gypsum board ceiling systems - knauf enbs ceiling manual.pdf · en-bs and din standards, to meet...

2019

GYPSUM BOARD CEILING SYSTEMS

3

To our Valued Customers,

Greetings!

Knauf is a family name and a corporate group of global dimensions at the same time synonymous with a type of corporate culture which has become rare. Knauf is a typical family firm in spite of its size and this is precisely the reason for its amazing success. It is short and direct decision-making paths, the courage to tackle new ideas, innovations, investments and the wealth of ideas contributed by all Knauf employees that characterize the company.

From its beginnings in gypsum processing, Knauf has expanded and diversified to become a corporation with worldwide activities, Knauf UAE has been active in the Middle East for more than a decade.

Knauf shows its commitment not only in the GCC, headquarters in Dubai UAE, but also in the subcontinent.We have offices based in Saudi, Qatar and India to support the market and dealers.Knauf provides value-added products and services in the following fields:

• Building materials and systems based on gypsum and gypsum-related products• ASTM certified products & systems• Multi- Purpose Joint compounds• Knauf Aquapanel interior and exterior wall systems• Knauf Insulations sustainable, high-performance, cost-effective insulation solutions• Knauf Heradesign’s acoustic designs for Interior and Exterior in ceiling & partition systems• Knauf Integral’s Knauf GIFA Floor, sheet-panelled access floors• Thermal and sound insulation materials• Value engineering and technical consultancy for architects and consultants to meet specified design requirements• On site hands-on training and supervision for contractors when installing drywall systems• Knauf systems are approved by Dubai, Abu Dhabi, Ras Al Khaimah and Qatar Civil Defense

Sustainability is central to our vision of doing the right thing for our clients, our people and the communities in which we work. We maintain and provide certificates for individual products and designs to improve quality and performance. Knauf systems combine innovative products to realize speed of installation and warranted high performance-based systems as per ASTM, EN-BS and DIN Standards.

Knauf is not only committed towards it Products and System but also towards it employees. Within the framework of its four key K-Values; Partnership, Commitment, Entrepreneurship and Menschlichkeit meaning human touch Knauf looks after its people and drives a sense of passion in all its staff. This is what makes Knauf unique and special!

Safety is something that Knauf does not compromise on whether for its products or people and therefore all our products are tested and approved by Intertek to make sure that nothing leaves the plant which is not up to the mark.

Amer Bin AhmedManaging DirectorKnauf GCC & India

2

Contents

04System overview

05 - 08Construction details

09General information

10Installation steps

11Processing of gypsum boards

12Joint treatment

13 - 14Cladding of boards

15Certifications

1) Manual Ceiling (BS EN) Feb-26-2017.indd 2 3/9/17 10:40 AM

Manual Ceiling (BS EN)-UB.indd 2 3/30/17 11:37 AM

To Our Valued Customers,

Knauf is one of the leading voices in sourcing locally and manufacturing products that are truly “Made in UAE” as well as enabling collaboration with the major industry leaders towards technological advancements in manufactur-ing and logistics. This has made us fully equipped to efficiently cater the needs, wants and preferences of our valued customers and clients who over time have become a part of our big family.

Our commitment towards building environmentally responsible and economically sustainable products locally have been applauded, recognized and certified by esteemed UAE government authorities such as Ministry of Interiors, Civil Defense, Central Laboratory, Quality and Conformity Council.

Headquartered in Dubai, UAE, Knauf shows its customer service excellence and commitment in the Middle East and India. We ensure that the demand meets the supply, the first time and every time by utilizing our full range of flexibility and potential of our production facilities, human resources, technical expertise, logistics and cutting edge digitalisation, thereby facilitating rapid growth and development in the region.

Here is a highlight of some of Knauf’s products, systems and services:• Gypsum based high performance drywall building materials, system and accessories.• ASTM certified products & systems – Ceiling, Partition, Wall Lining and Cinema System.• Knauf Aquapanel cement boards for interior, exterior and universal usages.• Knauf Aquapanel Exterior Systems (Exterior walls, cladding and ceiling).• Knauf Heraklith’s acoustic designs for Interior and Exterior in ceiling & partition systems.• Knauf Integral’s Knauf GIFA Floor, sheet-paneled access floors systems.• Fire and acoustic rated sealants and materials.• Multi- Purpose Joint compounds.• Engineering and technical consultancy for architects, consultants, etc.• Knauf Training Academy: Hands-on training.

Knauf’s high performing, innovative systems are fast and easy to install and are manufactured to meet ASTM, EN-BS and DIN Standards, to meet any client requirements. Our dedicated Training Academy is committed to making sure that all our end users are up to date of our system.

