Masonry Design Guide

BORAL MASONRY

Build something great™

Masonry Design Guide STRUCTURAL, FIRE AND ACOUSTICS VICTORIA BOOK 1

www.boral.com.au/masonry

Updated February 2009

PAGE

PAGE

Victoria Book 1 A

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2

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

Fast Find Product & Application Guide . . . . . . . . . . . . . . . . . A3

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

A B

Introduction

Structural Design

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

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

Robustness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2

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

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

Reinforced Masonry Lintels. . . . . . . . . . . . . . . . . . . . . . . . . . B8

Bending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5

Design of Core Filled & Steel Reinforced Masonry Retaining Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . B9

Shear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6 Durability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6

C

Structural Design Guidelines for Core Filled & Steel Reinforced Masonry Retaining Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . B11

Fire Design

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

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

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

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

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

D

Acoustic Design

Acoustic Performance Ratings (STC & Rw) . . . . . . . . . . . . . . D2

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

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

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

E

Fire & Acoustic Systems

Finding Acoustic Systems & Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2

Scoria Quick Brick (SB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . E10 FireLight Quick Brick (FL). . . . . . . . . . . . . . . . . . . . . . . . . . . E12

Fire Rated Block - Scoria Blend (SB) . . . . . . . . . . . . . . . . . . . E4 Acousticell™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E14 Standard Ash Grey Block (AG) . . . . . . . . . . . . . . . . . . . . . . . . E6 Concrete-Basalt Bricks (B) . . . . . . . . . . . . . . . . . . . . . . . . . . E8

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

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February 2009 | BORAL MASONRY DESIGN GUIDE

Victoria Book 1 A

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

NLB = Non-loadbearing LB = Loadbearing

W al l Re

ta in in g

Li ni ng

te rb o

N o

Re

Pl as

nd

er ed

ar d

ry on M as

e Fa c

LL W A

BLOCK & BRICK PRODUCTS

FI N IS H

BORAL MASONRY

NLB LB NLB LB NLB LB NLB LB NLB LB

Scoria Blend (SB)

–

–

E4

–

E4

–

E4

–

–

–

Standard Ash Grey Block (AG)

–

–

E6

E6

E6

E6

E6

E6

–

–

Core Filled Block

E6

E6

E6

E6

E6

E6

E6

E6

E6

E6

Acousticell

E14

–

–

–

–

–

E14

–

–

–

Designer Block

➁

➁

–

–

–

–

–

–

–

–

Concrete-Basalt Brick (B)

–

–

E8

E8

E8

E8

E8

E8

–

–

1

2

Fast Find a Boral Solution Select your application criteria from the top of the table Go straight to the section letter and page number indicated at the intersection of product rows and application columns (e.g. Section E, Page E6 in this example)

➀ Best performance is achieved with plasterboard lining

➁ Please refer to MDG Book 2, Boral

Scoria & FireLight Bricks

–

–

E10 ➀

–

E10 ➀

–

E10 ➀

–

–

–

Masonry Block & Brick Guide

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

BORAL MASONRY DESIGN GUIDE

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February 2009

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Victoria Vi V icctttor oriiaa BBook ooook 1 A

Boral Engineered Blocks for Structural, Fire & Acoustic Wall Systems

• Standard Ash Grey Block (AG) Hollow Concrete Block suitable for loadbearing and non-loadbearing applications. Basalt content is >45% allowing the higher slenderness ratios of AS3700, table 6.1 to be used.

• Back-up Block Ash Grey Concrete Block in 162mm height (equivalent to 2 courses of standard brick). Designed for cost effective construction of the ‘back-up’ leaf in face brick veneer walls.

A4

• Scoria Blend High Fire Rated Block Manufactured in a unique Scoria Blend material offering High Fire Performance, ideal for high rise buildings with reinforced concrete frames or portal frame buildings. Suitable for non-loadbearing walls. If used for light load construction, the lower slenderness ratios of Designer Block apply.

February 2009 | BORAL MASONRY DESIGN GUIDE

Victoria V Vic icttor oria ia Book BBoo Bookk 1 A

Boral Engineered Bricks for Structural, Fire & Acoustic Wall Systems

• Core Fill Block

• FireLight Quick Brick (FL)

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

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

• Concrete-Basalt Brick (B) Standard Size and Quick Brick (162mm height) in Concrete-Basalt material for good fire performance and loadbearing characteristics.

BORAL MASONRY DESIGN GUIDE

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February 2009

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

• Scoria Quick Brick (SB) Medium weight Scoria Quick Brick for nonloadbearing fire and/or acoustic systems. Quick Brick format (162mm height) for faster, more cost effective construction.

A5

Victoria Book 1 A

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

What’s in this Guide The Boral Masonry Structural, Fire & Acoustic guide (this book), provides a summary of important design information for structural, fire and acoustic masonry applications and an extensive range of fire and/or acoustic systems to cater for many design scenarios.

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

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

Section D – Acoustic Design

This guide has been prepared as a comprehensive Boral Product Reference Guide. It does not attempt to cover all the requirements of the Codes and Standards which apply to masonry construction for structural, fire or acoustic applications. All structural, fire and acoustic detailing should be checked and approved by appropriately qualified engineers before construction. Boral reserves the right to change the contents of this guide without notice. Please note that this guide is based on products available at the time of publication from the Boral Masonry Victorian sales region. Different products and specifications may apply to Boral products sourced from other regions.

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

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

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

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February 2009 | BORAL MASONRY DESIGN GUIDE

BORAL MASONRY

Build something great™

Masonry Design Guide STRUCTURAL, FIRE AND ACOUSTICS VICTORIA BOOK 1 B STRUCTURAL DESIGN

1

B

Victoria Book 1 B

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

Legend to Symbols used in Robustness Calculations: H

tr

Robustness

B2

=

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

=

the minimum thickness of the member, in metres

=

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

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

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

Cv,Ch =

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

=

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

=

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

kt

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

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

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

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

=

Lr

February 2009 | BORAL MASONRY DESIGN GUIDE

Victoria Book 1 B

Formulae and Explanation

Worked Examples

Isolated Piers

Aim:

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

H tr

≤ Cv

To determine the Maximum Wall Height of an Isolated Pier

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

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

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

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

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

Formulae and Explanation

Worked Examples

Wall with Free Ends

Aim:

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

Criteria:

Formula (2) is:

H ≤ Cv kt x tr

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

H Cv

BORAL MASONRY DESIGN GUIDE

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

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

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February 2009

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Victoria Book 1 B

Formulae and Explanation

Worked Examples

Wall with Restraint at End or Ends

Aim:

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

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

Criteria:

Wall thickness tr = 110mm

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

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

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

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

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

Formulae and Explanation

Worked Examples

Wall with Restraint at Top and End or Ends

Aim:

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

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

Criteria:

Wall thickness tr = 110mm Wall length = 2m

= no limit

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

H tr

Cv +

Ch Lr – Chtr

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

( C + L C– C t ) t v

h

r

hr

r

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

( 36 + 2 – 1212x 0.11 ) 0.11

H ≤ 5.9m

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

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February 2009 | BORAL MASONRY DESIGN GUIDE

Victoria Book 1 B

Table B1 (Extract from AS3700 : Table 4.2) Cv Top and bottom edge restraints to wall panels

Vertically unreinforced

Vertically reinforced or prestressed

6

12 with reinforcement continuous into support. Otherwise 6.

Free

SUPPORT

Load other than concrete slab or no load Lateral Support

27

36

SUPPORT

Concrete Slab Lateral Support

36

48

SUPPORT

ISOLATED PIERS Lateral Support

13.5

30

SUPPORT

Ch Horizontally unreinforced

Horizontally reinforced or prestressed

12

24 with reinforcement continuous past support. Otherwise 16

SUPPORT

SUPPORT

SUPPORT

Edge restraints on vertical sides of wall panels

36

48

Table B2 (Extract from AS3700 : Table 7.2) Thickness Coefficient (kt) for Walls Stiffened by Monolithically Engaged Piers Pier Spacing/Pier Width (Refer to Note 1)

Thickness Coefficient (kt) Pier Thickness Ratio (twp/t) 1 2 3 1.0 1.4 2.0 1.0 1.3 1.7 1.0 1.2 1.4 1.0 1.1 1.2 1.0 1.0 1.0

6 8 10 15 20 or more

NOTES: 1. Pier spacing is taken as the distance between centrelines of piers. 2. Linear interpolation may be used. twp

Strength Compressive strength is resistance to load, measured by the amount of pressure to crush a masonry unit. The pressure, usually measured in megapascals (MPa), is the force in kilonewtons (kN) x 1000, divided by the loaded area in square mm. Unconfined compressive strength is compressive strength, multiplied by an aspect ratio, Ka (see AS4456.4, Table 1). The unit height divided by its thickness is used to determine the aspect ratio. A solid brick will give a lower compressive strength if crushed on its end rather than on its flat, as normally laid. In theory, the aspect ratio will convert both tests to the same unconfined compressive strength. The strength of hollow blocks is calculated by dividing the force by the face shells only. A 90mm hollow and 90mm solid block are both 10MPa, but since the area of the face shells on the hollow block is about half the area of the solid block, the hollow will only carry half the load of the solid. Characteristic Unconfined Compressive Strength of masonry UNITS is ƒ ’ uc. ƒ’uc is the average of crushing forces divided by loaded areas, multiplied by the aspect ratio, minus the standard deviation x 1.65. Characteristic Compressive Strength of a masonry WALL is ƒ ’ m. ƒ ’ m is the square root of ƒ ’ uc, multiplied by Km (a mortar strength factor), multiplied by Kh (a factor for the amount of mortar joints) as per AS3700, 3.3.2. The Km factor is 1.4 for M3 mortar on solid and cored units and is 1.6 for the face shells of hollow units. For the richer M4 mortar it is 1.5 (Table 3.1). The Kh factor is 1 for 76mm high units with 10mm mortar beds and is 1.3 for 190mm units with 10mm mortar beds. In other words, a wall of 190mm high units is 30% stronger than a wall of 76mm high units of the same ƒ ’ uc.

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

t Wall Leaf

Pier Width Pier Spacing

BORAL MASONRY DESIGN GUIDE

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B5

Victoria Book 1 B

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

Durability Masonry designed for ‘Durability’ is deemed to satisfy when it meets the requirements of AS3700 Section 5, which details what areas require Exposure, General Purpose and Protected grades. Assessment of these grades is defined in AS/NZS4456.10 Resistance to Salt Attack. AS3700 defines the usage of each of these grades as: Protected Grade (PRO) Elements above the damp-proof course in non-marine exterior environments. Elements above the damp-proof course in other exterior environments, with a waterproof coating, properly flashed junctions with other building elements and a top covering (roof or coping) protecting the masonry. General Purpose Grade (GP) Suitable for use in an external wall excluding severe marine environment. Exposure Grade (EXP) Suitable for use in external walls exposed to severe marine environments, i.e. up to 100m from a surf coast or up to 1km from a non surf coast. The distances are specified from mean high water mark. Mortar mix requirements for durability are detailed in AS3700 Table 10.1. Mortar joints must be ironed.

