RockShell Building Manual by Louise Matthews

nc energy efficie tem put into sys y

RockShell Wall System Building Manual

ROCKSHELL WALL SYSTEM速

26-28 Hammersmith Grove London W6 7HA Tel: +44 (0) 845 241 2586

Unit 11 Northwood Court Santry Dublin 9 Ireland Tel.: +353 (0) 1 891 1055 E-mail: rockshell@rockwool.ie www.rockshell.ie

Manual No: RSMan01. Version 1. 01/10/2011

ROCKWOOL LIMITED Registered Office Pencoed Bridgend CF35 6NY Tel.: +44 (0) 1656 868 400 E-mail: rockshell@rockwool.co.uk www.rockshell.uk.com

proservice.dk

Building Manual The RockShell wall system is an innovative, low energy solution for the construction of load bearing walls in low-rise buildings.

CREATE AND PROTECT

ROCKSHELL WALL SYSTEM®

This building manual is published by Rockwool Limited. Preparation, layout and graphics: ProService Reklamebureau A/S Photos: Behrendt, PJ Foto et al. The instructions and detailed information in this manual were deemed correct at the time of writing and are published in good faith. However, Rockwool Limited offers no guarantee as to their accuracy and thus, Rockwool accepts no legal responsibility for mistakes, errors or omissions within this manual . Rockwool also reserve the right to make necessary system and product changes at any time without notice.. Reproduction of this brochure (or any part herein) is only permitted by written agreement from Rockwool Limited. 1st printing – Nov. 2011 © Rockwool Limited

Y = The images within this Building Manual are taken from a European installation. They are shown for illustration purposes only and are indicative of the methods used during a RockShell construction. The images are not intended to illustrate UK best practice and personnel shown do not comply with UK health and safety regulations.

ROCKSHELL WALL SYSTEM

Building manual Content: 1

Introduction ................................................................... 4

Design specifications....................................................12

Performance .................................................................24

System components .....................................................34

References ....................................................................40

Assembly on site: 6

Foundation ....................................................................44

The RockShell wall ......................................................58

Windows and doors ......................................................62

Corners .........................................................................68

10 The exterior face of the RockShell wall .......................74 11

The interior face of the RockShell wall ......................80

12 Intermediate floor ....................................................... 86 13 Connecting to roof and gable .......................................92 14 Quality control ..............................................................98 15 Handling instructions ................................................100 16 Support and calculation tools ....................................102 17 Sustainability ..............................................................104

3 Y

1. Introduction

ROCKSHELL WALL SYSTEM速

1. Introduction The requirements for energy-efficient buildings are tightening every year

It is important to think “low-energy” from the beginning A building often has to last for 100 years or more. It is therefore sound economics to optimise the energy efficiency of new buildings, and reap the full economic benefits right from the start. Doing so at a later date would be both more expensive and more difficult.

Regulations are being introduced governing the energy efficiency of buildings, generating a need for innovation in structures, project engineering and construction processes In the western world around 40% of energy consumption originates from buildings. Most of the energy consumed is used for heating or cooling buildings. If we are to overcome the global challenges that we face concerning climate and energy supplies, it is vital to focus on reducing the energy consumption and CO2 emissions of buildings. The race for energy-efficient solutions has begun. The stricter requirements imposed by the authorities concerning energy losses and reduced CO2 emissions are making new demands on the construction industry regarding building design, materials, efficiency and overall economy.

Insulation is one of the quickest and most profitable ways of saving energy and reducing CO2

How to build a low-energy house: Minimise Energy Losses e.g. Passivhaus Example • Insulation thicknesses of 300 – 500 mm • No thermal bridges • Triple-glazed low-energy windows • Controlled ventilation with heat recovery • Air-tight joints • Building orientation: windows facing south, west and east for maximum utilisation of solar energy • Use of sun-blinds during hot periods • Energy consumption for heating and cooling max. 15 kWh/m2 per year. • Efficient low-energy appliances – total primary energy consumption max. 120 kWh/m2 per year Installation of alternative energy sources • Solar cells • Ground source heat • Small wind turbines • Energy collection systems

Studies carried out by McKinsey and Vattenfall show that insulating buildings is one of the most profitable ways of saving energy and reducing CO2 emissions. Insulation represents better value for money than biofuel, wind power or solar energy for example.

A well-insulated building with controlled ventilation is the healthiest solution Studies by the University of Jena in Germany show that more than 20% of our buildings have problems relating to draughts and indoor climate. A well-insulated home combined with controlled ventilation is the best and most economical way of preventing or overcoming this. Thermal insulation that provides an air-tight building guarantees a pleasant and constant temperature all year round.

5 1. Introduction

ROCKSHELL WALL SYSTEM速

RockShell wall system: Minimal energy loss with optimal construction methods

Today, it is already possible to build so energy-efficiently that 90% of the energy consumption of a current average building can be saved. However, the continued use of traditional methods, structures and construction processes can often make a building unnecessarily expensive, resource-intensive and less energy-efficient than possible. This was a key factor behind the development of the RockShell wall system.

6 Y

RockShell is an innovative system for constructing the load bearing walls of low-rise buildings. The RockShell wall system is a patented modular system, that meets future energy efficiency requirements, today. The RockShell wall system combines the requirements for sustainable lightweight constructions with optimal energy performance, efficient installation processes, technical support and end user benefits. In other words: The RockShell wall system is the ideal all-in-one construction system.

The RockShell wall system The RockShell wall system is the load bearing core of the walls. A service wall is installed on the interior face of the RockShell wall system and a wide range of exterior finishes can be installed as the exterior facade. The RockShell wall system is a unique combination of steel I-profiles, dense Rockwool insulation and interior OSB lining. This system results in a pioneering low energy wall system comprising minimal components and a slim profile.

The modular design also decreases the risk of making mistakes on the building site. For all interfaces between the RockShell wall system and other building solutions a standard detail with minimised thermal bridges has been created. Due to the modularity of the system, very few adjustments are needed between different house designs. As a result, details could be used for different house designs. The system comprises very few components, which are easily assembled with just a power drill on site. RockShell is quick and easy for installers to learn and understand. Actual installation is quick and simple versus other building solutions, meaning improved build times and less mistakes on site. The RockShell solution is delivered on-site to fit the specific house design. As almost no adjustments or modifications are necessary on site, the time spent on modifications and material waste is minimal.

A service wall will be installed on the interior face of the RockShell wall system.

Facing material is installed on the exterior face of the RockShell wall system.

7 1. Introduction

ROCKSHELL WALL SYSTEM速

Energy efficiency put into system

8 Y

Support from start to finish

With the RockShell wall system, you are always guaranteed: 1 Project engineering assistance (designs, calculations and delivery specifications. 2 On-site advice. 3 Installation advice & instruction. 4 After-sales service. The RockShell wall system is a completely new way of building lightweight load bearing walls. As a result Rockwool Group offer comprehensive technical advice and support,which will enable you to complete the entire construction process with confidence.

The RockShell wall system – inherent advantages: 1 The RockShell wall system can be specified to meet Passivhaus or Level 6 of the Code for Sustainable Homes. 2 U values can be optimised by altering the thickness of insulation within the service void. 3 Minimised thermal bridges. 4 No risk of moisture: Diffusing open structure which allows water vapour to pass through the wool, without condensing. 5 Suitable for standard construction components (doors, windows, roofs, etc.) 6 Optimal freedom with regard to architectural design: Free selection of the external façade. 7 Efficient construction process: Logical and rapid modular construction, which minimises assembly time and reduces mistakes and defects. 8 Bespoke deliveries produced specifically for each individual building. This minimises both adaption at the construction site and waste.

Reduced total costs The construction of a building is cost-intensive, right from planning and design through construction, until the building is ready for use. It is therefore important to optimise each individual phase, so that all unnecessary costs are eliminated, errors are avoided and the overall construction process takes place as smoothly as possible. A carefully considered system combined with a rational construction process results in faster construction and a total cost which is lower than with traditional construction methods. In a building which uses the RockShell wall system, the process and costs will typically be distributed as in the following chart.

Installed cost comparison: The RockShell wall system and a standard timber solution with a wooden façade

TRADITIONAL TIMBER ROCKSHELL WALL SYSTEM

NB: Costs associated with waste and disposals are not included in the table. In general, however, waste and disposal costs are considerably greater with a traditional solution than with a RockShell solution. The RockShell wall system is supplied as a complete, customised system, delivered for each particular building. This results in only minimal adaptation and waste in the construction process itself.

DESIGN PHASE

PLANNING

MATERIAL COSTS

INSTALLATION COSTS

FACADE

9 1. Introduction

ROCKSHELL WALL SYSTEM®

Rockwool means extra safety

Today, choosing the right insulation product is more important than ever because of the stricter requirements for energyefficient and sustainable buildings. Using Rockwool stone wool will guarantee you both efficient thermal insulation and a better technical solution. The product’s inherent qualities give extra performance compared with other types of insulation. Rockwool is shown by independent assessments to be amongst the most sustainable insulation products available anywhere, leading to an unrivalled combination of environmental savings, energy reduction, sound insulation and fire safety.

4-in-1 Rockwool can deliver 4 superior benefits from 1 product – Fire resistance, Superior Acoustics, Durability and Sustainability.

Fire resistance Rockwool products withstand temperatures up to 1000° C, making them exceptionally resistant to fire. This resistance can slow a fire’s progress and buy precious time for rescue operations while helping to protect the building’s structure from unnecessary damage. Yet while heat and flames are bad enough in a fire, smoke is the serious danger. It can suffocate occupants, and it can incapacitate people who might otherwise have been able to escape. Rockwool insulation keeps toxic smoke from insulation to a minimum for even greater safety.

Superior acoustics Buildings are noisier than many people think. Traffic outside, ventilation systems, music, talking, doors opening and closing.

So many sounds contribute to a typical room’s acoustic environment, we sometimes don’t even register them consciously. But we are affected by them. Environments with a high noise level can be stressful and make it hard both to concentrate and relax. Rockwool insulation and acoustic ceiling panels dampen noise to improve comfort and quality of life both at home and at work.

Durability Our products are built to perform over the long haul. Rockwool stonewool slabs and claddings remain stable over time, and they don’t allow cold bridges to form. But at Rockwool, it’s not just our products that are “rock solid”. So is our time-honoured name, and our reputation for delivering documented benefits and providing expert advice to architects, designers, contractors and building owners.

Sustainability Rockwool insulation is one of the most practical, cost effective and environmentally efficient means of reducing energy consumption in the home. It reduces the need to burn fossil fuels, reduces CO2 released into the environment and avoids climate change.

Comfort and indoor climate Insulation that provides an air-tight building envelope guarantees a pleasant and constant temperature all year round. Rockwool stone wool meets the strictest European requirements in relation to indoor climate, and is certifi ed in the Finnish M1 emission class for construction materials.

ALL-IN-ONE FET Y SYSTEM SA

Moisture-repellent Rockwool stone wool is moisture-repellent. If the insulation is exposed to rain, only the outermost few millimetres will get wet. This will disappear rapidly when the rain stops. Rockwool stone wool is also breathable and allows water vapour to pass through the wool – without condensing.

Documentations and approvals The RockShell system has been tested according to the requirements of European Technical Approval (ETA) and tests have been performed and certified at independent test facilities. Fire from the outside: REI 90 minutes. Performed by DBI in Denmark Fire from the inside: REI 60 minutes. Performed by DBI in Denmark Sound reduction: Minimum 54 DB. Performed by DELTA in Denmark Load bearing capacity per profile (height 2.7 m): 53.3 kN. Performed by SP in Sweden Passivehaus approval. The system has been certified by the Passivhaus Institute in Germany

All-in-one system safety Although the RockShell wall system is a new method of construction, it has been tried and tested at construction sites and is certified through independent laboratory tests. This guarantees the quality of every component in the system and ensures that the system functions in practice at the construction site and in the finished building. As a result it provides a safe, fast and efficient construction method, which gives planners, contractors, installers and home-owners maximum security throughout the construction process. The Rockwool Group, the world’s largest manufacturer of stone wool, is behind the development of the system. The RockShell wall system is also backed by comprehensive project support during all phases of the construction from the initial building design through to construction. Ensuring completion of the project without compromising end-user benefits such as energy performance, sustainability, indoor climate or total building quality. The RockShell wall system’s inherent characteristics with regard to fire protection, sound and noise insulation, moisture protection, etc. help make the system a complete solution for low-energy buildings of the future. The RockShell wall system is the optimum all-in-one building system.

European Technical Approval. Granted by ETA in Denmark. ETA-11/0013

11 1. Introduction

ROCKSHELL WALL SYSTEM速

2. Design specifications Content: 2.1

Modular concept......................................................13

2.2

Dimensions..............................................................13

2.3

Loads .......................................................................14

2.4

Foundation...............................................................16

2.5

Column profiles .......................................................16

2.6

End columns ............................................................17

2.7

Windows and doors..................................................17

2.8

Lintels......................................................................18

2.9

Bay windows............................................................18

2.10 Wool elements.........................................................19 2.11 External finishes......................................................20 2.12 Service walls............................................................21 2.13 Party walls...............................................................21 2.14 Interior walls ...........................................................21 2.15 Intermediate floors..................................................21 2.16 Second storey...........................................................22 2.17 Roofs........................................................................22 2.18 Gables......................................................................23 2.19 Maintenance and repair...........................................23

12 Y = The images within this Building Manual are taken from a European installation. They are shown for illustration purposes only and are indicative of the methods used during a RockShell construction. The images are not intended to illustrate UK best practice and personnel shown do not comply with UK health and safety regulations.

2.1 Modular concept The RockShell wall system is constructed as a modular system with a module width of 600 mm. The modules are enclosed by vertical I-profiled (RockShell column profile) bearing members, whose centre axes represent the module axes. When using RockShell end columns, e.g. at corners or windows, the module axis is located at the flat side of the end columns. The outer module axes of a building are defined by the outer side of the OSB boards, touching the RockShell columns. Wherever possible, all measurements should be adjusted suit these module sizes. 700

600

650

600

Figure 1: Modular grid setup of the RockShell wall system, including an opening. Numbers in red typing: Width of system modules. Numbers in grey typing: Widths of standard wool elements

600

650

600

600 275

In order to avoid mistakes in understanding, the names of the 75 dimensions of a RockShell building are defined in figure 2.400

Height

Length

The length of the building can theoretically be infinite. It is limited by the maximum wind load that can be applied to the building in relation to structural stability, especially in the gable walls and lifting forces on the fasteners to the foundation.

Length

Width

B Figure 2: Dimension names for a RockShell building

Width

Height

2.7 2.7

The height of the RockShell wall system is limited to two and a half storeys, Height in which the heights of the wall bearing members (column profile, end profile) are a maximum of 2.7 m. The roof pitch can be chosen freely as long as the maximum loads are accommodated. Figure 3 shows an example of the geometry of a building with a roof pitch of 45째, which, at Length a maximum width of 8 m, results in a total maximum building height of 9.4 m.

9.4

4.0

The reference building was limited to a width of 8 m which was equal to the span of the roof. In general, the width of the building depends on the maximum load on the RockShell wall system as well as on the maximum wind load that can be applied to the building (see chapter 3).

