Boral - Masonry Design Guide - NSW

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Masonry Design Guide STRUCTURAL, FIRE AND ACOUSTICS NEW SOUTH WALES BOOK 1

www.boral.com.au/masonry

Updated May 2008

New South Wales Book 1 A

A

Introduction

E G A P

E G A P

A2

Products @ a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4

Fast Find Product and Application Guide . . . . . . . . . . . . . . . A3

About This Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B

Structural Design

Introduction to the Structural Design of Masonry . . . . . . . . B2

Energy Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7

B2

Reinforced Masonry Lintels . . . . . . . . . . . . . . . . . . . . . . . . . B9

Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5

Design of Core Filled and Steel Reinforced Masonry Retaining Walls . . . . . . . . . . . . . . . . . . . . . . . . . . B10

Robustness

......................................

Bending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5 Shear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6 Durability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6

Structural Design Guidelines for Core Filled and Steel Reinforced Masonry Retaining Walls . . . . . . . . . . . . . . . . . . . . . . . . . . B12

Movement (Control Joints) . . . . . . . . . . . . . . . . . . . . . . . . . . B6

C

Fire Design

Masonry Design for Fire Resistance (FRL) . . . . . . . . . . . . . . C2

Effect of Chases on Fire Rated Masonry . . . . . . . . . . . . . . . C4

Masonry Design for Structural Adequacy FRL . . . . . . . . . . . C2

How to Select Boral Masonry Units for Fire Rated Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5

Masonry Design for Integrity FRL . . . . . . . . . . . . . . . . . . . . . C3 Structural Adequacy Selection Graphs and Tables . . . . . . . . C8 Masonry Design for Insulation FRL. FRL . . . . . . . . . . . . . . . . . . . . C4 Index to Structural Adequacy Selection Graphs . . . . . . . . . . C8

D

Acoustic Design

Acoustic Performance Ratings (STC and R w) . . . . . . . . . . . . D2

Guidelines for Optimum Performance . . . . . . . . . . . . . . . . . D4

Designing Masonry Walls for Acoustic Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3

Acoustic Performance On-site . . . . . . . . . . . . . . . . . . . . . . . D5 Home Cinema Rooms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6

E

Fire and Acoustic Systems

Finding Acoustic Systems and Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2

Basalt-Concrete Bricks (B) . . . . . . . . . . . . . . . . . . . . . . . . . E12 Standard Grey Block and Designer Block . . . . . . . . . . . . . . E16

FireBrick (F) Scoria Blend . . . . . . . . . . . . . . . . . . . . . . . . . . . E4 Acousticell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E18 FireBlock - Scoria Blend Blocks . . . . . . . . . . . . . . . . . . . . . . E7 FireLight Bricks (FL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E9

The information presented herein is supplied in good faith and to the best of our knowledge was accurate at the time of preparation. No responsibility can be accepted by Boral or its staff for any errors or omissions. Users are advised to make their own determination as to the suitability of this information in relation to their particular purpose and specific circumstances. Since the information contained in this document may be applied under conditions beyond our control, no responsibility can be accepted by us for any loss or damage caused by any person acting or refraining from action as a result of this information.

A2

May 2008 | BORAL MASONRY DESIGN GUIDE


The quickest way to find a Boral Masonry Structural, Fire or Acoustic Wall Solution. Simply follow the FAST FIND GUIDE on the right hand side of the table.

BORAL MASONRY

l l y a r H d r n W I S a g g d s o o N I n e a n b e r e r i n i i n i L F e M t d L a L s n t A F a c R e P l a N o R e W

BLOCK & BRICK PRODUCTS NLB = Non-loadbearing

Fast Find a Boral Solution

NLB LB NLB LB NLB LB NLB LB NLB LB

LB = Loadbearing

FireBrick (F) Scoria Blend

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E4

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E4

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E4

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Scoria Blend Blocks

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E7

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E7

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E7

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Select your application

1

criteria from the top of the table

FireLight Bricks (FL)

–

–

E9 E9

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

E21

Acousticell

–

–

E9

–



–

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E9 E9

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–

–

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–

–



–

E21

Go straight to the section

2

letter and page number

Basalt-Concrete (B)

–

–

E12 E12 E12 E12 E12 E12

–

–

indicated at the intersection of product

Designer Block

E19 E19 

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

rows and application

E19 E19 

columns (e.g. Section E,



Page E12 in this example)

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Standard Grey Block

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E19 E19 E19 E19 E19 E19

–

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 Best performance is achieved with plasterboard lining

E19 E19 E19 E19 E19 E19 E19 E19 E19 E19

Core Filled Block

 Please refer to MDG Book 2, Boral Masonry Block & Brick Guide

For technical support and sales office details please refer to the outside back cover

BORAL MASONRY DESIGN GUIDE

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May 2008

A3


Boral Engineered Blocks for Structural, Fire & Acoustic Wall Systems

• Standard Grey and Designer Block Hollow Concrete Block suitable for loadbearing and non-loadbearing applications. 60 minute insulation FRL as hollow blockwork. Higher FRLs are achieved when reinforced and core-filled.

• Scoria Blend High Fire Rated Block Manufactured in a unique Scoria Blend material offering Fire Resistance Levels (FRLs) to 240 minutes without core-filling. Ideal for high rise buildings with reinforced concrete frames or portal frame buildings. Suitable for nonloadbearing walls. If used for light load construction, the lower slenderness ratios of Designer Block apply.

A4

• Core Fill Block Grey Concrete Block or Designer Block coloured and textured finishes for reinforced retaining walls and loadbearing walls requiring increased robustness.

• Acousticell™ Engineered block for premium sound absorption and attenuation of low frequency industrial and commercial noise.



Boral Engineered Bricks for Structural, Fire and Acoustic Wall Systems

• Basalt-Concrete Brick (B) Standard Size, Brick-and-a-Half (119mm high) and Double (162mm high) in Concrete-Basalt material for good fire performance and loadbearing characteristics.

• FireLight Brick (FL) FireLight Brick for non-loadbearing fire and/or acoustic systems (high rise) where weight saving is important. Double Brick format (162mm height) for faster, more cost effective construction.

• FireBrick (F) Medium weight Scoria Brick for non-loadbearing fire and/or acoustic systems. Double Brick format (162mm height) for faster, more cost effective construction.


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May 2008

A5


Boral Masonry Commercial Construction Solutions

What’s in this Guide

This guide has been prepared as a comprehensive Boral Product Reference Guide. It does not attempt to cover all the requirements of the Codes and Standards which apply to masonry construction for structural, fire or acoustic applications. All structural, fire and acoustic detailing should be checked and approved byappropriatelyqualified engineers before construction. Boral reserves the right to change the contents of this guide without notice.

The Boral Masonry Structural, Fire & Acoustic guide provides a summary of important design information for structural, fire and acoustic masonry applications and an extensive range of fire and acoustic systems.

Please note that this guide is based on products available at the time of publication from the Boral Masonry New South Wales sales region. Different products and specifications may apply to Boral products sourced from other regions.

Section B – Structural Design

Additional Assistance & Information

Section B discusses design issues relevant to the selection of Boral Masonry products for structural adequacy, based on appropriate wall design criteria.

• Contact Details: Please refer to the outside back cover of this publication for Boral Masonry contact details.

Boral Masonry NSW offers a comprehensive range of proven products and systems including Masonry Blocks, Masonry Bricks, Fire and Acoustic Wall Systems, Segmental Block Retaining Walls and Segmental Paving Products.

Section C – Fire Design Section C discusses the relevant design processes for the selection of Boral Masonry Products for fire rated applications. This section includes a step-by-step selection guide and a series of tables and graphs which can greatly speed up the preliminary selection and comparison of suitable designs and products.

Section D – Acoustic Design

• Colour and Texture Variation: The supply of raw materials can vary over time. In addition, variation can occur between product types and production batches. Also please recognise the printed colours in this brochure are only a guide. Please, always ask to see a sample of your colour/texture choice before specifying or ordering. • Terms and Conditions of Sale: For a full set of Terms and Conditions of Sale please contact your nearest Boral Masonry sales office.

Section D provides a brief overview of acoustic rating methods, relevant considerations for acoustic design and guidelines for good acoustic design and detailing methods.

Section E – Fire & Acoustic Systems Section E of this guide provides an extensive range of fire and acoustic wall system solutions supported by test results and acoustic performance estimates.

A6


BORAL MASONRY


Masonry Design Guide STRUCTURAL, FIRE AND ACOUSTICS NEW SOUTH WALES BOOK 1 B STRUCTURAL DESIGN

New South Wales Book 1 B

Introduction to the Structural Design of Masonry The following design information is based on Australian Standard AS3700:2001 Masonry structures. Reference to ‘Clauses’ and ‘Formulae’ are those used in AS3700. This information is provided as a guide only to the processes involved in designing masonry. All masonry should be designed by a suitably qualified structural engineer.

Legend to Symbols used in Robustness Calculations: H

tr

Robustness

B2

=

for a member without top horizontal support, the overall height from the bottom lateral support, in metres

=

the minimum thickness of the member, in metres

=

in cavity-wall construction, the minimum thickness of the thicker leaf

or in diaphragm wall construction, the overall thickness of the wall, in metres kt

The following section is laid out with AS3700 formulae and explanation in the left hand column, while worked examples can be found in the adjacent right hand column.

the clear height of a member between horizontal lateral supports, in metres;

or two thirds the sum or thicknesses ofthe two leaves, whichever is greater, in metres

AS3700, Clause 4.6.1 requires walls to have an adequate degree of ‘Robustness’. Robustness is a minimum design requirement, and may be overridden by Fire, Wind, Snow, Earthquake, Live and Dead Load requirements. In robustness calculations, there are height, length, and panel action formulae. Byreworking the standard formulae provided and inserting known data, it is possible to determine whether a chosen design and Boral masonry product will provide adequate robustness. Should the initial product selected not provide a suitable solution, then a thicker Boral masonry product more suited to the application should be evaluated, or alternatively, add extra restraints or reinforcement.

=

=

a thickness coefficient, values as given in AS3700 Table 7.2 (see the end of this section)

C v ,Ch =

robustness coefficient,values as given in AS3700 Table 4.2(see end of this section) foredge restraints at top, bottom and vertical sides (either separately or in combination)

Lr

=

the clear length of the wall between vertical lateral supports, in metres; or

=

for a wall without a vertical support at one end or at a control joint or for walls containing openings, the length to that unsupported end or control joint or edge of opening, in metres.



Formulae and Explanation

Worked Examples

Isolated Piers

Aim:

Formula 4.6.2 (1) is used for isolated piers. Masonrywith a length less than one fifth of its height and ‘free’ ends, is considered to be an ‘isolated pier’. Formula (1) is:

H tr

C v

≤

To determine the Maximum Wall Height of an Isolated Pier

Example 1: Minimum wall thickness tr = 230mm A single leaf structure, unreinforced, then C v = 13.5 H ≤ 0.23 x 13.5 H ≤ 3.105m (maximum wall height)

By re-working formula (1), the maximum height for an isolated pier can be determined: H ≤ tr x C v

Example 2: Minimum wall thickness, tr = 140mm A single leaf structure, reinforced, then C v = 30

Where C v is obtained from AS3700 Table 4.2 (Refer to Page B5).

H ≤ 0.14 x 30 H ≤ 4.200m (maximum wall height)


Worked Examples

Wall with Free Ends

Aim:

Formula 4.6.2 (2) is used for walls spanning vertically (i.e. wall with free ends).

Criteria:

Formula (2) is:

H kt x tr

≤

C v

By re-working formula (2), the maximum wall height is: H ≤ kt x tr x C v . Where kt is obtained from AS3700 Table 7.2 (Refer to Page B5) or By re-working formula (2), the minimum wall thickness is: kt x tr ≥

H C v


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May 2008

To determine the Maximum Height of a Wall with Free Ends Minimum wall thickness, tr = 110mm kt = 1 (wall without piers)

Example 1: If wall is freestanding, then C v =6 (must be checked by an engineer for wind loads etc.) H ≤ 1.0 x 0.11 x 6 H ≤ 0.660m Example 2: If wall is laterally restrained along its top, then C v =27 H ≤ 1.0 x 0.11 x 27 H ≤ 2.970m Example 3: If wall is laterally restrained along its top and supports a slab, then C v =36 H ≤ 1.0 x 0.11 x 36 H ≤ 3.960m

B3



Worked Examples

Wall with Restraint at End or Ends

Aim:

Formula 4.6.2 (3) is for walls spanning horizontally [i.e. restrained end(s)]. Walls that have one or both ends laterally restrained and L ≤ Ch tr

To determine the Maximum Length of a Wall with Restraint at End or Ends

Criteria:

Wall thickness tr = 110mm

Example 1: If wall is restrained along one end, then Ch = 12

i.e. L ≤ tr x Ch Where Ch is obtained from AS3700 Table 4.2. (Refer to Page B5) H tr

= no limit

L ≤ 0.11 x 12 L ≤ 1.320m Example 2: If wall is restrained along both ends, then Ch = 36

NOTE: This means that although the wall height is not limited by its thickness, the wall length is limited. Stair wells and chimneys work to this formula.

L ≤ 0.11 x 36 L ≤ 3.960m NOTE: If the wall exceeds the permitted length, then a thicker wall is required or formula 4.6.2 (4) governs and H will be limited. (See below).


Worked Examples

Wall with Restraint at Top and End or Ends

Aim:

Formula 4.6.2 (4) is for walls spanning vertically and horizontally (i.e. with restraint along the top and one or two ends) and length L > tr x Ch.

To determine the Maximum Height of a Wall with Restraint at Top and End or Ends

Criteria:

Wall thickness tr = 110mm Wall length = 2m

Where Ch is obtained from AS3700 Table 4.2. (Refer to Page B5) Formula (4) is:

H tr

C v +

≤

Ch Lr – Chtr

By re-working formula (4), the maximum wall height is: H≤

( C + L C– C t ) t v

h

r

hr

r

Example 1: If wall supports a slab, then C v = 36, and if restrained along one end, then Ch = 12 H≤

(

36 +

12 2 – 12 x 0.11

) 0.11

H ≤ 5.9m

NOTE: Control joints, and openings greater than one fifth of wall height are treated as free ends unless specific measures are taken to provide adequate lateral support.

B4



Strength

Table B1 (Extract from AS3700 : Table 4.2)

Top and bottom edge restraints to wall panels

Cv Vertically unreinforced

Vertically reinforced or prestressed

6

12 with reinforcement continuous into support. Otherwise 6.

Free

SUPPORT

Load other than concrete slab or no load Lateral Support

27

36

Compressive strength is resistance to load, measured by the amount of pressure to crush a masonry unit. The pressure, usually measured in megapascals (MPa), is the force in kilonewtons (kN) x 1000, divided by the loaded area in square mm. Unconfined compressive strength is compressive strength, multiplied by an aspect ratio, Ka. (Details are in AS4456.4, Table 1). The unit height divided by its thickness is used to determine the aspect ratio.

SUPPORT

48

A solid brickwill give a lower compressive strength if crushed on its end rather than on its flat, as normally laid. In theory, the aspect ratio will convert both tests to the same unconfined compressive strength.

30

The strength of hollow blocks is calculated by dividing the force by the face shells only. A 90mm hollowand 90mm solid block are both 10MPa, but since the area of the face shells on the hollow block is about half the area of the solid block, the hollow will only carry half the load of the solid.

Concrete Slab Lateral Support

36 SUPPORT

ISOLATED PIERS Lateral Support

13.5

SUPPORT

Edge restraints on vertical sides of wall panels

Ch Horizontally unreinforced

Horizontally reinforced or prestressed

12

24 with reinforcement continuous past support. Otherwise 16

T R O P P U S

T R O P P U S

T R O P P U S

36

Table B2 (Extract from AS3700 : Table 7.2) Thickness Coefficient (kt) for Walls Stiffened by Monolithically Engaged Piers

Pier Spacing/PierWidth

Thickness Coefficient (kt)

(Refer to Note 1)

Pier Thickness Ratio (twp /t) 1

2

3

6

1.0

1.4

2.0

8

1.0

1.3

1.7

10

1.0

1.2

1.4

15

1.0

1.1

1.2

20 or more

1.0

1.0

1.0

NOTES: 1. Pier spacing is taken as the distance between centrelines of piers.

twp

Wall Leaf

Pier Width Pier Spacing

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Characteristic Compressive Strength of a masonry WALL is ƒ ’m.

The Km factor is 1.4 for M3 mortar on solid and cored units and is 1.6 for the face shells of hollow units. For the richer M4 mortar it is 1.5. (Details are in AS3700, Table 3.1). The Kh factor is 1 for 76mm high units with 10mm mortar beds and is 1.3 for 190mm units with 10mm mortar beds. In other words, a wall of 190mm high units is 30% stronger than a wall of 76mm high units of the same ƒ ’uc.

Bending Characteristic Flexural Tensile Strength is ƒ ’mt.

t


ƒ ’ uc is the average of crushing forces divided by loaded areas, multiplied by the aspect ratio, minus the standard deviation x 1.65.

