Plycem Appplications Guide

7/13/2019 Plycem Appplications Guide

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Version 1, October 2002

GENERALITIESCHAPTER 01

ITEM CONTENTS

1. DEFINITION 0011.1 Raw Materials 001

1.2 Properties and Advantages 0012. DESCRIPTION 0012.1 Thickness 0022.2 Dimensions 0022.3 Weight 0022.4 Tolerances 0023. TECHNICAL CHARACTERISTICS 0033.1 Typical Properties 0033.2 Durability 0033.3 Workability 0033.4 Maintenance 003

4. TRANSPORT AND HANDLING 0045. STORAGE 004


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ITEM CONTENTS

6. TOOLS AND EQUIPMENT 0056.1 Basic Equipment 005

6.2 Supplementary Equipment 0057. ADJUSTMENT TO WEATHER 0068. WORKING PROCEDURES 0068.1 Manual Cutting with a Hand Saw 0068.2 Manual Cutting with a Blunter 0068.3 Mechanical Cutting 0078.4 Drilling 0078.5 Paring 0079. MINIMUM REQUIREMENTS FOR

INSTALLATION 0089.1 Structural Bearings 008

9.2 Types of Structures 0089.3 Location and Span Between Fixings 00910. FIXINGS 010


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ITEM CONTENTS

10.1 Assembling of Galvanized SteelStructures 010

10.2 PLYCEM Sheets Fixings 01010.3 Assembling of Structural Elements 01011. JOINTS BETWEEN SHEETS 01111.1 Width of Supports for Joints 01111.2 Types of Joints 01112. USES 01213. SUPPLEMENTARY PRODUCTS 01313.1 Structural System 01313.2 Fixing System 01313.3 Additives System 013


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GENERALITIES 001CHAPTER 01

1. DEFINITIONPLYCEM represents technology implementedto manufacture asbestos-free fiber-cementproduc t s , to be used in cons t ruc t ion o fbuildings, houses and general type of works.Every PLYCEMproduct is manufactured followingthe strictest environmental regulations.

1.1 Raw MaterialsThe ma i n r aw ma t e r i a l s emp loyed f o r PLYCEM products come from traditional,

commonly used materials, like cement andnatural f ibers, which are processed andtransformed using an elaborate industrialsystem.

1.2 Properties and AdvantagesPLYCEMproducts are highly versatile; theycan be used with any conventional constructiveme t hod , and w i t h t h e mo s t mode r n o findustrialized constructive systems.

PLYCEMsheets are convenient for exteriorand interior application, offering severaladvantages:

They don't contain hazardous products. Their process of application is not aggressive. They can be cut, sanded, nailed, rougdressed,drilled and screwed with adequate conventionaltools.

They accept a wide variety of finishes

They resist moisture, don't disintegrate in thepresence of water, or decompose They provide good electrical isolation

They don't combust, generate smoke non toxicfumes They resist mold and mildew attack, insectsmicroorganisms and rodents.

PLYCEMproducts resist mechanical stress,have a good resistance to shock, are durable,and have a lasting endurance against thedamaging action of rain, sun, and wind evenwhen left unprotected.

2. DESCRIPTIONO u r m a n u f a c t u r i n g s y s t e m p r o d u c e s corrugated sheets for roofing and flatsheets; this chapter contains informationregardingflat sheets only, which complywith all requirements and demands expectedfrom ISO norm 8336 and ASTM C1186.

Flat sheets are of rectangular shape, and a

light gray color. The surface that is exposedto the atmosphere is smooth, not calibrated,and the opposite side is rough.

Depending on their final use, there are twokinds of flat sheets:

a. Non Moisture-Proof SheetsFor use in interior areas, unexposed to rain (5,6, and 8 mm. thickness).

b. Moisture-Proof SheetsFor use in exterior or humid areas (11 mm.thickness and above).


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Standard commercial thickness are specified inthe following table:

Table 1TYPE OF SURFACE THICKNESS (MM)

5 6 8 11 14 17 20 22 30

Flat,un-calibratedFlat,calibrated*

Un-calibrated,grooved*Calibrated,grooved*Wood

texture** Ask with the Customer Service Department in each country for thickness

and textures available

2.2 DimensionsSheets are manufactured under maximalnominal dimensions of 1220 mm. width and3050 mm. length.Commercial sheets are sold in the followingsizes:

Table 2NOMINAL DIMENSIONS THICKNESS (MM)

(Feet) (mm) 5 6 8 11 14 17 20 22 30

2x2 610x610

2x4 610x1220

4x8 1220x2440

4x10 1220x3050

Availability to be checked in each country

2.3 WeightPLYCEMsheets have a weight of around 1.05and 1.10 kg/m of area and for each millimeterof thickness; weight may vary depending ofambient humidity.

