ARCHITECTURAL
CATALOGUE 2015
COMMERCIAL PRECAST ǀ RESIDENTIAL PRECAST ǀ NOISEWALL BARRIERS ǀ INSITU CONCRETE
INTRODUCTION
DESCRIPTION & STRUCTURE OF THIS INFORMATION
This information, when used in conjunction with the New Zealand Building Code (NZBC), sets down the construction requirements for
the Litecrete lightweight precast concrete system.
Section 1: Litecrete Product Range
Section 2: Litecrete Lightweight Precast Concrete Properties
Section 3: Building Code Requirements and Compliance
Section 4: Design Information
Section 5: Litecrete system
Section 6: Structural Design Data
Section 7: Product Evaluation Results
Section 8: Residential Construction
Section 9: Installation
Section 10: External & Internal Finishing
Section 11: Commercial Construction
Section 12 Sustainable Building
Section 13: Construction Details
Section 14: Appendix – Architectural Specifications, Material Safety Data Sheet.
For further information please contact:
Philip Archer
Litecrete NZ Limited
Mobile: 0275 505 372
Email: [email protected]
Updated 1 June 2015
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1.0 PRODUCT RANGE
1.1 Litecrete Lightweight Precast Concrete System
Litecrete is a lightweight precast concrete developed and manufactured by Wilco Precast Ltd, Papakura. It has been designed to
conform to, and comply with, New Zealand Building Codes, practices and construction methods. Litecrete offers insulation, fire
resistance and acoustic properties, can be installed rapidly and can be used for a wide range of projects. Litecrete offers the following
features and benefits:
• Large panel sizes
• Peace and quietness between rooms and between floor levels
• Safer environment; Litecrete is fire resistant, non-toxic, mould and mildew resistant
• Design advantages; classic to contemporary; deep reveals around windows, doors
• Exterior finishes to suit; fine or accented plaster; smooth or textured paint systems
• Moisture resistant, rot-proof, strong, permanent
• Built-in insulation provided by the pumice aggregate provides a low humidity environment and ensures energy savings;
warm in winter, cool in summer
1.2 Standard Surface Finish
Mould face: This is usually the exterior face of the panel and is cast on steel casting beds. F5 finish is the typical specification. Tiny
pinholes caused by entrapped air, excess mould release agent, marks on the casting surface and mould release agent staining can
be expected. Minerals contained within the pumice aggregate can sometimes cause more surface figuring compared to normal
precast panels. Where a blemish-free surface is required, the application of masonry paint or a mineral-based stain is recommended.
Trowelled face: The trowelled face of the panels, usually the internal face, will have a U3 surface finish. The finish will be uniform
and provide full cement paste cover to the aggregates. Some trowel marks will be visible and colour and texture variation may be
expected, as well as colour variation from batch to batch. Where a uniform colour is required, the application of masonry paint or a
mineral-based stain is recommended.
“Clear” Concrete Finish:
A clear, natural concrete finish can be used for Litecrete panels. However, particularly for residential construction, there are some
important aspects to this finish which must be considered and these are detailed on Page 20.
1.3 Litecrete Residential Wall Panels
Litecrete precast residential wall panels have been designed to offer a durable alternative to traditional house construction methods,
and for the purposes of complying with the Building Code are classed as an “Alternative Solution”. Litecrete precast panels form an
integral wall - solid, continuous and airtight. Litecrete is manufactured using pumice as an aggregate, which reduces the weight of the
concrete yet achieves strength of 12 MPa. The air cells in the pumice provide excellent insulating properties. Litecrete is
manufactured under strict quality-controlled factory conditions, delivered to site and rapidly installed. Various thicknesses can be
manufactured to order, from a minimum of 150 mm. Panels have fully embedded steel reinforcing. Standard sized panels up to 7-8
metres x 2.8 metres and can be used for single-storey or two-storey applications. Larger panels are possible subject to freight/design
parameters.
1.4 Litecrete Commercial Cladding
The design, application, engineering, panel sizes and installation requirements for low-rise and high-rise Litecrete commercial
projects differ markedly from residential installations. Potential uses are for exterior cladding, sunshades, fins, acoustic or firewalls
and façade re-instatements. Standard sized panels up to 7-8 metres x 3.5 metres, subject to freight considerations and design
parameters such as window or door opening sizes. Litecrete will typically reduce the deadload on the structure by 50% compared to
standard precast concrete.
1.5 Litecrete Firewall System
The Litecrete Firewall system consists of Litecrete 150 mm thick solid walls, with tongue and groove vertical joints and also includes
a specific proprietary sealant for both the exterior and interior sides of the joints, thereby allowing it to be used in applications where a
demonstrated fire performance is required. The fire-rated system can also be used as a complete and finished wall system in its own
right. A BRANZ test (FR 3524) using 150 mm thick Litecrete panels achieved a 240-minute fire resistance rating.
1.6 Litecrete Acoustic Wall Systems
The Litecrete Acoustic Wall system provides excellent sound insulation and meets the performance requirements of NZBC G6.3.1 for
inter-tenancy walls. This approved acoustic system exceeds the Minimum Sound Transmission Class 55 when constructed in
accordance with the details contained in this manual. Results of the tests conducted at Auckland Uniservices Acoustic Test Centre
by Marshall Day Acoustic Engineers are available on request. Sound-rated wall systems ranging from low STC values - STC 47 - up
to STC 60 are available. The bare 150 mm thick wall achieves STC 47; bare 260 mm thick wall achieves STC55.
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1.7 Litecrete Motorway Noisewall Barriers
Litecrete noisewall barrier panels reduce the sound level by shielding the straight line path of noise from the source to receiver. The
received noise level is significantly reduced due to the shielding effect. Using modelling software, acoustic engineers can determine
the optimum height, length and placement of Litecrete panels to effectively minimise noise levels. Typically 150 mm thick, Litecrete
has been approved and used for as noisewall barriers by Transit NZ.
1.8 Litecrete Insitu Concrete
Litecrete is available as an insitu mix and is used particularly where weight is a major consideration. Applications such as screeds
over old or new concrete – balcony/roof toppings - streetscape remedial work, etc. It can also be used for insitu concrete house
construction. There are limitations on the distance from the batching plant to the construction site.
2.0 PRODUCT PROPERTIES
2.1 Composition
Standard concrete is made with cement and heavy aggregates - typically crushed rock. Litecrete uses pumice as an aggregate,
which reduces the weight of the concrete yet provides the required strength. The air cells in the pumice provide insulating properties,
convenient lightness, and ease of use. The combination of pumice and cement, together with steel reinforcing systems and
polypropylene fibre reinforcement, gives Litecrete its unique strength-to-weight ratio. The inclusion of the polypropylene fibres also
assists in fire prevention on the basis that, as the concrete is heated by fire, the fibres melt, creating conduits along which water
vapour can dissipate, so avoiding a build-up of pressure and preventing spalling from occurring. The image below, from a scanning
electron microscope at x50, shows a Litecrete sample from a compression test, with the polypropylene fibre still binding the pumice
concrete together.
2.2 Mix Components
• Pumice aggregate: 65-75% Si02, 10-20%
Ai203.
• Cement: HR brand GP General Purpose
Cement (Portland No 65997-15-1).
• Plasticiser: Sika ViscoCrete® 5-500.
• Polypropylene fibre: monofilament
concrete fibre, manufactured to comply
with ASTM C-1116.
2.3 Dimensions
The advantage of precast concrete is that a
variety of sizes can be accommodated. In some
instances the complete side wall of a house can
be manufactured as one panel. Standard
Litecrete residential wall panels are manufactured
to a maximum panel size of 7-8 metres x 2.8
metres, subject to design parameters. Commercial
panel sizes are tailored to suit the project.
2.4 Mass
Litecrete 150 mm wall panels weigh 200 kg/m²; 220 mm, 310 kg/m²; including typical steel reinforcing requirement. The Building
Code requires two layers of reinforcing for concrete panels over 200 mm thick. Note: These weights are calculated using a concrete
density of 1350 kg/m³.
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3.0 BUILDING CODE REQUIREMENTS
The Litecrete Construction System, which is subject to specific engineering design, meets the following performance requirements of
the Building Code:
• Clause B1 STRUCTURE: Performance B1.3.1, B1.3.2 and B1.3.4 for the relevant conditions as in B1.3.3. a, b, f, g, h, i, j
• Clause B2 DURABILITY: Performance B2.3.1, 50 years
• Clause C3 SPREAD OF FIRE: Performance C3.3.5
• Clause E2 EXTERNAL MOISTURE: Performance E2.3.2, E2.3.3, E2.3.6
• Clause E3 INTERNAL MOISTURE: Performance E3.3.1
• Clause F2 HAZARDOUS BUILDING MATERIALS: Performance F2.3.1
• Clause G6 AIR & IMPACT SOUND: Performance G6.3.1
• Clause H1 ENERGY EFFICIENCY: Performance H1.3.1, H1.3.2
Clause B1 STRUCTURE
Performance requirement B1.3.1
Litecrete Lightweight Precast Concrete Systems are required to withstand the combination of loads they are likely to experience
during construction or alteration and throughout their serviceable life. The systems have a low probability of rupturing, becoming
unstable, losing equilibrium, or collapsing and have a low probability of causing loss of amenity through undue deformation, vibratory
response, degradation or other physical characteristics throughout their serviceable life. Litecrete Lightweight Precast Concrete
Systems meet the requirements for loads arising from self-weight, imposed gravity loads, earthquake, wind, fire and human impact.
