Design Guide

Residential Walls

Designing for Future Living

HBL740-RWS Sept 2003

Contents
1.0 Introduction 3
2.0 Benefits of the Residential Wall System 4
3.0 Design 6
3.1 Component Inventory – screws, tophats, panels, tools 6
3.2 Residential Wall Systems Design Guidelines 9
3.3 100RWS Design Guidelines 11
3.4 Building Setout 15
3.5 Footings 17
3.6 Control Joints 17
3.7 Fire Rated Construction 18
3.8 Windows 18
3.9 Two-Storey Construction 18
3.10 Attached Garages 19
3.11 RWS Retrofit 19
3.12 Design and Detailing for Termite Resistance 19
4.0 Construction 20
4.1 Installation – 75RWS panels 20
4.2 Installation – 100RWS panels 22
4.3 Bracing of the Building 23
4.4 Installation of Services 24
4.5 75RWS panels Checklist 25
4.5.1 Checklist – Designer 25
4.5.2 Checklist –Builder 26
4.5.3 Checklist –Installer 27
4.5.4 Checklist –Inspector/Supervisor 28
4.6 Retrofit Construction 29
5.0 Construction Details 31
5.1 75RWS panels 31
5.2 100RWS panels 42
5.3 Two-Storey Construction 50
5.4 Two-Storey Additions 55
5.5 Retrofit Details 59
6.0 Estimating 63
6.1 Estimating Process 63
6.2 Worked Example 66
7.0 Coatings 67
7.1 Introduction 67
7.2 Wall Preparation 67
7.3 Sealing 67
7.4 Meshing Panel Joints 68
7.5 Recommended Systems 68
8.0 Fixings 69

9.0 Handling & Installation 70

Guidelines 9.1 Introduction 70
9.2 Panel Delivery 70
9.3 Layout 70
9.4 Layout Drawings 70
9.5 Site Preparation 70
9.6 Lifting 70
9.7 Bracing 70
9.8 Fixings 70
Appendix A: Sample Panel Installation Specification 72
Appendix B: Sample Coating Specification 74
Appendix C: Testing and Appraisals 75
Acoustic Opinion for External Walls, PKA Consulting, August 1998 75
Certificate of Test: No. 555 76
Certificate of Test: No. 595 77
Notes 78

CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS 2

1.0 Introduction
CSR™ Hebel®
CSR™ Hebel is 100% owned by
® and from other rooms within the home.
CSR™ Building Products Limited, one
of Australia’s leading building products
companies. CSR™ Hebel® manufactures
and markets a range of lightweight
Autoclaved Aerated Concrete (AAC)
blocks, reinforced panels, cladding and
lintels for use in the housing and
commercial construction industry.
CSR™ Hebel® also sells complimentary
mortars, tools and accessories.
In 1989, CSR™ became involved with
Hebel® and established the Australian
operation. Since then, CSR™ Hebel®
has won wide acceptance as an
innovative and environmentally friendly
building material due to its speed of
construction, excellent thermal/fire/acoustic
properties and its design versatility.
Design Overview
As environmental consciousness and
social responsibility increases, CSR Hebel
is striving to exceed these ideals and set
new standards in building materials and
residential living.
Designed for inner comfort
With CSR Hebel wall and floor solutions,
clients can enjoy a comfortable interior
in their home, and be comfortable with
their choice for the environment.
Manufacture of CSR Hebel materials
uses a small fraction of the energy and
natural resources used in manufacturing
conventional masonry, producing almost
no waste or by-products. And Hebel’s
highly efficient insulation saves power
in heating or cooling the home.
Designed for inner peace
CSR Hebel wall and floor solutions
help you create a tranquil inner space.
We have worked closely with acoustic
experts and testing authorities to
engineer inherently superior acoustics
from our wall and floor systems.They
create a sound barrier to external noise
Designed for peace of mind
Although it’s remarkably lightweight,
CSR Hebel is solid and durable.
CSR Hebel panels are reinforced with
steel for extra strength. CSR Hebel is also
extremely fire-resistant and immune to
termite attack.
Designed to save
As they’re lightweight, CSR Hebel
materials are quick to assemble, saving
building time and costs. They also minimise
the need for supporting materials, saving
budget resources and energy.
Use CSR Hebel for Better
Framed Construction
■ Using CSR Hebel wall panels for your
framed construction provides you with
cost savings and greater floor space for
the same building dimensions.
■ CSR Hebel panels are faster to install
than bricks, saving on building costs.
■ CSR Hebel products are lightweight,
reducing the structural load on the
frame and its design requirements
for supporting building materials.
■ Their low weight makes CSR Hebel
panels ideal for use in difficult
applications such as sloping sites.
■ An external wall of CSR Hebel panels
is steel-reinforced, solid and secure.
■ CSR Hebel panels have better thermal
efficiency than brick veneer or even
double brick walls, resulting in
reduced heating and cooling costs.
Further thermal efficiency may be
achieved by adding insulation to the
frame cavity.
■ CSR Hebel is fire-resistant, with
a fire rating of at least three hours.
3 CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS
■ CSR Hebel walls and floors provide
better acoustic insulation to brick,
whilst taking less space.
CSR Hebel systems for
Framed Construction
Residential Wall System
The CSR Hebel Residential Wall System
(RWS) is designed for homes built using
either timber or steel framing and can
be used in new dwelling construction,
extensions or re-cladding.
The system consists of 75mm thick,
steel-reinforced CSR Hebel RWS panels,
fixed vertically to horizontal battens
attached to the load-bearing frame. For
quick, clean construction, RWS panels
come in lengths of 2,400mm, 2,700mm
or 3,000mm and widths of 300mm
or 600mm.
Retrofit – an exciting
opportunity
The RWS system is excellent for
the retrofit or recladding of homes
that are clad in ‘fibro’, FC sheeting or
weatherboard. It can be externally face
fixed and site cut to suit most houses.
The RWS system will provide a solid,
thermally efficient wall to the dwelling
with minimal footing modifications,
at a significant cost saving to using
traditional brickwork with additional
strip footings.
75RWS panels as
delivered to site
Metal
strapping
Guidelines
Handling
Support pallet
Plastic shrink
wrap cover
Handling
Guidelines
2.0 Benefits of the Residential Wall System
Speed
■ With the CSR Hebel Residential Wall System
(RWS), your home will reach lock-up stage sooner.
The installation of CSR Hebel RWS panels is very
fast, especially on purpose-designed houses.
■ Any competent tradesperson can easily install RWS.
Two people can install up to 100m2 of external wall
in about three days.
■ The modular design of the dwelling minimises waste.
■ A standard panel weighs about 75kg, which two
people can position. No cranes or cement mixers
are required.

