ACCREDITED TEST LABORATORIES, meets the equal Australianstandard of ILAC and test RESULTS FROM THESE 2 ORGANISATIONS can be certified AND ACCCEPTED as such in Australia.

IMPORTANT NOTE TO ABOVE ****

AS ALL STRUCTURAL LOAD BEARING REQUIREMENTS VARY CONSIDERABLY THE FIRE TESTS ARE RELATED TO FIGURE 2 AND 3 ie STRUCTURAL

INTEGRITY 90MINS AND INSULATION 90MINS. THE REQUIRMENT IN LOAD BEARING MUST BE DETERMINED BY A STRUCTURAL ENGINEER RELATIVE

TO THE INDIVIDUAL LOAD BEARING SPECIFICATION REQUIRED AND APPROPRIATE SPECIFICATION IN STEEL OR TIMBER TO SUPPORT THE LOADING

REQUIREMENT IN ADEQUACY ( THE FIRST FIGURE 90 MINUTES) 2 LAYERS OF 10mm Firecrunch boards ARE REQUIRED FOR FRL 120/120/120 .

AS1530.1, AS1530.4, AS1530.8.2, ( NCC) AS 3837, AS4964, AS717 , (AS/5637 PENDING) CSIRO TEST FEB 2020


08 No1 2020firecrunch.com.au FIRE TESTED BY NATA / CSIRO & OTHERS

Board Thickness, SIzes and EdgesFRL • 30/30/30 • 60/60/60 • 90/90/9 • /120/120/120.FireCrunch is a product sold in 4 different thicknesses in stocked sizes . Other sizes and thickness are through special order and minimum quantities apply.

All boards from 10mm,12mm 16mm and19m are Fire tested in Walls, Floors, Ceilings and Roofings to BAL FZ . Check 1300 933 102 for details (Technical) or check manual link. 10mm, 12mm, 16mm and 19mm in sizes shown.

8.5 - 9mm

28-30mm

ORDER code: TG19-2700 X 600

10mm

10m

m

10mm Square Edge (SE)

GROOVED WEATHER BOARD 12mm SHIP LAP (TS12)FRL 30/30/30, 60/60/60, 90/90/90 AND.../120/120 more on FE assessment. There are also a few different types of edges see chart below.Drawings NOT to scale.

Timber appearance for Exterior & Interior walls (Non combustible) AS1530.8.2 and AS 1530.1 BAL FZSize: 2700 x1000mm x 12mm (TS12)

10mm Tapered or Recessed Edge (TE)

Order code: SE10-1200 X 2400 ( 2700mm) or (3000mm)

Order code: TE10-1200 X 2400 ( 2700) OR (3000)

Order code: TS12-2700X1000

Uses:

Eaves, Ceilings, Exterior & Interior lining (fire rated) (AS1530.4-2016)Sizes: 2400 x 1200mm 2700 x 1200mm 3000 x 1200mm

16mm Tongue & Groove (TG)Grooved DECKING Board 16mm (TG) Groove sections 5mm WIDE :140mm GROOVE BOARD WIDTH2700 x 600

Order code: TG16DK-2700 X 600

16m

m

14mm 5mm

19mm Tongue & Groove (TG)Uses: Interior and exterior flooring and deckingSize: 2700 X 600 19mm TG

19m

m

• AS/1530.1 Non Combustible materials test NATA• AS/3837 Smoke and flame Cone Calorimeter test NATA• AS/717 Acoustics To Rw 62 NATA• AS/4964 Non Asbestos content certification NATA• AS1530.4 FRL 90/90/90,90 minutes load bearing NATA/ CSIRO• MgSO4 New Generation Magnesium Oxide Cladding Boards

Australian Standards Tested (BCA) CSIRO /NATA AS/1530.4-2016FRL 30/30/30, 60/60/60 ,90/90/90 /...120/120. Load Bearing Walls 55kN (1.15 BMT) LightSteel 92 x45mm Frame

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Board Thickness, Sizes and EdgesFRL 30/30/30, 60/60/60 ,90/90/90 /.. .120/120.


STEEL FRAME CONSTRUCTION

Brisbane’s iconic Gabba used FireCrunch boards

11 No1 2020

STEEL FRAME CONSTRUCTION FIRE RATED WALL - LOAD BEARING FRL 90/90/90/ and over FIXING NOTES:• Steel framed walls, floors and ceilings are to be constructed strictly in accordance with AS/NZS 4600 (Cold Formed Steel Structures), the Building Code of Australia and all relevant Standards. • Fasten to the studs, joists and rafters min 15mm from the edge and 50mm from the corner of boards and staggered each side of sheets joints at maximum of 200mm centres.

• Fasteners should be recommended corrosion proof, ribbed head bugle screws and finish with the head 2mm below just below the surface of the FireCrunch boards and 2 pack fill.

• The boards are strong but care should be taken not to damage the core or face.

• All external wall must be surface sealed with approved MgO sealer primers to front face only and both side and top edges back left unsealed, see recommended products products web site before, or immediately after installation. Net cavity of 90mm and 20ga min (1.15 BMT) galvanised steel frame filled with 90mm min R 2.5 glass wool batts for single and double steel frames.

• Movement or control joints should be provided where the FireCrunch abuts dissimilar materials, where the construction changes within the plane of the wall, and at not more than 5 metre centres.

• External joints are to be filled with recommended fire sealant AS/1530.4 Tested and approved product information is available on our support website (AS/ 1530.4 APPROVED )

• For FRL 90/90/90 steel stud walls are to have a minimum cavity of 90mm, minimum 20ga (min 1.15 BMT) galvanised steel and external walls are to be filled with mineral wool /rockwool batts. (as per FRL required, SEE DETAILED NOTES THIS MANUAL) • Use corrosion proof screws.

1

2

3

4

5

6

7

1 Screw fix Boards to walls and at base which should be concrete plinth, if no concrete slab . use 0.75BMT galvanised steel U track or 90 deg steel angle section and fire seal the FireCrunch board to these joints sets.2 92 x45mm 20ga steel frame. use 1.15 BMT , for load bearing or check with structural engineer for project.3 Minimum 10mm FireCrunch external lining.4 Fire sealant, AS/ 1530.4 , Gun down 3x 3mm thick beads on stud face and comb down face before applying the next board and fixing with min 6mm gap and gun fire sealant into 6mm gap ,tool down 2 to 3mm for shadow line panel effect. Use DULUX 1 STEP primer sealer plus 2 FINISH COSTS using Dulux water based paints or use exture coats or render finishes.5 A vapour barrier/sarking must be used for all fire walls. between frame and FireCrunch board.6 Use min R 2.5 GLASSWOOL for FRL 60 minutes or mineral wool batt min 64 kg for FRL 90/90/90 and above.7 10mm FireCunch Internal lining/boards are NATA LABS CSIRO TESTED FRL 90/90/90 from both sides.

Table of : 01- Numbers related to drawings

COLD ROLL FORMED SECTION - STEEL FRAME CONSTRUCTION

INDICATIVE CONSTRUCTION DIAGRAM

RECOMMENDED PRODUCTS

Check website for all recommended PRODUCTSfor use with FireCrunch boards which are first updated on theweb site The latest products that have been tested andapproved for use on the FireCrunch product can be viewedon the website.

RIGHT ANGLE SECTION


12 No1 2020

3

INDICATIVE CONSTRUCTION DIAGRAM

FIRE TESTED FIRE SEPARATION WALL AND BOUNDARY WALLFRL 120/120/120STEEL FRAMED CONSTRUCTION 1.15 BMTFRL 120/120/120 NCC Performance tested solution90mm R 2.5 glasswool batt Screw at 200mm centres 12mm from EDGE

1

Table : 01- Numbers related to drawings1• For 60 and 90 minute WALLS use 1 LAYER 10mm FireCrunch SE10 and 1 LAYER 10mm TE10 (Recessed edge) on the inside for plaster set joints.2• USE TS12 FOR "Timber Groove" board look INTERIORS or Exteriors.3• 92 x 45mm steel framed CFS fire wall min 20GA (1.15 BMT).4• FireCrunch Board Use 90mm thick R 2.5 glass wool batt (with 2 x 10mm sheets) Screw at 200mm centres 15mm from EDGE.(EXTERIOR ONLY) gun in sealant. If plaster joint required Internally use ONLY recommended products plaster set compounds perinstructions web site FCA (TE) recessed edge board butt joint. Do NOT gun fire sealant into internal board joints . Gun Fire sealantdown the stud face joints only 3 x 3mm beads, just butt set TE10 boards.5• Vapour barriers/sarking must be used between frame cladding board for all fire walls.6• Use min 90mm R2.5 Glasswool batts where 2 sheets used per side for FRL 120 minutes.7• 2x 10mm X-Fire internal lining each side NATA TESTED FRL 120/120/120 ***** from both sides.

NOTE: This is an NCC PERFORMANCE TESTED "Alternative" solution and should be discussed with your fire consultant and Fire Certifieror surveyor first. SEE TEST REPORT and FIRE ENGINEER ASSESSMENT WEBITE. (Load bearing must be approved by structural Eng. for project)

4

2

3 5

6

7

Table of : 01- Numbers related to drawings

FIRE RATED SINGLE FRAME FIRE SEPARATION WALL FRL 120/120/120

NOTE:The first FRL figure is"Structural Adequacy and is determined by theproject structural and fire engineer relative to these FireCrunch tests.

FireCrunch is the 2nd figure materials integrity to withstand the FIRE test duration and control the temperature to 140 deg average on the unexposed face of the test sample.

