CEMENT BOARD INDOOR INORGANIC CEMENT WALL AND CEILING LINING SYSTEM

Transcription

1 CEMENT BOARD INDOOR INORGANIC CEMENT WALL AND CEILING LINING SYSTEM

2 Contents Disclaimer Products manufactured and systems designed by Knauf are produced in accordance with the Building Code of Australia and relevant Australian Standards. Cement Board Indoor installation and construction details are a guide only as many aspects of construction are not comprehensively covered. Knauf Plasterboard Pty Ltd will not be held responsible for any claims resulting from the installation of its products not in accordance with the manufacturer s technical literature or relevant Australian Standards. Knauf technical information is regularly updated. To ensure this guide is current with the latest information, visit knaufplasterboard.com.au or knaufplasterboard.co.nz or please contact Knauf Customer Service Centre on (AU) or (NZ). Warranty Knauf products are guaranteed by a 10 Year Warranty. Visit knaufplasterboard.com.au or knaufplasterboard.co.nz for details. Version 3 July 2014 Introduction 1 Cement Board Indoor System 2 Performance 5 Case Study 7 Applications 8 Systems 14 Installation 16 Construction Details 30 Cover Image: Wellness Centre, Berlin, Germany knaufplasterboard.com.au

3 Introduction Sage Headquarters, Newcastle, England Cement Board Indoor offers the ultimate design solution for water intensive areas due to the high dimensional stability when exposed to moisture, temperature and humidity variations. Using advanced cement board technology, Cement Board Indoor is made from aggregated Portland cement with glass fibre mesh embedded into the front and back surfaces. Cement Board Indoor is resistant to water and will retain its strength without degrading when immersed in water. With limited expansion or contraction when exposed to moisture and the capability of supporting surface finishes of up to 50 kg/m 2, Cement Board Indoor is the ideal substrate for tiles in wet areas including domestic and commercial swimming pools, spa areas, kitchens, laundries, bathrooms and leisure facilities. In addition, Cement Board Indoor has the superior impact resistance required in high traffic areas and being inorganic, it is resistant to mould growth. Coupled with excellent sound insulation and being non-combustible, Cement Board Indoor provides a versatile substrate solution and lightweight alternative to brick and block for any construction project. knaufplasterboard.co.nz 1

4 System Cement Board Indoor System Private Residence, Hampton, Victoria WALL AND CEILING LINING CEMENT BOARD INDOOR Cement Board Indoor is 100% water resistant and offers a solid and durable substrate for tiles or Skim Coat White in water intensive areas. It is made of aggregated Portland cement with glass fibre mesh embedded in the back and front surfaces. The ends are square cut and the edges reinforced. Thickness (mm) Width (mm) Length (mm) Weight* (kg/m 2 ) *Weights indicated are nominal 2 knaufplasterboard.com.au

5 System SYSTEM ACCESSORIES A range of accessories are required for Cement Board Indoor wall and ceiling installations. MAXI SCREW Maxi Screws have been developed for easy fixing of Cement Board Indoor onto timber and steel frames. They are countersinking and available in both needle point and drill point. Maxi Screws have Class 3 corrosion resistance. Needle point screws: SN 25: 1000 pieces/carton SN 39: 500 pieces/carton Drill point screws: SB 25: 250 pieces/carton JOINT ADHESIVE (PU) Joint Adhesive (PU) is used to glue sheet edges together on walls. The adhesive is applied to the sheet edges prior to fixing adjoining sheets. Coverage: approximately 8.5 m 2 per cartridge 310 ml cartridge BINDEX HIGH ABSORPTION PRIMER BindEx High Absorption Primer is a ready-to-use synthetic emulsion for priming Cement Board Indoor. It regulates absorption of the board for skim coating and ensures maximum adhesion for tiling. Dilution: 1:1 with water Coverage: approximately 150 m 2 per bucket 15 kg bucket REINFORCING MESH Reinforcing Mesh is a glass fibre mesh used to reinforce Skim Coat White. Coverage: approximately 45 m 2 per roll SKIM COAT WHITE Skim Coat White is a cement based compound for skim coating Cement Board Indoor in non-tiled areas. Reinforcing Mesh must be embedded. Coverage: approximately 4.5 m 2 per bag Width: 1000mm Length: 50m 20 kg bag knaufplasterboard.co.nz 3

6 System ADDITIONAL CEILING ACCESSORIES JOINT FILLER GREY Joint Filler Grey is a cement based compound for setting 100mm Tape on ceilings. Coverage: approximately 40 m 2 per bag 100MM TAPE 100mm Tape is made of glass fibre with an alkali resistant coating. 100mm Tape is used to reinforce joints in interior ceilings and is embedded into Joint Filler Grey. 20 kg bag Width: 100mm Length: 50m WATERPROOFING ACCESSORIES BINDEX WATERPROOF MEMBRANE BindEx Waterproof Membrane is a liquid applied waterproof membrane comprising synthetic latex and mineral fillers. Coverage: approximately 5 m 2 per bucket (includes first layer as a primer* and second and third layers as a waterproof membrane) BINDEX WATERPROOF FLASHING TAPE BindEx Waterproof Flashing Tape is a durable and highly flexible corner flashing tape. The 120mm polyester wide fabric is integrated with a central 70mm wide elastic strip. 5 kg bucket Width: 120mm Length: 10m BINDEX WATERPROOF CORNER FLASHING TAPE BindEx Waterproof Corner Flashing Tape is a 3-way flexible flashing tape to protect corners of a wet area room. BINDEX WATERPROOF PIPE COLLAR BindEx Waterproof Pipe Collar is a flat flexible pipe collar. It creates a permanent watertight seal around pipes. *Diluted with water 1:4 4 knaufplasterboard.com.au

