Builders

A Quarterly Publication from Boral Plasterboard Summer Edition 2001

Boral for
Avoiding
Maintenance
Streets ahead on
about this edition
2
Maintenance
W
ith a growing competitiveness in the building
industry and an increase in consumer
expectations and awareness on what is
acceptable and what is not, the need to
present a high quality finish with both paint
and plaster has never been greater.
Many difficulties are experienced in trying to satisfy
customer demands with their sometimes unrealistic
perceptions of what can economically be provided
with plasterboard jointed surfaces. Combine this with
the belief that an automotive finish can be achieved
on a shoestring budget and a somewhat suspect
reluctance to concede that restrictions are
encountered by the role glancing light plays in the
highlighting of surface variations. Only then can you
begin to understand how disputes arise.
Plasterboard in its present form is the most popular
interior lining material used in todays domestic
construction and provides the finish over many and
varied substrates, relying heavily on most other
trades conforming to correct building practice in
order to achieve the expected flat surface.
Unfortunately all too often quality suffers as a result
of price. It goes without saying there is no such
thing as a good cheap job. In the majority of cases,
you get only what you pay for, nothing more.
One again in this issue
we have taken the
opportunity to highlight
industry issues. Our
primary intent is to
prevent future problems
by highlighting existing
practices some of which
have unseen drawbacks;
and then provide
preferred alternative
procedures. We illustrate
what has happened in the
past and will happen
again if the approved
guidelines are not
followed. It is not our
intention to allocate blame
or responsibilities, our
goal is maintenance
prevention and if we all
work together everybody
wins. We thank you for
your interest.
Maintenance free finish 2- 6
Moisture related problems 7
Lets get cracking on
fibre glass adhesive tape 8-9
Stud Adhesive 9
Building Approvals Statistics 10-11
TecASSIST 12
contents
Quality has no substitute.
plasterboard maintenance
3
free finish?
at what cost
Builders, carpenters, roofing contractors,
electricians, painters etc all play a part
and contribute in some way to the final
presentation of plasterboard. The
contribution these trades can make
towards the finish is often beyond the
control of the plasterer who frequently
bears the brunt of any maintenance
related issues.
In the quest to remain competitive,
margins for maintenance can no longer
be built in to the price so any rectification
inevitably requires considerable discussion
on the subject of who pays.
Generally all eyes are on the plastering
contractor as it is his work that is on
permanent display for the sole purpose
of hiding the substrate.
Despite the many changes in construction
practice and building designs over the
last 30 years, the specification for the
installation of plasterboard remains
virtually unchanged.
Recessed light fittings
supported by plasterboard only?
Downlight complete with transformer
supported by plasterboard only?
The same ceiling from below.
Who takes responsibility for the
inevitable maintenance?

plasterboard maintenance
4
Maintenance
As builders compete for
individuality and an edge in the
market, the trend towards larger
homes with open plan living
areas is increasing.
The reliance on roof truss
engineering for the support of
these areas, significantly reduces
the possibility of producing
a maintenance free plasterboard
finish.
Metal ceiling battens installed in ceiling.
Roof truss of large open area. Consideration must
be given to expansion joints for large ceilings.
Noggings required at change of direction.
Industry
Maintenance reduction can be achieved
in large ceiling areas simply with the
installation of metal ceiling battens
backblocking and proper placement of
expansion joints.
We should never lose sight
of the fact that plasterboard
is produced as a decorative
product only and as such
provides little in the way of
structural qualities except in
the special case of bracing
walls where the specification
changes dramatically.
consumer awareness
5
free finish
Whether we like it or not, the days when
the builder worked on site as part of the
team along with the same subcontractors
that worked on his last job are fast
disappearing. These were days when any
problems that arose on site were dealt with
immediately and amicably. Nowadays, the
typical answer is its not my job or I
dont get paid for that, with the end result
being it probably doesnt get done.
In coming to terms with these industry
changes we must not lose sight of the
reasons behind some of them i.e. (providing
cost efficient homes in a price driven
market and thereby keeping
us all in a job).
However price
will never be
accepted as an
excuse when
disputes arise over
some owners
unrealistic
expectations.
Unfortunately
consumer awareness
has also changed along
with changes to the industry.
Media exposure of shonky
practices has automatically placed a stigma
on all builders and has eroded the position
of trust that once existed between builder
and client.
We now deal with a more educated owner,
one not prepared to overlook anything as
minute as a scratch, a pinhole or a popped
nail...and it gets worse. Quite often they
are receiving advice in the background
from a relative who, wouldnt you know
it, just happened to be a builder or a
plasterer in a past life!
Literature for the education of prospective
home owners is currently available by way
of publications on lighting and decoration,
levels of finish etc. They should be directed
to the customer prior to the commencement
of building, not at the time of dispute
resolution. Once it reaches this stage it is
always too late.
The majority of issues in relation to
callbacks are normally related to ceilings
and their appearance at night.
This in itself is sufficient to warrant attention
be paid to the lighting aspect i.e. (no bare
bulbs) not only to create a better first
impression. The facts are, that as more
and more home owners stretch their
budget simply to own a more up-market
piece of real estate, decorative lights are
low on the list of priorities when it comes
to buying accessories for the new home.
There have been many times when
carrying out inspections, that I have
witnessed bare bulbs still there two years
later well and truly after settlement has
taken place. Not a good look.
Lighting & Decoration The Facts
changes & expectations
Harsh ceiling light shows up imperfections.

