Gyproc Proflex Access Panels - Installation Guidance Notes
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1 Gyproc Proflex ccess Panels - Installation Guidance Notes The following notes are intended as guidance only, depicting the basic sequence of installation. In practice, consideration should be given to site conditions requiring specific project solutions. Please observe appropriate Health and Safety legislation e.g. protective clothing, equipment etc. when working on site. Gyproc Profilex Standard & FR Standard Panel Installation of a beaded frame into a British Gypsum GypLyner IWL. See detail drawings fig. Section - (FR panel shown) X = Panel frame dimension Y = Panel frame dimension, hinged side Clear aperture X - 70mm/Y - 50mm 6mm all round aperture clearance Fig. Wall application (Standard and FR) Framing out detail 6 6mm 5 = Framed opening in British Gypsum wall lining = Beaded frame flange to accept tape and joint finish or plaster finish = Continuous concealed hinge = Budget lock 5 = Suitable packers/fire resistant mastic (FR Panel) 6 = Fixing brackets = GypFrame Channel = GypFrame Metal Studs The panel is best best fitted with the hinge side running vertically (Standard Panels are not handed). Form the aperture using standard metal stud procedures making sure that the aperture is trimmed out correctly and the clear opening formed is 6mm larger all round than the panel size. Once the trimmed aperture is square and secure apply the plasterboard lining, cutting the board neatly to the trimmed opening. Offer the complete panel assembly into the aperture and secure with Gyproc Drywall screws through the face of the beaded frame, through the plasterboard and into the metal studs. Ensure that the panel is square and the gap between the door and the panel frame is equal all round. If required insert additional screws through the inside of the panel frame into the metal studs (strongly dditional instructions for FR panel Form an aperture using standard metal stud procedures. Offer the panel into the aperture, bedding the frame all round into a suitable fire resistant mastic. Screw-fix into position as described for beaded and plaster frames. ll FR fire rated wall panels are supplied with rear Note: The same principles are used for installation into GypWall and ShaftWall systems. recommended for panels larger than 600 x 900mm). Once the frame has been secured, open the door and release the set screws holding the hinge to the frame. Take the weight of the door and remove it from the frame, storing it safely with the set screws for refitting later. 5 Check that none of the screw heads are protruding from the beaded frame and then proceed with either jointing or finishing with the plaster skim. If the plasterboards are to be jointed, allow a (min.) 00mm margin around the frame to feather the jointing material into the field of the board. 6 When finishing is complete, refit the door ensuring the gap between door and frame is equal all round before tightening the set screws. fixing angles welded to the frame. This angle should be screw-fixed to the aperture through the pre-punched holes provided, using packing strips to prevent frame distortion as the screws are tightened. Seal any gaps between the rear of the frame and the aperture with suitable fire resistant mastic and proceed with either jointing or finishing with a plaster skim.
2 Gyproc Profilex Standard Panel Installation of a beaded frame into a British Gypsum CasoLine MF Ceiling Please refer to detail drawings fig. Ceiling application (Standard panel) Framing out detail Fig. Section - X = Panel frame dimension Y = Panel frame dimension, hinged side 6mm all round aperture clearance Clear aperture X - 70mm/Y - 50mm 6 = GypFrame MF5 Section = GypFrame MF6 Channel = GypFrame MF7 Channel = GypFrame G Steel ngle = CasoLine MF suspended ceiling = Continuous concealed hinge = Budget lock = Suitable packers 5 5 = Beaded frame flange to accept joint and tape finish or plaster skim 6 = dditional riveted support angles maybe required on larger ceiling panels or where location does not suit standard fixing position (for panels larger than 600 x 900mm) Form an aperture within the CasoLine MF ceiling which is 6mm all round larger than the access panel size. Fix additional G Steel ngle supports not less than 75mm outside each corner of the trimmed opening and connect to the structure. Once the trimmed aperture is square and secure apply the plasterboard lining, cutting the board neatly to the trimmed opening. Offer the complete panel assembly into the aperture and secure with Gyproc Drywall Screws through the face of the beaded frame, through the plasterboard and into the MF6 and MF5. Ensure that the panel is square and the gap between the door and the panel frame is equal all round. Insert the screws through the beaded frame 5mm from each corner on all sides and equally spaced at 50mm centres. Ensure that the screws pull the frame tight against the board and that the countersunk heads don t protrude otherwise the standard of finish may be compromised. Once the frame has been secured, open the door and release the set screws holding the hinge to the frame. Take the weight of the door and remove it from the frame, storing it safely with the set screws for refitting later. 5 dditional fixings are required for panels larger than 600 x 900mm; reduce screw centres to 75mm. 6 Check that none of the screw heads are protruding from the beaded frame and then proceed with either jointing or finishing with plaster skim. If the plasterboards are to be jointed, allow a (min.) 00mm margin around the frame to feather the jointing material into the field of the board. 7 When finishing is complete, refit the door ensuring the gap between the door and frame is equal all round before tightening the set screws. 8 The door is supplied factory finished in white etch primer and is ready to receive a coat of emulsion. Decorate only the face of the door, not the sides. This ensures that no excess material bridges the gap between door and frame which will affect the visual appearance of the finished panel and possibly impair the operation of the door.
