IMPORTANT NOTICE: FireCrunch MgO Board FCA is a “Non-Metal Corrosive”, MgO “Sulphate” Board (MgSO4), Australian NATA Labs Certified, Click Here for Non Chloride Non Corrosive Content Certificate.
FireCrunch can be used for protection in all Bushfire Attack Level (BAL) scenarios.
One layer of FireCrunch 10mm can achieve FRL 60/60/60 on a timber frame and FRL 90/90/90 on a steel frame. For more information on building in BAL zones, view the Fire System installation manual from the related link below.
Setting the joints on FireCrunch is a simple process.
It is very similar to standard joint setting however there are a few things to note.
Base Coat – Standard available base coats compounds.
Tape – Use Fibafuse paperless Drywall tape (Exterior joints only ) Use paper tape for all interior work.
Top Coat – Multipurpose topping compound
Used for everything from internal / external angles, suitable for second, finish texturing coats.
Manufacturer’s instructions should always be followed. Datasheets can be downloaded from links below.
Applying Hamilton Blue Dot / 4T Multi-purpose compounds to FireCrunch however most regularly available brands of plaster base and finish coats as natural air dried ( not fast chemical died) products will work well with FireCrunch.
Hamilton Blue Dot and 4T Multi Purpose compounds should be stored at room temperature for at least 24 hours prior to use. Mix lightly and test apply . Do not over mix as this can cause pocking. Add water 250 ml at a time as necessary; remix and test apply before adding additional water.
Any surface imperfections or damage that may have occurred should be repaired to the board surface prior finishing. Apply over dry surfaces only and allow each coat to dry completely before applying another coat. Maintain minimum air, joint compound and surface temperature of 13c within working area until joints are completely dry.
FireCrunch may show some light pin hole surface imperfection as it is an air dried carbonation molded product.
To obtain a class 4/5 finish mix an amount of 4 x diluted mix of plaster base coat and either roll or spray on the installed sheets. Apply light fine grade sand after 24 hours which will produce a class 5 finish
EXTERNAL ONLY Embed “Fibafuse” drywall tape, use paper tape for all INTERNAL walls etc ceilings etc to the FireCrunch; make sure no fasteners protrude above the FireCrunch, panel surface. Using a broad steel finishing knife, apply a continuous coat of BASECOAT compound to fill the channel formed by the taped edges of the panels. Centre and lightly press tape into fresh joint compound. Working within a convenient arms-reach area embed tape by holding knife at a angle to panel, draw knife along joint with sufficient pressure to remove excess compound, above and below tape and at edges.
Leave sufficient compound under taper for proper bond, while embedding, apply a thin coat of Blue Dot tapping compound over the tape. This thin coat reduces edge wrinkling or curling and makes the tape easier to conceal with following coats. Allow to dry completely.
After the tape embedding coat is dry, apply a topping using Pro Plaster 4T Multi Purpose or simlar approved compound, fill second coat approx 180mm to 250mm wide over taped joint. Feather edge of second coat 50mm beyond edge of first coat. Allow to dry.
After second coat is dry. Apply a thin finish coat of 4T Multi Purpose Compound over joints. Finish compound, should be applied at a slightly thinner consistency. Feather edge of third coats at least 50mm wider than second coat.
Apply a thin layer of compound to either side of the corner. Crease centre of tape and press into corner. Tightly embed tape with knife on both sides removing excess compound and apply it as a thin coat over tape. Apply second coat over one side at a time allowing it to dry before finishing opposite side.
Sand with a wet sponge to eliminate dust and scuffing . Remove high spots using as few strokes as necessary. Clean sponge often. If dry sanding, use 180 grit sand paper or finer. Avoid scuffing tape.
If dust is generated wear suitable protective clothing including PVC gloves (AS 2161), Eye protection (dust resistant AS/NZS 1336), and a respirator (AS/NZS 1715 and 1716.Wash clothes regularly.
FireCrunch will not be liable for incidental and consequential damages, directly or indirectly sustained, nor for any loss caused in application of these materials other than to the manufacturers specified instructions. Our liability is expressly limited to replacement of defective goods. Any claim shall be deemed waived unless made in writing Thirty (30) days from the date it was, or reasonably should have been, discovered.
