AAC WALL PANEL TECHNICAL MANUAL

February 2020
Building better and smarter starts with 50mm, 75mm or 100mm Eco Panel. CHAD Group Australia P/L
Aerated Autoclaved Concrete (AAC) Eco Panel provides ultra-high integrated insulation and facilitates
building a home quicker. Being clad much faster than conventional bricks, the speed of construction
reaches key stages quickly. Eco Panel is as solid and as durable as traditional masonry, yet its lightweight
properties get any project to “Lockup” quicker. Eco Panel adds to a safer and cleaner worksite with less
“cleanup” at the conclusion of the project. In comparison to traditional rendered masonry products, Eco
Panel saves time and money. The inherent

Thermal Mass and Thermal Resistance properties of Eco Panel showcases its energy efficiency properties.
Eco Panel also brings to the total package further benefits of higher fire resistance. Eco Panel does not
combust in the event of fire and will not omit toxic gases. 75mm Eco Panel provides a Load Bearing FRL of
240/240/240. 50mm Eco Panel provides a Load Bearing FRL of 120/120/120. Eco Panel also has sound
acoustic reducing qualities equivalent and better than traditional masonry products.

AAC Eco Panel is an environmentally friendly product. It is pollution free, emits no harmful emissions and
has an excellent environmental performance. It has fantastic design flexibility and it’s aesthetic appeal gives
designers the range and flexibility of using a masonry product where previously non-masonry products
could be used.

February 2020 – Version 7 PAGE 2

February 2020 – Version 7 PAGE 3
Introduction
ECO Panel (AAC) is manufactured via a combination of lime and/or cement, combined with finely divided
sand and other filler materials. This mix is poured into a mould, an expanding agent reacts with the other
elements, and the mix begins to rise in the mould while the reaction with the expanding agent creates
finely dispersed air bubbles. This is cured under high pressure and temperature to provide a relatively
strong, lightweight cellular structure, incorporating small uniformly distributed bubbles.

After the semi solid material is pre-cured, the block out of the mould is cut and sliced into the required
sizes. Once appropriately sized, the panels are steam pressure cured in auto- clave ovens. This
manufacturing process is central to what gives AAC panel its excellent

CEMENT LIME

WATER

SAND BALL MILL MIX

WIRE REINFORCEMENT CAST CUTTING MACHINE

CORROSION PROTECTION ASSEMBLING AUTOCLAVE

TREATMENT

PACKAGED FOR DELIVERY AAC PRODUCT

THE AAC MANUFACTURING PROCESS

February 2020 – Version 7 PAGE 4

ECO Panel Aerated Autoclaved Concrete (AAC)
The ECO PANEL (AAC) system is an innovative Autoclaved Aerated Concrete light-weight cement-based
material, incorporating small uniformly distributed bubbles that result in its unique properties of lightness,
high thermal resistance, workability and strength. ECO PANEL (AAC) are also steel reinforced AAC wall or
floor panels.

This manual is available in hardcopy, softcopy or electronic form and is intended for use by qualified and
experienced architects, engineers and builders. The authors, publishers and distributors of this manual,
sample specification and the associated drawings do not accept any responsibility for incorrect,
inappropriate or incomplete use of this information. It is the express intention that designers will edit them
to suit the particular requirements of specific construction projects.

This manual has been prepared in the context of the National Construction Code of Australia. Architects,
engineers and builders should make themselves aware of any recent changes to these documents, to any
Standards referred to therein, or to local variations or requirements. The authors, publishers and
distributors of this specification and the associated drawings do not accept any responsibility for failure to
do so.

There are many factors to be considered when designing building solutions from Eco Panel Autoclaved
Aerated Concrete (AAC) panels, and CHAD Group Australia P/L provides design tables and charts to assist
the designer. The Eco Panels are grouped into two basic types relating to application. These types being:-

• Floor panels;
• Wall panels;

February 2020 – Version 7 PAGE 5

Applications
AAC Panels are reinforced, and are designed for floors and walls in multi-residential, commercial,
residential (domestic) and industrial construction.

MULTI-RESIDENTIAL CONSTRUCTION
• Non-loadbearing external wall panels, generally panels are fixed to a reinforced concrete structural
frame.
• Internal wall panels – party walls / risers / shaft walls.

COMMERCIAL CONSTRUCTION
• Non-loadbearing external wall panels.

RESIDENTIAL (DOMESTIC) CONSTRUCTION

• External cladding for loadbearing wall panels, limited to 2 storey construction;
• Roof panels;
• Floor panels

INDUSTRIAL CONSTRUCTION
• Non-loadbearing wall panels, larger panels spanning vertically can be successfully incorporated
into industrial wall applications.
• Mezzanine doors
• Ceiling panels – fire exits.

February 2020 – Version 7 PAGE 6

Design Actions

CODES AND REGULATIONS

Design procedures for the verification of members and structures consisting of AAC panels generally follow
the design principles outlined in Australian Standard AS3600-2009 – Concrete Structures, with the exception
of cover requirements for durability and development length for reinforcement.

The loadings on the panel products are to be determined in accordance with the Australian Standard
AS1170 “Design Actions” series of codes. These codes cover typical loadings, such as dead load, live load,
wind load, earthquake load, as well as others.

GUARANTEE AND CERTIFICATION

CHAD Group Australia is a supplier of AAC products. CHAD Group Australia guarantee the products and the
products used in the systems described in CHAD Group Australia literature, subject to the terms and
conditions of CHAD Group Australia Guarantee. We do not however guarantee the components, products
or services, such as installation and specialist advice, supplied by others.

CHAD Group Australia conducts appropriate testing of its products and systems, and sources opinions to
determine performance levels. These include structural, fire and acoustic. CHAD Group Australia can
provide copies of test results and opinions presenting the performance characteristics of its products and
systems.

When using Eco Panel systems in specific projects, CHAD Group suggest specialists be consulted to ensure
compliance with the National Construction Code of Australia and relevant Australian Standards. CHAD
Group Australia can provide a certification for its panel products. For a specific project, an appropriate
specialist can provide the certification for the relevant performance criteria of the systems and supporting
structure.

February 2020 – Version 7 PAGE 7

Summary of Properties of the PANEL AAC Products

Application Wall Panels Wall Panels Wall Panels Floor Panels

50mm 75mm 100mm 75mm

Panel thickness, T, mm 50 75 100 75

Panel width, W, mm 600 600 450 600

Panel length, L, mm 2200 Varies Varies 1,800

Wet density kg/m3 (wout reo weight) 720-820 720 - 820 720 - 820 720 - 820

Oven-dry density, kg/m3 520-620 520 - 620 520 - 620 520 – 620

compressive strength average Mpa 5.0 5.0 5.0 5.0

Number of layers of Reinforcement 1 1 2 1

Main reinforcement diameter, mm 5 5 5 5

No of reinforcement strands 5 5 3 5

Reinforcement centres 25/25 37/37 18/64/18 37/37

Characteristic uncond compressive 1.1 1.1 1.1 1.1

Characteristic oven dry compressive 1.9 1.9 1.9 1.9

Mean elastic modulus E Mpa 1800 1800 1800 1800

Panel Kg weight per m2 approx 28 55 70 55

Acoustic Performance dBA1 28 32 36 32

With Insulation R2.0 R2.5 R3.0 R1.5 R2.0 R2.5 R1.5 R2.0 R3.5 R1.5 R2.0 R2.5

Thermal Resistance 2.5 3.0 3.5 2.32 2.82 3.32 2.46 2.96 3.46 2.32 2.32 3.32

1. S. Aroni, G de Groot, M Robinson, G Svanholm, F Wittman, Rilem Recommended Practice

Autoclaved Accelerated Concrete Properties Testing and Design.

