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7/17/2017 Using Gypsum Board for Walls and Ceilings Section I

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Other Uses of Gypsum


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Association Contact Information


Online Courses
GA Members
Account Access
About
About
History of the Gypsum Association
Gypsum Association Members
Gypsum Association Staff
Employment Opportunity
Gypsum Builds the Economy
The Miracle Mineral
Gypsum Association Archives
Publications
Publications
Bookstore
Free Technical Documents
Industry Statistics
View Past Editions: GA-216 & GA-600
Newsletter Archive
Article Reprints
Technical
Technical
Manufactured to the Highest Standards
Code Compliance
Evaluation Reports / Code Acceptances
Technical Assistance / FAQs / Errata
Technical Topical Papers
Using Gypsum Board for Walls and Ceilings
Innovative Uses of Gypsum Board
Stewardship
Stewardship
The Gypsum Industry: A Commitment to Sustainability and the Environment
Minimizing Environmental Impacts: Industry Efforts
Life Cycle Assessment Tools
Gypsum Works with Building Green!
Press
Press
News
Gypsum Board Key Facts
Photo Library
Resources
Resources
What is Gypsum?
What is Gypsum Board?
Making Gypsum Board
Multi-Family Applications for Specialty Gypsum Board
Commercial Applications for Specialty Gypsum Board
The Basics of Sound Control
Other Uses of Gypsum
Industry Resources
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7/17/2017 Using Gypsum Board for Walls and Ceilings Section I

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Using Gypsum Board for Walls and Ceilings Section I


Section I Gypsum Board Construction
Copyright Gypsum Association All rights reserved.

This document may be revised or withdrawn from circulation at any time.

1. I. GYPSUM BOARD CONSTRUCTION


2. What is Gypsum Board?
3. Advantages of Gypsum Board Construction
4. Ease of installation
5. Fire resistance
6. Sound isolation
7. Durability
8. Economy
9. Versatility
10. Types of Gypsum Board
11. Limitations of Use
12. Application of Gypsum Board
13. Storage and Handling
14. Jobsite Preparations
15. Tools
16. Application Sequence
17. Cutting and Fitting Procedures
18. Single-Ply and Multi-Ply Application
19. Control Joints

I. GYPSUM BOARD CONSTRUCTION

WHAT IS GYPSUM BOARD?

Gypsum board is the generic name for a family of panel products that consist of a noncombustible core,
composed primarily of gypsum, and a paper surfacing on the face, back and long edges. Gypsum board is one of
several building materials covered by the umbrella term gypsum panel products. All gypsum panel products
contain gypsum cores; however, they can be faced with a variety of different materials, including paper and
fiberglass mats.

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Gypsum board is often called drywall, wallboard, or plasterboard. It differs from other panel-type building
products, such as plywood, hardboard, and fiberboard, because of its noncombustible core and paper facers.
When joints and fastener heads are covered with a joint compound system, gypsum wall board creates a
continuous surface suitable for most types of interior decoration. A typical board application is shown in Figure
1.

Fig. 1 Horizontally Applied Gypsum Wallboard Showing Joints and Framing

Gypsum is a mineral found in sedimentary rock formations in a crystalline form known as calcium sulfate
dihydrate CaSO42H2O. One hundred pounds of gypsum rock contains approximately 21 pounds (or 10 quarts)
of chemically combined water. Gypsum rock is mined or quarried and transported to the manufacturing facility.

The manufacturer receives quarried gypsum, and crushes the large pieces before any further processing takes
place. Crushed rock is then ground into a fine powder and heated to about 350 degrees F, driving off three-
fourths of the chemically combined water in a process called calcining. The calcined gypsum (or hemihydrate)
CaSO4H2O is then used as the base for gypsum plaster, gypsum board and other gypsum products.

Synthetic gypsum, commonly known as the FGD (Flue Gas Desulphurization) gypsum or DSG (desulphurised)
gypsum may also be used in the production of gypsum board. This product is primarily derived from coal-fired
electrical utilities which have systems in place to remove sulfur dioxide from flue gasses. These systems capture
the sulfur dioxide by passing the gasses through scrubbers that contain limestone (calcium carbonate) which
absorbs and chemically combines with the sulfur dioxide to form pure calcium sulfate, or gypsum. The synthetic
gypsum is then transported to the gypsum board manufacturer; the production process for calcining synthetic
gypsum is largely the same as with mined gypsum only no primary crushing is necessary.

