Unit 5 Plaster Plasterboard Compressed Cement Products and Insulation

CPCCBC4006A Select, Procure and Store Construction Materials for Low-rise Projects
Unit 5
Plaster,
plasterboard,
compressed
cement products
and insulation
Building and Construction Sections Riverina Institute Version 1 2009 Revise 2010 0
Plaster, plasterboard, compressed cement products

and insulation
In previous sections in this Unit, building materials were divided
according to their nature of origin (eg. clay products). Because both wall
and ceiling linings and insulation materials can comprise any number of
different base materials or combinations of materials, it seems more
logical, in this case, to approach this section differently according to the
function which the materials perform, rather than the nature of the raw
material.
This section, therefore, is divided into two areas: the first deals with wall
and ceiling linings and the second with insulation.
Reference web sites

CSR Products for Gyprock and CSR Fibre Cement and Bradford
insulation
www.csr.com.au/
BORAL for plasterboard and plaster products

www.boral.com.au/
Wall and ceiling linings

The terms wall lining and ceiling lining refer to the internal wall and
ceiling covering of the building as opposed to cladding which refers to
the external wall covering or, sometimes, roof covering. Additionally, in
this section, wall and ceiling lining are defined as being distinct from
finishes (such as ceramic tiles, wallpapers and paints) which are usually
applied to the wall or ceiling lining.
The most common forms of wall lining used in Australia are gypsum
plasterboard, fibrous cement, timber or composite lining boards or
sheets, plastic coated wall sheeting and solid plaster.
1 Building and Construction Sections Riverina Institute Version 1 2009 Revise 2010
Timber and composite lining boards and sheets are covered in Section 2.
Timber and plastic coated wall sheeting is mentioned in Section 9. In
this section, we will concentrate on the other alternatives.
Plaster
The term plaster refers to a jointless and usually smooth lining applied
to the base wall or ceiling structure.
Solid plaster was one of the first lining materials to be used in buildings.
The plaster which was made of lime and sand, often with hair included,
was applied in situ to the masonry wall or, in the case of a timber stud
wall or ceiling, to timber laths which are thin battens fixed close together
to provide a base.
Today, solid or in situ plaster is reserved for solid masonry walls; timber
stud walls are lined with plasterboard. However, in situ plastering is a
wet and messy process and often internal masonry is left unplastered
(face brickwork, for example).
Composition
Plaster comprises a binder, clean sand and fresh water, which sets to a
comparatively hard, dense layer. The properties of the final product
depend largely on the type and quantity of the binder used.
The binders most commonly used in Australia are gypsum plaster,

Portland cement and lime (either quicklime or hydrated lime-refer to
Section 5) or organic binders.
Gypsum plaster
Calcium sulphate or gypsum plaster can be used for undercoats and
finishing coats. (Plaster of Paris is one type of gypsum plaster.) It is
derived from naturally occurring gypsum rock which has been pulverised
and heated to drive off most of the chemically combined water, resulting
in a white, pink or grey powder. When water is added to gypsum plaster
it sets and hardens into a crystalline solid, giving off heat and expanding
slightly in setting.
Two other similar binders are derived from gypsum plaster: hard wall
plasters which provide a harder finish and Keenes cement, which is the
hardest of the gypsum plaster mixes.
Portland cement
Portland cement is sometimes used as a binder in undercoats and
finishing coats where an exceptionally hard surface is required. Drying
which is too rapid increases the likelihood of cracking, and shrinkage
must be substantially complete before a further coat is applied.
Limes
Plasters in which limes are the only binders are rarely used today as the
final strength is very low.
Workability agents or plasticisers, based on non-hydraulic lime or organic

materials, are used to improve the workability of the mix and distribute
shrinkage stresses, thus reducing visible cracking.
Process
The process of applying solid plaster to a base structure is known as
rendering. Solid plasters are usually applied in two coats. The
undercoat is often referred to as the scratch coat and the finishing coat
as the set coat.
If the base is particularly smooth and the suction uniform, a single coat
only may be required; alternatively, a particularly irregular base may
require three coats.
In some applications the coats may not be of the same composition but it
is important that each coat be well matured before another coat is
applied, especially if cement is used. A general principle to be followed
is that each successive coat should be weaker than the preceding one.
The choice of a plastering system depends upon the base to which the
plaster is to be applied, the performance of the required finish and the
texture desired.
Cement-sand or cement-lime plasters are moisture-resistant plasters,

while gypsum-based plasters should be used internally in dry situations
only.
Mixes containing Portland cement make the hardest plasters, and have
the greatest resistance to impact damage. Keenes plaster is the hardest
of the gypsum plasters, while lime plaster is the softest. Table 1 and
Table 2 indicate suitable plaster mixes for two and three-coat internal plasterwork.
Finishing coat Undercoats (by volume)
Cement setting 1 cement
4 to 5 sand
1
/10 lime
Cement: lime: sand 1 cement
Gypsum plasters 5 to 7 sand
1
/10 lime
Gypsum plasters 1 plaster
2 to 3 sand
(or 1 : 3 to 1 : 4 by weight)
1 gypsum plaster:
1 sand: 1/10 lime
(or 1 : 2 by weight, plus lime 5% of
weight of plaster)
Table 1: Mixes for undercoats for internal two-coat and three-coat
work
Background or Finishing coats (by volume)

