Académique Documents
Professionnel Documents
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Unit 5
Plaster,
plasterboard,
compressed
cement products
and insulation
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This section, therefore, is divided into two areas: the first deals with wall
and ceiling linings and the second with insulation.
The most common forms of wall lining used in Australia are gypsum
plasterboard, fibrous cement, timber or composite lining boards or
sheets, plastic coated wall sheeting and solid plaster.
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Timber and composite lining boards and sheets are covered in Section 2.
Timber and plastic coated wall sheeting is mentioned in Section 9. In
this section, we will concentrate on the other alternatives.
Plaster
The term plaster refers to a jointless and usually smooth lining applied
to the base wall or ceiling structure.
Solid plaster was one of the first lining materials to be used in buildings.
The plaster which was made of lime and sand, often with hair included,
was applied in situ to the masonry wall or, in the case of a timber stud
wall or ceiling, to timber laths which are thin battens fixed close together
to provide a base.
Today, solid or in situ plaster is reserved for solid masonry walls; timber
stud walls are lined with plasterboard. However, in situ plastering is a
wet and messy process and often internal masonry is left unplastered
(face brickwork, for example).
Composition
Plaster comprises a binder, clean sand and fresh water, which sets to a
comparatively hard, dense layer. The properties of the final product
depend largely on the type and quantity of the binder used.
Gypsum plaster
Calcium sulphate or gypsum plaster can be used for undercoats and
finishing coats. (Plaster of Paris is one type of gypsum plaster.) It is
derived from naturally occurring gypsum rock which has been pulverised
and heated to drive off most of the chemically combined water, resulting
in a white, pink or grey powder. When water is added to gypsum plaster
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it sets and hardens into a crystalline solid, giving off heat and expanding
slightly in setting.
Two other similar binders are derived from gypsum plaster: hard wall
plasters which provide a harder finish and Keenes cement, which is the
hardest of the gypsum plaster mixes.
Portland cement
Portland cement is sometimes used as a binder in undercoats and
finishing coats where an exceptionally hard surface is required. Drying
which is too rapid increases the likelihood of cracking, and shrinkage
must be substantially complete before a further coat is applied.
Limes
Plasters in which limes are the only binders are rarely used today as the
final strength is very low.
Process
The process of applying solid plaster to a base structure is known as
rendering. Solid plasters are usually applied in two coats. The
undercoat is often referred to as the scratch coat and the finishing coat
as the set coat.
If the base is particularly smooth and the suction uniform, a single coat
only may be required; alternatively, a particularly irregular base may
require three coats.
In some applications the coats may not be of the same composition but it
is important that each coat be well matured before another coat is
applied, especially if cement is used. A general principle to be followed
is that each successive coat should be weaker than the preceding one.
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The choice of a plastering system depends upon the base to which the
plaster is to be applied, the performance of the required finish and the
texture desired.
Mixes containing Portland cement make the hardest plasters, and have
the greatest resistance to impact damage. Keenes plaster is the hardest
of the gypsum plasters, while lime plaster is the softest. Table 1 and
Table 2 indicate suitable plaster mixes for two and three-coat internal plasterwork.
Finishing coat Undercoats (by volume)
Cement setting 1 cement
4 to 5 sand
1
/10 lime
Cement: lime: sand 1 cement
Gypsum plasters 5 to 7 sand
1
/10 lime
Gypsum plasters 1 plaster
2 to 3 sand
(or 1 : 3 to 1 : 4 by weight)
1 gypsum plaster:
1 sand: 1/10 lime
(or 1 : 2 by weight, plus lime 5% of
weight of plaster)
Table 1: Mixes for undercoats for internal two-coat and three-coat
work
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Preparation
Porous bases, such as clay bricks and concrete blocks, which have a
comparatively high suction rarely require much preparation other than
raking of the joints and the removal of loose material.
Smooth, dense materials, such as concrete, have little suction and offer
no mechanical key and are either hacked or else treated with a spatter-
dish, sand-cement mix, often including a PVA adhesive, to provide a key.
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Fibrous plaster
Fibrous plaster is made of gypsum plaster reinforced with sisal hemp
fibre. Nowadays it has been replaced by plasterboard for sheeting
applications but is still used for the more complicated decorative
mouldings.
Gypsum plasterboard
Plasterboard is the most commonly used lining for timber-framed
construction and brick veneer. It comprises a core of gypsum plaster
reinforced with two outside layers of kraft paper, one on each face.
