COM M E RCI AL E XP R E S S PA N EL ®

External Installation
2 COMMERCIAL EXPRESSPANEL® – External Installation

01 INTRODUCTION

TABLE OF CONTENTS
01 INTRODUCTION 2 Fire Performance 21
Introduction 2 Extreme Climate Conditions 21
Corrosivity Categories 22
02 PRODUCT OVERVIEW 3 Other Design Considerations 22
Panel Information 4 Wash Down Process 23
Product Specifications 4 Inspection, Repair and Maintenance 23
03 SYSTEM OVERVIEW 5 05 COMPONENTS + ACCESSORIES 24
Pressure Equalised Ventilated
Cavity System 6 06 SYSTEM ENGINEERING 28
Sealant Filled Joints 7 Design, Detailing and Performance
Applications 8 Responsibilities 29
Benefits of the Cemintel’s Commercial Spacing of Horizontal H515 Top Hats 31
ExpressPanel with the ExpressWall ExpressWall and Intermediate Top Hat
Fixing System 8 Spacings 32
System Solutions 8 Panel Fixing Requirements 33

04 DESIGN + AESTHETIC 07 INSTALLATION 35

CONSIDERATIONS 9 Checklist – Prior to Installation 36
General 10 Installation Set-Out 37
Panel Appearance & Finish 10 Installation for Timber and Steel Framing 37
Panel Layout 11 Installation of Cemintel Rigid Air Barrier™ 43
Structural 11 Installation of Soft Air Barriers 45
Top Hats 13
Pre-Drilling Panel Holes 13 08 C
 ONSTRUCTION DRAWINGS
Face Fixings 13 + DETAILS 47
Window & Door Openings 14
09 S
 AFETY, HANDLING, GENERAL CARE
Eaves Junction 14
+ WARRANTY 65
Control Joints 14
Health, Safety and PPE 66
Moisture Management 15
Safety, Handling & Maintenance 66
Energy Efficiency & Thermal Design 18
Warranty 66
Climate Zones for Thermal Design 20

Introduction
Cemintel’s Commercial ExpressPanel® with intermediate knowledge level of building design and
Commercial ExpressWall® system combines a construction. In no way does it replace the services
pre-primed panel with a simple installation system of the building professionals required to design
to create the Cemintel Commercial ExpressPanel® projects, nor is it an exhaustive guide of all possible
wall systems that can be used for residential and scenarios. It is the responsibility of the architect,
commercial buildings. designer and various engineering parties to ensure
that the details in this Design and Installation Guide
This Design and Installation Guide recommends
are appropriate for the intended application.
good building practice methodology and has
been prepared as a general guide of design Commercial ExpressPanel can be installed in either
considerations, system engineering information horizontal or vertical orientations, and in external or
and installation procedures for common external internal applications.
applications. It assumes that the user has an
COMMERCIAL EXPRESSPANEL® – External Installation 3

02 PRODUCT OVERVIEW
4 COMMERCIAL EXPRESSPANEL® – External Installation

02 PRODUCT OVERVIEW

Panel Information
9mm
Cemintel Commercial ExpressPanel sheets are pre-
primed, square edged, compressed fibre cement
(CFC) panels, manufactured to AS/NZS 2908.2.
Consisting primarily of Portland Cement, cellulose
fibre, air and water, panels are compressed to
produce a dense 9mm panel that offers superior Front face is Back face is
performance in terms of strength and durability, sanded and not sanded
making Commercial ExpressPanel an excellent sealed and sealed
choice for commercial applications subject to higher
wind loads. 900mm
Panels are factory sealed on both faces and all edges or
1200mm
for increased weather resistance and durability.
Commercial ExpressPanel sheets are ready for
painting and can be either factory painted or finished
onsite with painted finishes (as per manufacturer’s
specifications).
Commercial ExpressPanel is popular with architects
and designers with its pre-primed face that can be
finished with a wide range of treatments.
Commercial ExpressPanel cladding conforms to the
requirements of AS/NZS 2908.2 – Cellulose-cement
products, Part: 2 – Flat sheets, Category 5, Type A.

Product Specifications
Property Specification Manufacturing Relevant
Tolerance Standard
Panel Width 900 and 1200mm + 0.0mm / - 2.0mm AS/NZS 2908.2
Panel Length 1800,2100,2400,2700 + 0.0mm / - 2.0mm AS/NZS 2908.2
and 3000mm
Panel Thickness 9mm + 0.9mm / - 0mm AS/NZS 2908.2
Panel Weight (EMC) 17.8kg/m
2
NA AS/NZS 2908.2

Product Code Thickness (mm) Width (mm) Length (mm) Mass (Nominal) Panels per pack
25681 9 900 1800 17.8kg/m2 20
25682 9 900 2400 17.8kg/m2 20
25683 9 900 3000 17.8kg/m2 20
25676 9 1200 1800 17.8kg/m2 20
25677 9 1200 2100 17.8kg/m2 20
25678 9 1200 2400 17.8kg/m2 20
25679 9 1200 2700 17.8kg/m2 20
17.8kg/m
2
25680 9 1200 3000 20
COMMERCIAL EXPRESSPANEL® – External Installation 5

03 SYSTEM OVERVIEW
6 COMMERCIAL EXPRESSPANEL® – External Installation

03 SYSTEM OVERVIEW

Pressure Equalised Ventilated

Cavity System
Cemintel Commercial ExpressPanel can be installed Panels are installed as a pressure equalised
horizontally or vertically onto steel or timber stud ventilated cavity system which is easy to install and
framing or masonry/concrete using the proven and delivers a high weather performance system. In
versatile Commercial ExpressWall® top hat fixing certain conditions, eg. higher corrosive zones, there
system. The ExpressWall system provides a versatile is the option of sealing joints and header to reduce
and durable façade which is suitable for an extensive the circulation of air behind the façade.
range of building types. Panels are pre-drilled and
This manual provides information on both systems.
then fixed with expressed joints to vertical metal
top hats using countersunk head screws. A vertical
gasket tape is placed on the top hat to provide
added weather resistance, and a backing strip is
used at horizontal joints to reduce water ingress.

Pressure Equalised Ventilated Cavity System

Cemintel Commercial ExpressPanel is installed over an air barrier onto ExpressWall™ top hats using Hex Head or Countersunk Head
Screws. This creates a pressure equalised cavity system which enhances weather resistance.

Air Barrier

Wall framing
Horizontal batten
fixed to frame

ExpressWall ExpressWall
Vertical Gasket Top Hat framing

Horizontal Joint
Backing Strip

ExpressWall
Countersunk
Head Screw
covered with
Epoxy
ExpressPanel

Top Hat
ExpressPanel

ExpressWall
Screw

Drilled and
countersunk
hole.
Countersunk
head screw
covered with
epoxy.
 COMMERCIAL EXPRESSPANEL® – External Installation 7

SYSTEM OVERVIEW 03

Typical Commercial ExpressPanel Wall System Cross In a pressure equalised system, a cavity is formed
Section for Steel Framing between an air barrier, cavity baffles at major corners
and the panels. Openings around the base and top
of the façade allow pressure equalisation, and create
the drying benefits of air circulation and drainage.
Cavity baffles limit the airflow between the cavities
Soffit either side of a major corner. This system reduces
the risk of moisture penetration and prevents
moisture build up, allowing the building shell to dry
Refer to
head detail out, creating a healthier, more breathable building.

Horizontal batten Panels are installed to give an express jointed

fixed to frame
appearance. A vertical gasket tape is placed on the
vertical top hat and a metal backing strip is placed at
ExpressPanel
horizontal joints. Horizontal joints at base of wall and
at inter-storey junctions are left open to maintain a
ventilated cavity and to allow for moisture drainage.

Support framing The air barrier may consist of a wall wrap or rigid
materials such as fibre cement, metal sheet, or
Top Hat
masonry. The installation of Bradford Enviroseal™
CW-IT wall wrap and Cemintel Rigid Air Barrier as air
barriers are detailed in this guide and the Cemintel
Rigid Air Barrier Design and Installation Guide. Other
wall wraps and sheet materials must be installed in
accordance with manufacturer’s instructions.
Masonry and concrete substrates must be sealed
to act as an air barrier for an effective waterproofing
system.

Wall Wrap
Sealant Filled Joints
In some applications it may be preferable to install
ExpressPanel
Commercial ExpressPanels with joints that are
sealant filled. In this case, horizontal backing strips
are used and joints are sealed to minimise moisture
Refer to getting into the cavity. Sealant is also applied to the
base detail
underside of slabs.
Flashing
Cemintel Commercial ExpressPanel shall be pre-
Ground clearance to
Concrete
drilled and then fixed onto supporting metal top hats
regulatory requirements
footing using countersunk head screws.
8 COMMERCIAL EXPRESSPANEL® – External Installation

03 SYSTEM OVERVIEW

Applications
Cemintel Commercial ExpressPanel is suitable for all building classes where metal top hats can be fixed to
framing however, site environmental factors such as wind and corrosivity zones must be taken into account to
determine its suitability for a particular application.
The panels and system have been designed to withstand ultimate wind pressures up to 7.0 kPa including
cyclonic conditions.

Benefits of Cemintel Commercial ExpressPanel with the

ExpressWall Fixing System

• Fire – fibre cement sheets can be used where • Cemintel’s pressure equalised ventilated cavity
non-combustible material is required under the system allows for higher wind loads, minimises
NCC provisions. water ingress and allows air flow and drainage.
• Systems are available for thermal, acoustic and • The countersunk head screws are covered and
fire requirements as part of an overall solution for filled with epoxy compound for a flush finish on
Australian conditions. the panel face.
• Suitable for a wide range of finishes. • Suitable for Bushfire Attack Level up to 40 (BAL-40)
• Large format, lightweight panels are designed when constructed in accordance with AS 3959.
to be fixed to top hats which can be fixed to • Panels are easy to cut using standard fibre
industry standard steel, timber or masonry cement cutting equipment e.g., around windows
structural frames. and power boxes.
• Cemintel’s express jointed fixing system is tested • Termite resistant.
and widely recognised for its high performance. • Durable and weather resistant:
• ExpressWall top hat has a wider fixing surface -P rovides effective protection against wind, rain
for increased installation tolerance, allowing and temperature extremes, mould and mildew.
panel movement with changes in wind pressures, -P anels will not rot, swell or warp when
thermal movement etc. correctly installed and maintained.

System Solutions
A technical Data Fire Resistance Level (FRL) Up to 120/120/120, -/180/180 when used in a Refer to Gyprock The Red Book
Sheet can be system with Gyprock fire grade plasterboard
downloaded from
Bushfire Construction BAL-40 (Construction for Bushfire Attack AS 3959
cemintel.com.au Level 40 for an external wall)
Weatherproofing Suitable for serviceability wind pressures of AS/NZS 4284
+2.5kPa with Cemintel Rigid Air Barrier and
+1.19kPa with Enviroseal CW-IT wall wrap,
when installed as a pressure equalised
system.
Wind actions Suitable for ultimate wind loads up to AS/NZS 4284 & AS 4040.3
(including Cyclonic) 7.0 kPa with Cemintel Rigid Air Barrier,
including cyclonic conditions, and up to
2.5 kPa with Enviroseal CW-IT
COMMERCIAL EXPRESSPANEL® – External Installation 9

04 DESIGN + AESTHETIC
CONSIDERATIONS
10 COMMERCIAL EXPRESSPANEL® – External Installation

04 DESIGN + AESTHETIC CONSIDERATIONS

This section outlines some important areas for consideration in determining whether
Cemintel Commercial ExpressPanel System is suitable for the required application. The
following points are not exhaustive. It is the responsibility of the Architect / Building Designer
to ensure the design conforms to NCC requirements and other relevant building standards
that may exist for that location. This guide should be read in conjunction with the NCC.

Panels, top hats and structural framing are required Once wind loads have been determined top hat
to resist wind loads that are specific to the building spans, fastener spacings, and sheet fixing details
site. Additional “local pressure factors” apply to the can be selected from the appropriate tables in the
panels and top hats in accordance with the wind ‘System Engineering’ Section of this guide. It is also
code AS/NZS 1170.2. the responsibility of the Architect/Building Designer
to select the appropriate corrosivity category.

Panel Appearance and Finish

Commercial ExpressPanel is factory sealed on Commercial ExpressPanel may be painted off-site
both faces and all edges. Sealing in this manner when exposed head screws are used. Refer to
increases the durability and stability of the panels. appropriate painting contractors for details and
The exterior surface of ExpressPanel must be coated colours. For pre-painted panels, it is a requirement
with an appropriate finish. Note that the back face of that all expressed joints are filled with sealant - refer
panels cannot be painted, and are not suitable as an to the Barestone External Design and Installation
exterior finish. Guide – Installation Section.
Where panels are cut onsite, sealing of the cut edges A minimum dry film thickness of 250 microns is
shall be Dulux Acra-Prime 501/1, also known as recommended to ensure adequate cover for the
AcraPrime WB. The minimum application rate shall concealed fasteners.
be 1 litre per 10m² (140 grams/m²) which results in a
High gloss and low build finishes will require
dry film thickness of 70 microns. Alternatively, coat
additional surface preparation to minimise
with undiluted Bondcrete before applying the finish
fastener show through. In all cases the coating
coating.
manufacturer’s application instructions must be
The exterior face of ExpressPanel can be finished followed. The inside face of the ExpressPanel is
with a wide variety of coatings, provided they are finished clear and is not suitable for painting.
compatible with the ExpressPanel seal coat, and
Before applying finishes, all panels must be
with the epoxy used to cover the countersunk head
thoroughly washed with fresh water to remove
screws. High build, exterior grade acrylic paint or
any salt residue. Refer to coating manufacturer for
aggregate finishes provide the best results. Exposed
additional requirements.
vertical gaskets should not be painted and Sikaflex
Pro sealant may be painted if required.

The BACK is NOT SANDED

and has white sealer marks

The face of panels have been sanded and have a single coat of The FACE IS SANDED with
primer applied, whereas the back of the panel is smooth with white a primer applied
sealer marks. If you are unclear on the distinction, please contact
Cemintel prior to installation.
 COMMERCIAL EXPRESSPANEL® – External Installation 11

DESIGN + AESTHETIC CONSIDERATIONS 04

Panel Layout FIGURE 4.04 Horizontal Sheeting Half-bond Pattern

Panel layout should take into account the following:

• Aesthetic design.
• Top hat spacing to allow for expressed joint widths
(Refer Fig. 4.01).
• 8-10mm recommended joint width.
• Type of structural support.
• Size and location of openings.
• Building size.
• Location of building control joints.
Panel layout can be in a grid pattern where vertical
and horizontal joints are continuous (Refer Fig. 4.02
FIGURE 4.05 Vertical Sheeting Half-bond Pattern
& Fig. 4.03). In these layouts, construction joints may
be positioned behind any vertical or horizontal sheet
joint (refer to “Construction Drawings & Details”
section).
Panel layout can also be in a vertical or horizontal
half-bond pattern where some joints are
discontinuous (Refer Fig. 4.04 & Fig. 4.05).
This is not an exhaustive list of panel layouts.

FIGURE 4.01 Typical Top Hat set-out - 1200mm Width

Vertical Panels with 10mm Joints shown
FIGURE 4.06 S
 kirt Panel (Floor to Floor in Excess
of 3m)

1200mm Sheet

600mm 600mm
nominal nominal

Top Hat Top Hat

Spacing Spacing

FIGURE 4.02 Horizontal Sheeting Aligned Grid Pattern

Structural
Framing and Substrate Options
Commercial ExpressPanel and ExpressWall system
can be fixed to either timber or steel framing, as well
as to masonry and concrete substrates.
FIGURE 4.03 Vertical Sheeting Aligned Grid Pattern For timber and steel framing, the minimum
requirement shall be in accordance with the
following standards:
• AS 1720 – Timber Structures.
• AS 1684 – Residential Timber-Framed Construction.
• AS/NZS 4600 – Cold-Formed Steel Structures.
• AS 3623 – Domestic Metal Framing.
12 COMMERCIAL EXPRESSPANEL® – External Installation

04 DESIGN + AESTHETIC CONSIDERATIONS

Timber Stud or Steel Framing FIGURE 4.08 Fixing to Steel or Timber Framing
Cemintel ExpressWall Top Hats and Intermediate Top Hats
must be installed vertically onto horizontal H515 top hats and
Top track
supported by a primary structural system (ie timber or steel stud
framing – Refer Fig. 4.07).
FIGURE 4.07 Fixing to Timber or Steel Stud Framing

Stud frame spacing

(600mm max.)

Top track
Structural steel
frame
Top Hat
(H515)

ExpressWall
Top Hat

Top Hat Intermediate

(H515) Top Hat

Spacing of
H515 top hats.
Refer to tables

Structural steel
frame

Top Hat
(H515)
Intermediate Bottom
Top Hat track
Concrete
Top Hat
(H515) footing

Masonry or Concrete Walls

ExpressWall framing can also be fixed over masonry or concrete
walls (Refer Fig. 4.09). All top hat connections must be designed
Bottom
track by the project engineer.
Concrete
footing

Alternatively ExpressWall framing can be fixed to appropriately FIGURE 4.09 Fixing to Masonry Wall
designed steel or timber framing. The frame must be designed to
support the top hats at the top and bottom of the wall and at cross
members within the span of the wall (Refer Fig 4.08).
The connection of Top Hats to the structural frame requires
engineering design. It is the responsibility of the project engineer to
specify the connection of the top hats to the support structure.
Masonry wall
It is critical that the frame is true and plumb. Industry best
practice for framed tolerance allows up to 5mm misalignment
over a 3m distance.
When retrofitting Commercial ExpressPanel to existing walls, the ExpressWall
Top Hat
suitability of the substrate must be assessed.
AS/NZS 1170.0 Table C1 suggests that support framing be
Intermediate
designed for a maximum deflection of span/250. Top Hat

Span tables are located in ‘System Engineering’ section.

