Cover: Houghton Estate, luxury residential estate This page: Protea Hotel, Umhlanga Ridge

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1 For Walls

2 1 Cover: Houghton Estate, luxury residential estate This page: Protea Hotel, Umhlanga Ridge

3 Mass per m 2 CTN BPN Overview Description Gyproc RhinoBoard is manufactured according to the ISO 9001 Quality Management System and the ISO Environmental Management System. RhinoBoard is a plasterboard and consists of an aerated or foamed gypsum core encased in, and firmly bonded to, special paper liners. RhinoBoard is used as lining/cladding for ceilings, drywalls and drylining. RhinoBoard is non combustible and it is used as a lining in fire rated drywall and ceiling systems. The face (unprinted) surface should receive all decoration (i.e. gypsum based plaster, paint, vinyl, etc.). Do not decorate the printed surface. Do not expose standard RhinoBoard to contact with water. It is not recommended for use in industrial kitchens and industrial bathrooms or exterior applications. Types of board 1. Gyproc RhinoBoard This is a standard grade board with no special additives in the gypsum core, but with specially treated paper liners. 2. Gyproc FireStop This gypsum plasterboard has added fibreglass strands and unexfoliated vermiculite impregnated into the gypsum core to provide increased fire resistance. It is lined with pink paper. 3. Gyproc MoistureResistant This gypsum plasterboard is moisture resistant and is lined on both sides with a distinctive green paper. The core of the board is impregnated with water repellant additives and is lined with a distinctive waxy green paper. RhinoBoard MoistureResistant is suitable for use in showers, bathrooms and kitchens and where ceramic wall tiling is required. It is not suitable for protection against continuous dampness or a base for cementitious rendering. Weber preparation compounds must be used as per Weber manufacturers instructions. 4. Gyproc SoundBloc Effective sound insulation is necessity as peace and quiet are essential to relaxation healing and concentration. Long-term noise disturbance may even lead to significant health problems. GypWall SoundBloc systems, with blue paper liners, have been designed and developed with sound insulating properties in mind. Gyproc RhinoBoard 12.5mm (standard widths) 8.9kg/m kg/m 2 Gyproc FireStop 12.5mm 11.3kg/m kg/m 2 Gyproc FireStop 15mm 13.7kg/m kg/m 2 Gyproc MoistureResistant 12.5mm 11.3kg/m kg/m 2 Gyproc MoistureResistant 15mm 13.7kg/m kg/m 2 Properties Fire resistance Gypsum plasters and plasterboard provide good fire protection in buildings due to the unique behaviour of their gypsum content when exposed to fire. Pure gypsum (CaSO 4 2H 2 0) contains nearly 21% chemically bonded water in crystallised form and about 79% calcium sulphate (CaSO 4 ) which is inert below a temperature of C. When gypsum protected elements of a structure are exposed to fire, the chemically combined water is gradually released in the form of moisture vapour. If a sufficiently high temperature is maintained, eventually all of the crystallised water will be expelled. 2