To produce gypsum board, the calcined gypsum is mixed with water and additives to form a slurry which is fed
between continuous layers of paper on a board machine. As the board moves down a conveyer line, the calcium
sulfate recrystallizes or rehydrates, chemically combining with the water that was removed during calcination
and reverts to its original rock state. The paper becomes chemically and mechanically bonded to the core. The
board is then cut to length and conveyed through dryers to remove any free moisture.

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Advantages of Gypsum Board Construction

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Gypsum board walls and ceilings have a number of outstanding advantages:

Ease of installation
Fire resistance
Sound isolation
Durability
Economy
Versatility

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Ease of installation

Gypsum board building systems are easy to install for several reasons. Gypsum board panels are relatively large
compared to other materials. They come in 48- and 54-inch wide sheets and in lengths of 8, 10, or 12 feet, so
they quickly cover large wall and ceiling areas. Gypsum board assemblies require only a few tools for their
construction. Gypsum board can be cut with either a utility knife or a variety of saws, and it can be attached with
a variety of fasteners, including screws, nails, and staples. It can also be adhesively attached to many substrates.
Gypsum board is a lightweight material. Two workers can easily handle most panels and cover large areas in
very short time periods. Gypsum board is easily finished using either a few hand tools or relatively modest
machines. Gypsum board installers can quickly learn most application techniques in a few hours.

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Fire resistance

Gypsum board is an excellent fire-resistive building material. In North America, it is the most commonly used
interior finish where fire resistance classifications are required. Its noncombustible core contains nearly 21%
chemically combined water, as described earlier, which, under high heat, is slowly released as steam. Because
steam will not exceed 212 degrees F under normal atmospheric pressure, it very effectively retards the transfer
of heat and the spread of fire. Even after complete calcination, when all the water has been released from its
core, gypsum board continues to serve as a heat-insulating barrier. Moreover, tests conducted in accordance with
ASTM E 84 show that gypsum board has a low flame-spread index and a low smoke-density index. When
installed in combination with other materials in laboratory-tested wall and ceiling assemblies, gypsum board
serves to effectively protect building elements from fire for prescribed time periods.

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Sound isolation

Preventing the transfer of unwanted sound to adjoining areas is a key consideration when designing a building,
specifically when taking into account the intended activities of the occupants in the various parts of the building.
For example, a building containing office spaces adjacent to manufacturing facilities requires more noise-
reducing features than are typically necessary in a building that has only office space in it. Gypsum board wall
and ceilings systems effectively help control sound transmission. Some construction techniques and gypsum
board building systems that are successfully used for sound isolation and control are described and illustrated in
Section VII.

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Durability

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Gypsum board is used to construct strong, high quality walls and ceilings that offer excellent dimensional
stability and durability. Surfaces created using gypsum board are easily decorated and refinished.

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Economy

Gypsum board is readily available and easy to apply. It is an inexpensive wall surfacing material that provides a
fire resistant interior finish. Gypsum board building systems can generally be installed at significantly lower
labor costs than most alternate systems.

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Versatility

Gypsum board satisfies a wide range of architectural requirements for design. Ease of application, performance,
ease of repair, availability, and its adaptability to all forms of decoration combine to make gypsum board
unmatched by any other surfacing product.

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Fig. 2 How Gypsum Retards Heat Transmission

Types of Gypsum Board

Using ever-developing new technologies, gypsum producers offer a variety of gypsum board products for many
specific applications, including: the surface layer of interior walls and ceilings; a base for ceramic, plastic and
metal tile; exterior sheathing and soffits; elevator and other shaft enclosures; area separation fire walls between
occupancies; and the fire-resistant layer over structural elements.

