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Properties and Advantages of the NRG Greenboard Walling System

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NRG Greenboard panel is manufactured from high density, rigid, expanded polystyrene. The raw material is gained as a by-product of the manufacture of oil.

Greenboard is manufactured without the use of CFC’s and does not contain or emit any poisonous gas. In  fact, NRG  Greenboard  is made  up of 98%  air entrapped  in  a  closed
cellular structure of polystyrene. This entrapped air accounts for the extremely good insulation properties of the Greenboard.

The off cuts of NRG Greenboard can be glued within the wall cavity prior to the installation of the internal linings as additional insulation. This cuts down on the impact to our environment as all the material is being used, leaving a minimal amount of material to be removed from site.

Insulation for Energy Efficient Buildings

The Greenboard system is the most cost efficient method of insulation in terms of R-value per dollar. Unlike some other methods of insulation that allow thermal bridging across the timber or steel studs framing. NRG Greenboard provides a continuous insulative sheath around the entire building.

Warranty – 10yr

NRG warrants that the Greenboard sheets (the “Product”) will be free from defects due to defective factory workmanship or materials prior to the installation of the Product for a period of 10 years from the date of purchase, subject to compliance with the conditions published in NRG Product Warranty 2007

 Easy to Render

The surface of the NRG Greenboard is grooved providing an excellent substrate for  Reinforced Render Systems.

Energy Efficient Production

Greenboard uses much less energy in its production than conventional building materials such as concrete and masonry

Fashionable Render Finishes

Available in a wide range of Architectural colours and styles (Refer to your selected manufacturers, texture coating specifications).

Design Freedom

Curved walls, rounded corners, embossed patterns, raised wall areas, mouldings and other architectural features are simple to achieve and cost-effectively with the versatile NRG Walling System.

 Vermin Retardant

NRG Greenboard is impregnated with a natural insect retardant, (Bithentrin)

 Biologically Inert

The board will not rot and provides no nutritive value for insects or micro-organisms.

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NRG Greenboard Installation Procedure

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Installation Procedures NRG Greenboard Walling System
This manual provides information on the correct procedures and materials to be used for the installation of NRG Greenboard Walling System over standard framed and solid structures. The drawings and details are provided to assist building designers in specifying the correct design and detail of the NRG Walling System. These details cover most common applications. If the details are to be altered or new ones proposed please contact NRG to discuss the changes. Failure to do so may void the systems warranty.

These components that make up the NRG Greenboard Insulative Walling System are.

• Screws and washers
• Vapor permeable sarking
• NRG Greenboard
• NRG PVC beads
• Polymer modified render
• Reinforced mesh
• Texture top coat

These components form part of the complete system and must not be substituted with other possible nonconforming materials.

Timber and Steel Framing
All timber and steel framing should conform to the relevant Australian Standards, as well as the local standards for structural requirements including wind loadings and bracing.

NRG Greenboard is not a structural material and therefore should not be considered or used as a bracing material.

Existing framing
When ‘over-cladding’ existing timber buildings, inspection should be carried out by a fully qualified person, to identify any deterioration or infestation by wood boring insects. Although NRG Greenboard is impregnated with an effective insect repellent, it will not arrest or prevent further infestations of the timber framing structure. Where necessary, repairs must be undertaken to ensure that the timber substrate is sound, straight and true.

Back Blocking (Off Stud Joints)
Where horizontal fixing of sheets ‘off stud’ join are to be made, it is necessary to back block as follows.

i. By fixing an ‘off cut’ of stud  material vertical, (widest face facing outwards) and  securely
nailing to bottom plate and noggin. Alternatively, between noggin and top plate, making sure to glue both Greenboard sheet edges with Bostik No-More Nails and fixing through each sheet into the ‘black block’ with washers and screws at maximum 300mm centre’s.

ii. Alternatively, horizontal ‘back block’ using ‘off cuts’ can be placed at maximum 300mm centre’s, following the above procedure except that, with the two sheets in place, take ‘off cuts’, smear with Bostik No-More Nails over one face, place ‘off cuts’ against the Green board sheets and screw through face of Greenboard into ‘off cuts’, pulling both sheets into alignment.

Solid Blocking of Fitting and Accessories
Consideration should be given to the installation of wall mounted accessories i.e. taps, electrical fittings, etc. It is important to allow for adequate backblocking for these items prior to the installation of the NRG Greenboard.