undercoat
Brick, block, or concrete 1 cement
4 sand
1
/10 lime
Cement: sand 1 cement
1 lime
5 sand
Cement: lime: sand 1 cement
1 to 2 lime
6 to 9 sand
Concrete background 1 lime
Cement: lime: sand to 4 gypsum plaster
(undercoat)
Gypsum plaster
Table 2: Mixes for finishing coats for internal work
Preparation
Porous bases, such as clay bricks and concrete blocks, which have a
comparatively high suction rarely require much preparation other than
raking of the joints and the removal of loose material.
Smooth, dense materials, such as concrete, have little suction and offer
no mechanical key and are either hacked or else treated with a spatter-
dish, sand-cement mix, often including a PVA adhesive, to provide a key.
Rough textured surfaces, such as rough concrete, provide a good

mechanical key and require little preparation.
Fibrous plaster
Fibrous plaster is made of gypsum plaster reinforced with sisal hemp
fibre. Nowadays it has been replaced by plasterboard for sheeting
applications but is still used for the more complicated decorative
mouldings.
Fibrous plaster is dimensionally stable and easily decorated but is not

satisfactory in moist conditions.
Gypsum plasterboard
Plasterboard is the most commonly used lining for timber-framed
construction and brick veneer. It comprises a core of gypsum plaster
reinforced with two outside layers of kraft paper, one on each face.
Some are available with an aluminium foil on the back which improves
thermal insulation performance.
Plasterboards are easily decorated and are reasonably tough and strong
in normal grades but are not satisfactory in damp situations. A water-
resistant board is available which is designed to be used in areas where
high humidity persists and in wet situations where they are protected with
tiles or a similar impervious material.
Sizes
Sheets are available in a broad range of sizes. Thicknesses commonly
used in domestic applications are 10 mm for walls and 13 mm for
ceilings. However, a 10 mm thick board is now available for ceilings
also.
Fixing
The boards are fixed to the studs or ceiling joists by gluing or nailing with
special flat-headed nails. Boards are available with either square or
recessed edges, the latter being used where a flush surface is required.
For a flush joint, a strip of perforated reinforcing paper is embedded in
bedding compound in the recess and the area is covered with a topping
cement (refer to Figure 1).
Figure 1: Joint for plasterboard with recessed edges
General properties of plaster and plasterboards

Thermal insulation
Plaster linings are relatively thin and make a correspondingly small
contribution to the thermal insulation of a building.
Fire resistance
Normal plasters are non-combustible, have no spread of flame and do
not produce smoke. Special fire-rated plasterboards are available for
applications which require a fire rating.
Often, the addition of a specified thickness of plaster or render on
internal masonry walls is used to achieve a required fire rating according
to the Building Code of Australia.
Sound absorption
Ordinary plasters have fairly low sound absorption values but special
acoustic plasters and plasterboards are available.
Sound insulation
As plaster linings are relatively thin, they contribute significant sound
insulation to lightweight components only. However, plaster can improve
sound insulation by sealing the surface to porous base structures.
Hardness
In housing, a fairly soft finish may be preferred but harder surfaces are
often required in public buildings and the choice of system should take
this into account. Metal angles are used to protect vulnerable corners
and provide a line for the plasterer to work to (refer to Figure 2).
Figure 2: Expanded metal reinforcement used at external

plasterboard corners
Durability
Gypsum-based products are not usually waterproof and the durability of
the finish depends largely on the composition of the plaster.
Texture
Smooth-trowelled surfaces comprising either neat gypsum or gypsum
with admixtures are most common but texture can be provided by special
trowelling or by including sand in the finish. Bagged finishes are
popular on masonry walls. These comprise a thin sand-cement mix
which is wiped over the wall surface with a piece of heshian. The
resultant thin coat allows the form of the masonry units to show through.
Plasterboard
This guide provides detailed installation information for the fixing of
Gyprock plasterboards in residential construction including wet area
applications.
For additional information or assistance with plasterboard fixing.
please contact the CSR Gyprock office in your region.
Description
GYPROCK plasterboard is a machine made sheet composed of a
gypsum core encased in a heavy duty linerboard. The linerboard is
folded around the long edges to reinforce and protect the core. The
board ends are cut square. GYPROCK plasterboard conforms with
manufacturing standard AS/NZS2588 Gypsum Plasterboard.
Applications
GYPROCK plasterboard is used as an internal lining board to provide
smooth, strong, long-lasting walls and ceilings for homes, offices,
hospitals, hostels for the aged, schools, shops and factories. Its
durable surface will accept most types of decorative finishing, including
paint, wallpaper and texture compounds.
Joints between GYPROCK plasterboard sheets are reinforced and
concealed to provide a smooth, durable finish to the whole surface.
Alternatively, the joints may be covered with a decorative moulding.
Standard GYPROCK plasterboard or GYPROCK AQUACHEK can be
used for exterior ceilings and eaves lining, provided the ceilings are
protected from the weather.
GYPROCK FLAMECHEK MR plasterboard is fire and moisture
resistant. When used in wet areas, installation is in accordance
with the Wet Area Installation section of this guide. When used in fire
risk areas, installation is in accordance with the General Installation
section of this guide.
Advantages
Strength and Stability
GYPROCK plasterboard is a stable building product when subjected