Regular and Type X gypsum board (described below) are available in several thicknesses. Different thicknesses
are typically used in the specific following applications:

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-inch A low cost gypsum board used as a base in a multilayer application for improving sound
control, used to cover existing walls and ceilings in remodeling and for curved surfaces.
5/16 -inch A specialty product primarily used in the production of manufactured housing and in
laminated double thickness for special sound control panels.
3/8-inch A gypsum board principally applied in a double-layer system over wood framing and as a face
layer in repair or remodeling.
-inch Generally used as a single layer wall and ceiling material in residential work and in double-layer
systems for greater sound and fire ratings.
5/8-inch Used in quality single-layer and double-layer wall systems. The greater thickness provides
additional fire resistance, higher rigidity, and better impact resistance.
-inch & 1 inch Used in interior partitions, shaft walls, stairwells, chaseways, area separation firewalls
and corridor ceilings. Special edged panels are used in some interior partitions.

Standard size gypsum boards are 48 inches wide and 8, 10, 12 or 14 feet long. The 48 inch width is compatible
with standard framing methods in which studs or joists are spaced 16 inches and 24 inches o.c. (Other lengths
and widths of gypsum board are available from the manufacturer on special order.)

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Edges available are rounded, tapered, beveled, square edge, and tongue and groove (V-edge).

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Fig. 3 Graphic of Edge Types

Common Types of Gypsum Board in Alphabetical Order:

Abuse-resistant gypsum panels offer greater resistance to surface indentation, abrasion and penetration
than standard gypsum panels.
Eased edge gypsum board, which has a tapered and slightly rounded or beveled factory edge. It may be
used as an aid in custom finishing of joints.
Exterior gypsum soffit board is board designed for use on the undersides of eaves, canopies, carports,
and other commercial and residential exterior applications with indirect exposure to the weather. Soffit
board is available in 1/2 or 5/8 -inch thicknesses with both regular and Type X core.
Foil-backed gypsum board has aluminum foil laminated to the back surface of regular gypsum board or
other gypsum panel products. Foil-backed panels serve as vapor barriers.
Gypsum base for veneer plaster serves as a base for thin coats of hard, high strength gypsum veneer
plaster.
Gypsum liner board serves as a liner panel in shaft walls, stairwells, chase ways, area separation fire
walls, and corridor ceilings. It has a special fire-resistant core encased in moisture-resistant paper. Liner
board is available in or 1 -inch thicknesses, widths of 24 or 48 inches and with square edges (sometimes
eased square edges). Gypsum liner board is also available with fiberglass mat facing that increases its
weather and mold resistance.
Gypsum sheathing is used as a protective fire resistive membrane under exterior wall surfacing materials
such as wood siding, masonry veneer, stucco and shingles. It also provides protection against the passage
of water and wind and adds structural rigidity to the framing system. The noncombustible core is surfaced
with water repellent paper; in addition, it may also have a water resistant core. Available in 2 feet and 4
feet widths, -inch and 5/8 -inch thick. It is also available with Type X core. Gypsum sheathing is also
available with a glass mat facing. This product is more weather resistant and mold resistant than paper-
faced gypsum sheathing, and it is often used as a substrate for Exterior Insulating Finishing Systems
(EIFS).
Impact-resistant gypsum panels offer greater resistance to the impact of solid objects from high traffic
and vandalism than standard gypsum panels.
Mold-resistant board incorporates various methods of preventing the growth of mold and mildew on the
boards surface.
Non-paper-faced gypsum board is unfaced or has a facing other than paper.
Regular gypsum board (gypsum wallboard) is used as a surface layer on walls and ceilings.
Sag-resistant board is a ceiling panel that offers greater resistance to sagging than regular gypsum
products used for ceilings where framing is typically spaced 24 inches o.c.

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Type C or Proprietary Type-X gypsum board is available in -inch and 5/8 -inch thicknesses and is
required in some fire rated assemblies. Additional additives give this product improved fire resistive
properties.
Type X gypsum board is available in -inch and 5/8 -inch thicknesses and has an improved fire
resistance made possible through the use of special core additives. It is also available with a predecorated
finish. Type X gypsum board is used in most fire rated assemblies.
Water-resistant gypsum board has a water resistant gypsum core and a water repellent paper. It serves as
a base for ceramic or plastic wall tile or plastic finish panels in non-wet areas. This product is available
with a regular or Type X core and in -inch and 5/8 -inch thicknesses.