FireCrunch Board 10mm HAS PASSED FIRST TIME WITHEVERY BNATA FIRE TEST IT AHASBEEN SUBJECTED TO WITHOUTVARIATION IN MATERIALS,CONTENT, OR DESIGN. ALLCERTIFICATES OF COMPLIANCE AREPOSTED on the website


Galvanised Right angled slim corner section

13 No1 2020

FIXING NOTES

• Movement or expansion control joints should be provided where the FireCrunch abuts dissimilar materials, where the construction changes within the plane of the wall, and at not more than 5 metres.• TIMBER FRAMES External joints are to be filled and backing studs facings applied with recommended fire sealant AS/1530.4 Tested and approved product information is available on our support website NCC) .

(NCC) ALTERNATE TESTED SYSTEM• For FRL 60/60/60 TIMBER STUD WALLS are to have a minimum cavity of 90mm x 45mm stud frame and a 10mm sheet

each side of frame min R 2.5 GLASS WOOL or R value to suit climate Zone of property but not below R 2.5 .

• NOTE :THE MAX FRL USING FCA ON TIMBER FRAMING IS FRL 60/60/60 SINGLE FRAME and FRL .90//90/90 ON DOUBLE STUD.

TIMBER AND STEEL FRAMING

• USE STEEL FRAMING for LOAD BEARING ( 55kN) FRL 60/60/60 to 90/90/90 and ABOVE• AS/1530.4 -2019 (Approved steel framing min 1.15BMT )• Steel framed walls, floors and ceilings are to be constructed strictly in accordance with AS/NZS 4600 (Cold Formed Steel Structures), the Building Code of Australia and all relevant Standards.• Fasten to the studs, joists and rafters min. 12mm to 15mm from edge of board and 50mm from the corner of boards and be staggered fixed each side of board joint at a maximum of 200mm centres.• Fasteners, use recommended corrosion proof, ribbed head bugle screws and finish 2mm below the surface of the FireCrunch boards. (2 pack fill)• The boards are strong but care should be taken not to damage the core or face.• All external walls must be surface and edge sealed with approved RECOMMENDED PRODUCTS WEB SITE) SEALER primers, before, or immediately after installation. Cavity of 90mm and (20ga) min (1.15 BMT Galvanised steel frame filled with 90mm min 64Kg minimum thickness mineral wool batt. Use R2.5 glasswool batts on timber frames, see recommended products web site.• Movement or expansion control joints should be provided where the FireCrunch abuts dissimilar materials, where the construction changes within the plane of the wall, and at not more than 5 metre centres.• External joints are to be filled with recommended fire sealants showing AS/1530.4 on package. Bostik Fireban, Tremstop PU, Sikka Fire stop ect SEE WEB SITE RECOMMENDED PRODUCTS.• Steel Frames minimum 20ga (min 1.15 BMT) Galvanised steel ) 90 X 45mm stud frames. TIMBER MIN 90x45mm STUD FRAMES.

• NOTE : USE TIMBER FRAMING TO FRL 60/60/60 SINGLE ,AND FRL 90/90/90 DOUBLE FRAMES (WHERE LOAD BEARING REQUIRED YOU WILL NEED STRUCTURAL ENGINEERS APPROVAL FOR THE PROJECT TIMBER FRAMING

NOTES FOR TIMBER FRAMING FRL 60/60/60 and 90/90/90*****Fix 10mm FireCrunch boards to the outer SINGLE timber frame install vertically . Put the FRL 60/60/60 R2.5 fire batt in the 90mmcreated cavity and screw fix the outer 10mm FireCrunch boards as per instruction on technical ref sheet at 200mm centres . Before fixing THE OUTER WALL SHEET, see that the fire sealant is gunned down the outer face of each joined stud point to boardand the 6mm gap left between boards is further filled AFTER FIXING with fire sealant to 2/3mm from top of edges, tool down forshadow line joint as Sealants have expansion joint capability. Screw fix at 200mm centres with self c/s bugle head screws.Then Undercoat seal the board with DULUX 1 step primer sealer, and apply 2 coats water based paints or render as required .

FIRE RATED FIRE SEPARATION WALL FRL 120/120/120STEEL FRAMED CONSTRUCTION 1.15 BMTBOUNDARY WALLS STEEL AND TIMBER FRAMINGFIRE RATED BOUNDARY WALLS, LOAD AND NON LOAD BEARING, FOR BOUNDARY WALLSFRL 60/60/60**** to FRL 90/90/90**** AS/1530.4-2019) BCA, CSIRO, NATA, FIRE, ON ASBESTOS AND NON CHLORIDE NATA TESTED. (CSIRO CERTIFICATES WEB SITE)


14 No1 2020

FRL /60/60/60*****& 90/90/90*****

TIMBER FRAMES: Use 2.5 Kg Glass wool fire batts min 90mm thick FRL 60/60/60 for timber single frames and for FRL 90/90/90 for double stud timber frames ALL min 90mm x 45mm MGP10 TIMBER. SEE NOTE END PAGE LOAD BEARING1 x FireCrunch 10mm each side single and double frames LOAD BEARING STEEL FRAMES (55kN), ( 5 Tonne) 60/60/60 and FRL 90/90/90 M R2.5 Glass wool batts, (min 1.15 BMT STEEL ). 92mmx 45mm stud frame 400 centres.

Minimum 10mmFireCrunch external lining

(1.15 BMT) 92mm x 45mmCFS steel frame FRL 90/90/90max or 90mm x 45mm timberstud frame FRL 60/60/60 max

Suitable moisture barriers ( BCA) must be used forall external walls between frame and board.

6mm fire sealant gap jointsin FireCrunch external lining sheets.set on vertical stud facings

*****NOTE: NO FRL LEVEL TEST CONFIRMATION can be obtained unless there is a corresponding Firecrunch board on the INNER face of the Frame. Whilstall Firecrunch board is NON combustible AS /1530.1 and AS/3837, for a tested DTS system rated IN FRL under AS/1530.4 and AS/1530.8.12 , there must be an FCA sheet each side of frame to qualify the FRL under BCA DTS. OTHERWISE NO PRODUCT FRL CAN BE FRL TEST RATED. IF PLASTER BOARD IS WANTED ON THE INTERIOR FIRE ATTACK SIDE THE NATA CSIRO FireCrunch CERTIFICATES CANNOT BE USED AND A FIRE ENGINEER WILL NEED TO RE ASSESS FCA WITH 13mm PLASTER BOARD . FIRE ENGINEERING ASSESSMENT FEES WIL BE INCURRED BY THE APPLICANT IN SUCH INSTANCES FireCrunch CAN ASSSIST WITH THIS IF REQUIRED 1300 933 102

IMPORTANT NOTE TO ABOVE ****STEEL FRAMING to above spec is tested to load bearing 55kN Timber framing requiers structural ENG opinion as to load of timber framing using 400 stud centres1st FRL fig.

*****NOTE:TIMBER FRAME LOAD BEARING, Drawing above (where timber framing is being used)MUST BE ASSESSED BY THE PROJECTS STRUCTURAL ENGINEER. THE CAPABILITY IN MATERIAL INTEGRITY AND INSULATION (2ND AND 3RD FIGURES) IS FULLY FIRE TEST ESTABLISHED BY THE CSIRO FIRE TESTS DTS.

**** LOAD BEARING WALL NOTES:-Please note that Timber frames 90mmX45mm have been tested in a non load bearing format.The 2nd figure “MATERIAL INTEGRITY” in containing no fire pass and the 3RD Figure “INSULATION PERIOD “ have all been tested to the BCA standard under NCC. Because all load bearing walls will vary . To “QUALIFY” the first figure “STRUCTURAL ADEQUACY” the project structural engineer must specify the timber framing dimensions to meet required load bearing in timber and timber type FIRE TEST REPORTS AVAILABLE. [email protected] or see web site browser manuals.If this is not a viable solution in timber then the frame must be built of steel as per CSIRO/NATA FRL 60/60/60 and FRL 90/90/90 fire tests assessment to MIN LOADBEARING OF 55kN achieved on 1.15BMT . ( CERTIFICATES OT TEST see WEB SITE)

LOAD BEARING MUST BE DETERMINED BY A STRUCTURAL ENGINEER RELATIVE TO EACH PROJECT SPECIFICATION . STEEL

FRAMNG IS FULL TEST CERTIFIED TO FRL 90/90/90 using 1.15BMT GAUGE STEEL

Pest protection is provided.NOTE: FireCrunch is of no interest to Termites. PROTECTS EXPENSIVE TIMBER FRAMING

Timber and Steel Framing up to FRL 90/90/90 (LOAD BEARING)BOUNDARY WALLS STEEL and TIMBER FRAMING

IMPORTANTFIRE WALL SHEETS CAN ONLY BE SET VERTICALLY.

SET boards MORE THAN 50 to 100mm from to of Slab or if BOARD set to of SLAB USE STEEL ANGLE OR "U" TRACK and FIRE SEAL to Firecrunch board to BASE.



FIRE RATED WALL : STEEL FRAME CONSTRUCTION

STEEL FRAME FRL RATED INTERNAL & EXTERNAL WALLSGENERAL INSTALLATION - INTERNAL & EXTERNAL FIRE WALLS

Firecrunch has fire rated tests certificates and assessments by NATA LABS up to FRL 90/90/90 and provides NCC performanceSolutions based on NCC alternative systems using two layers of 10mm FireCrunch each side for FRL 120/120/120 and over **** refer to technical section on website.

