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CREATING NEW DIMENSIONSin SUSTAINABLE BUILDING TECHNOLOGY

FIRE RATED INSULATED WEATHERTIGHT GREEN IWALLS CEILINGS ROOFS ICOMMERCIAL INDUSTRIAL ARCHITECTURAL RESIDENTIALFEATURES UTILISATION APPLICATION

0800 430 430Email [email protected] www.bondor.co.nz

StructuralInsulated

PanelGuide

2011

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Bondor New Zealand Ltd is a nationally established manufacturer of structural insulated panels,

fire rated insulation materials and expanded polystyrene (EPS) construction products. With over

40 years of trading experience in manufacturing and construction we are recognised as the

market leader in our industry we take pride that our name is associated with integrity and

professionalism.

With manufacturing sites in Auckland and Christchurch and branches in Dunedin and the Bay of Plenty, we provide an integrated

approach to the construction and supply of our products. Our construction teams travel throughout New Zealand, providing

professional and reliable advice to all our clients; and we like to do things to specification, on time and in full. Our services include:

Bondor New Zealand also offers and supplies a warranted installationservice as well as a complete range of flashings, aluminium extrusions,insulated doors and construction components.

INTRODUCTION TO BONDOR NEW ZEALAND

Services

National coverage for installationOur professional construction teams areconstantly travelling throughout New Zealand

for our clients. We have panel manufacturingplants in Auckland and Christchurch and

regional offices in Mt Mauganui and Dunedin

ensuring our staff and products are alwaysreadily available.

The flexibility to engage in buildingworks from design assistance andbuild through to a subcontractcapacityTo ensure our customers get the most

benefits from the construction spectrum,

we are comfortable in assisting with a fulldesign and build service though to being

engaged in a sub-contract capacity.No job is too big or too small.

Experienced, professional,construction staffFrom estimating through to practicalcompletion we have a commitment to

doing it once, doing it right, to specification,

on time, and in full.

Competitive supply ratesWe can provide fixed prices and short

lead times. We also offer the full range ofcomponents for constructing insulated panel

buildings.

Warranty and certificationBecause weve been around for four

decades, we stand by our workmanship,products and brands.

Technical information and CAD detailsAre all available online at www.bondor.co.nz

or call us for a hard copy. Insurance and firerating requirements for insulated panel can

be confusing contact one of our technical or

sales staff for some balanced advice.

XFLAMTo consolidate our position as a market

innovator, we have adopted XFLAM as one

of our leading brands. XFLAM is a globally

developed fire rated insulating material

that delivers exceptional solutions for the

construction of temperature controlled and

energy efficient buildings.

At Bondor New Zealand, we are committedto a healthy environment; our products aretruly green and sustainable, both in form andfunctionality. We strive to ensure that thesustainability features of our products are thebest for people, profits and the planet.

Uses

Bondor NZ structural insulated panelshave been produced in New Zealand

for more than 40 years during which

time have been used in the following

applications:

Controlled atmosphere storage, freezers,chillers, roofing, architectural cladding, highrise apartments, facades, distribution centres,gymnasiums, portable buildings, interior fitouts, partitions, commercial kitchens, producestorage, wineries, temperature controlledenvironments, laboratories, blast freezers,supermarkets, food processing facilities, dairyfactories, rearing sheds, cow sheds, residentialroofing, pharmaceutical manufacture, piggeries,

fish processing, canopies, bakeries, archives,swimming pools, stadium roofs, incubationfacilities, poultry sheds, kennels, housing,warehouses with offices.

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Passive temperaturecontrol

Fully encapsulated pre-finishedpanels containing Bondor New

Zealands range of insulating

core materials provide a

guaranteed and continuous

insulation rating, suitable for

all ambient and refrigerated

applications. When used as a

roofing product radiant heat

transfer and condensation build

up is eliminated.

Flexible designBondor New Zealands insulated

panel can clad vertically or

horizontally. There are three

different profile finishes andtwo roof profiles that can be

combined with a wide choice of

colours, including metallics, and

specialist paint finishes suitable

for both interior and exterior

applications.

Cost effectivespanning capabilitiesInsulated panels provide

excellent spanning capabilities

and are self supporting to long

lengths. Suitable for both load

bearing and non-load bearing

applications the structural detail

and framing requirements areminimal when compared to other

roof and cladding products.