ƒ ’m is the square root of ƒ ’ uc, multiplied by Km (a mortar strength factor), multiplied by Kh (a factor for the amount of mortar joints) as per AS3700, 3.3.2.

48

2. Linear interpolation may be used.

Characteristic Unconfined Compressive Strength of masonry UNITS is ƒ ’ uc.

May 2008

Masonry is good in compression but poor in tension. Mortar joint strength is generally zero or 0.2MPa for loads from wind, earthquake etc. Higher bending forces may require masonry to be partially reinforced.

B5


Shear Characteristic Shear Strength is ƒ ’ms. At damp course, it is zero unless tested. Elsewhere, mortar joints have ƒ ’ms values of between 0.15 and 0.35MPa. As with tension, high shear loads may require partially reinforced masonry.

Durability Masonry designed for‘Durability’ is deemed to satisfy when it meets the requirements ofAS3700 Section 5, which details what areas require Exposure, General Purpose and Protected grades. Assessment of these grades is defined in AS/NZS4456.10 Resistance to Salt Attack. AS3700 defines the usage of each of these grades as: Protected Grade (PRO) Elements above the damp-proof course in non-marine exterior environments. Elements above the damp-proof course in other exterior environments, with a waterproof coating, properly flashed junctions with other building elements and a top covering (roof or coping) protecting the masonry. General Purpose Grade (GP) Suitable for use in an external wall excluding severe marine environment. Exposure Grade (EXP) Suitable for use in external walls exposed to severe marine environments, i.e. up to 100m from a surf coast or up to 1km from a non surf coast. The distances are specified from mean high water mark. Mortarmix requirements for durability are detailed in AS3700 Table 10.1. Mortar joints must be ironed. Salt attack is the most common durability problem. The salt in salt water is in solution. It can be absorbed into masonry or at least, its mortar joints. When the water evaporates, it migrates towards the outside face taking the salt with it until the amount ofwater left is saturated. It can no longer hold all the salt in solution and salt crystals begin to form. The salt crystals then take up space, sometimes more than the texture of the masonry will allow. The crystal then ‘pops’ a piece of the outer surface off to make room and salt attack begins. Walls below damp course also require greater durability.

B6

Even if they are well away from the coast,they may be subjected to acidic or alkaline soils. In any case, moisture in the ground is absorbed into the masonry, creating an environment ideal for bacteria, which feeds lichens and algae which can eventually be detrimental. AS/NZS4456.10 gives methods of testing and definitions for durability (salt tests). An alternative to testing is a history of survival in a marine environment. Concrete masonry has been used for Surf Club construction around Australia fordecades.

Movement In general, concrete units contract as theycure while clay units will expand. They both expand as they take up water and contract as they dry. They both expand as they get hot and contract as they cool.

Curing Movement in Concrete Units AS/NZS4456.12 gives methods for determining coefficients of curing contraction and coefficients of drying contraction for concrete units. Drying Contraction The drying contraction test on masonryunits is an indication of their maximum amount of movement from totally saturated to ambient dry. Atypical result is 0.5mm/m but can be as high as 1mm/m for lightweight units that are more absorptive. For example, a drying contraction of 0.5mm/m, in an 8m panel of masonry, has the potential to shrink 4mm from saturated condition to dry.

External Control Joints AS3700, Clause 4.8 requires control joint spacing to limit panel movement to:• 10mm maximum for opening of control joints, • 15mm maximum for closing of control joints, and • 5mm minimum when closed. The Australian Masonry Manual recommends control joints at 8m centres for concrete units, 6m centres for lightweight (<1600kg/m3) units and at potential points of cracking such as at openings and at steps in the masonry. The Concrete MasonryAssociation ofAustralia Design Manual MA40 permits 16m spacing for bond beams and for panels with horizontal and vertical reinforcement. Spacing should be measured around corners, not from corners. Ideally, the control joint is located near the corner, concealed behind a down pipe.



External control joints should be finished with a flexible sealant. Control joints create a ‘free end’ in terms of ‘robustness’ and FRLs for structural adequacy, so their positioning is critical to the overall design of the structure. In portal frame construction, the control joint is positioned at a column so that both ends can be tied to the column flanges. The mason and renderer must keep the control joint clean, otherwise, bridging mortar or renderwill induce cracks from those points as the masonry moves. If ties are used over control joints, they must be sleeved to allow movement. Adding extra cement to mortar or render causes more shrinkage. Lightweight units are only5MPa, so are susceptible to cracking if laid in rich mortar or rendered with a cementrich mix.

Internal Control Joints The Australian Masonry Manual specifies the spacing of internal control joints for concrete units at 12m maximum.

Energy Efficiency for Class 2, 3 & 4 buildings in ACT The Building Code ofAustralia (BCA) 2005,Volume 1, requires the walls of Canberra home units, hotels and similar dwellings to have:“Total R-Value” rating of 1.9 (Climate Zone 7) or Wall mass > 220kg/m 2 and include insulation with an R value not less than 1. “Total R-Value” means the sum of thermal resistances (m 2.K/W) of wall components including air spaces and associated surface resistances.

In BCA Specification J1.5 “Wall Construction”, options (a) (b) & (c) for concrete masonry give their Total R-values without insulation. The R-value of the insulation needed to make up the required Total R-value for masonry veneer in Zone 7 is R1.5. Masonry minimum thickness is 90mm. The insulation is usually placed between the studs. Alternative verification can be achieved through a 4 star assessment forClass 2 & 4 buildings using calculations defined in BCA Clause JV1,and forClass 3 buildings,calculating energy consumption to meet values as per Clause JV2 or comparison with a reference building as per Clause JV3.

Energy Efficiency for ACT Houses In the ACT, houses are required to have a 4 star rating as assessed by an accredited ACT House EnergyAssessor or by equivalent assessment with R1.5 insulation material in the external walls of brick veneer construction. Cavity brick of 2 x 90mm minimum thicknesses is exempt.


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May 2008

B7


NSW Energy Efficiency: Class 1, 2, 3 & 4 buildings Class 1, 2 and 4 buildings The Building Code ofAustralia (BCA) 2005,Volume 1, requires the walls of home units in Sydney(and progressively elsewhere in NSW) to comply with BASIX(building sustainability index), a web-based planning tool at www.basix.nsw.gov.au

Class 3 buildings Walls of Class 3 buildings (hostels, hotels, motels) are required bythe BCA,J1.5 to have one ora combination of the following: “Total R-Value”rating of 1.4 in Climate Zone 2& 5 (North Coast to Sydney) A rating of 1.7 in Climate Zone 4 & 6 (Western NSW) A rating of 1.9 in Climate Zone 7(Armidale & Sthn Highlands) A rating of 2.8 in Climate Zone 8 (Thredbo)

Options for Increasing R values The insulating properties of masonry walls may be increased by the following means: • The addition of polyester or glasswool insulation between studs for masonry veneer construction. • The addition of polystyrene sheets between wall ties for cavity masonry construction. • The addition of polyester or glasswool insulation behind plasterboard, between battens on inside face of masonry. (Battens eliminate the need for chasing for plumbing and electrical services). • Incorporating reflective insulation within the cavity. • Incorporating foam insulation, pumice orvermiculite within the cores of the units or in the cavity.

or

• Using masonry units with a rough surface. (This traps a thicker air film at the surface).

Wall mass > 220kg/m 2 in Climate Zone 4 & 5 and in Zone 6, 7 & 8, include insulation with an R value not less than 1 (floor system in Zone 6 to be slab on ground).

• Using masonry units made from less dense material. (Tiny air pockets within the material disrupt the flow of heat energy through the wall).

“Total R-Value” means the sum of thermal resistances (m 2.K/W) of wall components including air spaces and associated surface resistances.

• Using thicker walls.

In Specification J1.5“Wall Construction”, options (a) (b) & (c) for concrete masonry give their Total R-values without insulation. The R-value of the insulation needed to make up the required Total R-value for masonry veneer is: R1.0 in Climate Zone 2 & 5 R1.3 in Climate Zone 4 & 6 R1.5 in Climate Zone 7 and R2.4 in Climate Zone 8. The insulation is usually placed between the studs. For cavity brick, these insulation R-values can be 0.3 lower than for brick veneer. The insulation is between battens on the inside face, under 10mm plasterboard. Minimum masonry thickness is 90mm. For 190mm hollow concrete blocks, partially core filled and with a bond beam at the top, the insulation R-values can be 0.1 lower than for brick veneer.

B8



Reinforced Masonry Lintels Moment and Shear Capacities for Series 150 Blocks (140mm leaf) Vertical

NOTES

Vertical

Bars

Vc

Mc

Bars

Vc

Mc

N12 N16

5.1 6.3

2.6 2.6

N12 N16

12.5 13.7

9.3 16.0

Vc = Shear capacity (kN) Mc = Moment capacity (kNm) Mortar type, M3 Block characteristic compressive strength, ƒ ’uc = 15MPa Grout compressive strength, ƒ ’ c = 20MPa

Horizontal

100

Bars

Vc

Mc

N12 N16

5.1 6.3

2.0 2.9

Cut on-site

Cement content min. (Grout) = 300kg/m3 Horizontal

300

15.12 70

Bars

Vc

Mc

N12 N16

10.2 12.6

4.0 4.7

15.12 70

Moment and Shear Capacities for Series 200 Blocks (190mm leaf) Vertical

Vertical

Bars

Vc

Mc

Bars

Vc

Mc

N12 N16 N20

7.9 10.2 13.1

3.6 3.6 3.6

N12 N16 N20

6.4 7.6 9.1

2.9 3.6 3.6

Horizontal

Horizontal Bars

100

N12 N16 N20

20.12

Vc

Mc

8.2 9.3 10.6

4.0 6.9 9.9

100

Bars

Vc

Mc

N12 N16 N20

6.4 7.6 9.1

2.9 5.0 6.5

20.12

129 (N12 bars) 127 (N16 bars) 125 (N20 bars)

95

Vertical

Vertical

Bars

Vc

Mc

Bars

Vc

Mc

N12 N16 N20

17.9 20.2 23.1

18.0 30.2 32.2

N12 N16 N20

16.4 17.6 19.0

9.5 16.6 24.4

20.20 or 20.01 cut on-site

20.20 or 20.01 cut on-site Horizontal

300

Horizontal

300

Bars

Vc

Mc

Bars

Vc

Mc

N12 N16 N20

16.4 18.6 21.3

8.0 13.4 17.2

N12 N16 N20

12.9 15.2 18.1

5.7 9.5 9.9

20.12

20.12 129 (Y12 bars) 127 (Y16 bars) 125 (Y20 bars)


95

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May 2008

B9


Design of Core Filled & Steel Reinforced Masonry Retaining Walls

Boundary

Introduction Backfill

The information presented here is supplied in good faith and to the best of our knowledge was accurate at the time of preparation. However,from time to time, additional or modified data may be released by the CMAA. Any such information will supersede the information presented in this guide. This section provides specifications, design tables and typical details for a range of reinforced concrete masonry retaining walls and their associated reinforced concrete bases. It is intended as a general guide for suitably qualified and experienced professional engineers, who for any particular proposed retaining wall, must accept the responsibility for carrying out a comprehensive site investigation, determining the soil characteristics and other design parameters of the particularsite, and for designing and detailing the structures.

Ground level Base Type 1 Foundation

Fig B1 – Typical Wall Layout for Base Type 1

Boundary

It is important for the professional engineer to determine the strength and stability of the foundation material and the drainage system required to ensure there will not be a build up of hydrostatic pressure behind the wall. Backfill

All designs are based on: • Reinforced Concrete Masonry Structures – AS3700 : 2001 SA Masonry Code. • Reinforced Concrete Base – AS3600 : 1988 Concrete Structures. • Reinforcement – AS1302 : 1982 Steel Reinforcing Bars for Concrete.

Ground level Base Type 2

• Concrete Blocks – AS4455 : 1997Concrete Masonry Units.

Wall Types Design tables in this section are given for walls up to 3.4 metres high and for two base types:

Loading Conditions These tables cover: • Sloping backfill (up to 1 in 4) without any surcharge or

Foundation

Fig B2 – Typical Wall Layout for Base Type 2

Construction Recommendations General

• Level backfill with a 5kPa surcharge

Recommendations specifically applicable to reinforced masonry retaining walls include:

Since typical cases only are presented, these tables may not provide an ideal solution for a particular application.

• The provision of clean-out openings in the bottom course to permit removal of mortar droppings and other debris

B10



Backfill

Free draining granular material

Locate the continuous drain at the bottom of the base

Free-draining gravel or stone Weepholes between blocks Drain

Fig B5 — Continuous Drainage Within the Backfill Walls with Base Type 2


Water Penetration

Extra agricultural pipe drain

If it is considered necessary to reduce the passage of moisture through the wall, for aesthetic or other reasons such as aggressive groundwater, the earth face of the wall should be treated with an appropriate sealer such as waterresistant render or water-resistant paint, or by tanking with bituminous materials.

Structural Design Guidelines Acceptable Soil Combinations • For retaining walls founded on sand (Type A soil), the retained material must be similar and with a friction angle of 38° or greater, eg Type A soil — clean sand or gravel. Fig B6 — Continuous Drainage for High Walls and/or Excessive Groundwater

Weepholes Weepholes should be provided above the finished ground level. A drain should be provided in front of the wall to prevent saturation of the ground. The horizontal spacing of the weepholes depends on the provisions made for directing water towards the holes. The simplest, but most effective, method is to place one or two buckets of free-draining gravel or crushed stone around the intake end of each hole. In this case, the horizontal spacing should not exceed 1.5 metres. If the layers of draining material are continuous for the full length of the wall, weephole spacing may be increased to an extent depending on the quantity of water expected. Note: For walls higher than 2200mm, a second row of weepholes may be required. However, staining of the wall could result. BORAL MASONRY DESIGN GUIDE

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May 2008

• For retaining walls founded on other soils, the retained material must be a free draining material with a friction angle of 27° or greater, eg Type A soil — clean sand or gravel, Type B soil — coarse grained with silt or some clay.

55mm cover to wall reinforcement

30mm

Clean-out course

50mm cover to all base reinforcement

Fig B8 — Typical Set-out Detail

B11


Backfill

Free draining granular material

Locate the continuous drain at the bottom of the base

Free-draining gravel or stone Weepholes between blocks Drain



Water Penetration

Extra agricultural pipe drain

If it is considered necessary to reduce the passage of moisture through the wall, for aesthetic or other reasons such as aggressive groundwater, the earth face of the wall should be treated with an appropriate sealer such as waterresistant render or water-resistant paint, or by tanking with bituminous materials.

Structural Design Guidelines Acceptable Soil Combinations • For retaining walls founded on sand (Type A soil), the retained material must be similar and with a friction angle of 38° or greater, eg Type A soil — clean sand or gravel. Fig B6 — Continuous Drainage for High Walls and/or Excessive Groundwater

Weepholes Weepholes should be provided above the finished ground level. A drain should be provided in front of the wall to prevent saturation of the ground. The horizontal spacing of the weepholes depends on the provisions made for directing water towards the holes. The simplest, but most effective, method is to place one or two buckets of free-draining gravel or crushed stone around the intake end of each hole. In this case, the horizontal spacing should not exceed 1.5 metres. If the layers of draining material are continuous for the full length of the wall, weephole spacing may be increased to an extent depending on the quantity of water expected. Note: For walls higher than 2200mm, a second row of weepholes may be required. However, staining of the wall could result. B12

• For retaining walls founded on other soils, the retained material must be a free draining material with a friction angle of 27° or greater, eg Type A soil — clean sand or gravel, Type B soil — coarse grained with silt or some clay.

55mm cover to wall reinforcement

30mm

Clean-out course

50mm cover to all base reinforcement

Fig B8 — Typical Set-out Detail



Sloping backfill or surcharge

Optional capping


190 Optional capping Longitudinal reinforcement: N12 in alternate courses commencing from top course. Omit on top of clean-out block

190

H = 2200 to 3400

K Bars 290 Height of 290mm blocks

600 min lap

V Bars

V Bars

V Bars

X Bars

X Bars

X Bars

200

250

300

400

350

180

450 min lap

H = 1400 to 2000

N12 @400 cts

450 min lap

Vertical reinforcement: N12 @400 cts

N12 @400 cts

Optional capping H = 800 to 1200

Height of 190mm blocks

Longitudinal reinforcement: N12 in alternate courses commencing from top course. Omit on top of clean-out block


140

Longitudinal reinforcement: N12 in alternate courses commencing from top course. Omit on top of clean-out block

550

N12 @400

N16 @400

N16 @400

230

B

B

330 B

Fig B9 — Construction Guidelines for Reinforced & Core Filled Retaining Walls with Base Type 1

Table B3 — Design Guidelines for Reinforced & Core Filled Retaining Walls with Base Type 1 Wall Height

Reinforcement

Base Dimensions

Total Height

Height of Blockwork

(mm)

150

200

300

X-Bars

Width, B (mm)

and

with following backfill conditions

H

Series

Series

Series

V-Bars

K-Bars

Level

Max 1 in 4 Slope

800

800

—

—

N12 at 400

—

800

1000

1000

1000

—

—

N12 at 400

—

1000

1200

1200

1200

—

—

N12 at 400

—

1100

1500

1400

—

1400

—

N12 at 400

—

1300

1700

1600

—

1600

—

N16 at 400

—

1400

2000

1800

—

1800

—

N16 at 400

—

1600

2200

2000

—

2000

—

N16 at 200

—

1700

2500

2200

—

1400

800

N16 at 400

N16 at 400

1900

2800

2400

—

1600

800

N16 at 400

N16 at 400

2000

3100

2600

—

1600

1000

N20 at 400

N20 at 400

2200

3300

2800

—

1800

1000

N20 at 400

N20 at 400

2400

3600

3000

—

2000

1000

N16 at 200

N16 at 200

2600

3900

3200

—

2000

1200

N20 at 200

N16 at 200

2800

4200

3400

—

2000

1400

N20 at 200

N16 at 200

2900

4500


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May 2008

B13


Surcharge or sloping backfill (1 in 4 max.) Surcharge or sloping backfill (1 in 4 max.)