In highly corrosive environments, appropriate measures should
be taken to protect the frame and metal components from
corrosion. Refer to Corrosive Zones table in ‘System Engineering’
section.
 COMMERCIAL EXPRESSPANEL® – External Installation 13

DESIGN + AESTHETIC CONSIDERATIONS 04

Wind Pressures Intermediate Top Hat is used to support the panels

Commercial ExpressPanel installation has been at intermediate locations in between ExpressWall
evaluated for use in all Australian wind zones up to top hats. The Intermediate top hat is a rolled steel
and including N6 and Cyclonic C4 in accordance with section which is manufactured from galvanised steel
AS 4055 for wind pressures up to 7.0 kPa under AS (Z275) of 1.15mm BMT.
1170.2 including cyclonic zones when fixed to steel
framing. Fibre cement is not resistant to the projectile 20 50 20
penetration specified in AS/NZS 1170.2.

35
Cavity Baffle
Used vertically at the major corners or other areas of
the building where differential cavity pressures either H515 Top Hat is installed horizontally to the face of
side of the corner can occur. The baffle provides an steel or timber stud framing to support the
obstruction to limit the airflow between cavities and ExpressWall Top Hats and Intermediate Top Hats.
promote pressure equilisation in each wall cavity Top Hat H515 is a Rondo rolled steel section which is
section. manufactured from galvanised steel (Z275) of 1.15mm
A cavity baffle solution can consist of a top hat BMT.
section, Z-flashing, angle, channel, a backing rod and
sealant, and/or self-adhesive expanding foam tape, 20 50 20
that will bridge and close the cavity width or gaps
between the corner sub-framing and air barrier layer. 15
The baffle shall be suitable for the project design
differential pressures. As required, use compatible
sealants to close of any gaps between the baffle
section and the air barrier layer, cladding and sub- Pre-Drilling Panel Holes
framing.
Holes for screws must be pre-drilled. This activity
can be done off-site prior to installation. Use the
Top Hats recommended counter sinking tool for countersunk
Cemintel’s ExpressWall Top Hat is a purpose head screws and a 6.0 – 6.5mm masonry or ceramic
designed rolled steel section for supporting the drill bit for pre-drilling.
vertical edges of the panels. The unique profile Dust must be cleaned our of holes.
acts to accommodate movement of the sheets
at the vertical joints. It is designed to be used in
conjunction with the ExpressWall vertical gasket for
Face Fixings
added weather resistance. The ExpressWall Top Hat
is manufactured from galvanised steel (Z275) and is Panels may be pre-drilled and painted off-site and
the subject of Patent No 2004240142. It is available fixed to top hats using exposed head screws.
in 1.15 BMT or 0.75 BMT. Refer to the Barestone External Design and
Installation Guide – Installation section, for screw
fixing details.
For pre-painted panels, it is a requirement that all
22 29 5 59 5 29 22
expressed joints are filled with sealant.

1.15 BMT
35

171

25 24 6 53 6 24 25

35 0.75 BMT

163
14 COMMERCIAL EXPRESSPANEL® – External Installation

04 DESIGN + AESTHETIC CONSIDERATIONS

Window & Door Openings

Cemintel Commercial ExpressPanel is compatible Vertical Control Joints
with industry standard aluminium windows. Vertical control joints to allow for differential
Aluminium windows MUST NOT have sill drain holes movement are required at the supports of fascia
that can direct water into the wall cavity. trusses and at the junction of structural elements
With the cavity created by the top hat system, of different stiffness, such as between concrete
particular attention needs to be given to the set out columns and stud frames (refer to the “Construction
of windows and doors. Drawings and Details” section).

The depth of the window needs to be taken into A control joint must also be installed when a masonry
account in the design of the building frame so wall adjoins framed construction, and at the junction
that the front face of the panel is properly aligned of framed additions or existing buildings, to allow
with the window and that the flashing is installed for differential movement. Refer to ‘Construction
correctly. Drawings and Details’ section.

If using a rigid air barrier or other sheeting, the Vertical joints in panels must be aligned and extend
thickness of this also needs to be accounted for to for the full height of continuous panelling, although
achieve a flush finish when determining window set additional joints may be placed over openings for
out and reveal depths. ease of installation. As the joints are expressed,
consideration to the positioning of joints is important
Cemintel recommends installing a sub frame with all for aesthetic reasons. Placing joints at sides or above
windows. Refer to typical window detail drawing in openings, or the use of full height windows can
‘Construction Drawings and Details’ section of reduce the visual impact of joints.
this guide.
ExpressWall Top Hats in both 1.15mm BMT (‘1.15BMT’)
and 0.75mm BMT (‘0.75BMT’) steel have been
Eaves Junction designed to elastically deform when pressure is
Air is circulated to the wall cavity. It is not re- applied during panel fixing. They have a recessed
commended that air be vented into the roof space. area to accept a vertical gasket tape which is made
from closed cell foam with good weathering and UV
resistance. It has a low compression set and low
water permeability.
Control Joints
Movement Control Joints Structural Bracing
Control joints provided in the panel layout should be Cemintel Commercial ExpressPanel sheets are
aligned with movement control joints provided in the indirectly attached to the structural framing by way
framing. of metal top hats. As a consequence, they are not
designed to provide wall bracing.
When undertaking building additions, a movement
control joint must be installed at the junction of the If required, bracing must be provided in the structural
existing framing and the new framing. Cladding framing with methods such as sheet or strap
systems must be discontinuous at this joint (refer to bracing. Where sheet bracing is used, the entire wall
the “Construction Drawings and Details” section). framing to be clad with Commercial ExpressPanel
must be sheeted to maintain a uniform fixing plane.
When setting out panels, design consideration Note: window setout will be affected.
should be given to the location of joints to ensure
that minimum panel lengths are observed. Termite Management
There is a wide variety of methods for managing
Horizontal Control Joints
termite entry to buildings, and selecting the
A horizontal control joint is required beneath every appropriate method for any structure depends on
floor junction to accommodate any expected specific risk factors and the form of construction.
deflection. The magnitude of the deflection must
be verified by the project engineer (refer to the Refer to your local pest management service, the
“Construction Drawings and Details” section). BCA, AS 3660: Termite Management, and your local
building authorities for more information about the
requirements for the design of a suitable termite
management system.
 COMMERCIAL EXPRESSPANEL® – External Installation 15

DESIGN + AESTHETIC CONSIDERATIONS 04

Moisture Management
To ensure occupant health, safety and comfort and zones exist within the cavity, typically at building
to protect the building’s water sensitive materials corners.
from damage, a condensation management strategy
For conventionally installed wall wrap/vapour control
with the following objectives is required:
membrane layers, typically the internal plasterboard
• Prevent external weather entering the building; lining is considered the predominant air barrier in the
• Mitigate the risks associated with the accumulation external wall system. Alternatively, the inner lining of
of internal moisture in a building; and the ventilated and drained cavity (i.e., wall wrap, rigid
air barrier, waterproofing layer, backpan) can be the
• Provide construction systems that have a drainage
air barrier. The design must ensure the air barrier is
and drying potential.
structurally adequate to resist the imposed design
The National Construction Code (NCC) volumes cover wind pressures.
requirements for weatherproofing, condensation,
Properly designed rigid air barriers including, fibre
water vapour, ventilation, air tightness and thermal
cement, masonry, concrete, timber and metal
performance which help manage associated risks
sheeting all require respective detailing and sealing
and resist ingress of weather and groundwater into
to be utilised as an air barrier. Alternatively, various
a building to minimise the impact on the health of
properly designed wall wraps may be utilised. The
occupants.
maximum serviceability limit state wind pressure
CSR provides several product options for thermal may be governed by the type of air barrier / air seal
and moisture control, and use as air barriers. The selected.
project designer, architect or engineer is responsible
The serviceability wind pressure for the
for determining what is appropriate for the
building is used to determine the suitability of
application.
a weatherproofing system. However, the design
Weatherproofing pressure for the air barrier is dependent on factors
such as cavity depth, ventilation openings, and any
The control of water ingress to a building is the
panel gaps. The air barrier should be designed to
responsibility of the building designer. All framing,
resist the building ultimate wind pressure unless a
wall wrap/sarking, flashings, damp proof courses
lower value is determined by the facade engineer.
and sealants must be installed in accordance with
design and installation guides, the relevant product The Commercial ExpressPanel system with a cavity
manufacturer’s instructions, applicable standards wall configuration using Cemintel Rigid Air Barrier has
and building codes. The selection of the appropriate been tested and assessed to AS 4284 to withstand
installation system is based on many factors, but water ingress for serviceability limit state wind
particular attention must be paid to weatherproofing pressures up to +/- 2.5kPa, and a maximum design
to ensure adequate long-term performance. ultimate limit state wind pressures up to +/- 7.0kPa.
Table 4.04 and Table 4.05 provide the ultimate design
Important: Windows must be a front draining style
pressure capacity of the Cemintel Rigid Air Barrier for
and have appropriate flashing to prevent moisture
different structural framing arrangements and sheet
ingress and penetrations should be effectively sealed
orientations.
and allow for differential movement between the air
barrier and at the cladding. Wall wraps can provide a water resistant and air
tight barrier when installed appropriately. When
Air Barriers installed in accordance with the Soft Air Barrier
An air barrier behind the cladding is an essential part construction details in this guide, the Bradford
of the Commercial ExpressPanel weatherproofing Enviroseal CW-IT wall wrap has been assessed as an
system. The air barrier is required to reduce air air barrier for a maximum design ultimate limit state
leakage between the external and internal areas of wind pressures up to +/- 2.5kPa. It is recommended
the building. It is important to note that air barriers that wall wraps used as an air barrier have an air
must be installed correctly as they are an integral resistance greater than 0.1 MNs/m3 when tested to
element of a pressure equalised self-draining cavity ISO 5636-5. Wall wraps in Table 4.02 meet this air
system. The extent of the barrier, including the resistance requirement. The construction details for
treatment at corners and at interactions with other a soft air barrier or rigid air barrier are presented in
facade elements, must be considered by the facade the ‘Construction Drawings and Details’ section of
designer. Vertical cavity barriers may be required at this guide and the Cemintel Rigid Air Barrier Design &
some locations to ensure effective positive pressure Installation Guide, respectively.
16 COMMERCIAL EXPRESSPANEL® – External Installation

04 DESIGN + AESTHETIC CONSIDERATIONS

Condensation Vapour Control/Vapour Permeable Membranes

Condensation occurs as warm, moist air cools and The fabric of the building separates the interior
contacts cold surfaces that are below the air’s dew and exterior environments and is subject to the
point. Absorptive materials such as brick, cement movement of heat, air, water, and water vapour.
sheet and timber are permeable and act as a Multiple materials are usually required to form
buffering material until they become saturated, whilst effective control layers in the interstitial spaces
nonabsorptive materials such as steel and glass between the exterior cladding and internal lining of a
reach saturation quickly. Water can then accumulate building.
and must be allowed to dry or drain away via a cavity.
The appropriate wall wrap for an application will
Moist surfaces and the right environment can lead to
depend on the local climate, building type, service
mould, creating potential health issues for occupants
wind pressure, use and orientation, material R-Value
and lead to degradation of building materials and
of the insulation, as well as the degree and location
loss of structural integrity.
of ventilation.
The likelihood and severity of condensation is largely
Vapour barriers restrict the transmission of water
a function of:
vapour, while vapour permeable membranes allow
• Climate (primarily temperature and humidity the transmission of water vapour.
including seasonal and diurnal variations).
The wall wrap must have a ‘water barrier’
• Occupancy and building use.
classification to AS/NZ 4201.4. A non-water barrier
• Material properties of the building envelope classification is not suitable. Wraps included in this
(including insulation material type and R-Value). manual, and Cemintel Rigid Air Barrier, have achieved
• Passive and mechanical ventilation. the classification water barrier. Wall wraps must
• Air tightness. meet the requirements of AS/NZS 4200.1: Pliable
building membranes and underlays – Materials and
• The building envelope’s ability to allow or prevent
be installed in accordance with AS 4200.2 – Pliable
the movement of vapour.
building membranes and underlays – Installation
• The building envelope’s ability to act as a water requirements.
barrier behind the primary cladding element.
For conventionally installed wall wraps, the
• The drying potential provided by a building
requirement to seal joins and penetrations may
envelope.
vary depending upon NCC, AS 4200.2 and/or state
CSR recommends that architects/designers requirements, CSR recommends sealing the external
undertake a condensation risk analysis prior to wall wrap/sarking to maintain vapour and wind
selecting vapour control membranes. A rigid air performance, and draught proofing effectiveness, as
barrier may be required where buildings are subject well as to ensure water barrier integrity. As there are
to higher wind loads, and in some climate zones a number of factors that need to be considered in
may require the incorporation of a vapour control assessing and managing condensation risk.
membrane in addition to the rigid air barrier. Greater
Note: The use of a Class 3 membrane such as
use of insulation, better sealing to restrict air
Cemintel Rigid Air Barrier may not be sufficient in
movement, and increased use of air conditioning
some cold climates. If a Class 4 membrane cannot
leads to larger differences between the temperature
be used, a solution may include the use of a material
and water vapour content of indoor environments
to the interior side of the insulation that acts as a
and adjacent outdoor areas and greatly increases
vapour barrier, e.g. a Class 1 or 2 membrane or a
the risk of condensation at surfaces and interstitial
vapour sealed plasterboard lining coupled with a
spaces.
mechanical ventilation solution. CSR recommends
The Australian Building and Construction Board seeking expert advice prior specifying systems for
(ABCB), “Condensation in Buildings Handbook”, 3rd these regions.
Edition 2019, discusses the condensation risks and
Additional literature on this subject is available from
provides guidance on managing condensation. This
CSIRO/BRANZ/ ASHRAE/ABCB and CSR DesignLINK
guidance includes review of Bureau of Meteorology
can help with this assessment.
climate statistics (including maximum and minimum
average monthly temperatures together with average
monthly dew point temperatures). This highlights
the likelihood of condensation which occurs when
minimum temperature falls below the dew point, and
identifies the daytime drying potential.
 COMMERCIAL EXPRESSPANEL® – External Installation 17

DESIGN + AESTHETIC CONSIDERATIONS 04

TABLE 4.01 Recommended CSR Products for Moisture Management of Walls

Climate Zone Guidance on Vapour Control Performance and Recommended CSR

Category Products(1)
(Refer to Table 4.02)
Warm humid, High Where vapour flow is typically Vapour Barrier • Bradford Thermoseal
humidity or Hot-dry inward, such as where the building Class 1 or 2 Wall Wrap
(tropical, coastal, is airconditioned for cooling, the or • Bradford Thermoseal
inland) climates membrane should function as a Vapour Permeable Wall Wrap XP
(Zone 1, 2, 3) vapour barrier. Class 3 or 4 • Cemintel Rigid Air
Barrier with a vapour
Climates with varying diurnal and barrier membrane
seasonal temperature changes can • Cemintel Rigid Air
affect the direction of the water Barrier
vapour flow. In most cases a vapour • Bradford Enviroseal
permeable membrane outside the RW/CW/CW-IT Wall
insulation is recommended to avoid Wrap
creating a moisture trap, allowing
drying in either direction.
Hot-Dry or Warm These climates have varying diurnal Vapour Permeable • Bradford Enviroseal
Temperate (coastal and seasonal temperature changes Class 3 or 4 RW/CW/CW-IT Wall
& inland) climates that can affect the direction of Wrap
(Zones 4, 5) the water vapour flow. A vapour • Cemintel Rigid Air
permeable membrane outside Barrier
the insulation is required to avoid
creating a moisture trap, allowing
drying in either direction. Where a
high level of thermal insulation is
used, a high degree of permeability
may be required.
Mild or Cool Where there is a strong tendency Vapour Permeable • Bradford Enviroseal
Temperate, or Cold for outward migration of vapour Class 4 RW/CW/CW-IT Wall
(alpine) climates and a high risk of condensation, Wrap
(Zones 6, 7, 8) vapour permeable membranes • Cemintel Rigid Air
should be installed on the cold, Barrier(2)
external side of the insulation.
(1) Expert guidance based on local experience should be sought.
(2) The use of a Class 3 membrane such as Cemintel Rigid Air Barrier may not be sufficient in some cold climates. If a Class 4
membrane cannot be used, a solution may include the use of a material to the interior side of the insulation that acts as a
vapour barrier, e.g. a Class 1 or 2 membrane or a vapour sealed plasterboard lining coupled with a mechanical ventilation
solution. CSR recommends seeking expert advice prior specifying systems for these regions.

TABLE 4.02 Vapour Control Properties of CSR Products

Product Vapour Permeance Vapour Permeance Weather Exposure Limit
Class AS/NZS 4200.1 ASTM E 96 (µg/N.s) Prior to Cladding
Bradford Thermoseal Wall Wrap XP Class 1 ≤ 0.002 4 weeks
Bradford Thermoseal Firespec Class 2 0.002 to 0.1429 4 weeks
Bradford Thermoseal Wall Wrap Class 2 0.0022 to 0.1429 4 weeks
Cemintel Rigid Air Barrier Class 3 0.25 6 months (panel)
2 months (tape)
Bradford Enviroseal CW/CW-IT Wall Class 4 > 1.1403 6 weeks
Wrap
Bradford Enviroseal RW Wall Wrap Class 4 > 1.1403 6 weeks
18 COMMERCIAL EXPRESSPANEL® – External Installation

04 DESIGN + AESTHETIC CONSIDERATIONS

Cemintel Soft Air Barrier

Soft Air Barrier to be installed in the following wind load situations

TABLE 4.03 Wall Wrap and Plasti-Grip spacing requirements for the following wind loads

Stud Maximum Bradford Plasti-Grip Washer Spacing (mm)

Spacing Ultimate Design Wind Pressure (kPa)
(mm)
0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50
300 300 300 300 300 300 300 300 300 300
400 300 300 300 300 300 300 250 250 200
450 300 300 300 300 300 250 250 200 200
600 300 300 300 300 250 200 - - -
Note: S
 crew fixings for attaching washers to timber or steel framing shall be a minimum 8g self-drilling screws. Screws into
timber shall have a minimum 25mm embedment.