Some are available with an aluminium foil on the back which improves
thermal insulation performance.
Plasterboards are easily decorated and are reasonably tough and strong
in normal grades but are not satisfactory in damp situations. A water-
resistant board is available which is designed to be used in areas where
high humidity persists and in wet situations where they are protected with
tiles or a similar impervious material.
Sizes
Sheets are available in a broad range of sizes. Thicknesses commonly
used in domestic applications are 10 mm for walls and 13 mm for
ceilings. However, a 10 mm thick board is now available for ceilings
also.
Fixing
The boards are fixed to the studs or ceiling joists by gluing or nailing with
special flat-headed nails. Boards are available with either square or
recessed edges, the latter being used where a flush surface is required.
For a flush joint, a strip of perforated reinforcing paper is embedded in
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bedding compound in the recess and the area is covered with a topping
cement (refer to Figure 1).
Fire resistance
Normal plasters are non-combustible, have no spread of flame and do
not produce smoke. Special fire-rated plasterboards are available for
applications which require a fire rating.
Often, the addition of a specified thickness of plaster or render on
internal masonry walls is used to achieve a required fire rating according
to the Building Code of Australia.
Sound absorption
Ordinary plasters have fairly low sound absorption values but special
acoustic plasters and plasterboards are available.
Sound insulation
As plaster linings are relatively thin, they contribute significant sound
insulation to lightweight components only. However, plaster can improve
sound insulation by sealing the surface to porous base structures.
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Hardness
In housing, a fairly soft finish may be preferred but harder surfaces are
often required in public buildings and the choice of system should take
this into account. Metal angles are used to protect vulnerable corners
and provide a line for the plasterer to work to (refer to Figure 2).
Durability
Gypsum-based products are not usually waterproof and the durability of
the finish depends largely on the composition of the plaster.
Texture
Smooth-trowelled surfaces comprising either neat gypsum or gypsum
with admixtures are most common but texture can be provided by special
trowelling or by including sand in the finish. Bagged finishes are
popular on masonry walls. These comprise a thin sand-cement mix
which is wiped over the wall surface with a piece of heshian. The
resultant thin coat allows the form of the masonry units to show through.
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Plasterboard
This guide provides detailed installation information for the fixing of
Gyprock plasterboards in residential construction including wet area
applications.
For additional information or assistance with plasterboard fixing.
please contact the CSR Gyprock office in your region.
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.
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.
Standard GYPROCK plasterboard or GYPROCK AQUACHEK can be
used for exterior ceilings and eaves lining, provided the ceilings are
protected from the weather.
GYPROCK FLAMECHEK MR plasterboard is fire and moisture
resistant. When used in wet areas, installation is in accordance
with the Wet Area Installation section of this guide. When used in fire
risk areas, installation is in accordance with the General Installation
section of this guide.
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Advantages
Strength and Stability
STANDARDS.
The entire range of Gyprock plasterboards, as referenced in this
technical literature, comply with following standards.
Plasterboard Manufacture.
AS/NZS2588 Gypsum Plasterboard. Plasterboard
Installation.
AS/NZS2589 Gypsum linings in residential and light commercial
construction Application and Finishing.
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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 G Y P R O C K p l a s t e r b o a r d ,
1 0 m m G Y P R O C K S U PA C E I L , 1 0 m m a n d 1 3 m m S q u a r e
Edge GYPROCK plasterboard, and most GYPROCK
plasterboard ceiling panels.
ARCHITECTURAL SPECIFICATION
SCOPE
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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/NZS 2589.1 Gypsum linings in residential and
light commercial construction Application and Finishing.
Framing must also conform to structural standards specified by the
appropriate building authorities and/or Australian Standard.
PLASTERBOARD INSTALLATION.
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SUPACEIL TM
10 1200 SN W 7.2
A
1350 W
10 1350 9.3
SOUNDCHEKTM
13 1200 13.0
1200 SN
TM
10 8.0
AQUACHEK 1350 SN SN WSN SN WSN
13 1200 W W 10.4
TM
IMPACTCHEK 13 1200 10.3
TM
BRACECHEK 10 1200 8.4
FLEXIBLE 6.5 1200 4.25
TM
FLAMECHEK MR 10 1350 8.0
13 1200 W 10.5
FYRCHEKTM
16 1200 SN W 12.5
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Indicates available in: = Australia wide; W = Western Aust.; S = South Aust.; N = Northern
Territory. Indicates NOT available in: W = Western Aust.; S = South Aust.; N = Northern
Territory.
