Product 1.1 The Graphex Masonry Overlay System is an exterior insulating and finishing system for concrete masonry, in-situ or pre-cast concrete walls. 1.2 The system consists of Neopor®, a graphite composite board fixed to the concrete masonry or concrete wall with adhesive mortar and mechanical anchors. The coating system consists of a 3-4 mm thickness of fibreglass mesh reinforced, polymer-modified, cement-based plaster (Graphex Plaster System), or an 8-10 mm thickness of fibreglass Appraisal No.706 [2011] mesh reinforced polymer-modified, cement-based plaster (Graphex Solid Plaster System), which is finished with a cement-based finishing plaster that is then painted with a 100% BRANZ Appraisals acrylic-based paint system. The chosen finishing plaster is applied to give a range of different appearances, such as a sponge, patterned, adobe or spray textured finish. Technical Assessments of products for building and construction

BRANZ APPRAISAL No. 706 (2011)

graphex masonry overlay system

Nuplex Industries Ltd C/- PSL a Nuplex Division PO Box 40-130 Glenfield Auckland

Tel: 09 444 6440 Fax: 04 444 9561 Scope Web: www.plastersystems.co.nz 2.1 The Graphex Masonry Overlay System has been appraised as an exterior insulating and finishing system for buildings within the following scope: • with substrates of concrete masonry, in-situ or pre-cast concrete, up to 3 storeys, with a maximum height from ground to eaves of 10 m; and, • with floor plan area limited only by seismic and structural control joints; and, • with supporting structures designed and constructed in accordance with the NZBC; and, BRANZ Limited • situated in NZS 3604 Building Wind Zones up to, and including ‘Very High’. Private Bag 50 908 2.2 The Graphex Masonry Overlay System has also been appraised for bond/fixing, Porirua City durability and weathertightness of the exterior insulating and finishing system for concrete New Zealand masonry, in-situ or pre-cast concrete buildings subject to specific up to a differential Tel: +64 4 237 1170 design ultimate limit state (ULS) wind pressure of 2.5 kPa. Fax: +64 4 237 1171 2.3 The Graphex Masonry Overlay System must only be applied on vertical surfaces www.branz.co.nz except for sills, concrete reinforced parapets and concrete reinforced balustrades which must have a minimum 10° slope and be waterproofed in accordance with the requirements of the Technical Literature and building . 2.4 Installation of components and accessories supplied by PSL and approved installers must be carried out only by PSL approved installers.