Cemintel Rigid Air Barrier

Cemintal Rigid Air Barrier sheet installed in the Cemintal Rigid Air Barrier sheet installed in the
vertical direction horizontal direction
TABLE 4.04 TABLE 4.05

Stud Centres Maximum Wind Loading Stud Centres Maximum Wind Loading
(mm) (Ultimate) (kPa) (mm) (Ultimate) (kPa)
600 1.14 600 1.76
450 2.03 450 3.13
400 2.57 400 3.96
300 4.57 300 7.00

Note: For specific installation information on Rigid Air Barrier, refer to the ‘Cemintel Rigid Air Barrier Design and Installation Guide’.

Energy Efficiency & Thermal Design

Energy efficiency requirements for buildings are compliant with the standard, and building elements
set out in the NCC, as performance requirements have thermal values sourced from the AIRAH
and acceptable construction practices, and are handbook. Thermal performances quoted are based
dependent on geographical climate zones. To meet on an assessment through the insulation path. The
the requirements, it is recommended that insulation contribution to Total R-Values depends on installation,
be installed in the wall framing and provision of workmanship and environmental conditions and it is
appropriate sealing of the building envelope. Check assumed that cavities are ventilated.
with local building authorities for minimum insulation
requirements. The level of insulation provided by a Thermal Bridging
wall is described by its Total R-Value. Thermal bridging is a path of least resistance for
heat to travel, which can significantly reduce the
Thermal Performance of Cemintel Wall Systems effectiveness of insulation. An example is where a
The Gyprock The Red Book presents Cemintel steel stud with high thermal conductivity interrupts
external wall systems that include thermal ratings the insulation layer. This can result in internal heat
expressed as Rt(WINTER) and Rt(SUMMER) to represent lose on a cold day and internal heat gain on a hot
Total R-values for the winter and summer design day. At thermal bridging locations, condensation
conditions as required by AS/NZS 4859.1, which is may occur where warm, moist air contacts a colder
called upon in the NCC. surface.
The Total R-Values presented in The Red Book are The detrimental impact of a thermal bridge can be
based on assumptions in accordance with the diminished with the installation of a thermal break,
methods of AS/NZS 4859.1 – Thermal insulation which increases the resistance for heat to travel at
materials for buildings - General criteria and the thermal bridging locations. Typically, the thermal
technical provisions. Any included bulk insulation is break has low thermal conductivity.
a CSR Bradford product that has a material R-value
 COMMERCIAL EXPRESSPANEL® – External Installation 19

DESIGN + AESTHETIC CONSIDERATIONS 04

Thermal Break
For some situations, e.g. Class 2 building or Class 4 Additional to the effects of thermal bridging through
parts of a building, an envelope consisting of a metal the framing paths of the structure, the designer will
framed wall with and external fibre-cement cladding need to allow for the following:
and an internal lining directly fixed to the frame,
• gaps in the bulk insulation layer in the wall
NCC2022 J3D6 (1) [2019: J0.5] requires a thermal
system due to structural framing (i.e., studs,
break to be installed between all points of contact
noggings, perimeter of wall openings) and services
between the external fibre-cement cladding and the
obstructing or limiting wall insulation coverage;
metal frame. The thermal break shall have a minimum
R-Value of R0.2. • slab edge insulation;
• wall cavity ventilation; and
The Australian Building and Construction Board
(ABCB), “Energy efficiency NCC Volume One • the effects of air leakage due to unsealed
Handbook”, June 2019, advises a thermal break architraves, unsealed door jambs, unsealed gaps
is not needed if a secondary framing member, between windows and the masonry wall or services
orientated perpendicular to the metal frame, is penetrating the inner leaf.
installed between the metal frame and lightweight These effects are to be compensated for as outlined
external cladding. This is the case for the in Section J of the NCC.
ExpressWall framing system, the cladding is indirectly
For projects conforming to NCC versions prior to
fixed to the structural framing with secondary
the NCC 2022, thermal bridging consideration is
members (top hats) perpendicular to the structural
not required in the Total R-Value calculation for all
framing (i.e., studs), therefore no thermal break is
building classes, such as:
required at the connection of the horizontal top hat
and the vertical structural stud framing. • Class 1 to Class 10 buildings (all building classes)
for NCC 2016 Amdt. 1 Volume One and NCC 2016
The Commercial ExpressPanel systems have a
Amdt. 1 Volume Two (and earlier).
‘well ventilated’ cavity and the project designer,
architect or engineer is responsible for assessing the • Class 1 and Class 10 only for NCC 2019 (incl. Amdt.
thermal bridging and determining the thermal break 1) Volume Two.
requirements to ensure the wall system provides an For product information, refer to ‘Components’
adequate Total R-Value inclusive of thermal bridging. section of this guide. Note, the insulation also
improves the acoustic performance of the wall
For the Cemintel direct fixed wall systems, the
against outside noise.
external cladding is in direct contact with the metal
framing a thermal break is applied to the face of the Building Envelope Sealing
frame to meet the deemed to satisfy requirements of Building envelope sealing is pertinent to the energy
the NCC. efficiency performance of a building. NCC 2022 J1V4
NCC Requirements [2019: JV4] outlines a method to verify compliance
NCC 2022 includes changes to energy efficiency with the building sealing requirements in NCC 2022
requirements. These requirements will express the Part J5 [2019: Part J3].
R-Value of the building fabric system as the Total Solar Reflectance/Absorptance
R-Value inclusive of thermal bridging. The Total
Cemintel Commercial Express has been tested to
R-Value will consider the project specific external
ASTM E 903-96 ‘Standard Test Method for Solar
wall configuration and materials used, so that the
Absorptance, Reflectance and Transmittance of
detrimental impact of the thermal bridging on the
Materials Using Integrating Spheres’.
added insulation is captured.
20 COMMERCIAL EXPRESSPANEL® – External Installation

04 DESIGN + AESTHETIC CONSIDERATIONS

Climate Zones for Thermal Design

The following map and tables show the performance levels required for walls (and floors) under the NCC.
110° 115° 120° 125° 130° 135° 140° 145° 150° 155° 160°

Oenpelli Nhulunbuy
Darwin
10°
Weipa 10°

Katherine

Wyndham
Timber Creek
Cooktown
Borroloola

Elliot Cairns
15° Derby
15°
Burketown
Broome
Halls Creek

Tennant Creek Townsville

Mount Isa

Port Hedland
Dampier
Mackay
Telfer
20°
20°
Exmouth Alice Springs
Longreach
Newman
Rockhampton

Yulara
Kulgera Birdsville
Gascoyne
Junction Warburton Amata Taroom
Carnarvon
Charleville Maryborough
Wiluna Oodnadatta

25° Innamincka
Thargomindah 25°
Brisbane
Coober Pedy
Yalgoo Goondiwindi
Tibooburra
Geraldton
Leigh Creek Bourke
Kalgoorlie–Boulder
Nullarbor
Coffs Harbour
Broken Hill Tamworth
Merredin Eucla
Ceduna
Norseman Port Macquarie
Whyalla Dubbo
Perth Ivanhoe
30°
30°
Newdegate Burra Lord Howe Island

Esperance Mildura Bathurst Newcastle

Bunbury
Renmark Griffith
Port Lincoln Adelaide Sydney
Margaret River
Kingscote Wollongong

Albany Climate Zones Albury–Wodonga

Canberra

Horsham
Kingston SE
Zone 1 Zone 5 Shepparton

Ballarat Melbourne
Mount Gambier
35° Zone 2 Zone 6
35°
Lakes Entrance
Zone 3 Zone 7

Zone 4 Zone 8

Devonport
Launceston

Strahan www.abcb.gov.au
Swansea
Local Government Area boundary Hobart Last amended: August 2015

40° Southport Developed from a map produced 40°

by the Bureau of Meteorology
VC00031.3
105° 110° 115° 120° 125° 130° 135° 140° 145° 150° 155° 160° 165°

Step 1: Determine which climate zone your project is located in Australia from the map above.
Step 2: From Table 4.06, determine the design conditions (‘Summer’ heat flow in or ‘Winter’ heat flow out)
according to the building class and climate zone for your project. (Note building classes are defined
by the NCC.)
Step 3: Refer to the roof, wall or floor system applicable to your construction type to determine Total R-Value.
Note: S
 ome applications may achieve Total R-Values sufficient to comply with the minimum performance levels of the
Deemed-to-Satisfy requirements contained in the Energy Efficiency Provision of the NCC.

TABLE 4.06 Design Conditions (‘Summer’ heat flow in or ‘Winter’ heat flow out). Source: ICANZ Handbook.

Climate Zone 1 2 3 4 5 6 7 8
<300m >300m
Altitude Altitude
Class 1&10 Summer Winter
Class 2-9 Summer Winter
 COMMERCIAL EXPRESSPANEL® – External Installation 21

DESIGN + AESTHETIC CONSIDERATIONS 04

Fire Performance
Façade Fire Performance
With respect to the Deemed-to-Satisfy requirements also suitable for use where a non-combustible
of NCC 2022 Volume One, C2D10 [2019: C1.9] sarking-type material is required as they do not
allows that fibre-reinforced cement sheeting may exceed 1mm in thickness and have a Flammability
be used wherever a non-combustible material is Index ≤ 5.
required. Cemintel Commercial ExpressPanel is fibre-
reinforced cement sheeting and is therefore suitable Fire Rated Wall Construction
as a component of, for example, external walls Cemintel Commercial ExpressPanel can be used
of buildings that are of Type A or B construction. in conjunction with Gyprock fire grade plasterboard
A similar allowance is made in the Acceptable as part of a fire rated wall. Systems may be
Construction section of NCC 2022 Volume Two. selected from Gyprock The Red Book series of;
The Red Book 01, The Red Book 02 and
Bradford Enviroseal and Thermoseal products are
The Red Book 03.

Extreme Climate Conditions

Bushfire Zones
A Bushfire Attack Level (BAL) rating is a means of wall systems can be suitable for use on buildings
measuring the severity of a building’s potential constructed in accordance with AS 3959 with a BAL
exposure to ember attack, radiant heat and direct rating up to and including BAL-40.
flame contact. It is the responsibility of the project
designer to assess the bushfire adequacy of the Cemintel Commercial ExpressPanel wall systems
wall system and determine any additional details to can achieve a 30/30/30 FRL rating (or higher) from
satisfy the project bushfire requirements (refer to the outside with the addition of a suitable Gyprock
the NCC, AS 3959 and any other relevant regulatory Fyrchek MR plasterboard lining to the outside of the
requirements). framing, (refer to Gyprock The Red Book 01 Design
Guide) and installed according to regulations and
Protection against bushfire attack requires a AS 3959 Section 9 Construction Requirements for
comprehensive and systematic approach to ensure Bushfire Attack Level FZ (BAL-FZ) for an external wall.
the construction of the whole wall system is Note that a 10m setback applies from the edge of
considered, that includes the specification of fire- the classified vegetation to the building.
resistant linings, framing, cavity treatment and other
materials (e.g., insulation, external wall cladding), Corrosive Zones
and construction details for the external walls and Consideration of corrosivity zones should be taken
junctions to neighbouring elements (e.g., eaves, into account. While Commercial ExpressPanels are
decks and floors). Bushfire zone walls require specific not subject to corrosion, consideration needs to be
treatments, such as but not limited to, all joints in the made regarding the impact of climate conditions
external surface material (cladding) of walls shall be on system components such as screws, rivets and
covered, sealed, overlapped, backed or butt-jointed, metal framing.
inclusion of a sarking-type material applied over the
Corrosivity zones are detailed in AS 4312-2019 and
frame prior to fixing any external cladding, and at all
set out in Table 4.07 at the end of this section.
gaps (e.g., vents and weepholes) in external walls
shall be screened with a mesh with a maximum Commercial ExpressPanel installed with the
aperture of 2mm, made of corrosion-resistant steel or ExpressWall fixing system is a pressure equalised
bronze. Also mesh coverings maybe required at the ventilated cavity system and may be used in
wall head, base, all gaps, eaves and junctions with environmental zones up to and including C3 –
roofs, etc., to ensure appropriate protection from fire Medium.
and ember attack.
Walls must be sufficiently exposed from above so
In accordance with AS 3959, the Cemintel that rain can perform natural wash-down of the wall.
Commercial ExpressPanel sheets comply with the Otherwise all walls which are protected by soffits
minimum thickness requirements of fibre-cement must be washed down twice per year to remove salt
external cladding of Section 8 Construction and debris build up, particularly around window/door
Requirements for Bushfire Attack Level 40 (BAL- openings.
40) for an external wall. Commercial ExpressPanel
22 COMMERCIAL EXPRESSPANEL® – External Installation

04 DESIGN + AESTHETIC CONSIDERATIONS

Note that a white deposit may develop on stainless screw heads Cyclonic Zones
over time. This can be prevented by regular washdown of the Cyclonic testing on the ExpressWall system has been
façade and the fastener heads. successfully carried out for positive and negative wind
The Architect/Building Designer is responsible for assessing the pressures of up to 7.0 kPa. In cyclonic areas, ExpressWall and
site in accordance with the standard and local conditions. Intermediate Top Hats of 1.15mm BMT must be used and a
minimum 14-G hex head screws are required for fixing top
Commercial ExpressPanel sheets installed with the ExpressWall hats to steel sub-framing. Wind loads in this guide refer
fixing system is not suitable for Corrosivity Zone C5 – Very High. to ultimate limit state design wind pressures.
This includes the beachfront in regions of rough seas and surf
beaches, and inland for several hundred metres, eg. around Temperature Extremes
Newcastle extending over half a kilometre from the coast. It also Commercial ExpressPanel External is not warranted for use in
includes aggressive industrial areas where the environment may freezing conditions where the ExpressPanel is in contact with
be acidic with a pH of less than 5. snow drifts or extremely hot conditions (that is above 60°C).

Corrosivity Categories
ISO 9223 has suggested five corrosivity zones based on the Some general statements from this document are below.
first year corrosion rate of mild steel. Refer to AS 4312 – 2019 for Wind loads in this guide refer to ultimate limit state design wind
details regarding Australian Atmospheric Corrosivity Categories. pressures.

TABLE 4.07 

ISO 9223 Corrosivity Steel Corrosion Typical environment

Category rate μm/y
C1 Very low <1.3 Dry indoors
C2 Low (most areas of Australia at least 50km from the coast or at least 1km from 1.3-25 Arid/urban inland
sheltered bays would be in this category)
C3 Medium (from 1km to 10-50km from breaking surf – much of metropolitan 25-50 Coastal or industrial
Wollongong, Sydney, Newcastle and Gold Coast are in this category)
C4 High (primarily coastal areas - from several hundred metres to about 1km inland from 50-80 Sea shore (calm)
breaking surf or from the shoreline to around 50m for sheltered bays)
C5 Very high (industrial or marine) – common offshore and on the beachfront in regions 80-200 Sea shore (surf)
of rough seas and surf beaches – can extend inland for several hundred metres (in
some areas of Newcastle extends around 500m)
CX Extreme (industrial or marine) - found on offshore structures and within 50m inland of 200 - 700 Sea shore (severe
the shoreline of coasts exposed to surf or very rough seas - can extend 200m under surf) of exposed
the most severe sea conditions and 100m in tropical locations. coasts

Other Design Considerations

Services Limitations
The ExpressWall fixing system will accommodate services that Commercial ExpressPanel is not suitable for the following
are run through the framing. Any notches or holes formed must applications:
be considered in the framing design.
• Panels with non-vertical face (e.g. parapet capping).
Renovations • Wet areas such as bathrooms.
When undertaking building renovations, remove all cladding, • Chimney cladding.
wall wrap/sarking and insulation from the original wall framing. • Exposure to temperatures greater than 60°C.
Ensure the condition of the framing is in accordance with
• Roofs, parapet cappings, sills and similar horizontal or near
current requirements and is as true and as plumb as possible
horizontal surfaces.
(within accepted industry tolerances of 5mm misalignment over
3000mm). • Contact with standing snow or ice.
• Fixing of tiles or other materials to the face of the panels as
Install additional framing, insulation, air barrier and flashing as
the face is prefinished.
required.
The above listing is not intended to be comprehensive. If in
doubt, please contact Cemintel.
 COMMERCIAL EXPRESSPANEL® – External Installation 23

DESIGN + AESTHETIC CONSIDERATIONS 04

Wash Down Process Inspection, Repair and Maintenance

Panels have been coated with a factory finish. The durability of the Cemintel Commercial
Consequently, where sufficiently exposed, rain can ExpressPanel range can be enhanced by periodic
perform a natural wash down of the wall and ongoing inspection and maintenance. Inspections should
maintenance should be limited to occasional rinse include examination of the coatings, flashings
down or using a soft cloth or soft brush (like a dust and seals. Any cracked or damaged finish or seals
pan brush). which would allow water ingress must be repaired
immediately by resealing the affected area, or by
Walls which are protected by soffits above must
removing the panel and replacing sealant. Any
be washed down twice per year to remove salt and
damaged flashings, sheets or sealant must be
debris build up particularly at joints.
replaced as for new work.
When cleaning the panels the following is
Regularly inspect panel surfaces and follow wash-
recommended –
down procedures when required.
• Normal dirt can be removed with a soft brush and
Ensure ventilation and drainage gaps between
warm water up to 50 degrees Celsius, to which a
panels and flashings are clear of any debris.
small amount of dishwashing liquid or soap has
been added. The panels should be rinsed with
clear water before they dry.
• Calcifications should be removed with a 5%
sulfamic acid solution or with a commercial lime
remover. The façade should be rinsed with clear
water after cleaning.
• Panels discoloured by algal growth should be
treated with an algicide without bleaching agents.
This application should be allowed to take effect
for several days. Afterwards, clean the panels
using the ‘normal dirt’ procedure above.
• When rinsing down panels, use no more than 700
psi (50kh/cm²) of water pressure at a minimum
of 3m distance from the face of the wall. Water
pressure should be applied downward to avoid
forcing water into joints.
• Use neutral detergent with a soft cloth or soft
brush when removing dirty spots from a panel.
When diluting the neutral detergent, follow the
manufacturer’s instructions and use the weakest
solution possible.
24 COMMERCIAL EXPRESSPANEL® – External Installation

05 COMPONENTS + ACCESSORIES
 COMMERCIAL EXPRESSPANEL® – External Installation 25

COMPONENTS + ACCESSORIES 05
Note: Codes can change from time to time. Refer to the website for the current list of components prior to ordering.