February 2020 – Version 7 PAGE 8

Simple Spans - Capacity Kpa

lm Wall Panels Wall Panels Wall Panels

50mm 75mm 100mm

0.3 4.66 32

0.45 6.51 14.22

0.600 3.66 8.00

0.750 2.35 5.12

0.9 1.63 3.56 15.71

1.2 0.92 2 8.84

1.5 1.28 5.66

1.8 0.89 3.93

2.1 0.65 2.89

2.4 0.5 2.21

2.7 1.75

3 1.41

3.3 1.17

February 2020 – Version 7 PAGE 9

ECO AAC Steel Reinforced Autoclaved Aerated Panels
ECO Panels AAC Steel Reinforced Autoclaved Aerated Panels have the following properties: Characteristic
compressive strength, fck = 5.0 MPa

Characteristic flexural strength, ff = 1.0 MPa Characteristic elastic modulus, E = 1,800 MPa

Panel thickness, T = 75 mm Panel width, B = 600 mm

Panel lengths (standard sizes), L = 2,400 mm, 2,550 mm, 2,700 mm, 2,850 mm, 3,000mm

Reinforcement yield strength, fsk = 235 MPa Reinforcement diameter, R = 5mm

Number of reinforcing strands, N = 5 (over a 600 mm width) Ns = 8 (0ver 2,700 to 3,000 mm panel length)

Depth of Reinforcement, d = 45 mm (30 mm from opposite face)

Moment capacity (medium reinforcement, 0.286 < s < 0.375), Φ Mu = 0.685 kN.m

Using this data, the ultimate bending capacities (expressed in terms of uniform pressure) for various spans
of ECO Panels AAC Steel Reinforced Autoclaved Aerated Panels are identified in the following table.

February 2020 – Version 7 PAGE 10

50 mm ECO PANEL (AAC) Steel Reinforced Autoclaved Aerated Wall
Panels with reinforcement in centre

75 mm ECO PANEL (AAC) Steel Reinforced Autoclaved Aerated Wall

Panels with reinforcement in centre

February 2020 – Version 7 PAGE 11

100 mm ECO PANEL (AAC) Steel Reinforced
Autoclaved Aerated Wall Panels

February 2020 – Version 7 PAGE 12

75 mm ECO PANEL (AAC) Steel Reinforced
Autoclave Aerated Floor Panels

• Spanning joists at 450 mm centres, are suitable for the support of 3.0 kPa distributed or a 1.8 kN
point load over an area of 350 mm2 (located at least 100 mm from the panel edge). This
corresponds to balcony loads for domestic housing.
• Spanning joists at 600 mm centres, are suitable for the support of 1.5 kPa distributed or a 1.8 kN
point load over an area of 350 mm2 (located at least 100 mm from the panel edge). This
corresponds to the internal loads for domestic housing.
• The specifier and builder must ensure that there is provision to prevent and/or control cracking of
any brittle floor coverings, such as tiles, particularly at 600 mm joist spacing. In the case of 600 mm
joist spacing, ductile surfaces are more appropriate.

February 2020 – Version 7 PAGE 13

Structural Design Procedure
This section covers the structural design of ECO PANEL (AAC) for compliance with the structural
requirements of the National Construction Code of Australia.

DESIGN AND CONSTRUCTION STANDARDS

The National Construction Code of Australia provides the overall regulatory framework for the design and
construction of buildings in Australia.

• Eco Panels AAC, provided as steel reinforced autoclaved aerated panels, are designed in
accordance with the recommendations of “RILEM Recommended Practice – Autoclaved Aerated
Concrete – Properties, Testing and Design”. Because this system is outside the scope of the most
relevant National Construction Code of Australia referenced document, AS3700, its use must be
treated, under the National Construction Code of Australia, as an Alternative Solution in a deemed
to satisfy capacity.
• Eco Panels AAC, provided as autoclaved aerated blocks set in thin-bed adhesive, are designed in
accordance with AS 3700-2001 Masonry Structures.

LOADS
Eco Panels AAC walls should be designed to withstand the loads set out in the National Construction Code
of Australia and Standards, as listed below:

• AS/NZS 1170.0 Structural design actions Part 0: General principles

• AS/NZS 1170.1 Structural design actions Part 1: Permanent, imposed and other actions
• AS/NZS 1170.2 Structural design actions Part 2: Wind actions
• AS/NZS 1170.3 Structural design actions Part 3: Snow and ice actions
• AS 1170.4 Structural design actions Part 4: Earthquake actions in Australia
• AS 4055 Wind loads for housing

February 2020 – Version 7 PAGE 14

Fire Design
Autoclaved Aerated Concrete (AAC) is one of the most effective building materials for providing a barrier to
fire. AAC has shown itself to be non-combustible and very stable under fire loading, resulting in structural
systems that have high fire resistance level (FRL) ratings. The properties that highlight the high level
performance of AAC under fire loading are following:-

NATIONAL CONSTRUCTION CODE OF AUSTRALIA AND AUSTRALIAN STANDARDS

The NCC Volume 1 Part C defines the fire resistance requirements for Class 2 to 9 buildings. The NCC
Volume 2 Part 3.7.1 defines the fire resistance requirements for Class 1 and 10a buildings. Various
Australian Standards, including AS 3700 set out the means of determining the fire resistance of masonry,
including AAC, for the three limit states described in the NCC. It requires designers to check three separate
fire performance limit states:

• Structural adequacy (resistance to collapse)

• Integrity (resistance to cracking)
• Insulation (resistance to the passage of heat).

FIRE DESIGN AND FIRE RESISTANCE LEVEL (FRL) RATINGS

The National Construction Code of Australia regulations express the fire performance of a wall with the
rating system called the ‘Fire Resistance Level’ (FRL). The FRL ratings in the CHAD Group Technical Manual
have been determined by testing in accordance with AS1530.4 – Fire Resisting Tests of Elements of Building
Construction – EXOVA.

The fire FRL rating consists of three performance criteria:

a) resistance to collapse
b) resistance to cracking
c) resistance to the passage of heat

For non-load bearing walls, there is no requirement to express the ‘structural adequacy’ criteria.

FIRE CERTIFICATE AND REPORTS

Copies of the test reports for fire testing performed on the CHAD Group blocks are available by contacting
CHAD Group.

ADDITIONAL DESIGN CONSIDERATIONS

Fire-rated block walls should comply with both strength and robustness requirements and minimum
slenderness ratios outlined in AS3700 – Masonry Structures code.

February 2020 – Version 7 PAGE 15

Fire Tests

Load Bearing Vertical Load Applied 50mm EcoPanel FRL 120/120/120

Fire Tests to AS1530.4 for 75mm Reinforced AAC Eco Panel as per Exova Warrington (Australia) P/L report
30864500.1 gave the following results. This information can be sued to check the fire performance of a
proposed structure.

Wall Structure Tested: AAC Eco Panel with R1.5 fiberglass batts, fixed to steel framing and 10mm standard
plasterboard.

Wall Dimensions
Height 3000mm
Width 3000mm
Panel Thickness 50mm
Insulation R1.5 fiberglass
Plasterboard Standard 10mm Recessed Edge Plasterboard
Framing 90x45 MGP10 Timber Framing
16mm – P301 Rondo Metal Batten

Time to Failure
Structural Adequacy Result 156 mins
Integrity 156 mins
Insulation 156 mins

Load Bearing Vertical Load Applied 75mm EcoPanel FRL 240/240/240

Fire Tests to AS1530.4 for 75mm Reinforced AAC Eco Panel as per Exova Warrington (Australia) P/L report
30908400 gave the following results. This information can be sued to check the fire performance of a
proposed structure.

Wall Structure Tested: AAC Eco Panel with R1.5 fiberglass batts, fixed to steel framing and 10mm standard
plasterboard.

Wall Dimensions
Height 3000mm
Width 3000mm
Panel Thickness 75mm
Insulation R1.5 fiberglass
Plasterboard Standard 10mm Recessed Edge Plasterboard
Framing 90x45 MGP10 Timber Framing
Channel Rondo P303 Top Bat Channel

Time to Failure
Structural Adequacy Result 241 mins
Integrity 241 mins
Insulation 241 mins

February 2020 – Version 7 PAGE 16

50mm AAC ECO Wall Panels

February 2020 – Version 7 PAGE 17

Acoustic Properties & Performance

SOUND
Sound will have two basic characteristics – amplitude and frequency (or pitch) of the sound. The amplitude
of the sound is a measure of the magnitude of the oscillation. The frequency of the sound is a measure of
how quickly the vibrating surface is moving back and forth.