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

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

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

External Control Joints AS3700, Clause 4.8 requires control joint spacing to limit panel movement to:• 10mm maximum for opening of control joints, • 15mm maximum for closing of control joints, and

Salt attack is the most common durability problem. The salt in salt water is in solution. It can be absorbed into masonry or at least, its mortar joints. When the water evaporates, it migrates towards the outside face taking the salt with it until the amount of water left is saturated. It can no longer hold all the salt in solution and salt crystals begin to form.

The Australian Masonry Manual recommends control joints at 8m centres for concrete units, 6m centres for lightweight ( 1500 ” 2200

400

February 2009 | BORAL MASONRY DESIGN GUIDE

BORAL MASONRY

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Masonry Design Guide STRUCTURAL, FIRE AND ACOUSTICS VICTORIA BOOK 1 C FIRE DESIGN

1

C

Victoria Book 1 C

Masonry Design for Fire Resistance

Masonry Design for Structural Adequacy FRL

Fire Resistance Levels (FRL)

Legend for the following formulae

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

Srf = the slenderness ratio in design for fire resistance for structural adequacy. See table C2 on page C7 for maximum Srf.

There are 3 figures in the Fire Resistance Level.

avf = 0.75 if the member is laterally supported along its top edge.

eg: FRL 60/120/120 meaning Structural Adequacy for 60 minutes / Integrity for 120 minutes / Insulation for 120 minutes.

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

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

= for a member without top horizontal support, the overall height from the bottom lateral support. t

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

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

= the clear height of a member between horizontal lateral supports; or

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

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

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

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

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February 2009 | BORAL MASONRY DESIGN GUIDE

Victoria Book 1 C

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

avf H t

Srf =

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

Srf =

√

0.7 t

avf H ah L

For cavity walls, two thirds of the total thickness can be used for t, provided that BOTH leaves are restrained in the same positions (eg: external leaf stops at slab also). If the external leaf is a veneer to the slab edge, the internal leaf must provide the Structural Adequacy FRL on its own. For reinforced masonry, the Srf of 36, from Table 6.1 may be used. Reinforcement can be horizontal, as bond beams when spanning between columns. Reinforcement can be vertical, as filled cores when spanning between slabs. In either case, reinforcement can be spaced up to 2m apart, depending on span. This reinforcement stiffens the masonry and resists bowing. Reinforced walls with Srf < 36 have a 240 minute FRL for Structural Adequacy. All calculations should be checked by an engineer. Other loads may supersede Structural Adequacy requirements.

6.3.2.2 (4) is the LENGTH formula. FORMULA 4 is:

Srf = ah

Masonry Design for Integrity FRL

L t

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

H =

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

Srf x t Avf

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

Avf x H Srf

where ‘t’ is the OVERALL thickness, whether the units are solid or hollow. NOTE:* Refer to the Structural Adequacy Selection Graphs on pages C9 to C15 for maximum height values.

BORAL MASONRY DESIGN GUIDE

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February 2009

C3

Victoria Book 1 C

Masonry Design for Insulation FRL

Effect of Chases on Fire Rated Masonry

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

Structural Adequacy FRL

‘Material thickness’ is defined in AS3700, Clause 6.5.2 as the overall thickness for solid and grouted units and units with cores not more than 30% of the unit’s overall volume.

Walls spanning vertically may be chased vertically. The horizontal chase is limited to 4 times the wall thickness.

For hollow units (cores > 30%), the material thickness is the net volume divided by the face area. For cavity walls, t = the sum of material thicknesses in both leaves. (not two thirds as for the Structural Adequacy FRL).

Options for Increasing FRLs The Structural Adequacy FRL can be increased by adding wall stiffeners, by increasing the overall thickness, by adding reinforcement or by protecting the wall with Boral Plasterboard ‘FireStop’ board, fixed to furring channels (on both sides of the wall if a fire rating is required from both sides). Integrity FRLs are increased by increasing the other two FRL values to the required Integrity FRL. Insulation FRLs can be increased by core filling, by adding another leaf of masonry, by rendering both sides of the wall if the fire can come from either side. NOTE: Only ONE thickness of render is added to the material thickness and that must be on the ‘cold’ side because the render on the exposed face will drop off early in a fire). Boral ‘FireStop’ plasterboard on furring channels can increase the Insulation FRL from either side. Unlike render, the Boral FireStop and furring system does not drop off the hot side so quickly due to the board’s fire resistance, the mechanical fixing of the board to furring and the furring to the wall.

C4

To assess the effect of chases on Structural Adequacy FRLs, the direction in which the wall spans must be taken into account.

Walls spanning vertically and horizontally may be chased horizontally up to half the wall length. Horizontal chases should be kept to a bare minimum. Walls spanning vertically and horizontally may be chased vertically up to half the wall height. If these limits are exceeded, the masonry design thickness must be reduced by the depth of the recess or, in the case of vertical chases, designed as 2 walls with unsupported ends at the chase. Integrity and Insulation FRLs Maximum depth of recess is 30mm. Maximum area is 1,000mm2. Total maximum area on both sides of any 5m2 of wall is 100,000mm2 If these limits are exceeded, the masonry design thickness must be reduced by the depth of the recess. Refer to the Boral Masonry Design Guide, (MDG Book 1) for more details.

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

February 2009 | BORAL MASONRY DESIGN GUIDE

Victoria Book 1 C

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

Step 1

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

Example

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

eg: 120/60/60

NOTE: For masonry wall design, the FRL for any given wall must comply with:

eg. If the BCA required FRL is: –/120/60

Structural Adequacy ≥ Integrity ≤ Insulation

Insulation Integrity Structural Adequacy

Then the chosen wall design must have an actual FRL of: 120/120/120 or better.

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

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

BORAL MASONRY DESIGN GUIDE

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February 2009

C5

Victoria Book 1 C

Step 2

Worked Example

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

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

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

• Fire Rated Block 12.401, 15.401, 15.483 and 20.401

Table C1 provides the ‘Insulation’ values for the various Boral units.

• Grout Filled Masonry (190mm) 20.42 and 20.48. (However, the use of Scoria Blend may be more cost effective).

Check the ‘Materials Attributes’ (see notes below the table) to ensure the selection is fit for its purpose.

Table C1 – FRL Insulation Values for Boral Masonry Units (Victoria) Fire Test

30

60

INSULATION FRL (minutes) 90 120 180

240

Material

Product Code/Type*

Yes Scoria Blend (SB) Yes Scoria Blend (SB) Yes Scoria Blend (SB) Yes Scoria Blend (SB) Yes FireLight (FL) d.t.s.. +render Ash Grey (AG) & Designer Block d.t.s.. Ash Grey (AG) & Designer Block d.t.s.. Ash Grey (AG) & Designer Block d.t.s.. +render Ash Grey (AG) & Designer Block d.t.s.. +render Grout Filled Masonry 140mm d.t.s. Grout Filled Masonry 190mm d.t.s. Grout Filled Masonry 290mm d.t.s. ‘deemed to satisfy’. +render = 10mm render both faces * Product Codes listed are for the ‘Full Size Unit’. Fractional size blocks in the same range have the same FRL rating.

15.01SC 15.301; 10.331; 10.383 12.401; 15.401; 15.483; 20.401 Scoria Quick Brick FireLight Quick Brick 10.01; 10.201 15.01; 15.201 20.01; Brick B1, Quick Brick Solid or Cored 15.01; 15.42; 15.48 20.01; 20.42; 20.48 30.48

Material Attributes (Victoria)

Designer Block. ƒ ’ uc = 10MPa.

Scoria Blend – High Fire Rated Block – ƒ ’ uc = 8 MPa.

Blocks provide a 60 or 90 minute Insulation FRL. Suitable for LOADBEARING applications.

Offers excellent Insulation and Structural Adequacy FRLs for NONLOADBEARING fire rated walls. 10% lighter than Standard Ash Grey units. Scoria Blend is hard, durable and suitable for paint or render. Acoustic performance with plasterboard linings is excellent. Acoustic performance with render is medium range.

Standard Ash Grey (AG) ƒ ’ uc = 10MPa. Basalt ≥45% Offers excellent Srf values for Structural Adequacy FRL. Suitable for LOADBEARING walls. Acoustic performance with plasterboard is excellent. Acoustic performance with render is excellent.

Scoria Quick Brick (SB) – ƒ ’ uc = 5 MPa

Reinforced Grout Filled Masonry. ƒ ’ uc = 15MPa.

Insulation FRL of 240 minutes. High slenderness ratio (Srf) for Structural Adequacy FRL. Suitable for NON LOADBEARING fire rated walls. Light weight, 20% lighter than Standard Ash Grey units. Acoustic performance with plasterboard linings is excellent.

AS3700 allows an Srf value of 36 for reinforced masonry. This in turn allows for the largest walls to be built using the thinnest masonry option. Suitable for LOADBEARING applications. Grout strength to be 20MPa.

FireLight Quick Brick (FL) – ƒ ’ uc = 3 MPa Insulation FRL of 120 minutes. High slenderness ratio (Srf) for Structural Adequacy FRL. Suitable for NON LOADBEARING fire rated walls. Light weight, 35% lighter than Standard Ash Grey units. Acoustic performance with plasterboard linings is excellent.

C6

February 2009 | BORAL MASONRY DESIGN GUIDE

Victoria Book 1 C

Step 3

Worked Example

Check the ‘Structural Adequacy’ of the selected units.

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

The Slenderness ratio (Srf) of a fire rated wall is calculated as per AS3700 : 2001, Clause 6.3.2.2, and must not exceed the Srf values given in AS3700 or calculated from Fire Tests. Table C2 provides the maximum Srf values for Boral masonry units.

See following page for an explanation on using the Boral Srf graphs to assist preliminary selection. eg. Fire Rated Block - Scoria Blend (SB) required to provide Structural Adequacy for 240 minutes has an Srf = 19.7. (refer to page C11). Also refer to the previous explanation and AS3700 for Srf calculation methods. In this example, the 6 x 6m wall, with lateral restraint on 4 sides, 190mm thick has an Srf = 19.2. as per formula 6.3.2.2 (3). Alternatives are 20.401 (SB) and 20.48 with reinforcement and core filling. As the wall in this example is non-loadbearing, the Scoria Blend 20.401 is the more economical solution.

Table C2 – Maximum Srf Values for Boral Masonry Units Srf Values Fire FRL (minutes) for Structural Adequacy Test 30 60 90 120 180 240 Yes 22.6 22.6 22.6 22.6 21.5 19.7 Yes 22.6 22.6 22.6 22.6 21.5 19.7 Yes 29 29 26.9 24.9 22.2 20.3 d.t.s. 25 22.5 21 20 18 17 d.t.s. 19.5 18 17 16 15.5 15 d.t.s. 36 36 36 36 36 36 d.t.s.= deemed to satisfy, as per AS3700 : 2001, Table 6.1.

