cop everest wall solutions

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Code of PracticeEverest Wall Solution

2008

Everest Industries Limited | 2008


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C O P | Ev e re st Wa l l So l u t io n | P a g e | 2

CONTENTSEverest Industries Limited

Everest Wall Solution

Types of Wall Solutions

Design Considerations for Walls

Structural

Acoustic

Thermal

Fire

Services

Impact Protection

Performance Requirements

Fire Performance Requirements

Acoustic Performance Requirements

Everest Dry Wall

General Guidelines

Technology

Basic Materials: Stud & Track, Board

Basic Materials: Everest Wall Board

Installing Steel Framework

Fixing Board over Steel framework

Fastener Spacing

Treatment of Corners

Treatment of Wall Endings

Treatment of Opening

Ducting / Conduiting

Checklist of materials and accessories

Checklist of Tools and Equipments

J ointing Systems

J ointing with groove finish

J oint-less with beveled boards

J oint-less with Square edge boards

Installation Details

Dry Wall in Double Skin Full Height/Half Height G.I. Framework

Dry Wall in Double Skin Full Height/Half Height Timber Framework

Dry Wall in Single Skin Full Height/Half Height Aluminium Framework

Dry Wall in Single Skin Full Height/Half Height Timber Framework

Paneling with G.I. Framework

Paneling with Timber Framework

Paneling without Framework

System Index

Everest Wet-Area Wall


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Appendices

EverestIndustriesLimitedEverest Industries Limited (EIL), as an established and reputed name in India since 1934 for

the manufac turing and marketing of Fibre Cement products. EIL's current productportfolio covers both roofing as well as plain boards and c omposite panels, which finds its

applications in different segments like industrial, commercial as well as residential for wall

and ceiling lining, dry wall partitioning and prefab shelters or portable cabins. EIL is a fast

growing c ompany and its turnover has reached US $ 75 million registering C AG R of 15%

over the last three years.

Company has the backing of vast experience and expertise, both organizational and

technical. The Ultra Modern Research and Development facility is manned with

experienced, skilled and dedicated personnel engaged in product, plant and

technology development.

The R&D ac tivities are directed towards modernization automation and technological

innovation, development and commercialization of value added products and towards

exploring new avenues for import substitution and utilize waste materials.

EverestKeyFacts

Sales of 303 cr. ($75m)

5 major production fac ilities

1100 employees

Over 3000 retail points

Fast growing export market in Europe, Africa , Australia & Asia


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EverestPresenceinIndia

EverestWallSolutionEver since the inception of mankind, the humans have always tried to protect themselves

from natural aggressions like storms, rain, hail and so on. They have always wanted to

create a space, where they can live with their families, work and spend time. A place

which safe, comfortable and protected.

With the population continuously increasing and the cost of conventional construction

material going up, people are looking for alternatives which are cost effective and can

match with the aesthetics and strength of the conventional construction. Also the

eventful and demanding life of today does not leave any time for waiting for the

construction to complete in months. The solution required is to be a fast construction

technology.

The solution comes from Everest Industries Limited, an organization pioneer and leader in

the field of new age construction material. With its vast experience of building solutions

technologies and state of the art research facilities EIL has come up with the Everest Wall

Solution Technology, the first of its kind in India. The technology is easy to use,

environmentally safe and has strength comparable to the conventional wall.

EILs wall solution is a fast, easy to build, cost effective and quality solution to all the wall

related problems in modern day construction. EIL provides a wide range of wall solutions,

which include Different thicknesses of walls with varied acoustic and thermal properties.


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The wall could be finished and textured in as many forms as one can think. EIL provides

different cladding options ranging from Everest Wall Board and Everest Heavy Duty Wall

Board, providing a plain finish which could be painted, covered with wallpapers or could

be given any other finish as the person likes. The Everest Designer wall board, a pre

embossed designer wall board, can give different textured looks.

The EILs wall solution can very well solve all the safety and space division concerns of the

customers. The walls could be (if required) uprooted and the space could be redesigned

as the needs of the user changes.

In pursuit of offering the need based solution for customers, Everest Wall Solutions provides

Strong, speedy and safe construction.


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TypesofEverestWallSystems

Everest offers three types of wall systems:

1) Eve rest Dry Wa ll System :Suitable for non-load beading walling in commercial,

residential and all other kind of buildings. This is a very versatile kind of system, accepted

and adopted worldwide. This system has tremendous flexibility to adapt to a particularneed. The frame sizes can be varied, the board sizes and thicknesses can be varied. We

have outlined three variations in this system as shown in sketches below.

Everest Wall Board

Everest Wall Board

Insulation

C-Stud

Everest Wall Board

Everest Wall Board Stri

Insulation

C-Stud

Everest Wall Board Stri

Everest Wall Board

Everest Wall Board

Plasterboard

Insulation

C-Stud

Plasterboard

Everest Wall Board

2) Eve rest Wet-A rea Wall System :This system is very similar to the previous kind. The

difference is that this is meant for wet area construction. Hence, this uses slightly different

categories of materials and accessories.

Wall Board

C-Stud

Everest Heavy Duty

Wall BoardEverest Heavy Duty

3) Eve rest So lid Wa ll Sy stem :This is made with ready-made solid wall panels. It is extremely

fast to construct and also gives a very solid look.

Everest Solid Wall PanelSolid Abutment


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DesignConsiderationsforWallsWalls are one of the three most important components of any building. These have to

play multiple roles, like:

Protection against natural elements (rain, sun, snow etc.)

protection against human beings and animals (intruders)

supporting the structure (in load bearing structure)

Hosting several other building components like plumbing pipes, door-windows, light

fittings etc .

providing visual barrier between two areas

cutting-off sound/noise

blocking/reducing heat propagation

preventing fire propagation

providing a bearing surface to accept treatments for aesthetics (pa int, stone

cladding etc)

Each of the above mentioned are very important features of any wall, and care should

be taken for the same. It is important to note that in different situations different features

play decisive role in wall design. For example:

Lec ture Hall/Auditorium > cutting-off sound

Outer walls in Tropical areas > blocking/ reducing heat propagation Outer walls in very cold areas > blocking/ reducing heat propagation

Boundary wall > protec tion against intruders, providing visual barrier

Bathroom wall > protec tion against elements (moisture), hosting fixtures

It is therefore important to know what is critical to the particular wall before designing it.

Various walling systems are in practice, and they should be chosen with utmost care. Also,

almost in all systems, there are ways available to modify the wall properties to suit the

particular need. This manual describes the wall systems available from Everest Industries

Limited and provides insight into which to use where. It also outlines the ways to c ustomize

the systems to suit the requirement.

StructuralConsideration


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In this manual, we do not talk about walls that bear the load of the structure.

Our systems described here are all non-load bearing wall systems. These are often called

partitions.

We should be, however, aware that even non-load bearing walls have to bear certain

loads, like:

Self load

Lateral load (horizontal push)

Load of any object/device hanging on the wall for example wall lights, shelves,

pictures, mirror

Load of cladding/finishing etc. Sometimes these are very heavy, ex marble

cladding.

Wa ll he ig ht :Height of the wall affects the bending moments that occur at its ends and

the amount of deflection at the centre. Greater the height, more the bending moment,

hence, stronger it has to be.

Horizontal span of the wall: Long straight walls are susceptible to failure due to lateral

loads. Interrupting them with perpendicular walls make them stronger and more stable.

AcousticalConsideration

Acoustics of a room can be divided into two parts:

Noise/Sound level maintained within the room. This is determined by the sound absorption

properties of wall, floor, ceiling and other room furnishings.

Sound transmitted from the room to the adjoining room through wall, ceiling, floor and

openings. This depends on sound insulation properties wall,

ceiling and floor.

Sound Absorption

Sound absorption depends upon the surface properties of wall.

Soft surfaces absorb more sound than hard surface. Sound

absorption requirement depends upon;

Required noise level to be maintained

Level of sound created in the room


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Places like church, hospital wards, song recording room require very low noise level. They

need good sound absorbing surfaces.