FireCrunch over FRL 120/120/120 REFER FireCrunch TECHNICALL 1300 933 102FRL.... /120/120 steel frame, NON load bearing ,90mm cavity orFRL 90/90/60 steel frame, load bearing 90mm cavity 55 kNFRL 60/60/60 steel frame, load bearing 90mm cavity 55 kNFRL 30/30/30 steel frame, load bearing 90mm cavity 55 kNFRL......./120/120 plus refer FirecrunchFRL ......../90/60 FRL........./60/60FRL........./30/30 Installation manuals are related directly to the FireCrunch warranty and must be adhered to exactly, To achieve the fire FRL rating specified in these formats , FireCrunch must be installed in accordance with these installation manuals. Mixing Fyrchek or similar other " Plasterboard" sheeting wil void the FCA warranty as installs must be exactly to the test parameters.To achieve the fire rating in these formats FireCrunch must be installed in accordance with this installation manual.

Frame Construction SpecificationSee FireCrunch CSIRO fire test certificates for details under "Certification of testing " please see web site.

• One layer of 10mm FireCrunch on studs, fixed vertically, to galvanised steel stud wall framing, with noggings.• Board must be screw fixed to steel framing, separator battens are not required. • Stud adhesive MUST NOT BE USED in flood prone areas.• Stud adhesive should not be used in flood prone areas FRL.• All joints must be backed by studs Nogs or back blocker for 450mm stud centre overruns.• Screw at 200 centres 10/12mm from edge and on studs and nogs. Stagger edge fixing 100 mm on each side board joints• Approved AS/1530.4 fire rated sealant must be used on all relevant joints. See website: recc products.• Studs should be at 400mm centres.If using 450mm studs CENTRES a vertical back blocker will be required for 300 over run using 1200 wide boards/sheets. 600mm stud centres cannot be used on fire walls.

FRL (FireCrunch side) STUD CAVITY depth CAVITY INFILL* (DTS SOLUTION)

120/120/120***** 2 layers 10mm (offset joints) min. 90mm 1.15 BMT 90mm thick 64 kG Rockwool / Mineral wool batts (NCC ) Load or Non load Bearing

90/90/90 1 layer 10mm min. 90mm 1.15 BMT 90mm thick R 2.5 GLASSWOOL BATT NCC /BCA TESTED

60/60/60 1 layer 10mm min. 90mm 1.15 BMT 90mm thick R 2.5 GLASSWOOL BATT NCC /BCA TESTED

Stud

Stagger screws on either side 200mmcentres at min. 10mm to 12mm from edge.Use recommended corrosion proof screwsfor external application.Note: Drawing not to scale in mm shown.

Rock wool or Mineral batt min64kg for FRL 90/90/90 and /orclimatic area required.

FireCrunch approved firerated sealant AS/1530.4

6mm min. gap, tool down 2mm from surface edge.

FireCrunch TE10 (10mm)Recessed edge

50mm widePaper tape internal

INTERNAL (INSIDE) WALL EXTERNAL (OUTSIDE) WALL

Moisture /vapour barrier

INTERNAL/EXTERNAL FIRE WALLS

Screed 3 x 3mm beadsrecommended productsFire Sealant AS/1530.4over stud face beforefixing FireCrunch board.

Butt set the 10mm firecrunch TE boardleave expansion joint every 5 meters .

Screed 3mm THICK recommendedproducts Fire Sealant over width andlength of stud face under joints beforefixing FCA board.

USE FCA 10mm (SE) SQUAREEDGE board for EXTERNALCLADDING

USE RECESSED EDGE BOARD TYPE FCA (TE) FOR INTERNAL PLASTER SETPaper Tape and Base coat,topping and feather out150mm usual practice.

Approx. 3x3mm thick beads gunned on ,approved AS/1530.4 fire sealant between stud face and sheet before fixing sheets.

Stagger screws on either side 200mm centres at min. 10/ 12mm from edge

Check recommended product section web site for plaster joint installs to retain FireCrunch warranty .

FIRE RATED WALL :STEEL FRAME CONSTRUCTION up to FRL 90/90/90STEEL FRAME FRL RATED INTERNAL & EXTERNAL WALLS GENERAL

Do not use fibre fuse type tapes internal and well 'pre soak' the recessed edge board, before applying the trade base coats and paper. see manual web site plaster set joints.


Stagger fixing at 200mmcentres on join

Screw fixing at200mm centres

Fastener Spacing

Fastener Position

Stagger fixing at 200mm centres on join

Screw fixing at 200mm centres

10 gauge, 16 TPI, 25mm, CSK rib, X Drive#1, DP

Set joints with fire rated sealant

Screw fix at 200mmMax centres top and

bottom frame

Screw fix at 200mm Max centres top and

bottom frame

NOTE: HORIZONTAL "single sheet" CLADDING CANONLY BE USED IN "NON LOAD BEARING" WALLS.

NOTE : DOUBLE 10mm LAYER INSTALL ,FireCrunch sheets must be laid in vertical configuration with 75mm offset fire joints.

10mm gap between board and floor /footings .

Caulk perimeter with approved fire rated

sealant

FIRE RATED WALL - INTERNALCOLD FORMED, STEEL FRAME CONSTRUCTION NON LOAD BEARING FRL 120/120/120

INTERNAL FIRE WALLS - INSTALLATION NON LOAD BEARING FRL - 120/120/120this FRL 120/120/120 is an NCC BCA STANDARDS tested alternative performance solution, Certifiers can download the actual full fire test reports in each from the website. LOAD BEARING FOR "FIRST" FRL FIGURE NEEDS TO BE DETERMINED AND APPROVED BY THE PROJECTS STRUCTURAL ENGINEER THE FireCrunch "MATERIAL INTEGRITY" AND "INSUALTION" MEET THE 120 MIN RATING.

STEEL Thickness 0.95/550//1.15mm/300 STUD CAVITY depth CAVITY INFILL* (DTS SOLUTION) FRL Load /NON Load Bearing

10mm* 2 layers 10mm (offset joints) min. 90mm 1.15 BMT 90mm min. R 2.5 GLASS WOOL BATT 120-/120/120

ALL Fixings at 200mm Centres

Fastener Position Fastener Spacing

Centre of board 200mm max. centres

Recessed edges 200mm max. centres staggered

Butt joints 200mm max. centres

Corners & openings 200mm max. centres

FireCrunch approved fire rated sealant must be used on all joints .

SCREWS : Use only Self Countersink Ribbed Head screws.

Fastener Spacing

ALL Fixings at 200mm Centres Fastener Position Fastener Spacing

Centre of board 200mm max. centresRecessed edges Fix at each studButt joints 200mm max. centresCorners & openings 200mm max. centres

SINGLE LAYER HORIZONTAL INSTALLATION NON LOAD BEARING

SINGLE LAYER VERTICALINSTALLATION LOAD BEARING WALL


FIRE RATED WALL - EXTERNAL CFS COLD FORMED SECTION - STEEL FRAME CONSTRUCTION

EXTERNAL FIRE WALLS - INSTALLATION FRL 90/90/90 and FRL ../90/90


Board Thickness STUD CAVITY depth CAVITY INFILL* (DTS SOLUTION) FRL NON Load Bearing

10mm Firecrunch min. 90mm 1.15 BMT 90mm min. R 2.5 GLASS WOOL BATT FRL 90/90/90 and FRL ---/90/90



Stagger fixing at 200mm centres on join Suitable moisture

barriers should be used for External walls.

6mm gap between board and floor. Caulk perimeter with approved fire rated sealant AS/1530.4 .If secured to top of concrete use steel U track and fire seal.

Fastener Spacing







Top & Bottom Frame 200mm max. centres

Approved AS/1530.4 Fire rated sealantmust be used on all joints as per the instructionsRECOMMENDED PRODUCTS see WEB SITE

NOTE: VERTICAL CLADDING MUST BE USED IN "LOAD BEARING" FIRE WALLS DO NOT USE HORIZONTAL CLADDING

SINGLE LAYER VERTICALINSTALLATION LOAD BEARING WALLInstall FireCrunch sheets in a vertical arrangement if using tapered/recessed edge board.

for 64mm and 76mm Steel Stud frames CONSULT FCA under NCCMaximum depth between surface of screw head and surface of FireCrunch should not be more than 1.5mm. 2 Pack fill C/Sink screw holes Exteriors. Minimum fastening distance from edge of board should be 12mm.



Screw fixing at 200mm MAX centres top and bottom

of FRAME.

Fastener Spacing




Recessed edges Fix at each stud





NOTE: HORIZONTAL "SINGLE SHEET" CLADDING WITHBACK BLOCKING ON ALL HORIZONTAL JOINTS CAN ONLYBE USED IN "NON LOAD BEARING" FIRE WALLS.

SINGLE LAYER HORIZONTAL INSTALLATION NON LOAD BEARINGInstall FireCrunch sheets in a horizontal arrangement ifusing square edge board.



all joints must be sealed with

recommendedproducts

76mm Steel Stud frames CONSULT FCA under NCC

FIRE RATED WALL -EXTERNAL

EXTERNAL FIRE WALLS - INSTALLATION FRL 60/60/60 and FRL ../60/60STEEL FRAME FRL 60/60/60 (LOAD BEARING)



Board Thickness STUD CAVITY depth CAVITY INFILL* (DTS SOLUTION) FRL Load Bearing

10mm Firecrunch 90mm 1.15 BMT 90mm min. R 2.5 GLASS WOOL BATT FRL 60/60/60 and FRL ---/60/60

Fastener Spacing









SINGLE LAYER VERTICALINSTALLATION LOAD BEARINGInstall FireCrunch sheets in a vertical arrangement if using tapered/recessed or chamfered edge board.

