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Code of PracticeEverest Wall Solution
2008
Everest Industries Limited | 2008
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CONTENTSEverest Industries Limited
Everest Wall Solution
Types of Wall Solutions
Design Considerations for Walls
Structural
Acoustic
Thermal
Fire
Services
Impact Protection
Performance Requirements
Fire Performance Requirements
Acoustic Performance Requirements
Everest Dry Wall
General Guidelines
Technology
Basic Materials: Stud & Track, Board
Basic Materials: Everest Wall Board
Installing Steel Framework
Fixing Board over Steel framework
Fastener Spacing
Treatment of Corners
Treatment of Wall Endings
Treatment of Opening
Ducting / Conduiting
Checklist of materials and accessories
Checklist of Tools and Equipments
J ointing Systems
J ointing with groove finish
J oint-less with beveled boards
J oint-less with Square edge boards
Installation Details
Dry Wall in Double Skin Full Height/Half Height G.I. Framework
Dry Wall in Double Skin Full Height/Half Height Timber Framework
Dry Wall in Single Skin Full Height/Half Height Aluminium Framework
Dry Wall in Single Skin Full Height/Half Height Timber Framework
Paneling with G.I. Framework
Paneling with Timber Framework
Paneling without Framework
System Index
Everest Wet-Area Wall
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Appendices
EverestIndustriesLimitedEverest Industries Limited (EIL), as an established and reputed name in India since 1934 for
the manufac turing and marketing of Fibre Cement products. EIL's current productportfolio covers both roofing as well as plain boards and c omposite panels, which finds its
applications in different segments like industrial, commercial as well as residential for wall
and ceiling lining, dry wall partitioning and prefab shelters or portable cabins. EIL is a fast
growing c ompany and its turnover has reached US $ 75 million registering C AG R of 15%
over the last three years.
Company has the backing of vast experience and expertise, both organizational and
technical. The Ultra Modern Research and Development facility is manned with
experienced, skilled and dedicated personnel engaged in product, plant and
technology development.
The R&D ac tivities are directed towards modernization automation and technological
innovation, development and commercialization of value added products and towards
exploring new avenues for import substitution and utilize waste materials.
EverestKeyFacts
Sales of 303 cr. ($75m)
5 major production fac ilities
1100 employees
Over 3000 retail points
Fast growing export market in Europe, Africa , Australia & Asia
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EverestPresenceinIndia
EverestWallSolutionEver since the inception of mankind, the humans have always tried to protect themselves
from natural aggressions like storms, rain, hail and so on. They have always wanted to
create a space, where they can live with their families, work and spend time. A place
which safe, comfortable and protected.
With the population continuously increasing and the cost of conventional construction
material going up, people are looking for alternatives which are cost effective and can
match with the aesthetics and strength of the conventional construction. Also the
eventful and demanding life of today does not leave any time for waiting for the
construction to complete in months. The solution required is to be a fast construction
technology.
The solution comes from Everest Industries Limited, an organization pioneer and leader in
the field of new age construction material. With its vast experience of building solutions
technologies and state of the art research facilities EIL has come up with the Everest Wall
Solution Technology, the first of its kind in India. The technology is easy to use,
environmentally safe and has strength comparable to the conventional wall.
EILs wall solution is a fast, easy to build, cost effective and quality solution to all the wall
related problems in modern day construction. EIL provides a wide range of wall solutions,
which include Different thicknesses of walls with varied acoustic and thermal properties.
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The wall could be finished and textured in as many forms as one can think. EIL provides
different cladding options ranging from Everest Wall Board and Everest Heavy Duty Wall
Board, providing a plain finish which could be painted, covered with wallpapers or could
be given any other finish as the person likes. The Everest Designer wall board, a pre
embossed designer wall board, can give different textured looks.
The EILs wall solution can very well solve all the safety and space division concerns of the
customers. The walls could be (if required) uprooted and the space could be redesigned
as the needs of the user changes.
In pursuit of offering the need based solution for customers, Everest Wall Solutions provides
Strong, speedy and safe construction.
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TypesofEverestWallSystems
Everest offers three types of wall systems:
1) Eve rest Dry Wa ll System :Suitable for non-load beading walling in commercial,
residential and all other kind of buildings. This is a very versatile kind of system, accepted
and adopted worldwide. This system has tremendous flexibility to adapt to a particularneed. The frame sizes can be varied, the board sizes and thicknesses can be varied. We
have outlined three variations in this system as shown in sketches below.
Everest Wall Board
Everest Wall Board
Insulation
C-Stud
Everest Wall Board
Everest Wall Board Stri
Insulation
C-Stud
Everest Wall Board Stri
Everest Wall Board
Everest Wall Board
Plasterboard
Insulation
C-Stud
Plasterboard
Everest Wall Board
2) Eve rest Wet-A rea Wall System :This system is very similar to the previous kind. The
difference is that this is meant for wet area construction. Hence, this uses slightly different
categories of materials and accessories.
Wall Board
C-Stud
Everest Heavy Duty
Wall BoardEverest Heavy Duty
3) Eve rest So lid Wa ll Sy stem :This is made with ready-made solid wall panels. It is extremely
fast to construct and also gives a very solid look.
Everest Solid Wall PanelSolid Abutment
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DesignConsiderationsforWallsWalls are one of the three most important components of any building. These have to
play multiple roles, like:
Protection against natural elements (rain, sun, snow etc.)
protection against human beings and animals (intruders)
supporting the structure (in load bearing structure)
Hosting several other building components like plumbing pipes, door-windows, light
fittings etc .
providing visual barrier between two areas
cutting-off sound/noise
blocking/reducing heat propagation
preventing fire propagation
providing a bearing surface to accept treatments for aesthetics (pa int, stone
cladding etc)
Each of the above mentioned are very important features of any wall, and care should
be taken for the same. It is important to note that in different situations different features
play decisive role in wall design. For example:
Lec ture Hall/Auditorium > cutting-off sound
Outer walls in Tropical areas > blocking/ reducing heat propagation Outer walls in very cold areas > blocking/ reducing heat propagation
Boundary wall > protec tion against intruders, providing visual barrier
Bathroom wall > protec tion against elements (moisture), hosting fixtures
It is therefore important to know what is critical to the particular wall before designing it.
Various walling systems are in practice, and they should be chosen with utmost care. Also,
almost in all systems, there are ways available to modify the wall properties to suit the
particular need. This manual describes the wall systems available from Everest Industries
Limited and provides insight into which to use where. It also outlines the ways to c ustomize
the systems to suit the requirement.
StructuralConsideration
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In this manual, we do not talk about walls that bear the load of the structure.
Our systems described here are all non-load bearing wall systems. These are often called
partitions.
We should be, however, aware that even non-load bearing walls have to bear certain
loads, like:
Self load
Lateral load (horizontal push)
Load of any object/device hanging on the wall for example wall lights, shelves,
pictures, mirror
Load of cladding/finishing etc. Sometimes these are very heavy, ex marble
cladding.
Wa ll he ig ht :Height of the wall affects the bending moments that occur at its ends and
the amount of deflection at the centre. Greater the height, more the bending moment,
hence, stronger it has to be.
Horizontal span of the wall: Long straight walls are susceptible to failure due to lateral
loads. Interrupting them with perpendicular walls make them stronger and more stable.
AcousticalConsideration
Acoustics of a room can be divided into two parts:
Noise/Sound level maintained within the room. This is determined by the sound absorption
properties of wall, floor, ceiling and other room furnishings.
Sound transmitted from the room to the adjoining room through wall, ceiling, floor and
openings. This depends on sound insulation properties wall,
ceiling and floor.
Sound Absorption
Sound absorption depends upon the surface properties of wall.
Soft surfaces absorb more sound than hard surface. Sound
absorption requirement depends upon;
Required noise level to be maintained
Level of sound created in the room
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Places like church, hospital wards, song recording room require very low noise level. They
need good sound absorbing surfaces.
Places like auditorium, shopping malls, crowded office are very noisy. Here noise needs to
be controlled by sound absorption.