Places like auditorium, shopping malls, crowded office are very noisy. Here noise needs to

be controlled by sound absorption.

Sound Insulation

Sound insulation is the reduction of sound passing from one place to another through a

dividing element. Sound insulation property of a wall depends upon the composition of

the wall. Sound insulation becomes critical when high level of privacy is required between

adjoining rooms.

ThermalConsideration

Thermal insulation is a very big issue in places where the climate is very hot or very cold.

In hot areas, people devise ways to cut heat propagation into the building. For example

the windows facing sun are either avoided or made small, usually with larger chhajas, so

that direct sun ray does not enter the room. Heat transmission through the wall is

minimized by:

Using materials with higher thermal mass (heat capacity)

Using reflective surface on the wall

Using materials with low thermal conductivity

Everest walls are designed to give high thermal performance. Thermal properties can be

varied in Everest Dry-Wall by changing following parameters:

Stud Depth: Greater depth gives greater insulation

Board Thickness: Increase in board reduces thermal transmission

Insulation Infill: Space inside the studs can be filled with insulating materials to

increase thermal performance.

FireConsideration

Fire is another crucial factor to consider. Fire can cause irreversible and insurmountable

damages in no time. It is one of the most talked about subject in building protection.

Construction codes of most of the countries in the world give spec ial emphasis on fire

protection.


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C O P | E v e re st Wa l l So l u t io n | P a g e | 1 0

Everest is very proud to talk about fire efficiency of its walls. The basic material of wall

Everest Wall Board is a cement based product and is completely incombustible. Everest

walls have been tested for very high level of fire resistances.

We offer fire rated walls ranging from hr to 2 hr which is enough to meet criteria of most

building codes.

ServiceConsideration

Walls have to take in service routes, like electrical conduits, plumbing lines etc.

Everest Dry-Wall and Everest Wet-Area Wall have capabilities to run electrical and

plumbing lines very easily. The methods are explained in detail in the respective chapters.

Impact

Protection

Walls may be subject to excessive loadings like hard body impacts, crowd pressure etc.

Areas like following are susceptible to such loads:

Corridors of cinema halls > subjec t to c rowd pressure

Corridors of hospitals > subjec t to trolley impacts

High Impact walls can be made with Everest heavy Duty Wall board. Thicknesses of board

used can be increased to increase impact strength. When we are trying t achieve high

strengths, along with boards, stud depth and thickness should also be increased.

Protective devices like

handrails,

crash rails,

buffer rails,

chair rails,

corner guards,

large splayed skirting,

protective plates and sheeting

Should also be used in public areas.


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PerformanceRequirementsFireRatedSystems

Genera l

To select the correct wall system from those detailed in this manual, you must first

determine your performance requirements for Fir e Resistance Level (FRL), Weighted

Sound Reduction Index (Rw) and impact sound insulation. To help you, the wall systems

have been divided in two sections, covering steel frames and timber frames. These

sections are further divided into non-rated and fire rated applications. The fire rated

applications contain information on load bearing and non-load bearing systems. Framing

arrangements such as single, staggered and dual frames are included. Special

applications such as security panels have also been included.

Note: Additional performance requirements, such as abrasion, impact and moisture

resistance, should also be considered.

No n-Fire Ra ted System s

Non-Fire Rated Wall systems are constructed using a layer of Everest Wall Boards Lining

applied to one or both sides of a steel or timber frame. The arrangement of the frame, the

thickness of the Wall Board Lining and whether or not an absorbent acoustic fill is placed

in the cavity depend upon the required resistance to damage by abrasion and impact

and the specified sound transmission properties.

Additionally, in some instances all the walls are not required to be fire rated but does

require the wall lining to be non-combustible. Everest Wall boards lining may be used in

these cases, because it is confirmed as a non-combustible material confirming to BS-476

standards.


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Fire Ra ted System s

Fire Rated Systems for an application are selected on the basis of the required Fire

Resistance Levels (FRL) as set out by the local governing regulations in addition to any

acoustic requirements.

Fire rated wall systems are constructed from light weight framing (steel or timber) that is

lined on both sides with one or two layers of fire resistant Everest Wall Board Lining and/or

an additional layer of plasterboard lining.

It is relatively simple to achieve a Fire Resistance Level (FRL). Irrespective of the frame type

(i.e. steel or timber framing), the lining thickness of both the layer of Fire Resistant

plasterboard and Everest Wall Boards Lining will always be the same for the specified FRL.

The use of load bearing and non-load bearing systems will depend on the application.

The timber framed systems detailed in this manual are generally used in non-load bearing

applications.

The steel framed systems detailed in this manual are propriety framed systems and are

generally used in non-load bearing applications. Steel frames can be designed by a

qualified structural engineer to be load bearing, provided minimum size sections are

equivalent to the systems in this manual to retain the FRLs.

AcousticsRatedSystems

Genera l

Soundproofing is any means of reducing the intensity of sound with respect to a specified

source and receptor. There are several basic approaches to reducing sound: increasing

the distance between source and receiver, using noise barriers to block or absorb the

energy of the sound waves, using damping structures such as sound baffles, or using

active anti-noise sound generators.

Soundproofing affects sound in two different ways: noise reduction and noise absorption.Noise reduction simply blocks the passage of sound waves through the use of distance

and intervening objects in the sound path. Noise absorption operates by transforming the

sound wave. Noise absorption involves suppressing echoes, reverberation, resonance and

reflection. The damping characteristics of the materials it is made out of are important in

noise absorption. The wetness or moisture level in a medium can also reflect sound waves,


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significantly reducing and distorting the sound travelling through it, making moisture an

important factor in soundproofing.

Three different types of sound transmissions need to be controlled for complete sound

insulation. Acoustic transmission in building design refers to a number of proc esses by

which sound can be transferred from one part of a building to another. Typically these

are:

1. Airborne transmission - a noise source in one room sends air pressure waves which

induce vibration to one side of a wall or element of structure setting it moving such

that the other face of the wall vibrates in an adjacent room. Structural isolation

therefore becomes an important consideration in the acoustic design of buildings.

Highly sensitive areas of buildings, for example recording studios, may be almost

entirely isolated from the rest of a structure by constructing the studios as effective

boxes supported by springs. Air tightness also becomes an important controltechnique. A tightly sealed door might have reasonable sound reduction properties,

but if it is left open only a few millimetres its effectiveness is reduced to practically

nothing. The most important acoustic control method is adding mass into the structure,

such as a heavy dividing wall, which will usually reduce airborne sound transmission

better than a light one.

2. Impact transmission - a noise source in one room results from an impact of an object

onto a separating surface, such as a floor and transmits the sound to an adjacent

room. A typical example would be the sound of footsteps in a room being heard in aroom below. Acoustic control measures usually include attempts to isolate the source

of the impact, or cushioning it. For example carpets will perform significantly better

than hard floors.

3. Flanking transmission - a more complex form of noise transmission, where the resultant

vibrations from a noise source are transmitted to other rooms of the building usually by

elements of structure within the building. For example, in a steel framed building, once

the frame itself is set into motion the effective transmission can be pronounced.

The ability of Everest fire and acoustically rated walls to reduce airborne sound depends

on four factors:

1. Mass of the linings and their intrinsic characteristics.

2. Width of the wall cavity.

3. Framing configuration.

4. Inclusion of a fibre blanket of batts as sound insulation into the cavity.


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To achieve the performance results stated in this manual, you must take particular care to

seal between the frame and primary structure (e.g. at a deflection head). Any gaps in

the wall system can lead to substantial losses of acoustic rating.

Repeated tests have shown that where Everest Wall Boards Lining is used, for the same

cavity width, there is no practical difference in performance between timber and steel

studs of the same depth.

Therefore results achieved on a steel frame may be applied to a timber frame with equal

cavity width and vice versa.

The systems presented in this manual provide excellent acoustic performance that range

up to an Rw of 69.


