NZSIP Technical Manual

NZSIP Smart Panel Construction System Version: 01 2019

Cromwell, Central Otago, New Zealand 0800 2 NZSIP / 0800 269 747 www.nzsip.co.nz

Table of Contents RELATED DOCUMENTS New Zealand Standards

6 6

Foreword

7

BACKGROUND INFORMATION

8

SCOPE, INTERPRETATION AND DEFINITIONS The scope of use – Buildings up to 10 m height

9 9

Specifier

10

Installer

10

Interpretation

10

General Workmanship

11 11

Tolerances

11

Co-Operation

12

Weather Exposure

12

Maintenance

12

Durability

13

Materials Description

13 13

Standard Panel Types

14

Timber Grade and Quality

21

Timber Treatment

21

Polyurethane insulation

21

Formaldehyde

22

Oriented Strand Board (OSB)

22

SOLITEX EXTASANA Wall Underlay

22

Air sealing tapes and fittings

22

Hardware and Sundry Items

23

Design Design Procedure

23 23

General Design Rules

24

Building Geometry

24

Panel Geometry

24

Engineering

26

Steelwork

26

Detailing

26

Design Stage Checklists

26

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Architect/Designer

26

Engineer

27

Documentation Requirements

27

Site Requirements Preparation

28 28

Storage & Handling

28

Concrete Separation

28

Panel Protection

28

Preparation

29

Installation General Panel Installation

29 29

Panel Erection Sequence

29

Alignment

29

Joints

29

Flashing Tapes and Fittings

29

Air sealing tapes and fittings

30

Blower door testing

30

Faster, Safer & Better Construction

30

Safe Work Practices

30

Bracing Design Bracing Criteria

31 31

Panel Bracing Values

31

Maximum Bracing Limits

31

Bracing Hold Down (also see Bottom plate details 9.4, 9.5 and 9.6)

31

Foundation & Subfloor Framing Foundation and Subfloor Construction

32 32

Floors Floor Construction

32 32

Timber Floors

32

Smart Panel Wall to Mid-Floor Connections

33

Joist Hangers

33

Beam Pocket

34

Fixings Required

34

Walls General

36 36

Vertical Load Resistance

36

Horizontal Load Resistance

36

Bottom Plate Details

36

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Concrete Floors Wall connection details

37

Timber Floors Wall Panel Connection details

37

Smart Panel Wall Fixings Smart wall junction Nail Fixings

39 39

Smart Wall Junction Nail Fixings (External)

39

Cam Locking Wall Junction Connections

40

Horizontal Smart wall Panel Connections

41

Smart Walls to Roof Junctions

43

Lintels NZSIP Smart Panel Roof

44 45

Building Envelope – Walls & Roof Cladding General

48 48

Exterior Wall Cladding

48

Roof Cladding Details

49

Interior Linings Ceilings

49 49

Services Electrical

49 49

Plumbing

49

Thermal Performance Building code compliance

50 50

Compliance with the Passive House Standard and use in Passive House Planning Package (PHPP) software 50 R - Values 50 Moisture transport

51

Indoor air quality

51

Appendices Appendix 1 Installation Manual

52 52

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RELATED DOCUMENTS New Zealand Standards

● ● ● ● ● ● ● ● ● ●

NZS 3601:1973 Metric dimensions for timber NZS 3602:2003 Timber and Wood Based Products for Use in Building.

NZS 3603:1993 Timber Structures Standard.

NZS 3604:2011 Timber Framed Buildings.

NZS 3622:2004 Verification of timber properties NZS 3631:1988 New Zealand timber grading rules NZS 3640:2003 Chemical preservation of round and sawn timber AS/NZS 1170:2002 Structural Design Actions.

NZS 4218:1996 Energy Efficiency – Housing and Small Building Envelope Other test reports as applicable

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Foreword NZSIP Ltd manufacture, supply and install Structural Insulated Panels (SIPs) to form walls and roof structures for residential buildings in New Zealand.

Typical NZSIP Smart Panels comprise of Oriented Strand Board (OSB) nominally 12mm thick foamed and bonded to a core of Polyurethane Insulation (PUR). Panels are nominally 1205mm wide with varying lengths and heights depending on the design location of the panel. Flexible roof and wall underlays must comply with NZBC Acceptable Solution E2/AS1 Table 23 or a breather-type membrane covered by a valid BRANZ Appraisal for use as a roof and wall underlays. Sealing tapes must be compatible with roof and wall underlays and OSB substrate. Individual wall panels have a wall underlay vapour control layer adhered to the external face.

The external wall envelope is clad over a drained cavity, the internal face is lined over a cavity to provide for electrical services.

Roof Purlin Fixing.

Roof purlins are 70mm x 45mm SG8 H1.2 and fixed using 8g x 75mm square drive stainless steel screws. The fixing spacing and purlin spacing can be selected for different wind zones using the relevant tables included in the technical literature in this document.

Joints between adjacent panels are taped and foamed with Gorilla Pro Expanding foam A simple to use cam lock system quickly pulls the Smart Panels together during the construction process, making for an easy, fast install and a strong bond between each panel, allowing you to create an airtight SIPs building envelope. The continuous PUR insulation ensures that thermal bridging is kept to a minimum. Once the windows are installed – the Smart walls, roof and or floors provide a structure that is weather resistant and vapour permeable. Service channels and structural timber can be installed in the panels when and where required as each Smart Panel is custom manufactured for the home.

We are proud to be New Zealand’s manufacturer of structural insulated panels.

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BACKGROUND INFORMATION Innovation in the building industry over the last fifty years has focussed on improving the thermal performance of buildings, reducing building waste, using more lightweight materials and enabling faster methods of construction. First developed in the 1930’s, Structural Insulated Panels (or SIPs) delivers all of these benefits and offers a real alternative to traditional timber framing.