2.4 TolerancesAs with every product, dimensions of PLYCEMsheets must be considered taking into accounttolerances al lowed by the correspondingnorms; the following table describes the range

of tolerances according to ISO norm 8336 andASTM C1186.

Table 3ISO 8336

Dimension Tolerance

Length 8,0 mm

Width 6,1 mm

Square 4,0 mm

Thickness < 6 mm 0,6 mm

Thickness > 6 mm 10%

3. TECHICAL CHARACTERISTICS3.1 Typical PropertiesTable 4Fire Resistance ASTM E84

Flame Spread 0

Fire Contribution 0 Smoke Development 0

Movement due to ASTM 1185Change of MoistureExpansion Contraction Work Conditions Wet Camera 30% to 90% RH 0,12 - 0,15%


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Maximun Density 0.95 gr/cm Mechanical Resistance (Ambient Humidity) Minimun Breakup Module 7 N/mm

3.1 FireproofPLYCEMis not a smoke generator: it doesntspread fire and is fireproof.

3.2 DurabilityBased on evidence and quick aging processes

applied to the material on laboratory, thedurability of the PLYCEMsheets used with theproper coatings and maintenance, can exceedthe 20 years, when exposed to climatic effects.

3.3 WorkabilityPLYCEMsheets have a flat surface; theyreun-calibrated and may be decorated.

Before applying any of the recommended

coatings, its recommended to wipe any dustwith a moist cloth.

IIn most applications its very important tobalance the level of humidity absorption inboth sides of the sheet in order to avoiddefacing.

PLYCEMsheets can be cut, drilled, screwed,sanded, pared, nailed, glued, carved ortransformed with hand or mechanical tools.In the case of repeated working, its essentialto use tools with tungsten blades only.

3.4 MaintenanceOwing to their nature,PLYCEMsheets dontrequire any special maintenance, only theroutine treatment demanded by any building.

Should there be any fissure or fracture, theycan be easily fixed. If the sheets have anyspecial kind of superficial coating applied,adequate maintenance for that specific finishmust be considered.

4. Transport and handlingPLYCEMsheets must be transported on a firm,flat platform, protected from moisture.

Never should they be transported withoutadequate support or they may break.


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To handle, take them by the longer edges andttransport them vertically.

5. STORAGEPLYCEMsheets must be stored indoors, wherethe floor is flat, over a plank or platform, raisedabove the ground with leveled supports.

The maximum distance between them should be0.60 meters.

Outdoors storage in not encouraged, and if so,only temporarily; for very brief periods,protecting them from moisture using someplastic, canvas or rubber covering.

The storing of one platform over the other ispossible if the stability conditions of the floorallow it and they are separated enough.




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6. EQUIPMENT AND TOOLS6.1 Basic Equipment Measuring Tape

Pencil or Chalk

Houseline to register

Metal Ruler

Metal Square of 0,6 m.

Sliding T bevel square

Leval 0,6 m. Hammer with Hooks

Utility Knife

Hand Saw

Wood Chisel

Bit Brace (manual drill)

Flat Screwdriver

Philips Screwdriver

Slip Joint Pliers

Pliers

Metal Clamp

Scraper, spatula

Caulker

Caulking Gun

Flat and Jagged Trowel

Straight cut snips

Half Round Bastard

Large Overall Helmet

Gloves

Safety Goggles

Tool Belt

Safety Belt

Ladder

6.2 Supplementary Equipment # 5 Bench Plane

3/8" Light Drill

Circular Saw

Jig Saw

Sanding Machine

Bits for Metal

Electric Cable

Electric Screwdriver 2500 rpm.,

w/adjustable Clutch and Torque


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7. ADJUSTMENT TO WEATHERCONDITIONSBefore their installation, sheets must be aired onsite, indoors, for a period of 24-48 hours.This will allow them to balance their humiditywith ambient air. Sheets should be storedhorizontally, by placing separators betweenthem, that will allow both sides to remainexposed to environmental humidity.

8. WORKING PROCEDURES

8.1 Cutting with a HandsawAlways trace a guiding line on the sheet.

Use an ordinary handsaw, 60 cm. long, with atleast 10 teeth per inchA gripper and triangular file will help you tokeep the handsaw sharp and in good shape.

8.2 Cutting with a BlunterUse a metal rule as guide, carve a 3mm depthgroove.

In sheets of 14 mm of thickness or more, carvecoincident groove in the opposed sides.

3mm


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Place a guideline piece under the sheet, theedge will be coincident with the groove, bendthe material until you can rip it off.

Using the rasp or the bench plane, even the cutdown.

8.3 Mechanical CutElectric Saw: use a tungsten disk, of at least40teeths. Avoid generating dust, use machinesequipped with dust vacuuming devices, andnever use water while cutting. Work in anopenspace, wearing safety goggles, mask andgloves.

Jaig Saw: useful for irregular cuts, generatesbigger shavings. Doesnt require water.

8.4 DrillingUse a bit brace, hand or electric drill withstandard metal drills.

8.5 ParingSheets are made of cement, but can be easilytrimmed by using conventional carpentry tools(brush, sander, rasp, router).


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9. MINIMUM REQUIREMENTS FORINSTALLATIONEach application must be done following therecommendations given in the correspondingchapter. Notwithstanding the Basic Norm, thefollowing should be taken into account:

9.1 Structural BearingsPLYCEM sheets require at least somestructural bearing along their sides and a

vertical support at an interval of 610 mmmaximum.

9.2 Types of StructureStructural bearings can be made of wood,

galvanized studs, iron steel or other material;in all cases, they should be protected againstc o r r o s i o n a n d a b ra s i o n . D e s i g n a n dcalculations should be performed by a relevantprofessional.

9.2.1 WoodIt should be dry, flat, of uniform sections,and protected against insect attack.

9.2.2 Red Iron Steel StructuresVarious dimensions and shapes may be used.They should be protected against corrosion.

9.2.3 Galvanized Steel StructuresThey are a safe and fast, adequate technicaloption. They provide a quick and economicsolution for construction.

610

610

610

2440

Mesaurements in mm.


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9.3 Location and Distance Between Fixing Elements

For floor systems and roofs use the fixingdiagram xplained in the cor respondingchapter.

A very important detail for fixing anyapplication is verifying that every elementbeing fixed is placed exactly as indicated in thediagram below:

B = depending of application E = 3 to 4 mm, rigid joints 3 to 6 mm, flexible joints

Each application requires a different kind offixing, depending on its own needs. Select theapplication and follow recommendationsindicated in its constructive diagram.

WIDTH

LENGHT

Interior WallsExterior Walls

50

B50mm

B

150mm

E


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10. FIXING ELEMENTSA successful application depends to a greatextent on the fixing of boards to thestructures.

Always use appropriate fixing systemsdepending on each need. As a referenceguide, without pretending it to be a norm orspecification, the recommendation is to usegalvanized steel structures and that fixingelements adhere to the following

recommendations:

10.1 Assembling of Galvanized Steel Structures #8x" or " extra flat-head, non-skidding,galvanized steel screws, High-Low screwthread, self-drilling kind fine tip (LH 8-050, LH8-075).Used to assemble galvanized steel structures ofa thickness up to 0.8 mm.

#8x" or " extra flat-head, non-skidding,galvanized steel screws, type "S" screw thread,self-drilling bit tip (LH 8-050, LH 8-075).Used to assemble galvanized steel structures ofa thickness within the range of 0.8-1.4 mm.

10.2 Fixing of PLYCEM Sheets #6x1" trumpet-head, galvanized steel screws,self-countersinking groove, High-Low screwthread, self-drilling fine tip (PL 6-100).Used to fix PLYCEMsheets of a thickness upto 8 mm., to a wood or galvanized structure ofa lesser thickness.

#8x-" trumpet-head, galvanized steel screws,self-countersinking groove, High-Low screwthread, self-drilling fine tip (PL 8-125).Used to fixPLYCEM sheets of a thickness up to11 mm., to a wood or galvanized structure ofa thickness of less than 0.8 mm.

8x1-" trumpet-head, galvanized steelscrews, self-countersinking groove, type S12screw thread, with self-drilling bit tip, andflaps for expanded perforations (PH 8-125)

Used for fixing PLYCEMsheets of a thicknessup to 11 mm. and 14 mm to galvanized steelstructures of a thickness between 0.8 and 2mm.


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# 10x1" and #10x1" trumpet-head,galvanized steel screws, self-countersinking groove,type S12 screw thread, with self-drilling bit tip, andflaps for expanded perforations (PH 10-150)Used for fixing 20, 22 and 30 mm PLYCEMsheetsto galvanized steel structures of a thickness withinthe range of 0.8 and 2 mm.

10.3 Assembling of Structural Elements #10x",#12x" and #12x1", hexagonalhead, galvanized steel screws, type S4 screwthread, self-drilling bit tip (MM10-050, MM10-075, MM12-150).Used for assembling galvanized steelstructural elements like beams, arches up to2 mm thick.

11. JOINTS BEWEEN SHEETSThe area of contact between two sheets musthave a bearing, wide enough to have bothsheets safely installed, with fixing screwsproperly placed.By no means shall the sheets

touch each other; there must be an openingbetween them.This should be executed according to the typeof joint chosen: Decorative Joint, Control Jointor Invisible Joint

11.1 Width of SupportingElements at JointsFor interior walls, the minimum width for abearing where two sheets join should be 50mm.For exterior walls, where PLYCEM sheetsare used as the only protective covering onthe walls, this width should be 100 mm.If there exists a waterproof covering,which completely insulates PLYCEMsheets, EIFS or DAFS type, it should sufficewith 50 mm.

11.2 Types of Joints11.2.1 Decorative JointBy means of a forced separat ion, a jo intc a n b e u s e d a s a d e c o r a t i v e e l e m e n t ;depending if its to be used for exterior orinterior wal ls, some addi t ional measureshave t o be t aken t o gua ran t ee i t s t o ta l

wa te r-t ightnes s. Width shou ld ot be be low

the recommended 4 mm.


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11.2.2 Control JointOpen joint created to absorb expansions andcontractions characteristic of sheets;it preventsfissures (in other places of application.

Movements originated by contraction andexpansion of components, vibrations andstructural adjustments will traduce themselves infissures on joints between sheets. ts highlyrecommended to incorporate control joints at adistance of every 6 meters maximum: different

functional or decorative treatments may beapplied to this joint.

If an elastic filler is chosen,the size of the jointhas to be designed considering a proportion of1:1 to 2:1 (width/depth), the minimum widthmust be 6 mm.; constructive joints have to beexecuted following the manufacturersrecommendations.

Its not recommended to apply any coating orpaint over control joints

1.2.3 Constructive JointPutting together materials of different naturesrequires designing a joint that will allow theirfree movement.By its nature, it should be visible and executedaccording to constructive techniques related tothat field; its minimum width should be 10 mm.

11.2.4 Invisible Rigid JointAs implied in its name, it will not be visible to theeye. This is achieved by applying epoxic pastelike PLYCEM-Gel or Pega-Cem. Its minimum

width should be 4 mm.Recommended only for interior use: it shouldnever be applied on exterior walls.

e

B

B = e Minimum

Plycem-Flex

10mm


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12.USESPLYCEM sheets have proved their versatility,their easy handling and features give themdiverse uses, the formal construction markethas identified some sectors where it representsan effective technical solution.The following table lists the applications whichhave been totally developed, and for whichtechnical information may be requested.

Any other application not lis ted in thistable, should be considered an informal ,non-official use, and therefore its reliabilitycant be guaranteed.

USE Minimum Width

5 6 8 11 14 17 20 22 30

Ceilings Suspended Anchored, 2"x2" Anchored, 4"x8" Panelled

Interior Walls

Divisions High Traffic Humid Exterior Walls Facades Low (up to 8 mm) Roof Sustrate

Asphalt Clay tiles

Plycem Tile Floors Residential Other uses

13. SUPPLEMENTARY PRODUCTSWith the purpose of rendering applications ofgood technical and esthetic performance, somecountries have adopted a commercial portfoliolisting the supplementary products required toguarantee a successful application.13.1 Structural System

Wood parts and galvanized steel or black steelprofiles, of different shapes, lengths andthickness, which conform the basic structuralbearing for sheets and make up the fundamentalassembling of the system.

13.2 Fixing SystemWide array of screws, specially designed toefficiently couple the structural bearings and tofix PLYCEMsheets to the structural bearing.

13.3 Additives SystemPutty, glue, and special coatings, designed to

treat joints and finish surfaces of sheets, torender an optimal quality.

13.3.1 PLYCEM-Gel, Pega-CemEpoxy sealant, to fill in rigid joints. Used to sealrigid jjoints between sheets on interior walls. Itsapplication requires mixing two components inthe recommended proportions specified in thetechnica l shee t . Appl ied wi th a spatu la,completely filling the joint between sheets and

over the screw heads.


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b


13.3.2 PLYCEM-FlexLow modulus polyurethane sealant, for jointssubject to movement. It's a filler for flexible jointsbetween sheets. Applied with a caulking gun.

13.3.3 PLYCEM-FondoBackroll used as a structural base to applyPLYCEM-Flex on flexible joints.It avoids PLYCEM-Flexfrom adhering itself tosupporting structures. It also contributes thedesigned depth for flexible joints.

Applied with a caulker or roller for joints.

13.3.4 PLYCEM-StuccoAcryl ic putty used as a surface stabil izer. Itimproves the finish of sheets. Applied in thinlayers, with a plastic or metal trowel, for interiorapplications.

13.3.5 PLYCEM-PegaAcrylic, flexible adhesive, for gluing ceramicveneer or similar. Used to fasten the veneer tointerior surfaces, not exposed to hydrostatic

load; applied with a dented trowel.

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Plycem Appplications Guide