Drywall

313D Issue 3

Plasterboard Installation Reference Manual8mm Drywall

2

DescriptionBoral Plasterboard Drywall Masonry systems aremethods of attaching plasterboard to brick,masonry and concrete walls to provide a quickand professional finish.

Depending on the particular type of surface, theplasterboard is bonded to the basewall with eitherBoral Plasterboard Cornice Adhesive or BoralPlasterboard Masonry Adhesive. The Drywall canalso be mechanically fitted using wall furringsystems.

AdvantagesThis fast, dry alternative to cement render andsolid plaster offers many advantages:

• Eliminates the delays associated with heavy,wet construction.

• Fast, economical drywall installation - avoidscleanup of wet trades.

• Allows correction of misaligned masonryand concrete walls.

• Electrical and telephone wiring can beinstalled between the Drywall and masonrysurfaces - avoids chasing of masonrybasewalls.

• Provides a smooth, clean, serviceable finish,ready for decoration.

• Boral Plasterboard and Adhesives, beingplaster based, possess good fire resistanceproperties.

System SelectionSecuring Drywall plasterboard using adhesivesystems is suitable when the basewall is:

• relatively flat, with irregularities not causingthe gap between the back of the Drywall andthe wall to consistently exceed 17mm; and

• the masonry or concrete surfaces must beclean, in good condition, dry and free ofrelease, waterproofing or other chemicalagents, dust, oil, grease or loose drummymaterial.

Alternatively, mechanical systems can be used inall cases, or specifically when the basewall isunsuitable for adhesive application.

LimitationsBoral Plasterboard Drywall Masonry Systems arealternatives to solid plastering and are not to beused for isolating dampness.

The suitability of exterior walls should be checkedby the building designer.

8mm Drywall System

IntroductionBoral 8mm Drywall Plasterboard System is afaster, cleaner and smoother alternative toconventional wet plaster and render.

This manual outlines the benefits, systemcomponents, installation procedures, tools andadhesives necessary for lining masonry walls indomestic and residential applications.

Installers will find Boral Drywall Plasterboard idealto work with. The sheets are lightweight, yetremarkably strong due to a special reinforced fibrecore. Because Drywall is prefabricated, there’s nodowntime waiting for wet plaster to dry. This cancut days off construction time; wall painting orpapering can commence almost immediately andthere’s none of the mess normally associated withplastering.

For use around fixtures such as windows andsliding door frames, the Drywall systemincorporates Boral Plasterboard Gypbeams, with aresult that is clean and professional. Drywallprovides a smoother, more attractive appearancethan normal plastering and is also far moreresistant to cracks, chips and scratches.

If you require more information on the 8mm BoralDrywall Plasterboard system or any other Boralproduct, contact your local Boral Plasterboardsupplier.

ContentsDescription .............................................................. 2Application notes ................................................... 3Vertical application ................................................. 4Horizontal application ............................................ 5Irregular wall surfaces ........................................... 6Door jambs ............................................................. 7Window reveals ...................................................... 7Gypbeam reveals.................................................... 8Corners .................................................................... 9Mechanical application ........................................ 10Accessories and trims .......................................... 12Compounds .......................................................... 13Jointing and finishing corners ............................ 14Butt joints .............................................................. 14Two and three coat application ........................... 15Mechanical tools .................................................. 16Trade tools ............................................................ 19Installation ............................................................ 21Wall tiling .............................................................. 22Bathroom construction ........................................ 23Bathroom construction details ............................ 24Wet area accessories ........................................... 25Guarantee .............................................. Back CoverTechnical Desk Details .......................... Back CoverAddress and Phone Number Details ... Back Cover

38mm Drywall System

Application Notes

Boral Plasterboard SizesThe range of Boral Plasterboard sizes is subject tochange. For details of sizes available contact yourlocal Boral Plasterboard supplier.

Masonry AdhesiveMasonry Adhesive will give you a working time ofup to 60 minutes.Take care not to mix more thancan be used in this time. Mixing instructions,printed on the bags, should be followed carefullyto ensure best results.

Adhesive ApplicationUse Boral Plasterboard Masonry Adhesive to bondplasterboard sheets to masonry walls.Thisproduct has exceptional bond strength and, whenmixed, is suitable for adhering to porous surfaces.

It is essential that all new concrete or masonrysurfaces be allowed to dry out to normal levelsbefore the installation of Boral DrywallPlasterboard. Where the surface is particularly dryor porous, it is advisable to dampen the wall orapply a bonding agent prior to the application ofthe adhesive.

• Always use clean coldwater and clean containersand tools - using dirtycontainers/tools may affectthe setting time and setstrength.

• For best results slowly addpowder to water (ratio of2kg powder to 1 litre water)and allow powder to soakfor 1-3 minutes beforemixing.

• Mix by hand or with apower mixer (maximum of400rpm) - mixing at higherspeeds will draw air intothe mix and may affectworking time.

• Mix only enough adhesivefor 60 minutes workingtime.

• Mix until a smoothworkable paste has beenachieved.

• Do not overmix, as thismay accelerate setting.

• Once setting hascommenced, the materialcannot be re-mixed andshould not be used further.

• Do not mix with previouslyprepared batches or otheradhesives. The inclusion ofother materials (e.g.retarders, filler etc.) in themix will impair theperformance of thisproduct, i.e. reducedstrength, poor adhesionand will void the productwarranty.

A bonding agent may be required to ensuresatisfactory adhesion particularly when the wall isdry or very porous.

If any doubt exists concerning the suitability of thewall surface, contact your local Boral Plasterboardsupplier.

