GYPROCK 547 Residential - Installation - Guide 201111 PDF
GYPROCK 547 Residential - Installation - Guide 201111 PDF
GYPROCK 547 Residential - Installation - Guide 201111 PDF
CONTENTS
INTRODUCTION
General Installation
Introduction
Description
Applications
Advantages
Architectural Specification
Design Considerations
DESCRIPTION
Gyprock plasterboard is a machine made sheet composed
of a gypsum core encased in a heavy duty linerboard. The
linerboard is folded around the long edges to reinforce and
protect the core. The board ends are cut square. Gyprock
plasterboard conforms with manufacturing standard
AS/NZS2588 Gypsum Plasterboard.
Levels of Finish
12
Framing
14
Sheet Layout
16
Fixing Systems
18
Masonry Walls
24
Curved Walls
26
30
Back-Blocking Joints
31
Jointing Systems
34
36
39
Arches
40
Cornice Fixing
41
Decoration
42
Description
43
Applications
43
Advantages
43
Components
44
Framing Preparation
44
Aquachek Installation
44
45
52
Joint Treatment
55
Surface Decoration
55
Maintenance
55
56
Contact Information
56
Product Manufacture
Gyprock plasterboard products are manufactured from
gypsum, paper and a small amount of additives. Gypsum is
a naturally occurring, non-toxic sedimentary rock. The paper
liner board used for plasterboard and cornice is made from
100% recycled newspapers and cartons and the additives
are benign materials such as starch and foam.
The energy used in the manufacture of Gyprock is amongst
the lowest of any building product. Emissions are limited to
water vapour and products of natural gas consumption.
Good Environmental
Choice Australia
CSRG-2011
GECA 04-2011
PANEL BOARDS
Green Building
Council of
Australia (GBCA)
The Green Building Council of Australia (GBCA) is
Australias leading authority on green building. The GBCA
was established in 2002 to develop a sustainable property
industry in Australia and drive the adoption of green building
practices. The GBCA promotes green building programs,
technologies, design practices and processes, and
operates Australias only national voluntary comprehensive
environmental rating system for buildings - Green Star.
Standards
APPLICATIONS
Gyprock plasterboard is used as an internal lining board
to provide smooth, strong, long-lasting walls and ceilings
for homes, offices, hospitals, hostels for the aged, schools,
shops and factories. Its durable surface will accept most
types of decorative finishing, including paint, wallpaper and
texture compounds.
Joints between Gyprock plasterboard sheets are reinforced
and concealed to provide a smooth, durable finish to the
whole surface. Alternatively, the joints may be covered with
a decorative moulding.
Gyprock
Aquachek
Standard
plasterboard or Gyprock
can be used for exterior ceilings and eaves lining, provided
the ceilings are protected from the weather.
ADVANTAGES
CD Technology
Controlled Density (CD) technology is a unique manufacturing
process which manipulates the core structure of plasterboard.
This creates greater strength, lighter weight and superior
paper to core bonding, meaning easier handling, better
cutting, and a better quality plasterboard. CD Technology
is used in the manufacture of 10mm and 13mm Recessed
Edge Gyprock plasterboard, 10mm Gyprock Supaceil,
and 10mm and 13mm Square Edge Gyprock plasterboard.
GYPROCK
PLASTERBOARD
RANGE
Table 1: Gyprock Product weights
Thickness
Mass
mm
kg/m2
10
13
10
13
10
10
13
10
13
13
10
13
13
13
6.5
13
16
13
6.5
8.5
6.5
8.5
6.5
7.2
13.0
8.0
10.4
10.3
10.4
9.3
10.5
12.1
4.25
10.5
12.5
10.7
16
13.5
PERFORATED SHEET
13
10.0
25
19.8
Gyprock Aquachek
Features
Specially processed
plasterboard.
Manufactured to the
requirements specified in
AS2588 : 1998 Gypsum
Plasterboard.
Manufactured to the
requirements specified in
American Society for Testing and
Materials C630.
Manufactured with CD
technology.
Applications
Internal walls and ceilings.
Applications
Gyprock Aquachek is a suitable substrate for ceramic tiles.
Features
The Gyprock Aquachek Wet Area Lining System is suitable for walls in
high, medium and low risk level wet areas as defined in AS3740.
Gyprock Soundchek
Features
Designed to provide enhanced
acoustic resistance in wall and
ceiling systems.
Manufactured to the
requirements specified in
AS2588 : 1998 Gypsum
Plasterboard.
13mm thickness.
Manufactured to the requirements
specified in AS2588 : 1998
Gypsum Plasterboard.
Applications
Internal walls.
Applications
Gyprock Supaceil
Features
10mm thick recessed edge
plasterboard.
Specially formulated to span
600mm on ceilings.
Manufactured with CD
technology.
Applications
Interior ceilings with joists at 600mm maximum centres.
Applications
Curved internal walls and ceilings.
Gyprock Superchek 10
Features
Features
CSRG-2011
GECA 04-2011
PANEL BOARDS
Applications
Applications
Features
Features
CSRG-2011
GECA 04-2011
PANEL BOARDS
Aplications
High traffic areas such as hallways, stairways, playrooms and garages.
Gyprock Cornice
Features
Cove Cornice in 55 and 90mm is
available in all states. 75mm cove is
available in W.A. and Victoria ONLY.
Gyprock Cornices are supplied in
a range of lengths from 3000mm to
5400m.
Additional profiles available.
CSRG-2011
GECA 04-2011
PANEL BOARDS
Cove Cornice
Applications
Provides an attractive finish to the junction of the walls and ceilings.
Can be used on a variety of surfaces, including: Gyprock Plasterboard,
plasterglass, cement render, masonry.
A necessary part to some fire-rated ceiling systems.
CSRG-2011
GECA 04-2011
PANEL BOARDS
ARCHITECTURAL
SPECIFICATION
Scope
The contractor shall furnish all materials, labour and
equipment required to satisfactorily complete the installation
and jointing of all Gyprock Plasterboard where indicated on
the drawings and/or as specified.
