Aquapanel tile backing systems - ESI.info · Performance tested to new European EN standards Interfaces seamlessly with other Knauf Drywall systems Full system approach Portland cement

Tile Backing Systems July 2005CI/SfB 41 (22.3) Rr2

AquapanelThe tile backing system for wet and humid areas

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Knauf is Europe’s leadingmanufacturer and supplierof cement building board.

And with two majormanufacturing sites in the UK,Knauf Drywall is one of thecountry’s leading suppliers ofgypsum based materials.

Knauf is a family ownedcompany with approximately18,000 employees worldwide.

Founded originally in Germanyin 1932, Knauf entered the UKmarket in 1988 and wasrebranded Knauf Drywall in 2003.

Introduction to Knauf Aquapanel Systems 3

Aquapanel Partitions 6

Aquapanel Linings 16

Special Applications 24

Aquapanel Data 25

Case Studies 27

Knauf Drywall - delivering solutions to meet customer needs Contents

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Aquapanel cement board

Customer Service 0800 521050 Technical Service 01795 416259 E-mail [email protected] Website www.knaufdrywall.co.uk

Aquapanel cement boardtechnology is alreadyrevolutionising the waybuildings are designed andconstructed across Europe.

Developed by Knauf USGSystems, Aquapanel cementboard gives architects andcontractors a proven alternativeto brick and block constructionin interior applications – where it offers significant performanceadvantages in wet and highhumidity areas together withlower installation costs.

Aquapanel cement board is an extremely durable buildingmaterial providing a solidsubstrate for wet indoor areassuch as bathrooms, showersurrounds, kitchens, swimmingpools and laundries.

Aquapanel delivers significantbenefits in sound insulation and fire safety, as well as long-lasting protection in highly humid and wetconditions.

Knauf Aquapanel systemsTile failure is extremely costly in all instances. If a tile fails in a wet area you would normallyexpect the substrate behind tobe damaged as well withtraditional materials. Not onlyare there replacement costs ofmaterials, but for manycommercial and leisureapplications tile failure maynecessitate closing part of the premises.

Knauf Aquapanel systemsprovide the peace of mind thatresults from specifying a partitionor lining that is specificallydesigned for the job. Galvanisedmetal components, special screwsand high quality Aquapanelcement board linings ensure thatAquapanel systems are easy toinstall and continue to perform,even when wet.

A single layer of Aquapanel(with studs at 600mm centres)can support up to 50kg/m2 oftiles. Performance figures of upto two hours for fire and 53dB Rw

for airborne sound can beachieved.

Knauf Aquapanel cement boardhas been developed solely as atile backing board and, as such,provides excellent adhesion fortiles. And if a tile should getdamaged, Knauf Aquapanelcement board will retain itsstrength – even if it is fullyimmersed in water.

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Benefits of Knauf Aquapanel systems

Knauf Aquapanel isexceptionally tough anddurable, providing a solidtile backing substrate forwet indoor areas such asswimming pools, leisurecentres, changing rooms,toilet areas, laundries,bathrooms and kitchens.

Productivity gainsKnauf Aquapanel systemsdeliver productivity gains byeliminating the time-consumingmethods usually associated withspecialised building methodsand materials.

With its unique score and snapfacility Aquapanel is easy to cut– making installation quick and

simple. The reliable EasyEdge(see page 26) design featureof Aquapanel in conjunctionwith polyurethane AquapanelJoint Adhesive improvesadhesion between boards,resulting in a stronger structure.

The Aquapanel surface is ready-keyed for tiling, so no sealant isrequired. More on-site timesavings result from the dryinstallation system.

Overall productivity gains are reflected in shorter jobschedules and lower in-placecosts. The Aquapanel systemmeans fewer call-backs and less maintenance.

Will not deteriorate in water

Supports up to 50kg/m2 of tiles

600mm stud centres, compared with 400mm formost other solutions

Resistant to mould and mildew

Excellent impact resistance

Simple score and snap cutting

Ready keyed for tiling

Non-combustible

Knauf is Europe’s leading supplier of cement board

The ideal tile backing system for wet and humid areas

Proven, complete systems from a single source

Fire and sound rated

Performance tested to new European EN standards

Interfaces seamlessly with other Knauf Drywall systems

Full system approach

Portland cement construction of Aquapanel boardscombined with Knauf metal studs will notdeteriorate over time

Exceptional toughness and ready-keyed surfaceminimises risk of tile failure

Tile failure will not result in further damage to theAquapanel system: reducing call-backs, maintenanceand whole-life costs

Whole life performance

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Aquapanel Partitions 6

Aquapanel Linings 16

Special Applications 24

Aquapanel Data 25

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This section identifies theareas that require carefulconsideration prior toinstallation. For furtherdetails, contact KnaufDrywall Technical Serviceson 01795 416259.

Sealing Wet AreasSealing tape and permanentlyflexible sealant should be usedat corners, at wall to floorconnections, and at interfaceswith baths and shower trays.Permanently flexible sealantshould also be used around cut-outs for pipes and otherpenetrations.

Perimeter FramingEnsure the background is suitableto support the channels andfixings.

Deflection Heads Where a deflection head detail is required to allow for movement, a Knauf Deep

Flange ‘U’ Channel should beinstalled at the ceiling in placeof a standard Knauf ‘U’Channel.

InsulationIf insulation is required, checkthe performance table on page 9to ensure the correct specificationis used.

Surface FixingsConsider the weight andleverage of any fixing prior toconstruction and add Knauf FlatFixing Plate or Knauf FixingChannel behind the boards asrequired.

DoorwaysThe weight of the door willdetermine the required jambconstruction.

Corners, Intersections andAbutmentsConsider the need for additionalstuds to accommodate corners,intersections and abutments.

Check the fire and sound ratingsof abutting systems. See also"Sealing Wet Areas" above.