7 Performance Performance WATER INTENSIVE SOLUTION Cement Board Indoor delivers peace of mind in wet area applications. Wet area defects such as leakages in pipes, damage to waterproofing membranes or unsealed penetrations are among the most common building defects in Australia. These defects compromise the substrate and in turn cause visible damage to the finished surface. The cost of wet area failure, considering both the cost of actual building works and the closure of facilities while rectification occurs, is often extremely high. In many construction areas, the ability to withstand damp and water is critical for the quality and durability of a building unit. Cement Board Indoor is the ideal lining for such areas, with exceptional resistance to water, humidity and temperature variations maintaining strength even with high moisture exposure. When subjected to water, Cement Board Indoor displays extremely slight and system-safe changes in form reducing the likelihood of cracking or debonding of the finished surface material. Furthermore, where defects occur traditional substrate materials would need to be replaced but with Cement Board Indoor this is not normally necessary and only requires a localised repair to the surface material as water will not harm the lining. Being made of inorganic material, Cement Board Indoor is resistant to mould growth making it suitable for use in areas where there is a high level of damp. [1] In addition, it has a ph of 12 which acts as a natural bactericidal and fungicidal barrier preventing mould growth as virtually no fungi can survive on surfaces with a ph over 10. [2] Cement Board Indoor also displays very good vapour-diffusion behaviour, with a diffusion resistance of μ = 50. [3] This means that the lining shows no vapour blocking behaviour, allowing excess moisture to pass through reducing build-up of excess water in the system. Source: 1 Institute of Building Biology in Rosenheim, Germany, Report A. 2 Indoor Air Quality, Healthy Buildings, and Breathing Walls, JF Straube, University of Waterloo, Canada and V Acahrya, Durisol Building Systems. 3 According to EN ISO knaufplasterboard.co.nz 5

8 Performance Terme Di Chianciano Spa, Siena, Italy AS TOUGH AS A ROCK Engineered to be tough, strong and impact resistant. Cement Board Indoor s aggregated Portland cement body and embedded coated glass fibre mesh in the front and back surface means it is capable of resisting impact without deformation or damage. The diagram highlights Cement Board Indoor s superior performance. Characteristic Compressive Strength Of Permarock Cement Board Indoor (Newtons of force per square millimetre) Aerated concrete: (500 kg/m³) >3 N/mm² Determined following DIN 1052: Standard plasterboard: >5 N/mm² PERMAROCK: >10 N/mm² The EasyEdge technology contained in Cement Board Indoor, where the straight edge is wrapped with a mesh embedded into the lining, combined with Joint Adhesive (PU) results in better adhesion between boards creating a stronger structure. In high humidity and water intensive areas the dimensional stability, with extremely low rates of expansion and contraction, is paramount in reducing the likelihood of tile peaking or popping and cracks to the joints in walls and ceilings. DESIGNED FOR SOUND Cement Board Indoor has excellent acoustic performance due to its high density core. This enhances sound insulation to reduce transfer of sound between rooms improving the quality of the indoor environment. Systems with Cement Board Indoor can achieve high levels of sound insulating performance from Rw 45 up to Rw knaufplasterboard.com.au

9 Case Study Case Study PROJECT: Crook Log and Erith Leisure Centres, Kent, England Water and moisture resistance were prime considerations when Cement Board Indoor was used as the poolside and changing room wall material for redevelopment of the swimming pools at the Crook Log and Erith leisure centres in Kent, England. The projects were undertaken as part of a total refurbishment of the leisure complexes. Cement Board Indoor lining was used as a tile backing on the 10m high walls that surround the competition and teaching pools at Crook Log and on the walls around the two pools at Erith. At both places Cement Board Indoor provided a solid background to support the low tolerance 2.5mm square mosaic tiles featured along the poolside. knaufplasterboard.co.nz 7

10 Applications Applications WATER INTENSIVE AREAS SWIMMING POOL WALLS AND CEILINGS The Natural Choice Easily handles sustained splash and spray water, and very high humidity. Humidity and thermal related expansion (which can cause tiles to crack or loosen) is minimised. Easy access to in-wall cables and ventilation systems. Boards are easily removed and replaced when designs change at a later date. Suitable For Chlorine Exposed Areas Cement Board Indoor is suitable for corrosive chlorine humid environments and even salt-water swimming pools. The system also includes Maxi Screws with a special corrosion resistant coating. Cement Board Indoor is also resistant to chlorine and disinfecting cleaning agents generally used in public swimming pools. 8 knaufplasterboard.com.au

11 Applications Ceiling System 1 1. Furring channel corrosion resistant metal profile Cement Board Indoor 3. Maxi Screw mm Tape embedded in Joint Filler Grey 7 5. BindEx High Absorption Primer 6. Skim Coat White with Reinforcing Mesh 7. Appropriate paint finish 2 Wall System 1. Corrosion resistant stud 3 2. Knauf EarthWool 3. Vapour barrier 4. Maxi Screw 5. Cement Board Indoor 6. Joint Adhesive (PU) BindEx High Absorption Primer or BindEx Waterproof Membrane if needed. [Refer to Table 1 Wet Area Installation Requirements] 8. Tile adhesive 9. Tiles Moisture ingress to the wall and ceiling cavities must be controlled. Use moisture prevention measures such as a waterproof membrane and/or moisture barrier. knaufplasterboard.co.nz 9

