Castellation Cladding Installation Guide

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Castellation CladdingInstallation Guidenewtechwood.com.auCastellation Cladding Installation Guide/ 2021AUS

IMPORTANT NOTE – READ ALL SECTIONS BEFORE YOU STARTFor the most up to date information, please visit our website @ www.newtechwood.comCONTENTSImportant Notes . 3Expansion and Contraction Values .4Castellation Cladding Parts . 5Under Construction .7Battens Installation.7Locking the Wall Cladding Board.8Castellation Cladding - Vertical Installation.9-Framing.9-Trim Installation. 12-Introduction of the Cladding Board Installation. 12-Installing the First course at the Inside Corner. 13-Installing the Second course at the Inside Corner.14-Installing the Last board at the Inside Corner. 16-Before installation on Wall C and Wall D. 19 Wall C: Cladding between two Outside Corner Trims (UH51). 19 Wall D: Cladding between Outside Corner Trim (UH51) & F-Trim (UH5O). 19-Installing the First course on Wall C and Wall D. 21-Installing the Second course on Wall C and Wall D. 23-Continuing the Remaining Installation. 23-The Final Appearance of the Completing Installation. 27Castellation Cladding - Horizontal Installation.28-Framing. 28-Installing the Trims on the Starting Point. 31-Starting Trim (AW02) Installation. 33-Installing the First Course.34-Installing the Second Course. 36-Installing the Last board. 38-The Final Appearance of the Completing Installation. 40Ceiling Lining Section.41Window Reveal Section.472 Castellation Cladding Installation Guide/ 2021AUS

The diagrams and instructions outlined in this guide are for illustration purposes only and are not meantor implied to replace a licensed professional.Any construction or use of NewTechWood must be in accordance with all local zoning and/or building codes.The consumer assumes all risks and liability associated with the construction and use of this product.SafetyWith any type of construction project, it is necessary to wear appropriate safety equipment to avoid any risk ofinjuries. NewTechWood recommends, but does not limit it to the following safety equipment, when handling,cutting, and installing NewTechWood: gloves, a respiratory protection, long sleeves, pants, & safety glasses.ToolsStandard woodworking tools may be used. It is recommended that all blades have a carbide tip. Standardstainless steel or acceptable coated deck screws and nails are recommended.EnvironmentA clean, smooth, flat, and strong surface is needed to install NewTechWood products correctly. Ifinstallation does not occur immediately, NewTechWood’s products need to be stored on a flat surface atall times. It should NEVER be stored on an uneven surface.PlanningPrior to installing any composite cladding system, it is recommended that you check with local buildingcodes for any special requirements or restrictions. Building codes and zoning ordinances generally applyto permanent structures, meaning anything that is anchored to the ground or attached to the house.Plan a layout for your cladding before starting it to ensure the best possible looking cladding for yourproject. We recommend drawing a site plan for your proposed cladding project to minimize errors andensure a successful outcome.Perform a pressure washing test on a scrap piece of material before using a pressure washer on thewall cladding to ensure that your settings will not damage the Ultrashield coating.ConstructionNewTechWood is NOT intended for use as columns, support posts, beams, joist stringers, support againsta force, or other primary load-bearing members. NewTechWood must be supported by a code-compliantsubstructure. While NewTechWood products are great for retrofits, NewTechWood ‘s products CANNOTbe installed on existing cladding boards.StaticStatic can be more prevalent in areas that are of higher altitude because the humidity is lower. For theseareas, be careful of using conductive objects such as metal railing and chairs as static shocks might occurmore often. A potential way to lower the amount of static shocks occurring is to apply Staticide(www.aclst aticide.com).VentilationNewTechWood products CANNOT be directly installed onto a flat surface. It must be installed onto asubstructure, so there is adequate and unobstructed air flow under the cladding to prevent excessivewater absorption. A minimum of 25 mm of continuous net free area under the cladding surface isrequired for adequate ventilation on all cladding, so air can circulate between adjacent members topromote drainage and drying.Heat and FireExcessive heat on the surface of NewTechWood products from external sources such as but not limitedto fire or reflection of sunlight from energy efficient window products. Low-emissivity (Low-E) glass canpotentially harm NewTechWood products. Low-E glass is designed to prevent passive heat gain withina structure and can cause unusual heat build-up on exterior surfaces. This extreme elevation of surfacetemperatures, which exceeds that of normal exposure, can possibly cause NewTechWood products tomelt, sag, warp, discolour, increase expansion/contraction, and accelerate weathering.Current or potential NewTechWood customers that have concerns about possible damage by Low-E glassshould contact the manufacturer of the product, which contains Low-E glass for a solution to reduce oreliminate the effects of reflected sunlight.CleaningWe recommend 'Urban Deck-Wash' to clean your cladding, available from all NewTechWood Resellers.Pressure washing on a scrap piece of material before using a pressure washer on the wall cladding toensure that your settings will not damage the Ultrashield coating.Castellation Cladding Installation Guide/ 2021AUS 3