Panels

Product Code Thickness (mm) Width (mm) Length (mm) Mass (Nominal) Panels per pack
25681 9 900 1800 17.8kg/m2 20
25682 9 900 2400 17.8kg/m2 20
25683 9 900 3000 17.8kg/m2 20
25676 9 1200 1800 17.8kg/m2 20
25677 9 1200 2100 17.8kg/m2 20
25678 9 1200 2400 17.8kg/m2 20
25679 9 1200 2700 17.8kg/m2 20
17.8kg/m
2
25680 9 1200 3000 20

Accessories

Note: The length of the fixings will need to be increased to ensure the same or greater embedment depth is obtained when
additional layers are added, such as a Rigid Air Barrier (RAB), fire-rated linings, and/or thermal break materials.
Accessories Description Size / Colour Quantity Product Code
TOP HATS
ExpressWall Top Hat – is a purpose designed rolled steel section for supporting
the vertical edges of the panels. The unique profile also acts to accommodate
movement of the panels at the vertical joints. It is designed to be used in
conjunction with the ExpressWall vertical gasket. Screws must be carefully
installed in 0.75 BMT ExpressWall top hats to avoid thread stripping.
ExpressWall Top Hat 0.75BMT – mass = 1.97kg/m 6000mm 1 each 84746
ExpressWall Top Hat 1.15BMT – mass = 3.25kg/m 6000mm 1 each 39124
(suitable for cyclonic zones – use with exposed head screws).
Intermediate Top Hat – is used to support the panels at locations other than
vertical joints. Intermediate top hat is a Rondo rolled steel section which is
20 50 20
manufactured from galvanised steel (Z275) of 1.15BMT.
35
Intermediate Top Hat 1.15BMT – mass = 1.38kg/m 3600mm 1 each 21086
Intermediate Top Hat 1.15BMT – mass = 1.38kg/m 7200mm 1 each 21083
H515 Top Hat – is fixed to structural steel framing to support the ExpressWall
and Intermediate Top Hats. Top Hat H515 is a Rondo rolled steel section which is
20 50 20
manufactured from galvanised (Z275) steel of 1.15mm BMT.
5
Top Hat H515 15x50x15mm 1.15BMT – mass = 0.91kg/m 3600mm 1 each 12884
Top Hat H515 15x50x15mm 1.15BMT – mass = 0.91kg/m 7200mm 1 each 100896
FASTENERS
Hex Head Screws – for fixing vertical ExpressWall Top Hats and Intermediate Top 12G-14 x 20mm 1000 per 84882
Hats to H515 or steel framing of minimum 1.15mm BMT in non-cyclonic areas. pack
Hex head self drilling screw 12G-14x20mm, Class 3.
Hex Head Screws – for fixing horizontal H515 Top Hats to steel framing minimum Supplied by others
0.75mm BMT and for fixing ExpressWall Top Hats and Intermediate Top Hats to
H515 or other steel framing of minimum 1.15mm BMT in cyclonic areas.
Hex head self drilling screw 14G, Class 3.
Hex Head Screws Type 17 – for fixing H515 top hats to timber framing in non- Supplied by others
cyclonic areas. Hex head self drilling type 17 screw 12Gx25mm, Class 3.
Commercial ExpressPanel Countersunk Head Screws 1000 per 114081
pack
Commercial ExpressPanel Countersinking Tool 1 each 114081

Drill Bit Ø 6.0mm – 6.5mm – for drilling accurate holes to install Commercial Supplied by others
ExpressPanel.
26 COMMERCIAL EXPRESSPANEL® – External Installation

05 COMPONENTS + ACCESSORIES
Note: Codes can change from time to time. Refer to the website for the current list of components prior to ordering.

Note: The length of the fixings will need to be increased to ensure the same or greater embedment depth is obtained when additional
layers are added, such as a Rigid Air Barrier (RAB), fire-rated linings, and/or thermal break materials.
Accessories Description Size / Colour Quantity Product Code

Exposed Head Screws 10Gx30mm Exposed Wafer Head Galvanised Class 3. 1000 114070
30mm
The exposed head screw has a buttress thread which is designed to provide per pack
maximum holding power in light gauge steel. It is available in Class 3 finish.
Suitable for 1.15 BMT top hats.
Exposed Head Screws 10Gx35mm Exposed Wafer Head SS302 (zinc coated 1000 122235
35mm
stainless steel). The exposed head screw has a buttress thread which is per pack
designed to provide maximum holding power in light gauge steel. It is available
in Stainless Steel (grade 302). Suitable for 1.15 BMT top hats. Not suitable for use
in C4 environments.
Weather Seal Gasket. The ExpressWall weather seal is a grey, UV stabilised 1000 36484
nylon washer. It is used with ExpressWall exposed head screws to provide an per pack
To Suit Hole

interference fit, delivering high weather resistance and acting to lock the screw
into position.
GASKETS
ExpressWall Vertical Gasket - Gaska 1510 self-adhesive tape is made from 3.2mm x 48mm
EPDM closed cell foam which has high UV resistance. The gasket has adhesive x 23m
on one side (with a release paper) and is adhered to the ExpressWall Top Hat to Black 1 each 133978
prevent moisture entry at vertical points.
BACKING STRIPS
ExpressWall Backing Strip – may be used in lieu of Surround Angled Backing 1194mm 1 each 21089
Strip for sealant filled system option. 2394mm 1 each 21088
60mm
21087
2994mm 1 each

Bond Breaker Tape – Tesa 7492. Required where horizontal joints are sealed. 3.2mm x 48mm 1 each 13172
x 25m
OTHER
Corner Backing Angle – metal angle flashing used in some corners. 50mm x 50mm 1 each 111498
Manufactured from steel with Galvalume AZ150 corrosion resistant coating. x 3030mm
Adhesive – for fixing spacer at head junction. Sikaflex 11FC Grey 310mL tube 1 each 39378
For use as a backing strip adhesive when installing ExpressWall Backing strips

Sealant – is used to seal joints for control joints, junctions etc. Sikaflex Sealant 310mL tube 1 each 11378
PRO-2HP Grey

Backing Rod – for sealant backing – used to enable correct filling of joints with 10mm diameter 1 each 11177
sealant. Also used as an air seal at window openings and construction junctions. x 50m roll
The diameter of backing rod must be appropriate for the width of the gap being
filled.
Cemintel Edge Sealer – for sealing panel edges after on-site cutting. 200ml 1 each 100166

2 litre 1 each 180928

Flashing & Capping – flashings are to be designed and installed in accordance Supplied by others
with SAA-HB39 2015 and good building practice.
Megapoxy P1 – Used to conceal the countersunk fastener heads, to prevent 1 litre 1 each 25464
moisture penetration, and to provide a flat surface for decorative coating.
Megapoxy products must be installed to the manufacturer’s recommendations.
In colder climates (eg. Tasmania), Megapoxy PF should be used.

Polyfilla Pro Deep and Large Cracks – for final filling of countersunk screw Supplied by others
holes following application of Megapoxy. Available from trade and specialty paint
outlets.
 COMMERCIAL EXPRESSPANEL® – External Installation 27

COMPONENTS + ACCESSORIES 05
Note: Codes can change from time to time. Refer to the website for the current list of components prior to ordering.

Note: The length of the fixings will need to be increased to ensure the same or greater embedment depth is obtained when additional
layers are added, such as a Rigid Air Barrier (RAB), fire-rated linings, and/or thermal break materials.
Accessories Description Size / Colour Quantity Product Code
CSR RIGID AIR BARRIER/WALL WRAPS
Cemintel Rigid Air Barrier* 1200mm x Pack of 30 170076
3000mm x 6mm sheets
Enviroseal™ RW 1500mm x 25m 1 roll 141306
Classification – Class 4 Vapour Permeable
1500mm x 30m 1 roll 192726

1500mm x 50m 1 roll 120923

Enviroseal™ CW 1500mm x 50m 1 roll 118593

Classification – Class 4 Vapour Permeable
Enviroseal™ CW-IT 1500mm x 50m 2 rolls 153675
Classification – Class 4 Vapour Permeable
Thermoseal™ Wall Wrap 1350mm x 30m 1 roll 40483
Classification – Non-permeable reflective Water Barrier 1350mm x 60m 1 roll 10576
Thermoseal™ Firespec 1500mm x 30m 1 roll 164674
Classification – Non-permeable reflective Water Barrier
Enviroseal Hightack Tape – used to seal wall wrap at overlap joins, around 60mm x 25m 1 roll 160950
openings, for repairs and at flashings. Black, single sided, aggressive adhesive
tape with a high initial grab and flexible carrier.

Enviroseal SLS Flexi Tape – used to tape corners of openings. 60mm x 5m 1 roll 124872
Enviroseal™ Double Sided Tape 24mm x 50m 1 roll 124873
Reinforced Aluminium Foil Tape 48mm x 50m 1 carton (24) 13054
Bradford Plasti-Grip Washers 45 x 5mm 1 carton 136770
(1000)

INSULATION
Bradford Gold HP Wall Batts – R2.0 (75mm) 1160mm x 420mm 12 pack 153643
1160mm x 570mm 12 pack 153648
Bradford Gold HP Wall Batts – R2.5 (90mm) 1160mm x 420mm 9 pack 181430
1160mm x 570mm 9 pack 181471
Bradford Gold HP Wall Batts – R2.7 (90mm) 1160mm x 420mm 5 pack 152191
1160mm x 570mm 5 pack 152197
OTHER TOOLS
Makita Plunge Saw Kit (1300W) includes 1400mm guide rail and bonus 165mm 1 165485
165mm fibre cement saw blade – excellent for cutting cement based sheets.
Must be used with a dust extraction system.

Makita 165mm Fibre Cement Saw Blade – ideal for use with the Makita Plunge 165mmx20x4T 1 165486
saw and other 165mm circular saws fitted with vacuum extraction systems

Dust Extraction 1 Supplied by

others

Grinder Tool 1 Supplied by

others

* Cemintel Rigid Air Barrier can be made in a range of sizes. Minimum order quantities and lead times apply. Contact Cemintel for more information.
28 COMMERCIAL EXPRESSPANEL® – External Installation

06 SYSTEM ENGINEERING
 COMMERCIAL EXPRESSPANEL® – External Installation 29

SYSTEM ENGINEERING 06

Design, Detailing And Performance Responsibilities

Commercial ExpressPanel System It is also the responsibility of the Architect/Building

Cemintel engages independent testing laboratories Designer to select the appropriate corrosivity
to test and report on the performance of a wall in category. Refer to appropriate details in this guide.
accordance with the relevant Australian Standards. The performance levels of walls documented in this
Consultants with relevant experience will use these guide are either what is reported in a test or the
test reports to provide opinions and assessments documented opinion of consultants. Performance
that extend the tested arrangement to include in projects is typically the responsibility of:
various on-site installation configurations and details
that meet appropriate criteria performance. Project Certifier and/or Builder
These professionals are typically responsible for:
Project Consultants
• Identifying the performance requirements for the
(Structural, Fire, Acoustic, Etc.)
project in accordance with the NCC and clearly
These consultants are typically responsible for the communicating this to the relevant parties.
following:
• Applicability of any performance characteristics
• Opinions on expected laboratory performance supplied by Cemintel including test and opinions
of wall configurations that vary from actual test for the project.
configuration, such as substitution products and
components. • The project consultants’ responsibilities detailed
above if one is not engaged in the project.
• Judgements about expected field performance
using laboratory test reports and practical Cemintel does not provide consulting services.
experience. Cemintel only provides information that has been
• Design, specification and certification of structural, prepared by others and therefore shall not be
fire, acoustic, durability, weather tightness and any considered experts in the field.
other required performance criteria for individual Any party using the information contained in this
projects. guide or supplied by Cemintel in the course of a
project must satisfy themselves that it is true, current
This involves the design and selection of building and appropriate for the application, consequently
elements, such as wall and floors and their accepting responsibility for its use.
integration into the building considering the
It is the responsibility of the Architect/Building
following:
Designer and engineering parties to ensure that the
• Interface of different building elements and to the details in this design guide are appropriate for the
structure / substrate. intended application.
• Wall and floor junctions. The recommendations in this guide are formulated
• Penetrations. along the lines of good building practice, but are
• Flashing issues. not intended to be an exhaustive statement of all
relevant data.
• Room / building geometry.
• Acoustic and water penetration field-testing. Cemintel is not responsible for the performance
of constructed walls, including field performance,
and does not interpret or make judgements about
Design Responsibility
performance requirements in the NCC in a specific
Panels, top hats and structural framing are required project application.
to resist wind loads that are specific to the building
site. Additional ‘local pressure factors’ can apply to Note: it is the responsibility of the Project Engineer to
the panels and top hats in accordance with the wind specify the connection of the top hats to the support
code AS/NZS 1170.2. It is recommended that the structure. It is also the responsibility of the Project
Architect/Building Designer assigns the responsibility Engineer to calculate the wind loads for the cladding
for the facade design to the Project Engineer. Once of a project.
wind loads have been determined, top hat spans,
fastener spacings, and sheet fixing details may be
selected from the appropriate tables in this manual.
30 COMMERCIAL EXPRESSPANEL® – External Installation

06 SYSTEM ENGINEERING

Stud Wall support framing

ExpressWall top hats and intermediate top hats can be fixed and bottom of the wall and at required spacing through the
to vertical structurally designed timber MGP10 or higher grade height of the wall. The stud frame walls designed to meet the
timber, or steel support framing of minimum 0.75mm BMT. structural requirements of the project, need to be designed
to also support the top hat configurations and Commercial
The ExpressWall top hats and intermediate top hats can be
ExpressPanel cladding.
supported by horizontally installed H515 top hats fixed at top

FIGURE 6.01 ExpressWall Top Hats and Intermediate Top Hats fixed over horizontal H515 Top Hats, fixed to structural stud frames

Steel stud framing Steel stud framing

Fixings Fixings

Rondo Rondo
H515 H515
Top Hat Top Hat

Fixings Fixings

ExpressWall ExpressWall
Top Hat Intermediate
Top Hat
Wall Wrap
Wall Wrap

Refer to Tables 6.01 & 6.02 for Horizontal H 515 top hat spacing requirements

Horizontal Structural Wall Supports

ExpressWall Top Hats and Intermediate Top Hats may be fixed to ExpressWall Top Hats and Intermediate Top Hats can be fixed at
horizontal structurally designed timber or steel support framing bottom plates and at horizontal structural supports positioned at
of minimum 1.15mm BMT, without the use of horizonal top hats. required spacings. Where top plate deflection is required, such
It is the responsibility of the project engineer to specify the as underside of inter-storey junction, the wall framing will need
support structure. to be appropriately designed to provide additional structural
support for the fixing of the vertical top hats.

FIGURE 6.02 ExpressWall Top Hats and Intermediate Top Hats fixed over horizontal structural wall supports

Steel stud framing Steel stud framing

Fixings Fixings

Rondo Rondo
H515 H515
Top Hat top hat

Fixings Fixings

ExpressWall
ExpressWall
intermediate
Top Hat
top hat
Wall Wrap
Wall Wrap

Refer to Tables 6.03 & 6.04 for Vertical ExpressWall Top Hats and Intermediate Top Hats spacing requirements
 COMMERCIAL EXPRESSPANEL® – External Installation 31

SYSTEM ENGINEERING 06
Stud frame spacing
(600mm max.)

Top track

Top Hat
Spacing of Horizontal H515 Top Hats (H515)

ExpressWall
Span Tables / Wind Loads Top Hat

ExpressWall Top Hats can be fixed to Top Hat

(H515)
appropriately designed timber or steel stud
framing. The frame must be designed to Spacing of
H515 top hats.
support top hats at the top and bottom of Refer to tables
the wall, and at cross members. Installing
H515 top hats horizontally over the designed Structural steel
frame
framing provides cross members to which Top Hat
(H515)
the ExpressWall top hats can be fixed to.
Intermediate
Top Hat
Wind loads in this guide refer to ultimate limit Top Hat
(H515)
state design wind pressures.

Bottom
track
Concrete
footing

H515 Horizontal Top Hats – AS 4055 Compliant, NCC Classes 1 and 10 Buildings - General & Corner Zones
TABLE 6.01
Wind Classification Spacing of H515 Top Hats - Horizontal Top Hats
(AS4055) Fixed to Three or More Studs - Timber & Steel Framing
Studs 0.75BMT @ 600mm centres maximum Studs 1.15BMT or Timber Studs @ 600mm centres maximum
General Zones Corner Zones General Zones Corner Zones
N1 1500 1500 1750 1750
N2 1500 1500 1750 1450
N3/C1 1400 750 1700 900
N4/C2 950 500 1125 600
N5/C3 625 325 775 400
N6/C4 475 250 550 300
Note: H515 Horizontal Top Hats connection to steel stud frame of minimum 0.75mm BMT use 2 x 14g hex head screws at each stud. For timber wall studs
MGP10 or higher grade timber use 2 x 12g-11TPI x 25mm Type 17 hex head screws at each stud.

