K-INSTALL - Knauf Australia · A JSA/SWMS should be completed for each task on site, and these must be available All workers must be trained in the relevant JSA/SWMS orkers must be

K-INSTALL

K-INSTA

LL

Supply & Install Solution for Residential Dwellings

Supply &

Install Solution for Residential Dw

ellings

Knauf Plasterboard Pty Ltd ABN 61 003 621 010 31 Military Road Matraville NSW 2036

Customer Service 1300 724 505 knaufplasterboard.com.au

Knauf Metal ABN 61 003 621 010 Cnr Quindus St & Spanns Rd Beenleigh QLD 4207

Customer Service 1300 725 675 knaufmetal.com.au

CONTENTS

SAFETY INDUCTIONPurpose of the Induction 14Items we will Cover 14General Expectations 15Site Risk Assessments 15Traffic Management 16Storage and Movement of Plasterboard 16Safe Work Method Statements 17Maintaining a Safe Work Area 17Tools & Equipment 18Electrical Safety 18Fall Protection 19Steps & Ladders 19Use of Stilts 20Material Safety Data Sheets 20Reporting of Incidents 21Recap 21K-Install Safety Induction Questionnaire 22

SAFETY RESOURCESK-Install Safety Checklist 24Site Risk Assessment 26Stilts Risk Assessment 28Risk Assessment Matrix 33

K-INSTALLAbout Knauf 4K-Install – Supply & Install Solution for Residential Dwellings 5K-Install Safety 6Other Safety Requirements 7The Minimum Site Safety Standards 8Responsibilities of the Contractor and Subcontractor 9K-Install Quality 10Other Quality Requirements 11Standard Procedures 12

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K-INSTALL

K-INSTALL FINAL INSPECTION

CERTIFICATE

Builder

Builder Site Manager

Job Address

Date Marked Up

Pre-paint Completed By

Date Checked

Date Handed Over

Comments

STANDARD PROCEDURES

83

QUALITY INDUCTIONPurpose of the Induction 36Items we will Cover 36Handling and Storage 37Condensation and Ventilation 37Things to Look for to Ensure Frame Ready 38Levels of Finish 38Plasterboard Fixing 40Installation Walls 41Installation Ceilings 42Ceilings General Requirements 46Installation Requirements for Garage Ceilings 47Installation Garage Ceilings 48External Ceilings General Requirements 49Installation External Ceilings 50Installation Requirements for External ceilings 51Wet Areas Plasterboard Fixing 52Back-Blocking 56Jointing 58Compounds 59Recap 60K-Install Quality Induction Questionnaire 62

QUALITY RESOURCES K-Install Quality Checklist 64Plaster Ready Assessment 66Builder Standard Specifications 68K-Install Subcontractor Annual Review 69STANDARD PROCEDURES FOR THE INSTALLATION OF PLASTERBOARD IN DOMESTIC DWELLINGSReferences 72Level of Finish 72Standard Timeframes 74How to Call up a Job for Delivery and Installation 75A Plasterboard Ready Site 76Plaster Start 78Safety Considerations 79Pre-Paint (Finish Off) 80Maintenance Work 81Credits/Back Charges 81Warranty 82K-Install Final Inspection Certificate 83

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SUPPLY & INSTALL SOLUTION

ABOUT KNAUF

Knauf, a family owned company, has a strong global presence in the construction materials industry. With 150 production facilities and sales organisations in over 60 countries, 26,000 employees worldwide, and sales of 6.27 billion Euro (in 2013), the Knauf Group is without doubt one of the biggest players in the market – in Europe, the USA, South America, Russia, Asia, Africa, and Australia.

Brothers, Alfons Knauf and Karl Knauf, started the company in 1932 with the production of conventional gypsum. Since then the company has steadily expanded its footprint and product offering. A clear vision for innovation that incorporates Knauf’s very best thinking, and a confidence for investments, gives Knauf the success it enjoys.

Knauf Australia is a manufacturer and major supplier of building materials to the light weight construction industry in Australia.

With manufacturing facilities in Matraville (Sydney), Altona (Melbourne) and Bundaberg (Queensland) manufacturing plasterboard and compounds, metal profile lines in Beenleigh (Brisbane), over 220 employees and a national distribution PlastaMasta network, Knauf is a major supplier to the lightweight construction industry and a one-stop-shop for a complete wall framing solution.

A quality range of products and systems designed for performance provide solutions for fire, water, impact, acoustic and decorative applications for all construction projects – commercial and residential.

Knauf’s innovative lightweight construction systems include plasterboard, steel framing systems for walls and ceilings, acoustic and air cleaning wall & ceiling linings, mineral fibre ceiling tiles, facades, plasters for internal and external applications, and glass and mineral wool insulation.

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K-INSTALL

K-INSTALL – SUPPLY & INSTALL SOLUTION FOR RESIDENTIAL DWELLINGS

K-Install provides the framework for the delivery of a consistent plasterboard supply and installation service for residential dwellings.

This manual sets out Knauf’s expectations in terms of delivering the service, with a particular focus on safety and quality outcomes. Satisfying these expectations is a fundamental requirement of achieving and maintaining Knauf “accredited installer” status.

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K-INSTALLSAFETY

The K-Install safety system is composed of several different elements. The basis of the Knauf accreditation system as it relates to safety revolves around setting the expectations, checking that those expectations are being met, and addressing issues where they arise. To maintain Knauf accreditation, subcontractors will be reviewed each year to ensure satisfactory performance.

INDUCTION

Having completed the training material, there is a questionnaire which must be completed in order to demonstrate an understanding of the requirements. A pass mark of 100% is required in order to successfully complete the Safety Induction.

Once successfully completed, there is a requirement to provide details such as your Construction Induction Card number and a recent photograph which will be included on the Knauf Accredited Installer Card.

SAFETY CHECKLIST

The Safety Checklist will be used by the contractors in observing behaviours of subcontractors on site. The checklist covers the main areas of risk on sites such as housekeeping, electrical safety, PPE, work methods and tools and equipment.

Non-conformances are to be addressed immediately with the relevant subcontractor, and a record of the checklist is to be maintained by the contractor.

ANNUAL REVIEW

Together with the contractors, Knauf will conduct an annual review of their subcontractor base to ensure the adequate performance of the subcontractor in relation to safety. Should the subcontractor not meet the performance expectations, their Knauf accreditation will not be renewed. If any subcontractors are in serious breach of safety requirements between annual reviews, their accreditation will be cancelled immediately.

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K-INSTALL

OTHER SAFETY REQUIREMENTS

In addition to these accreditation measures, a number of different tools have been developed to assist contractors and subcontractors manage the safety risks associated with completing the work.

While the format and content of the templates used may be different, it is required that subcontractors have the following processes in place;

Site Risk Assessment

Used to identify the risks on each site, and the control measures to be put in place to manage the risks

A Site Risk Assessment should be completed prior to starting work, and again at any stage the conditions on site change

Stilts Risk Assessment

To be completed if stilts are going to be worn

Used to identify the risks specific to the use of stilts

The Stilts Risk Assessment should be completed prior to putting the stilts on and starting work

Job Safety Analysis (JSA) or Safe Work Method Statement(s) (SWMS)

These describe the way in which a task is carried out in the safest way possible

There is an example included in the appendices of this manual which can be used as a guide by subcontractors in developing their own or using the sample JSA/SWMS if it is confirmed by them as relevant to the task

Material Safety Data Sheets (MSDS)

Any hazardous substance or dangerous goods on site require a Safety Data Sheet to be accessible

All MSDS for Knauf manufactured products are available on the Knauf website www.knaufplasterboard.com.au/sds

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THE MINIMUM SITE SAFETY STANDARDS

It is expected that subcontractors adhere to the following site safety rules as a minimum:

Compliance with legislative requirements

All workers must have completed the K-Install accreditation program

All workers must have completed the builder’s induction program where relevant

All workers must have their Construction Induction Card on hand (or a photo of it)

All workers are to wear safety footwear, and any other relevant Personal Protective Equipment required to safely undertake the task or any other Personal Protective Equipment as required on the particular site

A Site Risk Assessment must be undertaken prior to commencing work. All workers must be familiar with the Risk Assessment (and sign it), and the Risk Assessment must be kept available on site

A JSA/SWMS should be completed for each task on site, and these must be available

All workers must be trained in the relevant JSA/SWMS

Workers must be adequately supervised at all times

A well-stocked first aid kit must be available on site

Tools and equipment should be in good working order and appropriate for the task at hand

All electrical leads must be tested and tagged, and in date

An MSDS should be available for all hazardous substances or dangerous goods on site

If a situation arises which poses an immediate risk, stop work and fix the issue or advise the site manager

Injuries or incidents to be reported to the Site Manager are as follows:

An injury which requires medical treatment beyond simple first aid (seeing a doctor)

A notifiable incident

Any incident where an inspector from a statutory body attends site

Any incident which may result in legal action

If a hazard arises which can’t be controlled8

K-INSTALL

RESPONSIBILITIES OF THE CONTRACTOR AND SUBCONTRACTOR

In terms of the different elements of this safety system, the responsibilities of the contractor and subcontractor are set out in the table below. This ensures the checks and balances are in place to effectively manage risk.