to the normal range of ambient temperatures and humidity.
Thermal coefficient of expansion is 16.2 x 10 -6/C in the temperature
range 4C to 38C.
H y g r o m e t r i c co e ff i c i e n t o f e xp a n s i o n i s : 7.2 x 10 6mm/mm/%
R.H. (5%-90% R.H.).
Thermal Resistance R
10mm thickness = 0.062 m 2k/w.
13mm thickness = 0.074 m 2k/w.
16mm thickness = 0.08 6 m 2k/w.
STANDARDS.
The entire range of Gyprock plasterboards, as referenced in this
technical literature, comply with following standards.
Plasterboard Manufacture.
AS/NZS2588 Gypsum Plasterboard. Plasterboard
Installation.
AS/NZS2589 Gypsum linings in residential and light commercial
construction Application and Finishing.
Plasterboard In Wet Areas.

AS3740 Waterproofing of Wet Areas Within Residential Buildings.
CD TECHNOLOGY.
Controlled Density (CD) technology is a unique manufacturing
process which manipulates the core structure of plasterboard. This
creates greater strength, lighter weight and superior paper to core
bonding, meaning easier handling, better cutting, and a better
quality plasterboard. CD Technology is used in the manufacture of
10mm and 13mm Recessed Edge G Y P R O C K p l a s t e r b o a r d ,
1 0 m m G Y P R O C K S U PA C E I L , 1 0 m m a n d 1 3 m m S q u a r e
Edge GYPROCK plasterboard, and most GYPROCK
plasterboard ceiling panels.
ARCHITECTURAL SPECIFICATION
SCOPE
The contractor shall furnish all materials, labour and equipment

required to satisfactorily complete the installation and jointing of all
Gyprock Plasterboard where indicated on the drawings and/or as
specified.
DELIVERY & STORAGE OF MATERIALS.

All materials shall be delivered and stored in an enclosed shelter
providing protection from damage and exposure to the elements.
Damaged or deteriorated materials shall be removed from the

premises.
MATERIALS.
All lining materials shall be GYPROCK plasterboards,
adhesives, fasteners and jointing products as manufactured or
supplied by CSR Gyprock.
Non-loadbearing metal wall components and ceiling components
shall be those manufactured by Rondo Building Services Pty. Ltd
(or products of equivalent or better performance).
FRAMING OR SUBSTRATE.
All framing shall be prepared to *Level Finish specifications as
detailed in the Gyprock Plasterboard Residential Installation Guide,
NGYP547, and AS/NZS 2589.1 Gypsum linings in residential and
light commercial construction Application and Finishing.
Framing must also conform to structural standards specified by the
appropriate building authorities and/or Australian Standard.
PLASTERBOARD INSTALLATION.
The framing shall be lined on the first side with * layer(s) of mm

Gyprock.........plasterboard.
The framing shall be lined on the second side with * layer(s) of
.......mm Gyprock.............plasterboard.
PLASTERBOARD FIXING AND JOINTING.
Gyprock plasterboard shall be fixed, jointed and finished to a

*Level Finish as detailed in the Gyprock Plasterboard Residential
Installation Guide, NGYP547, and AS/NZS 2589.1 Gypsum linings
in residential and light commercial construction Application and
Finishing.
* Insert or select appropriate specification.
Gyprock Plasterboard Range.

TABLE 1. GYPROCK PLASTERBOARD AVAILABILITY.
Colour shading behind each product approximates the colour of the
product face liner sheets
Mass
Thickness Width Sheet Length (mm)
GYPROCK Product kg/m2
mm mm 2400 2700 3000 3600 4200 4800 5400 6000
1200 W W W W W W W W
10 6.5
1350 W W W W W W
CD
900 *WSN W W
RECESSED EDGE
13 1200 SN W SN WSN 8.5
1350 SN W
10 1200 W SN WSN W 6.5
CD SQUARE EDGE
13 1200 SN SN 8.5
900 W W W W
SUPACEIL TM
10 1200 SN W 7.2
A
1350 W
10 1350 9.3
SOUNDCHEKTM
13 1200 13.0
1200 SN
TM
10 8.0
AQUACHEK 1350 SN SN WSN SN WSN
13 1200 W W 10.4
TM
IMPACTCHEK 13 1200 10.3
TM
BRACECHEK 10 1200 8.4
FLEXIBLE 6.5 1200 4.25
TM
FLAMECHEK MR 10 1350 8.0
13 1200 W 10.5
FYRCHEKTM
16 1200 SN W 12.5
13 1200 WSN SN 10.7

FYRCHEKTM MR
16 1200 WSN
W
SN 13.5
PERFORATED SHEET 13 1200 10.0
SHAFT LINER PANEL 25 600 19.8
55

0.68kg/m
COVE CORNICE 75 W W W W 0 .93kg/m
90 1 .3kg/m
CLASSIC CORNICE 90 1.2kg/m
TEMPO CORNICE 90 1 .6kg/m
SYMPHONY CORNICE 75 0.90kg/m
CONCERTO CORNICE 90 1 .4kg/m
Indicates available in: = Australia wide; W = Western Aust.; S = South Aust.; N = Northern
Territory. Indicates NOT available in: W = Western Aust.; S = South Aust.; N = Northern
Territory.
* = Length is 2740. = 3300 and 3900mm lengths also available in WA only.
In Western Australia only, additional Recessed Edge/Square Edge products are available.
Gyprock Plasterboard Range.