Sound Insulation
Sound insulation is the reduction of sound passing from one place to another through a
dividing element. Sound insulation property of a wall depends upon the composition of
the wall. Sound insulation becomes critical when high level of privacy is required between
adjoining rooms.
ThermalConsideration
Thermal insulation is a very big issue in places where the climate is very hot or very cold.
In hot areas, people devise ways to cut heat propagation into the building. For example
the windows facing sun are either avoided or made small, usually with larger chhajas, so
that direct sun ray does not enter the room. Heat transmission through the wall is
minimized by:
Using materials with higher thermal mass (heat capacity)
Using reflective surface on the wall
Using materials with low thermal conductivity
Everest walls are designed to give high thermal performance. Thermal properties can be
varied in Everest Dry-Wall by changing following parameters:
Stud Depth: Greater depth gives greater insulation
Board Thickness: Increase in board reduces thermal transmission
Insulation Infill: Space inside the studs can be filled with insulating materials to
increase thermal performance.
FireConsideration
Fire is another crucial factor to consider. Fire can cause irreversible and insurmountable
damages in no time. It is one of the most talked about subject in building protection.
Construction codes of most of the countries in the world give spec ial emphasis on fire
protection.
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Everest is very proud to talk about fire efficiency of its walls. The basic material of wall
Everest Wall Board is a cement based product and is completely incombustible. Everest
walls have been tested for very high level of fire resistances.
We offer fire rated walls ranging from hr to 2 hr which is enough to meet criteria of most
building codes.
ServiceConsideration
Walls have to take in service routes, like electrical conduits, plumbing lines etc.
Everest Dry-Wall and Everest Wet-Area Wall have capabilities to run electrical and
plumbing lines very easily. The methods are explained in detail in the respective chapters.
Impact
Protection
Walls may be subject to excessive loadings like hard body impacts, crowd pressure etc.
Areas like following are susceptible to such loads:
Corridors of cinema halls > subjec t to c rowd pressure
Corridors of hospitals > subjec t to trolley impacts
High Impact walls can be made with Everest heavy Duty Wall board. Thicknesses of board
used can be increased to increase impact strength. When we are trying t achieve high
strengths, along with boards, stud depth and thickness should also be increased.
Protective devices like
handrails,
crash rails,
buffer rails,
chair rails,
corner guards,
large splayed skirting,
protective plates and sheeting
Should also be used in public areas.
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PerformanceRequirementsFireRatedSystems
Genera l
To select the correct wall system from those detailed in this manual, you must first
determine your performance requirements for Fir e Resistance Level (FRL), Weighted
Sound Reduction Index (Rw) and impact sound insulation. To help you, the wall systems
have been divided in two sections, covering steel frames and timber frames. These
sections are further divided into non-rated and fire rated applications. The fire rated
applications contain information on load bearing and non-load bearing systems. Framing
arrangements such as single, staggered and dual frames are included. Special
applications such as security panels have also been included.
Note: Additional performance requirements, such as abrasion, impact and moisture
resistance, should also be considered.
No n-Fire Ra ted System s
Non-Fire Rated Wall systems are constructed using a layer of Everest Wall Boards Lining
applied to one or both sides of a steel or timber frame. The arrangement of the frame, the
thickness of the Wall Board Lining and whether or not an absorbent acoustic fill is placed
in the cavity depend upon the required resistance to damage by abrasion and impact
and the specified sound transmission properties.
Additionally, in some instances all the walls are not required to be fire rated but does
require the wall lining to be non-combustible. Everest Wall boards lining may be used in
these cases, because it is confirmed as a non-combustible material confirming to BS-476
standards.
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Fire Ra ted System s
Fire Rated Systems for an application are selected on the basis of the required Fire
Resistance Levels (FRL) as set out by the local governing regulations in addition to any
acoustic requirements.
Fire rated wall systems are constructed from light weight framing (steel or timber) that is
lined on both sides with one or two layers of fire resistant Everest Wall Board Lining and/or
an additional layer of plasterboard lining.
It is relatively simple to achieve a Fire Resistance Level (FRL). Irrespective of the frame type
(i.e. steel or timber framing), the lining thickness of both the layer of Fire Resistant
plasterboard and Everest Wall Boards Lining will always be the same for the specified FRL.
The use of load bearing and non-load bearing systems will depend on the application.
The timber framed systems detailed in this manual are generally used in non-load bearing
applications.
The steel framed systems detailed in this manual are propriety framed systems and are
generally used in non-load bearing applications. Steel frames can be designed by a
qualified structural engineer to be load bearing, provided minimum size sections are
equivalent to the systems in this manual to retain the FRLs.
AcousticsRatedSystems
Genera l
Soundproofing is any means of reducing the intensity of sound with respect to a specified
source and receptor. There are several basic approaches to reducing sound: increasing
the distance between source and receiver, using noise barriers to block or absorb the
energy of the sound waves, using damping structures such as sound baffles, or using
active anti-noise sound generators.
Soundproofing affects sound in two different ways: noise reduction and noise absorption.Noise reduction simply blocks the passage of sound waves through the use of distance
and intervening objects in the sound path. Noise absorption operates by transforming the
sound wave. Noise absorption involves suppressing echoes, reverberation, resonance and
reflection. The damping characteristics of the materials it is made out of are important in
noise absorption. The wetness or moisture level in a medium can also reflect sound waves,
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significantly reducing and distorting the sound travelling through it, making moisture an
important factor in soundproofing.
Three different types of sound transmissions need to be controlled for complete sound
insulation. Acoustic transmission in building design refers to a number of proc esses by
which sound can be transferred from one part of a building to another. Typically these
are:
1. Airborne transmission - a noise source in one room sends air pressure waves which
induce vibration to one side of a wall or element of structure setting it moving such
that the other face of the wall vibrates in an adjacent room. Structural isolation
therefore becomes an important consideration in the acoustic design of buildings.
Highly sensitive areas of buildings, for example recording studios, may be almost
entirely isolated from the rest of a structure by constructing the studios as effective
boxes supported by springs. Air tightness also becomes an important controltechnique. A tightly sealed door might have reasonable sound reduction properties,
but if it is left open only a few millimetres its effectiveness is reduced to practically
nothing. The most important acoustic control method is adding mass into the structure,
such as a heavy dividing wall, which will usually reduce airborne sound transmission
better than a light one.
2. Impact transmission - a noise source in one room results from an impact of an object
onto a separating surface, such as a floor and transmits the sound to an adjacent
room. A typical example would be the sound of footsteps in a room being heard in aroom below. Acoustic control measures usually include attempts to isolate the source
of the impact, or cushioning it. For example carpets will perform significantly better
than hard floors.
3. Flanking transmission - a more complex form of noise transmission, where the resultant
vibrations from a noise source are transmitted to other rooms of the building usually by
elements of structure within the building. For example, in a steel framed building, once
the frame itself is set into motion the effective transmission can be pronounced.
The ability of Everest fire and acoustically rated walls to reduce airborne sound depends
on four factors:
1. Mass of the linings and their intrinsic characteristics.
2. Width of the wall cavity.
3. Framing configuration.
4. Inclusion of a fibre blanket of batts as sound insulation into the cavity.
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To achieve the performance results stated in this manual, you must take particular care to
seal between the frame and primary structure (e.g. at a deflection head). Any gaps in
the wall system can lead to substantial losses of acoustic rating.
Repeated tests have shown that where Everest Wall Boards Lining is used, for the same
cavity width, there is no practical difference in performance between timber and steel
studs of the same depth.
Therefore results achieved on a steel frame may be applied to a timber frame with equal
cavity width and vice versa.
The systems presented in this manual provide excellent acoustic performance that range
up to an Rw of 69.
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Ac oustic Insulat ion
Acoustic performance of a wall system can be improved (i.e. Rw values increased) by
installing an absorbent fill in the cavity. This is usually an acoustic grade fibreglass or
polyester blanket or batts not less than 25mm thick.