3 Installation of a picture frame into a British Gypsum GypLyner IWL Form the aperture as described in beaded frame installation section. Remove the door as described in beaded frame installation section. pply a bead of Gyproc Sealant to the rear of the picture frame and offer the frame into the aperture. Screw-fix through the inside of the frame (or the fitted angle brackets) into the metal trimmed aperture. Before securing all sides make sure the picture frame is tight against the board face, the frame is square and the fixings have not distorted the frame. Clean off any excess Sealant and refit the door as described earlier. 5 Wipe over with a damp cloth to remove any marks left during installation and buff clean. Installation of a plaster frame into a masonry wall to be finished with a two coat Thistle plaster system The opening in the wall should be approx. 0mm larger than the panel size i.e. 560 x 560mm for a 550 x 550mm panel. Ensure the frame fits into the opening square and level and screw-fix (into suitable rawl fixings as required) through the face of the frame into the masonry. If the face of the masonry is uneven, pack the frame to prevent distortion. Before fixing the frame on all sides, make sure that the door operates correctly and the gap between door and frame is equal all round. Once the frame has been secured, open the door and release the set screws holding the hinge to the frame. Take the weight of the door and remove it from the frame, storing it safely with the set screws for refitting later. 5 For additional rigidity, screw-fix through the internal fixing angles, inserting packers between the masonry and the angle to prevent distortion. 6 Plaster up to the frame in the same way as for a two-coat plaster stop-bead. 7 Remove any plaster from inside the door before it dries and refit the door. Finish as described previously for an etch primed door. NOTE: Refer to British Gypsum White Book Section b05 Plaster Systems for further details regarding Thistle Plaster selection and usage - pg 00.
4 Gyproc Profilex FR Ceiling Panel Installation of a beaded frame into a British Gypsum CasoLine MF suspended ceiling Please refer to detail drawings fig. Ceiling application (FR Ceiling Panel) Framing out detail B = GypFrame G Support ngles = GypFrame MF5 Sections = GypFrame MF6 Channel = GypFrame MF7 Channel Fig. B Section (Plasterboard face door) Y + 0 = Panel aperture dimension hinge side B Y = Outside frame dimension hinge side mm const. =.5mm Gyproc FireLine packers to sides = Dust seal at edges = Top Hat retainers (pivot pins) Section B-B (Plasterboard face door) X + 5 = Prepared aperture Y + 0 = Prepared aperture - Hinge side 5 80mm of all = Suitable fire resistant mastic = CasoLine MF suspended ceiling = 5mm Beaded frame to accept tape and jointing or plaster skim = Door Controlled ction Device (C..D.) - Safety feature 5 = Budget lock Section B-B (Flush metal door) X + 5 = Prepared aperture Y + 0 = Prepared aperture - Hinge side X = Outside frame dimension 80mm of all = Suitable fire resistant mastic = Door Controlled ction Device
5 Follow the installation procedure as described in the sequence to of the Standard panel, CasoLine MF Ceiling installation, with the exception that the trimmed opening size should be (for example, to suit 600 x 600mm panel) 65 x 60mm. The hinge side being the 60mm dimension. (X dimension + 5mm. Y dimension + 0mm. See fig.) The frame must be bedded into the trimmed aperture with a suitable fire resistant mastic to all sides. Once the frame has been secured, unlock the door and lower it to the check position. Lift slightly and pull towards the door front so allowing it to open to 90 degrees. Remove the split pin from the pivot rod collar, take the weight of the door and retract the two pivot rods and collar allowing the door to be removed. Store the door and pivot rod assembly safely for refitting later. Cut two plasterboard packer strips to approx. 0 x 50mm. Push each strip down into the gap between the MF6 and the frame sides. Insert Gyproc Jackpoint Screws through the pre-punched holes in the frame on the lock and hinge sides into the back of the MF7 sections. Screw or rivet G angle to the two MF7 sections near each corner of the access panel. 5 Reduce screw centres to 75mm, from 50mm when using panels larger than 600 x 600mm (fixings through beaded frames). 6 If the door has plasterboard and drywall edge beads fitted, then proceed with drywall jointing. 7 Refit the door by reversing the sequence described in step, above. 