Head Office 2/89 Somerset Road

Campbellfield Vic, 3061 T. 03 9359 2336 F. 03 359 9306

E-mail. info@ezylite.com.au www.ezylite.com.au

Installation Manual

Page 01 Contents

Page 02 Introduction Applications

Page 03 Material Properties Thermal properties Acoustic Properties

Page 04 Installation Details Roof to wall Details Eave Details Battening Walls

Page 065 Parapet Details Wall Details Slab Details

Page 06 Balcony Detail Sub Floor Detail

Page 07 Fixing Table

Page 08 Expansion Joints

Page 9 Installation Steps Page 10 Coating System

Page 11 Page 12 Warranty

Contents

Safety Wear

Cutting Tools

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Ezylite Astrix inorganic panel with characteristics of 100% Asbestos free, non-toxic, odourless, non-combustibility, corrosion resistance, acid-base resistance, insulation, sound and thermal insulation and honeycomb interior structure. Astrix panel is truly a lightweight wall cladding designed for all fire and acoustic rating needs, a 50mm Astrix panel achieved FRL 120/120/120, in accordance with AS/1530. 4 2005 and Non - Combustible AS/1530, 1. Astrix panels are designed with Tong $ Groove (T&G) joining system placed on the long ends for easy installation, a team of two installers can install between 200- 600 SQM per day without the use of heavy lifting machines or special cutting tools. The weight of a 600 x 2100 x 50mm Astrix Panel is approximately 18 kg per panel, which is under the lifting limits endorsed by work safe Vic. Efficiency - Sufficient, predictable strength, durability and stability - Resists moisture, decay and bio-contamination - Non-toxic and non-hazardous to occupants and installers - Able to be installed efficiently and effectively, does not negatively impact on the eco systems and none of components are harvested or mined. - All components are reclaimed or recycled materials from other industries. - Does not require damaging maintenance, operations or disposal practices

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Introduction

Applications All fire rated wall applications Highly recommended for acoustic wall applications. Widely applied in thermal insulation of building wall and roof; Lightweight aggregate of building material; Thermal insulation layer of kinds of industrial equipment and pipelines;

Detail 1: Tong & Groove

Important Note: This Manual is designed to ensure our product is installed correctly to serve

the purpose of protection against fire, Installers MUST follow all data provided in order to

obtain certification on completion. NO certificate will be issued if installation do not meet our

standards.

90 x 45 MGP10 Pine frame

Figure 3: Typical Wall Setup

Approved Fasteners 12-14g x 100

mm fixed @ 300 Centres

Thermal Properties. Astrix Panel tested in accordance with AS/NZS 4859.1 2005, provide a value of R-3.0 in a system combining Astrix Panel with R-2.2 fibreglass batts, making it excellent thermal efficiency with huge savings on energy bills. By increasing cavity and R value on fibreglass batts the efficiency will increase significantly. Acoustic Properties

Acoustic testing achieved Rw 63+ Ctr 51, with R-2.2 Fibreglass batts on timber frame lined with 10 mm Plaster board and 50 mm Astrix Panel.

Test Results to AS/1530,1, 2. 3, & 4

Test Results

Spread of Flame 0

Ignitability 0

Smoke developed 0

Toxic odours 0

Benefits

Lightweight Fire Rated Acoustic Rated Water Resistant (Not Waterproof) Anti Mould Termite Resistant High Impact Resistance Environmental Friendly Thermal Resistant Easy to cut and install Non contents of any hazardous

materials

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Material Properties

R-2.2 fibreglass insulation

between studs

Detail 1 Acoustic Level

Astrix Panel Lined horizontally

Breathable sarking

10 mm plasterboard Internal wall

lining for non exposed face

38 x 16mm steel batten fixed

vertically onto timber or steel

frame

Steel Battens

Astrix panels can be installed directly to frame or on Metal/timber

battens, we Highly recommend the use of battens.

Detail 2 Wall section

Detail 4: Roof to Wall

Astrix Panel under

eave lining

Typical Timber/steel

Frame

Standard timber/ steel Frame

Roof & Eave Details

Detail 6: Astrix on Battens

Steel/Timber battens

Astrix Panel

Roof flashing

Render finish

Roof to Wall Detail

Approved fasteners

Astrix Panel

P-04

Astrix Panel

Eave Detail

Extend Astrix Panel

above eave

Astrix Panel

Detail 5: Option 2

Detail 3 Eave Option 1

External Corner Details

Astrix Panel Note: Installing Ezylite Astrix panels directly on timber/steel battens, we strongly recommend the use of steel battens which are fixed vertically on each stud spaced 450 centres. Fix breathable sarking on stud behind battens and R - 2.5 fibreglass wall batts between studs.

