One
way to finish a room is to apply wallboard to the exposed timber
studs. A common type of wallboard is gypsum board, a sheet material
composed of a gypsum core and a paper outer facing. Some boards
are also available with an aluminium foil backing which has additional
insulating properties. This also serves as a moisture barrier from
the room into the wall space, reducing condensation problems. The
sheets are usually sold in two widths: 9.5mm (3/8") and 12.7mm
(1/2) the most common thickness being 12.7mm. The sheets are
sold in 1.2m widths (4ft) and in lengths up to 3.6m (12ft). Edges
along the length of the boards are recessed so they can be joined
with joint cement and tape.
The boards can be fixed to the wall either vertically or horizontally.
Normally they are fixed with the long side running from floor to
ceiling but they can be placed horizontally if this helps you keep
the number of joints to a minimum.
Ideally you should end up with as few joints as possible so plan
the placement of the boards with care to use the largest unbroken
sheets possible. To work out how much material you will need, calculate
the number of square metres in walls and ceiling. This number will
tell your supplier how much joint compound, tape and nails you will
need to put the board up.
The nails to fix gypsum wallboard should be long enough to penetrate
about three quarters the way into the wood stud or joist. They should
be cement coated flat-headed nails.
To cut wallboard, score along the board with a knife and straightedge,
just cutting into the face paper. Place the board over a sawhorse
or length of timber and press evenly on either side of the score
line. The gypsum core will snap along this line. Turn the panel
over and cut the paper on either side, smoothing the rough edges
with coarse sandpaper.
Follow
the steps below to line a room with gypsum board:
Step
1.
Make
a pair of ceiling braces from 2 x 4s, about 2cm longer than the
distance from floor to ceiling. Nail cross boards about a metre
long across the top of the 2 x 4s to form T-shaped braces.
Step
2.
Using
the braces to hold each sheet in place while you work, line the
ceiling using single widths of board to span the entire width if
possible. Starting from the centre of the sheet and working outwards.
Nail the sheet to each joint at 180mm intervals. Give each nail
an extra blow with the hammer to "dimple" it but do not
break the paper surface.
Step
3.
When
the ceiling is lined start on the walls. Space the nails at 150mm
to 180mm intervals and start nailing 150mm to 180mm down from the
ceiling. Butt the wall panels against the ceiling sheets.
Dimple all nails as you work and protect any outside corners with
metal corner bead strips from the wallboard supplier.
Step
4.
Provide
access for electrical out lets, switches etc: by making holes in
the wallboard. Draw a pattern of the hole to be cut and cut around
the lone using keyhole saw.
When all surfaces have been lined with wallboard, the sheets must
be "taped and bedded- using lengths of sealing tape and joint
compound. The channels between the boards should be filled evenly
and completely with joint cement. Mix the cement as directed by
the manufacturer and spread into the joints using a wide putty knife.
Ensure the compound is smoothed down even with the surrounding surface.
Place a piece of perforated wallboard tape over the joint, centring
it, and embed it firmly into the joint using the wide putty knife.
Cement compound, which squeezes out through the perforations in
the tape and from under the edges should be smoothed down as you
go.
Allow the compound to dry, usually for 24 hours, then apply a thin
coat of cement over the top. "Feather it" so it extends
out a few centimetres from the edges of the join.
When this coat has dried, apply a third coat of cement, this time
feathering it out to 200-250mm either side of the channel. After
a further 24 hours, sand the surface smooth and level with the surrounding
wallboard surface.
Where the nail heads have been dimpled, these should also be filled
with cement. Apply 3 coats, feathering and sanding them in the same
way as the joints.
Outside corners that have been edged with beading also require 3
coats of cement, with the last coat extending about 200mm onto the
walls on each side. Sand smooth.
Inside corners and the joints where walls and ceiling meet are taped
and bedded as follows. Cut the tape to length and fold it in half.
Lay a bed of cement as for the other joints then press the folded
tape into the cement, feathering it out to at least 50mm each side
of the joint. Add a second and third coat, ensuring the last coat
extends out to about 2mm on each surface. Sand smooth.
Cracks
at floor and ceiling can be covered with decorative mouldings and
skirting boards should be attached to finish the floor edge.
Allow
the compound to dry completely then allow a further 2 days before
sealing or priming the surface and painting.
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