Quality, sustainability, health and safety are central to our vision, actions towards our people and the local commu-nities ensuring every product that comes out of the line is rigorously tested, certified, approved and socio- environ-mentally responsible while producing them. Our ISO 9001 (Quality Management System), 14001 (Health, Environment and Safety), 18001 (OHSAS) and 50001 (Energy Management) certifications are a testament to our commitment to the same.

Our four dimensional core values called K-Values: Partnership, Commitment, Entrepreneurship and Menschlichkeit (“the human touch” in German) are the key drivers of our camaraderie and operational excellence throughout our multi-cultural organizational structure. It is this passion that subsequently reflects in our products and customer service excellence as well.

Thank you for being part of this big family and Let’s Build the Future together.

Amer Bin AhmedManaging DirectorKnauf Middle East & India

Global Board of Director Board of Director Intertek Certified ISO Certified

USCM

LISTED

OHSAS18001OccupationalHealth & SafetyManagement

ISO14001EnvironmentalManagement

ISO9001QualityManagement

ISO50001Energy Management

www. .ae

www.Knauf.ae 3

5

Construction details

These details represent some of the most common designs situations relevant to the Knauf KC B001 ceiling systems.

Abutment to wall, parallel to primary support channel

Abutment to wall, perpendicular to primary support channel

TN Screw Hat Furring Channel

Perimeter Wall fixingHammer Fixings

UD-Channel

200 mm1000 mm

Main ChannelL - angle

LN Screw

Wedge Anchor

Knauf Joint Compound Knauf Gypsum Board

400 mm150 mm

50 mm

Hat Furring Channel


TN Screw

LN Screw

Wedge Anchor

Knauf Gypsum Board

800 mm c/c L-angle

UD-Channel



4

System overview

Load test reportsTest report No. SR 0308 Rev.0, multi-layer, BS EN.Deflection Criteria L/240, under a static wind load of 500 Pa.

Maximum load including lightning devices, MEP, insulation, up to 50 kg/m2

Spacing of structureCladding thickness Upper

channels(mm)

Suspension Hangers

(mm)

Furring channels

(mm)

Approx. Weight (kg/m2)

1 x 12.5 mm 10.3 kg/m2

1 x 15 mm 13.4 kg/m2

2 x 12.5 mm 18.9 kg/m2

2 x 15 mm 25.0 kg/m2

800 1000 400

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



5


These details represent some of the most common designs situations relevant to the Knauf KC B001 ceiling systems.

Abutment to wall, parallel to primary support channel

Abutment to wall, perpendicular to primary support channel



UD-Channel

200 mm1000 mm


LN Screw

Wedge Anchor

Knauf Joint Compound Knauf Gypsum Board

400 mm150 mm

50 mm

Hat Furring Channel


TN Screw

LN Screw

Wedge Anchor

Knauf Gypsum Board

800 mm c/c L-angle

UD-Channel



4

System overview

Load test reportsTest report No. SR 0308 Rev.0, multi-layer, BS EN.Deflection Criteria L/240, under a static wind load of 500 Pa.

Maximum load including lightning devices, MEP, insulation, up to 50 kg/m2

Spacing of structureCladding thickness Upper

channels(mm)

Suspension Hangers

(mm)

Furring channels

(mm)

Approx. Weight (kg/m2)

1 x 12.5 mm 10.3 kg/m2

1 x 15 mm 13.4 kg/m2

2 x 12.5 mm 18.9 kg/m2

2 x 15 mm 25.0 kg/m2

800 1000 400

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



7


Change of level and bulkhead

Movement control joint

Main Channel

UD-Channel

Hat Furring ChannelKnauf Gypsum Board

Hat FurringChannel


UD-Channel

L - Angle

LN Screw

Wedge Anchor

Knauf Joint Compound

200 mm

UD-Channel

TN Screw

Hat Furring Channel

Main Channel

L - angleLN Screw

TN Screw Knauf MovementControl Joint

Knauf Approved Fixing


6

Abutment to wall, parallel to primary support channel, double layer

Abutment to wall, primary support channel, double layer




UD-Channel

200 mm1000 mm


LN Screw

Wedge Anchor

Knauf Joint CompoundKnauf Gypsum Board

400 mm150 mm

50 mm

Hat Furring Channel


TN Screw

LN Screw

Wedge Anchor

800 mm c/c L-angle

UD-Channel


Knauf Gypsum Board



7


Change of level and bulkhead

Movement control joint

Main Channel

UD-Channel


Hat FurringChannel


UD-Channel

L - Angle

LN Screw

Wedge Anchor

Knauf Joint Compound

200 mm

UD-Channel

TN Screw

Hat Furring Channel

Main Channel

L - angleLN Screw

TN Screw Knauf MovementControl Joint

Knauf Approved Fixing


6

Abutment to wall, parallel to primary support channel, double layer

Abutment to wall, primary support channel, double layer




UD-Channel

200 mm1000 mm


LN Screw

Wedge Anchor

Knauf Joint CompoundKnauf Gypsum Board

400 mm150 mm

50 mm

Hat Furring Channel


TN Screw

LN Screw

Wedge Anchor

800 mm c/c L-angle

UD-Channel


Knauf Gypsum Board



9

GeneralKnauf KC B001 Ceiling Systems must be installed inaccordance with Knauf 's recommendations. When creating an airtight space, methods for the reduction of potential “ceiling lift ’’ should be considered.

