Knauf Installation Manual

BS EN & ASTMInstallation Base Manual

Wall Linings

Partition walls

Suspended Ceiling

Dry

wal

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ContentKnauf EN-BS Systems

Introduction

3.0 Installation of Partition

Training and on Site - support 56

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363739404142

46-4845

4950-51

525354

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29-30

EN-BS Products

1.0 EN-BS Gypsum board Types

Walls overviewProfiles overview

Wall Lining

Installation guide for Knauf partitions

EN-BS Gypsum boardsGypsum Boards Special order

2.0 System Overview (Details)Knauf drywall systems for KW B111Knauf drywall systems for KW B112

Installation of profilesFormation of window openingLocation of noggins servicesFormation of Door OpeningsStuds positioning - Splicing of studsCladding of Knauf Gypsum BoardsScrew spacing

Curved PartitionsWet bending

5.0 Installation of Wall Linings

6.0 Installation of W611 Bonding Perlfix

7.0 Installation of Shaftwall

Cladding of Knauf Gypsum Boards“J” Channel pull out tab and “CT” Stud Joint

Formation of MetalApplication detailsCorner details

Installation of shaftwallFormation of door openingCeiling and floor connection

10-1112-13

1516

24-25

Formation of metal framingKnauf KC B001 ceiling system

Cladding of Knauf Gypsum Boards9.0 Installation of D112 Ceiling

8.0 Installation of KC B001 Ceiling

Knauf drywall systems for KW B115Knauf drywall systems for KW B116Deflection Head for KW B111, KW B112Deflection Head for KW B115, KW B116

17181920

59-6061

66-707173

74-76

636465

7778-79

Knauf Drywall Systems D112 Ceiling

Marking and installation of access panels10.0 Installation of Access Panel

11.0 Joint Application & Finishing

Determination of Suspender and Channel SpacingFormation of Metal framingCladding and screw spacing

Finishing and application of joint compound

555758

Application of Knauf perlfix

4.0 Installation of Curved Wall

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ContentKnauf ASTM Systems

14.0 Installation of Partition

87-8886

9192939495

99100-101

102103104

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109111112113

114-115117

118-119120121

123125126

127-128129-130131-132133-134

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138-139141

145146-150

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ASTM Products

12.0 ASTM Gypsum board Types

Walls overviewProfiles overview


ASTM Gypsum boardsASTM Type X Gypsum Boards

13.0 System Overview (Details)Knauf drywall systems for KW A111Knauf drywall systems for KW A112

Installation of profilesFormation of window openingLocation of noggins servicesFormation of Door OpeningsStuds positioning - Splicing of studsCladding of Knauf Gypsum BoardsScrew spacing

Curved PartitionsGypsum board bending General

16.0 Installation of Shaftwall

Cladding of Knauf Gypsum Boards“J” Channel pull out tab and “CT” Stud Joint

Installation of shaftwallFormation of door openingCeiling and floor connection

8182

Construction details for Non Fire Rated SystemsKnauf KC A001 ceiling system

General information

17.0 Installation of KC A001 Ceiling

Knauf drywall systems for KW A115Knauf drywall systems for KW A116Deflection Head for KW A111, KW A112Deflection Head for KW A115, KW A116

8385

Processing gypsum boardsInstallation Steps

Joint treatment

Formation of metal framingCladding of boards

Marking and installation of access panels18.0 Installation of Access Panel

19.0 Recommended Level of Gypsum Board FinishLevel of Gypsum Board Finish

152-153154-156

157

20.0 Components and AccessoriesComponents and AccessoriesCompany’s CertificationsBecome a Drywall Expert

15.0 Installation of Curved Wall

151

The information and drawings are intended for marketing purposes only. For any specific inquiry, Please contact the Technical Department for customized project proposal and load calculation. Data is subject to change without notice based on our continues research and development results. All right reserved. For more info. please visit http://www.knauf.ae

Disclaimer:

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Integrated, innovative systemsThese pages highlight which Knauf Drywall systems are most suited to

meet performance criteria and bring a variety of construction and end user benefits to the sector you are designing for.

The works of vertical internal partitioning and/or wall paneling are to perform within a building the basic functions delimitation of spaces, of appearance, of contribution to thermal insulation, acoustic insulation and fire resistance in case of fire. Their realization must also take into account the dimensions of the surfaces intended to receive them, the type of finish required, and the need to fix equipment above on the surfaces in relation to the intended use of buildings. Since, and this is not the case, the final performance depends mainly on the accuracy of the installation of the components, as well as the quality of the materials used, it is imperative for operators in the construction industry concerned (commissions, contracting authorities, businesses, installers, end-users) to be able to count on precise recommendations that limit the scope for interpretation of the operations to be performed and the solutions to be implemented."

Introduction

The Knauf training support team is available throughout the entire gulf regions to offer their outstanding technical expertise. Whether it is for general technical question & support or even on-site support with the drywall installation, the Knauf training team can support you all the way.

Both practical & theoretical trainings are offered at the Training academy in Dubai. We run courses from the basic level of drywall for those who are new to the world of drywall construction, through to specialized courses with highly technical content for the moreexperienced technicians.

We encourage our customers to co-ordinate with our training support team throughout the entire development of their projects to ensure that we together are providing the adequate drywall solutions to suit the projects needs, and also that the installation is carried out in the most professional and correct manner.

Our Training support team will frequently visit a project throughout its development and carry out a site inspection along with the relevant and concerned people related to the project. They inspect all aspects of the work already done and also offer support with any pending issue related to any further installation work that is to be carried out. After any site inspection a report is created and issued to all concerned persons to ensure that everyone has the same understanding with any pending issues, this helps ensure that the projects runs smoothly and is delivered on-time.

For further information on Training or on-site support:Please contact the Knauf Training Team at [email protected]

Training and on - Site support

5

mation one Knauf Tr

pportknauf

n Training or on-site suraining Team at info@k

Knauf Plasterboards contain a core layer of plaster, whose surfaces and the longitudinal edges are coated paper. They are manufactured in various types, thicknesses and sizes. The plaster core contains additives, in small percentages, in order to improve the functional performance. Knauf Plasterboards are produced according to the standards required by the Regulations UNI EN 520

Brand and identification of Plasterboards Knauf

Plasterboards Knauf are marked on the back with a linear marking positioned in the center on the length of the sheet. This inscription identifies the manufacturer, the factory, the production data, the reference standard and quality control.

Products

Knauf Plasterboards

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EN-BS

Walls overview

1) Knauf CW profile metal thickness 0.6 mm, flange 35 mm2) Maximum heights calculated based on a limiting deflection L/240 on 200 Pa3) Sound calculation base on ISO 1404) Glass wool insulation, 16 Kg/m3 5) Fire rating according to BS-EN 476, part 4 & BS EN 1364-1

For wet areas, we recommend the use of Moisture Resistant Board. Replacing the Regular Board with Moisture Resistant Board, or replacing the Fire Resistant Board with Fire and Moisture Resistant Board will have noinfluence on system’s parameters. Other systems are also available. Shouldyour requirements fall outside the above stated systems, pleased contactKnauf Technical Department at Landline +971 4 337 7170

The dry construction system refers to materials with high standardization that allow a large variability in the phase of design/assembly, so that it can vary the functional performance of the walls depending on the materials chosen. We produce self-supporting and non-bearing walls, high-tech and simple to make, as long as you take care of the detail either in the planning stage or in the stage of construction.The Knauf walls are composed essentially of:

- Cladding panels of coated plasterThe walls thus constructed are also identified as "light walls", since the specific weight of the "dry system" partition is 8-10 times lower than that of a partition wall in masonry. One of the biggest advantages of Dry System is that you can vary the stratigraphy of walls, false walls and ceilings in order to satisfy each time, the requirements of the Project.

The plasterboards in turn, differ as indicated in the previous pages in their special qualities of resistance to moisture, fire, etc.. The metal frame is connected to the adjacent carrier elements and can be single or double. The fittings can be arranged in double series in parallel, adjacent or spaced, separate or connected with strips of the panels properly placed and secured.

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Profiles overview

The KNAUF profiles are produced with steel conforming to European standard EN 10346:2009

The zinc coating conforms to UNI 5753-84 standard for the initial smelting,with Zn 98% quality (UNI 2013). All surfaces of the profiles are protected by chromic acid chemical passivation, oiling in profiling, and resistance to salt spray 72 hours.

KNAUF profiles are manufactured according to the standards specified inEN 14195, thickness of steel 0.5-0.6 mm with controlled tolerances.

Trademarks and identification of Knauf Profiles

KNAUF profiles are marked on the flange with a print that identifies the manufacturer, the enterprise, product information, the reference standard both for manufacture of the fittings or for the compliance of the raw material,quality control.

The strong integration engineering, the abiding presence of cavities allows a high flexibility for the passage of electrical plumbing and sanitary devices. One can also hang on the finished walls the loads of various weight and distribution, from simple framework of the mounted kitchen to the shelves of shops and warehouses. To achieve the maximum filling of the wall with equipment, you should only refer to the instructions given in the technical sheets of Knauf, which indicate all applicable loads depending on the fastening system.

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EN-BS Gypsum Board Types

1.0

1.1Regular Gypsumboard (RG)

EN-BS Gypsum boards

1.2Fire Rated (FR)Gypsum board

The panels coated with plaster are used in all typesOf buildings for interior finishing.

Thickness: 9.5 mm, 12.5 mm, 15 mm

Paper color: Ivory

Application field: paneling of walls, false ceilings or directly to blockwork, by the use of suitable adhesive based plaster (Perlfix).

Fire-resistant panels with plaster coating are furtherreinforced with mineral fibers within the core of plaster to improve the structural strength under theaction of fire.

Application field: the same as for the RG panels,but with high fire resistance performance.

Thickness: 12.5 mm, 15 mm

Paper color: Pink

1.3MoistureResistant (MR)Gypsum boardH1 & H2

Moisture Resistant plasterboards with reinforcedplaster coating specially processed to limit theabsorption of moisture.

Application field: the same as for RG panels,but designed for environments with high humidity such as bathrooms and kitchens.


Paper color: Green

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1.6Aquapanel® Fiber-reinforced concrete panel with reinforcing

mesh on the two surfaces, reaction to fire class A1.

Application: suitable for indoor high and / oraggressive indoor and outdoor humidity.

Thickness: 12.5 mmIndoor/Outdoor

Paper color: Green

1.4Fire & Moisture(FM) ResistantGypsum board

Plasterboard with fire-resistant performance, andalso subjected to special process to limit the absorption of moisture.

Application field: wall paneling and false ceilings,the same as for the MR panels, but are to be appliedin humid environments like bathrooms and kitchens.

Paper color: Green


ti

T

1.5Knauf Coreboard

Knauf Coreboards (FM) are gypsum wallboardsdeveloped specifically to be used in conjunction with Knauf Shaftwall systems where access from one sideis restricted, giving a high fire performance whilst being simple to construct.Knauf Coreboards are used as liner boards facingthe shaft of Knauf’s Fire Rated Shaftwall systems.Class A2-s1,d0 (B) According to DIN EN 13501-1

Application field: Fire resistant gypsum boardsare just part of a complete fire ratedassembly. To achieve a certain firerating on a Knauf drywall assembly,the complete system component hasto be installed according to Knauf’sinstallation guidelines.

Thickness: 25 mm

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Gypsum Boards Special order

1.8KnaufFireboard

1.9KnaufCleaneo

Knauf Fireboard gypsum boards are used in drywallsystems that provide particularly optimized fire protection.

Thickness: 12.5 mm, 15 mm, 25 mm

Application field: Application should be acc. to theapplicable standards and acc. to the Knauf SystemData Sheets of the respective drywall system.

