Technical Manual. ceiling - Seamless

Transcription

1 Technical Manual

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3 1. Introduction 1.1 General flex - Ceiling is an autoclave cellulose fibre reinforcement cement ceiling board manufactured by Hume Cemboard Industries Sdn Bhd, an ISO9001 and ISO14001 certified company. The basic compositions comprised of portland cement, cellulose fibre, fine ground sand and water. is a ceiling system complete with the supply of fasteners, jointing compound, perforated paper tape interlocking clip and ceiling batten by HCI utilising the flex - Ceiling board. 1.2 Application The is specially designed for internal & external ceiling application. It helps to diminish the usual array of problems such as water stains, mould, termite, fire and abrasive external weather conditions. However, the installers must ensure that the product meets the aesthetic requirement before installation. HCI will not be responsible for rectifying aesthetic surface variations upon installation. For internal usage, balconies, eaves, soffits and low rise external (4 stories height); it is recommended to use ceiling batten as the framing. For external high rise (above 4 stories height), it is recommended to use the Lexington Heavy Duty Ceiling System or other heavy duty ceiling batten system that s available. The installer is responsible to consult with Lexington s Expertise or other heavy duty ceiling system manufacturer prior to installation. 1.3 Features and Benefits Aesthetically-Appealing Low Maintenance Durable Mould Resistant Environmentally-Friendly Termite Resistant Hazard Free Weather Resistant Resistant to Moisture (water permeability, warm water, soak dry & heat rain) 1.4 Tests and Certification flex - Ceiling meets the national and international fibre cement standards, namely MS1296, ISO 8336, BS EN and ASTM C1186. It also meets the Fire Resistant Class O requirement. Rebated Area 1.5 Standard Size and Mass flex - Ceiling meets the national and international fibre cement standards, namely MS1296, ISO 8336, BS EN and ASTM C1186. It s also meets the Fire Resistant Class O requirement. Length (mm) Width (mm) Thickness Approx. Mass (kg/m2) Edge sides rebated 01

4 2. Accesories / Tools 2.1 Components Supplied by Hume Cemboard Industries ceiling batten Use ceiling batten which is a Light Gauge Cold Formed Galvanized Steel C-Section 38mm (width) x 12mm (depth) x 0.35mm (total coated thickness). It is rolled steel structure used for ceiling hanger, ceiling main runner, ceiling joist and ceiling nogging. interlocking clip Use interlocking clip which is Light Gauge Pre- Pressed Galvanized Steel with 0.5mm total coated thickness. It is used as the clip between the runner batten and joist batten. fastener - Needle Point Countersunk self-embedding head needle point, No 6 x19mm long. It is used for all fastening in, included fastening ceiling battens, fastening to ceiling battens (joist & nogging). jointing compound Appearance: White paste, 28kg / pail Drying time at EMC: 2 hrs, depending on the surrounding condition. Mix with 10% white cement mixing ratio to conceal the jointing recessed and square edge area and fastener heads to prevent moisture penetration and flat surface for decorative finishing. The jointing compound must be applied according to the jointing compound Technical Data Sheet (TDS). perforated paper tape 50mm x 150m / roll. Joint reinforcement paper tape used with flex - Ceiling sheets. access panel Available in 2 sizes, 450x450mm & 600x600mm in 3.5mm board thickness. scoring knife Use only Taping Tool that s provided by Hume Cemboard Industries for flush jointing application using perforated paper jointing tape. 02

5 2.2 Components / Tools which not supplied by Hume Cemboard Industries Hume Cemboard Industries recommends the following components and tools to be used in conjunction with flex - Ceiling sheets. Hume Cemboard Industries does not supply these components or a warranty. Please contact respective component manufacturers for information on warranties and information. Paintable Polyurethane Sealant Suitable Paintable Polyurethane is to be used in expansion joint and gaps between wall and ceiling board. It can be applied at internal & external areas. Recommended to use Bostik Seal N Flex 1. Backing Tape Backing tape is used to prevent the sealant from directly being attached to the ceiling joist / nogging It is applied on to the ceiling joist / nogging before installing the board at the gap area. Scrapper For flush jointing application purposes and removal of excessive compounds from the panel surface, the recommended size of the scrappers are 4 (100mm) and 6 (150mm) Pen Knife Tool for easy cutting of flex - Ceiling sheets. Scoring Knife Tool for easy scoring of flex - Ceiling sheets. Cordless Knife Use only cordless driver with adjustable torque selection. It s a requirement that the installer needs to check and select the suitable torque speed to prevent over fastening during the board installation. 03