Mechanical ApplicationAs an alternative to installing with adhesives,Boral Plasterboard Wall Furring Systems, utilisingsteel furring sections or steel/timber battensfastened to the basewall can be used.

These wall furring systems are stronglyrecommended for use where the masonry walland/or existing paintwork is in poor condition.

Mixing Masonry Adhesive

4 8mm Drywall System

True Wall SurfacesBoral Drywall Plasterboard can be appliedvertically or horizontally. Before commencingapplication, the basis of a true wall plane shouldbe established. Where there are irregularities inthe base-wall surface, levelling pads of Drywallwill be required for straightening, to establish atrue line for the finished Drywall surface.

Vertical Application• Clean off all protruding block mortar so as to

establish a true line for finished dry wallsurface.

• Apply daubs of adhesive to wall surface orDrywall approximately 50mm diameter by10mm minimum thickness, at not more than350mm centres horizontally and vertically.

• Apply adhesive daubs 50mm from boardedges and ends.

• Cut Boral Drywall Plasterboard sheets 16mmless than ceiling height, to allow for 8mmtop and bottom ventilation gaps.

• Position temporary offcuts of 8mm boardbetween the floor and bottom of sheetsbefore fixing. Remove when adhesive hasdried.

• Place Drywall in position, and using astraight edge press the sheets firmly intoplace top and bottom.

• Carefully level vertically and horizontally.• Hold sheets in position by shoring or other

temporary fixing until adhesive has set.• Ensure that the Drywall sheets are applied

within the setting time of adhesive daubsapplied.

When all sheets are fixed and the adhesive is set,flush joint, using your preferred Boral DrywallPlasterboard jointing system.

Layout of Masonry Adhesive Daubs onWall

50mm

350mm max.

350mm max.

Packers 8mm ventilation gaptop and bottom

58mm Drywall System

Horizontal Application• Clean off all protruding block mortar so as to

establish a true line for finished dry wallsurface.

• Apply daubs of adhesive to wall surfaceapproximately 50mm diameter by 10mmminimum thickness, at not more than350mm centres horizontally and vertically.

• Apply adhesive daubs only where bottomboard will be placed and 50mm from boardedges and ends.

• Position temporary offcuts of 8mm boardbetween the floor and bottom of sheetsbefore fixing. Remove when adhesive hasdried.

• Place bottom board in position and pressfirmly into place.

• Trim top board 16 mm less than ceilingheight to allow for 8 mm top and bottomventilation gaps.

• Apply adhesive daubs only where top boardwill be placed and 50mm from board edgesand ends.

• Place top board in position, and using astraight edge press the sheets firmly intoplace top and bottom.

• Carefully level vertically and horizontally,ensuring recessed edges are aligned.

• Hold sheets in position by shoring or othertemporary fixing until adhesive has set.

• Ensure that the plasterboard sheets areapplied within the setting time of adhesivedaubs applied.

When all sheets are fixed and the adhesive is set,flush the joint, using an approved BoralPlasterboard jointing system.

Butt Joints in Horizontal ApplicationWhen fixing plasterboard to masonry wallsurfaces, butt joints should be avoided.Where it is necessary to butt join sheet ends,these must be staggered min. 600mm and endsbutted neatly as follows:

• Where the sheet ends will fall, butter the wallwith a continuous ribbon of adhesive,approximately 50mm wide and a minimumof 10mm thick.

• Alternatively, butter along sheet ends with acontinuous ribbon of adhesiveapproximately 25mm wide, and a minimumthickness of 10mm.

• Press sheet ends firmly into position andhold in place by shoring or other temporaryfixing until adhesive has set.

Butt joints are then ready for jointing. Follow BoralPlasterboard standard procedure for flush buttjoints.

Layout of Masonry Adhesive Daubs on Wall

Stagger butt joints600mm min.

350mm max.

350mmmax.

50mm ribbonof adhesive atbutt joints

50mm min. fromboard edges

Packer 8mm ventilation gaptop and bottom

6 8mm Drywall System

Irregular Wall Surfaces• Mark out Boral Drywall Plasterboard widths

on the basewalls.• Check basewalls with plumb lines and

straight edges to find high spots, and toclear any wiring.

• Using these as a guide for the level to be set,attach 75mm x 75mm levelling pads of BoralDrywall Plasterboard to walls with adhesiveto a true line.

• Pads are to be positioned at 600mm centresmax. horizontally to intersect joints, and at1350mm centres max. vertically, on anadhesive bed at not less than 3mm thick onhigh spots, or more than 10mm thick.

• Apply daubs of adhesive to wall surface orboard approx. 50mm in diameter and 15mmthickness, at not more than 350mm centreshorizontally and vertically.

Note:Where the cavity width between the back ofthe board and the wall surface consistentlyexceeds 17mm, a furred system isrecommended, or alternatively, refer toBoral Plasterboard Sales Offices for advice.

• Cut Boral Drywall Plasterboard sheets 16mmless than ceiling height, to allow for 8mmtop and bottom ventilation gaps.(Positioning 8mm Plasterboard offcutsbetween bottom of sheets and floor, asdescribed in “True Wall Surfaces”.)

• Place Drywall in position, and using astraight edge press the sheets firmly intoplace.

• Carefully level vertically and horizontally.• Proceed as for true wall surfaces.

Layout of LevellingPads on Wall

8mm ventilation gaptop and bottom

600mmmax.

Levelling pad

1350mmmax

Layout of Masonry Adhesive Daubson Wall with Levelling Pads

8mm ventilation gaptop and bottom

350mmmax.