Width 8.0

Figure 3: Maximum height of RockShell wall system

13 2. Design specifications

9.4

2.2 Dimensions

275

ROCKSHELL WALL SYSTEM®

2.3 Loads Fv

2700

600

150

100

The loads on the RockShell wall system have been calculated according to EC 1991-1 for a predominant structure at a fictional but realistic location to show the possibilities of the system. Where necessary, British National Annexes of the Eurocode (EC) documents have been used to calculate the load resistance of bearing members of the RockShell wall system. A schematic overview of the load situation is given in figure 4.

Figure 4: Load situation and geometry of the RockShell wall system

Important: Loadings must be calculated for each individual project based on the specific location, especially those for wind and snow.

Specific weight of RockShell wall system Thickness

Density

Weight

(mm)

(kg/m³)

(kg/m²)

8.0

1900

15.20

Carrier Board

10.0

1110

11.10

Laminated veneer lumber, 98 mm

27.0

480

2.12

250.0

17.50

Column profile, steel, 150 x 80 mm

1.0

7850

6.67

C-profile top/bottom, steel, 152 x 50 mm

1.0

7850

1.47

Member

External render

RockShell insulation, 2700 x 600 mm

Screws

0.50

OSB board

12.0

600

7.20

Insulation in service wall

45.0

1.35

Internal Z-profile, 45 x 30/30 mm

0.56

7850

0.97

Gypsum plasterboard

12.5

736

9.20

Total, 2700 x 600 mm

73.28

Dead loads

1 RockShell wall system The specific weight of the RockShell wall (including one layer of gypsum plasterboard on the inside) has been calculated as 73.28 kg/m2. A value of 0.75 KN/m2 is used in the calculations. Specific weights have been calculated with a module distance of 600 mm between the RockShell column profiles. The typical U-value of this setup is 0.143 W/(m2K). 2 Roof The specific weight of a typical roof build-up with heavy roof tiles has been calculated as 88.15 kg/ m2. Because of the various materials that may be used, a value of 1.00 KN/m2 is used in the calculations. See table 2.

Table 1

3 Intermediate floor The specific weight of a typical lightweight intermediate floor has been calculated as 68.65 kg/ m2. Because of the various materials that may be used in the in floor construction, a value of 0.80 kN/m2 is used in the calculations. See table 3.

Specific weight of roof construction Member Roof tiles, 7.5 per m² Battens, 38 x 73 mm per 330 mm

Density

Weight

(kg/m³)

(kg/m²)

6 (kg)

45.00

600

5.00

Plastic underlay, 3.2 mm

3.00

Live load

A value of 2.0 KN/m2 is used in the calculations as the live load on intermediate floors. To take possible deviations in other countries into consideration, this value is higher than the value given in many national annexes of EC 1991-1.

Rafters, 60 x 250 mm per 600 mm

600

15.00

Insulation, 300 mm

8.64

Snow loads are calculated according to EC 1991-1-3. As mentioned before, snow loads need to be calculated for the specific location of each project.

Membrane, 0.2 mm

0.14

Lathing, 38 x 57 mm per 600 mm

600

2.17

Gypsum plasterboard, 12.5 mm

736

9.20

Total

88.15

Snow load

Wind load

Wind loads are calculated according to EC 19911-4. As mentioned before, wind loads need to be calculated for the specific location for each project.

Table 2

Specific weight of lightweight intermediate floor Density

Weight

(kg/m³)

(kg/m²)

Wooden flooring, 20 mm

600

12.00

Gypsum plasterboard, 2 x 12.5 mm

736

18.40

Trapezoidal sheets, 1.25 mm

7850

10.00

Other possible parameters influencing the structure of the RockShell wall system such as temperature, accidental loads or seismic loads are not considered for structural calculations of the RockShell wall system.

Member

C-profile, steel, 200 x 30 x 1.5 mm per 600 mm Insulation, 100 mm

3.50 32

3.20

Acoustic profile, 25 mm per 600 mm

7850

1.00

Gypsum plasterboard, 15.4 mm

736

11.35

Gypsum plasterboard, 12.5 mm

736

9.20

Total

Other

68.65

Table 3

15 2. Design specifications

ROCKSHELL WALL SYSTEMÂŽ

2.4 Foundation As the base for the RockShell wall system, the foundation is especially important. Careful attention needs to be paid to the design and a precise construction of the foundation to ensure the erection of a faultless wall system. The foundation must be constructed of concrete with a quality of at least C20/25. The use of lightweight concrete blocks, a layer of mortar or similar material on top of the foundation should be avoided, as this increases the risk of substrate failure due to high point loads acting on the substrate. The foundation must be levelled to an accuracy of Âą 1 mm over 3000 mm. In addition to the levelling of the foundation between two points, particular attention should be paid to ensure a smooth top surface free from holes or recesses or protrusions. In order to achieve this finish it is recommended that the shuttering is set-up accurately in order to use it as a stripping aid for the wet concrete. The foundation must be 12 mm wider than the bottom profile to accommodate the distance to edge fixing requirements for the foundation bolts used to anchor the RockShell system. This requires a minimum foundation width of 164 mm wide. Y

2.5 Column profiles

The major load bearing elements of the RockShell wall system are the RockShell column profiles. These are designed as I-shaped profiles. These bearing members are to be placed vertically between two RockShell wool elements. They serve as a support structure for fixing both the exterior finish and OSB boards on the inside. They are delivered to site in the length required (usually equal to the height of the storey). Due to their geometry and bearing capacity, column profiles cannot be used at corners or as lateral members for openings in the outer wall for doors or windows. In these locations, end columns are used.

2.6 End Columns RockShell end columns are supplied preassembled and delivered to site in the length required. All end columns are formed from two C-shaped profiles that are joined together so that a closed box is formed. There are four variations for the final setup of an end column concerning C-shaped profiles that might need to be fixed to the box-shaped end column, depending on the use of the end column.

Four variations are possible: Y

A Corners, C-shaped profile

B Corners, C-shaped

attached to one side of the end column.

profile attached to two sides of the end column.

C Doors, C-shaped profile attached to one side of the end column (storey height) and partly on the second side (for a lintel).

D Windows, C-shaped profile attached to one side of the end column (storey height) and partly on the second side (for parapet insulation and a lintel). For window and door sections, the second C-shaped profile is not expected to be placed where windows or doors are to be mounted.

2.7 Windows and doors As shown in figure 1 and figure 4, windows and doors are vertically framed by RockShell end columns. On top, a lintel between the end columns is used to bridge loads from above and lead them into the end columns. It is advisable to align openings for windows and doors to the modular grid of the RockShell wall system as a multiple of 600 mm; however, it is also possible to use elements that do not fit the modular grid. In such a case, both the lintel and the RockShell standard wool need to be produced and delivered in a special length/width that fits the elementâ&#x20AC;&#x2122;s width. Parapets of windows are not considered to be load bearing, though it is possible to load the top profile of a parapet temporarily with the load of an ordinary window before this is anchored to the end column on both sides.

17 2. Design specifications

ROCKSHELL WALL SYSTEM®

2.8 Lintels The RockShell wall system provides preassembled lintels to be used above openings for windows and doors. A lintel consists of at least four major parts: a top profile, a bottom profile and two side parts. These four parts form a box with two open ends, which is filled with stone wool to avoid thermal bridges. Lintels that span over more than one module are strengthened by one metal interior partition per module.

2.9 Bay windows The dimensions of bay windows should follow the modular grid of the RockShell wall system to minimise variations in the size of the RockShell wool elements. It is also recommended that bay windows are designed with sides displaying an angle of 45° to the main façade line. Other angles are possible but require special equipment for adoption of wool elements in the corners of the bay window.

2.10 Wool elements

570

600

450

600

255

600

450

600

285

To ensure an efficient production process it is recommended that as many RockShell wool elements as possible are used in the standard width. Ideally, at least 80% of the modules should be the standard width. Variations cause higher costs in production, cutting and installation. A width of 600 mm is regarded as standard (see Figure 1 for more information): RockShell wool elements must be at least 200 mm wide, thinner elements will increase the risk of breakage during handling on site.

570

315 315

600

365

600

155

600

550

Column profile

200

450

600

450

600

285

360

Figure 5: Module grid maximising use of standard wool elements Top: original layout of a faรงade with unfavourable positioning of openings. Bottom: modified module grid, optimised for to maximise standard wool elements.

End column

19 2. Design specifications

ROCKSHELL WALL SYSTEM速

2.11 External finishes External finishes are not part of the RockShell wall system. The system has been designed to accommodate a variety of finishes, such as wood cladding, panel systems, bricks, brick slips or render to protect the RockShell wall system from external influences. These finishes can be designed and specified separately. The interface for the external finish is provided by vertical laminated veneer lumber (LVL) boards mounted on the outside of the RockShell system over the joints between wool elements. The LVL boards are screwed through the outer part of the RockShell wool into the vertical bearing members (column profile, end column, lintel). Due to possible high loads from the cladding the LVL boards need to fastened to the roof construction. Where this occurs, it is essential that the LVL boards are installed in continuous lengths. Where render based finishes are used they need to be applied on a carrier board. To avoid cracks in the render layer, the carrier board must be fixed between the centres of two vertical LVL boards. In addition non-bearing LVL boards, e.g. at parapets, need to be bridged completely by a sheeting board to transfer loads from the cladding into the bearing system. The same applies for panels and wooden cladding.

2.12 Service walls The service wall is not an integral part of the RockShell wall system. The primary purpose of the service wall is to meet the service needs of the building. However, it is strongly recommended that a service wall is con-structed to assist with thermal/energy, acoustic and fire performance mentioned in chapter 3.

2.13 Party walls The design of party walls is independent of the RockShell wall system. However, a carefully designed connection between the two walls should be ensured to address various construction issues such as statics, fire and acoustic performance. The OSB board layer on the inside of the RockShell wall system may only be interrupted by the party wall construction if static calculations prove the global stability of the building and the air-tightness of the joint is provided by adequate measures.

2.14 Interior walls The construction of interior walls is not part of the RockShell wall system. Interior walls can be designed independently from the RockShell wall system, e.g., as dry lined wood/metal stud walls or as heavy masonry/concrete walls. In some circumstances the interior walls can be a vital contributor with the RockShell wall system to the global stability of the building. This will be determined when performing the structural calculations for the individual project and location, based on the external loads.

2.15 Intermediate floors The RockShell wall system is designed to be combined with light intermediate floors consisting of structural steel or timber elements. All issues concerning the design and statics of the intermediate floor are to be covered by the supplier of the intermediate floor. The intermediate floor should be mounted to the RockShell wall system on the inner side of the OSB boards into the LVL and C-shaped profiles and can also be fastened to the RockShell steel profiles placed behind the OSB boards. See chapters 3 and 12 for more information. When considering the overall structural system, it must be remembered that intermediate floors below occupied attics can be stressed by horizontal forces from the roof construction. Also, intermediate floors may serve as a shear panels for strengthening the building against wind loads. Therefore the joint between floor and wall must be calculated by a structural engineer.

21 2. Design specifications

ROCKSHELL WALL SYSTEM®

2.16 Second storey In two storey buildings, the modular grids of the RockShell outer wall system should correspond to each other on the two storeys to optimise the transfer of loads between the two storeys. It is also helpful to place windows (or doors) of the same size between the same vertical module line on top of each other. An end column on the second floor implies higher vertical loads at this module line and requires another end column at the same module line in the floor below. Unnecessary end columns in one of the storeys could lead to an increased number of wool elements (i.e. various widths) and a longer installation time and therefore to higher costs. The top of the second storey RockShell wall is completed by a 63 mm thick LVL board secured to the top profile. The roof construction is then mounted and securely fastened to this LVL board. Y

2.17 Roofs The roof construction is not part of the structural RockShell wall system. It can be designed independently from the RockShell wall system. Where possible it is advantageous to place rafters on top of the vertical bearing members of the RockShell wall system (column profiles or end columns), i.e. close to the module axes of the RockShell wall system. If this is not possible, a suitably designed horizontal element – preferably made of wood – needs to be placed on top the RockShell wall system to take up loads from those rafters that are placed in-between the RockShell column profiles. Special attention needs to be paid at openings for windows and doors.

Horizontal forces from the roof perpendicular to the wall plane need to be retained at the top of the RockShell wall system, either by joists of intermediate floors or by bottom chords of the roof construction.

2.18 Gables The principles of constructing a gable wall correspond to those of the ordinary RockShell wall. It is recommended to separate the triangular part of the gable wall from the storey part on the height of the eaves to provide a framing LVL board on the same level all around the building. In the case of a gable triangle with a height of more than 2.7 m, a horizontal intersection of the gable wall might become necessary. The construction is similar to this for the intersection at the bottom of the gable triangle.

2.19 Maintenance and repair Maintenance requirements for the RockShell wall system are minimal. Excluding internal and external finishes, which may need to be painted or treated periodically, as well as elastic joints around building components like windows or doors, the RockShell wall system itself is free of maintenance. Repair work can be performed as for any other light frame wall system.

23 2. Design specifications

ROCKSHELL WALL SYSTEM

3. Performance Content: 3.1 Statics...................................................................25 3.2 Acoustics...............................................................30 3.3 Tightness ..............................................................30 3.4 Fire .......................................................................31 3.5 Thermal ................................................................32 3.6 Moisture................................................................32

24 Y = The images within this Building Manual are taken from a European installation. They are shown for illustration purposes only and are indicative of the methods used during a RockShell construction. The images are not intended to illustrate UK best practice and personnel shown do not comply with UK health and safety regulations.

3.1 Statics The structural load-bearing capacity of the RockShell wall system has been verified both by fullscale tests and by theoretical calculations. From the calculations and tests performed, which include all designed elements, the RockShell wall system has been shown to possess the necessary strength and specifications to meet the requirements for the intended structures.

Design capacity

Calculations

All appropriate calculations have been carried out by independent consultants of Rambøll, Denmark. As the RockShell wall system can be used in a variety of building types (e.g. residential, commercial, industrial) and in various locations, structural calculations are based on a predominant structure at a fictional but realistic location to show the possibilities of the system.

Compression* (kN)

Shear (kN)

Bending (kN)

53.3

6.17

4.31

Table 4

6.00

Tests

Full-scale tests have been performed on a representative number of standard RockShell elements by the SP Technical Research Institute of Sweden. Test results were obtained for the standard I-shaped RockShell column profile as follows in table 4 and figure 6.

Load type

5.00 Bending moment (kNm)

Load carrying capacity of a standard RockShell wall element

4.00 3.00 2.00 1.00 0.00 0.00

5.0

10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0 50.0 55.0 60.0 65.0 Vertical load (kN)

Test value Design value Load, 1 1/2 storeys ref. str.

Load, 2 1/2 storeys ref. str.

Figure 6: The combined capacity of a standard RockShell wall element tested at SP, Sweden

Location: Leeds, UK Structure: 8 x 12 m, storey height 2.7 m, roof pitch 45° 2 storeys plus heated attic (alternative calculations: 1 storey plus heated attic) The results of the structural calculations are indicative and should not be transferred to any real project. Loading calculations should be performed individually for each project. The static report prepared by Rambøll states that: “The wall system benefits from the mechanical properties of the application of mineral wool elements as a part of the structural system.”