Materials
All lining materials shall be Gyprock plasterboards,
adhesives, fasteners and jointing products as manufactured
or supplied by CSR Gyprock.
Non-loadbearing metal wall components and ceiling
components shall be those manufactured by Rondo
Building Services Pty. Ltd (or products of equivalent or
better performance).
Framing or Substrate
All framing shall be prepared to *Level ........ Finish
specifications as detailed in the Gyprock Plasterboard
Residential Installation Guide, NGYP547, and
AS/NZS2589.1 Gypsum linings Application and Finishing.
Framing must also conform to structural standards specified
by the appropriate building authorities and/or Australian
Standard.
Plasterboard Installation
The framing shall be lined on the first side with *...... layer(s)
of .......mm Gyprock ............. plasterboard.
The framing shall be lined on the second side with *......
layer(s) of .......mm Gyprock ............. plasterboard.
Eaves Vents
DESIGN
CONSIDERATIONS
Control Joints
Lighting
Any imperfection in a completed lining installation will be
made obvious by a condition called critical lighting or glancing
light, where the incident light from an artificial or natural light
source is nearly parallel to the surface. Glancing light also
greatly exaggerates the size of imperfections making them
glaringly obvious.
Ways to minimise the effect of critical lighting from artificial
lighting sources are:
Locate fluorescent lights about 450mm below the ceiling
as this will give a more even distribution of light.
Use more rather than fewer lights and install at regular
spacings to give a more even, diffused light and to
minimise the shadows that can occur from a single row
or single light source.
Recess light fittings into a ceiling (although recessed lights
are more likely to be associated with glare problems).
Allow a generous angle of incidence to the surface
for feature lighting such as spotlights, to minimise the
highlighting of imperfections.
Do not locate a single or isolated unshaded light source
close to a wall or ceiling in a space which has generally
low levels of light.
Do not use uplights, wall-washers and spotlights in areas
with a smooth wall finish to eliminate light being emitted
at a glancing angle to the surface.
Design soft rather than harsh lighting conditions.
Heating
The following situations may give rise to localised high
temperature conditions (52) which may be detrimental to
wall and ceiling linings:
Radiant heaters,
Halogen lighting,
Heat pumps,
Reverse cycle air conditioners,
Gas Appliances
Where a gas stove in a domestic application is required to be
installed to AS5601 Gas Installations, there are requirements
for materials to protect surrounding construction.
Where a burner is within 200mm of a wall (including walls
covered with metal or toughened glass), protection methods
include:
Splashback attached to the stove intended to protect the
rear wall.
Fire Resistant material covered with 0.4mm steel sheet.
5mm ceramic tiles attached to plasterboard lining.
Protection is to be provided to a height of 150mm above
the hob and for the full extent of the cooking area. A list of
Fire Resistant materials is available from Energy Safe Victoria
and does not include plasterboard or fibre cement products.
Attaching Fixtures
Light weight fixtures such as picture frames may be attached
to plasterboard walls with proprietary fixings. Check with the
fixing manufacturer for allowable loadings.
Heavier loads such as shelves and appliances must be fixed
through the linings to the studs.
Garage Ceilings
Ceilings in garages are subjected to different environmental
conditions to those in habitable rooms. The following
conditions may occur:
Wind loads can disrupt uncured adhesive and prevent an
effective adhesive bond from ever forming.
Jack Trusses
Brick Veneer
Trimmers
GYPROCK plasterboard
fixed to underside of
framing
Main Trusses
Plasterboard
sheet
direction
10
Exterior Ceilings
Drop beam or
masonry wall
Joist
Trimmer
In these applications:
Ceilings must be installed after the roof cladding has been
completed and sealed.
Effective cross-ventilation for all spaces between the roof
and the ceiling is to be provided.
GYPROCK plasterboard
Wood trim
6mm Gap
Furring
channel
GYPROCK plasterboard
Metal Angle
Furring channel
GYPROCK plasterboard
Wall angle
GYPROCK plasterboard
Fix cornice to
ceiling with Gyprock
Cornice Cement
Cornice
Fastener (optional)
Flexible Mastic
11
Wall covering,
Wallpaper or Texture
Paint
Flat/Matt/Satin/
Low Sheen
Semi-gloss/Gloss
Pastel/
Mid-tones
Level 3 Finish
Dark tones
Non-critical
Lighting
Level 4 Finish
Critical
Lighting
Level 5 Finish
Levels of Finish
Levels of finish are defined in the Australian/New Zealand
Standard AS/NZS2589.1 Gypsum linings Application
and Finishing. This standard is intended to provide builders,
plasterboard installers and finishers, and their customers
with the various defined methods and practices necessary
to meet the customers expectations in terms of the Level
of Finish.
Three Levels of Finish (3, 4 and 5) are defined, and minimum
specifications to achieve each level of finish are detailed in
the standard for each of the installation processes from
framing preparation to finishing.
It is essential to determine the level of finish required before
the frame construction begins, as specific tolerances are
required for frame alignment as well as for plasterboard fixing
and finishing for each of the levels of finish. Unless these
requirements are met throughout construction, it may not be
possible to attain the desired finish level without extensive
corrective measures.
The level of finish specified also affects the methods of jointing,
particularly butt joints and back-blocking requirements, the
number of coats of joint compound applied, and the fitting
Selection
Factors affecting the level of finish include the surfaces
visibility, the texture and gloss level of the final decoration and
the lighting conditions. Critical light is that projected across
the surface at low angles of incidence, as opposed to diffuse
lighting or light striking the surface at close to right angles.
A good method to overcome differences in opinions of
quality is to prepare a sample area in a suitable position and
for all parties to agree on the finish.
For further information on levels of finish, refer to Plasterboard
Expectations, available from the Association of Wall & Ceiling
Industries.
Level 3
For use in areas that do not require a finish, such as above
ceilings and inside service shafts and other inaccessible
spaces. All joints are to be taped with two applications
of compound and all fastener heads are to be covered.