Demonstration of Compliance
Litecrete applications are subject to specific engineering design. Typical design and construction details of panel-to-panel, panels
and the connection details of the panels to the adjoining structure are shown in Section 13 Construction Details. All reinforcing shall
comply with the provisions of AS/NZS 4671; either grade 300 or grade 500.
Wall Panel Bracing Units
Litecrete 2400 x 1200 x 100 mm thick panels achieve 400 bu’s (Opus International report).
Clause B2 DURABILITY
Performance requirement B2.3.1 (a) not less than 50 years (b) 15 years and (c) 5 years
The NZBC sets durability requirements for building elements depending on the use and the ease of replacement and maintenance.
Within the building elements the different components can have different durability requirements. Litecrete exterior wall panels are
structural elements and therefore require a durability of not less than 50 years. This applies to the bracing panels and system
connection components. Litecrete associated sealants, seals, flashings and sealing systems are required to have 15 years durability.
Demonstration of Compliance
1. History of Pumice Concrete
Although lightweight precast pumice concrete is new to the New Zealand construction market, pumice concrete has been used for
various structures here for over 100 years. The first documented application was for structural wall elements in Tudor Towers, the
former Government Bathhouse in Rotorua, which was built in 1906. Since then proprietary systems have come and gone. Konka
Board, a factory-made panel (900 mm x 450 mm) was produced by Bassett & Co of Wanganui from 1914 until the 1950s. It was held
in place by patented clips and was used for both internal and external walls. Another pumice-concrete panel for walls and floors,
Fabricona, began production in the 1940s but closed down in 1951. Atlas Concrete Ltd in Wellington also manufactured pumice
concrete panels successfully for a number of years but widespread acceptance was generally suppressed due to (1) the relative
costs of the pumice concrete compared to the standard timber-framed cavity walls and (2) the reluctance of builders to use concrete
as they believed it had the propensity to take away a major part of their trade skill. However, of recent times problems such as leaky
homes, ongoing timber price rises and the increasing awareness of concrete as an energy efficient building material have gone a
long way towards increasing the acceptance of concrete in general, and pumice concrete in particular, as a viable alternative.
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2. Lightweight concrete durability
The durability of concrete is defined as its ability to resist weathering action, chemical attack, abrasion, or any process of
deterioration. The mechanism that can cause premature deterioration resulting in a serviceable life <100 years, is weathering action
caused by water. Water assists chemical processes of degradation (carbonation in concrete) and physical processes of degradation
(physical results of corrosion in reinforcement). Normal carbonation results in a decrease in pH to about 7, a value below the
passivation threshold of steel. The carbonation process requires the presence of water because CO2 dissolves in water forming
H2CO3. Similarly, the electrochemical process of steel corrosion relies on the presence of water. Hence, Litecrete’s resistance to
permeability (defined as the property that governs the rate of flow of a fluid into a porous solid) is the governing property, which
determines its durability. It is well known that the superior water absorption/desorption characteristics of pumice means that the
moisture held in the aggregate is not immediately available for chemical interaction with cement, so is extremely beneficial in
maintaining longer periods of curing, resulting in better strength and reduced permeability in the final concrete.
Auckland Uniservices have tested samples of Litecrete vs 30 MPa normal precast concrete, for water absorption. The test report
concluded that Litecrete does not saturate with water to the same extent when compared to 30 MPa concrete.
The minimum reinforcement cover requirements as per NZS 3101, Section 3, for 25 MPa concrete, is 40mm. Litecrete recommends
a minimum 50 mm cover for any steel reinforcement design.
3. Exterior Coatings
Exterior coatings (paints/plaster) where specified must be of a vapour-permeable type and comply with the relevant clauses of the
NZBC. In all cases the manufacturers’ application and maintenance instructions must be followed, with particular attention given to
the following areas:
1. Weathering, flashing and sealing systems at door and window openings, junctions with other materials and any other penetrations
of the exterior envelope. The need for specific flashings will depend on the configuration and design of the detail but are strongly
recommended in all circumstances.
2. The ground/ foundation/floor/wall interface. Particular care needs to be given to ensure that minimum distances between ground
and floor level, as stated in NZS 3604:2011, are complied with.
3. External plaster systems where specified are installed and cured within the temperature limitations, climatic and curing conditions
set by the manufacturer. The finished external plaster system is sealed and protected from the weather with a vapour-permeable
coating system such as Resene X200 or Mapei Elastocolor. Exterior paint systems will require 5-year durability as part of the
system.
Clause C3 SPREAD OF FIRE
Performance C3.3.5
The Litecrete Lightweight Precast Concrete System is naturally fire resistant being made from non-combustible materials.
Demonstration of Compliance
BRANZ test report FR3524 - Fire resistance of a lightweight concrete panel load bearing wall; the 150 mm thick wall achieved a 240-
minute fire resistance rating.
Clause E2 EXTERNAL MOISTURE
Performance E2.3.2, E2.3.5, E2.3.6
Exterior walls shall prevent the penetration of water that could cause undue dampness, or damage to building elements. Concealed
spaces and cavities in buildings shall be constructed in a way, which prevents external moisture being transferred and causing
condensation and the degradation of building elements. Excess moisture present at the completion of construction shall be capable
of being dissipated without permanent damage to building elements.
Demonstration of Compliance
This Litecrete Lightweight Precast Concrete System catalogue contains a well proven set of typical construction joint, penetration,
openings and attachment details that can be used for both residential and commercial construction (see Section 13, Construction
Details). The window design details are based on recommendations from the Window Association of New Zealand (WANZ).
Because engineers use a varied range of precast attachment details to cope with a diverse range of commercial building designs we
cannot cover all of these in this document. However, such design solutions have been used successfully for many years. Auckland
Uniservices have tested samples of Litecrete for water absorption and the report shows that when compared to normal concrete,
Litecrete does not saturate to the same extent with water (see Auckland Uniservices Report 10646.04).
Exterior Plaster/Coating Systems
If exterior plaster/coating (paint) systems are used they must comply with the relevant clauses of the NZBC. The combination of
pumice concrete and air entrainment used in the manufacture of Litecrete wall panels provides a built-in insulation value. This means
that the walls are able to “breathe”, allowing water vapour (condensation) to move through the wall to the exterior of the building.
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Therefore, where paint or plaster systems are used, they should be vapour-permeable. We recommend systems that have a BRANZ
Appraisal and/or meet the NZBC requirements.
Maintenance
External coating systems must be maintained in accordance with the respective manufacturer’s instructions and all damage repaired
promptly to ensure the ongoing weathertight properties of the coating systems. In addition to these system-specific requirements, the
following general maintenance procedures must also be implemented: Any dirt accumulation or organic growth that may occur should
be regularly removed from the external surface by cleaning with warm water and detergent and a soft bristled broom. Solvent-based
cleaners must not be used. The external cladding system should be checked yearly for damage to the system itself, deterioration of
seals and possible water entry at junctions and joints. Any damage to the coatings, which does occur, must be repaired in
accordance with the manufacturer’s instructions.
Clause E3 INTERNAL MOISTURE
Performance E3.3.1
The Litecrete Lightweight Precast Concrete System must take into consideration installation details for maintaining correct moisture
levels in buildings where normal occupancy levels exist and adequate ventilation is provided (e.g. complying with NZBC E3/AS1
Paragraph 1.2) ensuring the performance requirements of NZBC E3.3.1 will be met. Correct thermal design and installation must be
strictly followed to meet the minimum R-values in NZBC Acceptable Solution E3/AS1 Paragraph 1.1.1 (b) solid construction.
Demonstration of Compliance
The Litecrete Lightweight Precast Concrete System has test a report from Curtin University stating an achieved R Value of R0.6 for a
150 mm thick panel. The introduction of revised H1 in 2009 revised the R-value requirements for Litecrete:
Climate Zone 1, R-value of R0.8
This is achieved with 220 mm thick panels (“Solid Construction – excluding timber”)
Climate Zone 2, R-value of R1.0
This is achieved with 280 mm thick panels (“Solid Construction – excluding timber”).
Climate Zone 3, R-value of R1.2
This is achieved with 330 mm thick panels (“Solid Construction – excluding timber”).
Auckland Uniservices have tested samples of Litecrete for water absorption and the report shows that when compared to normal 30
MPa concrete, Litecrete does not saturate to the same extent with water.
Clause F2 HAZARDOUS BUILDING MATERIALS
Performance F2.3.1.
The materials and components used in the manufacture and site construction of Litecrete comply with NZS 3604:2011, which is an
NZBC referenced Compliance Document. The Litecrete Lightweight Precast Concrete System meets this requirement and will not
present a health hazard to people.
Demonstration of Compliance
A Material Safety Data Sheet is attached in Appendix.
Clause G6 AIRBORNE AND IMPACT SOUND
Performance G6.3.1
The sound transmission class of walls, floor and ceilings shall not be less than STC 55.
Demonstration of Compliance
The Litecrete Lightweight Precast Concrete System has acoustic testing on 150 mm thick wall panels strapped on one face, insulated
and an additional layer of 13 mm plasterboard applied. It achieved an STC 60 rating. (See Auckland Uni Acoustic Report T0607-3).