Preliminary calculations during the development of RockShell indicate an increased bearing load due to the RockShell column profiles of 20 to 30% compared to a corresponding wall system without mineral wool as infill. The load bearing potential of the final standard wall setup using a RockShell column profile has been tested but not calculated.

25 3. Performance

ROCKSHELL WALL SYSTEM

End column Load type Design capacity

1 Compression* (kN)

Tension (kN)

Shear (kN)

Bending (kNm)

Combined

72.2

178

27.6

9.13

n.a.

Table 5

*Capacity

Beam over openings Load type Design capacity

Shear (kN)

Bending (kNm)

53.8

24.2

End column

Calculation results for end columns are included in table 5.

Beam over openings

Design capacities have been calculated for beams over openings. Besides capacities for shear and bending (see table 6), there are restrictions on combined loads (shear and bending) and the vertical deflections of the beams.

Table 6

26 Y

12000 1800

4400

1800

2200

1800

1: Global stability The overall stability of the structure is highly dependent on the geographical conditions of the location and the individual geometry of each building. Therefore, overall stability must be verified by the responsible designer for each structure and location.

Wind load

1800

2200

1800

4400

For 1½ storey buildings, sufficient overall stability can be achieved by the OSB boards (12 mm) on the inner side of the RockShell wall system. For buildings with 2½ storeys, due to wind loads it may be necessary to strengthen the structure additionally, e.g., by utilising inner partition walls or stabilising concrete cores.

1800

1300 1800 1300 3000

3000

Figure 8: Stabilising walls, lateral Wind load

1800

8000

1300

1800

1300

1800

Figure 7: Stabilising walls, longitudinal

1800

Stability

2: Longitudinal stability (See figure 7) Three stabilising wall sections with a total length of 5.4 m in each façade wall, totalling 10.8 m of stabilising wall sections, are calculated to be sufficient for ensuring the longitudinal stability of the reference building. The 5.4 m in each façade wall can basically be set together at random in sections, e.g.: • 1.8 m + 1.8 m + 1.8 m or • 1.2 m + 3.0 m + 1.2 m 3: Lateral stability (See figure 8) Three stabilising wall sections with a total length of 5.4 m in each gable wall plus two internal stabilising wall sections of each 3.0 m, totalling 16.8 m of stabilising wall sections, are calculated to be sufficient to ensure the lateral stability of the reference building. The 5.4 m in each gable wall can basically be set together at random in three sections, e.g.: • 1.8 m + 1.8 m + 1.8 m or • 1.2 m + 3.0 m + 1.2 m 4: Temporary stability During construction the Rockshell walls should be strut braced using appropriate measures. Once the overall structural stability has been achieved as per the plans, e.g. by OSB boards and interior walls, the temporary strut-bracing may be removed.

27 3. Performance

ROCKSHELL WALL SYSTEM

Screwed connections

Connection

Detail

Screw

Fastener size (mm)

Number

Bottom joint

7,5 x 60

12/22

4,2 x 13

1 2)

4,2 x 13

1 2)

4,2 x 13

1 2)

12/22

4,2 x 13

21/51

4,8 x 80

2 1)

Top profile Top joint

2 3

Bottom joint, end column

End column

4,2 x 13

2 x n 4)

4,2 x 13

2 x n 5)

Corner joint

4,2 x 13

Bottom joint, end column

4,2 x 13

21/51

4,8 x 80

2 1)

4,2 x 13

1 2) 2 2)

Top joint, end column

Parapet top joint

4,2 x 13

OSB connections

31/61

4,8 x 35

32/62

4,8 x 35

6,3 x 50

4,2 x 13

2 x n 6)

4,2 x 13

2 x n 7)

Lintel

)

Lintel insulation

4,8 x 140

First floor joint

12/22

4,2 x 13

21/51

4,8 x 80

2 1)

4,2 x 13

1 2)

4,2 x 13

LVL nailer, fastening to eves

LVL nailer, fastening to gable

: : 3) : 4) : 5) : 6) : 7) : 8) : 9) : 10) : 2)

101

4,8 x 140 5,0 x 40

103

4,0 x 60

102

5,0 x 40

103

4,0 x 60

Fastener type: Plus washer Ø 22 mm, t= 2 mm, 5 mm < hole Ø 6 mm. Connection not regarded as bearing. Distance between screws: 120 mm (edges) and 250 mm (centre). n is the number is fastener pairs along the column height. Distance between screws: 200 mm. n is the number is fastener pairs along the column height. Distance between screws: 250 mm. n is the number is fastener pairs along half of the lintel length. Distance between screws: 100 mm. The number of screws here is equal to the number of screws needed to attach the short C-profile to the end column. Distance between screws: 600 mm. Not to be positioned near a module line. Washer Ø 80 mm, t = 1 mm. The number of screws is defined by the specific structural load. Distance between screws: 300 mm. The screws need to be placed alternating on both sides of the profile’s body At top and bottom of the LVL board, they are set as a pair.

102

Table 7 1)

2) 10)

24 12/22 13

21/51

12/22 41

Detail 1: Bottom joint

Detail 2: Top profile

Detail 4: Fixing of U Shaped Bracket

Detail 3: Top joint

72 71

21/51 53

52 43

Detail 6: Corner joint

Detail 5: End column

Detail 7: Bottom joint, end column

Detail 8: Top joint

81 25

32/62 31/61

33/63

Detail 9: Parapet top joint

Detail 10: OSB connections

Detail 11: Lintel

Detail 12: Lintel insulation

103

102

103

12/22 92 21/51 101 91

Detail 13: First floor joint

Detail 14: LVL nailer, fastening to eves

Detail 15: LVL nailer, fastening to gable

The illustrations may not display the actual number of fasteners used.

29 3. Performance

ROCKSHELL WALL SYSTEM

3.2 Acoustics The standard RockShell wall system comprising an internal service wall has been tested at the consultancy company Delta, Denmark for sound reduction properties according to EN ISO 140-3. Two tests have been conducted:

Test I:

In the first test, the RockShell wall section was “closed” on its external side by a 10 mm thick, carrier board used for various types of cladding. The sound reduction properties of the RockShell wall system with this carrier board can without further tests be used as a minimum value of the wall system with supplementary facing such as brick slips or bricks, or alternative facing such a 10 mm thick Rockpanel boards due to their higher mass.

The sound reduction index was measured as: Rw (C; Ctr) = 54 (-7; -15) dB

Test II:

For the second test, a rendered layer with a thickness of 8 mm was added to the carrier board of the wall section from test I.

The sound reduction index was measured as: Rw (C; Ctr) = 60 (-6; -14) dB

3.3 Tightness A

Air tightness

The air tightness of the RockShell wall system is mostly provided by the layer of OSB boards. The OSB boards are sealed at interfaces with other building components and at joints between the boards by permanently elastic sealant or air tight tape. To ensure the correct performance it is recommended that an individual blower-door test is carried out for each building project. Although OSB are not completely airtight, it is unlikely that the permeability of a building exceeds a value of n50 = 0.6 h-1 as long as the joints are sealed properly.

Wind tightness

The RockShell wall system offers sufficient wind tightness to minimise unwanted heat losses from inside the construction. There are three main reasons for this: • On the exterior face, cladding products such as plaster, brick slips or boards leave only a small ventilated air layer between cladding and insulation, taking the wind pressure off of the insulation. • The insulation material itself is a high density stone wool, making air movement inside the material almost impossible. • Behind the insulation, a wind and airtight layer of OSB boards is mounted, giving additional security against heat losses from the construction.

3.4 Fire The standard RockShell wall system including an internal service wall has been tested at the Danish Institute of Fire and Security (DBI) for fire resistance according to EN 1365-1. Two tests have been conducted, simulating fire resistance from both the outside and from the inside. The fire resistance classification for fire exposure from either side of the construction is REI 60. The fire resistance classification for fire exposure from the external side of the construction only is REI 90.

External exposure to fire

For this part of the test, no external cladding was applied to the RockShell wall system to prevent restrictions on the choice of external cladding. The RockShell wall system was finished on the outside by standard LVL nailers mounted in the normal way (27 x 98 mm, cc 600 mm). A 15 kN load was placed on each I-shaped RockShell column profile in the tested wall section at a distance of 25 mm perpendicularly to the wall surface. The rate of vertical deflection exceeded the critical value of 8.1 mm/min after 102 minutes of testing. Here, the load on the tested section could no longer be maintained due to a sudden bending of the vertical steel profiles. Until failure, no openings occurred in the tested section and the critical value for a total vertical deflection of 27 mm was not reached. The average temperature on the unexposed surface did not exceed 140 째C at a maximum temperature of 180 째C and cotton pads were not ignited during the test.

Internal exposure to fire

The structure of the tested RockShell wall section was the same as for the external fire exposure test. The load on the tested section could no longer be maintained after 66 minutes due to a sudden bending of the vertical steel profiles. Neither the rate of vertical deflection exceeded the critical value of 8.1 mm/min, nor did the value of the total vertical deflection within this time. Until failure, no openings occurred in the tested section and the criterion for a total vertical deflection of 27 mm was not reached. The average temperature on the unexposed surface did not exceed 140 째C at a maximum temperature of 180 째C and cotton pads were not ignited during the test.

31 3. Performance

ROCKSHELL WALL SYSTEM

3.5 Thermal Thermal calculations have been made by the consultancy company Belenos.

External cladding eg. 18 mm

U-value of the RockShell wall system

The calculations of the thermal transmission coefficient (U-value) of the RockShell wall system have been performed according to EN ISO 10211-1, using the program “Physibel Trisco”. The test included standard steel elements such as bearing RockShell column profiles and Z-profiles in the service wall as well as a ventilated cavity on the exterior. Using CE-marked Rockwool insulation with a thermal conductivity value of 0.035 and 0.034 W/(mK) gave a U-value of 0.143 W/(m²K).

RockShell wall system 289 mm

Service wall 57.5 mm, 82.5 mm or 107.5 mm

U-values Service wall

Total wall thickness

Total wall insulation thickness

U-value W/(m2K)

57.5 mm

364.5 mm

295 mm

0.143

82.5 mm

389.5 mm

320 mm

0.134

107.5 mm

414.5 mm

345 mm

0.127

Table 8

3.6 Moisture A

Interstitial condensation

Interstitial condensation in the RockShell wall system has been evaluated by the consultancy company Belenos. The RockShell construction shows no sign of relative humidity above 75%, which is the threshold value where growth of mould normally is initiated. It is therefore concluded that the RockShell wall system does not suffer from moisture related problems due to interstitial condensation.

Capillary moisture suction

Stone wool is not a capillary active material. In addition, stone wool fibres have a surface treatment to make them water repellent. Should the material come into contact with moisture in a liquid state, there is no immediate risk of penetration of the stone wool by this moisture without externally applied pressure.

Water tightness

Driving rain tests performed by the SP Technical Research Institute of Sweden according to EN 12865 have shown no sign of water penetration when the joints of the wool elements are covered by LVL boards (27 x 98 mm, cc 600 mm) on the external side of the system. In this test, water was only observed to a depth of less than 1 cm on the outside of the insulation. In areas where horizontal barriers stop the water from flowing down, e.g. at the ground plate, these areas will dry quickly due to the open cell characteristics of the stone wool fibres.

Moisture-repellent

The RockShell wall system is designed to avoid retaining moisture by specially designed temporary rain cover features and the water repellent properties of the stone wool. Should moisture accumulate during the building phase, moist areas will dry fast due to the open cell characteristics of the fibrous stone wool. The OSB boards on the inner side of the RockShell wall system should not be exposed to moisture. It is advisable to erect and close the roof construction before mounting the OSB boards, in order to protect them against unintended exposure to moisture in the form of rain or some other similar source of external moisture.

Mould

The calculations for interstitial condensation show that the growth of mould in the RockShell wall system is unlikely in any part of the RockShell onstruction at any time. Retained moisture cannot affect the growth of mould as the moisture will dry out faster than mould can establish itself.

Corrosion

Corrosion characteristics of the steel elements have been evaluated by Force Technology, Denmark. Based on earlier calculations made by the consultancy company Belenos, the metal parts in the wall construction are generally exposed to a dry environment as the relative air humidity only for shorter periods rises to 70-75%. It is evaluated that the coating thickness of the metal parts will provide good protection against corrosion under these conditions. It is necessary to ensure that the self-tapping screws have a minimum zinc coating thickness of 15 Îźm. Screws made of noble metals such as stainless steel cannot be used due to galvanic corrosion. It is expected that the metal parts in the RockShell wall system will remain durable for at least 50 years. This evaluation requires that the wall construction remains closed to avoid air leakage and furthermore that the profiles do not have contact with water absorbent materials or are otherwise exposed to water or humidity.

33 3. Performance

ROCKSHELL WALL SYSTEM速

4. System components Content: 4.1 System components.................................................35

34 Y = The images within this Building Manual are taken from a European installation. They are shown for illustration purposes only and are indicative of the methods used during a RockShell construction. The images are not intended to illustrate UK best practice and personnel shown do not comply with UK health and safety regulations.

4.1 System components A RockShell wool element

Insulation elements Length (mm)

max. 2700

With (mm)

max. 600

Thickness (mm)

250

Table 9

Make-up of the long side

RockShell wool element

Figure 9: Make-up of a standard RockShell wool element

B RockShell steel profiles

RockShell I-profiles Length (mm)

max. 2700

Web (mm)

150

Flange (mm)

Thickness (mm) Torsion (mm)

1 0.5 per 2700

Table 10

RockShell top- and bottom profiles Length (mm)

3000

Width (mm)

152

Height (mm)

Thickness (mm) Torsion (mm) RockShell I-profile

1 1 per 3000

Table 11

Top- and bottom profile

35 4. System components

ROCKSHELL WALL SYSTEM®

C RockShell end column

Box profile Length (mm)

max. 2700

Width (mm)

148.5

Height (mm)

Thickness (mm)

1.5

Torsion (mm)

1 per 2700

Table 12

Attached flanges Length (mm)

2700

Width (mm)

150

Height (mm)

Thickness (mm)

Torsion (mm)

1 per 2700

Table 13 Attached flanges

Box profile

1 2

4 3

Figure 10: Parts of an end column 1 C-shaped profile w = 40 x 150 x 40 mm, l = storey height minus 110 mm 2 Box profile w = 48 x 148.5 x 48 mm , l = storey height minus 6 mm 3 Box profile w = 48 x 148.5 x 48 mm, l = storey height minus 6 mm 4 C-shaped profile w = 40 x 150 x 40 mm, l = depending on adjacent building component Distance between pre-drilled screw holes: 200 mm to close the box profile (on both sides of the box). 250 mm to attach C-shaped profiles (in two lines). Max. 100 mm to attach a C-shaped profile for a lintel (in two lines). Max. 100 mm for pre-drilled holes in lintel flange (on both sides of the flange).

5 6

Figure 11: Different variations of end columns 5 Corner, “C” attached on one side 6 Corner, “C” attached on two sides 7 Door/window (top end, lintel invisible)

NB: The illustrations may not reflect the actual number of fasteners used.