GYPROCK Plasterboard CD
Recessed Edge.
Features.
1 .5mm recess on face side allows formation of shallow channel for
joint reinforcement.
Provides smooth. even and continuous surface once jointed.
10mm and 13mm thickness.
Manufactured to the requirements specified in AS2588 : 1998
Gypsum Plasterboard.
Manufactured with CD technology. Applications.
Internal walls and ceilings.
GYPROCK Plasterboard CD
Square Edge.
Features
Manufactured with CD technology. Square Edge Finishing.
The square edge allows sheets to be butted together neatly.
These joints may be covered with aluminium, vinyl or timber
mouldings.
Bevelled Edge Finishing.
Edges are slightly bevelled.
Edges are butted together to form a neat V-joint.
Joints do not need to be covered with battens or finished with
compounds.
Applications.
Internal walls.
Usually commercial construction, especially for office partitioning.
Aquacheck
Features.
Specially processed plasterboard.
Both the core and linerboard facing are treated in manufacture to
withstand the effects of moisture and high humidity.
Manufactured to the requirements specified in American Society for
Testing and Materials C630.
For use as a wall and ceiling lining in wet areas and high moisture
areas in residential and commercial applications.
Recessed edges allow flush jointing to Recessed Edge Plasterboard.
Applications.
GYPROCK AQUACHEK is a suitable substrate for ceramic tiles.
Usage areas include bathrooms, kitchens, laundries. garages and
ceiling applications such as walkways and verandahs.

The GYPROCK AQUACHEK Wet Area Lining System is suitable for
Category 1 Wet Areas (ie. shower recesses and bath installations as
defined in AS3740).
Soundcheck
Features.
Designed to provide enhanced acoustic resistance in wall and
ceiling systems.
A machine made sheet composed of a high density gypsum core
encased in a heavy duty linerboard.
Long edges are recessed to assist in producing a smooth, even
and continuous surface once jointed.
10mm and 13mm thickness.
Bracecheck
Features.
A 10mm thickness high strength plasterboard designed for bracing
applications.
A machine made sheet composed of a high density gypsum core
reinforced with cellulose and glass fibre, encased in a heavy duty green
coloured linerboard.
Long edges are recessed to assist in producing a smooth, even
and continuous surface once jointed.
Flexible Plasterboard
Features.
6.5mm thickness plasterboard with an enhanced core to allow

bending to small radii.
Designed for installation as a two layer system.
Long edges are recessed on the face side to assist in producing a
smooth, even and continuous surface once jointed.
Manufactured to the requirements specified in AS2588
Manufactured with CD technology.

Applications.
Curved internal walls and ceilings
Impactcheck
Features.
10mm thickness plasterboard reinforced with a woven fibreglass

mesh.
High strength to resist soft body impact damage.
Long edges are recessed on the face side to assist in producing a
smooth, even and continuous surface once jointed.
Violet coloured face linerboard for easy identification.
Applications.
High traffic areas such as hallways, stairways, playrooms and garages.
Flamecheck
Features
Fire and moisture resistant plasterboard.

10mm thickness with recessed edges for flush jointing.
Blue coloured face linerboard for easy identification.
For use as a wall and ceiling lining in wet areas and areas of high fire
risk.
Applications
Usage areas include kitchens, bathrooms, laundries. garages.
GYPROCK FLAMECHEK MR is suitable for Category 1 Wet Areas (ie.
shower recesses and bath installations as defined in AS3740) and as a
substrate for tiling.
Cornice
Features
Cove Cornice in 55 and 90mm is available in all states. 75mm cove

is available in W.A. and Victoria ONLY.
Classic Cornice and Tempo Cornice are 90mm decorative profiles,
and are available in all states.
Gyprock Cornices are supplied in a range of lengths from 3000mm
to 5400m.
Applications.
Provides an attractive finish to the junction of the walls and ceilings.
Can be used on a variety of surfaces, including: GYPROCK
Plasterboard, plasterglass, cement render, masonry.
A necessary part to some fire-rated ceilings.
Handling & Storage.
All materials must be kept dry, preferably by being stored inside the
building. Care should be taken to avoid sagging or damage to edges,
ends and surfaces.
All GYPROCK plasterboard should be stacked flat, properly
supported on a level platform or on support members which extend
the full width of the sheets and which are spaced at maximum 600mm
centres.
If stored outside, sheets are to be stored off the ground, stacked as

previously detailed and protected from the weather.
Design Considerations.
Levels of finish
Levels of finish are defined in the Australian/New Zealand Standard

