Installation Guides

Gyprock Plus (10mm)

•Standard plasterboard for residential walls

•Made with Optimised Core technology for greater breaking strength

•Lighter board with improved handling and crisper score-and-snap

•Mass: 5.7 kg/m²

Gyprock Supaceil (10mm)

•Designed to span up to 600mm in ceiling applications

•Enhanced sag resistance for ceiling installations

•Optimised Core technology for easier handling

•Mass: 6.1-6.2 kg/m²

Gyprock Aquachek (10mm)

•Moisture resistant for wet areas like bathrooms and laundries

•Both core and linerboard treated for moisture and humidity resistance

•Recessed long edges for flush jointing

•Mass: 7.9 kg/m²

Gyprock Superchek (10mm)

•High density core with heavy duty facing

•Double the impact resistance of standard plasterboard

•Enhanced sound resistance for quieter rooms

•Mass: 10.4 kg/m²

Gyprock Standard Plasterboard (13mm)

•Available in Recessed Edge (RE), RE/SE, and Square Edge (SE)

•Enhanced fire and acoustic performance

•Mass: 8.5 kg/m²

Gyprock Aquachek (13mm)

•Heavy duty moisture resistant board

•Suitable for commercial wet areas

•Mass: 9.8 kg/m²

Gyprock Soundchek (13mm)

•High density gypsum core for acoustic resistance

•Ideal for party walls and noise-sensitive areas

•Mass: 13.0 kg/m²

Gyprock Impactchek (13mm)

•Fire grade with woven fibreglass mesh reinforcement

•High impact resistance for hallways, stairways, schools

•Mass: 10.5 kg/m²

Gyprock Fyrchek (13mm & 16mm)

•Glass fibre reinforced gypsum core

•Meets AS1530.4 fire rating requirements

•Ideal for fire and acoustic rated walls and ceilings

•13mm Mass: 10.5 kg/m² | 16mm Mass: 12.5 kg/m²

Gyprock Fyrchek MR (13mm & 16mm)

•Fire grade with moisture resistant properties

•Core and liner treated for humidity resistance

•For fire-rated wet areas

•13mm Mass: 10.8 kg/m² | 16mm Mass: 12.9 kg/m²

Gyprock Shaft Liner Panel (25mm)

•For shaft systems, party walls, and intertenancy walls

•600mm wide square edge sheets

•Mass: 19.8 kg/m²

Gyprock EC08 Impact (13mm)

•Higher recycled content for Green Building projects

•Increased density for impact resistance

•Mass: 12.1 kg/m²

Gyprock EC08 Complete (13mm & 16mm)

•Premium solution with mould inhibitor

•Impact, moisture, sound, and fire resistance

•Low VOC plasterboard

•Mass: 12.4-14.8 kg/m²

Gyprock Flexible (6.5mm)

•Enhanced core for bending to small radii

•For curved walls and ceilings

•Designed for two-layer installation

•Mass: 4.3 kg/m²

Gyprock Glasroc F (30mm)

•Paperless gypsum board with glass fibre core

•Single-layer fire protection for steel columns and beams

•Mass: 25.5 kg/m²

Timber Framing

•All timber framing must comply with AS1684 (series) or AS1720.1

•Maximum stud centres depend on plasterboard thickness and wind load

•Standard centres: 450mm or 600mm for 10mm board

•Studs must be straight, dry, and free from defects

Steel Framing

•Must comply with AS/NZS4600 or NASH Standards

•Wall framing up to 2.4mm thickness

•Ceiling framing up to 1.6mm thickness

•Check manufacturer specifications for screw requirements

Frame Alignment

•Level 3 & 4 Finish: Maximum 4mm deviation

•Level 5 Finish: Maximum 3mm deviation

•Use straightedge to check alignment before lining

Screw Fixing (Recommended)

