CELLBOARD DECK CLIP FIXING INSTALLATION MANUAL CBWD14525 1
BEFORE YOU COMMENCE Please note that: The Product is subject to natural variation* in finish as part of the manufacturing process. The purchaser or their installer/ builder is responsible for inspecting, prior to installation, the colour, finish and size of the product, identifying whether the Product has any other defect or manufacturing fault, and for ensuring the Product meets surface appearance and product specification requirements. Subject to the terms of our warranty, CELLBOARD is not liable for claims made after the installation of the Product that relate to surface appearance and product specification. It is the responsibility of the specifier or other party to ensure that the information in this manual is appropriate for the intended application and further design detailing may have to be made for specific applications that fall outside the scope of the manual. Information contained on this document is the copyright of Composite Specialties. Use or copying of this document in whole or in part without the written permission of Composite Specialties is not permitted. CellBoard Deck Parts Profile Code CBWD14525 CBWD09023 Sizes available 145 x 4500 x 25mm 90x 4500 x 23mm Span centres*residential SPAN centres* commercial 400mm 350mm 400mm 350mm Accessories ( Clip fixing ) Clip Code AL14523 NOTE: *These are maximum spans however shorter spans may be required dependent on region and wind load, please confirm with structural engineer prior to installation. 2
Installation Tips and Requirements CellBoard products can be worked with ordinary woodworking tools such as: Circular Saw Crosscut Mitre Saw Carpenters Square Cordless Drill Level & Chalk Line Tape Measure NOTE: To ensure long- term performance, we recommend that a professional trade person carry out the installation. The installation MUST be carried out in accordance with these instructions including the use of all trims and accessories. Site storage & Product Handling CellBoard boards should not be stored in the open or covered or wrapped with plastic sheet. CellBoard are a finished product, do not dump or drop when loading or unloading. Always handle with care. CellBoard boards should be stored under cover and protected from the elements (including direct sunlight and rain) until ready to install. Keep packs strapped until ready to install. When removing CellBoard boards from the pack, do not slide boards against each other, lift the boards and set them down carefully. CellBoard boards should be unpacked and stored undercover on a dry and flat surface supported at max 450mm centres. CellBoard boards should be carried on their edge for better support. When handling CellBoard boards take care to avoid scratches, nicks and other damage to the boards. Thermal movement Any wood based products will expand and contract with changes in temperature. The amount of expansion varies according to the amount of change in temperature. Although thermal movements are reversible, these movements due to temperature change may vary by up to 1.5mm per meter during the installation process. CellBoard boards that have been exposed to direct sun for several hours, prior to installation will have expanded more than boards left in the shade. It is important to maintain an average consistent temperature for all boards as they are being installed. Avoid installing in full sun if ambient temperature is above 30 C. However if this cannot be avoided ensure the boards are kept out of the sun until installed to limit the boards expansion prior to installation. CellBoard products can tolerate a temperature range from -20 C to +65 C. If the product is to be used in an environment outside of this temperature range, please consult CellBoard. Please bear in mind that: UNDER COVER Screws must be minimum 15mm but maximum 25mm away from board edges (unless noted otherwise) CellBoard products must not be used for any structural purpose. When exposed to direct sunlight, surface temperature may be significantly hotter than ambient temperature. 450mm CTRS 450mm CTRS 3