H515 Horizontal Top Hats – COMMERCIAL – NCC Class 2 to 9 Buildings

TABLE 6.02
Design Wind Pressure Spacing of H515 Top Hats - Horizontal Top Hats
(Ultimate) kPa Fixed to Three or More Studs - Timber & Steel Framing
Studs 0.75BMT Stud Spacing (mm) Studs 1.15BMT or Timber Studs Stud Spacing (mm)
450 600 450 600
1.0 1750 1450 1950 1750
1.5 1150 950 1300 1150
2.0 850 700 950 850
2.5 700 550 750 700
3.0 550 450 650 550
3.5 500 400 550 500
4.0 400 350 450 400
4.5 350 300 400 350
5.0 350 250 350 350
5.5 300 250 350 300
6.0 300 200 300 250
6.5 250 200 300 250
7.0 250 200 250 250
Note: H515 Horizontal Top Hats connection to steel stud frame of minimum 0.75mm BMT use 2 x 14g hex head screws at each stud. For timber wall studs
MGP10 or higher grade timber use 2 x 12g-11TPI x 25mm Type 17 hex head screws at each stud.
32 COMMERCIAL EXPRESSPANEL® – External Installation

06 SYSTEM ENGINEERING

ExpressWall and Intermediate Top Hat Spacings

The design capacities of the Cemintel Commercial ExpressPanel Intermediate top hats. In cyclonic regions, use the 1.15mm
wall system are in ultimate limit state format and intended for BMT thick ExpressWall Top Hats with 14g hex head screws.
use with AS/NZS 1170.2. The deflection of the top hats as detailed in these tables is no
more than span/250 when subjected to serviceability wind load
To obtain equivalent permissible load capacity, divide the
of 68% of ultimate wind loads.
“ultimate wind capacity” in Table 6.04 or Table 6.06 by 1.5.
Top hat spacing will vary depending on wind loads and panels may
The top hat capacities have been calculated in accordance with
be installed with Single Spans (Refer Fig. 6.03) or Double Spans
AS/NZS 4600: Cold Formed Steel Structures and are applicable
(Refer Fig. 6.04). Top hat spacing is nominal and may be increased
for 0.75BMT and 1.15BMT ExpressWall top hats and for 1.15BMT
by up to 20mm to accommodate panel joint width.
ExpressWall and Intermediate Top Hats
– RESIDENTIAL – AS 4055 Compliant, NCC Classes 1 and 10 Buildings
TABLE 6.03  FIGURE 6.03 Single Top Hat Span Installation
Design Wind Pressure Maximum Span of Vertical ExpressWall
(Ultimate) kPa and Intermediate Top Hats Top Hat Spacing

Spacing of Vertical Top Hats (mm)

Nominal: Suitable for additional 10mm to fit with express joint width.
Cantilever
General Zones Corner Zones
400 600 400 600
N1 2650 2350 2150 1900
Top Hat Span
N2 2650 2350 2150 1900 (Table 5)
N3/C1 2300 2050 1900 1550
N4/C2 2050 1750 1600 1250
N5/C3 1800 1450 1250 1000
Cantilever
N6/C4 1550 1200 1050 800
See notes below.

ExpressWall and Intermediate Top Hats

– COMMERCIAL – NCC Class 2 to 9 Buildings
TABLE 6.04  FIGURE 6.04 Double Top Hat Span Installation
Design Wind Pressure Maximum Span of Vertical ExpressWall Top Hat Spacing
(Ultimate) kPa and Intermediate Top Hats
Spacing of Vertical Top Hats (mm)
Nominal: Suitable for additional 10mm to fit with express joint width. Cantilever

300 400 450 600

1.0 2450 2250 2150 1950
1.5 2150 1950 1900 1700
2.0 1950 1800 1700 1550 Top Hat Span
(Table 6)
2.5 1800 1650 1600 NA
3.0 1700 1550 1450 NA
3.5 1600 1400 NA NA
4.0 1550 1300 NA NA
4.5 1450 1200 NA NA
5.0 1350 1150 NA NA
5.5 1300 1100 NA NA Top Hat Span
(Table 6)
6.0 1200 1000 NA NA
6.5 1150 950 NA NA
7.0 1100 950 NA NA
Notes for Tables 6.03 & 6.04
Cantilever
Maximum Span for Single or Double Spans.

Values suitable only when ExpressPanels are fixed to three or more top hats.
NA Limited by ExpressPanel span
Cantilever maximum 0.2 x adjacent span
Note: Vertical ExpressWall Top Hats and Intermediate Top Hats connection to horizontal
H515 Top Hat or structural steel support of minimum 1.15mm BMT use 2 x 12g-14TPI x
20mm. In Cyclonic conditions, use 1.15mm BMT ExpressWall Top Hats with 14g hex head
screws.
 COMMERCIAL EXPRESSPANEL® – External Installation 33

SYSTEM ENGINEERING 06

Panel Fixing Requirements

Panel Fixing Requirements – AS 4055 Compliant, NCC Classes 1 and 10

Buildings – General & Corner Zones
FIGURE 6.07 Vertical Sheet Fixing TABLE 6.05 

40mm
Wind
Classification Panel Fixing Requirements and Maximum Top Hat Spacings
(AS4055
100mm
General Zones Corner Zones
Top Hat spacing Top Hat spacing
Max. Top Hat Max. Fixing Max. Top Hat Max. Fixing
Spacing (mm) Spacing (mm) Spacing (mm) Spacing (mm)

Fixing
N1 600 600 600 600
spacing
N2 600 600 600 600
N3/C1 500 600 500 450
Fixing
spacing
N4/C2 500 550 400 350
N5/C3 400 450 400 300
N6/C4 400 350 300 250
Panels fixed to Two & Three or More Top Hats.
See notes below.

Panel Fixing Requirements – COMMERCIAL – NCC Class 2 to 9 Buildings

FIGURE 6.08 Horizontal Sheet Fixing TABLE 6.06 

40mm Design
Wind
100mm Pressure Panel Fixing Requirements and Maximum Top Hat Spacings
(Ultimate)
Top Hat spacing Top Hat spacing kPa
Max. Top Hat Spacing Max. Fixing Spacing
Fixing
(mm) (mm)
Spacing
Panel Fixed to Panel Fixed to At ExpressWall and
Two Top Hats Three or more Top Hats Intermediate Top
Fixing Hats
Spacing
1.0 600 600 600
1.5 500 600 600
2.0 500 600 450
2.5 400 500 400
3.0 400 500 350
3.5 400 400 300
FIGURE 6.05 Panel Fixed to Two Top Hats Only 4.0 400 400 300
4.5 300 400 300
Top Hat spacing
5.0 300 400 300
5.5 300 400 250
6.0 300 400 250
6.5 300 400 200
FIGURE 6.06 Panel Fixed to Three or More Top Hats
7.0 300 400 200
Notes for Tables 6.05 & 6.06
Top Hat spacing Top Hat spacing
Countersunk head screws can be used with 1.15 BMT top hats. Care should be taken
when fixing ExpressPanel countersunk head screws to 0.75 BMT ExpressWall Top Hats
as screws they can strip the lighter gauge. The use of a screw gun with torque control to
prevent overdriving screws is recommended.
Commercial ExpressPanels that are pre-drilled and pre-painted offsite may be fixed to
Note: ExpressPanels fixed to vertical ExpressWall Top Hats and vertical ExpressWall Top Hats and Intermediate Top Hats using wafer head ExpressWall
Intermediate Top Hats using ExpressWall countersunk head Exposed Head Screws, fine or buttress thread, Class 3 or stainless steel, 10g x 30mm
screws.. minimum or Commercial ExpressPanel stainless steel rivet fasteners (4 x 18mm shaft,
15mm head).
34 COMMERCIAL EXPRESSPANEL® – External Installation

06 SYSTEM ENGINEERING

FIGURE 6.09 T
 ypical Commercial ExpressPanel External Fire Rated Installation.
Pressure Equalised Ventilated Cavity System

Soffit

Refer to
head detail

Horizontal batten
fixed to frame

ExpressPanel

Support framing

Top Hat

Wall Wrap

2 x 16mm Gyprock
Fyrchek MR Plasterboard

ExpressPanel

Refer to
base detail

Flashing

Ground clearance to
regulatory requirements Concrete
footing
COMMERCIAL EXPRESSPANEL® – External Installation 35

07 INSTALLATION
36 COMMERCIAL EXPRESSPANEL® – External Installation

07 INSTALLATION

CHECKLIST – Prior to Installation

The following pre-install checklist may assist to ensure you have the best possible outcome when
using Commercial ExpressPanel.

Ensure substrate is straight and plumb. Pack  lashings, membranes and air barrier should be
F
Check quality studs to straighten if necessary (timber frames as correctly installed, overlapped and taped at joints,
and quantity per AS 1684, steel frames as per AS/NZS 4600). prior to fixing panels.
of panels and Industry best practice for frame tolerance is 5mm
components Install windows so that the back of the front face
misalignment over 3000mm.
before installing. of the window (or any other protrusions including
If there is any Ensure studs are correctly located and of the doors or meter boxes) will be flush with the face of
sign of damage appropriate thickness. the panels.
or visible defects
in panels, or the Confirm bracing is in place. Where sheet bracing  it Head flashings over windows, doors and other
F
finish is not in is used behind panels, the entire wall area needs penetrations.
keeping with the
owner’s aesthetic
to be braced or bracing sheet packers fixed to the
 onfirm the chosen eaves/soffit details and
C
requirements frame to ensure a uniform fixing plane.
prepare accordingly.
DO NOT INSTALL.
Contact Cemintel
Remove any concrete that may foul the cladding
 onsider the need for structural support for
C
to address any line, particularly at steps in slabs and isolated
fixtures such as pergolas and balconies. No loads
issues. columns.
may be carried by the cladding.
Ensure there is adequate ground clearance to the
 onfirm membranes and flashings for balcony
C
bottom edge of the Commercial ExpressPanels as
areas have been installed in accordance with
per regulatory requirements (including for water/
manufacturers’ specifications.
rain runoff and termite management). These can
vary from 50-150mm depending on type of ground Arrange for a pre-cladding inspection by the
and termite requirements. appropriate local building authority if required.
Confirm your panel layout to determine the
location of joints and identify where additional
studs are required.
 COMMERCIAL EXPRESSPANEL® – External Installation 37

INSTALLATION 07

Installation Set-Out
Appropriate panel fixing layout and top hat spacing 100mm from the top and bottom edges of the panel
should be suitable for the project design wind and 40mm in from the side of the panels.
pressure. It is recommended that fasteners be fixed

FIGURE 7.01 Horizontal Sheet Fixing FIGURE 7.02 Vertical Sheet Fixing

40mm 40mm

100mm 100mm

Fixing
Spacing

Fixing Fixing Fixing

Spacing Spacing Spacing

Panels must be fixed in accordance with the tables set out in ‘System Engineering’ section. This provides fixing
Requirements and Maximum Top Hat Spacings for 1200mm wide panels based on 2 top hats or 3 or more top hats.

Installation for Timber and Steel Framing

Refer to ‘System Engineering’ and ‘Construction Drawings and Details’ sections for specific fixing information.

Step 1 – Install air barrier – as per Cemintel Rigid Air Use the recommended countersinking tool for
Barrier Design & Installation Guide or soft air barrier countersunk head screws, and a 6mm masonry bit
as per details in this guide. for exposed head screws (Refer Fig. 7.03). Holes
Step 2 – Fix base flashing to base of wall over air must be 6.0mm to 6.5mm in diameter. Dust must be
barrier (wall wrap or rigid air barrier) taping top edge cleaned out of holes.
of flashing to air barrier. If using exposed head screws, with offsite
Step 3 – Fix cavity baffle and top hats. Fix cavity pre-drilled and pre-painted ExpressPanel, refer to
baffle to suit cavity depth at major corners nominated Cemintel Barestone External Design and Installation
by the project designer. Fix H515 top hats horizontally Guide.
where required to substrate as per ‘System
Engineering’ section requirements. Fix ExpressWall FIGURE 7.03 Countersinking Tool – Screw Fix
and intermediate top hats vertically to H515 framing
as per ‘System Engineering’ section requirements.
Step 4 – Prepare panels. Cut panels as required. Run
a fine sandpaper block along the edge of the cut panel
(taking care not to scratch the panels surface). Seal cut
edges with Cemintel’s recommended edge sealant to FIGURE 7.04  re-drilling Panels – Countersunk Screw
P
protect against moisture entering the panels. Fix
Step 5 – Pre-drill panel holes. This should be done
prior to lifting panels into place and can be done off ExpressPanel
site. Panel holes need to be drilled a minimum 100mm
from the horizontal edge and a minimum of 40mm
from the vertical edge (refer to ‘System Engineering
Section’).
38 COMMERCIAL EXPRESSPANEL® – External Installation

07 INSTALLATION

Note: Use only the recommended tool as supplied At the beginning and end of a vertical joint, such as
by CSR. The use of other tools for this purpose with sheets installed in a half-bond pattern, continue
may reduce fixing capacity or reduce the weather the vertical gasket past the horizontal joint by 100mm
resistance of the system. minimum. (Refer Fig. 7.07)
DO NOT use hammering action when drilling.
FIGURE 7.07 Vertical Gasket and Fixing Detail for Half-
For efficiency you can neatly stack 3 or 4 sheets Bond Panel Layout – Screw Fixed
and drill through all at the same time. Take care to
avoid damaging the panel with the drill chuck when
approaching the end of the hole by using a timber
block.
HINT: One way of drilling holes is to drill the top
sheet of a pack with the counter sinking drill set to ExpressPanel Backing Strip
Panel
approximately 12mm depth. (Refer Fig. 7.04) This will
give a starter hole on the sheet below, saving on set
out time. 100mm min. 50mm

Clean/sweep away any dust from holes as

this can stick to the panel.
ExpressWall
Vertical Gasket
Step 6 – Install Vertical gaskets to the ExpressWall
Top Hats for the full extent of panels. Take care
ExpressWall
not to stretch the gasket when installing. (Refer Top Hat
Fig. 7.05) When joining gasket, cut ends cleanly
and push together before adhering. When top hat
is discontinuous, butt ends together tightly and
continue gasket over the joint. If a gap is present,
Screw Spacing
Countersunk head screws
install a steel strip to support the gasket. (Refer Fig. (refer to specification table)
either side of top hat
7.06)

FIGURE 7.05 Vertical Gasket – Screw Fixed

ExpressWall
Top Hat ExpressWall
Vertical Gasket

ExpressWall
Vertical Gasket
applied centrally ExpressPanel
in recess 100mm min. Panel

FIGURE 7.06 Gasket Support at Discontinuous Joint Backing Strip

– Screw Fixed

Steel
strip

10mm max.
 COMMERCIAL EXPRESSPANEL® – External Installation 39

INSTALLATION 07

Step 7 – Install wall panels. FIGURE 7.08 ExpressWall Backing Strip Positioning
When fixing panel using countersunk screws, lift
ExpressWall
panel into place, clamp down level to identify horizontal Backing Strip
and vertical planes. 3mm 3mm

When using the ExpressWall Backing Strip,

ensure ExpressWall Backing Strip is 6mm shorter
overall than the width of the panel (cut to length if Panel

necessary). (Refer Fig. 7.08)

Cemintel recommends the use of a screw gun with
torque control to prevent overdriving of screws.
Countersunk head screws can be used with 1.15BMT
Top Hats – care should be taken when fixing screws
FIGURE 7.09 H
 orizontal Joint with ExpressWall
to 0.75BMT ExpressWall Top Hats as screws can strip Backing Strip
in the lighter gauge. (Refer Fig. 7.11)
Fix panel starting at the bottom corner. Push
the panel firmly against the framing/gaskets and
screw through panel hole into the top hat with the
ExpressWall
countersunk head screw. Backing Strip

Before fixing top countersunk head screws to panel, Sikaflex-11FC

adhesive
insert ExpressWall Backing Strip-along horizontal
joint. Clip corners at an angle and bend. Commercial
Panel
ExpressPanels are generally installed with a nominal
8-10mm wide expressed joint in both horizontal and
vertical directions (a small cut piece of panel can be
used as a spacer to easily measure joint widths and FIGURE 7.10 Sealing Ends of ExpressWall Backing Strip
ensure consistency). Once positioned, fasten top row
of countersunk head screws.
Backing Strip

To seal the groove in the backing strip at the ends,

apply a small section of gasket to the rear of the
backing strip. This will be forced into the recess and
seal the end of the strip. Alternatively use Sikaflex
10mm wide x 18mm long
11FC to fill the groove. (Refer Fig. 7.10) strip of Horizontal Gasket
or Sealant
A fillet of Sikaflex 11FC is then placed along the top
Sikaflex-11FC
edge of the panel. This ensures that the joint drains
and salt and dirt do not build up in the joint. (Refer
Fig. 7.09, 7.10 & 7.12)
Barestone
Panel
When fixing panel using exposed head screws,
install the ExpressWall Weather Seal into the pre-
drilled hole in the panel. Drive the exposed head
screw through the weather seal and into the top hat FIGURE 7.11 Vertical Joint – Countersunk Screw
using an electric screw gun. For further information,
refer to Cemintel Barestone External Design and Epoxy over screw head
ExpressWall
Installation Guide. Countersunk
Head Screw
ExpressPanel
8-20mm

Joint widths – While panels are generally installed

with a nominal 8-10mm wide horizontal and vertical
expressed joint. However joints up to 20mm can Vertical
Gasket
be formed provided additional care is taken during
installation to ensure that panel edges cover the joint
gaskets by a minimum of 10mm.
40 COMMERCIAL EXPRESSPANEL® – External Installation

07 INSTALLATION

FIGURE 7.12 Horizontal Joint Detail with ExpressWall FIGURE 7.13 Countersunk screw head
Backing Strip – Sealant Filled and Screw
Fixed

ExpressWall Screw
(countersunk head)

Top Hat
ExpressWall
100mm Screw

ExpressWall
Backing Strip
8-20mm
Fillet of sealant
to horizontal
joint
100mm
Screw head
covered with
epoxy