8 Whether the door has been drywall jointed, finished with a plaster skim or white etch primed, it is now ready to receive an emulsion. Decorate only the face of the door, not the sides. This ensures that no excess material bridges the gap between door and frame which will affect the visual appearance of the finished panel and possibly impair the operation of the door. Gyproc Profilex FR Performance Panel Installation into British Gypsum ShaftWall or GypLyner IWL Follow the basic procedure as for the Gyproc Profilex FR Standard Panel described earlier. Gyproc Profilex Sealed Panel Installation into drylined systems Follow the basic procedure as for the Gyproc Profilex FR Standard Panel described earlier. Gyproc Profilex Loft Hatch Installation The Gyproc Profilex Loft Hatch is designed to fit between nominal 0mm thick timber trusses set at 600mm centres. If this is not the case, then timber framing should be constructed in the approved manner to achieve the correct size of opening (800 x 50mm or 50 x 50mm). Fix short trimmers between the trusses to complete the timber aperture. Once the correct structural aperture has been achieved, install the plasterboard lining using Gyproc Drywall Timber Screws or, cut away an existing soffit to leave the aperture in the ceiling clear. Ensure the aperture is completely unobstructed. Ensure that the plasterboard faces nearest to the cut edges are flat and remove any surplus paper. Offer the complete Loft Hatch assembly into the trimmed aperture until the beaded frame flange is flat against the ceiling. If resistance is detected during this procedure, the panel should be removed and the aperture checked for obstructions otherwise the frame may distort during installation preventing the correct operation of the door. 5 Once the beaded frame is flat against the ceiling lining 50mm woodscrews should be driven through the beaded frame and plasterboard, into the timber on opposite sides of the Loft Hatch, one either side at the mid-point to retain it in position.
6 6 t this point check that the frame is square and the gap between door and frame is equal all round before securing properly with 50mm screws through the beaded frame 5mm from each corner and at 50mm centres on each side. Ensure that the screws pull the panel tight against the ceiling lining without distorting the frame. 7 Once the assembly has been secured, open the door and release the clamping screws which retain the hinge, take the weight of the door and remove it to a safe place for refitting later. 8 Screw 75mm domed head woodscrews through the clearance holes on the inside faces of the frame into the timber surround. Take care not to over tighten the screws and use packers if necessary to prevent the frame distorting. 9 Check that none of the screw heads are protruding from the beaded frame and then proceed with either jointing or finishing with plaster skim. If the plasterboards are to be jointed, allow a (min.) 00mm margin around the frame to feather the jointing material into the field of the board. 0 When finishing is complete, refit the door ensuring the touch catch is properly adjusted and the gap between door and frame is equal all round. The door is supplied factory finished in white etch primer and is ready to receive an emulsion. Decorate only the face of the door, not the sides. This ensures that no excess material bridges the gap between door and frame which will affect the visual appearance of the finished panel and possibly impair the operation of the door. Finishing Gyproc Profilex ccess Panels with a Beaded Frame These instructions apply to beaded frame panels whether used to trim around the access panel itself or trim a plasterboard lining or background into which the panel is installed. Jointing Gyproc plasterboards should be fixed with the decorative side exposed. pply Gyproc Joint Filler to the beaded frame overlapping on to the plasterboard surface. Bed Gyproc Joint Tape firmly into the Filler, ensuring it covers the junction between the beaded frame and the plasterboard and does not overlap the lip of the panel door frame. F ollow immediately with a further application of Filler to fill out flush from the lip of the panel door frame to the plasterboard surface, feathering into the field of the board. Surplus Filler should be removed from the panel door frame with a damp cloth or sponge. 5 Finish the joint by applying one or two coats of Gyproc Joint Cement, Gyproc Ready-Mix Joint Cement or Gyproc ProMix LITE as required. lternatively, use Gyproc Easi-Fill throughout, adopting the same procedures. NOTE Refer to British Gypsum White Book Section n5 Jointing for further details - pg 66. Plastering 6 Use either Thistle Board Finish or Thistle Multi-Finish and apply to the decorative face of Gyproc plasterboards. 7 pply Thistle Board Finish or Thistle Multi-Finish to the beaded frame overlapping on to the plasterboard surface. 8 Bed Gyproc Joint Tape ensuring it covers the junction between the beaded frame and the plasterboard and does not overlap the lip of the panel door frame. 9 When this application has set finish as normal. Surplus plaster should be removed from the panel door frame with a damp cloth or sponge. The use of Gyproc Joint Tape provides maximum resistance to cracking, when compared to self-adhesive fibre tapes. Plaster finishes other than those described are not recommended. Decoration of metal access doors which are left with a white etch primer should be determined in consultation with the decoration supplier. Decoration of plasterboard doors can be carried out following the application of Gyproc Drywall Primer which provides a base for most types of decoration and forms part of the drywall jointing programme. NOTE Refer to British Gypsum White Book Section n0 Plaster Skimming for further details - pg 60
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