ACOUSTIC MATERIALS – SOUND BARRIERS AND SOUND ABSORBERS

There are materials that absorb sound and prevent it reflecting around a room for example, echo. These
materials are sound absorbers and are usually soft to touch for example Glasswool insulation, carpets,
curtains and mineral fibres.

The second categories of materials are those that reduce transmission of sound through the material from
one room to another. These materials are referred to as sound barriers for example Eco Panel Wall and
Floor Panels.

Both types of materials are necessary for providing a satisfactory acoustic environment in a building.

The careful combination of acoustic barriers and sound absorbent materials can provide a very cost
effective and space efficient solution.

STC & RW ACOUSTIC RATING SYSTEMS

The National Construction Code of Australia (NCC) presents the Performance Requirements for sound
insulation ratings. The sound insulation ratings set minimum values to consider for two types of sound:
airborne sound and impact generated sound.

The Rw rating curve (similar to the STC curve) was basically derived from sound insulation requirements for
speech. Modern living with its use of large television sets, home entertainment units for music and the
home cinema with its surround sound had increased the requirement for low frequency sound insulation.
In this regard, the Rw spectrum is inadequate. The ISO rating system has a correction factor for traffic noise
for external walls, roofs and windows. This correction factor Ctr when applied to the Rw curve also provides
better relationship of sound insulation for the low frequencies of the various home entertainment systems.
The term Rw + Ctr has been adopted in the Australian NCC and the Association of Australian Acoustical
Consultants Star Rating System for Apartments and Townhouses.

February 2020 – Version 7 PAGE 18

NCC VOLUME 1 CLAUSE F5.5 REQUIREMENTS

NCC Vol 1 Walls that separate sole occu- Rw + Ctr Impact sound resistance, if the
Clause F5.5 pancy units in a Class 2 or 3 (airborne) not wall separates a habitable room in
Requirements building or between two Class 1 less than 50, one sole occupancy unit from a
buildings bathroom, sanitary compart-
ment, laundry or kitchen of
another unit or plant room or lift
shaft).

Walls that separate a sole Rw (airborne) Impact sound resistance, if the

occupancy unit from a plant room, not less than 50 wall separates a habitable room
lift shaft, stairway, public corridor, in one sole occupancy unit from a
public lobby or the like in a Class 2 plant room, or lift shaft
or 3 building

Walls that separate two sole Rw (airborne) not Impact sound resistance if the wall
occupancy units or separates a less than 45, separates a habitable room in one
sole occupancy unit from a sole occupancy unit from a kitchen
kitchen, bathroom, sanitary or laundry.
compartment (not en-suite),
laundry, plant room or utilities
room in a Class 9c aged-care
building

A door incorporated in a wall that Rw (airborne) Walls requiring impact sound

separates a sole occupancy unit not less than 30 resistance shall consist of two
from stairway, public corri- dor, leaves separated by a gap of at
public lobby or the like in Class 2 least 20 mm (and in Class 2 or 3
or 3 building and a door where required, connected by
incorporated in a wall that resilient ties).
separates a sole occupancy unit
from a kitchen or laundry in a
Class 9c aged care building.

February 2020 – Version 7 PAGE 19

NCC VOL 2 CLAUSES [Link] TO [Link] REQUIREMENTS

Walls that separate a bath- Rw + Ctr Discontinuous construction. For

NCC Vol 2
room, sanitary compartment, (airborne) not cavity walls, a minimum of 20 mm
Clauses [Link] cavity between two separate
laundry or kitchen of one Class 1 less than 50
to [Link] leaves, which may be connected, if
building from a habitable room
Requirements (other than a kitchen) in an required for structural purposes,
adjoining Class 1 building with resilient ties. Northern Territo-
(dwelling) shall have: ry, Queensland and Western
Austra- lia have varied this
requirement to
Rw not less than 50 and Impact
Sound Resistance

Walls are required to be detailed in accordance with NCC Vol 2 Clause [Link], which make provision for the
sealing of sound insulated walls at junctions with perimeter wall and roof cladding. This clause also requires
that masonry joints be filled and provides for sound insulated articulation joints. NCC Vol 2 Clause [Link]
makes provision for services in sound insulated walls.

Walls required to have a sound insulation shall be constructed to the underside of:

• A floor above
• A ceiling with the same acoustic rating
• A roof above.

Flanking and Indirect Sound Leaks

February 2020 – Version 7 PAGE 20

Acoustic Performance of AAC ECO Panels
Weighted sound index,

Rw = 27.7 log10(M) – 11.6 dB

Where M = the surface mass of the wall in kg/m2

Based on a bulk density of 520 kg/m3 and a panel thickness of 75 mm, the resulting predicted weighted
sound index would be 32 dBA

Weighted sound index data, used to support designs to NCC Volume 1 Part F5 or NCC Volume 2 Clause
3.8.6, should be determined in accordance with AS/NZS 1276.1.

EFFECT OF JOINTS AND GAPS ON SOUND ATTENUATION

Gaps reduce the sound attenuation of a wall. Laboratory tested walls have full joints. Site construction must
also have full joints to ensure similar sound attenuation. Gaps around the vertical edges of a wall and at the
ceiling will diminish the sound resistance of a wall. A gap 0.l% of wall area (corresponding to a 3 mm gap
along the length of a 3 m high wall) can reduce the sound transmission resistance by typically 10-20 dB.
Gaps around the periphery of walls should be sealed using a high-density acoustically-rated mastic or
similar sealant. Sealants should have a typical density of 1600 kg/m.

Sealants should be applied to both faces of the wall and should be applied to a depth equal to the width of
the gap. Typical penetrations in walls include mechanical services ducts, refrigerant pipes, hydraulic
reticulation lines, waste pipes, fire sprinklers, and electrical cables. It is essential to provide an acoustically
rated seal around the penetration.

EFFECT OF CHASES ON SOUND ATTENUATION

Chases in walls diminish the sound attenuation. Chases should not extend deeper than 25mm into the wall.
All chases should be rendered over after the pipes or cables are installed.

Water services should not be chased whatsoever into Eco Panel.

February 2020 – Version 7 PAGE 21

Energy Efficiency and Thermal Performance

THERMAL DESIGN
Energy savings in the operation of buildings are of particular importance as the cost of energy for heating
and air conditioning in most cases represent the major cost factor in the operating cost of a building. The
energy retention or loss characteristics of a building are directly related to the thermal performance of the
building components.

The entrained air in the cellular structure of CHAD Group EcoPanel AAC gives the product excellent thermal
insulation properties, as well as good heat retention characteristics. These characteristics contribute
significantly to the energy saving performance of the building.

Thermal performance is concerned with the energy retention or loss characteristics of a building system
and the consequential reduction of greenhouse gas emissions.

The thermal performance of buildings is affected by a relationship between all components of the
structure, and the environment. Some elements of this relationship include:

Windows which occupy a large percentage of the perimeter of the building

The materials of which the walls are constructed affect not only steady state heat transfer, but also the
transient response of the internal environment to daily external temperature changes.

Internal temperatures which vary throughout the day and from room to room; and

During the day, solar radiation produces external temperatures which are higher than ambient shade air
temperature, and which vary around the building envelop in accordance with orientation and exposure to
the sun.

DYNAMICS OF THERMAL MASS

If a building with high thermal mass experiences a heating and cooling cycle which crosses the comfort
zone, the roof, walls and floor will store the heat energy for an extended period, gradually releasing it over
time. In winter, high thermal mass buildings will remain relatively warm, while in summer, they will remain
relatively cool.

In winter, heat trying to pass through the wall will become trapped in the wall and part will slowly pass back
into the room. In summer the reverse occurs. Heat trying to pass through the wall from the outside will
become trapped in the wall and part will slowly pass back out of the building. The thermal mass of the
member (wall, roof/ceiling, floor etc) is the combination of the properties of each of the components (e.g.
AAC, insulation, foil etc) and is a function of the mass and specific heat.