ExpressPanel

Screw Head Covering for Countersunk screws

All countersunk head screws must be covered with • Fill the remainder of the countersunk screw hole
epoxy compound and flush finished with the face of with Polyfilla Pro Deep and Large Cracks, using a
the panel. (Refer Fig. 7.13) The epoxy shall be installed steel spatula to achieve a flush finish with the face
in the following manner: of the panel. Allow appropriate setting time as per
manufacturer’s instructions.
• Deburr edges of the countersunk screw hole and
clean of any dust using compressed air. • Should shrinkage of the initial application of Polyfilla
Pro Deep and Large Cracks occur, apply additional
• Mix Megapoxy P1 accurately in accordance with the
Polyfilla Pro Deep and Large Cracks as required.
packaging/manufacturer’s instructions. In colder
climates, eg. Tasmania, use Megapoxy PF. Only mix • The surface should be reasonably smooth with
sufficient epoxy for area of panels being worked on no sanding required. Should sanding be required,
and immediately use mixed epoxy. lightly sand back Polyfilla Pro with fine grit
sandpaper ensuring care is taken to minimise
• Apply epoxy 1 to 2mm thick to cover the screw
damage to the surface of the panel. Remove any
head. Do not completely fill the hole with epoxy and
dust prior to applying any finish to the panel.
ensure care is taken to avoid spreading of epoxy
over the panel surface. Clean any excess epoxy • Apply compatible surface coatings to the panel
immediately otherwise it will set. in accordance with manufacturer’s instructions.
Note: additional surface penetration may be
• Allow epoxy sufficient time to fully cure and
required to minimise show-through of filled
harden in accordance with the manufacturer’s
countersunk screw holes.
recommendations.
 COMMERCIAL EXPRESSPANEL® – External Installation 41

INSTALLATION 07

In certain conditions such as corrosive environments remain open, to allow pressure equalisation to be
or where there is a preference to have flush sealed maintained and for any water moisture to drain from
joints, horizontal and vertical joints may be filled with the cavity. Refer to the sealant filled joint details of
recommended joint sealant and in accordance with the “Construction Drawings and Details” section of
manufacturer’s instructions. Base of walls including this manual.
horizontal joints at inter-storey junctions must

FIGURE 7.14 Joint Construction – Sealed Option

ExpressWall
Top Hat

ExpressWall
Vertical Gasket

ExpressWall
Countersunk
Head Screw

ExpressWall Countersunk
Head Screw covered and
filled with Epoxy

Sealant filled joints

Bond Breaker Tape

ExpressWall
Backing Strip

ExpressPanel

FIGURE 7.15 Horizontal Joint Sealed Side FIGURE 7.16 Horizontal Joint Sealed Side FIGURE 7.17 Backing Strip & Bond Breaker Tape

ExpressWall Bond Breaker Tape

Backing Strip
ExpressPanel 3mm 3mm
ExpressPanel

Backing Strip Backing Strip ExpressPanel

Bond Breaker Tape Bond Breaker Tape
adhered to face of adhered to face of
backing strip backing strip

8-20mm 8-20mm

Backing Strip Sealant filled

adhesive fixed to back horizontal gap
of lower panel

ExpressPanel ExpressPanel
42 COMMERCIAL EXPRESSPANEL® – External Installation

07 INSTALLATION

FIGURE 7.18 Horizontal Joint Fixing – Sealed Option FIGURE 7.19 Vertical Joint – Sealed Option

Epoxy over screw head

ExpressWall Screw
(countersunk head) ExpressWall
Countersunk
Sealant filled Head Screw
Bond vertical gap ExpressPanel
Breaker 8-20mm
Tape
100mm

Backing Strip

8-20mm
Vertical
gasket
Sealant filled
horizontal ExpressWall Top
joint 100mm Hat 1.15BMT

ExpressPanel
 COMMERCIAL EXPRESSPANEL® – External Installation 43

INSTALLATION 07

Installation of Cemintel Rigid Air Barrier™

The Cemintel Rigid Air Barrier may be installed steel framing using screws. A small joint (maximum
horizontally or vertically across the frame. 3mm) is acceptable. Joints are taped using HighTack
An appropriate panel fixing layout should be selected tape to form an air barrier. Similarly, all corners,
for the project design wind pressure and frame penetrations and junctions are sealed with HighTack
spacing. Panels must be fixed in accordance with the tape or with flexible sealant.
tables set out in the ‘System Engineering’ Section.
All flashings should be fixed over the top of the Rigid
Panels are fixed to timber framing using nails to Air Barrier and taped with HighTack tape. Check quality
and quantity
of panels and
components
Procedure for Horizontal or Vertical Sheet Application before installing.
If there is any
1  ut sheets to ensure vertical joints are supported by
C with ProctorWrap™ HighTack tape. sign of damage
studs and horizontal joints are backed by noggings. Seal junctions and penetrations with Sikaflex Pro or visible defects
Position sheets (refer to Head & Base details in flexible sealant. in panels
2

DO NOT INSTALL.
‘Construction Details’ section). Screw fix (to steel 5 Seal
 any openings in head, sill and jamb framing
Contact Cemintel
frame) or nail (to timber frame) at the detailed with ProctorWrap™ HighTack tape. to address any
fastener centres. issues.
6
Apply ProctorWrap™ SLS FlexiTape to corners of
3
Install adjacent sheets. window and door openings.
4 Seal
 vertical joints, horizontal joints, and corners

FIGURE 7.20 Typical Rigid Air Barrier Installation

Sealant filled joint

with backing rod

Cemintel Rigid Air

4 Barrier installed 6
horizontally

3
Steel or timber Seal around
framing front edge of
opening with
Enviroseal
HighTack Tape

Seal around
corners of
opening with
4 SLS Flexi
3 Tape
Stud required
behind vertical
6 sheet joints

1 Nogging or other
similar framing
required behind
horizontal sheet
joints Cemintel Rigid Air
Barrier installed
vertically
HighTackTape
continuous at all 4
joints and corners

Refer to alternative
junction details at base
44 COMMERCIAL EXPRESSPANEL® – External Installation

07 INSTALLATION

FIGURE 7.21 Treatment at Window/Door Openings – Rigid Air Barrier

STEP 3: Seal around

STEP 1: Form opening in front edge of opening with
Cemintel Rigid Air Barrier Bradford Tape

STEP 2: Fix Cemintel

Rigid Air Barrier at 50mm
from corners and 200mm STEP 4: Seal around
max. centres between corners of opening with
Bradford Flexi Tape
100mm
min.

100mm min.
 COMMERCIAL EXPRESSPANEL® – External Installation 45

INSTALLATION 07

Installation of Soft Air Barriers

Wall wraps intended to be used as air barriers are restrain the wall wrap edges. The wall wrap is then
fixed to timber or steel framing. Enviroseal™ CW- folded over and taped to the main body wrap with
IT has an inbuilt adhesive strip which allows fast, HighTack Tape. As detailed, sealant or tape is to be
consistent and reliable sealing to adjoining rolls of applied to maintain an effective air seal.
CW-IT.
All flashings should be fixed over the top of the wall
At internal corners, penetrations and perimeters wrap and taped.
of areas with wall wrap, a metal strip is required to

Procedure for installation of Soft Air Barriers

1
Install wall wrap to outside face of timber or steel 2
Install minimum 20mm x 1.6mm aluminium strips
wall framing using Bradford Plasti-Grip Washers. horizontally at head and base of wall. Pass wall
Horizontal laps must be overlapped by 150mm. wrap under aluminium strip and fix strip at 100mm
max. cts. Then fold wall wrap back over strip and
tape with HighTack tape to main body.

FIGURE 7.22 Typical Soft Air Barrier Installation

See Wall Wrap

details

See lap
3 details

4
Wall Wrap with
integrated tape
See window
details

1
3 Bradford
Plasti-Grip
Washer fixed to
studs/framing at
300mm max.
vertical centres

See lap ExpressWall

details Top Hat

Vertical cavity
bafflle detail Fold wrap over
by designer and tape to
main body

Sealant

Bradford Plasti-Grip
Washer fixed to
studs/framing at 300mm
max. vertical centres at WRAP ENDS HOLD
Intermediate overlapping stud locations. DOWN DETAIL
Top Hat
see Wall Wrap
details
46 COMMERCIAL EXPRESSPANEL® – External Installation

07 INSTALLATION

3
Install aluminium strips at vertical joints/ends/ 5
 t openings, cut the wrap at 45 degrees from
A
corners (where required). Pass wall wrap under each corner to the centre.
aluminium strip and fix at 100mm max cts. Fold 6
 ass wall wrap under aluminium strip and fix at
P
wall wrap back over strip and tape with HighTack
100mm max. cts. Then fold wall wrap back over
tape to main body.
strip and tape with HighTack tape, cutting away
any excess wall wrap.
4
 nviroseal™ CW-IT to be overlapped at horizontal
E
joints and taped continuously with in-built 7
 pply SLS Flexi Tape to the corners of window
A
adhesive strip. Vertical lap joints to be overlapped and door openings. Press tape over the frame
across adjoining studs, fixed with Bradford Plasti- edge onto the face of the wall wrap.
Grip Washers, aluminium strips and taped with
HighTack tape along overlap joint. (Refer to
Table 4.03).

FIGURE 7.23 Treatment at Window/Door Openings – Soft Air Barrier

STEP 2: Pass Wall

Wrap under
aluminium strip
5 fixed at 100mm
max. centres
6
STEP 1: Slit
wall wrap from
the corners of STEP 3: Fold Wall
the opening and Wrap back over strip
remove centre and tape
section 7
STEP 4: Bradford Flexi SLS Tape
to seal wall wrap at corners of
openings and extend back
beyond the sealant line of the
window framing 100mm
min.
6

100mm min.
COMMERCIAL EXPRESSPANEL® – External Installation 47

08 CONSTRUCTION
DRAWINGS + DETAILS
48 COMMERCIAL EXPRESSPANEL® – External Installation

08 CONSTRUCTION DRAWINGS AND DETAILS

Note: Drawings are interchangeable for timber or steel substrates with the exception of the fasteners.

Drawings Index
SECTION DESCRIPTION FIGURE PAGE NUMBER
REFERENCE
VENTILATED CAVITY SYSTEM
Overview Joint Construction – Ventilated Cavity System 8.01 49
Joint Details 10mm Horizontal Joint – Sealant Filled 8.02 49
Horizontal Joint – Angled Backing Strip 8.03 49
Vertical Joint – Exposed Head Screw 8.04 49
Cross Section Details Typical ExpressWall System Cross Section for Steel Framing 8.05 50
Head Details Eaves/Deflection Head – Ventilated 8.06 50
Base Details Base Detail – Drained 8.07 50
External Corner 8.08 51
Corner Details External Corner – Obtuse Angle 8.09 51
Internal Corner Detail 8.10 51
Framed Soffit 8.11 52
Control Joint – Vertical 8.12 52
Inter-Storey Junction with Flashing 8.13 52
Junction Details
Inter-Storey Junction with Flashing 8.14 52
Abutment 8.15 53
Vertical Gasket and Fixing Detail for Half-bond Panel Layout 8.16 53
Window Details Typical Window Installation 8.17 53
Parapet Capping Parapet Capping 8.18 54
Balcony Details Balcony Base 8.19 54
Drain Typical Drain 8.20 54
Power/Meter Box Details Typical Power/Meter Box 8.21 55
VENTILATED CAVITY SYSTEM – SEALANT FILLED JOINT DETAILS
Overview Sealant Filled Joint Construction – Ventilated Cavity System 8.22 56
Backing Strip Preparation 8.23 56
Joint Details – Sealant filled Horizontal Joint – Sealant filled 8.24 56
Vertical Joint – Sealant filled 8.25 56
Typical ExpressWall System Cross Section for Steel Framing
Cross Section Details – Sealant filled 8.26 57
– Joints sealant filled
Head Detail – Sealant filled Eaves/Deflection Head – Sealant filled 8.27 57
Base Detail – Drained Base Detail – Drained 8.28 57
Internal Corner Detail – Sealant filled 8.29 58
Corner Details – Sealant filled
External Corner – Sealant filled 8.30 58
SOFT AIR BARRIER
Overview Typical Installation Overview - Soft Air Barrier 8.31 59
Corner Details External Corner – Wall Wrap Continuous 8.32 60
Externsl Corner – Wall Wrap Overlapped 8.33 60
Internal Corner – Wall Wrap Continuous 8.34 60
Internal Corner – Wall Wrap Overlapped 8.35 60
Junction Details Abutment to Concrete or Masonry Wall 8.36 60
Wall Wrap Installation to Wall, Soffit and Base 8.37 61
Wall Wrap Installation at Intermediate Level Junction
8.38 61
– Non-loadbearing Steel Framing With Deflection Head
Vertical Wall Wrap Junction – Overlapped Double Strip Join 8.39 62
Vertical Wall Wrap Junction – Overlapped Single Strip Join 8.40 62
Vertical Wall Wrap Junction – At Control Joint 8.41 62
Vertical Wall Wrap Junction – No Lap double Washer 8.42 62
Window Details Wall Wrap Installation at Window/Door Opening 8.43 63
Junction Details Wall Wrap Installation at Drain Penetration – Timber or Steel Framing 8.44 63
Wall Wrap Installation at Parapet Junction – Timber or Steel Framing 8.45 64
 COMMERCIAL EXPRESSPANEL® – External Installation 49

CONSTRUCTION DRAWINGS AND DETAILS 08

Note: Drawings are interchangeable for timber or steel substrates with the exception of the fasteners.

Ventilated Cavity System

FIGURE 8.01 Joint Construction – Ventilated Cavity System

ExpressWall
Top Hat

ExpressWall
Vertical Gasket

ExpressWall
Countersunk
Head Screw

ExpressWall Countersunk
Head Screw covered and
filled with Epoxy

Selected Horizontal Joint

method (refer to joint options)

Sealant when required

(refer to joint options)

Sikaflex-11FC
ExpressWall Top Hat
Backing Strip ExpressPanel
when required
(refer to joint
options)
ExpressWall
Screw
ExpressPanel

Screw
head
covered
with
epoxy

FIGURE 8.02 1 0mm Horizontal Joint – FIGURE 8.03 H

 orizontal Joint – Angled FIGURE 8.04 Vertical Joint – Exposed Head Screw
Sealant Filled Backing Strip

ExpressWall ExpressWall Epoxy over screw head

Screw Screw
(countersunk (countersunk ExpressWall
head) head) Countersunk
Head Screw
ExpressPanel ExpressPanel
8-20mm
100mm 100mm
ExpressWall
Backing
Strip Angled
Backing
8-20mm Strip Vertical
8-20mm
Fillet of Gasket
sealant to
horizontal
joint 100mm 100mm

ExpressPanel
ExpressPanel
50 COMMERCIAL EXPRESSPANEL® – External Installation

08 CONSTRUCTION DRAWINGS AND DETAILS

Note: Drawings are interchangeable for timber or steel substrates with the exception of the fasteners.

Ventilated Cavity System

FIGURE 8.05 T
 ypical ExpressWall System Cross Section for Steel FIGURE 8.06 Eaves/Deflection Head – Ventilated
Framing

Drip groove
Soffit Wall Wrap
Soffit sealed to
frame/soffit

Refer to
head detail Deflection gap to
be specified by
project engineer
Horizontal batten
fixed to frame Corrosion resistant
angle embedded in
sealant and fixed to
soffit only
5mm gap
ExpressPanel

Horizontal batten Support

fixed to frame Framing

ExpressPanel
Support framing

Top Hat
Top Hat
Wall Wrap

FIGURE 8.07 Base Detail – Drained

Wall Wrap
Wall Wrap

Flashing over
Wall Wrap
ExpressPanel and taped

ExpressPanel

Horizontal
Refer to batten fixed
base detail to frame

Flashing
ExpressWall 200mm
Top Hat min.
Ground clearance to
regulatory requirements Concrete
footing
Flashing Support
Frame

5-10mm
gap

Wall Wrap Concrete

taped to frame footing
 COMMERCIAL EXPRESSPANEL® – External Installation 51

CONSTRUCTION DRAWINGS AND DETAILS 08

Note: Drawings are interchangeable for timber or steel substrates with the exception of the fasteners.

Ventilated Cavity System

FIGURE 8.08 External Corner

Wall Wrap Vertical cavity 8-20mm

ExpressPanel sealed at all baffle, detail Flashing angle
junctions by designer by others

Intermediate
Top Hat

100mm
max.

Support
Framing

Support
Framing
Intermediate
Top Hat
reversed

ExpressPanel

Wall Wrap

FIGURE 8.09 External Corner – Obtuse Angle FIGURE 8.10 Internal Corner Detail
Intermediate
Top Hat

Support
Framing

Horizontal
batten

Wall Wrap
ExpressPanel sealed at
all junctions
Wall Wrap
Support sealed at all
Framing junctions

Intermediate
Top Hat Panel
(reversed)
8-20mm

Support
Framing Flashing angle
100mm
max.
Intermediate
Top Hat
Vertical cavity Horizontal batten
baffle, detail
by designer
ExpressPanel

Support
Framing
Flashing angle
by others

Intermediate Top Hat

(reversed)

ExpressPanel

Horizontal batten fixed to framing

Intermediate
Top Hat
52 COMMERCIAL EXPRESSPANEL® – External Installation

08 CONSTRUCTION DRAWINGS AND DETAILS

Note: Drawings are interchangeable for timber or steel substrates with the exception of the fasteners.

Ventilated Cavity System

FIGURE 8.11 Framed Soffit FIGURE 8.12 Control Joint – Vertical

FIG 43: Control Joint – Vertical

Backing Rod 8-20mm nom.

and Sealant joint
Top Hat 100mm max. 100mm max.

ExpressPanel
Wall Wrap sealed
ExpressPanel to flashing

Intermediate
Top Hat
Wall Wrap Flashing angles

Flashing
Horizontal
Support framing
batten Seal junction to Movement joint
100mm Wall Wrap detail in structure to
max. engineer's
specifications

30-50mm
Soffit lining
Soffit Casing Bead
5-10mm gap

FIGURE 8.13 Inter-Storey Junction with Flashing FIGURE 8.14 Inter-Storey Junction with Flashing

Air Barrier (rigid air

barrier shown)
Wall Wrap

ExpressWall Top Hat

Horizontal batten
ExpressPanel
ExpressWall Horizontal batten
Top Hat
Flexible air barrier installed
continuously or locally over
ExpressPanel slab edge and taped to rigid
air barrier
Concrete
structure Flashing taped Horizontal batten
to Wall Wrap where required
Cantilever

Flashing caulked directly to

slab or installed over flexible
air barrier
100mm Intumescent cavity
45mm closer where required
Flashing 10-20mm
detail by Clearance to suit slab deflection
others 100mm
10-20mm
Inter-storey flashing (by others)
5mm min. 5mm Gap min.