AS/NZS 2589.1 : 1997 Gypsum linings in residential and light
commercial construction Application and Finishing. This standard is
intended to provide builders, plasterboard installers and finishers, and
their customers with the various defined methods and practices
necessary to meet the customers expectations in terms of the
Level of Finish.
Six Levels of Finish (0, 1, 2, 3, 4 and 5) are defined, and minimum
specifications to achieve each level of finish are detailed in the
standard for each of the installation processes from framing
preparation to finishing.
It is essential to determine the level of finish required before the frame
construction begins as specific tolerances are required for frame
alignment as well as plasterboard fixing and finishing for each of the
levels of finish.
Unless these requirements are met throughout construction, it may
not be possible to attain the desired finish level without extensive
corrective measures.
The level of finish specified also affects the methods of jointing,

particularly butt joints and back-blocking requirements, the number of
coats of joint compound applied as well as the fitting and finishing of

stopping and corner accessories.
It should be noted that, generally, domestic applications should

be prepared to a minimum Level 4 Finish unless specifically a higher
or lower level of finish is agreed to by all contracting parties.
ROOF SPACE VENTILATION.
GYPROCK plasterboard will give many years of satisfactory

performance under a wide range of climatic conditions, but to ensure
long term performance to both lining material and paint finishes, the
roof spaces should be adequately ventilated. A failure to do so may
result in the plasterboard sagging, or the excessive moisture
movement of the timber framing causing nail popping or joint
deformation.
The aluminium foil sarking on roofs should be installed in
accordance with the relevant Australian Standards for reflective foil
laminates.
Condensation within a building is the result of a temperature

difference from one side of a building element to the other. The
temperature differential forces water vapour contained in the warmer
air to flow towards the cooler region where it condenses on any
surface below the dew point temperature of the air.
Vapour barriers are incorporated into the structure to prevent the

flow of water vapour from the warm to the cool regions. As a general
rule, locate the vapour barrier as close as possible to the surface
which will normally be at the higher temperature at the time of the

condensation hazard.
Attics or similar unheated spaces above ceilings can be adequately

ventilated as follows:
Provide effective cross-ventilation for all spaces between roof and
top floor ceilings by screened louvres or other approved and
acceptable means.
Ratio of total net free ventilating area to area of ceiling shall not
be less than 1/150.
In rooms such as bathrooms, kitchens, and laundries, moisture laden

air should be exhausted to the outside of the building, not in to the roof
space.
Roof space ventilation
FIRE RESISTANCE.
All Gyprock plasterboard is fire
resistant to some degree. Gyprock FlamechekMR TM, however, has
been formulated to have even greater performance than standard
board. In comparison to 10mm Gyprock plasterboard CD,
FlamechekMR TM was found to be up to 50% better at resisting the
effects of fire on walls and ceilings where there were no penetrations
or openings. In any case, penetrations and openings can reduce the
fire resistance of a system.
Smoke alarms save lives and CSR Gyprock recommends that
suitable alarms be installed. Fire extinguishers and fire blankets
should also be accessible.
Gyprock FlamechekMR TM cannot be used as a substitute for

Fyrchek. Systems with Fire Resistance Levels incorporating Gyprock
FyrchekTM plasterboard are presented in the Gyprock Fire & Acoustic
Design Guide.
Control Joints
Movement and stresses created by temperature and humidity
fluctuation, can result in deformation and damage to internal linings
and partitions.
It is recommended that GYPROCK plasterboard surfaces be isolated
from structural elements, except the floor, by the use of control joints
or other means where:
A GYPROCK plasterboard surface abuts any structural
element or dissimilar wall or ceiling assembly
The construction changes within the plane of the partition, wall or

ceiling lining
Control joints incorporated in a building to permit movement in the
structure must be carried through all areas lined with GYPROCK
plasterboard.
Refer to page 25 for installation details.
LIGHTING.
Any imperfection in a completed lining installation will be made

obvious by a condition called critical lighting or glancing light, where
the incident light from an artificial or natural light source is nearly
parallel to the surface. Glancing light also greatly exaggerates the

size of imperfections making them glaringly obvious.
Ways to minimise the effect of critical lighting from artificial lighting
sources are:
Locate fluorescent lights about 450mm below the ceiling as this

will give a more even distribution of light.
Use more rather than fewer lights and install at regular spacings
to give a more even, diffused light and to minimise the shadows
that can occur from a single row or single light source.
Recess light fittings into a ceiling (although recessed lights are more
likely to be associated with glare problems).
Allow a generous angle of incidence to the surface for feature
lighting such as spotlights, to minimise the highlighting of
imperfections.
Do not locate a single or isolated unshaded light source close to a
wall or ceiling in a space which has generally low levels of light.
Do not use uplights, wall-washers and spotlights in areas with a

smooth wall finish to eliminate light being emitted at a glancing
angle to the surface.
Design soft rather than harsh lighting conditions.
Ways to minimise natural lighting problems, particularly from
direct sunlight, are:
Do not take window glazing right up to the ceiling level.
Avoid placing windows immediately adjacent to the end of a wall.

Provide sun shades over the window.
Recess the window to stop the sunlight reaching the wall.
HEATING.
The following situations may give rise to localised high temperature

conditions (45) which may be detrimental to wall and ceiling
linings:
Radiant ceiling heaters,
Heat pumps,
Reverse cycle air conditioners,
Solid fuel stoves.
Refer to heating unit manufacturer for more information.
APPLIED FINISH SELECTION.
Finishes applied to the GYPROCK plasterboard can have a significant

effect on the perceived quality of the installation, particularly where
critical lighting conditions exist.
General rules when selecting the applied finish are:
The diff ere nce in textur e and absorption characteristic

between the body of the sheet and the joint may show through
some thin paint coatings.
Imperfections show more readily on ceilings than on walls.
Textured or heavy patterned finishes tend to hide imperfections.

