insulclad Pre-meshed Board

1 INTRODUCTION
insulclad® Pre-Meshed Board is an insulating
lightweight crack-resistant pre-meshed
polystyrene cladding system. Suitable for most
climate conditions it provides an insulation
and weatherproof barrier for commercial and
residential constructions.
insulclad® Pre-Meshed Boards consist of
M-grade expanded polystyrene reinforced with
fibreglass mesh that is imbedded in a polymer
modified cement-based render.
insulclad® Pre-Meshed Board offers an option
of a unique form of cavity construction. Using
polystyrene battens (as an alternative to timber)
fixed to the framing or substrate this allows for
nominal overall wall thicknesses. For example
a 40mm insulclad® Pre-Meshed Board with
35mm packers will achieve an overall cladding
thickness of 75mm. Due to the rigidity of
the board sheets can be fixed horizontally
without requiring the need for support
therefore reducing waste and cutting down
on installation time.
2 BUILDING REGULATIONS
The insulclad® Pre-Meshed Board system when installed
applied and maintained in accordance with the instructions
of Novatex Products will meet provisions of the
Australian standards 1366 1170 and 1648. (refer to Appraisals)
2.1 APPRAISALS
The insulclad® Pre-Meshed Board system is currently
undergoing extensive testing.
All technical information provided in this data sheet has been
based on the standard insulclad® system CSIRO Technical
opinion 107 and complies with Australian building practices.
3 MATERIALS
3.1 POLYSTYRENE
M-grade expanded polystyrene.
Standard panel sizes:
• 2.500 x 1.200 x 40mm
• 2.500 x 1.200 x 75mm
• 2.500 x 1.200 x 100mm
3.2 FIXINGS
Timber frame – 100mm galvanised class 3 screws with
a 40mm PVC washer. Self-tapping screws for steel framing.
Use 75mm screws for fixing 40mm board directly to the stud.
To fix to concrete or masonry substrates mix one 20kg
bag of jointing compound with one litre of resin and water.
Alternatively use mechanical fasteners of polypropylene
construction driven into pre-drilled holes. Adhesive for PVC trim.
3.3 PVC BEADS
Exterior grade UV resistant PVC beads available in 2.5 and 3m
lengths for external corners bottom edges sills and jambs.
3.4 REINFORCEMENT MESH
An alkali-resistant self-adhesive fibreglass 200mm wide
woven mesh weighing 160g/m2.
Coverage: One roll will cover 50 lineal metres of joins.
3.5 JOINTING C OMPOUND
insulclad® Pre-Meshed Board jointing patch: A special
blend of acrylic modified cement-based render mix packed
in 20kg bags.
Coverage: One bag does approximately 50m2.
3.6 SCRATCH & DRAG
insulclad® Pre-Meshed Board scratch & drag:
A special blend of acrylic-modified cement-based render mix
packed in 20kg bags.
Coverage: One bag covers approximately 6m2.
3.7 EZYTEX® FINISHING RENDERS
A range of cement-based renders which must be finished with
one coat of sealer and two coats of 100% acrylic paint.
The range of EZYTEX® finishes are:
• Fine skim
• Medium Float
• Course Float
• Scratch and drag
Alternative finishing options: Any good quality 100% acrylic
render finish can be applied over a scratch coat and a medium
sponge finish.
4 HANDLING & STORAGE
All pre-meshed sheets must be stored properly to reduce
exposure to direct sunlight. To protect sheets from physical
damage all sheets must be stored on their flat surface. Bags
of render must be stored in a dry area preferably off the
floor on timber pallets. Rotate the stock to ensure the oldest
stock is used first. Discard any render that is more than six
months old.
When transporting bags of render all care must be taken to
protect the product from moisture (rain) or from being damaged.
Store rolls of fibreglass mesh in a dry area.
4.1 HEALTH AND SAFETY
Render dust is an irritant and paper dust masks must be worn
while the render is being mixed. The wet render mix is alkaline
and prolonged skin contact must be avoided.
5 CONSTRUCTION
INFORMATION
INSTALLATION
All work must be carried out in accordance with Novatex
Products installation and current data sheets.
5.1 FRAMING
Framing set-out requires studs at 600mm maximum centres.