FastenersWhen fastening NewTechWood products all screws that are face fixed should always be stainless steeland be driven in at a 90 degree angle to the cladding surface. Toe screwing should never be done to theproducts. An extra joist should be added if a 90 degree angle cannot be driven into the board. All fastenersshould be on their own independent joists, and when two boards ends meet each other there must be asister batten. The end of each board must sit on its own batten.Use white chalk, straight boards, or string lines as templates for straight lines. NEVER USE COLOUREDCHALK. Coloured chalk will permanently stain NewTechWood’s products and are highly not recommended.Depending on the screws that you use when face fixing, there could be potential bulging ormushrooming. It is recommended to take care of these mushrooms/bulges by taking a rubber mallet andpatting them down to smooth out and improve the appearance.Always look to select screws that have been engineered specifically for composite wood. These screws willalways work and give NewTechWood ‘s products the best looking outcome, using other screws that arenot recommended for composite could potentially damage/harm the cladding. If you are unsure whichscrew to use, contact your manufacturer for more information.Pre-drillWhen face fixing, it is recommended to pre-drill the holes slightly larger than the screw’s shank sizeon the cladding profiles and the trims to allow for expansion and contraction response to temperaturechange, as shown in below diagram.Screw's Head SizeCladding ProfilesorTrimPredrilled Hole SizeScrew's Shank SizeEXPANSION AND CONTRACTION VALUESNewTechWood cladding boards will experience expansion and contraction with changes in temperature.Expansion and contraction are most significant where extreme temperature changes occur. Fasteningthe cladding boards according to the gapping requirements noted in the following table accommodatesfor this 70.81.01.1GAP (mm)InstallationTemperature (C)LENGTH (METRES)Please Note:1. T he above table shows the OVERALL GAP required. If boards have a gap at each end, then halve thevalue shown.2. If you are still unsure of what gap to use, contact the manufacturer and they will give you the correctgapping requirements based on your environment and area.4 Castellation Cladding Installation Guide/ 2021AUS

CASTELLATION CLADDING PARTSProductPurposeAW-02Used for the installation ofthe first boardAW-08Used at every joist to fixeach board to the battenT-7Used on the support forthe last boardUH61Castellation CladdingBoardUH5OF-Trim, used as the firstand last boardUH51Outside Corner Trim, usedon the outside cornersPartCastellation Cladding Installation Guide/ 2021AUS 5

CASTELLATION CLADDING SCREWSPurposeUsed when locking the claddingboard into AW08 clip(Screws supplied by NTW andpurchased with cladding boards)ForTIMBERBattensForMETALBattensM3 X 12 SS304Part code: WJ063Used when installing AW08 clips into battens(Screws not included, sourced/suppliedby builder/ installer)8G x 20 SS304(Pan Head)8G x 20 SS304(Pan Head)8G x 20 SS304(Flat CSK Head)8G x 20 SS304(Flat CSK Head)8G x 50 SS304Colour HeadComposite Screw(Supplied by NTWand purchased withcladding boards)8G x 20 SS304(Flat CSK Head)(Screws not included,sourced / supplied bybuilder / installer)Used when installing trims into timber battens(Screws not included, sourced/supplied by builder/ installer)Used for face fixing the first and lastcladding boards next to trims*Note: All screws are based on our recommendation and if the installation requires something differentthan what is shown, a professional should be consulted before installing. The following installation guidewill use the above screw sizes.6 Castellation Cladding Installation Guide/ 2021AUS