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Clause H1 ENERGY EFFICIENCY & INTERNAL MOISTURE
Performance H1.3.1 & H1.3.2
Buildings constructed using the Litecrete lightweight precast concrete system, are able to meet the performance requirements for
energy efficiency as required by NZBC Clause H1.3.1 and H1.3.2. It should be noted that compliance with NZBC H1 will also include
a large number of other factors resulting from the design of the building, all of which have an effect on the energy efficiency of a
building. The excellent thermal insulation properties of the Litecrete wall panel system ensures that when used with both an adequate
level of ventilation and an appropriate level of ceiling / roof insulation, Litecrete will satisfy the internal moisture provisions of NZBC
Clause E3.3.1. Appropriate or adequate levels of ventilation and insulation are provided in the NZBC Acceptable Solution E3/AS1.
NZBC Acceptable Solution E3/AS1 Paragraph 1.1.1(b) requires a current minimum wall R-value. Higher levels are required to meet
the new energy efficiency requirements of NZBC Clause H1.
Demonstration of Compliance
A Test Report from Curtin University shows that Litecrete achieved an R-value of 0.6 for a 150 mm thick panel.
NZBC Clause H1 – Energy Efficiency to NZS 4218:2009
The Building Code Clause H1 Energy Efficiency is defined in New Zealand Standard 4218:2009. Residential construction categories
are changed to:
1. Non-solid Construction; eg (timber framing with various types of exterior cladding), or
2. Solid Timber Walls (such as “Lockwood” type system), or
3. Solid Construction – excluding timber (concrete or masonry)
Litecrete falls under the definition of Solid Construction – excluding timber. Because of the benefits of the thermal mass of the
concrete (its ability to absorb and slowly dissipate energy) this category has been allocated a dispensation in R-value requirements
compared to Categories 1 and 2. Following are Category 3 requirements for the various climate zones:
Climate Zone Min R-values Litecrete Building Code compliance solution
Zone 1: Northland, Auckland and R0.8 Solid Construction – excluding timber
Coromandel, Option 1 (a) 220 mm thick panels (R0.8)
Zone 2: Rest of North Island R1.0 Solid Construction – excluding timber
except Volcanic Plateau, Option 2 (a) 280 mm thick panels (R1.0)
Zone 3: South Island and R1.2 Solid Construction – excluding timber
Volcanic Plateau, Option 3 (a) 330 mm thick panels (R1.2)
The Standard provides for three methods of compliance:
1. The Schedule Method shall only be used where:
(a) The glazing area is 30% or less of the total wall area;
(b) The combined area of glazing on the east, south and west-facing walls is 30% or less of the
combined total area of these walls;
(c) The skylight area is no more than 1.2 m² or 1.2% of the total roof area (whichever is the
greater);
(d) The total area of decorative glazing and louvers is 3 m² or less
2. The Calculation Method shall only be used where:
The glazing area is 40% or less of the total wall area
3. The Modelling Method shall only be used where:
The glazing area is more than 40% of the total wall area
* Note that installing insulation on the internal face of precast concrete or masonry negates the benefits of thermal mass.
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Residential External Wall in Climate Zone 1
Litecrete wall thickness of 220 mm complies with Building Code insulation requirements - “Solid Construction
(excluding Timber)” - with an R-value of R0.8
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4.0 Design Information
All Litecrete applications are subject to specific engineering design by a registered structural engineer (not by Litecrete) prior to lodging
a Building Consent application.
4.1 Residential Construction
Following is the design information, detailing and construction practices that can be used for Litecrete wall and mid-floor systems for
buildings within the following limitations:
4.1.1 Single-Storey Residential Dwellings:
Walls, ground floor connections, mid-floors and roof connections are constructed in accordance with the design details in the
4.1.2 Litecrete Lightweight Precast Concrete Manual. Ground floor slab, internal timber walls and roof framing are constructed in
accordance with NZS 3604:2011.
4.1.4 Two-Storey Residential Dwellings:
4.1.5 Either 2-storey high Litecrete wall panels or Litecrete panels for the ground floor installed in accordance with the
4.1.6 manufacturer’s recommendations, with light timber frame walls, constructed in accordance with NZS 3604:2011, for the
4.1.7 upper storey. Suspended timber floor shall be of light timber construction complying with the relevant requirements of NZS
4.1.8 3604:2011. Roof shall be of light timber construction complying with the relevant requirements of NZS 3604:2011.
4.1.3 A maximum inter-storey height of 3.2m.
A maximum roof plane slope of 45º to the horizontal.
Buildings are to be category IV buildings as described in table 2.3.1 of NZS 4203.
A maximum design wind speed (V’s) for the building of VH (very high), as defined in section 5.3 of NZS 3604:2011.
Suspended timber floors and roofs shall be of light timber construction complying with the relevant requirements of
NZS 3604:2011.
Maximum suspended floor imposed live load of 1.5 kPa or a concentrated live load of 1.8 kN.
Site requirements are as per NZS 3604:2011, Section 3. Each part of the building or structure shall be within the limitations stated in
the relevant section or tables of this manual.
4.2 Commercial Construction
Litecrete wall panels can be used in other structures, which are subject to specific engineering design, including multi-story buildings.
Such structures are designed / engineered by a registered structural engineer, not by Litecrete. Most connections and attachments can
be used for both residential and commercial construction, others may be design specific.
4.3 Reinforcing Requirements
All reinforcing shall comply with the provisions of AS/NZS 4671. Typical reinforcing configuration for a residential panel: D12 @ 300
mm centres each way. Note that the Code requirement for precast concrete panels over 200 mm thick is for two layers of reinforcing.
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5.0 Litecrete System
5.1 General
5.1.1 Litecrete wall panels: steel reinforcing bars fully embedded in the specified Litecrete lightweight precast concrete. Conduits
for services can be set into the panel during the casting process, or trenched into the surface on site, using a diamond-tipped router.
Paint or plaster finishes can be applied, if required to the exterior face and a variety of render-set finishes/paint systems are available
for internal walls. These exterior and interior finishing systems must be vapour-permeable. Natural (“clear”) concrete finish is optional
(see Page 25). Buildings designed with Litecrete panels are subject to specific engineering design.
5.1.2 Fire/acoustic inter-tenancy walls for apartment and other residential buildings, eg hospitals, hotels, etc. Litecrete 150 mm
achieves a 240-minute fire resistance rating (refer BRANZ Fire Resistance Test FR 3524) and offers acoustic systems that achieves up
to STC 60.
5.1.3 Litecrete exterior cladding panels for high-rise construction. The system is based on panels with a typically 150 mm
assymetrical thickness, although thicker panels can be supplied if required. They can be shipped as individual panels or as unitised
(factory-built) modules, delivered to site, craned up and attached to the sub-structure of the building. Litecrete can also be used for
lightweight concrete balustrades, fins and other applications.
5.2 Supply of Litecrete Panels
Once it has been decided to use Litecrete in a project the architect/designer will consult an engineer, who will design the foundation
and structural requirements for the project. The architect/builder will usually send drawings, with the engineer’s designs/calculations,
so that Litecrete (Wilco Precast) can supply a firm quotation. Further to acceptance of the quotation, Litecrete produce workshop
drawings detailing the panel design. These drawings are then signed off by the architect/engineer before manufacture of the panels
can begin. Prior to delivery of the panels the builder arranges a crane for installation. Panels for a typical house could be installed in
one to two days.
5.3 Durability
Litecrete does not rot, or harbour mould or mildew. When used and installed in accordance with the limitations and instructions of the
manufacturer, the specifically designed components of the Litecrete wall panel system can be expected to meet the New Zealand
Building Code durability requirement of 50 years, provided the Litecrete wall panels are installed and finished as recommended and all
protective linings and coating systems, where applied, are correctly maintained. Associated sealants and flashing systems are
required to have 15 years durability.
5.4 Thermal Properties
Litecrete wall panels painted and/or plastered internally and externally have a thermal resistance of 0.12 +/- 0.6 m²KW-¹. Refer to
NZBC, Building Code Requirements, Section 3, Clause H1 Energy Efficiency & Internal Moisture.
5.5 External Moisture
Due to the mix design containing 20% more cement content than normal 30 MPa precast concrete, plus proprietary additives, Litecrete
has proven to have a superior secondary water absorption rate compared to 30 MPa normal precast concrete. This is detailed in
Auckland Uniservices test report (to ASTM C1585-04) dated 30 October 2006.
5.6 Internal Moisture
The excellent thermal insulation properties of the Litecrete wall panel system ensures that when used with both an adequate level of
ventilation and an appropriate level of ceiling/roof insulation, Litecrete will satisfy the internal moisture provisions of NZBC Clause
E3.3.1. Appropriate or adequate levels of ventilation and insulation are provided in the NZBC Acceptable Solution E3/AS1.
5.7 Energy Efficiency
Buildings constructed using the Litecrete lightweight precast concrete system is able to meet the performance requirements for energy
efficiency as required by NZBC Clause H1.3.1 and H1.3.2. It should be noted that compliance with NZBC H1 would also include a large
number of other factors resulting from the design of the building, all of which have an effect on the energy efficiency of a building.
5.8 Retaining Walls
Typical precast concrete retaining walls have minimum strength of 25 MPa. However, 12 MPa Litecrete can be designed by the
structural engineer for moderate retaining purposes but must be appropriately tanked.
5.9 Fire
5.9.1 General Properties
Litecrete is fire-resistant to 240/240/240 (refer BRANZ Report FR 3524).
5.9.2 Control of Internal Fire and Smoke Spread
Internal surface finish requirements are as per Table 6.2 of NZBC Acceptable Solution C/AS1.