Fastener Spacing




Recessed edges Fix at each stud





NOTE: HORIZONTAL "SINGLE SHEET" CLADDING WITHBACK BLOCKING ON ALL HORIZONTAL JOINTS CAN ONLYBE USED IN "NON LOAD BEARING" FIRE WALLS.

SINGLE LAYER HORIZONTAL INSTALLATION NON LOAD BEARINGInstall FireCrunch "single" sheets in a horizontal arrangement and back block all horizontal joints and fire seal .

Maximum depth between surface of screw head and surface of FireCrunch should not be more than 1.5mm. 2 Pack fill exteriors. Minimum fastening distance from edge of board should be 10/12mm.

For screwing FireCrunch to steel framing use recommended stainless steel or corrosion proof screws.





Screw fixing at 200mm MAX centres top and

bottom of FRAME.

Suitable moisture barriers should be used for External walls.

6mm gap between board and floor. Caulk perimeter with approved fire rated sealant AS/1530.4 .If secured to top of concrete use steel U track and fire seal.


FRL 60/60/60 FRL 90/90/90 *******

FIRE TESTED SINGLE WALL, TIMBER FRAME CONSTRUCTION

FIRE TESTED DOUBLE FRAME, PARTY WALL SYSTEM CONSTRUCTION

FRL ....../90/90 DOUBLE STUD FRAME PARTY WALLS ONLY 220MM******** ACOUSTIC RW62

FIRE TESTED DOUBLE FRAME, PARTY WALL SYSTEM INSTALLATION - TIMBER FRAME CONSTRUCTION FRL .....90/90 ****

FIRE SEPARATION WALL TIMBER FRAMING AND FRL 90/90/90

NATA LABS TESTED NCC ALTERNATIVE PERFORMANCE FIRE TEST SOLUTIONS FIRE TESTED DOUBLE TIMBER FRAME, PARTY WALL SYSTEM

TIMBER FRAME CONSTRUCTION


FIRE RATED WALL - LOAD BEARING TIMBER FRAME CONSTRUCTION FRL 60/60/60****

FIXING NOTES: (TESTED/ Solution NCC / BCA)

• Timber framed walls, floors and ceilings are to be constructed strictly in accordance with AS/NZS 1684 (Timber structures), the Building Code of Australia and all relevant Standards.

• Fasten to the studs, joists min. 10 to 12mm from the edge and 50mm from the corner of boards and staggered each side at a maximum of 200mm centres .

• Fasteners should finish with the head just below the surface of the FireCrunch. USE TWO PACK FILLER and sand off.

• The boards are strong but care should be taken not to damage the core or face.

• Exterior FireCrunch cladding only ...must be properly weather sealed ON THE EXTERIOR FACE , at the ends and joints . USE TREMCO UC200 ROLL on WEATHER MEMBRANE prior to, or very soon after installation, to avoid prolonged exposure unprotected to weather. IF BOARD HAS HAD PROLONGED EXPOSURE TO RAIN IT , MUST BE DRIED 24/48 HOURS OUT BEFORE (UNDER 10% HYDRATION) APPLYING EXTERIOR MEMBRANE and PAINTS etc. WHILST THE BOARD IS WATER RESISTANT AND WILL QUICKLY DRY OUT, IN GOOD BUILDING PRACTICE KEEP UNDER COVER BEFORE USE AND SEALING SURFACE.

• Movement or control joints should be provided where the FireCrunch abutts dissimilar materials, where the construction changes within the plane of the wall, and at not more than 5 meter centres.

• External joints are to be filled with a recommended expandable fire sealant. AS/1530.4 Approved product information is available on our support website

• Timber stud walls are to have a minimum cavity of 90mm.

• All walls are to have a cavity depth to accommodate a 90mm R 2.5 GLASSWOOL BATT fire batt for single framed timber stud walls. minimum R2.5 for TIMBER FRAMING Radiata Pine/ MGP 10 or similar softwoods to FRL.....60/60 ALL STUDS to MAX 400mm CENTRES or LESS. ( if 450mm in place an extra stud will be required to meet 300mm overun on 1200 wide boards/sheets.

• Recommended products WEB SITE

**** LOAD BEARING WALL NOTES:-Please note that Timber frames 90mm x 45mm have been tested in a non load bearing format.The 2nd figure “MATERIAL INTEGRITY” in containing no fire pass and the 3RD Figure “INSULATION PERIOD “ have all been tested to the BCA standard under NCC. Because all load bearing walls will vary . To “QUALIFY” the first figure “STRUCTURAL ADEQUACY” the project structural engineer must specify the timber framing dimensions to meet required load bearing in timber and timber type FIRE TEST REPORTS AVAILABLE. see web site for manuals. If this is not a viable solution in timber then the frame must be built of steel as per CSIRO/NATA FRL 60/60/60 and FRL 90/90/90 fire tests assessment to MIN LOAD BEARING OF 55kN achieved on 1.15BMT . ( CERTIFICATES OT TEST WEB SITE )


TIMBER FRAME WALLS FRL 60/60/60 (LOAD BEARING)

Minimum 10mm FireCrunch EXTERNAL Lining

Timber framed stud wall

FRL 60 /60/60 can only be achieved if min 10mm FireCrunch is applied both sides as per the NATA RESOLUTE LABS FIRE TEST.(Certification) . Fire attack containment for attack each side requires Firecrunch 10mm each side Interior and Exterior.

Suitable moisture vapourbarriers to be used for allexternal walls.

Use recommended R 2.5 Glasswool batts

90mm x45mm timber MGP10 single stud frame

Ensure the finished ground level ismore than 50-100mm from the topof the floor slab and appropiate vermin and pest protection is provided by the FCA board. Fire /weather seal with u trackor furring channel on base edge of board where required. NOTE: FireCrunch is of no interest to termites

plaster board 13mm can be used for interior walls in free standing homes, However FireCrunch CSIRO Certificates can not be used and a separate assessment is required by a fire engineer as if the test materials are changed it invalidates the certificates.

**** LOAD BEARING WALL NOTES:- Please note that Timber frames 90mmX45MMM have been tested in a non load bearing format.The 2nd figure “MATERIAL INTEGRITY” in containing no fire pass and the 3RD Figure “INSULATION PERIOD “ have all been tested to the BCA standard under NCC. Because all load bearing walls will vary To “QUALIFY” the first figure “STRUCTURAL ADEQUACY” the project structural engineer must specify the timber framing dimensions to meet required load bearing in timber and type for 60 or 90 minutes. FIRE TEST REPORTS AVAILABLE [email protected] For timber walls a structural engineer will be required to assess the project timber framing material 1st figure “ STUCTURAL ADEQUACY” for the FRL required 60 OR 90, the 2nd figure material “INTEGRITY” and the “INSULATION” the 3rd figure have both passed the fire tests in 60 and 90 minutes . As all walls vary in LOAD bearing requirement, the structural engineer for each project will need to confirm the capability of the load bearing in timber framing. If this is not a viable solution in timber then the frame must be built of steel as per CSIRO/NATA FRL 60/60/60 and FRL 90/90/90 fire tests to MIN LOAD BEARING OF 55kN achieved on 1.15BMT .

Minimum 10mmFireCrunch external lining

Use approved AS/1530.4 fire sealant with min 6mm gap on External FireCrunch 10mm lining sheets .


.

* use recommended product onlyFRL (FireCrunch side) STUD CAVITY depth CAVITY INFILL* (DTS SOLUTION)

60/60/60 1 layer 10mm Min. 90mm x 45mm 90mm thick R 2.5 GLASSWOOL BATT NCC /BCA TESTED

Minimum 10mm SE10FireCrunch external lining

Stud

FireCrunch (10mm)

EXTERNAL (OUTSIDE) WALLTimber frame FRL 60/60/60 useonly R 2.5 Glasswool Fire batts

FireCrunch approvedfire rated sealant

6mm min. gap

50mm wide stop tapePaper stopping tape

INTERNAL WALLSdo not use fibre mesh

tape with FCA INTERNALLY

Moisture barrier

Approx. 3 X3mm of thick gunned onapproved AS/ 1530.4 fire sealant ONSTUD FACE before fixing sheets.

INTERNAL (INSIDE) WALL

Note: Drawing not to scale in mm shown.

USE approved AS/NZS 1530.4 fire rated sealant

on stud faces only internal

Stagger screws on either side 200mm centres at min. 12 to 15mm from edge.Use recommended corrosion proof screws for external applications.

Fire System EXTERNAL Wall fire attackFRL 60/60/60 Timber Frame Construction

No separator battens requiredscrew fix direct to frame.

Screed 3X 3mm recommendedproducts Fire sealant AS 1530.4

over stud face before fixing FCA board.

FIRE RATED WALL TIMBER FRAME CONSTRUCTIONAlternative Perfomance Fire Wall System

INSTALLATION - INTERNAL & EXTERNAL FIRE WALLSFireCrunch has been FIRE TESTED at: FRL 60/60/60**** for TIMBER framing.FIRE ENGINEERING CERTIFICATE (NCC) RE RESOLUTE LABS FIRE TESTS

• One layer of 10mm F ireCrunch fixed directly to each SIDE frame, timber stud wall framing, and noggings.• Board is SCREW FIXED directly to timber framing over sarking . Do not nail, nailing will void the warranty.• Stud adhesive should not be used.