Subcontractor Contractor

Site Risk Assessment Plaster Ready Checklist

Stilts Risk Assessment Safety Checklist

Job Safety Analysis (JSA)Safe Work Method Statement (SWMS)

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K-INSTALL QUALITY

The K-Install Quality Induction works in much the same way as the K-Install Safety system. Both of the Safety and Quality Inductions must be successfully completed prior to the Knauf Accredited Installer Card being issued.

INDUCTION

Having completed the training material, there is a questionnaire which must be completed in order to demonstrate an understanding of the requirements. A pass mark of 100% is required in order to successfully complete the Quality Induction.

Once successfully completed, there is a requirement to provide details such as your Construction Induction Card number and a recent photograph which will be included on the Knauf Accredited Installer Card.

QUALITY CHECKLIST

The Quality Checklist will be used by the contractors in observing installation practices of subcontractors on site. The checklist covers the main areas of correct installation of plasterboard.

Non-conformances are to be addressed immediately with the relevant subcontractor, and a record of the checklist is to be maintained by the contractor.

ANNUAL REVIEW

Together with the contractors, Knauf will conduct an annual review of their subcontractor base to ensure the adequate performance of the subcontractor in relation to quality. Should the subcontractor not meet the performance expectations, their Knauf accreditation will not be renewed. If any subcontractors are in serious breach of quality requirements between annual reviews, their accreditation will be cancelled immediately.

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K-INSTALL

OTHER QUALITY REQUIREMENTS

For the best possible quality of finish, it is important to make sure that the dwelling is plaster ready. That is, all of the basic requirements that should have been completed prior to installation of plasterboard have actually been completed. This also helps to reduce re-work at later stages of the build.

The Plaster Ready Assessment should be completed prior to commencing work. Any obvious issues should be brought to the attention of the Site Manager for rectification. The template in this manual is a guide to identify the important aspects to have right before starting work.

The contractor is responsible for ensuring the Plaster Ready Assessment is completed prior to commencement of the work, as well as completing the Quality Checklist during installation to ensure correct installation methods are being followed by the subcontractor.

Once all work is completed, the contractor should inspect the job and complete a Final Inspection Certificate to be issued to the builder.

OTHER RESOURCES TO ASSIST WITH QUALITY INSTALLATION

Subcontractors must be familiar with the Knauf guide which covers Plasterboard Installation Guide - Low Rise Residential Dwellings. A copy is available on the Knauf website www.knaufplasterboard.com.au/brochures-installation-guides. The Guide is available in English and Chinese. Aside from being familiar with the guide, subcontractors must ensure they install the plasterboard and associated products in line with the guide.

The Australian Standard which governs plasterboard installation is AS/NZS 2589:2017 – Gypsum Linings – Application and Finishing. All works must be completed in accordance with both the Australian Standard and the Knauf Installation Guide.

Having a standard builders specification is also a useful way to ensure the plasterboard and associated products are installed to the particular requirements of the builder. K-Install includes a template to assist with capturing this information. 11


STANDARD PROCEDURES

To standardise the delivery of the supply and installation service, K-Install includes a standard set of procedures to describe how the service works.

The procedures cover;

Levels of finish

Timeframes prior to starting and timeframes on site

Calling a job up to start

Plaster ready and plaster start

Safety considerations

Pre-paint process

How to organise rectification work (maintenance)

How to organise credits and back charges

How to organise warranty works

KNAUF ACCREDITATION

As indicated earlier, in order to achieve Knauf accreditation, it is a requirement to successfully complete the K-Install Safety and Quality Induction Assessments.

Aside from the induction assessments, Knauf will also undertake a practical assessment of the subcontractor on site to observe the safety behaviour and quality of workmanship demonstrated. This will be done using the safety and quality checklists contained in the Appendices to this manual.

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SAFETY INDUCTION

K-INSTALL - SUPPLY & INSTALL SOLUTION FOR RESIDENTIAL DWELLINGS

13

The safety induction forms part of the Knauf accreditation process

We want to ensure you are aware of the expectations around safety

It also aims to provide some practical tips to help you prevent injuries

It is the beginning of us working together, and a very important part of that is to understand that safety is non-negotiable.

General expectations

Site Risk Assessments

Traffic Management

Storage and movement of plasterboard

Safe Work Method Statements

Maintaining a safe work area

Tools and equipment

Electrical safety

Fall protection

Steps and ladders

Use of stilts

Hazardous substances

Reporting of incidents

PURPOSE OF THE INDUCTION

ITEMS WE WILL COVER

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Compliance with legislative requirements

Ensure all work is conducted in a safe manner and is supervised

All workers are to have their construction induction card on them (or a photo of the card on their phone)

Other induction requirements have been met (e.g. builder induction, site specific induction)

All workers are to have been trained in the Safe Work Method Statement (SWMS) relevant to the work they are doing

There should be a stocked first aid kit on site and accessible

Personal Protective Equipment (PPE) is to be worn

Safety footwear (steel capped boots or shoes)

Other task appropriate PPE (e.g. dust masks for mixing or sweeping, gloves for handling metal). All task specific PPE should be noted on the SWMS

The purpose of the Site Risk Assessment is to identify any hazards that may present a risk of injury

Once a hazard has been identified, then something needs to be done about it to ensure it is fixed

All workers on site should sign off on the Site Risk Assessment prior to starting work so they are aware

If work cannot proceed safely, then do not start. Call the Site Manager to help resolve the issue

Each day, things on site may have changed. If they have, complete another Site Risk Assessment to see if there are any new hazards everyone needs to be aware of

There are no right or wrong answers on the Site Risk Assessment – it needs to reflect what is actually on site

GENERAL EXPECTATIONS

SITE RISK ASSESSMENTS

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SAFETY INDUCTION

Traffic management refers to keeping machinery and people away from each other

This is especially the case on larger sites, but also when material deliveries are being made

When deliveries are being made, it is important that you keep out of the way of the truck as sometimes board or cornice may fall off the truck

A good reference guide is 'Move It – The GBMA Way' from the Gypsum Board Manufacturers of Australasia (GBMA)

Plasterboard should preferably be stacked horizontally on the floor

Sometimes due to space restrictions, it may be necessary to stack the board vertically against the frame.

TRAFFIC MANAGEMENT

STORAGE AND MOVEMENT OF PLASTERBOARD

It may be a good idea to use a spotter when reversing a vehicle to assist in the driver’s ability to notice obstructions and people

If there are traffic signs or rules on the site, these need to be observed

Councils are becoming more concerned about vehicles taking mud onto council roads – they are fining builders for this

The board should then be restrained properly. Be very careful when handling board from vertical stacks – if it falls on you, it could cause serious injury

Use correct manual handling techniques when cutting, lifting and carrying board

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A Safe Work Method Statement (SWMS) is a description of how the task you are performing is safely carried out

It is your responsibility to have the relevant SWMS on site and available for everyone to refer to if required

All workers must be trained in the SWMS before carrying out the task

Messy work areas can lead to trips and falls, which may cause an injury

The safest way to work is to tidy up as you go

Before you start work, the site should be handed over to you in a tidy manner. If it isn’t, let the Site Manager know

You should sweep the site regularly during the day

SAFE WORK METHOD STATEMENTS

MAINTAINING A SAFE WORK AREA

If there are site specific requirements or hazards, these should be captured in a site specific SWMS

Knauf has developed a generic SWMS for you to adapt as may be needed

Keep doors and hallways clear of trip hazards

Store tools correctly (e.g. in a milk crate) and put them away properly at the end of each day

Ensure that any plasterboard stacked vertically against the frame is restrained at the end of each day or while not being used

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SAFETY INDUCTION

Ensure the tools and equipment you have are the right ones for the task you are performing

Tools and equipment should be in good working order and well maintained. Check before you start work

Some of the tools used in plastering are sharp, and a number of injuries occur due to cuts on scrapers and Stanley knives. It is advisable to wear cut resistant gloves when handling scrapers or knives, as well as when handling metal products

Before connecting any power tool to the power supply, ensure there is a residual current device in place and that it is working

Domestic power boards and double adaptors are not allowed on site

Electrical leads are to be tested and tagged every 3 months as a minimum. All electrical leads on site must be tagged and in date

Where possible, keep electrical leads off the ground and out of water

TOOLS & EQUIPMENT

ELECTRICAL SAFETY

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K-INSTALL

The risk of falling from a height on a housing site is real

Voids, stairwells, windows and balcony doors are just some examples of areas you could fall from

Ladders, steps, stilts and trestles will also likely be used in plastering, and you can fall from these too

It is important to ensure that all these potential risks are identified and controlled before you start working

Make sure you move trestles and ladders as required, and do not over stretch when you are on them – this could cause a loss of balance

If you move any part of the void protection (for example when passing sheets upstairs), it needs to be replaced immediately and not left open

Steps and ladders should be well maintained with treads regularly cleaned

Do not use milk crates or compound buckets instead of steps or ladders, as it is easy to lose balance on them

Use industrial grade ladders, not domestic ones

Do not stand on the top step or second top step of a ladder – read the warnings on the ladder

Do not over reach when on ladders

Ladders between floors should be secured at the top and bottom

Include safety precautions for the use of ladders in your SWMS

FALL PROTECTION

STEPS & LADDERS

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SAFETY INDUCTION

If at all possible, avoid using stilts and look for alternate methods such as trestles or steps

