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K3T WALL SYSTEMState of the Art Magnesium Oxide Structural Panel Technology

The Story of Magnesium Oxide and the K3T Wall System

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The K3T Wall System is a CodeMarked, modular, prefabricated, load bearing, self-supporting wall panel system that provides both the exterior cladding and the interior drywall board all in one, and has incredible load bearing and tensile strength. It is lightweight, maintenance free, fireproof, waterproof, moisture, mould & mildew proof, rot proof, insect, termite & borer proof and impact, earthquake and cyclone category 5 resistant.

K3T Wall System was developed by local New Zealand company Global Fibre8 Ltd. Xfactorbuild Ltd holds a license to distribute and supply the panels throughout New Zealand. Xfactorbuild Homes Ltd markets new builds using the K3T Wall System.

Keeping it SimpleK3T Wall System consists of four components:

Integral one-piece Magnesium Oxide panel

Perlite (Volcanic rock) jointer/column,

Stainless steel screws

Ring beam of concrete and steel reinforcing.

Compare that with a timber frame wall: timber frame, building paper or Rigid Air Board (RAB), plaster/gypsum drywall board, cavity battens, exterior cladding, nails & screws, and all the specifications for each component that you have to match up to comply with the Building Code. Then it requires seven separate building inspections to be signed off. K3T requires only two inspections for sign off: Save time and money with the K3T Wall System.

Innovation on Ancient and Classical Structural Design PrincipleWith its “jointers”(essentially columns) and “ring beams” of concrete and steel re-bars built into the K3T Wall System, it’s based on the ancient and classical structural design principle of columns and beams, as were such antiquities as the Coliseum and the Pantheon. Columns and beams form the Super-structure at heart of robust construction. They are the structural building blocks of single to multi-storey high-rise buildings.



The unique ring beam and columns are made by pouring structural grade concrete into the top of the K3T Panels

K3T Wall System in Brief

One man can install a panel with this crane

SAI Global CodeMarkK3T Wall System has a SAI Global CodeMark and Certificate of Conformity for Australia and New Zealand. The CodeMark covers both the Product and the Building System for Class 1 to 10 buildings – everything from a garden shed to a high-rise building and all in between such as housing, apartments, hotels, motels, schools, hospitals, retirement villages, malls, shopping centres, warehouses, factories, light & heavy commercial and light & heavy industrial.

K3T for every kind of residential, commercial and industrial build

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SAI Global CodeMarkThe Manufacturing Plant, the Product and the Installation/Building System are all under the CodeMark. The power of the CodeMark is that under New Zealand government legislation it supersedes and overrules Local Body and Council building rules & regulations. This is because CodeMark, being a building product certification scheme, provides a nationally and internationally accepted standard for products to be assessed for compliance with building codes applicable in any country. In this way, a CodeMark provides impartial

What is Magnesium Oxide: MgO?Magnesium is the eighth most abundant element on the Planet and covers up to 8% of the Earth’s surface, and it is the third most plentiful element dissolved in seawater. It is processed into a metal oxide to become Magnesium Oxide and is often mixed with other magnesium


certification of building products as proof of compliance with the Building Code.

Indeed, many City and District Councils demand CodeMarks with certain products for their own use on maintenance and construction projects, as it gives them confidence and certainty knowing they have been rigorously tested to New Zealand standards and conditions. In the case of K3T, all standards for fire rating, water resistance and load bearing were far surpassed.

compounds like magnesium chloride and magnesium phosphate, and combined with other ingredients to form various cements and building materials and these are often generically referred to as MgO, the formulaic chemical symbol for magnesium oxide.

Great Wall of China, MgO mortar still holding after thousands of years Parthenon – Athens, Greece


This Certificate of Conformity is issued by an accredited certification body under arrangement with JAS-ANZ. The ABCB does not in any way warrant, guarantee or represent that the Product the subject of this Certificate of Conformity conforms to the BCA, nor accepts any liability arising out of the use of the Product. The ABCB disclaims to the extent permitted by law, all liability (including negligence) for claims of losses, expenses, damages and costs arising as a result of the use of the product(s) referred to in this Certificate

It is advised to check that this Certificate of Conformity is currently valid and not withdrawn, suspended or superseded by a later issue by referring to the ABCB website, www.abcb.gov.au.

