forterra cladding systems wonderwall 1...

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TECHNICAL APPROVALS FOR CONSTRUCTION

APPROVAL

INSPECTION

TESTING

CERTIFICATION

Forterra Building Products Limited5 Grange Park CourtRoman WayNorthampton NN4 5EATel: 0330 123 1018 Fax: 01530 273183e-mail: [email protected]: www.forterra.co.uk

British Board of Agrément tel: 01923 665300Bucknalls Lane fax: 01923 665301Watford e-mail: [email protected] WD25 9BA website: www.bbacerts.co.uk©2014

The BBA is a UKAS accredited certification body — Number 113. The schedule of the current scope of accreditation for product certification is available in pdf format via the UKAS link on the BBA website at www.bbacerts.co.uk

Readers are advised to check the validity and latest issue number of this Agrément Certificate by either referring to the BBA website or contacting the BBA direct.

FORTERRA CLADDING SYSTEMS

WONDERWALL 1 CLAY BRICK SLIP CLADDING SYSTEM

This Agrément Certificate Product Sheet(1) relates to the Wonderwall 1 Clay Brick Slip Cladding System, an insulated backer board and clay brick slip system for use as protective/decorative cladding over external masonry, concrete, timber and steel-frame substrate walls of new and existing domestic and non-domestic buildings.(1) Hereinafter referred to as ‘Certificate’.

CERTIFICATION INCLUDES:• factors relating to compliance with Building

Regulations where applicable• factors relating to additional non-regulatory

information where applicable• independently verified technical specification• assessment criteria and technical investigations• design considerations• installation guidance• regular surveillance of production• formal three-yearly review.

KEY FACTORS ASSESSEDStrength and stability — the system can be designed to transfer the design wind loads to the substrate wall (see section 6).Behaviour in relation to fire — the system may be regarded as having a designated A1 surface to in England and Wales and ‘low risk’ in Scotland in accordance with the national Building Regulations (see section 7).Thermal properties — the system can contribute to the overall thermal performance of the wall construction (see section 9).Condensation risk — the system can contribute to limiting the risk of interstitial and surface condensation (see section 10).Weathertightness — the system resists water penetration and the risk of damage to the inner wall (see section 11).Durability — the system has adequate durability and an ultimate service life exceeding 25 years (see section 13).

Agrément Certificate14/5114

Product Sheet 1

The BBA has awarded this Certificate to the company named above for the system described herein. This system has been assessed by the BBA as being fit for its intended use provided it is installed, used and maintained as set out in this Certificate.

On behalf of the British Board of Agrément

Date of First issue: 23 April 2014 Brian Chamberlain Claire Curtis-Thomas Head of Approvals — Engineering Chief ExecutiveCertificate amended on 30 September 2015 to update front page information.

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In the opinion of the BBA, the Wonderwall 1 Clay Brick Slip Cladding System, if installed, used and maintained in accordance with this Certificate, will meet or contribute to meeting the relevant requirements of the following Building Regulations (the presence of a UK map indicates that the subject is related to the Building Regulations in the region or regions of the UK depicted):

The Building Regulations 2010 (England and Wales) (as amended)

Requirement: A1 Loading

Comment: The system can sustain and transmit wind loads to the substrate. See sections 4.3, 4.4, 4.6 and 6.2 of this Certificate.

Requirement: B4(1) External fire spread

Comment: The system outer surface is designated A1 and, therefore, meets this requirement. See sections 7.1 to 7.4 and 7.6 to 7.8 of this Certificate.

Requirement: C2(b) Resistance to moisture

Comment: The system will resist the passage of rainwater to the supporting structure. See sections 11.1 to 11.8 of this Certificate.

Requirement: C2(c) Resistance to moisture

Comment: The system contributes to minimising the risk of surface and interstitial condensation. See section 10.1 of this Certificate.

Requirement: L1(a)(i) Conservation of fuel and power

Comment: The system can contribute to meeting this Requirement. See sections 9.1 to 9.4 of this Certificate.Regulation 7 Materials and workmanship

Comment: The system is acceptable. See section 13 and the Installation part of this Certificate.Requirement: 26 CO2 emission rates for new buildingsRequirement 26A Fabric energy efficiency rates for new dwellings (in England only)

Comment: Walls incorporating the system can contribute to meeting the Target Emission Rate. See sections 9.1 to 9.4 of this Certificate.

The Building (Scotland) Regulations 2004 (as amended)

Regulation: 8(1)(2) Durability, workmanship and fitness of materials

Comment: The use of the system satisfies the requirements of this Regulation. See sections 12.1, 13 and the Installation part of this Certificate.

Regulation: 9 Building standards applicable to constructionStandard: 1.1(b) Structure

Comment: The system can sustain and transmit wind loads to the substrate. See sections 4.3, 4.4, 4.6 and 6.2 of this Certificate.