Impact Sound Insulation
Where the application is required to reduce
impact sound, you must select a system that is
either staggered or dual stud. Resilient
channels can be used to reduce impact
sound; however, they will not achieve
isolation of the walls
Resilient Channels
Where the wall is required to minimize the transmission of
impact sounds, either select a staggered or dual stud
system. Where cost is a constraint, resilient channels, fixed
to the side of the wall subject to impact, may be used as
an alternative.
While less effective than staggered or dual stud systems, the level of sound isolation may
be adequate for applications such as between a corridor and an office space.
FramingArrangements
Genera l
Generally, there are three basic types of walling systems available to designers: the single,
staggered and dual frame systems. All three wall
systems can achieve the same FRL levels when the
same lining materials are
selected, but they willprovide different
acoustic properties.
Sing le Stud Fram e System
The single stud frame system is a single leaf wall with lining on each side. This system has
the lowest acoustic rating when compared with the other two systems and will not
adequately insulate against impact sound.
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Stag g ered Stud Fram e System
The staggered stud frame system in a series of
staggered studs that are fixed to the same top
and bottom plate. The linings are fixed to the
outside faces of the studs. This system has higher
acoustic properties than the single stud framed
system and will insulate against impact sound.
Note: This system should not be selected if services
are required to run though the walls. Services
require support battens that will bridge frames, reducing acoustic properties and
preventing impact sound isolation.
Dua l Stud Fram e System
The dual stud frame system uses two separate frames that are not connected. The outside
face of each frame is then lined. This system will achieve the best acoustic properties and
will insulate against impact sound.
SpecialApplications
Genera l
Everest Dry Walls can be used in a range of special applications.
Walls Designe d for Imp a c t
Everest Dry Wall Lining has a harder surface than plasterboard, so it offers increased
resistance to surface abrasion, indentation and impact. Using Everest Wall Boards Lining
can therefore reduce maintenance costs, particularly in areas such as hospitals, airports,
schools and similar buildings subject to above-average wear and tear.
Service Ca vi ties
In quality buildings, you should avoid services in fire and acoustically rated walls. While it is
not difficult to maintain the fire resistance levels, the acoustic property of the wall may be
diminished. If this cannot be avoided, we recommend that services be run through a
service cavity, fixed on the face of the wall.
Where you cannot avoid putting services within the wall, you should select a dual stud
frame system, and take care in the selection of framing systems and the method of
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installation of services. Ensure that services do not bridge wall frames as this will reduce
acoustic performance and prevent impact sound isolation.
Sec urity Pa ne ls
Everest Dry Wall Lining (typically 9 mm thickness) may be used to construct wall in areas
that are required to be secure. Steel sheeting (0.55 mm thickness) may be either glued tothe back of the sheets or pop riveted to the frame prior to sheet fixing. This construction
greatly increases resistance to impact (e.g. from hammer blows). It is recommended as a
lining to one or both sides of wall where security is a major issue, e.g. holding cells in police
stations or equipment store rooms in schools.
Where security needs to be higher, you can use a laminate that consist of Everest Wall
Boards to one or both sides of a steel sheet. Typically 0.5, 0.75, 0.95, 1.15, 1.5 or 1.95 mm
BMT steel sheet is bonded between 6
mm or 9 mm sheet of Everest Wall
Boards. These laminates show
remarkable resistance to impact
penetration.
Balance laminates that have fibre cement sheets on each side of steel sheet must be
used for external walls. For internal walls and ceilings where temperature and humidity
variations are small, the single sided laminate is acceptable.
Sm ok e Wal ls
Everest Wall Boards have the best possible Early Fire Hazard properties and does not
generate any smoke in a fire. For these reasons, Everest Wall Boards is commonly used to
create smoke Walls in hospitals.
Ra d iation Shield ing Wa lls
Radiation shielding walls may be constructed using fire and Acoustically Rated Light
Weight Walling methods by laminating lead to Everest Wall Boards. Typically 9mm sheet is
used as a substrate for lead sheet of a thickness determined by a designer to meet the
radiation shielding specification. Care in design and installation is essential to maintain the
continuity of the lead sheet. Design, installation and certification should be carried by
specialists in this field.
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EverestDryWallGeneralGuidelines
In ter ior Ap p l ic at ions
General Guidelines for Dry Walls & Paneling
Everest Wall Boards can be fixed to both timber and steel frame construction, both in load
bearing and non-load bearing framework. The following general guidelines for installation
are applicable for joint-less (for rendering joint-less finish with Everest Wall Boards it is
recommended to use only Low Hydric Movement board conforming to IS 14862 Type B
Category III) and non joint-less finishes for partitions and panelling applications.
The following principles must be followed:
At all nailed or screwed board joints the centre line of the joint must coincide with the
centre line of the stud, runner or plate. This is to ensure sufficient edge clearance for
fixing of adjoining boards along the board edges.
Fix board across the door, ceiling or window openings then cut away waste board.
All end joints in the boards must be laid to an offset pattern.
In all joint-less applications, the end joints must not coincide with corners of door,
window or ceiling openings as these joints may crack due to minor frame movement.
Studs, plates or runners must be provided behind all vertical, sloped and horizontal
board joints and edges.
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All Everest Boards edges must be fully supported by the framing except for specific one-
way framing specifications. Framing must have sufficient lateral fixing so as not to rely on
the Everest Boards for stability.
For standard-impact areas the timber or steel framing specification is to have studs at 600
mm horizontal c/c and runner at 1200 mm vertical c/c. Use 6/8 mm Everest Board.
For high-impact areas or heavy-use commercial areas, studs must be at 600 mm
horizontal c/c and runner at 600 mm vertical c/c. Use only 8/10/12 mm Everest Board.
Boards must be fixed 15 mm clear of the floor for panelling / partitioning applications.
Care must be taken to ensure that this gap does not become filled with other materials
during finishing procedures.
Fix the board from the centre working towards the outside to avoid drumminess.
It is recommended that when ever possible boards are to be fixed horizontally to minimise
the number of joints and give structural stability and for increased impact resistance.
However, for application up to 3000 mm height boards may also be laid vertically as well.
For applications of one board width or less, boards must be fixed vertically only.
Timber Frame
Chemically treated kiln seasoned, timber sec tions should only be used for structural
framework. Chemically treated kiln seasoned timber section is required to minimise
shrinkage. This is particularly important for applications which are more than one board
length in height. Wall Boards must not be fixed to timber framing with moisture content in
excess of 20%.
Timber framing to be either, say 50 mm wide or, when chemically treated kiln seasoned is
used, 35 mm wide sections may also be used for non load bearing partitions/ panelling.
Fix 6/ 8/ 10 mm thick Everest Boards to timber frame using 50 mm x 2.5 mm long
galvanised flat-head nails to the centres shown in the relevant diagrams to the perimeter
of all boards, intermediate studs and runners.
Alternatively 6, 8, 10mm thick Everest Boards may be fixed to the timber framework using
self embedding type Everest Board fibre cement screws. Do not fix the screws closer than
15mm from the board edges or 50 mm from the corner of the board.
Steel frame
Steel framing for Everest Boards applications can be both non-load bearing or load
bearing. For steel framing follow the same guidelines as detailed for timber framing.
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However, load-bearing steel studs must have sufficient strength and thickness to resist all
vertical and horizontal loads.
Usually for steel framing, members of load-bearing construction must be fabricated from
light-gauge board steel 0.75 mm to 1.25 mm thick. If heavier sections are used difficulties
may be experienced in fixing the self-drilling, self-tapping fasteners.
At all Everest Board joints the minimum flange width of 34 mm is required to adequately fix
the boards with the correct edge distances.
For 6/ 8/ 10 mm thick Wall Boards use 3.8 mm dia. x 25 mm long self embedding Everest
Board Fibre C ement screws.
Fixings for steel frame to be at the same edge distances as for timber frame.
Boa rd Insta l lat ion
Correct Method
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For the correct board installation sequence, boards should always be fixed in staggered
manner on both sides as well as in same surface. The first board is screwed to the open
side of the stud flange. The flange deflects at first, but is then pulled tight as the screw
takes up the slack.
It is important to fully screw off the board on this side of the stud before continuing. Ensure
the stud is adequately supported to avoid it twisting.