1.7Diamant ImpactResistantGypsum Board

Knauf Diamant is an impact resistant gypsum boardoffering toughness, durability and excellent loadcarrying capacity


Paper color: Blue

Application field: Knauf Diamant are used in allfields of interior works as cladding of premium drywallsystems with enhanced requirements for soundinsulation and fire protection, and in case of specialrequirements on mechanical resistance, inrooms with moderately high humidity.

Panel on whose surfaces have been performed in the factory drilling and milling and coupling on the back of felt soundproofing.Class A2-s1, d0 fire reaction.

Application field: coating of walls and ceilings with high sound absorption performance and high aesthetic and design.

Thickness: 12.5 mm

1.9KnaufCleaneo

PthbC

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1.10Safeboardpanels

Knauf Safeboard panels are FR panel complyingthe standards EN 520 and DIN 18180 with additional capacity of shielding against radiation.

Application: suitable to create protective wallsin medical clinics / hospitals where X-ray is used.

Thickness: 12.5 mm

1.11Silentboardpanels

Knauf FR Silentboard panels are FR panels coatedaccording Plasterboards standards DIN 18180 and DF in conformity with regulations UNI EN 520 that thanks to the innovative and exclusive core of modified plasters have a high sound insulation. Application: especially suitable use for walls, false ceilings and ceilings: hotels, meeting rooms,recording studios, radio studios, Zencapsulation industrial machines (low frequencies).

Thickness: 12.5 mm

1.12Vidiwall® panels

The panel of fiber board Knauf Vidiwall ® is extremelydurable and is able to withstand the most challengingmechanical stresses and endures the highest loads.Applications: Schools, Hospitals, Hotels, Residential,Hangars, Warehouses, Gyms

Thickness: 10 mm, 12.5 mm, 15 mm

Description

Tapered edge

Square edge

Type of edge - form

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System Overview (Details)

2.0

KW B111

System OverviewsKnauf Drywall Systems

Sound Reduction (RW) 38 - 49 db

Partition Width 75 - 176 mm

Height Up to 8.05 m

Economical solution

Description:

Fast space division

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Elevation

Plan

KW B111 Ceiling connection,up to 10 mm deflection

KW B111 T-Junction

Knauf ‘UW’ Deep Track

Knauf 'CW' Stud

Knauf Approved SealantKnauf Wedge Anchor

Knauf Drywall Screw

Knauf Gypsum Board

Knauf Insulation Material

SOFFIT

5-10 mm

Knauf 'CW' Stud

Knauf Corner Tape

Knauf Gypsum BoardKnauf ‘UW’ Runner

Knauf Drywall Screw


46 - 54 db

100 - 206 mm

Up to 9.7 mHeight

Description:

KW B112


Sound Reduction (RW)

Up to 120 min.Fire Resistance

Partition Width

Optimum solutionMeets most design criteriaSmall footprint

High fire resistance

Plan

Plan

KW B112 T-Junction

KW B112 Corner detail

Knauf Gypsum Board


Knauf Drywall Screw Knauf 'CW' Stud

Knauf Alux Corner Bead or Corner Trim if necessary

Knauf 'UW' Runner

Knauf Corner Tape

Knauf 'CW' Stud

Knauf Gypsum BoardKnauf 'UW' Runner

Knauf Drywall Screw


Knauf Corner Tape

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Description:

KW B115


56 - 60 db

155 - 249 mm

Up to 6.75 mHeight



Partition Width

High acoustic performances

Optimum for separation wallsHigh fire resistance

Plan

Plan

KW B115 T-Junction



Knauf Drywall Screw

Knauf Corner Tape


Knauf Insulation MaterialKnauf 'CW' Stud

Knauf 'UW' Runner

Knauf Corner Tape

Knauf 'CW' StudKnauf Drywall Screw


Knauf Gypsum Board

Knauf Sealing Tape

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Description:

KW B116


≥ 58 db

300 - 450 mm

Up to 6.95 mHeight



Partition Width

Very good acoustic performances

High fire resistanceAccomodates large services

Elevation

Plan

Adjustable footprint



Knauf 'UW' Runner

Knauf Corner Tape

Knauf 'CW' Stud

Knauf Gypsum Board

Knauf DrywallScrew

Knauf Corner Bead

Knauf InsulationMaterial

SOFFIT

X

Knauf UW Bracing


Knauf 'CW' Stud

Knauf Wedge Anchor

Knauf Drywall Screw

Knauf Gypsum Board

Knauf Approved Sealant


5-10 mm

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H

S

F

P

System OverviewsDeflection Head for KW B111 & KW B112* For fire rated head deflections

Elevation


* For fire rated head detail please contact Knauf technical teamat [email protected] or call +971 4 337 7170

Elevation


Knauf ‘CW’ Stud Profile


Knauf Drywall Screw

Knauf Concrete Screwbolt

Knauf Gypsum Board

Knauf Board Strips

Deflection Allowance 25 mm




Knauf Drywall Screw


Knauf Gypsum Board

Knauf Board Strips





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System OverviewsDeflection Head for KW B115 & KW B116* For fire rated head deflections

Elevation KW B116 Ceiling connection,up to 25 mm deflection

Elevation KW B115 Ceiling connection,up to 25 mm deflection


SOFFIT


Knauf Drywall Screw


Knauf Gypsum Board

Knauf Board Strips





SOFFIT

X

Knauf UW Bracing


Knauf Drywall Screw


Knauf Gypsum Board

Knauf Board Strips




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Installation of Partition

3.0

Mark location of partitions accurately on concrete structure with stringline/laser

Stringline


Installation Guidelines are as per BS 8212-1995

Formation of Metal Frame

Marking and Installation of profiles

The parameters of the wall is made of metal profiles: cold worked profiles in thin plate steel and protected against corrosion by hot-dip galvanizing, with zinc coating. The profiles are of two types:- U-shaped tracks, to be placed on the floor and ceiling- C-shaped uprights to be inserted into the track.

The construction of a plasterboard wall begins by tracking the position of the U-shaped tracks on the floor. Having determined the final thickness of the wall, mark the position of the guide to the floor and then bring it back, with a plumb line or laser on the ceiling to position the upper track (Photos 1,2,3).

inne

Photo 1

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Use Knauf or Acoustical Sealant under Knauf 'CW' Studs UW Tracks forming the perimeter

Photo 3

Photo 2

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CWStud

Top Track

Bottom Track

CWStud

CWStud

Top Track

Bottom Track

Installation of profiles

1) Runners shall be aligned accurately at the floor and ceiling and securely anchored approximately 50mm from the runner ends, and spaced no more than (600mm) on centers.

2) Friction fit Knauf 'CW' Studs vertically into Knauf UW Tracks with maximum spacing of (600mm), this will allow for adjustment when boarding. Extra studs should be provided at openings,corners and stop ends. Studs at corners, stop ends, T junctions and openings should be fixed to floor and ceiling channels by metal framing screws or pierce punching.

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Typical Window Framing Out Detail

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Knauf Plasterboard to suitspecification

Ends of Knauf Deep Flange ‘U’ Channel snipped, bent and turned up or down minimum 300mm and fixed to studs,See Figure 1 & 2

Knauf CW-Stud with Treated Timber (by Others)

Figure - 1U-Channel 2

1

Knauf UW-track withtreated timber (by others)

300mmMinimum

3

Figure - 2U-Channel Knauf UW-track with

treated timber (by others)

300mmMinimum

3

2

1

Formation of window opening

Shown detail of correct widow installation, timber inserts provide more stability and a better fix for window frames.

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Nogginfor Services

CWStud

Top Track

Bottom Track

sCWStud

Top Track

Bottom Track

A ANoggin for Services

Plywood insert for services such as hand dryers or towel rails.

Location of noggins services

Correct noggin installation, marine plywood (by others) inserts provide more stability and a better fix for services such as hand dryers or towel rails.

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18mm Marine Plywood / by others

CW Stud

TN ScrewGroveL Angle 25 x 25 x 0.5 mm

Section A - A

A head shall be formed over metal door with a cut-to- length section of track.The section of track then placed horizontally at the relevant height with flanges cut and bent vertically at

each end, then securely attached to the vertical studs A cut-to-length section of stud shall then be positioned vertically above the door head and extending to the ceiling track

Formation of Door Openings

To make openings, which doors can be installed, there should be profiles placed as shown below:

Knauf CW-Stud Interlaced asBoxed with Treated Timber (by Others)

100mm

150mm

Min

imum

300

mm

Knau

f Tra

ck R

etur

n:

Figure-1

Figure-2a

Figure-3

Min

imum

300

mm

CW Profile

UW Profile

Figure-2b (Opposite side)

Door Opening Frame

Doors and openings

See Figure-1 & 2

See Figure-3

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Note: For installation of fire doors, you will have to follow the installation as described in the specific manufacturer's Test Reports on doors.

To create the joint at right angle at the foot of the opening, Extend the track 300mm larger than needed, Snip both sides of flange then bend it at an angle and fix it to the upright stud as shown. The floor rail must be fixed at not more than 150 mm from the door jamb.

It is possible to make the door jamb connections using:

(Detail-1) C-shaped upright profile, double boxed with insertion of wooden walls to facilitate the fixing of the door frame.

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Door Framing / Door opening with CW studs

Detail-1

Knauf CW-Stud interlaced as boxed with

treated timber (by Others)

3 15/16” (100 mm)

≥ 5 15/16" (150 mm)≥ 5 15/16" (150 mm)

3 15/16” (100 mm) Varies

Load classProfileDoor weight

Medium duty 100 slams

Min. CW 50x35x0.6 mm2+2Up to 60 kg

Severe duty 20 slamsMin. CW 50x35x0.6 mm2+2Up to 100 kg

No. of layers on each side

Studs positioning - Splicing of studs

If the wall is high and it becomes necessary to join the profiles, Follow one of the overlap options as shown below:

Splicing method of Knauf of CW studs

Displace stud joints vertically

Stamp Plier

In the overlap area, rivet, screw attach or crimp the studs

Vertical extension of studs (splicing)

Tips:

OverlapStud size

CW 50 ≥ 50 cm

≥ 70 cm

≥ 92 cm

≥ 146 cm

CW 70

CW 92

CW 146

Calculation example:

Option 1 CW 50 – overlap 50 cm

Option 2 CW 50 – additional piece of UW 50 cm

u

2 CW studs interlaced like a box

Option 1 Option 2

2 CW studs. Jointconnected with

additional UW stud

Stud 1

Stud 2

u

AdditionalUW Profile

Stud 1

Stud 2

uu

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Cladding of Knauf Gypsum Boards

Boards should be staggered both vertically (600mm) and horizontally (min. 300mm) when cladding. For multi layer applications second layer should again be staggered both horizontally and vertically. Joints on opposite side of a partition shall not occur on the same stud.

Firs

t Lay

er C

ladd

ing

Sec

ond

Laye

r C

ladd

ing

1200

600

2400

1200

600 600600 600

2400

600 600 600600 600

1200 1200

2400

2400

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Screw spacing

Correct screw head position

Drive screws to just below the sheet surface, taking care not to breakthe paper linerboard Screw heads must be approx. 1 mm inside the board surface

Screws should be 10 mm away from joints

Screws should penetrate studs by min. 9 mm

Screw location and penetration depth

Fastening of the cladding

Second layerFirst layerBoard thickness

TN 3.9 x 35 mmTN 3.9 x 25 mm12.5 mm

TN 3.9 x 45 mmTN 3.9 x 25 mm15 mm

Maximum screw spacing – framing at 600 mm center to center

Second layerFirst layer

-

300 mm750 mm

300 mm

Number of layers

1 layer

2 layers

* For fire rated systems both 1st + 2nd layers of cladding to be fixedwith screws at 300 mm o.c.