BORAL MASONRY DESIGN GUIDE

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February 2009

Material Scoria Blend (SB) Scoria Quick Brick FireLight Standard Ash Grey (AG) and Basalt Quick Brick Designer Block Reinforced & Grout Filled Masonry

Condition of use Non loadbearing ONLY Non loadbearing ONLY Non loadbearing ONLY Any Any Any

C7

Victoria Book 1 C

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

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

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

How to Use the Boral Structural Adequacy FRL Graphs Fire Rated Block - Scoria-Blend (SB)

Worked Example 1. Select the appropriate page and graph for the chosen masonry unit material.

Laterally supported both ends and top

SUPPORT

SUPPORT

SUPPORT

Structural Adequacy 180 minutes FRL

SUPPORT

2. Select the appropriate graph with Structural Adequacy for the required minutes. (180 minutes for this example).

9

Leaf Thickness

8

Height of wall between supports (m)

7 6 190mm 5 4

140mm

3

110mm 90mm

2 1 0 0

1

2

3

4

5

6

7

8

Length of wall between supports (m)

9

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

Index to Structural Adequacy FRL Graphs & Tables Product Group

FRL Minutes (Structural Adequacy)

Page

Scoria Blend (SB) & Scoria Quick Brick Scoria Blend (SB) & Scoria Quick Brick Scoria Blend (SB) & Scoria Quick Brick FireLight Quick Brick (FL) FireLight Quick Brick (FL) Standard Ash Grey (AG) Standard Ash Grey (AG) Designer Block Designer Block Walls Restrained at Top (Unrestrained Ends) Reinforced & Grout Filled Masonry Walls

60 — 120 180 240 90 120 60 90 60 90 60 — 240 60 — 240

C9 C10 C11 C12 C13 C14 C15 C16 C17 C18 C18

C8

February 2009 | BORAL MASONRY DESIGN GUIDE

Victoria Book 1 C

Scoria Blend (SB) High Fire Rated Block -

Srf = 22.6

SUPPORT

Laterally supported both ends, top free

8

8

7

7

6

190mm

5 140mm

4

110mm 3

90mm

2 1 0 1

2

3

4

5

6

7

8

SUPPORT

Laterally supported one end and top

5 4 3

1 0 0

SUPPORT

6 190mm 5 140mm

4

110mm

3

90mm 2 1 0 6

7

8

|

5

6

7

8

9

SUPPORT

Leaf Thickness

6 5 4 3 2 190mm 140mm 110mm 90mm

1 0 0

1

2

3

4

5

6

7

8

9

Length of wall between supports (m)

Length of wall between supports (m)

BORAL MASONRY DESIGN GUIDE

9

Height of wall between supports (m)

Height of wall between supports (m)

7

5

4

9

7

4

3

Laterally supported one end top free

SUPPORT

8

3

2

Structural Adequacy 60 – 120 minutes FRL

8

2

1

Length of wall between supports (m)

Leaf Thickness

1

190mm 140mm 110mm 90mm

2

9

9

0

Leaf Thickness

6

Length of wall between supports (m)

Structural Adequacy 60 – 120 minutes FRL

SUPPORT

9

Leaf Thickness

Height of wall between supports (m)

Height of wall between supports (m)

9

0

SUPPORT

Structural Adequacy 60 – 120 minutes FRL

SUPPORT

Laterally supported both ends and top

SUPPORT

SUPPORT

SUPPORT

Structural Adequacy 60 – 120 minutes FRL

SUPPORT

Structural Adequacy for 60-120 minutes Fire Resistant Level (FRL)

February 2009

C9

Victoria Book 1 C

Scoria Blend (SB) High Fire Rated Block -

Srf = 21.5

SUPPORT

Laterally supported both ends, top free

8

8

7

7

6 190mm 5 4

140mm

3

110mm 90mm

2 1 0 1

2

3

4

5

6

7

8

SUPPORT

Laterally supported one end and top

5 4 3 190mm 2

0 0

SUPPORT

6 190mm 5 4

140mm

3

110mm 90mm

2 1 0 6

Length of wall between supports (m)

C10

7

8

9

Height of wall between supports (m)

Height of wall between supports (m)

7

5

4

5

6

7

8

9

SUPPORT

9

7

4

3

Laterally supported one end top free

SUPPORT

8

3

2

Structural Adequacy 180 minutes FRL

8

2

1

Length of wall between supports (m)

Leaf Thickness

1

140mm 110mm 90mm

1

9

9

0

Leaf Thickness

6

Length of wall between supports (m)

Structural Adequacy 180 minutes FRL

SUPPORT

9

Leaf Thickness

Height of wall between supports (m)

Height of wall between supports (m)

9

0

SUPPORT

Structural Adequacy 180 minutes FRL

SUPPORT

Laterally supported both ends and top

SUPPORT

SUPPORT

SUPPORT

Structural Adequacy 180 minutes FRL

SUPPORT

Structural Adequacy for 180 minutes Fire Resistant Level (FRL)

Leaf Thickness

6 5 4 3 2 190mm 140mm 110mm 90mm

1 0 0

1

2

3

4

5

6

7

8

9

Length of wall between supports (m)

February 2009 | BORAL MASONRY DESIGN GUIDE

Victoria Book 1 C

Scoria Blend (SB) High Fire Rated Block -

Srf = 19.7

SUPPORT

Laterally supported both ends, top free

8

8

7

7

6

6

5

190mm

4

140mm

3

110mm 90mm

2 1 0 1

2

3

4

5

6

7

8

SUPPORT

Laterally supported one end and top

4 3 190mm 2

0 0

SUPPORT

6

6

190mm

5 4

140mm

3

110mm 90mm

2 1 0 6

7

8

|

5

6

7

8

9

SUPPORT

Leaf Thickness

5 4 3 2 190mm 140mm 110mm 90mm

1 0 0

1

2

3

4

5

6

7

8

9

Length of wall between supports (m)

Length of wall between supports (m)

BORAL MASONRY DESIGN GUIDE

9

Height of wall between supports (m)

Height of wall between supports (m)

7

5

4

9

7

4

3

Laterally supported one end top free

SUPPORT

8

3

2

Structural Adequacy 240 minutes FRL

8

2

1

Length of wall between supports (m)

Leaf Thickness

1

140mm 110mm 90mm

1

9

9

0

Leaf Thickness

5

Length of wall between supports (m)

Structural Adequacy 240 minutes FRL

SUPPORT

9

Leaf Thickness

Height of wall between supports (m)

Height of wall between supports (m)

9

0

SUPPORT

Structural Adequacy 240 minutes FRL

SUPPORT

Laterally supported both ends and top

SUPPORT

SUPPORT

SUPPORT

Structural Adequacy 240 minutes FRL

SUPPORT

Structural Adequacy for 240 minutes Fire Resistant Level (FRL)

February 2009

C11

Victoria Book 1 C

FireLight Quick Bricks (FL) -

Srf = 26.9

SUPPORT

Laterally supported both ends, top free

9

7

7

6

6

5

140mm

4

110mm 100mm 90mm

3 2 1 0 1

2

3

4

5

6

7

8

5 4 3

190mm

2

140mm 110mm 100mm 90mm

1 0 0

9

SUPPORT

Laterally supported one end and top

SUPPORT

7

7

6 190mm

5 4

140mm

3

110mm 100mm 90mm

2 1 0 4

5

6

Length of wall between supports (m)

C12

7

8

9

Height of wall between supports (m)

Height of wall between supports (m)

8

3

4

5

6

7

8

9

SUPPORT

9

8

2

3

Laterally supported one end, top free

SUPPORT

Leaf Thickness

1

2

Structural Adequacy 90 minutes FRL

9

0

1

Length of wall between supports (m)

Length of wall between supports (m)

Structural Adequacy 90 minutes FRL

Leaf Thickness

8

Height of wall between supports (m)

Height of wall between supports (m)

8

SUPPORT

9

Leaf Thickness 190mm

0

SUPPORT

Structural Adequacy 90 minutes FRL

SUPPORT

Laterally supported both ends and top

SUPPORT

SUPPORT

SUPPORT

Structural Adequacy 90 minutes FRL

SUPPORT

Structural Adequacy for 90 minutes Fire Resistant Level (FRL)

Leaf Thickness

6 5 4 3 2 190mm 140mm 110mm 90/100mm

1 0 0

1

2

3

4

5

6

7

8

9

Length of wall between supports (m)

February 2009 | BORAL MASONRY DESIGN GUIDE

Victoria Book 1 C

FireLight Quick Bricks (FL) -

Srf = 24.9

Structural Adequacy 120 minutes FRL

SUPPORT

Laterally supported both ends, top free

9

Leaf Thickness

8

7

7

190mm

6 5

140mm

4

110mm 100mm 90mm

3 2 1 0 1

2

3

4

5

6

7

8

6 5 4 3 190mm 2 1 0 0

9

SUPPORT

Laterally supported one end and top

SUPPORT

7

7

6 190mm 5 4

140mm

3

110mm 100mm 90mm

2 1 0 4

5

6

7

8

Length of wall between supports (m)

BORAL MASONRY DESIGN GUIDE

|

February 2009

9

Height of wall between supports (m)

8

3

4

5

6

7

8

9

SUPPORT

9

8

2

3

Laterally supported one end top free

SUPPORT

Leaf Thickness

1

2

Structural Adequacy 120 minutes FRL

9

0

1

Length of wall between supports (m)

Length of wall between supports (m)

Structural Adequacy 120 minutes FRL

140mm 110mm 100mm 90mm

SUPPORT

0

Height of wall between supports (m)

Height of wall between supports (m)

SUPPORT

9

Leaf Thickness

8

Height of wall between supports (m)

SUPPORT

Laterally supported both ends and top

SUPPORT

SUPPORT

SUPPORT

Structural Adequacy 120 minutes FRL

SUPPORT

Structural Adequacy for 120 minutes Fire Resistant Level (FRL)

Leaf Thickness

6 5 4 3 2 190mm 140mm 110mm 90/100mm

1 0 0

1

2

3

4

5

6

7

8

9

Length of wall between supports (m)

C13

Victoria Book 1 C

Ash Grey (AG)

(Basalt •45%)

Srf = 22.5

SUPPORT

Laterally supported both ends, top free

8

8

7

7

6

190mm

5 140mm

4

110mm

3

90mm

2 1 0 1

2

3

4

5

6

7

8

SUPPORT

Laterally supported one end and top

5 4 3

1 0 0

SUPPORT

6 190mm 5 4

140mm

3

110mm 90mm

2 1 0 6

Length of wall between supports (m)

C14

7

8

9

Height of wall between supports (m)

Height of wall between supports (m)

7

5

4

5

6

7

8

9

SUPPORT

9

7

4

3

Laterally supported one end, top free

SUPPORT

8

3

2

Structural Adequacy 60 minutes FRL

8

2

1

Length of wall between supports (m)