Adehesive daub

1350mmmax

Levelling PadApplication

Adhesive

Levellingpad

75mm

75mm

Adhesive

Levelling pad

7Construction Details

Door Jambs

Window RevealsBoral Plasterboard window reveals fordrywall masonry systems are applied asfollows:

• Cut narrow widths of Boral DrywallPlasterboard to line up with the wall levellingdots.

• Use linerboard edge of square edge board toabut the window frame. Alternatively useRondo Stopping Angle.

• Fix by applying daubs of Masonry Adhesiveto the back of the reveal lining and pressdirectly into position, accurately preservingmargins to the frame.

• Temporarily support the head lining.• The face sheets should be fixed to overlap

the leading edge of the reveal linings.• Apply Rondo Corner Bead P32 and finish

with your preferred Boral Plasterboardjointing system.

Door jamb

Standard Metal Door Jamb

Door jamb

Metal Door Jamb

Standard Timber Door Jamb

Door jambArchitrave

Window Reveal

Masonry adhesivedaubs

Set over cornerbead (P32)

Set over stopping angle(P25 or P26)

8 Construction Details

GypbeamTM Reveals

Window Reveals

25mm Min.

Daubs 50mm fromboard edges

250mmMax.

250mm Max.

Window Reveals

ApplicationGypbeamTM Plasterboard can be fixed vertically orhorizontally. GypbeamTM Window Reveals fordrywall masonry systems are applied as follows:

• Clean off all protruding block mortar so as toestablish a true line for finished GypbeamTM

reveal.• Measure and cut GypbeamTM reveal to

length, width and depth.• Starting with bottom GypbeamTM reveal

apply daubs of adhesive to wall surfaceswidth and depth of no more than 250mmapart.

• Apply adhesive daubs 50mm from boardedges and a minimum of 25mm fromwindow frame.

• Where butt joints occur, butter the wall witha continuous ribbon of adhesive to a widthof approximately 50mm and a minimum of10mm thick.

• Place GypbeamTM reveal in position andusing a combination square press firmly onwidth and depth surfaces along the beam toachieve a 90o angle.

• Repeat process for each GypbeamTM revealstarting with the top gypbeam and then thesides.

• When all GypbeamTM reveals are fixed andthe adhesive is set, flush butt joints using anapproved Boral Drywall Plasterboard jointingsystem.

9Construction Details

Applying External Corner Bead

Dowell Windows

Internal Corner

Wall Junction

Aluminium WindowsDowell windows, working closely with BoralPlasterboard, have developed a window frameinnovation ideal for 8mm Drywall and GypbeamTM

Reveals. The GypbeamTM reveals slot neatly intothe window frame to give a stylish window revealfinish.

Corners

Internal CornersWhere two block walls form an internal wallcorner, plasterboard is adhered to the wall bydaubs of Masonry Adhesive at 350 mm centresand 50mm from edges, fixed as follows:

• Position the bottom and top sheets for onewall firmly into the angle and hold inposition.

• Butt the bottom and top sheet for the otherwall firmly against the first wall sheets.

• Fill and tape the angle, and finish, asdescribed under "Jointing and Finishing".

External CornersPlasterboard external corners should bereinforced and protected with a metal corner beadbefore finishing with jointing compounds. Thecorner beads (Rondo External Corner Bead, PartNo. P32) are applied to the full length of thecorner, and adhered to plasterboard with MasonryAdhesive as follows:

• Butter a bead of Masonry Adhesive (15 mmwide, 10 mm thick) down both sides of thebead and apply to the plasterboard.

• Ensure that the corner bead is plumb andstraight before leaving Masonry Adhesive toset.

• Flush finish the angle with BoralPlasterboard Jointing Compound.

10

Rondo Steel Components

16mm

38mm 308

38mm

28mm

129

237 16mm

38mm 30113mm

19mm

19mm13mm

33313mm

100mm

40mm68mm581

Drywall Masonry Systems

Mechanical ApplicationAs an alternative to installing 8mm Drywallwith adhesives, 10mm Boral DrywallPlasterboard with a Wall Furring System canbe used. These wall furring systems arestrongly recommended for use where themasonry wall and/or existing paintwork is inpoor condition.

Boral Drywall Plasterboard can be fixed to steelfurring or to steel/ timber battens. The steelsections listed below are manufactured by RondoBuilding services Pty. Ltd. and supplied by BoralPlasterboard:

• Furring Channel - Part No. 129 or 308.• Face Recessed Furring Channel - Part No.

333.• Resilient Channel - Part No. 581.• Batten - Part No. 301.• Furring Channel Anchor Clip - Part No. 237

or 239.

The Resilient Channel (Part No. 581) is usedmainly in acoustic wall construction.

Application - BoraI Drywall Plasterboard• Cut Drywall sheets 16mm less than ceiling

height to allow for 8mm top and bottomventilation gaps.

• Apply 1200mm wide Drywall vertically, withedges centred over furring channel.

• Fasten with 25mm screws to furringchannels at 400mm centres in the field of theboard, and at 200mm centres on edges, (orto timber battens with 30mm nails or screwsat 230 mm centres in the field of the board,and at 200mm centres on edges).

Furring InstallationFixing and layout of Timber Battens, SteelBatten (301), Furring Channel (333) orResilient Channel (581).

• Fix timber/steel battens or steel furringchannel vertically at 600mm maximumcentres, with suitable masonry fasteners,after packing out to achieve a true line.

• Provide and fix short lengths of furring/batten at top and bottom of wall to supportplaster edges, leaving a 25mm ventilationgap between ends and main furring.