Movement Control JointsMovement control joints aregenerally recommended atmaximum 7.5m intervals instraight Aquapanel Partitionruns. They should also beinstalled to coincide with anymovement joints in the structure.

Knauf Movement Control Jointsprovide up to 7mm of lateralmovement.

ServicesThe cavity within a partitionmay be used to concealservices. For larger pipes andservices, consider the use of atwin-frame plumbing wall (seepage 15).

Part TilingFor part-tiled applications, apply Knauf Aquapanel towithin 20mm of the line of tiles,then board the remainder of thepartition height with 12.5mmKnauf Sound Moistureshield,leaving a 3mm gap betweenthat is filled with tile adhesive.The tiles should overlap theKnauf Sound Moistureshield by at least 10mm.

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Aquapanel PartitionsKnauf AquapanelPartitions are purpose-designed for full or parttiled situations incommercial non-loadbearingapplications. They use fastdrywall constructiontechniques and can bespecified with confidenceeven in wet areas.

These systems utilise KnaufAquapanel cement board toreceive tiles, and moistureresistant Knauf SoundMoistureshield for any non-tiledelements of the partition.

The boards are fixed onto alightweight galvanised metalframework of Knauf Acoustic ‘C’ Studs and Knauf ‘U’ Channels.

Knauf Aquapanel should betiled using a quality polymermodified based flexible tileadhesive, following themanufacturer’s instructions.

Knauf Sound Moistureshield can be taped and jointed usingKnauf Jointing Compounds andAccessories, or a 2 to 5mmskim coat of Knauf FP90 orKnauf Universal Board Finishcan be applied to achieve amore traditional finish.

Fire and sound-rated partitions

600mm stud centres

Up to 50kg/m2 tiles

Full or part tile

Tile one or both sides

Design Considerations

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Knauf Aquapanel

Tile adhesive

Tiles

Cut-outs forService Runs

Knauf Acoustic ‘C’ Stud

Joints glued with Knauf Aquapanel Joint

Adhesive

Joints glued with Knauf Aquapanel Joint

Adhesive

Knauf Aquapanel

Knauf Sound Moistureshield

to non-tiled side

Tile adhesive

Tiles

Cut-outs forService Runs

Note that unlike KnaufAquapanel, Knauf SoundMoistureshield will be damagedif it is allowed to get wet (seeLimitations).

FinishingTiling (Aquapanel)Tiles with a maximum weight of50 kg/m2 can be applied toKnauf Aquapanel, with studs at600mm centres. Always use aquality polymer modified basedflexible tile adhesive, followingthe manufacturer’s instructions.

Taping and jointing (SoundMoistureshield)Ensure the outer facing is atapered edge plasterboard toaccommodate taping and

jointing. As soon as the jointshave dried, one coat of KnaufWallboard Primer should beapplied to the drylined surface.This will reduce moistureabsorption and the risk ofdiscolouration when decorating.

Skimming (Sound Moistureshield)The surface must be pre-treatedwith Knauf Betokontakt. Considerthe extra 2 to 5mm veneer coatof plaster to the overall partitionthickness.

LimitationsTemperatures over 50°C caninduce a change of state inKnauf Sound Moistureshieldwhich would reduce its physicalperformance and serviceability.

Constant humidity over 95% or continual subjection to water will also reduce theserviceability of Knauf SoundMoistureshield.

High levels of water absorptionwill not affect the long termperformance of Knauf Aquapanelbut to ensure the correctadhesion of tile adhesives andAquapanel Joint Adhesive theboards must be installed dry. Wet Aquapanel boards can beallowed to dry out and theninstalled once a moisture contentof less than 15% has beenreached (typically within 48hours in a dry environment) with no loss of performance.

Tiled both sides Tiled one side

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Knauf Acoustic ‘C’ StudLightweight steel sections usedto form the vertical frame of theKnauf Aquapanel Partitionsystem.

Knauf ‘U’ Channel25mm deep channel used to formhead and sole plates, and toframe openings.

Knauf Deep Flange ‘U’ ChannelAlternative deep channel used toform head plate for deflectionhead detail.

Knauf Fixing Channel or Flat PlateBoth the products can be used toprovide fixing for horizontal jointsin facings and as support forfixtures.

Knauf Movement Control JointGalvanised steel ‘V’ section usedto bridge gaps left for expansionand contraction.

Knauf Angle SectionsKnauf Angle Sections are used toretain mineral wool packing indeflection head details.

Knauf Aquapanel Maxi ScrewsSpecially developed screws forfixing Knauf Aquapanel cementboards. Climate-X corrosionprotection coating provides aguaranteed 1,500 hours corrosionresistance in salt-spray tests.

Knauf Aquapanel Joint AdhesivePU gun applied adhesive usedfor jointing individual KnaufAquapanel cement boards.Each tube contains enough forapproximately 6m2 of wall.

Knauf SealantUsed to seal gaps to preventairborne transmission of soundand vibration. Note: KnaufSealant is not a permanentlyflexible sealant.

Knauf Drywall ScrewsBlack phosphated drywall screw for fixing Knauf SoundMoistureshield to Knauf Acoustic‘C’ Studs.

Knauf Jointing CompoundsA range of air drying and fastsetting jointing compounds areavailable to achieve a seamlessfinish to Knauf SoundMoistureshield.

Knauf Finishing PlastersKnauf FP90 or Knauf UniversalBoard Finish can be used to skimKnauf Sound Moistureshield.