Leaf Thickness

1

190mm 140mm 110mm 90mm

2

9

9

0

Leaf Thickness

6

Length of wall between supports (m)

Structural Adequacy 60 minutes FRL

SUPPORT

9

Leaf Thickness

Height of wall between supports (m)

Height of wall between supports (m)

9

0

SUPPORT

Structural Adequacy 60 minutes FRL

SUPPORT

Laterally supported both ends and top

SUPPORT

SUPPORT

SUPPORT

Structural Adequacy 60 minutes FRL

SUPPORT

Structural Adequacy for 60 minutes Fire Resistant Level (FRL)

Leaf Thickness

6 5 4 3 2 190mm 140mm 110mm 90mm

1 0 0

1

2

3

4

5

6

7

8

9

Length of wall between supports (m)

February 2009 | BORAL MASONRY DESIGN GUIDE

Victoria Book 1 C

Ash Grey (AG)

(Basalt •45%)

Srf = 21.0

SUPPORT

Laterally supported both ends, top free

8

8

7

7

6

6

190mm 5 4

140mm

3

110mm 90mm

2 1 0 1

2

3

4

5

6

7

8

SUPPORT

Laterally supported one end and top

4 3

1 0 0

SUPPORT

6

6

190mm

5 4

140mm

3

110mm 90mm

2 1 0 6

7

8

|

5

6

7

8

9

SUPPORT

Leaf Thickness

5 4 3 2 190mm 140mm 110mm 90mm

1 0 0

1

2

3

4

5

6

7

8

9

Length of wall between supports (m)

Length of wall between supports (m)

BORAL MASONRY DESIGN GUIDE

9

Height of wall between supports (m)

Height of wall between supports (m)

7

5

4

9

7

4

3

Laterally supported one end, top free

SUPPORT

8

3

2

Structural Adequacy 90 minutes FRL

8

2

1

Length of wall between supports (m)

Leaf Thickness

1

190mm 140mm 110mm 90mm

2

9

9

0

Leaf Thickness

5

Length of wall between supports (m)

Structural Adequacy 90 minutes FRL

SUPPORT

9

Leaf Thickness

Height of wall between supports (m)

Height of wall between supports (m)

9

0

SUPPORT

Structural Adequacy 90 minutes FRL

SUPPORT

Laterally supported both ends and top

SUPPORT

SUPPORT

SUPPORT

Structural Adequacy 90 minutes FRL

SUPPORT

Structural Adequacy for 90 minutes Fire Resistant Level (FRL)

February 2009

C15

Victoria Book 1 C

Designer Block™

Srf = 18.0

SUPPORT

Laterally supported both ends, top free

8

8

7

7

6

6

5 190mm 4 140mm 3 110mm 90mm

2 1 0 1

2

3

4

5

6

7

8

SUPPORT

Laterally supported one end and top

4 3 2

0 0

SUPPORT

6

6

5 190mm 4 140mm 3 110mm 90mm

2 1 0 6

Length of wall between supports (m)

C16

7

8

9

Height of wall between supports (m)

Height of wall between supports (m)

7

5

4

5

6

7

8

9

SUPPORT

9

7

4

3

Laterally supported one end, top free

SUPPORT

8

3

2

Structural Adequacy 60 minutes FRL

8

2

1

Length of wall between supports (m)

Leaf Thickness

1

190mm 140mm 110mm 90mm

1

9

9

0

Leaf Thickness

5

Length of wall between supports (m)

Structural Adequacy 60 minutes FRL

SUPPORT

9

Leaf Thickness

Height of wall between supports (m)

Height of wall between supports (m)

9

0

SUPPORT

Structural Adequacy 60 minutes FRL

SUPPORT

Laterally supported both ends and top

SUPPORT

SUPPORT

SUPPORT

Structural Adequacy 60 minutes FRL

SUPPORT

Structural Adequacy for 60 minutes Fire Resistant Level (FRL)

Leaf Thickness

5 4 3 2 190mm 140mm 110mm 90mm

1 0 0

1

2

3

4

5

6

7

8

9

Length of wall between supports (m)

February 2009 | BORAL MASONRY DESIGN GUIDE

Victoria Book 1 C

Designer Block™

Srf = 17.0

SUPPORT

Laterally supported both ends, top free

8

8

7

7

6

6

5 190mm

4 3

140mm

2

110mm 90mm

1 0 1

2

3

4

5

6

7

8

SUPPORT

Laterally supported one end and top

4 3 2

0 0

SUPPORT

6

6

5 190mm

4 3

140mm

2

110mm 90mm

1 0 6

7

8

|

5

6

7

8

9

SUPPORT

Leaf Thickness

5 4 3 2 190mm 140mm 110mm 90mm

1 0 0

1

2

3

4

5

6

7

8

9

Length of wall between supports (m)

Length of wall between supports (m)

BORAL MASONRY DESIGN GUIDE

9

Height of wall between supports (m)

Height of wall between supports (m)

7

5

4

9

7

4

3

Laterally supported one end, top free

SUPPORT

8

3

2

Structural Adequacy 90 minutes FRL

8

2

1

Length of wall between supports (m)

Leaf Thickness

1

190mm 140mm 110mm 90mm

1

9

9

0

Leaf Thickness

5

Length of wall between supports (m)

Structural Adequacy 90 minutes FRL

SUPPORT

9

Leaf Thickness

Height of wall between supports (m)

Height of wall between supports (m)

9

0

SUPPORT

Structural Adequacy 90 minutes FRL

SUPPORT

Laterally supported both ends and top

SUPPORT

SUPPORT

SUPPORT

Structural Adequacy 90 minutes FRL

SUPPORT

Structural Adequacy for 90 minutes Fire Resistant Level (FRL)

February 2009

C17

Victoria Book 1 C

Walls Restrained at Top (Unrestrained Ends)

SUPPORT

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

SUPPORT Material

Thickness

Maximum Wall Height (metres) Structural Adequacy (FRL minutes) 90 120 180

60

Fire Rated Block - Scoria Blend (SB) & Scoria Quick Brick (SB)

FireLight Quick Brick (FL)

Ash Grey (AG)

Designer Block

Reinforced & Grout Filled*

240

90mm

2.430

2.430

2.430

2.430

2.364

110mm

2.970

2.970

2.970

2.970

2.889

140mm

3.780

3.780

3.780

3.780

3.677

190mm

5.130

5.130

5.130

5.130

4.991

110mm

2.970

2.970

2.970

2.970

2.970

90mm

2.430

2.430

2.400

2.160

2.040

110mm

2.970

2.970

2.933

2.640

2.493

140mm

3.780

3.780

3.733

3.360

3.173

190mm

5.130

5.130

5.067

4.560

4.307

90mm

2.160

2.040

1.920

1.860

1.800

140mm

3.360

3.173

2.987

2.893

2.800

190mm

4.560

4.307

4.053

3.927

3.800

140mm

5.040

5.040

5.040

5.040

5.040

190mm

6.840

6.840

6.840

6.840

6.840

*Governed by Robustness. Can be higher if supporting a slab. These heights can be exceeded when one or both ends are restrained as well as the top.

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

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

Structural Adequacy 60 – 240 minutes FRL

Structural Adequacy 60 – 240 minutes FRL

Single Steel reinforced

Single Steel reinforced and Core fill spacing

and fully grouted cores

Slab or broad footing

Maximum Wall Height (metres)

Lateral support at both ends

fully grouted bond beams

SUPPORT

Steel

Core Fill Spacing (metres)

Leaf Thickness (mm)

4.000

N12

Every 10th core — (2m)

5.040

N16

4.800

Slab or broad footing

Maximum Wall Length (metres)

140

Every 10th core — (2m)

N12

6.400 6.840

Bond beam spacing

SUPPORT

SUPPORT

SUPPORT

SUPPORT

Lateral support along top

Steel

Bond Beam Spacing (metres)

Leaf Thickness (mm)

4.000

N12

Every 10th course — (2m)

140

140

5.040

N16

Every 10th course — (2m)

140

Every 10th core — (2m)

190

4.800

N12

Every 10th course — (2m)

190

N16

Every 10th core — (2m)

190

6.400

N16

Every 10th course — (2m)

190

N16

Every 8th core — (1.6m)

190

6.840

N16

Every 8th course — (1.6m)

190

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

C18

February 2009 | BORAL MASONRY DESIGN GUIDE

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Masonry Design Guide STRUCTURAL, FIRE AND ACOUSTICS VICTORIA BOOK 1 D ACOUSTIC DESIGN

1

D

Victoria Book 1 D

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

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

Masonry with Plasterboard on Furring Channels

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

Furring channels are rollformed galvanised metal battens to which plasterboard can be fixed, using self tapping screws. Popular products include Rondo rollformed steel furring channel (N 129 which is 28mm deep) or (N 308 which is 16mm deep).

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

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

Masonry with Render

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

Impact Sound Resistance

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

D2

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

February 2009 | BORAL MASONRY DESIGN GUIDE

Victoria Book 1 D

Masonry with Plasterboard on Stud Framing

How loud is noise?

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

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

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

BORAL MASONRY DESIGN GUIDE

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February 2009

D3

Victoria Book 1 D

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

Structure-borne Noise & Weighted Normalised Impact Sound Pressure Level (L’n,w) When a building element is directly, or indirectly, impacted or vibrated then some of the energy passes through the partition and is re-radiated as noise to the room on the other side. This is called structure-borne noise or impact noise. For walls, the most common sources of structure-borne noise are: • Cupboard doors, fixed to party walls, being closed • Kitchen appliances being used on benches touching walls • Plumbing fittings, particularly taps, being connected to walls • Light switches being turned on and off, and • Dishwashers, washing machines, clothes dryers etc. touching walls Walls satisfy ‘impact’ or structure-borne noise isolation either by conforming to the ‘deemed to satisfy’ provisions of the Building Code of Australia ‘Impact Sound’ or ‘Test of Equivalence’, using a single number description for impact insulation or the Opinion of a suitably qualified acoustic engineer.

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

Sound Isolation Criteria From May 2004, the Building Code of Australia (BCA) specifications for minimum levels of sound isolation have been increased. These increased specifications are: • Unit to corridor or stairs

Rw • 50

• Unit to unit

Rw + Ctr • 50

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

Guidelines for Optimum Performance To achieve the optimum performance for a wall system, the exact construction as specified including perimeter sealing must be adopted.

The generally accepted test for impact is Weighted Normalised Impact Sound Pressure Level or L’n,w. In this method of interpreting impact sound resistance, lower values represent better impact insulation.

Any variations from the systems detailed in this guide should be approved by the project acoustic consultant as it can increase or decrease the acoustical isolation of wall systems.

Another single number description used for impact is the Impact Insulation Class or IIC. When used for walls it may be called WIIC for laboratory testing or WFIIC for field testing. Unfortunately, as there are different test methods used to obtain the impact rating for walls, results cannot always be directly compared.

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

The larger the value of the WIIC the better the impact insulation.