Fixing and layout of Furring Channel 129 or308.

• Furring Channel 129 or 308 are attached tofurring channel clips (Rondo Part No. 237)which are in turn fixed to the wall.

• Mark out on the wall surface fixing locationsfor the furring channel clips (237) as follows:

1. Clips to be positioned at 600mm centres inhorizontal rows, with rows spaced at 900mmcentres apart vertically when applyingFurring Channel 308, and 1200mm apartvertically when applying Furring Channel129.2. Fix clips to the wall surface with suitablemasonry fasteners, after packing out toachieve a true line. Furring Channel (129 or308) is then attached to the clips vertically.3. Additional furring channel is appliedhorizontally at the top and bottom of the wallto support the edges of the Drywall. Thefurring clips are positioned in a row at thetop and bottom of the wall spaced at1200mm centres for Furring 129, and 900mmcentres for Furring 308.

11Drywall Masonry Systems

Mechanical Application (continued)

Fixing and Layout of Timber Battens, Steel Battens (301),Furring Channels (333) or Resilient Channels (581)

200mm

400mm

Furring fixed to wallwith masonry fasteners

600mm

Fixing and Layout of FurringChannel 129 or 308

Part 237 Clips @ 1200mmmax.for vertical furringPart 129; 900mm max.for Part 308

100mm max. Part 237 Clips @ 1200mm max. for horizontalfurring Part 129; 900mm max. for Part 308

400mm

200mm

Part 237 Clips @ 600mmspacing for vertical furring

Furring Part 129 or308 @ max.600mmvertical centres

12 Accessories and Trims

The major accessories and trims shown on thispage are manufactured by Rondo BuildingServices Pty. Ltd., and supplied by BoralPlasterboard. All steel components are coatedwith corrosion resistant finishes either withZincanneal or G2-Galvbond Z275 (refer to RondoBuilding Services Pty. Ltd. for details).

Plasterlock Corner Bead

Use:

Designed to provide true,straight lines and strong durable protectionat external corners. The exposed bead-headresists impact and forms an exact screed for finishing.

Part No. P32

32mm

32mm

Expansion Joint Components

RemovableTape

Expansion Bead

Part No. P35

Use:Provides a finish to expansion joints where requiredin locations for walls and ceilings.

Filament

Plasterlock Arch Bead

30mm

10mmPart No. P30

Use:

Reinforcing edges of BoralPlasterboard lining of archways.

Casing Bead

Part No. P04

8mm

ShadowLine Stopping Angle

30mm

Part No. P50

10mmUse:

Designed to provide a cleanstraight edge for walls or ceilings.Suitable for use around timber door jambs.

Bullnose Corners

Part No's R05 and R06

Stopping Bead

8mm Part No. P10

Use:

For 8mm Boral Plasterboard.Provides a neat finish edge around doorand window openings in place of architraves.

13Jointing and Finishing

Compounds

Mixing Powder CompoundsDetailed mixing instructions printed on thebags should be carefully followed - mixinginstructions can vary for differentcompounds.

Correct mixing of jointing compound powders isimportant to ensure good jointing and finishing.

Generally

• Always use clean drinking water, containersand tools.

• Add powder to water, sifting slowly.• Do not mix with other materials, or previous

batches.• Avoid entrapment of air if mixing by hand,

or if by power blade mixer do not operateabove 400 rpm max. This will avoidwhipping air into the mix.

• Plaster based setting type powders(BaseBond, SuperSmooth™ BaseCote MidSet, SuperSmooth™ BaseCote Long Set, andAll Purpose Plaster) should not beovermixed, as this accelerates setting. Oncehardening has commenced thesecompounds cannot be remixed.

Premixed Compounds• Keep containers and tools clean, and seal lid

when not in use.• Do not mix with other compounds.• Stir contents thoroughly, but lightly before

use, if necessary.

Storage• Store jointing compounds under cover in a

dry location, at moderate temperatures.• Stocks should be rotated.

Supe Sm oth

Taping and BasecoatingCompounds

All Purpose JointingCompounds

Finishing Compounds

14 Jointing and Finishing

Jointing CoatsTo achieve best results it is recommendedthat a three coat system is used for flushjointing and finishing, using perforatedpaper tape.

This particularly applies in locations experiencingconsiderable variation in climatic conditions, andsituations where above normal building framestresses can be experienced.

Internal Corners• Gaps in excess of 4mm should be filled with

BaseBond, SuperSmooth™ BaseCote MidSet or SuperSmooth™ BaseCote Long Setcompound.

• Allow to set.• Measure and cut perforated paper tape to

length.• Apply basecoating compound to both sides

of the angle, using a 50mm broad knife.• Fold perforated paper tape along it’s centre

line and bed into the compound, using a50mm corner tool.

• When set (or, for pre-mixed compounds,completely dry), apply a finishing coat ofcompound, ensuring edges are featheredwith a 100mm corner tool.

• When thoroughly dry, sand lightly.

External Corners• Apply BaseBond, SuperSmooth™ BaseCote

Mid Set or SuperSmooth™ BaseCote LongSet to both sides of the previously nailedcorner bead, forcing the compound into theperforations of the bead, and level off.

• Allow to set.• Apply finishing compound, feathering back

from the nose of the corner bead.• When thoroughly dry, sand lightly.

Butt JointsButt or end joints that have been adhered shouldbe flush jointed and finished as described forrecessed edge board jointing procedures.However, in order to give a flatter finish andminimise any apparent surface build-up ofcompound, each jointing coat is considerablywidened, so that the finished joint isapproximately 500mm to 550mm wide.