6 3. Ceiling Installation 3.1 ceiling batten FRAMING INSTALLATION a. Install the ceiling hanger at 900mm c/c (max.). b. Install the ceiling runner at 610mm c/c (max.) span between 2 runners and fasten to ceiling hanger. c. Install the ceiling joist at 407mm c/c (max) span between 2 perpendicular joists and lock it using the interlocking clip to the runner batten. d. For ceiling joist, at the board jointing, adjust the joist to be at the centre of 2 joining boards. e. Ensure the ceiling runners & joists are reasonably flat and level. f. Kindly refer to Figure 1 for the ceiling batten installation guide and specification. g. The joists at ceiling parameter should be installed at 50mm (max.) gap from wall. h. A nogging is required at 1220mm board joint. Kindly refer Figure 1, Detail C. Use ceiling batten manually flange pre-cut as nogging to fit perpendicular of web to the joist. The nogging is installed by slotting in the back of the board and then fasten the board to nogging accordingly as shown in Figure 2. Fastener is not required for the ceiling nogging to joist as it will create additional gap to the flush joint area. i. All the ceiling battens are fastened using the fastener - Needle Point screws. 100mm 900mm max. c/c Ceiling 407mm c/c Ceiling 610mm max. c/c c ceiling batten mm 900 c/ ax. m 900mm max. c/c 61 Wall 0m m ma Interlocking clip Main 900mm max. c/c xc /c 2mm 34mm x12mm x 0.3mm nominal TCT for Ceiling Hanger, Ceiling Main Runner, Ceiling Joist, Ceiling Nogging and Protrusion Line Ceiling 50mm from side end Support batten soffit of slab or fixed to roof truss flex - Ceiling 1220mm(W) x 2440mm(L) x 3.5mm(T) 50mm 34m m 100mm 900mm max. c/c 50 mm 61 0m m DETAIL A ma x. c Board joint mm 40 mm DETAIL C 1220mm(W) x 2440mm(L) x 3.5mm(T) (Long sides edges to be laid parallel to ceiling joist) m 7m /c m 7m Ceiling 610mm max. c/c Wall Ceiling 407mm c/c 50mm DETAIL B Ceiling nogging Interlocking clip Ceiling nogging joist Board joint Runner DETAIL B Figure 1: DETAIL C ceiling batten guide & specification. Slot in the nogging then only fasten it Figure 2: Installation of ceiling nogging mm max. c/c Ceiling 407mm c/c Ceiling 50mm from side end Main 900mm max. c/c Support batten soffit of slab or fixed to roof truss

7 Flush Jointing Method 3.2 Board Installation board are to be in dry condition when installed. If board is wet, please allow it to dry. Board in wet condition is difficult to install because they are heavier and will have tendency to break due to moisture that is still retained in the board INSTALLATION a. Install board at along the ceiling joist in a staggered pattern. Refer to Figure 3. b. At least 2 workers are required for board installation. Workers are required to hold the board on each side. Fasten the board from center to side, refer to Figure 4. This will minimize the board undulating effect. c. Fasten the board to ceiling joist as per Figure 3. The fasteners distance is at 200mm c/c maximum at board edges and 300mm c/c maximum at board center for internal and external. Use only fastener - Needle Point screws. d. Fasten the board 12mm minimum from edge and 50mm minimum from corners as shown in Figure 3. e. All fasteners must be embedded into the board. Use the scrapper to check the fasteners levelness. 610mm max. c/c Ceiling nogging Ceiling 407mm c/c Ceilling 610mm max. c/c 407mm max. c/c 12mm min. 50mm min. 300mm 1220mm 407mm 300mm 200mm 407mm 407mm 300mm 2440mm Figure 3: Board installation layout Side Side Center Side Side Fastening start from center to side Figure 4: Board fastening method 05

