Construction Manual Ver2

CONSTRUCTION MANUAL
CONSTRUCTION MANUAL BUILDING SYSTEMS FOR MODULAR HOUSING

Force 10 International Pty Ltd 63 Factory Road, Oxley Qld 4075 Australia PO Box 126, Brisbane Markets, Qld Australia 4106 Phone: 61 7 3379 5200 Fax: 61 7 3379 5211 e-mail: force10@gil.com.au www: http://www.force10.com.au
Note: This manual is subject to revision and updates are available on request from Force 10 International Pty Ltd. Issue Date: November 2003
Document Reference: CONSTRUCTION MANUAL_Ver2.doc 11/03
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CONSTRUCTION MANUAL
Table of Contents
1 2 3 INTRODUCTION..........................................................................................................................................................7 SAFETY REQUIREMENTS ........................................................................................................................................7 PRE-REQUISITES ........................................................................................................................................................7 3.1 3.2 3.3 3.4 3.5 4 5 4.1 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 6 FORCE 10 DOCUMENTS .............................................................................................................................................7 STANDARDS..........................................................................................................................................................7 LOCAL AUTHORITY REQUIREMENTS .........................................................................................................................7 ALLOCATION OF WORK.............................................................................................................................................8 SERVICE CONNECTIONS ............................................................................................................................................8 DURABILITY ..............................................................................................................................................................9 STEP 1. UNLOADING MATERIALS ....................................................................................................................9 STEP 2. PREPARATION OF SITE .........................................................................................................................9 STEP 3. FOUNDATION..........................................................................................................................................9 STEP 4. FLOOR FRAMING AND SHEETING....................................................................................................10 STEP 5. WALL SYSTEM......................................................................................................................................10 STEP 6. FLOOR BEARERS (SECOND STOREY) ..............................................................................................10 STEP 7. ROOF SYSTEM.......................................................................................................................................10 STEP 8. WINDOWS AND DOORS ......................................................................................................................10 STEP 9. SERVICES ...............................................................................................................................................10 STEP 10. CEILING................................................................................................................................................10 STEP 11. CUPBOARDS AND JOINERY .............................................................................................................10
CONSTRUCTION .........................................................................................................................................................8 SUGGESTED CONSTRUCTION PROCEDURE......................................................................................................9
UNLOADING AND STORING MATERIALS.........................................................................................................10 6.1 PART NUMBERS ......................................................................................................................................................11 6.1.1 Wall Components ...........................................................................................................................................11 6.1.2 Floor Components..........................................................................................................................................12
FOUNDATIONS ..........................................................................................................................................................12 7.1 GENERAL ................................................................................................................................................................12 7.2 FOOTINGS................................................................................................................................................................12 7.2.1 Setting Out......................................................................................................................................................12 7.2.2 Boundary Pegs ...............................................................................................................................................12 7.2.3 Corners...........................................................................................................................................................12 7.2.4 Profiles ...........................................................................................................................................................13 7.2.5 Excavation......................................................................................................................................................14 7.2.6 Stump /Post Foundation Types.......................................................................................................................14 7.2.7 Stump /Pile Length and Set-Out .....................................................................................................................15 7.2.8 Position ..........................................................................................................................................................15 7.3 CONCRETE ..............................................................................................................................................................16 7.4 POUR THE CONCRETE SLAB ....................................................................................................................................16
FORCE 10 FLOOR SYSTEM ....................................................................................................................................17 8.1 8.2 8.3 8.4 8.5 BEARERS AT GROUND FLOOR .................................................................................................................................17 FLOOR JOISTS ..........................................................................................................................................................19 FLOOR SHEETING ....................................................................................................................................................20 FLOOR FLASHING ....................................................................................................................................................22 BEARER COVER.......................................................................................................................................................23 THE GRID SYSTEM ..................................................................................................................................................26 Page 2 of 68
FORCE 10 WALL SYSTEM ......................................................................................................................................26 9.1
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9.2 9.3 10 10.1 10.2 10.3 10.4 10.5 10.6 10.7 11 11.1 11.2 11.3 11.4 11.5 11.6 12 12.1 12.2 12.3 13 WALL FLOOR BRACKETS ........................................................................................................................................26 GENERAL EPOXIED INSTALLATION GUIDELINES (REFER TO SPECIFICATION)..........................................................28 FORCE 10 WALL PANEL SIZES AND CODING..............................................................................................29 ERECTING EXTERNAL WALL PANELS ..........................................................................................................31 EXTERNAL PANEL RUNS..................................................................................................................................32 ERECTING DOUBLE JOINERY PANEL ............................................................................................................34 ERECTING INTERNAL WALLS.........................................................................................................................34 PLASTIC COVERSTRIPS ....................................................................................................................................35 INTERNAL WALLS .............................................................................................................................................36 ERECTING DIAGONAL WALL PANELS ..........................................................................................................37 FORCE 10 TWO STOREY CONSTRUCTION ...................................................................................................39 TWO STOREY CONSTRUCTION.......................................................................................................................39 BEARERS OVER GROUND FLOOR WALLS ....................................................................................................39 BEARERS OVER GROUND FLOOR DOUBLE PANELS..................................................................................40 FLOOR JOISTS .....................................................................................................................................................41 TWO STOREY CEILING BATTENS...................................................................................................................42 TWO STOREY FLASHINGS................................................................................................................................43 FORCE 10 POST AND BEAM SYSTEM .............................................................................................................43 75X75 RHS WALL POST / COLUMN .................................................................................................................44 COLUMN BETWEEN PANELS...........................................................................................................................44 RHS BEAMS .........................................................................................................................................................45 FORCE 10 ROOF SYSTEM...................................................................................................................................48
13.1 ROOF .....................................................................................................................................................................48 13.2 TRUSS ASSEMBLY .............................................................................................................................................48 13.3 PRELIMINARY WORK .......................................................................................................................................48 13.4 FIXING OF TRUSSES ..........................................................................................................................................48 13.5 GABLE END ROOF ..............................................................................................................................................49 13.6 TRUSS BINDERS .................................................................................................................................................51 13.7 ROOF PURLINS....................................................................................................................................................52 13.8 EAVES PURLINS .................................................................................................................................................53 13.9 HIP ROOF ASSEMBLY........................................................................................................................................54 13.10 GIRDER TRUSSES ...........................................................................................................................................56 13.11 HIP PURLINS....................................................................................................................................................58 13.12 EAVES LININGS ..............................................................................................................................................59 13.13 ROOF SHEETING.............................................................................................................................................59 13.14 GABLE END CLADDING................................................................................................................................59 13.15 SPOUTING AND FASCIA................................................................................................................................59 13.15.1 Fixing and Fitting Facia /Gutter Brackets (Fall).......................................................................................60 14 15 16 16.1 16.2 17 17.1 17.2 18 18.1 18.2 SOUND CONTROLS ..............................................................................................................................................60 FIRE CONTROL .....................................................................................................................................................61 INTERNAL JOINERY............................................................................................................................................61 CUPBOARDS........................................................................................................................................................61 SKIRTING BLOCKS.............................................................................................................................................61 SERVICES................................................................................................................................................................62 PLUMBING...........................................................................................................................................................62 ELECTRICAL .......................................................................................................................................................62 CEILINGS ................................................................................................................................................................62 CEILING BATTENS .............................................................................................................................................62 CEILING LINING .................................................................................................................................................63