consumer awareness
6
Cheap plastic shades will save you money
and reputation. Any minor imperfections
identified when inspections are undertaken
with bare bulbs as the source of lighting,
should not receive recognition as part
of the maintenance program, as chances
are, given the identical lighting conditions,
the repairs will also fail to meet the
standard expected.
A
s we strive to find solutions to a
maintenance free finish the answers
are not always obvious.
Although well known but not widely
recognised, moisture is a common enemy
of both timber and plasterboard,
particularly in the early stages of building.
Following prolonged periods of wet
weather (well known in Queensland for
bringing the building industry almost to a
stand still) due to delayed delivery and
roof installation, the timber framing
becomes exposed to more than its fair
share of moisture.
The inability of the subcontractor to gain
site access during this time ensures that
when the rain finally ceases its full speed
ahead to make up for lost time.
Wet framing is a common cause of
popping in plasterboard. Rooves with
no ridge capping or gable ends exposed
during wet weather are well known for
their contribution to both popping and
board sag problems. However, it is not
until some time later when the house is
occupied and the moisture is long gone
that these problems become an issue
with the home owner. Once again it is
usually the plasterers work that is on
display and unfairly questioned.
Moisture related problems
The effects of lighting
Maintenance
Shade directs light downwards
illuminates the room, not the ceiling surface.

moisture
7
free finish
Stud Adhesive
Note that the gable ends are not
enclosed prior to the installation
of plasterboard.
The effects of moisture are well
known for their contribution to
maintenance.

T
ight scheduling of the building process
can push the systembeyond its limits
simply by reducing the actual nominated
drying times.
It should be noted that stud adhesive
should not be adhered over wet framing,
failure to comply may void warranties.
J ointing of plasterboard should not
commence until stud adhesive has had
time to cure. 24 hours under normal
conditions and 48 hours during wet periods.
Screws or nails should not be driven
through stud adhesive.
The need to complete the jointing process
immediately after fixing does not always
allow for the proper curing times. J ointing
of plasterboard should not commence until
the stud adhesive has had time to cure.
The benefits, if any, that may be gained
from a quick job are soon forgotten when
the responsibilities for maintenance related
issues are decided.
fibre glass
8
T
hree types of J oint Reinforcement
Tapes are currently available: Paper,
Cotton and Fibre Glass Self-Adhesive.
The benefits and contributions of these
tapes to the overall finish and strength of
the finished plaster joint vary considerably
and are the subjects of much debate and
differing opinions.
It is only when carrying out maintenance
inspections, following settlement of a new
dwelling, that the limitations of fibre glass
tape are exposed. These limitations have
been recognised for some time now and,
as a result, specifications have been
tailored to suit and information sheets
issued accordingly.
We at Boral Plasterboard are concerned
with the increasing number of complaints
on joint cracking nationally, many of which
are due to the use of fibre glass tape.
Fibre glass tape is the weakest form of
joint reinforcing and its
use in the trade should
be limited to specified
areas. Expansion and
contraction of building
materials and sudden
temperature change
contribute to the
problem and though
more prevalent in
Queensland is now
surfacing in other states.
The following is a list of areas where
the use of fibre glass tape is not
recommended.
1. Metal frame construction
2. All butt joints
3. Hardwood frames
4. Any ceiling applications such as Truss
Roof Construction where wind load
or settlement cause movement
AS/NZS 2589.7.2.4.1997 (unless
back-blocked).
5. Internal angles
6. Masonry application
7. Must not be used in location with
adverse weather conditions or in
climates where a wide range of
temperature and humidity levels are
encountered in a given day.
Lets get cracking
Fibre glass tape incorrectly bedded.
No pressure on application and base-coat too thick.