Keep out of reach of children. For further health and safety handing instructions, refer to the Material Safety Data Sheets for these products available from www.proplaster.com.au.
Yes. FireCrunch is not that dissimilar to fibre cement board when it comes to uses.
FireCrunch has been trialled with budget tile adhesives and worked perfectly.
No special tools are required to use FireCrunch.
It can be sawn, drilled, screwed and planed just like timber. USING TIMBER TOOLS.
It is recommended that fasteners, not stud adhesives, are used when fixing the sheets in the wet areas of steel and timber framed buildings.
FireCrunch is easy to work and machine with normal woodworking tools and equipment. Cut sheets with a fine tooth handsaw or power saw. Edges may be trimmed with a smoothing plane, power plane or sandpaper.
Panels with thicknesses 10mm and under can be scored with a cutting knife and snapped along the straight edge in the same way as you would with gypsum boards. Where holes are required clean cutter bits or twist drills are satisfactory.
Woodworking shapers, spindle moulders and high speed routers may be used to shape or mould the edges of FireCrunch. Tungsten carbide tipped cutters are preferred for long production runs.
Note: FireCrunch does not require the use of expensive countersinking to fix which takes extra time time and requires expensive tungston tipped drills and saws. As with CFC cement sheeting and is some 35% less in price
FireCrunch is CSIRO FIRE TEST CERTIFIED TO AUSTRALIAN BCA AND ALSO COMPLIES WITH THE FOLLOWING SECTIONS AND VOLUMES OF THE BCA
BCA Volume 1 Section C FRL (Timber Frame 60/60/60 Metal frame 90/60/60) Non Load bearing FRL -240/240
BCA Volume 2 Part 18.104.22.168 Fibre cement planks and weatherboard cladding.
BCA Volume 2 Part 22.214.171.124 Fibre cement sheet wall cladding.
BCA Volume 2 Part 126.96.36.199 Eaves and soffit linings.
BCA Volume 2 Part 3.7.1 Fire separation for FRL to (Timber Frame 60/60/60 Metal frame 90/60/60)
Non Load bearing FRL -240/240. *** DENOTES SEE SPECIFIC INSTRUCTIONS RE THESE HIGH FRL FOR STEEL FRAMING ONLY.
BCA Volume 2 Part 3.7.4 Bushfire areas including all state variations to Part 188.8.131.52 and 184.108.40.206 as tested under AS 1530 parts 8.1 and 8.2. BCA Volume 2 Part 3.8.6, Sound insulation to Rw +Ctr 62.
CSIRO CERTIFIED AS/1530.4/2014.
Yes we do.
Installation manuals can be found on the web site www.firecrunch.net.au under support and FAQ.
Internal Walls / Floors / Ceilings / Wet Areas / FIRE RATED AREAS
FireCrunch must always be sealed and finished regardless of where or how it is used, however this is particularly important in areas of high humidity. Extra care must be taken to ensure the board is sealed correctly on the face, top and side edges.
FireCrunch WILL NOT ATTRACT MOULD OR, MILDEW AND BACTERIA CANNOT SURVIVE ON (MgO) FireCrunch
Correct preparation and sealing will ensure a long life for your building.
FireCrunch differs from plasterboard in a number of ways in that it is:
SEE CSIRO FIRE CERTIFICATION ON WEBSITE www.firecrunch.com.au (FRL 30/30/30 TO 90/90/90).
* Prelonged submersion in water without an opportunity to dry out WILL VOID THE FireCrunch WARRANTY, TREAT THIS PRODUCT AS AN INDOOR PRODUCT STORE OUT OF WEATHER, UNDER COVER, PRIOR TO SEALING AND PAINTING. ENSURE HYDRSCOPIC LEVEL NOT OVER 15% PRIOR SEALING.