Aquapanel Partitions

Components Key Accessories


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Performance Information

Specification Guide 126E Aquapanel/Plasterboard Metal Stud Partition(s)

Boarding Boarding Insulation Stud Size O/A Width Fire Sound Weight* Max HeightSide 1 Side 2 (50mm) & Gauge (mm) (hours) (Rw dB) (kg/m2) (mm)

Aquapanel Aquapanel Crown Acoustic 50 (0.6) 75 - 44 32 2700

Aquapanel 12.5mm Sound Crown Acoustic 50 (0.6) 75 - 45 29 2700

Aquapanel Aquapanel Rocksilk RS33 70 (0.6) 95 0.5 44 32 3600

Aquapanel 12.5mm Sound Rocksilk RS33 70 (0.6) 95 0.5 45 29 3600

Aquapanel 12.5mm Sound Rocksilk RS33 70 (0.6) 107.5 1 48 41 3600Moisturesheild

(2 layers)

Drawing reference(s):.........

Product reference:Aquapanel Partition System, to be fully constructed with componentssupplied by Knauf Drywall.Strength category to BS 5234: Part 2.........

Performance criteria:Fire resistance of complete partition assembly to BS EN 1363-1:1999-10 Integrity/insulation (Minutes): .........Sound Insulation to BS 2750: Part 3:......... Rw dB (100-3150 Hz).

Framing:Stud configuration: Single Knauf ........mm (0.6mm gauge) Acoustic ‘C’ Studs at 600mm centres, .........mm Knauf ‘U’ Channel toform head and floor tracks.

(Utilising Knauf Deep Flange ‘U’ Channel as head track if deflectionallowance is specified) and Knauf Acoustic ‘C’ Studs at corners andabutments.

Head condition:......... Deflection allowance:.........

Linings:12.5mm Knauf Aquapanel to first side, ......... x 12.5mm Knauf......... to the other side.

Cavity insulation:Type:......... Thickness:......... Density:.........kg/m3

For Aquapanel:Fixings: 25mm Knauf Aquapanel Maxi Screws as clause 590

Board joints: Glued using Knauf Aquapanel Joint Adhesive as perKnauf Aquapanel literature recommendations.

Sealant: Knauf Sealant as clause 515

Finishing: ……….

For Sound Moistureshield (if specified):Fixings: Knauf Drywall screws as clause 590Sealant: Knauf Sealant as clause 515Primer/Sealer: Knauf Wallboard PrimerFinishing: …….. Primer/sealer:.........

Other Requirements:To be installed in accordance with Knauf Drywall’s recommendationsand technical literature.

Partition Roll Acoustic ‘C’

Acoustic ‘C’

Acoustic ‘C’

Acoustic ‘C’

Acoustic ‘C’

Partition RollMoistureshield

Moistureshield

* Weight does not include the weight of finishing materials, eg tiles.Note: Higher performance figures can be achieved using Knauf Aquapanel partitions. For details contact Knauf Drywall Technical Services on 01795 416259.

General Knauf Aquapanel Partitions mustbe installed in accordance withKnauf Drywall’s recommendationsand the relevant recommendationsof BS 8212: 1995 and BS 8000: Part 8: 1994.

Health & Safety Knauf Aquapanel, Knauf SoundMoistureshield and metal must becut to length and this should bedone in well ventilated areaspaying attention to the cut edgesof metal sections which may besharp. For further, updatedinformation refer to the KnaufDrywall Health and Safety sheetsand to HSE publications.

Perimeter FramingKnauf ‘U’ Channels should beused for the head and base ofthe partition. Knauf Acoustic ‘C’Studs should be used to form anyabutments and to frameopenings. Bed each section ontwo continuous beads of KnaufSealant and secure with KnaufNailable Plugs at maximum600mm centres and 50mm fromends of channels or studs.Separate studs and channelsforming the perimeter need notbe joined, but should be tightlybutted together. Replace Knauf‘U’ Channel with Knauf DeepFlange ‘U’ Channel whenforming a deflection head.

Partitions should always run upto the structural soffit. Where anexisting suspended ceiling cannotbe cut back to allow forpartitioning, bracing must beprovided for lateral support atthe partition head.

Vertical StudsStuds should be positioned withinthe channels to coincide with theabutments of the boards, whichwill be fixed later, at maximum

600mm centres. In general thereis no requirement to secure themetal at this point as this will beachieved once the boards arescrew-fixed.

Knauf Acoustic ‘C’ Studs shouldbe trimmed to within 5mm of theinternal channel. For deflectionheads only: studs should be cutshort to allow for requiredclearance within Knauf DeepFlange ‘U’ Channel, up to a maximum of 25mm.

Knauf Acoustic ‘C’ Studs can beextended by forming an overlap,boxing them at that point andsecuring them with Knauf WaferHead Jackpoint Screws. Theoverlap must be at least 600mm.

InsulationOnce the studs have beenlocated in the Knauf ‘U’Channels and one side has been boarded, the insulationquilt (see performance table onpage 9 for specification) shouldbe inserted between the studsvertically. Care should be takento ensure that the insulation isfitted neatly without gaps atabutments or vertically betweendifferent rolls.

DoorwaysThe head is formed with Knauf‘U’ Channel, snipped and bentback and screw fixed with KnaufWafer Head Jackpoint Screws tothe studs. For a lightweight doorweighing up to 25kg, KnaufAcoustic ‘C’ Studs are used for the frame openings insertedwith full height treated timbergrounds cut to the size of thestud. For doors weighing up to 50kg, fully ‘boxed’ KnaufAcoustic ‘C’ Studs are used forthe frame openings inserted withfull height treated timber grounds,cut to the size of the stud.

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Installation Procedure: Framework

Fixing Knauf ‘U’ Channel

Inserting Knauf Acoustic ‘C’ Studs


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Boarding (KnaufAquapanel)

The sequence used whenboarding with Knauf Aquapanelis very important, and different toplasterboard, so please read thissection carefully.

It is particularly important to notethat for a combination of strengthand moisture resistance, theAquapanel board joints areglued during the boardingprocess using Knauf AquapanelJoint Adhesive. The first board isfixed, then adhesive is applied tothe adjacent edge beforeoffering up and fixing the nextboard. This process is repeated.

