Aerogel-HF

Installation guidelines

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Handling and Storage

AEROGEL-HF are size 1500x1000 mm panels provided on pallet (Fig.1.a). 

AEROGEL-HF should be protected from moisture; wet boards should be allowed to dry out completely on a level surface before use. The stacking of boards on their edges can lead to deformation of the boards and damage to the edges. Boards should generally be carried upright and the use of board lifters is advised when ftting boards to ceilings (Fig.1.b).

  Fig.1.a    Fig.1.b

Before starting installation please check availability in-site of the necessary equipment listed here.

 

Cutting

AEROGEL-HF can be machined and cut with ease. Special tools are not required. Standard tools which are normally used for dry lining work are right.

Proceed with cutting outside the rooms, in open environment. If it is not possible, confine working area and to ensure enought ventilation.

Cutting of panels must be done

1. manually with the engraving & breaking technique by using fibreboard scoring knife HF5908 and

2. with grinder for the insulation component.

Main steps are the follow:

Fig.2.a | Place AEROGEL-HF on the work table with insulation side at view. By using a straight edge or similar tool, with a pencil mark on the surface the cutting line; 

Fig.2.b | Use a grinder with cutting disc 1.0 mm-thickness to cut the insulation layer along the cutting line, or aid by the straight edge. Cut the insulation layer entirely, until tap the panel;

Turn the board

Fig.2.c, Fig.2.d | On the other side -gypsum board at view- engrave the panel with the fibreboard scoring knife HF5908 , or if not available by using a strong cutter. Perform the scoring in two or more steps, using a straight edge or similar tool;

Fig.2.e | Place the engraved line section on the edge of the working table: the larger board section is clamped down and the protruding section is then broken over the edge;

Fig.2.f | If needed cuts can be be finished by use of abrasive paper or scraping knife.

IMPORTANT NOTE: it is not possible or advisable to cut fibreboard and insulation layer in a single operation, for example by using an alternative saw.

a  b  c

d  e    Fig.2

For non-linear cuts - such as, for example, corners or special shapes - it is possible to use electro-tools such as alternative saw or circular saw with vacuum cleaner. In this case, it is important to cut the corresponding insulation layer section on the back of the board before proceeding with the cut of fibreboard component. It is not possible to cut fibreboard and insulation layer in a single operation.

 

Wall/ceiling conditions under

Before proceeding with the installation make sure that wall is plastered and finished, planar, free of irregularities, dry, not subject to rising damp, free of efflorescence and molds.

If going to install AEROGEL-HF on an old plaster, make sure that well anchored; otherwise relevant irregularities must be removed and restored. Old paint as long as healthy and well anchored can be not removed.

Uneven walls or parts, deteriorated or inconsistent, could compromise the seal of the anchors. In this situation it is advisable to perform some tests at different points and study results.

 

Installation

AEROGEL-HF must be installed in adherence to the wall, without the need of substructure, unless this is not required by the intervention specificity. Maximum height of the counter-wall must not exceed 3,5 mt.

Laying scheme is with short edge placed horizontally and full-height vertical joints. Horizontal joints shall be spaced by at least 200 mm. Cross joints are not allowed (Fig. 3).

Lower panels are placed on a thin elastic support, such a synthetic separation strip.

AEROGEL-HF shall be installed at a distance of approx 6-7mm from all the adjacent elements (ceiling and partition walls), thus cutting of the panels will be made considering that 6-7mm gap.

Contact between AEROGEL-HF and adjacent building elements should be avoided.

  Fig.3    Fig.4

Cutted side should be placed to ceiling,floor or wall so all joints between panels will be tapered edge provided.

Tapered edge panels shall be installed in direct contact without leaving gap (Fig. 4). 1-2mm gap is however allowed. 

Where installataion of two panels with different edges will be needed -one tapered and one cutted- a gap of 6-7mm between of two is necessary.

 

Fixing

Before start AEROGEL-HF installation, apply a strip of tape with fuction of separation element in correspondence of walls and ceiling connection points. See technical details in point 1.1.

During drilling operations the use of vacuum cleaner for dust extraction is recommended.

Place the first AEROGEL-HF panel oriented as picture, with the short side on the strip on the floor and leaving a 6-7mm gap from the side wall if existing (Figure 3). Check the verticality and adjust if necessary. Correct installation of the first panel will make easy the installation of all next ones.

By use of a power drill makes holes and proceed with insert nr. 8 frame plugs/m2 (=nr.12 per panel) and screws, with a distance of approx 25mm from the edge (Fig. 4). Start by the central screws and continue with along the edges.