The next board is screwed to the web side of the stud. Not only is the deflection at this
part of the flange very small, but the previously installed board helps keep the assembly
rigid during the installation of the second board.
Incorrect Method
When the incorrect fixing procedure is used, the outer side of the flange can deflect
away leaving a permanent step to the outside face of the boards. The stud must be firmly
supported while the correct method is used. When adequate stud support is not given,
twist can take place resulting in a permanent lipped distortion.
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Provision for control joints
Control joints must be provided to relieve stresses imposed by structural movement
including those due to excessive changes in temperature and humidity. For joint less finish
correc t provision for horizontal or vertical control joints are very important for the better
integrity of the structures and durability of the system.
Horizontal control joints: For large height partitions and panelling horizontal control joints
must be provided at 4800 mm vertical centres from the base of the wall for all framing
constructions.
Vertical Control joints: Vertical control joints must be provided to all long partitions /
panelling at 7200mm c/c maximum. These control joints must be full height from floor to
ceiling.
Provision for relief joints
Relief J oints are basically provision for space between two adjoining boards and play avital role in sustenance and integrity of structure against stress developed on account of
variation in temperature, moisture or due to vibrations and impacts.
The jamb line of wall openings such as doors and windows is an ideal location for relief
joints. The relief joint must be formed from the bottom of the window to the floor and from
the top of the window to the ceiling in the line of the jamb.
Relief J oints are essential between two heterogeneous surface junction namely door or
window or ventilator opening, internal and external corners etc.
Where Everest Board abuts exterior concrete, brick or concrete block hallow walls it must
be isolated by a flexible sealant, otherwise moisture transfer could occur.
Notes: Seal the joint with a non acetic or acetic cure flexible fungal resistant silicone
sealant for the full length of the application and when aceticure silicones are used special
priming requirements are necessary. Use acoustic sealant for this detail when acoustic
performance is required.
Provision for external and internal
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corners
External corners: For extra
impact resistance and a
straight edge, PVC/Steel
perforated external corner
angle must be fixed and
topping up bevelled edges of
the boards. Flush finish the
angle with perforated synthetic self adhesive tape/putty jointing compound and finishing
compound / putty.
Internal corners: Use bevelled-edge boards to internal corners and finish with jointing
compound, perforated or synthetic self adhesive tape and top coat/ putty.
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Provision for electrical and plumbing facilities
Wherever electrical or plumbing facilities are
to be provided within the partitions or
panelling, special care should be taken to
make the framework as well as board fixing.
Additional members are needed to support
plumbing or electrical facilities.
In case of additional storage facilities
supported over partitions or panelling
additional horizontal members are to be
provided and studs are suitably spaced to
take care of the loading requirements.
Batten requirements
Battens are required to fix the boards when the boards are fixed over:
Gypsum board exceeding 15 mm in thickness
Soft board, polystyrene or similar
Concrete, masonry block or brick
Battening specification:
Timber battening is to be a minimum 50 mm wide x 25
mm deep to give adequate board to nail penetration.
Steel battens are to be a minimum of 52 mm wide x 26
mm deep x 0.55 mm thick and to have a bearing
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surface of 52 mm. Battens are to be galvanised steel with 220 grams / sq. m. coating
of zinc as per IS 277.
All battening centres and board fixing is to be strictly in accordance with the framing and
fixing required by this guideline. Care must be taken to ensure the battens are packed
and aligned to give a true even surface for the boards to be fixed. Check the face of the
battens with a long straight-edge before fixing the boards.
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DryWallTechnologyBasicMaterial:SteelStudandTrack
Steel stud and track are used to make the structural framework on which boards are fixed
to create the wall. GI framework consists of following
basic components:
The basic concept of metal framing is that tracks are
run around the floor, ceiling and wall surfaces to form
the boundary of the plane in which the partition has
to come. This boundary is spanned across by metal
studs in vertical direction and spacing bars in
horizontal direction. The studs, held at top and
bottom by tracks, form the load bearing frame to
which the cladding sheet is fixed. The spacing bars
ensure that the studs are in right place and their
spacing is accurate.
There are two sizes of tracks and studs. The sizes
determine the thickness of the partition wall as well as
its strength. Whereas thinner sections are for usual
partitions, thicker ones are useful where greater
strength is required or where thicker pipes are to be
taken inside the partition wall. The sizes should be
chosen as per the individual requirement of the
project and the place of application. Please consult
a qualified engineer.
BasicMaterial:EverestWallBoard
Everest Wall Boards are fibre cement building boards manufactured from a homogenous
mixture of Portland cement treated cellulose fibres, quartz and other select mineral fillers.
The cement ac ts as a hydraulic binder while the cellulose fibres get interlocked with the
cement and quartz matrices, thereby making the boards stronger and more durable.
Everest Wall Boards can be used in a wide variety of segments like residential, commercial
and industrial installations.
InstallingSteelFramework
Check the level of the ground with water level tube. Mark the lay
out of the partitions plan on the floor and corresponding positions
of trac ks on wall and ceiling.
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Calculate the various lengths of tracks required and cut them to size. First, fix the tracks on
floor by using expandable screws and caps. Then fix tracks on wall and ceiling.
Cut Studs of desired sizes. Insert them between the top and bottom track and fix with self
drilling screws. These studs come with punctures at certain intervals. Check out if these
punctures are sufficient for your ducting needs. Else, make necessary punctures in the
web of the stud before fixing to the framing.
Caut ion :In cases where a significant slab live load deflection must be accommodated,
the anchoring of these studs may restrict slab movement and
cause partition cracking. In these cases, anchoring of these studs
may need to be omitted. The services of a design professional are
desirable to identify these instances and address them on a case-
specific basis.
Where a stud directly abuts an exterior wall and
there is a possibility of condensation or water
penetration through the wall, place an asphalt
felt strip between stud and wall surface.
Where Door and window frames are coming,
follow the instructions given in the Framing
Openings section.
FixingBoardoverSteelFramework
Fixing
Place 6mm packers along floor as temporary support for sheets. This will allow for any
frame movement/ shrinkage. Put first sheet in place as shown.
Ensuring the sheet is level, fix the first sheet starting from the centre of sheet and working
outwards to avoid any drumminess.
Sheet joints must coincide with the
centre line of the framing member.
At door and window openings fix
sheets around the opening in a way
that the sheet joints do not coincide
with the edges of openings. The
sheet joint must be 200mm min. awayfrom the opening edge.
Everest Heavy Duty Wall Boards lining
joints are set with proprietary jointing
compounds reinforced with perforated paper tape. Both
recessed edge and butt joints require joint setting by using the
jointing products outlined.
There are various factors that can affect the performance of
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jointing compounds on edge recessed fibre c ement substrates. These factors include the
framing, movement, installation quality, vibrations, moisture, humidity, temperature, etc.
To ac hieve satisfactory joint performance these factors need to be carefully considered
and understood by the installer and designer when positioning joints and selecting jointing
compounds. Furthermore, it is important that the jointing compound used has the physical
attributes required to perform considering these factors.
Sheet layo ut on w al l
Cut the Wall board approximately 12mm less than floor to ceiling height to allow for
building tolerances. Ensure that a 6mm building tolerance gap is provided at the floor
and ceiling junctions with the board lining. Everest Wall Boards may be laid on the frame
either horizontally or vertically.
Fa stene r Sp a c ing
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Trea tme nt o f Co rners
Framing at the corner must be such that Everest Wall Boards can be firmly attached to
the vertical studs and leave sufficient space from the inside corner to do so. Studs should
be attached to the tracks a minimum of 2 but not exceeding 6 from where the tracks
intersect. The edges of first applied panels will extend slightly beyond these corner studs,
and the edges of second applied panels will overlap the plane of first enough to ensure
good tapping of the inside corner.
Outside corners of partition intersec tions require firm attachment of panels to
perpendicular edges of the outside corner stud.