You need to have undertaken the appropriate training in order to use stilts

Prior to starting work, you should complete a stilts risk assessment

You should check that the stilts are in good working order and well maintained

You should also check that the area you will be working in is appropriate for the use of stilts – there should be no trip hazards

Do not use stilts in stairwells or outside

To avoid over-balancing, do not over stretch and do not lift heavy or awkward items (and do not lift from below your feet)

A current Material Safety Data Sheet (MSDS) must be on hand for all hazardous substances or dangerous goods on site

The MSDSs for all of Knauf’s products are on the website

You should also ensure that you have an MSDS for any hazardous substances you bring on site, and store and handle them the correct way

Remember to use appropriate PPE when handling hazardous substances

USE OF STILTS

MATERIAL SAFETY DATA SHEETS

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Some incidents must be notified to the relevant authorities

So that there is no doubt, report all incidents to your Site Manager when they are identified

The purpose of reporting incidents is so that we learn from them, and also to make sure you are okay. You will not get in trouble for reporting an incident

REPORTING OF INCIDENTS

Do a Site Risk Assessment at the start of work, and any time something on site changes

Have your Construction Induction Card on you (or a photo)

Everyone is to be trained in the SWMS for the tasks they are doing

Ensure there is a well stocked first aid kit on site

All electrical leads are to be tested and tagged every 3 months. They must be current

Wear the appropriate Personal Protective Equipment

Safety footwear (boots or shoes) Dust masks, gloves, safety

glasses when required

Keep your work area tidy as you go and avoid tripping hazards

Check that all equipment including ladders, trestles, stilts are in good working order before starting

RECAP

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SAFETY INDUCTION

K-INSTALL SAFETY INDUCTION

QUESTIONNAIREThis questionnaire is designed to check your understanding of the material presented. Please circle the most appropriate answer.

1. Which of the following are you required to have on site? a. Construction Induction Card b. First aid kit c. Safe Work Method Statements d. Material Safety Data Sheets for hazardous substances e. All of the above

2. All members of the team are to have been trained in the Safe Work Method Statement relevant to the tasks they are performing before they do the work.

a. True b. False

3. Who should sign off on the Site Risk Assessment? a. The builder b. All workers on site c. Knauf d. WorkSafe

4. When should a Site Risk Assessment be conducted? a. Before starting work b. If anything changes on site c. Both of the above

5. Using a domestic power board or double adaptor on site is okay as long as it is tested and tagged.

a. True b. False

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6. Standing on the top rung of a step ladder is okay, as long as you don’t overreach.

a. True b. False

7. How often should electrical leads be tested and tagged? a. Every week b. Once per year c. Every 3 months d. Never

8. Personal Protective Equipment (PPE) is not required if no-one else is on site. a. True b. False

9. The following are examples of Personal Protective Equipment which may be required when plastering. Match the PPE to the task which it is appropriate for by connecting with a line.

a. Safety footwear e. Handling metal or using a Stanley knife b. Dust mask f. To be worn on site at all times c. Safety glasses g. Sweeping up and sanding d. Cut resistant gloves h. Using power tools

10. You should just tidy your work area at the end of the job, as it will save time. a. True b. False

I acknowledge that I have received this safety induction training, and I agree to comply with the safety rules when I am working on a K-Install site.

Name: ................................... Signature: ...................................

Subcontractor organisation: ………………………………………………

Date: ………………………………

Inducted by:

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SAFETY INDUCTION

K-INSTALL

SAFETY CHECKLISTSubcontractor Date

Builder

Job Address

Item Y/N/NA Comment

Access/Housekeeping

Safe access/egress to/from site

Good housekeeping in work area (no slip or trip hazards)

No washing waste to drains, footpaths, gutters etc.

No smoking on site other than in designated areas

Risk Assessments

Site Risk Assessment completed and on site K-install template available as a guide

Stilts Risk Assessment completed and on site K-install template available as a guide

Inductions, Personal Protective Equipment

All workers on site have their Construction Induction Cards on them (the card or a photo on their phone)

All workers on site have proof of completion of the builder’s induction process as required

All workers have and are wearing all required PPE

First aid kit on site

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Work Methods

Appropriate supervision is in place

SWMS available for all tasks, and filled in with any site specific risks

K-install template available as a guide

Plasterboard stacked correctly

Electrical Safety

Electrical leads in good working order, tagged and in date

No double adapters are used

No domestic power boards are used

Tools and equipment

Steps, ladders and trestles are in good working order, treads cleaned, and appropriate for task

Tools are in good working order and appropriate for the task

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SAFETY RESOURCES

SITE RISK

ASSESSMENTSubcontractor Date

Builder

Job Address

Mark the correct column Yes No N/A

The Work Area

There is safe access to the houseTrip hazards have been identified and controlledPlasterboard is stacked correctlyStair void protection is in placeAppropriate fall protection is in place for areas such as balconiesAll windows and external doors have been fittedWater, toilet and power are available on siteWhere working at a height greater than 2 metres, appropriate safe access is availableAn appropriate area has been nominated for plasterboard offcuts

Inductions, Personal Protective Equipment

All workers on site have their Construction Induction Cards on them (the card or a photo on their phone)All workers on site have proof of completion of the builder’s induction process as required All workers have and are wearing all required PPEA stocked first aid kit is available on site

Work Methods

SWMS available for all tasks, and filled in with any site specific risksSteps, ladders and work platforms are in good working order, treads cleaned, and appropriate for the taskAll tools and equipment are in good working order and appropriate for the taskA Stilts Risk Assessment has been completedManual handling risks have been identified and are being controlled

Electrical Safety

Electrical leads are in good working order, tagged and in dateNo double adapters are usedNo domestic power boards are used

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Hazards Identified (list any additional hazards and what you will do to manage them)

Hazard What could happen? How is it controlled?

Subcontractor Sign Off

Name Signature Date

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SAFETY RESOURCES

STILTS RISK


Builder

Job Address


The Work Area

Floor is flatAll debris has been swept upAll trip hazards have been identified and managedLarge windows and doors are closedScaffold and void protection are in placeA bench or seat of an appropriate height is available for fitting and removing stilts safelyTools and materials are positioned so that there is no need to reach below feet level, or another person can pass these up

Training

The person using stilts has been trained in the use of the stilts or is sufficiently experiencedA copy of the manufacturer’s instruction manual is available

Work Methods

Alternative methods for completing the task have been investigatedSWMS is available and any site specific risks included

The Stilts

The stilts have been inspectedThe stilts are in good working order

If the response to any of the above questions was 'No', avoid using stilts. This Risk Assessment should be completed prior to commencing work, and should be re-checked if anything changes on site. It should be kept on site for the duration of the project.

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Hazards Identified (list any additional hazards and what you will do to manage them)

Hazard What could happen? How is it controlled?

Subcontractor Sign Off

Name Signature Date

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SAFETY RESOURCES

JOB SAFETY ANALYSIS JOB: Installation of Plasterboard

FACILITY/SITE: PREPARED BY:

DEPARTMENT: PARTICIPANTS:

SUPERVISOR:

DATE:

REVIEW DATE:

Required Personal Protective Equipment: Safety footwear (mandatory), other PPE as may be required for task - safety glasses, dust mask, hearing protection, cut resistant gloves

List Associated Procedures/Work Procedures or Temporary Work Procedures:

Step No Describe Job Step Potential Hazards Risk Hazard Management

(controls) Risk Completed By/Date

1 Arrive at site Site may be unsafe if access is not clear, if there are other trades working on site, or if the work area is not tidy On a double storey house, fall from height

48 Complete Site Risk Assessment, maintain tidy work area

On a double storey house, work must not commence unless there is adequate stair void protection installed

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2 Preparing tools and equipment to start job

Manual handling issues, cuts, scrapes

40 Locate vehicle appropriately to minimise distance to carry tools

Use correct manual handling techniques for lifting tools and equipment

Ensure sharp tools are face down in container or otherwise in a sheath

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3 Connecting tools and equipment to power supply

Electrocution 42 Ensure the Residual Current Device is in place and confirm it works

Ensure all tools and equipment are in good working order and do not have frayed cords

All electrical leads must be tested and tagged, and the tag must be current

Do not use domestic power boards, or double adapters

Electrical leads should not be left in water and should preferably be off the ground

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4 Cutting of plasterboard

Cut from Stanley knife when scoring plasterboard

30 Use safety knife where possible

Use cut resistant gloves Ensure cutting direction is away from the body, with legs and hands out of the way

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5 Moving plasterboard

Manual handling issues, trips

40 Use correct manual handling techniques (stretch prior to lifting, team lifts where required, etc.)

Ensure work area is kept tidy and offcuts are not left lying around

20

6 Use of power tools

Cuts, eye injury 36 Person using power tools must be trained in the correct use of the tool

Before starting, ensure tool is in good working order

Wear appropriate PPE

18

7 Handling metal products (e.g. external angles)

Cuts 36 Wear appropriate PPE (cut resistant gloves)

Be aware of the position of the metal so that it doesn’t come in contact with the body when moving or cutting it

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8 Use of ladders, trestles, step ups

Fall from height 60 Before starting, ensure ladder, trestle or steps are in good working order and fit for purpose If working on a trestle, mark wall to show where ends of the trestle are Ensure treads of ladders are clean and free from plaster and dirt build up When using ladders, trestles and steps, ensure safety footwear is not slippery Use industrial grade ladders, trestles and steps – not domestic

Do not use milk crates as steps Do not over-reach when using ladders, trestles or steps – move the ladder, trestle or steps closer to the work area so as not to over-stretch Do not use a trestle, ladder or step up near the edge of an open floor, door, window etc. Do not use a ladder, trestle or step on scaffolding

30

9 Preparing and using compounds

Exposure to potentially hazardous chemicals

18 Use relevant PPE where required as recommended on the Material Safety Data Sheet

Ensure washing up is done in the wash pit to avoid run off into drains, gutters etc.