•Use Gyprock drywall screws for timber studs

•Use self-drilling screws for steel studs

•Screw heads should dimple the paper without breaking it

•Minimum 10mm from sheet edges, 15mm from ends

Adhesive + Screw Fixing

•Apply Gyprock Stud Adhesive in continuous beads

•Use screws as temporary fixings until adhesive sets

•Not permitted for fire-rated or tiled installations

Screw Spacing

•Walls: 300mm maximum centres

•Ceilings: 200-230mm maximum centres

•Reduce spacing near edges and at joints

Horizontal vs Vertical Installation

•Horizontal installation preferred for walls over 2.4m

•Reduces number of butt joints

•Creates stronger wall with joints at mid-height

Joint Types

•Recessed edge joints: Easy to finish flush

•Butt joints: Require back-blocking for level 4+ finish

•Square edge joints: For expressed joint or cover moulding finish

Back-Blocking

•Required for butt joints in level 4 and 5 finishes

•Use 200mm wide plasterboard strip behind joint

•Adhere with Gyprock Stud Adhesive

•Essential for preventing joint cracking

Surface Preparation

•Masonry must be dry, clean, and free of loose material

•Apply waterproof membrane if rising damp is present

•Check wall flatness - maximum 10mm variation over 2.4m

Adhesive Application

•Use Gyprock Masonry Adhesive

•Apply in vertical dabs 50-75mm diameter

•Space dabs at 400mm centres

•Press board firmly and check alignment

Temporary Bracing

•Support sheets until adhesive sets (24-48 hours)

•Use timber props at mid-height

•Do not apply loads until fully cured

Maximum Joist Centres

•10mm Gyprock Plus: 450mm centres

•10mm Gyprock Supaceil: 600mm centres

•13mm Standard: 600mm centres

•Check span tables for specific conditions

Joist Alignment

•Critical for flat ceiling finish

•Maximum 4mm deviation for Level 4 finish

•Maximum 3mm deviation for Level 5 finish

•Pack or plane joists as required

Ceiling Battens

•Use when joist spacing exceeds board capacity

•Install perpendicular to joists

•Secure with two nails or screws at each crossing

General Requirements

•Always start from one corner and work across

•Stagger end joints between adjacent sheets

•Maintain 3-4mm gap at walls for movement

•Use ceiling support "T" for installation

Screw Fixing

•Screw at 200mm centres along joists

•First screw 50mm from sheet end

•Screws should dimple paper without breaking

Adhesive + Screw Fixing

•Apply continuous bead of Stud Adhesive along joists

•Use screws as temporary fixings

•Reduces screw popping in timber frame ceilings

Causes of Ceiling Sag

•Excessive joist spacing

•Inadequate fastening

•High humidity in roof space

•Insulation directly on plasterboard

•Water damage

Prevention Methods

•Use Supaceil for 600mm spans

•Ensure adequate roof ventilation (1:150 ratio)

•Keep insulation batts off plasterboard surface

•Install vapour barriers in high humidity areas

•Check moisture content of timber before lining

Roof Space Ventilation

•Cross-ventilation via screened louvres

•Minimum 1:150 ratio of vent area to ceiling area

•Exhaust bathroom/kitchen fans to outside, not roof space

Access Panel Installation

•Frame opening with timber or steel noggins

•Allow 3mm clearance around panel

•Use proprietary access panel frames

•Seal edges with Gyprock flexible sealant

Light Fitting Penetrations

•Cut holes after installation

•Use appropriate hole saw for downlights

•Maintain minimum clearances from recessed lights

•Check AS/NZS3000 for electrical requirements

Service Penetrations

•Frame around large openings

•Use appropriate fire collars where required

•Seal gaps with acoustic sealant for sound control

Required Products

•Gyprock Aquachek (10mm or 13mm)

•Both core and liner treated for moisture resistance

•Green face liner for easy identification

•Do NOT use standard plasterboard in wet areas

Where to Use Aquachek

•Bathroom walls (all surfaces)

•Behind showers and baths

•Laundry walls

•Kitchen splashback areas

•Any area subject to intermittent moisture

Not Suitable For

•Constant water contact (use tile backer boards)