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Ac oustic Insulat ion

Acoustic performance of a wall system can be improved (i.e. Rw values increased) by

installing an absorbent fill in the cavity. This is usually an acoustic grade fibreglass or

polyester blanket or batts not less than 25mm thick.

Impact Sound Insulation

Where the application is required to reduce

impact sound, you must select a system that is

either staggered or dual stud. Resilient

channels can be used to reduce impact

sound; however, they will not achieve

isolation of the walls

Resilient Channels

Where the wall is required to minimize the transmission of

impact sounds, either select a staggered or dual stud

system. Where cost is a constraint, resilient channels, fixed

to the side of the wall subject to impact, may be used as

an alternative.

While less effective than staggered or dual stud systems, the level of sound isolation may

be adequate for applications such as between a corridor and an office space.

FramingArrangements

Genera l

Generally, there are three basic types of walling systems available to designers: the single,

staggered and dual frame systems. All three wall

systems can achieve the same FRL levels when the

same lining materials are

selected, but they willprovide different

acoustic properties.

Sing le Stud Fram e System

The single stud frame system is a single leaf wall with lining on each side. This system has

the lowest acoustic rating when compared with the other two systems and will not

adequately insulate against impact sound.


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Stag g ered Stud Fram e System

The staggered stud frame system in a series of

staggered studs that are fixed to the same top

and bottom plate. The linings are fixed to the

outside faces of the studs. This system has higher

acoustic properties than the single stud framed

system and will insulate against impact sound.

Note: This system should not be selected if services

are required to run though the walls. Services

require support battens that will bridge frames, reducing acoustic properties and

preventing impact sound isolation.

Dua l Stud Fram e System

The dual stud frame system uses two separate frames that are not connected. The outside

face of each frame is then lined. This system will achieve the best acoustic properties and

will insulate against impact sound.

SpecialApplications

Genera l

Everest Dry Walls can be used in a range of special applications.

Walls Designe d for Imp a c t

Everest Dry Wall Lining has a harder surface than plasterboard, so it offers increased

resistance to surface abrasion, indentation and impact. Using Everest Wall Boards Lining

can therefore reduce maintenance costs, particularly in areas such as hospitals, airports,

schools and similar buildings subject to above-average wear and tear.

Service Ca vi ties

In quality buildings, you should avoid services in fire and acoustically rated walls. While it is

not difficult to maintain the fire resistance levels, the acoustic property of the wall may be

diminished. If this cannot be avoided, we recommend that services be run through a

service cavity, fixed on the face of the wall.

Where you cannot avoid putting services within the wall, you should select a dual stud

frame system, and take care in the selection of framing systems and the method of


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installation of services. Ensure that services do not bridge wall frames as this will reduce

acoustic performance and prevent impact sound isolation.

Sec urity Pa ne ls

Everest Dry Wall Lining (typically 9 mm thickness) may be used to construct wall in areas

that are required to be secure. Steel sheeting (0.55 mm thickness) may be either glued tothe back of the sheets or pop riveted to the frame prior to sheet fixing. This construction

greatly increases resistance to impact (e.g. from hammer blows). It is recommended as a

lining to one or both sides of wall where security is a major issue, e.g. holding cells in police

stations or equipment store rooms in schools.

Where security needs to be higher, you can use a laminate that consist of Everest Wall

Boards to one or both sides of a steel sheet. Typically 0.5, 0.75, 0.95, 1.15, 1.5 or 1.95 mm

BMT steel sheet is bonded between 6

mm or 9 mm sheet of Everest Wall

Boards. These laminates show

remarkable resistance to impact

penetration.

Balance laminates that have fibre cement sheets on each side of steel sheet must be

used for external walls. For internal walls and ceilings where temperature and humidity

variations are small, the single sided laminate is acceptable.

Sm ok e Wal ls

Everest Wall Boards have the best possible Early Fire Hazard properties and does not

generate any smoke in a fire. For these reasons, Everest Wall Boards is commonly used to

create smoke Walls in hospitals.

Ra d iation Shield ing Wa lls

Radiation shielding walls may be constructed using fire and Acoustically Rated Light

Weight Walling methods by laminating lead to Everest Wall Boards. Typically 9mm sheet is

used as a substrate for lead sheet of a thickness determined by a designer to meet the

radiation shielding specification. Care in design and installation is essential to maintain the

continuity of the lead sheet. Design, installation and certification should be carried by

specialists in this field.


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EverestDryWallGeneralGuidelines

In ter ior Ap p l ic at ions

General Guidelines for Dry Walls & Paneling

Everest Wall Boards can be fixed to both timber and steel frame construction, both in load

bearing and non-load bearing framework. The following general guidelines for installation

are applicable for joint-less (for rendering joint-less finish with Everest Wall Boards it is

recommended to use only Low Hydric Movement board conforming to IS 14862 Type B

Category III) and non joint-less finishes for partitions and panelling applications.

The following principles must be followed:

At all nailed or screwed board joints the centre line of the joint must coincide with the

centre line of the stud, runner or plate. This is to ensure sufficient edge clearance for

fixing of adjoining boards along the board edges.

Fix board across the door, ceiling or window openings then cut away waste board.

All end joints in the boards must be laid to an offset pattern.

In all joint-less applications, the end joints must not coincide with corners of door,

window or ceiling openings as these joints may crack due to minor frame movement.

Studs, plates or runners must be provided behind all vertical, sloped and horizontal

board joints and edges.


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All Everest Boards edges must be fully supported by the framing except for specific one-

way framing specifications. Framing must have sufficient lateral fixing so as not to rely on

the Everest Boards for stability.

For standard-impact areas the timber or steel framing specification is to have studs at 600

mm horizontal c/c and runner at 1200 mm vertical c/c. Use 6/8 mm Everest Board.

For high-impact areas or heavy-use commercial areas, studs must be at 600 mm

horizontal c/c and runner at 600 mm vertical c/c. Use only 8/10/12 mm Everest Board.

Boards must be fixed 15 mm clear of the floor for panelling / partitioning applications.

Care must be taken to ensure that this gap does not become filled with other materials

during finishing procedures.

Fix the board from the centre working towards the outside to avoid drumminess.

It is recommended that when ever possible boards are to be fixed horizontally to minimise

the number of joints and give structural stability and for increased impact resistance.

However, for application up to 3000 mm height boards may also be laid vertically as well.

For applications of one board width or less, boards must be fixed vertically only.

Timber Frame

Chemically treated kiln seasoned, timber sec tions should only be used for structural

framework. Chemically treated kiln seasoned timber section is required to minimise

shrinkage. This is particularly important for applications which are more than one board

length in height. Wall Boards must not be fixed to timber framing with moisture content in

excess of 20%.

Timber framing to be either, say 50 mm wide or, when chemically treated kiln seasoned is

used, 35 mm wide sections may also be used for non load bearing partitions/ panelling.

Fix 6/ 8/ 10 mm thick Everest Boards to timber frame using 50 mm x 2.5 mm long

galvanised flat-head nails to the centres shown in the relevant diagrams to the perimeter

of all boards, intermediate studs and runners.

Alternatively 6, 8, 10mm thick Everest Boards may be fixed to the timber framework using

self embedding type Everest Board fibre cement screws. Do not fix the screws closer than

15mm from the board edges or 50 mm from the corner of the board.

Steel frame

Steel framing for Everest Boards applications can be both non-load bearing or load

bearing. For steel framing follow the same guidelines as detailed for timber framing.


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However, load-bearing steel studs must have sufficient strength and thickness to resist all

vertical and horizontal loads.

Usually for steel framing, members of load-bearing construction must be fabricated from

light-gauge board steel 0.75 mm to 1.25 mm thick. If heavier sections are used difficulties

may be experienced in fixing the self-drilling, self-tapping fasteners.

At all Everest Board joints the minimum flange width of 34 mm is required to adequately fix

the boards with the correct edge distances.