Optional capping N16 in top course only

190 Height of 190mm blocks

Optional capping Longitudinal reinforcement N12@400cts. commencing from top course. Omit on top of clean-out course

N12@400 cts Longitudinal reinforcement: N12@400

N16 in top course only

190

Surcharge or sloping backfill (1 in 4 max.) 140

Longitudinal reinforcement N12@400 cts. Omit on top of clean-out course

Optional capping

600 min. lap

H = 2200 to 3400

Longitudinal reinforcement 2 x N12@400cts. Omit on top of clean-out course

N12@400 cts H = 1400 to 2000

290

N12@400 cts

H = 800 to 1200

V Bars

K Bars

Height of 290mm blocks

V Bars

V Bars

600 min. lap

450 min. lap

SL72 Fabric

SL72 Fabric

250

SL72 Fabric

250

D

D

300 D

N16@400

N16@400

N16@400

N12@400 N12@400 W

W

W B

B

B

Fig B10 — Construction Guidelines for Reinforced & Core Filled Walls with Base Type 2

Table B4 — Design Guidelines for Reinforced & Core Filled Walls with Base Type 2 Wall Height

Reinforcement

Base Dimensions Max. 1 in 4

Total

Level Backfill

Height

Height of Blockwork

Sloping Backfill

Heel Width Base Width Heel Depth Base Width Heel Depth

(mm)

150

200

300

(mm)

(mm)

(mm)

(mm)

(mm)

H

Series

Series

Series

V-Bars

K-Bars

W

B

D

B

D

800

800

—

—

N12 at 400

—

450

600

500

800

500

1000

1000

—

—

N12 at 400

—

450

800

500

1000

500

1200

1200

—

—

N12 at 400

—

450

1000

500

1200

600

1400

—

1400

—

N16 at 400

—

450

1200

500

1400

600

1600

—

1600

N16 at 400

—

450

1400

600

1600

700

1800

—

1800

N16 at 400

—

450

1600

700

1800

800

2000

—

2000

N16 at 200

600

1800

700

2000

800

2200

—

1400

2400

—

2600

—

2800

800

N16 at 400

N16 at 400

600

2000

800

2200

900

1600

800

N16 at 400

N16 at 400

600

2200

900

2400

1000

1600

1000

N20 at 400

N20 at 400

900

2400

900

2600

1000

—

1800

1000

N20 at 400

N20 at 400

900

2600

900

2800

1100

3000

—

2000

1000

N16 at 200

N16 at 200

900

2800

1000

3000

1200

3200

—

2000

1200

N20 at 200

N16 at 200

900

3000

1100

3200

1300

3400

—

2000

1400

N20 at 200

N16 at 200

900

3200

1200

3400

1500

B14



190

Starter bar to match wall reinforcement above

Floor slab reinforcement N12 at 200 cts

One-course bond beam with N12 bar

20.20 knock-out block saw-cut at floor soffit level

Series 200 blocks

2700 max.

Horizontal reinforcement, N12 at 400 cts

Note: Wall blocks and reinforcement as for 'Typical Details'

Tanking to back face of wall e.g. Bituminous coating

Vertical reinforcement: N16 @400 cts, central

False wall

Floor slab reinforcement

Drained cavity

200

55mm cover

N16 @400 cts or N12 at 200 cts

N12 @400 cts

Ag. drain

200

Ag. drain

1000

Fig B11 — Typical Details — Fully Propped Wall


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May 2008

Fig B12 — Alternative Details — Fully Propped Wall

B15


290 190 140

190

Timber floor Timber floor

One-course bond beam using 20.20 knock-out block with 1xN12 bar Pole plate fixed to bond beam

65mm cover to back face Vertical reinforcement N16 at 400 cts, central

2700 max. Natural soil Note: Reinforcement as for ‘Typical Details’

Series 200 blocks

Tanking to back face of wall


1200

290

65mm cover to back face

Series 300 blocks

False wall Clean-out course

Natural soil

Floor slab reinforcement

Drained cavity

300

N12 at 400 cts

1500

N16 at 200 cts or N20 at 400 cts

55mm cover

Fig B13 — Typical Details — Unpropped or Partially Propped Wall

300

Ag. drain

Ag. drain

Fig B14 — Alternative Details — Unpropped or Partially Propped Wall

NOTE: Backfill must be completed prior to construction of timber floor.

B16



190

Note: Retaining wall shall be propped prior to backfilling and remain in place for a minimum of 7 days after placing floor slab

Floor slab reinforceme reinforcement nt to suit site conditions 450 lap

Vapour barrier and sand bedding under slab

Knock-out block saw-cut at floor soffit level

N12 at same spacing as vertical reinforcement N12 at same spacing as vertical reinforcement (spacing 'S') lapped 450 in wall and floor


Free-draining Free-drain ing gravel Vertical reinforcement: N12 at spacing 'S', centrally placed

'H' (2200 max.) Natural soil

Ag. drain 65mØ fall at 1:100 to outlet

Use Double-U or H blocks for sub-floor wall section

Bars 450 lap Clean-out course

Starter bars, N12 @ spacing 'S', centrally placed

450 min.

600 min.

Note: Footing size and reinforcementt to suit reinforcemen site conditions

Fig B15 — Typical Details — Subfloor Retaining Walls

Vertical Reinforcement Spacing Height H(mm) 1500

600

1500  2200

400

 >


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Spacing S(mm)

May 2008

B17


NOTES

B18


BORAL MASONRY

Build something great™

Masonry Design Guide STRUCTURAL, FIRE AND ACOUSTICS NEW SOUTH WALES BOOK 1 C FIRE DESIGN

New South Wales Book 1 C

Masonry Design for Fire Resistance

Masonry Design for Structural Adequacy FRL

Fire Resistance Levels (FRL)

Legend for the following formulae

FRL come from the Building Code of Australia’s (BCA) tables for Type A, B or C construction. The Type of construction depends on the Class of building and the number of stories or floors.

Srf = the slenderness ratio in design for fire resistance for structural adequacy. See table C2 on page C7 for maximum Srf . a vf = 0.75 ifthe memberis laterallysupported along its top edge.

There are 3 figures in the Fire Resistance Level. eg: FRL 60/120/120 meaning Structural Adequacy for 60 minutes / Integrity for120 minutes / Insulation for120 minutes.

= 2.0 if the member is not laterally supported along its top edge. H

Structural Adequacy This governs the wall height, length, thickness and restraints. Masonry unit suppliers do not control the wall height, length or restraints, therefore do not control Structural Adequacy. However, information that is useful in the design of masonry walls is the maximum Slenderness ratio (S rf ). Boral Masonry provides Srf information for all of its masonry units, and its use is discussed in more detail later.

Integrity This is the resistance to the passage of flame or gas. To provide ‘integrity’, masonry walls must be structurally adequate because cracks that form when it bows can allow flame through the wall. Since the masonryunit supplier does not control Structural Adequacy, they cannotcontrol ‘integrity’ either.

Insulation This is resistance to the passage of heat. Insulation is governed by the type and thickness of the material used to produce the masonry unit. This is controlled by the masonry unit manufacturer. In relation to FRL, masonry must always provide ‘Insulation’ to an equal or better level than is required for ‘Integrity’.

= the clear heightof a memberbetween horizontal lateral supports; or = for a memberwithout top horizontal support, the overall height from the bottom lateral support.

t

= the overall thickness of the member cross-section perpendicular to the principal axis under consideration; for members of cavity wall construction, the wall thickness assessed is in accordance with AS3700 Clause 6.3.2.1(a) and (b).

ah = 1.0 if the member is laterally supported along both its vertical edges. = 2.5 if the member is laterally supported along one vertical edge. L

= The clear length of a wall between vertical lateral supports; or = for a wall without vertical support at one end or at a control joint or forwalls containing openings, the length to that unsupported end or control joint or edge of opening.

NOTE: A control joint in a wall, or an edge to an opening in a wall, shall be regarded as an unsupported edge to the wall unless specific measures are taken to provide adequate lateral support at the edge. Structural Adequacy may be overridden by design for robustness; wind; live or earthquake loads. A fire on one side of a wall will heat that side, making it expand and lean towards the fire. When the lean or bow reaches half the thickness of the original wall, the wall becomes structurally inadequate. The formulae in AS3700, Clause 6.3.2.2 limits masonry panel size, depending on its restraints and thickness.

C2



The Slenderness ratio (Srf ) of the proposed wall is calculated as per Clause 6.3.2.2. If this value is less than the maximum Srf in Table 6.1 [or the Srf calculated from Fire Tests and Clause 6.3.3(b)(ii)], then the wall complies. If the Srf of the wall is greater than the maximum permissible, it is recalculated foran increased thickness and/orextra restraints. There are 4 formulae for calculating Srf : 6.3.2.2 (1) and (2) are the HEIGHT formulae. FORMULA 1 and 2 is:

a vf H t

Srf =

6.3.2.2 (3) is the PANEL ACTION formula. FORMULA 3 is:

Srf =

0.7 t

a vf H ah L

Forcavity walls, two thirds of the total thickness can be used for t, provided that BOTH leaves are restrained in the same positions (eg: external leaf stops at slab also). If the external leaf is a veneerto the slab edge, the internal leaf must provide the Structural Adequacy FRL on its own. For reinforced masonry, the Srf of 36, from Table C2 on page C7 may be used. Reinforcement can be horizontal, as bond beams when spanning between columns. Reinforcement can be vertical, as filled cores when spanning between slabs. In either case, reinforcement can be spaced up to 2m apart, depending on span. This reinforcement stiffens the masonry and resists bowing. Reinforced walls with S rf < 36 have a 240 minute FRL for Structural Adequacy. All calculations should be checked by an engineer. Other loads may supersede Structural Adequacy requirements.

6.3.2.2 (4) is the LENGTH formula. FORMULA 4 is: S = a rf h

Masonry Design for Integrity FRL

L t

The actual Srf is the lesser of the resulting figures. Formula (1) and (2) always govern where there is no end restraint, and often govern where walls are long, relative to their height. Projects with multiple wall lengths (eg: home units) can use this formula as a ‘one size fits all’ method of calculating the masonry thickness. Formula (3) allows a wall to exceed the height given by formula (1) and (2) provided at least one end is restrained as well as the top. Formula (4) governs the wall length, often where there is no top restraint (eg: portal frame factories) and where walls are short, relative to their height (eg: a lift well or vent shaft). From a suppliers perspective, it is helpful to be able to calculate the maximum height* for a given thickness (masonry unit), eg:

H =

It is impractical to provide test results forall possible masonry wall designs, and therefore ‘Integrity’ must be proved in some otherway. With masonry wall design, the most practical way to prove ‘Integrity’ is to prove ‘Structural Adequacy’ and ‘Insulation’ equal to or betterthan the ‘Integrity’requirement. (Logically, if the wall is designed to minimise ‘bowing’ it will not crack and therefore resist the passage of flame and gas for the specified time). This method is also the best way to prove ‘integrity’ even when a wall may not be required to comply with a ‘structural adequacy’ FRLvalue,such as is the case with non loadbearing walls. eg: if the BCA requires an FRL of -/90/90, the wall has no actual ‘structural adequacy’ requirement, but to prove integrity of 90 minutes, the wall must be structurallyadequate for 90 minutes.

Srf x t a vf

and calculate the thickness from a given wall size. t =

a vf x H Srf

where ‘t’ is the OVERALL thickness, whether the units are solid or hollow. NOTE:* Refer to the Structural Adequacy Selection Graphs on pages C9 to C20 for maximum height values.


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May 2008

C3


Masonry Design for Insulation FRL

Effect of Chases on Fire Rated Masonry

Insulation is the one FRL component that a masonry unit manufacturer does control. It is governed by the ‘type of material’ and the ‘material thickness’.

Structural Adequacy FRL

‘Material thickness’ is defined in AS3700, Clause 6.5.2 as the overall thickness for solid and grouted units and units with cores not more than 30% of the unit’s overall volume. For hollow units (cores > 30%), the material thickness is the net volume divided by the face area. For cavity walls, t = the sum of material thicknesses in both leaves, (not two thirds as for the Structural Adequacy FRL).

To assess the effect of chases on Structural Adequacy FRLs, the direction in which the wall spans must be taken into account. Walls spanning vertically may be chased vertically. The horizontal chase is limited to 4 times the wall thickness. Walls spanning vertically and horizontally may be chased horizontally up to half the wall length. Horizontal chases should be kept to a bare minimum. Walls spanning vertically and horizontally may be chased vertically up to half the wall height.

Options for Increasing FRLs

If these limits are exceeded, the masonry design thickness The Structural Adequacy FRL can be increased by adding must be reduced by the depth of the recess or, in the case of wall stiffeners, byincreasing the overall thickness, byadding vertical chases, designed as 2 walls with unsupported ends reinforcement or byprotecting the wall with Boral Plasterboard at the chase. ‘FireStop’ board, fixed to furring channels (on both sides of Integrity and Insulation FRLs the wall if a fire rating is required from both sides). Maximum depth of recess is 30mm. Maximum area is Integrity FRLs are increased by increasing the other two FRL 1,000mm2. Total maximum area on both sides of any 5m2 of values to the required Integrity FRL. wall is 100,000mm2 Insulation FRLs can be increased by core filling, by adding another leaf of masonry, by rendering both sides of the wall if the fire can come from either side. NOTE: Only ONE thickness of render is added to the material thickness and that must be on the ‘cold’ side because the render on the exposed face will drop off early in a fire). Boral ‘FireStop’ plasterboard on furring channels can increase the Insulation FRL from either side. Unlike render, the Boral FireStop and furring system does not drop off the hot side so quickly due to the board’s fire resistance, the mechanical fixing of the board to furring and the furring to the wall.

C4

If these limits are exceeded, the masonry design thickness must be reduced by the depth of the recess.

Recesses for Services Recesses that are less than half of the masonrythickness and are less than 10,000mm2 for both sides within any 5m2 of the masonry, do not have an effect on fire ratings. If these limits are exceeded, the masonry design thickness must be reduced by the depth of the recess.



How to Select Boral Masonry Units for Fire Rated Walls All design information, table data and graphs in this guide are derived from formulae in AS3700 : 2001 Masonry Structures, Part 6.3 for Structural Adequacy Fire Resistance Levels (FRL) and Part 4.6 for Robustness.

Step 1

Tables and graphs assume all walls are built on concrete slabs or broad footings and have adequate restraints. Piers, cavity walls, freestanding walls, earthquake, wind and other loads are not addressed in this guide. All fire rated walls should be designed by a suitably qualified engineer.

Example

Determine required wall FRL from the Building Code of Australia (BCA). The Building Code of Australia (BCA), Section C defines the CLASS and TYPE of building and designates the required Fire Resistant Level (FRL) in terms of three criteria. See adjacent example.

NOTE: For masonry wall design, the FRL for any given wall must comply with: Structural Adequacy ≥ Integrity ≤ Insulation

eg: 120/60/60 Insulation Integrity Structural Adequacy

eg. If the BCA required FRL is: –/120/60 Then the chosen wall design must have an actual FRL of: 120/120/120 or better.

Refer to the section ‘Design for Integrity’ on page C3 for additional explanation.

Worked Example A 6m high, 6m long fire rated, non-loadbearing wall in a 3 storey warehouse. BCA specifies Class 7, Type b Construction. BCA Section C1.1, Table 4 specifies an FRL 240/240/240.


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May 2008

C5


Step 2

Worked Example

Select an appropriate Boral Masonry Unit based on the FRL ‘Insulation Requirement’.

From Table C1, the following units all achieve 240 minutes FRL for ‘Insulation’:–

The third figure in an FRL rating is the ‘Insulation’.

• Scoria Blend 15.401, 20.401, and 11.119F

Table C1 provides the ‘Insulation’ values for the various Boral units. Check the ‘Materials Attributes’ (see notes below the table) to ensure the selection is fit for its purpose.

• Calcium Silicate Basalt 165S119B • Grouted Masonry (190mm) 20.42 and 20.91. If the wall is non loadbearing, the use of Scoria Blend may be the more cost effective.

