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British Gypsum Innovation Seminar - Newman Street
- 2. Supply chain meeting Agenda Session 1 Introduction Technical presentation – Basic principles of partition Session 2 Bespoke solutions New and Innovative products NPD pipeline overview Q & A Account review/actions Private A Saint-Gobain company and Confidential 2
- 3. • The Saint-Gobain Group employs over 200,000 people. Comprising 1200 companies in 55 countries • Saint-Gobain filed 388 patents in 2009 . 16 R & D Centres throughout Europe, the United States and Asia • €386 million invested in R & D annually • 3500 researchers working on major strategic projects
- 5. SpecSure / BES6001 certification
- 6. Supply chain meeting British Gypsum Leads The Way With First Five EPDs Environmental Product Declarations Private A Saint-Gobain company and Confidential 6
- 7. Technical expertise, innovative systems and preferred products
- 8. British Gypsum provides solutions for: •Partition Wall Systems •Wall Lining Systems •Floor Ceiling and Soffit Systems •Steel Encasement systems •Cavity fire barriers •Thistle range of plasters
- 9. Current Legislation, Standards & Influences
- 10. Duty Ratings
- 11. BS5234 Partition Duty Ratings
- 12. Acoustics
- 14. Acoustic Definitions • (Rw) Performance standards for partitions are typically laboratory tested and expressed in terms of sound reduction index • (DnT,w) HTM 08-01 specifies on site performance standards • (DnT(Tmf,max),w BB93 Education Document performance Standards • DnTw + Ctr • Residential Approved Documents E; • Lnw Impact Sound Insulation on separating floors • LnTw Measured on Site • Dncw Performance of Suspended ceilings through laboratory tests
- 15. Flanking Transmission 4-5dB Reduction in performance
- 17. Fire Performance
- 18. Fire Protection BS & EN
- 19. Deflection Heads Designed for Fire performance. 1 Hour Deflection head 2 Hour Deflection head
- 20. Steel within partitions Intumescent paint and partitions • Partitions provide excellent integrity and Insulation performance; • The structural columns contained within the partition should be considered separately; • Intumescent paint requires 25 -50mm of room to expand.
- 22. Building Partitions and Height
- 23. Height L/240 at 200pa UDL
- 25. Heights of less than 4900mm Robust Partitions
- 26. Example of Height Selection Type Required dB Rw Stud Partition Performance dB Rw Partition max Height L/240 Fire Resistance Duty Rating Gyproc Boards to each side Isover APR 1200 1 GypWall Classic 57 70 AS 50 58 4700mm 60mins Severe 2 x 12.5mm SoundBloc 25mm 2 GypWall Classic 57 70 AS 50 58 5000mm 90mins Severe 2 x 15mm SoundBloc 25mm 3 GypWall Classic 57 92 AS 50 57 5000mm 60mins Severe 2 x 12.5mm SoundBloc 50mm 4 GypWall Classic 57 146 S 50 59 7900mm 90mins Severe 2 x 15mm SoundBloc 50mm 5 GypWall Classic 57 146 AS 50 59 8100mm 90mins Severe 2 x 15mm SoundBloc Not req
- 27. Channel Types
- 28. Height Stud Selection • Do not use ‘C’ Studs with a single sided board option
- 29. An Effective Specification Type Partitio n Width dB (Rw) Height (mm) Fire (mins) Duty Rating Partition Type Board Stud Isover APR 1200 (mm) Type 1 102mm 42 4000 60 mins Severe GypWall Robust 1 x 15mm Duraline 70 AS 50 Non Required Type 2 102mm 48 4000 60 mins Severe GypWall Robust 1 x 15mm Duraline 70 AS 50 25mm Type 3 102mm 50 4000 60 mins Severe GypWall Robust 1 x 15mm Duraline 70 AS 50 50mm Type 4 122mm 53 4700 60 mins Severe GypWall Classic 2 x 12.5mm SoundBloc 70 AS 50 Not Required Type 5 122mm 58 4700 60 mins Severe GypWall Classic 2 x 12.5mm SoundBloc 70 AS 50 25mm Type 7 200mm 61 7500 60 mins Severe GypWall Quiet 2 x 15mm SoundBloc 48 S 50 25mm Type 8 250mm 63 7500 60 mins Severe GypWall Quiet 2 x 15mm SoundBloc 48 S 50 75mm Type 9 200mm 66 2800 60 mins Severe GypWall Quiet IWL 2 x 15mm SoundBloc 48 I 50 25mm Type 8 250mm 70 3300 90 mins Severe GypWall Quiet IWL 2 x 15mm SoundBloc 60 I 50 100mm
- 31. Deflection Head