Under ConstructionWe recommend for the underconstruction metal/aluminium TopHat Battens or Pre-primed H3 TimberBattens. Each cladding board needs tobe supported by a batten spanning NOMORE than 500mm on centres. Extracare is required in order to providesufficient joisting in and aroundobstacles such as windows, fascia's,soffits, guttering, ventilation points, etc.Here is an example of the layers thatwould occur in a typical installation,however, a licensed professional shouldalways be consulted prior to leNewTechWoodUltrashieldCladdingBattens InstallationA building professional should be consulted regarding vapour barriers and insulation for your project.Where a vapour barrier is to be used, it should be a breathable type and must be positioned behind thebattens. The batten needs to have a minimum thickness of 25mm.Battens should be fixed into position at a maximum of 500mm centres using a suitable A4 Stainless SteelCountersunk Wood/Masonry screw.All battens need to be flat and levelled against the wall surface using shims if necessary.Batten500mm500mmBattenHorizonal InstallationVertical InstallationCastellation Cladding Installation Guide/ 2021AUS 7

Locking the Wall Cladding BoardEvery AW - 08 clip comes with a separate hole in the case there is a need to lock the board. The wallcladding boards will expand and contract and to take care of this movement, we must lock the board inone position, ONLY ONE LOCKING SCREW USED PER BOARD, and then allow the board to expand andcontract readily in the other direction .You can see how we lock the board in Diagram A, B, and C.Please Note: DO NOT LOCK EVERY CLIP.General rule of thumb is every board willonly need one locking/ fixation point.BattenScrewM3 x 12(part codeWJ063)Clip (AW08)BoardNo LockingLockingwith screwOriginal Imagesneeded or file nameDiagram ADiagram BDiagram C8 Castellation Cladding Installation Guide/ 2021AUS

CASTELLATION CLADDING - VERTICAL INSTALLATIONInstallation ProcedureStep 1: Framing- Measure and Chalk the Battens- Battens Installation Step 2: Trim InstallationStep 3: Cladding Board Installation- Installing the First Course- Installing the Second Course- Continuing the Remaining Installation- Installing the Last Board1FramingThe frame needs to be level before installing the cladding boards. Diagram 1 shows the wall replicatingdifferent scenarios potentially occuring when installing the cladding boards.Wall Side A: Cladding between the F-Trim (UH50) and the Inside CornerWall Side B: Cladding between the Inside Corner and the Outside Corner Trim (UH51)Wall Side C: Cladding between two Outside Corner Trims (UH51)Wall Side D: Cladding between the Outside Corner Trim (UH51) and the F-Trim (UH50)WallSide DWall Side AInsideCornerOutsideCornerOutermostEdgeWall Side BWall Side CDiagram 1Castellation Cladding Installation Guide/ 2021AUS 9

Measure and chalk the battensaccording to the span data specified onpage 4 of this installation guide, as shownin Diagram 2.2Fix the battens onto the wall that youintend to install with screws. Pleasereview page 4 to see what span isneeded, as shown in Diagram 3.3Detail 3-4Detail 3-2Detail 3-5Detail 3-3Min 500mmMax 1000mmDiagram 2Detail 3-1Diagram 3Please Note:Please Note:1. We are using timber battens for thisinstallation. If you are using metal/aluminium battens, please refer to page6 of this installation guide for the correctrecommended screws.1. A minimum clearance of 40mm needs to beleft between the lowest batten and the floor, asshown in Detail 3-1.Batten40mm2. An adequate span between the battens isrequired to keep the boards from bending.Please review page 4 of this installation guideto see what span is neededWallFloorDetail 3-110 Castellation Cladding Installation Guide/ 2021AUS