Solidity
■ CSR Hebel is a solid choice. It’s extremely
strong, and each RWS panel is steel reinforced.
■ With a fire rating of at least three hours
you can’t beat CSR Hebel.
■ CSR Hebel offers excellent protection
against vermin and does not provide
a food source termites.

Space
■ The RWS gives you great freedom in designing your
home, and you can customise the style by applying
coloured and textured coatings to the panels.
■ A thinner external wall results in greater internal
living space and design flexibility. A 55mm reduction
in external wall thickness can provide about 2% extra
internal space for the same external dimensions.

CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS 4

Lower Energy Costs
■ As with all CSR Hebel products, the RWS has excellent thermal properties. This feature results in lower heating and cooling costs
at no additional building expense.

CSR Hebel RWS Legend

CSR Hebel Timber
RWS panels beam

Concrete Steel

Relevant Documents
■ CSR Hebel Technical Manual – No.HBL 700, June 2001
■ CSR Hebel PowerpanelTM, Design Calculations, May 1995,
August 2000
■ CSR Hebel Powerwall, Design Calculations, June 1995
■ AS/NZS 1170 Series – Structural Design Actions
■ AS 1684 – 1999 Residential timber-framed construction
■ AS 1720.1 – 1997 Timber Structures Code –
Part 1: Design Methods
■ AS 2870 – 1996 Residential Slabs and Footings
■ AS 3623 – 1993 Domestic Metal Framing
■ AS 3660.1 – 2000 Termite Management – New building work
■ AS 3566 – 2002 Series – Self-drilling screws for the
building and construction industries
■ ABCB Guideline Document – Durability in Buildings: 2003
■ AS/NZS 2312: 2002 Guide to the protection of structural
steel against atmospheric corrosion by the use of
protective coatings
■ ISO 9223: 1992 – Corrosion of metals and alloys
– corrosivity of atmostpheres – classifiaction
■ AS2331 Series

5 CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS

3.0 Design
3.1 Component Inventory
Table 3.1 Screws Specification

Note: Design Capacity = (Average - 2 x Std Dev) / Safety Factor, Safety Factor = 3.0 (for pullout design capacity) and 5.0
(for shear design capacity). The pullout and shear values in the above table have been provided by the screw manufacturer
or determined by testing carried out by CSR Hebel through registered testing laboratories such as ETRS.

Photo 1 Photo 2 Photo 3 Photo 4

Durability of Components
It is the responsibility of the building designer to ensure that the components, such as screws, tophat battens,
and other steel components, have the appropriate corrosion protection to suit the required project design life.

CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS 6

Table 3.2 Tophat Specification

Typical Cross Section

Note: Batten dimensions are nominal and may vary depending on the source. Suitability of tophat alternatives to be approved
by the tophat manufacturer.
Table 3.3 Panel: Sizes & Weights

Note: Mass of 75RWS panels are based on an average product working density of 670kg/m3 (30% moisture content by
weight, average dry density of 510 kg/m3, characteristic compressive strength of 2.5MPa).
Mass of 100RWS panels are based on an average product working density of 720kg/m3 (30% moisture content
by weight, average dry density of 550kg/m3, characteristics compressive strength of 2.5MPa.

Note: BTM is the smooth face.

