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,12.5 to Flame Zone
Meets AS/1530.8.2 walls roofs and floors AS/1530.1 , AS/1530.4-2014 FIRE ENGINEERS CERTIFICATE NCC.
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. FCA Bushfire Manual 16MM
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 – Use Proplaster base compounds
Specifically formulated extra bonding adhesive for embedding fibafuse drywall tape to FireCrunch Joints and internal angles. (Use for taping only, not suitable for 2nd and topcoat).
Tape – Use Fibafuse paperless Drywall tape (do not use paper tape as joint cracking may occur)
Fibafuse is a mould-resistant, glass mat drywall jointing tape, a pre-creased for easy installation in internal corners. And is ideal for use with mold-resistant and paperless drywall systems for high-humidity and moisture-prone applications.
Top Coat – Use Pro Plaster 4T Multi purpose compound
Used for everything from internal / external angles, suitable for second, finish texturing coats. This light-weight joint compound feathers superbly and delivers a virtually pock free smooth finish.
Manufacturers instructions should always be followed. Data sheets can be downloaded from links below.
Applying ProPlaster / 4T Multi-purpose compounds to FireCrunch will retain the warranty for joint flushing with FCA products
ProPlaster base compound 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 when painted. ALTERNATIVELY USE DULUX PREP COAT IF REQUIRED
Embed “Fibafuse” drywall tape to the FireCrunch; make sure no fasteners protrude above the FireCrunch, panel surface. Using a broad steel finishing knife, apply a continuous coat of Hamilton Blue Dot taping compound to fill the channel formed by the taped edges of the panels. Centre and lightly press Fibafuse glass mat drywall 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 Pro Plaster 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 Pro Plaster 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 coat 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.
Light 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.
For further health and safety handling instructions, refer to the ( SDS) Safety Data Sheets for these products available from www.firecrunch.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 screw 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 deep 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 CERTIFED TO AUSTRALIAN STANDARDS 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 90/90/90) Non Load bearing FRL -240/240.
BCA Volume 2 Part 220.127.116.11 Fibre cement planks and weatherboard cladding.
BCA Volume 2 Part 18.104.22.168 Fibre cement sheet wall cladding.
BCA Volume 2 Part 22.214.171.124 Eaves and soffit linings.
BCA Volume 2 Part 3.7.1 Fire separation for FRL to (Timber Frame 60/60/60 Metal frame 90/90/90)
Non Load bearing FRL -240/240. *** DENOTES SEE SPECIFIC INSTRUCTIONS RE THESE RATES OF FRL FOR
TIMBER AS THE FRL VARIES ACCORDING TO TIMBER TYPE
BCA Volume 2 Part 3.7.4 Bushfire areas including all state variations to Part 126.96.36.199 and 188.8.131.52 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/1530.4/2005.
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)
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.net.au (FRL 30/30/30 TO 90/90/90).
* Prolonged submersion in water without an opportunity to dry out will void the FireCrunch WARRANTY, TREAT THIS PRODUCT AS AN INDOOR PRODUCT STORE OUT OF WATER, UNDER COVER, PRIOR TO SEALING AND PAINTING.
Although FireCrunch does not degrade in water it should not be left out in the rain as there will be a low % of HYDRATION IE, absorption of water. If this does happen the board will have to be dried out before use… drying out the board will not cause warping or any loss of integrity.
FireCrunch should always be stored flat in a dry undercover space on a horizontal pallet or on supports spaced at 450mm centres. It should not be stored laid directly on the ground.
AND DO NOT LEAVE THE BOARD HANGING OVER THE PALLET EDGES OR GLUTS OVER 450MM IT MUST BE SUPPORTED FLAT as all time prior to use.
Always handle with at least one person at each end of the board. With hands apart, lift the board and tilt 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.
We cannot give you price variations here as plasterboard prices vary between suppliers, however, the cost of maintaining plasterboard in the long term well outweighs the cost of installing FireCrunch to begin with. PLUS ONLY 1 LAYER OF 10MM FCA, EQUALS 3 LATERS OF 13MM
PLASTERBOARD SUBSTANTAILLY LOWER INSTALL COST IN MATERIALS AND LABOUR
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 has one tenth the carbon footprint of fibre cement plaster board 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 manufacturing 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 four (4) hours and board did not ignite or pass flames) CSIRO.
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 )
AS/NZS 1530.8.2 see burn down attempt CSIRO, video, posted web site late January 2017 .
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; meets 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),which is 90 minutes not 30 single 10mm sheet per side of frame
FIRE RESISTANCE LEVEL (FRL) 90/90/90
FireCrunch has a high sound insulation rating : Rw62 PLUS ctr NET Rw 52.
FireCrunch exceeds BCA minimum requirements for airborne sound insulation for a wall between
Termites, one of the worst contributors to home damage, have no interest in FireCrunch, they cannot consume it and are repelled by (MgSO4) TOTAL PROTECTION FOR EXPENSIVE TIMBER FRAMING
FireCrunch contains no formaldehyde, no asbestos and no toxic chemicals. OR CORROSIVE MAGNESIUM CHLORIDE Fire crunch uses Magnesium Sulphate (MgSO4) being a non-corrosive element and in this regard is unique at present in Australia ( NO VOC)
Standard FireCrunch is a highly water resistant product in that it does not retain water if unsealed.
