insulclad Exterior Cladding System

INTRODUCTION

insulclad® is a crack resistant plastered exterior wall
system that provides full insulation and a weatherproof
barrier for residential and commercial constructions.
The system consists of sheets of polystyrene fixed to
the exterior framing or bonded directly onto concrete or
masonry surfaces.

The polystyrene surface is then coated with an acrylic
modified cement-based plaster reinforced with a strong fibreglass
mesh. The base coat is then finished with an Ezytex®
finishing render painted with two coats of 100% acrylic paint.

1.1 Building Regulations
The insulclad® System when installed applied and maintained
in accordance with the instructions and recommended
details of the Novatex Products will meet the relevant
provisions of the Australian Standards 1366 1170 and 1648.

1.2 Appraisals
The insulclad® System has been subject to extensive
testing and complies with Australian building practices.
insulclad® has been assessed by various building
appraisal schemes and holds the following accreditations:
CSIRO Technical Opinion No. 107 (1989) Australian
National Certificate of Accreditations No. 90/013. For the
NZ Branz Appraisal go to www.plastersystems.co.nz.

1.3 PVC Materials
Polystyrene: White expanded S M and H grade polystyrene
sheets 40 50 60 75 and 100mm thick.
Fixings: To timber frame – hot-dipped galvanised flathead
nail used in conjunction with a 40mm diameter plastic
insulclad® washer. Alternatively Class 3 screws with
40mm PVC washers.

 

To steel frame – Class 3 self-drive steel screws used in
conjunction with 40mm plastic insulclad® washers.
To concrete or masonry – bonding compound of mixed
insulclad® base to which one litre of insulclad® resin
has been added per bag of base mixed. Alternatively
mechanical fasteners of polypropylene construction driven
into pre-drilled holes in the concrete substrate.
Adhesive for PVC trims – Bostik No More Nails or
similar equivalent. A solvent-free synthetic rubber and resin
construction adhesive.

Reinforcement mesh:

An alkali resistant fibreglass
woven mesh weighing 152g/m2 for standard construction
and 370g/m2 for high impact risk areas.
Coverage: One 1.2 metre roll covers approximately 55m2.
insulclad® Base: A specially blended acrylic modified
cement-based mix packed in 20kg bags.

Coverage:

Reinforced mesh coat approximately 2mm thick
– One bag covers approximately 4m2. If the insulclad®
base is also used for the hopper gun sprayed texture coat
over the reinforced mesh coat total coverage for both coats
is 3m2 bag. The texture coat of insulclad® must be painted
with at least one coat of sealer plus two coats of 100%
acrylic paint.
Ezytex® Finishing Renders: A range of cement-based
textures which must be finished with one coat of sealer plus
two coats of 100% acrylic paint.
Coverage: One 20kg bag of Ezytex® will cover approximately
4 to 8m2 depending on the finish specified.

The Range of Ezytex® finishes are:
• Fine Skim
• Medium Float
• Coarse Float
• Scratch and Drag
For further information refer
to the Ezytex® Data Sheet.

 

Extra Finish Options

Based Mix: Hopper gun sprayed texture
which must be over coated with one coat of sealer plus two
coats of 100% acrylic paint.
PVC Beads: Exterior grade UPVC beads available in 2.5 &
3.0 metre lengths for external corners bottom edges sills
and jambs.
1.4 Handling & Storage
Polystyrene sheets must be stored to reduce exposure to
direct sunlight. Protect sheets from physical damage. Bags
of render must be stored in a dry area preferably off the
floor on timber pallets or timber dunnage. Rotate the stock
to ensure that the oldest material is used first. Discard any
render which is more than six months beyond its manufacturing
date.
When transporting bags of render protect the product
from moisture and from being damaged. Do not transport or
wrap in any way which could lead to “sweating”.
Store the rolls of fibreglass mesh in a dry area.

1.5 Health & Safety
Render dust is an irritant and paper dust-protection masks
must be worn while the render is being mixed. The wet
render is alkaline and prolonged skin contact must be
avoided.

1.6 Installation
CONSTRUCTION
INFORMATION
2.1 Framing
Framing set out requires studs at 600mm maximum centres.
Support for all edges and all exterior walls straightened
prior to fixing any sheets.
Only the 75mm insulclad® can be joined horizontally
without support providing the sheets are glued.
At bottom plate level ensure the plate is flush or slightly
past the outer edge of the flooring platform.

2.2 Joinery Details
Detailed in the construction detail drawings Section 8 of
this Manual.
The application and finishing of the insulclad® System
requires specialist skills and is to be installed only by
approved Novatex contractors. All work must be carried
out in accordance with Novatex Products installation
and current detail sheets.
Please contact Novatex Products for a list of contractors
in your area.

2.3 Ground Clearance
The insulclad® System can be carried on below the minimum
bottom plate coverage of 50mm to provide a uniform
line either down to or into the finished ground level If this
construction detail is chosen it can only be used on concrete
perimeter footing or concrete slab constructions.
When using timber foundations any sub-floor ventilation
requirements must still be met. Note that the minimum
paved or unpaved distance of 150mm must be maintained
below finished floor level or bearer plate level. Details for
this construction option are shown in the insulclad® Data
Sheet Manual.

