NRG TWS technical installation guide

CodeMark Certificate

  • Changes to the 2010 version of Building Code of Australia are that all building products must comply with the BCA.
  • CodeMark certified products comply with the BCA.
  • NRG Greenboard has achieved CodeMark Certification.
  • Each state has regulations, ensuring that a CodeMark building solution can not be rejected.
  • For their own protection, local authorities (certifiers, councils, surveyor, designers, home insurance companies) are insisting on CodeMark Certification.

GREENBOARD Insulated wall cladding

Greenboard is an Insulated Wall Panel that combines exterior cladding with insulation so designers can achieve the 6 star energy ratings that have been introduced into the building code. Greenboard‘s insulated core of high quality expanded polystyrene puts the Greenboard insulated panel in the best place of the building, as far towards the outer side as possible.

Greenboard Insulated Wall Panel is a lightweight, energy efficient product and once coated the system provides a weather resistant, seam free rendered finish.

Greenboard Advantages

CodeMark Certification

All building products must comply with the BCA (Building Code of Australia). NRG Building Systems has achieved CodeMark on Greenboard Insulated Wall Cladding meaning Greenboard complies to the BCA.

Insulation Qualities

All insulation materials are rated for their performance in restricting heat transfer. This rating is expressed as an R-value which is a measure of the material’s resistance to heat transfer (thermal resistance). The higher the R-value the greater insulating effect.

Total Wall R-value for using Greenboard
Thickness (mm) 50mm 60mm 75mm 100mm
R-value on total wall 2.18 R 2.44 R 2.83 R 3.48 R
Sound Rating

NRG Building Systems has tested 60mm Greenboard total wall system and the acoustic performance result was Rw 35,Ctr -6. Please refer to NRG test results. The Greenboard walling system can be further enhanced by using a “sound rated” insulation batt. Please refer to insulation manufacture’s specifications.

Fire Retardant

Greenboard contains a flame retardant additive and will not support fire, it has a spread of flame index of zero. If in a fire situation the toxic fumes are no greater than that of timber and other building materials.

Grooved Panel

The surface of the Greenboard panel is Grooved both sides allowing the inside surface to breathe and channel any possible condensation away through the Grooves, downwards to the base of the wall. This is particularly important where “insulation” or “breather sarking” is used. The additional advantage being that when the Grooved face of Greenboard is rendered the system becomes stronger as the render gets into the Groove to form a core shape for better adhesion and a stronger more rigid Greenboard system.

Easy to Use

Greenboard‘s lightweight panel size is 2500 x 1200 allowing installers to cover the external walls quicker and easier. For the builder and their client, Greenboard gets the project to lock up stage quicker allowing other trades to start and complete their tasks.

Environmentally Friendly

Greenboard requires less energy to produce than other traditional building materials and contains no CFC’s nor HCFC’s. Greenboard does not contain ozone depleting substances and none are used in the manufacturing of this product. Greenboard can be recycled or NRG recommends left over Greenboard can be placed in the walls as extra insulation.

Termite Retardant

Greenboard contains a termite retardant (Bifenthrin) and NRG uses 62% more in their product than the minimum required.

Render Levels of Finish

Reinforced render is applied to the Greenboard substrate at approximately 4-8mm in thickness which allows qualified applicators to screed out usual imperfections and form a seam free level 5 finish. NRG recommends render over Greenboard should be specified by a coating manufacturer.

Greenboard Product Data

Greenboard Energy Efficient Insulative Walling System Product Information. NRG Greenboard is an insulative walling system suitable for external cladding of timber or steel framed buildings as well as solid concrete and masonry walls. The system provides a weather resistant, seam free rendered finish in a wide range of textures and colours. It also provides continuous thermal insulation over the entire wall. Developed in Germany in 1973, these systems have been extensively used throughout Western Europe and North America where strict environmental laws are in place governing the energy efficiency of both private and commercial buildings. The system is now well established in Australia ranging from dry arid areas, to tropical and alpine regions, whilst proving energy efficiency, cost effective and flexible construction alternative. The NRG Company is providing and increasing research and development of the system to improve the product.

NRG Greenboard Insulative Walling System consists of:

14.1.1   An enhanced expanded polystyrene (EPS) insulation board impregnated with an insect repellent compound and flame retardant. The board is mechanically fixed to timber/steel stud framing or reinforced concrete or masonry wall. The surface of the Greenboard panel is grooved both sides allowing the inside surface to breath and channel any possible condensation away through the grooves, downwards to the base of the wall. This is particularly important where ‘insulation‘ or ‘breather sarking‘ (refer 16.1.9) is used. The additional advantage being that the grooved ‘face’ surface of the Greenboard panel provides an excellent ‘key‘ to accept the reinforced render system.

14.1.2   NRG Greenboard Washers and Screws (Class 3) are used for fixing to timber or steel framing, while special anchors are used for fixing to masonry wall surfaces.

14.1.3   External PVC (UV Stabilised) angle beads and window trims.

14.1.4   A polymer modified cement render reinforced with an alkali resistant fiberglass mesh.

14.1.5   Acrylic texture coating and or pigmented membrane finished in your selected colour.

14.1.6   The NRG Walling System incorporating reinforced renders and textured finish coatings form a complete cladding system from the frame to the finished surface.