For 6/ 8/ 10 mm thick Wall Boards use 3.8 mm dia. x 25 mm long self embedding Everest

Board Fibre C ement screws.

Fixings for steel frame to be at the same edge distances as for timber frame.

Boa rd Insta l lat ion

Correct Method


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For the correct board installation sequence, boards should always be fixed in staggered

manner on both sides as well as in same surface. The first board is screwed to the open

side of the stud flange. The flange deflects at first, but is then pulled tight as the screw

takes up the slack.

It is important to fully screw off the board on this side of the stud before continuing. Ensure

the stud is adequately supported to avoid it twisting.

The next board is screwed to the web side of the stud. Not only is the deflection at this

part of the flange very small, but the previously installed board helps keep the assembly

rigid during the installation of the second board.

Incorrect Method

When the incorrect fixing procedure is used, the outer side of the flange can deflect

away leaving a permanent step to the outside face of the boards. The stud must be firmly

supported while the correct method is used. When adequate stud support is not given,

twist can take place resulting in a permanent lipped distortion.


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Provision for control joints

Control joints must be provided to relieve stresses imposed by structural movement

including those due to excessive changes in temperature and humidity. For joint less finish

correc t provision for horizontal or vertical control joints are very important for the better

integrity of the structures and durability of the system.

Horizontal control joints: For large height partitions and panelling horizontal control joints

must be provided at 4800 mm vertical centres from the base of the wall for all framing

constructions.

Vertical Control joints: Vertical control joints must be provided to all long partitions /

panelling at 7200mm c/c maximum. These control joints must be full height from floor to

ceiling.

Provision for relief joints

Relief J oints are basically provision for space between two adjoining boards and play avital role in sustenance and integrity of structure against stress developed on account of

variation in temperature, moisture or due to vibrations and impacts.

The jamb line of wall openings such as doors and windows is an ideal location for relief

joints. The relief joint must be formed from the bottom of the window to the floor and from

the top of the window to the ceiling in the line of the jamb.

Relief J oints are essential between two heterogeneous surface junction namely door or

window or ventilator opening, internal and external corners etc.

Where Everest Board abuts exterior concrete, brick or concrete block hallow walls it must

be isolated by a flexible sealant, otherwise moisture transfer could occur.

Notes: Seal the joint with a non acetic or acetic cure flexible fungal resistant silicone

sealant for the full length of the application and when aceticure silicones are used special

priming requirements are necessary. Use acoustic sealant for this detail when acoustic

performance is required.

Provision for external and internal


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corners

External corners: For extra

impact resistance and a

straight edge, PVC/Steel

perforated external corner

angle must be fixed and

topping up bevelled edges of

the boards. Flush finish the

angle with perforated synthetic self adhesive tape/putty jointing compound and finishing

compound / putty.

Internal corners: Use bevelled-edge boards to internal corners and finish with jointing

compound, perforated or synthetic self adhesive tape and top coat/ putty.


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Provision for electrical and plumbing facilities

Wherever electrical or plumbing facilities are

to be provided within the partitions or

panelling, special care should be taken to

make the framework as well as board fixing.

Additional members are needed to support

plumbing or electrical facilities.

In case of additional storage facilities

supported over partitions or panelling

additional horizontal members are to be

provided and studs are suitably spaced to

take care of the loading requirements.

Batten requirements

Battens are required to fix the boards when the boards are fixed over:

Gypsum board exceeding 15 mm in thickness

Soft board, polystyrene or similar

Concrete, masonry block or brick

Battening specification:

Timber battening is to be a minimum 50 mm wide x 25

mm deep to give adequate board to nail penetration.

Steel battens are to be a minimum of 52 mm wide x 26

mm deep x 0.55 mm thick and to have a bearing


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surface of 52 mm. Battens are to be galvanised steel with 220 grams / sq. m. coating

of zinc as per IS 277.

All battening centres and board fixing is to be strictly in accordance with the framing and

fixing required by this guideline. Care must be taken to ensure the battens are packed

and aligned to give a true even surface for the boards to be fixed. Check the face of the

battens with a long straight-edge before fixing the boards.


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DryWallTechnologyBasicMaterial:SteelStudandTrack

Steel stud and track are used to make the structural framework on which boards are fixed

to create the wall. GI framework consists of following

basic components:

The basic concept of metal framing is that tracks are

run around the floor, ceiling and wall surfaces to form

the boundary of the plane in which the partition has

to come. This boundary is spanned across by metal

studs in vertical direction and spacing bars in

horizontal direction. The studs, held at top and

bottom by tracks, form the load bearing frame to

which the cladding sheet is fixed. The spacing bars

ensure that the studs are in right place and their

spacing is accurate.

There are two sizes of tracks and studs. The sizes

determine the thickness of the partition wall as well as

its strength. Whereas thinner sections are for usual

partitions, thicker ones are useful where greater

strength is required or where thicker pipes are to be

taken inside the partition wall. The sizes should be

chosen as per the individual requirement of the

project and the place of application. Please consult

a qualified engineer.

BasicMaterial:EverestWallBoard

Everest Wall Boards are fibre cement building boards manufactured from a homogenous

mixture of Portland cement treated cellulose fibres, quartz and other select mineral fillers.

The cement ac ts as a hydraulic binder while the cellulose fibres get interlocked with the

cement and quartz matrices, thereby making the boards stronger and more durable.

Everest Wall Boards can be used in a wide variety of segments like residential, commercial

and industrial installations.

InstallingSteelFramework

Check the level of the ground with water level tube. Mark the lay

out of the partitions plan on the floor and corresponding positions

of trac ks on wall and ceiling.


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Calculate the various lengths of tracks required and cut them to size. First, fix the tracks on

floor by using expandable screws and caps. Then fix tracks on wall and ceiling.

Cut Studs of desired sizes. Insert them between the top and bottom track and fix with self

drilling screws. These studs come with punctures at certain intervals. Check out if these

punctures are sufficient for your ducting needs. Else, make necessary punctures in the

web of the stud before fixing to the framing.

Caut ion :In cases where a significant slab live load deflection must be accommodated,

the anchoring of these studs may restrict slab movement and

cause partition cracking. In these cases, anchoring of these studs

may need to be omitted. The services of a design professional are

desirable to identify these instances and address them on a case-

specific basis.

Where a stud directly abuts an exterior wall and

there is a possibility of condensation or water

penetration through the wall, place an asphalt

felt strip between stud and wall surface.

Where Door and window frames are coming,

follow the instructions given in the Framing

Openings section.

FixingBoardoverSteelFramework

Fixing

Place 6mm packers along floor as temporary support for sheets. This will allow for any

frame movement/ shrinkage. Put first sheet in place as shown.

Ensuring the sheet is level, fix the first sheet starting from the centre of sheet and working

outwards to avoid any drumminess.

Sheet joints must coincide with the

centre line of the framing member.

At door and window openings fix

sheets around the opening in a way

that the sheet joints do not coincide

with the edges of openings. The

sheet joint must be 200mm min. awayfrom the opening edge.

Everest Heavy Duty Wall Boards lining

joints are set with proprietary jointing

compounds reinforced with perforated paper tape. Both

recessed edge and butt joints require joint setting by using the

jointing products outlined.

There are various factors that can affect the performance of


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jointing compounds on edge recessed fibre c ement substrates. These factors include the

framing, movement, installation quality, vibrations, moisture, humidity, temperature, etc.

To ac hieve satisfactory joint performance these factors need to be carefully considered

and understood by the installer and designer when positioning joints and selecting jointing

compounds. Furthermore, it is important that the jointing compound used has the physical

attributes required to perform considering these factors.

Sheet layo ut on w al l

Cut the Wall board approximately 12mm less than floor to ceiling height to allow for

building tolerances. Ensure that a 6mm building tolerance gap is provided at the floor

and ceiling junctions with the board lining. Everest Wall Boards may be laid on the frame

either horizontally or vertically.