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>10

Installation of Curved Wall

4.0

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Curved Partitions

Board thicknessd

mmWet bending

mmDry bending

mm

100015006 mm

250020008 mm

Other Knauf boards / bending radius on request

Bend radius in longitudinal directionr

Bending radius - Knauf boards

Connect the CW Stud with Knauf crimp connection

CW Stud spacing: 150 mm (external radius)Knauf fastener spacing: ≤ 300 mm

Concave - inner arch Convex - outer arch

Knauf UW profile (available in 50 / 75 / 100 mm)

Knauf UW track cut and bent

150

150

150

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Dry bending

1) Slowly bend the Knauf board laterally over the stud partition. Pre-bending on a template is recommended2) Fix with Drywall Screws continuously following the bending direction

Wet bending

1) Put the cut-to-length Knauf boards on a grid made of channels or similar with the side to be compressed on to (to ensure that excess water can drip off)2) Perforate the board laterally and longitudinally with a spiked roller3) Wet the board by spraying or use a lambskin roller and allow it to settle for a few minutes. Repeat the process until saturation is achieved and allow the excessive water to drain4) Place the board on the prepared template, bend and fix the board with adhesive tape and allow to dry

leng

th o

f lay

out

long

itudi

nal d

irect

ion

Template

angle or CD Channelto support boardsKnauf Board stripcut board

battento be fix theboard

Wet bending

Installation of Wall Linings

5.0

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Wall Lining

• Mark location of Knauf Universal Brackets on the concrete/block wall• Max, vertical spacing = 1500mm• Max. Horizontal spacing = 600mm

• Fix Knauf UD channels to ceiling and floor slab with Plastic Plug & Srew or approved dowel

• Max. Spacing of plugs = 1000 mm

• Fix Universal Brackets to marked locations with Knauf Plastic Plug & Screw or suitable dowel types• Bend flanges of brackets outwards afterwards

Universal Brackets

Need New Picture

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Formation of Metal

• Place mineral wool insulation in the cavity by pushing them inwards through the bent flanges of Universal brackets

• Friction fit Knauf CD channels inside the UD channels at the marked locations (max spacing = 600mm)• Fix Knauf Universal Brackets to CD Channels with the help of LN Wafer Head Screws from both sides• Bend back the excess bracket flange if necessary

300

300

300

300 300300Screw Spacing

Scre

w S

paci

ng

Stud Spacing Stud Spacing

Board width = 1200

Cladding and screw spacing

W623

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Application details

W623 Vertical Section

W623 Connection to floor


Knauf Gypsum Board

Knauf Drywall Screw TNKnauf UD Runner

Knauf Sealing Tape Knauf Approved Fixing

Knauf Universal Bracket

Knauf CD ChannelInsulation MaterialKnauf Metal screw LN

W623 Connection to Ceiling

SOFFIT


Knauf Gypsum Board

Knauf Drywall Screw TNKnauf UD Runner

Knauf Sealing Tape Knauf Approved Fixing


Knauf CD ChannelInsulation MaterialKnauf Metal screw LN

Knauf Gypsum Board

Knauf Drywall Screw TNKnauf Sealing Tape

Knauf Approved Fixing


Knauf CD ChannelInsulation Material

Knauf Metal screw LN

Knauf Joint Compound+ Joint Tape

43

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W623 External corner

Corner detail

W623 Movement Joint

W623 Internal Corner

Knauf Metal screw LN


Knauf CD Channel

Knauf Drywall Screw TN

Knauf Gypsum Board


Knauf Sealing Tape Insulation Material

Knauf Alux Corner Tape orCorner Trim if necessary

Knauf CD Channel

Knauf Drywall Screw TN

Knauf Gypsum BoardKnauf Universal Bracket

Insulation Material

Knauf Approved FixingKnauf Sealing Tape

≤20

≥20

≤20

W611 Bonding Perlfix

6.0

46

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N-B

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ms The substrate has to be substantial, solid, clean and dry, concrete surfaces

sufficiently dry and free of sinter layers and concrete release agents.

Pre-treatment of substrate


W611(Perspective - Perlfix-Dot)

W611 (Wall Details)Section & Elevation

W611 (Floor Details) Elevation

W611 (Joint Details) Plan

W611 (Floor Details) Elevation

Knauf Uniflott

Knauf Perlfix-Dots

Knauf Gypsum Board

Knauf Gypsum Board Strip

W611 (Joint Details) Plan

Knauf Perlfix-DotsKnauf Gypsum Board

Knauf Uniflott

W611 (W ll D t il )

47

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Application of Perlfix dabs

In the case of an uneven substrate apply dabs of Knauf Perlfix with a spacing of approx. 35 cm.For strongly uneven backgrounds underpin with 10 cm. wide board strips and Knauf Perlfix.


Sprinkle 30 kg Perlfix in approx. 16, water and mixwith Putty Mixer to a paste-like compound.

Mixing

48

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Press Knauf Boards perpendicular and horizontally on the substrate and attach by gently tapping with straight edge. Tapping and aligning of the boards has to be finished before hardening of Knauf Perlfix commences.The minimum thickness of dabs should be 5 mm after alignment of boards.


Installation of Shaftwall

7.0

50

Kna

uf E

N-B

S S

yste

ms Mark location of Shaftwall accurately on concrete structure with

stringline/laser

Use Knauf Sealant under J Tracks forming the perimeter (head, base and any Abutments)


Stringline gline

51

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J-Track

J-Track

J-Track

J-Track


1) Fix J track to substructure with Knauf Plastic Plug & Screw (with 600mm spacing) and 50 mm from the Channel ends.

2) Knauf C-T studs should be positioned within the J tracks in sequence with Knauf Core Board.

• Studs should be trimmed to within 5 mm. of the slab to soffit height.

• There is no real requirement to secure the studs at this point as this will be achieved once the boards are screw fixed.

CTStudJ-Track

J-Track

J-Track

J-Track

52

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J-Track

Formation of door opening

3) For Doors weighing up to 60kg, Knauf J-Track Channels are used for the frame openings, Inserted with treated timber , Cut to the size of the studs.

• A head shall be formed over metal door with a cut-to- length section of `J` Channel.

• The section of `J` Channel then placed horizontally at the relevant height with flanges cut and web bent vertically at each end, then securely attached to the vertical J-Track Channels.

53

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Ceiling and floor connection

Knauf’s standard ceiling and floor connection details provide deflection tolerance up to 10 mm.

Knauf Drywall Screw


Knauf Wedge Anchor

Knauf “J” Channel

5-10 mm

Knauf Gypsum Board

Knauf Coreboard

SOFFIT


5-10 mm

Knauf Drywall Screw



Knauf Gypsum Board

Knauf Coreboard

KSW A112 Ceiling connection

KSW A112 Knauf floor connection

Elevation

Elevation

54

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shaft wall.

• Cut the first Core Board to fit into the Knauf `J` channel frame, Pull out the tabs in the flange of the `J` channel to retain the Knauf Core Board.

• The Next Knauf Core Board is then fitted into the C-T stud and this process if repeated until the one side is complete.

• For Horizontal joints in the Knauf Core Board, install C-T stud to the top

Coreboard joints

“J” Channel pull out tab and “CT” Stud Joint

KSW 112 Joint

Knauf Joint Compound

Knauf “CT” Stud

Knauf Drywall Screw

Knauf Gypsum Board

Knauf Coreboard


Plan

C b d j i t

Cladding of Knauf Gypsum Boards• Boards should be staggered both vertically (600mm) and horizontally (min. 300mm) when cladding• For multi layer applications second layer should be staggered both

Firs

t Lay

er C

ladd

ing

Sec

ond

Laye

r C

ladd

ing

1200

600

2400

1200

600 600600 600

2400

600 600 600600 600

1200 1200

2400

2400



TB 3.9 x 35 mmTB 3.9 x 25 mm12.5 mm

TB 3.9 x 45 mmTB 3.9 x 25 mm15 mm



-300 mm300 mm

300 mm

Number of layers

1st layer2nd layers

55

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Installation of KC B001 Ceiling

8.0

• Mark location of ceiling height on concrete structure with stringline/laser.

• Fix UD Channel to perimeter using plastic plug and screw (with a spacing no more than 600mm on centers and 50mm from each end)

• Mark location of steel L-angle hangers on basic ceiling , spaced every 800mm apart

Knauf KC B001 ceiling system

KC B001Isometric view

• Maonstrin

• Marhanspa

• Fix usin(wit600from

• Mark the ceiling dowel and hanger wires on basic ceilingbased on the loads class of the ceiling

KIsKC B001sometric view

600 mm

600 mm

400

200

1000 mm

800 mm

200

150

400

400

Hat Furring Channel

L - angle

Main Channel Access Opening

Gypsum Board

Perimeter WallUD - Channel

58

Formation of metal framing

Overview Section

400 mm150 mm

50 mm

Hat Furring Channel

Main ChannelL - angle

TN Screw

LN Screw

Wedge Anchor


Knauf Gypsum Board

800 mm c/c L-angle

UD Channel or L angle

Perimeter Wall fixingPlastic Plug Screw

1111111111222223333333333333

•

•

The main channel is to be connected to the L-angle at the relevant height using Knauf LN screws and spaced every 1000 mm apart

•

2.

ThthKn10

•

2.

LN ScrewMain Channel

L-Angle

Knauf L-angle is to be sniped & folded as shown then secured with LN screw.

The L-angle should then be securelyfixed to the marked location (800mm spacing), using an approved KnaufWedge Anchor

•

•

Kas

TfixspW

1.

LN Screw

L-Angle

Wedge Anchor

59


Main channel should be kept 50 mm from the existing wallsubstructure.

•

3.

4.

5.

M50su

•

Main Channel

TN Screw

UD-Channel

50 mm


First hat furring channel should be positioned 150 mm from the existing wall structure to the center, all other hat furring channels shall be spaced 400 mm apart on centers.

•

be15exstrcehachspap

Hat Furring Channel150 mm

Main Channel

LN Screw

Hat furring channels are to be connected to the underneath of the main channels using LN screws on both sides

• •

Knauf Joint Compound Knauf Gypsum Board

Main Channel

60

Cladding of Knauf Gypsum Boards

• Knauf Boards should be fixed perpendicular to the metal stud framework

• Boards must be staggered by a minimum of 400mm to avoid continuous joints on short edges

• Along the perimeter of the ceiling the screw spacing should be reduced to 200mm on centers

• It’s vitally important to follow this spacing especially with ceilings to avoid future board sagging

j g

• Along the perimeter of the ceiling the screw spacing should be reduced

2400

1200

1200

1200

400400400400400 4002400 mm

1000

400 400 150400400400400400 400

1200

mm

300

300

300

300

200200

2400 mm 570 mm200200200200200

framing at 400 mm centerScrew tobe used

Board thickness

1 x 12.5 mm TN 3.9 x 25 mm1 layer

cladding 300 mm

No. of Layers 1st Layer 2nd Layer

-

61

Installation of D112 Ceiling

9.0

Knauf Drywall SystemsD112 Ceiling

• Galvanized 4.0 mm thick wires used as suspender• Attached to basic ceiling with the help of steel ceiling dowels• Load bearing Capacity = 25 kg

• Accessories to be used with hanger wires• Hanger wire is attached to the clips of rapid hanger• Connected to Upper Knauf CD channels

SYSTEM RECOMMENDED FOR CEILING HEIGHTS UP TO 1500 mm

System Components

Knauf Ankerfix / Rapid

• Knauf Nonius Hanger Top attached to structural soffit and main CD Channel as suspender• Load bearing capacity: 40 kg• Spacing of Suspender: 950 mm• Additional Accessories: Knauf Nonius Stirrup and Nonius Pin

SYSTEM RECOMMENDED FOR CEILING HEIGHTS UP TO 5000 mm

Nonius Hanger for CD Channel

Nonius Hanger Top

Nonius Pin

Ankerfix

Steel wires

Knauf Nonius Hangers

wires

nels

LING

Ankerfix

g

IL

us Hanger for CD Chann

LING

NNoNonius Pin

Steel wires

64

DIN

Sys

tem

s

Isometric View Wire Hanger

Determination of Suspender and Channel Spacing

40

40

11.5

12.510

9.5 15 18 25

30

35

43

50

45

(2x 1

2.5)

15

25

20

[ kg/m² ]

thickness of cladding

0.50 < p 0.65 *)

0.30 < p 0.50

0.15 < p 0.30

0.15

65

55

60

3345

20

load class [ kN/m² ]

0.50 kN/m² as wellacc. to DIN 18168

*) design of ceilings

y

x

(18+

15)

(2x 2

0)

(25+

18)

weight of ceiling lining / suspended ceiling

[ mm ]30

(2x 1

5)

sometrric View Wire Hanger

65

DIN

Sys

tem

s

spac

ing of carr

ying ch

annels

spacing of furring channels

spacing of suspenders

ca. 250

(anchors)

ca.100

ca.