4 Overview The process of dehydrating gypsum by exposure to heat, known as calcination, commences at the surface exposed to the fire and proceeds gradually through the gypsum layer (i.e. the thickness of the gypsum plaster covering or the core of the plasterboard). The covering of calcinated gypsum formed on the exposed face adheres tenaciously to the uncalcinated material and serves to retard the process, which becomes progressively slower as the thickness of calcinated gypsum increases. While this process continues, the temperature directly behind the plane of calcination is only slightly higher than that of boiling water (100 0 C) and therefore, until all the crystallised water has been liberated, the temperature of materials adjacent to, or in contact with, the unexposed side cannot exceed C. This temperature is well below that at which materials stored in buildings will ignite. Once the gypsum layer is completely calcinated, the residue (calcium sulphate) continues to act as an insulating barrier for as long as it remains intact. Non-combustibility RhinoBoard is listed as a non-combustible material in the National Building Regulations SANS 10400, part T. Thermal insulation Thermal conductivity (k) is the measure of a material s ability to transmit heat, and is expressed as heat flow in watts per square metre of surface area for a temperature difference of 1 0 C per metre thickness and is expressed as W/m 0 k. Generally, denser materials have high thermal conductivity and are inefficient thermal insulants. Lightweight materials have low conductivity and are efficient thermal insulants. The lower the (k) value of the material, the better is its insulation efficiency. RhinoBoard has a (k) value of 0.21W/m 0 k. The thermal resistance (R) of a material is obtained by the following calculation where: t = the thickness of the material in metres. R = t / k RhinoBoard 12.5mm R value = 0.059m 2 K/W RhinoBoard 15mm R value = 0.071m 2 K/W respectively Sound insulation The Sound Reduction Index quoted on the individual system datasheets are those of actual tests performed by the SABS over a range of frequencies and are based on an imperforate solid RhinoBoard. Copies of test certificates are available if required. Site installation will differ from stated figures due to air leakage paths between junctions with ceiling, floor and other walls, optimum performance requires that these junctions be sealed with suitable acoustic sealants. Performance Effects of temperature The boards are not suitable for use in temperatures above 49 o C, but can be subjected to freezing temperatures without risk of damage. When subjected to tests in accordance with SABS 266 : 1982, the Gyproc MoistureResistant absorbed less than 5% of water by weight in the total immersion test. Thermal properties K = 0.25 W/m o C R = 0.05m 2 K/W Gyproc MoistureResistant will give similar performance to a standard board when tested for fire rating or sound insulation. Technical specification The Gyproc RhinoBoard range is manufactured according to SABS The SABS specification incorporates ISO gypsum plasterboard specification with modifications. Profile Gyproc RhinoBoard 15mm is manufactured with tapered edge only. 12.5mm is manufactured with both tapered edge and square edge and are special orders. The tapered edge board is usually used for jointing to achieve a monolithic finish as in the Gyproc Drywall System. 3

5 Gyproc RhinoBoard storage RhinoBoard should be stacked on a level surface in a dry place, preferably inside a building and properly protected from damp and inclement weather. If boards are to be stacked on a concrete floor inside a building, a damp proof membrane should first be laid down, or a timber platform should be provided. The wooden platform provided can be in the form of Bangalalas. The Bangalalas should be spaced at intervals of 400mm across the width of the boards, to prevent sagging of the boards. The ends and edges of the boards should be neatly aligned. Boards stored outside should be stacked on a level platform of timber bearers as described above, away from the ground. The stack should then be completely covered with a securely anchored polythene sheet or tarpaulin. Product Edge Standard sizes Widths (mm) Gyproc RhinoBoard 12.5mm Square and taper-edged 1200 Gyproc Firestop 12.5mm Square and taper-edged 1200 Gyproc FireStop 15mm Taper edged 1200 Gyproc MoistureResistant 12.5mm Square and taper-edged 1200 Gyproc MoistureResistant 15mm Taper edged 1200 Gyproc SoundBloc 12.5/15mm Taper edged 1200 Gyproc DuraLine Tolerances Lengths (mm) Thickness Width Length (300mm increments) (300mm increments) (300mm increments) (300mm increments) (300mm increments) (300mm increments) *To be launched ± 0.6mm +0 to -5mm +0 to -6mm ± 0.6mm +0 to -5mm +0 to -6mm ± 0.6mm +0 to -5mm +0 to -6mm ± 0.6mm +0 to -5mm +0 to -6mm ± 0.6mm +0 to -5mm +0 to -6mm ± 0.6mm +0 to -5mm +0 to -6mm Notes: 1. Gyproc FireStop 12.5mm and 15mm are available in square edge, but minimum quantities and lead times apply. Please refer to Gyproc Service Charter. 2. Gyproc non-standard stock products require a lead time. 3. Taper edge board is used where drywall jointing is required. 4. Not all standard sizes are stocked at all Gyproc sales outlets. Please contact your nearest Saint-Gobain Service Centre or builders merchant outlet for stock sizes, or see the current price list. Gyproc RhinoBoard handling When RhinoBoard is manually off-loaded or stacked it should be carried, two men to a pair of boards. Boards should not be carried with the surfaces horizontal, since this imposes an undesirable strain on the core. When a board is stacked or removed from a stack, the long edge should be placed down before it is turned horizontal. Boards should not be slid over each other as this can scuff the surface. RhinoBoard is particularly suited to mechanical handling, but this should be done with care. Forklifts should be equipped with multipronged forks to handle boards exceeding 3000mm in length. 4