Seismic PerformanceThe lightweight modular nature

of Bondor Panel, particularly

with and EPS or XFLAM core,

produces minimal lateral loading

during an earthquake. This force

is comfortably accommodated by

the high bracing capacity of the

panel and the high strength of

the steel facings and associated

fixings. The steel skin also

provides significant protection

from falling objects. Thestructural couplings and fixings

are accessible for post event

damage inspection and repair.

Fire ratedChoose from the range of

Bondor New Zealands panelcores to meet the requirements

of global insurers and the

standards required in the New

Zealand and Australian Building

codes. The ranges of cores have

been comprehensively tested.

Bondor New Zealands Mineral

Wool and XFlam panels meet

the requirements of the NZBC

for a 30 or 60 minute fire rating

(FRR) as well as FM Global 4880

Class 1.

Fast build timesThe modular nature of insulated

panel can significantly reducebuild times. The Slip Joint panels

arrive on-site pre-finished and

are installed efficiently using

single fix construction techniques.

There are no curing times and

no multi-product combinations

to cause delays.

Made in New ZealandBondor panel is made in state-

of-the-art manufacturing plants

in Auckland and Christchurch.

All panels are manufactured to

the required length ensuring

continuous watertight panels and

no waste.

Production flexibility, the fast turn

around of orders, and short runs

are a feature of Bondor New

Zealands manufacturing

capabilities. Bondor New

Zealands unique position of

having operations in both

islands minimises transport, thus

reducing one of the contributors

to global warming.

Advanced insulationratings

Bondor New Zealands panelthicknesses provide a simple

solution to achieving a full

spectrum of insulation ratings

greater than the requirements

of the Building Code. Through

improving the insulation values,

the amount of fuel or energy

required to heat or cool a

building is reduced, benefiting

the environment and providing

savings to the building user.

Energy efficientGreen buildingsThe efficient control of energy

within the finished building andthe short build times offset the

minimal environmental impact

of the panels manufacture and

installation. Ongoing energy

savings are made through

outstanding climate control,

provided by the panels

continuous insulation properties,

reducing heating, refrigeration

and air conditioning costs. All

Bondor New Zealand insulation

cores can be recycled or

remanufactured at the end of

their useful life.

Low maintenanceand hygienicThe steel profiles and paint

finishes provide an easily cleaned,

hygienic, low maintenance

sterile surface approved for food

processing, food preparation and

cool storage facilities.

F

A

D

C

B

E

D

C

E

B

F

F

A Prefinished steel skin

Insulating core

Female slip joint

Male slip joint

Easy & effective slip joint installation

Rigid weathertight connection provides

continuous insulation and resistance to

fire deformation

Slip Joint technologyEvery panel incorporates Bondor New Zealands Slip Joint technology.

This uniquely designed system incorporates a male and female joint

on each steel face that provides a rigid and sealed connection between

adjacent pawhe tightness and quality of the joint resists deformity in fire

situations, provides a weathertight seal and enables effective and easy

installation.

THE ADVANTAGES OF BONDOR NEW ZEALANDSSTRUCTURAL INSULATED PANEL


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WALLS, CLADDINGS AND FACADESWall panels can be installed horizontally or vertically. Finished panels can be any combination of wall profile.

PANEL PROFILES

FLAT

SHADOWLINE

EPS, MINERAL WOOL or XFLAM CORE

50-300mm

EFFECTIVE WIDTH 1200mm

RIBBED

Micro Ribbed


50-300mm



50-300mm


THE RANGEBondor New Zealands range of structural insulated panel technologies providesystems that enable the fast and cost effective construction of energy efficient, controlled environment,and fire rated buildings.

SATINLINE Microcorrugate


-


Satinline XFLAM Panel installed horizontally Flat EPS Panel installed vertically Titania

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50-250mm

250mm

32mm


50-250mm

250mm

33mm


1018mm

EPS

METRIC 5-Rib

Bondor NZs prefinished metric roofing panels are a fully insulatedthrough fixed roof and ceiling system that is extremely fast toinstall requiring only one trade.The external continuous uniform end lap combined with an internalslip joint detail and insulated core provides an instant weather tightand thermally efficient roof with a prefinished ceiling.Metric roofing panels offer many advantages over traditional builtup systems including reduced installation costs, improved levels ofair tightness and no risk of condensation or cold bridging.