Note: Do not use water-resistant gypsum board on ceilings or soffits unless extra framing is installed; do not
exceed 12 inches o.c. between framing members. Do not use water-resistant gypsum board as a tile-backing
substrate material where the final surface is directly exposed to running water; select one of several specialty
products, including glass-mat-faced gypsum board or cement-based board, as a tile-backing substrate for areas
directly exposed to running water.

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Limitations of Use

For installation of gypsum board and finishes, maintain room temperature at not less than 40 degrees F for the
mechanical application of gypsum board and not less than 50 degrees for the adhesive application of gypsum
board and for joint treatment, texturing and decoration, unless recommended otherwise by the manufacturer.
CAUTION: When using a temporary heat source, do not allow ambient temperatures to exceed 95 degrees F in
any given room or area. Maintain adequate ventilation in the working area during installation and curing period.
Do not use gypsum board where exposure to moisture is extreme or continuous. Take care to ensure that the
gypsum board will not be exposed to temperatures exceeding 125 degrees F for extended periods of time, for
example, when located adjacent to wood burning stoves, electric lighting, electric heating appliances or other
heating units, or hot air flues.Note: Proper installation of lighting and other heatproducing electrical fixtures
requires strict adherence to the National Electrical Code (NFPA 70A). When using gypsum board in air handling
systems, keep the gypsum board surface temperature above the air stream dew point temperature but below 125
degrees F. Consult manufacturers literature for other limitations of use for specific products.

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APPLICATION OF GYPSUM BOARD

Gypsum board can be applied over wood or metal framing or furring. It can be applied to masonry and concrete
surfaces, either directly or to wood or metal furring strips. When applying board directly to masonry or concrete
surfaces, smooth or fill in any irregularities to ensure proper attachment and an acceptable final finished surface.
Furring properly attached to interior sides of exterior walls provides flat surfaces for standard fastener
application as well and sufficient separation from substrates to overcome dampness in exterior walls. Do not
allow gypsum board to directly contact surfaces, such as concrete or soil, with potentially high moisture
contents. Most common in residential construction is the gypsum wallboard system1in which the joints between
the panels and internal corners are reinforced with tape and covered with joint compound to create a surface
suitable for final decoration. External corners are normally reinforced with either a metal or plastic corner bead
which in turn is covered with joint compound. Exposed edges are covered with metal or plastic trim. The result
is a smooth, unbroken surface ready for final decoration of paint, textures, wallpaper tile, paneling, or other
materials.1 See GA-216, Recommended Specifications for the Application and Finishing of Gypsum Panel
Products.

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Storage and Handling

Schedule the delivery of gypsum board to coincide with its installation. (Fig.4)

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Fig. 4 Boom Truck Delivering Board to Jobsite

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Store boards or panels flat and protected from the elements. Be sure that materials used as storage supports
(risers) are at least 4 inches in width and of uniform depth or length. As the units of gypsum board are tiered,
align risers carefully from bottom to top so that the load of each tier is transferred directly to the next level of
risers, thus avoiding sagging or otherwise distorting the plane of the boards.

Avoid stacking longer boards on shorter boards to prevent the longer boards from warping or breaking. Avoid
leaning boards horizontally against vertical framing as they may shift and fall and in turn injure workers. Also
avoid leaning boards during periods of high humidity or else the boards may warp. Remove shipping bags
immediately after delivery to prevent the buildup of condensation. Keep materials protected from the weather
until ready for use on the jobsite. Take care while moving boards not to drag them and damage their edges and
corners.

Refer to Gypsum Association publication GA-801 Handling and Storage of Gypsum Panel Products: A Guide
for Distributors Retailers and Contractors and GA-238, Guidelines For Prevention Of Mold Growth On
Gypsum Board, for more detailed instructions. Also see Section IX.

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Click Image for PDF

Jobsite Preparations

Job conditions such as temperature and humidity can affect the performance of joint treatment materials and the
appearance of joints. These conditions can sometimes affect adhesive materials and their ability to develop
adequate bonds. Where materials are being mixed and used for joint treatment or the laminating of one layer of
board to another, maintain the temperature in the building no lower than 50 degrees F for 48 hours before and
continuously until applied materials are thoroughly dry.
If humidity is excessive, provide adequate ventilation. In glazed buildings, leave windows open to provide air
circulation. In enclosed areas without natural ventilation, use fans to create air movement. When drying
conditions are unfavorable, allow additional drying time between coats of joint compound. During hot dry
weather, avoid drafts so that joint compound will not dry too rapidly.