Although FireCrunch does not degrade in water it should not be left out in the rain before use or sealing as there will be a low % of HYDRATION IE, absorption of water. If this does happen the board will have to by dried out before use… drying out the board (24/48 hours warm weather) will not cause warping or any loss of integrity. HYDRO RATE 15% MAX BEFORE SEALING
FireCrunch should always be stored flat in a dry undercover space on a horizontal pallet or on supports spaced at 450mm centres. It should never be stored laid directly on ground outside without support gluts. And do not leave the board hanging over the pallet edges or gluts over 450mm it must be suported flat at all times prior to use.
Always handle with at least one person at each end of the board. With hands apart, lift the board and tilt up to prevent sagging. (See data sheet for more information).
FireCrunch is more expensive than plaster board due to the additional properties that make FireCrunch a superior lining product as described on the website.
We cannot give you price variations here as plasterboard prices vary considerably between suppliers, however, the cost of maintaining plasterboard in the long term well outweighs the cost of installing FireCrunch.
FireCrunch to begin with needs ONLY 1 LAYER OF 10MM FCA, EQUALS up to 3 LAYERS OF 13mm PLASTERBOARD OR 2 LAYERS OF 16mm PLASTERBOARD to achieve the same FRL.
FireCrunch substantially lowers overall labour cost and transport (weight) and crane up and site handling time all of which speeds the completion and lowers install cost in materials and labour. it also increases the roi to developer with thinner walls and more lettable space.
FireCrunch is recyclable, contains no toxic chemicals, FORMALDEHYDE OR ASBESTOS OR METAL CORROSIVE CHLORIDES (Ask us for copy MSDS or see website technical info) Australian Govt legal requirement) NATA Labs CERTIFIED NON ASBESTOS AND NON CHLORIDE (Website Certifications www.firecrunch.com.au) email@example.com. FireCrunch has a one tenth low carbon footprint of plaster board and due to the need for less repair, has less wastage.
FireCrunch has a one tenth low carbon footprint of fibre cement board Blue Board etc and due to the need for less repair, has less wastage.
During the manufacturing process, in carbonation, FireCrunch draws back 90% of the CO2 used in manufacture and makes it a virtually carbon neutral product. Any waste is just ground up and reused.
FireCrunch has a very high fire resistance and has been tested at temperatures up to 1200ºC for over (1.5) hours with a single 10mm board and board did not ignite or pass flames) CSIRO. Thickness of 20mm and 30m with move the FRL to 240/240/240 (NCC).
FireCrunch passed the following BCA tests:
AS/NZS 1530.4 / 2005
THE BCA MOST AGGRESSIVE FIRE TEST FRL 90/90/90
Method of test for heat and smoke release rates for materials and products using an oxygen consumption calorimeter (Cone calorimeter test) – Walls & Ceilings (AS/NZS 3837 replaces AS/NZS 1530.3)
AS/NZS 1530.4 / 2014 (LATEST TO 2018)
Methods for fire tests on building materials, components and structures, Part 4: Fire-resistance test of elements of construction covering fire resistance.
(CSIRO FULL REAL TIME EXTERNAL AREA BUSH FIRE SIMULATION TEST FEB 2012)
AS/NZS 1530.8.2 see burn down attempt CSIRO, video, posted web site.
Methods for fire tests exclusively for materials and elements of construction in bushfire-prone areas, namely: AS 1530.8.1 – Tests on elements of construction for buildings exposed to simulated bushfire attack; Part 8.1 – Radiant heat and small flaming source, which covers BAL 12.5 to BAL40 and; AS 1530.8.2 – Tests on elements of construction for buildings exposed to simulated Bushfire attack. Part 8.2: Large flaming sources, which covers BAL-FZ FRL 30/30/30. ( All contained within the AS 1530.4-2014 certification) a 90 minute wall section test plus, subsequent special bushfire roofing tests timber framed trusses, 2018 by resolute labs QLD obtained FRL —60/30 versus …30/30 under AS.3959 See website. plus, under technical specs see manuals, bushfire building manual.
FIRE RESISTANCE LEVEL (FRL) 90/90/90
*** DENOTES DBL STUD INTERTENANCY FIRE SEPARATION WALL FRAME (Australian NCC ALTERNATIVE certification FIRE ENGINEERS CERTIFICATE available ask us)
FireCrunch has a high ACOUSTIC and insulation rating: Rw62 PLUS ctr NET Rw 52.