Readers are advised to check the validity of this Appraisal by referring to the Valid Appraisals listing on the BRANZ website, or by contacting BRANZ. • Thermaclad is a fibre-reinforced, specially blended polymer- Building Regulations modified, Portland cement-based plaster supplied in 20 kg bags and mixed on site with clean drinking water. It is applied as the base coat in a minimum 5 mm layer. A 3 New Zealand Building Code (NZBC) mm thick layer is then applied as the second coat followed 3.1 In the opinion of BRANZ, the Graphex Masonry by the embedment of fibreglass mesh reinforcement in the Overlay System if designed, used, installed and maintained outer surface. in accordance with the statements and conditions of this • Ezytex is a polymer-modified, Portland cement-based Appraisal, will meet or contribute to meeting the following finishing plaster supplied in 20 kg bags and mixed on site provisions of the NZBC: with clean drinking water. It is available in three grades to Clause B1 STRUCTURE: Performance B1.3.1, B1.3.2 and provide a textured, patterned or sponge finish. B1.3.4. The Graphex Masonry Overlay System meets the requirements for loads arising from self-weight, wind, impact Paint System Specification and creep. [i.e. B1.3.3 (a), (h), (j) and (q)]. See Paragraphs • A latex exterior paint system complying with any of Parts 10.1 – 10.3. 7, 8, 9 or 10 of AS 3730 must be used over the finishing Clause B2 DURABILITY: Performance B2.3.1 (b), 15 years plasters to make the system weathertight and give the desired and B2.3.1 (c), 5 years. The Graphex Masonry Overlay System finish colour to exterior walls. Paint colours must have a light meets these requirements. See Paragraphs 11.1 and 11.2. reflectance value of 40% minimum regardless of gloss value. Clause E2 EXTERNAL MOISTURE: Performance E2.3.2. The Proprietary paint systems have not been assessed and are Graphex Masonry Overlay System contributes to meeting this therefore outside the scope of this Appraisal. requirement. See Paragraphs 16.1 and 16.2. Accessories Clause F2 HAZARDOUS BUILDING MATERIALS: Performance • Reinforcing mesh - alkali-resistant fibreglass mesh with a F2.3.1. The Graphex Masonry Overlay System meets this nominal mesh size of approximately 4 mm square and a requirement and will not present a health hazard to people. weight of 150 g/m2 for use in domestic and light commercial Clause H1 ENERGY EFFICIENCY: Performance H1.3.1 (a) and situations. Where a greater of impact resistance is H1.3.2E. The Graphex Masonry Overlay System contributes to required, 360 g/m2 alkali-resistant fibreglass mesh with meeting these requirements. See Paragraphs 17.1 and 17.2. a nominal mesh size of approximately 3 mm square is available. 3.2 This is an Appraisal of an Alternative Solution in terms • uPVC components - base caps, corner beads, Z-flashing and of New Zealand Building Code compliance. horizontal and vertical control joint flashings. • Hilti IDP Insulation Fastener – IDP 2/4 fasteners for fixing 20 mm thick Neopor® boards and IDP 4/6 fasteners for fixing Technical Specification 40 and 60 mm thick Neopor® boards. The fasteners consist of an integrated 60 mm diameter polypropylene washer and 4.1 System components and accessories supplied by PSL sleeve. for the Graphex Masonry Overlay System are: 4.2 Accessories used with the plaster systems which are Neopor® Boards supplied by the approved installer are: • Neopor® boards are 20, 40 or 60 mm thick with an • Flexible sealant - sealant complying with NZBC Acceptable approximate density of 24 kg/m3. 20 mm thick boards are Solution E2/AS1, or sealant covered by a valid BRANZ supplied with additional 5 mm high ribs at approximately Appraisal for use as a weather sealing sealant for exterior 100 mm centres and are specifically for use with the use. Graphex Solid Plaster System. The boards are supplied in • Adhesive - polystyrene compatible adhesive for adhering ® lengths ranging from 2.4 to 3.6 m x 1.2 m wide and are uPVC components to the Neopor boards, as and where manufactured to meet the requirements of AS 1366 Part 3. required. Other board thicknesses are available on request. • Waterproof membrane tapes - Tapes covered by a valid BRANZ Appraisal for use as waterproofing membranes over Plasters (Graphex Plaster System) the top of plastered parapets balustrades, fixing blocks and • Glue Bond Coat Mortar is a polymer modified, cement-based the like. adhesive plaster. The plaster is supplied in 20 kg bags and is mixed on site with PSL Resin. It is trowel applied to the back face of the Neopor® boards prior to them being applied Handling and Storage to the wall. 5.1 Handling and storage of all materials supplied by PSL • Coarse Mesh Render is a polymer-modified, Portland or the approved installer, whether on or off site, is under the cement-based plaster supplied in 20 kg bags and mixed on control of the PSL approved installers. Dry storage must be site with clean drinking water. It is applied as the base coat provided for the fibreglass mesh and bags and pails of plaster in a minimum 2 mm layer followed by the embedment of mix. Neopor® boards, uPVC flashings and profiles must be fibreglass mesh reinforcement in the outer surface. Coarse protected from direct sunlight and physical damage, and should Mesh Render can also be used to achieve a spray textured be stored flat and under cover. Liquid components must be finish. stored in frost-free conditions. • Ezytex is a polymer-modified, Portland cement-based 5.2 Handling and storage of all materials supplied by the finishing plaster supplied in 20 kg bags and mixed on site building contractor, whether on or off the site is under the control with clean drinking water. It is available in three grades to of the building contractor. Materials must be handled and stored provide a textured, patterned or sponge finish. in accordance with the relevant manufacturer’s instructions. Plasters (Graphex Solid Plaster System) • Glue Bond Coat Mortar is a polymer modified, cement-based adhesive plaster. The plaster is supplied in 20 kg bags and is mixed on site with PSL Resin. It is trowel applied to the back face of the Neopor® boards prior to them being applied to the wall. 2 Technical Literature Structure Impact Resistance 6.1 Refer to the Appraisals listing on the BRANZ website 10.1 The system has adequate resistance to hard body for details of the current Technical Literature for the Graphex impacts likely to be encountered in normal residential use. Masonry Overlay System. The Technical Literature must be Where a greater level of impact protection is required a heavier read in conjunction with this Appraisal. All aspects of design, grade of reinforcing mesh may be used. The heavy-grade use, installation and maintenance contained in the Technical fibreglass reinforcing mesh (360 g/m2) embedded in 5 mm thick Literature and within the scope of this Appraisal must be plaster provides approximately 4 times the hard body impact followed. strength of the standard grade mesh in 3 mm thick plaster. The likelihood of impact damage to the system when used in light commercial