1. Studs should be at 400mm to avoid 300mm run off with 1200mm wide boards.2. All FCA 10mm boards are 1200mm wide.3. All fire joints must be backed by studs and or noggins4. Screw at 200 centres at edges and on studs and noggs. Stagger edge fixing on vertical studs.5. Approved AS 1530.4 fire rated sealant must be used on all joints.

INTERNAL/EXTERNAL FIRE WALLS - FIRE RATED CONTROL JOINTS

PLAN VIEW TOP HAT SECTION

For internal plaster set walls joint comb 3 x 3mm fire sealant beads down face of studs before fixing board

NOTE: light butt joint edges Do not create plasterset joint ap and do not fill with fire sealant if

plaster setting joints. See special instructions for plaster set with FireCrunch boards "recommended products" and

'Manuals section web site to retain FireCrunch warrantysee website

Stagger screws on either side and at 200mm centres at min. 12mm from edge


Board (FireCrunch) STUD CAVITY depth CAVITY INFILL FRL Load and Non Load Bearing fire walls

10mm board Min. 90mm 90mm thick R 2.5 GLASSWOOL Fire BATTS FRL 60/60/60 and -FRL -/60/60

TIMBER FRAME CONSTRUCTIONINSTALLATION - INTERNAL FIRE RATED WALL



NOTE: Do not nail warranty will be voided.

Fastener Spacing








NOTE: VERTICAL CLADDING MUST BE USED IN "LOAD BEARING" FIRE WALLS DO NOT USE HORIZONTAL CLADDING

SINGLE LAYER 10mm each side VERTICALINSTALLATION LOAD BEARING WALLUse vertical or horizontal in Non Load bearing conditions FOR FIRE WALLS.

For 64mm and 76mm Steel Stud frames CONSULT FCA under NCC

Maximum depth between surface of screw head and surface of FireCrunch should not be more than 1.5mm. USE 2 Pack fill exteriors. Minimum fastening distance from edge of board should be 12mm.

Fastener Spacing

ALL Fixings at 200mm Centres Fastener Position Fastener SpacingCentre of board 200mm max. centresRecessed edges Fix at each studButt joints 200mm max. centresCorners & openings 200mm max. centresTop & Bottom Frame 200mm max. centres

NOTE: NOTE: Use vertical or horizontal cladding in NON LOAD BEARING conditions. FOR FIRE WALLS BACK BLOCK ALL HORIZON-TALL CLADDING AT JOINTS AND USE recommended products FIRE SEALANT .

SINGLE LAYER 10mm each side HORIZONTAL INSTALLATION NON LOAD BEARINGInstall FireCrunch sheets in a horizontal arrangement if using square/straight edge board.

For screwing FireCrunch panels to wood framing, we recommend using 8-10 Countersunk Ribbed Head Class 2 / 3 screws (depending on timber hardness).Maximum depth between surface of screw head and surface ot FireCrunch should not more than 1.5mm .


Stagger fixing at 200mm (2 ref points) centres on join

10mm gap between board and floor. Caulk perimeter with approved fire rated sealant

Set joints with recommended fire

rated sealant. Screw fixing at

200mm centresStagger fixing at 200mm

(2 ref points) centres on join

Screw fixing at 200mm Max centres.


FIRE TESTED DOUBLE FRAME, PARTY WALL SYSTEMINSTALLATION - TIMBER FRAME CONSTRUCTIONFRL 90/90/90 ****

Concreteground slab

FireCrunch can be used in many situations where adjoining or party walls are required to be fire and acoustic rated.The FireCrunch BOARD IS TESTED to FRL /90/90 on 90mm X 45mm TIMBER FRAMES and APPLIES TO LOAD BEARING FRL 90/90/90***** ON SUITABLY SPECIFIED LOAD BEARING WALL SYSTEMS.On a timber frame, one layer of 10mm FireCrunch,each side with a Minimum R 2.5 90mm thick Glasswool Batt and 10mm FCA boards suitably jointed with approved fire sealant will provide a minimum Fire Resistance Level (FRL) of FRL .../90/90 AND FRL 90/90/90 WITH APPROVED FIRE WALL SPECIFICATION FOR LOAD BEARING for fire attack equally from both sides and an acoustic minimum of Rw 62 plusctr, net Rw 52 Over Rw 62....uuse Hi density acoustic batt..

NOTE: Use only vertically set panels for "load bearing" Fire walls .Use corrosion proof fasteners as per GENERAL TECHNICAL DATA sheet web site Fire separation walls between apartments meet BCA definition of ‘discontinuous construction’. UNDER BCA ( DTS) and NCC Alternative performance system assessment by anindependant Fire engineer See all FireCrunch certificates on web site.

NOTE **** LOAD BEARING (1st FIG )TO BE ESTABLISED BY STRUCTURAL ENGINEER FRL 90/90/90

Minimum R2.5 90mm thick

Glasswool Batt each side for FRL 90/90/90

**** timber frames.

min. 20mm air space fire wall

separation gap

Set approved fire sealant on verticalstud faces 3mm thick and in min 6mmgap between boards external walls only.

Fire separation wall lining 10mm FireCrunch each side.

FireCrunch Board1 x 10mm sheet eachside of Timber frame

(NCC ) Alternative solution BCA 3mm layer of approved fire resistant sealant combed down stud face AND GUNNED into the 6mm joint gap.

Total 1 x 10mm FCAeach side FRL90/90/90****Timber frame.

FIRE TESTED DOUBLE FRAME, PARTY WALL SYSTEMINSTALLATION - TIMBER FRAME CONSTRUCTION FRL 90/90/90

Dual FramedTIMBER FIRE SEPARATION WALL90minute and acoustic Rw 62 AS/ 717

At base junction of Firecrunch sheet use 90 deg 0.75BMT furring channel or U track and fire seal with AS/1530.4 sealant.


Min. 220mmwidth 1 x10mmsheet each sidesystem.

Timber frame R 2.590mm thick

Glasswool fire batt

• 1 x 10mm FireCrunch boards each side of frame.• 2/3mm thick approved AS/1530.4 fire sealant on stud face between frame & board.• Min 6mm fire joint between boards/sheets (Exterior only)• Timber Stud (min.90mm)cavity with insulation R 2.5 Glass wool batts.• Acoustic is Rw 62 and Rw 52 net of ctr with 1 10mm sheet each side and R2.5• Glass wool batt in both cavities

• TOTAL 220mm width 1 x 10mm FireCrunch sheet each side.• 3 x 3mm thick beads approved AS/1530.4 sealant on stud face between frame and board.• Min 6mm fire joint between sheets• Steel Stud frame (90mm) with insulation R 2.5 glass wool batts.• Min. 20mm fire wall separation air gap• Acoustic TESTED system 1 layer 10mm each side Rw 62/net ctr 52.

Min 220mmwidth 1 x 10mm Firecrunch sheets system

Non load bearingFRL /90/90 and LOAD BEARING

FRL 90/90/90****with APPROVED

STRUCTURAL ENGINEERS

SPECS

****May require further fire engineer andstructural engineers assessment for specific value for the load bearing tonnage exterior timber framed wall.

Install: Steel Frame System Nom Width FRL Insulation Rw Rw+Ctr

62 52

FRL 90/90/90 Load Bearing

Load Bearingmin. 90/90/90both sides , NATA CSIRO TESTED

Steel frame (R 2.5) 90mm R2.5 Glasswool Fire batts

Install: Timber Frame System Nom Width FRL Insulation Rw Rw+Ctr

62 52

FIRE TESTED DOUBLE FRAME, PARTY WALL SYSTEMINSTALLATION - TIMBER and STEEL FRAME CONSTRUCTIONFRL 90/90/90 ****

Generic il lustration


This assessment was effected under the (BCA) Alternative FIRE PERFORMANCE TESTED system (NCC) using NATA /CSIRO fire test report.FSV 1708/15017025 ISO IEC 17025 and subsequent 90mmx 45mm Timber Framing with 600mm centre studs test by Resolute Labs QLD SEPT 2018 (NON LOAD BEARING) Assessed by YGL Fire Engineering Group SYDNEY NSW UNDER NCC ALTERNATIVETESTED PERFORMANCE SYSTEMS 2019

FRL.... /90/90 AS/ 1530.4-2014NATA LABS TESTS BY RESOLUTE QLD PROVED THE MATERIAL INTEGRITY 2nd FIG AND THE INSULATION 3rd FIGURE MEET THEAS1530.4 -2014 STANDARD IN MATERIALS INTEGRITY . THE STRUCTURAL ADEQUACY (1st fig) IS TO BE DESIGNATED BY THESTRUCTURAL ENGINEER IN EACH CASE AS ALL STRUCTURES and PROJECTS ARE DIFFERENT. Timber Framing.STEEL FRAMING IS TESTED UNDER DTS BY NATA LABS CSIRO TO FRL 90/90/90 . SEE MANUALS on WEB SITE.