D RockShell lintel

Top/bottom profiles Length (mm)

l minus 120

Width (mm)

150

Height (mm)

50/80

Thickness (mm)

Torsion (mm)

1 per 1200

Table 14

Side profiles Length (mm)

l minus 10

Width (mm)

Height (mm)

298

Thickness (mm) Torsion (mm)

1.5 1 per 1200

Table 15

Interior partition Lintel

Length (mm)

Width (mm)

145

Height (mm)

295

Thickness (mm) Torsion (mm)

1 1 per 1200

Table 16

8 9

13 10

12 11

Figure 12: Parts of a standard lintel (“X” is given as the number of modules): 8 Top profile w = 80 x 150 x 80 mm, l = “X” x 600 – 120 mm 9 Bottom profile w = 50 x 150 x 50 mm, l = “X” x 600 – 120 mm 10 Side part left w = 50 x 298 x 50 mm, l = “X” x 600 – 10 mm 11 Side part right w = 50 x 298 x 50 mm, l = “X” x 600 – 10 mm 12 Partition w = 50 x 145 x 50 mm, l = 295 mm

14 15 Figure 13: Steps of assembling of a lintel 13 Set partition and side parts together Min. number of screws: 3 on each side 14 Set side parts into bottom profile Distance between screws: Max 100 mm 15 Close box with top profile Distance between screws: Max 100 mm

37 4. System components

ROCKSHELL WALL SYSTEM®

E Brackets

L-shape Length (mm)

142

Width (mm)

Height (mm)

Thickness (mm)

Table 17

U-shape

L-shaped bracket

U-shaped bracket

Steel plate

t = 1.5 mm

Length (mm)

148

Width (mm)

Height (mm)

Thickness (mm)

Table 18

Steel plate

250 mm

t = 3.0 mm

Length (mm)

148

Width (mm)

Height (mm)

–

Thickness (mm)

Table 19 10 149 mm (ext) Figure 14: Shoe for locating L-shaped brackets

F Screws and bolts • Concrete anchor with hexagonal head • Metal drilling screw with washer head • Steel sheet metal self drilling screws with countersunk head or with pan framing head

G OSB board OSB/3 board (tongue and groove) Length (mm)

2440

Width (mm)

610 or 1205

Thickness (mm) Table 20

H Laminated veneer lumbers (LVL boards) Vertical boards

Horizontal board

Width (mm)

155

Thickness (mm)

Table 21

I Tape Width: 60 mm

J Asphalt Under bottom sill: ca. 60 g/m

K Bituminous roofing felt

39 Y

4. System components

ROCKSHELL WALL SYSTEM速

5. References Content: 5.1

The Flensburg house ...........................................41

40 Y = The images within this Building Manual are taken from a European installation. They are shown for illustration purposes only and are indicative of the methods used during a RockShell construction. The images are not intended to illustrate UK best practice and personnel shown do not comply with UK health and safety regulations.

5.1 The Flensburg House The first house built using the RockShell wall system was in Flensburg, Germany. The design is a standard type. This design was utilised to show how easy it was to integrate the RockShell wall system in an existing design and to prove that it is possible to build a standard house with excellent energy performance and low installation costs. The low-energy house was a KfW 70 energy-efficient house. Offering a 30% improvement in energy efficiency over traditional methods in line with market requirements.

41 5. References

ROCKSHELL WALL SYSTEM®

Sketches

23°

-0.055

±0.00

2 7 50 18

2.01

1.35 3

+1.33 3

+2.55 5

+2.00

54 5 5

+2.82 7 +2.60 7 +2.51

-0.20

-1.00

The southern façade

The building process

Fixing brackets to the foundation.

Raising RockShell wool elements.

Setting and fixing the pre-fabricated lintels.

A peek into the house during the building process.

House seen from the outside during the building process.

The house before completion of the façade.

The completed house Building owner: Gartenstadt Weiche Architect: Architektenbüro Lorenzen Site management: Höft Bauunternehmen Contractor: Carstensen Trockenbau

43 5. References

ROCKSHELL WALL SYSTEM速

6. Foundation Content: 6.1 Bottom profiles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 6.2 Mapping the module grid . . . . . . . . . . . . . . . . . . . . . 48 6.3 Brackets for column profiles . . . . . . . . . . . . . . . . . . 49 6.4 CAD-drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

44 Y = The images within this Building Manual are taken from a European installation. They are shown for illustration purposes only and are indicative of the methods used during a RockShell construction. The images are not intended to illustrate UK best practice and personnel shown do not comply with UK health and safety regulations.

Need to know: The foundation is not supplied as part of the RockShell wall system, but is an essential base for the erection of a RockShell structure. Requirements are given for the quality of the concrete and the evenness and level of the upper surface. A minimum width is prescribed for the foundation to ensure sufficient edge distance for the bolts used to fasten the RockShell wall system to the ground.

Special requirements: • Concrete ≥ C20/25 • Accuracy ± 1 mm over 3000 mm length • Width ≥ 164 mm

1 Bituminous roofing felt 2 RockShell bottom profile 3 L-shaped bracket for fixing RockShell column profile 4 RockShell column profile

45 6. Foundation

ROCKSHELL WALL SYSTEMÂŽ

6.1 Bottom profiles A

Requirements for the foundation

The foundation has to be made of concrete with a quality of at least C20/25. Light-weight concrete blocks or mortar on the top of the foundation concrete are not allowed. The concrete surface must be levelled, straight and without recesses. The required tolerance for the finished surface is Âą 1 mm over a length of 3 metres. The top of the foundation must be at least 164 mm wide. The length and width of the foundation should be checked at design stage and again before installation commences.

Waterproof felt

Use a strip of bituminous roofing felt at least with the width of the foundation to build up water and air-tight basis for the RockShell wall system. The roofing felt needs to be bonded to the concrete foundation by using cold asphalt in two lines with a diameter of 3 to 6 mm to seal the joint. Press the roofing felt firmly onto the foundation. Joints between the roofing felt sections have to be sealed with cold asphalt.

The evenness of the roofing felt has to be checked with a straightedge. It is important that the entire length of the bottom profile is properly supported.

Evenness of the roofing felt C

Levelling of the roofing felt

Where necessary, uneven sections have to be levelled with another layer of roofing felt that is glued to the base layer with cold asphalt.

Tightness between felt and bottom profile

Cold asphalt is also applied between the roofing felt and the bottom profile. One line of asphalt is sufficient. Press the bottom profile firmly into the asphalt.

Geometry of bottom profile at corners

The bottom profiles on the long sides of the building reach from one end of the foundation to the other. The bottom profiles on the short sides of the building are to be placed between the bottom profiles on the long side. At the corners of the foundation, 15 cm of the inner flange of the bottom profile on the long side of the building needs to be removed by cold cutting.

At the joint between the two adjacent inner flanges, a gap of 2 mm needs to left, to allow for accurate fixing of the U-shaped brackets.

Placing the bottom profile

The bottom profiles are to be fixed temporarily to the foundation at each corner of the foundation with an aluminium hammer rivet. A suitable dimension for the rivets could be 4.8 x 26 mm. Drill a hole with a diameter of 5 mm. Use a string fixed on both ends of a foundation section at the flange of the bottom profile.

Align the bottom profile along this string along the centre line of the foundation.

Temporarily mounting the bottom profile

Fasten all bottom profiles temporarily at both their ends with aluminium hammer rivets.

47 6. Foundation

ROCKSHELL WALL SYSTEM®

6.2 Mapping the module grid A

Measuring of module lines

Start measuring at the end of a bottom profile on the inner flange, then move along the bottom profile. The “point zero” for measuring needs to match a module line (see figure 1). To avoid measuring errors, use a continuous tape measure reaching between the two outer module lines of a foundation section. Tolerance for the measurement is ± 1 mm.

Position of module lines

Copy the position of all module lines from the installation plan to the bottom profile. Mark positions of both sides of end columns (50 mm) on the bottom profile. To mark the module lines at 90 degrees to the flanges of the bottom profile, use the shoe provided for setting L-shaped brackets as a guage (see chapter 3). Y

6.3 Brackets for column profiles A

Brackets for end columns

The bracket for fixing of end columns consists of two pieces: 1 U-shaped part with bottom dimensions of 53 x 150 mm and a thickness of 1 mm. 2 Flat bar, 5 mm thick, with a 14 mm hole in the centre. The flat bar goes into the U-shaped part. The flat bar and the U-shaped part are to be fixed to the foundation with the same bolt.

Placing of brackets

For RockShell column profiles, L-shaped brackets are used. For RockShell end profiles, U-shaped brackets are used. Place all brackets in the bottom profile close to the respective markings.

Adjusting the position of brackets

The bent edges of the brackets should correspond to the module lines drawn in the bottom profile. Use the shoe that was used for mapping the module lines to keep the brackets in the right position, at 90 degrees to the flanges of the bottom profile. L-shaped brackets for the RockShell column profiles need to be fixed centrally between the flanges of the bottom profile. U-shaped brackets are fixed flush to the flanges of the bottom profile.

Fixing L-shaped brackets to the foundation

Use a 6 mm concrete drill for setting the holes for the L-shaped brackets in the foundation. These are drilled through the elongated slot in the bracket. Before screwing the fixing bolt, ensure that the hole is free from dust and debris. L-shaped brackets are fastened with one bolt in the centre of the bottom flange. Y

For dimensions of the bolts, see chapter 3, table 7.

49 6. Foundation

ROCKSHELL WALL SYSTEM速

Fixing U-shaped brackets to the foundation

Brackets for the end columns are fixed to the foundation in the same way as the L-shaped brackets. Dimensions of bolts for brackets for end columns are part of a structural report as they may have to take major uplift and racking forces from the wall system.

Tools for screwing bolts

Use an impact wrench to fix the bolts. Using an ordinary drill can cause serious wrist injuries and overtighten the bolts.

Fixing all brackets

When all brackets are fastened properly, the RockShell wall elements can be mounted.

51 Y

6. Foundation

ROCKSHELL WALL SYSTEM®

6.4 CAD-drawings Foundation (vertical section)

250 mm Rockwool RockShell rigid insulation slab, density 70 kg/m³

27 x 98 mm LVL batten @ 600 mm c/c, fixed back to metal I-profile columns

10 mm Eternit Bluclad board

5 mm Rockwool RockShield TC base coat with embedded reinforcing mesh plus 2 mm Silcoplast finish coat

152 x 50 x 1 mm metal C-profile channel

7.5 x 60 mm concrete screw

12 mm T&G OSB/3 board, all joints and junctions taped with proprietary airtightness products (18 mm recommended for Passivhaus)

44 x 44 mm horiz s/w battens @ 600 mm vertical centres

3 4

250

12 45 12

8 10

2 1

19 9

6 FFL Min. 150 mm 25

150 x 80 x 1 mm metal I-profile column

Seal junction between screed and OSB with a continous strip of proprietary airtightness tape All junction and joints screed to be sealed with proprietary airtightness products

7 22

All junction and joints in OSB to be sealed with proprietary airtightness products

18 27

Eq 165

250

10. 45 mm Rockwool Flexi insulation 11. 12.5 mm plasterboard with skim coat

12. Bituminous roofing felt adhered to the concrete upstand with cold asphalt sealant

13. Reinforced concrete upstand 14. DPM 15. 90 mm XPS insulation 16. Sand/cement render 17. Concrete foundation 18. Lapped strip of proprietary airtightness tape to seal junction, suitable for adhesion to concrete substrate 19. Timber skirting board

Basement, heated (vertical section)

150 x 80 x 1 mm metal I-profile column

250mm Rockwool RockShell rigid insulation slab, density 70 kg/m³

27 x 98 mm LVL batten @ 600 mm c/c, fixed back to metal I-profile columns

10 mm Eternit Bluclad board

5 mm Rockwool RockShield TC base coat with embedded reinforcing mesh plus 2 mm Silcoplast finish coat

18 27

152 x 50 x 1 mm metal C-profile channel

7.5 x 60 mm concrete screw

12 mm T&G OSB/3 board, all joints and junctions taped with proprietary airtightness products (18 mm recommended for Passivhaus)

FFL

2 1

19 9 7

12 Eq

24 16

12 45 12

8 10 11

6 Min. 150mm 25

4 5

250

13 165

18 Eq

All junction and joints in OSB to be sealed with proprietary airtightness products Seal junction between screed and OSB with a continous strip of proprietary airtightness tape All junction and joints screed to be sealed with proprietary airtightness products

22. 30 mm RockFloor perimeter insulation

U-values (W/m²K): Wall = 0.15, Floor = 0.12 (assumed P/a = 0.45) Y values (W/mK): Internal = 0.08, External = 0.00 Indicates airtightness layer or component

44 x 44 mm horiz s/w battens @ 600 mm vertical centres

230

21. 250 mm RockFloor insulation

150

20. 75 mm sand/cement screed

10. 45 mm Rockwool Flexi insulation 11. 12.5 mm plasterboard with skim coat

12. Bituminous roofing felt adhered to the concrete upstand with cold asphalt sealant

13. Reinforced concrete upstand 14. DPM 15. 90 mm XPS insulation 16. Sand/cement render

24 23

17. 150 mm beam and block floor with AAC block infill 18. Lapped strip of proprietary airtightness tape to seal junction, suitable for adhesion to concrete substrate 19. Timber skirting board 20. 75 mm sand/cement screed 21. 250 mm RockFloor insulation 22. 30 mm RockFloor perimeter insulation 23. 100 mm block work to support beam and block floor 24. Telescopic floor vent

U-values (W/m²K): Wall = 0.15, Floor = 0.12 (assumed P/a = 0.45) Y values (W/mK): Internal = 0.03, External = - 0.04 Indicates airtightness layer or component

Basement, insulated slab

250 mm Rockwool RockShell rigid insulation slab, density 70 kg/mÂł

27 x 98 mm LVL batten @ 600 mm c/c, fixed back to metal I-profile columns

10 mm Eternit Bluclad board

5 mm Rockwool RockShield TC base coat with embedded reinforcing mesh plus 2 mm Silcoplast finish coat

152 x 50 x 1 mm metal C-profile channel

7.5 x 60 mm concrete screw

12 mm T&G OSB/3 board, all joints and junctions taped with proprietary airtightness products (18 mm recommended for Passivhaus)

44 x 44 mm horiz s/w battens @ 600 mm vertical centres

10. 45 mm Rockwool Flexi insulation

250

12 45 12

8 10 11

4 5

1 20 9 6

FFL Min. 150mm 25

150 x 80 x 1 mm metal I-profile column

12 18

150

18 27

11. 12.5 mm plasterboard with skim coat

12. Bituminous roofing felt adhered to the concrete upstand with cold asphalt sealant

250

13. 150 mm thk reinforced concrete floor slab 14. 250 mm RockFloor insulation

15. DPM 16. Sand blinding 17. 90 mm XPS insulation 18. Sand/cement render 19. Lapped strip of proprietary airtightness tape to seal junction, suitable for adhesion to concrete substrate 20. Timber skirting board U-values (W/mÂ˛K): Wall = 0.15, Floor = 0.12 (assumed P/a = 0.45) Y values (W/mK): Internal = 0.07, External = - 0.02 Indicates airtightness layer or component

53 6. Foundation

ROCKSHELL WALL SYSTEM速

7. The RockShell wall Content: 7.1 Raising RockShell end columns .............................. 56 7.2 RockShell wool elements ......................................... 56 7.3 Raising RockShell column profiles .......................... 57 7.4 RockShell wall system modules .............................. 58 7.5 Completing the upper end of the RockShell wall system ....................................... 58 7.6 CAD-drawings .......................................................... 60

54 Y = The images within this Building Manual are taken from a European installation. They are shown for illustration purposes only and are indicative of the methods used during a RockShell construction. The images are not intended to illustrate UK best practice and personnel shown do not comply with UK health and safety regulations.