12 Applications WET AND EXTREME TEMPERATURE AREAS RESIDENTIAL AND COMMERCIAL TOILETS, BATHROOMS, SPAS AND STEAM SAUNAS Fit For The Task Cement Board Indoor is suitable for sustained temperatures of up to 70ºC in spas and steam saunas. Being 100% water-resistant it will never swell, soften, flake or crumble. Provide security and peace of mind for coverings such as tile and stone since humidity-related expansion (which can cause tiles to crack or loosen) is minimised. Curve to create architectural walls and ceilings. Ultra Hygienic Cement Board Indoor is made with inorganic materials, so there is no food source to support mould growth in wet and extreme temperature environments. It is also resistant against chlorine cleaning agents. 10 knaufplasterboard.com.au

13 Applications Toilets and Bathrooms 3 1. WaterShield 2. Stud 4 3. Knauf EarthWool (optional) 4. Cement Board Indoor 5. Maxi Screw 6. Joint Adhesive (PU) BindEx High Absorption Primer or BindEx Waterproof Membrane if needed [Refer to Table 1 Wet Area Installation Requirements] 8. Tile adhesive (with decoupling system if tiles > 330 x 330mm) 9. Tiles 11 Moisture ingress to the wall and ceiling cavities must be controlled. Use moisture prevention measures such as a waterproof membrane and/or moisture barrier Spas and Steam Saunas 1. WaterShield 2. Corrosion resistant stud 3. Knauf EarthWool 4. Vapour barrier 5. Maxi Screw 6. Cement Board Indoor 7. Joint Adhesive (PU) 8. Diluted BindEx Waterproof Membrane (1:4) 9. Two coats of BindEx Waterproof Membrane 10. Tile adhesive 11. Tiles knaufplasterboard.co.nz 11

14 Applications HIGH LEVELS OF CLEANING AND HYGIENE HOSPITALS AND COMMERCIAL KITCHENS Versatile Solutions Cement Board Indoor is perfect for areas that need intensive cleaning and high pressure jet spraying, including disinfecting cleaning agents. Excellent sound insulation improving acoustic environment helping patients get peace and quiet. Superior impact resistance important for high traffic areas such as corridors. Inorganic material to combat mould and mildew. Suitable For Harsh Cleaning Routines The 100% water-resistance of Cement Board Indoor makes it ideal for medical and food preparation environments where hygiene and cleanliness are essential. Add to that the superior sound insulation and impact resistance and you have the perfect wall material for hospitals and commercial kitchens. 12 knaufplasterboard.com.au

15 Applications Theatres and Wards 1. Cement Board Indoor 3 2. Corrosion resistant stud 3. Knauf EarthWool 4. Cement Board Indoor Maxi Screw 6. Joint Adhesive (PU) 5 7. BindEx High Absorption Primer Skim Coat White with Reinforcing Mesh 9. Washable covering (e.g. Vinyl) Food Preparation 1. Cement Board Indoor 2. Corrosion resistant stud 3. Knauf EarthWool 4. Vapour barrier 5. Cement Board Indoor 6. Maxi Screw 7. Joint Adhesive (PU) 8. BindEx High Absorption Primer or BindEx Waterproof Membrane if needed [Refer to Table 1 Wet Area Installation Requirements] 9. Tile adhesive 10. Ceramic tiles Moisture ingress to the wall and ceiling cavities must be controlled. Use moisture prevention measures such as a waterproof membrane and/or moisture barrier. knaufplasterboard.co.nz 13

16 Systems Systems KSW860 WALL LINING: [Side 1] 1 layer of 13mm MastaShield [Side 2] 1 layer of 13mm Cement Board Indoor FRAME: Steel studs at maximum 600mm centres [13mm MastaShield may be substituted with 13mm WaterShield] FRL / / Stud Size (mm) Stud Depth Max Height UDL 0.25 kpa (m) Non-Load Non-Load Stud BMT Bearing Studs Bearing Studs at 600mm at 450mm Width (mm) Acoustics Rw (Rw + Ctr) 50mm No Insulation EarthWool 11 kg/m 3 75mm EarthWool 11 kg/m 3 65mm Polyester TSB3/ASB (29) 46 (36) 46 (36) (32) 48 (39) 48 (39) 48 (39) (35) 50 (41) 50 (41) 50 (41) Acoustic Report KSW861 WALL LINING: [Side 1] 2 layers of 13mm MastaShield [Side 2] 1 layer of 13mm Cement Board Indoor FRAME: Steel studs at maximum 600mm centres [13mm MastaShield may be substituted with 13mm WaterShield] FRL / / Stud Size (mm) Stud Depth Max Height UDL 0.25 kpa (m) Non-Load Non-Load Stud BMT Bearing Studs Bearing Studs at 600mm at 450mm Width (mm) Acoustics Rw (Rw + Ctr) 50mm No Insulation EarthWool 11 kg/m 3 75mm EarthWool 11 kg/m 3 65mm Polyester TSB3/ASB (30) 49 (39) 49 (39) (33) 51 (42) 51 (42) 51 (42) (36) 53 (44) 53 (44) 53 (44) Acoustic Report knaufplasterboard.com.au