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5.9.3 Control of External Fire Spread
External walls that comply with the external wall provisions of Clause 7.11 of NZBC Acceptable Solutions C/AS1 will meet the
performance provision of NZBC Clause C3.3.5. Litecrete lightweight precast wall panels will meet the requirements for a type A Heat
Release rate in applications covered by Table 7.5 of NZBC Acceptable Solutions C/AS1. Litecrete 150 wall panels will meet the
performance provision of NZBC Clause C3.3.5 when restricted to:
• Single storey buildings 1m or more from the boundary for all purpose groups.
• Buildings up to 7m high, 1m or more from the boundary, for all-purpose groups other than SC and SD.
• Fully sprinkled buildings up to 25m high, 1m or more from the boundary for all-purpose groups other than SC, SD,
SA and SR.
• Buildings containing purpose group SH, and with a building height less than 10m and located 1m or more from the
boundary.
5.10 Acoustics
Litecrete wall panels provide excellent sound insulation and meet the performance requirements of NZBC G6.3.1 for inter-tenancy
walls. The approved acoustic system achieved Sound Transmission Class (STC) 60 when constructed in accordance with the method
described in Litecrete Acoustic Systems. See details IW1 (STC47), IW2 (STC55) and IW3 STC 60).
5.11 Cast-in Surface Textures
Litecrete can offer cast-in surface textures and rebates similar to standard precast concrete. These can range from simple diagonal and
vertical lines up to intricate patterns using rubber formliners. Rough-sawn timber textures are currently in vogue, however there are
panel width limitations due to the extra suction experienced when de-moulding the panels off the timber planks.
5.11 Electrical Cabling/Conduits
Conduits for electrical and other wiring services can be cast-in during panel manufacture. However, it is relatively simple to cut a 40
mm deep chase into the Litecrete wall panels to provide extra plumbing/electrical channels. This can be achieved using an electrical
router with a masonry cutter or a diamond-tipped tile saw. Note that the plasticiser in PVC-sheathed electrical cables can migrate over
time causing deterioration, therefore cables must be contained within a plastic conduit if embedded in the Litecrete wall. The conduit
must be fixed at regular centres to the bottom of the chase before being plastered over.
Litecrete cladding panels with vertical rebates being installed on Waikato University Law Building 11
www.litecretesystems.co.nz © Copyright 2015
6.0 Structural Design
6.1 Definitions
Light roof
A roof and ceiling (structure, cladding, lining, insulation, services) having a mass not exceeding 20 kg/m2.
Heavy roof
A roof and ceiling (structure, cladding, lining, insulation, services) having a mass not exceeding 60 kg/m2.
Light wall cladding
An external wall having a mass not exceeding 50 kg/m2.
Internal timber frame partitions:
An internal partition having a mass not exceeding 30 kg/m2.
Lintel or floor beam span
Span of opening between concrete.
Suspended Concrete Floor
A specifically designed concrete floor system including super-imposed dead loads with a mass not exceeding 490kg/m2.
Sealants
Sealants approved for joint use in Litecrete lightweight precast concrete system’s construction details are: Sika Construction AP; Sika
AT Facade.
6.2 Structure
Loads from other parts of the building structure and fixtures must be transferred directly to the reinforced concrete walls. Structural
connections for roofs and floors and lateral support of the tops of walls must be designed appropriately to resist the imposed loads.
Walls are to be adequately anchored to floors, roofs, columns, pilasters, buttresses and intersecting walls.
6.3 Wall Panel Bracing Units
Litecrete 2400x 1200 x 150 mm panels achieve 400 bu’s (Opus International report).
6.4 Bracing Design Assumptions and Philosophy
We have assumed an approximately even distribution of bracing walls with nominated centres each way. Buildings, which are heavily
braced on one side and lightly braced on the other side, can suffer damage through tortional movement under wind or earthquake
forces. Bracing walls should be located as close as possible to the outside corners of the building. If there is any doubt as to the lateral
stability of the structure a structural engineer should be consulted.
6.5 Structural Diaphragms
For bracing line systems as defined by NZS 3604:2011 Litecrete walls must be connected to a structural diaphragm. The structural
diaphragm provides part of the system for spanning lateral earthquake and wind loads to adjacent supporting systems. Specifically
designed concrete floors may also be used as structural diaphragms. The structural diaphragm must comply with NZS 3604:2011, floor
diaphragms in accordance with clause 7.3 and ceiling diaphragms in accordance with clause 13.5.
6.6 General
Single-storey buildings designed with Litecrete Lightweight Precast Concrete shall consist of:
6.1.1 Foundations as designed by the engineer.
6.1.2 Ground floor must be concrete slab-on-grade constructed in accordance with Clause E11 of NZS 3604:2011, except the
minimum thickness shall be 100mm. The ground floor slab shall be connected to the walls as shown in details D(3)2 Litecrete
6.1.3 Panel/Floor Slab Connection and D(3)3 Litecrete Panel/Floor Slab Connection.
External walls shall be Litecrete solid walls to specified thickness, as detailed in the Litecrete Lightweight Precast Concrete
6.1.4 Manual. The bottom storey of two-storey buildings must have a minimum wall thickness of 220/180 mm. Upper walls shall be
no thicker than the wall below.
6.1.5 Internal walls shall be either Litecrete 150 mm thick solid walls to specified thickness or timber framed internal walls
constructed in accordance with NZS 3604:2011. Internal to External wall connections shall be in accordance with detail D9
Litecrete Wall/Timber Frame Connection
The roof shall be timber-framed and constructed in accordance with NZS 3604:2011. The connection of the roof to Litecrete
wall panels shall be in accordance with details D4 Litecrete Wall/Roof Connection, D11 Parapet/Wall, D12 Flush Fascia, D13
Wall/Roof Junction Apron Flashing and D14 Gutter/Wall Junction.
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6.1.6 Two-storey buildings shall consist of the above clauses 1 to 5 plus the following:
(a) Suspended first floors shall be timber floors in accordance with NZS 3604:2011. The connections of suspended timber
floors to Litecrete 220 /150 mm Solid walls must comply with details D8 Litecrete Wall/Mid-floor Connection.
(b) First-storey walls shall be Litecrete Solid walls, no thicker than the wall below, or timber walls in accordance with NZS
3604:2011. First floor internal Litecrete 150 mm solid walls must be directly supported by Litecrete minimum 150 mm solid
walls below. Suspended first floors supporting Litecrete Solid walls, or load bearing walls, must be specifically designed.
(c) Building lateral stability shall be checked in accordance with NZS 3604:2011 except that Bracing units required under
earthquake, provided by Litecrete 150 Solid walls, are 400 bu’s for a 2400 x 1200 x 150 mm panel, based upon the
recommended Litecrete panel/foundation connections.
6.7 Minimum Reinforcement
Litecrete 150 mm thick wall panels, 1 layer of D12 reinforcing at 300 mm centres each way;
220 mm walls, two layers of D12 reinforcing @ 300 mm centres each way.
Vertical Grade 300 reinforcing Grade 500 reinforcing
Horizontal D12 @ 300 mm centres H12 @ 300 mm centres
D12 @ 300 mm centres H12 @ 300 mm centres
6.8 Higher Strength Litecrete
Where R-values are not a consideration, Litecrete is able to be manufactured in the range of 16 to 20 MPa with a corresponding
increase in density. This could be useful to structural engineers for designing building components such as balcony panels or for insitu
toppings on metal tray flooring systems. Please contact us for further information.
Prefabricated timber midfloor being craned into position while the mobile crane is still on site 13
www.litecretesystems.co.nz © Copyright 2015
7.0 Product Performance Test Results
Test standard Criteria Results
FIRE PERFORMANCE:
Fire Spread and Burning ASTM E84 Maximum temp rise of 0
Smoke Development ASTM D136 36C° above 750C° 0
Smoke Generation CAN/ULC-S114-M80 0
No flaming Material classified as Non Combustible
Combustibility AS 1530.4 1997
Weight loss not
Fire Resistance Rating to exceed 20%
PHYSICAL PROPERTIES: Resistance to heat; refer BRANZ
Sorptivity - Initial Rate of Fire Resistance Test FR 3524 FRR 240/240/240
Water Absorption
Vapour Flow Resistance ASTM C1585.04 mm/sec^0.5 Litecrete = 0.0107 @ 12Mpa;
normal concrete = 0.0215 @ 20MPa
Thermal Conductivity AS/NZS 4859.1 N/A
(k) Value NZS 30 -100 (GN.s/kg.m)
4218:2009 0.32 +/- 0.003 Wm-¹K-¹
Thermal resistance 0.16 +/- 0.06 m² KW-¹ Tests conducted at Curtin University, Perth:
(R) Value (for 50 mm) ASTM C-177, ASTM C-653, ASTM C-167.
Meets Code requirements (solid construction)
for Climate Zone 1: 220 mm thick = R0.8
Environ. Compatibility EPA M 1311 No pollution No detrimental effects.