Table C1 – FRL Insulation Values for Boral Masonry Units (New South Wales) Fire Test

INSULATION FRL (minutes) 30

60

90

120

180

240

Material

Product Code/Type

Yes

FireBlock/FireBrick (F) Scoria Blend 10.201; 15.201; 20.201; 9.162F

Yes

FireBlock/FireBrick (F) Scoria Blend 10.331; 15.301; 20.301

Yes

FireBlock/FireBrick (F) Scoria Blend 15.401; 20.401; 11.119F

Yes

FireLight (FL)

10.01FL; 15.01 FL: 20.01FL; 9.162FL

Yes

FireLight (FL)

10.119FL; 11.162FL

Basalt-Concrete (B)

15.01B

Basalt-Concrete (B)

10.01B; 10.31B; 20.01B; 9.162B

Basalt-Concrete (B)

10.119B

Basalt-Concrete (B)

11.119B + other 110mm cored

d.t.s.

Calcium Silicate Basalt

M3H119B; + other 90mm

d.t.s.


S3H119B; + other 110mm

d.t.s.


140S119B; + other 140mm

d.t.s.


165S119B

d.t.s.

DesignerBlock and Standard Grey Concrete 15.01.

d.t.s. d.t.s.

+render

d.t.s. d.t.s.

+render

d.t.s.

DesignerBlock and Standard Grey Concrete 10.01; 10.31; 20.01

+render

d.t.s.

+render

d.t.s.

d.t.s.

‘deemed to satisfy’.

Grouted Masonry 140mm

15.42; 15.91

Grouted Masonry 190mm

20.42; 20.91

+render = 10mm render both faces

* Product Codes listed are for the ‘Full Size Unit’. Fractional size blocks in the same range have the same FRL rating.

Material Attributes (New South Wales) Scoria Blend – High Fire Rated Block – ƒ ’ uc = 4MPa. Offers excellentInsulation and Structural AdequacyFRLs forNONLOADBEARING fire rated walls. 10% lighter than Standard Grey units. Scoria Blend is hard,durable and suitable forpaintorrender. Acoustic performance with plasterboard linings is excellent. Acoustic performance with render is medium range.

for LOADBEARING walls. Acoustic performance with plasterboard is excellent. Acoustic performance with render is excellent. Designer Block ƒ ’uc = 15MPa. Blocks provide a 60 minute Insulation FRL. Suitable for LOADBEARING applications. Standard Grey Block ƒ ’uc = 10MPa.

FireLight (FL) – ƒ ’uc = 3MPa Insulation FRL of 90 to 120 minutes. High slenderness ratio (S rf ) for Structural Adequacy FRL. Suitable for NON LOADBEARING fire rated walls. Lightweight, 35% lighterthan Standard Grey units. Acoustic performance with plasterboard linings is excellent. B as al t ( B) ƒ ’ uc = 10MPa for blocks and 12MPa for bricks

Suitable for LOADBEARING walls. 60 minute insulation FRL as hollow blockwork. Reinforced Grout Filled Masonry ƒ ’uc = 15MPa. AS3700 allows an Srf value of 36 for reinforced masonry. This in turn allows for the largest walls to be built using the thinnest masonry option. Suitable for LOADBEARING applications. Grout strength to be 20MPa. 240 minute insulation FRL as fully grout filled blockwork.

Offers excellent Srf values forStructural Adequacy FRL. Suitable C6



Step 3

Worked Example

Check the ‘Structural Adequacy’of the selected units.

The calculated Srf value for your wall design MUST NOT EXCEED the value from the accompanying table.

The Slenderness ratio (S rf ) of a fire rated wall is calculated as per AS3700 : 2001, Clause 6.3.2.2, and must not exceed the Srf values given in AS3700 or calculated from Fire Tests. Table C2provides the maximum Srf values for Boral masonry units.

See following page for an explanation on using the Boral Srf graphs to assist preliminary selection. eg. Scoria Blend required to provide Structural Adequacy for 240 minutes has an S rf = 24. (refer to Table C2 below). Also refer to the previous explanation and AS3700 for Srf calculation methods. In this example, the 6 x 6m wall, with lateral restraint on 4 sides, 190mm thick has an Srf = 19.2. as per formula 6.3.2.2 (3). Alternative is 20.91 with reinforcement and core filling, however, as the wall in this example is non-loadbearing, the Scoria Blend 20.401 is the more economical solution.

Table C2 – Maximum Srf Values for Boral Masonry Units Srf Values Fire

FRL (minutes) for Structural Adequacy

Test

30

60

90

120

180

240

Material

Condition of use

Yes

25.9

25.9

25.9

25.9

25.9

24

Scoria Blend (F) FireBrick/FireBlock

Non loadbearing ONLY

Yes

20.4

20.4

20.4

20.4

20.4

20.4

Custom Scoria Blend (S)

Loadb’g 110mm made to order

Yes

29

29

26.9

24.9

22.2

20.3

FireLight (FL)

Non loadbearing ONLY

d.t.s.

25

22.5

21

d.t.s.

25

22.5

21

20

18

17

Basalt-Concrete (B)

Any

20

18

17

Calcium Silicate-Basalt

Any

d.t.s.

19.5

18

17

16

15.5

15

Standard Grey and Designer Block

Any

d.t.s.

36

36

36

36

36

36

Reinforced & Grouted Masonry

Any

d.t.s.= deemed to satisfy, as per AS3700 : 20 01, Table 6.1.


|

May 2008

C7


Boral Structural Adequacy Selection Graphs & Tables To assist with the preliminary selection of Boral masonry units for fire rated walls, a graphical selection method based on Srf values has been developed. The following pages provide graphs and tables for a selection of Boral masonry units where at least one end of the wall has lateral restraint.

IMPORTANT The following selection graphs are based on Specific Products manufactured at New South Wales Boral Plants. Should these units be sourced from other plants, the specification should be checked with the respective supply plant.

Additional tables are provided forwalls with no end restraint and for reinforced/grout filled masonry, following these graphs.

How to Use the Boral Structural Adequacy FRL Graphs Scoria-Blend

Worked Example 1. Select the appropriate masonry unit material.

Structural Adequacy 240 minutes FRL

T R O P P U S

Laterally supported both ends and top

SUPPORT

T R O P P U S

SUPPORT

9

Leaf Thickness

8 7 ) 6 m ( s t r 5 o p p u s 4 n e e w 3 t e b l l a 2 w f o t 1 h g i e H 0

190mm

140mm 110mm 90mm

0

1

2

3

4

5

6

7

8

9

2. Select the appropriate page with Structural Adequacyforthe required minutes. (240 minutes for this example). 3. Select the appropriate graph for the chosen wall restraint (support) criteria. (Support on both sides, top and bottom for this example). 4. Plot the intersection of the Wall Height and the Wall Length on the graph. (For this example 6m height x 6m length). 5. The result MUST FALL BELOW the coloured line indicated for the chosen masonry unit thickness. In this example, the result is above the line for 140mm units but below the line for190mm units. Therefore 190mm units would be suitable. (140mm units would not be suitable for this example).

Length of wall between supports (m)

Index to Structural Adequacy FRL Graphs & Tables Product Group

FRL Minutes (Structural Adequacy)

Page

NSW Firebrick™/Fireblock™ Scoria Blend Masonry (F) NSW Firebrick™/Fireblock™ Scoria Blend Masonry (F) FireLight Brick (FL) FireLight Brick (FL) Basalt – Concrete Masonry (B) Basalt – Concrete Masonry (B) Calcium Silicate – Basalt Masonry Calcium Silicate – Basalt Masonry Calcium Silicate – Basalt Masonry Calcium Silicate – Basalt Masonry Standard Grey and Designer Block Standard Grey and Designer Block Walls Restrained at Top (Unrestrained Ends) Reinforced Masonry Walls

60 – 180 240 90 120 60 90 60 90 120 180 60 90 60 – 240 60 – 240

C9 C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 C21 C22

C8



NSW FireBrick™/FireBlock™ Scoria Blend Masonry (F) -

Srf = 25.9

Structural Adequacy for 60-180 minutes Fire Resistant Level (FRL)

Structural Adequacy 60 – 180 minutes FRL

T R O P P U S


SUPPORT


T R O P P U S

SUPPORT

T R O P P U S

Laterally supported both ends, top free

9

Leaf Thickness

T R O P P U S

SUPPORT

9

Leaf Thickness

8

8 190mm

7 ) 6 m ( s t r 5 o p p u s 4 n e e w 3 t e b l l a 2 w f o t 1 h g i e H 0

140mm 110mm 100mm 90mm

0

1

2

3

4

5

6

7

8


T R O P P U S

Laterally supported one end and top

SUPPORT

7

7

) 6 m ( s t r 5 o p p u s 4 n e e w 3 t e b l l a 2 w f o t 1 h g i e H 0


190mm

140mm 110mm 100mm 90mm

4

5

6

7

8

|

5

6

7

8

9

T R O P P U S

9

SUPPORT

Leaf Thickness

190mm 140mm 110mm 90/ 100mm 0

1

2

3

4

5

6

7

8

9




4

9 8

3

3

Laterally supported one end top free

SUPPORT

8

2

2


Leaf Thickness

1

1


9

0

140mm 110mm 100mm 90mm

0

9



190mm

May 2008

C9


NSW FireBrick™/FireBlock™ Scoria Blend Masonry (F) -

Srf = 24

Structural Adequacy for 240 minutes Fire Resistant Level (FRL)


T R O P P U S


SUPPORT


T R O P P U S

SUPPORT


9

Leaf Thickness

8

7

7 190mm


140mm 110mm 100mm 90mm

1

2

3

4

5

6

7

8

T R O P P U S


SUPPORT

7



190mm

140mm 110mm 100mm 90mm

5

6


C10

3

4

5

6

7

8

9

7

T R O P P U S

8

9

SUPPORT

9

7

4

2


SUPPORT

8

3

1


8

2

190mm 140mm 110mm 100mm 90mm


Leaf Thickness

1

Leaf Thickness

0

9

9

0

SUPPORT




T R O P P U S

9

8

0

T R O P P U S

Leaf Thickness

190mm 140mm 110mm 90/ 100mm 0

1

2

3

4

5

6

7

8

9




FireLight Bricks (FL) -

Srf = 26.9



T R O P P U S


SUPPORT


T R O P P U S

SUPPORT


9

Leaf Thickness

8

190mm



110mm 100mm 90mm

1

2

3

4

5

6

7

8

T R O P P U S


SUPPORT

7

7



190mm

140mm 110mm 100mm 90mm

4

5

6

7

8

|

3

4

5

6

7

8

9

T R O P P U S

9

SUPPORT

Leaf Thickness

190mm 140mm 110mm 90/ 100mm 0

1

2

3

4

5

6

7

8

9




2

9 8

3

1

Laterally supported one end, top free

SUPPORT

8

2

140mm 110mm 100mm 90mm


Leaf Thickness

1

190mm


9

0

Leaf Thickness

0

9



SUPPORT

8 7

140mm

T R O P P U S

9

7

0

T R O P P U S

May 2008

C11


FireLight Bricks (FL) -

Srf = 24.9



T R O P P U S


SUPPORT


T R O P P U S

SUPPORT


9

Leaf Thickness

T R O P P U S

SUPPORT

9

Leaf Thickness

8

8 7

190mm


140mm 110mm 100mm 90mm

0

1

2

3

4

5

6

7

8



T R O P P U S


SUPPORT

7

7


190mm

140mm 110mm 100mm 90mm

4

5

6


3

4

5

6

7

8

9

7

T R O P P U S

8

9

SUPPORT

9 8

3

2


SUPPORT

8

2

1


Leaf Thickness

1

140mm 110mm 100mm 90mm


9

0

190mm

0

9


C12

T R O P P U S

Leaf Thickness


190mm 140mm 110mm 90/ 100mm 0

1

2

3

4

5

6

7

8

9




Basalt-Concrete Masonry (B) Srf = 22.5 Structural Adequacy for 60 minutes Fire Resistant Level (FRL)


T R O P P U S


SUPPORT


T R O P P U S

SUPPORT


9

Leaf Thickness

8

7

7


190mm

140mm 110mm 100mm 90mm

1

2

3

4

5

6

7

8

T R O P P U S


SUPPORT

7



190mm

140mm 110mm 100mm 90mm

5

6

7



|

3

4

5

6

7

8

9

May 2008

T R O P P U S

8

9

SUPPORT

9

7

4

2


SUPPORT

8

3

1


8

2

190mm 140mm 110mm 90mm


Leaf Thickness

1

Leaf Thickness

0

9

9

0

SUPPORT




T R O P P U S

9

8

0

T R O P P U S

Leaf Thickness

190mm 140mm 110mm 90mm 0

1

2

3

4

5

6

7

8

9


C13


Basalt-Concrete Masonry (B) -

Srf = 21



T R O P P U S


SUPPORT


T R O P P U S

SUPPORT


9

Leaf Thickness

8

7

7



190mm

140mm 110mm 100mm 90mm

1

2

3

4

5

6

7

8

T R O P P U S


SUPPORT

7

7



190mm

140mm 110mm 100mm 90mm

4

5

6


C14

3

4

5

6

7

8

9

7

T R O P P U S

8

9

SUPPORT

9 8

3

2


SUPPORT

8

2

1


Leaf Thickness

1

190mm 140mm 110mm 90mm


9

0

SUPPORT

Leaf Thickness

0

9



T R O P P U S

9

8

0

T R O P P U S

Leaf Thickness

190mm 140mm 110mm 90mm 0

1

2

3

4

5

6

7

8

9




Calcium Silicate-Basalt Masonry (Boral Calsil™) -

Srf = 22.5



T R O P P U S


SUPPORT


T R O P P U S

SUPPORT


9

Leaf Thickness

8

7

7



140mm 110mm 90mm

1

2

3

4

5

6

7

8

T R O P P U S


SUPPORT

7

7



140mm 110mm 90mm

4

5

6

7



|

3

4

5

6

7

8

9

May 2008

T R O P P U S

8

9

SUPPORT

9 8

3

2


SUPPORT

8

2

1


Leaf Thickness

1

140mm 110mm 90mm


9

0

SUPPORT

Leaf Thickness

0

9



T R O P P U S

9

8

0

T R O P P U S

Leaf Thickness

140mm 110mm 90mm 0

1

2

3

4

5

6

7

8

9


C15



Srf = 21



T R O P P U S


SUPPORT


T R O P P U S

SUPPORT


9

Leaf Thickness

8

7

7



140mm 110mm 90mm

1

2

3

4

5

6

7

8

T R O P P U S


SUPPORT

7

7



140mm 110mm 90mm

4

5

6


C16

3

4

5

6

7

8

9

7

T R O P P U S

8

9

SUPPORT

9 8

3

2


SUPPORT

8

2

1


Leaf Thickness

1

140mm 110mm 90mm


9

0

SUPPORT

Leaf Thickness

0

9



T R O P P U S

9

8

0

T R O P P U S

Leaf Thickness

140mm 110mm 90mm 0

1

2

3

4

5

6

7

8

9





Srf = 20



T R O P P U S


SUPPORT


T R O P P U S

SUPPORT


9

Leaf Thickness

8

7

7



140mm 110mm

1

2

3

4

5

6

7

8

T R O P P U S


SUPPORT

7

7



140mm 110mm

4

5

6

7



|

3

4

5

6

7

8

9

May 2008

T R O P P U S

8

9

SUPPORT

9 8

3

2


SUPPORT

8

2

1


Leaf Thickness

1

140mm 110mm


9

0

SUPPORT

Leaf Thickness

0

9



T R O P P U S

9

8

0

T R O P P U S

Leaf Thickness

140mm 110mm

0

1

2

3

4

5

6

7

8

9


C17



Srf = 18



T R O P P U S


SUPPORT


T R O P P U S

SUPPORT


9

Leaf Thickness

8

7

7



140mm 110mm

1

2

3

4

5

6

7

8

T R O P P U S


SUPPORT

7

7



140mm 110mm

4

5

6


C18

3

4

5

6

7

8

9

7

T R O P P U S

8

9

SUPPORT

9 8

3

2


SUPPORT

8

2

1


Leaf Thickness

1

140mm 110mm


9

0

SUPPORT

Leaf Thickness

0

9



T R O P P U S

9

8

0

T R O P P U S

Leaf Thickness

140mm 110mm

0

1

2

3

4

5

6

7

8

9




Standard Grey and Designer Block™

Srf = 18.0



T R O P P U S


SUPPORT


T R O P P U S

SUPPORT


9

Leaf Thickness

8

7

7



190mm 140mm 110mm 90mm

1

2

3

4

5

6

7

8

T R O P P U S


SUPPORT

7

7



190mm 140mm 110mm 90mm

4

5

6

7



|

3

4

5

6

7

8

9

May 2008

T R O P P U S

8

9

SUPPORT

9 8

3

2


SUPPORT

8

2

1


Leaf Thickness

1

190mm 140mm 110mm 90mm


9

0

SUPPORT

Leaf Thickness

0

9



T R O P P U S

9

8

0

T R O P P U S

Leaf Thickness

190mm 140mm 110mm 90mm 0

1

2

3

4

5

6

7

8

9


C19


Standard Grey and Designer Block™

Srf = 17.0



T R O P P U S


SUPPORT


T R O P P U S

SUPPORT


9

Leaf Thickness

8

7

7



190mm 140mm 110mm 90mm

1

2

3

4

5

6

7

8

T R O P P U S


SUPPORT

7

7



190mm 140mm 110mm 90mm

4

5

6


C20

3

4

5

6

7

8

9

7

T R O P P U S

8

9

SUPPORT

9 8

3

2


SUPPORT

8

2

1


Leaf Thickness

1

190mm 140mm 110mm 90mm


9

0

SUPPORT

Leaf Thickness

0

9



T R O P P U S

9

8

0

T R O P P U S

Leaf Thickness

190mm 140mm 110mm 90mm 0

1

2

3

4

5

6

7

8

9




Walls Restrained at Top (Unrestrained Ends)

SUPPORT

Walls without restraint to the ends, but with lateral restraint along their top have maximum heights irrespective of their length as detailed in the following table. (Most doorways and windows create free ends).