6 Overview Gyproc RhinoBoard cutting The following methods should be used when cutting RhinoBoard: 1. Place the board flat on a level surface, with the writing facing upwards. 2. Mark the cut on the face side of the board, using a chalk line of pencil. 3. Cut along this line with a utility knife. 4. Lift the board on its side and snap it back along the cut. 5. Cut the paper on the back of the board with the utility knife. Blade Runner Reduces risks of accidents No exposed blades - blades never in contact with fingers or hands. Cut in a forward motion - trip hazards are visible. Tool is pushed away from the body - reduced risk of injury. Less dust on site - reduced chance of slips. Saves time on site Cutting time is halved (no need to turn board around). Approximately 1000 linear metres per blade. Quick release blades at the touch of a button. Cuts shapes, corners and circles on RhinoBoard 12.5/15mm with a neat professional finish. Accessories Replacement Blades Holster Gyproc RhinoBoard decoration Before decoration check the entire surface to see that nail holes, taped joints, etc. have been filled and sanded satisfactorily. Ensure that the boards are free from powder/dust. For improved paint finishes, it is suggested that a good quality plaster primer be used on the entire surface. 5

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8 Gyproc DryWall design guidelines Preparation Additional support to drywall top track Provisions to be made for top track to be fixed accurately to a securely fixed framing member. Top track to be fixed at 600mm centres. Additional support for fixtures and fittings Provide or ensure provision of accurately positioned and securely fixed noggins to support fixtures, fittings and services. Service penetration Penetrations for services should be given careful consideration to ensure that the fire and sound performance of the wall is not compromised and also that services themselves do not act as pathways for the transmission of fire and sound. General Gyproc standards/design criteria The drywall should be built in accordance with Saint-Gobain Gyproc specifications. The specifications should be read in conjunction with the project specifications. The erection of the drywall should comply with SABISA guidelines for dry walls. Quality The installer should have experience and knowledge of the installation of drywall systems or be an approved Gyproc GypWall installer. Recommended quality control on site Donn UltraSTEEL TM metal framing should be inspected by a recognised site authority. All cavity services ducts and conduits should be installed before boarding. Plan the position of all service penetrations/fittings and provide the necessary framing. RhinoBoard should be inspected after each installation and before finishing. Manufacturer s specification should be properly interpreted and adhered to. It is the drywall contractor s responsibility to ensure that the specifications are properly adhered to. Inspection prior to installation Verify that site conditions are suitable for the commencement of work and that all labelled materials are as indicated in the Saint-Gobain Gyproc specification document or as instructed by the manufacturer. Ensure that there are no damaged materials. The building should be weather proof before the installation of the Gyproc drywall lining. Good Practice Detailing Acoustics Consider the layout and structure of buildings at the design stage in order to separate quiet and noisy areas. Plan properly to avoid retro-fitting of services and/or noggins. Control sound paths around walls and floors to reduce flanking sound transmission. Seal the base and top of the wall using non-hardening silicone sealant. It is general practice to lay the sound seal before fixing the bottom/top tracks and abutting studs. Tape and fill, or skim plaster plasterboard joints to increase air tightness. Keep penetrations to a minimum and as small as possible. Use an acoustic sealant for optimum sound insulation. Seal joints, junctions, penetrations, etc. to avoid transmission of sound through leakage. It is good practice to seal all service holes/ penetrations. Air conditioning ducts should be fitted with the appropriate proprietary dampers. Avoid back-to-back sockets. Gaps on either side of the socket box should be sealed with an appropriate fire or acoustic sealant. The gap between the socket box and opposite side lining should be filled. Closely follow manufacturers fixing details as deviations may negate any acoustic benefit. Insulation deflection heads, by definition, must be able to move and therefore achieving an airtight seal is very difficult without incorporating sophisticated components and techniques. Air leakage at the drywall heads will have a detrimental effect on the acoustic performance of any drywall. 7