Breathable sarking

Direct Fix or Battens

Fire rated sealants between joints

Parapet Installation

Astrix Panel

Metal Capping

Internal Wall lining

Allow 30mm above roof line

Metal Flashing

Angle Flashing

Concrete Slab

Timber Frame

Detail 8: Astrix To Brick

Detail 9: Astrix To Concrete Slab

Flashing

Breathable sarking

Brick Wall

Roofing

Typical timber frame

Steel Battens

25mm

P-05

Note: Astrix panels must NOT be buried into ground or concreted, keep

panels Min 50mm above natural ground level

Detail 7: Wall to Roof

50mm

50mm

P-06

Astrix panels

Timber or Steel frame

Angle flashing fixed over

Astrix panels to provide

protection from water flow

One row of tiles to wall over

flashing min 300mm high

Balustrade

Floor tiles optional

Detail 10: Astrix To Balcony

Fix angle flashing over Astrix panels then one row of tiles to wall min 300 mm high to ensure Astrix panels are not submerged in water, balcony floor must flow away from wall.

Water flow

Astrix panels

Timber or steel frame

Angle flashing fixed to frame

Ground level

Detail 11: Astrix To Sub Floor

Keep water flow away from walls

Seal underside of panels where

water may come in contact

NOTE: DO NOT render on dusty surface, remove all dust and loose particles before any rendering or painting

Timber or steel frame 450 centres spacing

2100 L x 600 W @ 50 mm thick

External/Internal wall cladding

12-14g x 75 mm bugle C3 spaced @ 300

Fire rated sealants on all joints

Timber or steel frame with battens 38 x 16 steel battens fixed vertically on each stud

2100 L x 600 W @ 50 mm thick

External/Internal wall cladding

12-14g x 100 mm bugle C3 spaced @ 300 centres

Fire rated sealants on all joints

NOTE: All Timber or Steel Frame Must Be Lined With Breathable Sarking Wrap

Frame Type Panel Size Use Fasteners Adhesive

Fixing Table

16 mm Min

Fixing Astrix Panel into timber frame, allow Min 25 mm penetration.

14g x 100 mm Galvanized Bugle Screw

@300 mm Centres max

Timber Frame

50mm Astrix

Panel

P-07

Screws Fixing must be countersunk Max 1 mm

Detail 13: Fixing of Fasteners

Note. All installers to follow installation manual to avoid warrantee conditions, all fixings must be spaced min 300 centres apart, only use approved fire rated sealants and expansion joints min 5.0 to max 6.0 meters apart.

Special Note: Ezylite P/L will not provide certifications or warrantee on any wall cladding that are not

installed, rendered or painted in accordance with current installation manual.

Detail 12: Safety wear

Control joints must be installed to allow for structural movement. Allowance for movement must be made through the frame, Control joints must be installed at all construction joints in the building and at the following locations: Expansion joints should be placed over windows, doorways, and no more than 5 min and Max 6.00 meters apart. Horizontal expansion joints should be placed between levels to allow movements and shrinkage of floors. The details below are location of expansion joints on walls with windows and doorways.

Expansion Joints

Place Sealant as shown in diagram below & compress the panels to achieve best result

Fire Rated Sealant

Astrix Panel

P-08

Backing Rod

Timber Frame

Vertical Expansion Joint

Astrix Panel

Door Expansion Joint

Horizontal Expansion

Joint

NOTE: Install and render to rough side of panel only

NOTE: Install and render to rough side of panel only

Detail 14: Expansion Joints

Vertical Expansion Joint

Step 1 Ensure frame is level and free from any bows then place breathable sarking over all walls then fix steel battens vertically on each stud

Step 3 Ensure first row is level then continue installation, place fire rated sealants between all vertical joints.

AstrixTM Panel

Internal wall

lining

Timber frame

Breathable wall wrap

Astrix Panel

Approved fasteners Refer to Fixing Table

Timber frame

Step 2 Start from bottom, fix Astrix panel onto steel battens using 14g x 100 Bugle screws spaced @ 300 centres.

Step 4

Place expansion joints on

windows or door openings

(see expansion joint details)

Approved Fire Rated sealant Fire Rated Sealant between joints

38 x 16mm steel battens

Handsaw

Fire Rated Sealant

between all vertical & horizontal joints

40 mm

40

mm

Installation Steps

Timber or steel frame

Use Spirit Level for first

row panels installed

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P-10

38 x 25 steel battens fixed vertically on each stud

Fix 14g x 100 Bugle screws @ 300 centres

38 x 16mm steel battens fixed vertically

Detail 15: Direct Fix or Battens

Detail 16: Installation on Battens

Coating System

1.1 Rendering (Ezylite Panels Must be coated after installation)

It is the renderer’s responsibility to use the appropriate compounds in the coating system sufficient to eliminate cracking of the joints under normal building settlement conditions. We recommend the use of Haymes, Quickcote or Dulux, other brands have not been used or tested on Ezylite products, and therefore we do not recommend the use of other brands. 1. Trowel on Patch approx 1 mm thick over joints then place 100mm wide alkaline-resistant

5mm weave fibre-glass mesh 160g/m2) over wet rendering. Apply aluminium angle beads to all external corners including window and door openings. Apply a 2nd layer of patch over fibreglass mesh while patch is still wet. (Allow drying time Min 24 hrs) refer to manufacturers specifications for drying periods.