Acoustic testing Tested NATA (Kilargo Labs QLD) Acoustic Rw 62 net ctr 52 ,obtained on 1 x10mm sheet each side. DBL STUD TIMBER FRAME

FIRECRUNCH (NCC) ALTERNATIVE SYSTEMFIRE SEPARATION WALL Timber and Steel FRAMINGFRL 90/90/90

FIRE Collars NOTE: (Fire wall penetrations) NATA CSIRO ASSESSED For interactive electrical and plumbing FRL protection to . FRL ../90/90 use SNAP SYSTEMS fire collars for carriage, in between and through fire separation walls. Both Snap and FireCrunch single sheet 10mm board have been fire tested (individually by the CSIRO) and ASSESSED TOGETHER to FRL ../90/90 eliminating 2/3 layers of 16mm fyrechek plaster board with 1 layer of 10mm FCA . See web site use CSIRO tested switches and power points withintumescent seal foam fire bloc, HPM , Clipsal etc ( FireCrunch tested with Clipsal)

LOAD BEARING FRL 90/90/90****Use 1 x 10mm sheet each sideTimber Frame Double stud. Acoustic rating Rw 62 minimum 1x10mm board. Total separation wall width 220mm

USE ONLY R2.5GLASSWOOL BATTS

(90 mm thick)

Studs to max 450 Centres ON 90minute fire walls.SET BOARDS VERTICALLYWITH 6mm FIRE GAPBETWEEN BOARDS.ALLOW FOR 6mm STUDCREEP EVERY 1200mm ONCONSTRUCTION OF FRAMES, AS YOU NEED TO KEEP TOCENTRE OF STUD FACE FORFIXINGS TO SECURETRACTION.

10mm FireCrunch Board (FCA)see under recommended products, plasterset instruction. Internal recessed edgeboards have a different FIRE SEALANTAPPLICATION and FCA BOARD JOINTS SPACING. End elevation view, total wall width 220mm

20mm 90mm90mm

END ELEVATION DOUBLE FRAME TIMBER FRL .../90/90 AND FRL 90/90/90***


FIRE TESTED DOUBLE FRAME , PARTY WALL SYSTEMSTEEL FRAME CONSTRUCTION FRL 90/90/90

FireCrunch can be used in many situations where adjoining FIRE SEPARATION AND INTERTENANCY WALLS are required to be fire and acoustic rated. The FireCrunch NCC ALTERNATIVE SYSTEM is assessed based on the DTS AS1530.4-2014 NATA / CSIRO tests using 1 x 10mm sheet either side of a 92mm x45mm steel stud frame 1.15 BMT. This assesses a double stud steel frame 92 x 45mm using 300 ,400 or 450 centres studs able to to withstand FRL 90/90/90 when 1 x 10mm FCA sheet each side is used .A single 10mm FCA sheet replaces multiple layers of Fyrchek ,cuts at least 50% labour and materials. On a double stud steel frame 1.15 BMT, install one layer of 10mm FireCrunch each side , insulated with an R 2.5 Glass wool batt or for higher acoustics over Rw 62 use a 80kg HD Mineral or Rockwool batt. Fire seal

joints with approved AS/1530.4 fire sealant, (See web site for support products) which will provide a minimum Fire ResistanceLevel (FRL) of 90/90/90 ***** Rw 62 ACOUSTIC / CTR 52 (AS 717).from both sides. Use corrosion proof screws as per DATA sheets .NCC ALTERNATIVE SOLUTION FRL ..../120/120If you do not require a structural Load Bearing rating, the installation stated above will provide a minimum FRL of -/120/120 on steel framing when 2 x10mm Firecrunch boards are used per side (NCC) (ask us) Use same 90mm R2.5 Glasswool batts.

NOTE **** LOAD BEARING WALL REQUIREMENTS Drawing ARE DETERMINED BY THE PROJECT STRUCTURAL ENGINEER ASSESSING THE MINIMUM 1.15 BMT TEST FRAME GAUGECAPABILITY USED BY FireCrunch.

Set approved fire sealant on stud faces3mm thick and leave 6mm gap betweenassemb led board on stud faces ,oncompletion then fill the 6mm gaps andscreed off SQ edge SE10 board FOR External only.

FOR INTERNAL PLASTER SET JOINTS use recessed edge (TE10) for internal and soft butt the joints. Do not use fire sealant on internal plaster set joints, set 3mm fire sealant BEADS on stud face only and comb down to provide even blanket cover where board joins on stud with no board gap .SET PLASTER JOINTS INUSUAL WAY SEE PLASTER JOINTS AND INSTRUCTIONS USING FIRECRUNCH THIS MANUAL. SEE MANUALS ON WEB SITE.

Dual STEEL Frames 1.15 BMTFRL 90/90/90

90mm Mineral orRockwool WOOLFIRE BATT(STEEL FRAMING )

use10mmFirecrunch eachside as wall lining

Concrete ground slab

min. 20mmDiscontinouosframe gap

3mm layer of approved fire resistantsealant on stud faces and min 6mm fire joint gap.

Min. 220mm STEEL FRAME90mm thick R 2.5GLASSWOOL BATT

• TOTAL 220mm width1 x FireCrunch each side.•3 x 3mm thick beads approved AS/1530.4sealant on stud face between frame and board•Min 6mm fire joint between boards( EXTERNAL WALLS ONLY)•Steel Stud frame (90mm) with insulation•Min. 20mm fire wall separation air gap•Acoustic TESTED system 1 layer 10mmeach side Rw 62/52 Rw and R2.5 glass batts.

Install: Steel Frame System Non Width FRL Insulation Rw Rw+Ctr

62 52

FRL 90/90/90 Load Bearing

Load Bearingmin. 90/90/90both sides CSIRO TESTED

At base junction of Firecrunch sheet use 90 deg 0.75BMT furring channel or U track and fire seal with AS/1530.4 sealant


FIRE RATED CEILINGS & FLOORS

29 No1 2020


FIRE RATED CEILINGS AND FLOORS

NOTE: TG board does not require back blocking.Apply fire sealant to groove section before finallyfixing tongue section in each board. Screw fix only, nailing will void the warranty.

289mm

Open cavity

2 x 10mm Firecrunch boards(1 x 10mm SE board )(1 x 10mm TE board Recessed Edge)

2 x 10mm Firecrunch Sheets offset Joints 50mm / 75mm

250mm x 75mm x 2.4 BMT C section Joists

( drawing not to scale)

1 x 100mm Rockwool or .2x 50mm thick 64kg m2 Rockwool

STEEL JOISTINGFRL90/90/90 ***** = 2 X Layer 10mm FCA UNDERSIDE plus1 x Layer 19mm TG ,Top side of joists PLUS ...Offset joints on underside ceiling (50mm to 75mm) with 10mm sheets and 100mm depth Mineral wool batt min 64Kg Minimum steel C section joisting 250x 75mm 2.4BMT min 450mm floor joisting centres.***** NOTE: The 1st figure ,load bearing ,must be assessed by the projects structural engineer based on the minimum BMT gauge testspecifications

TIMBER JOISTINGFRL TO 90/90/90Min 250mm/ to 300 mm Depth Laminated (LVL) Timber Joists OR Radiata Pine MGP 10 and min 90mmx 45mm 0.75 BMT steel top hats orsimilar batten separators between joist and 2 x 10mm FireCrunch ceiling boards. PLUS 19mm X-Fire TG19 flooring sheets on top of joists min 450mm joisting centres. Use 100mm min 75/ 80kg Rockwool or Mineral wool batts, for LVL and MGP10.

CEILINGS APPLICATION: FLOORING UNDERSIDE OF JOISTS OR CEILING BATTENSApply 1 layer of 10mm FireCrunch SQ EDGE board SE10 and at bottom the underside sheet use 1 layer of 10mm TE10 ( recessed plaster set edge), as the under finish board, offset joints (min 75mm) FireCrunch board to maintain 20mm solid depth SCREW FIX at 200mm centres,15mm from edges and 50mm from corners.. Insert required 64Kg TO 75Kg (100mm) depth Rockwool or Mineral wool fire batt to 250mm/300mm joist depth cavity.

FireCrunch Solution No Insulation

1 Layer 19mm FireCrunch TG flooringplus ceiling constructed with:

2 layers 10mm FireCrunch offset joints75mm SE10 and TE10 type edges below

FRL(from above)

90/90/90

FRL(from below)

90/90/90

RISF

90mins

Rw+Ctr(from above)

62+

Rw+Ctr(from below)

55

FireCrunch 19mm TG: 2700 x 600mmby using 19mm FireCrunch Tongue and Groove panels for TOP flooring, the rating from the top will be FRL 90/90/90

19mm Firecrunch board

CEILING FLOOR ILLUSTRATION CONSTRUCTION NOT TO SCALE

STEEL JOISTING 2.4 BMT


Specification floor ceiling system fire tested Resolute Labs QLD Dec 2017 steel C section 250mm x 75mm x 2.4 BMT FRL .../90/90

GENERAL INSTRUCTIONS ASSEMBLIES

• Gun on to underside joist faces 3 x 3mm beads of AS/1530.4 fire sealant and to perimeters of the board installation The single visible underside 10mm board joint will be plaster set. Do not leave more than 1/to 2mm gap between the underside recessed edge ceiling board and do not apply fire sealant to the 1/ 2mm gap between the boards, ONLY TO THE JOIST FACE JOINT POINT.

• Fix the 10mm FCA sheets direct to underside steel C section Purlins, no intermediate battens required for steel joists (offset thru joints OF BOARDS by 50mm/ 75mm TO RETAIN SOLID 20mm THICKNESS).