8 3.2.2 FLUSH JOINTING (At Board Jointing Areas & Fasteners) It is recommended to do the flush jointing when all the lighting fittings opening / manhole opening are completed. Prepare the jointing compound by mixing jointing compound with 10% White Cement. The allowable working period for the mixed jointing compound is 3 hourrs maximum. a. Use damp sponge to clean the board jointing surface and ensure the board surface is free from dust. b. Embed the perforated paper tape with jointing compound using the taping tool along the recessed joint area. c. Press and distribute the excessive jointing compound from the perforated paper tape using 150 mm scrappers. Immediately apply another jointing compound (approximately 150 mm wide) using 150 mm scrapers onto the perforated paper tape. Ensure the perforated layer of paper tape is fully covered by jointing compound. d. Do not over flush the jointing compound. The recommended times for flushing is 5. e. To flush onto fastener points, apply first and second layers of jointing compound. f. Ensure the fastener points are smooth. g. When dry (duration about 4 to 6 hours, depending on the surrounding condition and compound thickness), lightly scrap away the uneven surface of the flush joint areas and fasteners areas using scrapper to get an even finish before any finishing. Apply another layer of jointing compound if necessary. Refer to Figure 5 for flush joint detail. (Butt joint) moderate contact 1220mm(W) x 2440mm(L) x 3.5mm(T) Ceiling joist / ceiling nogging First coat jointing compound (Approximatery 100mm wide) perforated paper tape embeded in jointing compound (apply using Taping tool) Second coat jointing compound (Approximatery 150mm wide) Figure 5: Flush Joint Detail 06

9 4. Expansion Joint Expansion joints for is required in long runs of both directions. These joints are correspondence to thermal expansion between ceiling systems with supporting structure or any significant structural movement is expected. Expansion joint should be provided at every 9.0m. For installation under roof spaces less than 600mm, the expansion joint must be reduced to 6.0m for insulated ceilings and 3.6m for uninsulated ceilings in both direction. Put a backing tape (or any tape, just to prevent the sealant from directly attached to ceiling joist / nogging) on the ceiling joist / nogging before installing the board. Provide minimum 5mm wide gap between sheets and seal with paintable Polyurethane Sealant (Bostik Seal N Flex 1). Do not jointing compound at the control joint. Refer Figure 6 for expansion joint installation. apply Polyurethane PU Sealant Ceiling joist / ceiling nogging fastener - Needle Point 1220mm(W) x 2440mm(L) x 3.5mm(T) 5mm min. Backing tape Figure 6: Expansion Joint Installation 5. Side Elevation Side / edge installation can be either using protrusion line, shadow line trim or paintable PU sealant. 5.1 Protrusion Line Finishing at Ceiling to Wall Edges The installation of protrusion line finishing using for protrusion line finishing installation drawing. ceiling batten only can only be done after the ceiling frames are levelled. Refer Figure 7 a) Put a piece of off cut ceiling board to the aligned ceiling joist and mark the level of the board that touches the wall. b) Install the ceiling batten above the marked line approximately 3-4mm. flex - Ceiling board into the c) Slot the without any gap. ceiling batten that is attached to the wall surface. The flex - Ceiling board is tight fitted d) If any noticeable gap on the protrusion line finishing, white paintable sealant (Bostik Seal N Flex 1) can be used to cover it. Anchorage / Fastener Ceiling 407mm max. c/c fastener - Needle Point 1200mm(W) x 2440mm(L) x 3.5mm(T) ceiling batten Protrusion Line Figure 7: Protrusion Line Finishing Installation 07

10 5.2 Shadow Line Finishing at Ceiling to Wall Edges For shadow line installation, kindly refer to Figure 8. A shadow line stopping angle is required. a) At wall to ceiling edges, slot in the shadow line stopping angle. b) Fasten the shadow line stopping angle together with the flex - Ceiling and ceiling joist. Ceiling 407mm c/c fastener Needle Point 1220mm(W) x 2440mm(L) x 3.5mm(T) Shadowline stopping angle Figure 8: Shadow Line Trim 5.3 Paintable Sealant Finishing at Ceiling to Wall Edges For edge paintable sealant installation, a 6mm gap is required to be filled with paintable PU sealant. (Bostik Seal N Flex 1) Kindly refer to Figure 9. a) Apply the paintable PU sealant to the gap between walls to ceiling as per manufacturer s recommendation. b) Allow the sealant to fully cure / dry prior to painting. Ceiling hanger Ceiling 900mm max. c/c Ceiling 407mm c/c fastener - Needle Point 1220mm(W) x 2440mm(L) x 3.5mm(T) 6mm gap filled with Paintable PU sealant Figure 9: Paintable PU Sealant 08