Please Note:2. A minimum clearance of 10mm needs to beleft between the ceiling and the top of thebattens, as shown in Detail 3-2.CeilingWallWall10mmBattenDetail 3-4BattenDetail 3-2WallPlease Note:3. For the Outermost Edge (F-Trim UH50), pleaseinstall according to Detail 3-3.4 . For the Inside Corner (No trim is needed),please install according to Detail 3-4.Batten5. For the Outside Corner (Outside Corner trimUH51), please install according to Detail 3-5.Min 5mmMax 7mmDetail 3-5WallBattenEnd Trim (ST US44)Detail 3-3Castellation Cladding Installation Guide/ 2021AUS 11

4Trim InstallationFasten the F-Trim (UH50) onto theoutermost edges and the Outside Corner Trim(UH51) onto the outside corners with screws, asshown in Diagram 4.Wall Side Atg poininStartStWallSide Dartingpo5Cladding Board InstallationIt is recommended to start theinstallation according to Diagram 5.Wall Side AStartinStarointing pStartgpWallSide DtingStartingppointoinointointing pStarttintointing CornerOutermostEdgeOutermostEdgeWall Side BWall Side BWall Side CWall Side CDiagram 5Diagram 4Please Note:Please Note:1. A minimum clearance of 20mm needs to beleft between the trims and the floor, as shownin Detail 4-1.1. Wall Side A: Cladding between the F-Trim(UH50 and the Inside Corner,- Start from the Outermost Edge.2. Wall Side B: Cladding between the InsideCorner and the Outside Corner Trim (UH51),- Start from the Outside Corner.F-Trim (UH50)orOutside CornerTrim (UH51)3. Wall Side C: Cladding between two OutsideCorner Trims (UH51),- Start from one of the Outside Corners.4. Wall Side D: Cladding between the OutsideCorner Trim (UH51 and the F-Trim (UH50),- Start from the Outside Corner.FloorDetail 4-112 Castellation Cladding Installation Guide/ 2021AUS20mmWall

6Installing the First Course- Wall Side A (Cladding between theF-Trim (UH50) and the Inside CornerBattenWall- Wall Side B (Cladding between the InsideCorner and the Outside Corner trim (UH51)Put the first Castellation Cladding Board (UH61)in place, then face fix it the side next to the trimonto the batten with screws (NTW 8Gx50 colourhead composite screw), and fasten its otherside onto the batten with Clip (AW08), as shownin Diagram 6.F-Trim(UH50)Clip(AW08)12.5mmBoard(UH61)Face fixingthe board ontothe battenOutermost Edge (F-Trim UH50), as shown inDetail 6-1.Detail 6-1Outside Corner (Outside Corner Trim UH51), asshown in Detail 6-2.Clip (AW08)BattenWallDetail 6-3Clip(AW08)12.5mmBoard(UH61)Face fixingthe board ontothe battenBoard(UH61)OutsideCornerTrim(UH51)Detail 6-2Detail 6-4Diagram 6Please Note:Pre-drill the face fixing holes on the first boardbefore installation to allow for expansion andcontraction. Please review page 4, "Pre-drill", ofthis installation guide for further information.Castellation Cladding Installation Guide/ 2021AUS 13

Please Note:1. Since the composite wood must allow forexpansion and contraction due to temperaturechange, the board must be locked at one fixedpoint but only one point to allow the remainingboard to move freely. When installing vertically, itis required to lock the Clip (AWO8) at the top ofeach board, as shown in Detail 6-3.DO NOT LOCK any other Clip (AWO8) for thesame board.Please review page 13, "Locking the WallCladding Board" of this installation guide forfurther information.Lockingthe Clip (AW08)at the topof each board7Installing the Second Course- Wall Side A (Cladding between theF-Trim (UH50) and the Inside Corner- Wall Side B (Cladding between the InsideCorner and the Outside Corner trim (UH51)Put the second Castellation Cladding Board(UH61) over the first board's Clip (AW08) andfasten its other side onto the batten with the Clip(AW08), as shown in Diagram 7.Outermost Edge (F-Trim UH50), as shown inDetail 7- 1.Outside Corner (Outside Corner Trim UH51), asshown in Detail 7-2 .Clip (AW08)Detail 7-3Clip (AW08)ONLY ONE LOCKING SCREWTO BE USED PER BOARDBoard(UH61)Detail 6-3Please Note:Allow a gap of at least 20mm between the floorand the Cladding board.Clip (AW08)BoardFloor20mmWallDetail 6-414 Castellation Cladding Installation Guide/ 2021AUSDiagram 7