Fa stene r Sp a c ing


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Trea tme nt o f Co rners

Framing at the corner must be such that Everest Wall Boards can be firmly attached to

the vertical studs and leave sufficient space from the inside corner to do so. Studs should

be attached to the tracks a minimum of 2 but not exceeding 6 from where the tracks

intersect. The edges of first applied panels will extend slightly beyond these corner studs,

and the edges of second applied panels will overlap the plane of first enough to ensure

good tapping of the inside corner.

Outside corners of partition intersec tions require firm attachment of panels to

perpendicular edges of the outside corner stud.

Trea tme nt of Op ening

All the openings should be framed with steel studs and tracks. The recommended

prac tice for most installations is to position floor to ceiling height studs vertically, adjacent

to frames, and anchor them securely to the top and bottom tracks with screws. Fabricate

sill and header sections from steel tracks and install them over door openings and over

and below any other opening. Make these sections 6 longer than the rough openings

and at both ends slit flanges 3 deep and bend the web so that the flanges overlap tothe adjacent vertical studs. Securely attach them to the adjacent studs with self drilling

screws. Install cripple studs in the centre above the door opening and above and below

door and window opening.

The straightness and squareness of the framing or substrate must be checked thoroughly.

Any deformities must be correc ted prior to installing the sheet.

Duct ing / Cond u i ting


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Electrical and plumbing ducts may be taken through the framing. C heck out their sizes

before choosing the size of the framing members.

Joint ing a nd Finishing

Everest Wall Board lining joints are set with proprietary jointing compounds reinforced with

perforated paper tape. Both recessed edge and butt joints require joint setting by using

the jointing products outlined.

There are various factors that can affect the performance of jointing compounds on

edge recessed fibre cement substrates. These factors include the framing, movement,

installation quality, vibrations, moisture, humidity, temperature, etc . To achieve satisfactory

joint performance these factors need to be carefully considered and understood by the

installer and designer when positioning joints and selecting jointing compounds.

Furthermore, it is important that the jointing compound used has the physical attributes

required to perform considering these factors

Na il Fa stening

We recommend that fibre cement screws be used. They are self drilling type, and are also

capable of countersinking into the board so that the head flushes with the board surface.

Co ntrol Joints

The jamb line of wall openings such as doors and windows is an ideal location for control

joints. The control joint must be formed from the bottom of the window to the floor and

from the top of the window to the ceiling in the line of the jamb.

Wal l Ab utment

Where Everest Wall Boards abuts exterior concrete or

concrete block walls it must be isolated by a flexible

sealant joint, otherwise moisture transfer could occur.

Co rners reinforc ing w ith PVC Co rner An gle

For extra impact resistance and a straight edge to stop

to, a PVC angle must be fixed over recessed edges of

the sheets. Flush over the angle with bedding

compound and finishing compound.

Corne r re in fo rc em en t w ith pa pe r tap e a nd b edd ing c om pound

Use recessed-edge sheets to internal corners and finish with bedding compound, paper

reinforcing tape and finishing compound.

Flush joint finishing for no n tiled finishe s

For non-tiled finished, flush jointing may be done by beveling the edges, finishing with two

layers bedding compound with reinforcing paper/fiber tape between them.

Re lief Joints


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On large tiled wall areas, relief joints must be provided in the Everest Wall Boards and the

tiles at 4200 mm maximum horizontal centers and 3000 mm vertical centers. Wall areas

must be restricted to a maximum of 10 m2 in all cases.

Provide relief joints within tiled areas at the following locations:

At internal vertical corners

At junctions between background materials

Around the perimeter of tiled areas

At all changes of plane.

Relief joints must continue through the tiles and the Everest Wall Boards to the support

frame.

Relief joints must be a minimum of 5 mm wide and filled with a flexible silicone sealant

compound. When a waterproofing membrane is used, the membrane is to be continuous

across the joint.


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JointTreatmentThe joints between two adjoining Boards could be finished with variety of joint finishing

and the details are given as below:

JointlessFinish

J oint-less finish with Everest Wall Boards can only be obtained using factory finish bevelled

edged boards. However, site bevelled boards are required for joint-less finish at the

corners or wherever the bevelled edges of board been cut to fit to the dimensions.

To render joint-less finish, use only dry board and in

hot dry conditions the joint area may be dammed

to avoid premature setting of Everest J ointing

Compound. For the reinforcement of the joint use

synthetic perforated self adhesive tapes only of 48

mm nominal width.

At the internal corner joints centre the reinforcing

tape in to the internal angle pressing firmly on the

bevelled edges of Everest Wall Boards and

immediately embed the tape with the coat of

Everest jointing compound. Use perforated PVC

corner angle rather than G.I. angle on external corner to avoid corrosion in wet and semi

wet areas. Fix the external G.I. / PVC external corner angle at 300 mm c/c to each angle

leg in a staggered manner. Fill over the G.I. / PVC external angle to the edges of bevelled

edges of Everest Wall Boards with jointing compound.

The board joints and corner flush joints must be formed using only Everest jointing

compound. Adhesive property of jointing compound is important for flush vinyl finishes

therefore finishing compound must not be used over the Everest jointing compound.

Ensure the Everest jointing compound is finished smooth to accept the vinyl/laminate.

UniformGapFinish

Everest Wall Boards joints could be finished with uniform gap finished on fixed on to the

substrate framework of timber or steel using

suitable nails or Everest fibre cement screws.

Alternatively, the board edges could bejointed or covered with PVC, G.I. Timber

mouldings for better aesthetics. In wet areas

the uniform gaps are to be filled up with

flexible silicon sealant.


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UniformGrooveFinish

Everest Wall Boards joints can be finished with uniform groove keeping 1- 2 mm gap all

through the joints, fixed on to the substrate framework of timber or steel using suitable nails

or self embedding type Everest fibre cement screws. However, to achieve this finish,

boards are to be chamfered uniformly at edge on site before fixing or installation.


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JointlessFinishingProcedure

Dry a nd Sem i Wet A rea

Preparation of J ointing Compound

Take a clean stainless steel or plastic container

Mix the c lean water paste for 5-10 minutes with putty knife.

Do not apply jointing compound in a temperature less than 10C and more than 80% Rh.

If rain splashes observed on board, complete drying of board necessary for further

application of jointing compound.

Ensure all the screw heads are driven 0.5 mm below the surface of the board surface.

Application of First Layer

Clean the bevelled portion of the jointing area from dirt and other foreign particles or oil

substance and firmly press the 48 mm wide synthetic selfadhesive tape over the full width of bevelled portion.

Ensure that there is no void under the tape. Immediately

cover the tape completely

with a thin layer of Everest

jointing compound applied

with a 100 mm wide knife or

metal patti. Sand and smoothen the surface and allow the

joint to dry for a minimum period of 2 hours.

Application of Second Layer

Application of this layer is carried out using 200 mm trowel once the first layer joint is

completely dry. A minimum 200 mm wide layer is applied

using the same Everest jointing compound spreading

minimum 75 mm on each side of the bevelled joint and allow

to dry for a minimum of 24 hours.

The second layer of jointing

compound must be sanded

smooth suitably to accept level II finishes. Everest jointing

compound is difficult to sand

hence sanding operation

should be completed immediately after the joints are

completely dry.

Finishing coat (optional required for level III, IV or V finish)

Thoroughly check the undulations of the joint-less finish areas

using metallic scale or putty knife and if needed fill up the jointing area with an additional

skim coat (thin layer made out of lower consistency of jointing paste adding water

suitably) to remove dry undulations and to ensure appearance of any shade difference.


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When the skim coat dries up, sand the entire joint area including the adjoining board area

up to a minimum 300 mm on both side of the centre of the joint.

The board is now ready to accept cement primer.

If superior level of joint-less finish is needed (i.e. level IV or V finishes) applying the top coat

on the entire area of the boarding and repeat the same operations.