1. Align the boardKnauf Aquapanel cement boardsare laid horizontally. Start at oneend and align the first boardalong the studs. Take care toensure the board is alignedcorrectly horizontally and verticallyusing a spirit level. Secure theboard with Knauf AquapanelMaxi Screws at maximum250mm centres, ensuring that thescrews are at least 15mm fromthe board edge. Do notoverdrive the screws.

2. Clean the adjacentboard edgesIn order to ensure the maximumadhesion is achieved whenjointing, the adjacent edges ofthe fixed board and the nextboard in the sequence must becleaned. Simply clean the edgeswith a wet brush to removetraces of dust – the edges do notneed to be soaked.

3. Apply Knauf AquapanelJoint AdhesiveUsing a suitable gun, apply abead of Knauf Aquapanel JointAdhesive in a continuous rope to

the adjacent edge(s) of the fixedboard(s). The bead should be ofsufficient size to fill the joint fullywhen the next board is offered up.

Important note: Knauf AquapanelJoint Adhesive must be appliedbefore the next board is fixed,not after.

4. Place the next boardAlign the next board and push itfirmly into the bed of adhesive.The gap between boards shouldbe less than 1mm. Secure theboard with Knauf AquapanelMaxi Screws at maximum250mm centres, ensuring that thescrews are at least 15mm fromthe board edge.

5. Continue the processContinue to clean the adjacentedges, apply Knauf AquapanelJoint Adhesive and place andsecure the next board as 2, 3,and 4 above until the wall iscompleted.

6. Leave the KnaufAquapanel Joint Adhesiveto dryIn order to achieve a strong bond,and to form a complete joint, theKnauf Aquapanel Joint Adhesiveneeds to be left to cure andexpand before the excess can bescraped off. Knauf AquapanelJoint Adhesive can be left forbetween 7 and 30 hours beforescraping off the excess.

7. Scrape off the excessadhesiveScrape off the excess KnaufAquapanel Joint Adhesive usinga flexible steel scraper.

Installation Procedure: Aquapanel

Fixing Knauf Aquapanel using Knauf Aquapanel Maxi Screws

Cleaning the edges with a wet brush

Applying Knauf Aquapanel Joint Adhesive

Scraping off the excess adhesive once dry

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Cutting Knauf AquapanelKnauf Aquapanel can be cut toshape using a sharp knife andstraight edge. Score one sidewith a knife, cutting through themesh. Snap the board along thescore, then cut through the meshon the other side.

Alternatively, use a hand heldcircular saw fitted with a carbideor diamond-tipped blade and adust extractor.

Curving Knauf AquapanelKnauf Aquapanel can be curvedto a radius of 3 metres.

Part TilingFor part-tiled applications, apply Knauf Aquapanel to within 20mm of the line of tiles,then board the remainder of thepartition height with 12.5mmKnauf Sound Moistureshield,leaving a 3mm gap between that is filled with tile adhesive.The tiles should overlap theKnauf Sound Moistureshield by at least 10mm.

Note that unlike Knauf Aquapanel,Knauf Sound Moistureshield willbe damaged if it is allowed toget wet (see Limitations).

Finishing Tiling (Aquapanel)Tiles with a maximum weight of 50 kg/m2 can be applied toKnauf Aquapanel, with studs at600mm centres. Always use aquality polymer modified basedflexible tile adhesive, followingthe manufacturer’s instructions.Tile on the smooth side of theboard.

Taping and jointing (SoundMoistureshield)To achieve a seamless finish ontapered edge boards, KnaufDrywall provides a complete

range of jointing compounds and reinforcing tapes that allowsselection by speed, ease ofapplication and workingcharacteristics. As soon as thejoints have dried, one coat ofKnauf Wallboard Primer shouldbe applied to the drylinedsurface. This will reduce moistureabsorption and the risk ofdiscolouration when decorating.

Skimming (Sound Moistureshield)A 2 to 5mm veneer coat of eitherKnauf FP90 or Knauf UniversalBoard Finish plaster is applied to the face of the plasterboards,after pre-treating with KnaufBetokontakt. The board jointsshould be reinforced with eitherpaper or fibre tape.

Boarding (Sound Moistureshield)All boards should be offered upto the frame with the face of theboard outwards and secured withKnauf Drywall Screws at 300mmcentres. Fixing centres should bereduced to 200mm at corners.

Boarding should commence atone end and work across thepartition. At head, foot andabutments, board edges shouldbe bedded on to continuousbeads of Knauf Sealant. Boardjoints in multiple layers should bestaggered both vertically andhorizontally by at least 600mm.

Sealing interfacesPermanently flexible sealantshould be used at corners, atwall to floor connections, and at interfaces with baths andshower trays, in combinationwith sealing tape in wet areas.Permanently flexible sealantshould also be used around cut-outs for pipes and otherpenetrations.

Installation Procedure (continued)

Scoring and snapping Aquapanel to size

Applying tiles to the completed partition


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Partition Application DetailsConnection to a masonry wallVertical cross-section

Corner formation and nib

Permanently flexible sealant

Permanently flexible sealant

Permanentlyflexible sealant

Permanentlyflexible sealant

KnaufAquapanelMaxi Screw

Knauf ‘U’ Channel


Knauf Aquapanel Maxi Screw


Knauf Aquapanel MaxiScrew

Knauf Aquapanel cement board

Knauf Aquapanel

cement board


Knauf Aquapanelcement board

Knauf insulation

Knauf insulation

Knauf insulation



Glued joint with Knauf Aquapanel Joint Adhesive (PU)

Floor

Head

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Partition Application Details (continued)

Bath connection

Wall-to-floor connection

Cut out for pipe

Details for wet areas

Ceramic tiles

Flexible polymer modified adhesive


Permanently flexible sealant,fungicidal joint kit

Ceramic tiles


Sealing tape inserted at surface




Ceramic tiles



Sealing tape

Sealing tape



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Partition Application Details (continued)

Vertical cross-section

Corner formation




Knauf insulation

Ceramic tiles

Knauf insulation

Glued joint with KnaufAquapanel Joint Adhesive




Knauf Fixing Channel atmaximum 1200mm centres,fixed to studs with KnaufWafer Head JackpointScrews


Knauf insulation

Permanentlyflexible sealant Knauf Aquapanel Maxi Screw

Plumbing Wall

Head

Floor

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Knauf Aquapanel Liningsare purpose-designed forfull or part-tiled situationsin commercial non-loadbearing applications.They use fast drywallconstruction techniquesand can be specified withconfidence even in wetareas. The lining can befixed to most masonrybackgrounds dependingon the condition.

