Technical Details:
External Wall Cladding System

1. SmartStone Systems External Wall Cladding System

​

SmartStone Systems is a lightweight mechanically fixed weatherproof ventilated façade comprising a natural stone, reconstituted stone or porcelain veneer bonded to a backing panel and aluminium fixing components. It is designed to be fixed directly to a structural wall made of timber, steel, masonry, concrete or any other substrate that allows for mechanical restraint with screws or anchors.

 

SmartStone Systems Residential wall cladding system has been designed to meet the Performance Requirements specified in the NCC 2016 Volume 2 with respect to exterior cladding products for Class 1 and Class 10 buildings.

 

Structure: (P2.1 Structural stability and resistance to actions)

Tested and appraised for serviceability and strength under wind actions up to and including AS 4055 Wind Class N4.

 

Weatherproofing and Dampness: (P2.2.2 Weatherproofing, P2.2.3 Dampness)

Tested and appraised for resistance to penetration of water and moisture from the ground.

 

Fire Safety: (P2.3.1 Fire Separation)

SmartStone Systems External Wall Cladding System is combustible as defined by the NCC 2016 BCA Volume 2 and must not be located less than 900mm from boundaries or 1800mm from another building, as defined in Part 3.7.1.3.

 

Energy Efficiency: (P2.6.1 Building)

SmartStone Systems External Wall Cladding System incorporates insulation and has Total R-values which may be used to demonstrate compliance with Part 3.12.1.4 wall insulation requirements.

 

 

2. External Wall Cladding System: Summary

 

The SmartStone Systems natural stone, reconstituted stone, or porcelain veneer of 6mm to 15mm thickness is bonded to a backing panel using a chemically set industrial polyurethane adhesive less than 1mm thick with high pressure under factory-controlled conditions. The system is fixed to a structural wall using a series of continuous rail and clip extrusions made from 6063-grade aluminium that fit into a 4mm wide slot cut into the backing panel. The panels are sealed at the edges and between the blocks by way of aluminium and/or plastic extrusions that provide a physical water barrier and silicone or polyurethane sealant to ensure any gaps between these elements are filled.

 

The system provides a lightweight, weatherproof, ventilated facade that may be fixed directly to a structural frame. Once installed SmartStone Systems' design provides a thermal break between the interior of the building and the external stone skin, and the backing panel provides insulation. Its design also allows for movement of the structure while maintaining its weatherproofing integrity and thermal performance. It may also be used for internal applications as a decorative finish.

 

The variety of possible veneer finishes available are too numerous to be described here. For the purposes of calculation, the nominal maximum veneer density is 2800 kg/m3 , which represents the saturated mass of the heaviest veneer material. The overall maximum system weight is 42kg/m2 .

 

Product selection, and incorporation into the building design, must be made by a person who is conversant with the application and technical aspects of the product and has ready access to the relevant technical information related to the product use.

 

Product installation must be carried out by a competent carpenter or other tradesman under the direction of a builder, both of whom are conversant with the method of product installation, and have access to all relevant technical information on product installation.

​

​

3. External Wall Cladding System: Materials

 

No component substitution is permitted on any design. Installation of any nonstandard or non-approved SmartStone Systems External Wall Cladding System components will void any product warranty or claims in relation to product performance.

 

3.1 SmartStone Systems Residential Panel Components

• Natural stone laminated to Foamular XPS backing foam with polyurethane

• Veneer thickness between 6mm and 15mm thick depending on the material

• 50mm thick Foamular XPS Thermoplastic Extruded Insulation Sheet Backing Board

• Where the XPS varies from this specification, the mechanical, dimensional and thermal properties must be verified prior to incorporation into any structure.

• The density of XPS panel 43 to 45 kg/m3

• Thermal Conductivity 0.028 W/(m.K)

• Flexural Strength 962 kPa o Dimensional Stability 0.7 %

• Compressive Strength 590 kPa

• Fire Retardant chemicals added in production

• Maximum weight of system including veneer, extrusions & sealant 42 kg/m2

• Maximum size of individual panel 300 high x 1200 wide

• Overall system thickness (back of the clip to face of veneer) nominally 80mm.

 

3.2 Damp Proof Course

Minimum 300mm wide to be made of non-permeable material, e.g. Consolidated Alloys Plascourse 300mm x 500mm Polyethylene Dampcourse. Damp proof course (DPC) must meet the requirements of AS/NZS 2904.

 

3.3 Flashing

“Parapet-to-Wall” flashing shall be installed (see Installation Item # 20), conforming to the requirements of AS 2904:1995. E.g. Consolidated Alloys Group (CAG) Weatherflash Flashing, 300mm x 0.3mm.

 

“Bottom-Edge” flashing as shown in Construction Details 7.1 and 7.2 shall be installed e.g. “Damp Proof Course” as identified above

​

3.4 Fixing Screws

‘Type 17’ 12g 50mm long timber screw with rubber seal were used to fix to MGP10 pine studs and noggins. For steel frame or masonry fixing an alternative fixing with minimum pull-out strength of 3900 N, singe shear strength of 8400 N, axial tensile strength 13.9 kN and torsion strength 13.5 Nm may be used. When installed in high corrosion zones such as coastal locations, fasteners must be made of materials appropriate to the desired life of the system and geographical location. Class 4 Screws may be necessary in these zones. The advice of the fastener supplier should be sought. Class 3 screws (Class 4 or 304 or 316 stainless steel for corrosive environments). Screws must comply with the corrosion protection requirements of AS 4773 (Part 4 and Appendix C).