12

10 Removing plaster waste

Manual handling issues

Cut when cutting up off cuts

12 Use correct manual handling techniques

Refer Step 4 for cutting of plasterboard

12

11 Leaving site Site left in unsafe condition

36 Ensure work area is left tidy and is swept at the end of each day

If there is plasterboard stacked vertically, ensure that it is adequately restrained to prevent it falling

18

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Probability Exposure Consequence

1 = One in a million 1 = Rarely 1 = Minor or

negligible impact

2 = Remote 2 = Weekly

2 = Minor injury, damage, or

environmental impact

4 = Unexpected 3 = Daily

3 = Major injury, serious damage or environmental

impact

8 = Likely 5 = Hourly

7 = Fatality, major damage

or environmental impact

16 = Expected 10 = Constantly

17 = Multiple fatalities, critical

damage or environmental

impact

Risk Score Severity Action Required

< 20 Minor risk May not warrant action being taken

20 - 50 Moderate risk Consider cost benefit of corrective actions

50-200 Substantial risk Action should be taken to correct situation

>200 High risk Implement corrective actions as a high priority

RISK ASSESSMENT

MATRIX

Elimination

Substitution

Isolation

Engineering Controls/ Modifications

Administration Controls

Personal Protective Equipment (PPE)

Formula: Probability x Exposure x Consequence = Risk

Environmental Aspects with an inherent or raw risk impact score above

100; or a consequence of 7 and above, are deemed as "Significant Impacts".

MostEffective

LeastEffective

33

SAFETY RESOURCES

34

K-INSTALLK-INSTALL

K-INSTALL - SUPPLY & INSTALL SOLUTION FOR RESIDENTIAL DWELLINGS

QUALITY INDUCTION

35

The quality induction forms part of the Knauf accreditation process

We want to ensure you are aware of the expectations around quality

It is critical that plasterboard is installed in accordance with the Australian Standard and the Knauf installation guide – this is the safest outcome for the homeowner, and also provides for the best quality of finish once the plastering process is complete

Handling and storage of plasterboard

Condensation and ventilation

Levels of Finish

Fixing Methods for plasterboard

Walls

Ceilings Installation requirements for

garage ceilings Installation requirements for

external ceilings

Wet Areas

Back Blocking

Jointing

Compounds

PURPOSE OF THE INDUCTION

ITEMS WE WILL COVER

36

K-INSTALLK-INSTALL

Plasterboard must be kept dry and should be stacked clear of the floor using supports not more than 600mm apart as shown

Plasterboard must not be installed until the building is weather-proof

Condensation must not be allowed to form on plasterboard, otherwise this can lead to:

Joint distortion Mould growth Fastener popping Plasterboard becoming soft and sagging

HANDLING AND STORAGE

CONDENSATION AND VENTILATION

37

QUALITY INDUCTION

Prior to installation of plasterboard, the frame must be suitable to allow installation according to the standard

This will help to ensure the best possible finish, and reduce costly and time consuming re-work later in the process

Some of the basics are;

Perimeter noggings installed in external ceilings and garage ceilings

Change of direction noggings installed in all required areas

Insulation installed correctly in ceilings and walls

Electrical rough in complete

Plumbing rough in complete

Box gutters/flashings installed where applicable and house water-tight

Bulkheads appear square and level

Any obvious framing issues have been fixed

Ceiling trusses appear level

LEVEL 3

A Level 3 Finish is recommended where no decoration is required such as walls above ceilings and concealed storage areas. The requirements for a Level 3 Finish are:

Framing requirements,

A bedding coat and second coat on all face layer joints and corners.

THINGS TO LOOK FOR TO ENSURE FRAME READY LEVELS OF FINISH

AUSTRALIAN STANDARD 2589:2017

38

K-INSTALL

LEVEL 4

Level 4 is the default finish and is recommended for most applications, when lighting is favourable and light tone, flat or low sheen paints are used. The requirements for a Level 4 Finish are:

Framing and back-blocking requirements,

Face layer joints finished using a Three Coat Jointing System,

A quality three coat paint system.

From section 3.1.4 of ASNZS 2589:2017 Level 4 shall be the default level for gypsum lining, unless specified otherwise.Flat or low sheen paints shall be used for this level 4.All joints and interior angles shall have tape embedded in jointing cement/jointing compound and a minimum of two separate coats of jointing cement/jointing compound applied over all joints, angles, fastener heads and accessories. All jointing cement/jointing compound shall be finished evenly and be free of tool marks and ridges in preparation for decoration.NOTES:1. In critical lighting conditions, surface

imperfections may still be apparent in aLevel 4 surface finish.

2. Where gloss, semi-gloss and deep tonepaints are used, surface imperfections will bemore evident.

LEVEL 5

Level 5 involves skim coating the entire wall or ceiling to provide an even surface texture.

The requirements for a Level 5 Finish are:

Framing requirements

Back-blocking of all ceiling joints and wall butt joints,

Joints finished using a Three Coat Jointing System,

Application of a skim coat over the entire surface to provide uniform texture and porosity,

A quality three coat paint system.

39

QUALITY INDUCTION

Drive fasteners to just below the sheet surface, taking care not to break the paper liner board

Use laminating screws to fix floating butt joints in the second and third layer

Fastener and adhesive method

Apply MastaGrip Stud Adhesive after the frame is clean, dry, and free from grease, dust and other contaminants

Apply MastaGrip daubs 200mm minimum from fasteners and plasterboard edges

Fastener only method

Use the 'fastener only method' in tiled or fire rated areas. Stud adhesive is not permitted

PLASTERBOARD FIXING

40

K-INSTALL

SealantIf required, use sealant to maintain acoustic integrity

Butt Joints Stagger by 600mm min on adjoining sheets and an

opposite sides of the wall

300mm max

Butt Joints Float between framing for Level 4 and Level 5 finishes

Temporary holding block or screw, if required

Adhesive daubs 200mm min from screw points and plasterboard edges

Sheet Edges Fix screws 10 - 50mm from sheet edges

Field Knauf MastaGrip Adhesive daubs 25mm diameter, 15mm high and 300mm max spacing

Butt Joints permitted on a stud for Level 3 Finish

Recessed Edges Fix on each stud

Fix on each stud 10 - 50mm

300mm max

Corners 300mm max

Openings 300mm max

10 - 50mm

200mm min

10 - 50mm

Application of a daub of adhesive onto steel angle or strap bracing

between framing members will minimise the risk of the bracing rattling against the back of the gypsum linings.

FIXING PATTERN TABLE

Sheet Width Fixing Pattern

600mm F A A F900mm F A A A F1200mm F A A A A F1350mm F A A A A A F

F = One screw or nailA = One adhesive daub

MAXIMUM WIND CLASS TABLE

Plasterboard TypeMaximum Wall Stud Spacing

600mm 450mm 300mm

All 10mm plasterboards N5 / C1 N6 C2

1. Wind loads in accordance with AS 4055-2012 Wind loads for housing.2. Calculated using rational engineering means with a safety reduction factor of Φb = 0.8 for plasterboard bending, and Φc = 0.65 for fi xing point connections.3. Calculations do not include the framing which must be independently designed to suit the desired wind zone.

INSTALLATION WALLSNON-FIRE RATED 1 LAYER - HORIZONTALFastener and Adhesive Method

41

QUALITY INDUCTION

INSTALLATION CEILINGSNON-FIRE RATED 1 LAYER Fastener and Adhesive Method

Adhesive daubs 200mm min from screw points

Field Knauf MastaGrip Adhesive daubs 25mm diameter, 15mm high and 230mm max spacing

Stagger Butt Joints by 600mm min on adjoining sheets

Butt Joints - Level 4 or 5Float butt joints centrally between framing members for Level 4 or 5 Finish and back-block

Recessed EdgesFix on each framing member

Joist or batten framing at 600mm max centres

CenterlineSingle Screw or Double Nail

Butt Joints - Level 3, Openingsand Control JointsFix at 200mm max centres.Butt joints may be made on framing members for Level 3 Finish

10 - 50mm

200mm max staggered

10 - 50mmSheet EndsCornce: fix at 300mm max.Square Set: fix at 150mm max.

Gaps around the ceiling perimeter

may reduce acoustic performance



600mm F F F F900mm F A F/F A F1200mm F A A F/F A A F1350mm F A A F/F A A F

F = One screw or nailF/F = One screw or double nailsA = One adhesive daubNote: On 1350mm wide sheets use temporary fasteners until adhesive sets.