situations should be considered at the design stage, Design Information and appropriate protection such as the installation of bollards and barriers should be considered for vulnerable areas. Wind Zones Solid Substrates 10.2 The system is suitable for use in all Building Wind Concrete Masonry Zones of NZS 3604 up to, and including, ‘Very High’ where 7.1 Concrete masonry must be designed and constructed buildings are within the scope as detailed in Paragraph 2.1, or in accordance with NZS 4210 and either NZS 4229 or NZS up to a differential design ULS wind pressure of 2.5 kPa where 4230. The concrete masonry walls must be fully grouted. buildings are specifically designed. In-situ and Pre-cast Reinforced Concrete Neopor® Board 7.2 In-situ and pre-cast reinforced concrete walls must be 10.3 Neopor® boards must be installed in a brick pattern. specifically designed in accordance with NZS 3101 and AS/NZS Glue Bond Coat Mortar must be applied to the back face of 1170 using the design guidelines. the panel with a notched trowel. After adhering the Neopor® boards to the wall and leaving to set overnight, the panels must be mechanically fixed with the selected anchors at 600 mm General horizontal and vertical centres along the panel edges and in the 8.1 When the Graphex Masonry Overlay System is used middle of the board. for specifically designed buildings up to a differential design ULS wind pressure of 2.5 kPa, only the bond, durability and weathertightness aspects of the Neopor® boards, plaster and Durability finishing system are within the scope of this Appraisal. All other 11.1 The Graphex Masonry Overlay System meets the aspects of the building need to be specifically designed and are performance requirements of NZBC Clause B2.3.1 (b), 15 years outside the scope of this Appraisal. for the plaster system, and the performance requirements of 8.2 A minimum of 28 days must be allowed following NZBC Clause B2.3.1 (c), 5 years for the exterior paint system. placement of the concrete or grout before the installation of the Serviceable Life Graphex Masonry Overlay System begins. The approved installer 11.2 The Graphex Masonry Overlay System is expected must be satisfied that the substrate is sufficiently cured and dry to have a serviceable life of at least 30 years provided it is before starting. maintained in accordance with this Appraisal, the Neopor® 8.3 The ground clearance to finished floor levels as set boards, fixings and plasters are continuously protected by a out in NZBC Acceptable Solution E2/AS1, Table 18 must be weathertight paint system and remain dry in service and the adhered to at all times. NZBC external moisture and internal moisture provisions are 8.4 Where the system abuts other cladding systems, met. must detail the junction to meet their own requirements and the performance requirements of the NZBC. Details not included within the Technical Literature have not been assessed Maintenance and are outside the scope of this Appraisal. 12.1 Regular maintenance is essential for Graphex Electrical Cables Masonry Overlay System installations to continue to meet the 8.5 PVC sheathed electrical cables must be prevented from NZBC durability performance provision and to maximise their direct contact with the Neopor® boards. When cables must serviceable life. penetrate the Neopor® boards for exterior electrical connections, 12.2 Annual inspections must be made to ensure that all the cable must be directly supported by passing through an aspects of the cladding system, including the paint coating electrical conduit. system, plaster, flashings and any sealed joints remain in a weatherproof condition. Any cracks, damaged areas or areas showing signs of deterioration which would allow water ingress, Control Joints must be repaired immediately. Sealant, paint coatings and the 9.1 Control joints in the Graphex Masonry Overlay System like must be repaired in accordance with the sealant or PSL’s must be constructed in accordance with the Technical Literature, instructions. and be provided as follows: 12.3 Regular cleaning (at least annually) of the Graphex • aligned with any control joint in the solid substrate; and, Masonry Overlay System is recommended to remove grime, dirt • where the system covers different solid substrates. and organic growth, to maximise the life and appearance of the coating. Grime may be removed by brushing with a soft brush, warm water and detergent. 12.4 Recoating of the paint system will be necessary throughout the life of the plaster system. The interval between recoats depends on the paint colour, orientation and quality of the application, and will be at approximately 5-10 yearly intervals in accordance with the instructions of PSL. 3 Control of Internal Fire and Smoke Spread 13.1 Neopor® board used with the system meets the flame Installation Information propagation criteria of AS 1366. It must also comply with the requirements of NZBC C/AS1 Part 6, Paragraphs 6.20.11 and Installation Skill Level Requirements 6.20.12. Where required by NZBC C/AS1 Part 6, Table 6.3, 18.1 Installation and finishing of components and accessories flame barriers meeting the requirements of NZBC C/AS1 Part supplied by PSL and the approved installers must be completed 6, Paragraph 6.20.13 and Appendix C, Paragraph C10.1 must by P.P.C.S. qualified tradespersons, approved by PSL. be provided. Concrete masonry, in-situ or pre-cast concrete is deemed to comply with these requirements but joints between panels and openings for penetrations must be designed to System Installation prevent flame contact with the Neopor®. Graphex Masonry Overlay System 19.1 Components and accessories supplied by PSL and Control of External Fire Spread the approved installer must be installed in accordance with the 14.1 The Graphex Cavity System has a performance level Technical Literature by PSL approved installers. A in accordance with NZBC C/AS1 Table 7.5. The system is 19.2 The Graphex Masonry Overlay System must only be suitable for use as an external wall cladding system on buildings applied when the air and substrate temperature is within the in all Purpose Groups, at any distance to the boundary. range of +5ºC to 30ºC. 14.2 On buildings of three or more floors where the cladding Inspections system extends to cover at least three floors, the requirements 19.3 The Technical Literature must be referred to during the for barriers to vertical fire spread as set out in NZBC Acceptable inspection of Graphex Masonry Overlay System installations. Solution C/AS1 Part 7, Paragraphs 7.9.18 and 7.9.19 must be met. Design of the barrier joint must be specifically detailed Finishing by the designer to meet the NZBC. NZBC Acceptable Solution 19.4 Insulcote or other paint manufacturers’ instructions C/AS1, Part 7, Figure 7.12 gives an acceptable detail for must be followed at all times for application of the paint finish. barriers. These joints are not covered by the Technical Literature, The plaster must be cured for a minimum of 2-3 days and must therefore are outside the scope of this Appraisal. be dry before commencing painting.

Outbreak of Fire Health and Safety 15.1 The Graphex Masonry Overlay System must be 20.1 Safe use and handling procedures for the components separated from chimneys and flues in accordance with the that make up the Graphex Masonry Overlay System are provided requirements of NZBC Acceptable Solution C/AS1 Part 9 for the in the relevant manufacturer’s Technical Literature. protection of combustible materials. Basis of Appraisal External Moisture 16.1 Graphex Masonry Overlay System installations when The following is a summary of the technical investigations installed and maintained in accordance with this Appraisal and carried out: the Technical Literature will contribute to the building meeting code compliance with NZBC Clause E2.3.2 by providing a weatherproof coating system to the substrate. Tests 16.2 The weathertightness detailing of junctions between 21.1 The following testing has been completed by BRANZ: the Graphex Masonry Overlay System and wall penetrations, • Tensile bond strength of the Graphex Masonry Overlay e.g. window and door joinery, meter boxes, and other cladding System to concrete masonry. and roofing junctions are the responsibility of the designer for • Cone Calorimeter testing of the Graphex Masonry Overlay compliance with the NZBC. Details not included within the System plasters over EPS. The testing was carried out in Technical Literature have not been assessed and are outside the accordance with AS/NZS 3837. scope of this Appraisal.

Other Investigations Energy Efficiency 22.1 BRANZ expert opinion on NZBC B1 code compliance Building Thermal Envelope for the Graphex Masonry Overlay System was based on the 17.1 NZBC Acceptable Solution H1/AS1 or NZBC Verification tensile adhesion strength of the Glue Bond Coat Mortar. Using Method H1/VM1 can be used for housing, communal residential, the data from this testing, the characteristic strength of the communal non-residential and commercial buildings. glue bond was calculated using the BRANZ EM1 method. By factoring in a strength reduction factor, the maximum resistance Determining Thermal Resistance of the glue bond was determined. By comparing the resistance 17.2 The thermal resistance (R-values) of building elements of the glue bond with the demand wind pressures using the may be verified by using NZS 4214. The BRANZ ‘House NZS 3604 stipulated wind speeds and AS/NZS 1170 pressure Insulation Guide’ Fourth Edition provides thermal resistances coefficients, an opinion was given by BRANZ technical experts of common building elements and is based on calculations that determined the suitability of the cladding system for use in from NZS 4214. For this system, unless better information is the relevant Building Wind Zones. available for a specific case, the R-value of the Neopor® boards 22.2 A durability opinion has been given by BRANZ technical must be taken as R0.63 for the 20 mm thick board, R1.25 for experts. the 40 mm thick board, and R1.88 for the 60 mm thick board, 22.3 Site visits have been carried out by BRANZ to assess based on a thermal conductivity (k value) of 0.032 W/m ºC. the practicability of installation, and to examine completed installations.