Mould and Mildew MIL STD 810E Susceptibility Does not support fungal growth. Rated: 0
Modulus of Elasticity ASTM-C469-02 N/A 4580 MPa (28 days)
Modulus of Rupture NZS 3112 P2 N/A 1.45 MPa (28 days)
Coefficient of Thermal Exp. ASTM C531 N/A 5.51 (AVE) x 10-6/ F°
Shrinkage NZS 3151:1974 N/A
Compressive Strength NZS 3151:1974 N/A < 1000 με (microstrains)
Density NZS 3112 P3 N/A > 10 MPa (28 days)
N/A 1500 kg/m³ at delivery min 14 days
Opus 1350 kg/m³ (28 days) reinforced
1250 kg/m³ (28 days) un-reinforced
Tensile Strength NZS 3112 P2 1.3 MPa (28 days) Test Criteria
Bracing Units STC Class 2400x1200x150 mm panel ISO 140 Part 3
STC 60 = 400 BU’s ISO 140 Part 3
ACOUSTIC PERFORM STC 55
Specification Fire Resistance
150 wall panels strapped/ lined
260 mm thick panel 240/240/240
240/240/240
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8.0 Residential Construction
8.1 Health & Safety Act 1992
The principle objects of the Health & Safety Employment Act 1992 (HSE Act) are to prevent harm to employees at work. To achieve
this, the Act imposes duties on employers, employees, principals and others to promote excellent health and safety management by
employers. It also provides for the making of regulations and codes of practice. The “Approved Code of Practice for the Safe
Handling, Transportation and Erection of Precast Concrete” was developed by construction industry representatives to ensure safe
work practices are promoted and become standardised normal work practices in precast factories and on building sites. All Litecrete
panels should be installed by persons familiar with precast concrete installation. All of the major craneage companies offer skilled
precast concrete riggers as part of their installation service. It is also important that the builder is made familiar with the construction
procedures detailed below. Full guidance is available from Litecrete.
8.2 Handling and Storage
As with regular precast concrete, care must be taken with Litecrete panels to protect edges and corners from damage during shipping,
craneage and placement. For construction efficiency precast
concrete products are usually installed as soon as they are delivered
to site. If for some reason the Litecrete panels are to be stored on
site they must be placed vertically on A-frames with a resilient type
of dunnage (strips of carpet, etc) placed between the panels to
protect the panel face. Do not store the panels horizontally in a
stack.
8.3 Delivery
Access to the site. Check that the site has appropriate access for a
truck/truck and trailer unit and that the ground has sufficient stability
to support the weight.
8.4 Craneage
Cranes are one of the most expensive pieces of equipment used
during the installation of Litecrete panels. To minimise this cost it is
important to plan ahead for the optimum crane size needed and time
the unit is on site.
Considerations:
1. The load. Litecrete will supply weight and load dimensions well in advance of panel manufacture so that planning can start early.
2. Proximity of the crane to the lift load. The capacity of the crane is determined by the distance the load is from the centre of rotation.
3. Obstacles which the crane may incur. Power lines, trees and buildings can all impact on the operation of the crane.
4. Ground conditions. Ensure the ground area is big enough to support the weight of the crane when being positioned and working.
5. Impact of crane on the general public. If the operation results in extra traffic control or requires loads being lifted over roadways or
other property then permission from the appropriate authority will be required.
8.5 Lifting
Edge lifting is the predominant method used with Litecrete panels. This
ensures the panel is vertical for placement over starter bars or other
connections; allows panels to be able to be placed close to adjacent
structures and also leaves the face of the panel untouched. Because
of flexural stresses induced in edge lifting of the panels the maximum
residential panel size, with a standard smooth (F5) finish, is
approximately 7-8 metres x 3.5 metres, subject to design parameters
such as window/door openings. Because of design constraints there
may occasionally be the necessity to use face lifters, however these
are used as a last resort and in consultation with the customer.
8.6 Horizontal Weather Joints
When lifting panels or lintels which have a staggered horizontal
weather joint, the lifting shackles can cause damage to the joint
upstands. To mitigate this problem the standard precast method is to
cast-in polystyrene block-outs into the upstands, within the area of the
lifting eyes, so that the lifting shackle is free to move without breaking
out the concrete. Photo at right shows a horizontal weather joint
where the polystyrene block-out has been removed from the joint
upstand to expose the lifting eye. After panel installation the upstand is
remediated to restore the weatherproofing integrity of the joint.
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8.7 Propping
Props are used to temporarily support the
precast panels until permanent fixing are
made. Planning the placement of the props is
important as, although they are in place for a
relatively short period of time, they take up a
significant amount of room and can affect
other site works. Typically, external walls are
propped from the inside panel face back to the
existing floor slab. However, if the
construction design requires the walls to sit on
footings with the floor slab being poured
between the walls later, then the panels will
require propping from the exterior face and
attached to “dead men” positioned in the
ground outside of the floor area, as shown in
the photo at
right. It is
recommend that
M16 threaded
propping inserts
are cast in to
the inside panel
face of the
panels during
manufacture.
Two props are required for each single-storey panel, usually at the 2-metre height. Four props are
required for a two-storey panel; typically two at 2 metres high and two at 4/5 metres high. Photo (left) shows a Reid TIM threaded
insert used for propping. A reinforcing bar goes through the hole near the base of the insert. The open end of the insert is set about
3mm below the panel surface and can be covered over after use. Props are also available that have a G-clamp attachment which fit
over the top of the panels, removing the need for cast-in propping inserts.
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9.0 Installation
There are two typical methods of installing single-storey and two-storey Litecrete wall panels in conjunction with concrete floor slabs:
Option 1: Panels sit in a rebate in the floor slab and are attached using Drossbach tubes. The wall panels are manufactured with cast-
in 40 mm diameter Drossbach tubes, 800-900 mm high, typically at 600 mm (design by structural engineer). These tubes fit over D12
starter bars which have previously been cast-in to a 230 mm wide x 50 mm deep perimeter rebate when the floor slab was poured,
prior to the panels arriving on site. See detail D(3)2 Panel/Floor Slab Connection. Once the panels are installed and properly aligned
the tubes are filled with epoxy grout. The grout holes are plastered over after filling.
Option 2: Panels sit on concrete footings below the floor level, prior to the floor slab being poured. The Litecrete wall panels are
manufactured with one or two rows of cast-in Reid brand RB12ti inserts at the bottom of the panel, at centres as designed by the
engineer. The panels are positioned on concrete footings, Reid brand RB12 starters are screwed into the inserts and the concrete floor
slab is poured. See detail D(3)3 Panel/Floor Slab Connection. While single-storey walls are usually trucked standing up, panels over 3
metres high are delivered sitting on their long edge and require pitching to the vertical during the lifting process using rollers attached to
the crane boom.
9.1 Installation using Drossbach Tubes
9.1.1 The floor slab is poured with a 20 mm deep
rebate set around the perimeter slightly wider than the
specified width of the panel. Starters are cast-in to the
perimeter rebate at nominated centres. The base of the
rebate must be level to within +/- 5mm in 5m.
9.1.2 Before beginning panel installation, usually well
before the delivery truck arrives, mark chalk lines around
the perimeter of the floor slab rebate for correct alignment
of the panels. Also, mark chalk lines for the internal
Litecrete walls, if applicable. Spray chalk lines with clear
polyurethane so that they do not scuff or wash off.
Perimeter levels should be determined and shims placed
prior panel installation. The first panel is usually installed at
a corner furthest away from the crane.
9.1.3 Position the panel correctly on the shims, with
the inside edge of the panel sitting on the chalk line and the
outside panel edge flush with the outer edge of the
foundation.
9.1.4 Panels are manufactured with cast-in Drossbach
tubes (which are typically 3 x diameter of the starter bars) at nominated centres. These tubes fit over the starter bars, which are cast
into the slab and extend 600 mm above the slab.
9.1.5 Panels are lifted into position, ensuring the starter bars in the slab are guided into the Drossbach tubes in the panel. See
detail D(3)2 Panel/Floor Slab Connection.
9.1.6 Attach adjustable props to upright panel with a threaded bolt attached to the cast-in inserts on the panel face and to the floor
slab using Trubolts. If the floor slab is to have a polished surface, props should be attached to the external panel face and
secured to “dead men” in the ground outside the perimeter of the floor slab. Adjust props until panel is plumb. Epoxy grout
is gravity-fed into the tubes through grout holes after the panels are fully aligned. Apply same procedure to the other
external wall panels, working progressively around foundation perimeter
9.1.7 Ensure that nominal 12 mm vertical gaps are left between each panel. Install lintels, if necessary.
9.1.8 When the timber top plates are in place, weld plates are secured and the panel joints are sealed both sides, the props can
be removed. Plaster grout holes.
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9.2 Installation using Reid Screw-In Starter Bars
9.2.1 Footings are poured to engineer’s design to support the
9.2.2 Litecrete panels, nominally 400 mm below the floor level.
9.2.3 Levels for the footings should be determined and shims placed
in position prior to the panels being installed.
9.2.4 Lift panel and position in place on top of the footings. Align panel
and attach adjustable props with a threaded bolt attached to the
cast-in inserts on the internal/external panel face and secure to
(a) “dead men” in the ground outside the perimeter of the floor
slab or (b) prop off other panels already secured.
Adjust props until panel is plumb. Apply same procedure to the
other external wall panels, working progressively
around the foundation perimeter. See detail D(3)3 Panel/Floor
Slab Connection. Props should not obstruct the
pouring of the floor slab.
9.2.5 Ensure that nominal 12 mm vertical gaps are left between each
9.2.6 panel. Screw RB12 starters into inserts at the bottom of the
panels. The panels are now ready for pouring of the floor slab. Photo (above) shows panel with a row of cast-in inserts prior
to Reidbars being fitted and the floor slab being poured.
When the timber top plates are in place and weld plates are secured the props can be removed.
9.3 Installing Litecrete Panels on top of Retaining Walls
Litecrete panels can be stacked on top of standard precast or masonry retaining walls. A typical connection is shown in detail D3(4)
Panel to Masonry Connection.
