BORAL PLASTERBOARD Build something great. Section 4 Wall Lining Solutions

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1 BORAL PLASTERBOARD Build something great Section 4 Wall Lining Solutions

2 4.1 SYSTEMS INTRODUCTION Boral Direct Bond Wall Lining System Boral Direct Bond Wall Lining System provides a fast, efficient means of creating flat seamless plasterboard walls over masonry substrates with minor irregularities and offers a dry solution calling for skills more easily acquired than traditional sand/cement rendering or plastering. Ideal for use in housing, apartments and commercial buildings. With more than 30 years of use as a housing system in the UK it continues to provide a highly cost-effective means of lining masonry walls and complying with UK Building Regulations. Boral PROframe TM Close-Fit Wall Lining System Boral Close-Fit Wall Lining System is an ideal solution for lining more severe irregular dry masonry walls with plasterboard. The system is simple, fast to install, cost effective and can easily accommodates both mechanical and electrical services. Typically used in commercial projects it also offers particular benefits in reducing sound flanking transmission through the path of masonry walls which Boral partitions join onto. Boral PROframe TM Independent Wall Lining The Boral Independent Wall Lining system is especially suited for lining reinforced concrete walls and steel framed walls, walls which have severe irregular surfaces, and external walls that have suffered damp ingress, but then treated with appropriate damp proofing systems. Fixed clear of the external wall, this system allows space for both mechanical and electrical services, or for high levels of thermal and acoustic insulation This system is commonly for applications ranging from factories and warehouses to hotels and multiplex cinemas.

3 PERFORMANCE TABLES - INTRODUCTION 4.2 Max Height (m) Boral Close-Fit Wall Lining System The maximum heights given in the tables refer to the background masonry construction limitation. For maximum height of Boral Close-Fit Wall Lining system on another type of masonry background contact Boral Technical Support Centre. Boral Independent Wall Lining System Maximum heights shown are without extra bracing supports and based on a deflection criteria of L/240 under a static UDL (Uniformly Distributed Load) of 0.25kPa. For independent wall linings at 4.2m or above, Boral Deep Flange U-Track and Boral Deflection Head Brace should be used at the wall lining head to ensure C-Studs remain in the U-Tracks in the event of a fire or during any design movement of the building. Fire Rating and Acoustics With many years of fire and acoustic testing around the world Boral has accumulated a wealth of expertise and knowledge together with a wide range of system test reports. Indicates that a test report is available Indicates a prediction based on expert opinions, test reports from other similar tests or specialist calculation software like Marshall Day. With added bracing supports greater heights may be achieved, for more information contact Boral Technical Support Centre. Example Of Tables System Reference BP WL 4 Description Masonry : 100mm brickwork Lining : Boral Universal Channels at 610mm maximum attached to Boral Close-Fit Brackets at 800mm max vertical Board : Insulation : One layer 13mm Boral dbstop plasterboard each side 25mm glass mineral wool, density 16 kg/m 3 MAX HEIGHT (m) ACOUSTICS (RwdB) FIRE RATING (minutes)