•Steam rooms and saunas

•External applications without protection

AS3740 Compliance

•All wet areas must comply with AS3740

•Waterproof membrane required in shower recesses

•Membrane extends minimum 1800mm above floor

•Full floor waterproofing required

Membrane Installation

•Apply after plasterboard is fixed

•Use AS/NZS4858 compliant membranes

•Ensure membrane bonds to Aquachek surface

•Allow proper curing before tiling

Critical Areas

•Shower floor and walls to 1800mm

•Bath surrounds to 150mm above rim

•Around floor wastes and penetrations

•Junction of wall and floor

Framing for Showers

•Use treated timber or galvanised steel

•Maximum 450mm stud centres for tiled areas

•Install noggins for shower fixtures

•Provide solid backing for grab rails

Shower Recess Details

•Aquachek to full height of recess

•Hob or step-down at entry

•Fall to floor waste

•Waterproof all junctions and penetrations

Bath Surrounds

•Frame to support bath weight

•Access panel for plumbing maintenance

•Waterproof membrane behind bath

•Tile to minimum 150mm above bath rim

Tile Adhesive Selection

•Use AS/NZS2358 compliant adhesives

•Select adhesive suitable for Aquachek substrate

•Match adhesive to tile type and size

•Premixed adhesives for wall tiles up to 200x200mm

Maximum Tile Weight

•32 kg/m² for standard installation

•Heavier tiles require additional fixing

•Large format tiles need solid adhesive bed

•Check adhesive manufacturer recommendations

Grouting & Sealing

•Use flexible grout in wet areas

•Silicone seal at junctions and corners

•Allow proper curing before water exposure

•Regular maintenance of seals required

Base Coat Compounds (Setting Type)

•Gyprock Base Coat 20/45/60/90 minute

•Sets by chemical reaction, not drying

•Use for embedding tape and first coat

•Mix only what you can use in working time

Topping Compounds (Air Drying)

•Gyprock Gold Topping Compound

•Air drying - apply in thin coats

•Easy to sand for smooth finish

•Use for second and finish coats

Ready-Mixed Compounds

•Gyprock Easy-Base (all-in-one)

•Convenient but longer drying time

•Suitable for small jobs and repairs

Tape Coat (First Coat)

1.Apply thin bed of base coat over joint

2.Embed paper tape firmly into compound

3.Wipe off excess compound with knife

4.Cover tape with thin layer of compound

5.Allow to set/dry before next coat

Second Coat

1.Apply topping compound over tape coat

2.Feather edges 50mm beyond first coat

3.Fill any voids or imperfections

4.Allow to dry completely

Finish Coat (Third Coat)

1.Apply thin final coat

2.Feather edges 50mm beyond second coat

3.Final width approximately 250-300mm

4.Sand smooth when dry

Internal Corners

•Fold paper tape along centre crease

•Apply compound to both sides of corner

•Press tape firmly into corner

•Apply subsequent coats to each side alternately

•Use corner trowel for consistent angle

External Corners

•Use Gyprock metal corner angle

•Secure with screws or staples

•Apply base coat embedding the bead

•Apply finish coats feathering onto board

•Total three coats minimum

Stopping Beads

•Square stop angle for shadow line

•Bullnose bead for rounded corners

•Apply compound and feather onto board

Sanding Technique

•Use 120 grit for first sand

•Use 180 grit for final sand

•Sand in circular motion

•Don't over-sand paper surface

•Vacuum or brush dust before painting

Checking Your Work

•Use raking light to identify imperfections

•Mark problem areas with pencil

•Apply spot repairs as needed

•Re-sand repaired areas

Surface Preparation

•Dust entire surface before sealing

•Apply plasterboard sealer/primer

•Fills porosity and provides uniform suction

•Essential for paint finish

Applications

•Areas that don't require a decorative finish

•Above ceilings and inside service shafts

•Inaccessible spaces

•Behind permanent fixtures

Requirements

•All joints taped with two coats of compound

•All fastener heads covered

•Compound finished smooth (scrape ridges)