Trea tme nt of Op ening
All the openings should be framed with steel studs and tracks. The recommended
prac tice for most installations is to position floor to ceiling height studs vertically, adjacent
to frames, and anchor them securely to the top and bottom tracks with screws. Fabricate
sill and header sections from steel tracks and install them over door openings and over
and below any other opening. Make these sections 6 longer than the rough openings
and at both ends slit flanges 3 deep and bend the web so that the flanges overlap tothe adjacent vertical studs. Securely attach them to the adjacent studs with self drilling
screws. Install cripple studs in the centre above the door opening and above and below
door and window opening.
The straightness and squareness of the framing or substrate must be checked thoroughly.
Any deformities must be correc ted prior to installing the sheet.
Duct ing / Cond u i ting
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Electrical and plumbing ducts may be taken through the framing. C heck out their sizes
before choosing the size of the framing members.
Joint ing a nd Finishing
Everest Wall Board lining joints are set with proprietary jointing compounds reinforced with
perforated paper tape. Both recessed edge and butt joints require joint setting by using
the jointing products outlined.
There are various factors that can affect the performance of jointing compounds on
edge recessed fibre cement substrates. These factors include the framing, movement,
installation quality, vibrations, moisture, humidity, temperature, etc . To achieve satisfactory
joint performance these factors need to be carefully considered and understood by the
installer and designer when positioning joints and selecting jointing compounds.
Furthermore, it is important that the jointing compound used has the physical attributes
required to perform considering these factors
Na il Fa stening
We recommend that fibre cement screws be used. They are self drilling type, and are also
capable of countersinking into the board so that the head flushes with the board surface.
Co ntrol Joints
The jamb line of wall openings such as doors and windows is an ideal location for control
joints. The control joint must be formed from the bottom of the window to the floor and
from the top of the window to the ceiling in the line of the jamb.
Wal l Ab utment
Where Everest Wall Boards abuts exterior concrete or
concrete block walls it must be isolated by a flexible
sealant joint, otherwise moisture transfer could occur.
Co rners reinforc ing w ith PVC Co rner An gle
For extra impact resistance and a straight edge to stop
to, a PVC angle must be fixed over recessed edges of
the sheets. Flush over the angle with bedding
compound and finishing compound.
Corne r re in fo rc em en t w ith pa pe r tap e a nd b edd ing c om pound
Use recessed-edge sheets to internal corners and finish with bedding compound, paper
reinforcing tape and finishing compound.
Flush joint finishing for no n tiled finishe s
For non-tiled finished, flush jointing may be done by beveling the edges, finishing with two
layers bedding compound with reinforcing paper/fiber tape between them.
Re lief Joints
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On large tiled wall areas, relief joints must be provided in the Everest Wall Boards and the
tiles at 4200 mm maximum horizontal centers and 3000 mm vertical centers. Wall areas
must be restricted to a maximum of 10 m2 in all cases.
Provide relief joints within tiled areas at the following locations:
At internal vertical corners
At junctions between background materials
Around the perimeter of tiled areas
At all changes of plane.
Relief joints must continue through the tiles and the Everest Wall Boards to the support
frame.
Relief joints must be a minimum of 5 mm wide and filled with a flexible silicone sealant
compound. When a waterproofing membrane is used, the membrane is to be continuous
across the joint.
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JointTreatmentThe joints between two adjoining Boards could be finished with variety of joint finishing
and the details are given as below:
JointlessFinish
J oint-less finish with Everest Wall Boards can only be obtained using factory finish bevelled
edged boards. However, site bevelled boards are required for joint-less finish at the
corners or wherever the bevelled edges of board been cut to fit to the dimensions.
To render joint-less finish, use only dry board and in
hot dry conditions the joint area may be dammed
to avoid premature setting of Everest J ointing
Compound. For the reinforcement of the joint use
synthetic perforated self adhesive tapes only of 48
mm nominal width.
At the internal corner joints centre the reinforcing
tape in to the internal angle pressing firmly on the
bevelled edges of Everest Wall Boards and
immediately embed the tape with the coat of
Everest jointing compound. Use perforated PVC
corner angle rather than G.I. angle on external corner to avoid corrosion in wet and semi
wet areas. Fix the external G.I. / PVC external corner angle at 300 mm c/c to each angle
leg in a staggered manner. Fill over the G.I. / PVC external angle to the edges of bevelled
edges of Everest Wall Boards with jointing compound.
The board joints and corner flush joints must be formed using only Everest jointing
compound. Adhesive property of jointing compound is important for flush vinyl finishes
therefore finishing compound must not be used over the Everest jointing compound.
Ensure the Everest jointing compound is finished smooth to accept the vinyl/laminate.
UniformGapFinish
Everest Wall Boards joints could be finished with uniform gap finished on fixed on to the
substrate framework of timber or steel using
suitable nails or Everest fibre cement screws.
Alternatively, the board edges could bejointed or covered with PVC, G.I. Timber
mouldings for better aesthetics. In wet areas
the uniform gaps are to be filled up with
flexible silicon sealant.
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UniformGrooveFinish
Everest Wall Boards joints can be finished with uniform groove keeping 1- 2 mm gap all
through the joints, fixed on to the substrate framework of timber or steel using suitable nails
or self embedding type Everest fibre cement screws. However, to achieve this finish,
boards are to be chamfered uniformly at edge on site before fixing or installation.
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JointlessFinishingProcedure
Dry a nd Sem i Wet A rea
Preparation of J ointing Compound
Take a clean stainless steel or plastic container
Mix the c lean water paste for 5-10 minutes with putty knife.
Do not apply jointing compound in a temperature less than 10C and more than 80% Rh.
If rain splashes observed on board, complete drying of board necessary for further
application of jointing compound.
Ensure all the screw heads are driven 0.5 mm below the surface of the board surface.
Application of First Layer
Clean the bevelled portion of the jointing area from dirt and other foreign particles or oil
substance and firmly press the 48 mm wide synthetic selfadhesive tape over the full width of bevelled portion.
Ensure that there is no void under the tape. Immediately
cover the tape completely
with a thin layer of Everest
jointing compound applied
with a 100 mm wide knife or
metal patti. Sand and smoothen the surface and allow the
joint to dry for a minimum period of 2 hours.
Application of Second Layer
Application of this layer is carried out using 200 mm trowel once the first layer joint is
completely dry. A minimum 200 mm wide layer is applied
using the same Everest jointing compound spreading
minimum 75 mm on each side of the bevelled joint and allow
to dry for a minimum of 24 hours.
The second layer of jointing
compound must be sanded
smooth suitably to accept level II finishes. Everest jointing
compound is difficult to sand
hence sanding operation
should be completed immediately after the joints are
completely dry.
Finishing coat (optional required for level III, IV or V finish)
Thoroughly check the undulations of the joint-less finish areas
using metallic scale or putty knife and if needed fill up the jointing area with an additional
skim coat (thin layer made out of lower consistency of jointing paste adding water
suitably) to remove dry undulations and to ensure appearance of any shade difference.
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When the skim coat dries up, sand the entire joint area including the adjoining board area
up to a minimum 300 mm on both side of the centre of the joint.
The board is now ready to accept cement primer.
If superior level of joint-less finish is needed (i.e. level IV or V finishes) applying the top coat
on the entire area of the boarding and repeat the same operations.
Finally finish the entire board area including the joints with minimum 2 coats of 100% water
based acrylic cement primer
Wherever the boards meet the wall a gap of minimum 5 mm should be kept which can
be filled up using the same jointing paste and allow to dry. This can be finished in half
round using putty knife.
In ternal Co rners
Application of First Layer
Using a 75 mm chamfered broad knife, centre the synthetic self adhesive tape into theinternal corner pressing it firmly over the cleaned bevelled joint area, keeping the high
point of the knife direc ted into the corner.
Necessary precaution should be taken so that the synthetic
self adhesive tape does not get cut while pressing the same
in the bevelled area.
Repeat all other operations as stated in the straight joint-less
finishing procedure.
Externa l c orne rs
External corners are formed using a similar process to that for internal corners. Caution
should be taken while fixing vinyl / laminate layer in radius corners or square corners.