FireCrunch exceeds BCA minimum requirements for airborne sound insulation for a wall between attached dwellings and meets the highest possible AAAC acoustic rating of 5 stars.
Termites, one of the worst contributors to home damage, have no interest in FireCrunch and cannot consume it.
TOTAL PROTECTION FOR EXPENSIVE TIMBER FRAMING
FireCrunch contains no formaldehyde, no asbestos and no toxic chemicals. OR corrosive Magnesium Chloride FireCrunch uses Magnesium Sulphate (MgSO4) being a non-metal corrosive element and in this regard FireCrunch is a unique MgO product in Australia.
Standard FireCrunch is a highly water-resistant product in that it does not “retain” water if unsealed. fire crunch however is a breathable permeable product
This means that an unsealed board will absorb some moisture in damp or wet areas if unsealed. multiple wet/dry processes, before sealing will void the warranty, see earlier info on storage these FAQ documents, particularly without adequate water sealing with a product like ROCKCOTE special MgO sealants (See website Recommended products)
FireCrunch must not be left out in the rain or long periods of humidity before sealing /priming.
Because it is a breathable board it will hydrate when not sealed. However, in a dry environment FireCrunch will dry out very quickly without swelling or warping and hold its integrity when dried. FireCrunch that has been installed externally left to the weather for days or weeks and not pre-sealed could crack at fixtures due to residual moisture in the board being removed in the drying process, especially when exposed to multiple wet/dry processes.
BEST PRACTICE, STORE UNDERCOVER BEFORE USE, DO NOT ATTEMPT TO PAINT IF BOARD WET, OR BEFORE SEALING. ALL BOARDS MUST BE WATER SURFACE SEALED (front and sides with back unsealed)
IF LEFT IN RAIN ALLOW TO DRY COMPLETELY MIN 24/ 48 HOURS IN WARM DRY WEATHER BEFORE SEALING, PAINTING, OR RENDERING.
Tests have been carried out at the NATA Brick & Mortar Research Laboratory in Melbourne VIC. An Australian Accredited Laboratory.
Standard Square Edge 19mm and 20mm FireCrunch (Over 450mm AND 600 CENTRES 5.3 AND 6.0 kN respectively.
FireCrunch MUST NOT BE NAILED, USING NAILS WILL VOID THE WARRANTY, SCREW FIX ALWAYS. TAKE NOTE OF THE RECOMMENDED SCREWS THAT MUST BE USED.
Visit FireCrunch website www.firecrunch.com.au FOR THESE FIXINGS warrant the board only when the correct screws and system manuals are adhered to. Ask for copy of the warranty from your dealer or FireCrunch firstname.lastname@example.org
STEEL FRAME: For screwing FireCrunch panels to steel framing, we recommend using (RIBBED HEAD BUGLE SELF COUNTER SINKING SCREWS) AVAILABLE FROM ALL MAJOR HARDWARE STORES.
TIMBER FRAME: For screwing FireCrunch panels to wood framing, we recommend using, stainless steel (or suitably chemical corrosion protected) 8-10 Countersunk Ribbed Head Class
2 / 3 screws (depending on timber hardness).
Nail Fixing (Will void warranty) Screw fix only.
FireCrunch exceeds BCA minimum requirements for airborne sound insulation for a wall between attached dwellings and meets the highest possible AAAC acoustic rating of 5 stars.
BCA Compliant Rw 62 plus ctr =net Rw 52 on DOUBLE STUD DISCONTINUOUS FRAME 76mm and 90mm Ask us for AS 717 certificate BCA Volume 2 Part 3.8.6 – Sound insulation to Rw 62 Plus +Ctr net 52.
FireCrunch is made up of a combination of primarily Magnesium Oxide (MgO) and special non-metal corrosive magnesium sulphate Magnesium Sulphate (MgSO4)
NEW TECHNOLOGY 2018
FireCrunch is one of very few MgO products in the world to have the Magnesium Sulphate bonder (MgSO4) and no metal corrosive Magnesium Chloride (MgChl2) which can cause serious metal corrosion in less than 6 weeks if not very carefully water sealed.