17 Systems KSW800 WALL LINING: FRAME: [Side 1] Optional wall lining [Side 2] 1 layer of 13mm Cement Board Indoor Steel studs at maximum 600mm centres FRL / / Stud Size (mm) Stud Depth Max Height UDL 0.25 kpa (m) Non-Load Non-Load Stud BMT Bearing Studs Bearing Studs at 600mm at 450mm Width (mm) Acoustics Rw (Rw + Ctr) No Insulation 50mm EarthWool 11 kg/m (28) 37 (31) (28) 37 (31) (28) 37 (31) Acoustic Report KSW810 WALL LINING: FRAME: [Side 1] 1 layer of 13mm Cement Board Indoor [Side 2] 1 layer of 13mm Cement Board Indoor Steel studs at maximum 600mm centres FRL / / Stud Size (mm) Stud Depth Stud BMT Max Height UDL 0.25 kpa (m) Non-Load Bearing Studs at 600mm Non-Load Bearing Studs at 450mm Width (mm) Acoustics Rw (Rw + Ctr) No Insulation 50mm EarthWool 11 kg/m 3 75mm EarthWool 11 kg/m 3 65mm Polyester TSB3/ASB (34) 49 (39) 49 (39) (35) 51 (42) 51 (42) 51 (42) (36) 53 (44) 53 (44) 53 (44) Acoustic Report knaufplasterboard.co.nz 15

18 Installation Installation CARE AND USE SAFETY Material Safety Data Sheets (MSDS) for Cement Board Indoor are available at knaufplasterboard.com.au or by calling Some compounds have safe handling requirements. [Refer to the health and safety information printed on the compound packaging for details] HANDLING, DELIVERY AND STORAGE To ensure Cement Board Indoor remains in the best condition prior to installation it is important to follow these key recommendations. Generally the board should be protected from any damage or conditions which could affect the final appearance or performance. Cement Board Indoor must be kept dry and should be stacked clear of the floor using supports not more than 600mm apart, fully protected from the weather and delivered to sites when lock up stage is complete. To reduce the possibility of damage, delivery to site should occur immediately before installation. Care should be taken not to damage edges or the surface of the board. Boards which have become damp must be dried on both sides on a flat surface prior to installation (typically within 48 hours in a dry environment). High levels of water absorption will not affect the long term performance of Cement Board Indoor. To ensure the correct adhesion of tile adhesive and Joint Adhesive (PU), the boards must be installed dry. Before installing, condition the boards to the ambient temperature and humidity. The ambient air and component temperatures may not be below 5 C. Materials for priming or coating must not be applied in temperatures of less than 5 C. 16 knaufplasterboard.com.au

19 Installation Nautimo Wellness Centre, Germany CUTTING Score and snap Cement Board Indoor using a knife. [Figure 1] For sharp-edged cuts, use a circular saw with a dust extractor. A diamond-tipped saw blade is recommended. [Figure 2] Use a jigsaw or keyhole saw to make holes. [Figure 3 and 4] FIGURE 1 Regular Cutting FIGURE 2 Sharp Edged Cuts FIGURE 3 Making Holes With Jigsaw FIGURE 4 Making Holes With Keyhole Saw CONDENSATION AND VENTILATION To create a healthy indoor environment, use wall and ceiling insulation and especially ventilation. knaufplasterboard.co.nz 17

20 Wet Areas WET AREAS Different wet areas require different levels of waterproofing. TABLE 1 Wet Area Installation Requirements Area Walls Ceilings Junctions Penetrations Shower area up to 1800mm high Use BindEx Waterproof Membrane on walls to: 150mm minimum above the finished shower floor level or lip of bath And 25mm minimum above the maximum retained water level Apply wet area sealant to wall/ wall, and wall/floor junctions. Then use BindEx Waterproof Flashing Tape on all wall/wall and wall/floor junctions. Use BindEx Waterproof Corner Flashing Tape in the corners. Use BindEx Waterproof Pipe Collar to waterproof penetrations. Bathrooms Cover with tiles or Skim Coat White with Reinforcing Mesh. Apply wet area sealant to wall/wall, and wall/floor junctions. Then use BindEx Waterproof Flashing Tape on all wall/floor junctions. Use BindEx Waterproof Corner Flashing Tape in the corners. Areas adjacent to baths and spas Cover with tiles or Skim Coat White with Reinforcing Mesh. Apply wet area sealant. Where the lip of the bath is supported by a horizontal surface, use BindEx Waterproof Membrane over the area. Use BindEx Waterproof Pipe Collar to waterproof penetrations on horizontal surfaces. Walls adjoining other vessels Cover with tiles or Skim Coat White with Reinforcing Mesh on walls within 75mm of a vessel such as a sink, basin or laundry tub. Apply wet area sealant at wall to vessel junctions. Use BindEx Waterproof Pipe Collar to waterproof penetrations on horizontal surfaces. Laundries and water closets Use BindEx Waterproof Flashing Tape at wall/floor junctions and BindEx Waterproof Corner Flashing Tape in the corners. COMMERCIAL AND COMMON USE AREAS Splash areas in public showers and toilets in public and commercial sectors, indoor swimming pools, commercial kitchens, dairies and breweries that have limited chemical exposure. Use BindEx Waterproof Membrane across the entire surface. Cover with tiles or Skim Coat White with Reinforcing Mesh. Use Skim Coat White with Reinforcing Mesh and cover with a suitable paint system. Apply wet area sealant to wall/ wall, and wall/floor junctions. Then use BindEx Waterproof Flashing Tape on all wall/wall and wall/floor junctions. Use BindEx Waterproof Corner Flashing Tape in the corners. Use BindEx Waterproof Pipe Collar to waterproof penetrations. Non-splash areas in public showers and toilets in public and commercial sectors, indoor swimming pools, commercial kitchens, dairies and breweries that have limited chemical exposure. Cover with tiles or Skim Coat White with Reinforcing Mesh. Use Skim Coat White with Reinforcing Mesh and cover with a suitable paint system. Apply wet area sealant to wall/ wall, and wall/floor junctions. Then use BindEx Waterproof Flashing Tape on all wall/wall and wall/floor junctions. Use BindEx Waterproof Corner Flashing Tape in the corners. 18 knaufplasterboard.com.au