February 2020 – Version 7 PAGE 22

THERMAL RESISTANCE OF ECO PANELS AAC EXTERNAL WALLS

Thermal Properties 50 mm
Material External Thickness mm Thermal Resistance
RM2.K/W
External Air Film 0.04
AAC 50mm ECO Panel 50mm 0.15
Internal Air Film 0.12

Total 0.31

External Air Film 0.04

AAC 50mm ECO Panel 50mm 0.15
Air Space 39mm 0.17
Internal Plasterboard 10mm 0.06
Internal Air Film 0.12

Sub Total 0.54

With Insulation R2.0 R2.5 R3.0 R2.0 R2.5 R3.0

TOTAL WITH INSULATION 2.5 3.0 3.5

THERMAL RESISTANCE OF ECO PANELS AAC EXTERNAL SINGLE WALLS

Thermal Properties 75 mm
Material External Thickness mm Thermal Resistance
RM2.K/W
External Air Film 0.04
AAC 75mm ECO Panel 75mm 0.43
Internal Air Film 0.12

Total 0.59

External Air Film 0.04

AAC 75mm ECO Panel 75mm 0.43
Air Space 39mm 0.17
Internal Plasterboard 10mm 0.06
Internal Air Film 0.12

Sub Total 0.82

With Insulation R1.5 R2.0 R2.5 R1.5 R2.0 R2.5

TOTAL WITH INSULATION 2.32 2.82 3.32

February 2020 – Version 7 PAGE 23

Thermal Properties 100mm
Material External Thickness mm Thermal Resistance
RM2.K/W
External Air Film 0.04
AAC 100mm ECO Panel 100mm 0.57
Internal Air Film 0.12

Total 0.73

External Air Film 0.04

AAC 100mm ECO Panel 100mm 0.57
Air Space 39mm 0.17
Internal Plasterboard 10mm 0.06
Internal Air Film 0.12

Sub Total 0.96

With Insulation R1.5 R2.0 R2.5 R1.5 R2.0 R2.5

TOTAL WITH INSULATION 2.46 2.96 3.46

• The Thermal resistance for 50, 75 and 100 AAC ECO Panel is based on 0.336 W/m.k
• The Stud wall is to incorporate a vapor barrier or thermal break

February 2020 – Version 7 PAGE 24

CONDENSATION CONTROL

VAPOUR BARRIER / SARKING OR SISLATION MUST BE INCORPORATED IN CONSTRUCTION

Atmospheric water vapour will condense when it, or air containing it, comes into contact with a surface that
is at or below the dew point temperature. Condensation of vapour within the building system should be
considered by the designer.

Condensation is a complex problem, and can occur under a variety of conditions, not just cold conditions –
hence the appropriate designer should check and approve the building solution for the particular
conditions of the project.

To control condensation, an appropriate vapor barrier or thermal break should be incorporated into the
wall system.

February 2020 – Version 7 PAGE 25

Foundations
For residential application, the selection of the foundation type for use is based on AS2870, “Residential
Slabs and Footings”.

This standard covers the selection of footing designs for the usual range of site conditions, ie soil types and
slopes. Where unusual site or load conditions are encountered, advice should be obtained from a practicing
Structural Engineer. It is recommended that a practicing Structural Engineer is consulted concerning the
application of AS2870 to any particular building construction or site.

The approach to foundation design using AS2870 is to first classify the foundation soil, then assess the
topography and select the appropriate footing design to be used. Following is a guide to this foundation
design approach. The Structural Engineer should approve this approach before adopting.

For other applications of AAC panels, the foundation or supporting structure should be designed by the
project structural engineer to satisfy the masonry.

Cracking in Masonry
As a result of the low tensile strength and negligible ductility, all forms of masonry construction behave as a
brittle material and are therefore prone to cracking. Similar to other forms of masonry, careful
consideration at design stage and attention to detail during construction of AAC masonry can minimize
such adverse effects.

It is important to note that the National Construction Code of Australia is performance based. The
performance based approach acknowledges the possibility of cracking and does not consider it to be a
defect so long as the structural resistance and other design requirements are maintained.

Cracks up to 1mm, whilst not considered a defect in these documents, may allow water ingress in single
skin masonry construction and therefore could be considered a defect under the NCC. This highlights the
importance of good coating systems. Coating systems should be able to bridge minor cracking.

CRACKING CAN BE DUE TO EXTERNAL EFFECTS:-

• Foundation and support movement
• Deformation (shortening, shrinkage, creep, bridging control joints in structure, etc) in adjacent
materials.
• Workmanship.

February 2020 – Version 7 PAGE 26

AAC differs slightly from clay brick and concrete block masonry so in addition to general behaviour of
masonry, the effect of the following differences must be considered”

• Lower compression capacity.

• Lower tensile strength.
• Lower modules of rupture.
• Lower coefficients of thermal expansion and contraction and drying shrinkage.
• Larger unit size.
• Laid in thin bed mortar which typically has higher compression capacity than units.
• Units are autoclaved.
• Dissipates and absorbs moisture from atmosphere with associated volume change.

Considerations for Design and Detailing

• Elements of masonry blockwork must be isolated from movement.
• Control joints
• Wall restraints
• The compressive strength of render coatings must not exceed that of the blockwork.
• Use plasterboard linings internally
• Use flexible coating systems that are able to bridge hairline cracks.
• Apply mesh within the render over areas of high stress.

Movement Joints
The backing rod should be placed into the AAC at a depth which permits a finish of the control joints to
finish the mortar joints.

Where a ‘movement joint is adjacent to a door or window frame, a 10mm gap should be provided between
the edge of the frame and AAC panel to allow for movement.

During the life cycle of a building, the building and the materials that it is constructed from will move. These
movements are due to many factors working together or individually, such as foundation movement
(shrink- age and swelling), thermal expansion and contraction, differential movements between materials,
climate and soil condition. This movement, unless relieved or accommodated for, will induce stress in the
materials, which may be relieved in the form of cracking. To accommodate these movements and relieve
and induced stresses, which could potentially crack the wall, movement joints (vertical gaps) shall be
installed. There are two categories of joints:

• Articulation joints are provided to relieve induced stresses due to foundation movement. The joints
make the walls more flexible by breaking the wall into a series of small panels, which is espe cially
required on reactive ground conditions (clay, peat). Differential movement between the AAC block
work and adjacent structural elements need to be accommodated with articulation joints, such as
blockwork infill between the structural frames.
• Control Joints (for example an expansion joint), are provided to relieve the induced stresses
resulting from thermal expansion or contraction of the AAC, or differential movement between
the AAC and another material or structure, such abutting walls or columns of concrete or
brickwork. Control joints can delineate coating shrinkage breaks. A joint may perform the function

February 2020 – Version 7 PAGE 27

 of either an articulation joint or control joint or both.
• 6 metres maximum for continuous runs of walls
• When measuring the 6 metre run of wall, the measurement continues around corners till the end
of the wall or a movement joint.
• For horizontal panels, a vertical movement joint shall be provided at the ends of the panels.

Additionally, the NCC presents the following requirements for articulation joints in unreinforced masonry
walls, which is applicable for AAC masonry construction:

Articulation joints must have a width not less than 10mm and be provided:

• in straight, continuous walls having no openings, at not more then 6m centres and not closer
than the height of the wall away from corners; and
• where the height of the wall changes by more than 20% at the position of change in height; and
• where openings more than 900 x 900mm occur, at more than 5m centres, and positioned in
line with one edge of the opening; and
• at control or construction joints in the footing slabs; and
• at junctions of walls constructed of different masonry materials; and
• at deep chases (rebates) for service pipes.”

The project architect and engineer shall be responsible for determining the optimum location of
movement joints, as their location is dependent on a variety of factors including most importantly the
structural stability and bracing requirements of the building.

Areas to be considered but not limited to, include:

• At corners and supports

• Adjacent to openings
• Adjacent to small openings in long walls
• Walls built in different substrates or different materials
• Geometrical change in wall height ie two story to single story walls
• Locations or junctions of different foundation types and steps in foundations
• Change in thickness or junction of load bearing and non load bearing walls

Attention should be given to ensure that these joints are kept free of all debris and that the connectors
are installed as per the manufacturers recommendations It is most important that under no
circumstances should a movement joint be rendered across.