With better spanning capabilities and fewer purlins than traditionallong run roofing, the installation time is reduced and therequirement to install underlays, foils, building papers, mesh andblankets is eliminated.Savings of up to 25% can be made on both material and labour incomparison to conventional roofing systems.Ideal for where exposed rafters and purlins are detailed and forresidential applications a thickness between 150mm and 200mm isrecommended.

North Island Profile

South Island Profile

Metric XFLAM Metallic Silver Metric EPS Titania

ROOFING AND CANOPIES

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XFLAMXFLAM is a breakthrough product in the field of fire-resistant panel.It is a syntactic foam with

enhanced fire resistance, excellent mechanical properties, superior insulation values, low toxicity

and is completely recyclable. XFLAM combines the best attributes of Polyfoam EPS and phenolics

with new attributes of its own.

Developed initially as a high performance core for panel systems, XFLAM also has applications

in many other areas. XFLAM provides the following benefits:

XTRA Fire Resistance and Fire RatingsXFLAM consists of EPS pre-expanded beads with a hybrid phenolicresin, a catalyst, lightweight additives and carbon. The resin has highadhesive bond energy. It is hard to break down under fire energy andeliminates the exposure of the EPS bead to the flame source. At 1200Cthe phenolic honeycomb matrix remains intact and the fire behaviour islimited to surface charring which significantly delays the fire spread andprotects the core.

In comparison to other RCPs (rigid cellular plastics) such as PIR(polyisocyanurate and PUR (polyurethane) XFLAM provides superiorfire resistance. It achieves its FM Approval with simple and costeffective construction details and is the only RCP that achieves aGroup 1 BCA classification.

XFLAM meets global insurance

requirements: Factory Mutual Global. FM Wall - Ceiling Construction. Reference 3035839 Bondor New Zealand Ltd,

3025087 and 3029819 Austral Comnia Holdings PTY Ltd. Meets all the requirements of FM Approvals Standard 4880

for Metal-faced Building Insulations. Class 1 Fire Rated to max 9.1m High. Test Standard UBC 26.3.

XFLAM meets the NZ and Australianbuilding codes for fire resistance:

AS1530.4 Fire Resistant Test: 50mm panel - /120/15

INTEGRITY RATING 120mins INSULATION RATING 15mins 100mm panel - /120/30

INTEGRITY RATING 120mins INSULATION RATING 30mins

250mm panel - /120/115INTEGRITY RATING 120mins INSULATION RATING 115mins

ISO9705 Corner Room Test achievedGroup 1 BCA Classification.

Passes theFlame Barrier requirements for foamed plastics under theAcceptable Solution C/AS1 part 6 of the NZBC.

Specifiers and building owners can be confident when they use XFLAMthey are fulfilling the requirement of the New Zealand and AustralianBuilding Codes, Territorial Authorities and the insurance industry.

TM

Fire Rated & Architectural Panel Systems

PANEL CORES XFLAM


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XTRA Thermal PerformanceAs an insulating material XFLAM achieves a higher insulation ratingthan EPS or mineral wool.

Very low water transmission rates ensure XFLAM can be used in anyapplication previously regarded as the preserve of EPS, PUR, and PIRpanel.

Greater insulation value reduces the energy costs for maintainingcomfortable and efficient environments in the building.

XTRA StrongAs a construction product XFLAM has superior mechanical propertiesto EPS, PIR, PUR and mineral wool. It can span up to 30% further thanPIR and PUR reducing the cost of supporting structures and freeing up

internal spaces.

XFLAM provides extra strength and rigidity that enables long spanssuitable for use in the walls, ceilings, roofs and facades of all buildings.

XFLAM can be used as structural unit in commercial and residentialconstruction.

XFLAM is suitable for use as trafficable ceiling.

Structural costs can be significantly reduced through using XFLAM panel,in comparison to other building materials and insulated panels.

XFLAM does not require extra structural components to achieve its fireratings.

XTRA SustainableNo blowing agents are used in the manufacture of XFLAM.