21 Wet Areas Joint Adhesive (PU) Cement Board Indoor Wet area sealant Joint Adhesive (PU) Cement Board Indoor Wet area sealant BindEx Waterproof Flashing Tape embedded in BindEx Waterproof Membrane Tile Adhesive BindEx Waterproof Membrane FIGURE 5 Basin FIGURE 6 Private Bath (Without Shower) Installation On Timber Flooring Cement Board Indoor Cement Board Indoor Joint Adhesive (PU) Joint Adhesive (PU) BindEx Waterproof Flashing Tape embedded in BindEx Waterproof Membrane BindEx Corner Flashing Tape BindEx Waterproof Flashing Tape embedded in BindEx Waterproof Membrane Tile adhesive BindEx Waterproof Membrane Tile adhesive Timber floor FIGURE 7 Internal In-Situ Tray For Unenclosed Shower On Concrete Or Compressed Fibre Cement Floor FIGURE 8 Enclosed Shower On Timber Flooring Shower areas consist of enclosed and unenclosed areas: Unenclosed shower areas extend 1500mm horizontally from the shower connection on the wall, up to a height of 1800mm from the finished floor. Enclosed shower areas are bounded by walls or screens up to a height of 1800mm from the finished floor. Walls or screens include hinged or sliding doors that control the spread of water to within the enclosure. knaufplasterboard.co.nz 19

22 Wall Installation Wall Installation GENERAL REQUIREMENTS Install control joints in Cement Board Indoor walls at: 7.5m maximum intervals 4.5m in tiled areas according to AS Ceramic tiles All control joints in the structure Any change in the substrate material. Only use Joint Adhesive (PU) for jointing sheets. Use wet area sealant at all: Wall/wall junctions Wall/floor junctions The bottom edge over a preformed shower base. [Refer to Construction Details] Attach heavy fixtures to framing members only. Use Cement Board Indoor for all layers in multi-layer installations. Masonry adhesive and stud adhesive are not permitted. Frame movement should be restricted at junctions in high risk areas such as showers. To prevent condensation forming, insulation in the wall cavity should not come in contact with plumbing pipes. FRAMING Use a deflection head if: Wall heights are 4800mm or greater Ceiling, roof or floor movement is expected. Space studs at 600mm maximum centres. Face studs in the same direction if possible, to allow easier fastening of Cement Board Indoor. However, installation of some services may require the studs to be positioned in opposite directions. Push studs down completely into bottom track. For non-load bearing walls, do not fix studs to top track. For load bearing walls, fix studs to top track. Box studs around windows and door frames or follow frame manufacturer s requirements. Fix boxed studs to bottom and top tracks. TIMBER Use framing with a minimum 45mm fixing face for vertical joints. This will enable easy fixing 15mm minimum from edges as required. Framing members must be spaced at 600mm maximum centres. Noggings are permitted to assist the fixing of services. Copper Chromium Arsenate (CCA) treated timber must not be used. Plumbing and electrical services must not protrude beyond the face of the stud. STEEL Use framing with a minimum 45mm fixing face for vertical joints. This will enable easy fixing 15mm minimum from sheet edges as required. Fix the bottom track and top track or deflection head at 600mm maximum centres and 100mm maximum from each end. 20 knaufplasterboard.com.au

23 Wall Installation FIGURE 9 Steel Frame Layout Top track Track Nogging for services Nogging Box studs around openings Steel stud Bottom track FIGURE 10 Timber Frame Layout Top plate Additional nogging for services Opening (Door) Nogging Timber stud Internal corner Bottom plate External corner knaufplasterboard.co.nz 21