150

a

c

bb

Formation of Metal framing

Recommended spacings for 1x12.5 mm Cladding

Determination of Spacings - D112

1) use suspenders of load capacity class 0.40 kN

1100

950

1000

1050

900

900

1200

1100

1000

900

800

700

-

800

750

750

800

850

-

-

700

2)

not valid for spacing of furring channels of 800 mm2)

2)

2)

-

-

1150

1200

600

500

750900

950 800

load class kN/m²

0.15

Spacings of suspendersSpacings ofcarrying channel

0.50 0.301)

Maximum grid spacings

c a

* For fire protection requirements please contact Knauf Technical Team.66

DIN

Sys

tem

s


• Mark location of ceiling height on concrete structure with stringline/laser.

•

•

Fix UD Channel to perimeter using plastic plug and screw (max. spacing 600 mm) to form perimeter ceiling

Mark the ceiling dowel and hanger wires on basic ceilingbased on the loads class of the ceiling

• Maon stri

• Fixusi(maform

Knauf Board

Shadowgap Option(need longer plug)

Non-load bearing perimeterconnection

Screw spacing ≤ 170 mmscrewing of cladding in UD Runner is necessary

Standard Option

67


•

•

Fix Knauf ceiling dowels on the marked locations and attach hanger wires through the dowels hook.

Slide the Knauf rapid hanger through the wires via its adjustable clips

•

•

Attach wire hanger wires the upper/main CD channel by sliding the rapid hanger through the channels flanges.

Lay upper CD channels on top of the UD perimeter channels with calculated spacing's (standard spacing= 1000mm)

68

DIN

Sys

tem

s


•

•

Fix lower/furring CD channels under the upper/main CD channels to form a grid.(standard spacing of 400mm)

Connect lower/furring CD channels to upper/main CD channels at every intersection point with 2x Knauf clips

•

•

Nonius top hanger suspender fixed to ceiling with knauf approved fixing's.

(suspenders spaced every 950mm)

Nonius hangers fixed to the carrying channel and secured at the correct height using the nonius pin.

69

DIN

Sys

tem

s


• CD channel is then positioned into perimeter UD channel at the correct center spacing (400mm)

• Lower furring channel is secured to the upper furring using2x channel clips.

100 mm 400 mm

250 mm


Knauf Nonius Hanger

Knauf CD clip


Knauf TN ScrewKnauf Gypsum BoardKnauf UD Runner

Knauf Plastic plug & screw

Knauf CD Channel

Knauf CD Channel

150 mm

Knauf Nonius Hanger



Knauf TN ScrewKnauf Gypsum Board Knauf UD Runner

Knauf Plastic plug & screw

Knauf CD Channel

70

DIN

Sys

tem

s

71

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Cladding and screw spacing

• Cladding of Knauf Gypsum Boards

• Use control joints for continuous ceiling spans >15 m

Screw SpacingsScrew to be used Board Thickness

12.5 / 15 mm TN 3.9 x 25 mm 1 layer cladding 200 mm

No. of Layers 1st Layer 2nd Layer

-

2 x 12.5 mm TN 3.9 x 35 mm 2 layer cladding 500 mm 200 mm

600 mm

Furring CD Channel Spacing

600 mm

200

200

Scre

w s

paci

ng

Long EdgeDirection Sh

ort E

dge

Dire

ctio

n

Edge Trim 23x13(if necessary)

Knauf Board Strip,glue at one side withreadygips

>25

ca. 100 mm

>25

a >a

a ≤ 20 mm

a

>25

Expansion joints

Installation of Access Panel

10.0

74

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Marking and installation of access panels

1) Open the Access Panel packaging and you will find the template corresponding to the size of the access panel. Take the sheet of card and place it on the wall or ceiling where panel has to be installed. Mark out a line along the borders of the sheet.

2) Cut out the marking with a piercing saw. The card mounting jigs are exactly : 200 x 200, 300 x 300, 400 x 400, 500 x 500 and so on. The outside of the frame to be mounted is 195 x 195, 295 x 295, 395 x 395 and so on. So there is a 5 mm difference between frame and opening.

75

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3) Now insert the frame after slightly tilting it.

4) Take care of the C-Channel position. C-Channels should not be more than 100 mm away from the outside of the frame and not be less than 80 mm The reasoning for this it to provide sufficient support to the surrounding opening.

5) Now insert the frame in the correct position. If the cut out has been done correctly, there will be a 5 mm gap between frame and opening. Position the frame in the opening so that the gap is 2.5 mm on all sides. Fix the frame in this position with a C-clamp and screw the frame using the available screws from the outer side of panel opening. Distance from screw to screw should not be more than 150 mm.

76

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6) Before you start finishing the Access Panel, please check its functionality: put in the flap and see whether shutting and opening works well.

In order to avoid joint filler from entering the joints between frame and flap, take out the inner flap while smoothening.Insert the flap/panel in the frame and check for final function.


Installation of Jointing Finishing

11.0

78

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• After waiting for 2 hours, second coat of Knauf Joint filler should be applied with 20 cm width



• Board surface should be cleaned of materials such as dust, oil etc. • Filling and covering of joints should only take place after the board have been allowed to rest in the given humidity and temperature zones, and no more longitudinal changes can be expected, i.e. expansion or contraction. • In case of mastic asphalt screed, fill in joints after screed has been applied.

• First coat of Knauf Joint filler should be applied with 10 cm width• Knauf Joint Tape should be embedded into the joint filler afterwards

Jointing

Jointing

Preparation

79

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Corner Reinforcements• Knauf Corner Bead should be used for exterior corner reinforcements• Alternatively Knauf Alux Corner Tape can be used to reinforce interior or exterior corners

• Alternatively Knauf Alux Corner tape can be used to reinforce interior or exterior corners or exterior corners

• A very thin third coat of Knauf Joint filler should be applied with 30 cm width

• Once third coat has dried, surface should be sanded and smoothed


Corner Beadcladded on to putty

First coat with10cm width

Second thin coatwith 20cm width

Third thin coatwith 30cm width

Exterior Corner

Product

Knauf Plasterboards

Knauf Plasterboards contain a core layer of plaster, whose surfaces and the longitudinal edges are coated with the special perfectly clinging part. They are manufactured in various types, thicknesses and sizes. The plaster core contains additives, in small percentages, in order to improve the functional performance. Knauf Plasterboards are produced according to the standards required by the Regulations ASTM C1396

Brand and identification of Plasterboards Knauf

Plasterboards Knauf are marked on the back with a linear marking positioned in the center on the length of the sheet. This inscription identifies the manufacturer, the factory, the production data, the reference standard and quality control.

ASTM

USCM

Walls overview

1) Knauf CW profile metal thk. 0.5, 0.9 mm, flange is available 33 mm.2) Max. heights calculated based on a limiting deflection 1/240, 1/360 on 240 Pa3) Sound calculation base on ASTM E904) Glass wool insulation, 16 Kg/m3 5) Fire rating in accordance with ASTM E119 & E2226

For wet areas, we recommend the use of Moisture Resistant Board (GB-WR) Replacing the Regular Board (GW-R) or replacing the Fire Resistant Board GW-TX (Type X) with Fire and Moisture Resistant Board GBWR-TX (Type X) This will have no influence on system’s parameters. Other systems are also available. Should your requirements fall outside the above stated systems, pleased contact:Knauf Technical Department at Landline +971 4 337 7170

The dry construction system refers to materials with high standardization that allow a large variability in the phase of design/assembly, so that it can vary the functional performance of the walls depending on the materials chosen. We produce self-supporting and non-bearing walls, high-tech and simple to make, as long as you take care of the detail either in the planning stage or in the stage of construction.The Knauf walls are composed essentially of:

- Cladding panels of coated plasterThe walls thus constructed are also identified as "light walls", since the specific weight of the "dry system" partition is 8-10 times lower than that of a partition wall in masonry. One of the biggest advantages of Dry System is that you can vary the stratigraphy of walls, false walls and ceilings in order to satisfy each time, the requirements of the Project.

The plasterboards, in their turn, differ as indicated in the previous pages in their special qualities of resistance to moisture, fire, etc.. The metal frame is connected to the adjacent carrier elements and can be simple or double. The fittings can be arranged in double series in parallel, adjacent or spaced, separate or connected with strips of the panels properly placed and secured.

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Profiles overview

Trademarks and identification of Knauf ProfilesKNAUF profiles are marked on the flange with a print that identifies the manufacturer, the enterprise, product information, the reference standard both for manufacture of the fittings or for the compliance of the raw material,quality control.

The strong integration engineering, the abiding presence of cavities allows a high flexibility for the passage of electrical plumbing and sanitary devices. One can also hang on the finished walls the loads of various weight and distribution, from simple framework of the mounted kitchen to the shelves of shops and warehouses. To achieve the maximum filling of the wall with equipment, you should only refer to the instructions given in the technical sheets of Knauf, which indicate all applicable loads depending on the fastening system.

The KNAUF profiles are produced with steel conforming to ASTM C1003

KNAUF profiles are manufactured according to the standards specified inASTM C645 with thickness of steel 0.5-0.9 mm with controlled tolerances.Profile are also certified and listed under the Intertek Certification Programme.

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ASTM Gypsum Board Types

12.0

1.1Regular Gypsumboard (GW-R)

ASTM Gypsum boards

The panels coated with plaster are used in all typesOf buildings for interior finishing.

Thickness: 12.7 mm, 15.9 mm

Paper color: Ivory

1.2MoistureResistant (GB-WR)Gypsum board

Moisture Resistant plasterboards with reinforcedplaster coating specially processed to limit theabsorption of moisture.

Application field: the same as for RG panels,but designed for environments with high humidity such as bathrooms and kitchens.


Paper color: Green

Application field: paneling of walls, false ceilings or directly to blockwork, by the use of suitable adhesive based plaster (Perlfix).

86

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ASTM Type X Gypsum Boards

Paper color: Green

1.3Type XFire & Moisture(FM) ResistantGypsum board

Plasterboard with fire-resistant performance, andalso subjected to special process to limit the absorption of moisture.

Application field: wall paneling and false ceilings,the same as for the MR panels, but are to be appliedin humid environments like bathrooms and kitchens.

Paper color: Green


1.4Type XKnauf Coreboard

Knauf Coreboards (FM) are gypsum wallboardsdeveloped specifically to be used in conjunction with Knauf Shaftwall systems where access from one sideis restricted, giving a high fire performance whilst being simple to construct.Knauf Coreboards are used as liner boards facingthe shaft of Knauf’s Fire Rated Shaftwall systems.