- 32. Door Jam
- 34. Service support plate detailing
- 35. Hand wash basin detailing
- 36. Access support rail detailing
- 37. Grab rail – vertical detailing
- 38. Recessed/flush skirting detailing- 1 layer
- 39. Recessed/flush skirting detailing- 2 layer
- 40. Morgan Sindall presentation – Bespoke options
- 41. Bespoke length board and metal. Bespoke length board and metal available in 10mm increments. Both board and metal is cut off the production line so there is no waste at all. Minimum order quantity of 1,000Lm metal and 2,500m2 board Managed projects have a lead time of 10 working days. Bespoke logistics also available include: 1 tonne lifts. Specific vehicle types including self off load. Out of hours deliveries. Goods in, waste out. Delivery lorry can remove plasterboard waste.
- 42. Bespoke length board and metal. Reduction in waste through design Reduction in Waste/CO2 Using Bespoke product sizes to minimise site waste on drywall. Nido Spittalfields – 20% reduction in site waste for Drywall materials
- 43. Morgan Sindall presentation – Plaster and New Products
- 44. GypFrame Folded edge channel and Angle. In response to safety issues raised by Main Contractors and House Builders. Patented Ultrasteel product. Reduction in injuries on site. Currently incorporating folded edge to all standard channels and angles. Large investment in tooling at no extra cost to the customer Only manufacturer currently producing a folded edge to channels .
- 45. GypFrame 92 AS 50 acoustic stud. Larger system cavity to allow services. Improved acoustic performance, up to Rw 59 dB in a double layer partition. Rw 52 dB in a single layer partition.
- 46. British Gypsum Partition Systems Achieving 60 minutes in a single layer
- 47. Glasroc Rigidur ‘H’ board Rigidur = Rigid and Durable board. High impact paperless board. Paper reinforced gypsum core. Inherently moisture resistant. Smooth paperless face, decorated in normal way. Superb fixings capability.
- 48. Glasroc TileBacker board. Lightweight and easy to cut, score and snap. Gypsum based tile backer board. Easy to fix. Pre primed for tiling. High water resistance. Recyclable with British Gypsum PRS service. Good fire and acoustic performance. Compatible with British Gypsum systems. Mould resistant. Part of the British Gypsum SpecSure system Warranty Now available in 6mm for floors
- 50. Thistle DuraFinish. Thistle DuraFinish is a new, more robust kind of plaster. Unlike anything else on the market. Increased resistance to accidental damage. Ideal for high traffic areas. Reduction in whole life costs. High adhesion. Samples available on request.
- 51. What is Magnetic Plaster? A skim coat plaster that attracts magnets. Turning any wall into a massive fridge door It is applied using standard skills and methods, the only practical difference is that is must go on at a minimum of 3mm & does not trowel up to a shiny finish Private A Saint-Gobain company and Confidential 52
- 52. What is Unifinish? Thistle UniFinish is a plaster which can be used for re-skimming over a wide rangeof backgrounds without the need for pre‑treatment. Thistle UniFinish is a plaster which is ideal for refurbishment jobs on a number of different backgrounds without the need for pre-treatment. Very high suction backgrounds may still need pre-treatment with PVA, but not having to treat the whole area means quicker application and less mess. Product benefits — Thistle UniFinish frees you from the hassle of pre-treatment — Tried and tested by plasterers on a variety of backgrounds — Excellent workability on high* and low suction backgrounds Private A Saint-Gobain company and Confidential 53
- 54. British Gypsum ACTIVair Board/Plaster options
- 55. British Gypsum Acoustic Ceilings. Range of acoustic ceiling tiles, boards and planks. Various patterns available including: Performance classes D to B. Now to include A Point. Quattro. Line. Sixto. Samples available on request.
