EzyLite Astrix External Wall Cladding System

for NCC 2016, Vol. 2, BCA Class 1 & Class 10 Buildings

Version 1, 11th September 2018

2/89 Somerset Road, Campbellfield Vic, 3061

T. 03 9359 2336 F. 03 359 9306 [email protected] www.ezylite.com.au

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 Contents
1 Introduction .............................................................................................................. 4
1.1 EzyLite Astrix Panel .............................................................................................................4
2 EzyLite Astrix External Wall Cladding System ................................................ 5
2.1 Benefits ...................................................................................................................................5
2.2 Structural Performance .....................................................................................................5
2.3 Weatherproofing Performance ......................................................................................6
2.4 Thermal Properties .............................................................................................................6
2.5 Acoustic Properties ............................................................................................................7
2.6 Early Fire Hazard Properties ............................................................................................7
2.7 Building Code of Australia (BCA) 2016 .......................................................................7
3 Materials ..................................................................................................................... 8
3.1 Damp Proof Course ............................................................................................................8
3.2 Breathable Wall Wrap .......................................................................................................8
3.3 Reinforced Aluminium Foil Tape (48mm wide) ........................................................8
3.4 Aluminium faced Butyl Flashing Tape (48mm wide) ..............................................8
3.5 Backing Rod ..........................................................................................................................8
3.6 Fire Rated Adhesive Sealant ............................................................................................8
3.7 Astrix Panel ............................................................................................................................8
3.8 Screws .....................................................................................................................................9
3.9 External Angles ....................................................................................................................9
3.10 Fibreglass Mesh ...................................................................................................................9
3.11 Render .....................................................................................................................................9
4 Specifications .......................................................................................................... 10
5 Installation ............................................................................................................... 11
5.1 Typical Panel Layout for 450mm Stud Wall............................................................ 11
5.2 Typical Panel Layout for Openings ............................................................................ 12
5.3 Fastener Type, Spacing & Edge Distances .............................................................. 12
5.4 Installation Steps .............................................................................................................. 12
6 Construction Details ............................................................................................. 15
6.1 Direct Fix (directly to studs) ......................................................................................... 15
6.1.1 Concrete Slab Over Edge................................................................................. 15
6.1.2 Concrete Slab Rebate ....................................................................................... 16
6.1.3 Panel Over Masonry .......................................................................................... 17
6.1.4 Wall Over Roof .................................................................................................... 18
6.1.5 Garage / Bulkhead / Overhang / Drip......................................................... 19
6.1.6 Wall to Balcony ................................................................................................... 20

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 6.1.7 Parapet Wall ......................................................................................................... 21
6.1.8 Junction to Masonry Wall................................................................................ 22
6.1.9 Horizontal Expansion Joint ............................................................................. 23
6.1.10 Vertical Expansion Joint ................................................................................... 24
6.1.11 Internal Corner .................................................................................................... 26
6.1.12 External Corner .................................................................................................... 27
6.1.13 Window Head ...................................................................................................... 27
6.1.14 Window Sill ........................................................................................................... 28
6.1.15 Window Jamb ...................................................................................................... 29
6.1.16 Eave Soffit ............................................................................................................. 30
6.1.17 Large Penetration ............................................................................................... 31
6.1.18 Service Penetration ............................................................................................ 32
6.1.19 Downpipe Fixing ................................................................................................. 32
6.1.20 External Fixture .................................................................................................... 33
7 Warranty ................................................................................................................... 34

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1 Introduction

1.1 EzyLite Astrix Panel

Ezylite Astrix is a 100% asbestos free, non-toxic, odourless, non-combustible,

corrosion resistant, acid-base resistant, sound & thermal insulating, inorganic panel
with a honeycomb interior structure. EzyLite Astrix panels are available as a standard
size of 600 mm x 2100 mm and 50 mm thickness.

Astrix panel is truly a lightweight wall cladding designed for fire and acoustic rating
requirements. A 50mm Astrix panel wall system is capable of achieving a
120/120/120 FRL in accordance with AS/NZS 1530. 4 and is non-combustible in
accordance with AS/NZS 1530.1.

Astrix panels are manufactured with a Tongue & Groove

(T&G) edge along the long edges for easy installation.

The weight of a 600 x 2100 x 50 mm Astrix Panel is approximately 18 kg, which is

under the lifting limits endorsed by work safe Vic.

A team of two installers can install between 200-600 m2 per day without the use of
heavy lifting machines or special cutting tools.