Finally finish the entire board area including the joints with minimum 2 coats of 100% water

based acrylic cement primer

Wherever the boards meet the wall a gap of minimum 5 mm should be kept which can

be filled up using the same jointing paste and allow to dry. This can be finished in half

round using putty knife.

In ternal Co rners

Application of First Layer

Using a 75 mm chamfered broad knife, centre the synthetic self adhesive tape into theinternal corner pressing it firmly over the cleaned bevelled joint area, keeping the high

point of the knife direc ted into the corner.

Necessary precaution should be taken so that the synthetic

self adhesive tape does not get cut while pressing the same

in the bevelled area.

Repeat all other operations as stated in the straight joint-less

finishing procedure.

Externa l c orne rs

External corners are formed using a similar process to that for internal corners. Caution

should be taken while fixing vinyl / laminate layer in radius corners or square corners.

Plugg ing of Cut-Outs

If a cut-out has been made in the partitions, panelling or false ceiling at a wrong location

and if it needs to be plugged can be done as per the following steps:

If the area of the cut-out is less then 100sq cm, provide backup support with short

piece Everest Wall Boards larger than the size of the cut-out. Cut the Everest Wall

Boards in required shape and size of the cut-out. Paste that piece on to the support

board using rubberized adhesive. Leave the gap of 1-2 mm on all sides and treat the

gap/ joint as described in section above.

In case the cut-out area is more than 100sq cm then provide additional substructure

behind the cut-out. Cut the Everest Wall Boards in required shape and size of cut-out.

Fix the Everest Wall Boards with the substructure using self embedding type Everest

fibre cement screws. Leave a gap of 1-2 mm on all sides and treat type gap/ joints.

The joint is to be treated as described in section above.


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JointlessFinishingwithSquareEdgeBoards

The joints can be filled out or not. If they are filled out, the material used for the effect is a

mastic sealant. The filled out

joints should be tight against

the air and the water.

The width of the joint should

be such that the mastics can

support, permanently, the

daily and seasonal

deformations that happen.

The depth of the mastic should be adapted to the width of the joint and the nature of the

mastic.

The primer, when necessary, should assure the wanted adherence between the mastic

and the bearing. Its capacity should be evaluated jointly with the mastic and the

construction materials constituent of the elements to tie.

The stuffing material, after insertion, should possess a resistance enough for application

and smoothing of the

mastic. It should not

contain, besides, matters

that can harm the

adherence of the mastic

to the flanks of the joint. It

should still assure a

concave geometric form

of the mastic. It shouldnot impede, in an

inadmissible way,

alterations in the form of

the mastics, when movements of the construction elements take place.

The limitation, in the case of fire in the building, of a possible propagation of the fire to the

dry wall structure, implicates the evaluation of the behaviour of the mastics and stuffing

materials under fire.

The depth of the mastic should be equal to the width of the joints and in vertical joints; a

string of flexible polyethylene should control it.

CurvedApplications

Everest Wall Boards have an excellent dimensional stability and therefore it yields only very

small dimensional movements even under extreme temperature and humidity changes.

But, the boards may be used for curved applications using following procedure.

App l i ca t i ons


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1. Curved ceilings, walls and columns in offices, hospitals, schools concert halls

departmental stores and railway stations etc.

2. Curved area of eaves soffits, basement car parks, kitchens, toilets and other areas of

high humidity.

3. Curved areas for specially designed fire-resistant partitions, walls and panels.

Fram ew ork (Curved Pa rt it ions/Wal l l in ing s)

Mark the floor as per the layout plan.

Cut the floor and ceiling channel at one side of flange through its web at every

150mm.

Put this channel at the marking and bend the channel according to the layout

marking.

Fix it with nylon sleeves and wooden screws at every 150mm c/c to the floor.

Fix head channel, as described above in plumb and line with the floor channel, at the

soffit or ceiling as described above.

Insert metal studs at 305(12) mm intervals in between the floor and head channel.

Check if the frame work is properly aligned and plumbed, as per the layout marked at

the floor.

Boa rd ing Fixing

6mm boards are to be curved one by one, prior to installation by making them

sufficiently wet by sprinkling water on both sides of the boards.

Allow these boards to absorb water for 30 minutes.

Make 1220mm wide wooden structure of the required radius, but limited to 600mm,

minimum.

Put the wet boards on to this wooden structure and try to press the boards very gently,

starting from the centre to the ends on both sides. Keep pouring water during this

process.

As soon as the board gets the shape, it is to be removed from the wooden structures

and to be placed at floor vertically width-wise and left for air drying.

All the boards are to be bent like this before fixing.

Now place the first board along the frame work at one end.


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Start screwing the board from one end of the board, by using self tapping screws

12mm away from the edges and 40mm from the corners at 200mm c/c to each metal

stud and floor & ceiling channel.

Complete the entire area as above.

J ointing and finishing is to be done as per recommended practice.


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InstallationDetailsDryWallinDoubleSkinFullHeight/HalfHeightG.I.Framework

Ma ter ia ls Req uired :

G.I Sections as C vertical stud profile and U profile floor / ceiling trac k.

Everest Wall Boards/Everest Designer Wall Boards 6mm/8mm/10mm with specified texture

and finish.

Insta l la t ion Proc ed ure:

Step 1: Mark the layout of the partitions on the floor, and fix the U profiles on the floor and ceiling

and C profile vertical stud to abutment securely fixed @ 600 mm c/ c with 35 mm long stainless

steel wood screws with nylon sleeves/wooden gutka.

Step 2: Insert vertica l studs (C profile) @ 600 mm c/ c in the U profile with the allowance for board

width tolerance.

Step 3: Fix the U profiles as horizontal runners on to vertica l studs at sill / lintel level, around other

openings shown as per architectural drawings. In case the partitions height is more than 2400 mm,

fix the U profile as horizontal runner on to the vertical studs @ 1200 mm c/c. Extra studs to be

provided where the 600 mm spacing is disturbed.

Step 4 : Fix the Everest Wall Board on both sides of the studs and channel section with 25 mm self

embedding type Everest fibre cement screws in staggered fashion (both side) to avoid through

joints @ 300 mm c/c. Remove connecting screws of U profile used as horizontal runners, with stud

in alternate fashion to avoid uneven surface. External angle screws are to be fixed @ 200 mm c/c

using Everest fibre cement screws as well.

Step 5: For thermal and acoustic insulation, fill the infill space with the thermal/acoustic insulation

material preferably in chicken wire mesh of approved thickness and density.

Step 6: If joint less finish is required for the partition, refer to the sec tion on treatment of joints.

Step 7: For final finishing, Everest Wall Boards can be painted, polished or laminated whereas

Everest Designer Wall Boards can be painted or polished.

Notes on Usa ge :

1. At T or L junctions, the back of abutting stud to be fixed on the flange of main partition stud

(having the space between them equal to the thickness of Board with 35 mm long drywall screws.

2. Screws should be placed at no more than 300 mm c/c spacing and not less than 15 mm from

the edges and 50 mm from the corners.

3. The head of the screw must be embedded inserted 0.5 mm below the surface duly filled with

putty to conceal the screw.

4. If semi concealed joint is desired, a uniform gap of 2-3 mm must be left between the adjacent

Wall Boards which can be filled with recommended jointing compound/Sealants


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5. For durable joint less finish, used only Low Hydric Movement boards in dry condition, duly

primered on both sides and edges prior to fixing / installation.

6. Wherever doors and windows are coming, additional U sections are to be used to form door or

window opening fixed during the erection. The door or window frames are to be fixed with metal

frame using screws penetrating 35 mm into the vertical member.

7. In door and window openings minimum 50 mm wide chemically treated seasoned timber

framework, duly coated with 1-2 layers of bituminous paint, and is to be snap fitted on to the metal

frame.

8. 100/150 mm wide skirting of 12 mm thick Boards may also be provided, fixed with fully threaded

screws/ headless nails on to the finished partition.

9. Boards should be primered with a coat of 100% acrylic water based cement primer on both

surfaces and edges, before installing in place. Use dry boards only.