Noise Reduction Coefficient (NRC) Designers of theatres, music rooms and power transformer enclosures etc may often choose materials which have an efficient sound absorption value and incorporate them within the building design. The level of sound absorption for material is stated as the NRC (Noise Reduction Coefficient). This value is derived as a result of acoustic testing on the material, and determined by calculation from the average amount of sound energy absorbed over a range of frequencies between 250Hz and 2000Hz.

D4

Installation

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

February 2009 | BORAL MASONRY DESIGN GUIDE

Victoria Book 1 D

For a sealant to be effective at controlling noise passing through gaps, it must have the following properties. • Good flexibility, elastic set • Low hardness

IMPORTANT: The use of expanding foam sealants is not acceptable. Reference should be made to the manufacturer to ensure the particular type or grade of sealant is suitable for the purpose.

Noise Flanking

• Excellent adhesion, usually to concrete, timber, plaster and galvanised steel • Minimal shrinkage (less than 5%) • Moderate density (greater than 800kg/m3), and

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

• Fire rated where required (All walls required by the BCA to be sound rated also have fire ratings)

Typical flanking paths are shown in the Fig D1.

All of the above properties must be maintained over the useful life of the building, that is, greater than 20 years.

Acoustic Performance On-Site

Examples of a suitable sealant include: • Bostik Findley — Fireban One • Boral Plasterboard Fyreflex • Boral Plasterboard WR Sealant • Tremco synthetic rubber acoustical sealant • Some silicone sealants and • Some acrylic latex sealants

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

Through ventilation and service ducts

Through windows, doors, gaps and air leaks

Through ceilings and the above ceiling cavity

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

Through back to back cupboards Through light switches, or GPO's, located in the wall, poor sealing at penetrations

Through floors and the below floor crawl space Through shared building elements such as floor boards, floor joists, continuous plasterboard walls, continuous plasterboard ceilings, and even continuous concrete walls and floors

Fig D1 — Flanking Paths

BORAL MASONRY DESIGN GUIDE

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February 2009

D5

Victoria Book 1 D

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

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

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

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

Noise paths through vents or lightweight decorative panels

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

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

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

Noise paths through lightweight panel doors

Noise paths through vents

Noise paths through gaps

Fig D2 — Flanking Paths Fig D3 — Acoustic Performance Overview

D6

February 2009 | BORAL MASONRY DESIGN GUIDE

BORAL MASONRY

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Masonry Design Guide STRUCTURAL, FIRE AND ACOUSTICS VICTORIA BOOK 1 E FIRE AND ACOUSTIC SYSTEMS

1

E

Victoria Book 1 E

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

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

Finding Acoustic Systems & Technical Specifications Product Name Product Icons with dimensions for products available in your region/state

Product Introduction and Application Information

Product Specific Acoustic Test Results and Wall Lining System Information Product Identification

Victoria Book 1 E

1

E12 FireLight Quick Brick (FL)

162 162

110 110

INTRODUCTION INTRODUCTION Boral Boral Masonry Masonry Victoria Victoria is is constantly constantly developing developing new new and and innovative innovative products. FireLight Quick Brick products. FireLight Quick Brick (FL) (FL) utilises a unique low-density utilises a unique low-density blended blended which concrete concrete material material which provides provides high fire rated performance high fire rated performance together together with minimum with minimum weight. weight.

230 230

FireLight FireLight Quick Quick Brick Brick (FL) (FL)

FireLight FireLight Quick Quick Brick Brick is is ideal ideal for for non-loadbearing non-loadbearing applications applications such such as as walls walls in in concrete concrete framed framed office office buildings and high-rise buildings and high-rise home home units. units. FireLight Quick Brick is 230mm long FireLight Brick 230mm by 162mm Quick high, equal to 2iscourses of long by 162mm high, equal to 2 standard brick with mortar, making courses of standard brick them a highly efficient and with costmortar, making them a highly effective construction component. efficient and cost-effective construction component.

FIRE FIRE DESIGN DESIGN CONSIDERATIONS CONSIDERATIONS FireLight Quick Brick Brick is is aa fire FireLight Quick fire tested tested lightweight lightweight concrete concrete which which is is unique unique to to Boral, Boral, and and provides provides excellent excellent fire fire rating characteristics. rating characteristics. ACOUSTIC ACOUSTIC DESIGN DESIGN CONSIDERATIONS CONSIDERATIONS FireLight is not FireLight Quick Quick Brick Brick is not recommended for cement recommended for cement rendered rendered acoustic acoustic walls, walls, but but gives gives excellent excellent sound sound resistance resistance with with aa wide wide variety variety of tested board-lining board-liningsystems. systems. of tested The The 1st 1st test test on on page page E13 E13 qualifies qualifies for vent shafts shafts in in aa for walls walls enclosing enclosing vent 40. habitable room:RRww++CCtrtr••40. habitable room: The The 3rd 3rd test test qualifies qualifies for for unit-tounit-to50. corridor walls:RRw••50. corridor walls: w

The The 4th, 4th, 5th 5th and and 6th 6th tests tests qualify qualify for f o r unit-to-unit u n i t - t o - u n i t walls w a l l s where where +C • 50 and impact ratings R Rw w + Ctr tr • 50 and impact ratings are are required required and and can can also also be be used used in dry-to-dry,wet-to-dry wet-to-dryand and wetin dry-to-dry, wet-toto-wet areas. wet areas.

Availability information for your region/state

PAGE

Fire & Acoustic Systems

BOOK

PAGE

BOOK

Fire & Acoustic Systems

Victoria Book 1 E

1

E13

Acoustic Systems - 110mm Quickbrick Quickbrick FireLight FireLight (FL) (FL) ACOUSTIC ACOUSTIC RATING RATING Rw w (c, (c, ctr) ctr) R

WALL LINING LINING WALL

Boral Test Test Nº Nº Boral

45 45

(-1, -5) -5) (-1, T621-05s33 T621-05s33

47 47

(-1, -6) -6) (-1, T621-05s32 T621-05s32

51 51

(-2, -8) -8) (-2, T621-05s31 T621-05s31

60 60

(-3, -9) (-3, -9) T621-05s30 T621-05s30 ✓IIC ✓IIC

62 62

13mm Boral Boral Plasterboard Plasterboard daub daub fixed fixed •• 11 xx 13mm at 500mm 500mm centres. centres. at Suits vents vents in in habitable habitable rooms. rooms. •• Suits Rw ++ ctr ctr == 40 40 •• Rw

WALL LINING LINING WALL

126mm 126mm

13mm Boral Boral Plasterboard Plasterboard daub daub fixed fixed •• 11 xx 13mm at 500mm 500mm centres centres at

13mmBoral BoralPlasterboard Plasterboarddaub daubfixed fixed •• 11xx13mm at500mm 500mmcentres centres at 142mm 142mm

13mm Boral Boral Plasterboard Plasterboard daub daub fixed fixed •• 11 xx 13mm at 500mm 500mm centres centres at

13mmBoral BoralPlasterboard Plasterboardscrew screwfixed fixed •• 11xx13mm 28mmfurring furringchannel channelatat600mm 600mmcentres centres •• 28mm • Standard Clips

169mm • Standard Clips 169mm • Tontine TSB3 insulation in cavity

• Tontine TSB3 insulation in cavity

• 1 x 13mm Boral Plasterboard daub fixed • 1 x 13mm Boral Plasterboard daub fixed at 500mm centres at 500mm centres

• 1 x 13mm Boral Plasterboard • 1 x 13mm Boral Plasterboard • 70mm pine studs • 70mm pine studs • 20mm clear of masonry

Wall Cross section Icon and Overall System Thickness

229mm • 20mm clear of masonry 229mm • Tontine TSB6 insulation in cavity

• Tontine TSB6 insulation in cavity

(-4, -12) (-4, -12) Option based Option based on Test T621on Test T62105s25 05s25 ✓IIC ✓IIC

• • • • • • • •

1 x 13mm Boral Plasterboard 1 x 13mm Boral Plasterboard 28mm furring channel 28mm furring channel Standard clips Standard clips Tontine TSB3 in cavity Tontine TSB3 in cavity

63 63

• • • • • • • •

1 x 13mm Boral Plasterboard 1 x 13mm Boral Plasterboard 16mm furring channel 16mm furring channel Standard Clips Standard Clips TSB2 insulation in cavity TSB2 insulation in cavity

(-4, -11) (-4, -11) T621-05s29 T621-05s29 ✓IIC ✓IIC

110mm 110mm LIGHTWEIGHT LIGHTWEIGHT QUICK BRICK BRICK (FL) (FL) QUICK

• • • • • 250mm • 250mm • •

1 x 13mm Boral Plasterboard 1 x 13mm Boral Plasterboard 64mm metal studs 64mm metal studs 20mm clear of masonry 20mm clear of masonry Tontine TSB6 in cavity Tontine TSB6 in cavity

• 1 x 13mm Boral Plasterboard • 1 x 13mm Boral Plasterboard • 70mm pine studs • 70mm pine studs • 20mm clear of masonry

244mm • 20mm clear of masonry 244mm • Tontine TSB6 insulation in cavity

• Tontine TSB6 insulation in cavity

Availability Availability

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

Specifications Specifications Rw (Estimate or *Tested) ‡ Maximum Slenderness Ratio (Srf) Rw (Estimate or *Tested) ‡ Maximum Slenderness Ratio (Srf) With Lining System Nº Nº Insulation (minutes) With Lining System Nº Nº Insulation (minutes) FRL (minutes) per per ① ⑤ ➅ ⑥ FRL (minutes) per per ① ② ② ③ ③ ④ ④ ➄ m22 Pallet 60 90 120 180 240 ✓IIC m Pallet 60 90 120 180 240 ✓IIC 24.2 250 29 26.9 24.9 22.2 20.3 — 47 54 58 56 60 24.2 250 29 26.9 24.9 22.2 20.3 — 47 54 58 56 60 120 120 ① ② ③ ④ ⑤ ⑥ Refer to Lining Systems on Page E3. ✓IIC = Complies with BCA requirement for Impact Sound Resistance. ① ② ③ ④ ⑤ ⑥ Refer to Lining Systems on Page E3. ✓IIC = Complies with BCA requirement for Impact Sound Resistance. ‡ = Quantity may vary from plant to plant. ‡ = Quantity may vary from plant to plant. Product Product Code TxLxH (mm) Code TxLxH (mm) FireLight 110x230x162 FireLight 110x230x162 Quick Brick (FL) Quick Brick (FL)

E12

ƒ ’ uc ƒ’ uc MPa MPa 3 3

Unit Unit Wt Wt kg kg 4.5 4.5

February 2009 | BORAL MASONRY DESIGN GUIDE

Fire Performance Data

Acoustic Performance Data

IMPACT SOUND RESISTANCE ✓IIC = Systems comply with BCA requirements for IMPACT SOUND RESISTANCE. IMPACT SOUND RESISTANCE ✓IIC = Systems comply with BCA requirements for IMPACT SOUND RESISTANCE.