Bars: 4x5mmø longitudinal &
5-6 transverse bars depending
on panel length.
Tolerance: The width and
thickness of the panels are
manufactured to a tolerance
of + or - 1.5mm.
Typical Cross Section of 75RWS panel

7 CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS

 50 120 120 120 40 Note: BTM is the smooth face.
Bars: 4x5mmø longitudinal &
10 transverse bars in each face.

100 Tolerance: The width and thickness

of the panels are manufactured to a
20 tolerance of + or - 1.5mm.

450

Typical Cross Section of 100RWS panel

Table 3.4 Panel Loading Capacity

Lateral Permissible Wind Loads Note:

PERMISSIBLE • Capacities determined for permissible

wind load producing a panel deflection
of span/180;
• 75RWS panel spans between tophats;
and
• 100RWS panel spans between the top
and bottom fixing points.

Tools & Equipment

The tools required to assist in the
installation of the RWS panels that may
be purchased through CSR Hebel are:
1. Mixing Bucket
2. Stirrer
3. Notched Trowels
4. Sanding Float
5. Panel Lifters
6. Anti Corrosion Agent
Extra equipment will also be required
and includes the following:
■ Power drill (clutch driven)
■ Power saw with metal or diamond-
tipped cutting blades
■ Dust extraction system
■ Sockets for screws
■ Safety equipment such as goggles
and face mask, used when site
cutting the panels.

CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS 8

3.2 Residential
Wall System
Design Guidelines
Introduction
b) The design of the stud frame shall
This section provides the basic
information on the installation of the
Residential Wall System. The system has
been assessed by the Australian Building
c) The system is not considered as
System Appraisal Council (ABSAC) and
a summary of their technical opinion is
included in the appendices. The principles
on which the design is based include:
a) The lateral wind loads applied to the
panels are directly transferred to the
stud frame, which should be designed
in accordance with the relevant
Australian Standards for the imposed
loads. The frame should be designed
for all bracing and hold-down
requirements.
consider the weight of suspended
panels (such as the upper storey of
two-storey construction).
cavity construction, as the tophat
clearly bridges the cavity, hence the
details show the necessity of sealing
the windows and door frames, as
well as applying a water resistant
external coating.
d) The system specifications vary with
wind load. The notation used in
AS1684-1999 Residential timber
framed construction has been adopted.
e) The localised effects of wind around
corners of buildings have been
considered in the design and included
in the tables. The extent of this effect
is discussed towards the end of this
section.
The tables below set out the installation
criteria for the system, and are based
on design calculations using the material
specifications detailed in Section 3.1.
The following flow chart should be
used as a guide for the design process:

Flow Chart for Design Process

Stud capacity
and spacing

9 CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS

Table 3.5 Number of Tophats (Horizontal)

Note: 1. For the upper storey panels in two storey construction, a minimum of four tophats will be required.
2. Additional tophats will be required below all window openings and above openings if a panel or sill block is to be installed
in this location. In either case, the maximum spacing of the tophats should be maintained as set out in Table 3.6 below.

Table 3.6 Maximum Spacing of Tophats (mm)

Table 3.7 Number of Screws Per Panel for Each Tophat Location

Note: For fire rated construction a minimum of 3 screws per middle tophat is required (refer to section 3.7). Type of screw used
is the 14-10 x 65mm Hex Head Type 17 screw, fixed from inside the building, or 14-10 x 100mm MP Bugle Head Batten
screw, fixed from outside the building (as per Table 3.1).

Criteria for Corner Panels
Due to the increase of wind load
around the corners of buildings, extra
tophats and screws may be necessary
(N3 and greater) for a distance of 20%
of the wall length in each direction from
the corner.
Tables 3.5 to 3.7 identify the installation
criteria in these areas, in the columns
titled Corner Panels.
Cyclonic Loading Effects
The Residential Wall System has been
tested at the Cyclonic Loading Station
in Townsville to satisfy the requirements
of AS1170.2 – 1989 Section 2.6. The
pullout capacity of the screw into the
back of the CSR Hebel panel is the
critical element in the design. The results
from the cyclic testing showed that the
system, in particular the pullout load of

CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS 10

the screw, is unaffected by the cyclic
loading.The detailing presented in this
manual is satisfactory for cyclonic areas.
Coastal Regions
CSR Hebel RWS panels may be used
in coastal regions. It is the responsibility
of the building designer to ensure the
items specified will maintain their strength
and integrity for the project design life.
For guidance, refer to the following
documents when assessing durability:
• ABCB Guideline Document –
Durability in buildings: 2003
• AS/NZS 2312: 2002 – Guide to the
protection of structural steel against
atmospheric corrosion by the use
of protective coatings.
• ISO 9223: 1992 – Corrosion of
metals and alloys – Corrosivity of
atmospheres – Classification.
• AS3566: 2002 – Self drilling screws
for the building and construction
industries.
• AS2331 Series.
Reference to AS3566 – 1988 should
always be adhered to when selecting the
screws corrosion resistance classification.
a barrier between tophat and timber
member. Refer to screw manufacturer
for appropriate screw specification for
this application.
3.3 100RWS panel
Design Guidelines
Introduction
This section provides the basic
information on the installation of the
100RWS system. The principles on
which the design is based include:
(a) The 100mm thick panel has been
designed to resist all lateral wind
loads without the need for a stud
frame. The load reactions are
transferred to the top and bottom
supports via the fixings detailed in
the table below.
(b) The walling system has been
designed for use in N2 and N3
non-cyclonic wind regions. It is
recommended that the 75RWS
system be used in the higher
wind regions.
(c) The vertical dead and live loads
on the roof are taken by piers which
support a perimeter beam on which
all the roof framing/trusses bear. The
uplift forces are taken by the wall
system itself for N2 regions and by
steel SHS posts for the N3 regions.
(d) The localised effects of wind around
the corners of the building have also
been considered in the design of the
100RWS system and are included in
the following tables.
Tables 3.8 and 3.9 set out the installation
criteria for the system, based on design
calculations using the material specifications
detailed in Section 3.1. The following
flow chart should be used as a guide
for the design process.

Timber Treated Frames

The tophat section specified in this
manual can ONLY be used on untreated
and dry timber frames. CCA treated
pine or green timber frames have a
deleterious effect on the tophat
coatings which can lead to corrosion.
Where timber is CCA treated provide

Typical corner panel areas

11 CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS

Table 3.8 Fixing of Garage Angle to the Slab

Note: • The Spacing of Fixings applies for both single and double garages.
• Dynabolts can only be used for N2 Tiled Roof as this type of fixing has not been designed for the cyclic loading associated
with uplift, hence the M8 Trubolt should be used for N2 Sheet and all N3 conditions.

Table 3.9 Fixing of 100 RWS panels to Garage Angle

Note: • Load width based on 3.5m for a double garage and 2.0m for a single garage;
• *Identifies the need for an additional M8 bolt and 40x40mm washer through each panel (refer to the detail below); and,
• As per Table 3.1, the fixing used is the 14-10 x 65mm Hex Head Type 17 screw.

Detail for N3 Corner Panels

■ M8 galvanised bolt and 40x40x3
square washer fixed through the
centre of the corner panels only
■ Allow to recess the large washer
20mm maximum into the external
face of the panel
■ Refer to Section 3.2 for further
information on the corner panels

Connection detail for corner panels

CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS 12

Table 3.10 Fixing of 100RWS panels to Garage Beam

Note: • Load width based on 3.5m for a double garage and 2.0m for a single garage.
• As per Table 3.1, the fixing used is the 14-10x100 Bugle Head Batten screw.

Installation of Piers
The installation of 100mm thick piers is required each side of the garage door opening. These piers can be site-cut to a minimum
width of 200mm from a stock 100RWS panel. The piers are used to support the installation of a horizontal 100mm thick panel
across the head of the opening, as per Details 5.2.2/3.
Piers are also required along the side walls of the garage to support the perimeter beam.Table 3.11 below sets out the criteria of
these piers for the different wind categories, while Table 3.12 specifies the installation criteria for the SHS post used in N3 regions.

Table 3.11 Piers along the Side Walls

Note: • The pier capacities and spacings shown allow for the load of a tile roof spanning over a 6m wide double garage.
• The beam around the top of the wall which spans between the piers will need to be in accordance with
AS1684 – 1999 Residential Timber-Framed Construction or to Structural Engineers’s approval.
• The 75RWS panel piers and those around the garage door should be packed where necessary to the underside
of the beam above with FC sheeting or other non compressible material, when necessary.

13 CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS

Table 3.12 Fixing of SHS Post (N3 only)

Detail for SHS Posts in Garage

■ Refer to Table 3.12
■ 8mm steel angle used typically
■ Top fixing bolt is installed through full thickness of beam

Bracing Capacity of 100RWS panels

In some cases the side wall of the garage is required to resist a
racking wind load. Table 3.13 below provides the bracing capacity
for a number of panels.The theory associated with this table takes
into consideration the following items:
■ The self weight of the panels
■ The capacities of the various fixing systems
■ Assumes 3 screws per panel are installed
through the garage angle at the base
■ Assumes the garage angle is fixed with Trubolts
at a maximum spacing of 600mm

Table 3.12 Fixing of SHS Post (N3 only)

Note: Each section must contain full height panels that are fully glued with Thin Bed Adhesive, and contain no openings
or control joints.

CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS 14

3.4 Building Setout
CSR Hebel RWS is principally
designed for modular construction.
The full benefit of savings in time and
cost will be fully realised when the
houses are designed to suit a 300mm
module. In principle, thoughtful setout
on the drawing board will minimise
the site-cutting of panels, which is time
consuming and wasteful, as compared
to the installation of stock panels.
(A) Vertical Dimensions
A few important criteria affect the
vertical setout of the building:
(i) A stepdown from the main slab
is required for 75RWS panel
installation. The stepdown should be
greater than 50mm deep and a
maximum of 95mm wide.
The actual depth of the stepdown is
dependent on the height of the eaves
above the slab level, and is rarely greater
than 150mm.
The following quick check can be used
to confirm the stepdown dimensions.
Stepdown = Panel Length - Eaves
Height - 50
75
FGL min.
Typical stepdown detail
Example: top of the horizontal panel or
additional tophats to the panels
1. Stepdown = 2400-2200-50 = 150mm
over, to carry the weight of the
2. Stepdown = 2700-2500-50 = 150mm. gable panels above. Refer to Detail
Here, 450mm widepanels will be 5.1.7 for further information.
required over the windows which
(vi) As a guide, the following table gives
have a head height of 2100mm above
the appropriate panel lengths for a
the slab.
variety of possible building
(ii) For all Residential Wall System configurations:
installation the bottom of the
panel must remain 75mm above
the finished ground level (FGL).
This minimum distance satisfies
recommendations of the current
termite guidelines (refer, BCA Vol. 2,
3.1.3. and AS 3660.1.) The builder
should ensure that this requirement
is clearly communicated to the
future home owner.
(iii) The top of the panel should extend
50mm above the eaves to prevent
any water running down between
the panel and the stud frame.
Attention should be given to the
draining of the eaves. Typical eaves detail
(iv) The vertical setout and vertical
dimension of the windows and
other openings is not critical
for RWS construction,
as all the panels are site-cut to
accommodate this setout.
However, if windows are installed
in the garage, they must be located
up to the underside of the eaves
or to the top of the 100mm
panels, if there are panels above
(ie. in a gable wall).
(v) When 2.7m or 3.0m long panels
are used, a panel can be installed
horizontally over the openings, with
their length and width site-cut to
suit. No galvanised steel angle lintel
or additional top hat is required if
no other panels are seated directly
on top of this horizontal panel. In
gables, a steel angle is required on Typical window head detail
15 CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS
(B) Horizontal Dimensions

The horizontal setout of the building

is vital, as incorrect drawings lead to
problems with the frame and hence
the panel installation. Please note the
following items which require careful
consideration during the building
design stage.

(i) Setting the building out to a 300mm

or 600mm module is most
important. All openings should Typical modular layout of window
be clearly dimensioned on the plan,
as well as the exact size of the
opening. Although site tolerances can
be made up during the installation
process, it is important to achieve
an efficient layout on the drawing
board first.
(ii) Setting up a grid across the plan will
not help to achieve the required
layout, as the orientation of the panels
in each corner affects the setout.
There are no rules to setting out a
corner; however, be aware that a
10mm control joint is normally
required at every corner. Therefore Typical corner detail
an 85mm offset occurs along one side.

You may choose to set a standard

corner orientation. For example, joints
will occur only in the side walls, and
hence the offset will occur on these walls.
(iii) The location of all control joints
should be noted on the drawing
and a 10mm gap allowed in the
dimensioning of the building. Refer
to Section 3.6 for guidelines on
the location of control joints around
a building. Typical control joint detail

CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS 16

(iv) To assist in maintaining the modular
setout of the building, windows
should be ordered to suit the
300mm module. However, if the
length of panel required below the
sill is less than 600mm, then a site
cut horizontal panel (rather than
vertical panels) can be installed
here and hence the width of the
window is not critical. Typically,
external doors and sliding doors
are full height and hence their
width is not critical to the module,
as there are no panels required
above or below, but it should be
noted on the drawing.
Panels below window detail
While most standard window sizes
do not exactly fit the 300mm module,
often being 10mm greater in size,
this is easily incorporated into the
construction (Refer to Detail 5.1.4).
Typical bay window detail
Additionally, a number of manufacturers
are prepared to supply the windows to
the desired width with volume orders.
(v) The distance between openings
should not be less than 300mm,
obviously to suit a standard panel.
With regard to splays and bay
windows, the same principle applies.
Note that for 45° splays, a 600mm
wide panel can be site-cut to a
minimum width of 270mm.
3.5 Footings
Footings for the Residential Wall
System should comply with
conventional masonry veneer
construction as specified in Australian
Standard AS 2870 – 1996. This is a
minimum requirement.
Local engineering advice should always
be sought, especially in areas of highly
reactive ground conditions.
3.6 Control Joints
Control joints should be spaced at a
maximum of 6m centres. However local
engineering advice should always prevail.
At all corners the tophat section is
discontinuous and therefore a weakness
exists at the vertical panel joint in these
locations. Hence control joints should
be located at most external corners,
and all internal corners. Control joints
should also occur at the interface
between 75RWS and 100RWS panel
construction and next to openings, to
comply with the maximum spacing
Typical panel layout for window
17
requirements. Refer to the drawing on
Detail 5.1.8 for a typical control joint
layout around a dwelling.
The width of the control joint should
be between 5-10mm. During the
coating application all joints should
be sealed with a backing rod and
a polyurethane sealant.
For fire rated walls an approved fire
rated sealant should be used.
If an external corner has a full height
opening within 1200mm of the corner,
then the control joint in the corner
can be repositioned to the closest
edge of this opening. The panel joint
at the corner should, in this case, be
fully glued with Thin Bed Adhesive,
screwed with a maximum of 3 off
14 – 10 x 150mm Hex Head Type 17
coarse threaded screws at 900mm
maximum centres and meshed across
during the coating application (refer
to the Coating Specification).
At all control joints, the tophat
should be discontinuous to allow
for the effective movement of
the building at these locations.
Refer to Detail 5.1.3 for a typical tophat
layout across a control joint.
CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS

3.7 Fire Rated
Construction
The full Residential Wall System,
including the frame and CSR GyprockTM
has been fire assessed by the CSIRO
and cleared to achieve a Fire
Resistance Level (FRL) of 240/180/180
in accordance with the Building Code
of Australia (BCA), from the outside
of the wall only.
This excellent result enables the RWS
to be used in the following applications:
■ walls on zero line allotment blocks
■ multi-storey residential dwellings –
external walls
■ commercial developments
■ infill panels
Note that in the above applications, each
panel should be screwed as specified in
this manual, except a minimum of three
screws should be installed through the
middle tophat into each panel.
3.8 Windows
Further to the discussion on window
sizes in Section 3.4 (B) (iv) the builder
should also ensure that the reveal size is
CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS
correct to suit the Residential Wall
System. Refer to the table on next
column for recommendations:
The sizes above typically apply to
aluminium framed windows. If timber
windows are being used similar
tolerances and guidelines apply. Refer
to Detail 5.1.5 for a section through
the sill of a timber window.
In the garage, 100RWS panels are used,
the windows should be ordered
without reveals.
3.9 Two-Storey
Construction
The use of the Residential Wall
System in two-storey construction
involves a number of design issues that
require attention. In conjunction with
the following, refer to the Construction
Details in Section 5.3 & 5.4.
Note, when panels are suspended from
the stud frame the project engineer
shall design the frame to support the
weight of the panels.
Steel Frame Construction
Two storey construction suits a steel
framed dwelling as the weight of the
upper storey panels bear directly on
the lower storey panels. Note, lower
storey panels are to bear on the slab.
However consideration should be
given to the sectional size of the
lintels over openings on the lower
storey. As the details reveal, only an
‘Ableflex’ joint is required at the
horizontal panel junction between
the upper and lower panels.
Timber Frame Construction
In contrast, the upper storey panels
cannot rest on the lower storey panels
in timber framed dwellings, due to the
18
effects of timber shrinkage. Movements
in the order of 25mm can occur in a
two storey timber frame with a timber
first floor. The fixing method used in the
75RWS system does not allow for this
extent of differential movement
between the external skin and the
timber frame.
It is therefore recommended that the
upper storey panels be installed 35mm
clear of the lower storey panels.
During construction a temporary
packer is used to separate the panels
and is then removed after the panels
have been screwed to the tophats.
The impact of this construction is to
load the lower storey frame with the
weight of the upper storey panels. In
effect, an extra 55kg/m2 (for the
height of the upper panels) is being
added to the load already carried
by the timber frame. The load
approximates 1.3 kN/m (2.4m panel).
To simplify the design implications of this
extra load, it is recommended to add an
extra 1.5m of tributary width for a
90kg/m2 Tile Roof load (for 2.4m long
upper panels) for the design of the
lower storey frame and timber lintels,
when using AS1684 -1999.
The support of the full weight of the
upper storey panels can be adequately
supported by the tophat system. A full
design using a safety factor of five has
been undertaken and checked to
confirm this. The only requirement is
that a minimum of four tophats be
used to support the suspended panels,
and the panels screw fixed as per Table 3.7.
Design Tip
In order to reduce the load of
the upper storey panels and
make installation easier, the lower
storey panels should be specified as
2700mm/3000mm in length and the
upper storey panels as 2400mm in
length. The vertical dimensions can
be adjusted to suit.
A garage is considered ‘attached’ when
at least one full side of the garage is
connected to the main dwelling.
3.10 Attached Garages
The use of the 75RWS panels is not
possible in attached garages if a stud
frame is not included for the lateral
support of the panels. For this application
100RWS panels are required. These
panels can adequately span 2.6m
vertically between supports with a
maximum applied lateral wind load
of 2.58 kPa.
Piers along the side walls of the garage
should be installed to support a head
timber beam sized in accordance with
AS1684 – 1999 or to Structural
Engineers detail. Refer to Tables 3.11
and 3.12 in Section 3.3 for additional
information on the type and installation
of these piers.
Section 3.3 provides information on
the fixing requirements of this system.
Section 4.2 gives a detailed construction
sequence and Section 5.2 incorporates
the construction details. Refer to the
CSR Hebel web page or contact the
technical department for further details.
3.11 RWS Retrofit
Existing dwellings clad with FC or AC
sheeting and weatherboard are easily
re-clad with 75RWS panels
to provide a solid external wall with
excellent thermal insulation.
However, the original design of the
house frame would not have included
an allowance for the weight of the
panels. Therefore the panels need to
rest on a ‘shelf ’ angle (such as 100x75x8
galvanised angle) at the base of the wall.
The angle should be installed to span
between the piers or supports at a
maximum spacing of 2.0m. This angle
will also assist during the construction
process. For further details refer to
section 4.6. The project engineer
shall certify the structural adequacy
of the foundations.
The additional panel weight may result
in some footing settlement. The extent
of the movement and its effect on the
internal wall linings is impossible to predict.
The builder should consider allowing for
some rectification of possible hairline
cracks appearing in the internal walls.
Control joints between the panels
should be incorporated at all corners
and at no greater than 4.2m centres.
In either case, local engineering advice
should always prevail.
19
If existing two-storey dwellings are to
be retrofitted with 75RWS panels,
there may not be a need to provide
a gap between the lower and upper
panels (depending on the age of the
building) as all the timber movement
may have taken place. The upper panels
could sit directly on the lower panels
with 50mm wide ‘Abelflex’ in the joint.
Refer to Section 4.6 & 5.5 for additional
guidelines and details for retrofitting
with RWS panels.
3.12 Design &
Detailing for
Termite Resistance
It is the builder’s responsibility to ensure
that all council and Australian code
requirements are fully adhered to in
regard to the design of the house for
preventing termite attack.
The construction details contained
in this guide do not attempt to fully
address the issues, due to the variation
of requirements from state to state.
The specific Residential Wall System
is ideally suited to the exposed edge
method of perimeter protection.
CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS
4.0 Construction
4.1 Installation – 75RWS panels