Standard: 2.6 Spread to neighbouring buildings

Comment: The system can contribute to satisfying this Standard, with reference to clauses 2.6.1(1)(2), 2.6.2(1)(2), 2.6.4(1)(2), 2.6.5(1) and 2.6.6(2). See sections See sections 7.1 to 7.8 of this Certificate of this Certificate.

Standard: 2.7 Spread on external walls

Comment: The system can contribute to satisfying this Standard, with reference to clause 2.7.1(1)(2) and Annex 2A(1). See sections 7.1 to 7.8 of this Certificate.

Standard: 3.10 Precipitation

Comment: The system will resist the passage of rainwater to the inner face of the wall, with reference to clauses 3.10.1(1)(2), 3.10.2(1)(2) and 3.10.3(1)(2). See sections 11.1 to 11.8 of this Certificate.

Standard: 3.15 Condensation

Comment: The system will satisfy the requirements of clauses 3.15.1(1), 3.15.2(1), 3.15.4(1) and 3.15.5(1) of this Standard. See section 10.1 of this Certificate.

Standard: 6.1 Carbon dioxide emissionsStandard: 6.2 Building insulation envelope

Comment: The system can contribute to a building achieving the Target Emissions Rate, with reference to clauses (or parts of) 6.1.1(1)(2), 6.1.4(1), 6.2.1(1)(2), 6.2.3(1), 6.2.4(1)(2), 6.2.5(1)(2), 6.2.6(2) and 6.2.7(2). See sections 9.1 to 9.4 of this Certificate.

Standard: 7.1(a)(b) Statement of sustainability

Comment: The system can contribute to meeting the relevant Requirements of Regulation 9, Standards 1 to 6, and, therefore, will contribute to a construction meeting a bronze level of sustainability as defined in this Standard. In addition, the system can contribute to a construction meeting a higher level of sustainability as defined in this Standard, with reference to clauses 7.1.4(1)(2) [Aspects 1(1)(2) and 2(1)], 7.1.6(1)(2) [Aspects 1(1)(2) and 2(1)] and 7.1.7(1)(2) [Aspect 1(1)(2)]. See sections 9.1 to 9.4 of this Certificate.

Regulation: 12 Building standards applicable to conversions

Comment: All comments given for these systems under Regulation 9, also apply to this Regulation, with reference to clause 0.12.1(1)(2) and Schedule 6(1)(2).

(1) Technical Handbook (Domestic). (2) Technical Handbook (Non-Domestic).

Regulations

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The Building Regulations (Northern Ireland) 2012

Regulation: 23(a)(i)(iii)(b) Fitness of materials and workmanship

Comment: The system is acceptable. See section 13 and the Installation part of this Certificate.Regulation: 28 Resistance to moisture and weather

Comment: The system will satisfy this Regulation. See sections 11.1 to 11.8 of this Certificate.Regulation: 29 Condensation

Comment: The system will satisfy the requirements of this Regulation. See section 10.1 of this Certificate.Regulation: 30 Stability

Comment: The system is acceptable as set out in sections 4.3, 4.4, 4.6 and 6.2 of this Certificate.Regulation: 36 External fire spread

Comment: The system is judged to meet this requirement. See sections 7.1 to 7.4 and 7.6 to 7.8 of this Certificate.Regulation: 39(a)(i) Conservation measuresRegulation: 40(2) Target carbon dioxide emissions rate

Comment: The system will contribute to a building satisfying its target emission rate. See sections 9.1 to 9.4 of this Certificate.

Construction (Design and Management) Regulations 2007Construction (Design and Management) Regulations (Northern Ireland) 2007

Information in this Certificate may assist the client, CDM co-ordinator, designer and contractors to address their obligations under these Regulations.See section: 3 Delivery and site handling (3.2 and 3.4) and 15 Installation — General (15.2) of this Certificate.

Additional Information

NHBC Standards 2014NHBC accepts the use of Wonderwall 1 Clay Brick Slip Cladding System, when installed, used and maintained in accordance with this Certificate, in relation to NHBC Standards, Chapter 6.2 External timber framed walls, Chapter 6.9 Curtain walling and cladding and Chapter 6.10 Light steel framed walls and floors.