- 56. British Gypsum ACTIVair Ceilings
- 57. NPD pipeline Overview 2014
- 58. Overview of 2014 new product developments Contents • ACTIVfix & Gyproc DuraLine • Lifestyle Board • Robust Board Private A Saint-Gobain company and Confidential 59
- 59. ACTIVfix Plasterboards Gyproc DuraLine ACTIVfix OBJECTIVE: To develop and launch a plasterboard with fixing capability equivalent to current performance provided by pattressing Target Customer Segment Main contractors, Architects, Clients – commercial sector, facilities management and fit out contractors Customer Need Focus Reduction in build program, simplification of design and installation, performance data and future proofing Target Launch Date Q4 2014 Stage Of Development Stage 2 of project 2 •In test marketing phase • 23 projects, 63,000m2 • Mix across all commercial applications •Customer identification and launch planning Private A Saint-Gobain company and Confidential 60
- 60. Next Generation Plasterboards Lifestyle Board OBJECTIVE: To develop and launch a plasterboard to enhance performance of walls in UK residential market Target Customer Segment UK residential market, home buyers and house builders Customer Need Focus Improve performance of walls on three key areas, acoustics, impact resistance and fixing capability Target Launch Date Q4 2014 Stage Of Development Stage 2 of project 2 •In test marketing phase • Live on several test sites as part of consumer strategy • Validating business case for three builder types • Up seller, differentiator & self builder Private A Saint-Gobain company and Confidential 61
- 61. Next Generation Plasterboards Robust Board OBJECTIVE: Develop a board solution meeting customer requirements in robustness to provide a more user friendly solution to Rigidur Target Customer Segment Contractors – commercial sector, health & education Customer Need Focus Requirement for: Improved ease of installation over Rigidur – board weight, cutting, fixing to metal studs Target Launch Date 2014 – dependent on development phase and capital progress Stage Of Development Stage Two: Phase 3 (Business case, plant selection, initial trials, capital application) Private A Saint-Gobain company and Confidential 62
- 62. Supply chain meeting Thank You, any questions? Private A Saint-Gobain company and Confidential 63
Editor's Notes
- British Gypsum are committed to the environment. The size of our business means that we can have a major impact through our research and development teams. Since 2008 we have reduced the weight of the packaging of our bagged plaster by over 20 grams. In 2009 this reduced the weight of our plaster packaging by over 700 tonnes. To clients we offer a plaster board recycling service, BREEAM advice and even bespoke stud and board lengths to reduce waste.
- Five boards – WB, MR, SB, FL, DL BREEAM Lo-Carbon projects Clear differentiator to MC customers
- Introduction to White Book Sector Guide British Gypsum have recently developed and published a sector guide specifically for varying environments. The guides detail a portfolio of dry lining systems developed specifically to meet the requirements of modern buildings, they also takes you through the regulations and guidance that should be taken into account to meet these requirements.
- British Gypsum provides solutions for Partitions, Wall Linings, Floors, Ceilings, Soffit Systems, we provide Steel Encasement systems, Cavity fire barriers and Various types of plasters. We also provide market assistance at three main stages of construction. Pre Tender Train 6,000 professionals' a year in British Gypsum Systems so the products are well understood and installed to a high standard 10,000 calls per month are taken by our technical advise line Provide Project Specification Managers (PSM) such as myself who supply NBS’s, Typical and Example Details & Project Specific Detail Packs Site Support Area Technical Support Manager can arrange site visits to make sure that the system is installed as specified Our (PRS) Plaster Board recycling service is also available which monitors waste providing a report and ongoing performance data from site to site. After Sales More than 10,000 tests and substantiation reports are available and of course we provide the Spec Sure Warranty which guarantees the performance of our products.