Compound is to be finished smooth, such as by scraping
ridges etc with a trowel.
12
Level 4
This is generally the accepted level of finish for domestic
construction. Joints are to have a tape coat, and two
separate coats are to be applied over the tape coat and
fastener heads. All joint compound should be sanded to a
smooth finish free of tool marks and ridges. Full details can
be found in the Jointing section.
Level 5
This level of finish should be used wherever gloss or semigloss paints are to be used, where paint is mid or dark
coloured, or where critical light conditions occur such as
from windows, skylights, or silhouette and spot lighting.
A three coat jointing system is required as for level four.
All joint compound should be sanded to a smooth finish
free of tool marks and ridges. This should be followed by
the application of proprietary surface preparations by skim
coating to remove differential surface textures and porosity.
Skim coating is a term used to describe a thin finish coat,
rolled, trowelled or airless sprayed and then possibly sanded,
to achieve a smooth and even finish. It is normally less than
1mm in thickness and is applied over the entire surface to
fill imperfections in the joint work, smooth the paper texture
and provide a uniform surface for decorating.
It should be noted that, generally, domestic applications should be prepared to a minimum level 4 finish unless specifically
a higher or lower level of finish is agreed to by all contracting parties.
Key to Symbols:
Level
of
Finish
= Mandatory.
= Not Applicable.
Adhesive
+
Fastener
Fixing
OR
Fastener
Only
Fixing
OR
OR
OR
13
FRAMING
Materials
Gyprock plasterboard may be fixed to timber or metal
framing and masonry materials which conform to standards
specified by the appropriate government building authorities.
All timber framing shall be in accordance with AS1684
Residential Timber Framed Construction or AS1720.1
Timber Structures.
Metal framing shall be in accordance with AS/NZS4600 or
AS3623, as applicable.
Gyprock plasterboard may be fixed direct to structural
metal ceiling framing not exceeding 1.6mm thickness.
Brick or block masonry surfaces which comply with AS3700
can be sheeted with Gyprock plasterboard adhered directly
to the wall with Gyprock Masonry Adhesive. Alternatively,
these surfaces may have a furring system applied in
accordance with AS1684, and fixed in accordance with the
appropriate Gyprock system.
Preparation
14
Accurately align and level Fixing Clips and fix to the side
of the truss bottom chord.
Ceilings
Thickness/Product
High Humidity
General Applications
(mm)
(mm)
10mm Plasterboard CD
600
450
600
600
450
600
600
450
16mm FYRCHEK
600
600
450
Notes: Maximum 2.0 kg/m2 insulation material may be used in ceilings. Spans suitable for N1 and N2 wind classification only.
TABLE 4: MAXIMUM SPANS FOR METAL BATTEN/FURRING CHANNEL USED IN INTERIOR CEILINGS
N301
Gyprock Plasterboard
Layers x Thickness
N581*
N308*
N129*
Ceiling Batten
Resilient Furring
Furring Channel
Furring Channel
Batten Spacing
Spacing of Furring
Spacing of Furring
Spacing of Furring
450
450
450
600
450
600
600
600
1200
1000
600
600
1000
900
1550
1400
1 x 10mm Gyprock CD
1200
600
1000
1550
1 x 10mm SOUNDCHEK
1 x 13mm all products
1200
1000
600
600
1100
1000
1550
1400
1 x 16mm FYRCHEK
600
600
1100
1050
1550
1400
2 x 10mm SOUNDCHEK
2 x 13/16mm FYRCHEK
600
600
1100
900
1400
1300
NOTE: Furring to be continuous over 2 or more spans. Dead load deflection Span360. * Includes Internal UDL of 0.25kPa.
15
SHEET LAYOUT
Standard
Trusses
Plasterboard
Horizontal application of plasterboard on walls is generally
recommended because it:
Bottom
Cord of
Girder
Truss
Jack
Joist
GYPROCK
Plasterboard
Ceiling
Trimmers
Wall
Framing
Furring
Channels
perpendicular
to main
trusses
Main Trusses
GYPROCK
Plasterboard
Girder
Truss
Jack Joist
Trimmers
Wall Frame
16
Joint Location
Electrical Wiring
Plasterboard Cutting
Gyprock plasterboard can be cut by scoring the face
linerboard with a knife and snapping the plasterboard back
away from the scored face. The back linerboard can then be
cut from the back towards the front. Alternatively a saw may
be used from the front face.
Cut edges are to be smoothed as required to permit neat
joints. A metal T-square will assist in creating a clean, straight
cut.
All cut-outs for pipes, electrical installations, fixtures etc, are
to be scored on both faces before removal, or are to be cut
out with a suitable tool. The use of an impact tool such as
a hammer is not an acceptable method of producing
cut-outs.
If the plasterboard adhesive is not properly cured, hold the
sheet in place with temporary blocks on adjacent studs or
joists while making cut-outs.
Full width
sheet
Full width
sheet
Minimum 6mm
gap between
sheet and floor
17
200mm minimum
from joint to edge
of opening
Plasterboard Screws
FIXING SYSTEMS
N6 Type W
for timber framing.
Adhesive
Gyprock Acrylic Stud Adhesive can be used (in conjunction
with fasteners) to fix Gyprock plasterboard to timber or
steel framing. It is coloured blue for easy identification, and
can be used on both timber and steel in temperatures not
less than 5C. It has a low toxicity, and does not represent
a fire hazard when used in confined spaces. It is easily
removed from tools and hands before the adhesive cures
or in garages
Contact CSR Gyprock for recommendations that apply in
Western Australia.
The adhesive
is applied with
a broad knife
to form 25mm
diameter by
15mm high
walnuts.
Fasteners
The following fasteners are used with timber and steel
framing to accommodate most installation applications.
Available in 5.5kg
and 1kg buckets.