Application field: Fire resistant gypsum boardsare just part of a complete fire ratedassembly. To achieve a certain firerating on a Knauf drywall assembly, the complete system components haveto be installed according to Knauf installation guidelines.

Thickness: 25.4 mm

Type X Gypsum Board - a gypsum board with special core additives to increase the natural fire resistance of regular gypsum board.

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Description

Tapered edge

Square edge

Type of edge - form

1.6Type XKnauf Moisture and Mold Resistant Gypsum Board (GB-WR Mold)


Application field: Knauf Gypsum Boards are high performance gypsum boards used as the cladding component of drywall constructions in humid reas with exposure to mold.

( )

Knauf Moisture & Mold Resistant Gypsum Boardsare ASTM C1396 & D3273 compliant mold resistant gypsum boards, specifically designed for use in areas with extreme humidity and exposure to moisture to prevent the growth of mold.

ASTM Type X Gypsum Boards

Type X Gypsum Board - a gypsum board with special core additives to increase the natural fire resistance of regular gypsum board.

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1.5Type XFire RatedGypsum board (GW-TX)

Fire-resistant panels with plaster coating are furtherreinforced with mineral fibers within the core of plaster to improve the structural strength under theaction of fire.

Application field: the same as for the GW-R panels, but with high fire resistance performance.


Paper color: Pink

System Overview (Details)

13.0

KW A111


Sound Reduction (RW) 42 - 47 db

Partition Width 67 - 184 mm

Height Up to 7.99 m

Economical solution

Description:

Fast space division


Elevation

Plan

KW A111 Ceiling connection,up to 12 mm deflection

KW A111 T-Junction


Knauf 'CW' Stud

Knauf Approved SealantKnauf Wedge Anchor

Knauf Drywall Screw

Knauf Gypsum Board


SOFFIT

5-10 mm

Knauf 'CW' Stud

Knauf Corner Tape


Knauf Drywall Screw


92

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51 - 54 db

92 - 216 mm

Up to 9.59 mHeight

Description:

KW A112




Partition Width

Optimum solutionMeets most design criteriaSmall footprint

High fire resistance

Plan

Plan

KW A112 T-Junction

KW A112 Corner detail

93

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Knauf Gypsum Board


Knauf Drywall Screw Knauf 'CW' Stud


Knauf 'UW' Runner

Knauf Corner Tape

Knauf 'CW' Stud


Knauf Drywall Screw


Knauf Corner Tape

Description:

KW A115


62 - 65 db

184 - 373 mm

Up to 7.25 mHeight



Partition Width

High acoustic performances

Optimum for separation wallsHigh fire resistance

Plan

Plan

KW A115 T-Junction


94

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Knauf Drywall Screw

Knauf Corner Tape


Knauf Insulation MaterialKnauf 'CW' Stud

Knauf 'UW' Runner

Knauf Corner Tape

Knauf 'CW' StudKnauf Drywall Screw


Knauf Gypsum Board

Knauf Sealing Tape

56 - 62 db

189 - 378 mm

Up to 20 mHeight

Description:

KW A116




Partition Width

Very good acoustic performances

High fire resistanceAccomodates large services

Elevation

Plan

Adjustable footprint



95

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Knauf 'UW' Runner

Knauf Corner Tape

Knauf 'CW' Stud

Knauf Gypsum Board

Knauf DrywallScrew

Knauf Corner Bead

Knauf InsulationMaterial

SOFFIT

X

Knauf 'UW' Bracing


Knauf 'CW' Stud

Knauf Wedge Anchor

Knauf Drywall Screw

Knauf Gypsum Board



5-10 mm

System OverviewsDeflection Head for KW A111 & KW A112

Elevation



Elevation



Knauf Drywall Screw


Knauf Gypsum Board



25 x 60 mmKnauf Angle Section


Knauf Wedge Anchor

Knauf Board Strips


Knauf Drywall Screw


Knauf Gypsum Board





Knauf Wedge Anchor

Knauf Board Strips

96

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System OverviewsDeflection Head for KW A115 & KW A116* For fire rated head deflections

ElevationKW A116 Ceiling connection,up to 25 mm deflection



Elevation

SOFFIT


Knauf Drywall Screw


Knauf Gypsum Board





Knauf Wedge Anchor

Knauf Board Strips

97

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SOFFIT

X

Knauf 'UW' Bracing


Knauf Drywall Screw


Knauf Gypsum Board





Knauf Wedge Anchor

Knauf Board Strips

Installation of Partition

14.0

Mark location of partitions accurately on concrete structure with stringline/laser

Stringline


Installation Guidelines are as per ASTM C 754, C 840

Formation of Metal Frame:

Marking and Installation of profiles

The parameters of the wall is made of metal profiles: cold worked profiles in thin plate steel and protected against corrosion by hot-dip galvanizing, with zinc coating. The profiles are of two types:- U-shaped tracks, to be placed on the floor and ceiling- C-shaped uprights to be inserted into the track.

The construction of a plasterboard wall begins by tracking the position of the U-shaped tracks on the floor. Having determined the final thickness of the wall, mark the position of the guide to the floor and then bring it back, with a plumb line or laser on the ceiling to position the upper track (Photos 1,2,3).

ne

Photo 1

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Use Knauf or Acoustical Sealant under Knauf 'CW' Studs UW Tracks forming the perimeter

Photo 3

Photo 2

101

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CWStud

Top Track

Bottom Track

CWStud

CWStud

Top Track

Bottom Track

Installation of profiles

1) Runners shall be aligned accurately at the floor and ceiling and securely anchored approximately 50mm from the runner ends, and spaced no more than (610mm) on centers.

2) Friction fit Knauf 'CW' Studs vertically into Knauf UW Tracks with maximum spacing of (610mm), this will allow for adjustment when boarding. Extra studs should be provided at openings,corners and stop ends. Studs at corners, stop ends, T junctions and openings should be fixed to floor and ceiling channels by metal framing screws or pierce punching.

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Typical Window Framing Out Detail

24

Knauf Plasterboard to suitspecification

Ends of Knauf Deep Flange ‘U’ Channel snipped, bent and turned up or down minimum 300mm and fixed to studs,See Figure 1 & 2

Knauf CW-Stud with treated timber (by Others)

Figure - 1U-Channel 2

1

Knauf UW-track with treated timber (by others)

300mmMinimum

3

Formation of window opening

Shown detail of correct widow installation, timber inserts provide more stability and a better fix for window frames.

Figure - 2U-Channel Knauf UW-track with

treated timber (by others)

300mmMinimum

3

2

1

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Nogginfor Services

CWStud

Top Track

Bottom Track

CWStud

Top Track

Bottom Track

18mm Marine Plywood / by others

CW Stud

TN ScrewGroveL Angle 25 x 25 x 0.5 mm

Section A - A

A ANoggin for Services

Plywood insert for services such as hand dryers or towel rails.

Location of noggins services

Correct noggin installation, marine plywood (by others) inserts provide more stability and a better fix for services such as hand dryers or towel rails.

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A head shall be formed over metal door with a cut-to- length section of track.The section of track then placed horizontally at the relevant height with flanges cut and bent vertically at each end, then

securely attached to the vertical studs a cut-to-length section of stud shall then be positioned vertically above the door head and extending to the ceiling track. See Figure-2b


To make openings, which doors can be installed, there should be profiles placed as shown below:

Knauf CW-Stud interlaced asboxed with treated timber (by Others)

3’’ (76 mm)

Min

imum

300

mm

Knau

f Tra

ck R

etur

n:

Figure-1

Figure-2a

Figure-3

Min

imum

300

mm

CW Profile

UW Profile

Figure-2b (Opposite side)

Door Opening Frame

Doors and openings

See Figure-1 & 2

See Figure-3

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Note: For installation of fire doors, you will have to follow the installation as described in the specific manufacturer's Test Reports on doors.

To create the joint at right angle at the foot of the opening, Extend the track 300mm larger than needed, Snip both sides of flange then bend it at an angle and fix it to the upright stud as shown. The floor rail must be fixed at not more than 150 mm from the door jamb.

It is possible to make the door jamb connections using:

(Detail-1) C-shaped upright profile, double boxed with insertion of wooden walls to facilitate the fixing of the door frame.

Door Framing / Door opening with CW studs

Detail-1

Knauf CW-Stud interlaced as boxed with

treated timber (by Others)

3” (76 mm)

≥ 5 15/16" (150 mm)≥ 5 15/16" (150 mm)

3” (76 mm)

Varies

Load classProfileDoor weight

Medium duty 100 slams

Min. CW 64x35x0.5 mm2+2Up to 60 kg

Severe duty 20 slamsMin. CW 64x35x0.5 mm2+2Up to 100 kg

No. of layers on each side

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Studs positioning - Splicing of studs

If the wall is high and it becomes necessary to join the profiles, Follow one of the overlap options as shown below:

Splicing method of Knauf of CW studs

Displace stud joints vertically

Stamp Plier

In the overlap area, rivet, screw attach or crimp the studs

Tips:

Vertical extension of studs (splicing)

OverlapStud size

CW 41 ≥ 41 cm≥ 64 cm≥ 89 cm≥ 102 cm

CW 64CW 89

CW 102≥ 152 cmCW 152

Calculation example:

Option 1 CW 41 – overlap 41 cm

Option 2 CW 41 – additional piece of UW 41 cm

u

2 CW studs interlaced like a box

Option 1 Option 2

2 CW studs. Jointconnected with

additional UW stud

Stud 1

Stud 2

u

AdditionalUW Profile

Stud 1

Stud 2

uu

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Cladding of Knauf Gypsum Boards• Boards should be staggered both vertically (610mm) and horizontally (min. 300mm) when cladding• For multi layer applications second layer should be again staggered both horizontally and vertically.

Firs

t Lay

er C

ladd

ing

48’’ inch(1220 mm)

48’’ inch(1220 mm)

2400

mm

Spacing 24’’ inch (610mm)

2400

mm

Seco

nd L

ayer

Cla

ddin

g

2400

mm

2400

mm


48’’ inch(1220 mm)

48’’ inch(1220 mm)

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10

>10

Screw spacing

Correct screw head position

Drive screws to just below the paper surface, taking care not to breakthe paper linerboard Screw heads must be approx. 1 mm inside the board surface

Screws should be 10 mm away from joints

Screws should penetrate studs by min. 9 mm

Screw location and penetration depth



TN 3.9 x 35 mmTB 3.9 x 25 mm1/2” (12.7 mm)

TN 3.9 x 45 mmTB 3.9 x 25 mm5/8” (15.9 mm)



-12’’ inch (305 mm)12’’ inch (305 mm)

12’’ inch (305 mm)

Number of layers

1st layer2nd layers

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Installation of Curved Wall

16.0

Concave - inner arch Convex - outer arch

Bending radius for dry gypsum board shall be not less than those given in table 1

1) Slowly bend the Knauf board laterally over the stud partition. Pre-bending on a template is recommended2) Fix with Drywall Screws continuously following the bending direction

Dry bending

Bending radius - Knauf boards

Table 1 – Bending Radius for Dry Gypsum Board

Gypsum Board Thickness

Bent Lengthwise Bent Widthwise

1/4 in. (6.4 mm)

* Two 1/4 in. (6.4 mm) pieces bent successively may be used to obtain a final 1/2 in. (12.7 mm) thickness at the shorter bending radius.

‡ Shall not be permitted to be bent widthwise while dry.