Support for all edges and all exterior walls straightened prior
to fixing any sheets.
At bottom level plate ensure that the plate is flush or slightly
past the outer edge of the flooring.
5.2 JOINERY DETAILS
There are several options and all are detailed in the construction
detail data sheets.
5.3 GROUND CLEARANCE
insulclad® Pre-Meshed Board system can be carried on below
the bottom plate to a minimum of 50mm.
Please consult with a Novatex Products representative
when taking the cladding down into the ground.
When using timber foundations any subfloor 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 construction sheet manual.
5.4 FIXING BLOCKS
Timber backing blocks for items such as downpipe brackets
garden taps or outside light fittings should be fixed at the
appropriate locations. Use treated timber cut down to suit
the thickness of the wall panel. Timber blocks should be no
longer than 400mm in length.
5.5 BRACING
insulclad® Pre-Meshed Board is not a bracing element. Where
external bracing is required polystyrene battens can be reduced
in size to accommodate the extra thickness of the bracing.
5.6 IMPACT RESISTANCE
insulclad® Pre-Meshed Board has satisfactory impact strength
for residential and commercial applications. For areas that
require extra impact strength apply one full layer of mesh
imbedded in base render over the insulclad® panel.
5.7 PIPES AND OUTLETS
Make sure all plumbing is in place so it can be sealed prior
to rendering. This also applies to metre boxes outside taps
and certain types of light fittings etc.
All electrical cable that pierces through the insulclad® panel
e.g. for light fittings must be protected by a conduit or a timber
fixing block.
6 DESIGN CRITERIA
6.1 THERMAL INSULATION
insulclad® Pre-Meshed Board satisfies the insulation
requirements of Australian Standard 1366. The standard
grade used is M-grade (approximate density 19kg per m3).
The various wall constructions will have the following thermal
resistance values.
Wall system thermal performance made up from 10mm wall
lining 100mm stud thickness of polystyrene and render.
4 Thickness Total R value m2.K/W)
40mm 1.5
75mm 2.3

6.2 WIND LOADING
insulclad® Pre-Meshed Board will withstand wind forces
equivalent to a cladding design wind speed of 39.5m/sec.
This covers most normal design situations. Precise fixing
and framing centres are detailed in the CSIRO Appraisal
certificate. These recommendations cover Terrain Categories
1 to 4 in Australia.
Note: The above information is based on tests carried out
on the standard insulclad system.
insulclad® Pre-Meshed Panels bonded to concrete or masonry
are acceptable in all wind zones.
6.3 OUTBREAK OF FIRE
insulclad® Pre-Meshed Board must be separated from
chimneys heating appliances and flues as required by
Acceptable Solution CI / ASI.
Spread of fire:
• Ignitability: 0
• Spread of flame: 0
• Heat evolved: 0
• Smoke developed: 1
6.4 CONSTRUCTION JOINTS
Construction joints are required in walls longer than 20 metres
or higher than two storeys.
For residential a construction joint is not required for two
storeys plus a gable end.
6.5 SOUND INSULATION
The insulcad® Pre-Meshed Board system fixed over timber
framed construction lined with dry wall board has an
approximate sound transmission class (STC) rating of 40.
This calculation is based on the report of Novatex Products
Insulclad System which is a simular system in
composition to that of insulclad Pre-Meshed Board.
6.6 WEIGHT
The insulclad® Pre-Meshed Board weighs approximately 7kg/m2.
6.7 CURING
Cement-based finishes must be applied when temperature
is between 5 and 30 degrees celsius and must be protected
from rain and water run 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.
7 INSTALLATION
GUIDELINES
The long-term durability of the insulclad® Pre-Meshed Board
is dependant upon the correct preparation of all its components
in strict accordance with all the relevant written instructions
and detail sheets. On-site application is beyond the control
of Novatex Products and cannot guarantee workmanship
or the correct preparation and application of its products.
The contractor shall take overall responsibility for on-site
supervision staff training installation and quality control.
7.1 FRAMING SET-OUT PREPARATION
(TIMBER OR STEEL)
• Studs must be set out at 600mm maximum centres. Before
commencing work ensure the builder straightens any badly
bent studs.
• Perforated foil or breather type building wrap must be fixed
to the framing.