Need to know: The core of the RockShell wall system comprises a steel bottom profile, steel vertical structural members with RockShell wool elements in between, a steel top profile, as well as laminated veneer lumber (LVL) member at the upper end of the wall, a layer of OSB boards on the inner side and external LVL boards that serve as the mounting for the outer cladding. All joints

are fastened by screws. The airtightness of the system is ensured by a layer of OSB boards on the inner side with tape and sealants used to seal the joints. Based on this â&#x20AC;&#x153;core wallâ&#x20AC;? concept a wide variety of external finishes, service wall systems and standard building components like windows, doors or roof systems can be used.

1 RockShell bottom profile 3

2 L-shaped bracket for fixing column profile 3 RockShell column profile

4 OSB board 5 RockShell wool element 6 LVL board

2 1

55 7. The RockShell wall

ROCKSHELL WALL SYSTEM®

7.1 Raising RockShell end columns A

The 1st column profiles

It is recommended that the erection of RockShell wall elements is started with two end columns in one corner of the building. End columns are generally used at corners or as lateral bearing elements at openings for windows and doors. End columns must placed in between the flanges of U-shaped brackets. A pair of end columns for corners consists of: • One end column with one C-shaped profile attached • One end column with two C-shaped profiles attached The end column with two C-shaped profiles attached must be placed into the bottom profile at the longer side of the building.

Adjusting

Ensure that both end columns are in a vertical position before fastening them. Connect the two end columns with screws using the pre-drilled holes in the flange of the C-shaped profile being attached. Free standing end columns must be temporarily braced in both directions. Screws: See chapter 3, table 7.

Fastening

End columns must be screwed to the U-shaped bracket. A pair of screws should be used in each flange of the U-shaped bracket or, alternatively, two screws can be used in the accessible flange of the bracket and one screw in each flange of the bottom profile. When the second option is chosen, do not screw into the inner flange of the bottom profile at this point, this is done when the OSB boards are mounted. Screws: See chapter 3, table 7.

7.2 RockShell wool elements A

Setting the wool element in place

Wool elements have slits on all four sides to accept the flanges of adjacent steel profiles. Position the wool element in such a way that the part of the wool element measuring 150 mm between slit and element surface is placed between the flanges of the steel profiles.

By setting the RockShell wool element slantwise into position, it is easier to catch the flange of the column profiles. This also helps avoid damaging the edge of the wool element at the brackets in the bottom profile.

B Finally, raise the wool element into a vertical position. Make sure that the height of the wool element is equal to the height of the adjacent steel profile. When the RockShell wool element is in the correct position, the next RockShell column profile can be set.

7.3 Raising RockShell column profiles A

Setting a column profile in place

The I-shaped column profile is to be placed between the wool element and the L-shaped bracket inside the bottom profile. As with the wool element, it is easier to slide the column profile into place at an angle into the slit of the wool element. Press the RockShell column profile into the slits of the neighbouring wool element into a vertical position. Make sure that the column profile is in contact with the bottom profile.

Fixing

The RockShell column profile is then fixed with two screws through the pre-drilled holes in the L-shaped bracket. Use a further screw to fix the outer flange of the column profile to the outer flange of the bottom profile. Do not screw into the inner flange of the bottom profile at this point, this is done when the OSB boards are mounted.

Screws: See chapter 3, table 7.

Preparation of connection to first floor

If a first floor is to be erected, a clamping strap needs to be fixed to all column profiles and end columns with one screw (Screws: See chapter 3, table 7) approximately 80 mm below the top of the columns.

57 7. The RockShell wall

ROCKSHELL WALL SYSTEM®

7.4 RockShell wall system modules A

Adjusting

A section of the RockShell wall system consisting of a wool element and a column profile is called a “module”. Having set 3 to 5 modules, make sure that the wool elements are still in a vertical position and that the external joints of the wool are tight. If necessary, settle all wool elements into place by using the long side of a wooden board as a hammer on the last RockShell column profile.

Securing

The RockShell wall should be supported temporarily by bracing, preferably every 10 RockShell modules.

In front of end columns

The use of end columns causes a gap of 50 mm between two RockShell wool elements. The RockShell wall system provides insulation strips that are used to close this gap. At gaps around windows and doors these strips should be fixed temporarily with glue or mechanically with pins. Y

7.5 Completing the upper end of the RockShell wall system A

Setting top profiles

Having erected 5 or 6 RockShell modules, a top profile is to be mounted to hold the modules together. The top profile catches both flanges of the RockShell column profiles. Press the top profile down until it comes into contact with the RockShell column profiles.

To secure a wall section, temporarily fasten the top profile by screwing it into the first and the last L-shaped bracket on top of the RockShell column profiles with one screw per bracket.

In the corners, the top profile is same length as the bottom profile. There is also a top profile above lintels of windows and doors. Screw the top profile directly to the lintels using one screw per module.

Preparation of connection to first floor

Once the top profile is in place, the clamping bands must be fixed with another screw into top profile. Screws: See chapter 3, table 7.

Sill

Place a LVL board, dimensions 155 x 63 mm, on top of the top profile. The LVL board is aligned to the inner side of the top profile to correctly transfer vertical loads into the flanges of the column profiles. Fasten the LVL board through the top profile into the L-shaped brackets on top of the RockShell column profiles. Screws: See chapter 3, table 7

Upper insulation elements

To cover the height of LVL board any girt plate on top of the top profile, place the supplied upper insulation strips between the girt plate and vertical LVL boards before they are mounted.

59 7. The RockShell wall

ROCKSHELL WALL SYSTEM速

7.6 CAD-drawings Wall

Kerto Board, 27 x 98 mm / 600 mm

I-profile, 150 x 80 x 1 mm

Bolt, 7.5 x 60 mm

Angle bracket, 50 x 145 x 1 mm

RockShell wool, 250 mm, 70 kg/m続

C-profile, 152 x 50 x 1 mm

OSB board, 12 mm (tongue and groove)

10. Insulation, 45 mm, 50 kg/m続 11. Z-profile, 30 x 45 x 30 x 0,56 mm/600 mm (horizontal) 12. Gypsum plaster board, 12.5 mm

8 2710

1 2

100

Eternit bluclad Board/Rockpanel board, 10 mm

3 4

7 8

6 150

Render, 8 mm

5 9

12,5 45

10 11

Indicates airtightness layer or component

Kerto board

C-profile

RockShell wool

OSB board

Air-tight tape

Angle bracket

Box profile

10. Fastener acc. to structural requirements

1 2

Eternit Bluclad Board

Render

150

100

Bay window 8 1027

12,5

4 5

10 7

Indicates airtightness layer or component

61 Y

7. The RockShell wall

ROCKSHELL WALL SYSTEM速

8. Windows and doors Content: 8.1 Workflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 8.2 CAD-drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

62 Y = The images within this Building Manual are taken from a European installation. They are shown for illustration purposes only and are indicative of the methods used during a RockShell construction. The images are not intended to illustrate UK best practice and personnel shown do not comply with UK health and safety regulations.

Need to know: Openings for windows and doors are laterally framed by end columns, which are also used at corners, to provide high local structural strength to the system. The upper end is constructed using a pre-assembled lintel that is set in place on site.

Parapets for windows are constructed in a way similar to the RockShell wall. Window and door elements are fastened to the end columns.

1 RockShell wool element 2 RockShell column profile

3 RockShell end column 3

4 Door or window 5 OSB board and service wall 6 LVL board

2 5

6 3 1

63 8. Windows and doors

ROCKSHELL WALL SYSTEM速

8.1 Workflow Openings for windows and doors are framed vertically using the RockShell end columns. For ease of installation, it is best to set up an end column at one side of the opening, then parapet elements for windows, followed by the other end column. Finally, the lintel is set in position and insulation fitted on the outside face.

End columns

C-shaped profiles are pre-attached to end columns in order to hold the various elements i.e. parapet, wool and lintel. Mount and secure the end column as described in chapter 7.

Parapet elements

If installing a door section proceed to step C (see below). For windows sections, erect parapet elements, i.e. wool and column profiles, as described in chapter 7.

Second framing end column

The second end column is set in place in the same way as the first end column. Fixing of the end column is described in chapter 7.

Parapet top profile

If installing a door section continue to step E (see next page). The upper end of the parapet is completed with a C-shaped profile as used to finish the top profile used at the top of the wall system (see page 58, 7.5 A). The parapet top profile is fixed to the L-shaped brackets on top of the column profile in the parapet. Screws should not be fixed into the flanges of the top profile Y

Lintel

The final step for installing sections for windows and doors is to place and fix the pre-fabricated lintel in between the C-shaped profiles on the end columns above the section opening. Use the pre-drilled holes in both sides of the C-shaped profiles to fix the lintel. Screws: See chapter 3, table 7.

In front of lintels

100 mm insulation is provided to be added to the outside of the lintels over windows and doors.

Fix wool elements to lintels using screws according to chapter 3, table 7, and Ă&#x2DC;80 mm washers with 6 mm hole, thickness 1 mm. Use 1 screw per 600 mm to temporarily secure the wool in the middle between module lines. Setting top profiles, preparation of connection to second floor, sill, upper insulation elements and girt plate under rafters: See chapter 7.

65 Y

8. Windows and doors

ROCKSHELL WALL SYSTEM®

8.2 CAD-drawings A

Window, head and cill

150 x 80 x 1 mm metal I-profile column

250 mm Rockwool RockShell rigid insulation slab, density 70 kg/m³

27 x 98 mm LVL batten @ 600 mm c/c, fixed back to metal I-profile columns

10 mm Eternit bluclad board

5 mm Rockwool RockShield TC base coat with embedded reinforcing mesh plus 2 mm Silcoplast finish coat

152 x 50 x 1 mm metal C-profile channel

63 x 155 mm LVL board

12 mm T&G OSB/3 board, all joints and junctions taped with proprietary airtightness products (18 mm recommended for Passivhaus)

18 27

250

12 45 12.5

7 6 12 5 4 19 20

8 11

14 10

210

9 16 15 16 11

44 x 44 mm horiz s/w battens @ 600 mm vertical centres

10. 45 mm Rockwool Flexi insulation 11. 12.5 mm plasterboard with skim coat 12. 300 x 150 x 1 mm box lintel above opening (formed from 4 x C-profile metal channels) 13. Void in box lintel filled with 150mm Rockwool insulation, density 45 kg/m³

14. 100 mm Rockwool RockShell rigid insulation slab, density 70 kg/m³

15. 12 mm plywood box to frame window opened fixed to metal profiles. All junctions to be sealed with proprietary airtightness products

6 1

16. Continuous strip of proprietary airtightness tape to seal junction

10 2 11

19. 50 x 40 mm Rockwool RockShell rigid insulation cover strip, density 70 kg/m³

4 5

18. Pressed aluminum cill

16 9

17. Thermal broken Passivhaus standard triple glazed windows Uw 0.80 W/m²k or better

16 15

20. Elastic joint

250 mm Rockwool RockShell rigid insulation slab, density 70 kg/m³

27 x 155 mm LVL batten @ 600 mm c/c, fixed back to metal box columns

10 mm Eternit bluclad board

5 mm Rockwool RockShield TC base coat with embedded reinforcing mesh plus 2 mm Silcoplast finish coat

150 x 50 x 1 mm metal C-profile column

Outline of 152 x 50 x 1 mm metal C-profile base plate

12 mm T&G OSB/3 board, all joints and junctions taped with proprietary airtightness products (18 mm recommended for Passivhaus)

44 x 44 mm horiz s/w battens @ 600 mm vertical centres

3 2

9 10 8

13. Continuous strip of proprietary airtightness tape to seal junction 14. Thermal broken Passivhaus standard triple glazed windows Uw 0.80 W/m²k or better 15. Pressed aluminum cill

Seal junction between window frame and ply with a continous strip of proprietary airtightness tape

11 13 18 Seal junction between OSB and ply with a continous strip of proprietary airtightness tape

12. 12 mm plywood box to frame window opened fixed to metal profiles. All junctions to be sealed with proprietary airtightness products

18. S/W timber cill board

13 12

11. 12.5 mm plasterboard with skim coat

17. Elastic joint

10. 45 mm Rockwool Flexi insulation

16. 50 x 40 mm Rockwool RockShell rigid insulation cover strip, density 70kg/m³

5 4 6 1 18

150 x 50 x 1 mm metal box column (2 x C-profile channels)

250

Window, jamb

365

U-values (W/m²K): Wall = 0.15, Window = min 0.8 Y values (W/mK): Head install = 0.06, Cill install = 0.06 Indicates airtightness layer or component

45 12

22. 27 x 155 mm LVL batten @ 600 mm c/c, fixed back to metal I-profile columns

21. S/W timber cill board

U-values (W/m²K): Wall = 0.15, Window = min 0.8 Y values (W/mK): Installation = 0.04 Indicates airtightness layer or component

Door threshold

Aluminium threshold cill, 15 mm high

40 mm XPS insulation

Precast concrete door step

Proprietary threshold slot drain

100 mm concrete block dwarf wall supporting door step

90 mm XPS rigid insulation

Reinforced concrete upstand

Concrete footing to dwarf wall

10. Lapped strip of proprietary air tightness tape to seal junction between threshold and ply

10 11 12 13 14

2 4

15 Eq

Eq 165

12. 50 mm XPS rigid insulation 13. Bituminous roofing felt adhered to the concrete upstand with cold asphalt sealant

All junction and joints screed to be sealed with proprietary airtightness products FFL

11. 22 mm plywood deck glued and screwed to jamb ply to form continuous ply surround to door

Seal junction between screed and OSB with a continous strip of proprietary airtightness tape

Thermal broken Passivhaus standard door U = 0.80 W/mÂ˛k or better

18 250

17 16

14. Lapped strip of proprietary airtightness tape to seal junction, suitable for adhesion to concrete substrate 15. 30 mm RockFloor perimeter insulation 16. Concrete foundation 17. DPM

18. 250 mm RockFloor insulation 19. 75 mm sand/cement screed

U-values (W/mÂ˛K): Door = 0.80, Floor = 0.12 (assumed P/a = 0.45) Y values (W/mK): Installation = 0.09 Indicates airtightness layer or component

67 8. Windows and doors

ROCKSHELL WALL SYSTEM速

9. Corners Content: 9.1 Raising RockShell end columns . . . . . . . . . . . . . . . . 70 9.2 RockShell wool elements . . . . . . . . . . . . . . . . . . . . . 71 9.3 CAD-drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

68 Y = The images within this Building Manual are taken from a European installation. They are shown for illustration purposes only and are indicative of the methods used during a RockShell construction. The images are not intended to illustrate UK best practice and personnel shown do not comply with UK health and safety regulations.