14.1.7   Vermin Retardant.

14.1.8   A high impact strength finish.

14.1.9    NRG Greenboard Insulative Walling System: Sound insulation value – 60mm Greenboard Refer (16.1.5 – Acoustic Values (Table D)) = Rw 35,Ctr -6.

14.1.10  NRG Greenboard Insulative Walling System: is an extremely high-energy, efficient product reducing heating costs in winter and cooling costs in summer.

14.1.11  NRG Greenboard Insulative Walling Systems unique grooved surface provides strength and flexibility of finish, allowing a vast range of architectural designs, finishes and colours to complement any surroundings.

14.1.12  NRG Greenboard Insulative Walling Systems is the ideal substrate for lightweight construction, 2nd storey additions, reactive soil and mine subsidence areas are concerned.

Properties and Advantages of the NRG Greenboard Walling System

NRG Greenboard panel is manufactured from high density, rigid, expanded polystyrene. The raw material is gained as a by-product of the manufacture of oil. Greenboard is manufactured without the use of CFC’s and does not contain or emit any poisonous gas. In fact, NRG Greenboard is made up of 98%air entrapped in a closed cellular structure of polystyrene. This entrapped air accounts for the extremely good insulation properties of the Greenboard. The off cuts of NRG Greenboard can be glued within the wall cavity prior to the installation of the internal linings as additional insulation. This cuts down on the impact to our environment as all the material is being used, leaving a minimal amount of material to be removed from site.

  • 98% ENTRAPPED AIR
  • SUPPORTING THE ENVIRONMENT
  • NO CFC’S USED IN THE MANUFACTURING PROCESS
  • NO SITE WASTAGE – USING ALL OFF-CUTS AS ADDED INSULATION
 
  • SUPPORTING THE CONSUMER BY REDUCING HOME AND BUSINESS
 
  • GREENBOARD RENDER, REINFORCED WITH 150G/M
    FIBERGLASS MESH FOR HIGH IMPACT STRENGTH.
 
  • ADDED FIRE RETARDANT WILL NOT SUPPORT COMBUSTION
 
  • DESIGN FLEXIBILITY.
  • FULL RANGE OF COLOURED FINISHES AND STYLES.
 
  • EXCEPTIONAL THERMAL QUALITIES.
 
  • ACOUSTIC VALUES.
 
  • VERMIN RETARDENT.
 
15.1.1 Insulation for Energy Efficient Buildings

The Greenboard system is the most cost efficient method of insulation in terms of R-value per dollar. Unlike some other methods of insulation that allow thermal bridging across the timber or steel studs framing. NRG Greenboard provides a continuous insulative sheath around the entire building.

15.1.2 Warranty – 10yr

NRG warrants that the Greenboard sheets (the “Product“) will be free from defects due to defective factory workmanship or materials prior to the installation of the Product for a period of 10 years from the date of purchase, subject to compliance with the conditions published in NRG Product Warranty 2007.

15.1.3 Easy to Render

The surface of the NRG Greenboard is grooved providing an excellent substrate for Reinforced Render Systems.

15.1.4 Energy Efficient Production 

Greenboard uses much less energy in its production than conventional building materials such as concrete and masonry.

15.1.5 Fashionable Render Finishes

Available in a wide range of Architectural colours and styles (Refer to your selected manufacturers, texture coating specifications).

15.1.6 Design Freedom

Curved walls, rounded corners, embossed patterns, raised wall areas, mouldings and other architectural features are simple to achieve and cost-effectively with the versatile NRG Walling System.

15.1.7 Vermin Retardant

NRG Greenboard is impregnated with a natural insect retardant, (Bithentrin)

15.1.8 Biologically Inert

The board will not rot and provides no nutritive value for insects or micro-organisms.

Design Information General

The NRG Greenboard Insulative Walling System forms a continuous weather-resistant thermal envelope around the external walls of the building. The versatility of the building and the workable nature of the Greenboard composite panel permits greater design freedom. This system allows the designer to economically provide a fashionable, long lasting render finish as well as comply with the strictest energy ratings required in modern building codes. Tests show that a properly insulated building can reduce energy costs by up to 75%. This greatly reduces the running costs of the building in terms of energy savings and reduces the amount of green house gases released into the atmosphere.

16.1.1 Structure

NRG Greenboard 50mm, 60mm, 75mm and 100mm thick has sufficient strength and rigidity to be supported by wall framing spaced at 450mm maximum centres. NRG Greenboard can be installed over masonry walls (e.g. 40mm Greenboard) to increase the “R–value” of the masonry wall system or brick veneer construction.

16.1.2 Building – Wind Zones (Table A)  

When mechanically fixed to a variety of substrates in accordance with the “NRG Greenboard Walling System – Installation Manual for use in the following categories.

Intermediate Region Description pd =
Type B –  W33 Sheltered Suburban 0.990 kPa
Type B –  W41 Exposed Suburban 1.485 kPa
Type C –  W50 Open Rural (Tropical Cyclone) 3.289 kPa
Type D –  W65 Open Rural (Severe Tropical Cyclone) 4.719 kPa

16.1.3  Minimum Stud & Fastener Spacing’s (Table B)

NRG Greenboard Minimum Stud & Fastener Spacing’s
Regions – Wind Category Stud Spacings (mm) Fastener Spacings (mm-Vertically) Number of Fasteners /m_
Non Cyclonic N1 450 300 12
N2 450 300 12
N3 450 300 12
N4 450 200 18
N5 450 150 24
Cyclonic C1 450 200 18
C2 450 150 24
C3 450 100 37
* In accordance with AS1684 – 2006 / AS4005 – 1992
16.1.4 Insulation Values (Table C)

All insulation materials are rated for their performance In restricting heat transfer. This rating is expressed as An R-value which is the measure of material’s resistance To heat transfer (thermal resistance). The higher the R-value, the greater the insulating effect.