This system utilises KnaufAquapanel cement board toreceive tiles, and moistureresistant Knauf SoundMoistureshield for any non-tiledelements of the lining. Theboards are fixed onto alightweight metal framework of

Knauf Apertura ‘C’ Channelsfixed to Knauf Apertura ‘U’Mounting Brackets and KnaufApertura ‘U’ Channels.

The system provides a variablestand-off from the background ofbetween 27 and 125mm. Thismakes it capable of overridingsubstantial irregularities in thebackground.

The lining void facilitates theintroduction of thermal oracoustic insulation and providescontainment for service runs.

The system can be applied tothe majority of all commonbuilding substrates. Pretreatmentof the background is notrequired. Under good buildingpractice, however, any

deleterious deposits, such asmould, oil or grease, should beremoved as a precaution.

Knauf Aquapanel should betiled using a quality polymermodified based flexible tileadhesive, following themanufacturer’s instructions.

Knauf Sound Moistureshield can

be taped and jointed using

Knauf Jointing Compounds and

Accessories, or a 2 to 5mm

skim coat of Knauf FP90 or

Knauf Universal Board Finish

can be applied to achieve a

more traditional finish.

Aquapanel Linings

Up to 50kg/m2 tiles

Full or part tile

Allows a variable stand-off clearance between lining and background of 27 to 125mm

Deep service runs can be accommodated within the lining void

Insulation is easily installed within the lining void

Design Considerations

This section identifies theareas that require carefulconsideration prior toinstallation. For furtherdetails, contact KnaufDrywall Technical Serviceson 01795 416259.

Sealing Wet AreasSealing tape and permanentlyflexible sealant should be usedat corners, at wall to floorconnections, and at interfaceswith baths and shower trays.Permanently flexible sealantshould also be used around cut-outs for pipes and otherpenetrations.

Perimeter FramingEnsure the background issuitable to support the channelsand fixings.

Surface FixingsConsider the weight andleverage of any fixing prior toconstruction and add Knauf FlatFixing Plate or Knauf FixingChannel behind the boards asrequired.

Corners, Intersections and AbutmentsConsider the need for additionalchannels to accommodatecorners, intersections andabutments. Check the fire and sound ratings of abuttingsystems. See also "Sealing Wet Areas" above.

Movement Control JointsMovement control joints aregenerally recommended atmaximum 7.5m intervals instraight Aquapanel Lining runs.

They should also be installed tocoincide with any movementjoints in the structure.

Knauf Movement Control Jointsprovide up to 7mm of lateralmovement.

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Knauf Apertura ‘C’ Channel

Tile adhesive

Tiles

Knauf Apertura ‘U’ Channel

Part TilingFor part-tiled applications, apply Knauf Aquapanel towithin 20mm of the line of tiles,then board the remainder of thelining height with 12.5mm KnaufSound Moistureshield, leaving a3mm gap between that is filledwith tile adhesive. The tilesshould overlap the Knauf SoundMoistureshield by at least 10mm.


FinishingTiling (Aquapanel)Tiles with a maximum weight of50 kg/m2 can be applied toKnauf Aquapanel, with verticalchannels at 600mm centres.Always use a quality polymermodified based flexible tileadhesive.

Taping and jointing (SoundMoistureshield)Ensure the outer facing is atapered edge plasterboard to accommodate taping andjointing. As soon as the jointshave dried, one coat of KnaufWallboard Primer should beapplied to the drylined surface.This will reduce moistureabsorption and the risk of discolouration when decorating.

Skimming (SoundMoistureshield)The surface must be pre-treatedwith Knauf Betokontakt. Considerthe extra 2 to 5mm veneer coatof plaster to the overall liningthickness.

LimitationsTemperatures over 50°C caninduce a change of state inKnauf Sound Moistureshieldwhich would reduce its physicalperformance and serviceability.

Constant humidity over 95% or continual subjection to water will also reduce theserviceability of Knauf SoundMoistureshield.

High levels of water absorptionwill not affect the long termperformance of KnaufAquapanel, but to ensure the correct adhesion of tileadhesives and Aquapanel JointAdhesive the boards must beinstalled dry. Wet Aquapanelboards can be allowed to dryout and then installed once a moisture content of less

than 15% has been reached(typically within 48 hours in a dry environment) with no loss of performance.

Knauf Apertura ‘U’ Mounting Bracket

Joints glued with KnaufAquapanel Joint Adhesive

Knauf Aquapanel

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Knauf Apertura ‘C’ ChannelWall lining channel used as themain component in the KnaufAquapanel Lining system.

Knauf Apertura ‘U’ ChannelForms the floor and head trackin the Knauf Aquapanel Liningsystem.

Knauf Apertura ‘U’ MountingBracketLocates Knauf Apertura ‘C’Channel to background support.

Knauf Apertura ‘C’ ChannelConnectorFor connecting straight lengthsof Knauf Apertura ‘C’ Channel.

Knauf Aquapanel Maxi ScrewsSpecially developed screws forfixing Knauf Aquapanel cementboards. Climate-X corrosionprotection coating provides aguaranteed 1,500 hours corrosionresistance in salt-spray tests.

Knauf Aquapanel Joint AdhesivePU gun applied adhesive usedfor jointing individual KnaufAquapanel cement boards.Each tube contains enough forapproximately 6m2 of wall.