Plugg ing of Cut-Outs
If a cut-out has been made in the partitions, panelling or false ceiling at a wrong location
and if it needs to be plugged can be done as per the following steps:
If the area of the cut-out is less then 100sq cm, provide backup support with short
piece Everest Wall Boards larger than the size of the cut-out. Cut the Everest Wall
Boards in required shape and size of the cut-out. Paste that piece on to the support
board using rubberized adhesive. Leave the gap of 1-2 mm on all sides and treat the
gap/ joint as described in section above.
In case the cut-out area is more than 100sq cm then provide additional substructure
behind the cut-out. Cut the Everest Wall Boards in required shape and size of cut-out.
Fix the Everest Wall Boards with the substructure using self embedding type Everest
fibre cement screws. Leave a gap of 1-2 mm on all sides and treat type gap/ joints.
The joint is to be treated as described in section above.
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JointlessFinishingwithSquareEdgeBoards
The joints can be filled out or not. If they are filled out, the material used for the effect is a
mastic sealant. The filled out
joints should be tight against
the air and the water.
The width of the joint should
be such that the mastics can
support, permanently, the
daily and seasonal
deformations that happen.
The depth of the mastic should be adapted to the width of the joint and the nature of the
mastic.
The primer, when necessary, should assure the wanted adherence between the mastic
and the bearing. Its capacity should be evaluated jointly with the mastic and the
construction materials constituent of the elements to tie.
The stuffing material, after insertion, should possess a resistance enough for application
and smoothing of the
mastic. It should not
contain, besides, matters
that can harm the
adherence of the mastic
to the flanks of the joint. It
should still assure a
concave geometric form
of the mastic. It shouldnot impede, in an
inadmissible way,
alterations in the form of
the mastics, when movements of the construction elements take place.
The limitation, in the case of fire in the building, of a possible propagation of the fire to the
dry wall structure, implicates the evaluation of the behaviour of the mastics and stuffing
materials under fire.
The depth of the mastic should be equal to the width of the joints and in vertical joints; a
string of flexible polyethylene should control it.
CurvedApplications
Everest Wall Boards have an excellent dimensional stability and therefore it yields only very
small dimensional movements even under extreme temperature and humidity changes.
But, the boards may be used for curved applications using following procedure.
App l i ca t i ons
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1. Curved ceilings, walls and columns in offices, hospitals, schools concert halls
departmental stores and railway stations etc.
2. Curved area of eaves soffits, basement car parks, kitchens, toilets and other areas of
high humidity.
3. Curved areas for specially designed fire-resistant partitions, walls and panels.
Fram ew ork (Curved Pa rt it ions/Wal l l in ing s)
Mark the floor as per the layout plan.
Cut the floor and ceiling channel at one side of flange through its web at every
150mm.
Put this channel at the marking and bend the channel according to the layout
marking.
Fix it with nylon sleeves and wooden screws at every 150mm c/c to the floor.
Fix head channel, as described above in plumb and line with the floor channel, at the
soffit or ceiling as described above.
Insert metal studs at 305(12) mm intervals in between the floor and head channel.
Check if the frame work is properly aligned and plumbed, as per the layout marked at
the floor.
Boa rd ing Fixing
6mm boards are to be curved one by one, prior to installation by making them
sufficiently wet by sprinkling water on both sides of the boards.
Allow these boards to absorb water for 30 minutes.
Make 1220mm wide wooden structure of the required radius, but limited to 600mm,
minimum.
Put the wet boards on to this wooden structure and try to press the boards very gently,
starting from the centre to the ends on both sides. Keep pouring water during this
process.
As soon as the board gets the shape, it is to be removed from the wooden structures
and to be placed at floor vertically width-wise and left for air drying.
All the boards are to be bent like this before fixing.
Now place the first board along the frame work at one end.
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Start screwing the board from one end of the board, by using self tapping screws
12mm away from the edges and 40mm from the corners at 200mm c/c to each metal
stud and floor & ceiling channel.
Complete the entire area as above.
J ointing and finishing is to be done as per recommended practice.
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InstallationDetailsDryWallinDoubleSkinFullHeight/HalfHeightG.I.Framework
Ma ter ia ls Req uired :
G.I Sections as C vertical stud profile and U profile floor / ceiling trac k.
Everest Wall Boards/Everest Designer Wall Boards 6mm/8mm/10mm with specified texture
and finish.
Insta l la t ion Proc ed ure:
Step 1: Mark the layout of the partitions on the floor, and fix the U profiles on the floor and ceiling
and C profile vertical stud to abutment securely fixed @ 600 mm c/ c with 35 mm long stainless
steel wood screws with nylon sleeves/wooden gutka.
Step 2: Insert vertica l studs (C profile) @ 600 mm c/ c in the U profile with the allowance for board
width tolerance.
Step 3: Fix the U profiles as horizontal runners on to vertica l studs at sill / lintel level, around other
openings shown as per architectural drawings. In case the partitions height is more than 2400 mm,
fix the U profile as horizontal runner on to the vertical studs @ 1200 mm c/c. Extra studs to be
provided where the 600 mm spacing is disturbed.
Step 4 : Fix the Everest Wall Board on both sides of the studs and channel section with 25 mm self
embedding type Everest fibre cement screws in staggered fashion (both side) to avoid through
joints @ 300 mm c/c. Remove connecting screws of U profile used as horizontal runners, with stud
in alternate fashion to avoid uneven surface. External angle screws are to be fixed @ 200 mm c/c
using Everest fibre cement screws as well.
Step 5: For thermal and acoustic insulation, fill the infill space with the thermal/acoustic insulation
material preferably in chicken wire mesh of approved thickness and density.
Step 6: If joint less finish is required for the partition, refer to the sec tion on treatment of joints.
Step 7: For final finishing, Everest Wall Boards can be painted, polished or laminated whereas
Everest Designer Wall Boards can be painted or polished.
Notes on Usa ge :
1. At T or L junctions, the back of abutting stud to be fixed on the flange of main partition stud
(having the space between them equal to the thickness of Board with 35 mm long drywall screws.
2. Screws should be placed at no more than 300 mm c/c spacing and not less than 15 mm from
the edges and 50 mm from the corners.
3. The head of the screw must be embedded inserted 0.5 mm below the surface duly filled with
putty to conceal the screw.
4. If semi concealed joint is desired, a uniform gap of 2-3 mm must be left between the adjacent
Wall Boards which can be filled with recommended jointing compound/Sealants
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5. For durable joint less finish, used only Low Hydric Movement boards in dry condition, duly
primered on both sides and edges prior to fixing / installation.
6. Wherever doors and windows are coming, additional U sections are to be used to form door or
window opening fixed during the erection. The door or window frames are to be fixed with metal
frame using screws penetrating 35 mm into the vertical member.
7. In door and window openings minimum 50 mm wide chemically treated seasoned timber
framework, duly coated with 1-2 layers of bituminous paint, and is to be snap fitted on to the metal
frame.
8. 100/150 mm wide skirting of 12 mm thick Boards may also be provided, fixed with fully threaded
screws/ headless nails on to the finished partition.
9. Boards should be primered with a coat of 100% acrylic water based cement primer on both
surfaces and edges, before installing in place. Use dry boards only.
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Y
X
Y
DryWall
in
Double
Skin
Full
Height/Half
Height
Timber
Framework
Ma ter ia ls Req uired :
Timber Sections of 50/75mm x 50mm.
Everest Wall Boards 6mm/8mm with spec ified texture and finish.
Insta l la t ion Proc ed ure:
Step 1: Mark the layout of the partitions on the floor. Fix the timber sections on the floor and ceiling
securely fixed using 35mm long stainless steel wood screws with nylon sleeves/wooden gutka.
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Step 2: Fix and secure vertical timber sections @ 610mm c/c with ceiling and floor timber sections.
Step 3: Fix the horizontal timber sec tions @ 1220mm c/c on to vertical studs at sill / lintel level,
around other openings shown as per architectural drawings. All horizontal and vertical members
should be in same plane secured properly to each other through dove tailed joinery, adhesive and
stainless steel wood screws.
Step 4: Fix Boards on both sides of the framework with 25mm self embedding type Everest fibre
cement screws in staggered fashion (both side) to avoid through joints @ 300mm c/c. External
angle screws are to be fixed at 200mm c/ c using Everest fibre cement screws as well.