Thickness 50 60 75 100
Thermal conductivity at 23oC (W/m2.k) 0.037
R-value of insulation material 1.30 1.56 1.95 2.60
Total R-value of wall from Rendered Greenboard Reflective sarking, cavity plasterboard 1.92R 2.44R 2.83R 3.48R
16.1.5  Acoustic Values – NRG Greenboard (Table D)
Summary of Acoustic Test Results: – 60mm NRG Greenboard Acoustic Performance
Side 1 6mm concrete render applied to 60mm thick expanded polystyrene foam. The polystyrene applied with sheet lengths vertical. Rw 35,Ctr -6
Framing Side 2 90mm timber studs at 450mm centres 10mm Plasterboard applied with sheet lengths vertical. Edges caulked with expanding polyurethane foam.
Ron Rumble Pty Ltd, Consulting Acoustical & Vibration Engineers – 28th August 2006

The NRG Greenboard walling system can be further enhanced by using a ‘sound rated’ insulation batt (Refer to Insulation manufacturer’s specifications).

16.1.6 Impact Resistance

The Greenboard Walling System when installed in accordance with “NRG Specifications & Installation Manual” will have adequate resistance to impact loads likely to occur in normal residential and commercial use. The likelihood of damage in public areas in or around residential, commercial or industrial buildings where heavy impacts could occur should be considered at the design stage. Heavier grade fibreglass reinforcing mesh or multiple layers should be used and appropriate protection or barriers should be provided in vulnerable areas.

16.1.7 Hazardous Building Materials

When installation is complete the NRG Greenboard Walling System and the Greenboard Reinforced Render System is non-hazardous.

16.1.8 External Moisture

The “NRG Specifications & Installation Manual” contains specific details and instructions for flashing around windows, finishing to edges and sealing penetrations. Head, sill and jamb flashings must be used as specified. The NRG Greenboard Walling System must not be allowed to come into contact with the ground.

16.1.9 Sarking

NRG Building Systems highly recommends the use of vapor permeable sarking, equivalent to Sisalation Wall Wrap (Breather) or similar, fixed directly behind the NRG Greenboard Walling System.

16.1.10 Early Fire Hazard Properties (Table E)

NRG Greenboard contains a flame retardant additive to inhibit accidental ignition from small flame source.

Note: NRG Greenboard System must be separated from heat sources such as fireplaces, chimneys or flues. NRG Greenboard System Does not provide a fire rated wall.

NRG Greenboard Index Rating
Ignitability (0-20) 6
Spread of Flame Index (0-10) 0
Heat Evolved (0-10) 1
Smoke Developed (0-10) 4

NRG Greenboard Installation Procedure

17.1.1 Installation Procedures NRG Greenboard Walling System

This manual provides information on the correct procedures and materials to be used for the installation of NRG Greenboard Walling System over standard framed and solid structures. The drawings and details are provided to assist building designers in specifying the correct design and detail of the NRG Walling System. These details cover most common applications. If the details are to be altered or new ones proposed please contact NRG to discuss the changes. Failure to do so may void the systems warranty.

These components that make up the NRG Greenboard Insulative Walling System are.

  • Screws and washers
  • Vapor permeable sarking
  • NRG Greenboard
  • NRG PVC beads
  • Polymer modified render
  • Reinforced mesh
  • Texture top coat

These components form part of the complete system and must not be substituted with other possible nonconforming materials.

17.1.2 Timber and Steel Framing

All timber and steel framing should conform to the relevant Australian Standards, as well as the local standards for structural requirements including wind loadings and bracing.

NRG Greenboard is not a structural material and therefore should not be considered or used as a bracing material.

17.1.3 Existing framing

When ‘over-cladding’ existing timber buildings, inspection should be carried out by a fully qualified person, to identify any deterioration or infestation by wood boring insects. Although NRG Greenboard is impregnated with an effective insect repellent, it will not arrest or prevent further infestations of the timber framing structure. Where necessary, repairs must be undertaken to ensure that the timber substrate is sound, straight and true.

17.1-4 Back Blocking (Off Stud Joints)

Where horizontal fixing of sheets ‘off stud’ join are to be made, it is necessary to back block as follows.

i. By fixing an ‘off cut’ of stud material vertical, (widest face facing outwards) and securely nailing to bottom plate and noggin. Alternatively, between noggin and top plate, making sure to glue both Greenboard sheet edges with Bostik No-More Nails and fixing through each sheet into the ‘black block’ with washers and screws at maximum 300mm centre’s.

ii. Alternatively, horizontal ‘back block’ using ‘off cuts’ can be placed at maximum 300mm centre’s, following the above procedure except that, with the two sheets in place, take ‘off cuts’, smear with Bostik No-More Nails over one face, place ‘off cuts’ against the Greenboard sheets and screw through face of Greenboard into ‘off cuts’, pulling both sheets into alignment.