• TE10 recessed edge board is used for plaster set of the underside ceiling exposed area where flushed joints required. (IMPORTANT) See plaster set instructions : fire manual they are slightly different procedures and compound brand products for FireCrunch MgSO4 boards.• TOP SIDE of flooring joists 1 x 19mm FCA TG sheet fixed direct to the top ( floor area) of steel C section no intermediate battens required ( remove rest of words here)• Insert 100mm thick ( 0r 2 x50mm ) depth Rockwool or Mineral wool fire batt min 64 kg in ceiling floor cavity. Check FCA tech support manual see web site

• Fire seal all perimeters with the AS/1530.4 fire /weather sealant

FLOOR CEILING CSIRO FIRE TESTED SYSTEMAS/1530.4-2015 DTS/ BCA FRL ----/90/90 LOAD BEARING FRL 90/90/90 TO ENGINEERING/ ARCHTECTURAL SPECIFICATIONS

100mm Rockwool2x 50mm 64kg m2 Rockwool

289mm

Open cavity 19mm Firecrunch board

2 x 10mm FirecrunchSheets SE10 AND TE10offset Joints / 75mm

250mm x 75mm x 2.4 BMT C section Joists

STEEL Frame CEILING FLOOR 289mm Total Depth

2 x 10mm Firecrunch boards(1 x 10mm SE board )(1 x 10mm TE board Recessed Edge)

FRL ......90/90FLOORING: 19mm FireCrunch Tongue and Groove panels for flooring. ( TOP SIDE ).


STORAGE & HANDLINGAlways handle with at least one person at each end of the board. With hands apart, lift the board andTILT UPPRIGHT (See illustration to right) to prevent sagging. Always store FCA products out of theweather and off wet areas or ground do not leave exposed out in weather before use. Seal withrecommended external sealer sealer immediately after external installations. SEE recommendedproducts WEB SITE.Do not install erect in wet weather . if board exposed to weather prior to sealing it will not affectintegrity but allow 48 to 72 hours in dry conditions before applying primer and finish coats. checkhydration level with meter

OCCUPATIONAL HEALTH AND SAFETYMinimise dust created in sawing or cutting use a bench saw with vacuum extractor at cutting face and do this in a well-ventilated area or outside . Use a mask when cutting FireCrunch ,Wear Industrial safety glasses or non fogging goggles . see SDS web site FFC cuts with regular timber tools saws etc.See safety DATA sheet SDS web site

WHAT TOOLS ARE NEEDED?No special tools are required to use FireCrunch. It can be sawn, drilled,screwed and planed with timber tools .DO NOT use stud adhesive for firewalls in flood prone areas so as to allow easy unscrew removal. THEN Number boards for Relocation , dry out board and frames paint and plaster reset no mess, less expensive, better insurance premiums ...ask your insurer.

DO NOT NAIL FireCrunch.

CUTTING & MACHININGFireCrunch is easy to work and machine with normal woodworking tools and equipment. Cut sheets with a fine tooth handsaw or power saw. Edges may be trimmed with a smoothing plane, power plane or light fine grade sandpaper. Panels 10mm thick and under can be deep scored with a cutting knife and snapped along the straight edge in the same way as you would with gypsum board.Where holes are required clean cutter bits or twist drills are satisfactory. Woodworking shapers, spindle moulders and high speed routers can be used may be used to shape or mould the edges of FireCrunch. Tungsten carbide tipped cutters are preferred for long production runs.

Undercoat & Seal Before final installation undercoat /seal the board with TREMCO EC200 EXTERIOR WEATHER PRIMER ( TESTED WITH Firecrunch PRODUCTS)Do not nail this product screw fix only with recommended CORROSION PROOF screw fixings Non attention to these importantsteps will invalidate the warranty See recommended products sectionweb site main browser home page.

Always carry boards Vertical up right


GENERAL FIXING & INSTALLATIONAlways follow the latest installation manuals available on the FireCrunch website. Recommended and tested products on the FireCrunch website must be applied following the manufacturers guides.

INTERIOR/EXTERIOR LININGPosition fasteners a minimum of 50mm from corners and min. 10/12mm from edges. All facing surfaces must be finished withsuitable and approved finishes. Stud adhesives should only be used for board positioning, not fastening. Do not STUD ADHESIVEuse in fire walls, or in flood areas .Installed boards must be screw fastened. Board must be weather sealed prior to, or immediatelyafter installation in external applications with RECOMMENDED SEALER . SEE WEB SITE, RECOMMENDED PRODUCTS.

STEEL FRAMINGGeneral wall installation to conventional steel frame construction in most locations: USE self Countersinking RibbedHead bugle wing screws, spaced AT 200mm CENTRES 12mm in from panel edges edges and 50mm from corners

TIMBER FRAMINGGeneral wall installation to conventional wood frame construction in most locations: self countersunk ribbed head bugle needle pointscrews spaced 200mm centres at panel edges and 200mm intermediate framing members 10/ 12mm from edges and 50mm from corners

Internal and External FIRE JOINT SEALINGUse only recommended products sealants to FireCrunch main fire manual instructions 3mm x 3mm beads combed down stud face and 6mm gap between exterior walls panels . Do not use fire sealant in internal plaster set wall boards (butt joints) just on use on stud face .USE ONLY paper tape for internal walls not fibre mesh tape .TILING USE ONLY (Tongue and Groove 19mm ) FOR TILED FLOOR SURFACES max 450mm joist centres WET AREAS (Insert expansion joints 4 to 5m). remove last purple line insert etc NOTE: 10mm FireCrunch Board plaster set instruction for internal recessed edge boards, has a different FIRE SEALANT APPLICATION and Firecrunch BOARD JOINT SPACING IS ZERO. See manual.

FASTENINGFor screwing FireCrunch panels , use only corrosion proof self Countersinking Ribbed Head bugle screws for timber and appropriate winged screws for Steel.USE corrosion proof or (stainless steel ). For screwing FireCrunch boards to wood framing, use corrosion proof 8-10 Countersunk Ribbed Head Class 2 / 3 screws (depending on timber hardness). Maximum depth between surface of screw head and board should be no more than 2mm on 10mm.

Board Thickness Recommended Use Edges

10mm Cladding SE/TE Walls (Internal and External), Ceiling SQ,Recessed12mm Groove Board Walls (Internal and External), Ceiling Shiplap16mm Decking Board Decks , Floors Walls TG19mm Flooring Flooring TG

Recommended Screw SizesBoard Thickness Screw Length Thickness Screw Length 12mm 30mm10mm 30mm 19/16mm 45-50mm


Manual : Plaster joint setting and Painting

Attn: PLASTER JOINT SETTING INSTALLERS THIS IS FOR YOU Warranty provisions using FIRECRUNCH (FCA)

Read CAREFULLY before commencing....

Plaster joint setting using FireCrunch (FCA ) products are slightly different in procedures ,plaster compound products are warranted by Pro Plaster QLD, who have tested the FCA product with it's compounds . FCA does not warrant any other manufacturers compound products . Installers must ensure they proceed exactly to the Pro Plaster manufacturers instructions .FCA warrants the FireCrunch product in fire and other specified areas of the FCA material capability, see website.

1• You can use other brands of compounds and toppings, however for their own commercial interests BORAL, CSR, KNAUF ,BGC and other plasterboard manufcaturers, will only warrant their own SETTING COMPOUNDS with THEIR OWN supplied plaster board. Fiba Fuse and similar taping products can be used externally, please carefully check manufacturers instructions before use and only use paper tape internally.

2• IMPORTANT NOTE , Internal set joints DO NOT, leave a 6mm fire sealant gap between INTERIOR set FCA boards. If you are also the FCA board installer ,gun 3 beads of fire sealant down the internal wall stud jboard joint face only, press boards onto sealant and screw fix min 12mm from edge and at 200 mm centres leaving only a 1 to 2mm sealant pressured gap between boards, screw fix as to WEB site instruction manuals, firercrunch.com.au/technicalspecification.com.au/ Use other normal plaster set compound standard procedures . FIRE SEAL ALL PERIMETERS AND EDGES, before fixing the boards Use approved AS1530.4 FIRE / WEATHER SEALANT, BOSTIK FIRE BAN,TREMstop PU or SIikka products

3• NOTE: IF BOARDS HAVE ALREADY BEEN INSTALLED BY OTHERS AND DO NOT MEET THE ABOVE INSTALL SPECIFICATION, THEY WILL HAVE TO BE REMOVED RESET TO SPECIFICATION BEFORE SETTING PLASTER JOINTS, or warranty will be voided.

4• Set expansion joints at minimum 4 / 5 meter intervals, and over and around doors and window areas, in good industry practice.

5• IMPORTANT PRE COMMENCEMENT PROCEDURE . Ensure that the recessed edge AREA of FireCrunch board is WELL PRE SOAKED with a wet sponge, on warm days over 23 deg C , prior to applying the first coat of compoundand tape, as FireCrunch is more absorbent than plaster board and the compound moisture may be absorbed before the joint is set cured.

6• USE ( PRO PLASTER TRADES 40 ONLY ) with 40 minutes FASTER set time base compound, use with paper tapeinternally, 2nd coat screed out to 150 mm per side, or your experienced considered distance. Use PRO PLASTER 4 T fine topping and feathering out to 250mm for even flush finish. ( Observe Mfg mix and use Instructions)

7• PRIMING AND PAINTING FireCrunch is a fire and finish board which delivers a minimum class 4 finish. For paintapplication, first seal with Rockcote MgO primer sealer ,you can then apply water based paint or texture top coats orrender. Use prep coat for extra top class 5 commercial finish.https://www.rockcote.com.au/products/mgo-board-primer

8• FCA 10mm CAN BE DEEP SCORE SNAPPED . When cutting, USE BENCH SAW, use regular timber fine toothcutting blades and power dust extractor at blade ,always wear a mask.