11 6. Panel Finishes 8. Working Instruction Prior to application of paint finishes, remove any jointing compound residual and ensure the ceiling surfaces are dry. The water-based acrylic paint should be applied 2 layers minimum. Make sure the board surface is in smooth condition and free from dust or any contaminant prior to painting. Coating should be completed within 1 month from the board installation. Gloss paints are not recommended. Always follow the paint manufacturer s recommendation for paint suitability, mixing and application. 8.1 Cutting 7. Glancing Light Cutting must be carried out in a well-ventilated area using following method: Score and snap - Score the sheet with scoring knife. Repeat until depth reaches 1/3 sheet thickness. Snap sheet upward to achieve clean break. Trim cut edge with rasp if necessary. - Normal pen knife can also be used in score and snap method. In some installation areas, the glancing light may be noticeable in board joints. Thus, try to avoid using high gloss level paint for ceiling system. Work closely with the ceiling contractors to minimize this glance appearance. The effect of glance light can be reduced by using curtains or blinds to block the direct light at ceiling areas, artificial light shading devices or use light/ matt finished paints. 8.2 Drilling Small holes can be formed using high-speed (HSS) drill bits. Larger circular holes can be created by drilling a series of small holes around the perimeter of the proposed hole, and gently tapping out the waste piece. Smoothen the rough drilled edge with rasp if necessary. 8.3 Handling and Storage flex - Ceiling must be stacked on flat ground and supported with level bearers prior to installation. Ensure all timber bearers of a stacked sheet are aligned with other stacks. Improper sheet stacking may result in permanent sheet deformation that causes unsightly appearance such as undulating. flex - Ceiling must always be kept dry, preferably stored under a protected shade. When stored outdoors, it must be protected from water ingress and and weather by covering the board with tarpaulin sheet. Allow wet sheet to reach equilibrium under a natural ventilated condition prior to installation. 9. Best Practice for PRIMAceiling Seamless Aside from the normal installation guide, installers are recommended to refer the Best Practice guide for on the following items below: Downlight Installation Exhaust Fan Installation Manhole Installation Heavy Ceiling Light Fitting / Ceiling Fan Installation Air Conditional Cassette Unit Installation Repairing of Opening Hole Heavy Duty Ceiling System 09

12 50 Years 50 Years Durability WARRANTY Hume Cemboard Industries Sdn Bhd ( the Company ) warrants that it will at all times ensure that the products referred to herein ( the Products ) shall be supplied by it to the purchaser free of any manufacturing defects and defective materials used in their manufacture. In the event and if contrary to this assertion the Products prove to be defective, whether as a result of manufacturing defects or arising from the Company s use of defective materials, the Company will supply replacement Products. The Company shall, however, have the option and may choose to reimburse the purchaser the purchase price of the Products instead. The Company shall not be liable for any economic or consequential losses arising from any use of defective Products. This warranty shall be void unless the purchaser has, in its handling and installation of the Products, complied with the recommendations contained in this brochure and other good building practices expected of a reasonable purchaser. ADVISORY NOTE Successful installations of Hume Cemboard Industries Sdn Bhd s Products depend on a large number of factors that are outside of the scope of this brochure. Particular design, detail, construction requirements and workmanship are beyond the control of the Company. As such, Hume Cemboard Industries Sdn Bhd s warranty does not extend to non-usability of Products or damage to Products arising from poor or defective designs or systems or poor quality of workmanship in the installation of Products. For more information, please contact us at: No. 12 Jalan Tandang, Petaling Jaya, Selangor, Malaysia. Malaysia Sales Tel: Fax: sales@humecemboard.com.my Oversea Sales Tel: Fax: exporthci@humecemboard.com.my V2