17.1.5 Solid Blocking of Fitting and Accessories

Consideration should be given to the installation of wall mounted accessories i.e. taps, electrical fittings, etc. It is important to allow for adequate backblocking for these items prior to the installation of the NRG Greenboard.

17.1.6 Electrical Cables and PVC

Cables penetrating the NRG Greenboard Walling System must be installed in conduit or ducts sealed to the cladding or have a sheathing containing migration resistant plasticizer. Cable manufacturers should be contacted for details of suitable cable types.

17.1.7 Flashings

All flashing to wall openings, roof sections and parapets etc. to be installed prior to the fixing of NRG Greenboard Walling System (and is always capped off at the bottom edge of the Greenboard sheet using a Starter Bead refer DWG 11 – DWG 12) in accordance with good building practice and together with any requirements of the BCA. NRG Building Systems take no responsibility or liability for flashing or installations.

17.1.8 Fitting NRG Greenboard Walling Panels

I. Before commencing to fix panels check that the frames are straight, all windows and flashings are correctly installed and solid backing blocks are in place where required.

II. Timber frames must have a moisture content of less than 15% before Greenboard panels are fitted, horizontally (preferred) or vertically.

III. Measure and cut Greenboard Sheeting using a straight edge and masonry diamond blade in a standard power saw (use of handsaw not recommended).

IV. Glue both horizontal and vertical Greenboard sheet edges to each adjoining sheet using Bostik – No More Nails / Power trigger foam.

V. Fixing NRG washers and screws at 450mm stud spacings horizontally and 300mm spacings vertically (see fixing table for hight spacings) : – (Refer to DRW 08) Greenboard sheet lay horizontally, comprising of five (5) rows fixings vertically.

1st – When making butt joint, each sheet is fixed individually to the back-blocking or vertical noggin, corresponding with the above fixing set out. (Refer 17.1.4)

VI.Infill’ small areas with Greenboard (e.g. above and below windows, etc.) – It is recommended to use a minimum height of 300mm to allow for adequate fixing.

VII. Allow 3mm gap between Greenboard panel and openings for bead and sealing procedure ((Refer Table 17.1.15 Beading))

VIII. External corners – Greenboard sheets are overlapped the full thickness of the sheet and glued using recommended construction adhesive.

17.1.14  (Table J). (DRW 07
17.1.9 Curved walls

40mm and 60mm Greenboard panels can be fitted to curve walls with a radius greater than 2-4 metres’. Where a tighter radius is required use multiple layers by laminating 2 x 20mm thickness Greenboard panels (off set joints).

17.1.10 Expansion Joints (Table F)

Expansion joints allow for movement within the building and avoid unsightly cracking within the wall areas. Expansion joints must be provided where NRG Greenboard lengths exceed specified dimensions (see table). In addition, it allows for movement between different substrates while affording an opportunity to ‘weather seal’ such junctions. Refer DWG 09 & 10

Placement of Expansion (Control) Joints Maximum Distance
Horizontal wall areas: i.e. wall length 8 metres
Vertically: Construction joint between floor levels and gable ends, where the total wall height including gable exceeds maximum distance. 3 metres
Scribed’ control joints: above large window and door openings.
Internal Corner – When rendering, mesh up to but not across corner then later ‘scribe’ a control joint into the render, cutting (nick) the mesh intermittently to relieve the tension within the mesh. Fill with sealant prior to texture coating.
17.1.11  NRG Greenboard Specifications (Table G)
NRG Greenboard Technical Specifications Sheet Sizes
20mm – Flat panel (Laminate sheets to create curved wall) 2500mm 1200mm
40mm – Grooved 2500mm 1200mm
60mm – Grooved 2500mm 1200mm
75mm – Grooved 2500mm 1200mm
100mm – Grooved 2500mm 1200mm
 17.1.12  Fixings – Accessories (Table H)
NRG Greenboard Timber Framing Treated CSK Ribbed Head Steel Framing Treated CSK Drill Point
50mm 10 – 8 x 65mm 55mm
60mm 10 – 8 x 100mm 75mm
75mm 10 – 8 x 100mm 95mm
100mm 10 – 8 x 125mm 125mm
N.B. Screws are to be Galvanised or Treated (Class 3)
All NRG PVC Washers and fixings are required at 300mm maximum centre’s – Refer DWG 08
Extreme environments – consideration should be given to the use of T316 Stainless Steel fixings
 17.1.13  Cutting and Tools Required (Table I)
NRG Greenboard Tools
Power Saw – using diamond blade (This provides the most accurate and preferred method; it is also the most environmentally responsible way).
Screwing – Tek Gun
Straight Edge
Level
Chalk Line
Sealant Gun
Alternatively the use of a ‘hot blade’ knife. This will provide the ultimate answer to straight/detail cutting.
17.1.14  Gluing and Sealing (Table J)
NRG Greenboard- Gluing and Sealing Components
Construction Adhesives Bostik – No More Nails / power trigger foam (check compatibility – Polystyrene/Styrene Safe)
Sealants Bostik Seal ‘n Flex / Sika Pro2HP (or equivalent – compatibility:– Polystyrene Safe)
Gap Filler BOSTIK 5077
Primer Power Trigger Foam (i.e. polyurethane high-resistance foam)
Foam -Backing Rod 10mm diameter (leave 6mm gap)
17.1.15 Beading (Table K)

NRG have a full range of UV stabilized PVC beads specifically designed for Greenboard cladding .use only UV stabilized beads for external application.