Framing Construction Requirements Screws CellBoard decking may be fixed to seasoned timber joists or to a proprietary structural system. Joist spacing for CellBoard decking is nominally set at 400mm centres max for residential and 350mm centres max for commercial applications in urban and non- cyclonic wind load areas. For higher wind-load areas reducing joists may be required. All boards must span across a minimum of 3 joists. As with all decking products the adequacy of a proposed installation should always be checked by a qualified engineer. Screws must comply with AS 3566 Self Drilling Screws for the Building and Construction Industries. Screws must have a minimum Class 3 corrosion resistance, suitable for external applications in mild, moderate industrial and marine environments and Class 4 or stainless steel for severe environments. Screws with class 1 or 2 corrosion resistance may be used for internal use depending on the individual application. Joists must have a face not less than 45mm for timber and 38 mm for steel. Where butt joints occur, double joists must be set. Wafer Head Countersunk Head Timber Framing Decking/ Type 17 Self-drilling Self-tapping The joints between posts, bearers and joists need to be able to transfer load efficiently through the structure, refer to AS1684 for design of these elements. It is important to use adequately seasoned timber to minimise shrinkage and associated building movement which may damage the decking system. Steel Framing Steel framing must comply with AS/NZS 4600: Cold- Formed Steel Structure or AS 3623: Domestic Metal Framing. Where steel framing members are specified, use only corrosion resistant galvanized steel framing. Specific instructions for fixing to steel frames are included where appropriate. 4
Joist Spacing and Loading Dimensinos Table: Joist or batten spacing for InnoDeck is nominally set at maximum 400mm centres for residential and 350mm centres for commercial. Uniformly Distributed Load (kpa) Concentrated Load (kn) 3 1.8 Allowable long term uniformly distributed load kpa, is limited by the allowable bending strength of the InnoDeck and should not exceed the loads per support span, as shown in the table below. Description Millimetres a min dis. to solid structure 3mm b max joist centres 350mm Commercial 400mm Residential c min ground clearance 50mm d min dis. to sold structure at board end 3mm The allowable concentrated live load - kn, is limited by the deflection of the InnoDeck between the supporting joists, and should not exceed the maximum loads, as shown in table. Refer AS/NZS 1170.1 section 3 d a DOUBLE JOIST AT ALL BUTT JOINTS (REFER DETAIL BELOW) b c DOUBLE JOISTS MUST BE BOLTED TOGETHER AS SHOWN USING M10 NUT AND BOLT WITH FLAT WASHERS 30 Note: - Bolts to be Max 600mm CTRS with a Minimum of 2 bolts used. - Position bolts so as to ensure no obstruction to board screws. 5
CLIP FIXING Step 1 - Preparing Fist Board CELLBOARD CBWD14525 φ4.5mm Clearance 5~10mm Depth (Face fixing holes) CLIP SCREW (Bottom) 8g x 20mm COUNTERSUNK SELF TAPPING SCREW φ4.5mm Clearance 5~10mm Depth (Face fixing holes) Min15mm Max 25mm 25 25 MAXIMUM SPAN CTRS 400mm(RESIDENTIAL) MAXIMUM SPAN CTRS 350mm(COMMERCIAL) CLIP AL14523 CLIP AL14523 *IMPORTANT CLIP SCREW (BOTTOM) 8g x 20mm COUNTERSUNK SELF TAPPING SCREW Before commencing: If a fascia board is to be used take note of overhangs required as indicated at step 7 1. Cut first board to required length. 2. 3. 4. Drill 4.5mm diameter clearance holes for face fixing screws along starting edge of board in alignment with the centre line of the joists. Slide aluminuium clips into the groove on the opposite side of the board to where the holes were drilled. Align clips with the centre line of the joist then pre-drill and screw from underneath. To make screw heads beneath the board surface, needs to drill screw holes onto the board sides surface first before fixing onto the joists. The screw holes could be made from a two-step drilling process: i) using a small drilling heals (similar Dia. as the fixing screw) to first drill a through hole at the fixing point; ii) use a larger drilling head (similar Dia. as the screw head) drilling at the same through hole but only 5~10mm depth. 6