•No sanding required

Frame Tolerance

•Maximum 4mm deviation

Applications

•Standard residential finish

•Commercial areas with flat/matt paint

•Areas with non-critical lighting

•Most general applications

Requirements

•Tape coat plus two separate finishing coats

•All compound sanded smooth

•No tool marks or ridges visible

•Back-blocking on butt joints

Frame Tolerance

•Maximum 4mm deviation

Suitable Decorations

•Flat, matt, satin paints

•Wallpaper and wall coverings

•Texture coatings

Applications

•Gloss or semi-gloss paint finishes

•Dark or mid-tone paint colours

•Critical lighting conditions

•Feature walls and premium areas

Requirements

•Three coat jointing system (as Level 4)

•Plus skim coat to entire surface

•Removes differential texture and porosity

•Maximum attention to detail

Frame Tolerance

•Maximum 3mm deviation

Critical Lighting Conditions

•Large windows and skylights

•Spotlights and silhouette lighting

•Any light at acute angles to surface

Consider These Factors

1.Surface visibility and prominence

2.Paint type (flat vs gloss)

3.Paint colour (light vs dark)

4.Lighting conditions

5.Budget and time constraints

Decision Guide

•Hidden areas → Level 3

•Standard residential → Level 4

•Premium finish → Level 5

Agreement Required

•Determine finish level before framing begins

•Frame tolerances must match finish level

•All parties should agree on sample area

•Document in contract specifications

Site Storage

•Store flat on a level surface

•Keep dry and under cover

•Stack on timber bearers (3 minimum)

•Maximum stack height 600mm

•Allow air circulation around stacks

Environmental Conditions

•Protect from rain and moisture

•Avoid extreme temperature variations

•Store in enclosed building where possible

•Allow to acclimatise before installation

Handling Precautions

•Carry sheets on edge, not flat

•Use two people for large sheets

•Use sheet lifters for wall installation

•Avoid dropping or impact damage

Score and Snap Method

1.Mark cut line on face of board

2.Score along line with utility knife

3.Snap board away from score line

4.Cut through back paper

Straight Cuts

•Use T-square or straight edge

•Multiple light passes better than one deep cut

•Clean edges with rasp if required

Cutouts and Openings

•Use plasterboard saw for internal cuts

•Drill pilot hole for saw entry

•Cut from face side for clean edge

•Use hole saw for round penetrations

Before Installation

•Building should be weathertight

•Allow wet trades to dry out

•Heating can accelerate drying

•Check timber moisture content (<15%)

During Installation

•Maintain good ventilation

•Avoid installing in high humidity

•Keep work areas clean and dry

•Protect installed boards from damage

After Installation

•Allow joints to dry before decoration

•Maintain ventilation during drying

•Protect from impact and moisture

•Plan painting in appropriate conditions

Fire Grade Products

•Gyprock Fyrchek (13mm, 16mm)

•Gyprock Fyrchek MR (moisture resistant)

•Gyprock EC08 Impact

•Gyprock Shaft Liner Panel

Fire Resistance Level (FRL)

•Expressed as Structural/Integrity/Insulation

•Example: 60/60/60 = 60 minutes each

•System tested to AS1530.4

Installation Requirements

•Must follow tested system details exactly

•Screw fixing only (no adhesive)

•Specific screw sizes and spacings

•Fire-rated sealants at penetrations

Acoustic Products

•Gyprock Soundchek (13mm)

•Gyprock Superchek (10mm)