SIPs are a high-performance building system for low rise construction. They are manufactured under factory controlled conditions and can be fabricated to suit most building designs. The end result is a building system that is extremely strong, energy efficient and cost-effective Highly insulated and airtight, the Smart SIP Building System is an affordable, next-generation solution to building a comfortable, healthy, energy-efficient home.

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SCOPE,INTERPRETATION AND DEFINITIONS The scope of use – Buildings up to 10 m height NZSIP Smart Panel up to NZS 3604 Extra High Wind Zone (Note site specific factors may require adjustments) The NZSIP Smart Panel Building System is suitable for single unit (detached) Risk Group SH housing which meets the scope of Clause 1.1.2 of NZS3604 with the following limitations: ●

●

● ● ●

detached housing 1m or more from the relevant boundary, and, the ground floor construction platform must compromise of a concrete slab on ground constructed in accordance with NZS 3604, or a suspended timber framed floor supported on a concrete wall or piled foundation constructed in accordance with NZS 3604; and, the first (upper) floor is a suspended timber floor constructed in accordance with NZS 3604; and, the first-floor live load does not exceed 1.5 kPa; and, roof construction comprising trusses and roof framing which meet the provisions of NZS 3604; and/or,

●

where the roof is constructed solely using NZSIP Smart Panel’s supported on beams these are specific engineering design, SED, and,

●

situated in NZS 3604 Wind Zones, up to and including ‘Extra High’ or as evaluated by testing/assessment; and

●

in all NZS 3604 Earthquake Zones; and

● ●

with a NZS 3604 classified Light Roof of profiled metal roof cladding; and roof and wall claddings must comply with NZBC E2/AS1 or a current BRANZ Appraised system; and,

●

with a roof pitch between 3° and 30°.

●

refer to Figure 1.1 Flowchart for limitations and scope of NZS 3604.

●

the use of NZSIP Smart Panels in locations where they may be affected by high levels of moisture and/or heat, such as indoor pools, saunas and steam rooms, is not permitted.

The scope of application of all designs and construction shall be within the limits set out in the February 2019 V1 manual and shall be within the requirements and the tables set out in this manual. Always check that you have the latest version of this manual. Updates or version number is available at www.nzsip.co.nz or email enquiry@nzsip.co.nz. This technical manual should be used in conjunction with the NZSIP Codemark 2018 and BRANZ Appraisal 1032 (2019). Any changes in design or construction from the information contained herein must be confirmed in writing to an NZSIP representative or relevant engineer and signed off by an NZSIP representative and will be outside the scope of this technical manual. All action for

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remedial work to rectify problems with non-conforming panels/components must be notified and confirmed in writing NZSIP prior to action being carried out.

Specifier If you are a specifier or other responsible party for a project, ensure that the information in this document is appropriate for the application you are planning and that you undertake specific design and detailing for areas which fall outside the scope of these specifications.

Please note, NZSIP Smart Panels must be considered as one part of a wider strategy of improving energy efficiency in construction. Windows, foundation systems and ventilation strategy all play an important role in achieving energy efficiency. For this reason, we recommend the engagement of suitably qualified consultants to provide advice on how to best employ our product in your project. Please refer to our website for details.

Installer If you are an installer ensure that you follow the NZSIP installation manual, design principles, moisture management, associated details and material selection provided by the designer. All the details in this document must be read in conjunction with the specifier’s specification. As the installer, you must be a licensed building practitioner or have one supervising.

Interpretation Interpretation shall be as detailed in NZS 3604:2011, clause 1.2. â—?

Refer to Figure 1.2 Buildings covered by NZS3604.

1. General Supply and install Structural Insulated Panels (SIPs) to form the walls and roofs as identified and detailed on the drawings. All aspects of this work shall be in accordance

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with product manufacturers recommendations, and as shown on the drawings and the specification.

1.1 Workmanship Where required by the NZ Building Amendment Act 2012 it is the building contractors responsibility to ensure that all restricted building work is carried out by a Licensed Building Practitioner.

All work shall be carried out to current best trade practise by experienced and competent tradesmen, familiar with the materials and installation techniques and as shown on the drawings.

1.2 Tolerances Floor platforms must be constructed such that they are the correct dimensions, flat, straight, parallel, square and set to the exact level.

A guide to the recommended tolerances based on NZS 3604 Table 2.1 is given below:

1.3 Co-Operation Cooperate with other trades to ensure that all preliminary and preparatory works are completed to specification and as shown on the drawings prior to installation.

Coordinate with other trades as required.

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1.4

Weather Exposure

The building envelope must be fully enclosed and weatherproof, with any timber framing exposed at or below the required moisture content, before membrane installation commences. Once the wall panels have been erected the roof panels should be put on as soon as possible, preferably with the purlins and roof underlay and roofing, alternatively tarpaulins to mitigate the OSB getting wet. If there is a delay in putting the wall underlay up then an assessment of the OSB should be made before applying it. Although there is a notional 90 day exposure for the OSB this should be kept to the absolute minimum if possible and the OSB kept dry before installing the underlay.

1.5

Maintenance

NZSIP Smartpanels must be kept dry after close-in. The external envelope must be maintained to prevent ingress of water and internal water sources such as leaks must be repaired promptly.

If damage due to prolonged wetting does occur, contact NZSIP Limited for guidance with repair or replacement methods.

A document detailing the maintenance requirements should be placed in a suitable location in every SIP Smart panel house.

To the homeowner/occupier.

This house is constructed using the NZSIP Smart panel Building System. Like all houses it requires regular maintenance. Regular maintenance is required to meet the performance requirements of the New Zealand Building Code and will enhance the serviceable life of the building materials used.

Attention to the following is required: • Ensure adequate ventilation to wet areas is maintained.

• Ensure internal linings, floor covering and finishing, including joints, openings and the perimeters are maintained to provide protection from internal moisture. Ensure that Smartpanel wall and ceiling surfaces are not exposed to sustained high humidity, liquid water or high temperatures.