4 4.3 PERFORMANCE TABLES Boral Close-Fit Wall Lining systems for external walls System Reference BP WL 1 Description Masonry : Sand/cement render on solid 215mm concrete blockwork, density 2300Kg/m 3 Lining : Boral Universal Channels at 610mm maximum attached to Boral Close-Fit Brackets at 800mm max vertical Board : Insulation : 13mm Boral HeatSTOP plasterboard 50mm glass mineral wool, density 24 kg/m 3 MAX HEIGHT (m) ACOUSTICS (RwdB) FIRE RATING (minutes) System Reference BP WL 2 Description Masonry : 215mm brickwork Lining : Boral Universal Channels at 610mm maximum attached to Boral Close-Fit Brackets at 800mm max vertical Board : Insulation : 13mm Boral HeatSTOP plasterboard 50mm glass mineral wool, density 24 kg/m 3 MAX HEIGHT (m) ACOUSTICS (RwdB) FIRE RATING (minutes) Boral TM Close-Fit Wall Lining systems for internal walls System Reference BP WL 3 Description Masonry : 100mm brickwork Lining : Boral Universal Channels at 600mm maximum attached to Boral Close-Fit Brackets at 800mm max vertical Board : Insulation : 13mm Boral dbstop plasterboard None MAX HEIGHT (m) ACOUSTICS (RwdB) FIRE RATING (minutes) System Reference BP WL 4 Description Masonry : 100mm brickwork Lining : Boral Universal Channels at 600mm maximum attached to Boral Close-Fit Brackets at 800mm max vertical Board : Insulation : One layer 13mm Boral dbstop plasterboard each side 25mm glass mineral wool, density 16 kg/m 3 MAX HEIGHT (m) ACOUSTICS (RwdB) FIRE RATING (minutes) Note: The maximum heights given in these tables refer to the background construction. When using Boral Close-Fit Wall Lining system in conjunction with mineral wool, ensure a 10mm cavity between inner masonry and back of insulation. Performance values are for imperforate, jointed systems using only Boral components and installed to the Boral Plasterboard Philippines specification given. Any alterations may well impair the quoted performance criteria.

5 PERFORMANCE TABLES 4.4 Boral Independant Wall Lining systems System Reference BP WL 5 Description Masonry : 100mm brickwork or blockwork Lining : Board : Insulation : Boral back-to-back C-Studs at 610mm maximum Inner layer 13mm Boral FireSTOP HeatSTOP plasterboard. Outer layer 13mm Boral FireSTOP plasterboard. 100mm glass mineral wool, density 10.5 kg/m 3 System Reference BP WL 6 Description Outer leaf : Profiled metal cladding Lining : Board : Insulation : Boral back-to-back C-Studs at 610mm maximum Inner layer 13mm Boral FireSTOP HeatSTOP plasterboard,outer layer 13mm Boral FireSTOP plasterboard. 100mm glass mineral wool, density 10.5 kg/m 3 Systems BP WP 5 and BP WP 6 with back-to-back C-Studs Depth STUD SIZE (mm) Gauge MAX HEIGHT (m) Non-Load Bearing 406mm FIRE RATING (minutes) Note: Maximum heights shown are without extra bracing supports and based on a deflection criteria of L/240 under a static UDL (Uniformly Distributed Load) of 0.25kPa. For independent wall linings at 4.2m or above, Boral Deep Flange U-Track and Boral Deflection Head Brace should be used. With added bracing supports greater heights may be achieved, for more information contact Boral Technical Support Centre. Performance values are for imperforate, jointed systems using only Boral components and installed to the Boral Plasterboard Philippines specification given. Any alterations may well impair the quoted performance criteria.

6 4.5 DIRECT BOND WALL LINING SYSTEM Introduction Boral Direct Bond Wall Lining System Boral Direct Bond Wall Lining System provides a fast, efficient means of creating flat seamless plasterboard walls over masonry substrates with minor irregularities and offers a dry solution calling for skills more easily acquired than traditional sand/cement rendering or plastering. Ideal for use in housing, apartments and commercial buildings. This system is easy and quick to apply using bonding compound to bond up to 16mm thick Boral Standard Core, Boral dbstop or Boral FireSTOP plasterboard onto masonry substrates. Limitations This method of fixing is not recommended for solid external walls subject to the ingress of moisture. If ingress cannot be fully eliminated, then use the Boral PROframe TM Close-Fit Wall Lining System or Boral PROframe TM Independent Wall Lining System. Plasterboard limitation, Boral WetAREA, Boral WetAREA FireSTOP and Boral HeatSTOP plasterboards are not suitable for direct bonding and should be mechanically screw fixed using the Boral PROframe TM Close-Fit Wall Lining System or Boral PROframe TM Independent Wall Lining System. Height limitation, the maximum installation height for direct bond should not exceed 3 metres. Cavity limitation, the final cavity between masonry substrate and back of plasterboard can be a minimum of 10mm and a maximum of 30mm. Direct Bond Wall Lining System Main Components Plasterboard as Suitable Boral Plasterboards» Boral Standard Core» Boral FireSTOP» Boral dbstop» Boral MultiSTOP