Plasterboard TypeMaximum Internal Ceiling Frame Spacing

600mm 450mm 300mm

10mm MastaShield10mm WaterShield - N5 / C1 N6 / C2

10mm SpanShield10mm Opal

13mm MastaShieldN4 N5 / C1 N6 / C2

1. Wind loads in accordance with AS 4055-2012 Wind loads for housing.2. Calculations include a ceiling insulation with maximum weight of 2.5 kg/m2 (equivalent to R6.0 EarthWool Ceiling Batt).3. Calculated using rational engineering means with a safety reduction factor of Φb = 0.8 for plasterboard bending, and Φc = 0.65 for fi xing point connections.4. Calculations do not include the framing which must be independently designed to suit the desired wind zone.

42

K-INSTALL

INSTALLATION CEILINGSNON-FIRE RATED 1 LAYER 1/3 Fastener and Adhesive Method






10 - 50mm

200mm max staggered


Adhesive daubs200mm min - 230mm max from screw points

Knauf MastaGrip Adhesive daubs 25mm diameter, 15mm high

Additional perimeter framing and screws

required for garage ceilings





600mm F F F F900mm F A F A F1200mm F A F A F A F1350mm F A F A F A F

F = One nail or screwA = One adhesive daub



600mm 450mm 300mm





43

QUALITY INDUCTION

INSTALLATION CEILINGSNON-FIRE RATED 1 LAYER Fastener Only Method

Stagger butt joints by 600mm min on adjoining sheets




Butt Joints - Level 3, Openingsand Control JointsButt joints may be made on framing members for Level 3 Finish

10 - 50mm

Screws: 200mm max staggeredNails: 150mm max staggered


FieldRefer to Fixing Pattern Table

Additional perimeter framing and screws

required for garage ceilings




Sheet Width Screw Fixing Pattern Nail Fixing Pattern Double Nail Fixing Pattern

600mm S S S (3) N N N N N (5) N Dn N (3)900mm S S S S (4) N N N N N N (6) N Dn Dn N (4)1200mm S S S S S (5) N N N N N N N (7) N Dn Dn Dn N (5)1350mm S S S S S S (6) N N N N N N N N (8) N Dn Dn Dn Dn N (6)

S = One screwN = One nailDn = Double nail



600mm 450mm 300mm





44

K-INSTALL

For steel ≤ 0.75mm BMT minimum 6g fine thread needle point screws. For steel ≥ 0.75mm BMT minimum 6g fine thread drill point screws. *38mm – 10g Laminating screws may be used as detailed in installation diagrams.

Plasterboard Thickness 1st Layer 2nd Layer 3rd Layer

6.5mm30mm x 2.8 galvanised nail

or 25mm x 2.8 ring shank nail or 25mm screw

40mm x 2.8 galvanised nail or 30mm x 2.8 ring shank nail

or 30mm screw–

10mm40mm x 2.8 galvanised nail or 30mm x 2.8 ring shank nail

or 30mm screw

50mm x 2.8 galvanised nail or 40mm screw*

–

13mm40mm x 2.8 galvanised nail or 30mm x 2.8 ring shank nail

or 30mm screw



16mm 50mm x 2.8 galvanised nail or 45mm screw



Plasterboard Thickness 1st Layer 2nd Layer 3rd Layer

6.5mm 25mm screw 25mm screw –

10mm 25mm screw 40mm screw* –

13mm 25mm screw 40mm screw* 60mm screw*

16mm 30mm screw 45mm screw* 65mm screw*

SCREW TYPE AND MINIMUM SIZE FOR THE INSTALLATION OF: PLASTERBOARD TO STEEL

SCREW TYPE AND MINIMUM SIZE FOR THE INSTALLATION OF: PLASTERBOARD TO SOFTWOOD TIMBER

45

QUALITY INDUCTION

Install control joints in plasterboard ceilings at:

12m maximum intervals

All control joints in the structure

Any change in the substrate material

At the junction of a large room and passageway

CEILINGSGENERAL REQUIREMENTS

Garage ceilings are subject to conditions that are more demanding than in other parts of the home. This is the case even when garages are located under the same roof as the rest of the home. Garages have large doors that when open let in rain and strong wind. Cars are garaged wet and they are not normally heated spaces. These factors call for a more durable installation to avoid future maintenance issues.

GARAGE CEILINGSGENERAL REQUIREMENTS

MINIMUM CONDITIONS TO USE PLASTERBOARD IN GARAGE CEILINGS

The plasterboard framing must be designed for the appropriate wind loading conditions.

The cavity above the plasterboard ceiling must have cross ventilation.

46

K-INSTALLK-INSTALL

INSTALLATION REQUIREMENTS FOR GARAGE CEILINGS

Fix the ceiling sheets using the 'Screw Only Method' or the 'One Third Fixing Method'

Provide additional framing around perimeter by inserting trimmers between ceiling frames or installing steel angle

Fix the perimeter of the sheets using screws at 300mm maximum spacing

Avoid windy conditions during and immediately after installation to ensure adhesive sets intact

Back-block all plasterboard joints

Roll or brush on a high quality sealer undercoat designed for exterior use

Use a premium exterior paint system that includes a mould inhibitor

47

QUALITY INDUCTION






10 - 50mm

200mm max staggered

10 - 50mmSheet EndsCornice: fix at 300mm max.Square Set: fix at 150mm max.

Adhesive daubs200mm min - 230mm max from screw points

Knauf MastaGrip Adhesive daubs 25mm diameter, 15mm high



Additional perimeter framing and screws mid-way between ceiling frame members



600mm F F F F900mm F A F A F1200mm F A F A F A F1350mm F A F A F A F

F = One nail or screwA = One adhesive daub



600mm 450mm 300mm





INSTALLATION GARAGE CEILINGSNON-FIRE RATED 1 LAYER 1/3 Fastener and Adhesive Method

48

K-INSTALL

EXTERNAL CEILINGSGENERAL REQUIREMENTS

External ceilings include alfresco areas, carports, balconies and breezeways with plasterboard installed horizontally or sloping away from the main dwelling.

External ceilings are subjected to harsher conditions than internal ceilings, and therefore they need additional protection from the weather. This extra protection is designed to control the major causes of external ceiling faults.

MINIMUM CONDITIONS TO USE PLASTERBOARD IN EXTERNAL CEILINGS

The plasterboard must be designed for the appropriate loading conditions.

Cross ventilation above the cavity.

Condensation on the back and front of the lining must be controlled.

The plasterboard & compounds must not be subjected to direct water, high humidity, sea spray or dampness

The plasterboard and compounds must be installed after the roof covering has been installed and sealed.

Minimum 100mm clearance from external ceiling lining to lower edge of verandah beam or masonry lintel, otherwise provide protection against wind blown rain.

49

QUALITY INDUCTION

Stagger butt joints by 600mm min on adjoining sheets

Additional perimeter framing and screws mid-way between ceiling frame members


Recessed EdgesFix on each framing member and back-block


10 - 50mm

10 - 50mmSheet EndsCornice: refer to Maximum Screw Spacing Table.Square Set: refer to Maximum Screw Spacing Table, up to 150mm max.

FieldRefer to Maximum Screw Spacing Table

MAXIMUM SCREW SPACING TABLE FOR EXTERNAL CEILINGS (mm)

Plasterboard Type Wind ZoneMaximum External Ceiling Frame Spacing

450mm 300mm

10mm SpanShield13mm MastaShield13mm WaterShield

N1 300 300N2 250 300

N3 / C1 150 250N4 / C2 100 150N5 / C3 - 100

10mm Opal

N1 300 300N2 300 300

N3 / C1 200 300N4 / C2 150 250N5 / C3 - 150


INSTALLATION EXTERNAL CEILINGSNON-FIRE RATED 1 LAYER Screw Only Method

50

K-INSTALL

Use either 10mm SpanShield, 13mm MastaShield, 10mm OPAL, 13mm SoundShield, 13mm or 16mm FireShield

For improved water resistance, use either 10mm or 13mm WaterShield, 13mm or 16mm MultiShield, or 13mm TruRock

Ceiling framing at maximum 450mm framing centres

Provide additional framing around the perimeter by inserting trimmers between ceiling frames or installing steel angle, or installing additional ceiling battens

Fix the ceiling sheets using the 'Screw Only Method'. Nails are not permitted in this application. Additional screws may be required for high wind areas

INSTALLATION REQUIREMENTS FOR EXTERNAL CEILINGS

Fix the perimeter of the plasterboard sheets using screws at 300mm maximum spacing

Install control joints at 6m maximum intervals

Back-block all plasterboard joints

Plaster set joints using two coats of MastaBase or MastaLongset and any Knauf finish coat

Roll or brush on a high quality sealer undercoat designed for exterior use

Use a premium exterior paint system that includes a mould inhibitor

Please note that plasterboard must not be installed in eaves or as exterior cladding.

51

QUALITY INDUCTION

WET AREASWET AREA REQUIREMENTSDifferent wet areas require different levels of treatment to protect them from moisture.