SUPPORT

These heights can be exceeded when one or both ends are restrained as well as the top. Material

Thickness

Maximum Wall Height (metres) Structural Adequacy (FRL minutes) 60

90

120

180

240

Scoria Blend/FireBrick

90mm

2.430

2.430

2.430

2.430

2.430


100mm

2.700

2.700

2.700

2.700

2.700


110mm

2.970

2.970

2.970

2.970

2.970


140mm

3.780

3.780

3.780

3.780

3.780


190mm

5.130

5.130

5.130

5.130

5.130

FireLight (FL)

90mm

2.430

2.430

2.430

2.430

2.430

FireLight (FL)

100mm

2.700

2.700

2.700

2.700

2.700

FireLight (FL)

110mm

2.970

2.970

2.970

2.970

2.970

FireLight (FL)

140mm

3.780

3.780

3.780

3.780

3.780

FireLight (FL)

190mm

5.130

5.130

5.130

5.130

5.130

Basalt-Concrete (B)*

90mm

2.430

2.430

2.400

2.160

2.040


100mm

2.700

2.700

2.667

2.400

2.267


110mm

2.970

2.970

2.933

2.640

2.493


140mm

3.780

3.780

3.733

3.360

3.173


190mm

5.130

5.130

5.067

4.560

4.307

Calsil-Basalt*

90mm

2.430

2.430

2.400

2.160

2.040

Calsil-Basalt*

110mm

2.970

2.970

2.933

2.640

2.493

Calsil-Basalt*

140mm

3.780

3.780

3.733

3.360

3.173

Calsil-Basalt*

165mm

4.455

4.455

4.400

3.960

3.740


90mm

2.160

2.040

1.920

1.860

1.800


110mm

2.640

2.493

2.347

2.273

2.200


140mm

3.360

3.173

2.987

2.893

2.800


190mm

4.560

4.307

4.053

3.927

3.800

Reinforced & Grout Filled*

140mm

5.040

5.040

5.040

5.040

5.040

Reinforced & Grout Filled*

190mm

6.840

6.840

6.840

6.840

6.840

*Governed by Robustness. Can be higher if supporting a slab.


|

May 2008

C21


Reinforced Masonry Walls Reinforced cores spanning vertically, ie. restraint top and bottom

Reinforced bond beams spanning horizontally, ie. restraint bottom and both ends



Lateral support along top

Lateral support at both ends

SUPPORT

Single Steel reinforced

Single Steel reinforced and Core fill spacing

and fully grouted cores

fully grouted bond beams

SUPPORT

Slab or broad footing

Maximum

Leaf

Wall Height

Core Fill

Thickness

(metres)

Steel

Spacing (metres)

(mm)

4.000

N12

Every 10th core – (2m)

5.040

N16

4.800

Slab or broad footing

T R O P P U S

T R O P P U S

Bond beam spacing

SUPPORT

Maximum

Leaf

Wall Length

Bond Beam

Thickness

(metres)

Steel

Spacing (metres)

(mm)

140

4.000

N12

Every 10th course – (2m)

140


140

5.040

N16


140

N12


190

4.800

N12


190

6.400

N16


190

6.400

N16


190

6.840

N16

Every 8th core – (1.6m)

190

6.840

N16

Every 8th course – (1.6m)

190

Maximum vertical load on wall = 11.25 H kN/m where H is in metres.

C22


BORAL MASONRY


Masonry Design Guide STRUCTURAL, FIRE AND ACOUSTICS NEW SOUTH WALES BOOK 1 D ACOUSTIC DESIGN

New South Wales Book 1 D

Acoustic Performance Ratings STC and Rw. STC (Sound Transmission Class) and Rw (Weighted Sound Reduction Index) are similar in that they are a single number evaluation of STL (Sound Transmission Loss) measurements over 16 frequencies. The use of STC was changed to Rw in BCA Amendment 6, issued in January 2000. The lowest frequency measured in R w is 100Hz. (STC started at 125Hz). The highest frequency measured in Rw is 3150Hz. (STC finished at 4000 Hz). AS1276 gives a set contour that is positioned over the STL results so that the total of points above the results and below the contour (deficiencies) does not exceed 32. Rw is then read off where the contour crosses the 500Hz line. The maximum 8dB deficiency, which pulled the STC contour down, is not used for Rw. Instead, there are two numbers after Rw, eg: Rw45 (-1; -5). The first figure in the brackets is an indication of deterioration due to high frequencynoise (eg. a blender). The second figure indicates deterioration due to low frequency noise (eg. low speed trucks, bass guitar, or home cinema speakers).

Masonry with Plasterboard Systems Daub-fixed Plasterboard The cornice cement daubs, used to fixplasterboard to masonry, create a small cavity in which resonances can occur. The more dense, smooth and impervious the masonry is the more it will ‘bounce’or resonate the sound, allowing the plasterboard to re-radiate the sound. Tests on linings with extra daubs (spacing was halved) gave lower performances, presumably due to extra ‘bridges’through the daubs. Concrete masonry has a coarser texture and is more porous than clay. The noise energy that gets through the wall and ‘bounces’ off the plasterboard is re-absorbed into the concrete, where it dissipates, as a tiny amount of heat. Lightweight concrete masonry performs relatively poorlywhen bare. When lined, it gives a vast improvement. Higher density concrete units improve the Rw of the bare wall, but when plasterboard is daub fixed, the amount of improvement decreases as the concrete units begin to behave similarly to clay.

Masonry with Plasterboard on Furring Channels

From May 2004, the BCA required impact rated walls to be of ‘discontinuous construction’.

Furring channels are rollformed galvanised metal battens to which plasterboard can be fixed, using self tapping screws. Popular products include Rondo rollformed steel furring channel (Nº129 which is 28mm deep) or (Nº308 which is 16mm deep).

An impact rating is required for walls where a wet area (including a kitchen) is opposite a habitable room in an adjoining apartment.

Furring channels increase the gap between masonry and plasterboard, making it harder forresonating energy to build up pressure on the board.

Masonry with Render

Plumbing and electrical services can be fitted into this gap, avoiding the need to “chase” recesses into the masonry.

Impact Sound Resistance

Acoustic performance with single leaf rendered masonry follows the ‘Mass Law’. The acoustic performance of these walls depends on their mass. More mass gives better performance. The relationship is logarithmic: If a 110mm wall gives Rw45, a 230mm wall of the same brick may give Rw57, and a 450mm wall may give Rw63. Cavity walls behave differently. Sound waves can resonate in cavities. The narrowerthe cavity becomes, the more resonance occurs. Insulation in the cavity helps absorb resonating sound. Narrow cavities should have bond breaker board to prevent mortar from providing a bridge for sound to travel between leaves.

D2

A further increase of 3 or 4dB can be achieved with Tontine TSB3 polyester (or equivalent) insulation in the cavity between the plasterboard and masonry. Another increase of 3 to 5dB can be achieved with a second layer of plasterboard, fixed with grab screws to the first layer, (and no gaps). Boral Plasterboard now make ‘SoundStop’, a higher density board.



Masonry with Plasterboard on Stud Framing

How loud is noise?

In this system, vibrations are isolated by the gap between the masonry and the stud frame. Plasterboard is screwfixed to the outside of a stud wall, which is positioned 20mm from one face of the masonry. An extra 6dB can be gained byplacing Tontine TSB5 insulation between the studs. The other side of the masonry can be lined with daub fixed plasterboard or rendered. 13mm render can add an extra 1dB more than daub fixed board. This system complies with the BCA requirement of ‘discontinuous construction’ for impact rated walls.

Designing Masonry Walls for Acoustic Performance Building acoustics is the science of controlling noise in buildings, including the minimisation of noise transmission from one space to another and the control of noise levels and characteristics within a space. The term ‘building acoustics’ embraces sound insulation and sound absorption. The two functions are quite distinct and should not be confused. Noise has been defined as sound which is undesired by the recipient, but it is very subjective and it depends on the reactions of the individual. However, when a noise is troublesome it can reduce comfort and efficiency and, if a person is subjected to it forlong enough periods, it can result in physical discomfort or mental distress. In the domestic situation, a noisy neighbour can be one of the main problems experienced in attached dwellings. The best defence against noise must be to ensure that proper precautions are taken at the design stage and during construction of a building. This means that the correct acoustic climate must be provided in each space and that noise transmission levels are compatible with the usage. Remedial measures, after occupation, can be expensive and inconvenient. Ideally, the sound insulation requirements for a building should take into account both internal and external sound transmission.

Sound Insulation Any wall system that separates one dwelling from another, or that separates one room from another, should be selected to provide a sufficient level of insulation against noise. There are two types of noise transfer through partitions, airborne transfer, and structure-borne transfer. Both may need to be considered in order to achieve the desired result. Noise sources, such as voices, televisions and musical instruments, generate noise in the air in one room, and this noise passes through the partition and into the room on the other side. This is known as airborne noise. As we know,some partitions are betterthan others atisolating airborne noise. In order to simply compare the isolating performance of partitions Rw rating was developed. Apartition with a high Rw rating isolates sound better than a partition with a low Rw rating. If we compare two partitions, and one has an Rw which is 10 rating points higher, then the noise passing through the wall with the higher Rw will be about half the loudness when compared with the noise passing through the wall with the lower Rw. The Rw ratings are obtained from tests carried out in certified laboratories, under controlled conditions. When identical partitions are part of buildings and tested in-situ, it is often found that the actual Rw rating obtained, usually called the Weighted Standardised Level Difference (Dnt,w), is lower than


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May 2008

D3


the laboratory Rw. This reduction in performance can be due to flanking paths (that is to say that noise also passes through other parts of the building) or may be due to poor detailing such as incorrect installation of pipes, power points etc.

Structure-borne Noise & Weighted Normalised Impact Sound Pressure Level (L’ n,w) When a building element is directly, or indirectly, impacted or vibrated then some of the energy passes through the partition and is re-radiated as noise to the room on the other side. This is called structure-borne noise or impact noise. For walls, the most common sources of structure-borne noise are: • Cupboard doors, fixed to party walls, being closed

energy absorbed over a range of frequencies between 250Hz and 2000Hz. Boral Acousticell blocks have extremely high absorption rates (90%) at low frequency. Refer to Acousticell product page in this guide and the Boral Masonry Block Guide. The porous surface and lightweight aggregates in lightweight masonry give it high sound absorption values (> 50%) across all frequencies. Refer to the ‘Lightweight’ product page in the Fire Rated Walls section of this guide.

Sound Isolation Criteria In May 2004, the Building Code of Australia (BCA) specifications for minimum levels of sound isolation were increased. These increased specifications are:

• Kitchen appliances being used on benches touching walls

• Unit to corridor or stairs

Rw ≥ 50

• Plumbing fittings, particularly taps, being connected to walls

• Unit to unit

Rw + Ctr ≥ 50

• Light switches being turned on and off, and • Dishwashers, washing machines, clothes dryers etc. touching walls Walls satisfy ‘impact’ or structure-borne noise isolation either by conforming to the ‘deemed to satisfy’ provisions of the Building Code ofAustralia ‘Impact Sound’or‘Testof Equivalence’, using a single number description for impact insulation or the Opinion of a suitably qualified acoustic engineer. The generally accepted test forimpact is Weighted Normalised Impact Sound Pressure Level or L’n,w . In this method of interpreting impact sound resistance, lowervalues represent better impact insulation. Another single number description used for impact is the Impact Insulation Class or IIC. When used for walls it may be called WIIC for laboratory testing or WFIIC for field testing. Unfortunately, as there are different test methods used to obtain the impact rating for walls, results cannot always be directly compared. The largerthe value of the WIICthe betterthe impact insulation.

Noise Reduction Coefficient (NRC) Designers of theatres, music rooms, power transformer enclosures, etc, may often choose materials which have an efficient sound absorption value and incorporate them within the building design. The level of sound absorption for material is stated as the NRC (Noise Reduction Coefficient). This value is derived as a result of acoustic testing on the material, and determined by calculation from the average amount of sound

D4

• Where a wet area of one unit adjoins a habitable room in another unit, the wall construction must ‘be of a discontinuous type.’

Guidelines for Optimum Performance To achieve the optimum performance for a wall system, the exact construction as specified including perimeter sealing must be adopted. Anyvariations from the systems detailed in this guide should be approved by the project acoustic consultant as it can increase or decrease the acoustical isolation of wall systems.

Installation Unless careful attention to installation detail is followed,significant reductions in sound isolation can occur, particularly with high performance walls. The following need to be taken into account.

Perimeter Acoustical Sealing It should be noted that as the sound isolation performance of a partition increases, then the control of flanking paths becomes more critical. Consequently, the perimeter sealing requirements for a low sound rating wall, such as Rw30, are much less than for a high sound rating wall, such as Rw60. However, it is neither necessary, nor is it cost effective, to provide very high perimeter acoustic sealing for a low rating R w wall. The perimeter isolation for each leaf must be commensurate with the acoustic isolation of the leaf. It cannot be over emphasised, however, that for high performance walls, the sealing of each leaf must be virtually airtight.



For a sealant to be effective at controlling noise passing through gaps, it must have the following properties.

IMPORTANT: The use of expanding foam sealants is not acceptable.

• Good flexibility, elastic set

Reference should be made to the manufacturer to ensure the particular type or grade of sealant is suitable for the purpose.

• Low hardness • Excellent adhesion, usually to concrete,timber, plasterand galvanised steel • Minimal shrinkage (less than 5%) • Moderate density (greater than 800kg/m3), and • Fire rated where required (All walls required by the BCA to be sound rated also have fire ratings) All of the above properties must be maintained over the useful life of the building, that is, greater than 20 years. Examples of a suitable sealant include: • Bostik Findley – Fireban One • Boral Plasterboard Fyreflex • Boral Plasterboard WR Sealant • Tremco synthetic rubber acoustical sealant • Some silicone sealants and • Some acrylic latex sealants

Noise Flanking It is beyond the scope of this manual to provide full details for control of all flanking paths. However, flanking can significantly reduce the perceived isolation of a wall system and should therefore be given careful consideration. Typical flanking paths are shown in the Fig D1.

Acoustic Performance On-Site Laboratory Test results are achieved under ideal controlled conditions, and estimates are calculated from known performance, experience and computer simulation programs. To repeat the performance in the field, attention to detail in the design and construction of the partition and its adjoining floor/ ceiling and associated structure is of prime importance. Even the mostbasic principles, if ignored, can seriously downgrade the sound insulation performance of a building element.

Through ventilation and service ducts

Through windows, doors, gaps and air leaks

Through ceilings and the above ceiling cavity

Through perimeter joints between the wall and floor, or the wall and ceiling (or underside of the floor slab) or wall junctions

Through back to back cupboards Through light switches, or GPO's, located in the wall, poor sealing at penetrations Through floors and the below floor crawl space Through shared building elements such as floor boards, floor joists, continuous plasterboard walls, continuous plasterboard ceilings, and even continuous concrete walls and floors

Fig D1 – Flanking Paths


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May 2008

D5


Boral Masonry cannot guarantee that field performance ratings will match laboratory or estimated opinions. However, with careful attention during erection of the wall, correct installation to specification and proper caulking/sealing, the assembly should produce a field performance close to and comparable with tested or estimated values. Apart from installation procedures, workmanship and caulking, the following items can also affect the acoustic performance on site.

Doors Hollow, cored and even solid doors generally provide unsatisfactory sound insulation between rooms. Doors can also provide direct air leaks between rooms thus having a bad effect on the overall sound insulation of the partition in which they are inserted. The higher the insulation of the partition, the worse is the effect of doors. Where sound insulation is important, specialised heavyweight doors or, preferably, two doors separated by an absorbent lined airspace or lobby should be used.

Lightweight Panels Above Doors These are often incorporated for aesthetic reasons, however, the performance of a partition with good sound insulation can be considerably degraded by lightweight panels.

Air Paths Through Gaps, Cracks or Holes Gaps, cracks or openings, however small, readily conduct airborne sounds and can considerably reduce the sound insulation of a construction.