7 DIRECT BOND WALL LINING SYSTEM 4.6 Application Substrate Pre-Treatment Some masonry substrates may require abrasion or pre-treatment with a PVAC, see Pre-Treatment Of Masonry Substrates table below. application Apply to the walls as shown opposite. Dabs should be 50 to 75mm wide, 250mm long, and 25mm in from the board edges to avoid bridging of joints by the compound. The contact area of the dabs must be at least 20% of the board area. Certain floor/ceiling constructions can allow the circulation of air behind the boards and air may also enter at junctions with partitions and door/window frames. This circulation can reduce the thermal performance of the wall. To reduce this risk apply continuous horizontal and vertical bands of around electrical sockets, windows, wall perimeters, junctions and door frames of linings to internal faces of external walls. A continuous band of Boral Premium Bond at the floor line will ensure a solid base for skirting board fixing. Electrical cables should be protected by conduit. Movement control joints Movement control joints are required in wall linings at intervals not exceeding 10 metres, and where the wall lining crosses or abuts a structural movement joint. Jointing Bonded plasterboards should not be jointed for 24 hours to allow bonding compound to fully harden. All joints to be taped and jointed as in this manual, refer to Section 7 - Finishing Solutions for further details. Direct Bondng Of 13mm and 16mm Plasterboard Direct Bondng Of 9mm Plasterboard Pre-Treatment Of Masonry Substrates Background Examples High suction backgrounds Low and medium suction masonry Dabs at 600mm vertical Dabs at 400mm vertical Typical Type Dabs at 540mm horizontal centre Dabs at 360mm horizontal Aerated or lightweight aggregate concrete blocks Common clay bricks and concrete blocks, high density clay and concrete blocks Smooth pre-cast concrete 60mm 60mm Pre-treatment PVAC bonding agent None Plasterboard as Plasterboard as Remover shutter oil and concrete contaminates. Abrade to form a rough surface and pre-treat with a PVAC bonding agent Very low suction backgrounds High strength concrete PVAC bonding agent Note: 1. Extremely smooth surfaces may require abrasion prior to PVAC treatment. 2. Surfaces must be free of mould, oil and dust. Contaminted surfaces may require chemical cleaning. 3. Painted surfaces and limestone skimmed surfaces are not suitable for direct bonding.

8 4.7 DIRECT BOND WALL LINING SYSTEM Direct Bond Floor Level Detail Direct Bond Ceiling Level Detail 25mm 50~75mm Boral Premium Bond at floor level to provide support and fixing background for skirting Plasterboard finished 5mm short of floor level and gap sealed with Fire Acoustic Sealant or an acrylic sealant if non-fire rated Boral Premium Bond around perimeter of wall 50mm 250mm External Corner Detail Internal Corner Detail Window Opening Detail Junction With Partition Detail Fire Acoustic Sealant or an acrylic sealant if non-fire rated Boral Expansion Bolt Boral C-Stud Window Opening Detail