- Selecting partitions(Technical) So let us quickly look at the current legislation and standards' which influence our specification decisions. The first thing we need to know is what type of building are we considering
- Typically in most commercial projects, we see a minimum duty rating of Heavy, but more often than not the rating selected is severe. Severe duty can be achieved with a single denser board for example a single 15mm DuraLine board. Due to the denseness of the boards they are specified with A 0.5mm gauge acoustic stud such as 70 AS 50, 92 AS 50 or a 0.6 gauge ‘C’ stud. Some partitions will achieve severe duty by default due to the acoustic or fire requirements, but corridor walls for example where there are lower acoustic requirements, the duty rating will be one the first selection criteria to be considered There are products on the market that significantly out perform the severe standard, such as Rigidur H which British Gypsum term extreme duty partitions. As yet there is not an official designation for these. These can be used where the client wishes to exceed performance requirements such as where heavier impact damage is expected.
- The table on the left will give you an understanding of partition performance and what we are speaking of when we consider the acoustic performance. The table on the right shows that dB is a logarithmic scale and that although a partition may only have to reduce the performance by 3db this means that the partition has to reduce twice the power level, which clearly is not insignificant.
- There are a number of acoustic definitions in relation to buildings. This is why it is very important to be absolutely clear as to the performance criteria we are considering. Often within my role, I am asked to provide a 42dB partition. If this is an Rw 42dB, a laboratory figure, I can take a figure straight from the White book. However, If the 42dB figure is for example DnTw 42dB, a site based figure, then I would have to add somewhere between 5dB and 9dB in order to provide a partition that meets the criteria. Lets look at an education example…
- Clearly in a laboratory the optimum set up is used and time can be taken on the construction; but aside from on site construction a large part of the performance drop can be attributed to the deflection head which typically accounts for 4-5 dB. For historical reasons Shaftwalls are tested with a deflection head in place. Sound transmission paths in this case can be mitigated through the use of cloaking angles, as in the detail on the right and would be considered in acoustically sensitive areas.
- Walls with doors cannot be tested due to the noise ‘leakage’ that occurs around doors. Up to a point there is very little benefit in improving the performance of a partition that has standard doors in place. Therefore HTM suggests a laboratory figure of RW 40-45dB and BB93 standards suggest corridor walls have a laboratory performance of Rw 40dB. Music rooms should have Rw45dB The room of intended high acoustic performance should be provided with a secondary door i.e. lobby and be positioned carefully within the scheme . Now we shall consider fire.
- Fire Resistance is defined by BS 476: parts 20-23. Although currently unusual where fire is concerned it is important to recognise that should you be designing to the EN standards BS EN 1364 there are different performance results that partitions achieve due to the differing test methods. Generally there will be a reduction in the height allowed through the BS EN tests. Currently all projects I am dealing with are designed to the BS.
- Fire requirements can affect not just partition and board selection but also detailing in terms of the deflection head design. In the example above we can see that moving to a two hour fire resistance requires the utilisation of not timber, but of Gypsum Firecase F boards as well as additional stone mineral wool. Therefore you may not be able to use the same deflection head throughout a project
- We often incorporate columns, SFS sections or beams within the partition for the cleaner lines that will be provided. However as an example a 120 minute partition, does not provide 120 minutes of fire protection to the steel. A partition is not a load bearing member is only self supporting, therefore its performance in a fire is significantly different to a structural member under load. As we know steel starts to soften as 300C so a partition does not need to keep just its integrity but also needs to insulate the steel within it, in this case. For example 2 x 12.5mm will provide 120minutes Fire protection, but depending on the column size the requirements is unlikely provide the steel work with the necessary insulation. Note: should you wish to use a partition wall to support a partition roof. The partition is now a supporting element and you must double the fire performance requirements. Therefore a required 90mins roof requires a 180minute supporting partition. We often see intumescent paint installed and subsequently partition boards placed directly against the steel. This is not always satisfactory as depending on the paint type it may need 25-50mm of space in order to expand in a fire situation. Providing an independent wall liner in addition to the intumescent paint creates increased cost and time as two operations now need to be conducted.