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Y

X

Y

DryWall

in

Double

Skin

Full

Height/Half

Height

Timber

Framework


Timber Sections of 50/75mm x 50mm.

Everest Wall Boards 6mm/8mm with spec ified texture and finish.


Step 1: Mark the layout of the partitions on the floor. Fix the timber sections on the floor and ceiling

securely fixed using 35mm long stainless steel wood screws with nylon sleeves/wooden gutka.


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Step 2: Fix and secure vertical timber sections @ 610mm c/c with ceiling and floor timber sections.

Step 3: Fix the horizontal timber sec tions @ 1220mm c/c on to vertical studs at sill / lintel level,

around other openings shown as per architectural drawings. All horizontal and vertical members

should be in same plane secured properly to each other through dove tailed joinery, adhesive and

stainless steel wood screws.

Step 4: Fix Boards on both sides of the framework with 25mm self embedding type Everest fibre

cement screws in staggered fashion (both side) to avoid through joints @ 300mm c/c. External

angle screws are to be fixed at 200mm c/ c using Everest fibre cement screws as well.

Step 5: For thermal and acoustic insulation, fill the infill space with the thermal/acoustic insulation

material preferably in chicken mesh of approved thickness and density.

Step 6: If joint less finish is required for the partition, refer to the section on treatment of joints.

Step 7: For final finishing, Everest Wall Boards, can be painted, polished or laminated whereas

Everest Designer Boards can be painted or polished.

Notes on Usa ge :

1. Screws should be placed at no more than 300mm c/c spacing and not less than 15mm from the

edges and 50mm from the corners.

2. The head of the screw must be embedded 0.5mm below the surface duly filled with putty to

conceal the screw.

3. If semi-concealed joint is desired a uniform gap of 2-3mm must be left between the adjacent

Boards which can be filled with recommended jointing compound.

4. Wherever doors and windows are coming additional timber sections of minimum 50mm wide

chemica lly treated kiln seasoned, duly coated with 1-2 layers of bituminous paint are to be used to

form door or window opening fixed during the erection. The door or window frame is to be securely

fixed with wooden framework using 75 or 90mm long stainless steel wood screws penetrating 35mminto the vertical member.

5. 75mm wide timber section is to be used in conjunction with 8mm thick Everest Boards wherever

partition height is more than 2400mm.

6. 100/150mm wide skirting of 12 mm thick Everest Boards may also be provided fixed with fully

threaded screws/ headless nails on to the finished partition.




surfaces


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Y

Y


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DryWallinSingleSkinFullHeight/HalfHeightAluminiumFramework


Standard aluminium frame 63.5mm x 38.1mm (as per approved manufacturers

specifications)

Everest Wall Boards/Everest Designer Boards 10mm/12mm with spec ified texture and finish.

Aluminium beading/cleat (18mmx17mm or as per approved manufac turers specifications)with neoprene/EPDM gasket.


Step 1: Mark the layout of the partitions on the floor. Fix the aluminium sections on the floor and

ceiling securely fixed using minimum 50mm long stainless steel wood screws with nylon sleeves/

wooden gutka.

Step 2: Fix and secure vertical aluminium sections @ 915mm/1220mm c/c with ceiling and floor

using proper angle cleat and pan head screws.

Step 3: Fix and secure horizontal aluminium sections @ 1220mm c/c on to vertical studs and at sill/

lintel level, around other openings shown as per architectural drawings. All horizontal and vertical

members should be in same plane secured properly to each other through angle cleats and pan

head screws.

Step 4: Fix Everest Boards of specified thickness using aluminium beading and neoprene/EPDM

gasket, snap fitted on to the frame holding board on to the frame.

Step 5: For final finishing, Everest Boards can be painted, polished or laminated whereas Everest

Designer Boards can be painted or polished as per specifications or drawings, taking care of

aluminium framework such that paint or polish doesnt spill over the frame.

Notes on Usa ge :

1. Wherever shown in drawing c lear /float glass of 5mm/6mm thickness can be inserted in place of

Everest Boards using aluminium beading and neoprene/ EPDM gasket.

2. Wherever doors and windows are coming, additional aluminium sections are to be used to form

door or window opening fixed during the erection. The door or window frame is to be securely

fixed with aluminium framework using angle cleat and pan head screws.

3. To make the cabin airtight provide rubber gasket all along the perimeter of the shutter/window.



5. In case the textured finish is required on both sides, Everest Designer Boards of 4mm/6mm

thickness in required texture can be pasted back to back with the recommended adhesive

pressed completely for good bonding before inserting into the frame.


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DryWallinSingleSkinFullHeight/HalfHeightTimberFramework


Seasoned timber Sec tions of 50mm x 50mm.

Everest Boards 10mm/12mm with specified texture and finish.


Step 1: Mark the layout of the partitions on the floor. Fix the timber sections on the floor and ceiling

securely fixed using 35mm long stainless steel wood screws with nylon sleeves/wooden gutka.

Step 2: Fix and secure vertical timber sections @ 610mm c/c with ceiling and floor timber sections.

Step 3: Fix the horizontal timber sec tions @ 1220mm c/c on to vertical studs at sill / lintel level,

around other openings shown as per architectural drawings. All horizontal and vertical members

should be in same plane secured properly to each other through dove tailed joinery, adhesive and

stainless steel wood screws.

Step 4: Fix the wooden moulding of specified d imension or as per architectural drawing at one side

of partition using headless nails, along the perimeter of the frame work.

Step 5: Insert Everest Boards of specified thickness into the block of frame and fix securely by nailing

the wooden moulding with headless nails on the other side of the frame.



Notes on Usa ge :

1. Wherever doors and windows are coming additional timber sections (minimum 50mm wide,

chemically treated kiln seasoned, duly coated with 1-2 layers of bituminous paint) are to be used

to form door or window opening fixed during the erection. The door or window frame is to besecurely fixed with wooden framework using 75mm or 90mm long stainless steel wood screws

penetrating 35mm into the vertical member.

2. Wherever shown in drawing c lear/float glass of 5mm/6mm thickness can be inserted in place of

Everest Wall Boards / Everest Designer Wall Boards using wooden moulding as per specifications.

3. While painting or polishing timber sections, adjacent boards and mouldings should be properly

covered, to avoid spill over of paint and polish.



5. In case the textured finish is required on both sides, Everest Designer Wall Boards of 4mm/6mmthickness in required texture can be pasted back to back with the recommended adhesive

pressed completely for good bonding before inserting into the frame.

6. Decorative mouldings may be fixed around the perimeter of the panel made out of the timber

framework using headless nail or countersunk stainless steel screws.


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PanelingwithG.I.Framework


G.I sections: Perimeter U profile, supporting W profile.

Everest Boards 6mm/8mm with spec ified texture and finish.

Fasteners and screws of spec ified material and dimension.


Step 1 : Fix the unequal flange U shaped channel with shorter flange facing outside, onto the

bottom, top and periphery of the wall by nylon sleeves / wooden gutka and expandable fasteners

inserted in to the wall using stainless steel wood screws placed @ 300mm c/c. and ensure that all

members are in same plane. If required, short pieces of Everest Boards / wooden gutka are

inserted to bring all the members in same plane.

Step 2: Fix the supporting W profile in between the U profiles @ 600 mm c/c vertically and @ 1200

mm c/c horizontally.

Step 3: Fix the Everest Wall Board/ Everest Designer Boards to the frame with self-tapping screws,

leaving an air gap of 15mm at floor level.

Step 4: Cover up the air gap with minimum 150mm wide skirting at floor level. The junction at the

ceiling / wall can be covered with decorative moulding or cornice as per architectural drawings or

engineer- in-charge.

Step 5: For joint less finish, refer to the section on treatment of joints.

Notes on Usa ge :

1. The air gap is necessary to prevent moisture retention in the Everest Wall Boards. For panelling,

Everest Boards are to be primered on both the sides with 100% ac rylic water based cement primer

before installing the boards on to the framework. Use dry boards only.