Astrix Panel Efficiencies:

- Sufficient, strength, durability and stability
- Resists moisture, decay & bio-contamination
- Non-toxic and non-hazardous to occupants and
installers
- Able to be installed efficiently and effectively
- Does not negatively impact on the eco-systems
- No components are harvested or mined
- All components are reclaimed or recycled materials
from other industries
- Does not require damaging maintenance,
operations or disposal practices

Other Possible Applications:

- Highly recommended for acoustic wall applications
- Thermal insulation of building walls and roofs
- Thermal insulation layer for all kinds of industrial equipment and pipelines
- Fire rated wall applications,
Note: A certificate of installation will be issued for fire rated wall applications on completion only
when inspection confirms our standards have been met.

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2 EzyLite Astrix External Wall Cladding System

This manual describes the performance and installation instructions for the Astrix
External Wall Cladding System for Direct-Fix applications.

EzyLite Astrix External Wall Cladding System achieves Total R-values which contribute
to achieving wall insulation requirements and can be input to house energy rating
software to achieve an energy rating.

EzyLite Astrix External Wall Cladding System consists of an Astrix panel screwed to
timber or steel wall framing through a breathable wall wrap. In the Direct-Fix system,
the panel is fixed directly to the studs. The maximum stud spacing is 450 mm.

EzyLite Astrix External Wall Cladding System is coated with a polymer-modified

render system that allows any number of different finishes to be achieved.

Incorporation of EzyLite Astrix External Wall Cladding System into the building design
must be made by a person who understands the application and technical aspects of
the system and has access to all relevant technical information. Ezylite will not
provide certification or warrant any installation that is not made in accordance with
this manual. Contact us if any of these instructions are not clearly understood.

2.1 Benefits

EzyLite Astrix Benefits:

- Lightweight - High Impact Resistance
- Fire Rated - Environmentally Friendly
- Acoustic Rated - Thermal Resistance
- Water Resistant (Not Waterproof) - Easy to cut and install
- Anti Mould - Non-hazardous material
- Termite Resistant

2.2 Structural Performance

EzyLite Astrix External Wall Cladding System:

- Meets BCA Volume 2 strength limit state wind pressures up to -4.1kPa, this
includes AS 4055 Wind Classification N3.
- Not tested as wall bracing, framing must be designed to resist loads.

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 - Control joints at regular intervals, maximum 6m spacing, must be specified by
the building designer.
- Only to be installed on buildings that conform with AS 4055.

2.3 Weatherproofing Performance

EzyLite Astrix External Wall Cladding System complies with the BCA Volume 2
performance requirements for weatherproofing and dampness confirmed by testing
in accordance with the verification method V2.2.1.
Astrix panels must be installed a least 50mm above finished ground level.
All windows must comply with AS 2047.
Every EzyLite Astrix External Wall Cladding System installation must have a “Risk
Score” of 20 or less determined in accordance with NCC 2016, BCA Volume 2 Table
V2.2.1a, as follows.

(Credit: The National Construction Code Series 2016© as released by the Australian Building Codes Board on behalf of the Commonwealth of
Australia and States and Territories of Australia. http://creativecommons.org/licenses/by-nc-nd/4.0/legalcode.)

2.4 Thermal Properties

The calculated Total R-value of Astrix Panel External Wall in accordance with AS/NZS
4859.1 is R2.8. This helps to provide excellent thermal efficiency of the home with
huge savings on energy bills.

EzyLite Astrix External Wall Cladding System with a 50 mm thickness panel,

breathable wall wrap, R2.5 glasswool insulation and 10mm plasterboard lining
achieves the following Total R-values in accordance with AS/NZS 4859.1.

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 Total R-value (m2.K/W)
Direct Fix 2.8

Total R-values can be increased with additional insulation between the wall studs,
e.g. Include up to R2.7 added glasswool insulation in a 90mm stud.

2.5 Acoustic Properties

Acoustic testing achieved Rw+Ctr = 51, with R2.2 glasswool batts on timber frame
lined with 10 mm Plaster board and 50 mm Astrix Panel.

Acoustic Ratings

2.6 Early Fire Hazard Properties

EzyLite Astrix panel has been tested in accordance with AS/NZS 1530.3 where the
Ignitability, Spread-of-Flame, Heat-Evolved, and Smoke-Developed Indices are 0, 0, 0,
0-1 respectively.

