DESIGN MANUAL

DESIGN MANUAL BUILDING SYSTEMS FOR MODULAR HOUSING

Force 10 International Pty Ltd 63 Factory Road, Oxley Qld 4075 Australia PO Box 126, Brisbane Markets, Qld Australia 4106 Phone: 61 7 3379 5200 Fax: 61 7 3379 5211 e-mail: force10@gil.com.au www: http://www.force10.com.au

Note: This manual is subject to revision and updates are available on request from Force 10 International Pty Ltd. Issue Date: November 2003

Document Reference: DESIGN MANUAL_Ver 2.0.doc 11/03

Page 1 of 18

DESIGN MANUAL

Table of Contents
1 2 3 INTRODUCTION......................................................................................................................................... 3 GENERAL..................................................................................................................................................... 4 SCOPE ........................................................................................................................................................... 4 3.1 CODES...................................................................................................................................................... 4 3.2 ENGINEERING REFERENCES ..................................................................................................................... 5 3.2.1 Index to Engineering Manual.......................................................................................................... 5 3.3 REFERENCED TEST REPORTS (REFER TO FORCE 10 INTERNATIONAL FOR DETAILS)................................. 5 3.4 WIND LOADS ........................................................................................................................................... 6 3.5 DURABILITY............................................................................................................................................. 7 4 FLOORING SYSTEM ................................................................................................................................. 8 4.1 FLOOR DESIGN AND LAYOUT ................................................................................................................... 8 4.2 FLOOR FRAME SPECIFICATION AND ALLOWABLE SPANS. ........................................................................ 9 4.2.1 Table: Allowable Span .................................................................................................................... 9 4.3 COLUMNS ................................................................................................................................................ 9 5 PANEL SYSTEM........................................................................................................................................ 10 5.1 PHYSICAL PROPERTIES PANELS ........................................................................................................... 11 5.2 EARLY FIRE HAZARD PROPERTIES ......................................................................................................... 11 5.2.1 Thermal Resistance ....................................................................................................................... 11 5.2.2 Equivalent Modulus of Elasticity .................................................................................................. 11 5.3 SECTION CAPACITIES ............................................................................................................................. 11 5.4 COMBINED LOADING ............................................................................................................................. 11 6 ROOFS......................................................................................................................................................... 12 6.1 6.2 6.3 7 7.1 7.2 7.3 8 8.1 8.2 9 9.1 9.2 9.3 9.4 10 GEOMETRIC PROPERTIES........................................................................................................................ 12 MEMBER PROPERTIES ............................................................................................................................ 12 DESIGN .................................................................................................................................................. 12 CEILING LINING SUPPORTS ..................................................................................................................... 13 OPENINGS IN CEILINGS ........................................................................................................................... 13 STRUCTURAL CEILING DIAPHRAGMS ...................................................................................................... 13 INTERNAL MOISTURE ............................................................................................................................. 14 ENERGY EFFICIENCY.............................................................................................................................. 14 STEEL COLUMNS /BEARERS ................................................................................................................... 17 WALL/TRUSS BRACKETS ....................................................................................................................... 17 FLOOR /WALL BRACKETS ...................................................................................................................... 17 WALL PANEL BOLTS .............................................................................................................................. 17 ENERGY EFFICIENCY CODE ........................................................................................................... 18

CEILINGS ................................................................................................................................................... 13

THERMAL RESISTANCE ....................................................................................................................... 14

FIXINGS...................................................................................................................................................... 17

Figures
Figure 1 Joist and Bearer Specifications............................................................................................................... 9 Figure 2 Truss Design .......................................................................................................................................... 13 Figure 3 Suspended Floor System - Insulated with Foil....................................................................................... 15 Figure 4 Concrete Slab on Ground ...................................................................................................................... 16