Weathertight flexible air barrier

5mm
or custom folded deflection
flashing (by others). Installed to
45mm accommodate engineer
Support nominated slab deflection
Framing
To suit expected ExpressWall Top Hat
movement
Horizontal batten
Seal junction
to Wall Wrap Air Barrier (rigid air
detail barrier shown)
Horizontal batten
Optional skirt panel

Window installed to
manufactures details
 COMMERCIAL EXPRESSPANEL® – External Installation 53

CONSTRUCTION DRAWINGS AND DETAILS 08

Note: Drawings are interchangeable for timber or steel substrates with the exception of the fasteners.

Ventilated Cavity System

FIGURE 8.15 Abutment FIGURE 8.17 Typical Window Installation

ExpressWall
Top Hat

Wall Wrap

Flashing taped
Support to Wall Wrap
Wall Framing
Horizontal
Support batten
Wall Wrap Framing
ExpressPanel

Wall Wrap Wall Wrap

taped to frame taped to
Horizontal framing
batten
Intermediate Flashing
Top Hat Backing Rod
and Sealant
10-15mm gap
Backing Rod Flashing ExpressPanel
and Sealant angle
8-20mm

Window Head Solid packing

and fixing to
window
manufacturer’s
specification
FIGURE 8.16 Vertical Gasket and Fixing Detail for Half-bond
Panel Layout

Window Sill

ExpressPanel Backing Strip Solid packing

Panel and fixing to
window
manufacturer’s
specification

50mm Backing Rod

100mm min. and Sealant

Wall Wrap
sealed to
framing
ExpressWall
Vertical Gasket Horizontal
batten
Wall Wrap
ExpressWall ExpressWall
Top Hat Support Top Hat
Framing
ExpressPanel

Screw Spacing
Countersunk head screws
(refer to specification table)
either side of top hat

Backing Rod
and Sealant Support
framing

Wall Wrap taped

to framing
Window
Jamb Wall Wrap
ExpressWall
Vertical Gasket

Horizontal
batten
ExpressPanel
100mm min. Panel ExpressPanel

Flashing angle with Intermediate

8-20mm vertical gasket tape, Top Hat
fixed to top hat
Backing Strip
54 COMMERCIAL EXPRESSPANEL® – External Installation

08 CONSTRUCTION DRAWINGS AND DETAILS

Note: Drawings are interchangeable for timber or steel substrates with the exception of the fasteners.

Ventilated Cavity System

FIGURE 8.18 P
 arapet Capping FIGURE 8.19 Balcony Base

Parapet Capping
by others ExpressPanel
Flashing Tape
Capping support ExpressWall
by others Top Hat

Tape flashing
Tape Wall Wrap to Wall Wrap
to framing Wall Wrap
taped to frame
Horizontal batten Support
fixed to frame Framing
Flashing

ExpressPanel
Horizontal
batten fixed 200mm
to frame min.
5mm solid
spacers
Support
Framing
ExpressWall
Top Hat
45mm
Wall Wrap

10mm

Mortar bed Waterproof Angle fixed

and tiles membrane to slab

Concrete
hob/footing

FIGURE 8.20 Typical Drain

Horizontal batten
fixed to frame

ExpressPanel Support
Framing

ExpressWall
Top Hat Drainage
gutter
Wall Wrap

Tape all sides

of drain to Wall
Wrap
Backing Angles Drain pipe
and Sealant to
all sides of drain
 COMMERCIAL EXPRESSPANEL® – External Installation 55

CONSTRUCTION DRAWINGS AND DETAILS 08

Note: Drawings are interchangeable for timber or steel substrates with the exception of the fasteners.

Ventilated Cavity System

FIGURE 8.21 Typical Power/Meter Box

Note: Refer to local authority for specific meter box installation requirements.

ExpressWall
Top Hat

Wall Wrap

Flashing taped
to Wall Wrap
Horizontal
Support batten
Framing
ExpressPanel

Wall Wrap
taped to
framing
Flashing
10-15mm gap

Solid packing Backing Rod

and fixing details and Sealant
by others Flashing and
angle fixed with
Meter Box sealant and rivets

Meter Box Backing Rod

and Sealant
Solid packing Backing Angle,
and fixing details Bond Breaker
by others and Sealant

Wall Wrap
taped to
framing

Horizontal
batten
Wall Wrap
ExpressWall
Support Top Hat
Framing
ExpressPanel

Meter Box

Solid packing
and fixing
details by
others
Jamb
Support
Backing Rod Framing
and Sealant

Wall Wrap

Wall Wrap
taped to
framing Horizontal
batten
Intermediate
Top Hat

Backing Angle, ExpressPanel

Bond Breaker
and Sealant
56 COMMERCIAL EXPRESSPANEL® – External Installation

08 CONSTRUCTION DRAWINGS AND DETAILS

Note: Drawings are interchangeable for timber or steel substrates with the exception of the fasteners.

Ventilated Cavity System – Sealant Filled Joint Detail

FIGURE 8.22 Sealant Filled Joint Construction – Ventilated Cavity System

ExpressWall
Top Hat

ExpressWall
Vertical Gasket

ExpressWall
Countersunk
Head Screw

ExpressWall Countersunk
Head Screw covered and
filled with Epoxy

Sealant filled joints

Bond Breaker Tape Sikaflex-11FC

ExpressWall
Backing Strip

ExpressPanel

FIGURE 8.23 B
 acking Strip Preparation FIGURE 8.24 H
 orizontal Joint – Sealant filled FIGURE 8.25 Vertical Joint – Sealant filled

ExpressPanel Epoxy over screw head

ExpressWall Bond Breaker Tape
Backing Strip ExpressWall
3mm 3mm Countersunk
Bond Sealant filled Head Screw
Breaker vertical gap ExpressPanel
Tape 8-20mm
100mm

Backing Strip
Sikaflex 11FC Cemintel
Adhesive fixing ExpressPanel
BareStone
Backing Strip to Panel 8-20mm
rear of panel Vertical
gasket
Sealant filled
horizontal ExpressWall Top
joint 100mm Hat 1.15BMT

ExpressPanel
 COMMERCIAL EXPRESSPANEL® – External Installation 57

CONSTRUCTION DRAWINGS AND DETAILS 08

Note: Drawings are interchangeable for timber or steel substrates with the exception of the fasteners.

Ventilated Cavity System – Sealant Filled Joint Detail

FIGURE 8.26 T
 ypical ExpressWall System Cross Section for Steel FIGURE 8.27 Eaves/Deflection Head – Sealant filled
Framing – Joints sealant filled

Soffit
Soffit Drip groove
Deflection Fill gap with Sealant
gap 8-20mm
specified by
project
engineer Bond breaker
tape and sealant
Deflection gap 8-20mm
to be specified by
Horizontal batten project engineer
fixed to frame
Bond Breaker Tape
35mm J-track or
Angle 0.55BMT, not
fixed to Top Hat Steel stud
ExpressPanel framing
Countersunk screw
(allow for deflection)
Horizontal batten
fixed to frame

Support framing
ExpressPanel

Top Hat

Top Hat Wall Wrap

Plasterboard
Wall Wrap lining

FIGURE 8.28 Base Detail – Drained

Wall Wrap
ExpressPanel Steel stud
Horizontal framing
Horizontal batten batten fixed
fixed to frame to frame
ExpressWall
Top Hat
Top Hat

Refer to ExpressPanel
base detail
Flashing
Plasterboard
8-10mm gap Flashing lining
Ground clearance
to regulatory Concrete
requirements footing

5-10mm gap

Concrete
Wall Wrap footing
taped to frame
58 COMMERCIAL EXPRESSPANEL® – External Installation

08 CONSTRUCTION DRAWINGS AND DETAILS

Note: Drawings are interchangeable for timber or steel substrates with the exception of the fasteners.

Ventilated Cavity System – Sealant Filled Joint Detail

FIGURE 8.29 Internal Corner Detail – Sealant filled

Top Hat

Wall Wrap

ExpressPanel

Structural Frame to
engineer’s details

35mm J-track
or Angle

Top Hat
8-20mm

Bond Breaker ExpressPanel

Tape and Sealant

FIGURE 8.30 External Corner – Sealant filled

Wall Wrap Flashing angle Bond 8-20mm

ExpressPanel sealed at all by others breaker
tape Sealant
junctions

Intermediate Vertical cavity

Top Hat baffle, detail
by designer
100mm
max.

Support
Framing

Support
Framing
Intermediate
Top Hat
reversed

ExpressPanel

Wall Wrap

Intermediate
Top Hat
 COMMERCIAL EXPRESSPANEL® – External Installation 59

CONSTRUCTION DRAWINGS AND DETAILS 08

Note: Drawings are interchangeable for timber or steel substrates with the exception of the fasteners.

Soft Air Barrier

FIGURE 8.31 Typical Installation Overview – Soft Air Barrier

FIG 1: Typical Installation Overview – Wall Wrap Air Barrier

Timber or
steel framing

Aluminium strip fixed

to nogging

Wall wrap overlapped

Wall wrap and looped back over
looped under aluminium strip fixed at
20mm width 100mm max. centres
continuous between horizontal top
aluminium hats. Tape
strips fixed at continuously to all
100mm max. joins.
centres
Wall wraps overlapped
Seal around and connected with
corners of integrated tape strips
opening with
Bradford SLS
Flexi Tape

Bradford Plasti-Grip
Washer fixed to studs

Wall wrap looped

under 20mm width
continuous
aluminium strips
fixed at 100mm
max. centres

Wall wrap overlapped and looped

back over aluminium strip fixed at
100mm max. centres between
horizontal top hats. Tape
continuously to all joins.
Bradford wall wrap continuous around
corners, or overlapped and looped over 20mm
width continuous aluminium strips fixed at
100mm max. centres

Page 1 FC1921 Soft Air Barrier Systems Final 13/03/23

Pty Ltd
 FIG 2: External Corner – Wall Wrap Continuous FIG 5: Inter

60 FIG 2: ExternalEXPRESSPANEL
COMMERCIAL Corner – Wall Wrap
® Continuous
– External Installation FIG 5: Internal Corner – Wall Wrap Overlapped
Support
Framing

08
Support Bradford Plasti-Grip Washer fixed to
Framing framing as per washer spacing table
& 300mm max. vertical centres

CONSTRUCTION DRAWINGS AND DETAILS

Support Wall wrap overlapped and looped back
Note: Drawings are interchangeable for timber or steel substrates with the exception of the
overfasteners.
aluminium strip fixed at 100mm
Framing
max. centres between horizontal top Support
hats. Tape continuously to all joins Framing

Support
Framing Tape Wall Wrap lap
Support
Framing Bradford Plasti-Grip
Wall wrap continuous WasherBradford
fixed to framing
Soft Air Barrier around corner Plasti-Grip
Washer fixed to framing

Bradford Plasti-Grip Wall wrap around

Wall wrap continuous corner taped to frame
FIGUREaround External CornerWasher
8.32corner – Wallfixed
Wrapto framing
Continuous FIGURE 8.33 External
FIG 3: External Corner
Corner – Wall– Wall
WrapWrap Overlapped
Overlapped

FIG2:
FIG 3:External
ExternalCorner
Corner––Wall
WallWrap
WrapContinuous
Overlapped FIG 5: Internal Corner – Wall
Support Wrap Overlapped
Support
Framing Framing

Bradford Plasti-Grip
Support
Support Washer fixed toPlasti-Grip
Bradford framing Washer fixed to FIG 6: Abut
Framing
Framing framing as per washer spacing table
& 300mm max. vertical centres
Bradford Plasti-Grip
Washer fixed to framing Bradford Plasti-Grip Washer fixed to
FIG 6: Abutment to Concrete
framing as per washerorspacing
Masonry
table Wall
Wallvertical
& 300mm max. wrap overlapped
centres and looped back
over aluminium strip fixed at 100mm
max. centres between horizontal top
Bradford Plasti-Grip Washer fixed to hats. Tape continuously to all joins
framing as per washer spacing table
& 300mm max. vertical centres
Support Support
Framing Framing
Tape Wall Wrap lap Concrete or
Support Packing and fixings if required
Framing masonry wall
Bradford Plasti-Grip
Support Washer fixed to framing
Framing Concrete or Support framing
Bradford Plasti-Grip masonry wall Wall wrap around
Wall wrap continuous Washer fixed to framing Wall wrap overlappedcorner
and looped
taped toback
frame
around corner Wall wrap over aluminium strip fixed at 100mm
around corner max. centres between horizontal top
and overlapped
and taped hats. Tape continuously to all joins
Wall wrap overlapped and looped back
FIGWall
3: wrap
External Corner
around corner
– Wallstrip
over aluminium Wrap Overlapped
fixed at 100mm Support
max. centres between horizontal top Framing Wall wrap
and overlapped
and taped hats. Tape continuously to all joins Backing rod Wall wrap looped back over 20mm
FIG 4: Internal Cornerand – Wall Wrap
sealant Continuous
aluminium strip fixed at 100mm
FIGURE 8.34 Internal Corner – Wall Wrap Continuous
FIG 2: External
Support Corner – Wall Wrap Continuous
FIGURE
FIG 5: 8.35 Internal
Internal toCorner
Cornergap– and
Wall– Wall
Wrap
max.Wrap Overlapped
Overlapped
centres between horizontal top
Wall Wrap Continuous FIG 5: Internal Corner – Wall Wrap Overlapped wall wrap hats. Tape continuously to all joins.
Framing
Bradford Plasti-Grip
FIG 4: Internal Corner – Wall Wrap Continuous Washer fixed to framing
Bradford Plasti-Grip
Support Washer fixed to framing Bradford Plasti-Grip Washer fixed to
Framing Bradford Plasti-Grip Washer fixed to FIG 6: Abutment to Concrete or washer
framing as per Masonry Wall
spacing table
framing as per washer spacing table & 300mm max. vertical centres
Bradford
& 300mm Plasti-Grip
max. vertical centres
Washer fixed to framing
Bradford Plasti-Grip Washer fixed to
framing as per washer spacing table Wall wrap under 20mm width
& 300mm max. vertical centresand looped back Wall wrap overlapped
aluminium strip fixed atand looped back
Wall wrap overlapped over aluminium strip fixed at 100mm
100mm max. centres
over aluminium strip fixed at 100mm max. centres
between between
horizontal tophorizontal
hats. top
max. centres between horizontal top Packing and fixings if required
Support hats. Tape continuously to all joins
hats. Wall
Tapewrap
continuously
under 20mm to width
all joins Framing Bradford Plasti-Grip
aluminium strip fixed at
Support Washer fixed to framing
Support Support
100mm max. centres
Framing
Framing Tape Wall Wrap lap
Framing Tape Wall Wrap
between lap top hats.
horizontal Concrete or
Support Support framing
Support masonry wall
Framing
Support Wall wrap around
Framing Bradford Plasti-Grip cornerBradford Plasti-Grip
and continuous
Framing
Bradford
Washer fixedPlasti-Grip
to framing Washer fixed to framing
Washer fixed to framing
Bradford Plasti-Grip Wall wrap around
Bradford Plasti-Grip Wall wrap continuous Wall
Wall wrapwrap around
around corner taped to frame
Washer
Wall wrap overlappedfixed
corner
corner and
and tolooped
taped framingback
to frame
continuous
Washer fixed to framing around
Wall corner
wrap over aluminium strip fixed at 100mm Support
around corner max. centres between horizontal top Framing Wall wrap
and overlapped
and taped hats. Tape continuously to all joins Backing rod Wall wrap looped back over 20mm
and sealant aluminium strip fixed at 100mm
Wall Wrap Overlapped FIG 3: External Corner – Wall
SupportWrap Overlapped
Support
to gap andSupport
max. centres between horizontal top
Framing wall wrap Framing
hats. Tape continuously to all joins.
Framing

FIG 4: Internal Corner – Wall Wrap Continuous

Support Page 2 FC
Framing
Bradford Plasti-Grip Pty Ltd

Washer Plasti-Grip
Bradford fixed to framing
dford Plasti-Grip Washer fixed to framing
her fixed to framing Page 2 FIG 6: Abutment
FC1921to Soft Air Barrier
Concrete Systems
or Masonry Final 13/03/23
Wall
FIG 6: Abutment
FIGURE to Concrete
8.36 Abutment or Masonry
to Concrete WallWall
or Masonry
Pty Ltd

Bradford Plasti-Grip Washer fixed to

Plasti-Grip Washer fixed to framing as perWall
washer
wrapspacing
under 20mmtablewidth
s per washer spacing table & 300mm max.aluminium
vertical centres
strip fixed at
max. vertical centres 100mm max. centres
between horizontal top hats. Packing and fixings if required
Packing and fixings if required
Support
Framing Bradford Plasti-Grip
Washer fixed to framing
Support
Support Framing
Framing Concrete or Support framing
Concrete or Support framing masonry wall
masonry wall Wall wrap around
corner and continuous

Wall wrap overlapped and looped back

overlapped and looped back Wall wrap over aluminium strip fixed at 100mm
nium strip fixed at 100mm around corner Support
max. centres between horizontal top Wall wrap
Framing Wall wrap
es between horizontal top and overlapped
and taped hats. Tape continuously to all joins Backing rod Wall wrap looped back over 20mm
continuously to all joins Backing rod Wall wrap looped back over 20mm and sealant aluminium strip fixed at 100mm
and sealant aluminium strip fixed at 100mm to gap and
to gap and max. centres between horizontal top
max. centres between horizontal top wall wrap hats. Tape continuously to all joins.
wall wrap hats. Tape continuously to all joins.

Wall Wrap Continuous FIG 4: Internal Corner – Wall Wrap Continuous

Page 2 FC1921 Soft Air Barrier Systems Final 13/03/23
Bradford Plasti-Grip
Pty Ltd
ford Plasti-Grip Washer fixed to framing
her fixed to framing
 COMMERCIAL EXPRESSPANEL® – External Installation 61

CONSTRUCTION DRAWINGS AND DETAILS 08

Note: Drawings are interchangeable for timber or steel substrates with the exception of the fasteners.