InternalCorners

ExternalCorners

Finishing coat

Basecoat

Paper tape

Finishing ButtJoint

500mm to 550mm wide

15Jointing and Finishing

Step 1. Fill the Recess

Step 2. Bed the Tape

Step 3. Skim Coat Over Tape

Step 4. Apply Second Coat

Step 5. Apply Finishing Coat

Step 6. Lightly Sand

Three-coat Application

First Coat• Evenly fill the recess formed by the tapered

edge of the plasterboard with BaseBond,SuperSmooth™ BaseCote Mid Set orSuperSmooth™ BaseCote Long Set.

• Measure and cut reinforcing tape. Centreand press the tape into the fresh compound.

• Hold the blade of the broad knife at 45o tothe board surface and draw along the jointwith sufficient pressure to remove excess.

• Ensure that all air bubbles have beenexpelled, taking care that sufficientcompound is left under the tape to provide astrong bond.

• After the tape is embedded, apply a skimcoat of compound. Feather edges of jointsand spot fastener heads.

• Allow to set for a minimum of one hourbetween coats.

Second Coat• Apply a second coat of compound,

feathering 50mm beyond the edges of firstcoat. Spot fastener heads again.

• When the second coat has set and dried,scrape back in preparation for the finishingcoat.

Finishing Coat• Ensure that basecoats have set/dried before

applying finish coat.• Use a trowel or broadknife to apply finishing

compound over the second base coat,feathering joint edges at least 50mm beyondedges of basecoat.

• After trowelling, apply a damp sponge toedges of joints and corners to reduce theneed for sanding.

• Allow a minimum of 24 hours in good dryingconditions (considerably longer in humid,damp conditions).

• When thoroughly dry, sand lightly to asmooth finish with 150 grit abrasive paper orequivalent.

Two Coat ApplicationWhere a two coat jointing and finishingapplication is used, a generous skim coat ofBaseBond, SuperSmooth™ BaseCote Mid Set orSuperSmooth™ BaseCote Long Set should beapplied after the paper tape has been embedded.

When this skim coat has set apply a thick coat ofan all purpose or finishing compound, featheringat least 50mm beyond edges of the skim coat.Allow to dry, and sand if necessary, taking carenot to scuff the paper on the plasterboard.

16 Jointing and Finishing

Mechanical ToolsThe use of mechanical tools has gained acceptance in the industry as a fast and professional method forapplying joint compounds. In the hands of a capable operator, mechanical jointing tools will save time andlabour.

The following table summarises those tools suitable for application of Boral jointing compounds:

When using mechanical tools to apply jointingcompounds, use the following procedure:

• Reinforce all joints with perforated papertape, using the taping tool.

• Remove excess compound with a broadknife, and allow to dry.

• Cover all fastener heads using a broad knifeor nail spotter.

• Tape internal angles using the corner roller,embedding the tape into the angles.

• When all joints are dry, apply a 2nd coat tofastener heads.

• Apply finish coat to internal angles using acorner finishing tool.

• Apply finish coat to joints with a flat finisher(2nd box).

• Apply finish coat to fastener heads.

• Allow compound to dry thoroughly betweenall coats - 24 hours in good dryingconditions, longer in humid situations.

• After final coat has dried, sand lightly to asmooth finish with 150 grit abrasive paper orequivalent.

Note:• Apply a setting-type compound promptly.• Do not leave compounds on tools for long

periods.• Clean all mechanical tools before and after

use.• Follow manufacturer's instructions.

TopCote 550Finishing

Compound

Jointing Compounds for Mechanical ToolsApplication

ProductBasecoat

SuitableMechanical

ToolsCategory

TapingPackaging Coverage

Finishing

All PurposeCompounds

FinishingCompounds

Taping &BasecoatingCompounds

SuperSmooth™BaseCoteLong Set

All Purpose DryMix Compound

All Purpose PreMix Compound

All PurposePlaster

FinalCoteFinishing

Compound

Mud Pump,Banjo Box (only),

Flat FinisherNote: BaseBond and SuperSmooth™BaseCote Mid Set are not suitable for use with mechanical tools

Mud Pump,Banjo Box (only),

Flat Finisher

Mud Pump,Automatic Taper,

Corner Roller,Corner Finisher,

Nail Spotter,Flat Finisher

(1st & 2nd boxes)

Mud Pump,Nail Spotter

Flat Finisher,Corner Finisher

20kg bag 125m2 NR

NR

NR

NR

NR

17kg bag

17kg bag

18kg pail

24kg pail

20kg carton

22kg pail

80m2 for3 coats

250m2 forfinishing

75m2 for3 coats

240m2 forfinishing80m2 for3 coats

240m2 forfinishing

300m2

250m2

280m2

17Jointing and Finishing

Mechanical Tools

Banjo Box

Taping and Basecoating

Automatic Taper

Using the Automatic Taper

Using the Flat Finisher

Flat Finishingof Joints

Flat Finishers(1st and 2nd Boxes)

Flat FinisherHandle

18 Jointing and Finishing

Mechanical Tools

Corner Finisher

Corner Roller

Finishingof Corners

Using the Corner Finisher

Nail Spotter

Corner Box

Additional Tools

GooseneckPump

19Trade Tools

Trade ToolsBoral Plasterboard supplies a range of qualitytradesman tools. The basic tools needed areshown on this and the following page.

SawFor cutting Boral Plasterboard at doorand windowopenings.

TrimmingKnifeFor cutting BoralPlasterboard.

Corner Tools

100mm for finishinginternal angles,giving a neat straightcorner.