XFLAM waste can be returned to the manufacturing process, andbecause its made locally, the carbon footprint of transportis minimal.

Its advanced insulation ratings ensure that energy consumption isreduced preserving the natural resources of the planet.

Sustainable construction is a critical factor in the consideration ofbuilding materials. XFLAM insulated panel ticks all the boxes and more.

XTRA SafeXFLAM is compliant with both aircraft and underground rail fireresponse requirements.

In a fire situation combustion is restricted to small clean burning cellswith very little smoke production and negligible toxic species.

Construction teams can easily work with XFLAM - protective work wear isnot required.

XTRA StableExtruded rigid cellular plastics such as PIR and PUR commonly sufferfrom out gassing, a post-production phenomenon that results insignificant loss of thermal insulation over time and deformation of thepanel and the likely release of toxic compounds into the environment.

XFLAM like EPS, provides astable and guaranteed thermal rating and is harmless and inert at thetime of its manufacture into panel.

XTRA ValueDollar for dollar, XFLAM achieves better thermal resistance (R-value)than PIR and PUR systems.Savings of up to 30% can be made when calculating the costs of

the panel system and the appropriate structural supporting elementstogether.

When considering the total construction cost of building, XFLAM offerssignificant cost savings in the reduction of structural elements whileoffering superior insulation values in comparison to other RCPs.

PANEL CORES XFLAM

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Mineral wool is manufacturedfrom molten rock, glass or slagthat is spun into wool-like fibreand bound with resin. Thefibres are compressed whichtrap air creating insulation andsound control attributes.

Classified as non-combustible,mineral wool does not conductheat and can withstand

temperatures above 1000C.

Where noise control isimportant mineral woolprovides significantacoustic ratings.

The inorganic nature andbonded structure of mineralwool makes it vermin andinsect proof.

Recommended for completebuildings, constructing fire cells,partition walls, and isolatingplant rooms wherethe ambient temperature isabove 5C.

Suitable also for cool storesand freezers with correctinstallation, and vapourbarrier installed.

At the end of its usefullife, mineral wool can bereprocessed or returned tothe earth without furthercontainment.

PANEL CORES EPS: MINERAL WOOL

MINERAL WOOL

Polyfoam EPS is the industryproven core used in insulatedpanel construction for morethan 40 years including theoriginal Rudnev panel. It isideally suited in temperaturecontrol applications and hasan impressive strength toweight ratio.

Polyfoam EPS is the costeffective solution to risingbuilding costs and itsexceptional lightweight

properties provide furthersavings in the costs forfoundations, framingand installation.

EPS has a significantsustainable advantage in that itis completely recyclable.

Bondor New ZealandsPolyfoam EPS panel meets theNZBC acceptable solutionC/AS1 for foamed plastics, andwhen detailed to Bondor NewZealands tested specificationachieves a fire resistance240/240/- rating for non-load

bearing walls.

The raw material used containsa fire retardant that is self-extinguishing. Burning it onlyresults in water vapour, carbondioxide and trace levels of ashsimilar to paper, and is lessharmful than burning timber.

In normal conditions energysaved in the first six monthsof a building constructed fromPolyfoam EPS panel is morethan the total energy used tomanufacture Polyfoam EPS

and convert it to an insulatingmaterial.

Polyfoam EPS has a lowcarbon footprint. It is a by-product obtained during therefining process of crude oil.The main component used inits manufacture as an insulatingmaterial is steam with anywaste water being recycledback through the steamingprocess.

Suitable for extremeenvironments.

POLYFOAM EXPANDED POLYSTYRENE (EPS)

Insulated Panel

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CORE COMPARISONS

TABLE 1

FIREPERFORMANCE

XFLAM MINERAL WOOL EPS (Polyfoam)

Insurer Approved YesFM 4880 Class 1

YesFM 4880 Class 1

YesCan depend on risk assessment

Fire rating of elementsAS 1530.4BS 476 pt22-24LPS 1208 and equivalents

- / 120 / 1550mm panel- / 120 / 30

100mm panel- / 120 / 115

250mm panel

- / 60 / 60100mm panel- / 120 / 90

150mm panel- / 240 /240

200mm panel

- / 240 / 0100mm panel

Flame barrierNZBC C/AS1 part 6

Yes Not required.Not a foamed plastic

Yes

ISO 9705

BCA Classification

Group 1 Group 1

Non-Combustible

Group 1* & 2

SMOGRASMOkeGrowthRAte

2.2 NA 3.8

Toxicity Very LowCO, CO2

Non Flammable LowCO, CO2, C

* Specific construction system required.