9 Where the party wall meets the external wall/gyproc drywall lining, appropriate detailing should be adopted to reduce leakage of sound and vibration transfer. Fire resistance Closely follow Saint-Gobain Gyproc specifications as deviations may negate fire resistance performance. Cut boards to a neat fit, avoiding any gaps If small gaps do occur, they must be backed by a framing member and filled with appropriate jointing material, or be skim plastered Tape and fill joints, or skim plaster plasterboard to achieve fire performance Fire-stop joints, junctions, penetrations, etc. to maintain integrity Keep penetrations to a minimum Avoid back-to-back sockets Thermal performance Seal lining perimeters and penetrations, etc. to avoid air leakage. Use insulation in the cavity to improve the thermal performance of the wall. Door detail Where heavy semi-solid and solid core doors are fixed onto aluminium door frames, additional bracing and reinforcement of the frame will be required, otherwise the door opening will undergo too much deflection and damage if the door slams. To reinforce Donn UltraSTEEL Studs use timber inserts. Load bearing studs can be used in place of the Donn UltraSTEEL Studs - no reinforcing is required. Maximum drywall heights Saint-Gobain Gyproc has adopted an internationally accepted methodology to determine maximum allowable wall heights, which is based on the level of lateral deflection under a given uniformly distributed load (UDL). The criterion is that the maximum lateral deflection of the drywall should not exceed L/240 (where L is the drywall height) when the drywall is uniformly loaded to 200Pa. Services installation Services can be incorporated in all Saint-Gobain Gyproc drywalls and ceilings. Donn UltraSTEEL Studs either have service holes or service holes have to be made on site to accommodate routing of electrical services When forming service holes on site, these need to be cut in-situ, paying attention to Health and Safety issues Grommets or isolating strip should be installed in the service holes to prevent abrasion of the cables Switch boxes and socket outlets can be supported on brackets formed from Donn UltraSTEEL Tracks 102mm x 25mm. Pipes or conduits should be fixed in position before lining work commences To maintain an airtight construction, the perimeter of any penetration through the lining should be sealed as necessary at the time the services are being installed Where heating pipes, particularly micro-bore systems, are to be located within the Gyproc drywalling system, it is recommended that only one pipe is passed through each aperture in the metal framework. If this cannot be accommodated for whatever reason, it may be necessary to incorporate proprietary pipe restraining clips, or other means of keeping the pipes apart, to prevent vibration noise Where a large number of electrical cables or pipes have to be accommodated when the framing is at 600mm centres, a service duct can be created by narrowing the stud centres to 300mm and boxing the opening Fixing electrical socket boxes into Gyproc drywalling systems can impair both fire and acoustic performance, but with careful detailing this can be minimised, particularly the avoidance of back-to-back services The Gyproc RhinoBoard should always be neatly cut and a proprietary sealant should be applied where optimum acoustic performance is required The fire resistant properties of the drywall are indicated by it's fire rating. A proprietary fire resistant sealant should be used For high acoustic performance, an acoustic expert should be consulted Access to services can be achieved by installing access panels. The access panels should be designed not to compromise the sound and fire rating of the drywall system By designing service zones through which all services pass, the number of individual service penetrations can be minimised Services and fittings can be fixed to the face of Gyproc drywalling systems, using plywood/fixing strap noggins within the cavity of the drywall. A minimum stud spacing of 400mm is recommended. An alternative to this would be to install a metal or timber support framework within the cavity of the drywall 8

