THE SITE BOOK - British Gypsum

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March 2018THESITE BOOKRevised 2007 Edition

ForewordThe SITE BOOK is an invaluable step-by-stepinstallation guide for British Gypsum systems. Itshould be used by site personnel regularly involvedin either building or supervising systems installation.The sequence photographs and guidance notesdepict the basic steps required for trouble-free fixing.In practice, consideration must be given to designcriteria requiring specific project solutions. Installationshots are indicative only - it is important that goodpractice is always followed on site including taking allnecessary safety precautions and wearing appropriatepersonal protection equipment.1

ContentsContents1General site guidance2611Quantity take-off details488Manual handling and lifting3812Products5083Technical support and product training524SpecSure 60562Installation - Partition and wall systemsInstallation - Wall lining systems622407Installation - Floor, ceiling and soffit systems2908Installation - Steelwork encasement systems3829Plaster systems408101british-gypsum.comFinishing systems and decorative effects428Plaster skimming428Jointing436Tiling450Decorative effects - Trims, Cove and Cornice472Boards508Plasterboard accessories526Fixings538Metal components546Insulation566Plasters and plaster accessories582Access panels600Ceilings (reference only)608Decorative products61413Glossary62814Index640For further details on all British Gypsumsystems and products visitbritish-gypsum.com

ContentsTechnical support: T 0115 945 6123 F 0115 945 161613

ContentsContents5a20 (inc. a15)462GypWall CLASSIC and GypWall ROBUST - the definitive metal stud partition system62GypWall EXTREME - ultimate impact and abrasion resistant partition system86a20.1GypWall CURVE - curved partition systema13GypWall RAPID dB Plus - metal stud housing partition system118a21GypWall QUIET - acoustic separating wall system136110GypWall QUIET IWL - independent twin-frame acoustic separating wall system146a24GypWall QUIET SF - single frame acoustic separating wall system156a23GypWall STAGGERED - staggered stud acoustic partition system166a32GypWall AUDIO - the ultimate sound insulating wall system180190a30ShaftWall - shaft and duct encasement systema25 & a26Specialist systems (GypWall SECURE and BlastWall) (reference only)216a35FireWall - High performance fire-resistant wall system218a60Timber stud - timber frame partitions and walls with single or twin frames226Installation - Wall lining systems24061Installation - Partition and wall systemsbritish-gypsum.comb10DriLyner BASIC, TL, SI, RF, MF - drywall masonry lining systems240b22GypLyner UNIVERSAL - metal framed wall lining system260b21GypLyner IWL - independent wall lining system276b35FlameLyner - industrial fire-resistant lining system (reference only)288

Installation - Floor, ceiling and soffit systems290c10CasoLine MF - concealed grid MF suspended ceiling system290c10.1CasoLine CURVE - concealed grid MF curved ceiling system306c15GypLyner UNIVERSAL - concealed grid ceiling lining system318c12CasoLine GRID - suspended grid ceiling system (reference only)3307c60Timber joist - ceiling and separating / compartment floors332c20GypFloor SILENT - sound insulating floor system348c55GypFloor SB - floating floor treatment for separating floors362SoffitLine - thermal lining system for semi-exposed soffits374Installation - Steelwork encasement systems382d12FireCase - frameless structural steel encasement system382d15GypLyner ENCASE - GypLyner framed structural steel encasement system396Plaster systems408Plaster systems40889b05ContentsTechnical support: T 0115 945 6123 F 0115 945 161615

General site guidance - Health and Safety16british-gypsum.com1General site guidance7Health and Safety8Board fixing11Good practice detailing15Fixings into drywall systems21Services installations26

General site guidanceAt British Gypsum, we recognisethe importance of following goodsite practice at all times. In thissection we detail general siteguidance outlining safe practice forhandling and storing British Gypsumproducts and systems, helping youto work better and stay safe.These notes are for guidancepurposes only and are notintended to be exhaustive.We advise that you read andfamiliarise yourself with all of therelevant information in this bookprior to commencement of work.Where other manufacturers’products or systems are being usedin association with British Gypsumsystems, reference should always bemade to the manufacturer’sown installation instructions andproduct data.General site guidance - Health and SafetyTechnical support: T 0115 945 6123 F 0115 945 161617