CERTIFICATE OF CONFORMITYThis is to certify that

K3T Wall Panel System Product description

Complies with the Building Code of Australia (2015):1. Volume One - B1.1, B1.2, B1.4, C1.1, C1.10, C3.16 and FP1.4.

2. Volume Two - P2.2.2, 3.7.1.5 and 3.7.1.8, 3.11.2, 3.11.3, 3.11.6

Subject to the following conditions and limitations:1. The system must be designed and installed, inclusive of panel jointing, in accordance with the K3T Wall Panel System Installation Guide, Version 2.2

March 2015.

2. Each building is to have its own individual structural analysis and certification that is applicable to the site subject to the load category on that particular site.

3. The system must be used for its intended purpose.

4. The concrete slab/footings must be designed in accordance with the BCA provisions and to allow for the K3T wall panels to be installed.

5. An exterior finish is to be applied to the external face of the wall to ensure the wall is weatherproof and prevent the penetration of water that could cause—

(a) unhealthy or dangerous conditions, or loss of amenity for occupants; and

(b) undue dampness or deterioration of building elements.

A pre-fabricated wall panel system for Class 1-10 buildings

Models : 100mm, 150mm and 200mm

Product purpose or use

The K3T wall is made from pre-fabricated panels that are assembled onsite to form walls. The

panels are mechanically fixed to the floor structure and each other and include jointing

components.

Certificate holderEsttar International Pty Ltd

ABN: 89 1612 2453 11 Gerald St Greystanes, NSW, 2145

Ph.: +612 8761 1196Email: [email protected]

www.esttar.com

CodeMark certification body

SAI Global Certification Services Pty Limited(ACN 108 716 669) Trading as “SAI Global”

JAS-ANZ Accreditation No. Z1440295ASAddress: 680 George Street, Sydney, NSW 2000

Website: www.saiglobal.com 28/06/2015 27/06/2018 SAIG-CM20069Samer ChaoukHead of Policy, Risk & Certification For and on behalf of SAI Global

Paul BaileyUnrestricted Building Certifier

Date of issue Date of expiry Certificate Number

The History of Magnesium Oxide in ConstructionMagnesium oxide is a tried and proven building material and its uses in construction are ancient. Going back to antiquity, it was primarily used as a mortar component and stabilizer in soil and clay bricks. It has been identified in the Great Wall of China and Greek and Roman

Magnesium Oxide Construction in Modern TimesIn the West, Portland cement replaced magnesia for masonry uses in the late 19th century when energy was cheap, mould infection was poorly understood, public health concerns weren’t an issue, and with little appreciation that they were replacing the superior with the inferior in every respect from quality, strength, durability, salubrity, eco-friendliness and longevity.

The modern use of MgO sheathing goes back several decades. MgO boards have been used in Asia, USA, Canada and the Middle East on large, world-class projects,

Close up of the Coliseum

The pride of China – steel & MgO construction Taipei 101 – 101 floor skyscraper in Taiwan withexterior, interior walls & sub-floor of MgO board

Beijing 2008 Olympics Opening Ceremony

A platoon in the 8,000 strong Terracotta Army Mausoleum

constructions like the Parthenon and the Coliseum. Qin Shi Huangdi’s Terracotta Army has large amounts of MgO, credited with keeping the ancient statues from crumbling with age, which may be a reason for MgO composites often being referred to as ceramic cement.

particularly for partitions and firewalls. MgO building products have a long successful track record.

MgO sheeting was the “o�cial” speci�ed construction material for the Beijing 2008 Summer Olympics’ buildings. The project cost $160billion and used over 8 million square feet (743,224m2) of MgO boards. MgO board was used on all 101 levels of Taipei 101 in Taiwan, one of the tallest buildings in the world. It was used for all the interior and exterior walls, fireproofing beams and the sub-floor sheathing.

K3T and Magnesium OxideWith Magnesium Oxide as K3T’s base ingredient, imbedding layers of an almost indestructible woven mesh, this propriety formula is a technologically advanced building material providing remarkable and prevailing performance in every comparison to timber, gypsum & Portland cement based products, and even steel.