​

3.5 Building Wrap (Breathable)

Sarking (Wall Wrap) – medium-duty breathable compliant with AS/NZS 4859.1, AS/NZS 4200.1 and AS 3959. It must have a Flammability Index (FI) not greater than 5 in accordance with AS 1530.2. E.g. Ametalin MD-40-B

​

3.6 SmartStone Systems Continuous Reveal Rail Extrusion

Proprietary aluminium extrusion to seal the bottom edge of the panel, provide weep holes for drainage and support the bottom edge of the construction.

 

3.7 SmartStone Systems Residential Joiner Extrusion

PVC or 6063-grade aluminium

 

3.8 Clip Bracket

Extruded 6063-grade aluminium

 

3.9 Continuous Batten (see window jamb detail)

Extruded 6063-grade aluminium

 

3.10 End Cap Extrusion

Extruded 6063-grade aluminium

​

3.11 Packing (see window jamb detail)

Packing is Aerobolt JDV01 and JDV02 plastic packing shims or similar made and tested in accordance with ASTM695 and compliant with AS3850.

 

3.12 Window / Door Flashing

Window & door flashing uses the SmartStone Systems Reveal Extrusion with all weep holes blocked with silicone or polyurethane sealant, and the top edge sealed to the sarking using the Ametalin IDT-5050 tape. Silicone or polyurethane sealant is applied between the reveal extrusion and the window or door frame.

 

3.13 Sill Block

The sill is 25mm thick x 115mm deep x nominally 600mm long solid stone sill block to match cladding selection with locating groove to underside and drip line 15mm from front edge.

 

3.14 Flashing Tape

Flashing Tape (e.g. Ametalin Foil Insulation Tape) for weatherproofing Building Wrap at all openings, penetrations, and connections.

 

3.15 Backing Rod

The ‘backing rod’ material is a closed-cell polyethylene foam, 10mm diameter as ‘back-blocking’ for flexible adhesive sealants placed in joints.

 

3.16 Adhesive Sealant

Neutral cure silicone or polyurethane adhesive sealant, e.g. B&L clear & dark grey neutral cure silicone.

 

3.17 Caulking

Caulking to be neutral cure silicone or polyurethane sealant in colour to match stone selection. E.g. B&L BLN192 translucent neutral cure silicone.

​

​

4. National Construction Code (NCC) 2016

 

The National Construction Code is a performance-based code that does not limit the use of new and innovative systems. It allows a building to be constructed to achieve so long as the relevant performance requirements are met. This may be demonstrated through compliance with an existing Deemed-to-Satisfy Solution, or by a Performance Solution (previously known as an Alternative Solution). Any building system that is not described in the Deemed-to-Satisfy provisions can only demonstrate compliance via a Performance Solution. This applies to External Wall Cladding Systems that are not listed in BCA Volume 2, Part 3.5.3.

 

4.1 Structural Performance

SmartStone Systems External Wall Cladding System is suitable for use in AS 4055 Wind Classifications N1, N2, N3 and N4 (and excludes AS 4055 Wind Classifications N5, N6, C1, C2, C3 and C4). Wind Classification is determined by the site and the height of the building in accordance with AS 4055.

 

SmartStone Systems External Wall Cladding System is non-load-bearing and not intended to act as wall bracing or to resist any other actions which must be designed into the wall framing prior to installation of the panels.

 

Control joints are required at regular intervals to allow for building movement. In all cases, SmartStone Systems External Wall Cladding System may only be installed on buildings that conform to the requirements of AS 4055 including:

• distance from ground level to the underside of eaves shall not exceed 6.0m,

• distance from ground level to the highest point of the roof, not including chimneys, shall not exceed 8.5m,

• width including roofed verandas, excluding eaves, shall not exceed 16.0m, and the length shall not exceed five times the width, and

• the roof pitch shall not exceed 35 degrees pitch.

 

4.2 Dampness and Weatherproofing Performance

SmartStone Systems External Wall Cladding System complies with the NCC 2016 performance requirements for weatherproofing and dampness confirmed by testing in accordance with the verification method V2.2.1 in the NCC 2016. Full-scale testing has been performed to check the performance of:

• vertical and horizontal control joints; and

• wall junctions; and

• windows or doors; and

• electrical boxes; and

• balcony drainage and parapet flashings; and

• footer and header termination systems.

 

4.3 Fire Safety Performance

As a combustible external wall system, SmartStone Systems External Wall Cladding System may not be installed less than 900mm from an allotment boundary or 1800mm from another building, as defined in NCC 2016 Part 3.7.1.3. Heat-producing appliances e.g. BBQs & Patio Heaters, Hot Water Services, Flues from Heating Appliances, all must be installed in accordance with manufacturers’ requirements for combustible building materials.

​

4.4 Thermal Performance

SmartStone Systems External Wall Cladding System incorporating a breathable reflective wall wrap and 10mm plasterboard lining achieves Total R-values in accordance with AS/NZS 4859.1.

 

​

​

​

​

​

​

Increased thermal performance can be achieved by adding insulation between the wall studs.

​

​

5. External Wall Cladding System: Specifications

​

SmartStone Systems Residential wall cladding system may be installed to steel or timber frame and masonry construction that have been constructed to comply with relevant performance requirements of the National Construction Code 2016 Volume 2 for Class 1 & 10 Buildings.

 

5.1 Prior to installation

All walls must be checked to ensure they are straight. Maximum stud spacing is 600mm. Eave linings, damp proof course, flashings, sarking, box guttering, windows, waterproof membranes, and any penetrations such as pipes, meter boxes, drain pipes and the like should be fixed in position prior to commencement of installation of SmartStone Systems product. Care should be taken to ensure that any additional studs and nogging that may be required to ensure that expansion joints and clips used to fix the system are in place prior to installation.