February 2020 – Version 7 PAGE 28

Reinforced AAC ECO Panel Wall Cladding for Domestic Construction
The following specification and details are generally suitable for Reinforced AAC wall cladding for domestic
dwellings, subject to confirmation by the Design Engineer. A suitable support framing system must also be
provided. Reinforced AAC Panels shall be screw fixed to horizontal light-gauge steel battens, which are fixed
to vertical steel studs. There shall be not less than four horizontal battens per panel, with this number
increas- ing for higher wind loads and for panels within 1,200 mm of the building corners. Panels within
1,200 mm of each end of each external wall of a building (i.e. the two 600 mm wide panels closest to the
corners) are subject to higher local wind pressures and suctions, and therefore require more battens and
more screw fixing than other panels.

Cold-formed sections and accessories shall be manufactured from Z350 galvanised steel (Grade G550) com-
plying with AS 1397, with a zinc coating not less than 350 g/m2 and shall comply with AS4600. All battens
shall be 24 x 30 x 0.55 BMT Top Hat, Grade G550) or equivalent. We recommend Rondo P303 24mm
Cyclonic Batten and Rondo P310 35mm Cyclonic Batten.

All screws shall be No 14 x 100 mm Bugle Batten self drilling galvanised steel screws, fixed from the outside
of the building through the AAC panels into the horizontal steel light gauge battens behind.

General Notes:

1. All wind classifications and ultimate pressure calculations are based AS 4055-2006.
2. If AAC Panels are required to provide racking resistance, the screws and supports shall be
determined by the structural engineer, taking into account the wind classification and the
overall building dimensions.
3. Top and bottom battens shall be positioned within 150 mm of the ends of the panels.
4. Aerosol penetration to an extent depending on distance from the coast:
RO – Nil
R1 – 10 g/m2/day
R2 – 20 g/m2/day
R3 – 60 g/m2/day
R4 – 300 g/m2/day

Reinforcement
Unlike conventional masonry, AAC incorporates thin-bed adhesive in lieu of relatively permeable cement-
based mortar joints. This feature, together with impermeable blocks, means that the risk of corrosion of
both horizontal and vertical reinforcement is significantly reduced.

February 2020 – Version 7 PAGE 29

Reinforced ECO Panel (ACC) Wall Cladding for Domestic Dwellings
The following specification and details are generally suitable for Reinforced AAC wall cladding for domes- tic
dwellings, subject to confirmation by the Design Engineer. A suitable support framing system must also be
provided.

Reinforced AAC Panels shall be screw fixed to horizontal light-gauge steel battens, which are fixed to
vertical steel studs. There shall be not less than four horizontal battens per panel, with this number
increasing for higher wind loads and for panels within 1,200 mm of the building corners

Panels within 1,200 mm of each end of each external wall of a building (i.e. the two 600 mm wide panels
closest to the corners) are subject to higher local wind pressures and suctions, and therefore require more
battens and more screw fixing than other panels.

Unless specified otherwise by the engineer, the following details and tables shall be used for the cladding of
domestic dwellings with 75 mm thick or 100 mm thick Reinforced AAC Panels.

Light gauge steel battens shall comply with the Drawings, Building Regulations and relevant Standards
(AS/NZS 4600, AS 3623). Cold-formed sections and accessories shall be manufactured from Z350 galvan-
ised steel (Grade G550) complying with AS 1397, with a zinc coating not less than 350 g/m2 and shall comply
with AS4600. All battens shall be Rondo P303 24mm Cyclonic Batten or P310 35mm Cyclonic Batten. The
surfaces of Zincalume battens that are in contact with the AAC panel shall be painted with a suitable high
build paint to guard against adverse chemical reaction.

All screws shall be No 14 x 100 mm Bugle-headed self drilling galvanised steel screws, fixed from the
outside of the building through the AAC panels into the horizontal steel light gauge battens behind.

General Notes:

1. All wind classifications and ultimate pressure calculations are based AS 4055-2006
2. If AAC Panels are required to provide racking resistance, the screws and supports shall be
deter mined by the structural engineer, taking into account the wind classification and the
overall building dimensions.
3. Top and bottom battens shall be positioned within 150 mm of the ends of the panels.

February 2020 – Version 7 PAGE 30

 AAC Panel fixed to steel
top-hat section, which is
fixed to the supporting
structural frame

Sisalation
Structural frame
Window

AAC Panel

AAC Panel fixed to steel

Structural frame top-hat section, which is
fixed to the supporting
structural frame

Combined flashing
and damp-proof
course

Concrete slab-footing/pier 75 mm minimum to provide

system, including for termite inspection
reinforcement, membrane
etc, designed to AS 2870 or
AS 3600 as appropriate

February 2020 – Version 7 PAGE 31

Vertical Fixing Details 75mm / 100mm

Screw Fixing of External Reinforced AAC Panels to Steel Channels

Wind Ultimate Number of Number of Number of Max. spacing of supports

Classification Suction kPa horizontal top screws on top screws on
hat supports and bottom internal supports
supports

N1 1.0 3 2 2 900

N2 1.4 3 2 2 900

N3 / C1 2.3 4 2 2 900

N4, C2 3.3 4 2 3 900

N5, C3 4.9 5 2 3 450

N6, C4 6.7 6 2 4 450

Notes:
This table applies for a distance of 1,200 mm from each end of each external wall of a building ie it applies to
the two 600mm wide panels closest to the corners, and not required to provide racking resistance.

All screws shall be No 14 x 100 mm Bugle-headed self drilling galvanised steel screws (100 mm long for 75 mm
thick panels, 125 mm long for 100 mm thick panels), fixed from the outside of the building through the ECO
PANELS ( AAC) into the horizontal steel light gauge battens behind.

February 2020 – Version 7 PAGE 32

Vertical Fixing Details 50mm

Vertical Screw Fixing of Steel Battens to Steel Studs 75mm / 100mm

Ultimate Number of Number of Number of Stud

Wind Classification horizontal top screws on top screws on Spacing,
Pressure or internal
and bottom
Suction kPa hat supports supports supports mm

N1 1.0 3 2 2 600
N2 1.4 3 2 2 600
N3 2.3 4 2 2 600
N4, C1 3.3 4 2 3 450
N5, C2 4.9 5 2 3 450
N6, C3 6.7 6 2 3 450

Notes
This table applies for a distance of 1,200 mm from each end of each external wall of a building. It
applies to the two 600 mm wide panels closest to the corners, and not required to provide racking
resistance.

All battens shall be (22.5 x 63 x 0.55 BMT, Grade G550) or equivalent. The surfaces of zincalume
battens that are in contact with the ECO Panel (AAC) panel shall be painted with a suitable high build
paint to guard against adverse chemical reaction.

All screws shall be No 14g x 100mm Type No 17 self drilling class 3 galvanized screws (or as required by
the engineer), fixed to the horizontal steel light gauge battens to the stud.

February 2020 – Version 7 PAGE 33

50mm Eco Panel Floor Systems Design and Installation
Floor systems at Eco Panel are designed to be used in every residential or commercial construction project.
With qualities like rigidity, lightweight composition, high fire resistance, and acoustic dampening, Eco Panel
performs very well. For fast and clean construction procedures our Floor Systems are available in standard
sizes of 2200mm in length and 600mm in width. A high level of quality is maintained in the project from
start to finish.

Eco Panel reinforced AAC floor systems are the preferred system in residential construction over timber or
steel framed floor joist systems. The 50mm thick, steel reinforced Eco Panel floor panels are manufactured
from autoclaved aerated concrete with an average density of 560kg/m³.

The Eco Panel floor panels are supplied in standard sizes of 2200mm in length and 600mm width and have
an average weight of approximately 36 kg/panel. Eco Panel floor systems are delivered in packs to site. We
take all care to avoid damage to the faces, ends and edges of the panels. Manual handling of floor panels is
kept to a minimum; we use trolleys and/or other mechanical devices for delivery of panels.

Health & safety MUST be maintained with respect to Eco Panel floor systems. However when cutting,
drilling, sawing, routing, chasing, sanding and in any way breaking up the material there is the potential for
health problems to occur. Standard precautionary measures are to be taken by the installer, as per the
occupational health and safety act.