50mm for tape applicationtointernal angles.

Trowels

200mm Waisted, Bowed or curved shank:

Specially shaped to ensure correct camberto second coat of joint compounds.

275mm Waisted:

Shaped to enable the finishing coat of jointcompounds to be feathered out at the edges.

275mm FlatTrowel:

Standard type plasterer's trowel used forscraping back joint compounds andfinishing external angles on columns,beams and archways.

Tee Square

1200mm or 1350mm blade, and 350mm stock

Used for making accurateknife cuts across boardwidth.

With notched head toenable knife to cut fromedge of sheet.

Measuring Tape

Straight Edges

Available in1500mm,1800mm &2400mm sizes

20 Trade Tools

Holesaw

For cutting holesand penetrations.

Small Tool

Used for flushing GypbeamTM

reveal junctions and cornices.

Broad Knives

50mm: For applicationof Boral Plasterboard StudAdhesive, and for stopping.

75mm: For taping internal angles and stopping.

100mm: For finishinginternal angles and stopping.

150mm: For embeddingtapes in recessed jointsand finishingfastener heads.

Sanders

Hand Sander

Pole Sander

150 grit sanding paper or 220 gritfibreglass mesh sanding cloth.

PlasterboardTrimmer

For trimming Drywall andGypbeam reveal edgesTM

Mixers

Hand Mixer

Jiffler Mixer

Bucket

Bucket - sized to suit mechanical pump

21Installation in Wet Areas

IntroductionThe following pages cover the use and applicationof Boral Plasterboard products in the lining of wetareas. Comprehensive details are providedshowing how drywall plasterboard is applied andjointed.

DescriptionBoral Wet Area 8mm Drywall Plasterboard isrecognised by its grey-blue multilayered face andback liners, which are resistant to moisturepenetration. The gypsum core is moisture resistantwith low absorption characteristics. This stopswater wicking up the board and inhibits thelikelihood of water vapour penetrating to the cavityof a partition.

Boral Wet Area Drywall Plasterboard ismanufactured with recessed edges for water-resistant jointing in tiled areas and normal jointingbeyond tiled areas. It is an ideal water-resistantbase for adhesive application for ceramic tiles andthe application of paint and wallpaper finishbeyond tiled areas.

Advantages• Choice of jointing methods• Dimensionally stable• Economical base for adhesively applied wall

tiles• Quick, dry installation• Easy to cut and form openings• Same thickness wall lining throughout all

rooms• Effective lining for masonry and block walls

Cautionary NotesBoral Wet Area Drywall Plasterboard must beinstalled in strict accordance withrecommendations of this manual and:

• is not to be installed over a vapour barrier oron a wall acting as a vapour barrier.

• is not to be used in critical exposure areassuch as group shower rooms or steamrooms.

• is not to be used in unprotected externalapplications.

• is to be applied with Masonry Adhesive only(with supplementary mechanical fasteners intiled areas) to masonry wall or block wall,never to other types of plasterboard, plaster(gypsum) or similar materials.

• must be faced with ceramic tiles wheninstalled in shower recesses and showercompartments over baths.

• must not be used if fractured or damaged.• must be stored under cover.

PlumbingPlumbing fittings abutting Boral Wet Area DrywallPlasterboard are to be installed in accordancewith Regulatory Authorities’ requirements.

Cutouts for plumbing penetrations are to be madeneatly, using an appropriate knife or hole saw, notwith a blunt instrument or hammer. Leave a gapas small as possible between the cut edges andthe pipe.

Seal thoroughly around penetrations with BoralWet Area Sealant finished with Boral Wet Areataping Cement. A Tap Penetration Flange ("FluidApron" by HPH Pty. Ltd. or equivalent) can beused over plumbing fitting but must be sealedwith an approved sealant.

InstallationBoral Wet Area Drywall Plasterboard is fixedhorizontally where possible in all wet area rooms.Edges of Wet Area sheets adjoining floor to allareas, except shower recess, are to be kept 8mmclear of finished floor levels.

Boral Wet Area Drywall Plasterboard when usedas a substrate for wall tiling in wet areas, must befixed with Boral Plasterboard Masonry Adhesiveand supplementary mechanical fasteners. Holdsheets in position by shoring until adhesive hasset.

Where wall tiles 6.5mm thick or less are to beused, space daubs of Masonry Adhesive at250mm maximum centres vertically/horizontallyand 25mm from where the sheet edges will belocated.Supplementary mechanical fasteners (BousteadNylon anchors or equivalent) should also be usedand spaced at 500mm centres horizontally and250mm centres vertically.

Fix fasteners through every second adhesive dauband into the masonry wall. Fasteners are to bedrilled out and applied only after MasonryAdhesive daubs have set and dried. Themechanical fasteners are then inserted and tappedhome, flush with the plasterboard surface.

Where wall tiles 6.5mm to 12mm thick are to beapplied, space daubs of Masonry Adhesive at250mm maximum centres horizontally and200mm vertically.Fastening anchors should be spaced at 500mmmax. centres horizontally and at 200mm centresvertically.

22

Note. Where jointing system ‘Method B’ has beenused to joint Wet Area Drywall Plasterboard in theshower recess, the system is incomplete until awaterproof sealer has been applied over the boardand finished joints before tiling. Check the sealerfor compatibility with tile adhesive.

• With a broad knife evenly fill the recess atthe joints with Wet Area Taping Cement andapply also to both sides of internal andexternal angles.

Joint Treatment beyond tiled areasIn areas not to be tiled, Boral Wet Area DrywallPlasterboard may be adhered with MasonryAdhesive as specified for normal 8mm BoralDrywall Plasterboard.