Technical Specification

1 Description1.1 The Wonderwall 1 Clay Brick Slip Cladding System (see Figure 1) comprises:• backerboard — 1200 mm wide by 2400 mm in length composite panels consisting of a 0.75 mm thick high impact

polystyrene (HIPS) profiled carrier sheet, bonded to a 25 mm or 50 mm thick rigid phenolic foam insulation board (density of 42 kg∙m–3) manufactured in accordance with BS EN 13166 : 2012 with a foil covering internal face. The HIPS carrier sheet is formed with horizontal bed joint ribs, at 75 mm centres, to aid application of brick slips

• brick slip adhesive — a one part polyurethane elastic adhesive (Korapur 126 grau) and applied in a 10 mm diameter bead to the backerbord panel to attach the brick slips

• clay brick slip — up to 215 mm in length, 65 mm in height and thicknesses between 18 mm and 30 mm, and available in a range of colours and finishes. Other lengths are available and the Certificate holder’s advice must be sought on these. The brick slips are frost resistant, and classified as durability designation F2, in accordance with BS EN 771-1 : 2011. L-shaped bricks are also available for external corners

• pointing grout/mortar — cement based mortar mix to class 12, 6 or 4 in accordance with BS EN 998-2 : 2010, or site batched mortar of equivalent specification to mortar mix designation (i), (ii) or (iii) in accordance with PD 6697 : 2010 and agreed with the Certificate holder.

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Figure 1 Typical Wonderwall 1 Brick Slip Cladding System

brickslip

ribbed sheet

phenolic insulation

10 mm diameter continuousbrickslip adhesive

pointing grout mortar

flat profile to rib

curved profile to rib

drainage channel

1.2 Ancillary components for use with the system, but outside the scope of the Certificate:• substrate wall• starter rail — aluminium L-shape, 2400 mm long, 60 mm by 35 mm• silicone sealant — in accordance with BS EN ISO 11600 : 2003 used as a decorative coat only and applied

over Ralliflame Caulk 360 joint sealant or other proprietary mastic brand in accordance with BS 6213 : 2000• adhesive bead – 5 mm bead applied along vertical edge between adjacent backerboard panels • fixings — zinc coated, black phosphorous coated or stainless steel screws with plugs tailored to suit timber or steel-

frame, masonry, dense and no-fines concrete substrates• support timber battens – minimum 75 mm wide by 20 mm deep to support the backerboard panels in timber frame

construction and to create a minimum 20 mm cavity• support steel rails – minimum 75 mm wide by 20 mm deep to support the backerboard panels in steel frame

construction and to create a minimum 20 mm cavity• sheathing — minimum 9 mm cement particle board installed behind the backerboard• movement joints• additional insulation — where used between substrate wall and backerboard component.

2 Manufacturing2.1 The backerboard insulation component is manufactured to BS EN 13166 : 2012.

2.2 The clay brick slips are fired, using conventional clay moulding techniques, extruded or cut from standard facing bricks.

2.3 As part of the assessment and ongoing surveillance of product quality, the BBA has:• agreed with the manufacturer the quality control procedures and product testing to be undertaken• assessed and agreed the quality control operated over batches of incoming materials• monitored the production process and verified that it is in accordance with the documented process• evaluated the process for management of nonconformities• checked that equipment has been properly tested and calibrated• undertaken to carry out the above measures on a regular basis through a surveillance process to verify that the

specifications and quality control operated by the manufacturer are being maintained.

3 Delivery and site handling3.1 The backerboard panels are delivered to site on pallets wrapped in polythene. Each pallet bears a ticket number.

3.2 The panels must be stored flat, level, clear of the ground on pallets out of direct sunlight and in dry conditions. Panels should ideally be stored indoors, however, if should short-term storage outdoors be necessary, the backerboard must be covered with tarpaulin. Backerboard panels must not be exposed to sunlight for more than 48 hours and volatile organic solvents.

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3.3 Brick slips are supplied on pallets and wrapped in purpose-made bags.

3.4 Containers of adhesive, mortar, sealants and expanding foam should be stored in dry conditions and protected against frost and excessive heat. Adhesive and mortar must be used within the time span indicated on the packaging or the supplier’s guidelines.

Assessment and Technical Investigations

The following is a summary of the assessment and technical investigations carried out on the Wonderwall 1 Clay Brick Slip Cladding System.

Design Considerations

4 General4.1 The Wonderwall 1 Clay Brick Slip Cladding System, is suitable for use as a durable non-structural weather resistant, thermally insulating external protective and decorative cladding finish for application on external vertical walls of new or refurbished buildings less than 18 m in storey height of solid and cavity masonry, dense or no-fines concrete, timber frame or light gauge steel frame construction.

4.2 The system will improve the weather resistance of a wall and provide a decorative finish. However, it may only be installed where other routes for moisture penetration have been dealt with separately and where dampness, other than that caused solely by condensation, is not evident on the inner surface of the wall. The system can contribute to minimising condensation on internal wall surfaces.

4.3 Existing buildings subject to national Building Regulations should have wall surfaces in accordance with section 4.5 of this Certificate.

4.4 New buildings subject to national Building Regulations should be constructed in accordance with the relevant recommendations of:

• BS EN 1996-1-1 : 2005, BS EN 1996-1-2 : 2005, BS EN 1996-2 : 2006 and BS EN 1996-3 : 2006• BS 8000-3 : 2001.

4.5 Other buildings, not subject to any of the previous requirements should also be built in accordance with requirements given in section 4.4.