Please Note:Outermost Edge (F-Trim UH50), as shown inDetail 7-1.1. Since the installation of composite wood mustallow for expansion and contraction due totemperature change, the board must be lockedat one fixed point but only one point to allow theremaining board to move freely. When installingvertically, it is required to lock the Clip {AWO8) atthe top of each board, as shown in Detail 7-3.WallClip(AW08)F-Trim(UH50)DO NOT LOCK any other Clip {AWO8) for thesame board.Board(UH61)WallClip(AW08)Please review page 13, "Locking the Wall CladdingBoard" of this installation guide for furtherinformation.Lockingthe Clip (AW08)at the topof each boardDetail 7-1Outside Corner (Outside Corner Trim UH51), asshown in Detail 8)Clip (AW08)WallClip(AW08)Detail 7-2ONLY ONE LOCKING SCREWTO BE USED PER BOARDDetail 7-3Castellation Cladding Installation Guide/ 2021AUS 15

When you are at the last cladding boardthat the installation is toward the insidecorner from the F-Trim (UH50), measureand record the distance between the adjacentbatten and the Clip (AW08), as shown in Diagram8-1 and Detail 8 -1.8When you are at the last cladding board that theinstallation is toward the inside corner from theOuside Corner Trim (UH51), measure and recordthe distance between the adjacent batten andthe Clip (AW08), as shown in Diagram 8-2 andDetail 8-2Detail 8-1Detail 8-2Diagram 8-1BattenClip (AW08)WallWallBattenBBoardDiagram 8-2Clip(AW08)ADetail 8-116 Castellation Cladding Installation Guide/ 2021AUSBoardDetail 8-2

Put a 90 degree metal flashing (Blackpowder-coated) in the inside corner andsecure it onto the battens with screws, asshown in Diagram 9.990 Flashing(Black powdercoated)10Fasten the Stoppers (T-7) beside both sidesof the 90 degree metal flashing, as shownin Diagram 10-1 and Diagram 10-2.90 Flashing(Black powdercoating)RubberStopperT-7BattenDiagram 10-190 Flashing(Black powdercoating)Diagram 9RubberStopperT-7BattenDiagram 10-2Castellation Cladding Installation Guide/ 2021AUS 17

1110mmCut the two last cladding boards accordingto the below calculation options,Option 1: "A" minus 38mm, "B" minusOption 2: "A" minus 10mm, "B" minus 38mmFace fix the two last cladding boards ontothe battens against the Rubber Stopper(T-7) with screws (NTW 8Gx50 colour headcomposite screw), as shown in Diagram 12-1 andDiagram 12-2.12Prior to cutting the boards, cut the scrap piece ofmaterial to determine which options can obtainthe better board adjoining appearance, as shownin Diagram 11 and Detail 11-1.Diagram 11Option 1orOption 2CutDiagram 12-1Detail 12-1Detail 12-2BoardDetail 11-1Diagram 12-218 Castellation Cladding Installation Guide/ 2021AUS

Option 1 installation ("A" minus 38mm, and "B"minus 10mm), as shown in Detail 12-1Face fixing theboard ontothe battenBlack ColourFlashingWall13Before Installation on- Wall Side C (Cladding between twoOutside Corner trims (UH51)- Wall Side D (Cladding between the OutsideCorner trim (UH51) and the F-Trim (UH50)Measure the distance in between the trims, asshown in Diagram 13-1.T-7BoardA min gapof 3 mmBattensDetail 12-1Option 2 installation ("A" minus 10mm, and "B "minus 38mm), as shown in Detail 12-2Face fixing theboard ontoBlack Colourthe battenFlashingWallT-7BoardDiagram 13-1Detail 13-1 shows the measurement "A" inbetween the Outside Corner trim (UH51) and theF-Trim (UH50).A min gapof 3 mmBattensDetail 12-2OutsideCornerTrim(UH51)AF-Trim(UH50)Detail 13-1Castellation Cladding Installation Guide/ 2021AUS 19