- An alternative solution is to use a board impregnated with glass fibres such as Glasroc Firecase F. These can provide necessary aesthetic and acoustic qualities but also provide the necessary insulation to the structural steel. In most conditions One layer of 15mm Firecase F will be sufficient for 1 hour (for Columns and beams with an A/V (Hp/A)m-1 less Than 260). The boards can be screwed or stapled together meaning no frame is required.
- Let us build as partition considering as we do the various parameters that we have discussed. As many of you will know the White book provided a vast range of options to achieve a given height
- There is a very useful table at the front of the Whitebook which shows the relative heights which can be achieved with different configurations. L/240 Is used to define the recommended maximum height. This is based on limiting the deflection that a partition will sustain with a pressure of 200Pa UDL. Below this i.e. L/200 the partitions will deflect to a greater level. In some situations for example with cinema walls this figure is less appropriate as the partition may be required to achieve a height of 8-10m with the limited load being placed. N.b. Wind pressure may need to be considered
- Just a brief note on part boarded partitions. As the boards forms part of the ‘support’ it is generally not beneficial to part board partitions as it requires larger studs and improved acoustic ceilings' in order to offset the height reduction. Take advice when considering this.
- As a starting point Up to 4.9m height we would generally select from the Robust range of boards, as this provides for severe duty rating, 1 hour fire resistance and a range of acoustic performance up to 52dB, with a single board. Above this you should consider partitions from the Classic range.
- If we consider our first examples severe duty, acoustic requirements 57dB, 1 hour fire resistance this can be achieved in the following ways when we are considering the height of the partition. As you can see the use of double boards provide us with by default severe duty rating and 60minutes fire, in some cases 90 minutes. Therefore our selections can be varied depending on the height we wish to achieve, but also if we wish to rationalise the board types or stud types to produce a simpler set of specifications. Were we to consider using ‘I’ Studs or using the above studs a 400mm centres, then we would be able to provide an even greater range of options.
- As you can see there are a number of different types to suit the varying heights required from a partition, but also the deflection head criteria. Above 4.2m Use Deep channel (DC), above 8.2m Extra Deep Channel (EDC). All robust partitions use Deep channel as a minimum
- I shall only briefly touch on independent walls liners or single sided boarding in order to say that we recommend an ‘I’ stud to do this and that the height that can be achieved are in a similar way to part boarded solutions much reduced.
- Here is a selection of partitions that may be considered on a typical education sector scheme. As you can see we have a wide range of acoustic and fire parameters provided for, however we are using only two boards and depending on the selections 2 or 3 stud types. To these we may need to add a ShaftWall an IWL, or if we have an Atrium with significant height or in some projects partitions requiring 2 hours fire protection. Therefore it is important to rationalise the specification at every stage to avoid having to many solutions on one project. In this example, we would try to avoid the use of 12.5mm and 15mm boards of the same type being used on site and would investigate alternative options.
- The deflection head criteria are set by the engineers and their design as previously said should consider the height, fire and acoustic requirements.
- There are a range of typical details for door sets depending on the doors specification, from heavy duty to severe duty.
- Fixtures and fittings depending on their type can be installed either by pattressing or by the use of fixing channels such as 99 FC 50. Advice is given on this within the whitebook and typical details are available. As you can see in the examples our recommended solution is not to overboard the studs. British Gypsum does recommend taking an acoustic or fire benefit from the presence of plywood.
- I previously mentioned that FireLine and DuraLine are commonly used when 60 minutes is required. We now have a variant of 15mm SoundBloc that can also achieve 60 minutes. This board is used when you don’t require the Severe duty rating that DuraLine provides but FireLine doesn’t provide you with a high enough acoustic rating. An example scenario of where this would be specified is a 40 dB wall in residential that requires 60 minutes due to the fire strategy.
- Level of VOC indoors>outdoor