Area Level of Risk Walls Junctions Penetrations*

Shower area HighWater

ResistantWaterproof Waterproof

Bathrooms Medium – Waterproof^ –

Areas adjacent to baths and spas

MediumWater

ResistantWaterproof Waterproof*

Walls adjoining other vessels

LowWater

ResistantWaterproof Waterproof*

Laundries and WCs Low – Waterproof^ –

Bathrooms and laundries requiring a floor waste

High – Waterproof^ Waterproof

+ Including mechanical fixings or fasteners. ^ Applies to wall/floor junctions only. * Horizontal surface waterproof, vertical surface water resistant.

Wet area installation requirements

Plasterboard Fixing

Use the ‘Fastener Only Method’ in tiled areas. Masonry or stud adhesives are not permitted.

Drive fasteners to just below the sheet surface, taking care not to break the paper linerboard.

Laminating screws can be used to fix butt joints in the second and third layer.

Tiles weighing up to 22 kg/m² (porcelain 9mm thick) may be installed when fasteners are spaced at 200mm maximum centres.

Tiles weighing from 22 to 32 kg/m² may be installed when fasteners are spaced at 200mm maximum centres on studs at 450mm centres, or fasteners spaced at 100mm centres on studs at 600mm maximum centres.

Also ensure that a hole saw is used to create penetrations – do not make a hole by hitting the board with a hammer, as the back of the board will break and lose its integrity

52

K-INSTALL

Water Resistant Walls

Use WaterShield covered with a waterproof membrane and tiles.

For all plasterboard joints, corners and fastener heads use MastaBase or MastaLongset.

[Refer to waterproof membrane manufacturer for application instructions]

Walls Adjoining Other Vessels

Ensure walls within 75mm of a vessel such as a sink, basin or laundry tub are water resistant to a height of 150mm minimum above the vessel.

Seal all edges where the vessel is fixed to the wall.

Waterproof Penetrations

Use a waterproof sealant or a proprietary flange system to waterproof penetrations.

Waterproof Vertical Junctions (where required)

Use a waterproof membrane as vertical flashing that has a minimum overlap of 40mm to the wall sheeting for each leg.

Wall/Floor Junctions in Shower Areas and Adjacent to Baths and Spas

Use a waterproof membrane on walls to: 150mm minimum above the finished shower floor level or lip of bath And 25mm minimum above the maximum retained water level And with the horizontal leg width a minimum of 50mm.

Wall/Floor Junctions Outside Shower Areas

Use a waterproof membrane or Knauf metal angle as flashing with a vertical leg a minimum of 25mm above the finished floor level with the horizontal leg width a minimum of 50mm.

Waterproofing Requirements by Area

53

QUALITY INDUCTION

WET AREASPLASTERBOARD FIXING

10 - 50mm

Sheet EdgesFix screws 10-50mm from sheet edges

SealantIf required, use sealant to maintain acoustic integrity

Recessed Edges Fix on each stud

Corners Refer to Maximum Screw Spacing Table

CornersRefer to

Maximum Screw Spacing Table

WaterShield in Tiled Areas - 1 Layer Horizontal Fastener Only Method

Openings Refer to Maximum Screw Spacing Table

200mm min

Butt JointsStagger by 300mm min on adjoining

sheets and on opposite sides of the wall. Butt joints may be made on studs.

Fix on each stud 10 - 50mm

10 - 50mm

Refer to Maximum Screw Spacing Table

Butt JointsRefer to Maximum

Screw Spacing Table.

For the installation of Watershield in untiled areas,

refer to the internal non-fire rated wall installation figures.

MAXIMUM SCREW SPACING TABLE FOR WET AREAS WALLS (mm)

Tile WeightInternal Wall Stud Spacing

600mm 450mm

Up to 22 kg/m2

(9mm porcelain) 200 200

22 to 32 kg/m2

(13mm porcelain) 100 200

Plumbing Penetrations Plan

Knauf WaterShield

Knauf Wet Area Sealant

Tiles and tile adhesive

10mm maxFlexible Wet Area Sealant

Isolate copper and brass fitting from steel framing

Plumbing Penetrations

54

K-INSTALL

Mortar bed

Additional nogging to support shower base

Waterproof membrane

Shower BaseInternal in-situ shower tray over particleboard flooring Class 2 membrane shown - Section

CONSTRUCTION DETAILSShower Wall Base in Wet Areas


Bond breaker


Optional nogging to support shower base

Tiles and tile adhesive (compatible with waterproof membrane)

Flexible wet area sealant compatible with tiles

Knauf WaterShield

Knauf WaterShield

Waterproof membrane

Mortar bed


Optional nogging to support shower base

Tiles and tile adhesive (compatible with waterproof membrane)


Knauf WaterShield

Waterproof membrane

Mortar bed

Shower BaseInternal in-situ shower tray with slab drop down Class 3 membrane shown - Section

Shower Base Pre-formed shower tray - Section

6mm gap and flexible wet area sealant

Shower Corner Plan

Optional vertical reinforcing angle in shower area

5-10mmclearance to plasterboard

Fix 10 - 50mm from sheet bottom

5-10mmclearance toplasterboard


5-10mmclearance to plasterboard

Fix 50mm max from

sheet bottom



Refer to proprietry waterproof membrane manufacturer for

specific application instructions.

55

QUALITY INDUCTION

Back-blocking is a method for reinforcing plasterboard joints to minimise joint cracking and peaking

Knauf recommends that all ceiling joints are back-blocked

Back-blocked joints use strips of plasterboard adhered to the back of the joint between the framing members

Back-blocking adhesive must be set before commencing jointing

Back-blocks must be minimum 200mm wide for recessed joints, and minimum 400mm wide for butt joints

WET AREASPLASTERBOARD FIXING

BACK-BLOCKING

Knauf WaterShield

Flexible Wet Area Sealant

Plumbing Penetration Mixer Tap - Section

Metal mixer tap


10mm max

Isolate copper and brass fitting from steel framing

Plumbing Penetrations

56

K-INSTALL

Placement of Back-Blocking Batten and Back-Blocking Strips for Recessed and Butt Joints

Creating a recess at butt joints using back-blocking battens - Elevation

200mm min

100mm min

400mm min wide

300mm max

Furring channel

Plasterboard ceiling

Tapered edge back-blocking strip

Back-blocking batten (KNAUF BBB)

Butt joint back-blocking strip

Gap 30mm max

Back-blocking batten (KNAUF BBB)

Screws

Knauf plasterboard

Butt joint with back-blocking batten

Compound

57

QUALITY INDUCTION

The Three Coat Jointing System consists of:

Bedding Coat with Tape,

Second Coat,

Finish Coat

Level 4 Finish and Level 5 Finish must use the Three Coat Jointing System for all joints and external corners. Internal corners only require a Bedding Coat and a Finish Coat.

JOINTING

250mm

170mm

*

500mm

340mm240mm

Bedding Coat Bedding Coat

Second Coat Second Coat

Finish Coat Finish Coat

* Fill recess completelyRecessed Joint and back-blocked Butt Joints

Minimum Coat Widths

Butt Joint made over a framing member

250mm

170mm

*

500mm

340mm240mm

Bedding Coat Bedding Coat

Second Coat Second Coat

Finish Coat Finish Coat

* Fill recess completelyRecessed Joint and back-blocked Butt Joints

Minimum Coat Widths

Butt Joint made over a framing member

Paper Tape is strongly recommended for all joints

Joints made using paper tape are stronger and less prone to defect than those made with fibreglass tape. For the strongest joint, paper tape is recommended with two coats of MastaBase or MastaLongset and a final coat of MastaFinish, MastaGlide, MastaLite or MastaLine.

If fibreglass tape is used, all joints must be back-blocked. Fibreglass tape is not permitted for use in wet areas or fire rated systems

58

K-INSTALL

MastaBase

MastaFinish

MastaLite

MastaGlide

MastaLine MastaBlock MastaGrip

MastaCove75MastaCove45

MastaLongset MastaTape Universal

BEDDING

FINISHING

ALL PURPOSE

CORNICE CEMENT

SPECIALTY

COMPOUNDS

BASEBEDDING CEMENT HIGH JOINT STRENGTH EASY TO SCRAPE BACK QUICK DRYING

20kg

LONGSETBEDDING CEMENT FREE FLOWING SMOOTH EDGES EASY TO RETROWEL

20kg

FINISHFINISHING COMPOUND SUPERIOR FINISH EASY TO TROWEL EASY TO SAND

20kg

GLIDEFINISHING COMPOUND SMOOTH TROWELLING GREAT SANDING LOW SHRINKAGE

20kg

COVE45CORNICE CEMENT MIXES EASILY TO A CREAMY GAUGE EXCELLENT WORKBACK GOES OFF EVENLY

20kg

COVE75CORNICE CEMENT MIXES EASILY TO A CREAMY GAUGE STABILISED SET EXTENDED WORKING TIME

20kg

LITEJOINTING COMPOUND GOOD BODY IDEAL FOR ELECTRIC SANDING FREE FLOWING

17kg

BLOCKBACK-BLOCKING CEMENT STRENGTHENS JOINTS MINIMISES JOINT CRACKING LONG SETTING TIME

20kg

GRIPSTUD ADHESIVE STICKS TO TREATED TIMBERS COMPLIES WITH AUSTRALIAN STANDARD AS 2753-1985 FAST TACK

5.2kg

GRIP

1.25kg

STUD ADHESIVE STICKS TO TREATED TIMBERS COMPLIES WITH AUSTRALIAN STANDARD AS 2753-1985 FAST TACK

59

QUALITY INDUCTION

Internal ceilings

Either fastener and adhesive method (centre fixed or conventional fixing) or one third fixing method

Adhesive daubs minimum 200mm and maximum 230mm from fastener points and plasterboard edges

Control joints installed at maximum 12m intervals

Ceilings are non-trafficable

Garage ceilings

One third fixing method or screw only method

Additional framing required around perimeter, screwed off at 300mm centres

Backblock all plasterboard joints

External ceilings

Maximum 450mm framing centres

Use Screw Only method

Perimeter to be fixed at maximum 300mm centres subject to wind loads

To avoid costly maintenance work down the track, ensure the frame is ready before proceeding with plastering

Use correct adhesive and fastener spacings

Use a hole saw to create penetrations

Do not use citric acid to assist in the setting of the compounds

Glue as you go – do not glue a whole room or house before hanging board, as the glue will develop a skin and not work as it should, especially in summer

RECAP

60

K-INSTALL

61

QUALITY INDUCTION

K-INSTALL QUALITY INDUCTION

QUESTIONNAIREThis questionnaire is designed to check your understanding of the material presented. Please circle the most appropriate answer.