N.B. External and internal ‘rail edges‘ must be precise to ensure a uniform complete ‘fit and finish’ in readiness for sealing as well as rendering.

NRG UV Stabilized PVC Beads Range

Application Guide (for 6mm Build Beads)

External Corner Bead • External Corners• Window Heads, Sills and Jambs 50mm & 75mm Refer to DWG 04 and 06
Render Starter Bead 40/60/75mm

Capping base of Greenboard Sheet
• Rebated Slab Edge.Refer to DWG 01• High Set (above roof – exposed subfloor areas – elevated projections) Refer to DWG 02, 11 and 12
Reveal Bead 40mm 60mm 75mm • Window and Door Jambs. 40mm – (60mm, 75mm and 100mm Should not be used Render sill recommended). Refer to DWG 03• Eave Line (optional)Refer to DWG 14

• Vertical, Horizontal (Gable) Expansion Joints Refer to DWG 09 and DWR 10

Sill Bead (15° incline) 50mm • Window Sill 50mm Refer to DWG 5 60mm, 75mm and 100mm is not recommended.
Expansion Joint Bead • Flexible control joint for vertical/horizontal and gable applications. Substitute for Reveal Bead as referred to in DWG 9 and DWG 10.

IMPORTANT INFORMATION

17.1.16  NRG Greenboard Bead and Sealant Procedure

Installing, Priming and Sealing of Bead – Procedure. N.B. Use only UV stabilized beads for external application. At this point particular care needs to be exercised to ensure that the installation of all beading around window, door openings etc.; it is imperative that this procedure is performed correctly. This is not just a gap filling exercise but an integral part of the total NRG Greenboard Walling System.

  • External and internal ‘rail edges’ must be precise to ensure a uniform complete ‘fit and finish’ in readiness for sealing as well as rendering.
  • Extra care needs to be taken to make sure all ‘beads’ are both ‘plumb/level’.
  • Priming (to prevent ‘roll-back’ of sealant) and sealing procedure stage requires extreme attention to detail to ensure water tightness of all windows, doors and openings.
  • Using Bostik Primer 5077, and a clean rag, dampen cloth with primer and quickly clean the internal joinery to NRG line that is to be sealed.
  • Using masking tape, accurately adhere to frame of joinery, 4mm form edge creating a neat parallel margin, ready for sealant application.
  • Cut a medium size end off nozzle of ‘Seal’n Flex.’ Proceed in applying sealant. Using a coving tool, neatly create an internal cove finish.
  • Remove masking tape from joinery leaving a 100% water proof joint seal.

I. External Corner Angles Beads – External Points of the building, columns etc. (Refer DWR 07)

a) Install external corner angle bead to external corner edges by applying a ‘liberal’ bead of Bostik ‘No More Nails’ to both sides of internal corner rails of the external corner angle bead, then press bead firmly into position. Make sure it is plumb, scraping of excess glue protruding through bead perforations (priming of beads in this case is not required).

II. External Corner Beads – Render return to windows and doors – head, jamb and sills. This is particularly recommended for 50mm, 75mm and 100mm Greenboard.

a) Allow 3mm gap between Greenboard panel and openings (this will provide a ‘key’ for the sealant). Tape around window and door perimeters.

b) Prime and tape around aluminum surfaces of window and door component edges prior to rendering, apply a bead of sealant into the ‘gap’ between the Greenboard and the component edge. This sealing process is repeated after rendering and prior to the texture painting system. (Refer DWR 04-06)

c) Install external corner angle bead to external corner edges. Refer I. a) above.

III. Reveal Beads/Render Reveal Trims (sill) return to head, jamb and sills of windows and doors.

a) Allow 3mm gap between Greenboard panel and openings (this will provide a ‘key’ for the sealant). Tape around window and door perimeters, priming both surfaces.

b) Prime (using Bostik Primer 5077) beads and tape around surfaces of windows and doors in readiness for application of the texture painting system. (Refer DWR 04-06)

IV. Render Reveal Trim (Sill) – 50mm

a) Allow 3mm gap, prime beads and tape around surfaces of window and door edges prior to sealing readiness for application of the texture paint system. (Refer DWR 05)

V. Expansion Joint – there are two options available – Either by using Reveal Beads or Render Expansion Joint.

1)  Reveal Beads as referred to in DWR’s 09 -10

a) Install ‘reveal bead’ to both edges of Greenboard by applying a ‘liberal’ bead of Bostik ‘No More Nail’, allowing a 6mm gap between both sheets, then insert a 10mm foam backing rod as shown.

b) Prime (using Bostik Primer 5077) both top and bottom outside exposed edges before applying sealant thus creating an ‘expressed’ joint as shown.

2) Expansion Joint Bead (illustration shown in Accessories)

a) Install ‘render expansion joint’ between both Greenboard surfaces (leaving required gap). Applying two beads of Bostik ‘No More Nail’ to either side of the internal corner rails (i.e. top and bottom sections), with sufficient glue to allow the glue to penetrate perforated rail edges. Scrape off excess.

b) Prime (using Bostik Primer 5077) within the ‘flexible’ joint, before applying the sealant thus creating an ‘expressed’ joint.