24 Wall Installation LAYOUT Install Cement Board Indoor sheets horizontally. Vertical joints must be 200mm minimum from the edge of any opening such as windows and doorways to minimise cracking at the joints. Stagger butt joints by 600mm minimum on adjoining sheets, between layers and on opposite sides of the wall. Butt joints must be backed by a stud. Stagger long edges by 300mm minimum between layers. FIXING Use Maxi Screws at maximum 250mm spacing and minimum 15mm from sheet edges. Do not overdrive screws. Use Maxi Screws only, adhesive is not permitted. Install tiles up to 50 kg/m². For tiles larger than 330 x 330mm use a tile decoupling system. SCREW TYPE AND MINIMUM SIZE FOR INSTALLATION Frame Steel Screw Type 25mm Maxi Screw Timber 39mm Maxi Screw For steel up to 0.8mm BMT use SN Maxi Screws. For steel 0.8mm to 2.0mm BMT use SB Maxi Screws. FIGURE 11 1 Layer Horizontal 50mm 250mm max 15mm 250mm max 250mm max 250mm max 50mm Butt joints 200mm min from openings Openings 250mm max Fixing Sheet Layout Perimeter Field Recessed Edges Butt Joints Internal and External Corners Openings Sealant Maxi Screws Horizontal Width (mm) 1200 Screw pattern S = Screw Perimeter screws 15mm from sheet edges except at top and bottom tracks. Cement Board Indoor must not be fixed to top and bottom tracks. Fix at 250mm maximum centres. Fix on each stud Fix on studs. Stagger butt joints by 600mm minimum on adjoining sheets and on opposite sides of the wall. Fix at 250mm maximum centres Fix at 250mm maximum centres Use wet area sealant on all gaps and around perimeter to maintain acoustic integrity. [Refer to Construction Details] S S S S S S 22 knaufplasterboard.com.au

25 Wall Installation INSTALLATION SEQUENCE Align the first Cement Board Indoor sheet using a spirit level. [Figure 12] Leave a 5-10mm gap at the floor and corners. [Refer to Construction Details] Screw sheet to stud at minimum 250mm spacing and at least 15mm from sheet edges. [Figure 13-15] 15-50mm 250mm FIGURE 12 Levelling Board FIGURE 13 Screw Clearance From Sheet Edges FIGURE 14 Screw Spacing FIGURE 15 Screwing Clean the edge of the board with a wet brush. This ensures a good bond with Joint Adhesive (PU). [Figure 16] Apply Joint Adhesive (PU) before next sheet is placed. [Figure 17 and 18] FIGURE 16 Clean The Edge FIGURE 17 Apply Joint Adhesive (PU) FIGURE 18 Do Not Apply Joint Adhesive (PU) After Installing Next Sheet CURVED WALLS Board size: 1200mm wide, minimum curving radius 3m Strip size: 300mm wide, minimum curving radius 1m Maximum stud spacing: 300mm (external radius). r 3m R 0.3m r 1m 1.2m r 3m knaufplasterboard.co.nz 23

26 Wall Installation FINISHING Scrape off hardened Joint Adhesive (PU) after one day. [Figure 19] Apply diluted BindEx High Absorption Primer over entire surface. [Figure 20] OPTION A: TILED AREAS Apply BindEx Waterproof Membrane in accordance with Table 1 Wet Area Installation Requirements. Install tiles according to AS Ceramic tiles. [Figure 21] FIGURE 19 Scrape Off FIGURE 20 Prime The Wall FIGURE 21 Installing Tiles FIGURE 22 Tiled Finish OPTION B: PAINTED AREAS Apply BindEx Waterproof Membrane in accordance with Table 1 Wet Area Installation Requirements. After priming, apply Skim Coat White to minimum depth of 4mm using an 8mm notched trowel. [Figure 23 and 24] Lightly embed Reinforcing Mesh, then add another layer (approximately 2mm) of Skim Coat White. [Figure 25 and 26] After stiffening has begun, smooth the surface with a float or sponge. The final thickness of Skim Coat White must be at least 6mm. Sand if needed. Finish with products suitable for splash areas. [Refer to coating manufacturer] 4mm 2mm FIGURE 23 Skim Coat White With Reinforcing Mesh FIGURE 24 Apply Skim Coat White FIGURE 25 Embed Mesh FIGURE 26 Apply Another Layer Of Skim Coat White 24 knaufplasterboard.com.au

27 Ceiling Installation Ceiling Installation GENERAL REQUIREMENTS Install control joints in Cement Board Indoor ceilings at: 15m maximum intervals All control joints in the structure Any change in the substrate material At the junction of a large room and passageway. All ceilings in this section are non-trafficable. Do not walk on Cement Board Indoor ceilings! Limit dead loads on Cement Board Indoor ceilings to 4 kg/m². Attach ceiling fixtures to framing members only. Ensure the framing is designed to carry any additional load. Only use Joint Filler Grey for jointing. FRAMING Space furring channels at 300mm maximum centres. Use wide furring channel (Rondo No. 155) to enable easy fixing 15mm minimum from edges as required. Cut Top Cross Rail (TCR) and furring channel to leave 20mm expansion gaps at each wall. Stagger joints in TCR and furring channel by 1200mm. Install additional framing members around openings. Steel framed ceiling systems must be designed by an engineer according to the relevant Australian Standard. External Cement Board ceilings must be installed according to the requirements in this section using Cement Board Indoor. FIGURE 27 Install Cement Board Indoor Perpendicular To Furring Channels Ceiling battens perpendicular to main truss Cement Board Indoor Cement Board Indoor Ceiling trimmers installed to support ceiling battens Bottom chord of standard truss Bottom chord of (truncated girder) truss Top plate Wall frame knaufplasterboard.co.nz 25