BORAL MASONRY DESIGN GUIDE

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February 2009

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

E13

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

Product Specifications

E2

February 2009 | BORAL MASONRY DESIGN GUIDE

Victoria Book 1 E

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

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

WALL LINING

Refer to product pages

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

BORAL MASONRY BRICK OR BLOCK

WALL LINING

As per product pages

①

• 13mm Render

②

Masonry Thickness +26mm

• 1 x 13mm Boral Plasterboard daub fixed

③

Masonry Thickness +32mm

• 1 x 13mm Boral Plasterboard daub fixed

④

Masonry Thickness +71mm Masonry Thickness +84mm or +77mm

• 1 x 13mm Boral Plasterboard daub fixed

• 13mm Render

• 1 x 13mm Boral Plasterboard daub fixed

• • • •

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

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

⑤

• • • •

1 x 13mm Boral Plasterboard screw fixed 28mm furring channel at 600mm centres Standard Clips at 1200mm centres Tontine TSB2 insulation in cavity

Masonry Thickness +98mm

• • • •

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

⑥

• • • •

1 x 13mm Boral Plasterboard screw fixed 28mm furring channel at 600mm centres Standard Clips at 1200mm cts Tontine TSB2 insulation in cavity

• • • Masonry Thickness •

1 x 13mm Boral Plasterboard screw fixed 51mm steel studs at 600mm centres 20mm gap Tontine TSB5 insulation in cavity

Acousti

+127mm

c Estim ate

s with these L ining

System

s

Fire & Acoustic Systems

PAGE

BOOK

Victoria Book 1 E

1

E4

Fire Rated Rated Block Block -- Scoria Scoria Blend Blend (SB) (SB) Fire Series 100, 100, 120, 120, 150 150 & & 200 200 Series INTRODUCTION INTRODUCTION Fire Rated Rated Block Block (SB) (SB) is is manufactured manufactured Fire from aa scoria-blend scoria-blend material material which which from reduces the the block block weight weight and and increases increases reduces the fire fire performance performance characteristics. characteristics. the Fire Rated Rated Block Block (SB) (SB) is is ideal ideal for for nonnonFire loadbearing walls walls of of commercial, commercial, loadbearing industrial and and high-rise high-rise buildings buildings industrial with concrete concrete and and portal portal framed framed with structures. structures. Fire Rated Rated Block Block (SB) (SB) is is also also suitable suitable Fire for loadbearing loadbearing walls, walls, however however the the S Srf rf for values from from Designer Designer Block Block masonry masonry values units apply. apply. Refer Refer to to Section Section C C of of this this units guide for for more more information. information. guide

Fire Rated Rated Block Block (SB) (SB) is is manufactured manufactured Fire in 90, 90, 110, 110, 140 140 and and 190mm 190mm thicknesses thicknesses in to suit suit most most types types of of fire fire and/or and/or acoustic acoustic to wall construction. construction. wall FIRE DESIGN DESIGN CONSIDERATIONS CONSIDERATIONS FIRE Fire Rated Rated Block Block (SB) (SB) utilises utilises aa Fire unique scoria-blend scoria-blend material, material, which which unique has been been shown shown through through fire fire testing testing has to provide provide excellent excellent fire fire insulation insulation to characteristics. characteristics. Please refer refer to to the the fire fire performance performance Please characteristics in in the the specifications specifications characteristics table. table.

Availability Availability

ACOUSTIC DESIGN DESIGN ACOUSTIC CONSIDERATIONS CONSIDERATIONS Fire Rated Rated Block Block (SB) (SB) provides provides excellent excellent Fire sound resistance resistance with with aa wide wide variety variety of of sound board-lining systems. systems. board-lining Please refer refer to to the the acoustic acoustic performance performance Please characteristics in in the the specifications specifications characteristics table. table. FRACTIONAL SIZE SIZE BLOCKS BLOCKS FRACTIONAL Boral Masonry Masonry Victoria Victoria manufactures manufactures Boral an extensive extensive range range of of special special purpose purpose an blocks and and fractional fractional size size blocks blocks to to blocks complement the the products products detailed detailed on on complement this page. Please refer to the the Boral Boral this page. Please refer to Block & & Brick Brick Guide Guide (MDG (MDG Book Book 2) 2) for for Block additional information. information. additional

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

Specifications Specifications Product Product Code Code

ƒ’’ uc ƒ uc MPa MPa 8 8

Unit Unit Wt Wt kg kg

Nº Nº per per m22 m

13.1 13.1

25 25

Rw (Estimate (Estimate or or *Tested) *Tested) Maximum Slenderness Slenderness Ratio Ratio (S (Srf)) ‡ Maximum R w rf ‡ With Lining Lining System System Insulation (minutes) (minutes) Nº With Insulation Nº FRL (minutes) (minutes) per ① ② ② ③ ③ ④ ④ ⑤ ⑤ ⑥ ⑥ FRL per ① Pallet 60 60 90 120 180 180 240 240 ✓IIC Pallet 90 120 ✓IIC 139 22.6 22.6 22.6 22.6 22.6 22.6 21.5 21.5 19.7 19.7 46 46 48 48 53 53 58 58 56 56 59 59 139 180 180

10.331 10.331

Type Type Full Solid Solid Full

10.383 10.383

Half Height Height Half

12.401 12.401

Full Cored Cored Full

8 8

12.5 12.5

12.5 12.5

120 120

22.6 22.6

21.5 21.5

19.7 19.7

45 45

46 46

50 50

55 55

53 53

56 56

15.01SC 15.01SC

Full Hollow Hollow Full

8 8

11.1 11.1

12.5 12.5

120 120

22.6 22.6

22.6 22.6 120 120

22.6 22.6

21.5 21.5

19.7 19.7

46 46

47 47

52 52

57 57

55 55

58 58

15.301 15.301

Full Hollow Hollow Full

8 8

12.6 12.6

12.5 12.5

120 120

22.6 22.6

22.6 22.6 22.6 22.6 180 180

21.5 21.5

19.7 19.7

48 48

49 49

54 54

59 59

57 57

60 60

15.401 15.401

Full Hollow Hollow Full

8 8

14.3 14.3

12.5 12.5

120 120

21.5 21.5

19.7 19.7

15.483 15.483

Half Height Height Half

8 8

9.3 9.3

25 25

192 192

22.6 22.6

22.6 22.6

22.6 22.6

21.5 21.5

19.7 19.7

48 48

49 49

54 54

59 59

57 57

60 60

20.401 20.401

Full Hollow Hollow Full

8 8

15.3 15.3

12.5 12.5

90 90

22.6 22.6

22.6 22.6

240 240 22.6 22.6 240 240

21.5 21.5

19.7 19.7

48 48

49 49

54 54

59 59

57 57

60 60

8 8

6.0 6.0

12.5 12.5

234 234

22.6 22.6

22.6 22.6

22.6 22.6

22.6 22.6

180 180 22.6 22.6 22.6 22.6 240 240

22.6 22.6

22.6 22.6 240 240

21.5 21.5

19.7 19.7

46 46

48 48

48 48

49 49

53 53

54 54

58 58

59 59

56 56

57 57

59 59

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

60 60

Refer to to Lining Lining Systems Systems on on Page Page E3. E3. ①② ②③ ③④ ④⑤ ⑤⑥ ⑥ Refer ①

✓IIC == Complies Complies with with BCA BCA requirement requirement for for Impact Impact Sound Sound Resistance. Resistance. ✓IIC ‡ == Quantity Quantity may may vary vary from from plant plant to to plant. plant. ‡

E4

February 2009 | BORAL MASONRY DESIGN GUIDE

BORAL MASONRY DESIGN GUIDE

|

February 2009

E3

Victoria Book 1 E

Fire Rated Block - Scoria Blend (SB) Series 100, 120, 150 & 200 INTRODUCTION Fire Rated Block (SB) is manufactured from a scoria-blend material which reduces the block weight and increases the fire performance characteristics. Fire Rated Block (SB) is ideal for nonloadbearing walls of commercial, industrial and high-rise buildings with concrete and portal framed structures. Fire Rated Block (SB) is also suitable for loadbearing walls, however the Srf values from Designer Block masonry units apply. Refer to Section C of this guide for more information.

Fire Rated Block (SB) is manufactured in 90, 110, 140 and 190mm thicknesses to suit most types of fire and/or acoustic wall construction. FIRE DESIGN CONSIDERATIONS Fire Rated Block (SB) utilises a unique scoria-blend material, which has been shown through fire testing to provide excellent fire insulation characteristics. Please refer to the fire performance characteristics in the specifications table.

Availability

ACOUSTIC DESIGN CONSIDERATIONS Fire Rated Block (SB) provides excellent sound resistance with a wide variety of board-lining systems. Please refer to the acoustic performance characteristics in the specifications table. FRACTIONAL SIZE BLOCKS Boral Masonry Victoria manufactures an extensive range of special purpose blocks and fractional size blocks to complement the products detailed on this page. Please refer to the Boral Block & Brick Guide (MDG Book 2) for additional information.

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

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

ƒ ’ uc MPa

Unit Wt kg

Nº per m2

Full Solid

8

13.1

25

139

22.6

22.6

Half Height

8

6.0

12.5

234

22.6

22.6

Product Code

Type

10.331 10.383

22.6

Rw (Estimate or *Tested) With Lining System

①

②

③

④

⑤

⑥ ✓IIC

21.5

19.7

46

48

53

58

56

59

21.5

19.7

46

48

53

58

56

59

21.5

19.7

45

46

50

55

53

56

22.6

21.5

19.7

46

47

52

57

55

58

22.6

21.5

19.7

48

49

54

59

57

60

21.5

19.7

48

49

54

59

57

60

21.5

19.7

48

49

54

59

57

60

21.5

19.7

48

49

54

59

57

60

180 22.6

180 12.401

Full Cored

8

12.5

12.5

120

22.6

22.6

22.6 240

15.01SC

Full Hollow

8

11.1

12.5

120

22.6

22.6

15.301

Full Hollow

8

12.6

12.5

120

22.6

22.6

15.401

Full Hollow

8

14.3

12.5

120

22.6

22.6

120 180 22.6 240 15.483

Half Height

8

9.3

25

192

22.6

22.6

22.6 240

20.401

Full Hollow

8

15.3

12.5

90

22.6

22.6

22.6 240

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

✓IIC = Complies with BCA requirement for Impact Sound Resistance. ‡ = Quantity may vary from plant to plant.