fibre glass
9
The success of any joint reinforcing tape
depends largely on the applicator,
especially in the case of fibreglass tape
and in particular the temptation to
substitute a two-coat system for the
preferred three-coat application.
The two-coat system, when used in
conjunction with fibreglass tape, provides
an opportunity to use a base coat or first
coat of somewhat thicker consistency than
that which can be used comfortably with
paper tape, thereby not allowing for
proper penetration of the joint compound
into the weave of the tape.
This practice, although not always
detrimental to the appearance of the finished
joint, significantly reduces the strength of
the overall system and guarantees cracking
will occur at some stage in the future.
Note
Paper Tape will provide the
strongest possible joint under
all conditions when used in
conjunction with plaster base
compounds.
Boral Plasterboard Warranty
applies to Boral Supa Weave
Fibre Glass Tape and only when
joints are back-blocked in
accordance with AS/NZS
2589.7.2.4. 1997.
Other brands of Fibre Glass
Reinforcing Tape are not
recommended by Boral
Plasterboard in residential
or commercial construction.
on Fibre Glass
Fibre glass tape correctly bedded.
Will be difficult to remove.
Self-Adhesive Tape

innovation
OutRWALL

The leader in light-weight building

systems, Boral Plasterboard has long been
providing low-cost alternatives to masonry
fire-resistant exterior walls.
With the Boral Plasterboard OutRWALL
Exterior Wall Systems, new buildings can
be constructed on or near the boundary
and still satisfy the fire resistance
requirements of the BCA.
Providing fire ratings of 1 or 1
1
/2 hours
(from the outside), Boral Plasterboard
OutRWALL Exterior Wall Systems
provide effective resistance to the spread
of fire from neighbouring buildings.
Perfect for extensions to existing buildings,
OutRWALL Exterior Wall Systems are a
cost-effective, labour-saving way to upgrade
the fire resistance rating of a boundary
wall to comply with the Building Vode.
OutRWALL Exterior Wall Systems comprise:
one (OutRWALL 60 - FRL 60/60/60) or two
layers (OutRWALL 90 - FRL 90/90/90) of
16mm Boral Wet Area Firestop
plasterboard fixed to the timber frame
Tyvek housewrap
stapled to outer face
of plasterboard
an additional layer of
16mm Boral Wet Area
Firestop fixed to floor
joists and plinth and
butted to underside of
bottom plate
an additional layer of
16mm Boral Wet Area
Firestop fixed to roof
framing and butted to
topside of top plate,
and
one layer of 10mm
Boral Standard Core
plasterboard fixed as
interior lining.
Vertical or horizontal
timber battens (on
outer face of plasterboard) fixed to studs,
with lightweight external cladding fixed
to timber battens.
Tyvek

and Homewrap

are regi st ered t o Dupont

Fire rated exterior wall systems

for residential construction
For more information or a technical manual on OutRWALL

Exterior Wall Systems:

Fill in the coupon below and fax it to: (03) 9645 1707; Or visit our website: www.plasterboard.boral.com.au
Or mail to: Marketing Services Department, Boral Plasterboard, Locked Bag 3, Port Melbourne, Vic 3207 Australia;
Or Call your local Direct Boral Plasterboard Distributor.
Name: ..........................................................................................................................................................................................................................
Address .................................................................................................................................................................. Postcode ..................................
Telephone ...................................................................................................... Facsimile ............................................................................................
Email address ..............................................................................................................................................................................................................
Indicate if you would like follow up:
Sales Representative to call Pricing Information
Technical Installation Assistance Store Locations
50mm
150mm
min.
Additional batten
required where
plasterboard
span exceeds
600mm
Concrete
plinth
2 layers 16mm
Wet Area Firestop
plasterboard
Tyvek housewrap
Lightweight
exterior cladding
1 layer 10mm
Standard Core
plasterboard
Project Type (Domestic, Commercial)
----------------------------
Location
--------------------------------------------------------------
Your Project (approx. value) $
--------------------------------------
Enquirer:
Architect Draftsperson Builder Plastering Contractor Student Other
Designers & Builders
To obtain your sample of Manly Cove Cornice
fill in this coupon and fax it to 03 9645 1707
or Mail to: Marketing Services Department, Boral Plasterboard Locked Bag 3,
Port Melbourne, Vic 3207 Australia
or visit to our website: http://www.plasterboard.boral.com.au
Name: ..................................................................................................................................................................................
Address .......................................................................................................................... Postcode ..................................
Telephone ................................................................................ Facsimile ..........................................................................
Email address ......................................................................................................................................................................
Architect/Interior
Designer
Builder
Plaster Contractor
Indicate if you would like follow up:
Sales Representative to call
Pricing Information
Technical Assistance
Your Project (approx. value $.............................)
Location............................................................
Distributor Address
new arrival
ClassiCove