Need to know: The corner solution of the RockShell wall system consists of two end columns that are connected to each other at right angles (other angles are possible for bay windows) and a single wool element that fills the outside of the corner gap.

1 RockShell wool element 2 LVL board

4 OSB board and service wall 5 RockShell end column

69 9. Corners

ROCKSHELL WALL SYSTEM®

9.1 Raising RockShell end columns A

The 1st column profiles

It is recommended that the erection of RockShell wall elements is started with two end columns in one corner of the building. End columns are generally used at corners or as lateral bearing elements at openings for windows and doors. End columns must placed in between the flanges of U-shaped brackets. A pair of end columns for corners consists of: • One end column with one C-shaped profile attached • One end column with two C-shaped profiles attached. The end column having two C-shaped profiles attached must be placed into the bottom profile at the longer side of the building.

Adjusting

Fastening

9.2 RockShell wool elements A

Setting the wool element in place

Wool elements have slits on all four sides to catch the flanges of adjacent steel profiles. Position the wool element in such a way that the part of the wool element measuring 150 mm between slit and element surface is placed between the flanges of the steel profiles. By setting the RockShell wool element slantwise into position, it is easier to catch the flange of the column profiles. This also helps avoid damaging the edge of the wool element at the brackets in the bottom profile.

B Finally, raise the wool element into a vertical position. Make sure that the height of the wool element is equal to the height of the adjacent steel profile.

When the RockShell wool element is in the correct position, the RockShell column profile can be set.

Corner insulation element

The RockShell corner insulation element is 250 x 250 mm wide and the height of the storey. The corner element should be mounted in the same way as the ordinary wool element, by setting it in place slantwise. The corner element is temporarily held in a vertical position by the C-shaped profile attached to one of the end columns at the corner. Later, it will be held by LVL boards at both sides of the corner

71 9. Corners

ROCKSHELL WALL SYSTEM®

9.3 CAD-drawings A

Corner with rainscreen

150 x 50 x 1.5 mm metal box column (2 x C-profile channels)

250 mm Rockwool RockShell rigid insulation slab, density 70 kg/m³

27 x 98 mm LVL battens @ 600 mm c/c, fixed back to metal box columns

10 mm Eternit bluclad board

5 mm Rockwool RockShield TC base coat with embedded reinforcing mesh plus 2 mm Silcoplast finish coat

150 x 50 x 1 mm metal C-profile column.

Outline of 152 x 50 x 1 mm metal C-profile base plate

12 mm T&G OSB/3 board, all joints and junctions taped with proprietary airtightness products (18 mm recommended for Passivhaus)

44 x 44 mm horiz s/w battens @ 600 mm vertical centres

10. 45 mm Rockwool Flexi insulation

1 6 6

7 2 12

9 10

4 5

Seal SOB joint between with proprietary airtightness tape

11. 12.5 mm plasterboard with skim coat 12. Continuous strip of proprietary airtightness tape to seal junction

All junction and joints in OSB to be sealed with proprietary airtightness products

18 27

250

12 45 13

U-values (W/m²K): Wall = 0.15 Y values (W/mK): Internal = 0.05, External = - 0.02 Indicates airtightness layer or component

Corner with brick

150 x 50 x 1.5 mm metal box column (2 x C-profile channels)

250 mm Rockwool RockShell rigid insulation slab, density 70 kg/m³

27 x 98 mm LVL battens @ 600 mm c/c, fixed back to metal box columns

Ancon STF6 timber frame wall ties

Facing brick

150 x 50 x 1 mm metal C-profile column.

Outline of 152 x 50 x 1 mm metal C-profile base plate

12 mm T&G OSB/3 board, all joints and junctions taped with proprietary airtightness products (18 mm recommended for Passivhaus)

4 3

1 6

2 1

44 x 44 mm horiz s/w battens @ 600 mm vertical centres

10. 45 mm Rockwool Flexi insulation

9 10

6 8

11. 12.5 mm plasterboard with skim coat 12. Continuous strip of proprietary airtightness tape to seal junction

Seal SOB joint between with proprietary airtightness tape

All junction and joints in OSB to be sealed with proprietary airtightness products

103

250

12 45 13

U-values (W/m²K): Wall = 0.15 Y values (W/mK): Internal = 0.05, External = - 0.02 Indicates airtightness layer or component

73 Y

9. Corners

ROCKSHELL WALL SYSTEM速

10. The exterior face of the RockShell wall Content: 10.1 Laminated veneer lumber on the outside of the RockShell wall system . . . . . . . . . . . . . . . . . . 76 10.2 CAD-drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

External cladding: RockPanel

External cladding: Brick slips

External cladding: Render

External cladding: Brick wall

74 Y = The images within this Building Manual are taken from a European installation. They are shown for illustration purposes only and are indicative of the methods used during a RockShell construction. The images are not intended to illustrate UK best practice and personnel shown do not comply with UK health and safety regulations.

Need to know: The external finish is not part of the RockShell wall system and the choice of finish is the decision of the building designers. Wooden elements, cladding panels, bricks, brick slips or render can be used to protect the RockShell wall system from external conditions.

Most types of external finish are mounted or fixed to the vertical LVL boards. Brick slips and render must be applied to a suitable base board

1 RockShell wool element 2 RockShell column profile 3 LVL board

4 OSB board and service wall

75 10. The exterior face of the RockShell wall

ROCKSHELL WALL SYSTEM®

10.1 Laminated veneer lumber on the outside of the RockShell wall system A

Function

The laminated veneer lumber boards (LVL) on the outside of the RockShell wall system have three basic functions: • Cover and tighten joints between RockShell wool elements • Establish a ventilated cavity • Serve as a fixing point for the external finish.

Positioning

LVL boards with a width of 98 mm are mounted and aligned centrally over all joints of wool elements. Next to windows and doors, LVL boards may need to be wider, depending on the construction details. Here, the LVL board should be aligned to the free edge of the wool.

In the case of a two-storey building, the length of the vertical LVL boards must span the height of both storeys in a continuous run.

Fastening

Fixing screws should be tightened sufficiently that the LVL board is held by friction on the surface of the wool, but does not compress the face. The fixing comprises a galvanised washer Ø22 mm, 2 mm thick, 6 mm hole, with appropriate screw: See chapter 3, table 7.

LVL boards must also be fastened securely to the roof construction to avoid settlement caused by loads from the external finish.

Upper insulation elements

To cover the gap caused by the extra height of LVL board above the top profile and girt plate, place upper insulation strips provided between the girt plate and vertical LVL boards before fixing the LVL boards. Y

Adjustment

A level surface is obtained by adjusting the screws. Use a long straight edge to check that LVL boards give a level surface. If the boards deviate more than 2 mm from level, the screws need to be adjusted.

Cover

Fix the provided roofing felt to all LVL boards, covering the entire outer surface of the LVL board. Use suitable fixings to secure the felt.

77 10. The exterior face of the RockShell wall

ROCKSHELL WALL SYSTEM速

10.2 CAD-drawing Wall

Kerto Board, 27 x 98 mm / 600 mm

I-profile, 150 x 80 x 1 mm

Bolt, 7.5 x 60 mm

Angle bracket, 50 x 145 x 1 mm

RockShell wool, 250 mm, 70 kg/m続

C-profile, 152 x 50 x 1 mm

OSB board, 12 mm (tongue and groove)

10. Insulation, 45 mm, 50 kg/m続 11. Z-profile, 30 x 45 x 30 x 0,56 mm/600 mm (horizontal) 12. Gypsum plaster board, 12.5 mm

8 2710

1 2

100

Eternit bluclad Board/Rockpanel board, 10 mm

3 4

7 8

6 150

Render, 8 mm

5 9

12,5 45

Indicates airtightness layer or component

10 11

79 Y

10. The exterior face of the RockShell wall

ROCKSHELL WALL SYSTEM速

11. The interior face of the RockShell wall Content: 11.1 OSB boards on the interior face of the RockShell wall system . . . . . . . . . . . . . . . . . . . . . . . 82 11.2 Service wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 11.3 CAD-drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

80 Y = The images within this Building Manual are taken from a European installation. They are shown for illustration purposes only and are indicative of the methods used during a RockShell construction. The images are not intended to illustrate UK best practice and personnel shown do not comply with UK health and safety regulations.

Need to know: Service walls are not an integral part of the RockShell wall system. Any service walls should be designed to match the service needs of the building. All issues related to the design of service walls should be handled by the service wall supplier.

It is recommended to install a service wall to assist achievement of thermal/energy, acoustic and fire performance as tested.

1 RockShell wool element 2 OSB board 3 Z-shaped profile 4 Rockwool insulation

4 2

5 Gypsum panel 3

6 RockShell bottom profile

81 11. The interior face of the RockShell wall

ROCKSHELL WALL SYSTEM速

11.1 OSB boards on the interior face of the RockShell wall system A

Sealing

Prior to mounting the OSB boards, apply a 4 mm wide strip of permanently elastic sealant to the flange of the bottom profile. Do the same for the full height of flanges of column profiles behind the vertical joints of OSB boards. Finish the sealing with a horizontal strip at the top profile before the last OSB board is mounted.

Orientation and position of OSB boards

OSB boards with a tongue and groove on one long edge must be used to obtain wind stability and air tightness of the RockShell wall system. OSB boards must be placed with their grooved edge pointing upwards. Their bottom edge should touch the roofing felt on the foundation. At the top, they should continue until level with top side of the LVL board under the girt plate. All vertical joints must be positioned at the centre of the flange of a RockShell column profile. If necessary boards should be cut to size to achieve this positioning.

For two storey wall constructions, refer to chapter 12.

Gluing of OSB boards

Horizontal joints must be glued to stabilise the system. It is recommended that glue is inserted in the groove side of the joint.

Fastening of OSB boards

All screws are fixed without pre-drilling into the OSB board. If screws are inadvertently placed in the wrong position, to maintain air-tightness do not remove them. Screws: See chapter 3, table 7

Tape

Use air-tight flexible tape provided with acrylic glue and a width of 60 mm to cover all joints.

11.2 Service wall Service walls are not an integral part of the RockShell wall system. Any service walls should be designed to match the service needs of the building. All issues related to the design of service walls should be handled by the service wall supplier. It is recommended to install a service wall to assist achievement of thermal/ energy, acoustic and fire performance as tested.

83 11. The interior face of the RockShell wall

ROCKSHELL WALL SYSTEM®

11.3 CAD-drawings 1.

150 x 50 x 1.5 mm metal box column (2 x C-profile channels)

Party wall junction

250 mm Rockwool RockShell rigid insulation slab, density 70 kg/m³

27 x 98 mm LVL batten @ 600 mm c/c, fixed back to metal box columns.

150 x 50 x 1 mm metal C-profile column.

Outline of 152 x 50 x 1 mm metal C-profile base plate

12 mm T&G OSB/3 board, all joints and junctions taped with proprietary airtightness products (18 mm recommended for Passivhaus)

44 x 44 mm horiz s/w battens @ 600 mm vertical centres

250

365

5 mm Rockwool RockShield TC base coat with embedded reinforcing mesh plus 2 mm Silcoplast finish coat

45 12

Bluclad board

5 4

9 8

15 13

10 11

10. 45 mm Rockwool Flexi insulation 11. 12.5 mm plasterboard with skim coat

12. Continuous strip of proprietary airtightness tape to seal junction

19 8 20 18

13. 100 mm Rockwool RockShell rigid insulation cover strip, density 70 kg/m³ 14. 60 mm Rockwool flexible cavity closer 15. Rockwool flexible cavity closer 16. Mastic sealant between rain screen panels 17. 60 mm Rockwool insulation, density 33 kg/m³

30 12 70

18. 70 mm steel drywall channel stud

19. 67 mm Rockwool Acoustic slab insulation 20. 2 x 15 mm 15 mm Soundbloc plasterboard 21. Permanent elastic sealant 22. 5 mm felt

Party wall junction with floor

2 x 15mm 15 mm Soundbloc plasterboard

12 mm T&G OSB/3 board, all joints and junctions taped with proprietary airtightness products (18 mm recommended for Passivhaus)

60 mm Rockwool insulation, density 33 kg/m³

70 mm steel drywall channel stud

67 mm Rockwool Acoustic slab insulation

Continuous strip of proprietary airtightness tape to seal junction

Permanent elastic sealant

Timber skirting board

75 mm sand/cement screed

70 12 30

284

U-values (W/m²K): Wall = 0.15, Floor = 0.12 (assumed P/a = 0.45) Y values (W/mK): Internal = 0.05, External = - 0.04 (divide by 2 per dwelling) Indicates airtightness layer or component

284 30 12 70

70 12 30

1 2 5 4 3

10. 250 mm RockFloor insulation 11. 30 mm RockFloor perimeter insulation 12. DPM 13. Concrete slab on grade

8 6 7

9 10

12 13

U-values (W/m²K): Wall = 0.15, Floor = 0.12 (assumed P/a = 0.45) Indicates airtightness layer or component

Party wall junction with floor

2 x 15 mm 15 mm Soundbloc plasterboard

12 mm T&G OSB/3 board, all joints and junctions taped with proprietary airtightness products (18 mm recommended for Passivhaus)

60 mm Rockwool insulation, density 33 kg/m³

60 mm steel drywall channel stud

67 mm Rockwool Acoustic slab insulation

Continuous strip of proprietary airtightness tape to seal junction

Permanent elastic sealant

45 mm Rockwool Flexi insulation

2 layers of 12.5mm plasterboard with skim coat

15 14

10. 44 x 44 mm s/w battens @ 600 mm centres

11. Vapour control and air tightness membrane 12. 100 mm Rockwool Roll insulation 13. 2 x 150 mm Rockwool Roll insulation. 14. Breather membrane or roofing felt 15. Roof cladding 16. 50 mm Rockwool acoustic slab flexible closer

17. Timber ‘bobtail’ roof truss

10 7

3 3

2 1

U-values (W/m²K): Wall = 0.15, Floor = 0.12 (assumed P/a = 0.45) Indicates airtightness layer or component

85 11. The interior face of the RockShell wall

ROCKSHELL WALL SYSTEM速

12. Intermediate floor Content: 12.1 Mounting an intermediate floor . . . . . . . . . . . . . . . 88 12.2 CAD-drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

86 Y = The images within this Building Manual are taken from a European installation. They are shown for illustration purposes only and are indicative of the methods used during a RockShell construction. The images are not intended to illustrate UK best practice and personnel shown do not comply with UK health and safety regulations.

Need to know: The RockShell wall system is designed to be combined with lightweight intermediate floors. The floor may comprise light gauge structural steel or timber elements. All issues relating to the design and statics of the intermediate floor should be handled by the supplier.

The intermediate floor is mounted on the RockShell system on the inner side of the OSB lining boards. The example detailed in this section is an indicative example and used for illustration purposes only.