5 ft. (1500 mm) * 15 ft. (4600 mm) *

5/16 in. (7.9 mm) 6-1/4 ft. (1900 mm) 20 ft. (6100 mm)

3/8 in. (9.5 mm) 7-1/2 ft. (2300 mm) 25 ft. (7600 mm)

1/2 in. (12.7 mm) 10 ft. (3000 mm) * ‡

5/8 in. (15.9 mm) 15 ft. (4600 mm) ‡

Curved Partitions

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leng

th o

f lay

out

long

itudi

nal d

irect

ion

Template

angle or CD Channelto support boardsKnauf Board stripcut board

battento be fix theboard

Evenly spray water on the surface which will be in tension when the board is hung such that the water is allowed to soak into the core before application. The board must be dried within 24 hours of wetting to prevent the development of mold. Fans and mechanical dehumidification should be used to accelerate drying when conditions are not conducive to natural drying. When the gypsum board dries thoroughly, its original hardness is regained.

Moistening:

Gysum board bending

Gypsum board, face and back papers and core are thoroughly moistened as described below. Wet gypsum board is easily damaged and shall behandled with care.

1) Put the cut-to-length Knauf boards on a grid made of channels or similar with the side to be compressed on to (to ensure that excess water can drip off)2) Perforate the board laterally and longitudinally with a spiked roller3) Wet the board by spraying or use a lambskin roller and allow it to settle for a few minutes. Repeat the process until saturation is achieved and allow the excessive water to drain4) Place the board on the prepared template, bend and fix the board with adhesive tape and allow to dry

Wet bending

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GENERAL

A stop shall be applied at one end of the curve to restrain one end or edge of the gypsum board during installation. Pressure shall be applied to the unrestrained end or edge of the gypsum board forcing the field of the gypsum board into firm contact with the framing. Gypsum board shall be fastened by working from the "stopped" end or edge. The gypsumboard shall be held tightly against the framing while fasteners are being driven.

One end of the gypsum board shall be attached to the framing with screws. The gypsum board shall be progressively pushed into contact and fastened to subsequent framing members, working from the fixed end to the free end. The gypsum board shall be held tightly against each framing member while fasteners are being driven.

Application of Gypsum Board to Form Convex Surfaces

Application of Gypsum Board to Form Concave Surfaces

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Connect the CW Stud with Knauf crimp connection

CW Stud spacing: 150 mm (external radius)Knauf fastener spacing: ≤ 300 mm

Knauf UW profile (available in 50 / 75 / 100 mm)

Knauf UW track cut and bent

GENERAL

Gypsum board may be applied to the inner face of almost any archway. For short radius the gypsum board shall either be moistened or have the back paper scored across the width with parallel score marks spaced approximately 1 in. (25 mm) on center with the core broken at each cut.The gypsum board shall be held tightly against the supporting framing while fasteners are being driven.

ARCHWAYS

When joint treatment is specified at corners of arches or other curved surfaces, one edge of the joint tape shall be snipped from the edge of the tape to the center of the tape at approximately 3/4 in. (20 mm) intervals. The uncut half of the tape shall be applied to the curved surface and the cut half to the flat surface.

Where corner bead is used, one leg of the corner bead shall be snipped at approximately 3/4 in. (20 mm) intervals. The uncut leg of the corner bead shall be applied to the curved surface and the cut leg to the flat surface.

Joints, fasteners, and accessories shall be finished in the normal manner.

FINISHING

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150

150

150


16.0

Mark location of Shaftwall accurately on concrete structure with stringline/laser

Use Knauf Sealant under J Tracks forming the perimeter (head, base and any Abutments)


Stringline SStringline

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Use Knauf Sealant under J Tracks forming the

J-Track

J-Track

J-Track

J-Track


1) Fix J track to substructure with Knauf Plastic Plug & Screw (with 610mm spacing) and 50 mm from the Channel ends.

2) Knauf C-T studs should be positioned within the J tracks in sequence with Knauf Core Board.

• Studs should be trimmed to within 5 mm. of the slab to soffit height.

• There is no real requirement to secure the studs at this point as this will be achieved once the boards are screw fixed.

CTStudJ-Track

J-Track

J-Track

J-Track

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J-Track

Formation of door opening

3) For Doors weighing up to 60kg, Knauf J-Track Channels are used for the frame openings, Inserted with treated timber , Cut to the size of the studs.

• A head shall be formed over metal door with a cut-to- length section of `J` Channel.

• The section of `J` Channel then placed horizontally at the relevant height with flanges cut and web bent vertically at each end, then securely attached to the vertical J-Track Channels.

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Ceiling and floor connection

Knauf’s standard ceiling and floor connection details provide deflection tolerance up to 10 mm.

Knauf Drywall Screw


Knauf Wedge Anchor


5-10 mm

Knauf Gypsum Board

Knauf Coreboard

SOFFIT


5-10 mm

Knauf Drywall Screw



Knauf Gypsum Board

Knauf Coreboard

KSW A112 Ceiling connection

KSW A112 Knauf floor connection

Elevation

Elevation

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• Knauf Core Board should commence at one end and work across the shaft wall.

• Insert the first Core Board to fit into the Knauf `J` channel frame, Pull out the tabs in the flange of the `J` channel to retain the Knauf Core Board.

• The Next Knauf Core Board is then fitted into the C-T stud and this process if repeated until the one side is complete.

• For Horizontal joints in the Knauf Core Board, install C-T stud to the top

Coreboard joints

“J” Channel pull out tab and “CT” Stud Joint

KSW 112 Joint


Knauf “CT” Stud

Knauf Drywall Screw

Knauf Gypsum Board

Knauf Coreboard


Plan

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Coreboard joints

Cladding of Knauf Gypsum Boards• Boards should be staggered both vertically (610mm) and horizontally (min. 300mm) when cladding• For multi layer applications second layer should again be staggered both horizontally and vertically.



TB 3.9 x 35 mmTB 3.9 x 25 mm

TB 3.9 x 45 mmTB 3.9 x 25 mm



-12’’ inch (305 mm)12’’ inch (305 mm)

12’’ inch (305 mm)

Number of layers

1st layer2nd layers

Firs

t Lay

er C

ladd

ing

48’’ inch(1220 mm)

48’’ inch(1220 mm)

2400

mm


2400

mm

Sec

ond

Laye

r C

ladd

ing

2400

mm

2400

mm


48’’ inch(1220 mm)

48’’ inch(1220 mm)

1/2” (12.7 mm)

5/8” (15.9 mm)

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Installation of KC A001 Ceiling

17.0

Knauf Fire Resistant Ceiling Assemblies, Tested in accordance to ASTM E-119

* Fire Protection to Floor or Roof Cavity above* Fire Protection to Steel Beams Supporting Concrete Floors

*Boards types: Knauf Type-X

1 x 12.7 mm1220 mm 1000 mm 406 mm

1220 mm 1000 mm 406 mm

-

-

60 min.

120 min.

1 x 15.9 mm

*2 x 12.7 mm

*2 x 15.9 mm

CladdingThickness* Suspension

Hangers (mm)

Spacing of Structure

UpperChannels (mm)

FurringChannels (mm)

FireResistance

Splicing of Main Channel

Construction details

Splicing of furring channel

609 mm

overlap

12.512.5

38

Knauf KC A001 ceiling system

Knauf Fire Resistant Ceiling Assemblies, Tested in accordance to ASTM E-119

Knauf KC A001 ceiling system

600 mm

600 mm

406

200

1000 mm

1220 mm

200

150

406

406

Hat Furring Channel

L - angle

Main Channel Access Opening

Gypsum Board


KC A001Isometric view

Hat Furring ChannelLN Screw406 mm

Hat Furring Channel

Splicing / End to End Connection126

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Optional Suspension Support

Option - 1 Option - 2

TN Screw Hat Furring Channel

Main ChannelWire HangerL-Angle

LN Screw

Wedge Anchor

Knauf Gypsum Board

Construction details for Non Fire Rated Systems

These details represent some of the most common designs situations relevant to the Knauf KC A001 ceiling systems.

Movement control joint

Hat Furring Channel

Knauf MovementControl Joint

TN Screw

Main ChannelL - angleWedge Anchor

LN Screw

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Construction details for Non Fire Rated Systems

Reinforcement of Board Joints (Square edge only)

Detail (A)

For Fire Resistant System

Main ChannelHat Furring Channel

TN Screw

Knauf Gypsum Board Knauf Joint Compound

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General

Perimeter Fixing

Suspension

Primary Support Channels – C Channels

Splicing of the Main C Channels

General information

Knauf KC A001 Ceiling Systems must be installed in accordance with Knauf 's recommendations. When creating an airtight space, methods for the reduction of potential “ceiling lift should” be considered.

Select the fixing centers suited to the ceiling loading. See page-113 for spacing of dowels.Fix with Knauf approved ceiling dowel to the structural soffit. use the Knauf L Angle or Wire and fix to the approved ceiling dowel (Step-3)

The centers of the primary support channels should be aligned at the required height.Knauf L Angle should be fixed to the Knauf Main C-Channels with two Knauf LN wafer head screws (Steps-4)

If straight lengths of Knauf Main C-Channels need jointing, place the channels back to back, with a minimumn 609mm overlap, and fix with 4 Knauf LN Wafer Head Screws.

Mark the position of the ceiling line with a Chalk Line (Step-1) Knauf UD channels should be secured to the walls at the required heights, at maximum 609mm centers and 50mm from the ends of channels. The Knauf UD forming the perimeter and the Knauf Main C Channels do not need to be mechanically fixed together (Step-2)

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Hat Furring Channels

Insulation

Movement Control Joints

Boarding

Board Joint Reinforcement(Only for Fire Resistant System) Detail (A)

General information

If insulation is required, Installed once the primary support and the ceiling channels have been connected and before the boarding has started, Knauf insulation as specified should be inserted above the primary support channels. Care should be taken to ensure that the insulation is fitted neatly without gaps at abutments or between rolls.

Create movement control joints where ceiling runs exceed 9m, coincidingwhere possible with movement joints in the surrounding structure.

All boards should be fixed to the ceiling grid with the decorative face of the boards outwards and secured with Knauf Screws at maximum 203 mm centers (Step-6)Boards should be mounted at 90° to the direction of the ceiling channels (Step-7)Second layer should be installed with staggered joints.as shown in detail (A) page 137

Where the cut end of Gypsum board end’s Reinforcement through the inclusion of additional Hat Furring Channels should be implemented. A piece of Hat Furring channel should be located approx. 1 inch back from each board edge.

The Knauf Hat Furring Channels should be positioned at 406mm centers within the perimeter channels to coincide with the abutments of the boards, which will be fixed later. Connect the Knauf Hat Furring Channels to the Knauf Main C-Channel by means of LN Wafer Head screws (Step-5)

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Installation Steps

Mark the position of the ceiling line (deducting the thickness of the boards) with a Chalk Line.

1

Fix the UD channel on the perimeter (at 609mm centers and 50mm from end of channel).

Predrill the holes for the dowels and fix the L-angle with the dowel (e.g. Wedge Anchor) at the recommended spacing.

2

3

Knauf Main C Channels should be fixed to the L-angle with two Knauf LN Wafer head screw at the desired length.

4

ls

KbKth

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Installation Steps

Connect the Knauf Hat Furring Channels to the Knauf Main C Channel by means of Knauf LN Wafer Head Screws (2 screws per fixing).

5

Screw spacing for fixing of the boards: max 203 mm

Fix the boards to the furring channel with Knauf screws.

6

7

g

Scbo

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Processing gypsum boards

Cut the paper face with a sharp knifeCut the paper face with a sharp knife

Score the board by pushing along the cut side, then cut the others paper side

Cut the board 45 degreesCut the board 45 degrees

600 mm

600 mm

200

1000 mm

1220 mm

200 150

406

406Hat Furring Channel

L - angleMain Channel

Access Opening

Gypsum Board


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▪ Knauf Boards shall be cut by scoring and breaking or by sawing▪ When cutting by scoring, the face paper shall be cut with a utility knife▪ Knauf boards shall be broken by snapping boards in the reverse direction, then cutting the back paper with a utility knife▪ Cut edges should be smoothed with Knauf Beveler / Rasp Combo to obtain neat joints when installed▪ Short edges should be chamfered with Knauf Beveler / Rasp Combo▪ Holes for pipes or other small openings shall be accurately marked on the face on the board before removal - additional support at the opening’s / cut out with a purposely designed tool.