2.4 Fixing Blocks
Timber backing blocks for items such as downpipe
brackets garden taps outside light fittings should be fixed
to the framing face at the appropriate locations. Use treated
timber ripped down to thickness to suit 40 50 & 75mm thick
polystyrene. Timber blocks should be no longer than 400mm
in length.
The approved contractor will cut the polystyrene around
these blocks and apply the reinforced rendered finish over
them.

2.5 Bracing
The insulclad® System is not a bracing element.
Where external bracing is required plywood panels
can be nailed direct to the framing. Over these bracing
panels sheets of polystyrene less the thickness of the plywood
are fixed to maintain a flat surface. Internal sheet
bracing is preferred.

2.6 Impact Resistannce
The standard reinforced insulclad® System has a long
history of satisfactory impact strength for residential and
commercial construction.
A heavy duty insulclad® System is available with four
times greater impact strength for use in areas likely to be
at risk from hard body impacts. Simply specify “insulclad®
Commercial Finish”. For areas such as insulclad® walls
abutting car parks additional protection or barriers must be
provided.

2.7 Pipes and Outlets
Before rendering begins make sure all the plumbing
that is going through the walls are in place. If the work can’t
be finished at least get short sections installed through the
walls so they can be sealed in place before the rendering
begins.
This also applies to meter boxes outside taps certain
types of light fittings etc.
All electrical cable that pierces through the polystyrene
e.g. for light fittings must be protected by a conduit or go
through a timber fixing block.

DESIGN CRITERIA

3.1 Thermal Insulation
The insulclad® System satisfies the insulation requirements
of Australian Standard 1366. The standard grade
used is ‘S’ Grade (approximate density 17kg/m3) or ‘H’ Grade
(approx. density 24kg/m3). The various wall constructions
will have the following thermal resistance values.

3.2 Wind Loading
insulclad® will withstand wind forces equivalent to a
cladding design wind speed of 67m/sec. This covers most
normal design situations. Precise nailing and framing
centres are detailed in the ABSAC certificate.
These recommendations cover Terrain Categories 1 to 4
in Australia.
Polystyrene sheets bonded to concrete or masonry
substrates are acceptable in all wind zones.
Specific Design: For specific design insulclad® fixed to
vertical framing at 600mm centres will have the following
Ultimate Limit State values:

3.3 Fire
C1 Outbreak of Fire: insulclad® must be separated from
chimneys heating appliances and flues as required by
Acceptable Solution C1/ASI.
C3 Spread of Fire: In order to meet the requirements of
the Australian Building Code for Spread of Fire the entire
building needs to be designed as required under the
performance requirements of BCA C3. Specific limitations
on the use of insulclad® are outlined below. insulclad®
finished with acrylic paint may be used as an exterior wall
cladding for unsprinklered buildings in any purpose group
other than SC and SD on buildings up to 25m in height
and at any distance from the boundary. There is no height
restriction if the building is sprinklered.

 

insulclad® may be used in SC and SD purpose groups if the
following conditions are satisfied:
• insulclad® is separated from the interior space of the
building by an element with a fire resistance rating (FRR)
of at least 15 minutes or it is applied to the exterior of a
concrete or masonry element.
• insulclad® is totally separated from the interior areas
of the building and any ceiling cavities by fire stopping.
Any penetration passing through the fire rated wall must
be fire stopped to an FRR of no less than that required for
the building element in which it is installed.
• In multi-storey buildings fire stopping is provided at each
floor level at the junction of floor and external wall.
Samples of insulclad® with 40mm EPS sheet substrate
and 4mm of fibreglass-mesh reinforced polymer-modified
cement-based render yielded the following indices when
tested in accordance with the requirements of AS 1530 Part 3:
The insulclad® surface finishing options have been tested
by BRANZ Fire Testing Laboratory in accordance with the
requirements of AS 1530 Part 3. The 100% acrylic paint
finish yielded an Ignitability Index of zero.
3.4 Construction Joints
Construction joints are required in walls longer than 20
metres or higher than two storeys.
For residential construction a construction joint is not
required for two storeys plus a gable end.
3.5 Sound Insulation
The insulclad® System over timber framed construction
lined with paper faced board has excellent sound insulation
properties.
Full scale testing on the 40mm insulclad® has shown
the system has a Sound Transmission Class (STC) Rating of 40.