• Regularly inspect (at least yearly) the external cladding and roofing systems and repair any damage or deterioration to prevent water ingress.

• Maintain minimum floor clearances: concrete floors – 150mm to permanent paving – 225mm to unprotected ground. Refer to the New Zealand Building Code Acceptable Solution E2/AS1.

Contact NZSIP Limited, the suppliers of Smart Panel, for further detail.

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1.6

Durability

Durability is covered in the New Zealand Building code (NZBC) in section B2 – Durability and Section E2 – External moisture. NZSIP Smart Panels are designed to meet these NZBC conditions, with Smart Panel Panel material consistency and specifications being checked in the factory according to the Manufacturing Quality Manual which is maintained by the Factory management team. Providing that panels are then constructed according to the supplied panel plan and under conditions and requirements defined in NZSIP Ltd Installation Manual, Smart Panels will function for a specified intended life of not less than 50 years. An acceptable solution to the building code is referenced in B2/AS1 where the New Zealand standards NZS3604 and NZS3602 specify the level of treatment and the application respectively. Alternative solutions may be accepted by Territorial Authorities if the solution meets the durability requirements of the Building Code. *For further information please refer to our durability statement a copy of which can be downloaded off our website www.nzsip.co.nz

2. Materials 2.1 Description

SmartPanel Size

115mmSmart Wall Panels

165mm Smart Wall & Roof Panels

Components

12mm OSB/90mm of High Density PUR foam core/12mm OSB

12mm OSB/140mm of High Density PUR foam core/12mm OSB

12mm OSB/190mm of 215mm Smart Roof High Density PUR foam Panels core/12mm OSB

R Values (centre\ panel)

Panel Dimensions

R value 4

1.22x3.6m

R value 6

1.22x3.6m

R value 8

1.22x3.6m

Typical Panel Weight/ sqm 20kg (wall) 22kg (wall) 25kg (roof)

~28kg (roof)

*R values shown allow for time dependent effects. To determine the installed (i.e. construction) R-value, assume a value of 4% timber in the PUR layer to account for typical thermal bridging.

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2.2 Standard Panel Types

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2.3 Timber Grade and Quality Unless otherwise noted or specified on the drawings or specification, all framing timber shall be minimum structural grade SG 8 Radiata pine in accordance with NZS 3622.

Panels are manufactured with embedded framing at locations as required by the building specific engineering design (SED). The timber framing is LVL, treated to meet the requirements of H1.2 and with a stress grade dependent on location and SED. Embedded framing is used as supports for load bearing elements at openings such as windows and doors. Header panels and solid lintel panels are used at openings.

Bottom plates are sized to suit the wall panel size and are solid timber SG8 or LVL8, treated H1.2. For 115mm Smart walls bottom plate is 90 x 45mm. For 165mm Smart walls bottom plate is 140mm x 45mm. Bottom plate may include a H3.1 treated plywood strip to raise the wall OSB edges off the floor. For details refer to the Technical Literature.

Framing timber shall be seasoned or kiln dried, and be straight and true and free from wind, warp and distortion, and in lengths suitable for the members required, and shall

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have a moisture content of between 12% and 18% before installation. Do not use damaged, faulty or defective materials.

2.4 Timber Treatment All non-durable timber framing shall be appropriately treated against moisture and/or insect decay by treatment plants with recognised quality assurance systems that are administered by the Timber Preservation Council (NZTPC). Treatment of timber and wood-based building products shall be to the requirements of NZS 3602 as an absolute minimum, and all treated timber shall be identified and marked as required.

Carefully manage treated framing during installation to avoid accidental use of timber with a lower performance or durability treatment than that required or specified.

2.5 Polyurethane insulation Injection formed during panel fabrication.

The PUR core is low VOC, zero Ozone depletion potential and low Global Warming Potential (GWP).

Structural insulated panels are one of the most environmentally responsible building systems available. A SIP building envelope provides:

● ● ● ● ●

higher levels of insulation greater reduction of thermal bridging is extremely airtight allows for better control over indoor air quality reduces construction waste, and helps save natural resources.

Life cycle analysis has shown that SIP homes have a tremendous positive environmental impact by reducing energy use and greenhouse gas emissions throughout the home’s life cycle.

Rigid Closed Cell PolyUrethane Foam (PUR) foam insulation is thermoset into each of our custom built Smart Panels. When cured it becomes chemically inert & will not outgas any harmful chemicals; there is also no formaldehyde in PUR foam. The HFO blowing agent that helps to generate the closed cell bubbles in the foam has Zero Global Warming Potential (GWP) and Zero Ozone Depletion Potential (ODP) - The Thermal Conductivity of the PUR foam (allowing for time dependent effects) is - 0.023 W/mK-1. Polyurethane foam insulation, due to its non sagging, water-phobic and adhesive qualities it will perform at optimal levels for the foreseeable life of the building

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2.6

Formaldehyde

NZSIP Ltd has an established primary supplier of PS2 Sheathing which is currently specified using the APA (The Engineered Wood Association) OSB panel Exposure 1 classification, manufactured with a minimum of 20% Phenol Formaldehyde (PF) with poplar wood oriented strands. PF is a thermosetting adhesive which produces a Type A-bond which are durable and permanent under conditions of full weather exposure, long term stress, and combinations of exposure and stress. When Phenol Formaldehyde is cured during the Exposure 1 panel manufacturing process under heat and pressure it forms a highly extended irreversible cross linked web of covalent bonds. It is this irreversible crosslinked nature of phenolics which gives them their hardness, good thermal stability and makes them impervious to most chemical attack and solvation. Formaldehyde-based resins have been well proven and documented as an adhesive in the wood industry for over 70 years.