4.6 The substrate to which the boards are fixed must be structurally sound and constructed in accordance with the requirements of the relevant national Building Regulations and Standards thus:

• Timber stud walls and timber battens must be structurally sound, designed and constructed in accordance with BS EN 1995-1-1 : 2004, and preservative treated in accordance with BS EN 351-1 : 2007

• Galvanized steel framework must be structurally sound, designed and constructed in accordance with BS EN 1993-1-1 : 2005 and BS EN 1993-1-3 : 2006

• New masonry buildings subject to national Building Regulations should be constructed in accordance with the relevant recommendations of BS EN 1996-1-1 : 2005, BS EN 1996-1-2 : 2005, BS EN 1996-2 : 2006 and BS EN 1996-3 : 2006.

4.7 The system transfers its self-weight and design wind loads to the backing wall. The substrate and any supporting framework should be capable of resisting the associated loads. Particular care is required around window and door openings to ensure that the structure is capable of sustaining the additional weight of the system.

4.8 The system does not make any contribution to the overall structural performance of the building and must not be used for the support of any temporary structure.

4.9 In severe exposure conditions, application of a high performance breather membrane to the substrate wall should be considered.

4.10 All externally exposed perimeters of, and penetrations through, the composite insulation panel (backerboard) must be protected by non-combustible material.

4.11 The fixing of rainwater goods, satellite dishes, clothes lines, hanging baskets and similar items is outside the scope of this Certificate.

5 Practicability of installationThe system is designed to be installed by installers who have been trained, approved and monitored by the Certificate holder.

6 Strength and stability6.1 A suitably qualified and experienced individual must check the design and installation of the cladding system to provide adequate resistance to design loads applicable in the UK.

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6.2 Design wind actions should be calculated in accordance with BS EN 1991-1-4 : 2005 and the UK National Annex. Due consideration should be given to the higher-pressure coefficients applicable to corners of the building as recommended in this Standard.

6.3 The contribution of the cladding system on the stability of the substrate is assumed to be negligible. The substrate wall without the Wonderwall 1 Clay Brick Slip Cladding System must be able to take the full wind actions, racking loads and the weight of the cladding system. A typical construction comprising 50 mm thick phenolic foam composite insulation backerboard, adhesive and pointed with 20 mm thick brick slips weighs 53.4 kg∙m–2. The adequacy of the substrate wall is outside the scope of this Certificate and must be verified by a suitably qualified and experienced individual.

6.4 Positive wind load (pressure) is transferred to the substrate wall directly via bearings and compression of the brick slips and backerboard.

6.5 Negative wind pressure (suction) is resisted by the bond between each component. The backerboard is retained by fixings.

6.6 Fixing type and spacing must be designed on a project specific basis. The maximum distance between fixings is 600 mm horizontally and 225 mm vertically as shown in Figure 2.

Figure 2 Fixing layout of backerboard — Front elevation

1200

600

20 5

2400

225

6.7 Tests carried out confirm that when fixed directly to a solid substrate wall or through vertical support battens at maximum 600 mm centres to framed substrate walls, the system has a characteristic wind load resistance of 2 kN∙m2 without damage or permanent deformation, provided the designer ensures:• the fixing of the system to the substrate wall has adequate pull-out resistance (not covered by this Certificate) for

the calculated loads. The characteristic pull-out resistance of the fixings to be used for securing the system to the substrate wall should be determined in accordance with the guidance given in ETAG 014 : 2002 Annex D.

• design of the supporting framework is such that the maximum deflection does not exceed 1/350 of its span• the vertical support battens are no more than 600 mm centres apart.

6.8 Tests carried out confirm that the bond strength between brick slips and insulated panel is 0.08 N∙mm–2 in accordance with the requirements of ETAG 004.

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Impact resistance6.9 When tested for hard and soft body impacts, the cladding system installed on solid and timber-frame substrates, achieved adequate resistance for use in areas classified as E’2, E3, E4 and E5 as defined in Table 3.1 of MOAT 043 : 1987 (an extract of which is reproduced in Table 1). The system when installed on steel frame substrates, with vertical support at no more than 600 mm centre, will have similar impact resistance.

Table 1 Classification of opaque vertical components according to the extent of exposure to external impacts

Category Description Examples of components(1)

E2 Readily accessible to public and others with littleincentive to exercise care. Chance of accident occurring and of misuse

Walls adjacent to pedestrian thoroughfares or playing fields, up to 1.5 m above pedestrianlevel, but not in vandal prone locations

E’2 Above zone of normal impacts from people butliable to impacts from thrown or kicked objects

1.5 m to 6 m above pedestrian level at locationcategory E2

E3 Accessible primarily to those with some incentive toexercise care. Some chance of accident occurring or of misuse

Walls adjacent to private open gardens. Back wallsof access galleries or balconies, up to 1.5 m abovepedestrian level

E4 Only accessible, but not near a common route, to thosewith high incentive to exercise care. Small chance ofaccident occurring or of misuse

Walls adjacent to small fenced decorative gardens with no through paths

E5 Above zone of normal impacts from people and notexposed to impact from thrown or kicked objects

Locations similar to E2, but over 6 m above pedestrian level. Locations similar to E3 and E4 but over 1.5 m above pedestrian level

(1) The height of 1.5 m corresponds to the region where human impacts with the energies established in Table 2.1 are likely to occur in normal buildings. However, for some types of building, such as gymnasia, warehouses, etc, greater heights may have to be considered.