Document Reference: DESIGN MANUAL_Ver 2.0.doc 11/03

Page 2 of 18

DESIGN MANUAL
1 Introduction
The purpose of this design manual is to describe the Force 10 Building System to Designers, Engineers and approving Authorities. The information given in this manual should be sufficient as a reference and guide to the design of buildings up to an ultimate wind speed of 61 m/sec without additional information. Standard plans and layout are available for use however non-standard designs may be achieved by using the guidance and Tables in this Manual. All designs when submitted for approval to the local authority must meet all the relevant performance requirements of the relevant Australian (or International) Building Code. The Force 10 Building System has been subjected to a through testing programme to ensure that the section capacities are correct and are in accordance with the Australian Standard Codes. The design information presented in the manual has been derived from engineering calculations or from testing This manual refers to building elements which are constructed in accordance with relevant building codes and standards. Where indicated, this manual must therefore be read in conjunction with that standard. Specific design will also be required for other elements such as strong backs, columns, beams, verandas etc. Specific design calculations will need to be prepared by appropriately qualified designers and a Design Certificate provided to cover each project. When designed in accordance with the requirements of this Design Manual and constructed in accordance with the Force 10 Construction Manual, the Force 10 building system will meet the relevant Australian Building Code and generally the relevant building codes in other countries.. Although care has been taken in the production of this information, Force 10 International Pty Ltd is not liable for any errors or omissions. For further information please contact Force 10 International Pty Ltd

Document Reference: DESIGN MANUAL_Ver 2.0.doc 11/03

Page 3 of 18

DESIGN MANUAL
2 General
The Force 10 Building System is a modular system using cold formed steel floor framing and roof framing, and prefabricated wall panel units. The basic module length is 1 metre. Elements of the system, such as the foundation, wall panel lengths, spans etc are based on multiples of the 1 metre module.

3 Scope
This section sets out the referenced documents, design loads, and materials properties of the Force 10 system. The loads noted in this section have been used to determine the parameters listed in this Design Manual.

3.1

Codes
Structural design actions - Permanent, imposed and other actions
Provides design values of permanent, imposed and other actions to be used in the limit state design of structures and members. It is intended to be used in conjunction with AS/NZS 1170.0. Other actions covered include liquid pressure, ground water, rain water ponding and earth pressure.

AS/NZS 1170.1:2002

AS/NZS 1170.2:2002 Structural design actions - Wind actions

Provides design values of wind actions for use in structural design. It is intended to be used in conjunction with AS/NZS 1170.0, which gives the procedure for structural design. Wind speeds and direction factors are provided for a range of probabilities of exceedance. Other factors cover the environment around the structure, the geometry of the structure and the dynamic interaction of the structure with the wind. This Standard sets out procedures for determining wind speeds and resulting wind actions to be used in the structural design of structures subjected to wind actions other than those caused by tornadoes.

AS 1684.2-1999

Residential timber-framed construction - Non-cyclonic areas

Specifies requirements for building practice and for the selection, placement and fixing of the various structural elements used in the construction of timber-framed Class 1 and Class 10 buildings, as defined in the Building Code of Australia, for non-cyclonic areas. It also sets out building practice procedures, which are given to assist in the correct specification and design of timber members, bracing and connections thereby minimizing the risk of creating an environment that might adversely affect the ultimate performance of the structure. Appendices specify a method of interpolation for Span Tables in the Supplements, and an alternative procedure for determining racking forces. Guidance is given on mass of roof, timber natural durability, moisture content, timber species and properties.

AS 3623 - 1993

Domestic Metal Framing

Specifies the loads and load combinations to be applied to the various components (e.g. studs, joists, etc.) of a metal frame for a domestic building up to two storeys in height and a roof pitch of up to 35 degrees. Requirements are also specified for the dynamic performance of floors.

AS 4055 - 1992

Wind Loads for Housing

This Standard sets out data and procedures for determining design wind speeds and wind loads for housing only. Wind speeds are specified for the serviceability and ultimate strength/stability limit states, and for permissible stress design.