Example of adhesive applied to bead.

Installation Procedures of NRG Greenboard Walling System over Concrete and Masonry Wall Surfaces

18.1.1 Preparation

All walls must be clean and dust free from dirt, oil, vegetation, and crumbling or loose materials.

18.1.2 Installation of Greenboard using Power’s Foam Adhesive System

i. When installing via the Foam adhesive system, apply a large “dob” of foam adhesive to the middle of each and every masonry block.

ii. Position the board and drill 8mm hole through the masonry at each corner offset in by approx 100mm.

iii. Hammer the Hilti IDP anchors in.

iv. Use a minimum of 8 IDP anchors for each 2500 x 1200 board with at least 2 x IDP anchors staggered in the mid section of the board.

Hilti IDP Polypropylene Anchors (Table M)

NRG Greenboard Hilti IDP Polypropylene Anchors Hilti IDP Anchors Maximum Fixing Centres
50mm 70mm Refer:- iv) above for spacing details
60mm 90mm
75mm 110mm
100mm 130mm

18.1.3 Final Checking of Greenboard installation on Concrete and Masonry Walls – Before rendering, any irregularities in the surface of the sheet or joints are sanded back using a coarse rasp.

18.1.4 Expansion Joints within The Greenboard installation on Concrete and Masonry Walls – All expansion joints in the substrate must be carried through the complete cladding system. (Refer to DWG 9 and 10)

Render Specifications

19.1.1 3.5mm Render

Option 1 1 coat polymer modified render (3.0mm) Reinforced Alkali Resistent Fibreglass Mesh (160g/mm) 1 coat Acrylic Render (1.0mm) 2 coats of Acrylic Membrane Paint

Option 2 1 coat polymer modified render (3.0mm) Reinforced Alkali Resistent Fibreglass Mesh (160g/mm) 1 coat Primer 1 coat Timted texture (1.0mm) (Clearcote optional)

6mm Render 1 coat polymer modified render (4mm) Reinforced Alkali Resistent Fibreglass Mesh (160g/mm) 1 coat polymer modified render (2mm) 2 coats of Acrylic Membrane Paint

NOTE: To be used only as a guide. Refer to Render/ Paint manufactureres specifications (example Rockcote RRR) for exact details and procedures.

19.1.2  Handling and Storage

i. NRG Greenboard should be laid flat with edges and corners protected from damage.

ii. NRG Greenboard should not be stored in the open or fixed to a building for prolonged periods. NRG Greenboard should to be protected from exposure to direct sunlight and kept away from extreme heat and organic solvents.

19.1.3  Health and Safety

i. NRG Greenboard Insulative Walling System and is non-hazardous.

ii. However, as with all composite materials basic safety clothing and gloves are to be worn when handling or cutting the NRG Greenboard.

iii. When cutting NRG Greenboard Insulative Walling System with a power saw it is recommended that a face mask and protective glasses be worn.

IMPORTANT INFORMATION Principal Contractor / Builder / Installer

Essential Related Trade Practices

  • General Construction and Flashing Principles must be adhered to in maintaining water tightness. NRG Building Systems cannot be held liable for inferior flashing and installation practices.
  • It is essential that all external surfaces of the framing structure are parallel, i.e. ground floor framing, mid floor framing and upper floor framing with no protrusions or setbacks. It is also a recommendation that where ply bracing is fixed externally, counter battens be fixed perpendicular to adjoining studs to level the wall surface prior to fixing Greenboard.
  • It is imperative that all exterior window/door and joinery are fixed into position prior to the installation of the NRG Greenboard to maintain water tightness and those components are fixed off plumb and level.
  • Consideration should be given to the installation of wall mounted accessories i.e. taps, electrical fittings, etc. It is important to allow for adequate back-blocking for these items prior to the installation of the NRG Greenboard.
  • Termite Barriers: It is the builder’s responsibility to arrange the installation of a suitable termite barrier system by a qualified professional installer, prior to the installation NRG Greenboard.
  • Internal Lining Fixing: If render application has been completed prior to plasterboard/wet area linings installation, it must be screw fixed to the internal side of all external wall surfaces. Failure to do so can result in defects to exterior render surface finish.

NRG Building Systems provides a full comprehensive construction advisory service, from pre plan to onsite construction advice. Product information and CD-Rom ‘how to’, assistance is available on request.

 Accessories



 

 

 

 

 

 

 

 Sunhoods & Blades

 

NRG Sunhoods and Blades are design for Aesthetic and Energy Efficiency Purposes and are engineered for wind loading, not as a trafficable area (i.e. platform/support area).