6.10 To avoid damage of the clay brick slips, the use of the system shall be restricted to locations where some incentive to exercise care and little chance of hard body impacts occur.

7 Behaviour in relation to fire7.1 For reaction to fire, the system incorporating 25 mm thick phenolic foam insulation and 20 mm thick clay brick slips achieved a fire classification of B-s1,d0 when tested in accordance with BS EN 13501-1 : 2007.

7.2 The brick slips and mortar are designated A1 to Table 6, Approved Document B (England and Wales) and ‘low risk’ in Scotland.

7.3 The systems are restricted for use in buildings less than 18 m in height.

7.4 For houses(1) in Scotland and for all buildings in England and Wales and Northern Ireland, the system is suitable for use on, or at any distance from the boundary.(1) ‘house’ means a dwelling on one or more storeys either detached or forming part of a building from all other parts of which it is divided on

vertically.

7.5 For flats and maisonettes and non-domestic buildings in Scotland, the system is suitable only for use more than 1 m from the boundary.

7.6 The system is not classified as ‘non-combustible’ therefore, calculations for unprotected areas may apply dependant on the fire resistance characteristics of the wall.

7.7 For application to second storey walls and above, it is recommended that the designer includes at least one stainless steel fixing per square metre and fire barriers in line with compartment walls and floors as advised in BRE Report 135 : 2013

7.8 To limit the risk of fire spread between floors in buildings subject to the national Building Regulations, fire barriers should be incorporated behind the cladding as required under these Regulations, but should not block essential ventilation pathways (see Figure 3). Care should be taken in the detailing of the system over fire barriers to prevent melting of the insulation board during a fire. Guidance on fire barriers can be found in BRE Report 135 : 2013.

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Figure 3 Cavity/Fire barriers

Wonderwall 1 clay brick slip cladding system

9 mm cement particle board

timber batten

weep holes at 900 mm centres

fire-resistant filler with external intumescent seal

cavity barrier

movement gap

substrate wall

8 Proximity of flues and appliancesWhen the system is installed in close proximity to certain flue pipes the relevant provisions of the national Building Regulations should be met:England and Wales — Approved Document JScotland — Mandatory Standard 3.19, clause 3.19.4(1)(2)

Northern Ireland — Technical Booklet L.(1) Technical Handbook (Domestic).(2) Technical Handbook (Non-Domestic).

9 Thermal properties9.1 Wonderwall 1 can provide additional thermal resistance to an external wall with extra insulation required to achieve the level of thermal performance required by the regulations. The U value calculations for specific constructions should be carried out in accordance with BS EN ISO 6946 : 2007 and BRE Report 443 : 2006.

9.2 The U value of a completed wall will depend on the selected insulation thickness, the number, type and method of fixing the insulating value of the substrate wall and its internal finish. The phenolic foam insulation has a declared thermal conductivity ( 90/90 value) of 0.020 W∙m–2∙K–1 for the 50 mm thick board and 0.021 W∙m–2∙K–1 for the 25 mm thick board.

9.3 When used in conjunction with timber or steel framed substrate walls, the effect of the vented cavity needs to be considered in accordance with Section 5.3 of BS EN ISO 6946 : 2007.

9.4 Junctions with other elements and opening in external walls should be designed to limit heat loss. Guidance on limiting heat loss at junctions can be found in:England and Wales — Approved Documents to Part L and, for new thermal elements to existing buildings, Accredited Construction Details (version 1.0) (for new-build, see also SAP 2009, Appendix K, and the iSBEM User Manual)Scotland — Accredited Construction Details (Scotland)Northern Ireland — Accredited Construction Details (version 1.0).

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9.5 In conjunction with a substrate wall providing the required airtightness (see section 10), the cladding system can contribute to the requirement for limiting heat loss through the building fabric and achieving the Target Emission Rate.

10 Condensation risk10.1 Provided the system is properly installed, the risk of surface and interstitial condensation under normal domestic use will be minimal. Any condensate that may occur will dissipate during the summer months.

10.2 Dynamic simulations to BS EN 15026: 2007 indicate that the cladding system is acceptable when installed creating a watertight masonry wall. The simulations were done for a particular location, orientation and vapour resistance of the masonry substrate. The suitability of other constructions/parameters may be assessed by using an appropriate dynamic modelling package.