Knauf SealantUsed to seal gaps to preventairborne transmission of soundand vibration. Note: KnaufSealant is not a permanentlyflexible sealant.

Knauf Drywall ScrewsBlack phosphated drywall screw for fixing Knauf SoundMoistureshield to Knauf Apertura‘C’ Channel.

Knauf Jointing CompoundsA range of air drying and fastsetting jointing compounds areavailable to achieve a seamlessfinish to Knauf Sound Moistureshield.

Knauf Finishing PlastersKnauf FP90 or Knauf UniversalBoard Finish can be used toskim Knauf Sound Moistureshield.

Aquapanel Linings

Components Key Accessories

Board Thickness No. of Channel Size Overall Lining Weight* Max Height(mm) Layers & Gauge (mm) Width (mm) (kg/m2) (mm)

12.5 1 60 (0.5) 40 - 138 16 3600


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Performance Information

*Weight does not include the weight of finishing materials, eg tiles.

Note: Higher linings can be achieved. For details contact Knauf Drywall Technical Services on 01795 416259.

Specification GuideDrawing reference(s):.........

Product reference: Knauf Aquapanel Wall Liner, to be fully constructedwith components supplied by Knauf Drywall.

Background:.........Stand off: (background to face of studs):.........

Framing:Knauf Apertura ‘C’ Channel Centres:……..mm

Knauf Apertura ‘U’ Mounting Bracket Centres: 900mm vertical centres(max). Include Knauf Apertura ‘C’ Channels (60 x 27mm),Knauf Apertura Universal Brackets (62 x 30mm), Knauf Apertura ‘U’Channel at floor/head (30 x 30mm), Knauf Apertura ‘C’ Channel

Connectors and Knauf Angle Sections as appropriate.

Linings:12.5mm Knauf Aquapanel.

Cavity insulation:Type:.........Thickness:.........Density: Not less than.........kg/m3

Fixings: Knauf Aquapanel Maxi Screws as clause 590.

Board joints: Glued using Knauf Aquapanel Joint Adhesive as per KnaufAquapanel literature recommendations.

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GeneralKnauf Aquapanel Linings mustbe installed in accordance withKnauf Drywall’s recommendationsand the relevant recommendationsof BS 8212: 1995 and BS 8000: Part 8: 1994.

Health & SafetyKnauf Aquapanel, Knauf SoundMoistureshield and metal mustbe cut to length and this shouldbe done in well ventilated areaspaying attention to the cutedges of metal sections whichmay be sharp. For further,updated information refer to theKnauf Drywall Health andSafety sheets and to HSEpublications.

PreparationMark guidelines on the floorand soffit to establish thepositions of floor and headtracks relative to the stand-offdistance required.

Mark vertical guidelines on thebackground to establish theKnauf Apertura ‘C’ Channelpositions at maximum 600mmcentres.

Depending on the requiredstorey height, mark the wall withthe location of intermediateKnauf Apertura ‘U’ MountingBrackets in line with the channelguidelines and at maximum1000mm vertical centres.

Position service runs and outlets.

PerimeterKnauf Apertura ‘U’ Channelsshould be used for the head andbase along the guidelines usingfixings appropriate for thebackground. Fix at nominal600mm centres.

Vertical Apertura ‘C’ChannelsFix the intermediate KnaufApertura ‘U’ Mounting Bracketsto the background, at themarked positions, using fixingsappropriate for the background.

Offer up the Apertura ‘C’Channels to engage with theKnauf Apertura ‘U’ MountingBrackets and with the floor andhead tracks. Extend the lengthof Knauf Apertura ‘C’ Channelswhere necessary by using KnaufApertura ‘C’ ChannelConnectors. Adjust the channelsfor position and alignment.

Secure the Knauf Apertura ‘C’Channels to the Knauf Apertura‘U’ Mounting Brackets usingKnauf Wafer Head JackpointScrews. Depending on thestand-off distance, bend backthe legs of the brackets so asnot to obstruct the fixing of the board.

Fix Knauf Angle Sections atexternal corners and reveals,where appropriate.

InsulationInstall insulation quilt whererequired, between and behindthe vertical Knauf Apertura ‘C’Channels for continuity and toprevent slumping.

Installation Procedure: Framework

Fixing Knauf Apertura ‘U’ Channel head track

Knauf Apertura ‘U’ Mounting Brackets fixed at marked positions

Fixing Knauf Apertura ‘C’ Channel to the bracket

Customer Service 0800 521 050 Technical Service E-mail [email protected] Technical Service 01795 416259 Website www.knaufdrywall.co.uk

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Boarding (KnaufAquapanel)The sequence used whenboarding with Knauf Aquapanelis very important, and differentto plasterboard, so please readthis section carefully.

It is particularly important tonote that for a combination ofstrength and moisture resistance,the Aquapanel board joints areglued during the boardingprocess using Knauf AquapanelJoint Adhesive. The first board isfixed, then adhesive is appliedto the adjacent edge beforeoffering up and fixing the nextboard. This process is repeated.

1. Align the boardKnauf Aquapanel cementboards are laid horizontally.Start at one end and align thefirst board along the studs. Takecare to ensure the board isaligned correctly horizontallyand vertically using a spiritlevel. Secure the board withKnauf Aquapanel Maxi Screwsat maximum 250mm centres,ensuring that the screws are atleast 15mm from the boardedge. Do not overdrive thescrews.

2. Clean the adjacentboard edgesIn order to ensure the maximumadhesion is achieved whenjointing, the adjacent edges ofthe fixed board and the nextboard in the sequence must becleaned. Simply clean the edgeswith a wet brush to removetraces of dust – the edges donot need to be soaked.