1 RockShell bottom profile 2 OSB board

3 Angel bracket 4

4 RockShell column profile 3

5 LVL board

6 Ring beam

5 9

7 RockShell wool element

8 Ring beam 9 Joist for intermediate floor

4 3

1 5 9 6

87 12. Intermediate floor

ROCKSHELL WALL SYSTEM速

12.1 Mounting an intermediate floor A

Bottom profile

Position a bottom profile on top of the LVL girt plate described in chapter 7, page 59, and temporarily fix it to the system below using one screw at each end.

OSB boards

On the ground floor level, the OSB boards must be attached to the inside of the RockShell system. They need to reach at least 20 cm higher than the horizontal LVL board to allow for the fixing of the intermediate floor on the inner side of the OSB boards. Y

The OSB boards can only be fastened to the steel profile and LVL construction up to the height of the LVL board. Once the first floor is erected the overlap can be fastened to the first floor column profiles.

Brackets

U-shaped brackets for end columns and L-shaped brackets for column profiles are positioned in the bottom profile as described in chapter 6. Screws: See chapter 3, table 7.

Bearing profile

Depending on the type of intermediate floor specified, the bearing profile could be a steel C or L section or a timber/LVL ring beam. For this indicative example we have utilised a steel C section combined with lightweight steel joists.

The ring beam should initially be positioned horizontally against the OSB boards of the RockShell system using one screw in each end. It should be positioned in the vertical so that the LVL board is centred with the C profile. The C section can then be secured to the LVL and Rockshell steel elements. Initially only the fixings up to the LVL board can be placed. The remaining fixings can be placed once the first floor modules are assembled. Y

The intermediate floor joists should be positioned to align with the I-columns and vertical members of the RockShell system.

The number, type and position of fasteners will be given in the structural calculations. All fixings should be approved by the RockShell engineer before use.

Intermediate floor

The remaining elements of the intermediate floor can now be positioned and fixed according to the suppliersâ&#x20AC;&#x2122; instructions. Once the floor construction is complete, a temporary covering should be used to provide protection whilst constructing the first floor RockShell wall. Depending on the floor design and loads, it may be necessary to provide temporary support to the floor from below.

Erecting the RockShell system

Once the intermediate floor is in place, the RockShell elements of the first floor may be set up. These are constructed as described previously.

Joining the storeys

The clamping bands on the outer face of the vertical steel members should be fastened to the first floor elements whilst erecting them. To fasten the bands use two screws (see chapter 3, table 7) per band; one of which must be fixed through the bottom profile.

Finally the OSB boards are fastened to the inner flanges of the RockShell steel elements. This is combined with fixing the remaining fasteners for the upper half of the ring beam.

89 12. Intermediate floor

ROCKSHELL WALL SYSTEM®

12.2 CAD-drawings Party floor junction 250 mm Rockwool Rockshell rigid insulation slab, density 70 kg/m³

27 x 98 mm LVL batten @ 600 mm c/c, fixed back to metal I-profile columns

10 mm Eternit Bluclad board

5 mm Rockwool RockShield TC base coat with embedded reinforcing mesh plus 2mm Silcoplast finish coat

152 x 50 x 1 mm C-profile

50 x 50 x 142 x 1 mm angle bracket

63 x 155 mm LVL board

95 mm Rockwool Rockshell rigid insulation slab, density 70 kg/m³

All junction and joints in OSB to be sealed with proprietary airtightness products

12 6

15 21

14. 12.5 mm plasterboard with skim coat 16. 15 mm OSB

13. 45 mm Rockwool Flexi insulation 15. 240 x 50 mm floor joist at 400 centres

12. 44 x 44 mm s/w battens @ 600 mm vertical centres

OSB to continue through floor zone for continuity of airtightness

8 6 7

11. 12 mm T&G OSB board, all joints and junctions taped with proprietary airtightness products (18 mm recommended for Passivhaus)

10. 50 x 240 mm LVL ring beam

Minimum 38mm bearing of OSB deck onto ring beam 15 50 15 18

150 x 80 x 1 mm metal I-profile (column)

240

30 16

4 5

17. 50 mm Rockwool RockFloor resilient layer

11 12

18. 15 mm Lafarge dBcheck wallboard 19. 18 mm T&G flooring grade chipboard 20. 100 mm Rockwool Flexi 21. 16 mm resilient bars fixed to joists @ 400 centres

Intermediate floor junction

150 x 80 x 1 mm metal I-profile (column)

250 mm Rockwool Rockshell rigid insulation slab, density 70 kg/m³

27 x 98 mm LVL batten @ 600 mm c/c, fixed back to metal I-profile columns

10 mm Eternit Bluclad board

5 mm Rockwool RockShield TC base coat with embedded reinforcing mesh plus 2mm Silcoplast finish coat

152 x 50 x 1 mm C-profile

50 x 50 x 142 x 1 mm angle bracket

63 x 155 mm LVL board

95 mm Rockwool RockShell rigid insulation slab, density 70 kg/m³

U-values (W/m²K): Wall = 0.15, Floor = 0.12 (assumed P/a = 0.45) Y values (W/mK): Internal = 0.08, External = 0.03 (divide by 2 per dwelling) Indicates airtightness layer or component

All junction and joints in OSB to be sealed with proprietary airtightness products

19 12 6

3 4 5

14 13 11 12

17. 100 mm Rockwool Flexi 18. 15 mm Lafarge dBcheck wallboard 19. Timber skirting board 18 27

250

12 45 13

U-values (W/m²K): Wall = 0.15 Y values (W/mK): Internal = 0.04, External = 0.04 Indicates airtightness layer or component

15 18

13. 45 mm Rockwool Flexi insulation

16. 18 mm T&G flooring grade chipboard

12. 44 x 44 mm s/w battens @ 600 mm vertical centres

15. 240 x 50 mm floor joist at 400 centres

8 6 7

11. 12 mm T&G OSB board, all joints and junctions taped with proprietary airtightness products (18 mm recommended for Passivhaus)

16 OSB to continue through floor zone for continuity of airtightness

10. 50 x 240 mm LVL ring beam

14. 12.5 mm plasterboard with skim coat

12 45 13

250

240

23. Timber skirting board

18 27

22. Ceiling finish, 2 x 15 mm Lafarge dBcheck wallboard (26 kg/m²)

91 12. Intermediate floor

ROCKSHELL WALL SYSTEM速

13. Connecting to roof and gable Content: 13.1 Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 13.2 Gable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 13.3 CAD-drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

92 Y = The images within this Building Manual are taken from a European installation. They are shown for illustration purposes only and are indicative of the methods used during a RockShell construction. The images are not intended to illustrate UK best practice and personnel shown do not comply with UK health and safety regulations.

Need to know: The roof construction is not part of the RockShell wall system and can be designed independently from the RockShell wall system. It is beneficial to place rafters, where possible, in line with the vertical bearing members of the RockShell wall system.

The LVL girt plate helps transfer loads from the roof into the vertical bearing members of the wall.

6 1

1 RockShell top-profile 2 LVL Girt Plate 3 RockShell wool element

4 RockShell column profile 5 Rafter 6 LVL Boards

93 13. Connecting to roof and gable

ROCKSHELL WALL SYSTEM速

13.1 Roof A

Roof construction

The roof construction is not part of the RockShell wall system and can be designed independently from the RockShell wall system. It is beneficial to place rafters, where possible, in line with the vertical bearing members of the RockShell wall system. The LVL girt plate helps transfer loads from the roof into the vertical bearing members of the wall.

B The roof provides a large degree of protection for the house and the RockShell system, both internally and externally. We recommend that the roof is completed as soon as possible after the RockShell wall is constructed. Loads from the external cladding are supported by the roof construction.

13.2 Gable A

Erecting of gable

The roof construction should be erected and secured before erecting the RockShell gable. The gable is built up as described in previous sections for wall construction.

B The upper end of the wool elements in the RockShell gable need to follow the pitch of the roof trusses. This end is then completed with a top profile. The roof battens for tiling are then connected to the top profile to secure the gable wall. The final steps are to place wool strips in front of the horizontal LVL boards as described in chapter 7, then to fasten the vertical LVL boards to the roof construction.

95 13. Connecting to roof and gable

ROCKSHELL WALL SYSTEM®

13.3 CAD-drawings Insulated loft

27 x 98 mm LVL batten @ 600 mm c/c, fixed back to metal I-profile columns or LVL plate

10 mm Eternit Bluclad board

5 mm Rockwool RockShield TC base coat with embedded reinforcing mesh plus 2mm Silcoplast finish coat

152 x 50 x 1 mm C-profile

63 x 155 mm LVL board

105 x 105 mm Simpson Strong angle bracket

250 mm high x 12 mm OSB/3 board, fixed to truss upright

27 24

11. 12 mm T&G OSB board, all joints and junctions taped with proprietary airtightness products (18 mm recommended for Passivhaus)

3 6

12. 44 x 44 mm s/w battens @ 600 mm vertical centres

18 13

4 5

16. 44 x 44 mm s/w battens @ 600 mm centres

8 25

14. 12.5 mm plasterboard with skim coat 15. 2 layers of 12.5mm plasterboard with skim coat

19 9

10. 67 mm Rockwool RockShell rigid insulation slab, density 70 kg/m³

13. 45 mm Rockwool Flexi insulation

15 16 17 All junction and joints in airtight membrane to be sealed with proprietary air tightness products

14 11

Seal joint between OSB and airtight membrane with proprietary airtightness tape

17. Vapour control and air tightness membrane 18. 100 mm Rockwool Roll insulation

18 27

250

All junction and joints in OSB to be sealed with proprietary airtightness products

12 45 13

19. 2 x 150 mm Rockwool Roll insulation. Top layer tucked behind LVL batten at eaves btwn packers 20. 350 x 70 mm Rockwool RockFall Overlay insulation board 21. Breather membrane or roofing felt 22. Roof cladding 23. Timber fascia and soffit

Insulated sloped ceiling

150 x 80 x 1 mm metal I-profile (column)

250 mm Rockwool RockShell rigid insulation slab, density 70kg/m³

27 x 98 mm LVL batten @ 600 mm c/c, fixed back to columns or LVL batten

24. Gutter 25. Continuous strip of proprietary airtightness tape to seal junction 26. Timber ‘bobtail’ roof truss 27. 170 mm twist strap support to LVL batten

U-values (W/m²K): Wall = 0.15, Loft ceiling = 0.10 Y values (W/mK): Internal = 0.05, External= - 0.03 Indicates airtightness layer or component

150

22 21

150

250 mm Rockwool Rockshell rigid insulation slab, density 70 kg/m³

100

150 x 80 x 1 mm metal I-profile (column)

25 45

225

63 x 155 mm LVL board

105 x 105 mm Simpson angle bracket

240 mm I-joists

10. 67 mm Rockwool RockShell rigid insulation slab, density 70 kg/m³

11. 12 mm T&G OSB board, all joints and junctions taped with proprietary airtightness products (18 mm recommended for Passivhaus)

20 21

18 13

29 8

18 19

25 23

13. 45 mm Rockwool Flexi insulation

14. 12.5 mm plasterboard with skim coat 15. 2 layers of 12.5 mm plasterboard with skim coat 17. Vapour control and air tightness membrane 18. 170 mm twist strap support to LVL batten

11 18 27

19. 2 x 120 mm Rockwool Rockfall Underlay insulation

4 5

16. 44 x 44 mm s/w battens @ 600 mm centres

250 365

25. Vapour permeable breather membrane

21. 40 mm Rockwool Rockfall Overlay insulation board

26. Roof cladding

22. 70 mm dp treated s/w rafter extension

27. Gutter

23. 70 mm Rockwool Rockfall Overlay insulation board above rafters

28. Timber fascia and soffit

NB: Roof structure design to ensure that lateral loads are tied horizontally and not transfeered to the Rockshell frame

Seal joint between OSB and airtight membrane with proprietary airtightness tape All junction and joints in OSB to be sealed with proprietary airtightness products

12 45 13

20. 38 x 38 mm treated s/w battens to form bearers to rafter extensions

24. 70 mm Rockwool Rockfall Overlay insulation boards across I-joist ends

12. 44 x 44 mm s/w battens @ 600 mm vertical centres

152 x 50 x 1 mm C-profile

5 mm Rockwool RockShield TC base coat with embedded reinforcing mesh plus 2mm Silcoplast finish coat

10 mm Eternit Bluclad board

20 26

29. Continuous strip of proprietary airtightness tape to seal junction

U-values (W/m²K): Wall = 0.15, Slope ceiling = 0.10 Y values (W/mK): Internal = 0.05, External = 0.00 Indicates airtightness layer or component

Roof, trussed rafters 395

10 mm Eternit Bluclad board

5 mm Rockwool RockShield TC base coat with embedded reinforcing mesh plus 2mm Silcoplast finish coat

152 x 50 x 1 mm metal C-Profile channel

63 x 155 mm LVL board

12 mm T&G OSB/3 board, all joints and junctions taped with proprietary airtightness products (18mm recommended for Passivhaus)

44 x 44 mm horiz s/w battens @ 600 mm vertical centres

10. 45 mm Rockwool Flexi insulation 11. 112.5 mm plasterboard with skim coat 12. 50 x 240 mm LVL ring beam

21 24 3

15. Void for services, vent ducts etc

20. Single ply membrane on fleece separation layer board, fixed in accordance with manufacturer’s recommendations 21. 2/3 layers, (as indicated) of 50 mm Rockwool RockFall Overlay rigid insulation slab, density 70 kg/m3 22. 19 mm plywood parapet capping fixed through RockFall insulation boards to timber stud

21 26 31 27

31 21 29

Seal joint between airtight membranes with proprietary airtightness tape

17. Vapour control and air tightness membrane

19. Min 35 mm thk Rockwool HardRock Dual Density insulation board, cut to 1 in 60 falls

17 16 20 19

16. 19 mm plywood deck 18. 2 layers of 150 mm thk Rockwool HardRock Dual Density insulation board

13. 15 mm plasterboard ceiling 14. 240 mm I-joists

Laid to 1 in 60 falls, min 35

27 x 98 mm LVL batten @ 600 mm c/c, fixed back to metal I-profile columns and parapet framing

300

23 22

250 mm Rockwool RockShell rigid insulation slab, density 70 kg/m³

6 1

10 2 18 27

11 8 9

250

45 13

15 13

Seal joint between OSB and airtight membrane with proprietary airtightness tape

240

150 x 80 x 1 mm metal I-profile (column)

min 150

All junction and joints in airtight membrane to be sealed with proprietary airtightness products

All junction and joints in OSB to be sealed with proprietary airtightness products

23. Proprietary aluminium parapet capping system 24. 150 x 38 mm C16 studs @ centres to match roof joists with skew nailed fixings to sole and head plate. 25. Simpson H LUS 230/50 truss shoe fixed with 30 x 3.75 mm square twist nails & 75 x 3.75 mm square twist nails

U-values (W/m²K): Wall = 0.15, Roof = 0.10 Y values (W/mK): Internal = 0.10, External = 0.01 Indicates airtightness layer or component

26. Simpson ES10/60 nail plate bracket each side of outtrigger. Secured with 30 x 3.75 mm square twist nails 27. Simpson EA554/2 angle bracket to fix 100 x 50 outrigger to batten. Secured with 30 x 3.75 mm square twist nails 28. 150 mm Rockwool Flexi insulation 29. Strip of vapour control and air tightness membrane to join OSB to vapour control layer at roof. Laid over 63 x 155 mm LVL board before installation of roof joists 30. 100 x 50 mm timber outriggers at centres to match I joists. Fixed to timber battens with skew nails, coach screw and Simpson brackets as illustrated 31. 100 x 50 mm timber battens. Inner batten fixed to ply deck and outrigger with Simpson brackets, outer batten secured with skew nails to outrigger and SD525312 coach screw to LVL beam below

97 13. Connecting to roof and gable

ROCKSHELL WALL SYSTEM速

14. Quality control The RockShell wall system has been developed as an all-in-one system, comprising all the necessary components to erect the system. The RockShell wall system has been designed to provide an efficient building method to meet the needs for low energy buildings.