28 Ceiling Installation FIGURE 28 Furring Channel Span and Spacing Floor/roof joists Furring channel wall track Furring channel span Furring channel spacing 300mm max. MAXIMUM SPAN OF FURRING CHANNEL Lining 28mm Furring Channel Rondo No.129 or 28mm Wide Furring Channel Rondo No. 155 at 300mm spacing Single Span (mm) Continuous Span (mm) 1 layer of 13mm Cement Board Indoor If furring channel track is not used, the furring channel must be supported 200mm from ends. 2 W ultimate = 0.5 kpa, Strength Load Case: 1.2G + Wu 3 W serviceability = kpa, Serviceability Load Case 1: G [Limit is L/600], Serviceability Load Case 2:G + Ws [Limit is L/200]. 4 Strength check of unrestrained fl ange in compression. 5 Connections to be independently checked. The framing tables in this section apply to Rondo steel components. Alternative components may only be used: In accordance with the manufacturer s literature, or If their performance is equivalent or better and they comply with the relevant standard. Use components with suitable corrosion protection designed specifically for the application especially in high levels of humidity or chemical use such as swimming pools, saunas, commercial kitchens, commercial laundries, laboratories etc. More ceiling framing combinations are available than those described in this section. [Refer to Rondo Building Services literature or equivalent] 26 knaufplasterboard.com.au

29 Ceiling Installation FIGURE 29 Top Cross Rail and Furring Channel Span and Spacing Floor/roof joists Furring channel wall track Top cross rail span Furring channel span and Top cross rail spacing Furring channel spacing (300mm max.) SELECTED TOP CROSS RAIL (TCR) AND FURRING CHANNEL FRAMING OPTIONS NON-FIRE RATED Lining TCR Rondo No. TCR Span (mm) TCR Spacing (mm) Furring Channel Rondo No. 1 layer of 13mm Cement Board Indoor /155 1 If furring channel track is not used, the furring channel must be supported 200mm from ends. 2 W ultimate = 0.5 kpa, Strength Load Case: 1.2G + Wu. 3 W serviceability = kpa, Serviceability Load Case 1: G [Limit is L/600], Serviceability Load Case 2: G + Ws [Limit is L/200]. 4 Strength check of unrestrained fl ange in compression. 5 Connections to be independently checked. LAYOUT Leave a 3-4mm gap between sheets. Sheet ceilings perpendicular to framing members. Align short joints on wide furring channel (e.g. Rondo No. 155) only. Stagger short joints by 600mm minimum on adjoining sheets. FIXING Use Maxi Screws at 250mm maximum spacing and 15mm minimum from sheet edges. Drive screws to just below the sheet surface. Use Maxi Screws only, stud adhesive is not permitted. knaufplasterboard.co.nz 27

30 Ceiling Installation SCREW TYPE AND MINIMUM SIZE FOR INSTALLATION Frame Steel Timber For steel up to 0.8mm BMT use needle point screws. For steel 0.8mm to 2.0mm BMT use drill point screws. Screw Type 25mm Maxi Screw 39mm Maxi Screw FINISHING Apply Joint Filler Grey to all screw heads and joints. Push the compound all the way into the gap between sheets to create the strongest joint. Embed 100mm Tape into Joint Filler Grey using a 150mm broadknife and allow to dry. Apply diluted BindEx High Absorption Primer over entire surface and allow to dry. [Figure 30] Apply Skim Coat White to a minimum average depth of 4mm using an 8mm notched trowel. Lightly embed Reinforcing Mesh, then add another layer (approximately 2mm) of Skim Coat White. [Figure 31] After stiffening has begun, smooth the surface with a float or sponge. The final thickness of Skim Coat White must be at least 6mm. [Figure 32] Sand if needed. Finish with appropriate paint. 4mm 2mm FIGURE 30 Apply Diluted BindEx High Absorption Primer FIGURE 31 Embed Mesh FIGURE 32 Skim Coat White With Reinforcing Mesh 28 knaufplasterboard.com.au

31 Installation PAINTING When painting, a three coat paint system must be applied in accordance with Australian Standard AS/NZS 2311, Guide to the painting of buildings. Both the quality of the paint and how it is applied have a large effect on the finished appearance of the Cement Board Indoor. The paint manufacturer s instructions for application must be followed. To achieve the best result it is strongly recommended that each coat of the three coat paint system be roller applied. For more information, contact Technical Services on or visit knaufplasterboard.com.au MATERIAL CONSUMPTION FOR WALLS AND CEILINGS Material Requirement Consumption (per m 2 ) Tiled Walls Painted Walls Ceilings Wide Fixing Face Stud 2m at stud spacing of 2m at stud spacing of 600mm 600mm Wide Furring Channel 4m at furring channel spacing of 300mm Cement Board Indoor 1m 2 1m 2 1m 2 Maxi Screw 25 at stud spacing 25 at stud spacing 25 at furring of 300mm of 300mm channel spacing of 300mm 15 at stud spacing of 15 at stud spacing of 600mm 600mm Joint Adhesive (PU) ml ml BindEx High Absorption Primer 100 g 100 g 100 g Skim Coat White 4.2 kg for 6mm thick layer 4.2 kg for 6mm thick layer Joint Filler Grey 0.5 kg Reinforcing Mesh 1.1 m m 2 100mm Tape Length of joints BindEx Waterproof Membrane 1000 g* 1000 g* * Includes fi rst layer as a primer (diluted with water 1:4) and second and third layers as waterproof membrane (undiluted). ** The material requirements are stated in the table are a guideline only. They do not include wastage or site specifi c scenarios. knaufplasterboard.co.nz 29