When fixing to timber that has been treated with copperbased compounds, such as CCA, ACQ and copper azole,
use hot-dip galvanised clouts or class 3 screws. For timber
framing with other treatments, contact the manufacturer for
the applicable class of fixing.
WARNING
Stud adhesive
MUST NOT be used on TILED WET AREA systems.
Daubs of adhesive must never coincide with fastener
points.
Hardwood 25 x 2.8mm.
Softwood 30 x 2.8mm.
Clouts
(Hot-dip galvanised).
30, 40 and 50mm x 2.8mm.
Adhesive
Nails
Screws
Adhesive + Nail
600
3.5 kg
1.0 kg
Adhesive + Screw
600
450
3.5 kg
4.2 kg
620
750
Fully Screwed
1150
820
1000
N/A
20 24 kg
18
Softwood
Metal
1.2mm
thickness
Clouts
(Hot Dipped Galvanised)
30
30
10
13
30
40
16
10
40
50
Ring Shank Nails
25
30
13
25
30
Combination Adhesive/Fastener
Fixing
Combination adhesive/fastener fixing may be used for
internal walls and ceilings. When used in accordance with
the following instructions the adhesive/fastener method of
fixing produces a system which is comparable in strength
to a fully nailed or screwed wall or ceiling. This method also
reduces the number of fasteners required and minimises the
possibility of nail pops due to frame movement.
Gyprock Acrylic Stud Adhesive has good gap-filling
properties and will bridge board and studs which are slightly
out of alignment.
When temporary fasteners are used, they should remain
in place for a minimum 24 hours, or longer in slow drying
conditions.
10
Screws N6 *
25W/25S
25W/30S
25S
13
25W/30S
30W/30S
25S
16
30W/30S
30W/45S
30S
Cautionary Notes:
* 30mm screws are the minimum for timber framed ceilings, while 25mm can
be used for walls.
Type W = Wood screw.
Type S = Steel frame screw, needle and drill point.
Needle point for steel frame up to 0.8mm thick and hardwood where
indicated.
Drill point for steel frame from 0.8 to 1.2mm thick.
Fastener Installation
For recessed joints and butt joints on framing, position
fasteners opposite each other and between 10mm and
16mm from sheet edges.
All fasteners are to be driven home with the head slightly
below the surface of the sheet, but not punched through the
face linerboard. Care should be taken to avoid damaging the
face or core of the plasterboard.
Cutting sheets
Mark the sheet to the length required. Use a trimming knife
to cut through the paper liner, and straight edge or T-square.
Always cut the face (non-printed) side first.
Push the off-cut side down and snap the sheet along the
score line.
Cut along the fold line
from the back of the
sheet (printed side)
and remove the off-cut.
TIP: SIte recessing tools
are available to treat cut
edges for easier jointing.
Walls
Ceilings
Conventional Spacing
Ceilings
1/3 Spacing
1200
FAAAAF
F A A F/F A A F
FAFAFAF
1350
FAAAAAF
F A A F/F A A F
FAFAFAF
19
Adhesive/Fastener Fixing to
Timber Framed Walls
Adhesive/Fastener Fixing to
Timber Framed Ceilings
Press the sheet firmly against the studs, then fasten along
the second recessed edge at each stud.
Temporary fasteners
through blocks
300mm
centres
Back-block joints
formed between studs
Adhesive
daubs at
300mm
max.
centres
Use adhesive daubs
to strap bracing to
reduce rattling
6-10mm Gap
between sheet
bottom edge
and floor
20
Adhesive/Fastener Fixing to
Metal Framing
Adhesive daubs
at max. 230mm
centres
1350mm
1200mm
Under slow drying conditions
use temporary blocks on
1350mm wide sheets
Two nails or
one screw at
sheet centre
in each frame
member
Adhesive daubs
at max. 230mm centres
200mm min.
INCORRECT METHOD
Incorrect spacing of
fasteners from
adhesive daubs
GYPROCK
plasterboard
lining
200mm min.
GYPROCK
plasterboard
lining
1200mm
1200mm
Two nails or
one screw at
sheet centre
in each frame
member
21
Fastener through
adhesive daub
Fastener Installation
Walls
Ceilings
Board Width
(mm)
Nails
900
1200
1350
900
1200
1350
7 nails or
5 screws
1200mm
6 nails or
4 screws
900mm
900mm sheets
5 nails or
4 screws
22
1200mm sheets
6 nails or
4 screws
1350mm sheets
7 nails or
5 screws
1200mm
7 nails or
5 screws
900mm
6 nails or
4 screws
300mm max.
900mm sheets
5 nails or
4 screws
and
1200mm sheets
6 nails or
4 screws
23
Fix ends at
200mm
max.cts for
set finish or
300mm max.
cts for cornice
finish
1350mm sheets
7 nails or
5 screws
Where permitted, butt joints
may be fixed on framing with
nails at 150mm max.cts or
screws at 200mm max. cts
Installation
MASONRY WALLS
Description
The Gyprock plasterboard may be used to line dry masonry
walls to provide an alternative to cement render and set
plaster finishes. Gyprock plasterboard can be laminated
directly onto the masonry, including concrete blocks, clay
bricks and calcium silicate bricks, using Gyprock Masonry
Adhesive (in WA, Gyprock Drywall Masonry Adhesive 100).
Joint treatment as detailed in the jointing systems section
creates a smooth flush surface ready for decoration.
Design Considerations
Lining masonry with plasterboard is an alternative to solid
plaster, not a means of isolating dampness. The adhesive
fixing method must not be used where walls are to be tiled
or walls are over 3m high.
Gyprock
24
Daubs of
Gyprock
Masonry
Adhesive
GYPROCK
plasterboard
460mm max.
230mm
max.
GYPROCK
plasterboard
6mm
gap
460mm
max.
GYPROCK
plasterboard
GYPROCK
plasterboard
Daubs of
Gyprock
Masonry
Adhesive
6mm
gap
25
Plasterboard Fixing
CURVED WALLS
Applications
Gyprock plasterboards of 10mm or greater thickness may
be used on curved walls where the radius of the curve is
900mm or greater, as detailed in Table 9.