Description (Standard length 2500mm) Width (mm) Front Height (mm) Rear Height (mm) Bracket Size
Sunhood -Window Awning 300mm 170mm 210mm 200mm
Sunhood -Window Awning 450mm 170mm 210mm 300mm
Sunhood -Window Awning 600mm 170mm 210mm 450mm
Sunhood -Window Awning 750mm 170mm 210mm 600mm
Sunhood -Window Awning 900mm 170mm 210mm 750mm
Sunhood -Window Awning 1200mm 170mm 210mm 1050mm
Blades As Above 170mm 170mm As Above

 

Benefits

  • Design Simplicity
  • Lightweight Construction
  • Speed of Installation
  • No more costly fabrication or forming-up
  • Suitable for Residential, Commercial, Industrial and Refurbishment
  • Providing a ‘polymer modified, fully reinforced render system’.
  • Extensive choice of textures & colour finishes. (applied by licensed trades persons on site)
  • Assist in Compliance* with BCA 2006 3.12.2.2 -Volume Two-Shading

 Australian Building Codes Board -3.12.2.2 Shading -Page 542

Where shading is required to comply with 3.12.2.1, it must–

a) be provided by an external permanent projection, such as a verandah, balcony, fixed canopy, eaves, shading hood …… which

I) extends horizontally on both sides of the glazing…..
II) provide the equivalent shading to (i)…..

b) be provided by an external shading device, which

I) is capable of restricting at least 80% of the summer solar radiation; &
II) if adjustable, is readily operated.

Explanatory information:

  1. Shading devices can include fixed louvers, However, such devices need to be designed for the climate and latitude to ensure that summer sun penetration is restricted, while winter sun access is achieved.
  2. Gutters can only be considered as providing shading if attached.
  3. Shading devices can be either attached or located … may be considered to provide shading to glazing if it complies with 3.12.2.2(b).

* Subject to site orientation of structure by qualified design professional and engineers specifications, together with the limitations governed by physical dimensions due to manufacturing processes.
** NRG Energy Building Systems reserves the right to alter dimensions of Sunhood and Blades.

*** Special Sizes’ within the limit of widths shown may be ordered –price on application.

 

 

WARRANTY

NRG Building Systems Pty Ltd (“NRG“) warrants to the purchaser of the Product and the last purchaser prior to the installation of the Product for a period of 10 years from the date of purchase that Greenboard sheets (the “Product“) will be free from defects due to defective factory workmanship or materials and, subject to compliance with the conditions below, will be resistant to cracking, rotting, damage from termite attacks to the extent set out in NRG’s relevant published Specifications current at the time of installation.

Nothing in this document shall exclude or modify any legal rights a customer may have under the Trade Practices Act or otherwise which cannot be excluded or modified at law.

CONDITIONS OF WARRANTY
The warranty is strictly subject to the following conditions:

i)  NRG will not be liable for breach of warranty unless the claimant provides proof of purchase and makes a written claim either within 30 days after the defect would have become reasonably apparent or, if the defect was reasonably apparent prior to installation, then the claim must be made prior to installation;

ii)  this warranty is transferable;

iii)  the Product must be installed and maintained strictly in accordance with the relevant NRG Specifications current at the time of installation and must be installed in conjunction with the components or products specified in the specifications;
To obtain copies of such specifications, contact NRG Building Systems on 1800 674 001. Further, all other products, including coating and jointing systems, applied to or used in conjunction with the Product must be applied or installed and maintained strictly in accordance with the relevant manufacturer’s instructions and good trade practice;

iv)  the project must be designed and constructed in strict compliance with all relevant provisions of the current Building Code of Australia, regulations and standards;

v)  the claimant’s sole remedy for breach of warranty is (at NRG’s option) that NRG will either supply replacement product, rectify the affected product or pay for the cost of the replacement or rectification of the affected product;

vi)  NRG will not be liable for any losses or damages (whether direct or indirect) including property damage or personal injury, consequential loss, economic loss or loss of profits, arising in contract or negligence or howsoever arising. Without limiting the foregoing, NRG will not be liable for any claims, damages or defects arising from or in any way attributable to poor workmanship, poor design or detailing, settlement or structural movement and/or movement of materials to which the Product is attached, incorrect design of the structure, acts of God including but not limited to earthquakes, cyclones, floods or other severe weather conditions or unusual climatic conditions, efflorescence or performance of paint/coatings applied to the Product, normal wear and tear, growth of mould, mildew, fungi, bacteria, or any organism on any Product surface or Product (whether on the exposed or unexposed surfaces);

vii)  all warranties, conditions, liabilities and obligations other than those specified in this warranty are excluded to the fullest extent allowed by law;

viii)  if meeting a claim under this warranty involves re-coating of Products, there may be slight colour differences between the original and replacement products due to the effects of weathering and variations in materials over time.

DISCLAIMER
The recommendations in NRG’s specifications manual are based on good building practice, but are not an exhaustive statement of all relevant information and are subject to conditions (iii), (iv), (vi) and (vii) above. Further, as the successful performance of the relevant system depends on numerous factors outside the control of NRG (e.g. quality of workmanship and design), NRG shall not be liable for the recommendations in that literature and the performance of the relevant system, including its suitability for any purpose or ability to satisfy the relevant provisions of the Building Code of Australia, regulations and standards.

Disclaimer: NRG Building Systems has endeavoured to produce this manual taking into account good building practices and experience gained over many years. NRG Building Systems will not be liable for omissions and or errors contained in this manual.’