Electrical Cables and PVC
Cables penetrating the NRG Greenboard Walling System must be installed in conduit or ducts sealed to the cladding or have a sheathing containing migration resistant plasticizer. Cable manufacturers should be contacted for details of suitable cable types.

Flashings
All flashing to wall openings, roof sections and parapets etc. to be installed prior to the fixing of NRG Greenboard Walling System and is always capped off at the bottom edge of the Greenboard sheet using a Starter Bead  in accordance with good building practice and together with any requirements of the BCA. NRG Building Systems take no responsibility or liability for flashing or installations.

Fitting NRG Greenboard Walling Panels

I. Before commencing to fix panels check that the frames are straight, all windows and flashings are correctly installed and solid backing blocks are in place where required.

II. Timber frames must have a moisture content of less than 15% before Greenboard panels are fitted, horizontally (preferred) or vertically.

III. Measure and cut Greenboard Sheeting using a straight edge and masonry diamond blade in a standard power saw (use of handsaw not recommended).

IV. Glue both horizontal and vertical Greenboard sheet edges to each adjoining sheet using
Bostik – No More Nails / Power trigger foam.

V. Fixing NRG washers and screws at 450mm stud spacings horizontally and 300mm spacings vertically (see fixing table for hight spacings) : -Greenboard sheet lay horizontally, comprising of five (5) rows fixings vertically.
1st – When making butt joint, each sheet is fixed individually to the back-blocking or vertical noggin, corresponding with the above fixing set out.

VI. ‘Infill’ small areas with Greenboard (e.g. above and below windows, etc.) – It is
recommended to use a minimum height of 300mm to allow for adequate fixing.

VII. Allow 3mm gap between Greenboard panel and openings for bead and sealing procedure ((Refer Table 17.1.15 Beading))

VIII. External corners – Greenboard sheets are overlapped the full thickness of the sheet and glued using recommended construction adhesive.

Curved walls
40mm and 60mm Greenboard panels can be fitted to curve walls with a radius greater than 2-4 metres’. Where a tighter radius is required use multiple layers by laminating 2 x 20mm thickness Greenboard panels (off set joints).

Expansion Joints

Expansion joints allow for movement within the building and avoid unsightly cracking within the wall areas. Expansion joints must be provided where NRG Greenboard lengths exceed specified dimensions (see table). In addition, it allows for affording an opportunity to ‘weather seal’ such junctions.

 

 

NRG Greenboard Specifications

Fixings – Accessories

Cutting and Tools Required

Gluing and Sealing

Beading

NRG have a full range of UV stabilized PVC beads specifically designed for Greenboard cladding .use only UV stabilized beads for external application.
N.B. External and internal ‘rail edges’ must be precise to ensure a uniform complete ‘fit and finish’ in readiness for sealing as well as rendering.

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NRG Greenboard Walling System over Concrete and Masonry Wall Surfaces

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1.  Preparation
All walls must be clean and dust free from dirt, oil, vegetation, and crumbling or loose materials.

2.  Installation of Greenboard using Power’s Foam Adhesive System

i. When installing via the Foam adhesive system, apply a large “dob” of foam adhesive to the middle of each and every masonry block.
ii. Position the board and drill 8mm hole through the masonry at each corner offset in by approx 100mm.
iii. Hammer the Hilti IDP anchors in.
iv. Use a minimum of 8 IDP anchors for each 2500 x 1200 board with at least 2 x IDP anchors staggered in the mid section of the board.

3.  Final Checking of Greenboard installation on Concrete and Masonry Walls – Before rendering, any irregularities in the surface of the sheet or joints are sanded back using a coarse rasp.

4.  Expansion Joints within The Greenboard installation on Concrete and Masonry Walls – All expansion joints in the substrate must be carried through the complete cladding system.

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NRG Greenboard Render Specifications

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1.  3.5mm Render
Option 1
1 coat polymer modified render (3.0mm)
Reinforced Alkali Resistent Fibreglass Mesh (160g/mm)
1 coat Acrylic Render (1.0mm)
2 coats of Acrylic Membrane Paint

Option 2
1 coat polymer modified render (3.0mm)
Reinforced Alkali Resistent Fibreglass Mesh (160g/mm)
1 coat Primer
1 coat Timted texture (1.0mm)
(Clearcote optional)

6mm Render
1 coat polymer modified render (4mm)
Reinforced Alkali Resistent Fibreglass Mesh (160g/mm)
1 coat polymer modified render (2mm)
2 coats of Acrylic Membrane Paint

NOTE: To be used only as a guide. Refer to Render/ Paint manufacturers specifications (example Rockcote RRR) for exact details and procedures.