* = Length is 2740. = 3300 and 3900mm lengths also available in WA only.
In Western Australia only, additional Recessed Edge/Square Edge products are available.
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GYPROCK Plasterboard CD
Square Edge.
Features
Manufactured with CD technology. Square Edge Finishing.
The square edge allows sheets to be butted together neatly.
These joints may be covered with aluminium, vinyl or timber
mouldings.
Bevelled Edge Finishing.
Edges are slightly bevelled.
Edges are butted together to form a neat V-joint.
Joints do not need to be covered with battens or finished with
compounds.
Manufactured to the requirements specified in AS2588 : 1998
Gypsum Plasterboard.
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Applications.
Internal walls.
Usually commercial construction, especially for office partitioning.
Aquacheck
Features.
Specially processed plasterboard.
Both the core and linerboard facing are treated in manufacture to
withstand the effects of moisture and high humidity.
Manufactured to the requirements specified in American Society for
Testing and Materials C630.
For use as a wall and ceiling lining in wet areas and high moisture
areas in residential and commercial applications.
Recessed edges allow flush jointing to Recessed Edge Plasterboard.
Applications.
GYPROCK AQUACHEK is a suitable substrate for ceramic tiles.
Usage areas include bathrooms, kitchens, laundries. garages and
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Soundcheck
Features.
Designed to provide enhanced acoustic resistance in wall and
ceiling systems.
A machine made sheet composed of a high density gypsum core
encased in a heavy duty linerboard.
Long edges are recessed to assist in producing a smooth, even
and continuous surface once jointed.
10mm and 13mm thickness.
Manufactured to the requirements specified in AS2588 : 1998
Gypsum Plasterboard.
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Bracecheck
Features.
A 10mm thickness high strength plasterboard designed for bracing
applications.
A machine made sheet composed of a high density gypsum core
reinforced with cellulose and glass fibre, encased in a heavy duty green
coloured linerboard.
Long edges are recessed to assist in producing a smooth, even
and continuous surface once jointed.
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Flexible Plasterboard
Features.
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Impactcheck
Features.
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Applications.
High traffic areas such as hallways, stairways, playrooms and garages.
Flamecheck
Features
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For use as a wall and ceiling lining in wet areas and areas of high fire
risk.
Applications
Usage areas include kitchens, bathrooms, laundries. garages.
GYPROCK FLAMECHEK MR is suitable for Category 1 Wet Areas (ie.
shower recesses and bath installations as defined in AS3740) and as a
substrate for tiling.
Cornice
Features
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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 ceilings.
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All materials must be kept dry, preferably by being stored inside the
building. Care should be taken to avoid sagging or damage to edges,
ends and surfaces.
All GYPROCK plasterboard should be stacked flat, properly
supported on a level platform or on support members which extend
the full width of the sheets and which are spaced at maximum 600mm
centres.
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Design Considerations.
Levels of finish
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FIRE RESISTANCE.
All Gyprock plasterboard is fire
resistant to some degree. Gyprock FlamechekMR TM, however, has
been formulated to have even greater performance than standard
board. In comparison to 10mm Gyprock plasterboard CD,
FlamechekMR TM was found to be up to 50% better at resisting the
effects of fire on walls and ceilings where there were no penetrations
or openings. In any case, penetrations and openings can reduce the
fire resistance of a system.
Smoke alarms save lives and CSR Gyprock recommends that
suitable alarms be installed. Fire extinguishers and fire blankets
should also be accessible.
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Control Joints
Movement and stresses created by temperature and humidity
fluctuation, can result in deformation and damage to internal linings
and partitions.
It is recommended that GYPROCK plasterboard surfaces be isolated
from structural elements, except the floor, by the use of control joints
or other means where:
A GYPROCK plasterboard surface abuts any structural
element or dissimilar wall or ceiling assembly
LIGHTING.
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HEATING.
Heat pumps,
Reverse cycle air conditioners,
Solid fuel stoves.
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S e m i - g l o s s a n d g l o s s f in i s h e s h i g h l i gh t imperfections.
Lighter colours (when compared to darker colours) are:
Garage Ceilings
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In areas of high humidity, use Gyprock Wet Area Base Coat in the
jointing system.
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Fibrous cement
Fibrous cement sheeting has replaced asbestos cement as a lining and
cladding material due to the health hazards associated with materials
containing asbestos.