9.4 Installing Suspended First Floor Walls
Some houses are designed with first storey Litecrete walls inset from the
vertical line of the ground floor walls. A steel beam is required to support
the weight of the Litecrete, as shown in detail D17 Suspended First Floor
Wall Panel Installation.
9.5 Installing Internal Litecrete Walls (if applicable)
As Litecrete internal wall panels are not required to be insulated, a 150
mm panel thickness is suitable. The panels can be installed using either
Drossbach tubes – as for external walls; see detail D3(7) Typical Internal
Wall/Floor Slab Connection, or sitting on purpose-built footings in the
ground prior to the floor slab being poured, see detail D3(6) Typical
Internal Wall/Floor Slab Connection. In detail D3(7) the starter bars may
be (a) cast-in to the floor slab when it is poured prior, or (b) installed by
drilling into the slab using Chemset adhesive, 24 hours prior to panel
arrival.
9.6 Installing Weatherboards
Designer will sometimes specify weatherboards as a feature, maybe on a
particular elevation, to be fixed over Litecrete panels. For this application
we can cast-in vertical H3 treated timber fillets at 600 mm centres which
provide fixing for horizontal battens to which the weatherboards are nailed
(see detail D23 Cast-in Timber Fillet for Weatherboard Attachment).
9.7 Supplementary External Cladding
Additional exterior cladding systems, such as brick or stone veneer, can
be attached to Litecrete exterior wall panels to create feature walls. Such
systems must be fit for purpose and must comply with the relevant
provisions of the New Zealand Building Code. In all cases the
manufacturers’ installation, application and maintenance instructions must
be followed.
9.8 Litecrete/Weatherboard Transition Stone veneer adhesive-fixed to Litecrete panels
Vertical connection showing typical weatherboards butting up to Litecrete.
See detail D10(1) Panel to Weatherboard Connection.
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9.9 Litecrete/Fibre-cement Transition
Vertical connection showing fibre-cement panels butting up to Litecrete. See detail D10(2) Panel to Fibre-cement Board Connection.
9.10 External Plant-Ons
There are proprietary products available, which can be attached to the exterior surfaces of Litecrete walls to replicate classic
architectural styles with features such as windowsills, quoins, cornices and mouldings. These can be manufactured from lightweight
concrete, expanded polystyrene or plaster and attached according to manufactures’ recommendations (see www.accumen.co.nz).
9.11 Timber/Ply Mid-floor Installation
Attach continuous ex 200 x 50 timber joists to wall using Ramset M12 Chemset Anchors at 800 mm centres. See detail D8
Litecrete Wall/Timber Floor Connection.
9.12 Insitu Concrete Mid-floor Installation
Attach continuous steel supporting bracket to wall, to engineer’s design, using Ramset M16 Chemset Anchors at centres as specified
by the engineer. For an example of an insitu concrete system see detail D8A Litecrete Wall/Insitu Concrete (Metal Tray System) Floor
Connection.
Photo shows “rib and infill” midfloor system prior to pouring insitu concrete topping. Reid starter bars have been screwed in to cast-in
threaded inserts (on left) which will lock the walls into the floor.
9.13 Wall Panel/Floor/Deck Connection
See detail D3(5) Typical Wall Panel/Floor/Deck Connection.
9.14 Door and Window Openings
Litecrete wall panels will have openings for windows and doors cast-in during manufacture. A weatherstrip is created at the window
head and a sloping sill at the bottom (see detail D5 Litecrete Window Details). Residential windows are installed as per
recommendations of the Window Manufacturers’ Association with regard to precast concrete (see detail D6 Litecrete Window
Installation - single glazing and detail D6(1) Window Installation - double glazing).
9.15 Ventilation Grilles
Where a suspended ground floor is designed, say 600 mm above the ground level, the cavity space underneath requires ventilation.
Cast-in openings can be provided through the Litecrete panels for the installation of proprietary concrete or metal vermin-proof grilles
(see detail D23 Typical Ventilation Grille Opening).
9.16 Internal timber-framed walls
Internal timber frame walls adjoining Litecrete exterior or interior wall panels are connected by fixing the vertical end stud against the
Litecrete wall panel using chemical anchors (see detail D9 Litecrete Wall/Timber Frame Connection).
www.litecretesystems.co.nz © Copyright 2015 19
9.17 Parapet Wall and Flush Fascia Details
See details D11 Litecrete Parapet Wall and detail D12 Litecrete Flush Fascia
9.18 Wall/Roof (Apron Flashing)
See detail D13 Litecrete Wall/Roof Junction.
9.19 Gutter/Wall Junction
See detail D14 Litecrete Gutter/Wall Junction.
9.20 Meter Box Installation
See detail D15 Litecrete Meter box Installation.
9.21 Attaching Top Plates
Fixings for all structural and non-structural fittings, where applicable, should be embedded in the Litecrete panels during manufacture.
Threaded rods for the attachment of a 50 mm thick timber top plate (if required) should extend 75 mm out of the top of the panel (see
detail D4 Litecrete Wall/Roof Connection).
9.22 Services and Wall Penetrations
In some instances through-services such as plumbing and electrical, are required to penetrate through Litecrete panels. The
advantage of precast panels is that openings can cast in at the time of manufacture. For smaller service holes the Litecrete panels can
be easily drilled out on site. Care should be taken when drilling to avoid hitting reinforcing bars. Note that the maximum allowable non-
specific dimension of such openings is 400 mm x 400 mm. See detail D16 Litecrete Pipe Penetrations.
10.0 External & Internal Finishing
10.1 External plaster and coatings
The smooth exterior surface of the panel (F5) is produced off a steel casting bed. This means that once installed the panels are ready
be painted. In this instance the V-joints between the panels are “expressed” and become a feature. If a plaster finish is specified to
hide the joints, they would be filled in treated as “control joints” - to cope with any structural movement in an earthquake - (see detail
D18). However, any paint or plaster system should be of the vapour-permeable variety. We recommend systems that have been
BRANZ appraised and/or meet the NZBC requirements. There are numerous proprietary exterior plaster/paint systems available. In all
cases the manufacturers’ application and maintenance instructions must be followed, with particular attention given to the following
areas:
• Weathering, flashing and sealing systems at door and window openings, junctions with other materials and any other penetrations
of the exterior envelope. The ground/foundation/floor/wall interface. Particular care needs to be given to ensure that minimum
distances between ground and floor level, as stated in NZS 3604:2011, are met.
• External plaster systems are installed and cured within the temperature limitations, climatic and curing conditions set by the
manufacturer. The finished external plaster system is sealed and protected from the weather with a vapour-permeable coating
system.
10.2 “Clear” Concrete Finish
A clear, natural concrete finish can be used for Litecrete panels in residential construction. However, the following aspects should be
considered:
The pumice aggregate contains minerals which can sometimes result in heavier surface figuring than is the case with normal precast.
Mafic (iron-bearing) aggregate can also occur spasmodically. This can present as small rust spots on the panel surface. It does not
have any effect on the structural integrity of the panels and is not considered a defect.
10.2.1 Any transit or site damage (chips) to panels can be repaired but the remedial material, being of a different composition, is
usually apparent, particularly if a clear sealer is being used.
10.2.2 There is a propensity for hairline cracking to occur from the corners of any openings in all precast concrete when the panels
are stressed during craneage in the plant, transportation to or during installation on site. Even when temporary steel bracing is
installed in panels with large openings prior to leaving the factory, surface cracks from corners of openings may occur despite all
precautions being taken to prevent them. While these cracks are not a structural problem - not more than 1 mm deep - they are often a
concern to the client and remedial work will in most cases be visible.
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10.2.3 As with any type of concrete, colours can vary slightly
from batch to batch. If a consistent, blemish-free surface is
required, then a vapour-permeable masonry paint or stain should
be considered. We strongly recommend that designers and their
clients visit the Wilco factory and view typical Litecrete panel
surface finishes prior to the start of panel manufacture. We also
suggest that breathable matt finish sealers are used on clear
precast concrete surfaces to keep panels clean and reduce or
eliminate rain or dew-induced shadowing. While sealers are not
required to “waterproof” Litecrete, they prevent streaking caused
by uneven drying after rainfall and runoff from glazing systems,
they resist surface mould growth and make cleaning down a lot
easier.
10.3 Exterior maintenance
External coating systems, if being used, must be maintained in
accordance with the respective manufacturer’s instructions and
all damage repaired promptly to ensure the ongoing weathertight
properties of the coating system and thermal performance of the
Litecrete wall. In addition to these system-specific requirements,
the following general maintenance procedures must also be Photo shows typical surface figuring on a Litecrete panel
implemented:
• Any dirt accumulation or organic growth that may occur should be regularly removed from the external surface by cleaning with warm
water and detergent and a soft bristled broom.
• Solvent-based cleaners must not be used.
• The external cladding system should be checked yearly for damage to the system itself, deterioration of seals and possible water
entry at junctions and joints.
• Any damage to the coatings which does occur must be repaired in accordance with the manufacturer’s instructions. Where exterior
plaster finish systems are used, it may be necessary to recoat the top paint coating, after 8-15 years, in accordance with the
manufacturer’s instructions, to restore the visual appearance.