32 Construction Details Construction Details Plasterboard Tile adhesive (compatible with BindEx Waterproof Membrane and ceramic tiles) Tile adhesive (compatible with BindEx Waterproof Membrane and ceramic tiles) Cement Board Indoor Sealant required to maintain acoustic integrity BindEx Waterproof Membrane when required Additional nogging to support shower base Wet area sealant BindEx Waterproof Flashing Tape embedded in BindEx Waterproof Membrane Masonry wall 50mm max Cement Board Indoor BindEx Waterproof Membrane when required Furring channel Steel angle for wall support Wet area sealant Floor screed Timber flooring 5-10mm 5-10mm Optional flashing angle continued through shower area Fibre cement underlay Floor screed Optional flashing angle continued through shower area BindEx Waterproof Flashing Tape embeded in BindEx Waterproof Membrane FIGURE 33 Wall Base In Shower Area Internal In-Situ Shower Tray FIGURE 34 Wall Base In Shower Area On Masonry Wall Internal In-Situ Shower Tray Elevation Plasterboard Cement Board Indoor Tile adhesive (compatible with BindEx Waterproof Membrane and ceramic tiles) BindEx Waterproof Membrane when required Cement Board Indoor Tile adhesive (compatible with BindEx Waterproof Membrane and ceramic tiles) BindEx Waterproof Membrane when required Sealant required to maintain acoustic integrity Additional nogging to support wall lining Fixing to nogging permitted with Maxi Screw 6mm gap and wet area sealant Timber flooring Wet area sealant Floor screed Optional vertical reinforcing corner angle in shower area 5-10mm Fibre cement underlay FIGURE 35 Wall Base In Shower Area Preformed External Shower Tray Elevation FIGURE 36 Corner Detail In Wet Area Plan View Installation of a vertical reinforcing corner angle (minimum 35 x 35 x 0.7mm) is one option to reduce corner movement which may cause waterproof membrane failure. 30 knaufplasterboard.com.au

33 Construction Details Cement Board Indoor Plasterboard Sealant required to maintain acoustic integrity Tile adhesive (compatible with BindEx Waterproof Membrane and ceramic tiles) BindEx Waterproof Membrane when required Wet area sealant Notch stud (max 25mm for bath installation) Tile adhesive (compatible with BindEx Waterproof Membrane and ceramic tiles) Wet area sealant Backing angle for membrane Joint Adhesive (PU) Cement Board Indoor BindEx Waterproof Membrane Nogging to support bath Timber flooring Floor screed Floor screed Floor screed 5-10mm Timber flooring Fibre cement underlay Fibre cement underlay FIGURE 37 Wall Detail For Bath Recess FIGURE 38 Wall Detail For Bath Recess Plasterboard Sealant required to maintain acoustic integrity Fix 50mm from sheet bottom. Do not fix through track. Cement Board Indoor Embedded Reinforcing Mesh in Skim Coat - white Tile adhesive and ceramic tiles to 100mm high minimum Wet area sealant BindEx Waterproof Flashing Tape embedded in BindEx Waterproof Membrane Plasterboard Sealant required to maintain acoustic integrity Timber flooring Cement Board Indoor Embedded Reinforcing Mesh in Skim Coat - white Tile adhesive and ceramic tiles to 100mm high minimum Wet area sealant BindEx Waterproof Flashing Tape embedded in BindEx Waterproof Membrane 5-10mm 5-10mm Concrete or compressed fibre cement floor Fibre cement underlay Floor screed FIGURE 39 Wall Base In Wet Areas (Outside Shower) With Waterproof Membrane As Flashing FIGURE 40 Wall Base In Wet Areas (Outside Shower) With Waterproof Membrane As Flashing knaufplasterboard.co.nz 31

34 Construction Details 5-10mm clearance to plasterboard Use masonry fixings at 500mm max centres vertically 100mm max 600mm max Wet area sealant Cement Board Indoor Joint Adhesive (PU) FIGURE 41 Intersecting Masonry Wall BindEx Waterproof Pipe Collar BindEx Waterproof Membrane BindEx Waterproof Pipe Collar Timber or steel batten Joint Adhesive (PU) FIGURE 42 Plumbing Penetrations Isolate copper and brass fittings from steel framing. 32 knaufplasterboard.com.au

35 Construction Details Furring channel track fixed to wall at 600mm max centres and 100mm max from ends 150mm max Top cross rail Furring channel 5-10mm clearance to Cement Board Indoor. Sealant only required to maintain acoustic integrity Top cross rail Top cross rail joiner for ceiling stability 5-10mm clearance to Cement Board Indoor. Sealant only required to maintain acoustic integrity 150mm max 20mm Cement Board Indoor Wall stud Cement Board Indoor Wall stud FIGURE 43 Ceiling To Wall FIGURE 44 Ceiling To Wall Furring channel perpendicular to control joint Furring channel joiner 150mm max Furring channel parallel to control joint Screw to one side only Control joint bead 15mm Cement Board Indoor 25mm 150mm max FIGURE 45 Ceiling Control Joint With Profile FIGURE 46 Ceiling Control Joint knaufplasterboard.co.nz 33

36 Knauf Plasterboard Pty Ltd ABN Military Road Matraville NSW 2036 Customer Service AU Customer Service NZ knaufplasterboard.com.au knaufplasterboard.co.nz Download the Knauf Australia iphone app