In essence the method of installation is the same as laying chipboard flooring except that joists have to be
laid out at 440mm centres to match the length of the standard panels. You can combine Eco Panel 50mm
Floor Panels with Compressed Sheet flooring to achieve the desired step down for wet areas.

Normal AAC panel tools and sundries are required such as a grinder fitted with a masonry cutting blade,
impact drill, bugle batten screws, construction adhesive and a straight edge (to get the first row of panels
straight) are a minimum requirement.

PLEASE NOTE: Joists MUST be set out at 440mm centres

• Minimum joist width of 45mm required, but joist width of 63mm or greater is preferred
• Apply construction adhesive to joist.
• Position panel over construction adhesive
• Fix panel to joist with 14gx75mm bugle batten screws (2 screws per joist)
• Min 50mm from panel edges
• •Apply construction adhesive on the edge of the panel previously laid where the new panel will
come into contact, and to the sections of joist the next panel length will sit on.
• Butt panels end to end
• Ensure panels are aligned by using a straightedge or a laser.
• On the 600mm butt joint, screw into the centre of the joint straight into the joist. The screws
should hold both panels down.
• Continue the process while maintaining a 440mm stagger in each new row.

February 2020 – Version 7 PAGE 34

75mm AAC ECO Panel Flooring

Reinforced Eco Panel AAC Flooring for Domestic Dwellings 450 centres
The following specification and details are generally suitable for Reinforced ECO FLOOR PANEL (AAC) for
domestic dwellings, subject to confirmation by the Design Engineer. A suitable supporting joist system must
be provided.

Reinforced ECO FLOOR PANEL (AAC) Panels shall be screw and adhesive fixed to timber or light-1gauge
steel joists, at centres not greater than 450 mm centres. Joists and bearers shall comply with the Drawings,
Building Regulations and relevant Standards.

Timber joists and bearers shall comply with AS1684.

Light gauge steel joists and bearers shall comply with (AS/NZS4600, AS3623). Cold-formed sections and
accessories shall be manufactured from Z350 galvanized steel (Grade G550) complying with AS1397, with a
zinc coating not less than 350 g/m and shall comply with AS4600. The surfaces of zincalume battens are in
contact with the Eco Panel AAC shall be painted with a suitable high paint to guard against adverse chemical
reaction.

Screws shall be bugle-headed Class 3 or Class 4 galvanized steel screws, fixed through AAC panels into the
joists. Timber joists: No 14 x 100 mm galvanized bugle headed screws

Cold-formed steel joists: No 14 x 95 mm hex head self drilling screws.

Construction Adhesive shall be applied between adjacent panels and between panels and joists, in
accordance with the manufacturer’s recommendations.

February 2020 – Version 7 PAGE 35

Note 1
75 mm floor panels spanning joists at 600 mm centres are suitable for the support of 1.5 kPa distributed or
a 1.8 kN point load over an area of 350 mm (located at least 100 mm from the panel edge). This
corresponds to the internal loads for domestic housing. The designer and builder must ensure that there is
provision to prevent and/or control cracking of any brittle floor coverings, such as tiles, particularly at
600mm joist spacing. In the case of 600mm joist spacing, ductile surfaces are more appropriate.

February 2020 – Version 7 PAGE 36

75mm Reinforced Eco Panel AAC Flooring for Domestic Dwellings 600
centres
The following specification and details are generally suitable for Reinforced ECO FLOOR PANEL (AAC) for
domestic dwellings, subject to confirmation by the Design Engineer. A suitable supporting joist system must
be provided.

Reinforced ECO FLOOR PANEL (AAC) Panels shall be screw and adhesive fixed to timber or light gauge steel
joists, at centres not greater than 600mm centres. Joists and bearers shall comply with the Drawings,
Building Regulations and relevant Standards.

• Timber joists and bearers shall comply with AS1684.

• Light gauge steel joists and bearers shall comply with (AS/NZS4600, AS3623). Cold-formed sections
and accessories shall be manufactured from Z350 galvanised steel (Grade G550) complying with
AS1397, with a zinc coating not less than 350 g/m and shall comply with AS4600.

Screws shall be bugle-headed Class 3 or Class 4 galvanised steel screws, fixed through AAC panels into the
joists.

• Timber joists: No 14 x 100 mm galvanized bugle headed screws

• Cold-formed steel joists: No 14 x 95 mm hex head self drilling screws.

Construction Adhesive shall be applied between adjacent panels and between panels and joists, in accor-
dance with the manufacturer’s recommendations.

February 2020 – Version 7 PAGE 37

Note 1
75 mm floor panels spanning joists at 600 mm centres are suitable for the support of 1.5 kPa distributed or
a 1.8 kN point load over an area of 350 mm (located at least 100 mm from the panel edge). This
corresponds to the internal loads for domestic housing. The designer and builder must ensure that there is
provision to prevent and/or control cracking of any brittle floor coverings, such as tiles, particularly at
600mm joist spacing. In the case of 600 mm joist spacing, ductile surfaces are more appropriate

February 2020 – Version 7 PAGE 38

Fixing AAC ECO Panels to Existing Brickwork Party walls
1. Apply ‘Seal N Flex’ Bostick adhesive in dabs onto the panel to glue it directly onto the existing
brickwork wall.
2. Prop the panel overnight to cure. Do not remove props until the panel is properly secured by
the permanent framing supports.
3. When the flexible sealant is cured, fix the wall frame (including the steel top-hat sections) to
the panel, using screws inserted from the inside of the building (rather than the normal
method of fixing from the outside of the building). The number of screw fixings should be
doubled from normal requirements.

Note

Because the screws are inserted 72mm and the head is not on the outside of the panel, the lateral load
capacity could be approximately half of that of the fixing from the outside. This should be provided for by
doubling the number of screws. Notwithstanding the reduced capacity, there will be virtually no lateral load
on the panel, provided the existing brickwork wall remains in place. If the existing brickwork wall is
removed, the wall could be subject to full external wind suction.

February 2020 – Version 7 PAGE 39

Structural Design Example
The purpose of the following worked examples is to provide guidance to structural engineers on the
structural design considerations and methodology for ECO PANEL (AAC) reinforced walls, reinforced floors
and unreinforced masonry.

• Eco Panel AAC provided as steel reinforced wall panels, are designed in accordance with the
recommendations of RILEM Recommended Practice – AAC Properties, Testing and Design. Because
this system is outside the scope of the most relevant National Construction Code of Australia
reinforced document, AS3700, its use must be treated, under the National Construction Code of
Australia, as an Alternative Solution.
• Eco Panel AAC provided as steel reinforced floor panels, are designed in accordance with the
recommendations of RILEM Recommended Practice – AAC Properties, Testing and Design.
• Eco Panel AAC provided as autoclaved aerated blocks set in this-bed adhesive, are designed in
accordance with AS 3700-2001 Masonry Structures.

Notes

1. Because these systems are outside the scope of the most relevant National Construction Code
of Australia referenced documents, AS3700 and AS3600, their use must be treated, under the
National Construction Code of Australia, as an Alternative Solution.
2. The designs in this manual are consistent with the requirements of AS3700-2011. The designs
are also generally consistent with AS3700-2001. The main difference between the two versions
of AS3700 is in the determination of robustness, AS3700-2011 being generally more
conservative.

February 2020 – Version 7 PAGE 40

Occupational Health and Safety
The following table sets out the principal considerations of occupational health and safety for the
construction of ECO PANEL (AAC) panels.

Activities Covered by these Procedures

1. Receive all materials required for ECO PANEL (AAC) panels onto the site and store off the
ground in a safe, secure location.
2. Move the materials to the work site, taking care to avoid back or muscle injury. Use mechani
cal aids, such as trolleys forklifts, cranes and multiple able bodied people to lift and move
panels. Plan the sequence of installation to minimize panel movements and avoid awkward
lifts. Keep the panels dry
3. Lift & Support Panels. Where appropriate, use appropriate cranes and slings, lift the panels
into position and immediately brace with supports designed and specified by the Structural
Engineer.
4. Permanent Fixings - As soon as practical, complete all permanent fixing of the panels to the
structure. All such fixings must be designed and specified by the Structural Engineer. Do not
remove temporary supports until permanent fixings are secured.
5. Flashing & Weatherproofing - Apply all flashings, renders, weatherproof coatings, and other
finishing, as specified in the Drawings and/or Specification.
6. Clean-up - Remove rubbish through out the installation process, to reduce the risk of slips trips
and falls, which can cause injury, carry out final check, hand over the project.