2.7

Oriented Strand Board (OSB)

Unless otherwise noted or specified on the drawings or specification, all Oriented strand board (OSB) shall be the following specification: Blue Ribbon OSB Oriented Strand Board Georgia Pacific Thickness 15/32CAT 32/16 Exposure 1 PS-2-10 APA Mill 531 Timber shall be straight and true and free from wind, warp and distortion, and shall have a moisture content of between 12% and 18% before installation.

Do not use damaged, faulty or defective materials.

2.8

Wall Underlay

Flexible roof and wall underlays must comply with NZBC acceptable solution E2/AS1 Table 23 or breather-type membranes covered by a valid BRANZ Appraisal for use as roof or wall underlays. The NZSIP Smart Panel Building System will contribute to the cladding system compliance with NZBC Clause E2.3.2. Sealing tapes must be compatible with roof and wall underlays and OSB substrate.

2.9

Joints & Penetrations

The Smart Panel system delivers superior airtightness and durability over traditional timber frame construction. A key component of this system is the sealing of all internal panel joints and penetrations with compatible air sealing products.

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Air sealing tapes, adhesives and pipe and cable sealing grommets are to be installed to the inside face of structural insulated wall and roof panels at all joint and penetration locations.

2.10 Hardware and Sundry Items The following items are used to assemble the structure · Adhesive tapes / Foam · Anchors or hold down bolts · SG8 45 mm x 45 mm H3.1 Timber cavity battens · Cavity Batten fixings (see table for fixing centres) o 75mm x 3.25 annular groove nails o 65mm x 2.8mm ring shank power driven nails o 8g x 65mm square drive st/st screws · Roof purlin fixings 8g x 75 mm square drive st/st screws · SPAX screws (see table below for correct sizing)

Table 2.1 Smart Panel Thickness

Screw

115mm Smart Panels - square connection corner, internal wall or gable

160mm x 8mm SPAX Screw

165mm Smart Panels - square connection corner, internal wall, gable or square roof beam

220mm x 8mm SPAX Screw

165mm Smart Panels - angled connection (30° max pitch) eave or angled roof beam

280mm x 10mm SPAX Screw

215mm Smart Panels - angled connection (30° max pitch) eave or angled roof beam

320mm x 10mm SPAX Screw

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3.

Design

Design Procedure When designing a NZSIP Smart Panel structure, the following process is recommended: • Draw the floor layout plan as desired within the scope of the particular District Scheme.

• Choose the roof and wall cladding systems to be used • Choose the level of insulation required for the site location.

• Design the foundations and the building platform in accordance with NZS 3604, NZS 4229.

• Determine the bracing requirements from NZS 3604:2011 and calculate the bracing values of the panels (refer to the relevant Section (Bracing) of this manual). NZSIP Limited can assist with the preparation of the bracing calculations upon request?

• Design the roof construction and/or trusses to comply with the truss designer’s requirements and NZS 3604:2011.

General Design Rules Building Geometry Gable, Monopitch and lean-to roof forms are the most straightforward geometry for designing with SIPs. These forms can be combined to provide more design options whilst maintaining simplicity.

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More complex roof forms such as hips, valleys, dormers and flat roofs will require careful consideration and detailing and should be discussed first with NZSIP. If roof overhangs are required, these should be formed using purlins and/or outriggers as per NZS3604 10.2.1.15 or SED

Panel Geometry While panels are 100% customisable, the best panel production efficiency is achieved by considering stock panel sizes; namely the 1220 x 3600mm module.

Roof spans longer than 3600mm should be reduced by employing additional lines of support in the form of beams or load bearing walls.

At the other end of the scale, minimum panel sizes should be considered. When setting out openings, ensure there is sufficient space to form lintels above windows.

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Structural considerations around lintels sizes/grades will normally determine minimum dimensions in these areas.

Also ensure there is sufficient space to form panels between windows and between windows and corners/other obstructions. Normally we recommend at least 300mm. If less space is required, please note that the supplied panels may be solid timber, or we may recommend a supporting timber post is installed onsite.

Engineering To resolve all structural requirements for a project, engage an engineer as soon as possible in the design process.

When it is practical and cost effective, structural components (such as timber beam pockets and posts) can be included in the panel manufacture.

Steelwork We recommend that any steel structure (beams, columns or portals) be located to the interior of the building, as opposed to inline, or in the same plane as the panels. This eliminates any potential thermal bridging and condensation issues and ensures construction sequence flows smoothly.

If steelwork within the panels is been considered, discuss with NZSIP prior to inclusion in documentation.

Detailing Please refer to the standard details during the design process and when assembling documentation for construction. The standard details represent best practice and ensure that your project will achieve all the benefits of speed of assembly and thermal performance. A downloadable version of our standard details can be accessed via our website www.nzsip.co.nz *If non standard construction or detailing is proposed, please discuss this with NZSIP prior to inclusion in documentation.

Design Stage Checklists Architect/Designer ❏ Sufficient space to form lintels above windows ❏ Sufficient space to form panels between windows and between windows and corners/other obstructions ❏ Max roof panel length ❏ Max wall panel height

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❏ Check standard panel construction. If non standard construction is proposed, please discuss this NZSIP prior to inclusion in documentation. ❏ Check standard details. If non standard connections are proposed, please discuss these NZSIP prior to inclusion in documentation. ❏ If steelwork within the panels is proposed, please discuss with NZSIP prior to inclusion in documentation.