Perimeter FixingMark the position of the ceiling line with a Chalk Line (1). Knauf UD channels should be secured to the walls at the required heights, at maximum 600mm 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 (2).

SuspensionSelect the fixing centers suited to the ceiling loading. See page 3 for spacing of dowels.Fix Knauf approved fixing to the structural soffit with suitable fixings. Use the Knauf L Angle and fix to the approved fixing dowel (3).

Primary Support Channels – C ChannelsThe 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 (4).

Splicing of the Main C ChannelsIf straight lengths of Knauf Main C Channelsneed jointing, place the channels back toback, with a minimum 150mm overlap, and fix withtwo Knauf LN Wafer Head Screws.

Hat Furring ChannelsThe Knauf Hat Furring Channels should bepositioned at 400mm centers within the perimeterchannels to coincide with the abutments of theboards, which will be fixed later. 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).

InsulationIf insulation is required, 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 different rolls. The maximum weight of the whole system including all components or added elements, should not exceed 50 kg/m2.

Movement Control JointsCreate movement control joints where ceilingruns exceed 10m, coinciding where possible with movement joints in the surrounding structure.

BoardingAll boards should be fixed to the ceiling gridwith the decorative face of the boards outwards and secured with Knauf Screws at maximum 300 mm centers (6). Fixing centers should be reduced to 100 mm at ends and perimeter.Boards should be mounted at 90° to the direction of the ceiling channels (7).Second layer should be installer with staggered joints.

General information


8

Splicing of furring channel

Junction with partition


Main ChannelUD-Channel

L - Angle

LN Screw

Wedge Anchor

Knauf Joint Compound TN Screw

Wedge Anchor


50 mm50 mm

Hat Furring ChannelSplicing / End to End Connection

400 mm

Hat Furring Channel

LN Screw



11

Cut the paper face with a sharp knife

Cut the board 45 degrees Smooth the cut edge with a beveler

Processing of gypsum boards

Cutting and processing the boards

nKnauf Boards shall be cut by scoring and breaking or by sawingnWhen cutting by scoring, the face paper shall be cut with a utility knifenKnauf boards shall be broken by snapping boards in the reverse direction, then cutting the back paper with a utility knifenCut edges should be smoothed with Knauf Beveler / Rasp Combo to obtain neat joints when installednShort edges should be chamfered with Knauf Beveler / Rasp CombonHoles for pipes or other small openings shall be scored on the back and the face outlined before removal / cut out with a purposely designed tool

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


1 0

1

4

6 7

2

5

3Mark the position of the ceiling line (deducting the thickness of the boards) with a Chalk Line.

Fix the UD channel on the perimeter (at 600mm 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.

Knauf Main C Channels should be fixed to the L Angle with two Knauf LN Wafer Head Screws at the desired length.

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

Fix the boards to the furring channel with Knauf screws.

Screw spacing for fixing of the boards : max. 300 mm.

Installation steps



13

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.

.

Single / First layer cladding

Fastening of claddingSpacing of screws

Screw Spacing second layer: 300 mm

Second layerFirst layerBoard thickness

TN 3.9X35 mmTN 3.9X25 mm12.5 mm

TN 3.9X45 mmTN 3.9X25 mm15 mm

2400 mm

1200

1200

1200

400400400400

300

300

300

300

400 4002400 mm

1000

Cladding of boards


1 2

Joint treatment

Cutting and processing the boardsnBoard surface should be cleaned of materials such as dust, oil etc.nFilling 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.

nFirst 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).nKnauf Joint Tape should be embedded into the joint filler to reinforce the joint between two gypsum boards.nOnce the first coat has dried, a second coat of Knauf Joint filler should be applied with 100 mm width on both sides of the center of the joint tape (200 mm width).nA very thin third coat of Knauf Joint filler should be applied with a minimum width no less than 150 mm beyond both sides of the center of the joint tape (300 mm width).nOnce third coat has dried, surface should be sanded and smoothed.



13


.





TN 3.9X35 mmTN 3.9X25 mm12.5 mm


2400 mm

1200

1200

1200

400400400400

300

300

300

300

400 4002400 mm

1000

Cladding of boards


1 2

Joint treatment

Cutting and processing the boardsnBoard surface should be cleaned of materials such as dust, oil etc.nFilling 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.

nFirst 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).nKnauf Joint Tape should be embedded into the joint filler to reinforce the joint between two gypsum boards.nOnce the first coat has dried, a second coat of Knauf Joint filler should be applied with 100 mm width on both sides of the center of the joint tape (200 mm width).nA very thin third coat of Knauf Joint filler should be applied with a minimum width no less than 150 mm beyond both sides of the center of the joint tape (300 mm width).nOnce third coat has dried, surface should be sanded and smoothed.