TABLE 2

ENGINEERINGDETAILS(Core materialonly unlessotherwise stated)

XFLAM MINERAL WOOL EPS (Polyfoam)

Density 32 kg/m3 100 kg/m3 16 kg/m3

Water absorptionASTM C272

Very Low NA Very Low

Crushing / compressivestrength to 10% deformation

156kPa 60kPa 83kPa

Cross breaking strength 240kPa NA 186kPa

Thermal conductivity(see table 4)

0.032 W/mK 0.041 W/mK 0.042 W/mK

Thermal Control(see table 4)

Best Good Better

Recyclable Yes Reusable Yes

Workability Excellent. Norequirement for

protection.Resistant to

pedestrian traffic(1 person/m2)

Protective clothingand dust masksrecommended.

No pedestrian traffic crawl boards

required.

Excellent. Norequirement for

protection.Resistant to

pedestrian traffic(1 person/m2)

Span capabilities ofpanel. See Table 6

Best Good Better

Acoustics of panel 25 STC 30 STC 22 STC


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WARRANTYBondor New Zealand Ltd typically supply a 15 year product warranty, and a 2 year labour

warranty subject to design conditions and maintenance. Contact Bondor New Zealand or

refer to Bondor New Zealands Design Guide or Maintenance Guide for further information.

1. Details and specifications in this brochure may change without notice.2. While every care has been taken to ensure the accuracy of information no responsibility will be accepted for any errors or

ommissions.3. All information supplied applies only to products manufactured, supplied and tested by Bondor New Zealand Ltd and companies

owned by Austral Comnia Holdings PTY Ltd. Use of the information in this document for generic specification is a breach ofcopyright. Substitution with other panel manufacturers products may contravene The Building Act 2004, and is at the buyers risk.

TABLE 7

DIMENSIONS ANDTOLERANCES

BuildingComponent

Profile Effective Cover+-1mm

Min. Length+-5mm

Min. RoofPitch

WALLS CEILINGS Flat, Ribbed, Satin Line 1200mm 1200mm NA

ROOFING MetricMin thickness 150mm

for residential

1000mm 1200mm 3o

Bondor NZ All WeatherRoof (Pan)

1o00mm 1200mm 4o

Freezer Roof / FlatFully supported

1200mm 1200mm 3o

Roof pitches will very depending on siteconditions, loads, purpose, configuration, snowloading and span requirements.

Under the building code insulated panel usedas a cladding is an Alternative Solution andrequires specific design. In a roofing applicationBondor NZ panel satisfies the requirements ofthe NZBC External Moisture-Clause E2, whencorrectly specified and installed with flashingswhich direct the flow of water away from thebuilding envelope.

MANUFACTURING PROCESSBondor New Zealands insulated panel manufacturing processroll forms & laminates two skins of steel to the selected coreusing a CFC-free two part thermosetting polyurethane systemapplied in a controlled temperature environment.

CORE COMPARISONS Continued

Contact Bondor

New Zealand or refer toBondor New Zealands

Design Guide or

Maintenance Guide for

further information.

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0800 430 430Email [email protected] www.bondor.co.nz

BAY OF PLENTY

11/19 Rerewai Place,Mt Maunganui. 3116Telephone: 07 574 3246Fax: 07 572 0922

DUNEDIN

137 Main South RoadPO Box 13-057, Dunedin 9013Telephone: 03 488 3087Fax: 03 488 1731

AUCKLAND

60 ORorke Road, PenrosePO Box 11-169, Ellerslie,Auckland 1061Telephone: 09 580 6600Fax: 09 580 6616

CHRISTCHURCH

51 Buchanans Road, SockburnPO Box 11-106Christchurch 8042Telephone: 03 342 8890Fax: 03 342 6176

All information contained in this brochure is available in

PDF format at www.bondor.co.nz

REVISED AND REPRINTED JULY 2011

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