ECO Panel Products are cement based which may irritate the skin resulting in itching and a rash may
appear. The wearing of gloves and suitable clothing to reduce abrasion and irritation of the skin is
recommended when handing ECO panel Products

Limitations:
The worker is not authorized to:

• Use electrical equipment, welding equipment and the like

• Use motorized equipment, except cranes. Separate procedures for the safe use of cranes must be
prepared and used.

February 2020 – Version 7 PAGE 41

 Risks Precaution

Impact by mobile equipment Wear brightly colored shirt or vest

Impact from falling items Wear a safety helmet near elevated work
Back injury or muscle injury Each 2,700 x 600 x 75 mm AAC panel weighs approximately 90 kg.
Do not lift heavy items without assistance. Bend knees and keep
back straight when lifting. Avoid strenuous activity if unfit or
suffering back or muscle strain

Foot injury Wear strong boots, preferably with steel caps

Heat exhaustion Drink plenty of fluids, Rest in shaded areas
Sun damage to skin Wear a hat, shirt & sunscreen
Fall from ladder Ensure top of ladder is secured & protruding at least 1.0m
above the floor
Electrocution Ensure electrical equipment is safe &
tagged Do not use electric power in wet
conditions Wear insulated footwear
Avoid overhead & hidden power cables

Fall from scaffold, roofs or Ensure all handrails are

elevated floors installed Do not lean on
Chemical attack to skin by Wear gloves and other protective clothing to avoid rash and
cement in concrete grout, in itchiness.
some cases leading to
dermatitis

Inhalation of dust, Wear respirators complying with AS/NZS1715 and AS/NZ1716, and
particularly while cutting eye protection, complying with AS1336, when cutting and chasing
AAC AAC. Refer to Eco Panel Material Safety Data Sheets.
Collapse of structure Ensure structure is correctly braced. In particular, ensure that
unfinished AAC not tied to permanent supports is braced.

February 2020 – Version 7 PAGE 42

Reinforced ECO Panel AAC Panels
Reinforced AAC Wall Panels and AAC Blocks shall be ECO PANEL (AAC) complying with the following:

• Architectural and Engineering Drawings

• National Construction Code of Australia
• Requirements of “RILEM Recommended Practice – AAC – Properties, Testing and Design”
• Relevant Australian Standard listed previously in this specification. Reinforced AAC wall panels are
generally in accordance with the RILEM Recommended Practice, while AAC Blocks are in
accordance with AS 3700.

Important Design and Construction Checks

These properties are based on advice from the suppliers.

• The designer must check the availability of the particular products and design accordingly,
selecting the appropriate properties.
• In the case of wall panels, the designer must consider loading from both sides of the wall. The
required construction detail must be indicated clearly on the drawings.
• The builder must check compliance of the product supplied to site. See also the checklist that
forms part of the specification.
• Where the reinforcement is not in the centre of the panel, the designer must indicate clearly on the
drawings which sides of the wall it must be placed, and the builder must install it correctly.
• The designer must correctly detail the required connections, and the builder must ensure that they
are correctly installed, properly fixing the AAC panels into the building.

Definitions

• Dimensional Category DW0 - No Requirements

• Dimensional Category DW1 - Average deviation of a sample of 20 units; +,- 2.5 mm (dimensions
under 150 mm); +,- 4.5 mm (dimensions 150 to 250 mm); +,- 5.0 mm (dimensions over 250 mm)
• Dimensional Category DW4 - For a sample of 20 units, the standard deviation of work sizes shall be
not more than 2 mm, and the difference between the mean and the work size shall be not more
than 3 mm. For split faces, the dimensional deviations shall not apply to the width of the unit,
provided the average width is not less than 90% of the work size.
• General Purpose Salt Attack Resistance Grade - Performance such that it is possible to demon
strate that the product has a history of surviving under non-saline environmental conditions
similar to those existing at the site considered, but not expected to meet the mass loss criterion for
Exposure Grade Salt Attack Resistance Grade
• Exposure Grade Salt Attack Resistance Grade - Performance such that it is possible to demon
strate that the product has a history of surviving under saline environmental conditions similar to
those existing at the site considered; and less than 0.2 grams mass loss in 40 cycles in AS/NZS
4456.10, Method B test.

February 2020 – Version 7 PAGE 43

Thin Bed Adhesive
Thin Bed Adhesive shall be mixed and applied in accordance with the manufacturer’s instructions. Most
important , the adhesive should not be re tempered as this will have a detrimental effect on the bond
strength on the panel adhesive.

Thin Bed Adhesive is used for gluing the panels together at all joints. Typically, panel joints are 2-3mm thick.
Sufficient pressure is to be applied to the joint to ensure full coverage of adhesive in the joint.

Provision for Timber Shrinkage

In AAC veneer construction, a gap in accordance with schedule below shall be left between the timber
frame and the top of the AAC, and at window sills, to accommodate timber shrinkage.

Location in timber framed buildings Minimum Clearances (mm)

Unseasoned hardwood Other timber frame

frame

Sills of lower or single storey windows 10 mm 5 mm

Roof overhangs of single storey buildings 16 mm 8 mm

Sills of second storey windows 20 mm 10 mm

Roof overhangs of two storey buildings 24 mm 12 mm

February 2020 – Version 7 PAGE 44

Extending Panels
ECO PANEL (AAC) panels may be extended up to 200mm by gluing additional pieces to them using thin-bed
adhesive; provided both parts are supported by timber or steel battens (or similar) and the overall length
between control or articulation joints does not exceed the values specified above.

Render and Paint Schedule

The following render and paint system shall be applied to AAC walls. Refer to Render and Paint Specification
for suitable products as tested by Ian Bennie & Associates Test Report No 2017-096-S1(A1) 50mm AAC ECO
PANEL wind load test to AS4040 and Test Report No. 2018-044-S1 Eco Panel (AAC) Wall Cladding System
Specimen tests to NCC-2016 Verification methods FVI and V2.2.1

Substrate : Autoclaved Aerated Concrete (AAC)

Finish : Acrylic render with Texture Coating.

Performance: Water-resistant and vapor-permeable decorative

coating, capable of bridging up to a 1 mm substrate
crack.

Surface Preparation: Clean, patch and remove any dags. Ensure that the
surface is free of all incompatible materials, such as
silicone sealants. If subject to sea spray or within 1 km of
a surf coast, wash with clean fresh water to remove all
traces of salt.

First Coat: Skim coat 3 to 4 mm thick CHAD Surface Coatings

Pro Render acrylic render, hawk and steel trowel to
level small irregularities. Do not render over
control joints.

Second Coat: Skim coat 3 to 4mm thick CHAD Trade Render

acrylic render, hawk and steel trowel to level small
irregularities do not render over control joints

Third Coat: Trowel-on or roll-on Chad Surface texture acrylic

coating. Dry for 24 hours before applying further coat.

February 2020 – Version 7 PAGE 45

Associated Materials Schedule

Renders and Paints

Renders and paints shall comply with the following::

First Coat: Skim coat 2 to 4 mm thick acrylic render, hawk or steel trowel to level small irregularities.
Second Coat: Primer suitable for acrylic overcoats. Third Coat:
Trowel-on or roll-on texture acrylic coating.
Fourth Coat: Roller, airless spray or brushed 100% acrylic heavy duty durable coating.

Specified Requirements Contact for further

Complying product reference
details

Acrylic Render – First Coat CHAD Surface Coatings Pro Render

CHAD Group Pty Ltd
Acrylic Render – Second Coat Trade Render
(03) 9544 8899
Textured acrylic coating – Texture Coatings: CHAD Surface Coatings Trowel-
1366 North Road
Third Coat on Marble Texture medium or coarse
Oakleigh South
Acrylic heavy duty Chad Surface Coatings Membrane Coating
durable coating if
requested.