AS 4100 - 1998

Steel Structures
Page 4 of 18

Document Reference: DESIGN MANUAL_Ver 2.0.doc 11/03

DESIGN MANUAL
This Standard sets out minimum requirements for the design, fabrication, erection, and modification of steelwork in structures in accordance with the limit states design method.

AS/NZS 4600 1996

Cold Formed Steel Structures

Sets out minimum requirements for the design of structural members coldformed to shape from carbon or low-alloy steel sheet, strip, plate or bar not more than 25 mm in thickness and used for load-carrying purposes in buildings and structures.

3.2

Engineering References

Force 10 has prepared and maintains an Engineering Manual that contains evidence of compliance.

3.2.1 Index to Engineering Manual

ITEM 1 CSIRO APPRAISAL (6 PAGES) ITEM 2 LETTER BURCHILL AND PARTNERS CERTIFYING ENGINEERS ITEM 3 WJ DALTON EARTHQUAKE RESISTANCE CAT 4 ITEM 4 WJ DALTON COMPARISON WIND SPEEDS VS CODES ITEM 5 WJ DALTON ROOF LOADS IMPOSED SNOW ACTION ITEM 6 BRANZ REPORT (2 PAGES) ITEM 7 CSIRO TEST CERTIFICATE ITEM 8 CSR RE WARRANTY FIBRE CEMENT ITEM 9 STRUCTRAFLOR TECHNICAL INFORMATION ITEM 10 CHEMIND PUR DESIGN SPECIFICATION ITEM 11 CHEMIND FORCE 10 RELATIONSHIP AND TESTING ITEM 12 CHEMIND PUR TEST RESULTS ITEM 13 CHEMIND PUR TERMITE, FIRE AND SOUND PROPERTIES (3 PAGES) ITEM 14 AS2269 TERMITE INFORMATION ITEM 15 LETTER NSW DEPT HOUSING ITEM 16 NT DEPT LANDS AND HOUSING ITEM 17 TRANSMITTED SOUND - ACOUSTIC LEVEL TEST REPORT (2 PAGES) ITEM 18 LETTER REGARDING ISO9001-2000 COMPLIANCE ITEM 19 LETTER AUSTRALIAN ARMY ITEM 20 LETTER SEYCHELLES PROJECT ITEM 21 LETTER COMMONWEALTH OF NORTHERN MARIANA ISLANDS

3.3

Referenced Test Reports (Refer to Force 10 International for details)

i) ii) iii) iv) v) vi) BRANZ T670 REPORT ON THERMAL RESISTANCE OF FORCE 10 BUILDING PANELS (JANUARY 1998) UNIVERSITY OF AUCKLAND THE BRACING RESISTANCE OF FORCE 10 SCREWED PANELS (JANUARY 1998) UNIVERSITY OF AUCKLAND THE BRACING RESISTANCE OF FORCE 10 GLUED PANELS (JANUARY 1998) UNIVERSITY OF AUCKLAND THE BRACING RESISTANCE OF FORCE 10 2400 HIGH SCREWED PANELS (NOVEMBER 1998) UNIVERSITY OF AUCKLAND THE BRACING RESISTANCE OF FORCE 10 2400 HIGH GLUED PANELS ON CONCRETE FOUNDATIONS [FOAM IN](NOVEMBER 1998) UNIVERSITY OF AUCKLAND THE BRACING RESISTANCE OF FORCE 10 2400 HIGH GLUED PANELS ON CONCRETE FOUNDATIONS [NO FOAM](NOVEMBER 1998)