Matt finishes minimise imperfection visibility.
S e m i - g l o s s a n d g l o s s f in i s h e s h i g h l i gh t imperfections.
Lighter colours (when compared to darker colours) are:
Less likely to show imperfections and impact damage.

More effective at diffusing the light and reducing shadow effects,
particularly in smaller rooms.
Gloss paints tend to highlight paint application variations (e.g.
where a good wet edge has not been maintained when painting).
Paint or thin wallpaper finishes are less tolerant of imperfections.

Paint applied with a longer pile roller tends to mask imperfections
better than those applied with a short pile roller.
Garage Ceilings
Ceilings in garages are subjected to different environmental

conditions to those in habitable rooms. The following conditions may
occur:
Wind loads can disrupt uncured adhesive and prevent an

effective adhesive bond from ever forming.
Door operation may induce vibration in ceiling framing,
adversely affecting nailed joints and disrupting adhesive bond.
Framing that changes direction in the garage may result in
insufficient perimeter support for the plasterboard.
Moisture and high humidity in the garage can result in poor joint
performance.
The above issues can also result in the poor performance of

any installed cornice.
While the performance expectations for garage ceilings remain

the same as for internal ceilings, additional details are required
to ensure this performance is achieved.
Use the 1/3 spacing method of fixing plasterboard, as detailed in
this manual.
Use screws not nails to fix ceilings.

Use trimmers across the sheet width for support (refer to FIG 1).
Back-block all joints in garage ceilings.
Use a good quality wallboard sealer and two coats of paint.
In areas of high humidity, use Gyprock Wet Area Base Coat in the
jointing system.
Fibrous cement
Fibrous cement sheeting has replaced asbestos cement as a lining and
cladding material due to the health hazards associated with materials
containing asbestos.
Composition
Fibrous cement is made from a mixture of Portland cement, sand,
cellulose fibre and water, compressed into sheets, boards or other
shapes.
Sizes
Sheets are available in a number of sizes. Thicknesses for domestic use

are generally as follows:
as lining material for eaves, verandahs or carports 4.5 mm or 6
mm sheet
for internal wall and ceiling linings 6 mm
compressed fibrous cement for wet area floors 15 mm or 18 mm
thick.
Fixing
Sheets can be glued or fixed with special galvanised flat-head fibrous
cement nails to timber frames. Sheet ends can be covered with PVC
end caps while joints can be covered with PVC sheet holders or fibre
cement cover moulds (refer to Figure 3).
Figure 3: PVC end and Caps cover and Junction moulds
Exposed internal linings can be flush jointed. Special recessed-edge

sheets are taped with a perforated paper reinforcing tape and finished in
a similar way to plasterboard sheets, with a topping cement.
Uses
Externally, fibrous cement products can be used as cladding in the form

of boards, sheets or shingles. However, internally, because they are
waterproof, fibrous cement sheets are used primarily as a base lining for
other finishes (such as tiles) in wet areas. Compressed fibrous cement
sheeting is also used as a base floor material for ceramic tile floors in
wet areas.
General properties
Thermal insulation
Fibrous cement sheets are relatively thin and make a correspondingly
small contribution to the thermal insulation of the building.
Fire resistance
Fibrous cement products will not burn, have a zero spread of flame
index and do not produce smoke.
Sound absorption
Unless special acoustic material is used, fibrous cement lining
contributes little to the sound absorption characteristics of a room.
Sound insulation
The sheets have a greater density than plasterboard but are thinner and
therefore do not significantly affect sound insulation.
Hardness
Care should be taken during handling and storage to prevent edges from
chipping since the material is particularly brittle. When painted or
otherwise finished, however, a hard surface finish can be obtained.
Durability
Fibrous cement sheets are unaffected by sunlight, moisture or termites
and should not split or rot. Hence its suitability for external and wet area
applications.
Thermal insulation
The question of thermal insulation really forms part of the problem of
energy efficient design of the building as a whole, which includes
consideration of the following points:
orientation of the building to maximise the use of solar energy (refer

to Figure 4)
location in relation to summer breezes (refer to )
protection from winter winds (refer to )
location and treatment of windows (refer to Figure 7)
use of wide eaves or pergolas which shade windows and walls from
summer sun but allow entry of winter sun (refer to Figure 8)
use of solar energy in the design to heat floors or walls (refer to
Figure 9)
interior planning (refer to )
prevention of heat loss through unnecessary gaps (refer to )
design of floors (refer to )
the colour of the exterior of the house.
Figure 4: Paths of the sun in winter and summer
Figure 5: Location in relation to summer breezes
Figure 6: Protection from winter winds
Figure 7: Location and treatment of windows
Figure 8: The use of wide eaves or pergolas
Figure 9: The use of solar energy to heat floors or walls
Figure 10: Interior planning
Figure 11: Prevention of heat loss through unnecessary gaps
Figure 12: Prevention of heat loss through the floor by enclosing