  Fig.4    Mov.1

 

We recommend the use of Ø8mm nylon frame plug with flathead screw as art. MQL-ST. 

Length of the plugs must be choose depending on the characteristics of the wall (material, consistence, thickness, presence of cavities) and on AEROGEL-HF thickness too. Check the "max. fixable thickness" value for the plug, usually indicated as "tfix".

      Fig.5

The head of the screws must be slightly inside of the panel. Hammer the plug into the hole until it is placed 3-4mm inside the panel.

After clamped the screw, the head will be placed approx 2mm inside the panel to allow covering them with joint filler (Mov.1).

 

Edge jointing

It is recommended to clean the surfaces of powder residue before proceeding. Joints must be clean and free from dust before filling.

For filling tapered edge joints, gaps between panels and covering screw heads, use Joint Filler art. HF5901 . It needs to be applied on two hands. Paper Jointing Tape art. HF5906 must be embedded in the first layer of Joint Filler. 

The edge jointing method differs depending on the joint is made by Two factory-made tapered edge boards or One factory-made tapered edge and one edge cut on-site:

TWO FACTORY-MADE TAPERED EDGE (Fig.7)

Reinforcement tape needed.

Paper Jointing Tape art. HF5906 must be embedded in the first layer of Joint Filler. The first hand of Joint Filler shall be dry before the second hand.

Please Note: Tape must be well integrated into the filler, otherwise it is possible have formation of air bubbles in the back side of the tape during drying. So, tape needs not be in contact with panel, but embedded in the filler.

ONE FACTORY-MADE TAPERED EDGE AND ONE CUT ON-SITE (Fig.8)

Reinforcement tape unneeded.

Joints must have adequate gap of 6-7mm that will be filled with Joint Filler.

Joint Filler should be pressed into the joints to the full depth.

In order to ensure adhesion to both board edges, the filler is pressed against the board edge and scraped to the opposite edge (herringbone pattern). The countersunk heads of the fixings and any damage is also flled at the same time. Any unevenness can be sanded down once the first fill has dried (mesh or sand paper, min. 160 grain/grit). Once the sanded dust has been swept away, fine finishing can take place.

  Fig.7   

 

Surface finishing

After cleaning of surfaces, AEROGEL-HF are ready to be covered by usually interior finishes:

- Thin plaster by Fine Surface Treatment art. HF5903 (Mov. 2)
- Plasters and decorative fine plasters 
Paints
- Covering by panels/tiles
Wallpapers

  Mov.2

Prior to any fnishing work the surface must be assessed for suitability. The surface including the joint must be dry, solid and free of dirt and dust. In particular please ensure that

- splashes of gypsum, mortar etc. are removed
- scratches, indentations, etc. are flled with Joint Filler
- all filled areas are smooth and sanded if necessary

Important notice: AEROGEL-HF is supplied with surface sealed at the factory. Additional undercoats and primer coatings are only required if stated by a system manufacturer for use with gypsum-based supports, f.e. for thin or textured plaster and tile adhesive.

- Finishing stucco

With regards to the most common finishing solution -Fine Surface Treatment art. HF5903- the product should be worked at a temperature of not less than 5°C.

Thin plaster must be applied in the thinnest layer possible. The maximum thickness of each hand should be approximately 0.5 mm. Typically it is applied in a minimum of two coats.

Small irregularities can be sanded using abrasive screened or sandpaper. Before any further finishing surface must be newly cleaned from dust.

Fine Surface Treatment art. HF5903 is a necessary layer before paints and wallpaper application. It is not needed for coverings solutions or plasters.

Covering

On AEROGEL-HF all types of ceramic tiles and synthetic materials tiles can easily be applied using the thin-bed method.
Check instructions of manufacturer of adhesive before use a dispersion and reaction resin adhesives or polymer- modified cement powder adhesives on gypsum-based supports. Specifically, check if a primer is needed.

Low-moisture and flexible tile adhesive should be used, f.e. polymer-modified cement powder adhesive.
The tile must be have at least 80% of the surface in the adhesive bed. Flexible grout should be used for the grouting.

In the case that AEROGEL-HF is installed in areas which are exposed to moisture -f.e. shower and bathtub areas, wall-floor edge- it must therefore be protected against moisture: first of tile application, apply an additional water-proofing: complete waterproofing systems or liquid sealants sheaths with plastic additives can be used.

Primer coating is needed before water-proofing treatment.

Please refer to your local building regulations and guidelines for waterproofing systems with regard to any specific application. The illustrated waterproofing areas are an example of surfaces that usually require water-proofing treatment. 

Areas behind showers and bathtubs must be protected against the penetration of water to a height of min. 2.20ml. The waterproofing should extend at least 30cm above the shower head for fixed shower rails.