Noise paths through vents or lightweight decorative panels

Appliances In cases where sound insulation is important, noise producing fixtures or appliances such as water closets, cisterns, water storage tanks, sluices, dishwashers, washing machines and pumps should be repositioned orisolated from the structure with resilient mountings and flexible service leads and connections. Where fittings are duplicated on opposite sides of partitions, they should be offset.

Electrical Outlets & Service Pipes Electrical outlets, switch boxes and similar penetrations should not be placed back-to-back. If power outlets are installed back-to-back, they will create a flanking path or sound leak. Seal backs and sides of boxes and the perimeter of all penetrations with acoustic sealant. Penetrations should be avoided where sound insulation is important. This includes recessed fittings or ducts such as skirting heating, electrical or telephone wiring trunking, light fittings, inter-communication systems and alarms, medical and laboratory gas outlets. Plumbing connections between fittings or appliances on opposite sides of a partition offer a path for transmission of sound and should be sealed. If possible introduce discontinuity in the pipework between fittings, such as a flexible connection within or on the line of a partition.

Home Cinema Rooms Boral Masonry and Plasterboard divisions have a number of high performance wall systems which have been specifically developed for home cinema applications. Please contact Boral Masonry for additional assistance and information on the available solutions, or visit the website: www.boral.com.au/cinemazone for solutions using Boral masonry products.

Noise paths through lightweight panel doors

Noise paths through vents

Noise paths through gaps

Fig D2 – Flanking Paths

Fig D3 – Acoustic Performance Overview

D6


BORAL MASONRY


Masonry Design Guide STRUCTURAL, FIRE AND ACOUSTICS NEW SOUTH WALES BOOK 1 E FIRE AND ACOUSTIC SYSTEMS

New South Wales Book 1 E

Boral Fire & Acoustic Masonry Wall Systems This section of the Boral Masonry Design Guide contains detailed information on the fire and acoustic performance of Boral masonry products, and provides System Solutions for fire and acoustic wall designs.

The following illustration details typical page layouts and the type and location of information you may need to complete your product selection and wall design.

Finding Acoustic Systems & Technical Specifications

Product Icons with dimensions for products available in your region/state

Product Name

Product Introduction and Application Information

Book 1 E

New South Wales

119

162

290

90

9.119B

9.162B

76

119

Availability information for your region/state

10.119B

11.76BS

119

230

110

11.119B

11.162B

• Nominimumorderquanti tiesapply. • Leadtime0-2weeks.

Natural Grey

Specifications

Fora thinneroption,see Lining System 6in the table belowand page E3for lining details. UNIT-TO-CORRIDOR/STAIR WALLS These walls require a minimum Rw 50 (no Ctr).

Fire

DUCTS IN A HABITABLE ROOM The BCA requires a minimum of Rw+ Ctr ≥ 40 forwalls around waste pipes etc. in habitable rooms. The first detail shows options of 16mm or2x 13mm plasterboard. If the ventis in a wetarea,only one layer of 13mm plasterboard is required.

Un it ƒ’ uc W t MPa k g

TxLxH (mm)

9.119B

90x290 x119

12

5.6

25.8

336

22.5

21.0

20.0

18.0

17.0

46

60

9.162B

90x290 x162

12

7.6

19.4

240

22.5

① 21.0

20.0

18.0

17.0

See tested systems page D13 46* 47* 49 57 56 60

60

10.119B

100x390 x119

12

7.9

19.4

165

22.5

11.119B

110x230 x119

12

5.1

32.3

350

22.5

11.162B

110x230 x162

12

6.8

19.4

250

22.5

110x230 x76

12

–

–

47

49

57

56

60

① 21.0

–

55

20.0

18.0

17.0

46

50

59

57

62

21.0

20.0

18.0

17.0

48* 46* 50

59

57

62

21.0

① 20.0

18.0

17.0

48

21.0

① 20.0

Rw + Ctr

for ⑥ –

90 90 4.0

48.4

500

Additional Insulation with

①

22.5

59

57

62

18.0

17.0

48

46

50

59

57

62

• 1x 13mm Boral Plasterboard daub fixed

• 13mm Render

• 13mm Render 136mm

•1 x13mm Boral Plasterboard screwfixed •28mm furring channelat 600mm centres •Standard Clips at 1200mm centres 169mm •Tontine TSB3insulation in cavity

52 •1 x13mm Boral Plasterboard daub fixed

59

•Nil Lining •2 leaves 11.119B Basalt-Concrete Bricks •30mm cavitywith Tontine TBL10/25 insulation and MPB board

(-1, -4) Impact Test 237

(-4, -12) Estimated f rom Tests 299 and 1 85

62 (-3, -9) Impact Test 239

55


59


66

181mm

•1 x13mm Boral Plasterboard screwfixed •28mm furring channel at 600mm centres •Boral Impact Clips at1200mm centres •Tontine TSB3insulation in cavity

•Nil Lining 250mm

•1x 13mm Boral Plasterboard screwfixed •28mm furring channel at600mm centres •Standard Clips at 1200mm centres •Tontine TSB3insulation in cavity

•1x 13mm Boral Plasterboard screwfixed •64mm steel studs at 600mm centres •20mm gap •Tontine TSB5insulation in cavity 250mm

•Nil Lining •2 leaves 11.119B Basalt-Concrete Bricks •30mm cavity between the Tontine TBL 10/25insulation and MPB board

•1 x13mm Boral Soundstop Plasterboard screwfixed •16mm furring channelat 600mm centres 281mm •Standard Clips at 1200mm centres •Tontine TSB2insulation in cavity

•1 x13mm Boral Soundstop Plasterboard screwfixed •16mm furring channel at600mm centres •Standard Clips at 1200mm centres •Tontine TSB2insulation in cavity •2 leaves 11.119B Basalt-Concrete Bricks

•30mm cavity between with Tontine TBL 10/25insulation and MPB board •1 x13mm Boral Soundstop Plasterboard screwfixed 312mm •Standard Clips at 1200mm centres •Tontine TSB2insulation in cavity

•Nil Lining •2 leaves 11.119B Basalt-Concrete Bricks •30mm cavity between with Tontine TBL 10/25insulation and MPB board

Wall Cross section Icon and Overall System Thickness

294mm

•1 x13mm Boral Soundstop Plasterboard •16mm furring channel at 600mm centres •Standard Clips at 1200mm centres •Tontine TSB2insulation in cavity

50

90 ① Impact = Complies with BCA2 005 requirementforImpact Sound Resistance.

Lining System (13mm renderboth sides).

139mm or •Nil 129mm f or 1 x 1 6 mm

142mm

(-2, -8) Test 185

50 50

See tested systems page D14

Impact= Systems complywith BCA 2005 requirements forImpact Sound Resistance.

‡ = Quantitymayvary from plantto plant.

E12

Product Specifications

50

Duct wall in a habitable room


(-2, -8) •1 x13mm Boral Plasterboard daub fixed Estimated f rom Test 185

53

See tested systems page D14 46

WALL LINING

48 (-2, -6) Test 197

64 50

BASALT-CONCRETE 110mm

46 (-1, -5) Test 183

–

See tested systems page D13 48

46 •2 x13mm Boral Plasterboard daub fixed (-2, -6) or Estimated f rom •1 x16mm Boral Plasterboard daub fixed Test 184

50 –

90

① ② ③ ④ ⑤ ⑥ Referto Lining Systems on Page E3. ①

–

50

Rw (Estimate or *Tested) With Lining System ① ② ③ ④ ⑤ ⑥ Impact

WALL LINING

Boral Test Nº

62

Acoustics

‡ Maximum Slenderness Ratio (Srf ) Insulation (minutes) Nº Nº FRL (minutes) pe r pe r m2 Pallet 60 90 120 180 240

ACOUSTIC

RATING Rw + C t r Rw ( c,ctr)

11.119B with the lining system on page E13,detail 4is the thinnestoption.

Product Code

11.76BS

E2

11.119B masonry lining systems that satisfy this requirementare on page E13,detail 6,7,8 9and 10.

ACOUSTICCONSIDERATIONS The BCA:2005 requires walls between sole occupancy units to have a minimum sound rating of Rw+ Ctr ≥ 50 and if theyseparate

Colour & Availability

Book 1 E

Acoustic Systems - 11.119B/11.162B Basalt-Concrete

a wet area from a habitable room, theymust also be of discontinuous construction.

FIRE DESIGN CONSIDERATIONS Boral Basalt-Concrete bricks have a basaltcontent> 45% which provides good fire performance characteristics in loadbearing conditions.

162

230

110

Basalt-Concrete Bricks (B)

Boral Basalt-Concrete bricks are a popularchoice forwalls in high-rise units where theyare commonlyused with a rendered finish. Theyare also commonlyused forloadbearing walls in 3-storeyunit construction with plasterboard or renderfinish.

230

110 390 100

Product Identification

New South Wales

INTRODUCTION Boral Basalt-Concrete bricks have an ƒ’uc of12MPa, making them excellent forloadbearing ornonloadbearing applications. They provide good fire and acoustic performance where minimising weightis nota primaryconsideration.

290

90

Product Specific Acoustic Test Results and Wall Lining System Information

January 2011 | BORAL MASONRY DESIGN GUIDE

Fire Performance Data

Acoustic Performance Data


|

January 2011

Acoustic Test Result (Rw) and Impact Isolation Information (IIC)

E13

Lining, Framing and Insulation Description for each side of the wall



Acoustic Systems Data

When information is provided in the table, it is tabulated, under the System Headings of ①, ②, ③, ④, ⑤ and ⑥.

Acoustic performance information forsix of the most popular wall lining systems may be provided within the Product Specification Tables on the following product pages. Alternatively, you may be referred to more detailed test information and alternative lining systems. LINING SYSTEM

The following Table details the wall lining and insulation information for these six systems, and provides thickness information to assist wall thickness calculation. Acoustic performance estimates have been calculated by Wilkinson Murray (Acoustic Consultants).

BORAL MASONRY BRICK OR BLOCK

WALL LINING

Refer to product pages

WALL LINING

As per product pages

①

• 13mm Render

②

• 1 x 13mm Boral Plasterboard daub fixed

③

Masonry Thickness +26mm



• 13mm Render



• • • •

Masonry Thickness +84mm or +77mm for Villaboard

• 1 x 13mm Boral Plasterboard screw fixed or 1 x 6mm Villaboard™ screw fixed over • 1 x 13mm Boral Plasterboard screw fixed • 28mm furring channel at 600mm centres • Boral Impact Clips at 1200mm centres • Tontine TSB3 insulation in cavity • • • •

④


⑤

• • • •

1 x 13mm Boral Plasterboard screw fixed 28mm furring channel at 600mm centres Standard Clips at 1200mm centres Tontine TSB3 insulation in cavity


⑥

• • • •


• • Masonry • Thickness •

Ac ou s t ic E st im a t es w it h

+140mm


1 x 13mm Boral Plasterboard screw fixed 28mm furring channel at 600mm centres Boral Impact Clips at 1200mm centres Tontine TSB3 insulation in cavity 1 x 13mm Boral Plasterboard screw fixed 64mm steel studs at 600mm centres 20mm gap Tontine TSB5 insulation in cavity

t he se L in i ng S ys te m s


119

FireBrick ™ (F) Scoria Blend

162

INTRODUCTION BoralFireBrickisanon-loadbearing, medium densityscoria-blend material which provides high fire ratedperformance.

290

90

290

90

9.119F

9.162F

F i r e B ri c k i s i d e a l f o r l a r g e commercial,industrialandhigh-rise UNIT-TO-CORRIDOR/STAIR homeunitbuildings. WALLS These walls require a minimum F o r l a rg e r m a so n ry p a ne l Rw50(noCtr). applications,alsoreferto Scoria BlendblocksonpagesE7andE8. 10.119Fwith the lining system on pageE5,detail5isthethinnestoption. FIRE DESIGN CONSIDERATIONS DUCTSINA HABITABLEROOM. Boral FireBrickutilises a unique The BCArequires a minimum of scoria-blendmaterialwhichhasbeen Rw+Ctr ≥ 40forwallsaroundwaste shown through fire testing to pipesetc.in habitablerooms. provide excellentfire insulation Thefirstdetail showsanoption for characteristics(see tablebelow). r e n de r a n d a n o p t i o n f o r ACOUSTICDESIGN plasterboard.Iftheventisin awet CONSIDERATIONS area,onlyone layerof13mm plasterboardisrequired. TheBCA:2005requiresparty walls to have a minimum sound rating of Rw+Ctr ≥ 50andiftheyseparate a wetarea from a habitable room, theymustalso beof discontinuous construction.

119

390 100

10.119F

119

162

230

110

230

110

11.119F

11.162F

Colour& Availability •No minimumorderquantities apply. •Lead time0-2weeks.

NaturalGrey

Specifications ƒ ’uc MPa

Fire

Unit

Nº

Wt kg

per m2

10.119Fmasonryliningsystemsthat satisfythisrequirementareonpage E5,detail 7(renderedcavity wall), details9;10and11.Thelastdetail isthethinnestoption forwet-to-wet andhabitable-to -habitablepa rtywalls.

‡ Nº

Acoustics

MaximumSlendernessRatio(S rf ) Insulation(minutes) FRL(minutes)

P ro du ct Code

T xL xH (mm)

per Pallet 6 0

9.119F

90x290 x119

4

4. 4

25.8

336

25.9

9.162F

90x290 x162

4

6.4

19.4

288

25.9

10 119 . F

10 0x 39 0 x119

4

6 9.

19. 4

19 8

25 9.

2 5. 9

11.119F

110x230 x119

4

4.3

32.3

350

25.9

25.9

11.162F

110x230 x162

4

5.8

24.2

30 0

25.9

25.9

90

120

25.9

180 25.9

24.0

25.9

① 25.9

120 25.9 120

Rw (Estimateor *Tested) WithLining System ①

②

③

④

45* 4 7* 4 8* 47

48

Rw+ Ctr

⑤ ⑥ Impact

240

25.9

for ⑥

57

55

60

–

57

55

60

–

24.0

45

① 25 9. 2 5. 9

24 0.

4 8* 4 8 * 52 * 6 0*

25.9

25.9

24.0

47*

25.9

24.0

47

56

Read off Acoustic Performance (Rw) from intersection of product row and lining system column

61

50

61

50

SeetestedsystemspageD7

180

49

52

59

57


240 25.9

49

52

59

57

61

50


240

① ② ③ ④ ⑤ ⑥ RefertoLiningSystemsonPage E3. Impact =ComplieswithBCA2005 requirementforImpactSoundResistance. ①

E4

AdditionalInsulationwith① LiningSystem(13mmrenderbothsides).

‡ =Quantitymayvaryfrom planttoplant.

January 2011 | BORALMASONRYDESIGNGUIDE


|

May 2008

E3


119

162

INTRODUCTION Boral FireBrickis a non-load bearing, medium density scoria-blend material which provides high fire rated performance.

290

90

290

90

9.119F

9.162F

100

10.119F

119

230 230

• No minimum order quantities apply. • Lead time 0-2 weeks.

Natural Grey

Specifications Product Code

TxLxH (mm)

ƒ’ uc MPa

Unit Wt kg

9.119F

90x290

4

4.4

Fire Nº per m2 25.8

11.119F 11.162F

336

25.9

25.9

4

110x230 x119

4

110x230

4

6.4

19.4

288

25.9

25.9

19.4

198

25.9

25.9

32.3

350

25.9

25.9

24.2

300

25.9

25.9

③

④

⑤

⑥ Impact

for ⑥

45* 47* 48*

57

55

60

–

25.9

① 25.9

24.0

45

57

55

60

–

25.9

① 25.9

24.0

48* 48* 52* 60*

56

61

50

25.9 25.9

240

47

48

See tested systems page D7 25.9

24.0

47*

49

52

59

57

61

50


240 5.8

②

Ctr

24.0

180 4.3

①

Rw +

25.9

120 6.9

Rw (Estimate or *Tested) With Lining System

25.9

120

100x390 x119

x162

Acoustics

Maximum Slenderness Ratio (S rf ) ‡ Insulation (minutes) Nº FRL (minutes) per Pallet 60 90 120 180 240

x119

10.119F

The first detail shows an option for r en der a nd a n o pt io n f or plasterboard. If the vent is in a wet a re a, on ly on e layer o f 13 mm plasterboard is required.

The BCA:2005 requires party walls to have a minimum sound rating of Rw + Ctr ≥ 50 and if they separate a wet area from a habitable room, they must also be of discontinuous construction.


4

DUCTS IN A HABITABLE ROOM. The BCA requires a minimum of Rw + Ctr ≥ 40 forwalls around waste pipes etc. in habitable rooms.

ACOUSTIC DESIGN CONSIDERATIONS

11.162F

90x290 x162

10.119F with the lining system on page E5, detail 5 is the thinnest option.

FIRE DESIGN CONSIDERATIONS Boral FireBrick utilises a unique scoria-blend material which has been shown through fire testing to provide excellent fire insulation characteristics (see table below).

162

110

9.162F

UNIT-TO-CORRIDOR/STAIR WALLS These walls require a minimum Rw 50 (no Ctr).