the sub-floor space
Thermal insulation can assist by improving the thermal efficiency of the

structural components of the house by reducing heat loss or gain through
the major surfaces, such as the walls and ceilings.
Heat transfer
Heat is transferred by:
conduction-heat is led from the side of the material at a higher
temperature to the side at a lower temperature
convection-when air is heated it expands and begins to circulate and
heat up colder surfaces by losing some of its heat to them
radiation-when air comes in contact with a warm object, heat is

transferred to the atmosphere.
Thermal resistance
A materials ability to resist the flow of heat is called its thermal
resistance or R-value. The higher the R-value of a material, the greater
its ability to resist the flow of heat.
The Energy Authority of NSW provides data on recommended R-values

for different areas in NSW. For instance, if you live in Coffs Harbour the
recommended minimum level of thermal insulation is R1.5 but if you live
in Cooma, which is colder, the recommended minimum level is R3.0
(refer to ).
Figure 13: Thermal insulation levels for NSW
The heat flow through a wall or ceiling is not reduced in direct proportion
to the R-value of any insulation added above the recommended level. In
fact the extra benefit to be gained diminishes fairly rapidly beyond this
level.
Thus, there is not much point in installing insulation to a value beyond

the recommended R-value for your area.
Required R-values in New South Wales

Recent amendments to the BCA have included requirements for the
inclusion of insulation in roofs, walls and under elevated floors. The
requirement depends on the location of the building.
New South Wales is divided into 4 zones and shown in on the next
page. The R-values that need to be achieved under the deemed-to-
comply provisions are given in Part 3.12 Energy Efficiency of Volume 2 of
the BCA 2008.
Figure 14: Climate zones in Australia

(reproduced from BCA Zone Map)
Types of insulation
Reflective
This type of insulation uses the heat-reflective properties of aluminium

foil which prevents heat transfer by radiation. The following types are
available:
Foil laminated to reinforcing membranes, supplied in rolls of varying
widths. This is used for roof sarking and wall sheathing.
Laminated foil layers separated by partition strips. When the foil is
installed over ceiling joists, the partition strips separate the two
layers and provide an additional air space to increase the
effectiveness by decreasing conduction.
Foil laminated to bulk insulation.
Foil-backed plasterboard.
Solar reflective film which can be applied directly to glass panes.
Metal reflective-treated fabrics for blinds, curtains and so on.
Bulk
This is normally a cellular material with entrapped air bubbles which slow
down heat transfer by conduction. Several forms are available.
Batts and blankets
Insulation batts and blankets are available in various materials as listed

on the next page.
Insulation batts and blankets are available in:

Mineral wool (fibreglass or rockwool) manufactured from
inorganic raw materials that are melted at above 1000C and spun
into fibres which are then bonded together to form flexible sheets.
Urethane foam sheet made from foamed polyurethane.
Expanded polystyrene sheet (EPS) made from foamed
polystyrene.
Loose fill
Loose fill insulation is available in:
Cellulose fibre manufactured from waste paper.
Exfoliated vermiculite manufactured from a micaceous material.
Mineral wool manufactured as explained above.
In-situ foam
In-situ foam insulation is available in:
Urea formaldehyde pumped in as a mixture of chemicals using
special equipment. The mixture foams up in situ and forms a rigid
foam filled area.
Urethane foam pumped as fluid foam into the space where it sets
chemically to form a rigid insulation.
Expanded polystyrene beads mixed on site with a bonding agent
and injected into the cavity.
Structural and decorative insulation

This type of insulation comprises a complete wall or ceiling lining system
combining thermal insulation and often acoustic modification with a
decorative lining.
Several forms are available:

Fibreglass panels laminated with decorative finishes.
Wood wool panels decorative boards made from wood straw
bonded with a cement-like adhesive.
Compressed straw panels manufactured from pine or straw
fibres which are compressed and bonded together.
Expanded polystyrene as above with decorative finishes.
General properties of insulation materials

Thermal performance
The type and thickness of the insulation is selected according to the
required R-value and the application. The R-value should be marked on
the product and manufacturers product information should comply with
SAA Standards and Test Methods.
Insulation products should be installed as specified by the manufacturer

to be most effective. For example, reflective foil used as insulation in
horizontal applications should be laid face down as settling dust renders
the upper face (usually coloured blue) ineffective.
Acoustics
Some insulation will also contribute to the acoustic performance of the
room, especially in the case of some of the decorative panels.
Fire resistance
Some insulation materials are combustible. Combustible insulation
should be covered with an appropriate non-combustible lining such as
gypsum plasterboard. Urethane foam, expanded polystyrene and
cellulose fibre insulation must contain fire-retardant chemicals.
Safety
Most bulk insulation materials should be handled with care to avoid dust
formation.
Gloves and long clothes should be worn when installing fibreglass to