2. Render entire board surface with polymer modified acrylic render Quickcote flexi patch/ Quickcote wet patch, or similar, at a minimum of 2mm thick.

3. The mesh is to be trowelled into the surface of the wet render, positioned just below the surface. Under no circumstances should the mesh be fixed to the walls and render applied over it. Overlap all fibreglass mesh sheets a minimum of 50mm.

4. Ensure the entire surface is level (taking into account the joint). Make sure that the joint is not proud of the remaining surface. Apply a second coat if the outline of the joint and fixings is not eliminated.

5. Apply trowel-on texture/colour to entire surface, Please note: all coatings must be applied and maintained in accordance with the coating manufacturer's instructions.

6. 7. Apply by roller (or mix in with colour when trowelling) sealer to entire wall. The sealer

protects the colour fading and waterproofing of wall.

NOTE: Install and render to rough side of panel only

Flexi wet patch

Base coat

Fiberglass mesh

Ezylite Astrix Panel

Color coat & Sealer

Detail 17: Render System

NOTE: DO NOT render on dusty surface, remove all dust and loose particles before any rendering or painting

Flexi wet patch

Warning: Ezylite P/L will not provide certifications or warrantee on any wall cladding that are

not installed, rendered or painted in accordance with current installation manual.

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P-11

When cutting Astrix Panel ensure to wear safety glasses, dust mask and ear muffs, Astrix Panel Has been tested for Asbestos, Celica, and formaldehyde, with NO traced found. Refer to Material Safety Data Sheet (MSDS) for a full test result prepared by AWTA Testing Laboratory.

Dust Mask Ear Muffs Safety Glasses

Safety Wear

Power Saw

Cutting Ezylite Astrix panels can be achieved using a hand saw or power saw with standard tungsten tip blade, ensure to wear proper safety mask, goggles and safety glasses.

Cutting Tools

Hand Saw

Warning: Ezylite P/L will not provide certifications or warrantee on any wall cladding that are

not installed, rendered or painted in accordance with current installation manual.

Detail 18: Safety Wear

Detail 19: Cutting Tools

Warranty: EzyLite Pty Ltd warrants for a period of two (15) years ("the warranty period") from the date of purchase that all EzyLite products ("the product") will be free from defects due to faulty manufacture or materials, and will be resistant to cracking, rotting, fire and damage to the extent set out in EzyLite Pty Ltd published literature current at the time of installation, and strictly subject to the conditions set out below. (NOTE: RENDER MUST BE APPLIED AS SHOWN) The Warranty is strictly subject to the following conditions:- 1. The product, and any other products including fasteners and joining systems, applied to or used in conjunction with the product must be used and installed strictly in accordance with the approved installation manual at the time of installation. 2. Under no circumstances will EzyLite Pty Ltd be liable for defects arising from:- (a) A failure to use and/or install the product, or any products, strictly in accordance with the product installation manual. (b) Render coating system not recommended or applied to EzyLite Panels, Render system must be applied as stated in coating system. (c) Defective materials not supplied by EzyLite Pty Ltd ; or (d) Impact. 3. EzyLite Pty Ltd will not be liable for breach of Warranty, and no breach of Warranty claim will be accepted, unless the Claimant makes a written claim and provides proof of purchase within 30 days of the alleged defect becoming apparent. 4. This Warranty is not transferable under any circumstances without the prior written consent of EzyLite Pty Ltd. 5. A Claimant's sole remedy for breach of Warranty is (at EzyLite Pty Ltd option) that EzyLite Pty Ltd will either replace or repair the defect, supply replacement product, or pay for the cost of replacement or rectification of the affected product. 6. Under no circumstances shall EzyLite Pty Ltd be liable for any consequential loss, property damage or personal injury, economic loss or loss of profits, arising in Contract or negligence or howsoever arising. Without limiting the foregoing, EzyLite Pty Ltd will not be liable for any claims, damages or defects arising from or in any way attributable to poor or defective workmanship, defective materials or poor design or detailing, settlement or structural movement and/or movement or materials to which the product is attached, incorrect design of the structure, acts of God including but not limited to earthquakes, cyclones, floods or other severe weather conditions or unusual climatic conditions, normal wear and tear, or growth of any organism on any product surface. 7. The express warranties set out above are in lieu of all other representations, warranties or conditions, express or implied including but not limited to implied warranties or conditions of merchantable quality and fitness for a particular purpose, and those arising by statute or otherwise in law or from a course of dealing or use of trade and which are excluded to the fullest extent permitted by law. The joint and coating system must be applied by experienced applicators, as suggested by the joint and coating manufacturer. Any sand based rendering systems must use ionised sand bases. The selected joint and coating system must be applied to dry, clean sheet only. Application must be completed within 30 days of the sheets being fixed on site. It is the applicator's responsibility to use the appropriate compounds in the coating system sufficient to eliminate cracking of the joints under normal building settlement conditions.

P-12