1. How far should adhesive daubs be from fasteners and plasterboard edges? a. 25mm b. Minimum 200mm, maximum 230mm c. Minimum 400mm, maximum 450mm

2. Control joints should be installed in internal ceilings at intervals no greater than…

a. 6 metres b. 12 metres c. 18 metres d. 24 metres

3. Garage ceilings are to be fixed using which fixing method? a. One third fixing method b. Screw only fixing method c. Conventional fixing method d. A or B

4. External ceilings are to be fixed using what fixing method? a. One third fixing method b. Screw only fixing method c. Conventional fixing method

5. Adhesive is allowed to be used in tiled areas. a. True b. False

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K-INSTALL

6. Back-blocks on recessed ceiling joints need to be a minimum width of... a. 100mm b. 200mm c. 400mm d. It doesn't matter

7. Citric acid should be used to set compounds a. True b. False

8. To achieve a Level 4 finish, the correct jointing system for all joints and external corners is…

a. Bedding coat and finish coat b. Three coat jointing system

9. Joints made using fibreglass tape are stronger and more durable than those made with paper tape.

a. True b. False

10. Fibreglass tape is able to be used in wet areas. a. True b. False

I acknowledge that I have received this quality induction training, and I agree to comply with the quality rules when I am working on a K-Install site.

Name: ................................... Signature: ...................................

Subcontractor organisation: ………………………………………………

Date: ………………………………

Inducted by:

63

QUALITY INDUCTION

K-INSTALL

QUALITY CHECKLISTSubcontractor Date

Builder

Job Address

Item Y/N/NA Comment

Ceilings

Fastener points correctly positioned

Adhesive daubs correctly positioned and adequate amount used

Adhesive is applied as the trades are going, not whole room or house before starting

Back-blocks are correct dimensions and have sufficient adhesive

Ceiling access point cut out

Walls

Fastener points correctly positioned

Adhesive daubs correctly positioned and adequate amount used

Wall sheets have temporary fasteners as required

64

K-INSTALL

Wet Areas

WaterShield installed to appropriate walls

Correct fixing spacings to tiled/mirrored areas

Electrical wires pulled through in wet areas

Garage

Ceiling fixed using one third fixing method or screw only method

Insulated wall(s) between house and garage are fully mechanically fixed

Fixings in perimeter noggings at maximum 300mm centres

Alfresco/porch/outdoor area

Ceiling framed at maximum 450mm centres

Ceiling fixed using the screw only method

Joints

Joints not hollow or peaked

Cornice joints in correct position and mitred

3 coat jointing system used and joint width of correct dimension

Identified Issues

Issue to be fixed What needs to be done When by?

65

QUALITY RESOURCES

PLASTER READY


Builder Start Date

Job Address


Site Requirements

A clear place for the truck to park as close to the house as possibleA clear path for the plasterboard to be carried to the houseTemporary fencing is in placePower and water are availableToilet is on site and cleanA bin or cage are on site and there is room in them to place plaster offcutsThe house has been swept out and is clear of rubbish and other trip hazardsDouble storey - stair void protection is in place, and ladder available and secured top and bottomSafety railing and/or scaffold is in place for upstairs balconiesWindows and doors have been installed

Frame Ready

House is water-tightRoof complete and water-tight - box gutters, flashings, etc. have been installedRoof safety rails have been removedSuitable wall wrap has been installedChange of direction noggings have been installed in all baysPerimeter noggings installed in garageBattens to external ceilings have been installedElectrical wiring has been installedPlumbing has been installedAir conditioning unit is in placeCross-bracing, electrical wiring, water pipes etc. are not protruding past stud workWall insulation has been installed, not excessive

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Ceiling insulation has been installed (not greater than cavity width)Openings, recesses and bulkheads are correctly framedCavity sliding doors have been installedAny obvious wall frame issues identifiedAny obvious truss issues identifiedCeiling access point identified and framedSkylights framedControl joints framed correctlySingle storey – garage and alfresco ready with houseDouble storey – balcony ready with houseAssessment - Can plaster installation commence?

Identified Issues

Issue to be fixed What needs to be done When by?

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STANDARD

SPECIFICATIONS

Walls 10mm MastaShield

Ceilings 10mm MastaShield on 16mm domestic battens @ 450mm centres, OR 10mm SpanShield direct fixed to trusses @ 600mm centres

Cornice 75mm ClassicLook

Wet Areas

Full height 10mm WaterShield to all walls of Wet Areas containing a shower or bath Half height 10mm WaterShield behind all tiled plumbing fixtures Tanking/waterproofing to be done by others

Garage Same requirements for walls, ceilings and cornice as above Screw only OR One-third fixing method

Alfresco 10mm SpanShield to framing @ 450mm centres Screw only fixing method Timber quad to be used around perimeter

Porch 10mm SpanShield to framing @ 450mm centres Screw only fixing method Timber quad to be used around perimeter

Lining under stairs 10mm MastaShield to walls Return trip required to install plasterboard under stairs

Plaster Waste Removal Included as standard

Insulation No allowance

Scaffold No allowance - to be provided by builder

General

Plasterboard bulk-loaded to 6m sheets in single storey and ground floor of double storey homes

Double-storey homes to have the largest practical sheets up to a maximum of 4.8m delivered upstairs No vertical joints within 200mm of edges of an opening Back blocking to all butt joints and where there are three or more recessed joints in a room

Mitred joints for cornice are recommended

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K-INSTALL SUBCONTRACTOR

ANNUAL REVIEWSubcontractor Review Date

Review By


Safety Performance

Did the subcontractor have any injuries or incidents during the period under review?If yes, did they follow the correct procedures such as reporting, investigating etc.?Did the subcontractor consistently perform well on safety checklist results?Does the subcontractor have adequate housekeeping standards?Do the subcontractor’s workers have a good attitude towards safety?Did the subcontractor’s workers consistently exhibit good safety behaviours on site (e.g. wearing appropriate PPE, ensuring work area tidy)?Do the subcontractor’s workers understand and comply with the K-Install safety requirements?Overall, did the safety performance of the subcontractor meet expectation?

Quality Performance

Did the subcontractor have any major quality non-conformances during the period under review?Did the subcontractor consistently perform well on quality checklist results?Do the subcontractor’s workers have a good attitude towards quality requirements?Do the subcontractor’s workers understand and comply with the K-Install quality requirements?Overall, did the quality performance of the subcontractor meet expectation?

General Performance

Were projects started and finished on time?Was the subcontractor easy to deal with?Was the subcontractor responsive to requests?Overall, should the subcontractor maintain Knauf accreditation?Comments:

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QUALITY RESOURCES

Call 1300 724 505 or visit knaufplasterboard.com.au/opal

OPALWITH TECHNOLOGY

Create beautiful, long lasting, quiet living spacesOPAL high performing plasterboard is the perfect solution for beautifully designed residential spaces where the quality of indoor life is important.

The high density gypsum core delivers both superior sound insulation and impact performance.

Create a home for life and living

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STANDARD PROCEDURES FOR THE INSTALLATION OF PLASTERBOARD IN DOMESTIC DWELLINGS

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

Victorian Building Authority's (VBA)Guide to Standards and Tolerances 2015

Knauf Plasterboard Installation Guide for Residential Buildings

Move it - the GBMA Way. A Guide to Safe Site Delivery of Plasterboard and Associated Products

Our standard level of finish is Level 4 as detailed in AS/NZS 2589:2017. To achieve a finish other than Level 4, this would need to be specified.

From the standard;

“Flat or low sheen paints shall be used for this Level 4.

All joints and interior angles shall have tape embedded in jointing cement/jointing compound and a minimum of two separate coats of jointing cement/jointing compound applied over all joints, angles, fastener heads and accessories. All jointing cement/jointing compound shall be finished evenly and be free of tool marks and ridges in preparation for decoration.