When planning the sheet layout, ensure that the sheet edges
of the first and second layers are staggered at least 200mm
to avoid aligned joints.
Framing Preparation
Prepare the curved framing in accordance with Table 9 or
10 and FIG 17, 18, 19, 20 or 21 appropriate for the chosen
plasterboard and curving radius. For small radius curves,
install double studs at each end of the curve to prevent
frame deflection.
Rondo Flexi-Track
TABLE 9: CURVING RADII AND MAXIMUM STUD CENTRES FOR 6.5, 10 AND 13MM GYPROCK PLASTERBOARDS
Plasterboard
Thickness
(mm)
Gyprock
Flexible
Plasterboard
<900
900-1000
1000-1500
1500-2000
2000-2500
2500-3000
3000-4000
>4000
Refer Table 10
200
250
300
350
450
450
10
150
200
250
300
350
400
500
13
150
200
250
300
400
500
16
250
350
26
TABLE 10: MINIMUM CURVING RADII AND MAXIMUM FRAME SPACING FOR GYPROCK FLEXIBLE PLASTERBOARD
Sheets Installed Vertically
Applications
Minimum Radius
Minimum Radius
Concave
450mm
150mm
650mm
200mm
Convex
250mm
125mm
450mm
200mm
27
Concave Curves
No curve in
this area
No curve in
this area
Concave Curved Area
450mm
minimum
radius
Recessed
edge of
first layer
10
0m
mm
0
10
Use stopping
bead at edge
of sheet where
possible
No curve in
this area
No curve in
this area
Recessed edge
of first layer
Recessed edge
of second layer
10
0m
0m
10
28
Convex Curves
Recessed
edge of
second
layer
0m
10
10
0m
Outer sheet
6mm above
finished
floor level
rve
cu rea
No this a
in
Recessed edge
of first layer
0m
10
m
0m
10
10
0m
N
in o cu
thi rv
sa e
rea
rve
cu rea
No his a
t
in
Outer sheet
6mm above
finished floor
level
Recessed edge
of second layer
29
Recessed
edge of
first layer
CONTROL JOINTS
Gyprock
The
Plasterboard Control Joint Part NP35 is
designed to form expansion or control joints in Gyprock
plasterboard walls and ceilings.
The control joint is located between the sheets and set
over. The filament tape is then removed leaving a clean,
well-formed joint.
Door frames extending from floor to ceiling constitute
control joints. For doors less than ceiling height, control
joints extending from both corners of the frame to ceiling
may be used.
Floor Joist
10mm gap
Additional
framing member
RONDO
P35 Control Joint
GYPROCK
plasterboard
20mm
max. gap
DOOR JAMBS
Standard Timber Jamb
Install Gyprock plasterboard to finish flush with the side
of the opening stud.
The appropriate width door jamb is then installed to the
side of the opening stud (with packing as required).
Architraves are then fitted over the junction of the
plasterboard and the door jamb by fastening them through
to the opening stud.
Opening
Stud
30
GYPROCK
plasterboard
wall lining
Back-Blocking of
Recessed Joints on Ceilings
BACK-BLOCKING
JOINTS
Back-blocking is a reinforcing system where pieces of
Gyprock plasterboard are laminated to the back of the
sheets, behind joints.
Back-blocking is to be used on all butt joints formed
between framing members and on recessed joints
where indicated. See requirements in Table 2 .
Where mid-span butt or end joints are not required but are
used to minimise plasterboard wastage, these joints must
also be back-blocked.
All mid-span joints must be positioned within 50mm of the
mid-span point between the framing members.
Fix back-blocks with Gyprock Back-Blocking Cement,
Base Coat or Cornice Cement applied with a notched
spreader to form beads 6mm x 6mm at approximately 20mm
centres over the entire face of the back-block.
ADHESIVE APPLICATION
Framing or
battens
Back-blocking cut to
fit loosely between
framing members
31
GYPROCK
plasterboard
back-block
Joint 50mm
max. off
centre
BACK BLOCKING
CEMENT, BASE COAT
45/60 or CORNICE
CEMENT 45/60
Packer such as
nail to produce
2 to 3mm depression
of plasterboard
Temporary batten
GYPROCK
plasterboard
ceiling
50mm min.
Framing or
battens
GYPROCK
plasterboard
back-block
400mm min.
2 to 3mm deep
depression suitable
for jointing
GYPROCK
plasterboard
ceiling
FIG 28: BUTT JOINT CONSTRUCTION USING RONDO B005 BATTENS AND BACK-BLOCKING (TOP VIEW)
Battens at
300mm max.
centres
400mm
Rondo NB005
Battens to form
recess
Back-blocking
100mm
min. overlap
at recessed joints
400mm
Cornice
adhesive
Plasterboard fixed
with 2 screws each
side of joint
NOTE: Install screws to battens carefully. Collated screw guns may not be suitable.
Gyprock
plasterboard
32
Strip nailed to
stud to support
back-block
Temporary
batten
GYPROCK
plasterboard
wall lining
GYPROCK plasterboard
wall lining
Temporary Gyprock
Laminating Screws
GYPROCK
plasterboard
wall lining
Joint 50mm
max. off centre
Temporary
batten
GYPROCK plasterboard
wall lining
33
JOINTING SYSTEMS
Jointing and finishing of Gyprock plasterboard interior
installations is to be carried out in accordance with the
requirement of Table 2 of this publication, and the following
details, so as to provide a smooth surface for decorating.
Stopping and external corner beads are to be applied to all
edges subject to damage.
A Level 4 Finish is generally the accepted level of finish
for domestic construction (as detailed in AS/NZS2859.1)
and requires a three coat system, consisting of:
tape (or base) coat
second coat, and
finish (or topping) coat.
Jointing Compounds
Gyprock jointing compounds are classified as either
setting type or drying type. Setting type compounds
produce stronger joints and reduce installation delays and
shrinkage associated with drying-type compounds. They
are recommended for experienced trades people and have
a defined setting time e.g. 45 or 60 minutes.
34
Jointing Tape
Important
Preparation
Fill any voids deeper than 4mm and gaps greater than 3mm
wide with Base Coat and allow to dry before jointing. All
surfaces must be free of dirt, oil or foreign matter that could
reduce bond.
Second Coat
Finish Coat
Base Coat 20
Base Coat 45
Base Coat 60
Base Coat 90
Multi-Purpose Compound
Multi-Purpose Compound
Total Coat-Lite
Total Coat-Lite
Easy Flow
Easy Flow
Tape coat
Second Coat
Finish Coat
Nil
Other areas
Base Coat 20
Base Coat 45
Base Coat 60
Base Coat 90
Base Coat 20
Base Coat 45
Base Coat 60
Base Coat 90
Nil
TABLE 13: APPROXIMATE QUANTITIES PER 100M2 GYPROCK PLASTERBOARD (HORIZONTAL SHEETING)^
Tape + Second Coats
Approx Qty
Finish Coat
Approx Qty
16kg
8kg
15kg
7kg
16kg
6kg
Total Coat-Lite
13kg
Total Coat-Lite
5kg
Easy Flow
15kg
Easy Flow
10kg
17kg
Easy Finish
8kg
Multi-Purpose Compound
17kg
8kg
Multi-Purpose Compound
8kg
35
JOINTING
HAND APPLIED
Fill
Recess
Cover all fastener heads and fill any surface damage with
compound.
Allow setting-type compounds (Gyprock Base Coat) to
set for at least one hour, and drying type compounds to
harden for 24 hours.
Second Coat
250mm
approx.
1.0mm minimum
depth of compound
GYPROCK
plasterboard
(recessed edge)
36
Paper
tape
Tape Coat
170mm approx.
170mm approx.
Sanding
250mm approx.
1.0mm minimum
depth of compound
GYPROCK
plasterboard
(square edge
butt joint)
Paper
tape
37
250mm approx.
y;;
;
@
yy;
@@
y
@
y
@
;
Internal Corners
;;
;;
Paper
Tape
External Corners
& Arch Beads
Position external angle bead over the corner and sight it to
ensure straightness before fastening both flanges at 300mm
centres.
External corners and arch beads are finished with a three
coat compound system applied to the same specifications
as for joints. The finish coat should be at least 250mm wide
each side of the corner.
When compound is dry, sand smooth with 150 grit paper
or cloth, or with 150/180/220 grit sanding mesh.
FIG 35: JOINTING OF EXTERNAL CORNERS
External
angle bead
Finish Coat
CSR
GYPROCK
plasterboard
3mm typical
build up
GYPROCK
Plasterboard
CSR GYPROCK
plasterboard
;;
;;;
;;;
38
JOINTING WITH
MECHANICAL TOOLS
The use of mechanical tools to joint Gyprock plasterboard
is becoming more popular, and used correctly, these tools
can significantly increase productivity by cutting the amount
of time taken to finish a job. The Gyprock range of drying
type compounds are designed for use when jointing with
mechanical tools.
Roll internal
corner
39
ARCHES
Gyprock plasterboard may be used to line arches in timber
and metal frame construction and may be formed as semicircular, segmental, elliptical or other profiles prepared by
the builder.
Arches are finished with arch bead and corner bead to
reinforce the corners and maintain an accurate profile. The
Gyprock Arch Bead is designed for use with all thicknesses
of Gyprock plasterboard.
P30 Arch Bead
Fasten the other end at the springing line and support the
soffit strip with props if necessary. Ensure that the soffit
sides are square to the wall face.
Where more than one length of soffit strip is necessary
and the ends are not supported by a template, support
the joints with pieces of Gyprock plasterboard glued to
the back of the soffit strip.
Fit and fasten reveal strips where required and allow all
strip to set in position.
Arch Bead
Frame Preparation
50mm
Springing Line
External Angle
Bead
Installation of Gyprock
Plasterboard
150mm
min.
Joint Finishing
Refer to Jointing External Corners.
40
CORNICE FIXING
Installation
To ensure equal projection on wall and ceiling surfaces,
measure down from the ceiling surface and mark lines on
the walls at; 55mm down for the 55mm cornice; 90mm
down for the 90mm cornice; and 75mm down for the
75mm cornice.
Mark and cut the cornice to the actual length required.
Important
For high gloss acrylic or oil based paint, coat with a PVA
adhesive such as Bondcrete.
Cove Cornice
41
Paint Finishes
DECORATION
Interior Gyprock plasterboard surfaces may be decorated
in any of a variety of finishes including flat, semi-gloss or
gloss paint, wallpaper or vinyl, texture or stipple.
Roll coated paints generally have a greater coating thickness
and create a similar texture on both the plasterboard and the
jointing compounds.
Surface Preparation
Preparatory Coat
Finishing Coats
Always follow the manufacturers instructions for application
and recoating.
For best results, apply the coatings with a roller. This helps
to achieve a full even coat and a light, uniform texture over
the entire surface.
Refer to Australian Standard AS2311 The Painting of
Buildings and/or paint manufacturers recommendations
for specific roller nap length for the desired finish.
42
ADVANTAGES
The advantages of Gyprock Aquachek plasterboard for
wet areas include:
Simple dry wall installation.
APPLICATIONS
43
COMPONENTS
Gyprock Aquachek Plasterboard
Refer to detailed information in the Components section at
the beginning of this publication. Please contact your CSR
Gyprock Sales Office in your region for details of stock sheet
widths and thicknesses available.
FRAMING
PREPARATION
Ensure that all timber or steel framing members to receive
sheeting are plumb and true in accordance with the chosen
Level of Finish, and studs are spaced at a maximum 600mm
centres.