10.3 When used in conjunction with timber or steel framed substrate walls, Wonderwall 1 cladding system will adequately limit the risk of interstitial condensation when the construction is designed and built in accordance with Annex G.4 of BS 5250 : 2011 and this Certificate. It is essential to maintain a drained and vented cavity behind the system and an internal vapour control layer on the warm side of the construction.

10.4 It is essential that walls incorporating the cladding system are rain resistant and show no sign of water ingress. Careful attention has to be paid to joints and junctions in and between components and elements.

10.5 The risk of interstitial condensation in the external walling is greatest when the building is drying out after construction. Guidance on preventing condensation is given in BRE Digest 369 and BRE Report 262 : 2002.

11 Weathertightness 11.1 The system resists the passage of moisture from the ground and from weather. Any water collecting in the cavity due to rain or condensation will be removed by drainage and ventilation.

11.2 The system is classified as Type 4, in accordance with BS 8104 : 1992, and suitable for use in areas subject to severe wind driven rain.

11.3 The system is classified as being F2 for resistance to freeze thaw, in accordance with DD CEN/TS 772-22 : 2006, and is therefore suitable for conditions of severe exposure.

11.4 When clad to timber- or steel-frame constructions, there must be a minimum 20 mm cavity provided. The cavity must be drained and ventilated, incorporating perpend weep vents at 1.5 m centres, as defined in BS EN ISO 6946 : 2007. Ventilation and drainage openings should be suitably protected, or baffled, to prevent the ingress of birds, vermin and rain.

11.5 At the top of walls, the system should be protected by an adequate overhang or other detail designed for use with this type of system (see section 16.9).

11.6 Designers and installers should take particular care in detailing around openings, penetrations and movement joints to minimise the risk of rain ingress.

11.7 A dpc must be provided through the thickness of Wonderwall 1. In new constructions, the substructure dpc should be carried through, and on existing building, an appropriate dpc is fitted adjoining the building’s existing dpc.

11.8 The fixing of external fittings, eg rainwater goods, satellite dishes, clothes lines, hanging baskets and similar items are outside the scope of this Certificate. However, support fixings must pass through the cladding into the substrate wall so as not to exert any loadings on the cladding. Care must be taken not to overtighten the fixings which could cause damage. Guidance must be sought from the Certificate holder.

12 Maintenance12.1 Regular maintenance inspections should be carried out to ensure that the ingress of water does not occur. Necessary repairs must be effected immediately. Annual inspections should be carried out to ensure the condition of sealants is satisfactory. Sealant should be reapplied where necessary. Damaged brick slips should

be replaced in accordance with Certificate holder’s installation instructions.

12.2 The brick finish may become soiled over time. For normal soiling, the surface may be cleaned using a hot water/household detergent mix, applied with a suitable cleaning pad or sponge. For more difficult chemical soiling, the advice of the Certificate holder should be sought.

13 DurabilityThe durability and service life of the panels will depend upon the building location and height, façade aspect, intended use of the building and the immediate environmental conditions to which it is exposed. Providing regular maintenance is carried out as described in section 12 and in accordance with the Certificate holder’s

instructions, the system should have an ultimate service life of over 25 years.

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Installation

14 Approved installersApplication of the system, within the context of this Certificate, is carried out by approved installers recommended or recognised by the Certificate holder. Such an installer is a company:• employing operatives who have been trained and approved by the Certificate holder to install the system• which has undertaken to comply with the Certificate holder’s application procedure, containing the requirement for

each application team to include at least one member operative trained by the Certificate holder• subject to at least one inspection per annum by the Certificate holder to ensure suitable site practices are being

employed. This may include unannounced site inspections.

15 General15.1 The Wonderwall 1 Clay Brick Slip Cladding System must be installed by approved installers, in accordance with the Certificate holder’s recommendations, the requirements of this Certificate and the specification laid down by the consulting engineer.

15.2 Backerboard panels can be handled on site and can be cut or trimmed using a sharp knife or fine-toothed saw. Reasonable precautions must be taken to ensure panels are not damaged during and subsequent to installation.

15.3 The panels must not be installed on wet walls, or in temperatures below 5°C. Pointing should take place not more than 72 hours after the installation of the backerboards and not at temperatures below 2°C or above 30°C.

15.4 The profiled carrier sheet surface of the backerboard and brick slip surface must be clean and dry before application of the adhesive. Any dirt/ debris or damp on the surface must be brushed away and the surface wiped with a clean dry cloth.

15.5 When fixed to a framed substrate (see Figure 4), a suitable breather membrane must be applied to the substrate wall sheathing board.

15.6 Horizontal movement joints in accordance with BS EN 13914-1 : 2005 must be provided at every floor to accommodate vertical shrinkage of up to 6 mm in the timber frame and to follow movement joints in the substructure. For steel-frame structures, reference to the Structural Engineer’s details for deflection at floor level and movement joints in the substructure should be made.