Engineer ❏ Max roof panel length ❏ Max wall panel height (Design additional support if over height) ❏ Check standard panel construction. If non standard construction is proposed, please discuss this with NZSIP prior to inclusion in documentation. ❏ Check standard details. If non standard connections are proposed, please discuss these with NZSIP prior to inclusion in documentation. ❏ If steelwork within the panels is proposed, please discuss with NZSIP prior to inclusion in documentation. ❏ Lintel sizes and grades ❏ Roofing/Cladding fixings ❏ Wall panel wind & axial load ❏ Roof panel span and cantilever ❏ Bracing

For inclusion in Producer statement scope of work ❏ Lintel sizes and grades ❏ Roofing/Cladding fixings ❏ Wall panel wind & axial load ❏ Roof panel span and cantilever ❏ Bracing

Documentation Requirements Architectural and Engineering drawings and models are the key inputs into creating the panel documentation for the Smart Panels. Proper planning requires the location of all panel joints and structural components to be identified and correctly located on the plans. This planning and review process ensures that panels delivered to site match your design intent and satisfy engineering requirements. It is therefore very important that the person signing off on the drawings is experienced with shop drawings and comfortable with the review process.

The panel plan and shop drawings can be produced efficiently if all the relevant information is submitted to NZSIP. This includes, but is not limited to the following:

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Foundation plans including details and dimensions

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Detailed Floor plans and dimensions

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Dimensioned Sections

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Elevations with floor to floor dimensions

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Window & Door schedules with clear indication of structural opening sizes (opening required in the panels) including lintel and sill heights.

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Structural Engineering Design and calculations

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Clear indication of any situations where the NZSIP Standard methodology and/or details have not been employed

The above inputs will ensure that approved shop drawings contain all the correct elements prior to manufacture commencing. Documentation should be provided in the following format: A set of all consent documentation in PDF format. Preferably a 3D RVT or IFC format file or 2D DWG plans, sections and elevations 3D PANEL PLANS, PHPP ANALYSES (energy modelling) and SHOP DRAWINGS are available from NZSIP. Contact NZSIP to provide you a free quotation for this work.

4. Site Requirements 4.1 Preparation 4.1.1 Storage & Handling Check SIPs upon delivery and reject sub-standard or damaged material. Store panels dry under cover, fillet stacked and well clear of the ground, and protect from damage, moisture, and contamination.

Ensure all appropriate personal protection equipment is worn at all times when handling.

4.1.2 Concrete Separation Confirm whether there is or could possibly be a requirement to separate SIPs with an approved continuous damp proof course when in direct contact with concrete or masonry. Ensure that the DPC material is compatible with the timber treatment.

4.1.3 Panel Protection Protect panels as required during installation against damage and moisture, and against significant variation of moisture content until ready for lining. Avoid ponding of water around floor plates.

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4.1.4 Preparation Cooperate with other trades to ensure that all preliminary and preparatory works are completed to specification and as shown on the drawings. Coordinate with other trades to install products as required. All installation work shall be carried out by experienced and competent installers, familiar with the specified products and installation techniques, in accordance with the manufacturer’s installation requirements and as shown on the drawings.

Store products undercover on a flat dry surface off the floor. Keep dry and out of direct sunlight and protect from damage at all times. Handle products in accordance with the manufacturers requirements. The building envelope must be fully enclosed and weatherproof, with timber framing at or below the required moisture content, before membrane installation commences.

Check that the framing construction is complete with all necessary insulation, plumbing, wiring and ducting services installed and complete, ready for pro clima installation. Check framing for fixings, splinters and other unnecessary protrusions likely to cause punctures.

5. Installation 5.1 General Panel Installation Please refer to the install manual.

Downloadable version is available via our website www.nzsip.co.nz

5.2 Panel Erection Sequence Please refer to the panel plan drawings provided in your site pack.All panels are clearly numbered. Refer to our install manual which you will also find in the site pack.

5.3 Alignment Please refer to the install manual.

5.4 Flashing Tapes and Fittings Flexible roof and wall underlays must comply with NZBC acceptable solution E2/AS1 Table 23 or breather -type membranes covered by a valid BRANZ Appraisal for use as roof or wall underlays. The Smart Panel system will contribute to the cladding system compliance with NZBC Clause E2.3.2. Sealing tapes must be compatible with roof and wall underlays and OSB substrate.

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5.5 Joints & Penetrations The Smart Panel system delivers superior airtightness and durability over traditional timber frame construction. A key component of this system is the sealing of all internal panel joints and penetrations with compatible air sealing products.

Air sealing tapes, adhesives and pipe and cable sealing grommets are to be installed to the inside face of structural insulated wall and roof panels at all joint and penetration locations.

All aspects of this work shall be in accordance with the standard details and manufacturers instructions.

Walls panels ● ● ● ● ●

Panel joints - all junctions between wall panels, headers, footers & gables, corner junctions - all internal and external corners floor junctions - ensure coverage of packing under bottom plate and seal to concrete for concrete slab floors window and door openings service penetrations - ensure all penetrations are completed at the pre lining stage

Roof panels ● ● ● ● ●

Panel joints - all junction between roof panels Ridge & beam junctions - ensure full coverage of beams, including joint between built up members and pocket to wall panels.

Gable and eave junctions - ensure coverage of timber wedge at eave.

Roof light openings service penetrations - ensure all penetrations are completed at the pre lining stage

5.6 Blower door testing As a check on the quality of construction, we recommend blower door testing at the pre-lining stage. Blower door testing is performed using a special fan and frame that fits within an external door frame, The building is then pressurized and unpressurized with the airflow results logged against the building’s volume.

Results are typically presented as the number of air changes (the total internal volume) per hour @ 50 pa. We recommend a Target air infiltration (air leakage) rate of less than 1.5 ach-1 @50Pa. Refer also to sections on internal moisture and thermal performance.

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5.7 Faster, Safer & Better Construction ● ● ●

●

As Smart Panels are custom built in our New Zealand factory using specialist software, accuracy and tolerances are far superior than traditional construction.

The modular nature of the prefabricated panels means building to the weathertight stage is up to 60% quicker than traditional construction Once weathertight, the Smart Panel system allows for quicker turnaround of the various trades involved during the build process – allowing for quicker construction and project delivery.

No onsite cutting is required by builder for the panels – creating lower site safety risk and a cleaner, safer workplace.