System sealing tapes, sealing corners and pipe penetration patches must be applied to wall/wall and wall/floor edge junctions and connection joints. Furthermore, the entire base area of the walls in a room with a shower or bathtub should be waterproofed to protect against any moisture rising from the floor.

In any case please follow the installation instructions of the manufacturer of the water-proofing system.

 

 

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Technical details

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1. Joints and corners

1.1 Jointing with existing elements


The point of connection with walls/ceilings and in general with elements made of different materials from gypsum fibreboard (bricks or cement plaster, concrete, steel, wood) must be worked by a clear separation between the different construction materials in order to avoid formation from cracks.

Before start AEROGEL-HF installation, apply a strip of tape as f.e. Trennfix or similar on walls or adjacent elements.

 

After installed the panels keeping a gap of 6-7 mm, fill the gaps between panel tape.

Excess of tape will be removed with cutter only after all jointing and finishing works.

In this way there will be no risk of cracking in the joint.

Before surface finishing -f.e. painting- apply on the entire perimeter a paintable acrylic sealant, then smoothing it by finger.

 

 

     

     

1.2 Corners/1


In order to ensure a good connection between two panels at 90° corner, please to remove a strip of insulation material from the rear side one of the two panels by cutter. The strip will be wide as the second panel thickness.

Install panels leaving a small gap of 1-2 mm that will be filled with Joints Filler.

Place the galvanized steel corner on the corners. The steel corner may be fixed by screws and/or on a layer of Joints Filler.

Apply one or more hands of Joint Filler in order to have a perfect surface.

 
 
     

1.3 Corners/2


Install the first AEROGEL-HF panel (dx panel on the picture), leaving a gap of 6-7 mm from the adjacent wall that will be filled with Joints Filler.

Install the second AEROGEL-HF panel (sx panel on the picture), leaving a gap of 6-7 mm too from the adjacent panel that will be filled with Joints Filler.

On the corner area, apply Joints Filler for at least 50 mm on both panels and place in the Paper Jointing Tape by folding at 90° along the center line.

Apply one or more hands of Joint Filler in order to have a perfect surface.

 

 

2. Fixing points loads 

Carichi isolati leggeri, che agiscono perpendicolarmente e parallelamente alla superficie della parete con una sporgenza contenuta, possono essere fissati direttamente ad AEROGEL-HF con i mezzi di fissaggio comunemente reperibili in commercio. Lo schema sotto riporta i carichi max. ammessi per tipologia di fissaggio (valori indicativi).

Light point loads that run vertically parallel to the wall surface can be fixed directly to AEROGEL-HF body. These can be fixed with suitable, simple commercial fixing components. For example nails, picture hooks with single or double nail fixing or screws and dowel (toggle fixings) are suitable for this purpose. Details on the load-carrying capacity of fixing components can be found below.

 18 Kg   28 Kg  38 Kg  30 Kg  55 Kg

 

Heavy loads as f.e. shelves, furniture, cabinets, brackets, shelves etc. must be fixed to the brick/cement structure through effective frame plugs.

 

VERS. 3.7.02

Le informazioni, le immagini, i disegni, gli schemi e le descrizioni, sia tecniche che generali, contenuti nella presente guida sono da considerarsi generici; le informazioni di dettaglio sono indicative e rappresentano schematicamente il funzionamento base di sistemi e prodotti. Le informazioni corrispondono alle nostre attuali migliori conoscenze ed esperienze. I dati sono stati elaborati con la massima cura e conoscenza, ma non esimono l’utente in linea di principio dal controllo autonomo del prodotto sotto il profilo della sua idoneità per l’impiego previsto. L’applicabilità e la compatibilità dei prodotti devono essere verificate in relazione al singolo intervento dal tecnico, dall'applicatore o dal cliente sotto la loro responsabilità. I nostri tecnici sono a disposizione per chiarimenti in merito all’impiego e alla lavorazione dei nostri prodotti. Tutti i documenti nella loro versione più aggiornata sono disponibili esclusivamente all'interno del portale www.ecofine.it.

 

COMPONENTS OF AEROGEL-HF SYSTEM


Joint Filler
art. HF5901

For filling tapered edge joints and gaps between panels, and screw heads

Paper Jointing Tape
art. HF5906

Paper tape used to reinforce tapered edge joints

Fine Surface Plaster
art. HF5903

A high quality finish used for fine filling on AEROGEL-HF surfaces

MQL-ST frame plug
art. MQL8ST

Ø8mm universal nylon frame plug with screw, for AEROGEL-HF fixing