9 CLOSE-FIT WALL LINING SYSTEM 4.8 Introduction Boral PROfame TM Close-Fit Wall Lining System Boral PROfame TM Close-Fit Wall Lining System is an ideal solution for lining more severe irregular dry masonry walls with plasterboard. The system is simple, fast to install and cost effective making it suitable for many internal applications. Typically used in commercial projects it also offers particular benefits in reducing sound flanking transmission through the path of masonry walls which Boral partitions abut. Boral PROfame TM Close-Fit Wall Lining System is fixed directly to the existing background, allowing a cavity between wall and back of plasterboard ranging from 20mm to 70mm. This system can therefore be used for all common lining applications: electrical services performance performance This system is also ideal for screw fixing of Boral plasterboards which can not be direct bonded: Boral WetAREA, Boral WetAREA FireSTOP and Boral HeatSTOP. Performance The selection of lining systems, insulation and boarding will depend on the wall height and the performance required for fire resistance, thermal and sound insulation: refer to performance tables on page 4.3 in this section. Close-Fit Wall Lining System Boral Universal Channel Main Components Boral J Channel Boral J Channel Boral Close-Fit Bracket Plasterboard as Boral Universal channel Boral Close-Fit Bracket Boral Smart Connector Boral Expansion Bolt Boral Screws (as appropriate) Add Components For fine and sound performance Insulation (as ) Fire Acoustic Sealant Boral Flat Strap used as fire stop on horizontal joints or as lightweight fixing support

10 4.9 CLOSE-FIT WALL LINING SYSTEM Close-Fit Wall Lining Detail 150mm Horizontal Boral J Channel above doorway cut and turned down 150mm and screw fixed onto vertical corner Boral J Channel as shown 610mm max Option 2 Boral J Channel Internal corners -2 option Option 1 Boral Universal Channel 800mm max Option 2 Boral Close-Fit Bracket Boral J Channel Boral J Channels used on external corners and at doorways Framing Centres Board Thickness (mm) Board width (mm) Horizontar Framing Centres (mm) Vertical Bracket Centres (mm) Jointing All joints to be taped and jointed as in this manual, refer to Section 7 - Finishing Solutions for further details. 13 and

11 CLOSE-FIT WALL LINING SYSTEM 4.10 Floor And Head Detail 10mm Deflection Head Detail Leave a 5~10mm gap above board and fill with Fire Acoustic Sealant Note: If no fire requirement an acrylic sealant can be used Boral J Channel fixed to suffit at 600mm maximum Leave a 15mm gap above board and fill with Fire Acoustic Sealant Boral Close-Fit Bracket fixed to background using Boral Expansion Bolt or appropriate fixings at 800mm vertical Plasterboard fixed to Boral Universal Channels and Boral J Channels Boral Universal Channel fixed to Boral Close-Fit Bracket using Boral Pan Head Self Tapping Screws Cut Boral Universal Channels 10mm shorter than the floor to ceiling height Note: Boral Universal Channels and plasterboard MUST NOT be fixed to the soffit J Channel to ensure deflection movement Boral Close-Fit Bracket fixed to background 100mm below soffit using Boral Expansion Bolt Screw fix Boral Universal Channels to Boral Close-Fit Bracket using Boral Pan Head Self Tapping Screws Boral J Channel fixed to floor at 600mm maximum Internal Corner Detail Leave a 5~10mm gap below board and fill with Fire Acoustic Sealant Note: If no fire requirement an acrylic sealant can be used External Corner Detail Boral J Channel Fire Acoustic Sealant or an Acrylic Sealant if non fire rated Boral Universal Channel set 50mm in from internal corn Boral J Channel Boral Universal Channel set 50mm in from external corner Junction With Partition Detail Boral J Channel Boral J Channel Movement Control Joint Movement control joints are required in wall linings at intervals not exceeding 10m or where the wall lining crosses or abuts a structural movement joint. Compressible packing Fire Acoustic Sealant or an Acrylic Sealant if non fire rated Boral Expansion Bolt Boral C-Stud Boral Universal Channel set 50mm in from partition Boral Universal Channel set 50mm in from the background movement control joint Boral Movement Control Bead stapled onto plasterboard using 13mm stainless steel staples at 150mm. Joint using Boral Premium Jointing compound