Joints and angles in areas not to be tiled are to befinished using any one of the range of BoralPlasterboard Jointing Systems. Use same jointingsystem also where sheet joint coincides with topedge of tile panel.

Method B (alternative method)Plasterboard taped and finished with BaseBond,SuperSmooth™ BaseCote Mid Set orSuperSmooth™ BaseCote Long Set overperforated paper tape.

Joint Treatment in tiled areasIn tiled areas, joints, angles and junctions are tobe treated with Boral Wet Area DrywallPlasterboard water resistant jointing system,described as either "Method A or Method B". Alljoints in wet areas are to be a minimum 1200mmabove the floor.

Method A ( recommended)Plasterboard taped and finished with Boral WetArea Taping Cement over perforated paper tape.

• Centre perforated paper tape reinforcementover joints, internal and external angles, andbed firmly into the Wet Area Taping Cement,ensuring no trapped air bubbles remain.

• When the tape is embedded, immediatelyapply a skim coat of Wet Area TapingCement with a broad knife ensuring the tapeis completely covered, with no tape curlingat the edges. Cover fastener heads with WetArea Taping Cement.

• Apply a skim coat of Wet Area TapingCement to the cut edges of the plasterboardsheets at (1) The junction of the board andthe shower base. (2) The junction of theboard and bath rim. Feather out across thesurface of the board.

Wall Tiling• Fix wall tiles to Boral Wet Area Drywall

sheets using only an organic based adhesivecomplying with Australian Standard AS2358"Adhesives For Ceramic Wall Tiles andMosaics" Part 1-1.3(a) Type 1.

• After adequate preparation of the surface,apply adhesive to the whole of the area to betiled, one square metre at a time, inaccordance with the Manufacturer’sSpecifications.

• Use a notched-edge trowel as recommendedby the adhesive Manufacturer in a horizontaldirection, never vertically or apply in daubs.

• Firmly press tiles into the ribs of theadhesive before skinning occurs, ensuringthere is contact over the entire back surfaceof each tile.

• When tile adhesive has hardened, fill jointscontinuously with grout approved by the tileManufacturer. Approved grouts providinghigh water resistance are recommended.

• Provide relief joints 6mm wide in accordancewith tile and adhesive Manufacturer’srecommendations at the following locations:

- internal corners;- penetrations;- jambs at wall openings; and- floor wall junctions.

Relief joints must be completely filled withan approved flexible waterproof sealant.

Installation in Wet Areas

SuperSmooth

9

Boustead Countersunk Head Nylon Anchors(ANC 05025, 05040, 06525 and 06540 orequivalent) spaced at centres shown fixedthrough adhesive daubs.

Note: Where wall tiles of thickness 6.5mm to12mm are used, the fastener centres mustbe spaced at 500mm centres horizontallyand 200mm centres vertically fixed throughadhesive daubs

Note: Where wall tiles of thickness 6.5mm to 12mm are used, space masonry adhesive daubs at500mm centres horizontally and 200mm centres vertically.

Masonry adhesive daubs approximately 50mm diam. by 10mm thick applied to either masonry/bricksurface or to 8mm Wet area Drywall Plasterboard at centres shown.

Note: Special attention should be paid tothe treatment of joints and fastener headsin wet areas. Joint treatment "Method A or B"or normal treatment may apply.

8mm Boral Wet Area Drywall Plasterboard

Wet area sealant around pipe penetrationfinished with wet area taping cement asper typical plumbing penetration detailoverleaf or alternatively aTap PenetrationFlange ("Fluid Apron" by HPH Pty. Ltd. orequivalent) sealed with an approved wetarea sealant.

CSIRO Appraisals approved in-situ membraneinternal lining applied to face of Wet Area DrywallPlasterboard surface by an approved installer.

Masking tape

Foam backing rod

Hob

Enlarged View of In-situ Membrane Shower Base

500mm max.

250mm max.

250mmmax.

250mmmax.

8mm Wet Area Drywall System - Typical Bathroom and Shower construction details

10

Ceramic wall tiles

Boral Wet Area Plasterboard

Flexible sealantrelief joint - 6mm

Tap body

Tap penetration flangeor wet area sealant

Type 1 organic based walltile adhesive

Typical Plumbing Penetration

Ceramic wall tiles

Boral Wet Area Plasterboard

Flexible sealantrelief joint - 6mm

Type 1 organic based walltile adhesive

Vanity Unit Wall Junction

Basin profile

Internal Corner Detail

6mm

Wall tiles

Flexible sealantrelief joint

Corner reinforcingtape

Vertical flashing angle

Mechanical fastenerfixed through adhesive

Boral Wet AreaPlasterboard

Flexible sealantrelief joint - 6mm

Ceramic wall tiles onType 1 organic based walltile adhesive

Skim coat of wet areataping cement atcut edge

Bath

Wet area sealant

Bath/Wall Junction Details

Boral Wet AreaPlasterboard

Flexible sealantrelief joint - 6mm

Ceramic wall tiles onType 1 organic based walltile adhesive

Skim coat of wet areataping cement atcut edge

Wet area sealant

Mechanical fastener

5-10mm

Preformed shower base

Preformed Shower Base/Wall Junction

Boral Wet AreaPlasterboard

Flexible sealantrelief joint - 6mm

Ceramic wall tiles onType 1 organic based walltile adhesive

10mm wet area sealant

Mechanical fastener

Floor tiles

Wet area flashing uPVC angle coveadhesively fixed to sub-floor withwet area flashing adhesive

Wall to Floor Junction

Boral Wet AreaPlasterboard

Flexible sealantrelief joint - 6mm

Ceramic wall tiles onType 1 organic based walltile adhesive

CSIRO Appraisals approved in-situinternal lining applied to faceof drywall by approved installer

Floor tiles onbed of mortar

Masking tape tohold rod in place -by membrane installer

Optional foam plasticrod used as essentialbond breaker - bymembrane installer

Impervious Floor/Wall Junction or Shower

8mm Wet Area Drywall System - Typical Bathroom and Shower Construction Details

25

Decoration Beyond Tiled Area

Paint FinishPrepare Boral Wet Area Plasterboard lining andcarry out paintwork in accordance with theSpecification of the paint Manufacturer. BoralPlasterboard PrimeCote is recommended as apriming coat.