Document Reference: DESIGN MANUAL_Ver 2.0.doc 11/03

Page 5 of 18

DESIGN MANUAL
vii) UNIVERSITY OF AUCKLAND THE BRACING RESISTANCE OF FORCE 10 3000 HIGH GLUED PANELS ON STEEL FLOOR (NOVEMBER 1998) viii) UNIVERSITY OF AUCKLAND THE BRACING RESISTANCE OF FORCE 10 3000 HIGH GLUED PANELS ON STEEL FLOOR [NO FOAM](NOVEMBER 1998) ix) UNIVERSITY OF AUCKLAND THE BRACING RESISTANCE OF FORCE 10 3000 HIGH GLUED PANELS ON CONCRETE FOUNDATIONS [FOAM IN](NOVEMBER 1998) x) UNIVERSITY OF AUCKLAND THE BRACING RESISTANCE OF FORCE 10 3000 HIGH SCREWED PANELS ON CONCRETE FOUNDATIONS [NO FOAM](NOVEMBER 1998) xi) QUT CET 2532 REPORT ON FORCE 10 WALL PANEL SYSTEMS (MARCH 1989) xii) QUT CET4999 MODULAR WALL PANEL TEST REPORT (JULY 1998) xiii) QUT CET4999/1 MODULAR PANEL TEST REPORT - COMPRESSION TESTING (AUGUST 1998) xiv) QUT CET5077 REPORT ON RESULTS OF TESTING MODULAR WALL PANELS (DECEMBER 1998) xv) QUT APPENDIX A CONSTRUCTION DATA (CET4999, CET4999/1, CET5077) xvi) QUTCET5115 MODULAR PANEL TEST REPORT RACKING TESTS (FEBRUARY 1999) xvii) QUT APPENDIX A CONSTRUCTION DATA (CET5115) xviii) CSIRO FIRE TEST TO UL1715. xix) BRANZ FIRE RESISTANCE TEST FP2599 AS1530.4 1997(JANUARY 1999) xx) BRANZ FIRE RESISTANCE TEST FR2600 AS1530.4 1997(FEBRUARY 1999)

3.4

Wind Loads Wind Classification

Region Terrain Category TC 3 TC 2.5 TC 2 TC 1 TC 3 TC 2.5 TC 2 TC 1 TC 3 TC 2.5 TC 1, TC 2 TC 3 TC 2.5 TC 1, TC 2 N1 N1 N2 N3 N2 N2 N3 N3 Topographic Classification T1 N1 N2 N2 N3 N2 N3 N3 N4 N2 N2 N3 N3 N3 N3 N3 N4 N1 N2 N3 N3 N2 N3 N3 N4 T2 N2 N3 N3 N4 N3 N3 N4 N5 N2 N3 N3 N4 N3 N4 N4 N5 N2 N2 N3 N4 N3 N3 N4 N4 T3 N3 N3 N3 N4 N3 N4 N4 N5 N3 N3 N4 N4 N4 N4 N5 N5 N3 N3 N3 N4 N3 N4 N4 N5 T4 N3 N4 N4 N5 N4 N4 N5 N6 N3 N4 N4 N5 N4 N5 N5 N6 N3 N3 N4 N5 N4 N4 N5 N6 T5 N4 N4 N5 N5 N4 N5 N5 N6 N4 N4 N5 N6 N5 N5 N6 N/A FS PS NS FS PS NS FS PS NS FS PS NS FS PS NS A

C1 C1 C2 C2 C2 C2 C2 C2 C3 C3 C3 C3 C3 C4 C4 C1 C2 C2 C2 C2 C3 C2 C3 C3 C3 C4 C4 C3 C4 C4 C2 C2 C2 C2 C3 C3 C3 C3 C4 C3 C4 C4 C4 N/A N/A C2 C2 C3 C2 C3 C3 C3 C4 C4 C4 C4 N/A C4 N/A N/A C2 C3 C3 C3 C3 C4 C3 C4 C4 C4 N/A N/A N/A N/A N/A C3 C3 C3 C3 C4 C4 C4 N/A N/A N/A N/A N/A N/A N/A N/A

For information on the derivation of these wind categories, please refer to AS4055 Wind Loading for Housing.