Fasteners
Jointing Materials
Flexible Sealant
Gyprock Wet Area Acrylic Sealant is used to seal the edge
of the Gyprock Aquachek against other surfaces such as
a preformed shower base or bath and around plumbing
fixtures. Wet Area Acrylic Sealant may be painted if required
after it is fully cured.
Waterproof Membrane*
A proprietary impervious barrier assessed and classified in
accordance with AS4858.
Bond Breaker*
Tape used at wall to floor junctions and movement joints and
compatible with the proprietary membrane.
AQUACHEK
INSTALLATION
Generally, Gyprock Aquachek wall sheets are applied
horizontally, unless a single sheet covers the whole wall.
Fasteners are to be positioned between 10 and 16mm from
sheet edges and at appropriate spacing for the application.
Sheets are to be held firmly against frame while fasteners
are positioned.
Fasteners are to be driven home with the head slightly below
the surface of the sheet, but not punched through the face
linerboard. Care should be taken to avoid damaging the face
or core of the plasterboard.
Stagger butt joints between different framing members. Refer
to FIG 8 for sheet joint arrangements.
Tiled Areas
Perimeter Flashing
Perimeter Flashing for Step-Down Slab: Such as
Hypalon Flashing Strip* 130mm width.
44
CONSTRUCTION
DETAILS SHOWER
AREAS
Preformed Shower Base
A preformed shower base has the advantage of being easy
to install over floors of timber, compressed fibre cement
sheet and concrete slabs, as well as ensuring that the wall
linings are kept clear of any free water likely to accumulate
on the shower floor.
A number of treatments for the shower wall junctions are
available depending on the class of membrane. Membranes
are classified as Class 1, Class 2 or Class 3, with Class 3
having the greatest elongation capabilities.
A preformed shower base must be installed before the wall
linings. Cut and install PVC angle to internal corner, fixing
the angle to studs at 600mm centres. Carry angle down
over the shower base lip, stopping 6mm above shower
base or floor finish. PVC angle is to extend a minimum
height of 1800mm from the finished floor surface.
Cut and fix the Gyprock Aquachek, leaving a 6mm gap
between the bottom edge of the sheet and the shower
base, and where detailed, between sheets forming an
internal corner. Neatly cut holes for plumbing penetrations.
200mm max.
150mm max.
900mm sheets
5 fasteners
or
1200mm sheets
6 fasteners
1350mm sheets
8 fasteners
45
GYPROCK
AQUACHEK
Vertical corner
angle flashing
GYPROCK
AQUACHEK
Waterproofing membrane
applied to face of
GYPROCK AQUACHEK
behind tiled area
Stud
Waterproof Membrane
applied to face of wall lining
Nogging
Ceramic Tiles
Ceramic Tiles
Vertical Corner
Angle Flashing
Preformed
Shower Base
Flexible Sealant
Impermeable Tray
6mm min.
Mortar Bed
150mm min.
6mm
Structural
Sheet Flooring
Wall Plate
Floor
Joist
Optional Flashing
Angle
Mortar bed
GYPROCK
AQUACHEK
plasterboard
Membrane to
1800mm min. above
finished shower floor
Refer to
corner detail
Membrane to
1800mm min. above
finished shower floor
Refer to
corner detail
Waterproof Membrane
Additional
noggings for
fixing
plasterboard
Refer to shower
base detail
Sealant
Noggings
25mm
above
shower
base for
plasterboard
fixing
Seal between
tray and
plasterboard
Refer to shower
base detail
Shower Tray
Preformed
Shower Base
Perimeter
Flashing
Perimeter
Flashing
46
Seal
flashing
angle to
tray
Insitu-Formed Shower
GYPROCK
AQUACHEK
Stud
Ceramic Tiles
Additional
Nogging for
plasterboard
fixing when
external angle
flashing is
installed
Vertical Corner
Angle Flashing
Class 2 Membrane
applied to face of
wall lining and floor
Flexible Sealant
25mm
Bond breaker
35mm min. each
side of corner
75mm
min.
Mortar Bed
Wall Plate
50mm
min.
Structural
Sheet Flooring
Floor Joist
Optional Flashing
Angle fixed to floor
only
GYPROCK
AQUACHEK
Stud
Ceramic Tiles
Additional
Nogging for
plasterboard
fixing when
external angle
flashing is
installed
Vertical Corner
Angle Flashing
Class 1 Membrane
applied to face of
wall lining and floor
Ceramic Tiles
Additional
Nogging for
plasterboard
fixing when
external angle
flashing is
installed
Flexible Sealant
25mm
GYPROCK
AQUACHEK
Stud
Vertical Corner
Angle Flashing
Class 3 Membrane
applied to face of
wall lining and floor
Flexible Sealant
25mm
Bond breaker
Foam Plastic Rod
75mm
min.
75mm
min.
Mortar Bed
Mortar Bed
Wall Plate
Structural
Sheet Flooring
Floor Joist
50mm
min.
Wall Plate
Optional Flashing
Angle fixed to floor
only
Structural
Sheet Flooring
Floor Joist
47
50mm
min.
Optional Flashing
Angle fixed to floor
only
GYPROCK
AQUACHEK
plasterboard
Membrane to
1800mm min. above
finished shower floor
Refer to
corner detail
Waterproof Membrane
Optional
continuation of
perimeter flashing
Refer to shower
base detail
Waterproof Membrane
Perimeter
Flashing
48
FIG Z610: MEMBRANE DETAIL FOR AN UNENCLOSED SHOWER OVER BATH OR SHOWER AREA
Membrane to 1800mm min.
above finished floor level
(Refer to corner details)
1500mm
GYPROCK
AQUACHEK
plasterboard
min.
Minimum extent
of membrane
and tiles
1500mm
min.
Seal all
penetrations,
refer to FIG Z625
Minimum
extent of
membrane
and tiles
Extent of
membrane and
tiles above the
bath 150mm min.
GYPROCK
AQUACHEK
plasterboard
Membrane to
extend
1800mm min.
from finished
floor
150mm
min.