This MgSo4 has been bonded with a small percentage of organic and composite materials, strengthened with fibre mesh.
What is Magnesium Oxide?
MgO or Magnesium Oxide (sometimes called magnesia), is an absorptive solid mineral, white in colour, that occurs naturally in metamorphic rocks and is source from magnesium. Magnesium oxide. FireCrunch is produced by the treatment of magnesium sulphate and lime followed by heat.
During the carbonation process of manufacturing, FireCrunch draws back 90% of the C02 used to produce it and makes it a virtually carbon neutral building product.
*** ( DENOTES– READ TIMBER FRAMING SPECS FOR FRL 30/30/30 AND FRL 60/60/60 BEFORE COMMENCING WORK ON FIRE WALLS web site www.firecrunch.com.au under Technical specs / manuals
Non-load bearing FRL of -/120/120, per side
The Building Code of Australia (BCA) defines the Fire Resistance Level (FRL as the testing period in minutes for three criteria:
Note: The longest test time recognised by the BCA is 240 minute period 4 hours.
The R-value of FireCrunch is a measure of its thermal resistance. The higher the numbers the better the insulator.
R-value is measured as m2/K/w
The values for FireCrunch are:
10mm FireCrunch = 0.066 m2K/w
19mm FireCrunch = 0.132 m2K/w
So the 10mm board has an R Value of 0.066
To work out the approximate R-value for a wall with a layer of 10mm FireCrunch each side of the stud with a R2.5 batt between them –
10mm FireCrunch + Batt + 10mm FireCrunch = Wall R-value
therefore 0.066 + 2.5 + 0.066 = 2.632 (So the approximate R-value for the wall would be 2.6)
Please note that the above is just an approximate guide. Actual figures would have to be calculated. There are a number of on line calculators that can do this for you.
You should do all you can to prevent FireCrunch getting wet before installation as there will be some water absorption. If this happens, don’t worry, it just means you will need to separate the hydrated boards from each other and allow to dry in a sheltered space, preferably with low humidity in hot weather for 24 / 48 hours. The boards will not be damaged or degraded if handled correctly. Once dry, install as per normal. Carry out hydrometer check for max 15% before sealing and painting.
The FireCrunch standard sizes are as follows:
NOTE: 3mm, 6mm and 8mm are special orders sizes with minimum quantities (Ask us) SEE SIZE AND TYPE SCHEDULE WEB SITE.
Other sizes and thickness available AS SPECIAL INDENT MIN ORDER 500 SHEETS MIX SIZES.
FireCrunch 16mm TG and 19mm TG is ideal for flooring.
FireCrunch is produced in 6 different thicknesses: 3mm; 6mm; 8mm, (special order sizes) 10mm; 16mm and 19mm, stocked sizes, in standard industry 2.4m, 2.7m and 3.0 m sizes with variable edges
10mm is all 1.2 m wide and TG 16mm and 19mm is 2700x 600mm
SQ edge (SE) 24/12, 27/12, 30/12
Recessed edge (TE) (Plaster setting) 24/12, 27/12, 30/12
Tongue and Grove edge (TG) edge 2700 x 600
Shiplap edge (TS) timber look alike grooved board, timber appearance grooved planking weather board appearance 2.7m x1.0m.
Most standard water based paints will work well on FireCrunch however we do have tested and recommended products that FireCrunch Australia have approved. You can find these under Recommended Products web site main browser.
Rockcote – Keycote – Pre-blended polymer modified cement adhesive basecoat MOST regular available proprietary brands Plaster set base and topping finish coat products apply well. More recommended products will be added as testing and reporting is completed. Board sealing use the Rockcote special MgO sealer.
Although FireCrunch tends to perform very well with most standard products, drying times may vary. There are some render products tested and approved to work with FireCrunch which we recommend and we will continue to add them to this website as products are tested.
Render Systems Australia – Multiple Render Products
Rock Cote Render products
We have distributors in NSW, QLD, VIC, AND SA with more to come in 2018. In other States or where FireCrunch has no local supplier, Application can be made for direct supply from FireCrunch.