Ceilings finished with water-based spray texture finishes require special attention to the spacing of framing
members, the thickness and type of gypsum board used, proper ventilation, placement of a vapor retarder,
presence of insulation, and other items that can affect the performance of the system. Failure to follow
recommendations for joist spacing, board application, vapor retarder and insulation placement may result in the
sagging of the ceiling. During cold or damp weather, insulate before installing gypsum board on a ceiling with a
vapor barrier.

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The following table shows maximum framing spacing for gypsum board that is to be covered with water-based
texturing materials:

(Note: 1/2-inch ceiling board may be applied


perpendicular to framing spaced at 24 o.c.)

Table I with framing spacing for textured gypsum board ceilings per board
thickness

Keep lumber dry during storage and installation at the


jobsite. Avoid using lumber with a moisture content
exceeding 15 % at the time of the gypsum board
application. Avoid using green lumber which may
contain up to 19% moisture at the time of sale for
framing. When green lumber is used, screw attachment
of gypsum board reduces the chances of fastener fastening problems. Because lumber shrinks across the grain as
it dries, it tends to expose the shanks of nails driven into the edge of the framing members.

Fig. 5 Stud

Shrinkage with Reduction in Moisture Content

If framing shrinkage is substantial or nails are longer than necessary, the gypsum board may separate from its
framing lumber, which often causes nail heads to protrude above the board surface (these blemishes are
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colloquially known as nail pops).

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Tools

Gypsum board installation and finishing require only some basic tools. While there are also many specialized
hand and power tools available for gypsum board installation, heres a list with brief descriptions of the basic
tools necessary for a typical wallboard job:

Measuring tape A steel retractable measuring tape, usually 25 feet in length.

Gypsum board T-square Square edge for measuring and cutting gypsum board to length and for cutting out
holes for square outlet boxes and other openings.

Utility knife Standard cutting tool with replaceable/reversible blades for scoring and cutting gypsum board.

Hammer Drives nails through gypsum board into wood framing.

Keyhole saw Small triangular saw for cutting out holes for outlet boxes, pipes, and other penetrations.

Rasp A tool for smoothing rough edges of wallboard after it has been scored and snapped.

Assorted trowels and taping knives Bladed tools for applying and smoothing tape and joint compound over
joints and fastener heads.

Mud tray Box to contain joint compound while finishing joints and fastener heads.

Sanding pole Tool that enables sanding walls from floor to ceiling and standard height ceilings without the use
of a ladder.

Screw gun Power tool that drives all types of gypsum board screws through gypsum board and into framing or
substrate.

Drywall Installation and Finishing Tools

Application Sequence

Use the following procedures to ensure a


successful gypsum board application:

1. Install ceiling panels first, then the wall


panels.

2. Once cut to size, position gypsum boards


into place without forcing them.

3. Match similar edges and ends, i.e.: tapered


to tapered, square-cut ends to square ends.

4. Plan to span the entire length of ceilings or


walls with single boards if possible to reduce
the number of butt joints, which are more
difficult to finish. Stagger butt joints and
locate them as far from the center of the wall and ceiling as possible so they will be inconspicuous.
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5. In a single-ply application, position all board ends and edges over parallel framing members to ensure that the
joints are supported. (Exception: In a two-ply assembly, with adhesive between the plies, the ends and edges of
face layers need not fall on supporting members.

Take care to install mechanical and electrical equipment at the proper distance relative to the framing to allow
for the gypsum board thickness so that the trim components, such as cover plates, registers, and grilles, fit
correctly. Do not allow the depth of electrical boxes to exceed the framing depth and avoid placing boxes on
opposite sides of a wall in the same stud cavity space. Avoid having electrical boxes, cabinets, and other devices
penetrate completely through walls as this can be detrimental to sound isolation and fire resistance.