2.7 Building Code of Australia (BCA) 2016

EzyLite Astrix External Wall Cladding System has been tested and appraised to the
following performance requirements of the NCC 2016, BCA Volume 2:

 Structure: (P2.1 Structural stability and resistance to actions)

Tested and appraised for serviceability and strength under wind actions up to and
including AS 4055 Wind Class N3.
 Weatherproofing and Dampness: (P2.2.2 Weatherproofing, P2.2.3 Dampness)
Tested and appraised for resistance to moisture from the ground and the
penetration of water.

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3 Materials

The EzyLite Astrix External Wall Cladding System can only be constructed with
materials that meet the requirements below.
EzyLite cannot be responsible for the performance of an external cladding system
that does not follow these requirements.

3.1 Damp Proof Course

Damp proof course (DPC) in accordance with AS/NZS 2904.

3.2 Breathable Wall Wrap

Breathable Wall Wrap in accordance with AS/NZS 4200.1 with a min. Medium Duty
(MD) classification and an AS 1530.2 Flammability Index less than or equal to 5.

3.3 Reinforced Aluminium Foil Tape (48mm wide)

Reinforced aluminium foil pressure sensitive tape, 48mm wide, must be used to seal
the Wall Wrap along its bottom edge at the base of the wall, and at joints.

3.4 Aluminium faced Butyl Flashing Tape (48mm wide)

Aluminium faced Butyl Flashing Tape, 48 mm wide x 1.5 mm thick must be used to
seal the Breathable Wall Wrap at all openings. (e.g. Tenacious Tapes – Waterproof /
Sealing).

3.5 Backing Rod

The ‘Backing Rod’ must be a 8mm closed-cell polyethylene foam, to create a gap
between panels, and as ‘back-blocking’ for the joint Fire Rated Adhesive Sealant.

3.6 Fire Rated Adhesive Sealant

Paintable flexible fire rated adhesive sealant.

3.7 Astrix Panel

Manufactured by EzyLite Pty Ltd:

 The two major components are Magnesium Oxide and Cellulose

 Dimensions are 2100mm x 600mm x 50mm

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 Panels have Tongue and Groove (T&G) jointing along their long edges.
 Weight is 18kg per panel, densities are 14.3kg/m2 and 350-400kg/m3.
(NOTE SOME OF THESE NUMBERS ARE WRONG??)

3.8 Screws

12-14G Bugle head, Class 3 screws to suit steel or timber framing.

Minimum 25mm penetration into timber stud.
Minimum 3-full threads into steel stud
(e.g. Buildex Bugle head batten 12-14G Climacoat 3)

3.9 External Angles

External Angles must be 32 mm x 32 mm Aluminium and must be installed at all

external corners, openings and edges.

3.10 Fibreglass Mesh

Fibreglass mesh must be 5 mm x 5 mm x 100mm wide, 160g/m2 alkali resistant

fibreglass mesh.

3.11 Render

Astrix panels must be sealed on all exposed edges.

Astrix Panels must be rendered as soon as practical after installation, and in all cases
within 30 days of installation .
It is the renderer’s responsibility to use the appropriate compounds in the coating
system sufficient to eliminate cracking of the joints under normal building conditions.
We recommend the use of Haymes, Quickcote or Dulux, pre-blended polymer
modified cement render systems. These must be installed according to the
manufacturer’s instructions. Other brands have not been used or tested on Ezylite
products, and therefore we do not recommend the use of other brands.

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4 Specifications

Before installation of the EzyLite Astrix External Wall Cladding System, the building
framing must be constructed in accordance with BCA requirements.
Wall frames must be in accordance with AS 1684 for timber, and steel frames must
be constructed to either the NASH Standard for Residential and Low-rise Steel
Framing, Part 1: Design Criteria, or AS 3623 Domestic Metal Framing.

The location of all expansion/control joints is the responsibility of the Engineer /

Builder so that the frame is constructed to withstand any building movement.
Generally, expansion joints should be made at each floor level (3m maximum height)
and at every 6m maximum width, and at windows and doors, at concrete slab joints,
and at all joints with other types of cladding.

The correct installation of windows and doors etc., are outside the scope of the
EzyLite Astrix External Wall Cladding System. The builder must ensure all openings
are flashed to prevent water entering the building.

EzyLite Astrix External Wall Cladding System may only be installed onto framing with
a maximum stud spacing of 450mm.

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5 Installation

5.1 Typical Panel Layout for 450mm Stud Wall

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5.2 Typical Panel Layout for Openings

5.3 Fastener Type, Spacing & Edge Distances

The maximum vertical fastener spacing is 260mm.

Fasteners must be a minimum of 40mm from the edges of the panel.
Fasteners must be a maximum of 50mm from the long edge of the panel along the
bottom edge of a wall.