15.7 Vertical movement joints in accordance with BS EN 13914-1 : 2005 should be provided at a maximum of 15 m intervals. The actual spacing and position of the joints should coincide with movement joints in the structure and allow for the same degree of movement (see Figure 4). The Certificate holder’s advice should be sought on movement joints.

16 Procedure16.1 Typical installation details of the systems are given in Figure 4.

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Figure 4 Typical installation details

masonry wall (cross section)

1

2

3

4

18

6

6

Key1 Brick slip2 Pointing mortar3 Brickslip adhesive4 Backerboard5 breather membrane

11 Steel frame wall12 Timber frame wall13 Timber batten14 5 mm 10 mm external mastic seal15 Compressible joint filler

�

6 Masonry wall7 Minimum 9 mm cement particleboard sheathing8 Minimum 20 mm drained and vented cavity9 Minimum 75 mm x 20 mm steel rail creating cavity

10 Additional insulation by others

16 dpc17 sheathing board18 breather membrane

(used with aerated blocks only)

1

2

3

4

7

9

10

5

metal frame (cross section)

11

timber frame (cross section)

1

2

3

4

12

5

13

12

16

17

7

vertical movement joint (plan view)

15 14 135 16 17

masonry wall with additional insulation (plan view)

6

10

4

1

13

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Figure 4 Typical installation details (continued)

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Figure 4 Typical installation details (continued)

Key1 Window frame2 Wonderwall 1 adhesive bead3 Backerboard4 Brickslip

5 Compressible sealing tape7 Movement gap8 External mastic seal9 VCL

4 3 2

5 1

7 8

jamb detail timber frame(plan view)

�

6

Backerboard

16.2 The starter rail is horizontally aligned with a spirit level and fixed to the base of the substrate wall or vertical steel rails/ timber battens. The backerboard panel is positioned against the starter rail and fixing positions marked as stipulated in section 6.6 (see Figure 2).

16.3 The panel is fixed to the masonry substrate with mechanical fixings. For timber/steel frame substrate walls, the panels are fixed through vertical timber/ steel rails at maximum 600 mm centres. Care must be taken to ensure the fixing holes are drilled perpendicular to the surface of the panel.

16.4 Prior to the next panel being installed, a 5 mm adhesive bead is applied along the full height of the vertical edge.

Brick slips

16.5 The brick slip adhesive is applied between the ribs of the carrier sheet in accordance with the Certificate holder’s instructions. A single continuous 10 mm diameter bead is applied between the carrier sheet ribs approximately two-thirds towards the top. Care must be taken to ensure that the drainage channels located within the ribs of the carrier sheet are not obstructed by ending and starting the line of adhesive bead at the corresponding gaps.

16.6 The clay brick slips are placed on horizontal bed joint ribs of the carrier sheet and must be placed within 10 minutes of the adhesive being applied. The ribs are 75 mm centres and the brick slips sit directly on top of the flat face and must be pressed firmly against the carrier. Alignment should be checked as work proceeds ensuring a typical 10 mm joint between adjacent brick slips is maintained.

16.7 Joints are filled with cement based pointing grout/ mortar mix to class 12, 6 or 4 in accordance with BS EN 998-2 : 2010. Pointing should not take place at temperatures below 2°C and above 30°C. When pointing is completed, tooling of the mortar joints is done to the desired effect and all the excess mortar is brushed off with a soft brush.

Finishing16.8 All window and door openings are sealed strictly in accordance with the Certificate holder’s installation instructions to ensure that they are weathertight.

16.9 At the top of walls, the system must be protected by an adequate overhang or by an adequately sealed, purpose-made flashing.

16.10 Care must be taken in the detailing of the system around openings and projections to ensure adequate protection against water ingress and to limit the risk of water penetrating the system.

16.11 All movement joints are sealed using mastic sealant after brick application.

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Technical Investigations

17 InvestigationsAn investigation was made of data relating to:• strength and stability• fire resistance• reaction to fire• resistance to weathering• freeze/ thaw resistance • thermal properties• condensation risk• durability.