Processing gypsum boards

Smooth the cut edge with a beveler

Cutting and processing the boards

KC A001

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ms▪ Board surface should be cleaned of materials such as dust, oil etc.

▪ Filling and covering of joints should only take place after the boards have been allowed to rest in the given humidity and temperature zones, and no more longitudinal changes can be expected, i.e. expansion or contraction.

▪ First coat of Knauf joint filler should be applied with tools of sufficient width to extend a minimum 50 mm beyond both sides of the center of the joint (100 mm width).▪ Knauf joint tape should be embedded into the joint filler to reinforce the joint between two gypsum boards.▪ Once the first coat has dried, a second coat of Kanuf joint filler should be applied with 100 mm width on both sides of the center of the joint tape (200 mm width).▪ A very thin third coat of Knauf joint filler should be applied with minimum width no less than 150 mm beyond both sides of the center of the joint tape (300 mm width).▪ Once third coat has dried, surface should be sanded and smoothed.

Joint treatment

▪ Board surface should be cleaned of materials such as dust, oil etc.▪ Filling and covering of joints should only take place after the boards have been allowed to rest in the given humidity and temperature zones, and no more longitudinal changes can be expected, i.e. expansion or contraction.

,

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▪ Boards should be mounted at 90° to the direction of the ceiling channels.▪ In case of multi layer cladding, apply layers with staggered joints according to application scheme.▪ Press boards of each layer firmly on to the substructure and screw each layer separately.

Cladding of boards

Single / First layer cladding

2436

1220

1220

203

203

203

203

406 406 406 406 406 406

2436 mm

1000

1000



TN 3.9 x 35 mmTB 3.9 x 25 mm12.7 mm

TN 3.9 x 45 mmTB 3.9 x 25 mm15.9 mm



-8’’ inch (203 mm)8’’ inch (203 mm)

8’’ inch (203 mm)

Number of layers

1st layer2nd layers

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Second layer should be installed with staggered joints.

Cladding of boards

2436

1220

610

203

203

203

203

406 406 406 406 406 406

2436 mm

1000

1000

Detail (A) page 128

Second layer cladding

System Component

Plastic Plug and screw

Wedge Anchor

LN Screw

TN Screw3.9 dia. X 25/35/45 mm Length

Main "C" Channel (1.4 mm. thk.)

12.5

38

67

22

12.5 35 12.5

Hat Furring Channel 0.5 mm. thk.

22

23

UD Channel 0.5 mm L-angle 0.5 mm. thk.

25

35

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Overview Section

406 mm150 mm

Hat Furring Channel

Main ChannelL - angle

TN Screw

LN Screw

Wedge Anchor


Knauf Gypsum Board

1220 mm c/c L-angle

UD-Channel


111111111222223333333333333

Knauf L-angle is to be sniped & folded as shown then secured with LN screw.

The L-angle should then be securelyfixed to the marked location (1220mm spacing), using an approved KnaufWedge Anchor

Kas

TfixspW

1.

LN Screw

L-Angle

Wedge Anchor

•

•

The main channel is to be connected to the L-angle at the relevant height using Knauf LN screws and spaced every 1000 mm apart

•

2.

ThtheKn10

•

2.

LN ScrewMain Channel

L-Angle


Main channel can rest on top of the UD channel to help with alignment.

•

3.

•

Main Channel

TN Screw

UD-Channel


4.

Hat Furring Channel150 mm

Main Channel

LN Screw

5.

Knauf Joint Compound Knauf Gypsum Board

Main Channel

First hat furring channel should be positioned 150 mm from the existing wall structure to the center, all other hat furring channels shall be spaced 400 mm apart on centers.

•

Hat furring channels are to be connected to the underneath of the main channels using LN screws on both sides

•

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Installation of Access Panel

18.0


1) Open the Access Panel packaging and you will find the template corresponding to the size of the access panel. Take the sheet of card and place it on the wall or ceiling where panel has to be installed. Mark out a line along the borders of the sheet.

2) Cut out the marking with a piercing saw. The card mounting jigs are exactly : 200 x 200, 300 x 300, 400 x 400, 500 x 500 and so on. The outside of the frame to be mounted is 195 x 195, 295 x 295, 395 x 395 and so on. So there is a 5 mm difference between frame and opening.

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3) Now insert the frame after slightly tilting it.

4) Take care of the C-Chanel position. C-Channels should not be more than 100 mm away from the outside of the frame and not be less than 80mm

The reasoning for this it to provide sufficient support to the surrounding opening.

5) Now insert the frame in the correct position. If the cut out has been done correctly, there will be a 5 mm gap between frame and opening. Position the frame in the opening so that the gap is 2.5 mm on all sides. Fix the frame in this position with a C-clamp and screw the frame using the available screws from the outer side of panel opening. Distance from screw to screw should not be more than 150 mm.

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6) Before you start finishing the Access Panel, please check its functionality: put in the flap and see whether shutting and opening works well.



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Recommended Level of Gypsum Board Finishh

19.0

The following levels of finish are established as a guide for specific final decoration. The minimum requirements for each level shall be as described herein.

No taping, finishing, or accessories required. This level of finish may be useful in temporary construction or whenever the final decoration has not been determined.

Level of Gypsum Board Finish

Level 0:

All joints and interior angles shall have tape set in joint compound. Surface shall be free of excess joint compound. Tool marks and ridges are acceptable. Frequently specified in plenum areas above ceilings, in attics, in areas where the assembly would generally be concealed or in building service corridors, and other areas not normally open to public view. Accessories optional at specifier discretion in corridors and other areas with pedestrian traffic. Some degree of sound and smoke control is provided; in some geograph-ic areas this level is referred to as “fire-taping.” Where a fire-resistance rating is required for the gypsum board assembly, details of construction shall be in accordance withreports of fire tests of assemblies that have met the fire-rating requirement. Tape and fastener heads need not be covered with joint compound.

Level 1:

All joints and interior angles shall have tape embedded in joint compound and wiped with a joint knife leaving a thin coating of joint compound over all joints and interior angles. Fastener heads and accessories shall be covered with a coat of joint compound. Surface shall be free of excess joint compound. Tool marks and ridges are acceptable. Joint compound applied over the body of the tape at the time of tape embedment shall be considered a separate coat of joint compound and shall satisfy the conditions of this level. Specified where gypsum board is used as a substrate for tile; may be specified in garages, warehouse storage or other similar areas where surface appearance is not of primary concern.

Level 2:

Level of finish

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All joints and interior angles shall have tape embedded in joint compound and shall be immediately wiped with a joint knife leaving a thin coating of joint compound over all joints and interior angles. One additional coat of joint compound shall be applied over all joints and interior angles. Fastener heads and accessories shall be covered with two separate coats of joint compound. All joint compound shall be smooth and free of tool marks and ridges. Note: It is recommended that the prepared surface be coated with a drywall primer prior to the application offinal finishes. See painting/wallcovering specification in this regard. Typically specified in appearance areas which are to receive heavy or medium texture (spray or hand applied) finishes before final painting, or where heavy-grade wallcoverings are to be applied as the final decoration. This level of finish is not recommended where smooth painted surfaces or light to medium wallcoverings are specified.

Level 3:

All joints and interior angles shall have tape embedded in joint compound and shall be immediately wiped with a joint knife leaving a thin coating of joint compound over all joints and interior angles. Two separate coats of joint compound shall be applied over all flat joints and one separate coat of joint compound shall be applied over interior angles. Fastener heads and accessories shall becovered with three separate coats of joint compound. All joint compound shall be smooth and free of tool marks and ridges.Note: It is recommended that the prepared surface be coated with a drywall primer prior to the application of final finishes. See painting/wallcovering specification in this regard. This level should be specified where flat paints, light textures, or wallcoverings are to be applied. In critical lighting areas, flat paints applied over light textures tend to reduce joint photographing. Paints with sheen levels other than flat and enamel paints are not recommended over this level of finish. The weight, texture, and sheen level of wallcoverings applied over this level of finish should be carefully evaluated. Joints and fasteners must be adequately concealed if the wallcovering material is lightweight, contains limited pattern, has a gloss finish, or any combination of these finishes is present. Unbacked vinyl wallcoverings are not recommended over this level of finish.

Level 4:

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All joints and interior angles shall have tape embedded in joint compound and shall be immediately wiped with a joint knife leaving a thin coating of joint compound over all joints and interior angles. Two separate coats of joint compound shall be applied over all flat joints and one separate coat of joint compound shall be applied over interior angles. Fastener heads and accessories shall be covered with three separate coats of joint compound. A thin skim coat of joint compound trowel applied, or a material manufac-tured especially for this purpose and applied in accordance with manufactur-er's recommendations, applied to the entire surface. The surface shall be smooth and free of tool marks and ridges.Note: It is recommended that the prepared surface be coated with a drywall primer prior to the application of finish paint. See painting specification in this regard. This level of finish is highly recommended where paint is specified orwhere severe lighting conditions occur. This highest quality finish is the most effective method to provide a uniform surface and minimize the possibility of joint photographing and of fasteners showing through the final decoration.

Level 5:

A skim coat of joint compound is intended to conceal small imperfections in joints and on the surface of the gypsum board, smooth the texture of the paper, minimizedifferences in surface porosity, and create a more uniform surface to which the final decoration can be applied. A "skim coat" is essentially a "film" of joint compound and is not a readily measurable thickness. There is no specific mil thickness that constitutes a proper skim coat. A skim coat is described in the foregoing text as being "trowel applied" with the intent being that the consistency (viscosity) of the joint compound be such that it can be applied by a trowel. Other tools may be used for application so long as the trowel consistency is achieved. The objective of the application is to achieve total coverage of the entire surface with the skim coat. This is typically accomplished by delivering the compound to the surface and using a drywall broad knife to force the compound into thesurface pores and imperfections while shearing off excess compound from the surface. A skim coat will not approximate a plastered surface. Once the skim coat dries, the gypsum board paper may show through and the treated joints, filled voids, and spotted fastener headswill likely be visible.

Comments: Skim Coat

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Wall and ceiling areas abutting window mullions or skylights, long hallways, or atriums with large surface areas flooded with artificial and/or natural lighting are a few examples of critical lighting areas. Strong sidelighting from windows or surface-mounted light fixturesmay reveal even minor surface imperfections. Light striking the surface obliquely, at a very slight angle, greatly exaggerates surface irregularities. If critical lighting cannot be avoided, the effects can be minimized by skim coating the gypsum board surfaces, by decorating the surface with medium to heavy textures, or by the use of draperies and blinds which soften shadows. In general: paints with sheen levels other than flat, enamel and dark paint finishes

Critical (Severe) Lighting Areas

The recommendations of individual manufacturers of gypsum board, joint tapes and compounds, accessories, drywall primers, wallcoverings, adhesives, texture materials, and paints may vary from what is recommend-ed herein and as such are not a part of this recommended specification.

Manufacturer Recommendations

Applied as a first coat to the entire prepared gypsum board surface with brush, roller, or spray, prior to decoration. Where final appearance is critical, the application of high quality high solids, drywall primer will minimize most decorating problems.

Drywall Primer

A good quality, white, latex drywall primer formulated with higher binder solids, applied undiluted, is typically specified for new gypsum board surfaces prior to the application of texture materials and latex wall paints. An alkali and moisture resistant primer and a tinted enamel undercoat may be required under enamel paints.Consult with the finish paintmanufacturer for specific recommendations.