Document Reference: DESIGN MANUAL_Ver 2.0.doc 11/03

Page 6 of 18

DESIGN MANUAL

Australian Wind Speed m/s

46 51 55 65 71

American Wind Speed mph Exposure B

166 180 196 240 257

Exposure C
114 125 133 160 175

NOTE: The Australian speeds take into account the various exposure conditions. 3.5 Durability

All steel members and fixings in floors, walls and roofs have a zinc coating which provides protection against corrosion. In normal circumstances, this is sufficient to avoid corrosion provided the steel components are maintained in a dry condition. In this regard, note that all wall and roof framing is protected from the exterior environment, i.e. completely encapsulated by weather tight linings, flashings and cladding. For steel sub-floor framing, there is a possibility that corrosion may occur due to wind borne sea spray in buildings close to the sea or subject to other aggressive environmental factors. Therefore for buildings within 1km of the sea or subject to aggressive environments, all subfloor components including columns, bracings, bearers, joists, fittings etc should be treated

Document Reference: DESIGN MANUAL_Ver 2.0.doc 11/03

Page 7 of 18

DESIGN MANUAL
after fabrication with an approved protection system (e.g. Xtroll Rust Conqueror) prior to dispatch to site. After erection of the sub-floor, all damaged mastic should be cleaned and touched up with an approved protection system (e.g. Xtroll Rust Conqueror) prior to installation of the StructaFlor, TermiFlor sheets or other flooring materials. The sub-floor should then be inspected annually and damaged areas (if any) cleaned and touched up with an approved protection system (e.g. Xtroll Rust Conqueror). Alternatively, the sub-floor may be fully enclosed (with minimal ventilation i.e. not more than 4000mm2 /m2 of floor area). In all areas, verandas and decks should be roofed to avoid corrosion in the sub-floor steel framing. The strength and stiffness of wall panels is related to the sandwich panel action which in part relies on the durability of the polyurethane foam that fills the cavity. It is expected that the durability of the foam will exceed 40 years and that adherence of the foam to the fibre cement board will also exceed this period.

4 Flooring System
The flooring system consists of floor sheeting material fixed to an in-plane framework of cold rolled steel joists and bearers. Joists are at half module (0.5 m) spacings and nest into and are screw fixed to bearers at each end of the span. Bearers require screw fixing through the flanges to the joists to resist wind loading. The bearers consist of 2 channel sections back to back.

4.1

Floor Design and Layout

The orientation of bearers and floor joists are arranged to suit the project house floor plan. It is recommended that shorter module joists or bearer spans be located under lounge and dining room areas to limit floor vibration. All exterior and interior load bearing and bracing walls must be directly supported by bearers. Floor joist spacing must not exceed 500 mm (one half a module). Note that some floor joists will need to be positioned to coincide with floor sheeting joints.

Document Reference: DESIGN MANUAL_Ver 2.0.doc 11/03

Page 8 of 18

DESIGN MANUAL
4.2 Floor Frame Specification and Allowable Spans.

The joist and bearer spans and specification are given below:

Figure 1 Joist and Bearer Specifications

4.2.1 Table: Allowable Span

Member Joist Bearer (single span) Bearer (double span) Thickness 1.2mm 1.6mm 2.0mm 2.0mm 2.0mm Spacing (*) 500 500 2000 4000 4000 Span 3000 4000 3000 2300 3000

Circular holes for services are permitted at mid-depth of joist and bearer webs provided they are no more than 35 mm in diameter, spaced no closer than 250 mm centres and not within 500 mm of any support. All other holes shall be subject to specific design. Apart from the holes noted below, joists or bearers may not be cut or modified in any way. Cantilevered floor joists must be subject to a specific design in accordance with the Building Code of Australia or AS/NZS4600. No in-span joist or bearer joints are permitted. The minimum bearing for floor joists within bearers is 50 mm. For openings in the floor, at least two opposite trimmers shall be bearers.