10 Gyproc DryWall design guidelines Dampers Fire and smoke resistant dampers may be installed in Saint-Gobain Gyproc s range of drywall systems. Because the performance of the complete assembly will depend on a number of elements, the precise details of the opening need to be determined in consultation with the damper manufacturers. Penetrations for dampers need careful scrutiny to ensure that the integrity of the element is not impaired, and also to ensure that the dampers do not act as a mechanism for the spread of fire. It is important to use only those dampers and installation methods which have been rigourisly fire tested and proven to be able to maintain the integrity of the construction. Service zones may be sealed after installation of the services using a tested and certified fire stopping system. In most situations, the services will be installed by drywall contractors. It is therefore important that all relevant contractors should be instructed as to where and how their service penetrations should be made and maintained. The necessity for independent structural support to dampers will depend on their size and weight Consult Saint-Gobain Gyproc Technical and Specifications Solutions Centre on for further detailed information. Access to services Access panels should be designed to offer practical, cost effective solutions. Care should be taken that the acoustic and fire performance of the wall is not compromised by the access panels. Health and Safety The details and guidance contained in this document have been written for the benefit of experienced trade professionals, to assist them in the use and installation of Saint-Gobain Gyproc s products. This document assumes a level of expertise which makes it unsuitable for use by a novice without the benefit of other guidance and instruction as to the use and installation of Saint-Gobain Gyproc s products. Saint-Gobain Gyproc provides training on the use and installation of all its products at the company s Academy Training Centres. The advice and guidance referred to does not seek to replace Health and Safety regulations, or the in-house systems of employers in relation to the use and installation of the Company s products, but should be considered supplementary to these. All users of such products and installation techniques should at all times ensure that they are familiar with, and adhere to, their employer s own Health and Safety procedures. While the advice and guidance given in the Specification Document meets relevant legislative and regulatory requirements and standards current at the date of publication, it is the responsibility of the user to ensure that these remain current prior to use. The Saint-Gobain Gyproc products and systems included in the Specification Document have been developed for use in domestic, commercial and industrial buildings. Guidance as to the correct application and installation of these products and systems is included in the installation sections. It is important to follow good site practice at all times and to ensure that appropriate safety precautions are taken (including the wearing of appropriate personal protection equipment and clothing) when working with Saint-Gobain Gyproc products. The following general notes are offered for guidance: Saint-Gobain Gyproc systems are non-load bearing and are not designed to support body weight Installers must work off an independantly supported platform Manual off-loading of boards, panels and bagged materials should be carried out with care to avoid unnecessary strain Keep sanding and other dust generation to a minimum. Maintain adequate ventilation and/or wear suitable protection When cutting boards or metal sections, hand and power tools should be used with care, keeping hands clear of blades and saw teeth, etc. Power tools should be used in accordance with manufacturers recommendations, and only be used by people who have been instructed and trained to use them safely and correctly When using plaster, mix with water in well ventilated conditions. Avoid contact with eyes and skin wear suitable eye and skin protection. In the event of contact with the eyes, irrigate with plenty of clean water immediately. (MSDS is available upon request) When handling insulation or cutting board products containing glass fibre, wear suitable face and skin protection. Wear eye protection when working overhead (MSDS is available upon request from Saint-Gobain Gyproc Technical Solutions Centre). Customers are also reminded that all the guidelines of the Occupational Health and Safety Act: 1993 should be adhered to. Donn UltraSTEEL TM metal stud framing Use components, accessories and methods recommended by Saint-Gobain Gyproc Set out floor/head tracks and perimeter studs to give a framework which is accurately aligned with a true vertical plane. Fix securely at all perimeters at not more than 600mm centres Position studs at equal centres to suit specified linings, maintaining sequence across openings. Provide additional studs as necessary to ensure support to all vertical edges of boards Accurately form openings to receive door sets using Donn UltraSTEEL Studs. Load bearing studs and suitable timber insert should be used to achieve the strength requirements of the framing assembly and adequately support the weight of the door 9

11 Insulation Fit securely with closely butted joints, leaving no gaps. Unless the insulation is of a self supporting batt type fitted between studs, fix at head of frame using galvanised steel angle 25mm x 25mm Acoustics Saint-Gobain Gyproc reference: SoundSeal Location: At junctions between drywall(s) and adjoining structure Apply as a continuous band to clean, dry, dust-free surfaces, leaving no gaps Seal any gaps and service penetrations Fire stopping Seal any gaps and service penetrations, etc. using tightly packed Ultimate insulation or fire resisting/intumescent sealant, to prevent penetration of flame Vertical joints Lightly butt boards together Centre joints on studs. Ensure that joints on opposite sides of studs are staggered. For double layer boarding, stagger joints between layers Horizontal joints RhinoBoards: Lightly butt boards together Horizontal joints will not be permitted in walls up to a height of 3600mm Walls over 3600mm (exceeding the maximum available length of board): Agree positions of joints where not specified. Provide horizontal framing to support the horizontal edges of the boards. Ensure that horizontal joints on opposite sides of studs are staggered For two layer lining, stagger joints between layers by at least 600mm. Provide horizontal framing to support the horizontal edges of the first layer lining Houghton Estate: luxury residential estate 10