K3T and PerliteAnother astonishing material in the K3T Wall System is Perlite, which the jointers or columns are made from, also imbedding woven mesh to form it. The jointers join the panels together. Perlite is a volcanic rock, which like MgO is non-flammable and incombustible. It does not conduct heat so that the concrete and rebar, providing additional structural strength within the jointer, are impervious to extreme temperatures with fire. (See fire rating)

K3T SuperiorityK3T is a superior alternative wall system for affordable, durable buildings. The panels are made from 9mm thick MgO boards that are a solid homogenous mass from front to back, and will not delaminate over time, unlike the cardboard facings of plaster/gypsum drywall, especially if it gets wet for prolonged periods. K3T panels have phenomenal absorption qualities taking on coatings and adhesives that decorative finishes such as plasters, textures, paint, wallpaper, stone, brick and tile veneers will adhere to with great bonding strength.

Global Fibre8 have panel samples coated with an exterior textured finish that have been fully submerged in water for four or more years and show no sign of delaminating, and the panel has maintained its original 9mm thickness, showing no signs of swelling, decay or distortion. The (Water) Drip Rate test conducted for the CodeMark returned a reading of zero drip rate through the panel sheeting, which confounded the scientists in the light of its amazing absorption characteristics: how is it able to absorb paints, adhesives and plasters for an incredible bond and yet water won’t pass through it to the other side? Part of the answer could be that MgO board has the characteristic of expelling water and moisture, which is the reason it never rots, or grows mould and mildew.

State of the Art Magnesium Oxide Structural Panel Technology K3T WALL SYSTEM

Numerous tiles & brick veneers – note K3T panel at the top

The Perlite Jointer joins the panels together

Pallet load of panels delivered on site

Various plaster & textured finishes


Benefits of K3T Panels Prefabricated, load bearing and self-supporting

Expels water & moisture, which is why it never rots or grows mould & mildew

Vapor permeable

Does not expand or contract under changes of temperature

Does not degrade when immersed in water or exposed to freeze/thaw cycles for prolonged periods

Does not conduct heat or cold

Non-flammable and cannot be ignited – will not burn

Insect, termite and borer proof

Earthquake & Cyclone resistant

K3T Wall Panels are more than competitively priced, without even consideration relative to its extreme durability and longevity. They also provide lower costs during installation due to speedy construction and reduced maintenance expenditure in the mid to long term.

K3T Wall System: Panel Sizes1220mm Wide x 2700mm High x 100mm Thick - 81kg1220mm Wide x 2700mm High x 150mm Thick - 108kg1220mm Wide x 2700mm High x 200mm Thick - 135kg


A team of three can erect the walls of a standard 3-bedroom house in 3 to 4 days. Installation times for other trades like electrical and plumbing fit out are virtually cut in half, resulting in cost savings of 20% or more on your overall build.

Speedy installation saves labour costsLightweight crane saves equipment costs

Quick and Easy Installation

ElectricalPlumbing

Windows


Technical Information

Footing Detail – Rebated Concrete Slab

Connection & Bracing – Internal/External Corner Connection

K3T WALL SYSTEM

Global Fibre8 wanted to test K3T to its limit. To do this they had to build the testing rig themselves to SAI Global’s specifications. K3T was tested against the standard: AS/NZS 1170 Structural Design Actions (Part 0, 1, 2 and 5). Part 0 is General. Part 1 is Permanent (dead load), imposed (live load) and other actions. Part 2 is Wind Actions. Part 5 is Earthquake Actions in New Zealand. The standard for the load-bearing requirement of a structural wall in New Zealand is 7 tonnes, Australia 9 tonnes and international 32 tonnes. The K3T Wall failed at 95 Tonnes from an imposed or live load. The permanent or dead load capacity is 60 tonnes, exceeding the NZ standard by over 8 times.

The test was conducted on a wall of two 150mm thick panels, with jointers and ring beam, which gives the individual wall panels a 30 tonne dead load strength. The weight of a tile roof on a standard 3-bedroom house is approximately 20 tonnes. However, what the SAI Global team found even more astonishing was the fact the MgO wall sheeting did not shatter or explode into pieces

K3T Performance - Earthquake and Cyclone Resistant

Tested for CodeMark under AS/NZ 1170 Structural Design Actions (Part 0, 1, 2 and 5)

Hydraulic Power Machine delivers 95 tonne of force on the wall

SAI Global engineers expected the wall to break along the bottom. Wall broke only along the line of the ring beam

Astonishing: the wall did not shatter or explode from the massive compression, demonstrating its great flexibility & tensile strength

The steel framing buckled under the load!

from the massive compression demonstrating K3T’s great flexibility and tensile strength. Compare that to a concrete Tilt-Slab panel, which would explode like it was set with dynamite charges under a fraction of the 95 tonne live load. The K3T panel had cracked just along the line of the bottom of the ring beam from the expansion of the concrete under the huge forces of compression.

Under the CodeMark a minimum of 25mpa concrete is to be used in the ring beam, being the minimum that can be used in structural concrete under the Building Code. Global Fibre8 decided to push the envelope and test the use of a cheap concrete in the ring beam and jointer on the basis K3T technology will be exported to the Pacific Islands where they might not always use or be able to use the best concrete because of expense.A cheap ready-mix was used and SAI Global analyzed it to be 17.5mpa. How much more of a live and dead load could it have taken if 25+ mpa concrete was used?


Tested for CodeMark under AS/NZ 1170 Structural Design Actions

95 TONNE LIVE LOAD 60 TONNE DEAD LOAD

Every K3T Wall is a Firewall Every other Wall

The K3T Firewall Difference

K3T was tested by CSIRO (Commonwealth Scientific industrial Research Organisation) in Sydney, Australia under the fire rating standard (FRL) AS-1530.4 – Part 4 is the highest fire rating test and standard. New Zealand does not have a fire rating standard.

Two and a half K3T wall panels, complete with concrete & steel in the jointers & ring beam, were set up in the controlled furnace of CSIRO’s testing rig, with gas-fired burners covering the fireside. The panels in the fire test rig were subjected to a temperature of 1,000° C for I hour 3 minutes 48 seconds. The CSIRO technicians wanted to cease the test at that stage as they had never seen a material last so long, especially at 1,000° C. At the request of Global Fibre8 the fire’s temperature was increased to 1,100° C, but at the nearly one and a half hour mark at 1,100° Celsius, CSIRO insisted the �re test be stopped as it was melting the steel in their rig – steel melts at 800 to 900°C. The fire test was terminated at 2 hours 32 minutes 17 seconds.

The non-fire side to the touch was 80° C – see sensors wired to monitors in photo – demonstrating the panels extremely low thermal transfer. Magnesium oxide board does not conduct heat or cold.

1:03:48 1:07:05 2:27:01

FIRE RATING AS1530.4 2005 -/120/60

Finally a breach in the wall after 2 hours 27 minutes, but still the cotton wool did not ignite in the cotton wool test

Test after 1 hour and 3 minutes at 1000oC

CSIRO had never seen a building product last more than 15 minutes

After 2 and a half hours CSIRO insisted that the fire test be shut down as the steel beams in their control furnace were melting.

CSIRO had never seen a building product last more than fifteen minutes when fire tested under these protocols. A timber frame will ignite in five seconds under a fire of 1,000° C. A concrete Tilt-Slab panel is not much better. One was tested in the same rig. After 15 minutes at 500° C, water started running down the non-�re side like a waterfall, the steel started to twist and the concrete started to explode.

Most wall systems collapse or are incinerated within fifteen minutes at 500°C. That makes K3T ten times better �re protection and gives ten times longer to get out of a burning room or building.


We have all heard the cautionary tales of what happened to Kodak, BlackBerry, and Nokia because they failed to see where the technology was going. As a consumer, when a disruptive technology is upon us, it’s the relative cost of trading up that causes us pain or not, and whether it makes an improvement in our lives – and who likes to make a bad decision when we make a purchase? Changing your old mobile for the latest smartphone and having buyer’s remorse because you realised you should have bought the iPhone instead of the Samsung Galaxy or visa versa, might be an aggravation you can live with until you are up for a new phone in a year or two, or when you

Disruptive Technology K3T vs Tilt-Slab Panels

K3T vs Timber Frames

decide you need a new phone. But choosing a building technology for your new home or commercial building is fraught with far greater pain if we make a bad decision, because we may be stuck with it for years, and it may even impact on your way of life as the Leaky Home Syndrome did to many New Zealand families. K3T Wall System will not only ever become a leaky home: it will prevent a leaky home. It’s the New Drywall. As the New Drywall it won’t crumble on its screws and fall off its timber frame wall like plasterboard/gypsum drywall has, especially if it becomes wet through or in an earthquake. For a start, K3T Wall System has no timber component.

We call K3T a disruptive technology because it can replace walls of timber framing and all its components with a wall of self-supporting panels, with the two opposite facings fused together with a web of ribs made from the same magnesium oxide board, making the panel integral and one piece; with any side or facing of the panel able to be used as the exterior side or the drywall side. Timber wall technology cannot compare with K3T’s �re rating, water, moisture, mould & mildew resistance, durability; impact, earthquake & cyclone resistance; and being rot and insect proof. Concrete & steel rebars in jointers & ring beam remain intact after fire test


The K3T Wall System can also replace concrete Tilt-Slab panels with superior load bearing strength, bending moment (18.5mpa), eco-friendliness, water, moisture, mould, �re, earthquake & cyclone resistance. K3T was tested for fire rating by CSIRO in Australia for two and a half hours at up to 1100° Celsius to achieve the highest possible fire rating of AS-1530 Part 4. A concrete Tilt-Slab panel was tested in the same controlled furnace under gas-fired burners and after 15 minutes at 500° Celsius, water started to run down the front of the non-fire side like a waterfall, the steel reinforcing started to twist and the concrete started to explode.

You may ask: what about the concrete and steel rebars in the K3T jointers and ring-beams during the fire-rating test? Good question. It was encased in the perlite jointers and magnesium oxide flange at the top of the panel, which provides a type of boxing or formwork for the ring-beam, and both these materials do not conduct heat, having minimal thermal transfer, and so protected the concrete and steel from twisting & exploding in the fire.

K3T and Wall Design & HealthIn a world of environmental pollution and contaminants we want to design homes and buildings that are so called Green and Eco-friendly. We want to design walls that breath to prevent Sick Building Syndrome, and K3T is a wall that breathes. We want to design walls that will protect us, and we want to design our environment to resonate at a natural biological level. K3T as a Green building product will provide all of this for healthy, eco-friendly and energy e�cient buildings.

Magnesium oxide is taken internally as a health supplement as a remedy for heartburn, indigestion and low magnesium levels. K3T magnesium oxide walls are non-hazardous, non-toxic, have anti-microbial properties and are mould & mildew resistant, making it ideal for those that have chemical sensitivities and allergies. K3T has no out-gassing, asbestos, silica or formaldehyde and is resistant to EMF – electromagnetic frequencies. Building products made from MgO save trees and forest resources, which may be better and sustainably used for furniture making and finishing work.

K3T creates a comfortable ambient environment: Cold outside warm inside, hot outside cool inside.

Avoid the heartbreak of a leaky home

K3T Wall System will never be a leaky home. Timber is timber and with all the will in the world to prevent water ingress into your timber frame home, if it gets in it will eventually rot. Why not take the risk right out of the equation with K3T magnesium oxide panels. Magnesium oxide board expels water and moisture, and is vapour permeable, which is why they don’t rot, or grow mould or mildew. K3T is a wall that breathes. As a mineral and non-nutrient, MgO is also inedible to insects, which is why it is borer and termite proof. MgO is also unignitable – it won’t burn, so every wall is a firewall.

K3T is a superior alternative wall system for a�ordable, durable buildings. The panels are made from 9mm thick MgO sheets that are a solid homogenous mass from front to back, and will not delaminate over time, unlike the cardboard facings of plaster/gypsum drywall, especially if it gets wet for prolonged periods. Paradoxical to its characteristic of expelling water and moisture, K3T has such phenomenal absorption qualities to take on coatings and adhesives that decorative finishes such as stucco, plasters, renders, paint, wallpaper, stone, tile and brick veneers will adhere to it with great bonding strength.