For finish paints:

White, self-sizing, water base, “universal” (all purpose) wallcovering primers have recently been introduced into the marketplace for use on new gypsum board surfaces. These products are claimed to minimize damage if wallcoverings are subsequently removed, bind poor latex paint, allow hanging over glossy surfaces and existing vinyls, hide wall colors, and to be water washable.

For wallcoverings:

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Texture material is applied by brush, roller, spray, or trowel, or a combination of these tools, depending on the desired result. Textured wall surfaces are normally overpainted with the desired finish; overpainting of textured ceiling surfaces may not be deemed necessary where an adequate amount of material is applied to provide sufficient hiding properties. A drywall primer may not be required undercertain proprietary texture materials; consult with the manufacturer of the texture materials for specific recommendations.

Texturing

A smooth surface may be achieved by lightly sanding or wiping joint compound with a dampened sponge. Care shall be exercised to ensure that the nap of the gypsum board facing paper is not raised during sanding operations. For additional information on the finishing of gypsum board surfaces consult Knauf Technical Team on ASTM Standard C840.

Tool Marks and Ridges

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Components and Accessories

Our product range is extended in order to serve better and faster drywall solutions

21.0


Spring Toggle is a cavity fixing with long threaded screw and it is ideal for superior loads especially for ceilings.

Cavity fixing is used for superior loads on partitions and it's design enables that the fixtures can be removed and refitted.

Spring Toggle with Screw

Cavity Fixings

Driva Plus with screw requires no drilling and can be screwed simply on the partitions for standard loads.

Ceiling Wire Anchor is as easy as the Wedge Anchor in terms of application and it can be used as a perfect solution for D112 Ceiling System with Hanger Wires. Ceiling Wire Hanger is a faster alternative to Ceiling steel dowel in case of D112

Ceiling Wire Hanger

Wedge Anchor

Driva Plus Self Drilling Metal Plug

Wedge Anchor is a very easy-to-apply accessory which can be used as a best solution for Knauf Ceiling systems (RCS and D112 with Nonius Hangers), perimeter fixings for ceilings, and even for partitions where fire resistance is required. Wedge Anchor is faster alternative to the ceiling steel dowel in case of RCS Ceiling systems and FR rated alternative to Plastic Plug & Screw in terms of fire rated partitions.

Hammer Fixings are light duty fixings which has a special thread lock design that prevents pre-expansion during transit installation and provides an option for faster fixing without screwdriver work. Both sizes are suitable for perimeter fixings for both partitions and ceilings. In addition to that, 8x45 mm is perfectly suitable with universal bracket in wall claddings.Hammer fixings are faster alternatives to the Plastic plug and Plastic plug screw.

Hammer Fixings

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Concrete Screwbolt is a non-expansion bolt with undercut technology for fixing into wood, brick, cracked or non-cracked concrete and it is a high performance bolt that cuts its own thread. It suits to perimeter fixings, to some details of Fire Resistant partition and it is specific for Head of Wall connections.

Concrete Screwbolt

Special Textile Fiber Glass joint Tape is a premium joint tape which performs at the best level to prevent cracks and to provide the best finishing.

Special textile fiber glass Joint tape

Corner finishing and protection for gypsum boards with fine expanded metal wings which provides superior keying to the plasters, which eliminates shadowing and avoiding cracking.

Corner Bead - Micro

Edge finishing and protection for gypsum boards with fine expanded metal wings provides superior Keying to the plasters, which eliminates shadowing and avoiding cracking.

Edge Bead - Micro

PVC Shadowing trim is preffered especially for aesthetic drywall finishing and it is used to create a shadow line which minimizes building imperfections.

PVC Shadowline Trim

Designed to provide movement to accomodate expansion and contraction caused by initial stucco shrinkage and minor thermal movement.

PVC Control Joint (Movement Bead)

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Company’s Certifications

As per Estidama & LEED requirements, our products have been tested for chemical materials banned or required to be in a very low concentration in third party well known laboratories.

Estidama and LEED compliant

For outstanding performances in water and energy management, our factory has been awarded the Environmental Performance Certificate from the Ministry of Environment and Water.

Environmental certifications

Our products are free from asbestos. Boards produced in Knauf factory in Ras al Khaimah have been tested for asbestos content, no asbestos was detected. Complies with international requirements regulating this substance.

Asbestos

The boards produced in Knauf factory in Ras al Khaimah have been tested on DIN EN ISO 16009 for formaldehyde emissions. Maximum recorded concentration levels on 30 days testing were 16μg / m3 ( 0.016 mg/m3) – below the limits required in international standards.

Formaldehyde

Knauf joint compound Readygips has been tested for VOC ( volatile organic compounds). Detected amount: 0.14 g/l is below the limits required in international standards.

VOC

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Knauf has Civil Defense Approval from RAK Civil Defense and Qatar Civil Defense for factory and systems. Our fire rated systems are not only certified with accredited international bodies, but also recognized by local authorities.

Civil Defense Approval

Knauf factory from Ras al Khaimah is holding ISO 9001:2008 Quality Management System certification since 2011. Recently Knauf has been certified on ISO 14001: 2004 and BHS OHSAS 18001:2007

ISO certifications

QUALITY MANAGEMENT SYSTEM - ISO 9001:2008

This is to certify that:

Knauf LLCPO Box 112871DubaiUAE

Holds Certificate No: FM 577441

and operates a Quality Management System which complies with the requirements of ISO 9001:2008 for the followingscope:

Manufacture of building materials specifically metal profiles for dry wall systemsinstallation and sales of complete dry wall systems.Manufacture of building materials specifically metal profiles for dry wall systemsinstallation and sales of complete dry wall systems.

For and on behalf of BSI:For and on behalf of BSI:of

Chair, Certification Body Management Committee.

Originally registered: 09/11/2011 Latest Issue: 27/11/2011 Expiry Date: 09/11/2014

Page: 1 of 2

This certificate was issued electronically and remains the property of BSI and is bound by the conditions of contract.An electronic certificate can be authenticated online.Printed can be validated at www.bsi-global.com/ClientDirectory or telephone +44 (0)20 8996 7033.

The British Standards Institution is incorporated by Royal Charter.BSI (EMEA) Headquarters: 389 Chiswick High Road, London, W4 4AL, United Kingdom

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Knauf Factory in RAS al Khaimah is Certified for production of TYPE X boards by Intertek USA.Knauf Boards are bearing the prestigious Warnok Hersey Mark that is guarantee for product compliance to ASTM C 1396 and Type X certification for fire rated boards.

The Warnock Hersey Mark (WH) is North America’s leading product safety and performance mark for building and construction products.

Products bearing the WH Mark indicate compliance to relevant building codes, association criteria, and product safety and performance standards. Intertek’s Warnock Hersey (WH) Mark has long been the building product industry’s preferred certification mark. The WH Mark can be found on more than 6,500 products ranging from fire doors and builders’ hardware to hearth, plumbing and construction products. Having Intertek’s WH Mark on product reflects our commitment to product safety, performance and quality to inspectors, builders and end users.

The mark also signifies that the product’s manufacturing site undergo periodic follow-up inspections to ensure ongoing compliance of the originally certified product.

Certified products

AUTHORIZATION TO MARK

This authorizes the application of the Certification Mark(s) shown below to the models described in the Product(s) Covered section when made in accordance with the conditions set forth in the Certification Agreement and Listing Report(s). This authorization also applies to the Multiple Listee model(s) identified on the correlation page of the Listing Report. This document is the property of Intertek Testing Services and is not transferable. The Certification Mark(s) may be applied only at the location of the Party Authorized to Apply Mark.

Applicant: Knauf LLCKnauf Head Office, 51b Zamarodah Building, KaramaP.O. Box 112871Dubai

Country: United Arab Emirates

Contact: Amer Bin Ahmed

Phone:

Fax:

Email: [email protected]

Party Authorized to Apply Mark: See following page(s)

Evaluation Center: Intertek (Elmendorf)

Control/Client Number: 228254

This document supersedes all previous Authorizations to Mark for the noted Report Number.

This Authorization to Mark is for the exclusive use of Intertek's Client and is provided pursuant to the Certification agreement between Intertek and its Client. Intertek's responsibility and liability are limited to the terms and conditions of the agreement. Intertek assumes no liability to any party, other than to the Client in accordance with the agreement, for any loss, expense or damage occasioned by the use of this Authorization to Mark. Only the Client is authorized to permit copying or distribution of this Authorization to Mark and then only in its entirety. Use of Intertek’sCertification mark is restricted to the conditions laid out in the agreement and in this Authorization to Mark. Any further use of the Intertek name for the sale or advertisement of the tested material, product or service must first be approved in writing by Intertek. Initial Factory Assessments and Follow up Services are for the purpose of assuring appropriate usage of the Certification mark in accordance with the agreement, they are not for the purposes of production quality control and do not relieve the Client of their obligations in this respect.

Testing Standard{s}: :ASTM E1966 (2007):ASTM C1396 / C1396M (2009)

Product: Knauf Gypsum Boards

ATM for Report G10966881; G100993201; G101095074 ATM Issue Date: 08/20/2013

Report prepared for: Michael Shokrian (Intertek) on 8/20/2013 4:49:47 AM

Knauf LLC | 29665 | Rev: May 22 2013 2:21PM | Uncontrolled Copy Page 1 of 9

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• Improve efficiency• Reduce wastage of materials• Learn proper application methods• Faster installation time• Practice in the use of high-end drywall tools• Ensure a successful delivery of project

Upon completion of any of the Knauf Training courses a Knauf training attendance certificate & Training recogni-tion card is awarded. This certificate gives you an edge over other competitors, as it is an endorsement that you have been instructed in the best practice of the industry, by the best in the industry. This in-turn gives us the confidence then to recommend you to future developers.

The Key Advantages of Knauf Training:

Knauf Training academy has purposely been developed to offer a variety of courses that provide practical training on the design and construction of plasterboard systems. Training also improves the safety on site and help companies to complete the project more efficiently whilst taking advantage learning hands-on experience whilst under the guidance of a Knauf Training Specialist.

The courses that we offer include partitions, wall linings, shaftwalls and suspended ceiling. Training is also provide on tape & jointing(Hand application).

The main aim of these courses is to provide knowledge and an understanding on the installation and the key purpose of Knauf drywall systems. Also we want to ensure that all trainees have full confidence in their ability when either proposing a Knauf system or constructing a system on-site. Knauf Training will also give you a better understanding of the products that we offer in the market, and allow you to understand what products are needed to assembly a Knauf system correctly and professionally. With the growing pressure & expectations of developers for fast and professionally constructed work, then you can be sure with the knowledge & guidance of Knauf expert trainers you will be on the road to perfection.

Become a Drywall Expert

d to offer aff

We reserved the right to amend technical specifications without notice. The current edition applies. Our guarantee applies only to the defect-free state of our materials. The structural, static and physical characteristics of Knauf systems can only be ensured where only Knauf system components or products recommended by Knauf are used. Consumption, quantity and design specification are typical figures, which may not be transferable under different circumstances. All rights reserved. Changes, reproductions and photo-mechanical and electronic repetition, even in part, the specific permission of Knauf LLC, PO Box 112871, Dubai, United Arab Emirates.

Knauf Qatar BranchP.O.Box 27111

Doha, State of QatarTel: +974 4452 8191Fax: +974 4452 8181

P.O.Box: 112871, [email protected]

Fax: +971 4 334 9659Phone: +971 4 337 7170

Knauf Head Office

Made in UAE

Knauf RAK PlantP.O.Box 50006

Ras Al Khaimah, UAETel: +971 7 221 5300Fax: +971 7 221 5301www. .ae

Knauf Installation Manual

Documents

Transcript of Knauf Installation Manual