2.   Handling and Storage
i. NRG Greenboard should be laid flat with edges and corners protected from damage.
ii. NRG Greenboard should not be stored in the open or fixed to a building for prolonged periods. NRG Greenboard should to be protected from exposure to direct sunlight and
kept away from extreme heat and organic solvents.

3.   Health and Safety
i. NRG Greenboard Insulative Walling System and is non-hazardous.
ii. However, as with all composite materials basic safety clothing and gloves are  to be worn when handling or cutting the NRG Greenboard.

iii. When cutting NRG Greenboard Insulative Walling System with a power saw it is recommended that a face mask and protective glasses be worn.

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Greenboard Advantages CodeMark Certification & ENVIRONMENT

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Greenboard is an Insulated Wall Panel that combines exterior cladding with insulation so designers can achieve the 6 star energy ratings that have been introduced into the building code. Greenboard‘s insulated core of high quality expanded polystyrene puts the Greenboard insulated panel in the best place of the building, as far towards the outer side as possible.

Greenboard Insulated Wall Panel is a lightweight, energy efficient product and once coated the system provides a weather resistant, seam free rendered finish.

Greenboard Advantages

CodeMark Certification

All building products must comply with the BCA (Building Code of Australia). NRG Building Systems has achieved CodeMark on Greenboard Insulated Wall Cladding meaning Greenboard complies to the BCA.

Insulation Qualities

All insulation materials are rated for their performance in restricting heat transfer. This rating is expressed as an R-value which is a measure of the material’s resistance to heat transfer (thermal resistance). The higher the R-value the greater insulating effect.

Sound Rating

NRG Building Systems has tested 60mm Greenboard total wall system and the acoustic performance result was Rw35, Ctr-6. Please refer to NRG test results. The Greenboard walling system can be further enhanced by using a “sound rated” insulation batt. Please refer to insulation manufacture’s specifications.

Fire Retardant

Greenboard contains a flame retardant additive and will not support fire, it has a spread of flame index of zero. If in a fire situation the toxic fumes are no greater than that of timber and other building materials.

Grooved Panel

The surface of the Greenboard panel is Grooved both sides allowing the inside surface to breathe and channel any possible condensation away through the Grooves, downwards to the base of the wall. This is particularly important where “insulation” or “breather sarking” is used. The additional advantage being that when the Grooved face of Greenboard is rendered the system becomes stronger as the render gets into the Groove to form a core shape for better adhesion and a stronger more rigid Greenboard system.

Easy to Use

Greenboard‘s lightweight panel size is 2500 x 1200 allowing installers to cover the external walls quicker and easier. For the builder and their client, Greenboard gets the project to lock up stage quicker allowing other trades to start and complete their tasks.

Greenboard requires less energy to produce than other traditional building materials and contains no CFC’s nor HCFC’s. Greenboard does not contain ozone depleting substances and none are used in the manufacturing of this product. Greenboard can be recycled or NRG recommends left over Greenboard can be placed in the walls as extra insulation.

Greenboard contains a termite retardant (Bifenthrin) and NRG uses 62% more in their product than the minimum required.

Render Levels of Finish

Reinforced render is applied to the Greenboard substrate at approximately 4-8mm in thickness which allows qualified applicators to screed out usual imperfections and form a seam free level 5 finish. NRG recommends render over Greenboard should be specified by a coating manufacturer.

NRG GREENBOARD AND THE ENVIRONMENT

  • NRG Greenboard is comprised of 98% air and therefore only 2% polystyrene making it a highly efficient use of raw material.
  • NRG Greenboard remains inert, is non toxic, odour free and non-biodegradable.
  • No CFC’s or HCFC’s foam agents are used in its manufacture, so NRG Greenboard causes no damage to the ozone layer.
  • Effective installation of NRG Greenboard can cut carbon dioxide emissions by up to 50%.
  • The R-value of NRG Greenboard does not deteriorate during its life time; therefore the reduction in emissions lasts the full lifetime of the building.
  • The energy used to manufacture NRG Greenboard is recovered within six months by the energy saved in the building in which NRG Greenboard is installed.
  • Typically, for every kg of oil used in NRG Greenboard manufacturing, about 200kg will be saved in reduced heating demands.
  • All NRG Greenboard waste is recycled. Either through installation of off-cuts in the wall cavity or it can be granulated and mixed with virgin material to make new products.