4.3

Columns

The following column specifications are used for all Force 10 sub-floor columns. Column Height (mm) 0 to 1800 1800 to 3000 Material 75 x75 x2.3 SHS C450 75 x75 x 5.0 SHS C450

Document Reference: DESIGN MANUAL_Ver 2.0.doc 11/03

Page 9 of 18

DESIGN MANUAL
5 Panel System

The Force 10 wall panel system comprises of 63x35 C section steel studs and a 60x73 C section top and bottom nog to give a steel perimeter channel frame that is then bonded on each face with a sheet of 6mm thick Fibre Cement board. The total thickness of the panel is nominally 76.2mm. Each panel interior cavity formed by the studs, nogs and sheeting is filled with polyurethane foam. The polyurethane foam acts as the insulation material as well as a bonding agent. The polyurethane has a design density of between 45-50 Kg /m3. The panel is attached to the floor system using a Force 10 floor /wall bracket. A special Force 10 M16x32 reduced shank bolt is used to attach the bracket to the steel stud. Two M10x45 bolts are used to clamp the bracket to the flange of the bearer.

Document Reference: DESIGN MANUAL_Ver 2.0.doc 11/03

Page 10 of 18

DESIGN MANUAL
The top of the panel is attached to the truss system using a 125mm truss bolt and the special Force 10 M16x32 reduced shank bolt. Alternatively the top of the panel can be attached to a second floor using a T section bracket and a reduced shank bolt.

5.1

Physical Properties Panels

DIMENSIONS 2435 x 995 2700 x 995 3000 x 995 WEIGHT 58 kg 64 kg 71 kg

5.2

Early Fire Hazard Properties

SPREAD OF FLAME INDEX 0 HEAT EVOLVED INDEX 0 SMOKE DEVELOPED INDEX 5 M2 0 C/W 2.5 1.36 1.60

IGNITABILITY INDEX 0

5.2.1 Thermal Resistance

l Thermal Resistance Centre of Panel Edge - Direct Bond 4mm foam insulation

5.2.2 Equivalent Modulus of Elasticity

2700 x 995 5.3 Section Capacities 30,000 MPa

The following capacities can be used to resist unfactored axial loads and permissible bending loads. All values have been determined by testing. Wall Height Lateral Bending Allowable Racking Load Allowable Area Pressure kN/Panel Compression kN Earthquake Wind 2400 2.68 4.0 3.5 41 2700 2.63 3.5 2.9 41 3000 2.34 2.4 2.9 38 5.4 Combined Loading

The following formulae can be used to determine combined bending and axial limits: Wall Height Design Gravity Load (kN)* 2400 and 2700 N* + Wp < 1.0 41 2.63(1-N* ) 179 3000 N* 38 + Wp 2.34(1-N* ) 166 < 1.0

Where:

N* = Actual axial load Wp = Permissible Wind pressure.

Document Reference: DESIGN MANUAL_Ver 2.0.doc 11/03

Page 11 of 18

DESIGN MANUAL
6 Roofs
All roofs must be subject to specific design subject to the following constraints:

6.1

Geometric Properties
Base slope angle max 200 (over this requires engineering certification) Span range - 3m to 10m in 1.0 m modules Truss spacing - 1.0 m (module spacing ) Location of truss joints/nodes - at module joint positions (i.e. multiples of 1.0 Bottom chord - one single length Top chord - 2 continuous lengths joined at the apex Load bearing internal walls - to be connected to bottom chord of truss. A vertical strut shall be inserted between the top and bottom truss chord if the wall does not coincide with a truss joint.

6.2

Member Properties
Top and bottom chords section: thickness grade - top hat - 1.6 mm - G 300, Z275

Web members

section - C section. thickness - 1.6 mm grade - G 300, Z275 section - top hat thickness grade spacing - 1.0 mm - G 300, Z275 - as per roof manufacturer

Purlins

Ceiling Battens

section - top hat thickness - 1.0 mm grade - G 300, Z275 Spacing - 500 mm, but dependant on roof cladding manufacturers instructions.