E4

February 2009 | BORAL MASONRY DESIGN GUIDE

Victoria Book 1 E

Fire Rated Block - Scoria Blend (SB) Series 100 Full Height Solid

Series 120 Half Height Solid

Full Height

190

190 90

90

390

390

90

12.401 Full (1 in every 5 blocks is universal solid)

10.383 Half Height

10.331 Full Solid

390

110

Series 150 Full Height

Full Height

Thick Wall

190

140

390

190

190

390

140

15.01SC Full

Half Height Solid

140

15.401 Full

15.301 Full

390

90

140

390

15.483 Half Height

Series 200 Full Height

190

190

390

20.401 Full

BORAL MASONRY DESIGN GUIDE

|

February 2009

E5

Victoria Book 1 E

Ash Grey Block (AG) Standard & Core Fill INTRODUCTION Boral Ash Grey (AG) blocks have been an integral part of Australia’s construction industry for more than 3 decades, and continue to provide cost effective, practical and engineered solutions for the full spectrum of construction applications. All ‘Standard Ash Grey Block (AG)’ and ‘Core Fill Block’ products are manufactured to AS/NZS4455 ‘Masonry units and segmental pavers 1997’ using modern high pressure moulding techniques and controlled dense-weight concrete materials. All Standard Ash Grey (AG) blocks have inherent fire and acoustic performance properties which automatically allocates them ‘deemed-to-satisfy’ values for

fire performance, and known acoustic performance values which will satisfy many common BCA requirements. Standard Ash Grey (AG) blocks are manufactured in 90, 110, 140, 190, and 290mm thicknesses to suit most wall construction applications. FIRE DESIGN CONSIDERATIONS The fire resistance performance of Boral concrete blocks is determined as per AS3700 : 2001 Section 6. These products can provide adequate fire performance for many common fire rated wall applications. Please also refer to fire performance graphs and design information in Sections A and B of this guide for additional selection information.

Availability • Please refer to the Boral Masonry Blocks & Bricks Guide (MDG Book 2) for detailed availability information on these products.

ACOUSTIC DESIGN CONSIDERATIONS Standard Ash Grey (AG) being of a relatively dense material provide inherent sound resistance. This performance may be sufficient for many applications without enhancement. Where higher performance is required, the addition of render is effective while board-lining systems using furring systems and Boral Impact Clips or plasterboard on light-weight studs and polyester insulation materials can provide high acoustic insulation. Please refer to acoustic test/ estimate data for appropriate systems. FRACTIONAL SIZE BLOCKS Boral Masonry Victoria manufactures an extensive range of special purpose blocks and fractional size blocks to complement the products detailed on this page.

Specifications ƒ ’ uc MPa

Unit Wt kg

Nº per m2

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

Product Code

Type

10.01 10.201 10.31

Full Hollow Full Hollow Solid

10 10 10

11.6 10.1 14.3

12.5 14.5 12.5

149 172 139

22.5

21

60 60

① ①

12.01

Full Hollow

10

14.0

12.5

120

22.5

21

20

21

20

18

17

Rw (Estimate or *Tested) With Lining System

①

②

③

④

⑤

⑥ ✓IIC

46

46

52

57

55

58

47

47

53

58

56

59

18

17

46

46

52

57

55

58

20

18

17

47

47

53

58

56

59

21

20

18

17

48

48

54

59

57

60

36.0

53

51

58

63

61

64

①

90 15.01 15.201

Full Hollow Full Hollow

10 10

13.0 11.0

12.5 14.5

120 120

22.5

20.01

Full Hollow

10

15.9

12.5

90

22.5

15.48

Core Filled & reinforced

15

13.9

12.5

120

36.0

36.0

36.0

36.0

20.48

Core Filled & reinforced

15

14.7

12.5

90

36.0

120 36.0

36.0

36.0

36.0

56

55

62

67

65

68

Core Filled & reinforced

15

36.0

240 36.0

36.0

36.0

59

59

66

71

69

72

60 90

30.48

18.3

12.5

60

36.0

①

240

① ② ③ ④ ⑤ ⑥ Refer to Lining Systems on Page E3. ✓IIC = Complies with BCA requirement for Impact Sound Resistance. ① Additional Insulation with ① Lining System (13mm render both sides). ‡ = Quantity may vary from plant to plant. E6

February 2009 | BORAL MASONRY DESIGN GUIDE

Victoria Book 1 E

Ash Grey Block (AG) Standard & Core Fill Series 100 Full Height

Series 120 Back-up

Full Height Solid

190

190

162

390

390

Full Height

90

390

90

90

10.01 Full

10.201 Full

10.31 Full Solid

Back-up

Core Fill Block

190

110

390

12.01 Full (1 in every 5 blocks is universal solid)

Series 150 Full Height

190

190

162

140

390

390

140

15.01 Full

140

15.201 Full

390

15.48 ‘H’ Block

Series 200 Full Height

Core Fill Block

190

190

390

190

390

190

20.01 Full

20.48 ‘H’ Block

Series 300 Core Fill Block

190

290

390

30.48 ‘H’ Block

BORAL MASONRY DESIGN GUIDE

|

February 2009

E7

Victoria Book 1 E

Concrete-Basalt (B) Bricks INTRODUCTION Boral Masonry Victoria Concrete-Basalt Bricks have an ƒ’uc of 12MPa, making them excellent for loadbearing or nonloadbearing applications. They provide good fire performance and acoustic performance characteristics where minimising weight is not a primary consideration. Concrete-Basalt Bricks are a popular choice for walls in domestic applications and high-rise units where they are commonly used with a rendered finish. They are also commonly used for loadbearing walls in 3-storey unit construction with plasterboard or render finish.

BORAL CONCRETE-BASALT QUICK BRICK Quick Brick (Victoria only) is 230mm long by 162mm high, equal to 2 courses of standard brick with mortar, making them a highly efficient and costeffective construction component. FIRE DESIGN CONSIDERATIONS These products are manufactured from a Concrete-Basalt blend which provides good fire performance characteristics in loadbearing conditions. Please refer to the fire performance characteristics in the specifications table.

ACOUSTIC DESIGN CONSIDERATIONS The mass of the Concrete-Basalt material is 7% heavier than Clay therefore walls from Concrete-Basalt products perform slightly better. Its texture is coarser and its porosity is higher than Clay, so it performs better with plasterboard, particularly when daub-fixed. Please refer to acoustic test/estimate data in this guide for appropriate systems.

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

Specifications Unit Wt kg

Nº per m2

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

Product Code

TxLxH (mm)

ƒ ’ uc MPa

B1 Brick

110x230x76

12

3.8

48.4

450

22.5

Quick Brick 110x230x162 Cored

12

7.9

24.2

250

22.5

Quick Brick 110x230x162 Solid

12

8.9

24.2

200

22.5

21.0

20.0

21.0

20.0

21.0

20.0

Rw (Estimate or *Tested) With Lining System

①

②

③

④

⑤

⑥ ✓IIC

18.0

17.0

48

46

51

59

57

60

18.0

17.0

48

46

51*

59

57

60

18.0

17.0

48

46

51

59

57

60

①

90

①

90 90

① ② ③④⑤⑥ ① Additional Insulation with ① Lining System (13mm render both sides).

①

Refer to Lining Systems on Page E3. ✓IIC = Complies with BCA requirement for Impact Sound Resistance.

E8

‡ = Quantity may vary from plant to plant.

February 2009 | BORAL MASONRY DESIGN GUIDE

Victoria Book 1 E

Concrete-Basalt (B) Bricks 162

162

76 230

110

110

Brick (B1)

230

Quick Brick (B) Cored

110

230

Quick Brick (B) Solid

(1 in every 7 bricks supplied is solid for corner applications)

Acoustic Systems - Quick Brick (B) ACOUSTIC RATING Rw (c, ctr)

WALL LINING

Boral Test Nº

110mm QUICK BRICK (B) (CORED)

WALL LINING

46 • 1 x 13mm Boral Plasterboard daub fixed

• 1 x 13mm Boral Plasterboard daub fixed Opinion 142mm

48 • 13mm Render

• 13mm Render Opinion 136mm

49 (-2, -8) RMIT 1211/705

• 1 x 13mm Boral Plasterboard screw fixed • 28mm furring channel at 600mm centres • Boral Impact Clips at 1200mm centres

• 1 x 13mm Boral Plasterboard daub fixed 181mm

51 (-3, -9) RMIT 1211/706

52 (-5, -12) RMIT 1211/708

57 (-4, -11) RMIT 1211/707

• 1 x 13mm Boral Plasterboard daub fixed 172mm

• • • •

1 x 13mm Boral Plasterboard screw fixed 28mm furring channel at 600mm centres Boral Impact Clips at 1200mm centres 38mm Glasswool insulation in cavity

• 1 x 13mm Boral Plasterboard screw fixed • 28mm furring channel at 600mm centres • Boral Impact Clips at 1200mm centres

• 1 x 13mm Boral Plasterboard screw fixed • 28mm furring channel at 600mm centres • Boral Impact Clips at 1200mm centres 220mm

• • • •

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

220mm

• • • •

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

IMPACT SOUND RESISTANCE ✓IIC = Systems comply with BCA requirements for IMPACT SOUND RESISTANCE.

BORAL MASONRY DESIGN GUIDE

|

February 2009

E9

Victoria Book 1 E

Scoria Quick Brick (SB)

162

110

INTRODUCTION Boral Masonry Victoria is constantly developing new and innovative products. Scoria Quick Brick (SB) utilises a unique low-density blended concrete material which provides high fire rated performance together with minimum weight.

230

Scoria Quick Brick (SB)

Scoria Quick Brick is ideal for nonloadbearing applications such as walls in concrete framed office buildings and high-rise home units. Scoria Quick Brick is 230mm long by 162mm high, equal to 2 courses of standard brick with mortar, making them a highly efficient and cost-effective construction component.

FIRE DESIGN CONSIDERATIONS Scoria Quick Brick is a fire tested lightweight concrete which is unique to Boral, and provides excellent fire rating characteristics. ACOUSTIC DESIGN CONSIDERATIONS Scoria Quick Brick is not recommended for cement rendered acoustic walls, but gives excellent sound resistance with a wide variety of tested board-lining systems. The 2nd test on page E11 qualifies for walls enclosing vent shafts in a habitable room: Rw + Ctr • 40. The 3rd test qualifies for unit-tocorridor walls: Rw • 50. The 4th and 5th tests qualify for unitto-unit walls where Rw + Ctr • 50 and impact ratings are required.

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

Specifications Product Code

TxLxH (mm)

Scoria 110x230x162 Quick Brick (SB)

ƒ ’ uc MPa

Unit Wt kg

Nº per m2

5

5.9

24.2

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

‡ Maximum Slenderness Ratio (Srf) Nº Insulation (minutes) FRL (minutes) per Pallet 60 90 120 180 240 250

22.6

22.6

22.6

21.5

19.7

Rw (Estimate or *Tested) With Lining System

①

②

③

④

⑤

⑥ ✓IIC

47

48*

56

59

57

60

240 ✓IIC = Complies with BCA requirement for Impact Sound Resistance.

‡ = Quantity may vary from plant to plant.