5.8 Safe Work Practices NZSIP is committed to Safe Working practices. Construction sites can contain multiple hazards and it is essential that installers follow all legal requirements when working on site. Please refer to the OSH regulations for all relevant legislation.

The Smart Panel instal manual outlines specific handling and installation of panels and recommends tools and accessories.

6. Bracing Design 6.1 Bracing Criteria Bracing unit requirements for wind and earthquake are determined by using the design criteria from Section 5 of NZS 3604:2011.

The bracing resistance of the building may be calculated by adding the bracing unit values of each panel type. All full height panels, without large openings, and a min. length of 1.2m, may be used as bracing elements.

6.2 Panel Fastening See Section 10 Smart Panel Wall Fixings

6.3 Panel Bracing Values Wall Panel size

Earthquake units

bracing

Wind bracing units

1200mm x 2400mm

139 (116 BU/m)

137 (114 BU/m)

1200mm x 3000mm

137 (114 BU/m)

123 (102 BU/m)

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6.4 Maximum Bracing Limits Please contact NZSIP for guidance

6.5 Bracing Hold Down (also see Bottom plate details 9.4, 9.5 and 9.6) Bottom Plate fixing: Hold down bolt with 50x50x3mm washer to be fitted within 50mm of strap & 100mm to end of bracing element.

Brace Strap to bottom connection: 6kN hold down strap (25 x 0.9mm*) located as per bracing plan. 5 x 14 gauge Type 17 screws into each side of structural insulated panel 50mm from edge of element. *strap length to suit 100mm minimum length up face of panel

CONCRETE FLOORS

TIMBER FLOOR

Hold Down:

Hold Down: SPAX screws

7. Foundation & Subfloor Framing 7.1 Foundation and Subfloor Construction The foundation and subfloor construction as given in: • NZS 3604: 2011 (timber & concrete) • NZS 4229 (concrete masonry and timber floors) • By specific design in accordance with NZBC B1/VM1

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8. Floors 8.1 Floor Construction Floor platforms or lower floor construction shall be specifically designed or constructed in accordance with NZS 3604:2011.

8.2 Timber Floors Load bearing and non load bearing wall panels shall be supported by joists and bearers in accordance with the requirements of NZS 3604:2011.

9. Walls 9.1 Smart Panel Wall to Mid-Floor Connections Floors may be face fixed to Smart wall panels with joist hangers or be supported by Smart wall system with beam pockets and support posts. See details below:

9.1.1 Joist Hangers MiTek Lumberlok joist hangers to be selected to suit beam width and depth. Fixings required to each flange as per table below.

Characteristic Load – Screws Joist Hanger Type No. Of screws per flange Down Uplift JH 47 x 90 1 3kN 3kN

Characteristic Load – Screws

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Joist Hanger Type

No. Of screws per flange

Down

Uplift

JH 47 x 90

1

3kN

3kN

JH 47 x 120

2

6kN

6kN

JH 47 x 190

3

9kN

9kN

JH 95 x 165

3

9kN

9kN

JH 70 x 180

3

9kN

9kN

Fix with Type 17-12g x 35mm Hex head screws ** IMPORTANT NOTE ** DO NOT overdrive screws as any damage to OSB face will affect load capacities listed in the above table.

9.2 Beam Pocket Smart Wall system can incorporate designed beam pockets that have structural supporting post/studs manufactured into the wall panel. Engineer to design beam and hold down fixings selected based on SED

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9.3 Lintels Are incorporated into our Smart Panels Lintel types a) Lintel supporting roof only b) Lintel supporting roof, wall and floor c) Lintel supporting floor only d) Lintel supporting roof and wall e) Lintel supporting wall and floor Lintels can be designed using NZS 3604:2011 and/or LVL manufactures span tables during the design stage. Sizes will need to be confirmed by structural engineer.

10.

General

NZSIP Smart Panel walls are manufactured with a nominal density. Batch testing is carried out at the factory for every project to ensure consistency is met.

10.1

Vertical Load Resistance

Please contact NZSIP

10.2

Horizontal Load Resistance

Please contact NZSIP

10.3

Bottom Plate Details

Before Smart Wall system can be installed bottom plates and appropriate packing are required to be fixed into place.

All bolts are at suitable lengths to secure plates with packing selected. Where bolts and washers are used for bottom plate, these need to be recessed into the bottom plate to ensure the Smart Wall panel will sit onto bottom plate. Please refer to relevant standard details on bottom plate dimensions.

10.4

Concrete Floors Wall connection details

Packing to underside of bottom plate is required, options of packing material can be determined by designer from the below: A) Timber packing 115mm(W)x45mm; H1.2 treated continuous plate; B) Plywood Packing 115mm(W)x18mm continuous H3.1 CD plywood.

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Bottom plate of 88mm x 45mm (for 115mm thick wall), H1.2 treated SG8 timber bottom plate, on Plywood or timber packing and DPC to concrete slab. All bottom plate fixings to comply with NZS3604.

10.5

Timber Floors Wall Panel Connection

Bottom plate of 88mm x 45mm (for 115mm thick wall), H1.2 treated SG8 timber bottom plate. Fixings for bottom plate to timber floor frames as per NZS3604. All fixings to be flush with the bottom plate.

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Allow for 12mm to edge of flooring for Smart wall panel when placing bottom plates to concrete or timber flooring.

11. Smart Panel Wall Fixings All Panels require nail fixings both internally, and externally for all junction to timber plates. This Includes top plates, bottom plates and spline connections to lintels

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headers and footers. Cam-Locking Smart wall panels do not require nailing at cam locked joint.

11.1 Smart Wall Junction Nail Fixings Top, bottom and Side plates to be fixed with 50mm D head ring shank nails at 100mm Cts. Fixings to start at 50mm from edge of OSB sheathing

11.2 Smart Wall Junction Nail Fixings (External) SPAX screws to connect SIP to SIP external Corner. Length of screw fixing as per table 2.1.