6.3

Design

Snow load - 0.5 kPa Design wind speed - 61 m/s maximum Design shall be in accordance with AS/NZS 4600: 1996. (Cold-formed steel structures)

Document Reference: DESIGN MANUAL_Ver 2.0.doc 11/03

Page 12 of 18

DESIGN MANUAL

Figure 2 Truss Design

7 Ceilings
7.1 Ceiling lining supports

Ceiling battens consist of top hat sections which are spaced according to the requirements of the ceiling lining manufacturer (normally 400 mm centres) but at a maximum of 500 mm centres. The battens are run continuously under the bottom chords of the trusses and fixed in place with 2 No. 10-16 x 25 Hex screws at each crossing. Where a ceiling is designed to act as a structural diaphragm, the outside ceiling battens perpendicular to the roof trusses shall be positioned within 100 mm of the centreline of the wall panel section supporting the trusses. Attachment of the ceiling lining to the supports must be carried out in accordance with the ceiling lining manufacturers specifications.

7.2

Openings in ceilings

Openings in ceilings shall comply with the Building Code of Australia.

7.3

Structural ceiling diaphragms

Where a ceiling acts as a structural diaphragm it shall meet the provisions of the Building Code of Australia. The exception is that sheets must be fixed with No.6 - 20 x 25 bugle head Tek screws at 150 mm centres around the diaphragm boundary and each sheet perimeter; and at 300 mm centres to intermediate supports. Fixings must be a minimum 10mm from the edge of the sheets.

Document Reference: DESIGN MANUAL_Ver 2.0.doc 11/03

Page 13 of 18

DESIGN MANUAL
8 Thermal Resistance
8.1 Internal moisture

Force 10 Building System wall panels have a thermal resistance value of 1.57W / m2 0 C. To minimise the likelihood of condensation, thermal breaks are included in some components and expanding foam type insulation is required in voids

8.2

Energy Efficiency

Force 10 walls will meet the wall requirement by providing the minimum roof and floor insulation requirements and by meeting the following conditions: glazing must not exceed 30% of the wall area suspended floors must have a continuous enclosed perimeter with 100 mm drooped foil.

For Climate Zone 3, or where the conditions of the Table cannot be met, use the Calculation Method to determine the roof and floor requirements using the Heat Loss equation HL = ARoof + AWall + AFloor + AGlazing RRoof RWall RFloor RGlazing

HLReference must first be calculated using the R values from the Table for Climate Zone 3 and the actual building areas. i.e. Rroof = 2.5 m2 0C/W Rwall = 1.9 m2 0C/W RFloor =1.3 m2 0C/W Rglazing values may be obtained from the Building Code of Australia or determined by calculation or measurement using the Building Code of Australia. For single glazed clear aluminium windows with no thermal break the value is 0.18 m2 0 C/W. R values for roof and floor may then be determined for the building such that the HL value does not exceed HL Reference with Rwall = 1.6 m2 0C/W. Thermal bridging in Force 10 Building System wall panels, due to the steel channels at the joints, is reduced by the inclusion of a 2mm thick foam tape, thermal break, placed between the channel flange and the exterior fibre cement panel. Note also that to minimise thermal bridging at the top and bottom of wall panels, voids must be filled with an insulating material such as expanding foam, as shown, before skirting/scotia and flashings are installed. Insulation details to meet the R value requirements for floor and roof are given as follows.

Document Reference: DESIGN MANUAL_Ver 2.0.doc 11/03

Page 14 of 18

DESIGN MANUAL

Amount of insulation within the ceiling - R - value of insulating material Total Construction R - value (m C/W) Total Construction with Anticon under roofing

Nil

R1.4

R1.8

R2.2

R2.6

R3.0

R3.4

R3.8

0.4 1.9

1.3 2.8

1.6 3.1

1.8 3.3

2.2 3.7

2.5 4.0.