General site guidance - Health and Safety18british-gypsum.comHealth and SafetyIMPORTANT:Please read the following notes beforespecifying, handling or installing British Gypsumproducts. The notes are for guidance purposesand are not intended to be exhaustive. Wheninstalling proprietary products, such as fixingdevices, reference should be made to themanufacturers’ instructions and product data.GeneralThe details and guidance contained in theSITE BOOK have been written for the benefit ofexperienced trade professionals, to assist them in theuse and installation of British Gypsum products. Thebook assumes a level of knowledge which makes itunsuitable for use by a novice without the benefitof other instruction as to the use and installation ofBritish Gypsum products. British Gypsum providestraining on the use and installation of all its productsat the Company’s Drywall Academy Training Centres.The advice and guidance referred to does not seekto replace the Health and Safety advice and systemsof employers in relation to the use and installation ofthe Company’s products but should be considered inaddition. At all times all users of such products andinstallation techniques should ensure that they arefamiliar with, and adhere to, their employer’s ownHealth and Safety procedures.Whilst the advice and guidance given in theSITE BOOK meets relevant legislative and regulatoryrequirements and standards current at the date ofpublication, it is the responsibility of the user toensure that these remain current prior to use.The British Gypsum products and systems includedin the SITE BOOK have been developed for use indomestic, commercial and industrial buildings.Guidance as to the correct installation and useof these products and systems is included in theinstallation sections.

It is important to follow good site practice at all timesand to ensure that appropriate safety precautions aretaken (including the wearing of appropriate personalprotection equipment and clothing) when workingwith British Gypsum products. When using powdered products, mix with waterin well ventilated conditions. Avoid contact witheyes and skin – wear suitable eye and skinprotection. In the event of contact with the eyes,irrigate with plenty of clean water immediately.The following general notes are offered for guidance: When handling insulation or cutting boardproducts containing glass fibre, wear suitableface and skin protection. Wear eye protectionwhen working overhead. British Gypsum systems are non-loadbearing andare not designed to support body weight. Fixersmust work from an independent support system. Manual off-loading of boards, panels and baggedmaterials should be carried out with care to avoidunnecessary strain. Keep sanding and other dust generation to aminimum. Maintain adequate ventilation and/orwear suitable protection. When cutting boards or metal sections, hand andpower tools should be used with care keepingblades and saw teeth clear of hands, etc. Power tools should be used in accordance withmanufacturers’ recommendations, and only beused by people who have been instructed andtrained to use them safely.Suitable protection should be to the followingstandards: Face masks to EN 149 FFP2. Eye protection to BS EN 166.General site guidance - Health and SafetyTechnical support: T 0115 945 6123 F 0115 945 1616Further information is available in Product DataSheets (giving safety, handling and storage details)for all British Gypsum products, which are availableon request from the British Gypsum Drywall AcademyAdvice Centre or are available to download frombritish-gypsum.com19

General site guidance - Health and Safety110british-gypsum.comCustomers are also reminded that under the Healthand Safety at Work Act 1974, and the followingsubsequent regulations, employers are under a dutyto ensure that all risks associated with the use ofequipment are properly risk assessed, that employeesare informed of the findings of these assessmentsand are instructed, trained and supervised in theproper use of such work equipment and protectiveequipment. The extent of instruction, training andsupervision required will depend on the employeesexisting competence necessary to use the workequipment with due regard for Health and Safety. Management of Health and Safety at WorkRegulations Provision and Use of Work Equipment Regulations Personal Protective Equipment RegulationsHandling and storageBritish Gypsum fully accepts its responsibilities as asupplier of building materials and systems as requiredby Section 6 of the Health and Safety at Work Act1974.However, in designing and installing systemsincorporating British Gypsum products, fullconsideration must be taken of the legalrequirements of:1 Manual Handling Operations Regulations.2 Construction (Design and Management)Regulations.3 Control of Substances Hazardous to HealthRegulations (COSHH).Guidance documents / approved codes of practiceregarding these regulations are available via theHealth and Safety Executive.