For larger masonry panel applications, also refer to Scoria Blend blocks on pages E7 and E8.

390

11.119F

10.119F masonry lining systems that satisfy this requirement are on page E5, detail 7 (rendered cavity wall), details 9; 10 and 11. The last detail is the thinnest option for wet-to-wet and habitable-to-habitable partywalls.

Fi re Br ick i s id ea l for la rge commercial, industrial and high-rise home unit buildings.

119

110

FireBrick™ (F) Scoria Blend

25.9

24.0

47

49

52

59

57

61

50


① ② ③ ④ ⑤ ⑥ Refer to Lining Systems on Page E3. Impact = Complies with BCA 2005 requirement for Impact Sound Resistance. ①

E4

Additional Insulation with ① Lining System (13mm render both sides).

‡ = Quantity may vary from plant to plant.



Acoustic Systems - 10.119F FireBrick ACOUSTIC RATING Rw + Ctr Rw (c, ctr)

WALL LINING

100mm FIREBRICK SCORIA-BLEND

WALL LINING

Boral Test Nº (-2, -5) Test 211

40

45 (-1, -5)

113mm

• 13mm Render


OR

Estimated from • 1 x 16mm Boral Plasterboard daub fixed

• Nil

119mm

Test 202

–

47 (-1, -6) Test 212 (-2, -6) Test 213

–

48 (-2, -7) Test 201

–

• 13mm Render

129mm 126mm

• 13mm Render OR • 1 x 13mm Boral Plasterboard daub fixed

132mm


190mm

52 –

(-3, -10) Estimated from

• 1 x 13mm Boral Plasterboard daub fixed 159mm

Test 203

54 –

(-3, -10) Test 203

55 51

–



• 13mm Render • 2 leaves of 10.119F FireBrick (no wall ties)


60

50

• 1 x 13mm Boral Plasterboard screw fixed • 16mm furring channel at 600mm centres • Boral Standard Clips at 1200mm centres Estimated from • Tontine TSB2 insulation in cavity Test 208

(-3, -10) Impact

59 50


50


• 1 x 13mm Boral Plasterboard screw fixed • 51mm steel studs at 600mm centres • 10mm gap • 1 x 13mm Boral Plasterboard screw fixed • 28mm furring channel at 600mm centres • Standard Clips at 1200mm centres • Tontine TSB3 insulation in cavity • 1 x 13mm Boral Plasterboard screw fixed • 28mm furring channel at 600mm centres • Boral Impact Clips at 1200mm centres • Tontine TSB3 insulation in cavity • 35mm cavity with Tontine TBL 10/25 insulation and MPB board • 13mm Render • 1 x 13mm Boral Plasterboard screw fixed • 51mm steel studs at 600mm centres • 10mm gap • Tontine TSB5 insulation in cavity

• 1 x 13mm Boral Plasterboard screw fixed • 64mm steel studs at 600mm centres • 20mm gap 228mm • Tontine TSB5 insulation in cavity • 35mm cavity with Tontine TBL 10/25 insulation and MPB board in cavity 267mm • 1 x 13mm Boral Soundstop Plasterboard daub fixed

• 13mm Render

• 1 x 13mm Boral Plasterboard screw fixed • 51mm steel studs at 600mm centres • 10mm gap – use 20mm for impact rating 187mm • Tontine TSB5 insulation in cavity


• 2 x 13mm Boral Plasterboard screw fixed • 28mm furring channel at 600mm centres 184mm • Boral Impact Clips at 1200mm centres • Tontine TSB3 insulation in cavity

60 (-4, -10) Test 205


• 1 x 13mm Boral Soundstop Plasterboard daub fixed • 2 leaves of 10.119F FireBrick (no wall ties)

60 51

261mm

57 (-3, -10) Test 208

• 13mm Render OR

51 (-3, -9) Test 206


Impact = Systems comply with BCA 2005 requirements for Impact Sound Resistance.


|

May 2008

E5


Acoustic Systems - 11.119F/11.162F FireBrick ACOUSTIC RATING Rw + Ctr Rw (c, ctr)

WALL LINING

110mm FIREBRICK SCORIA-BLEND

WALL LINING

Boral Test Nº

47 —

(-1, -5) Test 22

46 —

(-2, -7) Test 13

• 13mm Render


• 1 x 13mm Boral Plasterboard daub fixed • 10mm packer daub fixed

170mm

• 1 x 13mm Boral Plasterboard daub fixed • 10mm packer daub fixed

• 1 x 13mm Boral Soundstop Plasterboard daub fixed

• 1 x 13mm Boral Soundstop Plasterboard screw fixed • 51mm steel studs at 600mm centres 200mm • 10mm gap • Tontine TSB5 insulation in cavity


• 1 x 9mm Villaboard screw fixed over • 51mm steel studs at 600mm centres • 10mm gap 196mm • Tontine TSB5 insulation in cavity

60

50

• 1 x 13mm Boral Plasterboard screw fixed (-3, -10) • 28mm furring channel at 600mm centres Impact • Boral Standard Clips at 1200mm centres Estimated from • Tontine TSB3 insulation in cavity Test 263

• 1 x 13mm Boral Plasterboard screw fixed • 64mm steel studs at 600mm centres 250mm • 20mm gap • Tontine TSB5 insulation in cavity

61

51

• 1 x 13mm Boral Plasterboard screw fixed • 28mm furring channel at 600mm centres • Boral Standard Clips at 1200mm centres Estimated from • Tontine TSB3 insulation in cavity Test 264

• 1 x 9mm Villaboard screw fixed • 64mm steel studs at 600mm centres 246mm • 20mm gap • Tontine TSB5 insulation in cavity

57 —

(-3, -10) Test 263

58 —

(-3, -10) Test 264

(-3, -10) Impact


• 2 x 16mm Boral Firestop Plasterboard screw fixed • 51mm steel studs at 600mm centres 219mm • 10mm gap — use 20mm for impact rating • Tontine TSB5 insulation in cavity


• 1 x 9mm Villaboard screw fixed over • 1 x 16mm Boral Firestop Plasterboard screw fixed • 51mm steel studs at 600mm centres 212mm • 10mm gap — use 20mm for impact rating • Tontine TSB5 insulation in cavity

• 1 x 13mm Boral Soundstop Plasterboard screw fixed • 16mm furring channel at 600mm centres • Boral Standard Clips at 1200mm centres • Tontine TSB2 insulation in cavity

• 2 x 13mm Boral Soundstop Plasterboard screw fixed • 51mm steel studs at 600mm centres 228mm • 10mm gap — use 20mm for impact rating • Tontine TSB5 insulation in cavity

63 54


64 55


65 55



E6



FireBlock™ – Scoria-Blend Blocks 190

90

190

390

390

90

10.201 Full

10.331 Full Solid

390

390

20.201 Full

Boral FireBlock utilises a unique scoria blend material, which has been shown through fire testing to provide excellent fire insulation characteristics.

390

140

15.301 Full

15.401 Full

190

190

Core filling is not required to achieve the insulation FRL’s detailed in the specification table.

190

190

390

190

FIRE DESIGN CONSIDERATIONS

190

390

140

15.201 Full

FireBlock is ideal for large commercial, industrial, high-rise buildings and portal framed and concrete framed structures. 190

190

140

INTRODUCTION Boral FireBlock is a non-loadbearing, medium density, scoria blend material which provides high fire rated performance.

390

190

20.301 Full

20.401Full

Specifications

Fire

Product Code

TxLxH (mm)

ƒ ’uc MPa

10.201

90x390x190

4

Unit Wt kg

Nº per m2

9.5

12.5

Acoustics

Maximum Slenderness Ratio (S rf ) ‡ Insulation (minutes) Nº FRL (minutes) per Pallet 60 90 120 180 240 180

25.9

Full

25.9

Rw (Estimate or *Tested) With Lining System ①

②

③

④

⑤

⑥ Impact

25.9

25.9

24.0

45

46

48

55

53

58

25.9

25.9

24.0

46

48

51

58

56

61

25.9

25.9

24.0

46* 47* 50 57 55 60 See tested systems page E8

25.9

25.9

24.0

48

49

52

59

57

62

25.9

24.0

48

49

52

59

57

62

25.9

25.9

24.0

47

48

51

58

56

61

25.9

25.9

24.0

47

48

51

58

56

61

25.9

24.0

48

49

52

59

57

62

120

10.331 Full Solid

90x390x190

15.201 Full

140x390x190

15.301 Full

140x390x190

15.401

140x390x190

4

12.3

12.5

144

25.9

25.9

180 4

11.3

12.5

120

25.9

25.9

120 4

14.0

12.5

120

25.9

25.9

180 4

14.2

12.5

120

25.9

25.9

Full

25.9

240

20.201 Full

190x390x190

20.301 Full

190x390x190

20.401

190x390x190

4

12.8

12.5

90

25.9

25.9

120 4

14.5

12.5

90

25.9

25.9

180 4

14.9

12.5

Full

90

25.9

25.9

25.9 240

① ② ③ ④ ⑤ ⑥ Refer to Lining Systems on Page E3. Impact = Complies with BCA 2005 requirement for Impact Sound Resistance.



|

May 2008

E7


Acoustic Systems - 15.201 FireBlock™ Scoria-Blend Blocks ACOUSTIC RATING Rw (c, ctr)

WALL LINING

140mm FIREBLOCK SCORIA-BLEND

WALL LINING

Boral Test Nº

45 (-2, -6) Test 140


• Nil 156mm

46 (-1, -4) Test 147

• 13mm Render


47 (-1, -5) Test 139



52 (-2, -6) Test 143

• 13mm Render (Impact test applied to rendered side)

208mm

52 (-2, -7) Test 141

E8


• • • •

1 x 13mm Boral Plasterboard screw fixed 28mm furring channel at 600mm centres Boral Impact Clips at 1200mm centres Tontine TSB3 insulation in cavity

• • • •




119

90

162

INTRODUCTION B or al F i re Li gh t b ri ck s a re manufactured from a low-density material which provides high fire rated performance and minimum weight for non-loadbearing applications.

290 290

90

9.119FL

9.162FL

119

ACOUSTIC CONSIDERATIONS The BCA:2005 requires walls between sole occupancy units to have a minimum sound rating of Rw + Ctr ≥ 50 and if they separate a wet area from a habitable room, they must also be of discontinuous construction.

Boral FireLight is ideal for concrete framed office buildings and highrise home units.

390 100

The 10.119F masonry lining system that satisfies this requirement is on page E10, detail 7.

FireLightis manufactured in 90, 100 and 110mm thicknesses and in a range of size formats to suit all types o f f ir e a nd /o r a co ust ic wa ll construction.

10.119FL

119

110

FireLight™ Bricks (FL)

162

FIRE DESIGN CONSIDERATIONS FireLight is a fire tested lightweight concrete which is unique to Boral, and provides excellent fire rating characteristics.

230 230

110

11.119FL


11.162FL

See 10.119FL with the lining system on page E10, detail 3. DUCTS IN A HABITABLE ROOM The BCA requires a minimum of Rw + Ctr ≥ 40 forwalls around waste pipes etc. in habitable rooms. See 10.119FL lining, detail 2.


If the vent is in a wet area, only one layer of 13mm plasterboard is required.

• No minimum order quantities apply. • Lead time 0-2weeks.

Natural Grey

Specifications

Fire

Product Code

TxLxH (mm)

ƒ’ uc MPa

Unit Wt kg

9.119FL

90x290

3

3.4

Nº per m2 25.8

Maximum Slenderness Ratio (S rf ) ‡ Insulation (minutes) Nº FRL (minutes) per Pallet 60 90 120 180 240 336

29.0

x119 9.162FL 10.119FL 11.119FL 11.162FL

Acoustics Rw (Estimate or *Tested) With Lining System

Rw + Ctr

①

②

③

④

⑤

⑥ Impact

for ⑥

26.9

24.9

22.2

20.3

–

45

48

55

53

59

–

26.9

24.9

22.2

20.3

–

45*

48* 55

53

59

–

26.9

24.9

22.2

20.3

–

45*

51* 58*

55

61

52

90

90x290 x162

3

100x390 x119

3

110x230 x119

3

110x230

3

4.5

19.4

288

29.0

90 5.1

19.4

231

29.0

See tested systems page E10

120 3.1

32.3

350

29.0

26.9

24.9

22.2

20.3

24.2

300

x162

29.0

26.9

120

47

52

58

56

61

52


120 4.5

–

24.9

22.2

20.3

–

47*

52* 58

56

61

52


① ② ③ ④ ⑤ ⑥ Refer to Lining Systems on Page E3. Impact = Complies with BCA 2005 requirement for Impact Sound Resistance.



|

May 2008

E9


Acoustic Systems - 10.119FL FireLight ACOUSTIC RATING Rw + Ctr Rw (c, ctr)

WALL LINING

Boral Test Nº

100mm FIRELIGHT LIGHTWEIGHT CONCRETE

WALL LINING

45 –

40

(-3, -8) Test 229


46

• 1 x 13mm Boral Plasterboard daub fixed • 1 x 13mm Boral Plasterboard grab screw fixed

(-1, -6) Test 236

132mm


–



• 1 x 13mm Boral Wet Area Plasterboard screw fixed over 185mm • 1 x 13mm Boral Plasterboard screw fixed • 28mm furring channel at 600mm centres • Boral Impact Clips at 1200mm centres • Tontine TSB3 insulation in cavity


• 1 x 13mm Boral Plasterboard screw fixed • 51mm steel studs at 600mm centres • 10mm gap 191mm • Tontine TSB5 insulation in cavity

–


• 1 x 13mm Boral Plasterboard screw fixed • 64mm steel studs at 600mm centres • 20mm gap 214mm • Tontine TSB5 insulation in cavity

58 (-3, -9) Test 234

58 (-2, -9) Test 230

60 51

(-2, -9) Impact Estimated from

Test 230

• Nil

• 1 x 13mm Boral Plasterboard screw fixed • 28mm furring channel at 600mm centres • Boral Impact Clips at 1200mm centres 172mm • Tontine TSB3 insulation in cavity

53 (-2, -8) Test 232

129mm


Test 232

–


• 1 x 13mm Boral Plasterboard screw fixed • 28mm furring channel at 600mm centres • Standard Clips at 1200mm centres 160mm • Tontine TSB3 insulation in cavity

51 –



E10



Acoustic Systems - 11.119FL/11.162FL FireLight ACOUSTIC RATING Rw + Ctr Rw (c, ctr)

WALL LINING

110mm FIRELIGHT LIGHT CONCRETE

WALL LINING

Boral Test Nº

45 —

(-1, -6) Test 289


• Nil

126mm

46

40

Duct wall in a non-habitable room

• 1 x 16mm Boral Plasterboard daub fixed (-1, -6) or Estimated from • 2 x 13mm Boral Plasterboard daub fixed Test 289

Duct wall in a habitable room 130mm or • Nil 139mm for 2 x 13mm

47 —

(-2, -8) Test 288



• 1 x 13mm Boral Plasterboard screw fixed • 28mm furring channel at 600mm centres 169mm • Standard Clips at 1200mm centres • Tontine TSB3 insulation in cavity


• 1 x 13mm Boral Plasterboard screw fixed • 28mm furring channel at 600mm centres 181mm • Boral Impact Clips at 1200mm centres • Tontine TSB3 insulation in cavity

• 13mm Render (Impact test applied to render side)

• 1 x 13mm Boral Plasterboard screw fixed • 51mm steel studs at 600mm centres 197mm • 10mm gap — use 20mm for impact rating • Tontine TSB5 insulation in cavity

• 1 x 13mm Boral Plasterboard screw fixed • 16mm furring channel at 600mm centres • Standard Clips at 1200mm centres • Tontine TSB2 insulation in cavity


• 1 x 13mm Boral Plasterboard screw fixed (-4, -12) • 16mm furring channel at 600mm centres Impact Estimated from • Standard Clips at 1200mm centres Test 229 • Tontine TSB2 insulation in cavity



• 1 x 9mm Villaboard screw fixed • 51mm steel studs at 600mm centres • 10mm gap — use 20mm for impact 211mm rating • Tontine TSB5 insulation in cavity

• 1 x 9mm Villaboard screw fixed over • 16mm furring channel at 600mm centres • Standard Clips at 1200mm centres • Tontine TSB2 insulation in cavity

• 1 x 9mm Villaboard screw fixed over • 51mm steel studs at 600mm centres • 10mm gap — use 20mm for impact 207mm rating • Tontine TSB5 insulation in cavity


• 1 x 9mm Villaboard screw fixed over • 1 x 13mm Boral Plasterboard screw fixed • 51mm steel studs at 600mm centres 224mm • 10mm gap — use 20mm for impact rating • Tontine TSB5 insulation in cavity

52 —


Test 290

54 —

(-4, -11) Test 290

59 50


60 —

(-4, -12) Test 229

62

50

65 53


67 53


67 54



Impact = Systems comply with BCA 2005 requirements for Impact Sound Resistance. BORAL MASONRY DESIGN GUIDE

|

May 2008

E11


119

162

INTRODUCTION Boral Basalt-Concrete bricks have an ƒ ’uc of 12MPa, making them excellent for loadbearing or nonloadbearing applications. They provide good fire and acoustic performance where minimising weight is nota primary consideration.