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19 19.1 20 20.1 20.2 21 21.1 21.2 22 22.1 22.2 22.3 22.4 DOORS .....................................................................................................................................................................63 DOORS ..................................................................................................................................................................63 FINISHING TRADES .............................................................................................................................................66 TRADES ................................................................................................................................................................66 WET AREAS .........................................................................................................................................................66 EXTERNAL FINISHING .......................................................................................................................................66 WINDOW DETAILS ...................................................................................................................................................66 WINDOW COVERSTRIPS...................................................................................................................................67 FINISHING SYSTEM .............................................................................................................................................67 EXTERNAL FINISH REQUIREMENTS ..........................................................................................................................67 FORCE 10 RECOMMENDED EXTERNAL FINISHES ......................................................................................................67 FACADES .................................................................................................................................................................67 INTERNAL FINISHING ..............................................................................................................................................68
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CONSTRUCTION MANUAL
Table of Drawings
Figure 1 Panel Identification Sticker __________________________________________________________________11 Figure 2 Panel Identification Sticker 2 _________________________________________________________________11 Figure 3 Boundary Site Layout_______________________________________________________________________12 Figure 4 Profiles (Stump /post Foundations) ____________________________________________________________13 Figure 5 Inner profiles _____________________________________________________________________________14 Figure 6 String Line Profiles ________________________________________________________________________14 Figure 7 Cross Bracing_____________________________________________________________________________15 Figure 8 Measure and Align Stumps /posts to stringline ___________________________________________________15 Figure 9 Stumps /posts - concreting details _____________________________________________________________16 Figure 10 Fix bearer_______________________________________________________________________________17 Figure 11 Adjoining bearer _________________________________________________________________________17 Figure 12 Corner bearers on stumps /posts _____________________________________________________________18 Figure 13 Intersecting bearers _______________________________________________________________________18 Figure 14 Intersecting bearer on stump ________________________________________________________________18 Figure 15 Joists to bearers __________________________________________________________________________19 Figure 16 Non load bearing and non bracing panel ______________________________________________________19 Figure 17 Floor system overview of components _________________________________________________________20 Figure 18 Applying adhesive ________________________________________________________________________20 Figure 19 Staggered floor sheets _____________________________________________________________________21 Figure 20 Floor Sheet fixings ________________________________________________________________________21 Figure 21 Panel sheet layout ________________________________________________________________________22 Figure 22 Sheet joint and diaphragm floors _____________________________________________________________22 Figure 23 Wall /floor flashing________________________________________________________________________23 Figure 24 Wall bearer flashing_______________________________________________________________________23 Figure 25 Deck bearer flashing ______________________________________________________________________24 Figure 26 Flashing - Mitred details ___________________________________________________________________24 Figure 27 Grid location ____________________________________________________________________________26 Figure 28 Chalk out grid lines _______________________________________________________________________26 Figure 29 Hole layout ______________________________________________________________________________27 Figure 30 Wall/floor bracket ________________________________________________________________________27 Figure 31 Slab hold down bracket ____________________________________________________________________27 Figure 32 Epoxy Installation guidelines (Internal 90mm and External 120mm) _________________________________28 Figure 33 Single module panels ______________________________________________________________________29 Figure 34 Double module panels _____________________________________________________________________30 Figure 35 45 Degree module panels___________________________________________________________________30 Figure 36 Corner floor bracket layout _________________________________________________________________31 Figure 37 Corner floor bracket layout - Slab floor _______________________________________________________31 Figure 38 Corner intersecting panel___________________________________________________________________32 Figure 39 Panel Erection Runs_______________________________________________________________________33 Figure 40 Window head support______________________________________________________________________34 Figure 41 Textureline PVC Cover strip ________________________________________________________________35 Figure 42 External corner PVC cover strip _____________________________________________________________35 Figure 43 Internal wall fixings - Wall panel on gridline ___________________________________________________36 Figure 44 Internal wall fixing Wall panels off gridline ____________________________________________________37 Figure 45 Internal wall panels Wall panels on concrete slab on ground_______________________________________37 Figure 46 Diagonal panel fixing______________________________________________________________________38 Figure 47 45 Degree floor bracket ____________________________________________________________________38 Figure 48 Diagonal panels Shifting of centreline_________________________________________________________39 Figure 49 Wall Tee bracket__________________________________________________________________________40 Figure 50 Bearers supported by ground floor panel ______________________________________________________40 Figure 51 Lintel bearer plate ________________________________________________________________________41 Figure 52 Lintel bearer plate to bearer ________________________________________________________________41 Figure 53 Joists to bearers __________________________________________________________________________42 Figure 54 Two storey ceiling battens __________________________________________________________________42 Figure 55 Fitting wall/floor flashing __________________________________________________________________43 Figure 56 Two storey galvanised flashing ______________________________________________________________43 Figure 57 One way column Figure 58 Two way column ________________________________________________44 Document Reference: CONSTRUCTION MANUAL_Ver2.doc 11/03 Page 5 of 68
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Figure 59 Three way column Figure 60 Four way column _____________________________________________44 Figure 61 Column to panel connection_________________________________________________________________45 Figure 62 Column to panel connection_________________________________________________________________45 Figure 63 Beam to truss fixings ______________________________________________________________________46 Figure 64 Beam to column fixings ____________________________________________________________________46 Figure 65 Beam to panel junction_____________________________________________________________________47 Figure 66 Beam bracket to external corner panel ________________________________________________________47 Figure 67 Factory assembled trusses __________________________________________________________________48 Figure 68 Truss fixing details ________________________________________________________________________49 Figure 69 Typical gable end truss ____________________________________________________________________49 Figure 70 Gable End Detail _________________________________________________________________________50 Figure 71 Gable end truss assembly #1 ________________________________________________________________50 Figure 72 Gable end truss assembly #2 ________________________________________________________________51 Figure 73 Gable end roof space brace _________________________________________________________________51 Figure 74 Truss binders ____________________________________________________________________________52 Figure 75 Purlin joints _____________________________________________________________________________52 Figure 76 Purlin location screws _____________________________________________________________________52 Figure 77 Purlin location Details _____________________________________________________________________53 Figure 78 Purlin location screws _____________________________________________________________________53 Figure 79 Gable end purlins_________________________________________________________________________54 Figure 80 Gable end purlin details____________________________________________________________________54 Figure 81 Typical hip end roof layout _________________________________________________________________55 Figure 82 Hip end bottom chords _____________________________________________________________________55 Figure 83 Typical girder truss _______________________________________________________________________56 Figure 84 Fixing hip end bottom chords________________________________________________________________56 Figure 85 Corner assembly__________________________________________________________________________56 Figure 86 Fixing centre jack rafter at apex _____________________________________________________________57 Figure 87 Hip roof module sizing and framing layout _____________________________________________________57 Figure 88 Hip ridge purlins _________________________________________________________________________58 Figure 89 Hip ridge purlins at apex ___________________________________________________________________58 Figure 90 Fixing roof purlins to hip ___________________________________________________________________59 Figure 91 Eaves linings ____________________________________________________________________________59 Figure 92 Skirting Blocks ___________________________________________________________________________62 Figure 93 Door frame finish ________________________________________________________________________63 Figure 94 Door fixings details drawing ________________________________________________________________64 Figure 95 Window /door packer detail fixings___________________________________________________________64 Figure 96 Window fixing detail drawing _______________________________________________________________65 Figure 97 Packer details____________________________________________________________________________65 Figure 98 Wet area fixings __________________________________________________________________________66 Figure 99 Window Reveals __________________________________________________________________________66
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CONSTRUCTION MANUAL
1 Introduction
The full details of the Force 10 Building Systems Construction procedure are contained in this easy to follow manual. The stage by stage format is designed to ensure that any possible problems during construction are avoided.
2 Safety Requirements
Site Safety must be a prime concern at all times Refer to the attached documents for details.
CAUTION PERSONAL PROTECTIVE EQUIPMENT MUST BE WORN AT ALL TIMES WHEN OPERATING EQUIPMENT BE AWARE OF DANGEROUS SITUATIONS THAT MAY ARISE AT ANY TIME ON A CONSTRUCTION SITE 3 PRE-REQUISITES
3.1 Force 10 Documents
All Force 10 home owners are supplied with the following documentation for a Building Consent application and for construction.
ITEM A3 CONSTRUCTION DRAWINGS A4 LAMINATED CONSTRUCTION DRAWINGS CONSTRUCTION MANUAL BILL OF MATERIALS COMPLIANCE MANUAL /ENGINEERING CERTIFICATES CRATINGS LIST
QUANTITY 2 1 1 1 1 1
3.2
STANDARDS
The specific design details the foundations required and other special aspects referred to for construction in accordance with local standards. You will need a copy of the relevant standard to work with.
3.3
Local Authority Requirements
Your local authority may require the following information before a Building Consent can be issued: A floor plan at each level An elevation of each external wall The type and location of each foundation element
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Adequate information on all walls and subfloor, floor, and roof framing, including the type and location of each subfloor brace, diagonal brace, and wall bracing element and the number of wall bracing units assigned to each wall bracing element. The type and location of roof cladding and ceiling and wall linings Building Consent application form
After the local authorities have issued Consent, please contact your Force 10 Customer Services Officer for any alterations the local authority may require to approve plans. Only stamped plans are used and considered valid. There will be an extra fee payable if changes are to be made to existing plans unless the changes are required to obtain a Building Consent.
3.4
Allocation of Work
The following table identifies the recommendations for who may carry out the work for the various tasks. A B C Work that may be undertaken by building owner Work that must only be undertaken by registered Tradesperson Work that is recommended undertaken by specialist subcontractor
Work Concrete or masonry foundation walls Post or stump foundation Concrete-slab-on-ground Construction of floor, walls and roof Installation of linings, floor sheathing and roof cladding Exterior joinery Electrical work Plumbing and Drainage Gas Carpentry and tiling Plasterboard fixing and stopping
Who may carry out the work B A A and C A A A and C B B B A and C A and C
3.5
Service Connections
Connections associated with electricity, gas and telephone must be lodged with the appropriate service authorities, through a registered Tradesperson. Drainage and water connections are covered by the Building approval for the project.
4 CONSTRUCTION
Now you are ready to start your Force 10 building and transform it to your very own home. The construction procedure follows a step-by-step pattern and is normally adhered to, although it may vary according to subcontractor availability. After the arrival of your Force 10 kit, check carefully for any damage. Contact your Force 10 Customer Services Officer (CSO) (technical@force10.com.au) and report any damages or missing parts within three days, or no responsibility can be expected.
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4.1 Durability
Steel floor framing, sub floor framing, steel roof trusses and connections have a zinc coating which provides protection against corrosion resulting from wetting during construction and temporary leakage associated with damaged cladding. The long term durability is dependent on the steel components being maintained in a dry condition. Where floor, wall and roof framing is protected from the exterior environment i.e. completely encapsulated by weather tight linings, flashings and claddings, this condition is met. The strength and stiffness of wall panels is related to the sandwich panel action which in part relies on the durability of the polyurethane foam that fills the cavity. It is expected that the durability of the foam will exceed 40 years and that adherence of the foam to the fibre cement board will also exceed this period. Some injection of foam into wall panels may be necessary beyond this time to maintain structural integrity.
5 SUGGESTED CONSTRUCTION PROCEDURE