Step 5: For thermal and acoustic insulation, fill the infill space with the thermal/acoustic insulation
material preferably in chicken mesh of approved thickness and density.
Step 6: If joint less finish is required for the partition, refer to the section on treatment of joints.
Step 7: For final finishing, Everest Wall Boards, can be painted, polished or laminated whereas
Everest Designer Boards can be painted or polished.
Notes on Usa ge :
1. Screws should be placed at no more than 300mm c/c spacing and not less than 15mm from the
edges and 50mm from the corners.
2. The head of the screw must be embedded 0.5mm below the surface duly filled with putty to
conceal the screw.
3. If semi-concealed joint is desired a uniform gap of 2-3mm must be left between the adjacent
Boards which can be filled with recommended jointing compound.
4. Wherever doors and windows are coming additional timber sections of minimum 50mm wide
chemica lly treated kiln seasoned, duly coated with 1-2 layers of bituminous paint are to be used to
form door or window opening fixed during the erection. The door or window frame is to be securely
fixed with wooden framework using 75 or 90mm long stainless steel wood screws penetrating 35mminto the vertical member.
5. 75mm wide timber section is to be used in conjunction with 8mm thick Everest Boards wherever
partition height is more than 2400mm.
6. 100/150mm wide skirting of 12 mm thick Everest Boards may also be provided fixed with fully
threaded screws/ headless nails on to the finished partition.
7. For durable joint less finish, used only Low Hydric Movement boards in dry condition, duly
primered on both sides and edges prior to fixing / installation.
8. Boards should be primered with a coat of 100% acrylic water based cement primer on both
surfaces
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Y
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DryWallinSingleSkinFullHeight/HalfHeightAluminiumFramework
Ma ter ia ls Req uired :
Standard aluminium frame 63.5mm x 38.1mm (as per approved manufacturers
specifications)
Everest Wall Boards/Everest Designer Boards 10mm/12mm with spec ified texture and finish.
Aluminium beading/cleat (18mmx17mm or as per approved manufac turers specifications)with neoprene/EPDM gasket.
Insta l la t ion Proc ed ure:
Step 1: Mark the layout of the partitions on the floor. Fix the aluminium sections on the floor and
ceiling securely fixed using minimum 50mm long stainless steel wood screws with nylon sleeves/
wooden gutka.
Step 2: Fix and secure vertical aluminium sections @ 915mm/1220mm c/c with ceiling and floor
using proper angle cleat and pan head screws.
Step 3: Fix and secure horizontal aluminium sections @ 1220mm c/c on to vertical studs and at sill/
lintel level, around other openings shown as per architectural drawings. All horizontal and vertical
members should be in same plane secured properly to each other through angle cleats and pan
head screws.
Step 4: Fix Everest Boards of specified thickness using aluminium beading and neoprene/EPDM
gasket, snap fitted on to the frame holding board on to the frame.
Step 5: For final finishing, Everest Boards can be painted, polished or laminated whereas Everest
Designer Boards can be painted or polished as per specifications or drawings, taking care of
aluminium framework such that paint or polish doesnt spill over the frame.
Notes on Usa ge :
1. Wherever shown in drawing c lear /float glass of 5mm/6mm thickness can be inserted in place of
Everest Boards using aluminium beading and neoprene/ EPDM gasket.
2. Wherever doors and windows are coming, additional aluminium sections are to be used to form
door or window opening fixed during the erection. The door or window frame is to be securely
fixed with aluminium framework using angle cleat and pan head screws.
3. To make the cabin airtight provide rubber gasket all along the perimeter of the shutter/window.
4. Boards should be primered with a coat of 100% acrylic water based cement primer on both
surfaces and edges, before installing in place. Use dry boards only.
5. In case the textured finish is required on both sides, Everest Designer Boards of 4mm/6mm
thickness in required texture can be pasted back to back with the recommended adhesive
pressed completely for good bonding before inserting into the frame.
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DryWallinSingleSkinFullHeight/HalfHeightTimberFramework
Ma ter ia ls Req uired :
Seasoned timber Sec tions of 50mm x 50mm.
Everest Boards 10mm/12mm with specified texture and finish.
Insta l la t ion Proc ed ure:
Step 1: Mark the layout of the partitions on the floor. Fix the timber sections on the floor and ceiling
securely fixed using 35mm long stainless steel wood screws with nylon sleeves/wooden gutka.
Step 2: Fix and secure vertical timber sections @ 610mm c/c with ceiling and floor timber sections.
Step 3: Fix the horizontal timber sec tions @ 1220mm c/c on to vertical studs at sill / lintel level,
around other openings shown as per architectural drawings. All horizontal and vertical members
should be in same plane secured properly to each other through dove tailed joinery, adhesive and
stainless steel wood screws.
Step 4: Fix the wooden moulding of specified d imension or as per architectural drawing at one side
of partition using headless nails, along the perimeter of the frame work.
Step 5: Insert Everest Boards of specified thickness into the block of frame and fix securely by nailing
the wooden moulding with headless nails on the other side of the frame.
Step 6: For final finishing, Everest Wall Boards can be painted, polished or laminated whereas
Everest Designer Wall Boards can be painted or polished.
Notes on Usa ge :
1. Wherever doors and windows are coming additional timber sections (minimum 50mm wide,
chemically treated kiln seasoned, duly coated with 1-2 layers of bituminous paint) are to be used
to form door or window opening fixed during the erection. The door or window frame is to besecurely fixed with wooden framework using 75mm or 90mm long stainless steel wood screws
penetrating 35mm into the vertical member.
2. Wherever shown in drawing c lear/float glass of 5mm/6mm thickness can be inserted in place of
Everest Wall Boards / Everest Designer Wall Boards using wooden moulding as per specifications.
3. While painting or polishing timber sections, adjacent boards and mouldings should be properly
covered, to avoid spill over of paint and polish.
4. Boards should be primered with a coat of 100% acrylic water based cement primer on both
surfaces and edges, before installing in place. Use dry boards only.
5. In case the textured finish is required on both sides, Everest Designer Wall Boards of 4mm/6mmthickness in required texture can be pasted back to back with the recommended adhesive
pressed completely for good bonding before inserting into the frame.
6. Decorative mouldings may be fixed around the perimeter of the panel made out of the timber
framework using headless nail or countersunk stainless steel screws.
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PanelingwithG.I.Framework
Ma ter ia ls Req uired :
G.I sections: Perimeter U profile, supporting W profile.
Everest Boards 6mm/8mm with spec ified texture and finish.
Fasteners and screws of spec ified material and dimension.
Insta l la t ion Proc ed ure:
Step 1 : Fix the unequal flange U shaped channel with shorter flange facing outside, onto the
bottom, top and periphery of the wall by nylon sleeves / wooden gutka and expandable fasteners
inserted in to the wall using stainless steel wood screws placed @ 300mm c/c. and ensure that all
members are in same plane. If required, short pieces of Everest Boards / wooden gutka are
inserted to bring all the members in same plane.
Step 2: Fix the supporting W profile in between the U profiles @ 600 mm c/c vertically and @ 1200
mm c/c horizontally.
Step 3: Fix the Everest Wall Board/ Everest Designer Boards to the frame with self-tapping screws,
leaving an air gap of 15mm at floor level.
Step 4: Cover up the air gap with minimum 150mm wide skirting at floor level. The junction at the
ceiling / wall can be covered with decorative moulding or cornice as per architectural drawings or
engineer- in-charge.
Step 5: For joint less finish, refer to the section on treatment of joints.
Notes on Usa ge :
1. The air gap is necessary to prevent moisture retention in the Everest Wall Boards. For panelling,
Everest Boards are to be primered on both the sides with 100% ac rylic water based cement primer
before installing the boards on to the framework. Use dry boards only.
2. If the panelling is to be done on a damp wall, all the G.I. Sections are to be duly coated with
zinc chromate primer/bituminous paint, secured to the wall with G.I. cleats.
3. For panelling on very damp wa lls, only vertical sections should be used and an air gap of 15 mm
left at the ceiling level to permit air to percolate.