2. If the panelling is to be done on a damp wall, all the G.I. Sections are to be duly coated with

zinc chromate primer/bituminous paint, secured to the wall with G.I. cleats.

3. For panelling on very damp wa lls, only vertical sections should be used and an air gap of 15 mm

left at the ceiling level to permit air to percolate.

4. For fixing Cornice or Mouldings, the surface is to be made thoroughly clean and preferably

apply a coat of rubberised adhesive at the back of the cornices/mouldings. Fix Cornice/mouldings

using headless nail/ counter sunk stainless steel screws.

5. Electrical wiring or any other service lines should be embedded in the wall leaving outlets at

required position. If the service lines are not laid before, then use 12.5 mm dia. conduits clamped

on the wa ll and main supporting W profile can be trimmed at the required position.




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HEAD AND BASE DETAIL

DETAIL AT JUCTION OFPANELLING AND PARTITION

DETAIL AT X

ISOMETRIC VIEW


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PanellingwithTimberFramework


Seasoned timber Sec tions of 50mm x 50mm, of grid size 1220mm x 610mm / 610mm x

610mm.

Everest Wall Boards 6mm/8mm with spec ified texture and finish.

Fasteners and screws of spec ified material and dimension.


Step 1: Fix the timber sections onto the wall with nylon sleeves/wooden gutka inserted into the wall

using stainless wood screws @ 300 mm c/c, to form a grid of 1220 mm x 610 mm / 610 mm x 610 mm

leaving 15 mm air gap from the floor.

Step 2: Adjust the unevenness of the surface, if any, using wooden gutka to bring the entire frame

in same plane.

Step 3: Fix the Everest Wall Boards/Everest Designer Wall Boards on to the frame using self

embedding type Everest fibre cement screws, leaving an air gap of 15 mm at floor level.

Step 4: Cover up the air gap with minimum 100mm wide skirting at floor level. The junction at the

ceiling can be covered with wooden decorative moulding or cornice as per architectural

drawings or engineer-in-charge.

Step 5: If joint less finish is required for panelling, refer to the section on the treatment of joints.



Notes on Usa ge :

1. The air gap is necessary to prevent moisture retention in the Wall Boards. For panelling, EverestWall Boards are to be primered on both the sides and edges with 100% acrylic water based

cement primer before installing the boards on to the frame work.

2. If the panelling is to be done on a damp wall, only chemically treated kiln seasoned timber

sec tions duly painted with a coat of bituminous pa int should be secured to the wall with G.I. cleats.

3. For panelling on very damp wa lls, only vertical sections should be used and an air gap of 15 mm

left at the ceiling level to permit air to percolate.

4. For fixing Cornice or Mouldings, the surface is to be made thoroughly clean and preferably

apply a coat of rubberised adhesive at the back of the cornices/mouldings. Fix Cornice/mouldings

using headless nail/ counter sunk stainless steel screws.

5. Electrical wiring or any other service lines should be embedded in the wall leaving outlets at

required position. If the service lines are not laid before, then use 12.5mm dia. conduits clamped

on the wall and the timber sections can be trimmed at the required position.




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HEAD AND BASE DETAILDETAIL AT JUCTION OFPANELLING AND PARTITION

DETAIL AT X

ISOMETRIC VIEW


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PanelingwithoutFramework

Notes on Usa ge :

1. For panelling without framework, use 8/10/12mm thick Everest Wall Boards duly coated with oil

bound bituminous primer on its rear side. Boards are to be fixed onto the wall with PVC/Nylon

sleeves/wooden gutka inserted into the wall using self embedding type Everest fibre cement

screws @ 300 mm c/c on expandable fasteners.

2. In case of a damp wall, it is advisable to leave an air gap in between the Everest Wall Boards

and the wa ll or insert a layer of damp proof material such as bituminous felt.


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EverestWetAreaSystemsWet area lining may be done in wall and floor as well as countertops (Kitchen) etc.

Fixing Sub strate

Everest Heavy Duty Wall Boards may be fixed over timber framing, light gauge steel

framing or battens fixed over masonry.

Everest Heavy Duty Wall Boards Fixed Over Light Gauge Steel Framing

Everest Heavy Duty Wall Boards Fixed Over Wooden Framing

Everest Heavy Duty Wall Boards Fixed Over Masonry wall with metal/wooden Furring

In regular partition walls and c eilings the maximum frame distances is 600mm c/c. For

flooring application, the maximum frame distance is 450mm. Before fixing Everest Heavy

Duty Wall Boards, one should ensure that the timer frame or masonry wall is not wet; if so,

allow it to dry before fixing Everest Heavy Duty Wall Boards. The straightness and


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squareness of the framing or substrate must be checked thoroughly. Any deformities must

be corrected prior to installing the sheet.

Sheet joints must coincide with the centre line of the framing member. At door and

window openings fix sheets around the opening in a way that the sheet joints do not

coincide with the edges of openings. The sheet joint must be 200mm min. away from the

opening edge.

Cut Everest Heavy Duty Wall Boards approximately 12mm less than floor to ceiling height

to allow for building tolerances. Ensure that a 6mm building tolerance gap is provided at

the floor and ceiling junctions with the Everest Heavy Duty Wall Boards lining.

Fastener spa c ing o n w al l


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Fixing a nd Jo int ing

J ointing and fixing would be carried out as per the points mentioned in the general

guidelines specified in the General guidelines section.

Spe c ia l Trea tme nt for Co rner Reinforcem ent

The corners are vulnerable areas for damages and leakages. They should be reinforced

as shown below:

Wall Corners

Fix PVC corner angle if edges are bevelled, else fix fibreglass mesh

Lay waterproof membrane over it

Put tile adhesive and lay the tile

Floor Corners

Fix fibre-glass mesh at the corners

Lay waterproof membrane Put the tile adhesive and lay the tile.

Fig: Corner reinforcements with PVC corner angle and

fiberglass mesh


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Waterproof ing

It is recommended that waterproofing

be done over the sheets before laying

tiles or any other finishing. Based on the

water usage, the areas can be divided

into three zones:

Wet areas

Semi-wet areas

Dry areas

The entire of the wet area like the floor and walls of bath cubicles is to be waterproofed.

All the semi wet areas, like baths, wash basin, sinks, laundry tubs etc, should be

waterproofed to a distance of 300mm from the splash zones.

Waterproof membranes are available from different manufacturers in liquid form. Around

1.5 litres of waterproofing compound covers a 1 sq m area with a film thickness of 1mm

per coat. Refer to manufacturers instruction for application method.

Co ntrol Joints/ Exp a nsion Joints

Control joints are required in long runs of Everest Heavy Duty Wall Boards lining walls or

floors in either direction. These joints are designed to take up the structural movement

between the sheets and the building frame. Control joints should also be provided at

frame junctions / joints such as wall intersections. Whenever the span exceeds 4.5m, a

control joint is necessary.

Tile Fix ing

Tile Thicknesses

The thicknesses of tiles used over Everest Heavy Duty Wall Boards lining are restricted

based on stud centers and the thickness of the sheet.

Maximum Tile Thickness

Maximum Tile Thickness (mm)Everest Heavy Duty Wall Board Thickness (mm)

600 mm Studs C/C 450mm Studs C/C

6 9 13

9 13 18

Som e Imp ortant co nstruc t ion Deta i ls


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Drawings

Instal lat ion of Plum b ing Fixtures

Hole Forming: Small rec tangular or circular holes can be achieved by

drilling a series of small holes around the perimeter of the hole then

tapping out the waste piece from the sheet face. Tap carefully toavoid damage to sheets and clean rough edges with rasp.

Fixing Pipe: All the pipes, other than

soil pipe, can be taken through the

space between the boards fixed on

either side. Where ever required, cut

the flange portion of studs that have

been fixed horizontally over the

vertical studs, and fold them apart as shown in picture below.

7/27/2019 Cop Everest Wall Sol

cop everest wall solutions

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