10.4 Internal Surface finishing
Some designers specify Litecrete panels in their natural state as the finished interior wall surface, to achieve an “industrial” or “honest”
ambiance. Be aware that the interior face of the panel has a rougher, trowelled finish (U3) as opposed to the exterior face, which is off
a smooth steel mould. Because Litecrete is manufactured from natural materials no one panel is exactly the same colour and
variations must be accepted from one batch of concrete to another. Litecrete recommend that the trowelled exposed interior panel
surface has a 1-2 mm thick cementitious skim coat (eg Mapei Planitop 200) as the base, which can then be finished with paint or
plaster systems. If the panels are to be plastered, control joints should be installed over each vertical panel joint so that they can cope
with any seismic or structural movements without fracturing the plaster (see detail D18). We strongly recommend that designers and
their clients visit the Wilco factory and view typical Litecrete panel surface finishes prior to the start of panel manufacture. If the
Litecrete panels are to be left exposed on the internal face a matt finish sealer should be applied to prevent dusting of the surface.
10.5 Weld Plates
Often weld plates are specified by the engineer to connect panels at corners or to attach suspended panels, such as garage door
lintels, between walls. They are installed on the internal face of the panels and in most cases are hidden by ceilings, etc. However,
sometimes for structural design reasons they will be visible. If requested, the weld plates can be rebated 20mm deep into the surface of
the Litecrete panel so that they can be plastered over after being welded together. See detail D21 Typical Cast-in Weld Plates – Flush
and Recessed. When exposed, the plates can be treated with “Fishoilene” (which smells a bit for a few days) or similar which results in
a rust-proof charcoal grey (“blued”) colour.
10.6 Internal Lining
Plasterboard.
Plasterboard can be either glue-fixed direct to Litecrete panels, or attached to timber battens fixed to the walls. Use Sikacil C or Selleys
Liquid Nails (or similar) adhesive in beads at 250mm centres. Lining materials can be screw fixed into 40 x 20 mm vertical timber
battens attached to Litecrete panels at 600 mm centres. The battens provide a cavity for the installation of through services. Coarse
thread screws 32mm x 6mm are required at max 300mm centres around the sheet edges and at max 450mm centres horizontally and
vertically within the body of the sheet, or as recommended by the manufacturer. The sheet/edge distance is usually a minimum of
12mm.
www.litecretesystems.co.nz © Copyright 2015 21
Insulating board
Aerated phenolic resin-based insulating board (Kingspan), with a plasterboard panel already attached, can be glue-fixed to the
Litecrete walls. After joints are stopped the surface is painted or decorated to suit. Note that placing insulation on the inside of a
concrete wall negates the benefits of thermal mass.
Adhesives
Adhesives used for the fixing of internal linings must be suitable for use on lightweight concrete surfaces. Approved products are:
Sikacil C, Fullers Maxbond, Gib® Allbond, Holdfast Gorilla Glue, Selleys Liquid Nails.
Ceramic tiles
Litecrete provides an excellent surface for the direct fix of ceramic tiles for wet areas, etc.
10.7 Attaching Fittings/Cabinets to Walls
When attaching such items as mirrors, towel rails, picture supports, shelves or light fittings to any Litecrete wall, mechanical fasteners
should be used. Do not use nails. We suggest fasteners such as Mungo brand (or similar) MN10 x 50 mm long metric screw, from
Powers Fasteners Ltd. For heavier objects, such as kitchen cabinets, M8 Ramset Chemset Anchors or similar should be used. These
fixings should be installed strictly in accordance with their respective manufacturers’ recommendations.
Rough-sawn timber finish on Awhitu beach house panels 22
www.litecretesystems.co.nz © Copyright 2015
11.0 Commercial Cladding
For many years architects have chosen to specify precast concrete
cladding because it offers exceptional versatility, speed of enclosure
and durability. Litecrete lightweight precast concrete, from Wilco
Precast, has further extended the boundaries. No other material
provides the combination of textures, shapes, surface details, fire
resistance, acoustic values, insulation, moisture resistance, low
maintenance and accelerated construction schedules. But the key
benefit is that Litecrete can also offer solutions to designers and
engineers when developing a building’s steel or concrete
superstructure – especially in poor soil, high seismic or re-cladding
applications. The structural capabilities of all precast components
offered by Litecrete should be verified by the project structural
engineers. Litecrete does not, therefore, offer to provide structural
certification.
Litecrete cladding panels are up to 50% lighter than normal precast
cladding panels and offer insulation and fire-resistance standards
that exceed the Building Code requirements. Higher strength/denser
panels (16 to 20 MPa) are available; please enquire.
Litecrete is manufactured with pumice aggregate, which reduces the
weight of the concrete yet provides its unique strength-to-weight
ratio. The air cells in the pumice provide insulating properties light
weight. The combination of pumice and cement, together with steel
reinforcing systems and polypropylene fibre reinforcement, gives
Litecrete its exceptional durability. Engineers and architects have
depended upon the strength, durability and design possibilities of
precast concrete to achieve a variety of outcomes:
• Design freedom: unlimited aesthetic options; excellent plan
• Flexibility Chatham Apartments, Pitt Street, Auckland
• Outstanding durability, including fire and moisture resistance
• Excellent acoustic properties
• Fast-track construction: faster to erect; unaffected by inclement weather
• Low maintenance and life-cycle costs
• Fewer truck movement
• Environmentally friendly; less embedded energy; recyclable
• Peace of mind: quality-assured, consistent factory manufacture enables greater quality control and superior consistency of finish.
Litecrete’s in-built R-value will improve the thermal efficiency of the structure leading to corresponding reductions in HVAC demand.
In Climate Zone 1, for example, NZS4243 Part 1:2007, states an R-value for walls in commercial applications of R0.3. Litecrete, at 150
mm thick, offers R0.6, whereas normal precast concrete is R0.124. This removes the requirement to strap and line Litecrete in this
situation.
Litecrete is vapour-permeable; it allows water vapour (condensation) to move through the panel to the exterior of the building. When
the weight of structural components is reduced a multitude of benefits follow, such as: lighter (and less costly) foundations, reduced
seismic loads, fewer connectors, cheaper shipping costs, smaller cranes.
Deadload Reduction
Litecrete can also be used in conjunction with normal precast concrete where the structure’s deadload is critical. Specific Litecrete
components such as eyebrows installed above windows, balconies, balustrades, parapet panels and lift-well panels, when considered
within the total structural design, can make a surprising contribution to deadload reduction, compared to using standard precast
concrete.
www.litecretesystems.co.nz © Copyright 2015 23
Shape, size and finish options – appearance and cost guide
SHAPES Appearance relative
Perimeter 4-sides Uniformity cost
Perimeter 5 or more sides
Non-rectangular ■ $
Curved shapes/surfaces ■ $$$$$$
Punched shapes (openings) ■ $$$$$
Returns ■ $$$$$
■ $$
■ $$$
SIZES ■ $$$$
Small panels ■ $
Large panels ■ $$
Thicker panels (>180 mm)
ACCENTS ■ $
Plain (no reveals) ■ $$
Shallow reveals (<15 mm) ■ $$$
Deep reveals ■ $$$
Reliefs (repetitive) ■ $$$
Precast trims and projections
COLOURS ■$
Grey cement ■ $$$$
White cement ■ $$$
Black cement
FINISHES ■ $
Form finish (F5) ■ $
Coatings (paint) ■ $$
Plaster systems ■ $$$$$
Formliner (custom, low repetition) ■ $$$
Formliner (high repetition) ■ $$$$$$
Stone veneer (on site by others)
■ low ■ medium ■ high
Concrete is made from natural materials which vary in the colours
they yield over time. Samples will represent one colour in the
range of colours produced by a mix design. Older samples should
only be used as a guide for initial colour and finish selection. Fresh
300 x 300 mm samples should always be used to make final colour
and finish selections. As with natural stone, mock-ups produced
near to the time of actual production should be used to confirm
final colour and finish selections.
The design, application, engineering and installation requirements
for Litecrete panels installed on low-rise and high-rise commercial
projects differ markedly from residential installations. Potential
uses are for clip-on exterior cladding, sunshades/fins, balustrade
and balcony panels, intertenancy walls, acoustic/firewalls and
façade re-instatements.
Acoustics
Building acoustics is the science of controlling noise in buildings,
including the minimisation of noise transmission from one space to
another and the control of noise levels and characteristics within a
space. The term “building acoustics” embraces sound insulation
and sound absorption. The two functions are quite distinct and
should not be confused. Noise has been defined as sound which
is undesired by the recipient, but it is very subjective and it
depends on the reactions of the individual.
Sills being fixed to Litecrete walls – Countdown Orewa
www.litecretesystems.co.nz © Copyright 2015 24
However, when a noise is troublesome it can reduce comfort and efficiency and, if a person is subjected to it for long enough periods,
can result in physical discomfort or mental distress. In the domestic situation a noisy neighbour can be one of the main problems
experienced in attached dwellings.
The best defence against noise must be to ensure that proper precautions are taken at the design stage and during construction of a
building. This means that the correct acoustic climate must be provided in each space and that the sound transmission levels are
compatible with the usage. Remedial measures, after occupation, can be expensive and inconvenient. Ideally, the sound insulation
requirements for a building should take into account both internal and external sound transmission.
The Litecrete Acoustic Wall system provides excellent sound insulation and meets the performance requirements of NZBC G6.3.1 for
inter-tenancy walls. This approved acoustic system exceeds the Minimum Sound Transmission Class 55 when constructed in
accordance with the details contained in this manual. Results of the tests conducted at University of Auckland Acoustic Test Centre by
Marshall Day Acoustics are available on request. Sound-rated wall systems ranging from low STC values - STC 47 - up to STC 60 are
available. The bare 150 mm thick wall achieves STC 47; bare 260 mm thick wall achieves STC55. See details IW1, IW2 and IW3.