GYPROCK AQUACHEK
plasterboard, membrane and tiles
Floor waste
Refer to wall/floor
junction details
Membrane to 1500mm
horizontal projection from
shower rose and grade to
a floor waste
49
Refer to
wall/floor
junction
details
FIG Z611: MEMBRANE DETAIL FOR AN SEMI-ENCLOSED SHOWER OVER BATH OR SHOWER AREA
Membrane to 1800mm min.
above finished floor level
(Refer to corner details)
1500mm
GYPROCK
AQUACHEK
plasterboard
min.
Minimum extent
of membrane
and tiles
GYPROCK
AQUACHEK
plasterboard
Extent of
membrane and
tiles above the
bath 150mm min.
Membrane to
extend
1800mm min.
from finished
floor
Seal all joints between
GYPROCK
plasterboard and
bath
AQUACHEK
plasterboard
150mm
min.
GYPROCK AQUACHEK
plasterboard, membrane and tiles
Floor waste
Refer to wall/floor
junction details
Refer to wall/floor
junction details
Membrane to 1500mm
horizontal projection from
shower rose and grade to
a floor waste
Wall Framing
Wall Framing
Refer to
wall/floor
junction
details
Wall Framing
Stud
Stud
Sealant
Paper tape and
Gyprock Wet Area
Base Coat
Sealant
Sealant
Flashing angle
Membrane Class 2
Membrane
Class 1, 2 or 3
GYPROCK
AQUACHEK
GYPROCK
AQUACHEK
Ceramic Tiles
Membrane
Class 3
GYPROCK
AQUACHEK
Ceramic Tiles
Ceramic Tiles
50
Masonry Wall
Waterproofing membrane
applied to face of
GYPROCK AQUACHEK
behind tiled area
GYPROCK
AQUACHEK
Ceramic Tiles
Vertical Corner
Angle Flashing
Ceramic Tiles
Furring Channel
N129 (vertical)
Masonry Wall
Class 1 membrane
applied to face of
wall lining and floor
Furring Channel
Nogging
Recessed Channel
N333 (or other)
Flexible Sealant
Flexible Sealant
Bond breaker
Mortar Bed
75mm
min.
Mortar Bed
50mm
min.
51
Optional Flashing
Angle fixed to floor
only
CONSTRUCTION DETAILS
GENERAL WET AREAS
GYPROCK
AQUACHEK
Ceramic Tiles
Membrane
finished
minimum 25mm
above highest
point of finished
floor level
Class 1 membrane
applied to face of
wall lining and floor
Stud
GYPROCK
AQUACHEK
Stud
Ceramic Tiles
Nogging for wall
lining fixing
Flexible Sealant
Flexible Sealant
Bond Breaker
6mm
25mm min.
Mortar Bed
50mm min.
Wall Plate
Wall Plate
Structural
Sheet Flooring
Structural
Sheet Flooring
Floor Joist
Floor Joist
50mm
min.
Mortar Bed
Approved Flashing
adhesive fixed to
floor only
GYPROCK
AQUACHEK
GYPROCK
AQUACHEK
Ceramic Tiles
Approved Flashing
75mm
typical
Flexible Sealant
Ceramic Tiles
6mm
Mortar bed
75mm
typical
52
GYPROCK
AQUACHEK
Batten
6mm
Flexible
Sealant
Waterproof membrane
to wall to 150mm
above vessel
Nogging
Ceramic Tiles
Flexible Sealant
Tap Body
Stud
Ceramic Tiles
Tub or
Sink
GYPROCK
AQUACHEK
Stud
GYPROCK
AQUACHEK
Flexible
Sealant
Ceramic Tiles
Waterproof membrane
to wall to 150mm
above vessel
Nogging
Bath
Membrane to extend
5mm min, above the
tile surface
Ceramic tiles,
adhesive and grout
Stud
Flexible Sealant
Nogging
to support
bath
6mm
Waterproof
membrane
Support
framing
GYPROCK
AQUACHEK
Notch
Stud
20mm
max.
Bath
53
GYPROCK
AQUACHEK
plasterboard
GYPROCK
AQUACHEK
plasterboard
Refer to
FIG Z626
Waterproof
Membrane
150mm
min.
GYPROCK AQUACHEK plasterboard,
membrane and tiles
Refer to wall/floor
junction details
Refer to wall/floor
junction details
50mm min.
on floor
Extent of tiles
and membrane
150mm min.
GYPROCK
AQUACHEK
plasterboard
54
Refer to wall/floor
junction details
JOINT
TREATMENT
It recommended that a water resistant base coat be used
at sheet joints in areas that are required to be waterproof or
water resistant. Set all joints with Gyprock Wet Area Base
Coat and paper tape. When the tape coat has dried, apply
a second coat of Wet Area Base Coat. Cover all fastener
heads with Wet Area Base Coat.
Joints in wet areas that are not tiled and not required to be
waterproof or water resistant should be set with Gyprock
compounds and tape as detailed earlier in this publication.
MAINTENANCE
SURFACE
DECORATION
Surface Preparation
All joint stopping must be sanded smooth. Remove all loose
dirt and dust with a soft brush or dry cloth.
Ensure that the joint treatment is thoroughly dry before
applying sealer or paint.
Tiling
Tiles are required in waterproof and water resistant areas.
The tile adhesive must be compatible with the proprietary
waterproofing membrane used.
Painting
Select a proprietary paint system, and apply all paints strictly
in accordance with the respective paint manufacturers
instructions.
Because the texture and porosity of uncoated plasterboard
differs from those of the jointed areas, the use of a preparatory
55
Contact Details
Telephone: 13 17 44
Facsimile: 1800 646 364
www.gyprock.com.au
CSR Gyprock Sales Support
Guarantee
CSR Building Products guarantees its Gyprock products
to be free of defects in materials and manufacture.
Queensland
Victoria
21 Sheffield Road,
Welshpool WA 6106
Tasmania
PO Box 61,
Glenorchy TAS 7010
Northern Territory