Board fixingGeneral Fix boards with decorative side out to receive jointtreatment or a skim plaster finish. Lightly butt boards together. Never force boards intoposition. Install fixings not closer than 13mm from cut edges and10mm from bound edges. Position cut edges to internal angles whenever possible,removing paper burrs with fine sandpaper. Stagger horizontal and vertical board joints betweenlayers by a minimum of 600mm. Locate boards to the centre line of framing where thissupports board edges or ends. Where autofeed power screwdrivers are employed, useGyproc Drywall Collated Screws (supplied in strips). Use Gyproc Drywall Screws for fixing Gypframe ‘C’ Studsand associated framing up to and including 0.7mmgauge (e.g. 70 S 60), and for fixing to Gypframe ‘I’ Studsup to and including 0.5mm gauge (e.g. 70 I 50). Use Gyproc Jack-Point Screws for fixing Gypframe‘C’ Studs and associated framing 0.8mm gauge orgreater (e.g. 92 S 10), and for fixing to Gypframe ‘I’ Studs0.7mm gauge or greater (e.g. 70 I 70).Understanding the codes for metal studs and channels.The first 2 or 3 digits refer to the component width, theletter/s refer to the component type, and the last twonumbers indicate the metal thickness in mm, e.g. 92 S 10refers to 92mm wide ‘C’ Stud, metal thickness of 1.0mm.Gyproc plasterboards should not be consideredas a means of isolating dampness or used in areas subjectto persistently damp or humid conditions. Use Gyproc Wafer Head Drywall Screws for fixingGypframe metal to metal. Their thin head minimises therisk of subsequent bulging of the lining board overfixings.Screw fixing to Gypframe metal framing Use Gyproc Wafer Head Jack-Point Screws for fixingGypframe metal to metal where one or both of thesections is between 0.8mm and 2mm thick. Always fix‘thin’ to ‘thick’ so that the thin metal is trapped betweenthe ‘thick’ metal and the screw head. Select Gyproc screws to give a nominal 10mmpenetration into the metal. See Table 1.General site guidance - Health and SafetyTechnical support: T 0115 945 6123 F 0115 945 1616111

General site guidance - Health and Safetybritish-gypsum.comTable 1 - Fixing to metal sectionsLining boardthicknessmm69.51012.512.5 or 2nd layer of 6 over 615192nd layer of 12.5 over 12.52nd layer of 15 over 152nd layer of 12.5 over 193rd layer of 12.5 over 2 layers of 12.5Gyproc Drywall Screwlengthmm222525221252532364242501 Gypframe RB2 SureFix Bar and DriLyner MF112Thermal laminatesthicknessmm2227, 30354048, 5060Gyproc Drywall Screwlengthmm324250506075Gyproc Jack-Point Screwlengthmm––––25253535414160

Fixing to timber supportsSelect the correct length of fixing, see Table 2. Use Gyproc Drywall Timber Screws when fixing tostandard softwood, super-dried timber andengineered ‘I’ beams. They provide a superiorfixing to nails and minimise the risk of fixingdefects occurring.Where autofeed power screwdrivers areemployed, use Gyproc Collated DrywallTimber Screws (supplied in strips).Drive fixings firmly home without fracturing theboard surface but leaving a shallow depression tofacilitate spotting.Table 2 - Fixing to timber sectionsBoardmmGyproc Drywall Timber Screwsthickness to fix board for directdecoration or plasteringmm9.53212.5381538194112.5 over 12.55115 over 156012.5 over 196015 over 1960General site guidance - Health and SafetyTechnical support: T 0115 945 6123 F 0115 945 1616Adhere to the fixing tolerances shown in Figure 1.If the timber support has insufficient bearingsurface, fix a further timber support to it as shownin Figure 2. Alternatively, in the case of joists ortrusses, use suitable counter battens.113

General site guidance - Health and Safetybritish-gypsum.comFigures35mmA6mmminFixing tolerancesLightly butt boards with a max. separation of 3mm. Where a cutedge occurs dimension A is 13mm min; where a bound edge occurs1 dimension A is 10mm min.11425mm2 Increasing the bearing surface e.g. fixing boards to trussed rafters.

Avoiding fixing defects into timberDO Use seasoned or kiln dried timber (preferablyNo.1 grade) to minimise the risk of dryingshrinkage. BS 8212 refers to 20% as being themaximum moisture content before drylining. Ensure timber supports are accurately spaced,aligned and levelled. Ensure that the dimensions and assembly oftimber supports is sufficient to allow positivefixing of boards without bounce or unduedeflection. If these fixing conditions can not bemet, securely fix a timber batten to the side ofthe timber support to increase bearing surface. Fix boards tight to framing members. Use Gyproc Drywall Timber Screws to minimiseany risks of nail popping. Alternatively, for timberjoists fix Gypframe RB2 SureFix Bar to theunderside to eliminate nail popping and toprovide a positive fixing for boards using GyprocDrywall Screws.In all cases where defective or inadequatetimber framing has been identified, defects must berectified by suitable measures such as adjustment,inserting shims or replacement of affected timberprior to board fixing.The use of timber which meets BS 8212 moistureresistance, can still mean that nail popping canoccur. The timber in use can ‘dry down’ to 8%causing shrinkage and twisting.Good practice detailingGeneralBS 8000 Part 8: 1994 Workmanship on Building Sitesprovides general guidance on good site practice.Specific reference is drawn to section 2.2 ‘Preparationof work, materials and components’, covering liason,working conditions, distributed components andmaterials, cleanliness and protection, and suitabilityof backgrounds.General site guidance - Health and SafetyTechnical support: T 0115 945 6123 F 0115 945 1616115