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Cutting and Fitting Procedures

Gypsum board installations require careful planning: accurate measuring, cutting and fitting are very important.
In residential buildings with ceiling heights under 81, wallboard is best installed at right angles (perpendicular)
to framing members as this orientation of the panels leaves fewer joints to finish. On long walls, horizontally
attaching boards of the maximum practical length will minimize the number of butt joints. Avoid using damaged
board.

Carefully measure where board ends and edges will meet corners and ceilings (Fig. 6). Accurate measuring
reveals irregularities in framing and furring that require corrective allowances when cutting boards. Correct
poorly aligned framing before attaching gypsum board (see Section II, Supporting Construction).

Fig. 6 Measuring from Edge before Cutting Board

To cut gypsum board, working from the face side , first score the board by cutting through the paper to the core
with a sharp knife (Fig. 7).

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Fig. 7 Using Utility Knife to Score Board

Then snap the board back and away from the scored cut on the face of the board(Fig 8).

Fig. 8 Snapping Scored Board

Sever the boards backing paper by snapping the board in the reverse direction or by cutting the backing paper
with a scoring knife. Gypsum board may also be cut using a hand saw. Smooth all cut edges and ends of the
gypsum board to form neat, tight-fitting joints when installed. Smooth ragged ends or broken edges with a rasp
or sandpaper, or trim them with a sharp knife. If burrs on the cut ends are not removed, they will form visible
ridges in the finished surface.

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Single-Ply and Multi-Ply Application

In light commercial and residential construction, single-ply gypsum board systems (Fig. 9) are the most
commonly used wall and ceiling systems. Usually such systems meet fire resistance and sound control
requirements2. Multi-ply systems (Fig. 10) have two or more layers of gypsum board that will typically increase
sound isolation and fire resistive performance.Multi-ply systems also provide better surface quality because face
layers are often laminated over base layers, so fewer fasteners are needed to attach the face layer. As a result,
surface joints of the face layer are reinforced by the continuous base layers of gypsum board. Nail popping and
joint ridging problems are less frequent, and imperfectly aligned supports have less effect on the finished

surface.

2SeeGA-600, Fire Resistance Design Manual, for specific details and description of fire rated and
sound rated assemblies.

Fig. 9 Single-Ply Application

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Fig. 10 Multi-Ply Application

Ensure satisfactory results with either single-ply or multi-ply assemblies by requiring proper:

framing details (straight, correctly spaced, properly cured lumber)

job conditions (controlled temperature and adequate ventilation during application)

application of the board (measuring, cutting, aligning, fastening)

joint and fastener treatment

special requirements for proper sound isolation, fire resistance, thermal properties, or moisture resistance.

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Control Joints

Ceilings exceeding 2500 sq. ft. in area, and partition-, wall-, and wall-furring runs exceeding 30 ft. all require
control joints. Do not exceed 50 ft. between ceiling control joints in either direction. Install a control joint
wherever ceiling framing or furring changes direction. Do not exceed 30 ft. between control joints in walls or
wall furring. Be sure to install a control joint where an expansion joint occurs in the base of an exterior wall.
Wall- or partition-height door frames may serve as control joints. Whenever possible, ensure that control joints
coincide with any building control joints. NOTE: Where a control joint occurs in an acoustically rated assembly,
provision may be necessary to block the sound at the joint opening by using backing material, such as gypsum
board, mineral fiber or equivalent, or filling the void created with resilient insulating material.

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Control joint in 1-hour fire rated system

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Walls and Ceiling Section


Section I Gypsum Board Construction
Section II Supporting Construction
Section III Single-Ply Application
Section IV Multi-Ply Application
Section V Joint and Fastener Treatment
Section VI Decorating
Section VII Special Construction
Section VIII Mold, Moisture, Vapor & Air Penetration
Section IX Material Handling & Storage, Stocking, Safety

Our Member Companies

The Gypsum Association is honored to be comprised of the following member companies.

American Gypsum Company LLC


CertainTeed Gypsum Canada, Inc.
CertainTeed Gypsum, Inc.
CGC Inc.
Continental Building Products
Georgia-Pacific Gypsum LLC
National Gypsum Company
PABCO Gypsum
United States Gypsum Company

2012-2017 Gypsum Association

About
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Employment Opportunity
Gypsum Builds the Economy
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The Miracle Mineral


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