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NRG GreenBoard CodeMark Certification

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CodeMark is a new building product certification scheme. Third-party CodeMark Certification bodies evaluate and certify products to ensure they meet specified requirements of the Building Code.

CodeMark gives users the confidence that their building comply. Building materials, forms of construction and designs can come under the scheme.

Relevant legislation requires Building Certifiers, Designer, Architects, Builders, Home Insurance companies, Customers etc. to accept CodeMark certified products*.

WHY CODEMARK?

Impressive benefits for everyone:

  • Confidence – legislated product acceptance by building control authorities* (product opinions, appraisals etc. do not have the legislated acceptance);
  • Confidence – managing legal liability;
  • Confidence – national operation across Australia, therefore increasing market potential and improving efficiency;
  • Confidence – for designers, architects, builders, building control authorities, consumers and others who specify use, approve or invest in CodeMark certified products;
  • Confidence – underpinning the performance-based BCA through facilitating the use of new and innovative products; and
  • Confidence – listing current CodeMark certified products and accredited CodeMark certification bodies in Australia at the ABCB website.

NRG – CodeMark Accreditation Advantages

  • Offering increased credibility and acceptance, boosting consumer confidence in, NRG & Distributor network as well as ‘Accredited Installers’.
  • Assurance, that the NRG Greenboard system meets stringent national standards, encompassed by CodeMark  Accreditation.
  • Quality Assurance in the manufacturing process of NRG Greenboard, through constant product testing, reporting procedures etc.
  • Quality Assurance – NRG Greenboard profile cutting procedure, recording and documentation to the point of distribution by NRG.
  • Accreditation of installers, rendering and painting of the NRG Greenboard system through the introduction of ‘new structured’ training courses and information material, as this will, ‘underpin’ the ‘CodeMark’ Accreditation (essential).
  • Builders and Owner Builders, NRG Greenboard will also develop a ‘new structured’ training courses and information material and as well for this large market segment.
  • CodeMark Accreditation is a ‘holistic’ approach to this marketing strategy and encompasses all of the above. Without the authorised and accredited structure proposed, CodeMark accreditation would not be given, therefore it is essential that this fact is made known when promoting and marketing the NRG Greenboard system.

Additional benefits for Certificate Holders:

  • Confidence – offering increased credibility and acceptance of a certificate holder’s CodeMark certified products, whether established or new, therefore boosting consumer confidence in their organisation:
  • Confidence – entitling certificate holders to display the CodeMark “Mark of Conformity” ; and
  • Confidence – introducing a choice of certification bodies, therefore encouraging a timely and cost effective service.

Additional benefits for Certification Bodies:

  • Confidence – providing accreditation from an internationally recognised accreditation body, therefore increasing credibility;
  • Confidence – increasing acceptance and credibility of a certification body’s relevant product testing and evaluation methods; and
  • Confidence – entitling certification bodies to display the CodeMark “Mark of Conformity”.

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NRG Greenboard Wall Cladding System

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NRG Greenboard Energy Efficient Wall Cladding System
NRG Greenboard is an insulative walling system suitable for external cladding of timber or steel framed buildings as well as solid concrete and  masonry walls. The system provides a weather resistant, seam free rendered finish in a wide range of textures and colours.

Design Freedom, NRG Greenboard -Curved walls, rounded corners, embossed patterns, raised wall areas, mouldings and other architectural features are simple to achieve and economically viable with the versatile NRG Energy Efficient Wall Cladding System.

Additional Benefits:
• Sound Insulation – 60mm Greenboard (Rw 35, Ctr – 6)
• Environmentally Friendly – Recyclable, Re-usable Products.
• Insect Repellent
• Flame Retardant

NRG Fencing
NRG Fencing looks great, its sturdy profile and attractive appearance will give any development that distinctive architectural appearance. No more costly strip footings and engaged pier construction.