Step 2 - Installing First Board CELLBOARD CBWD14525 FIXING CLIP AL14523 CLIP SCREW (TOP) FACE FIX SCREW 25 JOISTS MAXIMUM SPAN CTRS 400mm(RESIDENTIAL) MAXIMUM SPAN CTRS 350mm(COMMERCIAL) SCREW TYPES REQUIRED: Joist Type Face Fix Clip Screw (Top) Clip Screw (Bottom) Metal 8g x 35mm CSK Self-drilling Screw 8g x 20mm CSK Self-drilling Screw 8g x 20mm CSK Self-tapping Screw Seasoned Timber 8g 65mm CSK Decking Screw 8g 40-50mm CSK Decking Screw 8g 20mm CSK Self-tappig Screw 5. 6. It is preferable to install board from the outside edge of the deck and work inwards, to ensure the boards along the outside edge are full boards (not ripped down) Use a string, spirit or laser level to establish the starting point of the decking. Screw the first board down onto the structure as indicated above. 7
Step 3 - Preparing Second Board CELLBOARD CBWD14525 CLIP SCREW (Bottom) 8g x 20mm COUNTERSUNK SELF TAPPING SCREW MAXIMUM SPAN CTRS 400mm(RESIDENTIAL) MAXIMUM SPAN CTRS 350mm(COMMERCIAL) CLIP AL14523 CLIP AL14523 CLIP SCREW (BOTTOM) 8g x 20mm COUNTERSUNK SELF TAPPING SCREW 7. Cut board to required length. 8. Slide aluminuium clips into the groove on the opposite side of the board to where the holes were drilled. Align clips with the centre line of the joist then pre-drill and screw from underneath. Ensure Deck is pre-drilled using a φ2.5mm drill bit at approximately 15mm deep. Take care not to break through the surface of the board. 8
Step 4 - Installing Second Board SOFT HAMMER CELLBOARD CBWD14525 SOFT TIMBER BLOCK JOISTS FIXING CLIP AL14523 CLIP SCREW (TOP) MAXIMUM SPAN CTRS 400mm(RESIDENTIAL) MAXIMUM SPAN CTRS 350mm(COMMERCIAL) 9. Lay second board onto joists as indicated above and tap the board edge with a soft hammer and a soft timber block near each clip location until full engagement is achieved with the clips. Take care not to damage the boards. 10. Screw board to joists through holes in clips using screws as indicated in table shown at step 2. 9
Step 5 - Assembling & Installing Remaining Boards TWO CLIP MUST BE USED AT ALL BUTT JOINTS DOUBLE JOIST AT ALL BUTT JOINS MAX 60 M M AXI AX M IM UM UM S SP PAN AN C CT TRS RS 40 35 0m 0m m m (RE (C SI OM DE M NT ER IA CI L) AL ) 0mm 11 Repeat steps 3 and 4 until last board is installed. 10
Step 6 - Installing Last Board φ4.5mm CLEARANCE FACE FIXING HOLES LAST BOARD FACE FIX SCREW 25-35mm RIP LAST BOARD DOWN IF REQUIRED 12. Cut last board to length and rip down in width if required. 13. Drill clearance holes φ4.5mm diameter 25-35mm from the outside edge of board in alignment with joist centres. 14. Lay last board on joists and tap the board edge with a soft hammer and a soft timber block until full engagement with clips is achieved. 15. Screw the last board to joist through φ4.5mm clearance holes using screws as indicated in table shown at step 2. 11
Step 7 - Finishing Option Fascia If desired a fascia board can be added around the perimetre of the deck. We recommend the following methodology: 1. Using a router or power saw, rebate the decking board as indicated along entire length to create a fascia Board. 15 23 2. Screw fascia boards to framing using 8g x 65mm CSK Decking Screws at max 450mm CTRS. Decking and fascia boards must be pre-drilled with φ4.5mm drill bit. 13mm Board Overhand 10mm Board overhand 2mm Gap 40 JOIST 65 12
Step 8 - Protection Remember - InnoDeck is a pre-finished product so it must be protected during and after the installation process. CellBoard recommend the following precaution to avoid damage and/or scratching: 1. Limit construction foot traffic over boards when possible during construction; 2. Anyone walking over deck during or after construction should ensure their boots are clean of dirt, sand, etc and without objects such as stones or glass wedged in the soles; 3. Sweep deck clean and cover with corflute once installation is completed if trafic over deck cannot be avoided throughout the remainder of the construction period. ENSURE CLEAN BOOTS ONLY LIMIT FOOT TRAFFIC PROTECT 13
14 NOTES
For more information, please visit CELLBOARD at www.compositespec.com.au CELLBOARD DECK CLIP FIXING OCTOBER 2016 15