98 Y = The images within this Building Manual are taken from a European installation. They are shown for illustration purposes only and are indicative of the methods used during a RockShell construction. The images are not intended to illustrate UK best practice and personnel shown do not comply with UK health and safety regulations.

The RockShell wall system interfaces with most standard building components such as roofs, windows and doors, as well as a variety of external finishes. The modular system is pre-fabricated to a high standard comprising minimal components. The simple design allows for efficient construction and decreases the risk of mistakes being made on the building site. Suggested standard details are available for all interfaces between the RockShell wall system and other building components, all detailed to minimise thermal bridges. The modular design of the system means that few adjustments are required between different house designs. As a result, many of the standard details are transferable between house designs.

The quality process

1: To assist in a problem free installation and ensure a high level of quality, Rockwool offers training courses for installers. 2: At the Rockwool factory all aspects of the manufacture of the RockShell system are controlled to ensure the quality and accuracy of specifications, materials and despatch quantities according to the specification of the system. 3: The RockShell wall system is calculated for each individual building and a bespoke system of all components is then packed at the Rockwool factory. 4: The bespoke system is then shipped to site as a single delivery for each house. The delivery will be in accordance with the agreed build date, meaning no waiting time and no delays.

At the construction site

5: The delivery should be inspected on arrival at the site, to ensure the correct number of pallets are delivered and to check for damage in transit. Any shortages or damage must be notified immediately. 6: Before commencing the installation of the RockShell system, it is vital to check that foundations meet the required dimensions and tolerances as prescribed earlier in this manual. 7: We recommend that a start-up meeting is held before the erection process begins to review the installation process. This would involve the contractors, installers and your RockShell engineer. 8: Installation inspections should be carried out periodically throughout the build. 9: We recommend that the first inspection should be carried out on the first 150 m2. Subsequent inspections should be each 250 m2. 10: Specific inspections and controls should be made for wetrooms (bathrooms) and the completion of joints in low energy houses.

Final control

11: Rockwool can perform a of final inspection of the RockShell wall by appointment and as needed.

99 Y

14. Quality control

ROCKSHELL WALL SYSTEM速

15. Handling instructions Transport and storage A

Delivery

The RockShell wall system is delivered to a site as a complete system comprising all necessary components, i.e. wool, steel elements, fasteners, etc. Most are unassembled, although some steel elements such as end columns or lintels may come pre-assembled. All components are delivered to the dimensions specified and according to the size of the modular grid and the floor height. These sizes will be according to the technical drawings, in some cases exceptions may occur. Y

All components are delivered on pallets. The stone wool modules with a height of 2.70 m are delivered on oversized pallets (1.25 x 2.75 m). The pallets must be handled using a forklift. Pallets must not be stacked more than two layers high.

Protection

When the RockShell wall system is delivered on the pallets, they will be protected from the weather by a waterproof covering. The covering should be replaced when a pallet is opened and left overnight with system components on it. The corners and edges of all pallets are protected to prevent damage during transport and storage.

RockShell wool elements

RockShell insulation must not be stored in its wrapping for more than three months, including a maximum of one month on the building site. Once installed, the insulation can be exposed to natural UV radiation for three months provided it is protected from rainwater.

100 Y = The images within this Building Manual are taken from a European installation. They are shown for illustration purposes only and are indicative of the methods used during a RockShell construction. The images are not intended to illustrate UK best practice and personnel shown do not comply with UK health and safety regulations.

On-site cutting and waste

Whilst waste will be minimal, any that occurs must be disposed in accordance with local requirements. Any cutting should be carried out with tools approved for the purpose. Cutting should be performed on a firm and clean surface, in accordance with health and safety regulations.

E Water protection during erection Once the top profile and LVL girt plate have been mounted and fastened to the column profiles, the wall should be temporarily covered with a waterproof membrane. The membrane should be removed when another storey has been erected on top or when the roof construction is completed and the structure is watertight Y

Steel profiles

The steel profiles for the RockShell wall system must be stored flat on pallets. Care should be taken to protect corners, ends, etc. from impacts and other forces.

OSB boards

All the OSB boards used in the RockShell wall system are CE-marked. The OSB boards have to be protected from getting wet; therefore we recommended that the OSB boards are installed after the roof has been finished.

101 15. Handling instructions

ROCKSHELL WALL SYSTEM

16. Support and calculation tools From the initial design phase to finished building â&#x20AC;&#x201C; RockShell will support you. RockShell is a completely new way of building lightweight external wall structures. As a result we offer extended technical service and support, which will enable you to complete the entire construction process with confidence. The technical support consists of a wide range of services ranging from calculation and design assistance to on-site support, providing you with a fast response for your project.

102 Y = The images within this Building Manual are taken from a European installation. They are shown for illustration purposes only and are indicative of the methods used during a RockShell construction. The images are not intended to illustrate UK best practice and personnel shown do not comply with UK health and safety regulations.

SPECIFICATION NOTES: 1. Thermal broken Passivhaus standard door U= 0.80 W/m²k or better 2. Alumimiun threshold cill, 15mm high 3. 40mm XPS insulation 4. Precast concrete door step

Installation videos

5. Proprietary threshold slot drain

CAD-drawings

6. 100mm concrete block dwarf wall supporting door step 7. 90mm XPS rigid insulation 8. Reinforced concrete upstand 9. Concrete footing to dwarf wall 10. Lapped strip of proprietary air tightness tape to seal junction between threshold and ply

11 12 13

11. 22mm plywood deck glued and screwed to jamb ply to form continuous ply surround to door

All junction and joints screed to be sealed with proprietary airtightness products

10 1 2 3

12. 50mm XPS rigid insulation 13. Bituminous roofing felt adhered to the concrete upstand with cold asphalt sealant

Seal junction between screed and ply with a continuous strip of proprietary airtightness tape

14. Lapped strip of proprietary airtightness tape to seal junction, suitable for adhesion to concrete substrate 15. 30mm Rockfloor perimeter insulation 16. Concrete foundation

FFL

17. DPM

18. 250mm Rockfloor insulation

19. 75mm sand/cement screed

250

165 6 7 8 9

NOTES: U-values (W/m²K) Door = 0.80 min, Floor = 0.12 (assumed P/a = 0.45) Ψ values (W/mK) Installation = 0.09

Brochures

Cold outside 0 °C Hot inside 20 °C Black/dark = no heat flow White/light = high heat flow

Isotherms (lines of constant temperature) Heat Flux (heat flow through materials)

energy efficiency put into system

2018 Door details Threshold with cladding

ROCKSHELL WALL SYSTEM ®

Building and construction

The RockShell wall low energy solution system is an innovative, load bearing walls for the construction of in low-rise building s.

Create and

Calculation and planning assistance

Right from the first stage of design, you will have the opportunity to use our special RockShell design and calculation service. All you need to do is send your outline plans to us. We will then perform the design calculations and prepare the final bill of materials and material specifications. We will also suggest any adaptations and adjustments, which can further rationalise your project and provide even greater savings.

proteCt

Service: You are always welcome to call or e-mail our RockShell specialists if you have any questions regarding the system or a specific construction project. Contact: Service line: + 44 (0) 1656 868 400 E-mail: rockshell@rockwool.co.uk

On-site support

We can provide on-site support, where a trained RockShell specialist will ensure that the construction goes smoothly. The RockShell specialist will guide and advise you during the construction process to ensure that you always have the most efficient work processes and achieve the best possible result.

RockShell installation courses

To ensure that the many advantages of building with a RockShell wall system are exploited to the full, Rockwool is offer courses for installers. These courses help to ensure an efficient and smooth construction process from start to finish. The courses can be tailor-made to suit your company. Please feel free to contact us if you are interested or register your details at www.rockshell.uk.com

Support tools at www.rockshell.uk.com

We have created a comprehensive website for the RockShell wall system at www.rockshell.uk.com. On our website, you will find a variety of resources from general system information to example CAD illustrations, installation videos, product and material information and much more. We have also created a comprehensive e-learning module, providing answers to virtually all aspects relating to designing, constructing, and using the RockShell system.

103 16. Support and calculation tools

ROCKSHELL WALL SYSTEM®

17. Sustainability Rockwool stone wool is fundamentally a natural product. Manufactured from diabase stone and recycled materials in a process that resembles the natural action of a volcano. Rockwool is one of the most environmentally friendly insulation materials in a building in terms of both the total energy usage and the total CO2 saving. Within the Rockwool Group, sustainable production and processes are an important part of our business strategy.

Through energy savings in our production processes, intensified recycling and CO2-reducing products, we are committed to a continuous process of environmental improvement. In this chapter, we briefly outline some of our key areas regarding sustainability. You can find out more in our “Sustainability report”.

Insulation is the fastest and most profitable way of saving energy Insulating buildings is one of the most profitable ways of saving energy and reducing CO2 emissions. Insulation represents better value for money than biofuel, wind power or solar energy for example. By retrospectively insulating our buildings and building new low energy houses, we can reduce energy consumption by up to 90%.

Rockwool stone wool – a natural material The chemical composition of Rockwool stone wool is very similar to the composition of the Earth’s crust. The production of Rockwool stone wool is primarily based on the use of diabase stone, which nature itself creates. Rockwool stone wool is one of the few products that can be considered as being made of renewable materials, and therefore does not contribute to the deplenishment of natural resources.

You can read more about the Rockwool Group and sustainability in our “Sustainability report 2010” that can be downloaded on www.rockwool.com

Rockwool is manufactured by melting rock, limestone, recycled briquettes and raw materials at 1,500 °C.

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Every time the Rockwool Group emits 1 tonne of CO2, the environment is spared 162 tonnes of CO2 Sustainability is about managing the future now and about taking responsibility for the results of our current actions. Life cycle assessments of Rockwool stone wool verify our overall contribution to the environment. A life cycle analysis carried out by Force Technology shows that Rockwool stone wool has very low energy consumption in its total life cycle.

Rockwool insulation, life cycle balance Units consumed through production

Units saved throughout 50 years

CO2

162

Energy

128

Force Technologyâ&#x20AC;&#x2122;s study also shows that Rockwool stone wool is one of the most environmentally friendly materials amongst those tested with regards both the total energy account and total CO2 saving.

Sustainable product development A key area of our sustainable business strategy is product development. In our research and development functions, we maintain a constant focus on how we can reduce the environmental impact of our products, e.g. through the clever use of packaging.

Every year, Rockwool converts more than 400,000 tonnes of waste products from other industries into actual energy savings Another important approach to sustainability within the Rockwool Group is maximising recycling of both our own products and materials from other industries. Every year, we convert more than 400,000 tonnes of waste products from other industries into insulation and energy savings.

A tradition of recycling For over 10 years, Rockwool has accepted waste products from both construction sites and horticultural centres, and has extensive experience of recycling these waste products into our own production.

The life cycle balance shows that, over 50 years, Rockwool stone wool saves 128 times the amount of energy and 162 times the amount of CO2 that is used for production, transport and disposal. The CO2 account is therefore positive after just four months! The energy saved corresponds to 503 litres of fuel oil per m2 over 50 years. Source: Force Technology. The example is based on 250 mm ceiling insulation.

Rockwool was the first company in the market to introduce a pallet system where the pallet itself is made from Rockwool stone wool and can be used directly in the building itself. In this way, we have reduced our wood consumption by thousands of cubic metres.

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ROCKSHELL WALL SYSTEMÂŽ

Process water is recirculated at the Rockwool factories Water is one of the most limited resources in the world. UNESCO predicts that, within the next 20 years, we will be facing an unprecedented shortage of drinking water as a result of pollution and global warming. The Rockwool Group carries out its production based on a general requirement for minimal water consumption, and since 2002 we have reduced our water consumption by approximately 20%. The only loss in production occurs through evaporation.

Environmental damage caused by fire Every year, people die or are injured in building fires and substantial financial assets are lost. Fire can also have major adverse consequences for the environment and climate due to the gasification of hazardous substances and chemicals. Rockwool stone wool can resist temperatures of more than 1,000 Â°C and acts as an effective fire barrier, which can prevent a fire from spreading. It is also important that the total gasification of harmful substances and chemicals is minimised, which is the case when Rockwool stone wool is used.

Environmental impact per m2 building in case of fire Type

Kg CO2 per. m2

Fire, extinguished after 15 min.

14 - 40 kg

Rockwool stone wool gives a pleasant indoor climate, absorbs noise and regulates sound

Building burned to the ground

400 kg

Studies by the University of Jena in Germany show that more than 20% of buildings have problems relating to draughts and the indoor climate.

Source: Fire Risk Management April 2008

A well-insulated home combined with good ventilation is the best and most economical way of preventing or overcoming this. Insulation that provides a tight seal guarantees a pleasant and constant temperature all year round.

OR C MATE LI

TH E I N

Rockwool stone wool insulation meets the strictest European requirements in relation to indoor climate, and is certified in the Finnish M1 emission class for construction materials. Rockfon acoustic products carry the Danish Indoor Climate Mark.

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Product safety Rockwool stone wool is one of the most comprehensively tested and well documented construction materials and is a safe product to work with. Conclusions concerning the properties of our products are based on major epidemiological studies carried out in collaboration with external partners.

Environmental management We follow the international environmental standards ISO14001 and EMAS, and our factories are subject to third-party certification.

Local responsibility and dialogue We continually strive to maintain good relationships and dialogue with our local communities to ensure optimal conditions for our neighbours. Many of our factories have won awards and recognition for their efforts to optimise their local environment.

Testing and documentation are important factors to the Rockwool Group

THE L IS ONE OF O O W E N O T S STED R OCKW OOL SIVELY TE N E H E R P MOST COM ION MATERIALS EVER T CONSTRUC

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RockShell Wall System Building Manual

ROCKSHELL WALL SYSTEM速

26-28 Hammersmith Grove London W6 7HA Tel: +44 (0) 845 241 2586

Unit 11 Northwood Court Santry Dublin 9 Ireland Tel.: +353 (0) 1 891 1055 E-mail: rockshell@rockwool.ie www.rockshell.ie

Manual No: RSMan01. Version 1. 01/10/2011

ROCKWOOL LIMITED Registered Office Pencoed Bridgend CF35 6NY Tel.: +44 (0) 1656 868 400 E-mail: rockshell@rockwool.co.uk www.rockshell.uk.com

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Building Manual The RockShell wall system is an innovative, low energy solution for the construction of load bearing walls in low-rise buildings.

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