Composition
Fibrous cement is made from a mixture of Portland cement, sand,
cellulose fibre and water, compressed into sheets, boards or other
shapes.
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Sizes
Fixing
Sheets can be glued or fixed with special galvanised flat-head fibrous
cement nails to timber frames. Sheet ends can be covered with PVC
end caps while joints can be covered with PVC sheet holders or fibre
cement cover moulds (refer to Figure 3).
Uses
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General properties
Thermal insulation
Fibrous cement sheets are relatively thin and make a correspondingly
small contribution to the thermal insulation of the building.
Fire resistance
Fibrous cement products will not burn, have a zero spread of flame
index and do not produce smoke.
Sound absorption
Unless special acoustic material is used, fibrous cement lining
contributes little to the sound absorption characteristics of a room.
Sound insulation
The sheets have a greater density than plasterboard but are thinner and
therefore do not significantly affect sound insulation.
Hardness
Care should be taken during handling and storage to prevent edges from
chipping since the material is particularly brittle. When painted or
otherwise finished, however, a hard surface finish can be obtained.
Durability
Fibrous cement sheets are unaffected by sunlight, moisture or termites
and should not split or rot. Hence its suitability for external and wet area
applications.
Thermal insulation
The question of thermal insulation really forms part of the problem of
energy efficient design of the building as a whole, which includes
consideration of the following points:
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Heat transfer
Heat is transferred by:
conduction-heat is led from the side of the material at a higher
temperature to the side at a lower temperature
convection-when air is heated it expands and begins to circulate and
heat up colder surfaces by losing some of its heat to them
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Thermal resistance
A materials ability to resist the flow of heat is called its thermal
resistance or R-value. The higher the R-value of a material, the greater
its ability to resist the flow of heat.
The heat flow through a wall or ceiling is not reduced in direct proportion
to the R-value of any insulation added above the recommended level. In
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fact the extra benefit to be gained diminishes fairly rapidly beyond this
level.
New South Wales is divided into 4 zones and shown in on the next
page. The R-values that need to be achieved under the deemed-to-
comply provisions are given in Part 3.12 Energy Efficiency of Volume 2 of
the BCA 2008.
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Types of insulation
Reflective
Bulk
This is normally a cellular material with entrapped air bubbles which slow
down heat transfer by conduction. Several forms are available.
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Loose fill
Loose fill insulation is available in:
Cellulose fibre manufactured from waste paper.
Exfoliated vermiculite manufactured from a micaceous material.
Mineral wool manufactured as explained above.
In-situ foam
In-situ foam insulation is available in:
Urea formaldehyde pumped in as a mixture of chemicals using
special equipment. The mixture foams up in situ and forms a rigid
foam filled area.
Urethane foam pumped as fluid foam into the space where it sets
chemically to form a rigid insulation.
Expanded polystyrene beads mixed on site with a bonding agent
and injected into the cavity.
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Acoustics
Some insulation will also contribute to the acoustic performance of the
room, especially in the case of some of the decorative panels.
Fire resistance
Some insulation materials are combustible. Combustible insulation
should be covered with an appropriate non-combustible lining such as
gypsum plasterboard. Urethane foam, expanded polystyrene and
cellulose fibre insulation must contain fire-retardant chemicals.
Safety
Most bulk insulation materials should be handled with care to avoid dust
formation.
Suitability
The type of construction will limit your choice of insulation system.
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For instance,
Loose-fill insulation is generally only suitable on flat surfaces.
Loose-fill insulation is good for difficult corners.
In situ insulation may make access to the roof space extremely difficult.
Where to insulate
For the minimum requirements, refer to Part 3.12 Energy Efficiency
of Volume 2 of the BCA 2008.
Because heat rises, most heat loss occurs through the ceiling. Figure 15
illustrates the proportion of heat loss through various paths for a typical
uninsulated detached brick veneer dwelling in Canberra.
(Note that the figures given have been calculated specifically for the
Canberra region and may not apply to other areas although the general
pattern these figures reveal would apply for this type of construction
elsewhere.)
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Although the percentage figure for heat loss through the walls is the
highest, in terms of unit area the diagram suggests that (for this type of
construction) the greatest heat losses are in fact through the ceiling and,
next, the floor. Consequently, the first place to consider insulating is
above the ceiling (refer to Figure 16).
In extremely cold climates rigid foam insulation around the edges of the
slab is advantageous (refer to Figure 18).
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