9• Non carcinomas ,see Safety Data Sheet (SDS) web site firecrunch.com.au/technical-spcifications

10• See general technical manual for screws and fixings www.firecrunch.com.au-technical-specifications


SUMMARY INSTALLATION, SINGLE TIMBER FRAME FIRE WALL (INTERNAL & EXTERNAL)

WHAT YOU NEED1 • 90mm x 45mm TIMBER FRAMING MGP10 or SIMILAR .2 • Steel Self C/S TIMBER PENETRATION NEEDLE POINT screw fixings (see web site “Tech Specs”)3 • Steel Self C/S corrosion proof steel penetration bugle head fixings see web site tech specs.4 • R 2.5 Glass Wool batts Bradford/ CSR or similar (R 2.5 minimum).5 • AS/1530.4 Fire / weather sealant web site Recommended Products.6 • FireCrunch SHEETS sizes: • 2400 x1200mm, • 2700 x 1200mm • 3000 x 1200mm

STEPS1 • ASSEMBLE THE TIMBER FRAMING FRAMING MAX STUD CENTRES 400mm allow for 6mm fire seal gap creep on linear assembly

2 • INSERT THE 90mm R2.5 FIRE BATTS.

3 • GUN 3 BEADS 2/3mm THICK BEADS FIRE SEALANT DOWN THE STUD FACE WHERE THE BOARD JOINTS MEET.

4 • START BOARD ASSEMBLY( VERTICALLY FROM LEFT SIDE OF SIDE ONE ,1.2M WIDE SHEETS . SCREW FIX TO STUDS and NOGS AT 200mm CENTRES (DO NOT ASSEMBLE HORIZONTALLY AS FIRE JOINTS WILL FAIL)

5 • CONTINUE TO ASSEMBLE LINEAR TO RIGHT, LEAVING A 6mm FIRE SEALANT GAP BETWEEN BOARDS. GUN FIRE SEALANT INTO 6mm GAP AND TOOL DOWN 2/3mm FOR EXPOSED PANEL EFFECT . SEAL THE SURFACE WITH ONE COAT OF ROCKCOTE MgO SEALER (See web site recommended products ) THE BOARD CAN THEN BE RENDERED OR TEXTURE PAINTED.

NOTE. ****Load bearing rating (1st figure of FRL) must be assessed by a structural engineer as all support framing and types vary. The FireCrunch product in 10mm has a structural integrity and insulation of 90 minutes using steel or timber framing and will not allow fire pass during that max period on a SINGLE 90mm x 45mm steel frame 1.15 BMT or MGP 10 timber DOUBLE stud Discontinuous Frame NATA / CSIRO and ResLabs TESTED See general technical manual web site for corrosion proof for screw types and lengths scaleUse TREMCO EC200 sealer .GOOGLE TREMCO for local stockists Fire sealant use Bostik Fire Ban 1 or any AS/1530.4 fire sealant see recc. products website.NOTE : LOAD BEARING COMMENT LEFT, BELOW ****

SINGLE TIMBER FRAMED FIRE WALLS

FRL 60/60/60


STEEL FRAMED FIRE WALLS FRL 60/60/60 and 90/90/901 x 10mm sheet each side of frame (DTS , BCA , NATA LABS TESTED)

SUMMARY INSTALLATION, STEEL FIRE WALLS

WHAT YOU NEED1 • COLD FORMED STEEL 92mm x 45mm framing, available major steel suppliers shelf stock items.2 • Steel Gauge 1.15 BMT 300 density , or 0.95 BMT using 550 density steel.3 • Steel Self C/S steel penetration winged screw fixings see web site tech specs4 • 64kg to 75kg MINERAL OR ROCKWOOL wool fire batt.5 • AS/ 1530.4 Fire / weather sealant web site Recommended Products.6 FireCrunch SHEETS sizes: • 2400 x1200mm, • 2700 x 1200mm • 3000 x 1200mm .

STEPS1 • ASSEMBLE THE STEEL FRAMING MAX STUD CENTRES 400mm.

2 • INSERT THE 90mm MINERAL or ROCKWOOL FIRE BATTS into cavity.

3 • GUN 3 BEADS 2/3mm THICK FIRE SEALANT DOWN THE STUD FACES WHERE THE JOINTS MEET AND ALL PERIMETERS OF FRAME.

4 • START BOARD 10mm ASSEMBLY( VERTICALLY ) FROM LEFT SIDE SIDE ONE 1.2m WIDE SHEETS SCREW FIX TO STUDS AND NOGS AT 200mm CENTRES (DO NOT ASSEMBLE HORIZONTLLY AS FIRE JOINTS WILL FAIL). Exterior wall base use metal U Track and fire seal

5 • CONTINUE TO ASSEMBLE LINEAR TO RIGHT , LEAVING A 6mm FIRE SEALANT GAP BETWEEN BOARDS. ALLOW FOR 6mm CREEP OVER STUD FACE EACH 1200mm IN STUD SET POINTS IN SETTING UP FRAMING CREATE 10mm EXPANSION JOINT EVERY 5 TO 6m.

6 • GUN FIRE SEALANT INTO THE 6mm GAP AND TOOL DOWN FOR EXPOSED SHADOW LINE PANEL EFECT BETWEEN SHEETS. FIRECRUNCH BOARD MUST BE SEALED WITH TREMCO EC 400 PRIMER MEMBRANE SEALER TO MFGS INSTRUCTIONS THEN PAINT, TEXTURE COAT, OR RENDER AS REQUIRED.


SINGLE TIMBER FRAMED FIRE WALLS FRL 90/90/90Double Stud "Discontinuous" timber frame ACOUSTIC INTERTENANCY FIRE WALL FRL 90/90/90(TOTAL WALL WIDTH ONLY 220mm) NOTE LOAD BEARING COMMENT BELOW ****

SUMMARY INSTALLATION :DOUBLE FRAME TIMBER FIRE WALL (INTERNAL & EXTERNAL) .......

WHAT YOU NEED :-1 • 90mm x 45mm TIMBER FRAMING MGP 10 OR SIMILAR .2 • TIMBER Self C/S RIBBED HEAD BUGLE Timber penetration Needle point screw fixings (see web site “Tech Specs”)3 • For Fire penetrationuse SNAP fire collar connectors for electrics and plumbing NATA CSIRO Assessed to FRL 90/90/904 • R 2.5 Glass Wool batts Bradford/ CSR or similar in each cavity not less than R 2.5 minimum) or to climate zone of property.5 • AS/ 1530.4 Fire / weather sealant web site Recommended Products6 • FireCrunch SHEETS sizes: • 2400 x1200mm, • 2700 x 1200mm • 3000 x 1200mm

STEPS1• ASSEMBLE THE TIMBER FRAMING MAX STUD CENTRES 400mm IE 3 studs PER 1200 WIDTH SHEET TO AVOID 300mm over run ON 450mm studs. Allow for 6mm gap creep ea.1200mm Sheet linear for fire seal gap.

2• INSERT THE R2.5 FIRE BATTS TO THE FRAME CAVITY .

3• GUN 3 BEADS 2/3mm THICK FIRE SEALANT DOWN THE STUD FACES WHERE THE JOINTS MEET.

4• START BOARD ASSEMBLY VERTICALLY FROM LEFT SIDE OF SIDE ONE ,1.2m WIDE SHEETS . SCREW FIX TO STUDS AND NOGS AT 200mm CENTRES (DO NOT ASSEMBLE HORIZONTALLY IN LOAD BEARING WALLS AS FIRE JOINTS WILL FAIL !!) ( Leave 10mm expansion joints each 5 to 6m)

5• CONTINUE TO ASSEMBLE LINEAR TO RIGHT , LEAVING A 6mm FIRE SEALANT GAP BETWEEN BETWEEN each board (EXTERNAL walls ONLY) ALLOW 6mm“CREEP” OVER LINEAR EACH 1200mm ON 45mm STUD WIDTH .. SEE PLASTER BOARD AND PAINT SUMMARY FOR INTERNAL FLUSHED JOINT PROCEDURES WHERE THERE ARE NO 6mm FIRE SEAL GAPS MADE (Internal only).

NOTE: load bearing timber walls may require a structural engineers confirmation as to load bearing weight in Timber framing, Steel framing already confirmed to FRL 90/90/90 WITH NATA CSIRO TEST, FCA SE10mm PRODUCTS (1.15BMT )steel frame 55kN.

****NOTE The 1st figure is the structural adequacy of the load bearing frame ,the 2nd figure is the structural integrity of the cladding product.the 3rd figure is the insulation capability to control the temperature required to BCA level for period of the test. As load bearingrequirements vary considerably the load bearing providing the structural adequacy is determined by the projects structuralengineer by relating to the time temperature curve in the fire test report Not applicable in slab to slab construction

FLOOD | F IRE | TERMITE | PROOF FIRE TESTED BY NATA LABS, CSIRO & OTHERS

ONE BUILDING PRODUCT MULTIPLE APPLICATIONSWALLS, FLOORS AND CEILINGS INTERNAL AND EXTERNAL

AUSTRALIA'S MOST SUSTAINABLE, DURABLE AND RELIABLE BUILDING BOARD

FIRE TESTED BY CSIRO / BCA

ONE BUILDING PRODUCT MULTIPLE APPLICATIONS WALLS, FLOORS AND CEILINGS INTERNAL AND EXTERNAL FIRECRUNCH.COM.AU

call today 1300 933 102 sales@fi recrunch.com.au

no1 technical manual - firecrunch australia · 2020. 1. 23. · as/1530.4 -2014 iso/iec 17025 nata...

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