12 4.11 INDEPENDENT WALL LINING SYSTEM Introduction Boral PROfame TM Independent Wall Lining System Boral PROfame TM Independent Wall Lining system is especially suited for lining reinforced concrete walls and steel framed walls, walls which have severe irregular surfaces, and external walls that have suffered damp ingress, but then treated with appropriate damp proofing systems. Fixed clear of the external wall, this system allows space for both mechanical and electrical services, or for high levels of thermal and acoustic insulation. This system is commonly for applications ranging from factories and warehouses to hotels and multiplex cinemas. The system uses Boral I Studs or back-to-back Boral C Studs and Boral U Tracks as used in the Boral PROframe TM Partition systems. Glass mineral wool batts can be inserted into the framing to improve the thermal and acoustic performance of the system. Performance The selection of lining systems, insulation and boarding will depend on the wall height and the performance required for fire resistance, thermal and sound insulation: refer to performance tables on page 4.4 in this section. Jointing All joints to be taped and jointed as in this manual, refer to Section 7 - Finishing Solutions for further details. Independent Wall Lining System Main Components Boral U Track Boral C Studs (back-to-back) or Boral I Studs Boral U Track Boral C Stud Insulation as Plasterboard as Boral I Stud For wall linings at 4.2m or above, Boral Deep Flange U Track and Boral Deflection Head Brace should be used. Boral Screws (as appropriate) Boral Deep Flange U Track Boral Deflection Head Brace Add Components For fire wall linings For wall linings with Insulation For fixing support Fire Acoustic Sealant Boral Flat Strap Boral Insulation Hold Strap Insulation (as ) Boral Fixing Channel

13 INDEPENDENT WALL LINING SYSTEM 4.12 Independent Wall Lining Detail Boral U Track fixed to soffit and floor at 600mm maximum centre C Stud screw fixing back-to-back Boral back-to-back C Studs or Boral I Studs at maximum 610mm C Studs 50mm to 92mm Single screw fixing at 200mm 50mm Boral C Studs at wall ends Boral C Studs at openings 200mm Boral U Tracks fixed top and bottom to form openings with Boral C Studs above and below for fixing plasterboard 200mm C Stud 148mm Staggered screw fixing at 200mm 50mm 200mm 200mm Plasterboard as Insulation as Timber sole plate (if required for uneven floors) Head Detail 10mm Deflection Head Detail Boral Expansion Bolt Leave a 5~10mm gap above board and fill with Fire Acoustic Sealant Leave a 15mm gap above board and fill with Fire Acoustic Sealant Boral U Track Boral back-to-back C Studs or Boral I Studs cut 5mm shorter than floor to soffit height Insulation as Boral Deep Flange U Track 10mm gap allowance for deflection between Boral U Track and Boral Flat Strap Boral Flat Strap Boral back-to-back C Studs or Boral I Studs cut 10mm shorter than floor to soffit height Plasterboard as Minimum 10mm cavity Note: Boral back-to-back C Studs or Boral I Studs and plasterboard MUST NOT be fixed to the soffit Deep Flange U Tack to ensure deflection movement Note: if no fire requirement an Acrylic Sealant can be used in place of Fire Acoustic Sealant

14 4.13 INDEPENDENT WALL LINING SYSTEM Floor Detail Internal Corner Detail Minimum10mm cavity Plasterboard as Insulation as Boral back-to-back C Studs or Boral I Studs Fire Acoustic Sealant or an Acrylic Sealant if non fire rated Boral C Stud Boral U Track Leave a 5~10mm gap below board and fill with Fire Acoustic Sealant Note: If no fire requirement an acrylic sealant can be used Boral back-to-back Boral C Studs or Boral I Studs External Corner Detail Junction With Partition Detail Boral C Stud Fire Acoustic Sealant or an Acrylic Sealant if non fire rated Boral C-Stud Boral back-to-back C Studs or Boral I Studs Boral C Stud Movement Control Joint Detail Movement control joints are required in wall linings at intervals not exceeding 10m or where the wall lining crosses or abuts a structural movement joint. Door Or Window Detail Boral Metal Angle Compressible packing Boral C Stud Boral back-to-back C Studs or Boral I Studs Boral back-to-back C Studs or Boral I Studs Boral Movement Control Bead stapled onto plasterboard using 13mm stainless steel staples at 150mm. Joint using Boral Premium Jointing

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