Following is a suggested construction program:
5.1
STEP 1.
UNLOADING MATERIALS
Check all items against the given Bill of Materials list. Arrange covered storage for materials in dry conditions clear of the ground (Note always use dunnage to store materials off the ground).
5.2
STEP 2.
PREPARATION OF SITE
Check survey information and position of services. Remove topsoil and prepare site for hardfill (slab-onground) or for excavation (stump /pile or foundation wall footings). Ensure the finished ground surface immediately adjacent to the building is shaped adequately to facilitate surface drainage away from the building and the site and building floor levels meet the provisions of required standards. Arrange for the excavation and placement of all buried services, eg. water, gas stormwater and sewer drains.
5.3
STEP 3.
FOUNDATION
Slab-on-ground:
Erect profiles, place and compact hardfill. Excavate footings, place Damp Proof Membrane (DPM), install formwork and fix footing and slab mesh reinforcing in place. Call for local authority inspection prior to placing concrete. Set out holding down bolts in the wet concrete where desired as an alternative to chemical anchors. All concrete work should be carried out in accordance with the relevant standard.
Using Stumps or a Post foundation:
Erect profiles, excavate for footings, fabricate floor framing on stumps /posts, lift and support framework in position and call for Local authority inspection before placing concrete in the footings. Note that some footings will be anchor stump /pile footings.
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5.4 STEP 4. FLOOR FRAMING AND SHEETING
Bolt bearers to foundation wall or stump /pile tops (This is required for stumps /posts before placing footing concrete - see step 3). Fix joists into bearers. Erect stairs. Fit stump /pile bracing in accordance with the specific design. Lay flooring sheets and screw fix into position. For a slab-on-ground, wall panels are fixed directly to the slab.
5.5
STEP 5.
WALL SYSTEM
Following the wall panel layout plan, mark out grids and wall panel positions. Fix floor brackets, fit floor flashings, then erect walls. Check that all wall frames are plumb.
5.6
STEP 6.
FLOOR BEARERS (SECOND STOREY)
Bolt bearers to wall tee brackets which are fixed to bottom storey wall panels and install joists, flooring sheets and walls as in Steps 4 and 5 above.
5.7
STEP 7.
ROOF SYSTEM
Place trusses, purlins, binders, barge, fascia and gutter. Fix gable end braces to gable ends if applicable. On hip roof, fix girder trusses first, then standard trusses between. Brace up roof where required and fix purlins. Attach gutter brackets, fascia/barge, gutter (valleys if applicable) and do not forget downpipe droppers. Frame up eaves and gables, fix ceiling and soffit battens, and fix soffit linings (where applicable).
5.8
STEP 8.
WINDOWS AND DOORS
Window frames are factory pre-fitted. Fixing of pre-hung door frames. Fit door furniture.
5.9
STEP 9.
SERVICES
Installation of plumbing and drainage. Run all electrical cables prior to plastering or installing ceiling. This work must be undertaken by a licensed Tradesperson.
5.10 STEP 10.
CEILING
Locate ceiling battens and fix ceiling linings.
5.11 STEP 11.
CUPBOARDS AND JOINERY
Install cupboards and fix skirtings, joinery and architraves.
6 UNLOADING AND STORING MATERIALS

If crane and forklift services are unavailable on the site, packs should be opened on the truck and manhandled to the ground. Check all items against Bill of Materials list.
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Components should be kept dry and under suitable covers during construction. Take special care of cement, plaster, etc. if provided. Stack materials into related component groups, ensuring access to all items is maintained. Timber linings and mouldings should be stacked carefully to prevent damage or warping. Learn names of components and how and where they are to be used. At each stage of the project lay out materials in the proximity of their eventual position. This will save time and increase the speed of erection. Extreme care should be exercised when handling glass. Windows should be supported and carried to the appropriate position according to the Panel Plans. Do not apply loads directly to glass.
6.1
Part Numbers
The major components of the wall have code labels affixed, which describe their size, type and finish. Each code number will have a corresponding number on the component layout plans within the drawings supplied, to assist in the erection of the house. Carefully check the location of each part on the plans before assembly. The erection process will be greatly assisted if parts are laid out or marked out prior to commencement. The product type is identified by a series of letters and numbers with the following meanings: A, B,C X, I W D 1 to 10 Prefix 45 SP = = = = = = = Width of the panel External or Internal panel Window panel Door panel Window height Diagonal panel Special Panel
6.1.1 Wall Components

Solid wall panels are prefixed with the type code which relates to width and whether the panel is an internal or external panel. Window panels are prefixed with the letter W and door panels with the letter D. The number following is a code, indicating the type, size and finish of the panels. The following quality control labels are affixed to panels Always check the product type label on solid wall panels to determine if the panel is an internal or an external panel (designated by an I or X respectively). Never use an Internal panel on an External wall. Electrical panels contain either single or double 48mm vertical ducts, which can be seen at either end of the panels. Always check for the existence of this duct before erecting external panels in accordance with the electrical layout. With windows and door panels a label advising the fitting of jambs and removal of packers is attached to the panels.
Figure 1 Panel Identification Sticker
Figure 2 Panel Identification Sticker 2
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6.1.2 Floor Components
It is not necessary to mark bearers and joists as the module length and type are self evident.
7 FOUNDATIONS
7.1 General
Foundations will comprise one of the following: Steel square hollow section (SHS) ordinary or braced stumps Concrete slab on ground. The details of the foundation for each project are part of the specific design in the project drawings.
7.2
Footings
7.2.1 Setting Out

It is important to note that the precise layout of footings is essential to the assembly of the system. The exact location of stumps /posts is critical at this stage of the construction. We recommend you have a Tradesperson on site for this procedure.
7.2.2 Boundary Pegs

Check survey information and boundary pegs. Ensure that the building is correctly sited on the block and that all Local authority requirements are met.
7.2.3 Corners
Mark corners of building with temporary pegs, roughly square by measuring diagonal distances and adjusting line position of the pegs until the diagonal measurements are equal. Check again that all pegs are still clear of boundary requirements.
Figure 3 Boundary Site Layout
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7.2.4 Profiles
Profiles are to support the string lines used in the setting out of the proposed new building. They are constructed using timber pegs, with timber horizontal rails nailed to the pegs at a determined height which is normally the top of finished floor level. The length and width of the building are marked onto the top edge of the horizontal rail. A nail is then fixed either side of the mark to identify the mark and make sure the string is always in the same position. You will then be required to write on the horizontal rail, the purpose of this string line, eg. building line, centre of stump, etc. Figure 4 Profiles (Stump /post Foundations)
After the profile pegs have been driven into the ground, the next thing to do is determine the floor height and mark it onto the corner peg. For a suspended floor, ground floor level must be a minimum of 650mm from finished ground level or to local authority requirements. For a concrete slab, the finished floor level must be poured to the local authority requirements. The dumpy level can now be set to the height. Transfer this mark to the other pegs and nail the horizontal rail onto the pegs with the top edge on the mark. Note: Make sure profiles are kept back from building line approx. 900mm when setting out the profiles.
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Figure 5 Inner profiles If the building has breaks in the building line, further profiles will be required. These can be constructed using 2 pegs and 1 rail.
Figure 6 String Line Profiles
7.2.5 Excavation
Check the specific design for stump /pile or/and foundation wall footing details. Excavate holes for footings in accordance with the project requirements and clean out all holes carefully.
7.2.6 Stump /Post Foundation Types

Refer to the specific design for layout of braced and ordinary stumps /posts. Lengthen bracing set to its maximum extension and position other end diagonally across bay to the bottom of the next stump /pile. Mark and drill dia.17mm hole through stump /pile and fix bracing with M16 x 120 bolts
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Figure 7 Cross Bracing
7.2.7 Stump /Pile Length and Set-Out

The length of stumps /posts will very dependant upon the slope of the land. Position stumps /posts beside the respective holes. (Refer to the Site Footing Plan).
Figure 8 Measure and Align Stumps /posts to stringline
7.2.8 Position
Support the whole assembly over the excavation so that the stump /pile is accurately located to the centre of the grid line and to the string lines strung from profiles. The bottom of the stump /pile should be at least 150mm above the bottom of stump /pile hole.
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7.3 Concrete
Figure 9 Stumps /posts - concreting details Check that the structure is both square and level. Subject to an inspection of the footing by local Building Inspector or Certifier, concrete can be poured to all foundations. Stumps /posts should be temporarily supported while pouring and compacting the concrete. Care should be taken not to disturb the structure during the pouring of concrete. Check the final position of the stumps /posts before the concrete sets. Adjust position as necessary and recompact the concrete ensuring all stumps are plumb.
7.4
Pour the Concrete Slab
Force 10 recommends that you employ tradespersons to complete the slab. The concrete slab is a very important part of the construction and if it is not completed in a satisfactory manner then there will be trouble all the way through construction of the building. Concrete slab-on-ground foundation details (where applicable) will be in accordance with a specific design based on a soil investigation (A minium of 20 MPa is the Design Strength). Specific designs will detail all elements necessary, such as ground beams and stumps /posts and also give the details for slab mesh and other foundation requirements. Items to check as work progresses on the slab are: The building has been sited in the correct position on the section of land The drainage contractor has completed all under slab drainage and has council approval Stumps /posts and ground beams are constructed in accordance with the specific design When used the polythene damp proof membrane is in place and all joints are taped together All reinforcing steel is correct Accurate formwork dimensions
Note: If required by the local authority to be installed care must be taken not to puncture the damp proof membrane and any joins and holes must be taped. For slab on ground construction the flashing fitted over the joint between the wall panel and the edge of the slab must lap at least 50mm with the damp proof membrane (DPM) so that the wall/floor bracket is protected from external moisture. Bolt the wall panels to the slab at each end using the 85 x 50 x 8mm yellow zinc coated steel wall floor brackets. Refer to the fixing appendix attached to the manual for the correct fixing to be used.
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8 FORCE 10 FLOOR SYSTEM
8.1 Bearers at Ground Floor
Starting at one corner, align the two (2) holes at end of bearer with bolts attached to stumps /posts
Figure 10 Fix bearer Abut next bearer and continue to secure bolts and washers.
Figure 11 Adjoining bearer At the corner, simply lap flanges of bearers, align holes in lapped top flanges with M16 tapered bar and secure the position by fixing a wafer Tek screw in the corner.
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Figure 12 Corner bearers on stumps /posts Where a bearer intersects with a row of bearers:
Figure 13 Intersecting bearers
Cut the top flange of the bearer only to accommodate intersecting bearers The slot is to be formed on site
Figure 14 Intersecting bearer on stump Insert web of intersecting bearer into gap between flanges of abutting bearers. Locate holes over the stumps /posts. Align holes in top flanges with M16 tapered bars. Secure bottom flanges to stump /pile with bolts, nuts and washers.
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Again check that all bearers are level and at the required height. If levelling is required, locate highest point, jack and support all other bearers to this level.
8.2
Floor Joists
Distribute floor joists in accordance with the Floor Framing plans. Stack the floor joists into related module sizes, ensuring access is maintained. Before fixing any floor joists, start from one end and set out the floor joists at the centres shown on the Framing plan. Locate the ends of floor joists between flanges of bearers at each of the 5mm pre-punched holes. The centre line of the floor joist flanges should be aligned to these pre-punched holes. Fix one joist in place with 10-16 x 16 wafer Tek screws through these holes into both the top and bottom flanges of the joist.
Figure 15 Joists to bearers Note: Joists are more effective if they are rotated and not clipped in facing the same way Where non-load bearing / non bracing wall panels run between floor joists, the detail is as shown in Figure 16 and no blocking is required.
Figure 16 Non load bearing and non bracing panel
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Figure 17 Floor system overview of components
8.3
Floor Sheeting
Particleboard flooring sheets supplied with each kit set are 3600 x 900 x 22mm thick and have a polypropylene tongue. Plywood flooring sheets can also be used as a flooring alternative provided all edges are supported by floor framing. Always start on the long side of the building making sure that the first sheet is parallel to the outside of building. The sheeting should finish flush with, but not extend past the exterior edge of the bearer flange. Adhesive is to be applied to all floor joists and bearers. Remove oil and dust from all surfaces. Apply the adhesive only to small segments at a time to ensure good bonding to the flooring.
Figure 18 Applying adhesive Note: Great care must be taken with the first run of flooring, ensuring that the edges of the first sheet are placed at the end of the first run. This eliminates waste and ensures that joints are staggered, thus providing a stronger floor.
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Figure 19 Staggered floor sheets Adhesive used should be modified acrylic adhesive suitable for bonding timber to metal (i.e. Ramset Safe-TBond or similar). The flooring is then to be screwed using 10-16 x 45 CSK wing Tek screws to every joist and bearer. Perimeter edge fixings should be spaced at 150mm centres maximum. Intermediate fixings should be spaced at 200mm centres maximum. Note: Refer to the flooring manufacturers specifications for more detailed information.
Figure 20 Floor Sheet fixings Fixings at perimeter bearers should be staggered so that the floor sheeting is restrained by both flanges of the bearer. When sheet flooring is used as part of a diaphragm screw fixings are required at 150mm centres around the perimeter of each sheet and at 200mm centres to intermediate supports. Where polypropylene tongue jointers are used, additional screw fixings are required at joist crossings as shown. When sheet flooring is used as part of a diaphragm floor screw fixings are required at 150mm centres around the perimeter of each sheet and at 500mm centres to intermediate sheets. Where polypropylene tongue joins are used additional screw fixings are required at the joint crossing as shown in Figure 22.
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Figure 21 Panel sheet layout
Figure 22 Sheet joint and diaphragm floors Note: Compressed Fibre Cement Floor Fixing is 10-16x45 SEH Wing Tek Hint: Dot drill the floor sheet with a masonry drill to get the head of the screw below the finish sheet line. Nogs are required for the long side of the sheet and joints screwed with 10-16x25 Hex Tek. Ensure Hydro Epoxy is applied to all butt joints of the sheets see the manufacturers instructions.
8.4
Floor Flashing
Fit the Stainless Steel wall/floor flashing from edge of flooring and between the flooring and bearer. Note: This flashing must be fitted before erecting the wall panels. The flashing will carry on around the perimeter of the building. This flashing can be fixed after the flooring has been laid. Note: Inspect the joint regularly for sealant separation on the outer flashing and replace as necessary.
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Figure 23 Wall /floor flashing
8.5
Bearer Cover
After all external wall panels have been erected, the Wall Bearer Flashing can now be fixed. This flashing is wrapped over the bearer profile and screwed off.
Figure 24 Wall bearer flashing At decks/patios, a smaller but similar (to Wall Bearer) Deck Bearer Flashing is fixed to sit over the timber decking and wrapped over the bearer profile and screwed off.
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Figure 25 Deck bearer flashing These flashings will carry on around the perimeter of the building and decks. At corners, trim and fold Wall Bearer/Deck Bearer Flashing as per diagram. Run a bead of silicone between all overlaps and fix tabs with pop rivets. Note: Corner of flashing should be mitred to assist placement of bearer cover and prevent penetration of water into floor sheeting.
Figure 26 Flashing - Mitred details
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Internal /External Flashing Details
Wall Deck Flashing
Wall /Floor Flashing
Wall /Slab Flashing
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9 FORCE 10 WALL SYSTEM

9.1 The Grid System
The assembled floor frame has groups of four (4) 14mm holes at every 500mm centres in the bearers. These holes should be used to establish the location of the 1000 grid on the floor sheeting and for fixing of floor brackets at the intersection of grids. A grid line occurs at every second group of holes at the centre of the four (4) holes layout.
Figure 27 Grid location After accurately chalking out all the grids on the flooring, mark location of the wall panels and identify their panel codes from the Panel Layout plan.
Figure 28 Chalk out grid lines
9.2
Wall Floor Brackets
Find the position and direction of floor brackets at ends of each panel. Drill two (2) 12mm holes through the flooring to align 10mm bolt holes in the bracket. It is important that these holes accurately align with two of the pre-punched holes in the top flange of the bearers. This may be achieved by drilling through the floor at centre of the pre-punched holes with a small electric drill using a 3mm (1/8) bit. Alternatively, the four holes layout can be determined from the intersection of the chalked grid lines.
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When drilling through the top flange of the joist to fix wall brackets and flooring ensure that all swarf is removed from the lower flange of the floor framing members.
Figure 29 Hole layout Locate bracket with vertical leg directly over the intersection of the grid and fix to floor with two M10 bolts. Ensure placement of washers on bearer side of fixing.
Figure 30 Wall/floor bracket Note: All external panels and any other panels that are positioned over a bearer must be fixed through the floor and bearer with two M10 bolts. For any non-load bearing and non-bracing internal wall panels which are not positioned over a bearer, no drilling is required, the brackets are fixed with two M10 x 50 bolts or 2/14-10x50 Hex Tek Type 17 Screws through the two smaller holes in the floor brackets. For a concrete slab situation, place Brackets over M12-120 epoxied in threaded rod. Refer to Figure for installation details.
Figure 31 Slab hold down bracket
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9.3 General Epoxied Installation Guidelines (Refer to Specification)
Drill a hole to the size and embedment required.
Blow the hole clean with compressed air, brush the hole, and blow it clean again. Holes should be clean and sound. They may be dry or damp, but should be free of standing water or frost.
Be sure to properly balance the mixing nozzle prior to dispensing and when changing cartridges. Fill the hole approximately half way with epoxy starting from the rear of the hole. Slowly with the static mixing nozzle as the hole fills to avoid creating air pockets within the hole. Push the threaded rod into the hole while turning slightly to ensure positive distribution of the epoxy. Be sure the rod is fully seated at the bottom of the hole and that some epoxy has flowed from the top of the hole. The threaded rod should be free of dirt, grease, oil, etc.
Allow the epoxy to cure for the specified time prior to applying any load. Do not disturb or load the anchor until it is fully cured.
Figure 32 Epoxy Installation guidelines (Internal 90mm and External 120mm)
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10 FORCE 10 WALL PANEL SIZES AND CODING
The Force 10 wall panel system which consists mainly of two sizes of panels in each of the single module, double module and 45 degree infill panels.
Figure 33 Single module panels
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Figure 34 Double module panels
Figure 35 45 Degree module panels Document Reference: CONSTRUCTION MANUAL_Ver2.doc 11/03 Page 30 of 68
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Panel heights are 2435mm, 2700mm and 3000mm. windows and doors. Wall panels are either solid or leave openings for
The type of sheeting on wall panels is dependent upon the type of wall finish required. Generally, the outside sheeting of exterior panels is Fibre Cement textureline board whilst the external face is bevelled edge Fibre Cement Board to provide a bond for plastering. Both external and internal panels have PVC conduits for electrical wiring. Panels are symmetrical, so they are able to be fixed to the floor using either end (top and bottom). This feature allows conduit placement to be either on the left or on the right side of the panels.
10.1 ERECTING EXTERNAL WALL PANELS

Always start erecting wall panels at an external corner and work around it. At any external corner one panel will end on grid intersection and one panel will be off grid (i.e. typically these panels would be 1000mm and 962mm respectively.)
Figure 36 Corner floor bracket layout At the corner, establish which wall panel will end off the grid line intersection (i.e. 1000mm panel). Drill two adjacent 12mm holes through the flooring, directly below the on-grid panel, to match the holes in the end of the bearer. This method will be similar for a concrete slab-on-ground; this will mean that on-grid panel (1000mm) will be fixed to the cast-in external M12 bolt via the Floor Brackets in lieu of drilling or by the epoxy bolt system..
Figure 37 Corner floor bracket layout - Slab floor Commence by bolting the first two Floor Brackets of the long wall to the suspended floor concrete slab or foundation wall. NOTE: The horizontal legs of these two brackets should face each other. Then bolt down the bracket for the end wall panel so that its horizontal leg faces toward the corner. Document Reference: CONSTRUCTION MANUAL_Ver2.doc 11/03 Page 31 of 68
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Continue bolting brackets around the perimeter allowing for doors and windows. All external brackets should be securely bolted to the floor/slab and flashing fixed prior to erecting panels. See the previous note re the Stainless Steel Flashing.
Figure 38 Corner intersecting panel Refer to panel layout drawing and select panels. Check coding on panel label against layout drawings. Raise panel between floor brackets. Align holes in bottom of panel with holes in the upright of Floor Brackets and fix M16 bolts in place. Insert Truss Bracket to top of panel and fit M16 bolt through the studs and Truss Bracket. Secure Structural tie angles with four 10-16x16 wafer Tek screws, each at equal spacings. Tighten the M16 nut and check for plumb in two directions. Fix structural tie angles top and bottom of panels with 10-16x16 wafer Teks.
Always start walls by erecting both panels at an external corner and erect the first panel of each intersecting wall as work progresses. This will provide a stable and plumb wall that will resist damage which could be caused by a wind gust.
10.2 EXTERNAL PANEL RUNS

Working from an erected corner, check location and fixing of Floor Bracket at next grid. Panel Alignment Brackets must be fixed between studs of all adjoining panels to ensure correct alignment of walls. Generally, single solid panels and single window panels require two Panel Alignment Brackets each located about 1/3 from the top and bottom of panels. Undo M16 bolt at Floor Bracket below, raise next panel into position ensuring the floor flashing engages at bottom and re-fasten the M16 bolt to fix the bottom studs of both panels to the floor bracket. At top of panels place a Truss Bracket between adjoining studs and fix together with a M16 x 32 bolt. Continue this process for the remaining panels in the wall. Erect the first panels of intersecting walls as approached.
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Figure 39 Panel Erection Runs
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10.3 ERECTING DOUBLE JOINERY PANEL

Erection of these panels is similar to that of external solid wall panels. NOTE: Adjoining studs of door and window panels should be fixed together, 300mm either side of the mid point of the opening using 12-14x30 Hex Tek screws. For Double Joinery Panel (external or internal), remove bolt from top of lintel and screw fix a M12x250 threaded rod into hole. The B size double panels have two 12mm holes @ 38mm centres in the lintel head. Use only the hole from one end which directly falls over the grid when fixing trusses (i.e. 1000mm from the nearest truss bracket). Place Window Head Support Bracket over the threaded rod. Note: The bolt that has been removed can be saved for the use of the 45 Bracket as described in the following sections.
Figure 40 Window head support
10.4 ERECTING INTERNAL WALLS

All internal walls should be erected before trusses are placed. All wall panels must be fixed to both floor and truss to meet structural requirements. The exception to this is non-load bearing walls which run between and parallel to floor joists. These walls must be fixed to ceiling battens using the Truss Bracket.
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10.5 PLASTIC COVERSTRIPS

External wall panels are finished with textured board on the outside face and flat finish board on the inside face. Interior lining is tapered edge board. If this is the case on your Force 10 kit, you will then be required to insert a patterned PVC jointer strip into joints between abutting external panels. The jointer is inserted during erection of external panels. The tongue of these cover strips should be notched so as not to interfere with the connection brackets between the panels. In most cases this will require notching at the top, bottom and in the centre of the cover strip. Leave at least one barb on the tongue. Use a timber off-cut of about 600x100x50mm as a softener when hammering in cover strips to prevent bruising and this will also keep cover strips straight. Figure 41 Textureline PVC Cover strip
Figure 42 External corner PVC cover strip
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10.6 INTERNAL WALLS
The system for locating internal walls is through the use of the four hole floor layout as described in the The Grid System section. When erecting an internal wall panel: determine the location of the wall align to grid and fix floor bracket by two M10x50 bolts for floor system or one M16 hex head bolt with Loxin shield for concrete slab. raise the panel and fix into place insert the Truss Bracket between top of panels.
Figure 43 Internal wall fixings - Wall panel on gridline Where possible place the long sheet sides of internal panels to face the wet areas. This will allow easier sealing at the floor.
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Figure 44 Internal wall fixing Wall panels off gridline
Figure 45 Internal wall panels Wall panels on concrete slab on ground
10.7 ERECTING DIAGONAL WALL PANELS

Refer to Panel Layout plan and select the appropriate panel. Raise panel into position and align 45 Degree Bracket to stud holes at the top and bottom of adjoining panels. Note: It is important to note the 45 Degree panel is not actually at 45 Degrees Refer to Figure 53. Position 45 Degree Brackets to each corner of the panels, insert stud on bracket through M16 hole in 45 degree Panel Stud, fit washer and secure nuts.
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Figure 46 Diagonal panel fixing These 45 Degree Brackets should be used to fix the top and bottom of diagonal panels to adjoining panels and are used in conjunction with Floor Brackets and Truss Brackets.
Figure 47 45 Degree floor bracket NOTE: The centre line of the 45 Degree Panel does not line up exactly with a line drawn between grid line intersections.
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Figure 48 Diagonal panels Shifting of centreline
11 FORCE 10 TWO STOREY CONSTRUCTION

11.1 TWO STOREY CONSTRUCTION
Two storey construction is similar to single floor construction. The ground floor and walls are constructed in exactly the same manner. However, at the top of the ground floor wall, different brackets are used to fix the floor structure of the upper floor (also referred to as First Floor). The floor structure uses the same components as the ground floor, although the layout and brackets may be different. Flashing also varies.
11.2 BEARERS OVER GROUND FLOOR WALLS

When bearers are supported by ground floor walls, the Wall Tee Brackets are used to provide the structural connection. This bracket is fixed between the top of adjacent panels with an M16 bolt in the same manner as fixing a Truss Bracket.
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Figure 49 Wall Tee bracket
Figure 50 Bearers supported by ground floor panel Bearers are bolted to the bracket with four M10x25mm bolts at the intersection of each panel. The majority of these bearers are perimeter bearers of the first floor.
11.3 BEARERS OVER GROUND FLOOR DOUBLE PANELS

Where bearers sit over double joinery window or door panels, locate the M12 hole on top of the lintel. This hole is in the centre of the lintel. Thread a M12 x 220mm threaded rod down into the hole until the top of the rod is about 10mm below the top of the panel. Loosely thread two locknuts onto the rod. Align the top of a lintel bearer plate to the top edge of the panel and centre of the middle hole directly over the rod.
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Figure 51 Lintel bearer plate Thread the M12 rod into the plate stopping it flush with the top of the plate. Secure by tightening the locknuts, one each against the plate and lintel. Bolt bearer to bracket with M10x25mm bolts and nut.
Figure 52 Lintel bearer plate to bearer
11.4 FLOOR JOISTS

Distribute floor joists in accordance with Floor Framing plans. (Stack floor joists into related module sizes, ensuring access is maintained). Before fixing any floor joists, start from one end and set out the floor joists at the centres shown on the Framing plans. Locate the ends of floor joists between flanges of bearers at each of the 5mm pre-punched holes. The centre line of the floor joist flanges should be aligned to these pre-punched holes. Fix 1 off 10-16 x 16 wafer Tek screw through these holes into both the top and bottom flanges of the joist.
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Figure 53 Joists to bearers Floor sheeting to upper floor may then be fixed to bearers and joists. Great care must be taken with the first run of flooring, ensuring that the edges of the first sheet are placed at the end of the first run. This eliminates waste and ensures that joints are staggered, thus providing a stronger floor. Note: Floor nogs may be required for compressed fibre cement flooring. Refer to Section FLOOR SHEETING for fixings.
11.5 TWO STOREY CEILING BATTENS

Ceiling battens for ground floor of two storey construction are continuous C Section which are fixed to the underside of the joists. These are used to fix the top of non load bearing walls.
Figure 54 Two storey ceiling battens Truss Brackets are used at the top of adjacent panels in these instances in lieu of a Wall Tee Bracket. Drill a 12mm hole in the middle of the Ceiling Batten, fit hole over truss bracket and secure with M12 flanged nut. Fix the ceiling battens to the underside of joists with 10-16x16 Wafer Tek screws.
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11.6 TWO STOREY FLASHINGS
Around the perimeter of the upper floor, fit the Stainless wall/floor flashing so that it covers the flooring and the bearer.
Figure 55 Fitting wall/floor flashing Upon erection of the upper floor walls, lay a 5mm bead of silicone sealant on the top face of the flashing. After all external wall panels have been fix the two storey wall bearer flashing. This flashing capped over the wall floor flashing and over the bearer profile and screwed off, ensures a good continuous bond between the flashing and the top flange of cover.
Figure 56 Two storey galvanised flashing The construction of the remainder of the building is as previously described for single storey construction.
12 FORCE 10 POST AND BEAM SYSTEM

The details which follow in this section are typical and shall be confirmed or varied by a specific design for each project as appropriate. It is assumed that these parts of the system are fully enclosed with claddings and linings.
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12.1 75X75 RHS WALL POST / COLUMN
The following column specifications are normally used for all Force 10 wall columns: 75 x 75 x 3.0 SHS 75 x 75 x 5.0 SHS These columns are used in various places throughout the building (i.e., between wall panels, stand alone supporting carport and support structural steel).
12.2 COLUMN BETWEEN PANELS

These columns are situated between several wall panels in various combinations. (Refer to the figures below).
Figure 57 One way column
Figure 58 Two way column
Figure 59 Three way column
Figure 60 Four way column
Column faces are fabricated with pre-drilled tapped holes or brackets for connection to wall panels or beams. These connections vary to accommodate their purposes and positions. The column face that connects to wall panels has a 17mm diameter hole with M16 Kwikspan nut welded to the inside of column wall, top and bottom. This is known as side option P. This face will be positioned next to a wall panel and will be bolted together with M16x32 Kwikspan bolt to top and bottom.
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Figure 61 Column to panel connection
Figure 62 Column to panel connection
12.3 RHS BEAMS

The following beam specification is used for most Force 10 truss beams: 125 x 75 x 3 RHS
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These beams come in lengths of 1 module, 2 module, 3 module and on a rare occasion, 4 modules. They are used for supporting trusses and outrigger rafters over carport areas. All beams have pre-drilled holes for bolts connecting to trusses, and to columns use 12-24x32 Series 500 Hex Teks.
Figure 63 Beam to truss fixings RHS beams are fixed to the column (post) bracket with four (4) 12-24 x 32 series 500 hex Tek screws at each end and using one (1) M12x250 cup head for the remainder of the intermediate holes to truss bottom chord fixings. Where beams meet perpendicular to a wall, the RHS beams are fixed to a similar bracket at the panel junction, also with four (4) 12-24x32 series 500 hex Teks. Note that two (2) 14-10x25 Hex Teks are used to locate this bracket centrally with a 3mm gap at the top, and four (4) 12-14x30 Hex Teks to screw the bracket into the panel studs.
Figure 64 Beam to column fixings
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Figure 65 Beam to panel junction At external corners where beams require connection, the method is the same as above, but a stud section and 6mm fibre-cement packer need to be fixed within the void of the external corner to provide a similar connection.
Figure 66 Beam bracket to external corner panel
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13 FORCE 10 ROOF SYSTEM
13.1 ROOF
Erection of roofing can be greatly simplified by undertaking some preliminary work prior to raising of trusses. This work includes: Marking out and fixing of location screws for purlins Fixing of gable end framing and Marking centre lines of grid on top chord if trusses support diminishing trusses.
Figure 67 Factory assembled trusses
13.2 TRUSS ASSEMBLY

Trusses are manufactured and assembled on the Force 10 factory floor ensuring that every component is fitted and screw fixed in place, ready for transportation to the job site. Trusses can also be assembled and then dismantled for containerising ready for shipment to an overseas job site. They are then unloaded on site and ready for re-assembly. All connections are labelled to allow ease of reassembly.
13.3 PRELIMINARY WORK

Stand standard trusses side by side so that they align accurately with each other. On the top chords, mark locations of lower edge of the purlins, using a string line. Refer to Truss Framing plan for purlin spacing.
13.4 FIXING OF TRUSSES

Check that all Truss Brackets are vertical and tightened securely. Lower standard trusses, ensuring the trusses run across the house, as per plan over the 125mm truss brackets through the hole provided at the intersection of the top and bottom chord at the external walls. Place 20 degree truss washers over the rod and top chord and tighten with M12 flanged nut.
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Figure 68 Truss fixing details
13.5 GABLE END ROOF

The trusses at gable ends must be framed to support exterior sheeting. This framing should be fixed before the truss is raised and bolted in position.
Figure 69 Typical gable end truss
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Figure 70 Gable End Detail Fix 40mm x 65mm angles to the outer flange of the top chord of gable end truss with 10-16 x 16 wafer Teks. Fix the pre-cut top hat section gable end vertical struts to angles with 10-16 x 16 wafers at the top and with 1410 x 25 at bottom to truss bottom chord. Gable end struts should be spaced at 500mm centres.
Figure 71 Gable end truss assembly #1 Raise and bolt trusses into place at end of building (Section Fixing of Trusses) Check that the gable end trusses are plumb, the gable end trusses are braced (roof space brace) with a length of top hat section fixed at the top chord of the gable end trusses and tied back to the binder which is fixed to the top of the bottom chord of all trusses.
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Figure 72 Gable end truss assembly #2
Figure 73 Gable end roof space brace
13.6 TRUSS BINDERS

Check that all trusses are true and vertical. Run two rows of top hat section down the length of the building on top of the bottom chord of trusses, as per engineers drawings. Fix Truss Binders to each truss with two 1410x25 Hex Tek screws.
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Figure 74 Truss binders
13.7 ROOF PURLINS

Roof purlins are in modular lengths and must be fixed so that the purlin ends finish on a grid line or the centre line of truss top chords. The different Module lengths are used to stagger purlin joints.
Figure 75 Purlin joints Place purlins in position resting against locating screws, fix flanges to truss top chord with four (4) 14-10 X 25 Hex Tek screws. The purlin location screw may be re-used after securing on flange).
Figure 76 Purlin location screws
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Figure 77 Purlin location Details
Figure 78 Purlin location screws
13.8 EAVES PURLINS

A special purlin for a gable roof which overhangs the gable end, and provides support for soffit linings and barges
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.
Figure 79 Gable end purlins These purlins are placed in line with the other purlins running the length of the building. Place these purlins on top of the last two (2) trusses so that the part which supports the soffit lining rests on the top chord bottom flange and abuts to its web.
Figure 80 Gable end purlin details Fix the rear end of the gable end purlins to the centre line of the second truss top chord with two (2) 14-10 x 25 Hex Tek and then four (4) at the gable end trusses.
13.9 HIP ROOF ASSEMBLY

The hip roof is erected in a similar manner to the conventional roof. All structural framing components are erected over grid lines for ease of location.
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Figure 81 Typical hip end roof layout
Figure 82 Hip end bottom chords
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13.10 GIRDER TRUSSES
Assemble and raise Girder truss #1 over the first grid back from the end wall and secure with flanged nuts and the 20 Washer to the Truss Brackets as previously described for the fixing of standard trusses.
Figure 83 Typical girder truss Continue to erect the remaining girder trusses which have #2, #3, or #4 as their coding. To close in the one (1) metre gap between the end walls and Girder Truss #1 for ceiling lining, use a top hat section called a Hip End Bottom Chord.
Figure 84 Fixing hip end bottom chords Place the hole ends of Hip End Bottom Chords over the truss brackets along the end walls. Fix other end of hip end bottom chord to flange of Girder Truss #1 bottom chord with two (2) 10-16x16 wafer Tek screws. These screws should be fixed from the underside of the flange so as not to interfere with laying of ceiling sheeting. These Hip End Bottom Chords are spaced at every 1000mm centres starting from side walls.
Figure 85 Corner assembly
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Notch one web of the Hip End Bottom Chords at corners (over side walls) so as not to interfere with the flange of the angled top chord of Girder Truss #1.
Figure 86 Fixing centre jack rafter at apex
Figure 87 Hip roof module sizing and framing layout Document Reference: CONSTRUCTION MANUAL_Ver2.doc 11/03 Page 57 of 68
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13.11 HIP PURLINS
Place a hip purlin each side of (and parallel to) the line of the hip ridge. These purlins should start in line with the end of trusses or jack rafters and follow the hip until they intersect with the ridge purlin from the other side.
Figure 88 Hip ridge purlins
Fix wherever they cross the jack rafters and top chords of trusses with two (2) 14-10x25 Hex Tek screws. Where hip purlins intersect with each other at apex of hip cut to lengths so that one flange of each overlaps and fix together with 14-10x25 Hex Teks.
Figure 89 Hip ridge purlins at apex Mitre the other hip purlins to run into and rest on bottom flange of the hip ridge purlins. Fix overlapping flanges with 14-10x25 Hex Tek screws.
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Figure 90 Fixing roof purlins to hip To be used in cases where portals are attached to the slab. The Threaded rod placed in position before concrete is set. The Portal is then secured in place with heavy-duty nut/washer.
13.12 EAVES LININGS

Fit ceiling batten to bottom chord of truss at wall. Nest edge of lining into groove at the back of fascia and fix in place.
Figure 91 Eaves linings
13.13 ROOF SHEETING

Roof sheeting systems, including cladding, flashings and fixings shall be installed in accordance with clearly presented and adequate technical literature supplied by the manufacturer.
13.14 GABLE END CLADDING

Gable end cladding, including cladding, flashings and fixings, shall meet the provisions of relevant standards.
13.15 SPOUTING AND FASCIA