•High density cores for mass

Rating Systems

•Rw: Weighted Sound Reduction Index

•Rw + Ctr: Rating adjusted for low frequency

•Higher number = better performance

Improving Acoustic Performance

•Use acoustic grade plasterboard

•Install acoustic insulation in cavity

•Seal all gaps and penetrations

•Resilient mounting reduces transmission

Plasterboard R-Values

•10mm thickness: R 0.04 - 0.05 m²K/W

•13mm thickness: R 0.05 - 0.07 m²K/W

•16mm thickness: R 0.07 - 0.09 m²K/W

Working with Insulation

•Install insulation before lining

•Don't compress insulation batts

•Keep batts clear of downlights

•Follow BCA energy efficiency requirements

Building Sealing

•Seal plasterboard at junctions

•Caulk around penetrations

•Reduces air leakage

•Improves energy efficiency

Work Cannot Be Deemed Defective If:

•Inspected under raking light (light at an angle to highlight imperfections)

•Inspected using torches, spotlights, or work lights

•Inspected under direct low-angle sunlight

•Viewed from less than 1.5 metres distance

•Surface is unpainted or paint not fully cured (minimum 7 days)

•Viewed from extreme angles (outside 45° cone of vision)

Standard Assessment Conditions:

•Normal room lighting or diffused daylight only

•Minimum 1.5 metre viewing distance

•2 coats of paint applied and fully cured

•Viewer positioned at normal standing height

Reference Standards:

•Victorian Guide to Standards and Tolerances 2015 (current edition)

•AS/NZS 2589:2017 Gypsum linings – Application and finishing

•NCC Volume Two

Wall Tolerances (AS/NZS 2589:2017):

•Maximum deviation: ≤4mm over 1.2m straightedge

•Frame tolerance: ±3mm over 1.8m straight edge

•Internal corner gaps: ≤3mm acceptable

Ceiling Tolerances:

•Maximum deviation: ≤5mm over 1.2m straightedge

•Ceiling sag at centre: ≤L/360 (L = span length)

Joint Compound Widths (Level 4):

•Tapered edge joints: 250mm wide compound

•Butt joints: 500mm wide compound (requires back-blocking)

•External corners: 250mm wide compound

Normal Building Movement:

•Hairline cracks (≤0.5mm) at internal corners are normal

•Minor corner cracking from thermal/structural movement is acceptable

•Cracks at door/window corners may occur from framing movement

Level 3 - Concealed Areas

•All joints taped with two coats of compound

•All fastener heads covered with smooth finish

•NOT suited for public view or decoration

•Used for: service shafts, above ceilings, concealed storage

Level 4 - Standard Residential/Commercial (Default)

•Three-coat system: tape coat + two subsequent coats

•Applied over tape and all fastener heads

•Sanded to smooth finish free of tool marks and ridges

•Suitable for: flat, matt, or low-sheen paints in favourable lighting

•This is the default level unless otherwise specified

Level 5 - Premium Critical Lighting

•Level 4 requirements PLUS full skim coat over entire surface

•High standard of frame flatness and alignment required

•Skim coat (under 1mm) rolled, trowelled or sprayed then sanded

•Creates even surface texture and porosity

•Required for: gloss/semi-gloss paints, spotlighting, skylights, dark colours

•Must be specified in contract with additional pricing

•Significantly higher cost than Level 4

Regulatory Authority:

•Victorian Building Authority (VBA)

•Building Act 1993 (Victoria)

•National Construction Code (NCC) 2022, mandatory from 1 May 2024

Primary Standards:

•AS/NZS 2588 Gypsum plasterboard

•AS/NZS 2589:2017 Gypsum linings – Application and finishing

Plastering Requirements:

•Materials must meet AS/NZS 2588 and AS/NZS 2589:2017

•3-coat jointing system for Level 4 finish (tape coat + 2 top coats)

•Each coat must be fully dried before applying next

•Frame deviation max ±3mm over 1.8m straight edge

Energy Rating:

•7-star NatHERS rating required from 1 May 2024 (up from 6-star)

•Focus on thermal bridging prevention

•Continuous insulation barriers required

•Garage-to-dwelling separation walls require insulation

•Metal-framed walls require thermal breaks at cladding contact

Mandatory Inspections Required For:

•Framework stage (before plasterboard installation)

•Fire-rated plasterboard systems (before covering)