4. For fixing Cornice or Mouldings, the surface is to be made thoroughly clean and preferably
apply a coat of rubberised adhesive at the back of the cornices/mouldings. Fix Cornice/mouldings
using headless nail/ counter sunk stainless steel screws.
5. Electrical wiring or any other service lines should be embedded in the wall leaving outlets at
required position. If the service lines are not laid before, then use 12.5 mm dia. conduits clamped
on the wa ll and main supporting W profile can be trimmed at the required position.
6. For durable joint less finish, used only Low Hydric Movement boards in dry condition, duly
primered on both sides and edges prior to fixing / installation.
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HEAD AND BASE DETAIL
DETAIL AT JUCTION OFPANELLING AND PARTITION
DETAIL AT X
ISOMETRIC VIEW
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PanellingwithTimberFramework
Ma ter ia ls Req uired :
Seasoned timber Sec tions of 50mm x 50mm, of grid size 1220mm x 610mm / 610mm x
610mm.
Everest Wall Boards 6mm/8mm with spec ified texture and finish.
Fasteners and screws of spec ified material and dimension.
Insta l la t ion Proc ed ure:
Step 1: Fix the timber sections onto the wall with nylon sleeves/wooden gutka inserted into the wall
using stainless wood screws @ 300 mm c/c, to form a grid of 1220 mm x 610 mm / 610 mm x 610 mm
leaving 15 mm air gap from the floor.
Step 2: Adjust the unevenness of the surface, if any, using wooden gutka to bring the entire frame
in same plane.
Step 3: Fix the Everest Wall Boards/Everest Designer Wall Boards on to the frame using self
embedding type Everest fibre cement screws, leaving an air gap of 15 mm at floor level.
Step 4: Cover up the air gap with minimum 100mm wide skirting at floor level. The junction at the
ceiling can be covered with wooden decorative moulding or cornice as per architectural
drawings or engineer-in-charge.
Step 5: If joint less finish is required for panelling, refer to the section on the treatment of joints.
Step 6: For final finishing, Everest Wall Boards can be painted, polished or laminated whereas
Everest Designer Wall Boards can be painted or polished.
Notes on Usa ge :
1. The air gap is necessary to prevent moisture retention in the Wall Boards. For panelling, EverestWall Boards are to be primered on both the sides and edges with 100% acrylic water based
cement primer before installing the boards on to the frame work.
2. If the panelling is to be done on a damp wall, only chemically treated kiln seasoned timber
sec tions duly painted with a coat of bituminous pa int should be secured to the wall with G.I. cleats.
3. For panelling on very damp wa lls, only vertical sections should be used and an air gap of 15 mm
left at the ceiling level to permit air to percolate.
4. For fixing Cornice or Mouldings, the surface is to be made thoroughly clean and preferably
apply a coat of rubberised adhesive at the back of the cornices/mouldings. Fix Cornice/mouldings
using headless nail/ counter sunk stainless steel screws.
5. Electrical wiring or any other service lines should be embedded in the wall leaving outlets at
required position. If the service lines are not laid before, then use 12.5mm dia. conduits clamped
on the wall and the timber sections can be trimmed at the required position.
6. For durable joint less finish, used only Low Hydric Movement boards in dry condition, duly
primered on both sides and edges prior to fixing / installation.
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HEAD AND BASE DETAILDETAIL AT JUCTION OFPANELLING AND PARTITION
DETAIL AT X
ISOMETRIC VIEW
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PanelingwithoutFramework
Notes on Usa ge :
1. For panelling without framework, use 8/10/12mm thick Everest Wall Boards duly coated with oil
bound bituminous primer on its rear side. Boards are to be fixed onto the wall with PVC/Nylon
sleeves/wooden gutka inserted into the wall using self embedding type Everest fibre cement
screws @ 300 mm c/c on expandable fasteners.
2. In case of a damp wall, it is advisable to leave an air gap in between the Everest Wall Boards
and the wa ll or insert a layer of damp proof material such as bituminous felt.
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EverestWetAreaSystemsWet area lining may be done in wall and floor as well as countertops (Kitchen) etc.
Fixing Sub strate
Everest Heavy Duty Wall Boards may be fixed over timber framing, light gauge steel
framing or battens fixed over masonry.
Everest Heavy Duty Wall Boards Fixed Over Light Gauge Steel Framing
Everest Heavy Duty Wall Boards Fixed Over Wooden Framing
Everest Heavy Duty Wall Boards Fixed Over Masonry wall with metal/wooden Furring
In regular partition walls and c eilings the maximum frame distances is 600mm c/c. For
flooring application, the maximum frame distance is 450mm. Before fixing Everest Heavy
Duty Wall Boards, one should ensure that the timer frame or masonry wall is not wet; if so,
allow it to dry before fixing Everest Heavy Duty Wall Boards. The straightness and
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squareness of the framing or substrate must be checked thoroughly. Any deformities must
be corrected prior to installing the sheet.
Sheet joints must coincide with the centre line of the framing member. At door and
window openings fix sheets around the opening in a way that the sheet joints do not
coincide with the edges of openings. The sheet joint must be 200mm min. away from the
opening edge.
Cut Everest Heavy Duty Wall Boards approximately 12mm less than floor to ceiling height
to allow for building tolerances. Ensure that a 6mm building tolerance gap is provided at
the floor and ceiling junctions with the Everest Heavy Duty Wall Boards lining.
Fastener spa c ing o n w al l
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Fixing a nd Jo int ing
J ointing and fixing would be carried out as per the points mentioned in the general
guidelines specified in the General guidelines section.
Spe c ia l Trea tme nt for Co rner Reinforcem ent
The corners are vulnerable areas for damages and leakages. They should be reinforced
as shown below:
Wall Corners
Fix PVC corner angle if edges are bevelled, else fix fibreglass mesh
Lay waterproof membrane over it
Put tile adhesive and lay the tile
Floor Corners
Fix fibre-glass mesh at the corners
Lay waterproof membrane Put the tile adhesive and lay the tile.
Fig: Corner reinforcements with PVC corner angle and
fiberglass mesh
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Waterproof ing
It is recommended that waterproofing
be done over the sheets before laying
tiles or any other finishing. Based on the
water usage, the areas can be divided
into three zones:
Wet areas
Semi-wet areas
Dry areas
The entire of the wet area like the floor and walls of bath cubicles is to be waterproofed.
All the semi wet areas, like baths, wash basin, sinks, laundry tubs etc, should be
waterproofed to a distance of 300mm from the splash zones.
Waterproof membranes are available from different manufacturers in liquid form. Around
1.5 litres of waterproofing compound covers a 1 sq m area with a film thickness of 1mm
per coat. Refer to manufacturers instruction for application method.
Co ntrol Joints/ Exp a nsion Joints
Control joints are required in long runs of Everest Heavy Duty Wall Boards lining walls or
floors in either direction. These joints are designed to take up the structural movement
between the sheets and the building frame. Control joints should also be provided at
frame junctions / joints such as wall intersections. Whenever the span exceeds 4.5m, a
control joint is necessary.
Tile Fix ing
Tile Thicknesses
The thicknesses of tiles used over Everest Heavy Duty Wall Boards lining are restricted
based on stud centers and the thickness of the sheet.
Maximum Tile Thickness
Maximum Tile Thickness (mm)Everest Heavy Duty Wall Board Thickness (mm)
600 mm Studs C/C 450mm Studs C/C
6 9 13
9 13 18
Som e Imp ortant co nstruc t ion Deta i ls
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Drawings
Instal lat ion of Plum b ing Fixtures
Hole Forming: Small rec tangular or circular holes can be achieved by
drilling a series of small holes around the perimeter of the hole then
tapping out the waste piece from the sheet face. Tap carefully toavoid damage to sheets and clean rough edges with rasp.
Fixing Pipe: All the pipes, other than
soil pipe, can be taken through the
space between the boards fixed on
either side. Where ever required, cut
the flange portion of studs that have
been fixed horizontally over the
vertical studs, and fold them apart as shown in picture below.
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