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11.3

Cam Locking Wall Junction Connections

Smart Wall panels that contain Cam-Locking mechanism will not require any further nailing on this joint line. All top and bottom plate connections on a Cam-Locking panel will require nailing as per above.

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12. Smart Panel Wall to Roof Junctions 12.1

NZSIP Smart Panel Roof

Smart Walls are manufactured with a void to top side of panel for top plate continuous timber to be inserted on site.

Where Smart Roof is applied to a Smart Wall system a “rake plate” to be provided to support panel pitch to the wall system.

Smart Roof support fixing is required at 200mm crs for all supporting structure Nailing of all panel splines still required

Roof Ridge; Ridge beam supporting SIP panels require SPAX screw fixings at 200crs with screw embedment at 45mm into beam.

Packing to ridge beam to support Smart roof may be required as shown in standard detail SIP511.

Roof Mid Support: Roof support beams are required to be fixed with 2x SPAX screws through panel with 45mm embedment into supporting beam as shown in standard details SIP 525/526.

Allowable Spans (m) for 165mm Thick NZSIP Roof Panels 1.0 kPa Snow Load Wind Zone

Light Roof Cladding

Heavy Roof Cladding

Max Roof Pitch 25 degrees

45 degrees

Low

3.0

3.4

Medium

3.0

3.4

High

3.0

3.4

Very High

3.0

3.4

Extra High

3.0

3.4

Low

2.7

3.1

Medium

2.7

3.1

High

2.7

3.1

Very High

2.7

3.1

Extra High

2.7

3.1

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Allowable Spans (m) for 165mm Thick NZSIP Roof Panels 1.5 kPa Snow Load Wind Zone

Light Roof Cladding

Heavy Roof Cladding

Max Roof Pitch 25 degrees

45 degrees

Low

2.7

3.1

Medium

2.7

3.1

High

2.7

3.1

Very High

2.7

3.1

Extra High

2.7

3.1

Low

2.5

2.9

Medium

2.5

2.9

High

2.5

2.9

Very High

2.5

2.9

Extra High

2.5

2.9

Allowable Spans (m) for 165mm Thick NZSIP Roof Panels 2.0 kPa Snow Load Wind Zone

Light Roof Cladding

Heavy Roof Cladding

Max Roof Pitch 25 degrees 45 degrees

Low

2.5

2.9

Medium

2.5

2.9

High

2.5

2.9

Very High

2.5

2.9

Extra High

2.5

2.9

Low

2.4

2.7

Medium

2.4

2.7

High

2.4

2.7

Very High

2.4

2.7

Extra High

2.4

2.7

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Allowable Spans (m) for 215mm Thick NZSIP Roof Panels 1.0 kPa Snow Load Wind Zone

Light Roof Cladding

Heavy Roof Cladding

Max Roof Pitch 25 degrees

45 degrees

Low

3.3

3.6*

Medium

3.3

3.6*

High

3.3

3.6*

Very High

3.3

3.6*

Extra High

3.3

3.6*

Low

3.1

3.4

Medium

3.1

3.4

High

3.1

3.4

Very High

3.1

3.4

Extra High

3.1

3.4

Allowable Spans (m) for 215mm Thick NZSIP Roof Panels 1.5kPa Snow Load Wind Zone

Light Roof Cladding

Heavy Roof Cladding

Max Roof Pitch 25 degrees

45 degrees

Low

3.0

3.5

Medium

3.0

3.5

High

3.0

3.5

Very High

3.0

3.5

Extra High

3.0

3.5

Low

2.8

3.2

Medium

2.8

3.2

High

2.8

3.2

Very High

2.8

3.2

Extra High

2.8

3.2

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Allowable Spans (m) for 215mm Thick NZSIP Roof Panels 2.0 kPa Snow Load Wind Zone

Light Roof Cladding

Heavy Roof Cladding

Max Roof Pitch 25 degrees

45 degrees

Low

2.8

3.3

Medium

2.8

3.3

High

2.8

3.3

Very High

2.8

3.3

Extra High

2.8

3.3

Low

2.7

3.1

Medium

2.7

3.1

High

2.7

3.1

Very High

2.7

3.1

Extra High

2.7

3.1

12.2 Truss Roof Connections between roof trusses and NZSIP are SED. Please discuss connections with your engineer and truss manufacturer and confirm with NZSIP.

13. Building Envelope – Walls & Roof Cladding 13.1 General Ensure specification for all products used for cladding meet with the manufacturers specification. Please contact NZSIP if you are unsure on compatibility.

13.2 Exterior Wall Cladding Cavity batten spacing to be determined by cladding type

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13.3 Cavity Batten Fixing The selection of fixing, fixing spacing and cavity batten spacing can be selected for different wind zones using Tables 1, 2 and 3 and in the technical literature.

Table 1 75mm x 3.25 annular grooved stainless nails Batten Spacing (mm)

Fixing Spacing (mm)

Allowable Wind Zone (from NZS3603)

600

150

Extra High

600

200

Very High

600

300

Medium

450

200

Extra High

450

300

High

400

200

Extra High

400

300

Very High

Table 2 65mm x 2.8mm ring shank Paslode nails Batten Spacing (mm)

Fixing Spacing (mm)

Allowable Wind Zone (from NZS3603)

600

100

Very High

600

150

High

600

200

Medium

600

250

Low

450

150

Very High

450

200

High

450

300

Low

400

150

Very High

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400

200

High

400

300

Medium

Table 3 8g x 65mm CSK square drive stainless steel screws Batten Spacing (mm)

Fixing Spacing (mm)

Allowable Wind Zone (from NZS3603)

600

150

Extra High

600

200

Extra High

600

300

Extra High

600

400

Very High

450

200

Extra High

450

300

Extra High

450

400

Extra High

13.4 Roof Cladding Details This document covers NZS 3604 classified Light Roof of profiled metal roof cladding.

Please contact NZSIP if considering using roof claddings outside of this scope.