•Waterproofing in wet areas

•Registered building practitioner required for fire-rated work

Fire Grade Products Required:

•Type F (fire-rated) board between dwellings

•Required in stairwells and service ducts

•Party walls between units/apartments

Fire Resistance Levels (FRL):

•Expressed as Structural/Integrity/Insulation (minutes)

•Example: 60/60/60 = 60 minutes each property

System-Dependent Ratings:

•FRL depends on COMPLETE SYSTEM (studs, fixings, insulation, linings)

•13mm Fyrchek on both sides of wall can achieve 30/30/30 FRL

•Higher ratings (60/60/60) require specific tested system configurations

•16mm Fyrchek for higher ratings

•Consult CSR Red Book for specific system configurations

Installation Requirements:

•Entire system must be installed exactly as per tested configuration

•Product certifications and installation details required

•Screw fixing only (no adhesive for fire-rated systems)

•Fire-rated sealants at all penetrations

•Compliance inspection required BEFORE covering

•Registered building practitioner required

Moisture Resistant Board:

•Green-faced moisture-resistant board mandatory

•Required in bathrooms, laundries, toilets

•Both core and linerboard treated for humidity

Jointing Requirements:

•Paper tape recommended for joints (stronger, industry standard)

•Fibreglass mesh requires setting-type compound only

•Setting compounds preferred in wet areas

Waterproofing:

•Waterproofing membranes required per NCC Part 10.2

•Applied over plasterboard before tiling

•Shower recesses, bath hobs, floor junctions

Limitations:

•Not suitable for direct water immersion

•Not for external use or unprotected outdoor areas

•Adequate ventilation required in all wet areas

Climate Zone 6 (Melbourne, Geelong, Coastal):

•Ceilings: R5.1 minimum (R6.0-R7.0 typical)

•Walls: R2.8 minimum (R2.5-R2.7 batts in 90mm studs)

•Floors: Zone-specific downward R-value required

Climate Zone 7 (Inland Victoria):

•Ceilings: R6.3 minimum (R7.0+ typical)

•Walls: R3.0 minimum (R3.0-R4.0 in 140mm studs possible)

•Slab edge: R0.64 minimum

Climate Zone 8 (Alpine):

•Ceilings: R6.3+ minimum

•Walls: R3.2 minimum (R3.5-R4.0 batts)

•Slab edge: R1.0 minimum

Installation Requirements:

•Continuous thermal barrier (no gaps at frames)

•No compression of batts (reduces R-value)

•Metal frames need R0.2 thermal breaks

•Clearances required around electrical fittings, flues, transformers (AS 3999:2015)

•Reflective insulation requires specific airspace width

Not Responsible For:

•Framing variations beyond tolerance (document before starting)

•Damage from other trades after plastering complete

•Building structural movement

•Water damage from roof/plumbing leaks

•Normal building settlement cracks

•Damage from fixtures installed by others

•Paint or coating defects (painter's responsibility)

Client Responsibilities:

•Ensure framing is within tolerance before plastering

•Protect finished plasterwork from other trades

•Maintain appropriate building conditions (weather-tight)

•Allow adequate drying time before painting/covering

•Obtain required building permits and inspections

Documentation:

•Take photos of framing before lining

•Document any variations or issues in writing

•Note any special requirements in contract

•Record inspection dates and outcomes

Party Wall Requirements:

•Walls between dwellings must meet NCC acoustic requirements

•Compliance inspection required BEFORE finishing

•Acoustic sealant at perimeter for best results

Acoustic Products:

•Gyprock Soundchek (13mm) - High density for party walls

•Double-layer systems for higher ratings

•Acoustic insulation in cavity essential

Rating Systems:

•Rw: Weighted Sound Reduction Index

•Rw + Ctr: Rating adjusted for low frequency noise

•Higher number = better sound reduction

Installation Tips:

•Seal all gaps and penetrations

•Resilient mounting reduces transmission

•Stagger joints in double-layer systems

•Use acoustic sealant at floor/ceiling junctions