3.6 Weight
The 40mm insulclad® System weighs approx. 7kg/m2.
3.7 Curing
Cement-based renders must only be applied when the
temperature is between 5° and 30°C and they must be
protected from rain and water run-off for the first 24 hours.
To aid curing cement-based renders should be protected
from hot drying winds and direct sunlight for the first 16
hours.
4 MAINTENANCE
Damaged areas cracks or sealant details which could
allow water to penetrate the cladding must be repaired to
ensure the building remains watertight.
Accidental damage can be repaired using new render
and where required additional fibreglass mesh. Finish the
repair with the appropriate product. Minor cracks can be
sealed with a polyurethane type sealant and be repainted.
Suspect sealant joints must be raked out the points cleaned
and the sealant replaced.
5 TERMITES
Please seek expert advice for termite prevention.
6 CLEANING
The chosen finishing render system should be regularly
hosed down. Localised grime or ingrained dirt may be removed
by cleaning with a suitable detergent and water. The
exterior finishes can also be cleaned with a low pressure
water blaster using a fan water jet and a cleansing agent.
7 RECOATING
Acrylic painted surfaces will need repainting after 5 to 10
years depending on location and the condition of the paint.
Simply clean the painted wall surfaces with a suitable
chemcal or detergent wash and rinse off. Ensure any lichen
or moss growth is removed and any loosely adhered paint is
wire brushed off. Repaint with two coats of acrylic paint.
Technical Advice
An advisory service is available to specifiers of the
insulclad® Exterior System.
Simply contact:
Novatex Products at info@novatexproducts.com.au

 

8.1 INSULCLAD® CONSTRUCTION DETAILS
These details represent typical insulclad® construction techniques and are designed
to assist specifiers. These details are not a complete and comprehensive range
but do describe the most commonly used applications of the system. If you wish to
Installation
The insulclad® System must only be applied by approved contractors who have a good
Due to the specialist nature of the system all the render products fibreglass mesh and
PVC flashing components that make up the insulclad® System shall be supplied directly to
the contractor by Novatex Products.
General
modify a detail to suit a different design you must contact Novatex Products to discuss the
intended modification. All of the construction details on the following pages have been
appraised by the Australian Building Systems Appraisal Council Ltd to ensure the insulclad®
System meets all the relevant provisions of the Australian Building Code.
Novatex Products reserve the right to revise and change its construction details
without notice. Please consult a Novatex Products Technical Adviser to confirm the validity
of our current details or to seek advice regarding new developments.
Novatex Products guarantees that its pre-mixed render products are manufactured to a high
specification. Novatex Products liability (in contract tort negligence or otherwise) for any
loss damage expense cost or liability arising from application of the product is limited to
making good any defect solely attributable to the Novatex Products manufacturing process.
Novatex Products shall not be liable for any defective workmanship or application of its
products by any contractor approved or otherwise or any other person.
The long-term durability of the insulclad® Syst
m is dependant on the correct
preparation and application of all of its components in strict accordance with the relevant written
instructions and detail sheets. On-site application is beyond the control of NP and it cannot
guarantee workmanship or the correct preparation and application of its products or systems.
The approved insulclad® contractor shall take the overall responsibility for: on-site
supervision staff training installation and quality control.
The purchaser of the components of this system will indemnify Novatex Products and
its personnel of any damage loss or expense incurred by Novatex Products which is not proved
to be the direct consequence of defective manufacture of the product and the customer will
pay the amount of that damage loss or damages within 10 days of Novatex Products or its
personnel making demand in writing on the customer for payment of the same.
working knowledge of Novatex Products products and who are aware of Novatex Products
current product information and are kept up-to-date with proprietary detailed application
instructions.

 

8.1 INSULCLAD® CONSTRUCTION DETAILS
These details represent typical insulclad® construction techniques and are designed
to assist specifiers. These details are not a complete and comprehensive range
but do describe the most commonly used applications of the system. If you wish to
Installation
The insulclad® System must only be applied by approved contractors who have a good
Due to the specialist nature of the system all the render products fibreglass mesh and
PVC flashing components that make up the insulclad® System shall be supplied directly to
the contractor by Novatex Products.
General
modify a detail to suit a different design you must contact Novatex Products to discuss the
intended modification. All of the construction details on the following pages have been
appraised by the Australian Building Systems Appraisal Council Ltd to ensure the insulclad®
System meets all the relevant provisions of the Australian Building Code.
Novatex Products reserve the right to revise and change its construction details
without notice. Please consult a Novatex Products Technical Adviser to confirm the validity
of our current details or to seek advice regarding new developments.
Novatex Products guarantees that its pre-mixed render products are manufactured to a high
specification. Novatex Products liability (in contract tort negligence or otherwise) for any
loss damage expense cost or liability arising from application of the product is limited to
making good any defect solely attributable to the Novatex Products manufacturing process.
Novatex Products shall not be liable for any defective workmanship or application of its
products by any contractor approved or otherwise or any other person.
The long-term durability of the insulclad® System is dependant on the correct
preparation and application of all of its components in strict accordance with the relevant written
instructions and detail sheets. On-site application is beyond the control of NP and it cannot
guarantee workmanship or the correct preparation and application of its products or systems.
The approved insulclad® contractor shall take the overall responsibility for: on-site
supervision staff training installation and quality control.
The purchaser of the components of this system will indemnify Novatex Products and
its personnel of any damage loss or expense incurred by Novatex Products which is not proved
to be the direct consequence of defective manufacture of the product and the customer will
pay the amount of that damage loss or damages within 10 days of Novatex Products or its
personnel making demand in writing on the customer for payment of the same.
working knowledge of Novatex Products products and who are aware of Novatex Products
current product information and are kept up-to-date with proprietary detailed application
instructions.