Frame Type Fasteners

Timber or steel frame max. stud spacing 12-14g x 75 mm, bugle head, Class 3, max.
450 mm. spacing 260mm
Timber or steel frame max. stud spacing 12-14g x 100 mm, bugle head, Class 3, max.
450 mm, 38 x 16 steel battens fixed spacing 260mm
vertically on each stud

All fasteners shall be countersunk into the panel to a maximum depth of 1mm.

5.4 Installation Steps

Installation Steps:

1. Ensure the wall frame is level and free from any bows.
2. Check that the stud spacing is not more than 450 mm.

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 3. Ensure all other required works e.g. Eave linings, flashings, damp proof course
etc. are provided as per the project requirements.
4. Place Breathable Wall Wrap over the studs and tape all joins and edges with
Reinforced Aluminium Foil Tape.
5. Seal around all penetrations with Bitumen Flashing Tape in accordance with
the manufacturer’s instructions.
6. Before installing each Astrix panel, ensure all exposed edges are sealed from
the weather.
7. All Astrix panels must be installed with the rough side to be rendered.
8. Starting from the bottom, fix the Astrix panel onto the framing.
9. Apply Fire Rated Adhesive Sealant at all panel joints
10. At all openings ensure a 3 mm expansion gap is made between the panel and
the opening frame. Cut the panel at window sills to provide for fall away from
the opening. Install external angles and butterfly mesh to all corners.
11. Horizontal Control Joints – Make horizontal control joints at all locations as
noted in the project specification. Horizontal control joints consist of an 8 mm
gap with backing rod with fire rated sealant applied to the joint.
In all cases horizontal control joints must be made at construction joints and
at the intersection of different claddings.
12. Vertical Control Joints – make vertical control joints at all locations as noted in
the project specification. Vertical control joints consist of an 8 mm gap with
backing rod with fire rated sealant applied to the joint. In all cases vertical
control joints must be made at construction joints and at the intersection of
different claddings.
Coating System- Rendering
13. DO NOT render onto a dusty surface, remove all dust and loose particles
before rendering painting.
14. Trowel on Patch approx. 1 mm thick over joints then place 100mm wide alkaline-
resistant 5mm weave fibre-glass mesh 160g/m2) over wet rendering.
15. Apply a 2nd layer of patch over fibreglass mesh while patch is still wet. (Allow
drying time Min 24 hrs) refer to manufacturer’s specifications for drying periods.
16. Apply aluminium angle beads to all external corners including window and door
openings.
17. Render entire board surface with polymer modified acrylic render Quickcote flexi
patch/ Quickcote wet patch, or similar, at a minimum of 2mm thick.
18. The mesh is to be trowelled into the surface of the wet render, positioned just
below the surface. Under no circumstances should the mesh be fixed to the walls

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 and render applied over it. Overlap all fibreglass mesh sheets a minimum of
50mm.
19. Ensure the entire surface is level (taking into account the joint). Make sure that
the joint is not proud of the remaining surface. Apply a second coat if the outline
of the joint and fixings is not eliminated.
20. Apply trowel-on texture/colour to entire surface, Please note: all coatings must be
applied and maintained in accordance with the coating manufacturer's
instructions.
21. Apply by roller (or mix in with colour when trowelling) sealer to entire wall. The
sealer protects the colour fading and waterproofing of wall.

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6 Construction Details

EzyLite Astrix External Wall Cladding System must be installed in accordance with this
Installation Manual and with all relevant building codes and regulations.
Typical construction details are provided as a guide for construction industry
professionals. They do not constitute a project specification and should only be
made use of within the context of the entire project specific specifications.
Modifications to these drawings must not be made without the approval of EzyLite.

6.1 Direct Fix (directly to studs)

6.1.1 Concrete Slab Over Edge

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6.1.2 Concrete Slab Rebate

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6.1.3 Panel Over Masonry

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6.1.4 Wall Over Roof

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6.1.5 Garage / Bulkhead / Overhang / Drip

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6.1.6 Wall to Balcony

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6.1.7 Parapet Wall

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6.1.8 Junction to Masonry Wall

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6.1.9 Horizontal Expansion Joint

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6.1.10 Vertical Expansion Joint

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6.1.11 Internal Corner

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6.1.12 External Corner

6.1.13 Window Head

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6.1.14 Window Sill

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6.1.15 Window Jamb

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6.1.16 Eave Soffit

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6.1.17 Large Penetration

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6.1.18 Service Penetration

6.1.19 Downpipe Fixing

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6.1.20 External Fixture

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7 Warranty

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

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