1. Frames and Trusses

Complete

2. Fix Tophats

■ 2 screws/stud
■ Check number of tophats required
■ Extras under openings

3. Install DPC
■ Check overlap at corners
■ Check detail around control joints,
ensuring tophats are discontinuous ■ Fix to bottom plate
at Control Joint locations
■ Cover step completely
■ Lap at corners

4. Install RWS panel

■ Corner panel installed first

■ 3 screws from outside ■ Check number of screws per tophat
■ Check panel orientation at corners ■ Check control joint locations
■ First panel vertical with level

■ Thin bed adhesive to vertical joints ■ Site-cutting to suit

■ Coating of exposed reinforcement
CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS 20
4.1 Installation – 75RWS panels (Cont.)

5. Window Detail

■ Panel hard against window frame ■ Weather strip down sill

■ Flashing behind panel
■ Site-cut sill with slope
■ Apply anti-corrosion agent

6. Prepare for Coating

■ Add special feature eg. Quoins etc ■ Sand joints flush

■ Fill joints and patch any damage ■ Fill external screw holes as required

7. Coatings

■ Seal windows ■ Refer to specification from coating

■ Seal control joints manufacturer for further details

21 CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS

4.2 Installation – 100RWS panels

1. Frame/Beam and 2. Install Garage Angle

Trusses Complete

■ Fix angle to slab to specification

and details

3. Install DPC

■ 110mm wide DPC on top of angle

4. Install RWS panels

■ 65mm long Hex Head screws at ■ 100mm long screws at top

base as per specifications of beam asper specifications
■ Thin bed adhesive to joints (pre-drilling required)

5. Install Piers

■ Install 300 x 75 piers to underside ■ Install panel over garage door, refer
of garage beam as per specifications to details

7. Prepare for Coating

■ Refer to 4.1:6.

8. Coatings
6. Window Details ■ Refer to 4.1:7.

■ Refer to details

CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS 22

4.3 Bracing of the Building

The walls of the dwelling should be

braced using steel cross bracing
wherever possible, to allow the fixing
of the panels from inside the building,
such as Teco speed bracing.
Ply or sheet bracing should be used
on the external wall, if the walls are
too short for the steel cross bracing
(Refer AS 1684-1999). In this case, the
full length of the wall should be sheeted
to prevent misalignment of the panels.
Alternatively, localised strips of the
sheeting can be fixed to the intermediate
studs, between the areas of full sheet
bracing, to maintain the panel alignment.
The panels to be installed over the areas
of full plywood sheeting will need to be
fixed from the outside of the building
using the 100mm long Bugle Head
Batten screw (refer to Table 3.1).
The extent of the bracing should
be determined by the timber frame
designer or Structural Engineer.
CSR Hebel do not recommend fixing
RWS panels from the inside when
sheet bracing is installed.
If sheet bracing is used over steel or
timber frame construction then increase
the length of the screw (for fixing the
tophats – refer to Section 3) by the
thickness of the sheet bracing.

23 CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS

4.4 Installation of Services

The installation of services in the building

is very similar to the methods currently
being used throughout the industry.
The gap between the panel and the
frame, which nominally measures 20mm,
is quite adequate to allow electrical
services to be installed as usual. The
electrical meter box can be face fixed to
the outside of the panels, or alternatively,
recessed into the stud frame through the
panels. In the latter case, appropriate
setout of the opening should also suit
the 300mm module and all sides of the
box should be sealed to the panels with
an approved sealant.
With regard to plumbing services,
the hot and cold water pipes can be
externally face fixed to the studs, if
necessary. As the Residential Wall System
is not classified as cavity construction, this
installation technique is satisfactory. The
only difficulty occurs when the pipes are
run vertically. In this case the pipes must
be mounted between the studs, so as
not to foul the horizontal installation of
the tophats. Tophats are not to be cut
to allow clearance for services.
Penetrations through the panel for
services should be neatly filled and the
joint sealed with a polyurethane sealant.

CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS 24

4.5 75RWS panel Checklist

4.5.1 Checklist – Designer

25 CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS

4.5.2 Checklist – Builder

Note: It is important that the builder understands his responsibilities as outlined in the previous two checklists and refers to the
construction details in the manual, in order to ensure that the greatest benefit is achieved through the use of the Residential
Wall System, and to avoid incurring additional costs.

CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS 26

4.5.3 Checklist – Installer

27 CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS

4.5.4 Checklist – Inspector/Superviser

CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS 28

4.6 Retrofit Construction
(A) Preliminaries
The installation of 75RWS panels on
an existing dwelling involves a number
of issues that require consideration prior
to commencing.
(i) Council Approval
The installation of the Residential
Wall System to an existing building
will add a minimum of 95mm to the
external dimensions of the building.
The local council may require a
building application to be lodged
for this change in building size.
(iv) Subfloor Zone
The type of construction of the external
face of the house below floor level varies
from open with piers, clad with sheeting
to continuous brickwork. Consideration
of the finish in this area is necessary. The
details in Section 5.5 show the variety of
possible finish alternatives, some using the
installation of panels. However, it may be
decided to keep this zone open and infill
with timber or fibre cement lattice work.
(v) Existing Frame
As the Residential Wall System panel
is directly connected to the frame
of the house, the qualityof the existing
frame is an important consideration.
If the frame is out of alignment in any
way, the final quality of the installed
panels can be affected. It may be
necessary to pack the tophats to
ensure a vertical and straight wall.
(ii) Windows
The existing windows may or may not
suit the proposed change in the dwelling’s
appearance. In addition, the actual
profile of the window frame should be
checked to consider how well the panels
will butt up to the edge of the frame.
A storm mould may be required to
bridge a gap if the window frame does
not extend out 20mm to pass the tophat.
These issues raise the question of
whether or not the windows should
be completely replaced.
(iii) Services
A number of services are typically
mounted on the external face of the
building, such as down pipes, water pipes
and possibly sewer pipes. The cost of
removal and replacement (or relocation)
of these items will need to be
considered in the project budget.
(vi) Structural Adequacy
We recommend consultation with
a practicing structural engineer to
investigate the structural adequacy of
the existing footings and foundation
to support the additional load that will
be imposed upon them after the panels
have been installed.
29 CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS
(B) Construction
The installation of the panels is very similar to the processes already detailed
in this manual, with consideration given to the following items.
(i) Tophat Installation
If the building is sheeted with fibre
cement or asbestos cement sheets,
the trims and mouldings need only be
removed. The sheeting can remain fixed
to the building. The tophats can be
screwed straight through the sheeting
into the studs. If the building has timber
cladding, such as weatherboards, it will be
necessary for this type of cladding to be
removed, prior to the installation of the
tophats.
(ii) Cutting Panels
It may be necessary for more panels
to be cut to size (in width) on site to fit
the geometry and setout of the dwelling
than that necessary for a new home. In
this regard, the usual restriction applies,
being a 270mm minimum width cut
from a 600mm wide panel.
An example of where this applies is for
say, an 800mm wide section. Here the
section cannot be installed with a
600mm (stock) panel and a 200mm
wide (cut) panel. The correct solution
is to use a 300mm (stock) panel and
a 500mm wide (cut) panel. In this case,
still only one site-cut panel is required.
If the distance between two openings is
less than 270mm, it will be necessary to
frame this section with timber, clad with
FC sheeting to suit, and coat to match
the rest of the dwelling.
CSR™ HEBEL® RESIDENTIAL WALL SYSTEMS
Some of these setout problems may be
overcome if the windows are replaced
and sightly relocated to allow for the
300mm module.
(iii) Installation
All the panels will need to be fixed
to the tophat from the outside of the
building using the 100mm long Bugle
Head Batten screw (refer to Table 3.1).
The screw should stop a maximum of
5mm below the face of the panel and
should be patched prior to coating
using CSR Hebel Patching Mortar or
a mixture of thin bedded adhesive
and dust (created from cutting panels)
to form a paste.
The shelf angle should be installed with
consideration of the length of the stock
panels available. For instance, if using a
2700 mm long panel then allow a
distance of 2715mm below the eaves
lining to the angle. The 15mm gap at the
top will make installation easy and can be
covered with a timber moulding.
If the wall is higher than 3000mm to
the eaves, a horizontal panel (possibly
300mm wide) could be installed on top
of the vertical panels. In this case, two
additional tophats will be required to fix
this extra panel to the wall.
Panels over the windows and in the
gables should be installed as already
detailed in this manual.
30