Boral Plasterboard proudly announces

the arrival of a new design in the
ClassiCove range of cornices.
Called Manly Cove, this fashionable close
relation of ClassiCove Sydney is a smart
new look that is derived from seductive
Sydneys famous smooth curved profile.
With one less ridge, slimline Manly Cove
is a stylish and affordable 75mm cornice
that suggests a modern elegance fitting
comfortably with todays homes and
lifestyles.
Flaunting subtle pared down curves
Manly Cove will make a lasting
impression creating stylish interiors on
all walls and ceilings in apartments,
townhouses and new or renovated homes.
Celebrate Boral Plasterboards new arrival
and install the sleek and affordable Manly
Cove in your latest projects.
There are three profiles in the ClassiCove
range, New York, Sydney and Manly Cove.
Features and Benefits:
Classic profile complements a variety of
decors
75mm profile in 4.2 metre lengths
A decorative effect at less than decorative
cornice price
Flawless finish when decorated
Easy to handle paper coated extruded
cornice with a decorative look
An affordable contemporary design.
Manly Cove Cornice
Sydneys New Arrival
Number of houses & other residential
buildings approved by Statistical Division (SD)
Building Approvals
September Quarter 2000
Prepared for Boral Plasterboard November 2000
Source: Australian Bureau of Statistics
Sydney 4285 5175 9460 2349 2397 4746 -45.18 -53.68 -49.83
Hunter 1011 417 1428 528 401 929 -47.77 -3.84 -34.94
Illawarra 711 181 892 340 55 395 -52.18 -69.61 -55.72
Richmond-Tweed 345 133 478 187 30 217 -45.80 -77.44 -54.60
Mid-North Coast 507 134 641 276 75 351 -45.56 -44.03 -45.24
Northern 123 17 140 89 14 103 -27.64 -17.65 -26.43
North Western 132 50 182 66 6 72 -50.00 -88.00 -60.44
Central West 239 57 296 127 17 144 -46.86 -70.18 -51.35
South Eastern 436 24 460 283 51 334 -35.09 112.50 -27.39
Murrumbidgee 205 40 245 106 10 116 -48.29 -75.00 -52.65
Murray 162 10 172 95 0 95 -41.36 -100.00 -44.77
Far West 5 0 5 2 0 2 -60.00 0.00 -60.00
New South Wales 8161 6238 14399 4448 3056 7504 -45.50 -51.01 -47.89
NSW
Dwelling Approvals
September Quarter 1999
Dwelling Approvals
September Quarter 2000
Variance
Total Total other Total Total Total other Total Total Total other Total
houses residential residential houses residential residential houses residential residential
Regions building building
Melbourne 6741 3281 10022 3980 2858 6838 -40.96 -12.89 -31.77
Barwon 695 38 733 387 108 495 -44.32 184.21 -32.47
Western District 87 18 105 61 11 72 -29.89 -38.89 -31.43
Central Highlands 233 7 240 130 25 155 -44.21 257.14 -35.42
Wimmera 64 0 64 18 0 18 -71.88 0.00 -71.88
Mallee 149 8 157 86 20 106 -42.28 150.00 -32.48
Loddon 279 15 294 170 18 188 -39.07 20.00 -36.05
Goulburn 404 21 425 245 20 265 -39.36 -4.76 -37.65
Ovens-Murray 212 11 223 95 4 99 -55.19 -63.64 -55.61
East Gippsland 115 10 125 78 0 78 -32.17 -100.00 -37.60
Gippsland 322 23 345 220 19 239 -31.68 -17.39 -30.72
Victoria 9301 3432 12733 5470 3083 8553 -41.19 -10.17 -32.83
Victoria
Dwelling Approvals
September Quarter 1999
Dwelling Approvals
September Quarter 2000
Variance
Total Total other Total Total Total other Total Total Total other Total
houses residential residential houses residential residential houses residential residential
Regions building building
Brisbane 2322 606 2928 1660 1206 2866 -28.51 99.01 -2.12
Moreton 1734 831 2565 991 671 1662 -42.85 -19.25 -35.20
Wide Bay-Burnett 398 54 452 237 69 306 -40.45 27.78 -32.30
Darling Downs 310 41 351 169 2 171 -45.48 -95.12 -51.28
South West 21 0 21 16 0 16 -23.81 0.00 -23.81
Fitzroy 204 41 245 99 23 122 -51.47 -43.90 -50.20
Central West 4 0 4 5 0 5 25.00 0.00 25.00
Mackay 280 14 294 95 137 232 -66.07 878.57 -21.09
Northern 415 152 567 110 21 131 -73.49 -86.18 -76.90
Far North 295 307 602 134 30 164 -54.58 -90.23 -72.76
North West 15 8 23 23 14 37 53.33 75.00 60.87
Queensland 5998 2054 8052 3539 2173 5712 -41.00 5.79 -29.06
Queensland
Dwelling Approvals
September Quarter 1999
Dwelling Approvals
September Quarter 2000
Variance
Total Total other Total Total Total other Total Total Total other Total
houses residential residential houses residential residential houses residential residential
Regions building building
Adelaide 1338 386 1724 875 345 1220 -34.60 -10.62 -29.23
Outer Adelaide 372 32 404 199 2 201 -46.51 -93.75 -50.25
Yorke and Lower North 71 18 89 46 0 46 -35.21 -100.00 -48.31
Murray Lands 104 7 111 45 0 45 -56.73 -100.00 -59.46
South East 71 7 78 40 0 40 -43.66 -100.00 -48.72
Eyre 48 2 50 42 12 54 -12.50 500.00 8.00