General site guidance - Health and Safety116british-gypsum.comAcoustics Consider the layout and structure of buildings at thedesign stage to separate quiet and noisy areas Control sound paths around walls and floors to reduceflanking sound transmission Closely follow manufacturers’ fixing details asdeviations can negate any acoustic benefit Seal the base of the wall/dryliningWhen installing drylining, it is general practice toposition the plasterboard so that a gap/break in contactoccurs between the bottom edge of the plasterboard andthe floor. It is important to seal this gap with a suitablefiller prior to installation of the skirting. Furthermore, it isimportant to ensure that the base of the masonry wall isproperly sealed prior to drylining to prevent an airspacebeing created straight under the wall. Tape and fill, or skim plaster plasterboard joints toincrease airtightness Seal joints, junctions, penetrations, etc. to avoidair leakage Keep penetrations to a minimum Avoid back-to-back socketsDeflection head details – acoustic performanceDeflection heads, by definition, must be able to moveand, therefore, achieving an airtight seal is very difficultwithout incorporating sophisticated components andtechniques. Air leakage at the partition heads will havea detrimental effect on acoustic performance of anypartition. The approach shown in Figure 3 - Deflectionhead A could, for example, result in a loss of around4dB to 5dB due to air leakage, in addition to that lostdue to flanking transmission, etc.Where acoustic performance is a key consideration,steps can be taken to minimise this loss of performance.Figure 4 - Deflection head B shows the generallyaccepted method of achieving this and, provided care istaken to ensure a tight fit between cloaking angle andlining board surface, the loss in performance can bereduced. A loss in performance of around 1dB to 2dBwould be typical with this method. Other factors, suchas flanking transmission through the structural soffit, cansignificantly affect the overall level of sound insulation.Therefore, to optimise sound insulation performance,other measures may need to be taken.

Figures1125mm25mm25mm25mm30mm3 Deflection head A (subject to fire performance)1 Gyproc Sealant for optimum sound insulation2 Uppermost board fixings3 50mm timber head plate equivalent to channel widthforming fire-stop433230mm2General site guidance - Health and SafetyTechnical support: T 0115 945 6123 F 0115 945 16164 Deflection head B (subject to fire performance)4 Gypframe GA4 Steel Angle for optimum sound insulation117

General site guidance - Health and Safetybritish-gypsum.comA suspended ceiling installed on both sides of thepartition may provide a similar cloaking effect to thatof steel angles. CasoLine MF can deliver a similarreduction in air leakage at the partition head. A tightfit between the ceiling perimeter and the surfaceof the partition lining board is important, althoughmechanically fixed perimeters are not essential.Ceilings with recessed light fittings may be lesseffective and if these cannot be sealed in some way,the installation of cloaking angles at the partitionhead should be considered. A suspended ceiling mayalso reduce the level of sound flanking transmissionvia the soffit.Fire resistance118 Follow closely British Gypsum’s installationinstructions as deviations can negate any fireperformance, e.g. plasterboard must be fullyscrew-fixed to framing supports Cut boards to a neat fit, avoiding any gapsIf small gaps do occur, they must be backed by aframing member and filled with appropriate jointingmaterial or skim plastered. Tape and fill joints, or skim plaster plasterboard toachieve fire performance Fire-stop joints, junctions, penetrations, etc. tomaintain integrity Keep penetrations to a minimum Avoid back-to-back socketsThermal performanceSeal lining perimeters and penetrations, etc. to avoidair leakage. Consider the use of Gyproc SoundcoatPlus on block external wall construction to reduce airleakage.Robustness - partition duty ratingsAll British Gypsum partition systems have a dutyrating established in accordance with all therequirements of BS 5234. This rating relates to thestrength and robustness characteristics of the partitionsystem against specific end use applications. Table 3gives details of the four duty categories.

Table 3 - Duty ratingsPartition CategoryDutyExamplesLightAdjacent space only accessibleto persons with high incentiveto exercise care. Small chance ofaccident occuring or misuse.DomesticaccommodationMediumAdjacent space moderately used,primarily by persons with someincentive to exercise care. Somechance of accident occuring ormisuse.OfficeaccommodationHeavyAdjacent space frequently used byt

d15 GypLyner ENCASE - GypLyner framed structural steel encasement system 396 9 Plaster systems 408 Plaster systems 408 c10 b05 d12. 6 british-gypsum.com 1 General site guidance - Health and Safety 1 General site guidance 7 Health and Safety 8 Board fixing 11 Good practice detailing 15