• When fixing VH polystyrene battens to studs fix a small
offcut to the bottom plate between the studs.
• For reclads fix battens over existing cladding. Remove any
decaying areas first.
7.2 WINDOWS
• New windows should be set out over the cavity.
• For wooden windows same as aluminium.
• There are several options for the sills. Refer to detail drawing
number 14.
7.3 FLASHINGS
• Windows – refer to detail drawing number 13.
• Roof flashings and parapets – refer to detail drawing
numbers 6 7 and 11.
• Joists designed to carry decking must have a continuous
flashing fitted.
7.4 PENETRATIONS
• All electrical cable must go through a conduit or a timber
block; place mesh over the top.
• Seal around tap fittings; use expandable foam to fill holes
and mesh over.
• Use timber fixing blocks 300mm long for down pipe
brackets; mesh over the top.

7.5 FIXING PANELS
• To avoid excessive waist fix sheets horizontally and
cut around window and door openings. Sheets can
be fixed vertically.
• All joints must be glued.
• External corners can be lapped or mitred.
• Internal corners butt joined and glued.
• All fixings must be 300mm apart; screws should be placed
50mm away from the edge of the sheet.
7.6 PVC AND JOINTING
• Use 200mm self-adhesive mesh for all joints.
• Place a 200mm x 300mm strip of mesh diagonally across
the corners of all openings.
• Fix PVC beads in place. Refer to construction details.
• Mix insulclad® base with 1 litre of resin and 3.8 litres of
water to a fine consistency and trowel over the top of the
self-adhesive mesh. Skim only and feather out the sides.
Stop over washers with a mix that is slightly thicker
in consistency. (If it slumps it is too thin.)
• All external corners must be reinforced with a pre-meshed
corner bead imbedded into a layer of insulclad® base
or glued on first.
7.7 MESHING AND FINISHING
• Place 200mm self-adhesive mesh over all joins; glue on premeshed
corners to all externals.
• Mix one bag of insulclad® base with 1 litre of resin and 3.8
litres of water. Mix to a creamy consistency let stand for five
minutes then re-stir. Spread thinly over joins and feather
out all edges.
• Use a stiffer mix of the above to cover screw fixings and
PVC edges.
• Allow jointing to dry then apply one coat of scratch & drag.
Finish off with a plastic float.
• For a quick and easy texture apply one coat of Ezytex®
medium sponge finish over a dry scratch & drag.
• Finish with a good quality 100% acrylic paint applied to
manufacturer’s specifications
8 MAINTENANCE
Damaged areas cracks or sealant details which could allow
water to penetrate the cladding must be repaired to ensure
the building remains water tight.
Accidental damage can be repaired using base and finish
and where required by using additional fibreglass mesh.
Minor cracks can be repaired with a polyurethane type sealant
and be repainted. Suspect sealant joints must be raked out
and resealed.
Termites: Please seek expert advice for termite prevention.
8.1 CLEANING
The chosen finish should be regularly hosed down. Localised
grime or ingrained dirt may be removed with a suitable
detergent and water; the exterior can also be cleaned with
a low pressure water blaster. Check all sealant joints and if
required reseal.
8.2 RECOATING
Acrylic painted surfaces will need repainting after five to 10
years depending on location and the condition of the paint.
Clean the painted wall surface with a suitable chemical 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 good quality 100%
acrylic paint.

insulclad ®
insulclad® is a lightweight insulating cladding system for domestic or commercial
construction. Unlike the Pre-Meshed Board all work is carried out on site by
approved contractors.
The system utilises sheets of expanded polystyrene fixed to timber steel framing
or over existing exterior wall surfaces.
The polystyrene is then reinforced with fibreglass mesh imbedded in a polymermodified
cement-based render then finished with a coat of Ezytex finishing render
painted with a good quality 100% acrylic paint
Architectural Mouldings
Made to measure Novatex Architectural Mouldings are finished in a fine sand
ready-to-paint finish.
Refer to catalogue for sizes and shapes.
Ezytex® Finishing Renders
Ezytex® finishing renders are pre-mixed polymer-modified cement-based renders
with workability aids and fibres to add strength and bond characteristics not achievable
with site-mixed renders.