Soft Air Barrier

FIG8.37
FIGURE 7: Wall
WallWrap
WrapInstallation
Installation totoWall,
Wall, Soffit
Soffit andand
BaseBase FIG 8: 8.38
FIGURE Wall Wrap
W Installation
 all Wrap atatIntermediate
Installation Level
Intermediate Level Junction
FIG 7: Wall Wrap Installation to Wall, Soffit and Base Junction – Non-loadbearing
FIG 8: Wall
– Wrap Installation
Non-loadbearing Steel Framing
at Framing
Steel Withwith
Intermediate Level Head
Deflection
Deflection
Junction –Head
Non-loadbearing Steel Framing with
Deflection Head

Bradford Plasti-Grip
Washer fixed to framing
Bradford Plasti-Grip
Washer fixed to framing
Soffit
Framing Wall wrap
Soffit
Framing Wall wrap
Wall wrap looped back over
aluminium strip fixed at 100mm
Nogging Wallcentres.
max. wrap looped back over
Tape continuously
continuous
orNogging
similar Sealant continuous toaluminium
all joins strip fixed at 100mm
at wall soffit junction Soffit max. centres. Tape continuously
continuous
framing
or similar Sealant continuous lining to all joins
at wall soffit junction Soffit
framing lining
Wall wrap looped back over Sealant continuous
aluminium strip fixed at 100mm at junction
Wall wrap looped back over Sealant continuous
max. centres. Tape continuously at junction
toaluminium
all joins strip fixed at 100mm Dampcourse
max. centres. Tape continuously
to all joins Slab or if required
Framing Dampcourse
Slab or if required
Deflection head track to
Framing engineer’s specifications
Wall wrap Deflection head track to
Support Sealant continuous
engineer’s specifications
Framing Wall wrap at junction
Support Sealant continuous
Framing Doatnot fix to studs or above studs
junction
100-200 Do wrap
Wall not fixlooped
to studs or above studs
loosely
mm between metal strips
100-200 Wall wrap looped loosely
mm Wall wrap looped
between back over
metal strips
Bradford Plasti-Grip Washer
fixed to framing aluminium strip fixed at 100mm
Wallcentres.
max. wrap looped back over
Tape continuously
Bradford Plasti-Grip Washer
fixed to framing toaluminium
all joins strip fixed at 100mm
max. centres. Tape continuously
to all joins
Wall wrap under 20mm width
aluminium strip fixed at 100mm
Wallcentres
max. wrap under 20mm width
aluminium strip fixed at 100mm
max. centres
Additional nogging
or similar framing
Additional nogging
or similar framing
Wall wrap
Wall wrap
Bradford Plasti-Grip Washer
fixed to framing
Bradford Plasti-Grip Washer
Bradford Plasti-Grip Washer fixed to framing
fixed to framing
Bradford Plasti-Grip Washer
fixed to framing

Support Wall wrap

Framing
Support Wall wrap
Framing

Wall wrap looped back over

aluminium strip fixed at 100mm
max.Wallcentres.
wrap looped back over
Tape continuously
toaluminium
all joins strip fixed at 100mm
max. centres. Tape continuously
to all joins
Sealant continuous
at junction
Sealant continuous
at junction
Dampcourse
Slab or if required
Framing Dampcourse
Slab or if required
Framing
62 COMMERCIAL EXPRESSPANEL® – External Installation

08 CONSTRUCTION DRAWINGS AND DETAILS

Note: Drawings are interchangeable for timber or steel substrates with the exception of the fasteners.

Soft Air Barrier

FIGURE 8.39 Vertical Wall Wrap Junction – Overlapped Double Strip Join
FIG 9: Vertical Wall Wrap Junction – Overlapped Double Strip Join
FIG 9: Vertical Wall Wrap Junction – Overlapped Double Strip Join
FIG 9: Vertical Wall Wrap Junction – Overlapped Double Strip Join
FIG 9: Vertical Wall Wrap Junction – Overlapped Double Strip Join
Support Support
Framing Framing
Support Support
Framing Framing
Support Support
Framing Framing
Support Support
Bradford
FramingPlasti-Grip Washer Wall wrap Wall wrap overlapped and looped back Bradford
FramingPlasti-Grip Washer
fixed to framing overlapped and over aluminium strip fixed at 100mm fixed to framing
Bradford Plasti-Grip Washer Wall
tapedwrap
to seal Wall
max.wrap overlapped
centres betweenand loopedtop
horizontal back Bradford Plasti-Grip Washer
fixed to framing overlapped and over fixed to framing
hats.aluminium strip fixed
Tape continuously toat
all100mm
joins
taped to seal max. centres between horizontal top
Bradford Plasti-Grip Washer Wall wrap Wall wrap
hats. Tape overlapped
continuously and
to looped
all joinsback Bradford Plasti-Grip Washer
fixed to framing overlapped and over aluminium strip fixed at 100mm fixed to framing
Bradford Plasti-Grip Washer tapedwrap
Wall to seal Wall
max.wrap overlapped
centres between and loopedtop
horizontal back Bradford Plasti-Grip Washer
FIG 10: fixed Wall
Vertical to framing
Wrap Junction
– overlapped and
Overlapped Single Strip
over
hats. Tape Join
aluminium strip fixed
continuously to at
all100mm
joins fixed to framing
taped to seal max. centres between horizontal top
FIG 10: Vertical Wall Wrap Junction – Overlapped Single Strip
hats. Tape Join
continuously to all joins
FIGURE 8.40 Vertical Wall Wrap Junction – Overlapped Single Strip Join
FIG 10: Vertical Wall Wrap Junction – Overlapped Single Strip Join
FIG 10: Vertical Wall Wrap Junction – Overlapped Single Strip Join
Support Support
Framing Wall wrap Framing
Support Support
Framing taped to seal Framing
Wall wrap
Support taped to seal Support
Framing Wall wrap Framing
Support taped to seal Support Washer
Bradford Plasti-Grip
Framing
Bradford Plasti-Grip Washer Wall Wall
wrapwrap
overlapped and looped back Framing
fixed to framing as per washer
fixed to framing over aluminium strip fixed at 100mm Bradford Plasti-Grip
spacing table & 300mm Washer
max.
Bradford Plasti-Grip Washer Wall taped to seal
wrap overlapped and looped back fixed
fixed to framing
max. centres between horizontal top
over aluminium strip fixed at 100mm vertical centres as per washer
to framing
hats. Tape continuously to all joins spacing table & 300mm max.
max. centres between and horizontal Bradfordcentres
Plasti-GripWall
Washer
wrap taped
Bradford Plasti-Grip Washer Wall wrap overlapped loopedtopback vertical
fixed to framing as topersealed
washerto stud
hats. aluminium
Tape continuously to at
all100mm
joins Wall wrap
fixed to framing over strip fixed Bradford Plasti-Grip
spacing table & 300mm max. taped
Washer
Bradford Plasti-Grip Washer Wall wrap
max. overlapped
centres between and loopedtop
horizontal back fixed framing as to
to centres
vertical persealed
washerto stud
fixed to framing over
hats. aluminium strip fixed
Tape continuously to at
all100mm
joins spacing table & 300mm max. taped
Wall wrap
max. centres between horizontal top vertical centres to sealed to stud
hats. Tape continuously to all joins Wall wrap taped
to sealed to stud

FIG 11: Vertical Wall Wrap Junction – At Control joint

FIGURE 8.41 Vertical Wall Wrap Junction – At Control joint
FIG 11: Vertical Wall Wrap Junction – At Control joint
FIG 11: Vertical Wall Wrap Junction – At Control joint
FIG 11: Vertical Wall Wrap Junction – At Control joint
Support Backing Rod Support
Framing and Sealant Framing
Support Backing Rod Support
Framing and Sealant Framing
Support Backing Rod Support
Framing and Sealant Framing
Support Backing Rod Support
Framing
Bradford Plasti-Grip Washer Wall wrap looped back over and Sealant FramingPlasti-Grip Washer
Bradford
fixed to framing aluminium strip fixed at 100mm max. fixed to framing
Bradford Plasti-Grip Washer Wall wrap looped back over Bradford Plasti-Grip Washer
fixed to framing centres between horizontal top hats. fixed to framing
aluminium strip fixed at 100mm max.
Tape continuously to all joins
Bradford Plasti-Grip Washer centres between
Wall wrap loopedhorizontal
back overtop hats. Bradford Plasti-Grip Washer
fixed to framing Tape continuously
aluminium to at
strip fixed all 100mm
joins max. fixed to framing
Bradford Plasti-Grip Washer Wall wrap
centres loopedhorizontal
between back overtop hats. Bradford Plasti-Grip Washer
fixed to framing aluminium strip
Tape continuouslyfixed
to all joins max.
at 100mm fixed to framing
FIG 12: Vertical Wall Wrap Junction – No Lap Double Washer
centres between horizontal top hats.
FIG 12: Vertical Wall Wrap Junction – No Lap Double Washer
Tape continuously to all joins

FIGURE 8.42
FIG 12: VerticalWall
Vertical WallWrap
Wrap Junction
Junction – No LapLap
– No Double Washer
Double Washer
FIG 12: Vertical Wall Wrap Junction – No Lap Double Washer
Support Wall wrap folded Support
Framing into gap to allow Framing
Support Wall wrap folded Support
Framing for movement Framing
into gap to allow
Support for movement Support
Wall wrap folded
Framing into gap to allow Framing
Support Wall wrap folded
for movement Support
Framing
Bradford Plasti-Grip Washer Bradford Plasti-Grip
into gap to allow Framing
Bradford Plasti-Grip Washer
fixed to framing Washer fixed to framing
for movement fixed to framing
Bradford Plasti-Grip Washer Bradford Plasti-Grip Bradford Plasti-Grip Washer
fixed to framing Washer fixed to framing fixed to framing
Bradford Plasti-Grip Washer Bradford Plasti-Grip Bradford Plasti-Grip Washer
fixed to framing Washer fixed to framing fixed to framing
Bradford Plasti-Grip Washer Bradford Plasti-Grip Bradford Plasti-Grip Washer
fixed to framing Washer fixed to framing fixed to framing
 COMMERCIAL EXPRESSPANEL® – External Installation 63

CONSTRUCTION DRAWINGS AND DETAILS 08

Note: Drawings are interchangeable for timber or steel substrates with the exception of the fasteners.

Soft Air Barrier

FIGURE 8.43 Wall Wrap Installation at Window/Door Opening

FIG 13: Wall Wrap Installation at Window/Door
Opening

STEP 2: Pass
Wall Wrap under
aluminium strip
fixed at 100mm
max. centres
STEP 1: Slit
wall wrap from
the corners of STEP 3: Fold Wall
the opening and Wrap back over strip
remove centre and tape
section
STEP 4: Bradford SLS
Flexi Tape to seal wall
wrap at corners of
openings and extend back
beyond the sealant line of
the window framing 100mm
min.

100mm min.

FIG 14: Wall Wrap Installation at Drain Penetration –

FIGURE 8.44 Wall Wrap Installation at Drain
Timber Penetration
or Steel Framing – Timber or Steel Framing

Bradford Plasti-Grip Washer

fixed to framing

Wall Wrap
Support
Framing

Cut penetration in wall wrap and

seal to drain on all sides with
Bradford SLS Flexi Tape

Page 5 FC1921 Soft Air Barrier Systems Final 13/03/23

Pty Ltd Drain

Support
Framing

Wall Wrap

Bradford Plasti-Grip Washer

fixed to framing

FIG 15: Wall Wrap Installation at Parapet Junction – Timber or Steel Framing

Bradford Plasti-Grip Washer

 Drain

64 COMMERCIAL EXPRESSPANEL® – External Installation

08 CONSTRUCTION DRAWINGS
Support
AND DETAILS
Framing
Note: Drawings are interchangeable for timber or steel substrates with the exception of the fasteners.
Wall Wrap

Bradford Plasti-Grip Washer

Soft Air Barrier fixed to framing

FIGURE 8.45 Wall Wrap Installation at Parapet Junction – Timber or Steel Framing
FIG 15: Wall Wrap Installation at Parapet Junction – Timber or Steel Framing

Bradford Plasti-Grip Washer

fixed to framing

Seal wall/parapet junction with

Bradford SLS Flexi Tape

Wall wrap looped over 20mm

width continuous aluminium
strips fixed at 100mm max.
centres and taped
Overlap wall wrap 150mm min.
and fix under 20mm width
continuous aluminium strip fixed
at 100mm max. centres and taped

Page 6 FC1921 Soft Air Barrier Systems Final 13

Pty Ltd
 COMMERCIAL EXPRESSPANEL® – External Installation 65

09
SAFETY, HANDLING, GENERAL CARE
+ WARRANTY
66 COMMERCIAL EXPRESSPANEL® – External Installation

09 SAFETY, HANDLING, GENERAL CARE

+ WARRANTY

Health, Safety and Personal Protection Equipment (PPE)

Fibre Cement contain silicas that are harmful An approved dust mask (AS/NZS 1715 and
if inhaled. Protective clothing and breathing AS/NZS 1716) and safety glasses (AS/NZS 1337)
equipment should be worn when cutting products. must be worn. Cemintel recommends that hearing
When cutting, drilling or grinding fibre cement panels protection also be worn.
using power tools, always ensure the work area is
Safety Data Sheet information is available at
properly ventilated.
www.cemintel.com.au

Managing Respirable Crystalline Silica Dust

Crystalline Silica is everywhere. It is found naturally silica. This dust is of concern due to its size as it gets
in stone, rocks, sand, gravel and clay. Sand is one caught deep in your lungs and can cause long term
of the raw materials in Fibre Cement. Respirable damage.
Crystalline Silica dust is the fine dust that’s created
IF YOU USE THE CORRECT SAFETY EQUIPMENT AND
when you use power tools to cut, drill, grind, chip or
PPE, FIBRE CEMENT IS SAFE TO USE.
sand materials and products that contain crystalline

Cemintel Safety Requirements

1 - Cut Outdoors* The ventilation outdoors is greater than that indoors, and therefore should reduce exposure.
2 - Use On-Tool Dust Extraction Use on-tool dust extraction when using power tools to drill and cut Fibre Cement, with a vacuum that
contains a HEPA M Class filter.
3 - Correct Saw and Blade Use a plunge saw with a specifically designed Fibre Cement blade.
4 - Don’t Sweep, Vacuum instead When completing your work vacuum with a HEPA M Class filter, rather than a broom as sweeping
creates more dust.
5 - Use Correct Respirator Use a half face P1 or P2 respirator. It is essential that the respirators are Fit Tested and workers are
cleanly shaven to obtain a good seal.
* Even though not recommended, indoor cutting can be completed when using an onsite cutting room with exhaust ventilation and a M class filter at a
minimum, on-tool dust extraction with a vacuum with a HEPA M Class filter, a Full Face P2 respirator and conducting local occupational and static air
monitoring to validate effectiveness of control measures.

Safety, Handling, and Maintenance

Storage Cutting
All Cemintel panels must be stacked flat, clear of the ground Panels should be fully supported and cut from the back using
and supported at 300mm maximum centres on a level platform. a power saw. Cemintel recommends using the Makita Plunge
Panels must be kept dry, preferably stored inside the building. Cut Saw with guide rail and appropriate blade, together with
Panels must be dry prior to fixing, hence if it is necessary to store the appropriate dust extraction system. All exposed cut edges
outside, the product must be protected from the weather. MUST BE SEALED WITH CEMINTEL EDGE SEALER TO PREVENT
MOISTURE ABSORPTION.
Handling
Mitres
Prefinished products and must be treated with care during
handling to avoid damage to edges, ends and prefinished surface. It is not recommended to mitre panel edges as this can cause
Panels should be carried horizontally on edge by at least two delamination of the face.
people.
Penetrations
Consideration should be given to planning the order of other
Penetrations in panels may be cut or drilled prior to installation.
trades that might stain or damage the panels.
Cut from the back or drill from the front. Mask, prime and fill gaps
Any splashings of mud, cement, mortar and the like should be with sealant in accordance with recommended methods and
removed immediately. products.

Warranty
Cemintel Commercial ExpressPanel sheets have a product
warranty of 10 years.
The full product warranty is available for download at
cemintel.com.au
COMMERCIAL EXPRESSPANEL® – External Installation 67
Our Offices
Sydney Melbourne Brisbane
376 Victoria Street 277 Whitehall Street 768 Boundary Road
Wetherill Park NSW 2164 Yarraville VIC 3013 Coopers Plains QLD 4108
Adelaide Perth Hobart
Lot 100 Sharp Court 19 Sheffield Road 11 Farley Street
Mawson Lakes SA 5095 Welshpool WA 6106 Derwent Park TAS 7009
Darwin
Cnr Stuart Highway
& Angliss Street
Berrimah NT 0828

cemintel.com.au For Design and Technical Support:

1300 236 468 DesignLINK – 1800 621 117

Cemintel is a trading entity of CSR Building Products Limited (ACN 008 631 356).
The products referred to in this document have been manufactured by or on behalf of CSR Building Products Limited
(“CSR”) to comply with the Building Code of Australia and any relevant Australian Standards. While any design or usage
guidelines set out in this document have been prepared in good faith by CSR, they are of a general nature only and are
intended to be used in conjunction with project specific design and engineering advice.
It is the responsibility of the customer to ensure that CSR’s products are suitable for their chosen application, including
11/2023 REV04

in respect of project-specific matters such as, but not limited structural adequacy, acoustic, fire resistance/combustibility,
thermal, and weatherproofing requirements. All information relating to design/installation/application of these products
is offered without warranty and no responsibility can be accepted by CSR for errors and omissions, or for any use of the
relevant products not in accordance with CSR’s technical literature or any other relevant industry standards. For current
technical and warranty documentation relating to Cemintel’s products, visit Cemintel’s website at www.cemintel.com.au.