4 22.4 The Technical Literature for the Graphex Masonry Overlay System has been examined by BRANZ and found to be satisfactory.

Quality In the opinion of BRANZ, Graphex 23.1 The manufacture of the plasters has been examined by BRANZ, including methods Masonry Overlay System is fit adopted for quality control. Details regarding the quality and composition of the materials for purpose and will comply with used were obtained by BRANZ and found to be satisfactory. the Building Code to the extent 23.2 The quality management system of PSL is covered by the Nuplex Industries Ltd specified in this Appraisal provided quality management system which has been assessed and registered as meeting the it is used, designed, installed requirements of AS/NZS ISO 9001:2008 by Telarc Limited, Registration Number 158. 23.3 Quality on site is the responsibility of the PSL approved installers. and maintained as set out in this 23.4 Designers are responsible for the , and building contractors are Appraisal. responsible for the quality of construction and installation of the solid substrates, joinery, The Appraisal is issued only to flashing tapes, airseals and joinery flashings in accordance with the instructions of the Nuplex Industries Ltd C/- PSL building designer. a Nuplex Division, and is valid 23.5 Building owners are responsible for the maintenance of the Graphex Masonry until further notice, subject to the Overlay System in accordance with the instructions of PSL. Conditions of Appraisal. Conditions of Appraisal 1. This Appraisal: Sources of Information a) relates only to the product as described • AS/NZS 1170: 2002 Structural design action – General principles. herein; • NZS 3101: 1995 Concrete structures standard. b) must be read, considered and used in full • NZS 4210: 2001 Masonry construction: Materials and workmanship. together with the technical literature; c) does not address any Legislation, • NZS 4214: 2006 Methods of determining the total thermal resistance of parts of Regulations, Codes or Standards, not buildings. specifically named herein; • NZS 4229: 1999 Concrete masonry buildings not requiring specific design. d) is copyright of BRANZ. • NZS 4230: 2004 Design of reinforced concrete masonry structures. 2. Nuplex Industries Ltd C/- PSL a Nuplex Division: • Compliance Document for New Zealand Building Code External Moisture Clause E2, a) continues to have the product reviewed by Department of Building and Housing, Third Edition July 2005. BRANZ; • New Zealand Building Code Handbook, Department of Building and Housing, Third b) shall notify BRANZ of any changes in product specification or quality assurance Edition May 2007. measures prior to the product being • The Building Regulations 1992, up to, and including August 2008 Amendment. marketed; c) abides by the BRANZ Appraisals Services Terms and Conditions. d) Warrants that the product and the manufacturing process for the product are maintained at or above the standards, levels and quality assessed and found satisfactory by BRANZ pursuant to BRANZ’s Appraisal of the product. 3. BRANZ makes no representation or warranty as to: a) the nature of individual examples of, batches of, or individual installations of the product, including methods and workmanship; b) the presence or absence of any patent or similar rights subsisting in the product or any other product; c) any guarantee or warranty offered by Nuplex Industries Ltd C/- PSL a Nuplex Division. 4. Any reference in this Appraisal to any other publication shall be read as a reference to the version of the publication specified in this Appraisal. 5. BRANZ provides no certification, guarantee, indemnity or warranty, to Nuplex Industries Ltd C/- PSL a Nuplex Division or any third party. For BRANZ

P Burghout Chief Executive

Date of issue: 23 June 2011