More information is available on the Litecrete website (www.litecretesystems.co.nz) in Acoustic Systems section.
Fire Resistance
The Litecrete Firewall system consists of Litecrete 150 Solid walls, with tongue and groove vertical joints and also includes a specific
proprietary sealant for both the exterior and interior sides of the joints, thereby allowing it to be used in applications where a
demonstrated fire performance is required. The fire-rated system can also be used as a complete and finished wall system in its own
right. Litecrete 150 achieves a 240-minute fire resistance rating (refer to BRANZ Fire Resistance Test FR 3524 and installation details
on Litecrete website).
Litecrete panels on Westpac bank in Tauranga were produced off a rubber formliner; panel thickness varied from 150 mm to 225 mm
www.litecretesystems.co.nz © Copyright 2015 25
12.0 Sustainable Building
Sustainable building is the concept of constructing homes and buildings
that we need today without depleting resources for future generations. In
this new world of “sustainability” information about the strength, durability
and indestructible nature of concrete as a resourceful building material is
emerging. Amid the tear-down-and-replace mentality still pervasive in
the world today, concrete stands out defiantly. Try to replace concrete
with an alternative building material and you’ll be hard pressed to find a
substitute possessing the same thermal qualities, design flexibility, and
permanence. Fortunately, a paradigm shift is taking place in attitudes
about resource conservation and sustainability. More builders and
homeowners are now embracing sustainable building, and concrete is
emerging as a champion rather than a rebel. Read on to find out why,
and learn how you can use concrete to build environmentally responsible
homes without compromising beauty, comfort, or economy. For most
homebuilders and homeowners, expressions such as “sustainable
development,” “green building,” and “eco-friendly design” weren’t part of
the vernacular several years ago (although commercial builders have
long been familiar with these terms). But with mounting concerns about
rising energy costs and the continued depletion of finite resources, these
environmental buzzwords are becoming mainstream.
In New Zealand, green building is slowly beginning to show some
popularity in both the residential (and commercial) construction sectors
and more and more homebuyers are making environmental issues a top
priority for new construction and remodelling. Sustainability expands on
the basic concept of “reduce, reuse, and recycle.” It seeks to balance
sensitivity for the environment with economic and social values. For
homeowners, the benefits of green living go beyond environmental stewardship. Sustainable homes also offer many practical,
personal, and economic advantages including:
• Lower utility costs. Through such strategies as proper site orientation, the use of insulating building materials, and tighter
construction to reduce drafts, sustainable homes require much less energy to heat and cool. Sometimes off-grid energy sources, such
as solar power, can be used to meet all or part of the home’s electricity needs.
• Reduced impact on the surrounding environment and community. Sustainable homes make more use of materials manufactured
or harvested in an environmentally responsible manner. They also use materials available locally, not only to reduce transportation
impacts (such as fuel consumption and pollution) but also to stimulate the local economy. Attention to landscaping is important as well,
with consideration given to minimizing stormwater runoff, which can pollute local waterways.
• A healthier, more comfortable living environment. By using non-toxic materials, sustainable homes have better indoor air quality.
They also use materials resistant to moisture and rot to eliminate concerns about the growth of hazardous mould and mildew. Exterior
walls typically have greater thermal mass, which offers the dual benefits of reducing
temperature fluctuations and muffling outdoor noise.
• Greater durability with less maintenance. Building with highly durable, low-maintenance materials, such as concrete, extends the
useful life cycle of a sustainable home and reduces maintenance and replacement costs. Many homeowners are unaware of the
negative impacts their homes and surrounding paved surfaces can have on environmental health. But the effects are dramatic, ranging
from resource depletion to climatic changes to disruption of fragile ecosystems. Consider these disturbing facts:
• With about 25,000 homes built each year, prior to 2008, homes represent 55% to 60% of all environmental impacts of buildings.
• It can take over 40 trees to build one timber-framed home.
• Operating a typical home or building over time consumes far more energy than it does to build it, according to Vera Novak, a US
environmental specialist and one of the ConcreteNetwork’s industry leaders. While investigating the life cycle of buildings, she found
that a mere 2% of total energy is expended for materials and construction and a staggering 98% are used to heat, cool, and power the
building.
• Studies have shown that urban environments have higher temperatures in areas where there are few trees and lots of buildings and
paved surfaces. This additional heat (called the “urban heat-island effect”) causes air conditioning systems to work harder, consuming
up to 18% more energy.
• Stormwater runoff is a leading source of the pollutants entering our waterways; about 90% of surface pollutants are carried by the
first 150 mm of rainfall.
• As much as 95% of the hydrocarbons in urban runoff are from the binder and sealer used in asphalt pavements.
www.litecretesystems.co.nz © Copyright 2015 26
Litecrete lightweight concrete is a friend of the environment in all stages of its life span, from raw material production to demolition,
making it a natural choice for sustainable construction. Here are some of the reasons why:
Resource efficiency. The predominant raw material for the cement in concrete is limestone, the most abundant mineral on earth.
Litecrete uses pumice aggregate which is also available in large quantities and is recovered from open-cast deposits using very little
energy.
Durability. Litecrete builds durable, long-lasting structures that will not rust, rot, or burn. Life spans for concrete building products can
be double or triple those of other common building materials.
Thermal mass. Homes built with concrete foundations and Litecrete concrete walls, and floors are highly energy efficient because they
take advantage of concrete’s inherent thermal mass—or ability to absorb and retain heat. This means homeowners can significantly cut
their heating and cooling bills and install smaller-capacity HVAC equipment.
Reflectivity. Concrete minimises the effects that produce urban heat islands. Light-coloured concrete pavements and roofs absorb
less heat and reflect more solar radiation than dark-coloured materials, such as asphalt, reducing air conditioning demands in the
summer.
Minimal waste. Litecrete can be produced in the quantities needed for each project, reducing waste. After a concrete structure has
served its original purpose, the concrete can be crushed and recycled into aggregate for use in new concrete pavements or as backfill
or road base.
Healthier Environment. VOC emissions from concrete building products are much lower than those for most other building materials.
The use of natural lime-cement plaster wall finishes can also significantly reduce total VOC concentrations inside a home. Exposure to
toxic mould in homes and buildings has been blamed for ailments ranging from headaches to severe respiratory infections and immune
system disorders. Mould can thrive on any organic material, especially in warm, moist, humid conditions. In addition to carpeting, mould
can feed on drywall, timber joists and framing and wall sheathing. Litecrete lightweight concrete floors and walls won’t support the
growth of toxic mould.
Concrete Reabsorbs CO² Emissions
During the life of a Litecrete lightweight concrete structure, the concrete carbonates and absorbs the CO² released by calcination
during the cement manufacturing process. Once concrete has returned to fine particles, full carbonation occurs, and all the CO²
released by calcination is reabsorbed. A recent study indicates that in countries with the most favourable recycling practices, it is
realistic to assume that approximately 86% of the concrete is carbonated after 100 years. During this time, the concrete will absorb
approximately 57% of the CO² emitted during the original calcination. About 50% of the CO² is absorbed within a short time after
concrete is crushed during recycling operations.
Litecrete fins being installed on AUT’s Sir Paul Reeves Building 27
www.litecretesystems.co.nz © Copyright 2015
13.0 Construction Details
Note that the following details are based upon 220 mm thick panels. This thickness achieves an
R-value of 0.8, which is the requirement for “Solid Construction” (concrete and masonry) in Climate Zone 1, as specified in NZBC
Clause H1 Energy Efficiency. Both 220 and 150 mm thick panel details, in various formats, are available for downloading on the
Litecrete website: www.litecretesystems.co.nz.
D1 Panel Joint Detail – Butt Joint
D2 Panel Joint Detail – Internal/External Corners
D3(2) Panel Joint Detail – Panel/Floor Slab Connection (Option 2)
D3(3) Panel Joint Detail – Panel/Floor Slab Connection (Option 3)
D3(4) Panel Joint Detail – Panel/Masonry Connection
D3(5) Panel/Floor/Concrete Deck Connection
D3(6) Internal Panel/Floor Connection Option 1
D3(7) Internal Panel/Floor Connection Option 2
D4 Panel Detail – Wall/Roof Connection
D5 Window Edge Detail – Sill, Head and Jamb
D6 Window Installation Detail – Single Glazing
D6(1) Window Installation detail – Double Glazing
D7 Panel Detail – Garage Door Lintel
D8 Mid Floor Connection Detail – Timber Joist End/Side Fixing
D8(1) Mid Floor Connection Detail – Metal tray insitu concrete system
D9 Connection Detail – Wall/Timber Frame Connection
D10(1) Panel/Weatherboard Transition
D10(2) Panel/Fibre-cement Board Transition
D11 Parapet Wall Details
D12 Flush Fascia Details
D13 Details – Wall/Roof Junction (Apron Flashing)
D14 Details – Gutter/Wall Junction
D15 Meter Box Details – Head, Sill and Jamb
D16 Pipe Penetration Details
D17 Suspended First Floor Wall Panel Installation
D18 Vertical Control Joint for Paint/Plaster Systems
D19 Narrow Panel Parameters
D20 Horizontal Panel Joint
D21 Cast-In Weld Plates - Flush and Recessed
D22 Ventilation Grille Opening
D23 Cast-in Timber Fillet for Weatherboard Attachment
IW1 Intertenancy Wall - To achieve STC 47
IW2 Intertenancy Wall - To achieve STC 55
IW3 Intertenancy Wall - To achieve STC 60
www.litecretesystems.co.nz © Copyright 2015 28
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