NRG Fencing has less than ten components are lightweight and easily to handle. It can be purchased in kit form or erected by our skilled team of tradespeople.
NRG Fencing is finished off with stylish and decorative Hebel post caps, top rail and post capping moulds and finished with a decorative textured paint.

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NRG Greenboard Installation Guide

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This guide provides information on the correct procedures for the installation of NRG Greenboard The details are provided to assist carpenters/ installers and cover most common applications.

START

(A) Before commencing to fix NRG panels check that

i. The frames are straight and plumb

ii. All windows and flashing are correctly installed

iii. Breathable sarking has been fitted

iv. Solid back blocking where required

Consideration should be given to the installation of wall mounting accessories i.e. taps, electrical, fittings etc.  It is important to allow for adequate back blocking for these items.

(B) POSITIONING OF STARTER BEAD:

FIXING / CUTTING / BACK BLOCKING

(A) NRG panels can be layed horizontally or vertically depending on what suits the job.
• Position NRG panel into starter bead, check for level and fix into studs using NRG washers and screws.

• Standard fixings are 300c vertically and 450c horizontally  (refer to fixing table)

(B)  Adjoining NRG panels are to be glued on both horizontall and vertical edges using recommended construction adhesive (i.e. Bostik No More Nails) or an expanda foam.

(C) Measure and cut NRG panels using a straight edge and a standard power saw with a masonary diamond blade.

(D) At external corners, NRG panels are overlapped the full thickness of the sheets and glued using recommended construction adhesive.

(E) Allow a 3mm gap between NRG panels and openings (door, windows) for sealing.  It is recommended the straight edge of the sheet be fixed next to the openings for easier sealing.

BACK BLOCKING

(F) Where the NRG panel has a vertical join off a stud it is necessary to back-block as follow.

i. Fixing stud material vertically (widest facing outwards) and securing between bottom plate and noggin.  Alternately between noggin and top plate, making sure to glue both NRG panels and fix through each panel with screws and washers into back block at 300c.

(G) Fill any gaps or holes with expanda foam.

3 BEADING & SEALING

At this point particular care needs to be exercised to ensure that the installation of all beading around windows and doors is completed correctly.  This is not a gap filling exercise but an intregral part of the total NRG Greenboard walling system.

(A)  Rendered Reveals 60mm, 75mm, 100mm Greenboard

i.   All sills, heads & jambs to be rendered.

ii.  Using marking tape, accurately adhere to frame of joinery, 4mm from the edge creating a neat parallel margin.

iii.   Using Bostik Primer 5077, and a clean rag, dampen cloth with Primer and quickly clean the window reveal, ready for sealant application.

iv.   Cut a medium size end off the nozzle of the sealant.  Apply a bead of sealant into the gap between the Greenboard and the taped window reveal.  Using a coving tool, neatly create an internal cove finish.

v. Remove masking tape from joinery leaving a 100% water proof seal.

vi. This peocedure is repeated after rendering and prior to texture coating, to ensure double sealing around windows and doors.

(B) External Beads

i.   External points of building, columns etc.

ii.   All sill, head and jambs (60mm, 75mm, 100mm)

iii.   Install external bead by applying a bead of Bostik No More Nailst o internal sides of the bead.

Then press firmly into position, check for plumb and straightness, scraping of excess glue, tacking into position until dry.

(c) 40mm Reveal Bead

i.   Allow a 3mm gap between Greenboard and opening .

ii.   Glue 40mm reveal bead into 3mm gap pressing firmly against the Greenboard.  Make sure there is sufficient glue to fix beadto Greenboard.

iii. Tape and prime reveal bead and opening reveal.   Apply a bead of sealant into the gap between the reveal bead and opening reveal.  Smear sealant with tool.  Remove tape and Paint.

(d) Expansion Beading Joints

Expansion Joints allow movement within the building & avoid unsightly cracking.

i.   Vertical Expansion Beading Joints: Every 8 metres (above/ below window)

ii. Horizontal  Beading Expansion Joints: Located between floor levels.

iii. Install ‘Render Expansion Bead’ between both Greenboard surfaces, applying a bead of No More Nails to both internal surfaces of bead.  Press into position, scrape off excess glue, and tack fix until dry.

(Expansion Joints) Option 2

i. Chalk line after render

ii. 10mm cut through render and into panel

iii. Tape either side of joint

iv. Seal

v. Remove tape  and Paint

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