3. Apply Knauf AquapanelJoint AdhesiveUsing a suitable gun, apply abead of Knauf Aquapanel Joint

Adhesive in a continuous ropeto the adjacent edge(s) of thefixed board(s). The bead shouldbe of sufficient size to fill thejoint fully when the next boardis offered up.

Important note: KnaufAquapanel Joint Adhesive mustbe applied before the nextboard is fixed, not after.

4. Place the next boardAlign the next board and push itfirmly into the bed of adhesive.The gap between boards shouldbe less than 1mm. Secure theboard with Knauf AquapanelMaxi Screws at maximum250mm centres, ensuring thatthe screws are at least 15mmfrom the board edge.

5. Continue the processContinue to clean the adjacentedges, apply Knauf AquapanelJoint Adhesive and place andsecure the next board as 2, 3,and 4 above until the wall iscompleted.

6. Leave the KnaufAquapanel Joint Adhesiveto dryIn order to achieve a strongbond, and to form a completejoint, the Knauf Aquapanel JointAdhesive needs to be left tocure and expand before theexcess can be scraped off.Knauf Aquapanel Joint Adhesivecan be left for between 7 and30 hours before scraping off theexcess.

7. Scrape off the excessadhesiveScrape off the excess KnaufAquapanel Joint Adhesive usinga flexible steel scraper.

Installation Procedure: Aquapanel

Fixing Knauf Aquapanel using Knauf Aquapanel Maxi Screws

Cleaning the edges with a wet brush

Applying Knauf Aquapanel Joint Adhesive

Scraping off the excess adhesive once dry

22

Cutting Knauf AquapanelKnauf Aquapanel can be cut toshape using a sharp knife andstraight edge. Score one sidewith a knife, cutting through themesh. Snap the board along thescore, then cut through the meshon the other side.

Alternatively, use a hand heldcircular saw fitted with acarbide or diamond-tippedblade and a dust extractor.

Curving Knauf AquapanelKnauf Aquapanel can be curvedto a radius of 3 metres.

Part TilingFor part-tiled applications, applyKnauf Aquapanel to within20mm of the line of tiles, thenboard the remainder of thepartition height with 12.5mmKnauf Sound Moistureshield,leaving a 3mm gap betweenthat is filled with tile adhesive.The tiles should overlap theKnauf Sound Moistureshield byat least 10mm.

Knauf Sound Moistureshieldshould be offered up to theframe with the face of the boardoutwards and secured withKnauf Drywall Screws at300mm centres. Fixing centresshould be reduced to 200mm atcorners. At head, foot andabutments, board edges shouldbe bedded on to continuousbeads of Knauf Sealant.


FinishingTiling (Aquapanel)Tiles with a maximum weight of50 kg/m2 can be applied to

Knauf Aquapanel, with verticalchannels at 600mm centres.Always use a quality polymermodified based flexible tileadhesive, following themanufacturer’s instructions. Tileon the smooth side of the board.

Taping and jointing (SoundMoistureshield)To achieve a seamless finish on tapered edge boards, KnaufDrywall provides a completerange of jointing compoundsand reinforcing tapes thatallows selection by speed, easeof application and workingcharacteristics. As soon as thejoints have dried, one coat ofKnauf Wallboard Primer shouldbe applied to the drylinedsurface. This will reducemoisture absorption and the risk of discolouration whendecorating.

Skimming (SoundMoistureshield)A 2 to 5mm veneer coat ofeither Knauf FP90 or KnaufUniversal Board Finish plaster is applied to the face of theplasterboards after pre-treatingwith Knauf Betokontakt. Theboard joints should be reinforcedwith either paper or fibre tape.

Sealing interfacesPermanently flexible sealantshould be used at corners, atwall to floor connections, and at interfaces with baths andshower trays, in combinationwith sealing tape in wet areas.Permanently flexible sealantshould also be used around cut-outs for pipes and otherpenetrations.

Installation Procedure (continued)

Scoring and snapping Aquapanel to size

Applying tiles to the completed lining

Customer Service 0800 521 050 Technical Service 01795 416259 E-mail [email protected] Website www.knaufdrywall.co.uk

23

Linings Application Details

23


Floor and Head Internal corner

25 x 25mm Knauf Angle








Knauf Apertura ‘U’ MountingBracket with leg snippedand bent to retain channel

Knauf Apertura ‘U’ MountingBracket secured to backgroundand scrrew-fixed to channel

24

Special ApplicationsKnauf Aquapanel cementboard is tough, durable,non-combustible, freeze-thaw resistant and can becurved, making it suitablefor many demanding andunusual applications thatwould normally call for abespoke product.

In addition to the systems shownin this brochure, Aquapanelsystems can be designed withfire resistances of up to twohours and to provide sound

reduction of up to 53dB.Shaftwall and ceiling variantsare also available.

Knauf Drywall TechnicalServices can advise on anyspecial requirements orsituations you have where KnaufAquapanel can provide asolution.

Knauf Drywall TechnicalServices

Knauf Drywall TechnicalServices are on hand to advise

and help no matter what size of project or at what stage theproject is at.

The Knauf Drywall SpecificationTeam have a wealth of experiencein value engineering, specifyingand supporting major projects,with countless large contractssuccessfully completed acrossthe UK over the past 10 years.

The specification team are ableto offer advice and guidancefrom the very start of the

project, at the design stage,right through to providing on-sitesupport to the contractor duringthe installation phase.

This is backed up by anexperienced telephone basedtechnical support team,comprehensive literature and an award winning website,www.knaufdrywall.co.uk/themanual.

You can contact Knauf DrywallTechnical Services on 01795 416259.

Sage plc headquarters, Newcastle:Prior to completion of the atrium, Knauf Aquapanel weatherproofed the sides of the office buildings, enabling outfitting to proceed inside.Aquapanel was later used with Knauf Apertura Perforated Plasterboard for the atrium drylining.