Detail 13-2 shows the meaurement "A" inbetween two Outside Corner Trims (UH51).Once you know the measurement "A”, you mustcalculate:- The number of full profiles requiredCoverage of 186mm per board-- The width that the final profile will need topossibly be ripped down toThis will allow you to determine the overall gapvalue of “E”, between the trim and the claddingboard, as shown in Detail 13-3.NOTE: Depending on your façade size, you couldlook to create a gauge of installed cladding piecesthat can be held up to your façade, to facilitateease of calculating these H51)Detail 13-2EEADetail 13-320 Castellation Cladding Installation Guide/ 2021AUS

14Installing the First Course- Wall Side C (Cladding between twoOutside Corner trims (UH51)- Wall Side D (Cladding between the OutsideCorner trim (UH51) and the F-Trim (UH50)Put the first cladding board in place with theclearance value of "E" between the trim, and facefix it the side next to the trim onto the battenswith screws (NTW 8Gx50 colour head compositescrew), as shown in Diagram 14.OutsideCornerTrim(UH51)Detail14-1EBoardFace fixing theboard ontothe battenDetail 14-1BoardClip (AW08)WallDetail 14-2Please Note:1. Pre-drill the face fixing holes on the first boardbefore installation to allow for expansion andcontraction. Please review page 4, "Pre-drill", ofthis installation guide for further information.2. A minimum clearance of 20mm needs to beleft between the cladding board and the floor,as shown in Detail 14-2.Floor20mmDiagram 14-1Detail 14-2Castellation Cladding Installation Guide/ 2021AUS 21

Secure the board onto the battens with the Clip(AW08), as shown in Diagram 20 .Please Note:1. Since the composite wood must allow forexpansion and contraction due to temperaturechange, the board must be locked at one fixedpoint but only one point to allow the remainingboard to move freely. When installing vertically, itis required to lock the Clip (AW08) at the top ofeach board , as shown in Detail 14-3.Lockingthe Clip (AW08)at the topof each boardDO NOT LOCK any other Clip (AWO8) for thesame board.Clip (AW08)Please review page 13, "Locking the Wall CladdingBoard" of this installation guide for furtherinformation.Clip(AW08)Detail14-3Diagram 14-222 Castellation Cladding Installation Guide/ 2021AUSONLY ONE LOCKING SCREWTO BE USED PER BOARDDetail 14-3

15Installing the Second Course- Wall Side C (Cladding between twoOutside Corner trims (UH51)- Wall Side D (Cladding between the OutsideCorner trim (UH51) and the F-Trim (UH50)Please process the installation procedure same asStep 7 on page 19 to 20 of this installation guide.16Continuing the Remaining Installation- Wall Side C (Cladding between twoOutside Corner trims (UH51)- Wall Side D (Cladding between the OutsideCorner trim (UH51) and the F-Trim (UH50)The width of the cladding boards and the widthalong the installed cladding boards shouldbe a bit different versus the design due to thetolerance that occurred in the board productionprocess and installation work. Therefore, whenyou are at near 300mm beyond the next trim, it isrecommended to measure the distance betweenthe Clip (AW08) and the trim again to checkwith the result generated by the ''your initialmeasurements and calculations" spreadsheetand determine whether the last board rippingwidth needs to be adjusted, as shown in DiagramDetail 16-1Detail 16-216 -1 .Diagram 16-1Castellation Cladding Installation Guide/ 2021AUS 23

Detail 16-1 shows how to measure thedetermination measurement from the OutsideCorner Trim (UH51).Rip the cladding board according to the value offinal determination, as shown in Diagram 16-2and Detail 16-3.Cutting dimensionCutBoardThe automatic calculation spreadsheet resultDetail16-1 ONLYis for yourreferenceDetail 16-2 shows how to measure thedetermination measurement from the F-Tri

4 Castellation Cladding Installation Guide/ 2021AUS Fasteners When fastening NewTechWood products all screws that are face fixed should always be stainless steel and be driven in at a 90 degree angle to the cladding surface.

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