avoid contact with glass fibres, which may irritate the skin. In all cases it
is advisable to wear a mask covering the mouth and the nose.
Suitability
The type of construction will limit your choice of insulation system.
For instance,
Loose-fill insulation is generally only suitable on flat surfaces.
Loose-fill insulation is good for difficult corners.
In situ insulation may make access to the roof space extremely difficult.
Where to insulate
For the minimum requirements, refer to Part 3.12 Energy Efficiency
of Volume 2 of the BCA 2008.
Because heat rises, most heat loss occurs through the ceiling. Figure 15
illustrates the proportion of heat loss through various paths for a typical
uninsulated detached brick veneer dwelling in Canberra.
(Note that the figures given have been calculated specifically for the
Canberra region and may not apply to other areas although the general
pattern these figures reveal would apply for this type of construction
elsewhere.)
Figure 15: Heat loss through a building
Although the percentage figure for heat loss through the walls is the
highest, in terms of unit area the diagram suggests that (for this type of
construction) the greatest heat losses are in fact through the ceiling and,
next, the floor. Consequently, the first place to consider insulating is
above the ceiling (refer to Figure 16).
Figure 16: Insulation above the ceiling

If the floor is a raised timber floor the sub-floor space should be
enclosed, allowing for the required ventilation, and bulk insulation can be
supported between the joists or reflective foil can be placed over the
joists (refer to Figure 17).
Figure 17: Insulation below the floor
In extremely cold climates rigid foam insulation around the edges of the
slab is advantageous (refer to Figure 18).
Figure 18: Insulation around the edges of the slab
In timber walls bulk insulation can be placed between studs (refer to

Figure 19).
Figure 19: Insulation between the studs
Foam in-situ insulation can significantly increase the thermal

performance of cavity brick walls (refer to Figure 20).
Figure 20: Insulation between walls
The thermal performance of windows can be increased dramatically with

double glazing or even triple glazing in extremely cold climates. Another
solution is to use full length drapes with pelmets will also greatly reduce
heat loss.
Figure 21: Drapes and pelmets

Although materials can be introduced to improve the thermal
performance of the building, total energy efficiency requires attention to
the design of the building as a whole. Some of the aspects which
deserve attention, mainly those which can be easily attended to, have
been touched upon in this section.

Unit 5 Plaster Plasterboard Compressed Cement Products and Insulation

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CPCCBC4006A Select, Procure and Store Construction Materials for Low-rise Projects

Plaster, plasterboard, compressed cement products

Reference web sites

BORAL for plasterboard and plaster products

Wall and ceiling linings

The binders most commonly used in Australia are gypsum plaster,

Workability agents or plasticisers, based on non-hydraulic lime or organic

Cement-sand or cement-lime plasters are moisture-resistant plasters,

Background or Finishing coats (by volume)

Rough textured surfaces, such as rough concrete, provide a good

Fibrous plaster is dimensionally stable and easily decorated but is not

Figure 1: Joint for plasterboard with recessed edges

General properties of plaster and plasterboards

Figure 2: Expanded metal reinforcement used at external

GYPROCK plasterboard is a stable building product when subjected

Plasterboard In Wet Areas.

The contractor shall furnish all materials, labour and equipment

DELIVERY & STORAGE OF MATERIALS.

Damaged or deteriorated materials shall be removed from the

The framing shall be lined on the first side with * layer(s) of mm

PLASTERBOARD FIXING AND JOINTING.

Gyprock plasterboard shall be fixed, jointed and finished to a

* Insert or select appropriate specification.

Gyprock Plasterboard Range.

13 1200 WSN SN 10.7

Gyprock Plasterboard Range.

ceiling applications such as walkways and verandahs.

6.5mm thickness plasterboard with an enhanced core to allow

Manufactured with CD technology.

10mm thickness plasterboard reinforced with a woven fibreglass

Fire and moisture resistant plasterboard.

Cove Cornice in 55 and 90mm is available in all states. 75mm cove

Handling & Storage.

If stored outside, sheets are to be stored off the ground, stacked as

Levels of finish are defined in the Australian/New Zealand Standard

The level of finish specified also affects the methods of jointing,

coats of joint compound applied as well as the fitting and finishing of

It should be noted that, generally, domestic applications should

ROOF SPACE VENTILATION.

GYPROCK plasterboard will give many years of satisfactory

Condensation within a building is the result of a temperature

Vapour barriers are incorporated into the structure to prevent the

which will normally be at the higher temperature at the time of the

Attics or similar unheated spaces above ceilings can be adequately

In rooms such as bathrooms, kitchens, and laundries, moisture laden

Roof space ventilation

Gyprock FlamechekMR TM cannot be used as a substitute for

The construction changes within the plane of the partition, wall or

Any imperfection in a completed lining installation will be made

parallel to the surface. Glancing light also greatly exaggerates the

Locate fluorescent lights about 450mm below the ceiling as this

Do not use uplights, wall-washers and spotlights in areas with a

Avoid placing windows immediately adjacent to the end of a wall.

Recess the window to stop the sunlight reaching the wall.

The following situations may give rise to localised high temperature

Refer to heating unit manufacturer for more information.

APPLIED FINISH SELECTION.

Finishes applied to the GYPROCK plasterboard can have a significant

General rules when selecting the applied finish are:

The diff ere nce in textur e and absorption characteristic

Textured or heavy patterned finishes tend to hide imperfections.

Less likely to show imperfections and impact damage.

Paint or thin wallpaper finishes are less tolerant of imperfections.

Ceilings in garages are subjected to different environmental