25

Knauf Aquapanel boardsare manufactured fromhigh quality aggregatedPortland cement withcoated glass fibre meshembedded in the front andback surfaces. The ends ofthe board are square cutand the edge reinforcedand finished smoothly(EasyEdge, see page 26) to ensure a strong joint.

Knauf Aquapanel should be tiledon the smooth side of the board.

LimitationsHigh levels of water absorptionwill not affect the long termperformance of KnaufAquapanel, but to ensure thecorrect adhesion of tileadhesives and Aquapanel JointAdhesive the boards must beinstalled dry. Wet Aquapanelboards can be allowed to dryout and then installed once amoisture content of less than15% has been reached(typically within 48 hours in adry environment) with no loss ofperformance.

Owing to the high alkalinity ofthe products, acids will degradethe board’s composition.

Storage on SitePacks should be lifted with afork lift truck, the forks being setso there is an even weightdistribution and no deformationof the pack. Ensure handlingequipment is of adequatecapacity and that the personnelare advised of handlingprocedures and safety clothing.

Care should be taken at alltimes to avoid strain to thehandlers.

Carry the boards upright, twopersons per board, by supportingone long edge and grippingupper edge to avoid breakingdue to flexing. Take care not todamage corners and edgeswhen setting them down.

Knauf Aquapanel must bestored flat in a clean dryenvironment on a flat surface. If timber bearers are used tostore boards on site, they shouldbe a minimum 40mm wide andplaced at maximum 450mmcentres. Boards which havebecome damp must be dried onboth sides on a flat surface priorto fitting.

Note: If handling manually,consider risks as required bymanual handling operationsregulations 1992.

Before installing, condition theboards to the ambient temperatureand humidity. The ambient airand component temperaturesmay not be below +5°C.

Knauf Aquapanel is not designedto support body weight. Fixersshould work from an independentsupport system.

An on-site risk assessment shouldbe carried out before use.

Health & SafetyKnauf Aquapanel should behandled with care. Whencutting, ensure adequateventilation as dust may begenerated which may irritate the respiratory system, eyes or sensitive skin.

Knauf Aquapanel is notclassified as hazardous underCHIP2 Regulations 1994 andthe Control of SubstancesHazardous to Health (COSHH)Regulations 1994.

The latest full Material SafetyDatasheets on the specificproducts can be downloadedfrom our website:www.knaufdrywall.co.uk/themanual

Fire PerformanceKnauf Aquapanel providesexcellent natural fire resistanceand is designated as Class Omaterial under the BuildingRegulations 1992, approvedDocument B, and as non-combustible: A1 to DIN 4102.

SiteworkKnauf Aquapanel Partitions andLinings must be installed inaccordance with Knauf Drywall’srecommendations and therelevant recommendations of BS 8212: 1995 and BS 8000:Part 8: 1994.

DimensionsThickness (mm) Width (mm) Length (mm) Weight (kg/m2) Article No.

12.5 900 2400 15 670 60 627

Aquapanel Data

Aquapanel Data (continued)

26

CuttingTo cut Aquapanel cementboard, mark the requiredsize on the board with a ruleand pencil. Score one side with aknife cutting through the mesh.Snap the board along the score.Then cut the mesh on theopposing side.

For sharp-edged cuts use ahand-held circular saw witha dust extractor or a pendulumjigsaw, each fitted with a carbideor diamond-tipped blade.

Drilling, bendingTo make cut-outs for wiring andpipes, use a jigsaw or compasssaw. The diameter of the hole fora pipe should be approximately10mm greater than that of the pipe.

For applications such as arches,the cement board can be curved.Knauf Aquapanel can be curvedto a radius of 3m as a full sheet.Tighter radii can be achieved byfirst cutting the Aquapanel into300mm wide strips.

Physical propertiesWidth (mm) 900Length (mm) 2400Thickness (mm) 12.5Minimum radius for 900mm wide board (m) 3Minimum radius for 300mm wide strips (m) 1Weight (kg/m2) 15Dry density (kg/m3) 1050Flexural strength - minimum (N/mm2) 6Alkalinity (pH) 12Thermal conductivity (W/mK) 0.27Thermal expansion (10-6K) 7Water diffusion resistance coefficient (µ) 30Change in dimension from dry to saturated air (%) 0.1Building Material Class Non-combustible: A1 acc. DIN 4102

Material ConsumptionAquapanel Joint Adhesive (PU) 50ml/m2 (25ml/m)Aquapanel Maxi Screw 15 pcs/m2, stud spacing 600mm

Material requirements

Knauf Aquapanel features the specialEasyEdge design. The straight edge iswrapped with mesh embedded into thecement for extra strength.

EasyEdge ensures the best possible bondusing Knauf Aquapanel Joint Adhesive,resulting in a stronger structure.

Further information is contained within

The Complete Drywall Manual, available

online at our award winning website:

www.knaufdrywall.co.uk/themanual

together with a range of interactive tools

to aid the specifier and contractor.

Customer Service

Freephone: 0800 521 050

Freefax: 0800 521 205

E-mail: [email protected]

Technical Service

Tel: 01795 416 259

Literature

Tel: 08700 613 700

Website

www.knaufdrywall.co.uk

Knauf Drywall

PO Box 133

Sittingbourne

Kent ME10 3HW

Tel: (01795) 424 499

Fax: (01795) 428 651

Knauf Drywall Factory

LocationsRidham DockSittingbourneKent

Queens RoadImminghamN.E. Lincolnshire

© Copyr ight Knauf Dr ywal l 2004

The information given in this document is believed to be current and accurate as at the date of publication, but no warranty expressor implied is given. Updates will not be automatically issued.

As part of our policy of continuous product development, we reservethe right to revise specifications without notice. The informationgiven in this publication is provided for guidance only and is correct to the best of our knowledge and belief. It is inevitablygeneralised and users should satisfy themselves as to the suitabilityfor the specific circumstances in which they seek to apply it.

July 2005Ref: AQ1-01

Documents

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