Notes:

1. In critical lighting conditions, surface imperfections may still be apparent in a Level 4 surface finish.

2. Where gloss, semi-gloss and deep tone paints are used, surface imperfections will be more evident.”

REFERENCES LEVEL OF FINISH

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A further guide to Quality of Finish and Tolerances

Appendix E to AS/NZS2589:2017 provides a further guide for assessment of surface deviations and tolerances in evaluating whether or not joints, angles and fastener points in gypsum wall or ceiling linings have been finished to an acceptable standard. This covers recess edge joints, butt joints, external angles and internal corners. Some basic points:

1. For walls and ceilings measured over a 1.8m straight edge at any point, there is a tolerance of 4mm over 90% of the area, and 5mm over the remaining area.

2. A joint can be overbuilt by up to 2mm.

3. Joints are unacceptable if they show a distinct peak. The joint should be crowned.

4. An underbuilt or hollow joint is unacceptable.

5. When testing walls for adequate fixings, they should be pressed rather than banged. If there is movement between plasterboard and frame, additional screw fixings will be required.

6. Screw pops and mitre cracking up to 1mm are usually caused by frame movement and are not a plaster defect.

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STANDARD PROCEDURES

The number of days to allow for the various processes are summarised in the table below. The days referred to are normal working days, and therefore do not take into account weekends or public holidays.

Call ups need to be made by 4pm to meet the above timeframes. If after 4pm, an additional day would be required.

For larger houses, there may be a requirement to extend the timeframe depending on the extent of works involved, but this would be a discussion at the beginning of the project. As a general guide, an allowance of 1 day per 100m² of plasterboard is required to complete installation.

STANDARD TIMEFRAMES

Process Number of working days

Call up for delivery and installation 5

Installation of single storey house 6

Installation of double storey house 10

Call up for pre-paint 5

Pre-paint works 5

Call up for maintenance work 5

Maintenance works Depends on scale

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Call ups can be made by phone or email to the contractor, with email being preferred.

The delivery address and delivery date will be needed, and confirmation that the site is plasterboard ready (see next section for a description of what this means).

The installation start date would normally be the next working day after delivery, unless the job has been called up as a frame stage delivery.

Confirmation of the call up will be made by phone or email (or through your proprietary system if applicable).

HOW TO CALL UP A JOB FOR DELIVERY AND INSTALLATION

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STANDARD PROCEDURES

A plasterboard ready site is one that has clear and unobstructed access. This means;

Externally

All rubbish is removed to allow a clear place for the truck to park and a clear pathway for the plasterboard to be carried

The truck parking location needs to be as close to the house as possible to enable passing of the plasterboard straight to the building

Any trenches are covered with suitable ramps

The walkway is clear and is not blocked by other tradespeople or equipment

Internally

Hallways are clear of rubbish and obstacles

The storage floor area is clear of any rubbish and obstacles

As far as possible, there are no other tradespeople working in the hallways and storage room area

A PLASTERBOARD READY SITE

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It also means that plasterboard can be stored in a safe place where it is unlikely to be damaged. This typically means that;

The roof is installed

The building is water/weather proof

The floor area where the plasterboard is to be stored is clean, clear, dry and free of obstacles

Sites that are not plasterboard ready can increase the risk of injury and product damage.

If Risk Assessment performed by the delivery carrier indicates that the site is not 'plasterboard ready', the GBMA recommends that delivery of plasterboard not go ahead until a 'plasterboard ready' site can be confirmed.

Source: Move it the GBMA Way

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STANDARD PROCEDURES

Before sending trades to site to install plasterboard, the contractor's Plastering Co-ordinator will make sure the job is ready to start. The Plastering Co-ordinator will check to see whether services (electrical and plumbing) are installed, whether insulation has been installed, and whether there are any other obvious issues which could delay installation of the plasterboard.

It is important that when the project is called up, the frame will provide a suitable substrate for the plaster work.

The site should be handed over to the Plasterers in a clean and tidy state - it should be swept out, and clear of other building materials which could cause trip hazards and the like.

Some examples of issues that can delay the plastering process are:

No access to water and power on site

Change of direction noggings not installed

Perimeter noggings not installed

Bowed or twisted studs

Protruding noggings

Steel angle braces not set in flush with the surface of the framing

Services not installed (e.g. plumbing, electrical)

Pipes or wires not correctly set back into the cavity

Excess insulation forced into cavity

Alfresco and garage not ready at the same time as the house for a single storey (and alfresco ready at the same time as the house for a double storey)

PLASTER START

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There are some important safety considerations that need to be taken into account in the plastering process.

Stair void protection in a double storey house must remain in place throughout the plastering process

Kitchens and fix materials should not be delivered while plasterers are on site, as this creates a potential trip hazard

Where at all possible, other trades should not be on site at the same time as the plasterers. This sometimes has the potential of trades working above other trades, as well as their tools and materials being in the way of the other

If there is not enough room to stack plasterboard horizontally, it may be a requirement that the board is stacked vertically against the frame. This introduces a risk that the board could fall and cause injury, so the plasterboard must be correctly restrained.

SAFETY CONSIDERATIONS

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STANDARD PROCEDURES

On a single storey dwelling, the pre-paint is carried out after the house has been fixed out and the kitchen cupboards have been installed.

On a double storey dwelling, the pre-paint is carried out after the house has been fixed out, kitchen installed and under stairs framed out. If the garage and porch were not ready with the main part of the house on a double storey, these areas should also be ready to be done at the same time as the pre-paint.

A call up for pre-paint is similar to the original delivery and installation call up - telephone or email through your requested pre-paint date to the contractor, and provide the site address.

The standard lead time for a pre-paint call up is 5 working days, and the standard time allocated for pre-paint work is generally 5 working days (depending on the extent of work required). The pre-paint process works as follows;

Day 1 - the house will be inspected to identify any areas which require rectification works and will be marked up to show those areas. This is preferably done with the contractor's Plastering Co-ordinator and the Site Manager together so that there is agreement as to the extent of work required

Day 2 to 4 - all items marked up during the pre-paint inspection will be fixed

Day 5 - the plasterers will return to complete the work and sand off any patches

Where rectification work is required as a result of other trades damaging the initial work, or as a result of frame issues, and depending on the extent of the work, it may be necessary to treat the rectification as maintenance work.

Once pre-paint work has been finished, the Painter should apply the first coat of paint. If minor plaster defects are identified after the first coat of paint, the painter should rectify. If the plaster defects are excessive or identified as a major issue, the painter should contact the Site Manager before applying any further coats of paint. The Site Manager would then contact the Plastering Co-ordinator to arrange rectification.

PRE-PAINT (FINISH OFF)

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Maintenance work can be called up with 5 working days’ notice. The contractor will arrange to visit site and determine the extent of works required, and provide a timeframe and price to undertake the work.

The intention is that the rectification work is completed in one visit.

Where the Site Manager has reason to back-charge the contractor for damage caused or other identified reasons, the Site Manager should discuss the issue with the Plastering Co-ordinator and request the relevant reference number from the Plastering Co-ordinator. If the issue is not agreed, it should be escalated for resolution.

MAINTENANCE WORK

CREDITS/BACK CHARGES

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STANDARD PROCEDURES

Where warranty issues are identified, an appointment needs to be made with the contractor to attend site and undertake an investigation as to the root cause of the issue. The contractor will liaise with the necessary parties in terms of determining the best way to resolve the issue.

WARRANTY

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CONTENTS

SAFETY INDUCTIONPurpose of the Induction 14Items we will Cover 14General Expectations 15Site Risk Assessments 15Traffic Management 16Storage and Movement of Plasterboard 16Safe Work Method Statements 17Maintaining a Safe Work Area 17Tools & Equipment 18Electrical Safety 18Fall Protection 19Steps & Ladders 19Use of Stilts 20Material Safety Data Sheets 20Reporting of Incidents 21Recap 21K-Install Safety Induction Questionnaire 22

SAFETY RESOURCESK-Install Safety Checklist 24Site Risk Assessment 26Stilts Risk Assessment 28Risk Assessment Matrix 33

K-INSTALLAbout Knauf 4K-Install – Supply & Install Solution for Residential Dwellings 5K-Install Safety 6Other Safety Requirements 7The Minimum Site Safety Standards 8Responsibilities of the Contractor and Subcontractor 9K-Install Quality 10Other Quality Requirements 11Standard Procedures 12

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K-INSTALL FINAL INSPECTION

CERTIFICATE

Builder

Builder Site Manager

Job Address

Date Marked Up

Pre-paint Completed By

Date Checked

Date Handed Over

Comments

STANDARD PROCEDURES

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K-INSTA

LL

Supply & Install Solution for Residential Dwellings

Supply & Install Solution for Residential D

wellings

Knauf Plasterboard Pty Ltd ABN 61 003 621 010 31 Military Road Matraville NSW 2036

Customer Service 1300 724 505 knaufplasterboard.com.au

Knauf Metal ABN 61 003 621 010 Cnr Quindus St & Spanns Rd Beenleigh QLD 4207

Customer Service 1300 725 675 knaufmetal.com.au

Version 2 February 2019

Documents

K-INSTALL - Knauf Australia · A JSA/SWMS should be completed for each task on site, and these must be available All workers must be trained in the relevant JSA/SWMS orkers must be