Prevention is Better than Cure

No more LEAKY HOME SYNDROME with K3T Wall System


K3T Wall System in Commercial and Industrial BuildsThe K3T Wall System can be used for the construction of a complete single or multi-storey building, with the super-structure provided by its jointers and ring beams, and all the exterior and interior walls. However, it can also be incorporated into a building with other column and beam technologies - such as concrete or steel frame super-structures - providing either the interior or

Concrete frame super-structures: K3T Wall System replaces out timber frames and all the required linings: building wrap, rigid air boards, cavity battens, exterior cladding, and drywall. Note the timber framing in the photo: 140mm x 35mm (6”x 2”) with 200mm centres – a lot of timber to burn, and never mind the rigid air barrier if it’s plywood or (OSB) Oriented Strand Board. There is no rigid air barrier required with K3T and it’s a firewall for inter-tenancies.

For non-load bearing walls there is no concrete ring beam: The panel is turned upside down so the 300mm flange at the top slots into the P4 plate, which is a perlite jointer fixed to the floor.

The “non-loading” 100mm panel was tested to a load bearing strength of 19 tonne.

The K3T Wall System can also replace concrete Tilt-Slab panels in a steel or concrete super-structure with all the benefits of superior load bearing, fire rating, eco-friendliness, and moisture, mould, earthquake and cyclone resistance; and making huge savings with product cost, delivery lead time, crane hire, installation and speed of construction.

Steel Frame Super-structures: specify K3T over Tilt-Slabs (shown left) for superior load bearing, fire rating, moisture & mould resistance and savings on product cost, delivery lead-time, crane hire, installation and speed of construction.


exterior walls, or both. For example: in an apartment block, hotel, motel, retirement village or high-rise.

K3T is a firewall and is soundproof using a particular insulation, so it’s ideal for inter-tenancy walls such as in an apartment, motel or high-rise building.

Acoustics: STC 52 19 tonne loadbearing strengthP4 Plate

State of the Art MgO Technology and the K3T Point of DifferenceWith the myriad of building technologies out there, good and bad, it can be confusing as to what to use for your build.

There are timber frames with building wraps and various Rigid Air Barriers (RAB) made from fibre cement, plywood or oriented strand board (OSB), which then need Drywall and exterior cladding. There’s Structural Insulated Panel Systems (SIPS), which consist of two layers of a so-called structural board, (some even faced with MgO board), sandwiching an insulation layer of foam in between.

None of these wall systems have the column and beam design principle built into them like the K3T Wall System with its concrete and steel centred jointers and ring

beams, and so don’t have the load bearing strength of K3T which was tested to an incredible breakpoint of a 95 tonne live load and 60 tonne dead load on just two panels (150mm thick). The approximate weight of a tile roof on a standard 3-bedroom house is 20 tonnes. As a self-supporting panel system, the two facings are fused together with a web of ribs made from the MgO board, making it integral and one piece; and any side or facing of the panel can be used as the exterior side or the drywall side. These other wall systems also cannot compare with K3T’s �re rating, waterproo�ng, durability, comfortable ambient environment (Cold outside warm inside, hot outside cool inside) and impact, earthquake and cyclone resistance.

Walls Straight Plumb & TrueWith every panel being square and the MgO board having no expansion/contraction under changing temperatures, all the walls are and will stay straight plumb and true. When fixing anything to the wall - for example kitchen wall cabinetry – no need to find a stud (there aren’t any) just screw straight into the wall. Every stainless steel screw has a 59kg pull strength.

Wall panel showing webbing/ribs: integral and one-piece with exterior side & drywall side

Internal walls

Walls straight plumb and trueEvery stainless steel screw has a 59kg pull strength.

Quick and easy to install

HOUSING

SCHOOLS HOSPITALS RETIREMENT VILLAGES

HOTELS MOTELS

SHOPPING CENTRES, MALLS & SUPERMARKETS WAREHOUSES & FACTORIES

APARTMENTS

Calling all builders, architects, engineers, developers and home builders Builders who are interested in installing the K3T Wall System Architects, engineers & developers interested in more information for your next project Anyone who is planning to build a house or home

Please contact Xfactorbuild Ltd on +6427 2388 555 or email [email protected]

The K3T Wall System was developed by local New Zealand company Global Fibre8 Ltd. Xfactorbuild Ltd holds a license to distribute and supply the panels throughout New Zealand.

Xfactorbuild Homes Ltd markets new builds using the K3T Wall System. © 2018 Xfactorbuild Limited

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