Joint Material
Joint material shall comply with the Drawings, National Construction Code of Australia and relevant
Standard

(AS 3700). Unless stated otherwise:

• Backing rod for control joints, expansion joints and articulation joints shall be expanded
polystyrene tube or bead or, rigid steel backing profile with closed cell foam adhered to the metal
profile face.
• Joint sealant shall be gun grade multi-purpose polyurethane sealant.
• Control joints and articulation joints shall incorporate de-bonding tape.

Intumescent seals shall be one-part, water-borne, urethane polymer blended with acrylic co-polymer to
give a tough and gunnable sealant capable of providing the requisite fire performance as specified in the
Drawings and/or National Construction Code of Australia as appropriate.

February 2020 – Version 7 PAGE 46

Damp Proof Course
Damp-proof courses (DPCs) shall comply with the Drawings, National Construction Code of Australia and
relevant Standard (AS 3700, AS/NZS 2904). Unless stated otherwise damp-proof courses (DPCs) shall consist
of one of the following options.

• A material complying with the Standard AS/NZS 2904;

• Embossed black polyethylene film of high impact resistance and low slip, with a nominal thickness
of 0.5 mm prior to embossing, and meeting the requirements of the relevant Standard (Clause 7.6
of AS/NZS 2904);
• Polyethylene coated metal damp proof courses with an aluminium core not less than 0.1mm thick,
shall be coated both sides with bitumen adhesive enclosed in polyethylene film not less than 0.1
mm thick on each face, and has a nominal total thickness of not less than 0.5 mm prior to
embossing;
• Bitumen impregnated materials of not less than 2.5 mm thickness, that meet the requirements of
the relevant Standard (Clause 7.5 of AS/NZS 2904), when used in walls that are not higher than 7.8
m above the level of the DPC;

Termite shields (with no penetrations) continuous throughout the wall or pier.

Notes: Metal and metal-cored damp-proof courses and termite shields shall not be used in locations with
saline ground water or subject to rising salt damp

February 2020 – Version 7 PAGE 47

Flashings
Flashings shall comply with the Drawings, National Construction Code of Australia and relevant Standard
(AS3700, AS/NZS 2904).

• Metal and metal-cored flashings shall not be used in locations that expose them to saline ground
water or rising salt damp.
• Metal flashings shall be compatible with the materials with which they are in contact, and shall not
give rise to electrolytic action. If there is potential for electrolytic action to occur, flashings shall be
isolated by inert materials.
• Flashings intended to hold their shape shall be manufactured from rigid material. (e.g. metal cored
material)

Unless stated otherwise flashings shall consist of one of the following options: Flashing in Concealed
Locations (e.g. cavity flashings) shall be one of the following:

• Uncoated annealed lead having a mass not less than 10 kg/m in lengths not exceeding 1.5 m, shall
not be used on any roof that is used to catch potable water;
• Uncoated copper having a mass not less than 2.8 kg/m and having a thickness of 0.3 to 0.5 mm;
• Bitumen coated metal (normally aluminium) with a total coated thickness of 0.6 mm to 1.0 mm;
• Zinc coated steel with a thickness not less than 0.6 mm;
• Embossed/quilted polyethylene sheet with an average thickness not less than 0.5 mm Flashings in
Exposed Locations (e.g. flashings from the roof to wall) shall be one of the following:
• Uncoated annealed lead having a mass not less than 20 kg/m in lengths not exceeding 1.5 m, but
shall not be used on any roof that is used to catch potable water;
• Uncoated copper having a mass not less than 2.8 kg/m and having a thickness of 0.3 to 0.5 mm;
• Bitumen coated metal (normally aluminium) with a total coated thickness of 0.6 mm to 1.0 mm;
• Zinc coated steel of thickness not less than 0.6 mm.

Wall Wrap (Breathable)

Breathable Wall Wrap must meet the requirements of the AS/NZS 4200.1 and shall achieve a minimum
Medium Duty (MD) classification in accordance with this standard.

Flashing Tape
Butyl Flashing Tape (Aluminium / Butyl self-adhesive) 48 mm wide x 1.5 mm self-adhesive for
weatherproofing around all around the openings, penetrations and connections.

February 2020 – Version 7 PAGE 48

Cladding of a Domestic Dwelling
The following specification and details are generally suitable for Reinforced AAC wall cladding for domestic
dwellings, subject to confirmation by the Design Engineer. A suitable support framing system must also be
provided.

Reinforced AAC Panels shall be screw fixed to horizontal light-gauge steel battens, which are fixed to
vertical steel studs. There shall be not less than four horizontal battens per panel, with this number
increasing for higher wind loads and for panels within 1,200 mm of the building corners.

Panels within 1,200 mm of each end of each external wall of a building (i.e. the two 600 mm wide panels
closest to the corners) are subject to higher local wind pressures and suctions, and therefore require more
battens and more screw fixing than other panels.

Unless specified otherwise by the engineer, the following details and tables shall be used for the cladding of
domestic dwellings with 75 mm thick or 100 mm thick Reinforced AAC Panels.

Light gauge steel battens shall comply with the Drawings, Building Regulations and relevant Standards
(AS/NZS 4600, AS 3623). Cold-formed sections and accessories shall be manufactured from Z350 galvanised
steel (Grade G550) complying with AS 1397, with a zinc coating not less than 350 g/m2 and shall comply
with AS4600. All battens shall be 24 x 30 x 0.55 BMT Top Hat, Grade G550) or equivalent.

All screws shall be No 14 x 100 mm Bugle-headed batten self-drilling galvanised steel screws, fixed from
outside of the building through the AAC panels into the horizontal steel light gauge battens behind General
Notes:

1. All wind classifications and ultimate pressure calculations are based AS 4055-2006.
2. If AAC Panels are required to provide racking resistance, the screws and supports shall be
determined
1. by the structural engineer, taking into account the wind classification and the overall building
dimensions.
2. Top and bottom battens shall be positioned within 150 mm of the ends of the panels

February 2020 – Version 7 PAGE 49

AAC ECO WALL & FLOOR PANEL & BLOCK PRODUCT RANGE WARRANTY
Warrants that this product will be free from defects in material and workmanship for a period of 7 years
from the date of purchase.

This warranty will not apply if, in the opinion of CHAD GROUP P/L the product has been:
• installed and maintained other than in compliance with the manufacturer's specifications and
technical manual;
• handled in a manner which contravenes CHAD GROUP P/L warnings or Material Safety Data
Sheet;
• misused, abused, altered or damaged by you in any way;
• attached to materials of poor quality, workmanship, design or detailing or which are subject to
movement whether structural or otherwise;
• attached or used in a project that has not been designed and constructed in strict compliance
with current, National Construction Code regulations and standards; or
• damaged through normal wear and tear including exposure to the elements (on both exposed
and unexposed surfaces) resulting in the growth of any organism including but not limited to
mildew, mould, bacteria or other growth on the Product.
• CHAD GROUP P/L reserves the right at its sole discretion to determine whether to repair or
replace any faulty product free of charge for parts and labour or to give a refund in respect of the
faulty product.

The benefits conferred by this warranty are in addition to all other non-excludable rights and remedies in
respect of the product which the you may have under the Trade Practices Act and any similar laws in
Australia or elsewhere. To the maximum extent permitted by law, CHAD GROUP P/L liability for any non-
excludable condition or warranty is limited, at CHAD GROUP P/L discretion to the replacement of the
relevant product or supply of equivalent product; the repair of the relevant product, the payment of the
cost of having the relevant product replaced or acquiring equivalent product, or paying the costs of any
necessary repair.

To the maximum extent permitted by law, CHAD GROUP P/L excludes all other conditions and warranties
implied by custom, the general law or statute. CHAD GROUP P/L also excludes the provisions of the United
Nations Convention on Contracts for the International Sale of Goods. Proof of purchase must be provided
when making any claim under this warranty, and should be retained by the purchaser at all times.

February 2020 – Version 7 PAGE 50