E10

February 2009 | BORAL MASONRY DESIGN GUIDE

Victoria Book 1 E

Acoustic Systems - Scoria Quick Brick (SB) ACOUSTIC RATING Rw (c, ctr)

WALL LINING

48

110mm QUICK BRICK (SB)

• 1 x 13mm Boral Plasterboard daub fixed at 500mm centres

(-1, -6) T621-05S22

WALL LINING

• 1 x 13mm Boral Plasterboard daub fixed at 500mm centres 142mm

47 (-1, -6) T621-05S21

• 1 x 13mm Boral Plasterboard daub fixed at 500mm centres one side only

• Bare Wall (vent) 126mm

55 (-4, -10) T621-05S20

• • • •

• 1 x 13mm Boral Plasterboard daub fixed at 500mm centres

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

169mm

61 (-4, -11) T621-05S19 ✓IIC

62 (-4, -10) T621-05S17 ✓IIC

• 1 x 13mm Boral Plasterboard daub fixed at 500mm centres

• • • •

• 1 x 13mm Wet Area Boral Plasterboard screw fixed to 70mm pine studs 20mm clear of masonry • Tontine TSB6 insulation in cavity 229mm

1 x 13mm Boral Plasterboard screw fixed 28mm furring channel at 600mm centres Standard Clips at 1200mm centres Tontine TSB2 insulation in cavity

• 1 x 13mm Boral Plasterboard screw fixed to 70mm pine studs 20mm clear of masonry • Tontine TSB6 insulation in cavity 256mm

IMPACT SOUND RESISTANCE ✓IIC = Systems comply with BCA requirements for IMPACT SOUND RESISTANCE.

BORAL MASONRY DESIGN GUIDE

|

February 2009

E11

Victoria Book 1 E

FireLight Quick Brick (FL)

162

110

230

FireLight Quick Brick (FL)

INTRODUCTION Boral Masonry Victoria is constantly developing new and innovative products. FireLight Quick Brick (FL) utilises a unique low-density blended concrete material which provides high fire rated performance together with minimum weight.

FIRE DESIGN CONSIDERATIONS

FireLight Quick Brick is ideal for non-loadbearing applications such as walls in concrete framed office buildings and high-rise home units.

FireLight Quick Brick is not recommended for cement rendered acoustic walls, but gives excellent sound resistance with a wide variety of tested board-lining systems.

FireLight Quick Brick is 230mm long by 162mm high, equal to 2 courses of standard brick with mortar, making them a highly efficient and costeffective construction component.

FireLight Quick Brick is a fire tested lightweight concrete which is unique to Boral, and provides excellent fire rating characteristics.

ACOUSTIC DESIGN CONSIDERATIONS

The 1st test on page E13 qualifies for walls enclosing vent shafts in a habitable room: Rw + Ctr • 40. The 3rd test qualifies for unit-tocorridor walls: Rw • 50. The 4th, 5th and 6th tests qualify for unit-to-unit walls where Rw + Ctr • 50 and impact ratings are required and can also be used in dry-to-dry, wet-to-dry and wet-towet areas.

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

Specifications Product Code

TxLxH (mm)

FireLight 110x230x162 Quick Brick (FL)

ƒ ’ uc MPa

Unit Wt kg

Nº per m2

3

4.5

24.2

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

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

250

29

26.9

24.9

22.2

20.3

Rw (Estimate or *Tested) With Lining System

①

②

③

④

➄

➅ ✓IIC

—

47

54

58

56

60

120 ✓IIC = Complies with BCA requirement for Impact Sound Resistance.

‡ = Quantity may vary from plant to plant.

E12

February 2009 | BORAL MASONRY DESIGN GUIDE

Victoria Book 1 E

Acoustic Systems - 110mm Quickbrick FireLight (FL) ACOUSTIC RATING Rw (c, ctr)

WALL LINING

Boral Test Nº

45 (-1, -5) T621-05s33

47 (-1, -6) T621-05s32

51 (-2, -8) T621-05s31

• 1 x 13mm Boral Plasterboard daub fixed at 500mm centres. • Suits vents in habitable rooms. • Rw + ctr = 40

110mm LIGHTWEIGHT QUICK BRICK (FL)

126mm

• 1 x 13mm Boral Plasterboard daub fixed at 500mm centres

• 1 x 13mm Boral Plasterboard daub fixed at 500mm centres 142mm

• 1 x 13mm Boral Plasterboard daub fixed at 500mm centres

• • • 169mm •

• 1 x 13mm Boral Plasterboard daub fixed at 500mm centres

• • • •

60 (-3, -9) T621-05s30 ✓IIC

62 (-4, -12) Option based on Test T62105s25 ✓IIC

• • • •

1 x 13mm Boral Plasterboard 28mm furring channel Standard clips Tontine TSB3 in cavity

63

• • • •

1 x 13mm Boral Plasterboard 16mm furring channel Standard Clips TSB2 insulation in cavity

(-4, -11) T621-05s29 ✓IIC

WALL LINING

229mm

1 x 13mm Boral Plasterboard screw fixed 28mm furring channel at 600mm centres Standard Clips Tontine TSB3 insulation in cavity 1 x 13mm Boral Plasterboard 70mm pine studs 20mm clear of masonry Tontine TSB6 insulation in cavity

• • • 250mm •

1 x 13mm Boral Plasterboard 64mm metal studs 20mm clear of masonry Tontine TSB6 in cavity

• • • 244mm •

1 x 13mm Boral Plasterboard 70mm pine studs 20mm clear of masonry Tontine TSB6 insulation in cavity

IMPACT SOUND RESISTANCE ✓IIC = Systems comply with BCA requirements for IMPACT SOUND RESISTANCE.

BORAL MASONRY DESIGN GUIDE

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February 2009

E13

Victoria Book 1 E

Acousticell™ 190

INTRODUCTION Boral Acousticell is a purpose designed block which combines excellent acoustic absorption and sound transmission loss characteristics. Boral Acousticell has been successfully integrated into a wide variety of industrial and commercial acoustic applications, providing both acoustic performance and unique and attractive aesthetic qualities.

390 140

Acousticell Full

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

Availability • • • •

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

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

Essential Colours

Alabaster

Almond

Pearl Grey

Charcoal

Natural Grey

SOUND ABSORPTION Boral Acousticell blocks combine the high transmission loss characteristics generally associated with a dense, non-porous material (concrete block) with efficient absorption of sound, resulting in a very low radiated sound level and effective control of both high frequencies and troublesome low frequency noise. Boral Acousticell blocks provide maximum absorption in the frequency range of 80Hz to 500Hz, peaking at 1.0 at 200Hz and providing absorption of 0.6 at 100Hz. Where high frequency noise is to be absorbed, fibreglass insulation pads can be inserted into the ‘Helm-Holtz’ cells. In this case, absorption of low frequency noise drops slightly, but absorption of other frequencies improves. (Note: Fibreglass is not suitable for external use. Carbon fibre pads are more suitable in external situations). Refer to accompanying absorption graph for application results. COLOURS Boral Acousticell Block is ‘Madeto-Order’ and can therefore be manufactured in any of the Boral Designerblock colours. Minimum order quantities apply to all colours.

Accent Colours

Sandune

Rust E14

Paperbark

Wilderness

Terrain

Midway

Specifications Code

Product Description

150mm

Acousticell Full

MPa

Wt kg

N /Pallet

10

14.0

120

February 2009 | BORAL MASONRY DESIGN GUIDE

Victoria Book 1 E

Acousticell™ Acoustic Performance Sound Transmission Loss for Acousticell is similar to standard dense-weight concrete masonry. Refer to Fig E1. Rw Contour Line Acousticell Test Results

50

Before construction of Boral Acousticell enclosure

40

After construction of Boral Acousticell enclosure 30

70

20 60 10 0

125

250

1K

500

2K

5K

Centre Frequency of Octave Band (Hz)

Fig E1 — Sound Transmission Characteristics of Boral Acousticell Block

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

Sound pressure level in dB

Sound Transmission Loss (dB)

60

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

50

40

30

20

10 4

8

16 31.5 63 125 250 500 1K

2K

4K

8K 16K 32K

Octave band centre frequency Hz (CPS)

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

Sound Absorption

0.9

0.7 0.6 0.5 0.4 0.3 0.2

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

0.1 4

COMMENTS ON THE RESULTS. The measurement results show a dramatic reduction in noise level from the transformers, especially under conditions when the internal cooling fans, together with secondary ventilation fans fitted into the enclosure were operating. The result is a situation where there is now negligible annoyance to surrounding residences from the transformers. Previously the level of low frequency noise was such that special double glazing of both doors and windows would have been necessary to achieve acceptable community noise levels.

0.8

0

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

8

16

31.5

63

125

250

500

1K

2K

4K

8K

1/3 Octave Band Centre Frequency Hz (CPS)

Fig E2 — Sound Absorption Characteristics of Boral Acousticell Block

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

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February 2009

E15

eBC 04021 February 2009

Customer Support New South Wales 1. Stock colours Colours other than stock colours are made to order. Not all colours displayed in this brochure are available in all states. (Contact your nearest Boral Masonry office for your area’s stock colours.) A surcharge applies to orders less than the set minimum quantity. 2. Brochure colours The printed colours in this Masonry Design Guide are only a guide. Please ask to see a sample of your colour/texture before specifying or ordering. 3. Colour and texture variation The supply of raw materials can vary over time. In addition, variation can occur between product types and production batches. 4. We reserve the right to change the details in this publication without notice. 5. For a full set of Terms and Conditions of Sale please contact your nearest Boral Masonry sales office. 6. Important notice Please consult with your local council for design regulations prior to the construction of your wall. Councils in general require those walls over 0.5m in height and/or where there is loading such as a car or house near the wall be designed and certified by a suitably qualified engineer.

Technical Enquires

Specifier Line Internet

1300 360 255 www.boral.com.au/masonry

Orders, Product Samples and Sales Enquires Victoria

Level 1 Port IT, 63-85 Turner Street, Port Melbourne, 3207

T: (03) 9363 1944 F: (03) 9363 6008

Other Regional Sales Offices NSW

Clunies Ross Street, Prospect, 2148

T: (02) 9840 2333 F: (02) 9840 2344

231 Wisemans Ferry Road Somersby 2250

T: (02) 4340 1008 F: (02) 4340 1308

ACT

16 Whyalla Street, Fyshwick, 2609

T: (02) 6239 1029 F: (02) 6280 6262

South Australia

Main North Road, Pooraka, 5095

T: (08) 8262 3529 F: (08) 8260 3011

Queensland

62 Industrial Ave, Wacol, 4076

T: (07) 3271 9292 F: (07) 3271 1581

Cairns

8 Palmer Street, Portsmith, 4870

T: (07) 4035 1888 F: (07) 4035 1208

Townsville

360 Bayswater Road, Garbutt, 4814

T: (07) 4725 6285 F: (07) 4725 6043

Mackay

David Muir Street, Slade Point, 4740

T: (07) 4955 1155 F: (07) 4955 4130

North Queensland:

™ Acousticell, Designer Block and FireLight are registered trademarks of Boral Masonry. ® Keystone and Gardenwall are each registered trademarks of Keystone Retaining Wall Systems, Inc. under licence by Boral Masonry Limited. ABN 13 000 223 718 © Boral Masonry - all rights reserved 2004.