This means that an “unsealed board will absorb some moisture in damp or wet areas ” if left unsealed. You should not expect the board to hold it’s integrity if submerged in water or exposed to multiple wet/dry processes, before use particularly without adequate MgO sealing.
USE SPECIAL MgO Sealer by Rockcoat and Dulux ( warranty) see under recommended products
web site firecrunch.com.au/recommended-products/
FireCrunch should not be left out in the rain or humidity before sealing /priming . Because it is a
breathng permeable board it will hydrate when not sealed. However, IF INADVERTENTLY LEFT IN THE WET OR IN EXTERIOR WEATHER moved to a dry environment with seperated sheets FireCrunch will dry out quickly without swelling or warping and hold it’s integrity . FireCrunch that has been installed externally 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. ALLOW TO DRY COMPLETELY BEFORE PAINTING or RENDERING. Hydroscopic reading 15 or under
FireCrunch board called (Type FCA) is SOLD in 10mm SE AND TE and 19mm TG Tongue and
Groove for flooring and bush fire roofing substrate and is designed for internal/external use so it the best choice for flooring and decking in wet area or external applications PRE SEAL FCA
BOARDS WITH MgO primer sealer Dulux or Rockcoat
Tests have been carried out at the NATA Brick & Mortar Research Laboratory in Melbourne VIC. AN AUSTRALIAN NATA ACCREDITED TESTING AUTHORITY
Standard Square Edge 19/20mm FireCrunch (Over 450mm AND 600 CENTRES 5.3 AND 6.2
KN see span test web site
FireCrunch MUST NOT BE NAILED, USING NAILS WILL VOID THE WARRANTY, SCREW FIX ALWAYS. TAKE NOTE OF THE RECOMMENDED SCREWS THAT MUST BE USED.
FireCrunch www.firecrunch.com.au FSEE WEB FOR THESE FIXINGS Technical manual FCA warrant the board only when the correct screws and system manuals are adhered to. firecrunch.com.au/recommended products
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 corrosion protected) 8-10 Countersinking 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 or intertenancy walls 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 Rw62 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 made up of a combination of primarily Magnesium Oxide (MgO) and Magnesium Sulphate (MgSO4) This has been bonded with a small percentage of organic and IP composite materials, strengthened with fibre mesh.
MgSO4 is a new development in the FCA range and replaces Mag chloride ( MgChl2) with Mag sulphate and eliminates all metal corrosion, a common problem with ordinary MgO chloride boards (MgChl2)
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 sourced from magnesium mining. Magnesium oxide is a waste by product of external use process in steel manufacturing .
ENVIRONMENTAL — FCA is 100% better
FireCrunch is produced by the addition of magnesium sulphate to the mag oxide and lime followed by a heat process
using low Co2 kiln temperatures ,50% LESS than plaster board products, so 50% less Co2 .
During the carbonation process of manufacturing, FireCrunch draws back 90% of the 50% Co2 created to produce FCA
and makes it a virtually carbon neutral product.!!
Further, FCA eliminates the “additional destruction “of millions of oxygen producing trees each year to manufacture
weak ineffective low R value insulation, paper lined plaster board and protecting them from termites, floods and fire !!
*** ( DENOTES– READ TIMBER FRAMING SPECS FOR FRL 30/30/30 ( Bush fire manual ) AND FRL 60/60/60 (Main Fire Manual)before commencing work on any fire walls web site firecrunch.com.au /manuals
Load bearing FRL of —/120/120 more on application of additional 10mm sheet per side
The Building Code of Australia (BCA) defines the Fire Resistance Level (FRL as the testing period in minutes for three criteria:
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 warm space, preferably with low humidity. The boards will not be damaged or degrade if handled correctly. Once dry, install and immediately before or after installation seal the exposed face of the board with the recommended “MgO sealer” by RockCoat or Dulux. see recommended products. once sealed you can use most normal water based paints and renders
The FireCrunch standard ranch of sizes is as follows:
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 four different thicknesses: 3mm; 6mm; 8mm,( SPECIAL ORDER )10mm; and 19mm TG which cover most 80/90% of all fire requirements
There are also a few different types of edges for different types of application. To simplify this, please view the chart on web site under technical /home page browser
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 from the links below. or on web site home page browser Recommended products.
Rockcoat – and Dulux mfg MgO sealer primers, you must use one of these before applying other paints finishes or renders ( warranty issue).
Although FireCrunch tends to perform very well with most standard products, drying times may vary. All standard type renders can be used with FCA FireCrunch, Render Systems Australia – Multiple Render Products. check suppliers instructions.
Render Systems Australia – Multiple Render Products
Rock Cote Render products
Pro Plaster base and – 4T Multi-Purpose topping compounds “must be used with FCA” to retain the warranty, other manufacturers products will not be warranted with FCA products. Set in usual way but use only fiber mesh type Fiber fuse tapes exterior and interiors or to Mfg specs
We have stockists IN NSW, QLD,VIC, with more to come soon. In other states or where FireCrunch has no local supplier , APPLICATION CAN BE MADE FOR DIRECT SUPPLY FROM FireCrunch.