2.8 4.3

3 4.5

Notes:
1 2 3 4 5 Deduct 0.2 if roof space is ventilated or building paper is omitted Add 0.2 if 12mm sheet soft board is used. Deduct 0.1 if metal cladding is primed or painted on the underside Deduct 0.14 if the profile of the roof cladding is flat with narrow ribs Add 0.2 if there is a 20mm air gap between rigid insulation and the ceiling lining

Figure 3 Suspended Floor System - Insulated with Foil

Document Reference: DESIGN MANUAL_Ver 2.0.doc 11/03

Page 15 of 18

DESIGN MANUAL
Notes
1 2 3 4 5 Add 0.4 if carpet and underlay are fitted to the floor. The floor should be constructed using double-sided perforated aluminium foil. Care should be taken to achieve a close fit around pipes and other penetrations. Those R-values are based on laboratory measurement Foils must be attached to the floor deck at each end, or closed off to keep wind out. They must be well fitted at joints.

Figure 4 Concrete Slab on Ground

Notes:
1 2 Add 0.4 if all carpet and underlay are fitted to the floor. How to use this graph: Calculate the "floor area/perimeter length" ratio. Determine the appropriate value of "w". Use these two figures to calculate the "slab floor R-value" from the vertical axis. If there is a high water table under the concrete slab, the whole underside of the slab must be insulated and this table does not apply. If the concrete slab has embedded floor heating, it is recommended that the whole underside of the slab be insulated. The R-value above the heating element should be <0.3m C/W.
Page 16 of 18

3 4

Document Reference: DESIGN MANUAL_Ver 2.0.doc 11/03

DESIGN MANUAL
5 If the whole underside of the concrete slab is insulated, the R-value is calculated by using the "w=0.0m" line, and adding this to the R-value of the insulation.

9 Fixings
The following fixings are required to ensure that the Force 10 system performs to suit all conditions. The allowable resistance value of the connection is also given.

9.1

Steel Columns /Bearers

Connection of bearers to steel columns will be by 4 x 10mm mild steel bolts to column end plates in all cases. Allowable resistance Uplift 16.4 kN Horizontal 11.2 kN

9.2

Wall/Truss Brackets

Proprietary 86 x 49 x 8 mild steel plate with M12 mild steel threaded rod in all cases Allowable resistance Uplift 9 kN Horizontal 6 kN

9.3

Floor /Wall Brackets

Proprietary 8mm thick L brackets fixed to the flooring system with 2 x M10 bolts in all cases. Allowable resistance Uplift 8.4 kN Horizontal 5.6 kN

9.4

Wall Panel Bolts

Panels to be bolted together top and bottom of panel with M16 mild steel bolts Allowable resistance Uplift 8.8 kN Horizontal 6 kN

Document Reference: DESIGN MANUAL_Ver 2.0.doc 11/03

Page 17 of 18

DESIGN MANUAL
10 Energy Efficiency Code
PERFORMANCE CRITERIA
P13

ACCEPTABLE SOLUTIONS
A13 Walls (excluding windows and glazed areas) achieve an overall R- value not less than Rl.O A14 Roof/ceiling structures (excluding garages, open verandahs and pergolas) achieve an overall R-value ofR2.5

FORCE 10 RATING

Walls must achieve an acceptable level of heat resistance

Rwall = 1.9 m2 0C/W

P14

Roofs and ceilings must achieve an acceptable level of heat resistance

Rroof = 2.5 m2 0C/W

PI5

The residential building must achieve an acceptable level of cross ventilation through habitable rooms

A15.1 Each habitable room is ventilated by a window or door in two opposite walls which are openable to the outside OR A15.2 A direct flow path is provided from an openable window in the room through the doorways or other openings within the house to another window or opening to the outside

Based on specific design for the building

Document Reference: DESIGN MANUAL_Ver 2.0.doc 11/03

Page 18 of 18