 

NRG GREENBOARD AND THE ENVIRONMENT

  • NRG Greenboard Energy Efficient Insulative Walling System Product Information.
  • NRG Greenboard is comprised of 98% air and therefore only 2% polystyrene making it a highly efficient use of raw material.
  • NRG Greenboard remains inert, is non toxic, odour free and nonbiodegradable.
  • No CFC’s or HCFC’s foam agents are used in its manufacture, so NRG Greenboard causes no damage to the ozone layer.
  • Effective installation of NRG Greenboard can cut carbon dioxide emissions by up to 50%.
  • The R-value of NRG Greenboard does not deteriorate during its life time; therefore the reduction in emissions lasts the full lifetime of the building.
  • The energy used to manufacture NRG Greenboard is recovered within six months by the energy saved in the building in which NRG Greenboard is installed.
  • Typically, for every kg of oil used in NRG Greenboard manufacturing, about 200kg will be saved in reduced heating demands.
  • All NRG Greenboard waste is recycled. Either through installation of off-cuts in the wall cavity or it can be granulated and mixed with virgin material to make new products.

ENVIRONMENTALLY RESPONSIBLE. ENERGY EFFICIENT. BUILDING SYSTEMS.

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NRG Install Guide

1 START

(A) Before commencing to fix NRG panels check that

 

  1. The frames are straight and plumb
  2. All windows and flashing are correctly installed
  3. Breathable sarking has been fitted
  4. Solid back blocking where required Consideration should be given to the installation of wall mounting accessories i.e. taps, electrical, fittings etc. It is important to allow for adequate back blocking for these items.

(B) POSITIONING OF STARTER BEAD:

 

INTO A REBATE FOR SLAB DETAIL

 

INTO BEARER/ JOIST FOR TIMBER FLOOR DETAIL

 

INTO FLASHING FOR ROOF/ WALL DETAIL

 

2 FIXING / CUTTING / BACK BLOCKING

(A) NRG panels can be layed horizontally or vertically depending on what suits the job.

  • Position NRG panel into starter bead, check for level and fix into studs using NRG washers and screws.
  • Standard fixings are 300c vertically and 450c horizontally (refer to fixing table).
NRG Greenboard Minimum Stud & Fastener Spacing’s
Regions – Wind
Category
Stud Spacings
(mm)
Fastener Spacings
(mm-Vertically)
Number of
Fasteners /m_
Non Cyclonic N1 450 300 12
N2 450 300 12
N3 450 300 12
N4 450 200 18
N5 450 150 24
Cyclonic C1 450 200 18
C2 450 150 24
C3 450 100 37

* In accordance with AS1684 – 2006 / AS4005 – 1992

 

(B) Adjoining NRG panels are to be glued on both horizontall and vertical edges using recommended construction adhesive (i.e. Bostik No More Nails) or an expanda foam.

(C) Measure and cut NRG panels using a straight edge and a standard power saw with a masonary diamond blade.

(D) At external corners, NRG panels are overlapped the full thickness of the sheets and glued using recommended construction adhesive.

(E) Allow a 3mm gap between NRG panels and openings (door, windows) for sealing. It is recommended the straight edge of the sheet be fixed next to the openings for easier sealing.

 

BACK BLOCKING

(F) Where the NRG panel has a vertical join off a stud it is necessary to back-block as follow.

 

i. Fixing stud material vertically (widest facing outwards) and securing between bottom plate and noggin. Alternately between noggin and top plate, making sure to glue both NRG panels and fix through each panel with screws and washers into back block at 300c.

 

 

3 BEADING & SEALING

At this point particular care needs to be exercised to ensure that the installation of all beading around windows and doors is completed correctly. This is not a gap filling exercise but an intregral part of the total NRG Greenboard walling system.

(A)  Rendered Reveals 60mm, 75mm, 100mm Greenboard

 

i. All sills, heads & jambs to be rendered.

ii. Using marking tape, accurately adhere to frame of joinery, 4mm from the edge creating a neat parallel margin.

iii. Using Bostik Primer 5077, and a clean rag, dampen cloth with Primer and quickly clean the window reveal, ready for sealant application.

iv. Cut a medium size end off the nozzle of the sealant. Apply a bead of sealant into the gap between the Greenboard and the taped window reveal. Using a coving tool, neatly create an internal cove finish.

v. Remove masking tape from joinery leaving a 100% water proof seal.

vi. This peocedure is repeated after rendering and prior to texture coating, to ensure double sealing around windows and doors.

(B) External Beads

 

i. External points of building, columns etc.

ii. All sill, head and jambs (60mm, 75mm, 100mm)

iii. Install external bead by applying a bead of Bostik No More Nailst o internal sides of the bead.

Then press firmly into position, check for plumb and straightness, scraping of excess glue, tacking into position until dry.

(C) 40mm Reveal Bead

i. Allow a 3mm gap between Greenboard and opening.

ii. Glue 40mm reveal bead into 3mm gap pressing firmly against the Greenboard. Make sure there is sufficient glue to fix bead to Greenboard.

iii. Tape and prime reveal bead and opening reveal. Apply a bead of sealant into the gap between the reveal bead and opening reveal. Smear sealant with tool. Remove tape and Paint.

(D) Expansion Beading Joints

 

Expansion Joints allow movement within the building & avoid unsightly cracking.

i. Vertical Expansion Beading Joints: Every 8 metres (above/ below window).

ii. Horizontal Beading Expansion Joints: Located between floor levels

iii. Install ‘Render Expansion Bead’ between both Greenboard surfaces, applying a bead of No More Nails to both internal surfaces of bead. Press into position, scrape off excess glue, and tack fix until dry.

(Expansion Joints) Option 2

  1. Chalk line after render
  2. 10mm cut through render and into panel
  3. Tape either side of joint
  4. Seal
  5. Remove tape and Paint

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