13


.





TN 3.9X35 mmTN 3.9X25 mm12.5 mm


2400 mm

1200

1200

1200

400400400400

300

300

300

300

400 4002400 mm

1000

Cladding of boards


1 4

Cladding of boards

Second layer cladding Second layer should be installer with staggered joints.

System’s components10

00

4002400 mm

600

600

1200

1200

400

300

300

300

300

TN Screw3.9 dia. X 25/35/45 mm Length LN Screw Hammer Fixings Wedge Anchor

ACCESSORIES

Main "C" Channel (0.5 mm. thk.)

12

38

68

22

11 35 11

Hat Furring Channel (0.5 mm. thk.)

22

23

UD Channel (0.5 mm.thk.) L-Angle (0.5 mm.thk.)

23

25


Manual Ceiling (BS EN)-UB.indd 12 4/1/17 12:01 PM

on ISO 14001: 2004 and BHS OHSAS 18001:2007

Estidama and LEED compliant products

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.

AsbestosOur 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.

FormaldehydeThe 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.

VOCKnauf 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.

Regional materialsOn a range of 500 miles from factory and quarry location, our boards can provide points for regional materials mentioned in different evaluation criteria (LEED, Estidama, etc.)

For outstanding performances in water and energy management, our

from the Ministry of Environment and Water.

COMPANY’S CERTIFICATION

Certi�cate of RegistrationQUALITY MANAGEMENT SYSTEM - ISO 9001:2008

This is to certify that: Knauf LLCPO Box 112871DubaiUnited Arab Emirates

Holds Certi�cate No: FM 577441

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

The production of Metal Pro�les, Plasters, Plasterboards, Ready Fix and all supporting activitieswithin the Middle East.

For and on behalf of BSI:Gary Fenton, Global Assurance Director

Originally registered: 09/11/2011 Latest Issue: 25/09/2014 Expiry Date: 09/11/2017

Page: 1 of 2

This certi�cate was issued electronically and remains the property of BSI and is bound by the conditions of contract.An electronic certi�cate can be authenticated online.Printed copies can be validated at www.bsi-global.com/ClientDirectory or telephone +971 (4) 3364917.

Information and Contact: BSI, Kitemark Court, Davy Avenue, Knowlhill, Milton Keynes MK5 8PP. Tel: + 44 845 080 9000

BSI Assurance UK Limited, registered in England under number 7805321 at 389 Chiswick High Road, London W4 4AL, UK.

1 4

Cladding of boards

Second layer cladding Second layer should be installer with staggered joints.

System’s components

1000

4002400 mm

600

600

1200

1200

400

300

300

300

300

TN Screw3.9 dia. X 25/35/45 mm Length LN Screw Hammer Fixings Wedge Anchor

ACCESSORIES

Main "C" Channel (0.5 mm. thk.)

12

38

68

22

11 35 11

Hat Furring Channel (0.5 mm. thk.)

22

23

UD Channel (0.5 mm.thk.) L-Angle (0.5 mm.thk.)

23

25



[email protected]

Fax: +971 4 334 9659

Phone: +971 4 337 7170

Knauf Head Office

www.Knauf.ae

Knauf Gypsum India Pvt.LtdKnauf Manufacturing Plant

No. 8 - C, 8th Floor Commercial ComplexDoshi Tower, New No. 205, (Old No.156)Poonamallee High Road, Kilpauk Chennai - 600010 Tamil Nadu, IndiaTel: +91 44 49580000Fax: +91 44 49575300

P.O.Box 50006Ras Al Khaimah, U.A.E.Tel: +971 7 268 9837Fax: +971 7 221 5301

Disclaimer:

The information provided in this leaflet is only intended to give guidance in selecting and using Knauf products. While we make every effort to ensure its accuracy, neither Knauf LLC and its branches nor any of tis employees or affiliates warrant or assume any legal liability or responsibility for the completeness or usefullness of any failure in installation or constructing any structure installation or building or caused by using this leaflet. Readers are adviced to independently verify this information prior to rely on it. In particular, readers must obtain appropriate independent advice on the use in specific structures, insllations or buildings to ensure compliance with all regulations, including health and safety regulations. Knauf reserves the right to amend technical specification.

The constructional and structural properties, and characteristic building physics Knauf system can solely beensured with the exclusive use Knauf system components, or other product expressly recommended by Knauf.

P.O.Box: 112871, Dubai

gypsum board ceiling systems - knauf enbs ceiling manual.pdf · en-bs and din standards, to meet...

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