13.5 Purlin Spacing Roof Purlin Fixing. Roof purlins are 75mm x 45mm SG8 H1.2 and fixed using 8g x 75mm CSK square drive stainless steel screws. The fixing spacing and purlin spacing can be selected for different wind zones using Tables 4 and 5 and in the technical literature.

Table 4 Allowable Wind Zones For Roof (Kl = 2 or less)

Purlin Spacing Fastener Spacing (mm) (mm)

100

200

250

300

400

500

EH

EH

EH

VH

H

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600

EH

EH

VH

VH

M

650

EH

EH

VH

H

M

800

EH

VH

H

M

M

900

EH

VH

H

M

M

1000

EH

H

M

M

M

1005

EH

H

M

M

M

1150

EH

H

M

L

-

1200

EH

M

M

L

-

1400

EH

M

L

L

-

1800

VH

L

-

-

-

Table 5

Allowable Wind Zones For Roof (Kl = 3)* Purlin Spacing Fastener Spacing (mm) (mm)

100

200

250

300

400

500

EH

EH

H

H

M

600

EH

VH

H

M

L

650

EH

H

M

M

L

800

EH

H

M

L

-

900

EH

M

M

L

-

1000

EH

M

L

L

-

1050

VH

M

L

-

-

1150

VH

L

L

-

-

1200

VH

L

L

-

-

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1400

H

L

-

-

-

1800

M

-

-

-

-

*These zones apply for roof slopes less than 10° within 2.4 m of a roof corner and for buildings no wide or longer than 12 m.

14. Interior Linings Plasterboard can be direct fixed to walls. If direct fixed consideration to services must be given as the cavity has been removed.

14.1

Ceilings

Please contact NZSIP for options

15. Services Do not modify the panels to accommodate services in any way other than as described in this manual and the standard details.

15.1 Electrical Electrical services are to be located within the internal lining cavity. Small Penetrations to connect to electrical services to the exterior of the building are permitted provided they are installed as per the standard details.

15.2 Plumbing Plumbing services are to be located within the internal lining cavity. Small Penetrations to connect to plumbing services to the exterior of the building are permitted provided they are installed as per the standard details.

16. Thermal Performance High density polyurethane is one of the best performing forms of insulation for a given unit of thickness. When combined with the low levels of thermal bridging possible with

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structural insulated panels, the result is superior than most construction systems.

16.1 Building code For housing and small buildings, compliance with New Zealand Building Code Clause H1 Energy Efficiency, in via the acceptable solution is NZS 4218.

When using NZS 4218 to determine compliance, please refer to Installed R-values listed in this section

16.2 Compliance with the Passive House Standard and use in Passive House Planning Package (PHPP) software Smart Panels have been utilized in a number of Certified Passive House projects and are an excellent method of achieving the stringent performance requirements of the standard.

For input of panels into PHPP, please contact NZSIP.

16.3 R - Values Thermal performance of individual components Timber framing -

Thermal conductivity = 0.13 W/(mK)

Oriented Strand Board -

Thermal conductivity = 0.13 W/(mK)

Polyurethane foam -

Thermal conductivity = 0.023* W/(mK)

*allowing for time dependent effects

17. Air Quality Internal Moisture The NZSIP Smart Panel building system will create an airtight, energy efficient building envelope. Due to the inherent airtightness of the NZSIP Smart Panel Building System, it is necessary for the designer to manage adequate air changes and suitable moisture control management to maximise energy savings, occupant comfort and building durability.

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When constructed in accordance with this Appraisal the NZSIP Smart Panel Building System will assist with the system’s compliance with NZBC Clause E3.3.1.

The NZSIP Smart Panel Building System will contribute to meeting the requirements of NZBC Acceptable Solution E3/AS1, Paragraph 1.1.1 (a) when the building design includes for an adequate combination of thermal resistance, ventilation and space temperature to all habitable spaces, bathrooms, laundries and other spaces where moisture may be generated or may accumulate.

Ventilation must meet the performance requirements of NZBC Clause G4.3.1. Floors, walls and roofs complying with the Schedule Method for Compliance with Clause H1.3.2 (E) will have adequate thermal resistance to comply with NZBC Acceptable Solution E3/AS1.

Wet areas are spaces where sanitary fixtures and sanitary appliances are located such as bathrooms, toilets, laundries and kitchens. There are two general categories of wet areas as follows: Water Splash – These are areas subject to intermittent splashing of water such as around baths, vanities, tubs and sinks.

Shower Areas – These are areas subject to frequent and heavy water splash such as enclosed showers, unenclosed shower zones and showers over baths.

Both the above wet area categories must be finished with surfaces and joints that are impervious and easily cleaned. In addition, shower areas must be waterproofed. This can be achieved using proprietary rigid shower lining systems, flexible vinyl shower wall finish, or tiling. Tiled shower areas must include a wet area waterproofing membrane system under the tiles.

17.1 Ventilation The typical NZSIP Smart Panel construction creates an airtight, energy efficient building envelope. Due to the inherent airtightness of the NZSIP Smart Panel Building System some permanent ventilation, not reliant on window openings, must be provided in wet areas, such as bathrooms and laundries. The Technical Literature contains details for how this may be achieved. Vented windows, wall or ceiling mounted extract fans, or similar fittings are recommended in all building wet areas.

Extract fans for moisture laden air must be vented externally.

Due to the airtight performance of the NZSIP type construction, the use of mechanical ventilation is required. It is recommended that the minimum design ventilation rate of 0.35ach but no less than 7.5l/s person. (ASHRAE 62-1999) Natural ventilation must also be provided with the minimum area of openable window as 5% of the floor area in each room.

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