Northern 57 4 61 32 0 32 -43.86 -100.00 -47.54
South Australia 2061 456 2517 1279 359 1638 -37.94 -21.27 -34.92
S A
Dwelling Approvals
September Quarter 1999
Dwelling Approvals
September Quarter 2000
Variance
Total Total other Total Total Total other Total Total Total other Total
houses residential residential houses residential residential houses residential residential
Regions building building
Perth 3569 890 4459 2140 572 2712 -40.04 -35.73 -39.18
South West 933 160 1093 419 34 453 -55.09 -78.75 -58.55
Lower Great Southern 144 19 163 73 6 79 -49.31 -68.42 -51.53
Upper Great Southern 26 8 34 20 0 20 -23.08 -100.00 -41.18
Midlands 150 1 151 107 10 117 -28.67 900.00 -22.52
South Eastern 81 15 96 22 45 67 -72.84 200.00 -30.21
Central 113 23 136 64 17 81 -43.36 -26.09 -40.44
Pilbara 26 0 26 1 0 1 -96.15 0.00 -96.15
Kimberley 66 6 72 68 0 68 3.03 -100.00 -5.56
Western Australia 5108 1122 6230 2914 684 3598 -42.95 -39.04 -42.25
W A
Dwelling Approvals
September Quarter 1999
Dwelling Approvals
September Quarter 2000
Variance
Total Total other Total Total Total other Total Total Total other Total
houses residential residential houses residential residential houses residential residential
Regions building building
Greater Hobart 148 22 170 87 21 108 -41.22 -4.55 -36.47
Southern 44 0 44 38 0 38 -13.64 0.00 -13.64
Northern 114 5 119 79 0 79 -30.70 -100.00 -33.61
Mersey-Lyell 57 4 61 61 0 61 7.02 -100.00 0.00
Tasmania 363 31 394 265 21 286 -27.00 -32.26 -27.41
Tasmania
Dwelling Approvals
September Quarter 1999
Dwelling Approvals
September Quarter 2000
Variance
Total Total other Total Total Total other Total Total Total other Total
houses residential residential houses residential residential houses residential residential
Regions building building
Darwin 119 134 253 54 88 142 -54.62 -34.33 -43.87
Northern Territory - Bal 117 9 126 89 18 107 -23.93 100.00 -15.08
Northern Territory 236 143 379 143 106 249 -39.41 -25.87 -34.30
NT
Dwelling Approvals
September Quarter 1999
Dwelling Approvals
September Quarter 2000
Variance
Total Total other Total Total Total other Total Total Total other Total
houses residential residential houses residential residential houses residential residential
Regions building building
Canberra 388 226 614 258 117 375 -33.51 -48.23 -38.93
ACT - Bal 2 0 2 1 0 1 -50.00 0.00 -50.00
ACT 390 226 616 259 117 376 -33.59 -48.23 -38.96
ACT
Dwelling Approvals
September Quarter 1999
Dwelling Approvals
September Quarter 2000
Variance
Total Total other Total Total Total other Total Total Total other Total
houses residential residential houses residential residential houses residential residential
Regions building building
TecASSIST
12
The Service
Based at the Boral Plasterboard Port Melbourne site, the service provides advice and
technical assistance to builders, architects, contractors, distributors, engineers, regulators
and home owners throughout Australia.
To date TecASSIST has handled some 16,000 technical enquiries, helping to build major and
minor projects across Australia and Asia.
And weve had em all! Everywhere, everyone, everything.
From Hobart to Cape York, Darwin to Wollongong, Broome to Newcastle, England to Fiji,
Colombia to Sweden, New Zealand to the United States
Fire Inspectors to Architects, DIYers to Contractors, Builders to Sculptors
Offices to Schools, Bungalows to Brothels, Cinemas to Navy ships, Airports to TV shows.
The team
The TecASSIST Team represents over 100 years of practical and professional experience and
a coverage of professions ranging from architecture to engineering, building to design,
drafting to IT and trades to business management.
When in doubt, ask!
Telephone: 1800 811 222
Facsimile: 03 9645 1812
Email: techdesk@plasterboard.boral.com.au
Sales Offices
QLD 733 Nudgee Rd Northgate 4013 Telephone (07) 3215 2244 Facsimile (07) 3215 2299
NSW Thackeray St Camellia 2142 Telephone (02) 9638 0571 Facsimile (02) 9638 5557
SA 119 - 121 Bedford St Gillman 5013 Telephone (08) 8240 8888 Facsimile (08) 8341 1004
VIC 676 Lorimer St Port Melbourne 3207 Telephone (03) 9214 2138 Facsimile (03) 9646 1912
WA 12 Hoskins Rd Landsdale 6065 Telephone (08) 9400 2666 Facsimile (08) 9302 1133
ACT 7 Barrier St Fyshwich 2609 Telephone (02) 9280 4243 Facsimile (02) 9280 5816
TAS 93 Albert Rd Moonah 7009 Telephone (03) 6278 9966 Facsimile (03) 6278 9865
NT Crn Coonawarra Rd & Mataram St Winnellie 0820 Telephone (08) 8984 4484 Facsimile (08) 8984 3778
Export Dept 676 Lorimer St Port Melbourne 3207 Telephone (03) 9214 2138 Facsimile (03) 9646 1109
Danny Docherty and Bernie Shalekoff