290

90

290

90

9.119B

9.162B

76

119

390 100

10.119B

11.76BS

119

110

230

11.119B

230

11.162B

• No minimum order quantities apply. • Lead time 0-2 weeks.

Natural Grey

Specifications Product Code

TxLxH (mm)

ƒ’ uc MPa

Unit Wt kg

9.119B

90x290 x119

12

5.6

90x290 x162

12

100x390 x119

12

110x230 x119

12

110x230

12

10.119B 11.119B 11.162B

7.6

Fire

110x230 x76


11.119B with the lining system on page E13, detail 4 is the thinnest option. DUCTS IN A HABITABLE ROOM The BCA requires a minimum of Rw + Ctr ≥ 40 forwalls around waste pipes etc. in habitable rooms. The first detail shows options of 16mm or 2 x 13mm plasterboard. If the vent is in a wet area, only one layer of 13mm plasterboard is required.

Nº per m2 25.8 19.4

336 240

22.5

21.0

60

① 21.0

22.5

60 7.9

19.4

Acoustics

Maximum Slenderness Ratio (S rf ) ‡ Insulation (minutes) Nº FRL (minutes) per Pallet 60 90 120 180 240

165

22.5

20.0 20.0

18.0 18.0


Rw + Ctr

①

②

③

④

⑤

⑥ Impact

for ⑥

17.0

46

47

49

57

56

60

–

17.0

See tested systems page D13 46* 47* 49 57 56 60

–

① 21.0

20.0

18.0

17.0

46

48

50

59

57

62

50

21.0

20.0

18.0

17.0

48* 46*

50

59

57

62

50

21.0

① 20.0

21.0

① 20.0


90 5.1

32.3

350

22.5

90 6.8

19.4

250

x162 11.76BS

For a thinner option, see Lining System 6 in the table below and page E3 for lining details.

ACOUSTIC CONSIDERATIONS The BCA:2005 requires walls between sole occupancy units to have a minimum sound rating of Rw + Ctr ≥ 50 and if they separate


9.162B

11.119B masonry lining systems that satisfy this requirement are on page E13, detail 6, 7, 8 9 and 10.

FIRE DESIGN CONSIDERATIONS Boral Basalt-Concrete bricks have a basalt content > 45% which provides good fire performance characteristics in loadbearing conditions.

162

110

a wet area from a habitable room, they must also be of discontinuous construction.

Boral Basalt-Concrete bricks are a popularchoice forwalls in high-rise units where theyare commonlyused with a rendered finish. They are also commonly used forloadbearing walls in 3-storey unit construction with plasterboard or render finish.

230

110

Basalt-Concrete Bricks (B)

22.5

90 12

4.0

48.4

500

22.5

90


17.0

48

46

50

59

57

62

50


17.0

48

46

50

59

57

62

50

①

① ② ③ ④ ⑤ ⑥ Refer to Lining Systems on Page E3. Impact = Complies with BCA 2005 requirement for Impact Sound Resistance. ①

E12

Additional Insulation with ① Lining System (13mm render both sides).




Acoustic Systems - 11.119B/11.162B Basalt-Concrete ACOUSTIC

RATING + Ctr Rw ( c, ctr) Rw

WALL LINING

BASALT-CONCRETE 110mm

WALL LINING

Boral Test Nº

46

–

• 2 x 13mm Boral Plasterboard daub fixed (-2, -6) or Estimated f rom • 1 x 16mm Boral Plasterboard daub fixed

Test 184

–

–


48 (-2, -6)

• 13mm Render


(-2, -8) • 1 x 13mm Boral Plasterboard daub fixed Estimated f rom Test 185

52

55

(-2, -8) Test 185


59

• Nil Lining • 2 leaves 11.119B Basalt-Concrete Bricks • 30mm cavity with Tontine TBL 10/25 insulation and MPB board


62 50

(-4, -12) Estimated f rom Tests 299 and 1 85

62 53


64 55


66 59

• 1x 13mm Boral Plasterboard daub fixed 142mm

50

–

139mm or • Nil 129mm f or 1 x 16mm

46 (-1, -5) Test 183

Test 197

–



• 1 x 13mm Boral Plasterboard screw fixed • 28mm furring channel at 600mm centres • Standard Clips at 1200mm centres 169mm • Tontine TSB3 insulation in cavity • 1 x 13mm Boral Plasterboard screw fixed • 28mm furring channel at 600mm centres 181mm • Boral Impact Clips at 1200mm centres • Tontine TSB3 insulation in cavity

• Nil Lining 250mm

•1 x 13mm Boral Plasterboard screw fixed •28mm furring channel at 600mm centres •Standard Clips at 1200mm centres •Tontine TSB3 insulation in cavity

•1 x 13mm Boral Plasterboard screw fixed •64mm steel studs at 600mm centres •20mm gap 250mm •Tontine TSB5 insulation in cavity

• Nil Lining • 2 leaves 11.119B Basalt-Concrete Bricks • 30mm cavity between the Tontine TBL 10/25 insulation and MPB board

• 1 x 13mm Boral Soundstop Plasterboard screw fixed • 16mm furring channel at 600mm centres 281mm • Standard Clips at 1200mm centres • Tontine TSB2 insulation in cavity

• 1 x 13mm Boral Soundstop Plasterboard screw fixed • 16mm furring channel at 600mm centres • Standard Clips at 1200mm centres • Tontine TSB2 insulation in cavity • 2 leaves 11.119B Basalt-Concrete Bricks

• 30mm cavity between with Tontine TBL 10/25 insulation and MPB board • 1 x 13mm Boral Soundstop Plasterboard screw fixed 312mm • Standard Clips at 1200mm centres • Tontine TSB2 insulation in cavity

• Nil Lining • 2 leaves 11.119B Basalt-Concrete Bricks • 30mm cavity between with Tontine TBL 10/25 insulation and MPB board

• 1 x 13mm Boral Soundstop Plasterboard • 16mm furring channel at 600mm centres • Standard Clips at 1200mm centres 294mm • Tontine TSB2 insulation in cavity



|

May 2008

E13


Acoustic Systems - 9.119B/9.162B Basalt-Concrete ACOUSTIC RATING Rw (c, ctr)

WALL LINING

90mm BASALT-CONCRETE

WALL LINING

Boral Test Nº

45 (-1, -5) Test 162

• 13mm Render

• Nil 103mm

46 (-1, -4) Test 163

• 13mm Render


46 (-1, -5) Test 156


• Nil 106mm

47 (-1, -6) Test 161



47 (-1, -5) Test 155


51 (-2, -7) Test 159


• 13mm Render

158mm

51 (-3, -9) Test 157

E14


• • • •


• • • •




Series 100, 150 and 200 Basalt-Concrete Blocks (B)

190

390

90

INTRODUCTION Boral Basalt-Concrete blocks have an  ’uc of 10MPa, making them excellent for loadbearing or nonloadbearing applications. They provide good fire performance and acoustic performance characteristics where minimising weight is not a primary consideration.

10.01B Full

190

390

140

15.01B Full

FIRE DESIGN CONSIDERATIONS Boral Basalt-Concrete blocks comprise of > 45% basalt which provides a better Structural Adequacy FRL than Standard Grey blocks.

Boral Basalt-Concrete blocks are a popular choice for walls in factories and warehouses requiring a fire rating of FRL 60/60/60. 190

390

190

20.01B Full

Colour and Availability • Basalt-Concrete Blocks are manufactured at the Boral Somersby plant only, and are made to order.

Natural Grey

Specifications

Fire

Unit  ’uc Wt MPa kg

Product Code

TxLxH (mm)

10.01B

90x390

x190

15.01B

140x390 x190

10

20.01B

190x390 x190

10

10

11.5 13.0 15.0

Acoustics

‡

Maximum Slenderness Ratio (Srf )

N° per m2

N° per Pallet

Insulation (minutes) FRL (minutes) 60

90

120

180

240

12.5

180

22.5

21.0

20.0

18.0



120

60 22.5

21.0

20.0

90

60 22.5

21.0

20.0

60



12.5 12.5


 Impact

Rw + Ctr











17.0

46

46

50

57

55

60

—

18.0

17.0

47

47

51

58

56

61

—

18.0

17.0

48

48

52

59

57

62

50

for 

      Refer to Lining Systems on Page E3. 

Additional Insulation with  Lining System (13mm render both sides)



|

May 2008

E15


Standard Grey, Core-Fill and Designer Blocks

190

390

90

INTRODUCTION Boral concrete blocks have been an integral part of Australia’s construction industry for more than 3 decades, and continue to provide cost effective, practical and engineered solutions for the full spectrum of construction applications.

10.01

190

390

90

10.31

All Boral ‘Standard Grey’, ‘Designer Block ™’ and ‘Core Fill Block’ products are manufactured to AS/NZS4455 ‘Masonry units and segmental pavers 1997’ using modern high pressure moulding techniques and controlled denseweight concrete materials.

190

140

390

15.01

190

190

All Boral concrete blocks have inherent fire and acoustic performance properties which allocates them ‘deemed-to-satisfy’ values for fire performance.

390

20.01

190

140

390

15.91

190

190

390

20.91

190

290

390

ACOUSTIC CONSIDERATIONS The BCA:2005 requires walls between sole occupancy units to have a minimum sound rating of Rw + Ctr  50. Core-filled and reinforced 20.91 masonry with 10mm of render on both sides complies with this.

Townhouse party walls with an adjacent stairway and timber floor may require this system to satisfy the Structural Adequacy FRL as the wall may have span up to 6.8m high, from the ground floor to roof truss. If the wall separates a wet area from a habitable room, it must also be of discontinuous construction. Core-filled and reinforced 15.91 or 20.91 masonry with Lining System 6 (details on page E3) complies with this.

Boral concrete blocks are manufactured in 90, 140, 190, and 290mm thicknesses to suit most wall construction applications. FIRE DESIGN CONSIDERATIONS The fire resistance performance of Boral concrete blocks is determined as per AS3700 : 2001 Section 6. These products can provide adequate fire performance for many common fire rated wall applications. Please also refer to fire performance graphs and design information in Sections B and C of this guide for additional selection information.

30.91

Colour and Availability • Please refer to the Boral Masonry Blocks Guide for detailed availability and colour information on these products.

E16



Specifications

Fire

Acoustics

Maximum Slenderness Ratio (S rf ) Product Code

TxLxH (mm)

10.01 Hollow

90x390 x190

10.31 Solid

90x390 x190

Unit  ’uc Wt MPa kg 10

10

15.01 140x390 Hollow x190 (without grout fill)

10

15.91

15

140x390

11.1

14.2

12.5

12.5

N° per m2

N° per Pallet

60

90

120

180

240

12.5

180

18.0

17.0

16.0

15.5

144

60 18.0

17.0

16.0

120

60 18.0

17.0

120

60 36.0

36.0

90

18.0

120 17.0

90

60 36.0

12.5

12.5

12.5

Insulation (minutes) FRL (minutes)

Groutx190 filled and reinforced 20.01 190x390 Hollow x190 (without grout fill)

10

20.91 190x390 Groutx190 filled and reinforced

15

30.91 290x390 Hollow x190 (without grout fill)

15

30.91 290x390 Groutx190 filled and reinforced

15

14.2

14.4

17.6

17.6

12.5

12.5

12.5

12.5

 Impact

Rw + Ctr











15.0

46

46

50

57

55

60

—

15.5

15.0

47

47

51

58

56

61

—

16.0

15.5

15.0

47

47

51

58

56

61

—

36.0

36.0

36.0

53

51

56

63

61

66

52

48

48

52

59

57

62

50

56* 55

60

67

65

69

54

for 





 16.0

15.5

15.0

36.0

36.0

36.0

36.0

15.5

15.0

49

49

54

61

59

63

50

36.0

36.0

59

59

64

71

69

72

56



60

18.0

17.0

240 16.0

60

60 36.0

36.0

36.0

240

      Refer to Lining Systems on Page E3. *Rw + Ctr = 50



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May 2008



Additional Insulation with  Lining System (13mm render both sides).

E17


Acousticell™ 190

INTRODUCTION Boral Acousticell is a purpose designed block which combines excellent acoustic absorption and sound transmission loss characteristics.

Boral Acousticell has been successfully integrated into a wide variety of industrial and commercial acoustic applications, providing both acoustic performance and unique and attractive aesthetic qualities.

390 140

Acousticell Full

The face slots and closed core base of the Boral Acousticell block form ‘Helm-Holtz’ absorbers which control low frequency noise where other walling materials reflect noise, adding to the original noise source.

Availability • • • •

All Acousticell blocks are made-to-order Lead time 6-8 weeks. Minimum quantities apply. Part size blocks are best cut/bolstered on-site to maintain colour consistency. Part size blocks can be cut-to-order. • Contact Boral Masonry for further details.

Typical applications include auditoria, theatres, radio, television and cinema studios, churches, schools, canteens, plant rooms, factories and workshops, sports centres, multi-purpose centres and wherever sound reverberation can cause problems. Boral Acousticell Blocks are compatible with Series 150 bond beams and part size blocks.

Essential Colours

Alabaster

Almond

Pearl Grey

Charcoal

Natural Grey

SOUND ABSORPTION Boral Acousticell blocks combine the high transmission loss characteristics generally associated with a dense, non-porous material (concrete block) with efficient absorption of sound, resulting in a very low radiated sound level and effective control of both high frequencies and troublesome low frequency noise. Boral Acousticell blocks provide maximum absorption in the frequency range of 80Hz to 500Hz, peaking at 1.0 at 200Hz and providing absorption of 0.6 at 100Hz.

Where high frequency noise is to be absorbed, fibreglass insulation pads can be inserted into the ‘Helm-Holtz’ cells. In this case, absorption of low frequency noise drops slightly, but absorption of other frequencies improves. (Note: Fibreglass is not suitable for external use. Carbon fibre pads are more suitable in external situations). Refer to accompanying absorption graph for application results. COLOURS Boral Acousticell Block is ‘Madeto-Order’ and can therefore be manufactured in any of the Boral Designerblock colours. Minimum order quantities apply to all colours.

Accent Colours

Sandune

Rust E18

Paperbark

Wilderness

Terrain

Midway

Specifications Code

Product Description

150mm

Acousticell Full

MPa

Wt kg

N°/Pallet

10

14.0

120



Acousticell™ Acoustic Performance Sound Transmission Loss for Acousticell is similar to standard dense-weight concrete masonry. Refer to Fig E1. Rw Contour Line Acousticell Test Results 60 ) 50 B d ( s 40 s o L n o 30 i s s i m s 20 n a r T d 10 n u o S

0

Boral Acousticell has also been shown to provide a proven and practical solution for Transformer Sub-Station Enclosures. The test results from one such installation are shown in Fig E3, and comments from the project acoustic engineers are provided below the figure. Before construction of Boral Acousticell enclosure After construction of Boral Acousticell enclosure 70

60

125

250

500

1K

2K

5K

Centre Frequency of Octave Band (Hz)

Fig E1 — Sound Transmission Characteristics of Boral Acousticell Block

It is the absorption characteristics of Acousticell that make the difference where noise is to be controlled within a room or prevented from ‘bouncing’ around an enclosure wall and escaping over the top.

B d n 50 i l e v e l e r 40 u s s e r p 30 d n u o S

20

10

4

8

16 31.5 63 125 250 500 1K

2K

4K

8K 16K 32K

Octave band centre frequency Hz (CPS)

Boral Acousticell is an excellent choice for generator, pump and plant rooms, as it offers maximum absorption in the frequency region 80Hz to 500Hz (which is also peak acoustical range for most diesel engines) providing better noise reduction than that offered by alternative construction systems. Refer to Fig E2. as 1.1 1.0 0.9

0.3 0.2

Louis A Challis and Associates Pty Ltd. Consulting Acoustical and Vibration Engineers.

0.1 4

COMMENTS ON THE RESULTS. The measurement results show a dramatic reduction in noise level from the transformers, especially under conditions when the internal cooling fans, together with secondary ventilation fans fitted into the enclosure were operating.

The result is a situation where there is now negligible annoyance to surrounding residences from the transformers. Previously the level of low frequency noise was such that special double glazing of both doors and windows would have been necessary to achieve acceptable community noise levels.

n 0.8 o i t p r 0.7 o s b 0.6 A d n 0.5 u o S 0.4

0

Fig E3 — Octave Band Analysis of Noise Level from large distribution transformer before and after fitting Boral Acousticell Masonry Enclosure

8

16

31.5

63

125

250

500

1K

2K

4K

8K

1/3 Octave Band Centre Frequency Hz (CPS)

Fig E2 — Sound Absorption Characteristics of Boral Acousticell Block

Because the transmission loss through the main wall structure is typically 44 STC or greater, noise reductions as high as 40 decibels or more can be readily designed and achieved in practice. BORAL MASONRY DESIGN GUIDE

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May 2008

E19

Boral - Masonry Design Guide - NSW

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