Spouting and fascia shall be fit for purpose and meet the relevant provisions of the relevant standard. Spouting and fascia shall be fixed to truss chords in accordance with clearly presented and adequate technical literature supplied by the manufacturer. Spouting shall have a slope to facilitate drainage and the design shall ensure that if blockage occurs that overflow into the roof space will not occur.
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13.15.1
Fixing and Fitting Facia /Gutter Brackets (Fall)
There are various facia and gutter systems used and the appropriate tradesperson and manufacturers specifications should be used. Always ensure that there is adequate fall in the gutter to allow water to drain from the roof area. Refer Fig 91.
14 SOUND CONTROLS
These are various ways to reduce sound readings in a Force 10 building. Refer to the attached chart for roofing or contact Force 10 for further information regarding the use of CSR SoundChek.
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15 FIRE CONTROL
To improve the fire resistance rating of force 10 systems CSR Fyrchek can be used over the Fibre cement panels as attached drawing. For further information refer to Force 10 International.
16 INTERNAL JOINERY
16.1 CUPBOARDS
Fixing of cupboards will vary upon the type of unit and finishes. The units generally come pre-assembled to site and should be fixed to wall and sealed around edges to prevent dirt or moisture penetrating behind the unit. Always fasten directly into the steel panel studs when fixing units to walls.
16.2 SKIRTING BLOCKS

After all panels are erected, glue fix skirting blocks to flooring at 500 centres under open recess of panel with adhesive. The vertical face of these angles should be flush with the face of the panel. Allow the adhesive adequate time to set before fixing skirting.
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Figure 92 Skirting Blocks Skirtings should be fixed with 6-20 x 50 CSK Wing Tek screws. Where possible fix skirting after installation of plumbing and electrical services as this will allow easier location of services.
17 Services
17.1 PLUMBING
All plumbing services should be brought up through the floor, inside cupboards or from directly below the unit, as is the case with conventional construction. Cutting chases in bracing wall panels for plumbing services such as a shower combination will destroy the structural integrity of bracing wall panels. Wet walls (False walls) built out with surface mounted plumbing is a more acceptable practice. NOTE: DO NOT DRILL OR CUT STEEL JOISTS OR BEAMS WHEN INSTALLING SERVICES AS THIS MAY AFFECT THE STRUCTURAL CAPACITY OF THE SYSTEM.
17.2 ELECTRICAL
Electrical panels are provided to allow concealment of cables within the wall. These panels have a 45mm duct running vertically down one side. Care should be taken during construction to ensure that these are installed and correctly oriented where electrical services are required. The duct may be located by viewing either the top or bottom of the panel. To install switches and power outlets, simply cut as required through the sheeting and the duct. A hole saw may be useful for this purpose. Fix switches, etc., in the same manner as required when fixing to any other sheeted walls. Meter boxes should be fixed directly into panel studs.
18 CEILINGS
18.1 CEILING BATTENS
For single storey or the upper level of a two storey building, ceiling battens are run continuously at maximum 500 mm centres and fixed to the bottom chord flanges of trusses. All edges of plasterboard sheets must be fixed to ceiling battens.
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18.2 CEILING LINING

Ceilings shall meet the provisions of the building code except that 9.5 mm Standard Board ceiling lining shall be used and support is provided by ceiling battens at max 500 mm centres. Fixings are 6-20x25 bugle head Tek screws in conjunction with stud adhesive glue in accordance with the manufacturers instructions.
19 DOORS
19.1 DOORS
Two types of doors are used in the Force 10 building system:
aluminium sliding doors, see Section Walls timber primed external and internal doors.
Timber framed doors come to site sized, pre-hung and have solid jambs to provide simplicity in fixing. Select door frame to match panel opening. Check the type of door frame (external or internal), and its location. External doorframes have a thicker weatherproof door and a sill below the door. When fixing external doorframes, care should be taken to ensure that the bearer over/flashing engages correctly. To install door frames: Fit the frame on which the door is hung, into the panel opening Screw fix jambs into steel packers inside the wall panel stud Fit handles and latches to complete installation. Refer to the hardware manufacturers instructions for details.
Figure 93 Door frame finish
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Figure 94 Door fixings details drawing
Figure 95 Window /door packer detail fixings
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Figure 96 Window fixing detail drawing
Figure 97 Packer details
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20 FINISHING TRADES
20.1 TRADES
The finishing trades include plastering, painting, tiling, and carpet laying. Each trade varies considerably with each brand and type of finish chosen. Most of these trades require special tools and skills. Subcontractors should be used if you have had no previous experience. Refer to manufacturers specifications for instructions if you wish to do it yourself.
20.2 WET AREAS

In wet areas, such as bathrooms and laundries, tiles will often be used to finish the floor and walls. It is important to provide firm continuous support, at the back of tiles and flashings.
Figure 98 Wet area fixings Where possible, place the long sheeted sides of internal wall panels to face wet areas. At panels where sheeting does not extend to floor, fix 40x40 galvanised angle flashing support to floor. This angle should align with the face of the panel. Fix waterproof flashings to all flooring joints and internal angles between floor and walls. Seal flooring with a suitable epoxy sealer prior to laying mortar bed.
21 External Finishing
21.1 Window details
Figure 99 Window Reveals
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21.2 WINDOW COVERSTRIPS
To fit aluminium fixing cover strips to interior frames of windows: measure sides of window frame and select the appropriate size place the covers in position aligning mitred ends to each corner and press firmly home, fix with 1016x22 Wafer Head Tek Screws.
22 Finishing System
The exterior finish shall be either a latex based coating system or a proprietary plaster system. The latex based coating system must: Provide an effective barrier to liquid water Allow water vapour transmission Have a proven performance record on fibre cement material in exterior applications Be inspected, maintained and re-coated as necessary to ensure it remains weather tight.
22.1 External finish requirements

Ensure adequate ventilation during use Ensure the finish is of uniform colour and consistency Verify the manufacturers recommended preparation requirements are complied with The surface should be clean, dry and free of dirt, dust, grease, sap stains and any other contaminants The fibre cement panels must be clean and dry Do not apply the finish where there is a risk of rain and /or frost as product properties may be impaired Ensure that the air and surface temperatures are as the manufacturers specification. Avoid application in direct sunlight and windy conditions. Ensure metal etch primer is used on all exposed metal site cut surfaces.
22.2 Force 10 recommended external finishes 22.3 Facades

The Force 10 system can be finished in a variety of facades: English Cottage Dutch Mexican Adobe American French Tuscan refer to Force 10 for details Hebel external finishes are options and are specialised finishes where professional assistance is recommended. Document Reference: CONSTRUCTION MANUAL_Ver2.doc 11/03 Page 67 of 68
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22.4 Internal Finishing

Interior finishing is conventional, i.e. plastering and wall coverings or paint. Particular care must be taken in wet areas to ensure the performance requirements are met by ensuring moisture does not penetrate the wall joints. Note: Refer to CSR Technical Literature on board finishing. For best results the surface of the fibre cement panel should be primed with a high quality latex primer before painting, anti fungal additive is to be added to Wet Area Paints. The paint manufacturers instructions are to be followed in all cases.
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CONSTRUCTION MANUAL

CONSTRUCTION MANUAL BUILDING SYSTEMS FOR MODULAR HOUSING

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FORCE 10 WALL SYSTEM ......................................................................................................................................26 9.1

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Local Authority Requirements

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5 SUGGESTED CONSTRUCTION PROCEDURE

Using Stumps or a Post foundation:

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FLOOR BEARERS (SECOND STOREY)

WINDOWS AND DOORS

5.10 STEP 10.

Locate ceiling battens and fix ceiling linings.

5.11 STEP 11.

CUPBOARDS AND JOINERY

Install cupboards and fix skirtings, joinery and architraves.

6 UNLOADING AND STORING MATERIALS

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6.1.1 Wall Components

Figure 1 Panel Identification Sticker

Figure 2 Panel Identification Sticker 2

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7.2.1 Setting Out

7.2.2 Boundary Pegs

Figure 3 Boundary Site Layout

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Figure 6 String Line Profiles

7.2.6 Stump /Post Foundation Types

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Figure 7 Cross Bracing

7.2.7 Stump /Pile Length and Set-Out

Figure 8 Measure and Align Stumps /posts to stringline

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Pour the Concrete Slab

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Figure 13 Intersecting bearers

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Figure 16 Non load bearing and non bracing panel

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Figure 17 Floor system overview of components

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Figure 21 Panel sheet layout

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Figure 23 Wall /floor flashing

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Figure 26 Flashing - Mitred details

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Wall /Floor Flashing

Wall /Slab Flashing

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9 FORCE 10 WALL SYSTEM

Figure 28 Chalk out grid lines

Wall Floor Brackets

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Figure 31 Slab hold down bracket

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