Wallpaper FinishPrepare Boral Wet Area Plasterboard lining andcarry out wallpapering in accordance with theSpecification of the wallpaper Manufacturer.

CeilingsBoral Plasterboard Standard Core isrecommended for use in ceilings of wet areas,such as bathrooms, shower rooms, laundries andtoilets.

Architectural SpecificationBoral Wet Area Plasterboard Systems shallincorporate materials supplied by BoralPlasterboard and shall be installed as detailed anddescribed in Installation Reference Manual 204DBooklet 4 "Fixing in Wet Areas".

For Commercial Wet Area Details refer also toBoral Technical Manual 305C “Wet Area Systemsfor Commercial and Institutional Construction”.

Further shower construction details are availableon request from all Boral Plasterboard SalesOffices.

CautionPlease refer to containers or Safety Data Sheets(available from Boral Plasterboard Sales Offices)when handling relevant products.

8mm Wet Area Drywall System

Wet Area AccessoriesTap Penetration Flange

Used to seal around tap penetrations.

Tap Penetration Flange(Fluid Apron© by H.P.H. Pty. Ltd.or equivalent)

Acrylic water resistant sealant in 450 gramcartridges, for sealing junctions and cutoutsin tiled areas.

Wet Area Sealant

Wet Area FlashingExtruded uPVC angle flashing 100mm x 50mmfor flashing wall/floor junctions. Supplied in3 metre lengths.

100mm

50mm

Plasterer’s Metal AngleMetal angle 32mm x 32mm for flashing internalcorners. Supplied in lengths of 2400mm.

32mm

32mm

Wet Area Flashing Adhesive

Two part adhesive

Wet area flashing adhesive for adhering wet areaflashing uPVC angle cove to sub-floors

Boral Plasterboard Website: http://www.plasterboard.boral.com.au

Western Australia12 Hoskins Road Landsdale 6065Telephone (08) 9400 2666Fax (08) 9302 1133

ACT7 Barrier Street Fyshwick 2609Telephone (02) 6280 4243Fax (02) 6280 5816

Tasmania93 Albert Road Moonah 7009Telephone (03) 6278 9966Fax (03) 6278 9865

Northern TerritoryCnr Coonawarra Road & MataramStreetWinnellie 0820Telephone (08) 8984 4484Fax (08) 8984 3778

Queensland733 Nudgee Road Northgate 4013

Telephone (07) 3215 2244Fax (07) 3215 2299

New South Wales3 Thackeray Street Camellia 2142

Telephone (02) 9638 0571Fax (02) 9638 5557

South Australia119-121 Bedford Street Gillman 5013

Telephone (08) 8240 8888Fax (08) 8341 1004

Victoria676 Lorimer Street Port Melbourne 3207

Telephone (03) 9214 2138Fax (03) 9646 1912

Export Department676 Lorimer Street

Port Melbourne 3207Telephone (03) 9214 2138

Fax (03) 9646 1109

GuaranteeProducts manufactured and supplied by Boral AustralianGypsum Limited (BAGL) A.C.N. 004 231 976, trading asBoral Plasterboard, are guaranteed to be of consistentquality and free from any defects.

Boral Plasterboard products must be installed using thecomponents and accessories specified and inaccordance with the instructions detailed in BoralPlasterboard’s technical literature.

Our products are manufactured to suit the requirementsof the building industry in Australia.

Boral Plasterboard may limit its liability under thisguarantee to, at its option, the replacement or paymentof the cost of replacing OR supplying equivalent orpayment of the cost of supplying equivalent OR therepair or payment of the cost of repairing products foundto be defective.

The information contained in this brochure isavailable on TecSYS - a comprehensive technicalcatalogue on CD-ROM.

Important NoteThe technical information contained within this manualwas correct at the time of printing. Building Systems anddetails are, however, subject to change. To ensure theinformation you are using is current, Boral Plasterboardrecommends you review the latest building information

© Boral Australian Gypsum limited 1999

available electronically on TecSYS (our technicalcatalogue on CD) or the Boral Plasterboard Website.Alternatively, contact your nearest Boral PlasterboardSales Office or TecASSIST (see details below).

Through TecASSIST Boral Plasterboard is demonstratingits commitment to providing excellent technical serviceand support to design, building and constructionprofessionals Australia wide.

A free-call architectural support line, TecASSIST isavailable to provide sound advice on all matters relatingto drywall plasterboard construction.

Combining years of professional experience with thelatest design information and technology, the TecASSISTteam has the skills to help you.

Boral Plasterboard TecASSIST phone line is open toreceive calls from 9.00am to 5.00pm Monday to Friday,Melbourne time (Victorian public holidays excepted).

FREE-CALL 1800 811 222

24 hour fax: (03) 9645 1812email: [email protected].