BibliographyBRE Digest 369 Interstitial condensation and fabric degradationBRE Report 135 : 2013 Fire Performance of External Insulation for Walls of Multi-storey BuildingsBRE Report 262 : 2002 Thermal insulation: avoiding risksBRE Report 443 : 2006 Conventions for U-value calculations,BS 5250 : 2011 Code of practice for control of condensation in buildingsBS 6213 : 2000 Guide to selection of constructional sealantsBS 8000-3 : 2001 Workmanship on building sites — Code of practice for masonryBS 8104 : 1992 Code of practice for assessing exposure of walls to wind-driven rainBS EN 351-1 : 2007 Durability of wood and wood-based products — Preservative-treated solid wood — Classification of preservative penetration and retentionBS EN 771-1 : 2011 Specification for masonry units — Clay masonry unitsBS EN 998-2 : 2010 Specification for mortar for masonry — Masonry mortarBS EN 1991-1-4 : 2005 Eurocode 1 : Actions on structures — General actions — Wind actionsBS EN 1993-1-1 : 2005 Eurocode 3 : Design of steel structures — General rules and rules for buildingsBS EN 1993-1-3 : 2006 UK National Annex to Eurocode 3 : Design of steel structures — General rules — Supplementary rules for cold-formed members and sheetingBS EN 1995-1-1 : 2004 Eurocode 5 : Design of timber structures — General — Common rules and rules for buildingsBS EN 1996-1-1 : 2005 Eurocode 6 : Design of masonry structures — General rules for reinforced and unreinforced masonry structuresBS EN 1996-1-2 : 2005 Eurocode 6 : Design of masonry structures — General rules — Structural fire designBS EN 1996-2 : 2006 Eurocode 6 : Design of masonry structures — Design considerations, selection of materials and execution of masonryBS EN 1996-3 : 2006 Eurocode 6 : Design of masonry structures : Simplified calculation methods for unreinforced masonry structuresBS EN 13166 : 2012 Thermal insulation products for buildings — Factory made phenolic foam (PF) products – SpecificationBS EN 13501 : 2007 + A1 : 2009 Fire classification of construction products and building elements — Classification using data from reaction to fire testsBS EN 13914-1 : 2005 Design, preparation and application of external rendering and internal plastering — External renderingBS EN 15026 : 2007 Hygrothermal performance of building components and building elements — Assessment of moisture transfer by numerical simulationBS EN ISO 6946 : 2007 Building components and building elements — Thermal resistance and thermal transmittance — Calculation methodBS EN ISO 11600 : 2003+ A1 : 2011 Building construction — Jointing products — Classification and requirements for sealantsDD CEN/TS 772-22 : 2006 Methods of test for masonry units — Determination of freeze/thaw resistance of clay masonry unitsETAG 004 : 2000 Guideline for European Technical Approval of External Thermal Insulation Composite Systems with RenderingETAG 014 : 2002 Guideline for European Technical Approval of Plastic Anchors For Fixing Of External Thermal Insulation Composite Systems With Rendering

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MOAT No 43 : 1987 UEAtc Directives for Impact Testing Opaque Vertical Building ComponentsPD 6697 : 2010 Recommendations for the design of masonry structures to BS EN 1996-1-1 and BS EN 1996-2

Conditions of Certification

18 Conditions18.1 This Certificate:• relates only to the product/system that is named and described on the front page• is issued only to the company, firm, organisation or person named on the front page — no other company, firm,

organisation or person may hold or claim that this Certificate has been issued to them• is valid only within the UK• has to be read, considered and used as a whole document — it may be misleading and will be incomplete to be

selective• is copyright of the BBA• is subject to English Law.

18.2 Publications, documents, specifications, legislation, regulations, standards and the like referenced in this Certificate are those that were current and/or deemed relevant by the BBA at the date of issue or reissue of this Certificate.

18.3 This Certificate will remain valid for an unlimited period provided that the product/system and its manufacture and/or fabrication, including all related and relevant parts and processes thereof:• are maintained at or above the levels which have been assessed and found to be satisfactory by the BBA• continue to be checked as and when deemed appropriate by the BBA under arrangements that it will determine• are reviewed by the BBA as and when it considers appropriate.

18.4 The BBA has used due skill, care and diligence in preparing this Certificate, but no warranty is provided.

18.5 In issuing this Certificate, the BBA is not responsible and is excluded from any liability to any company, firm, organisation or person, for any matters arising directly or indirectly from:• the presence or absence of any patent, intellectual property or similar rights subsisting in the product/system or any

other product/system• the right of the Certificate holder to manufacture, supply, install, maintain or market the product/system• actual installations of the product/system, including their nature, design, methods, performance, workmanship and

maintenance• any works and constructions in which the product/system is installed, including their nature, design, methods,

performance, workmanship and maintenance• any loss or damage, including personal injury, howsoever caused by the product/system, including its manufacture,

supply, installation, use, maintenance and removal• any claims by the manufacturer relating to CE marking.

18.6 Any information relating to the manufacture, supply, installation, use, maintenance and removal of this product/system which is contained or referred to in this Certificate is the minimum required to be met when the product/system is manufactured, supplied, installed, used, maintained and removed. It does not purport in any way to restate the requirements of the Health and Safety at Work etc. Act 1974, or of any other statutory, common law or other duty which may exist at the date of issue or reissue of this Certificate; nor is conformity with such information to be taken as satisfying the requirements of the 1974 Act or of any statutory, common law or other duty of care.

British Board of Agrément tel: 01923 665300Bucknalls Lane fax: 01923 665301Watford e-mail: [email protected] WD25 9BA website: www.bbacerts.co.uk©2014