12 Gyproc DryWall design guidelines Fixing lining to Donn UltraSTEEL TM metal supports Single layer drywall face layer: Fix securely to all supports at maximum 220mm centres using Gyproc RhinoBoard Sharp Point Screws 3.5mm diameter x 25mm. Double layer drywall first layer: Fix securely to all supports at maximum 220mm centres using Gyproc RhinoBoard Sharp Point Screws 3.5mm diameter x 25mm. Double layer drywall face layer: Fix securely to all supports at maximum 220mm centres using Gyproc RhinoBoard Sharp Point screws 3.5mm diameter x 42mm. Stagger the screws along RhinoBoard butt joints. Fix working from the centre of each board. Position screws not less than 13mm from cut edges and 10mm from bound edges of boards. Set heads in a depression; do not break paper or gypsum core. Deflection heads To be specified by the project structural engineer. For details contact Saint-Gobain Technical and Specification on Jointed finish to plasterboard Joint compound: RhinoGlide. Joints/gaps/internal corners: RhinoTape. External corners: Donn Corner Bead. Primer/sealer: Oil based Plaster Primer. Lightly sand cut edges of boards to remove paper burrs. Cover all joints, gaps and internal angles with RhinoTape. Cover with RhinoGlide feathered out to give a flush, smooth finish. Sand if required. Reinforce external angles, stop ends, etc. with the Donn Corner Bead embedded in RhinoGlide. Spot nail/screw depressions with joint compound to give a flush surface. After joint, angle and spotting treatments have dried, lightly sand to remove any minor imperfections. Plaster finish Thickness: 3mm to 6mm. Reinforcement: Joints/gaps/internal corners: RhinoTape. External corners: Donn Corner Bead embedded in skim coat plaster. Fill and tape all joints. Trowel/float to a tight, matt, smooth surface with no hollows, abrupt changes of level or trowel marks as per skim coat plaster specification. Painting: plaster finish/jointed finish Primer: As per manufacturer s specification. Do not apply epoxy paints. Wallpaper: plaster finish/jointed finish Primer: As per manufacturer s specification. Apply wallpaper as per manufacturer s specifications. 11

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14 Gyproc DryWall installation guide 1 2 Apply SoundSeal as a continuous application to the perimeter of the framework. Determine and mark wall position and make allowance for openings. Fix Donn UltraSTEEL Track at 600mm centres using suitable fixings. 3 4 Measure the wall height and cut stud to size. Install the stud into Donn UltraSTEEL Floor Track. Twist Donn UltraSTEEL Stud into place. 5 6 Ensure the stud is plumb and mark stud position. Fix the UltraSTEEL Stud to the abutting wall at 600mm centres using suitable fixings. 7 8 Insert top UltraSTEEL Track into position. Fasten the top UltraSTEEL Track at 600mm centres. 13

15 9 10 Insert UltraSTEEL studs at 600mm centres to a friction fit within the channel sections this allows for adjustment during boarding. Position the UltraSTEEL Studs so all face the same way. Fasten Gyproc RhinoBoard 12.5mm to the framework using Gyproc RhinoBoard Sharp Point Screws 25mm spaced at 220mm centres After the boarding is complete, apply Gyproc RhinoTape to all joints. Apply Gyproc RhinoGlide to the joints using a 150mm taping knife Fill all screw heads using Rhinoglide. Apply a second coat off Rhinoglide using a 300mm steel trowel. 14

16 Saint-Gobain s SpecSure system warranty Unique to Saint-Gobain Construction Products South Africa, the 10 year system warranty is designed to give you total confidence that the systems you have chosen will meet the most rigorous of building requirements. All of our systems are developed using the highest quality components designed to work together, and are specifically developed to give you a lifetime of confidence. SpecSure is more than just a performance warranty. It means that the Saint-Gobain Construction Products SA systems you specify: Have a guaranteed 10 year performance. Have the technical expertise and experience of the SA s leading construction products specialist behind it. Have been tested in accredited fire, acoustic and structural test laboratories. Have been site tested to demonstrate installation integrity and simplicity. Will be supported at every stage of the project by SA s leading on and off-site technical support personnel. Will perform to published parameters if installed in accordance to our specifications. Will be repaired or replaced by Saint-Gobain Construction Products South Africa in the unlikely event of system failure attributed to unsatisfactory product/system performance. Project Packs offer technical guidance and compliance to the building methodology prescribed which will ensure optimal system performance. Customer contact centre: