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INSTALLATION MANUAL FOR NEWDECOR G.R.G SCULPTURAL PANEL V1.1.11

This installation is aimed to our modular G.R.G panel products. For the custom panels or suspension ceilings, metal rod or bracket may be embedded in the plaster as designing requirement. In this case, please follow up the architect or designer instruction.

1. PRODUCTS

1.1. Products Name Newdecor None-combustible Glass-fibred Reinforced Gypsum (G.R.G) Sculptural Panels

1.2. Product Dimension L500mm*W500mm, L600mm*W600mm, W600mm*L1200mm or by the custom designing Thickness will be varied for the different pattern, or by designing.

1.3. Product Weight 1.65kg/M2 per 1mm thickness (averagely), not including the glues, screws and fillers.

1.4. Tolerance ±2mm by standard panels and ±1% by weight Possibly, there will be minor scratch or chips on the surface for this hand finished product, which can be patched easily by drywall fillers.

2. LIMITATIONS

2.1. General Limitation

2.1.1. G.R.G panels are interior use only.

2.1.2. G.R.G panels are not aimed to take place of any substrates. Newdecor G.R.G panels can be installed on the flat and even substrates, such as plasterboard, cement fiber board, and concrete cement wall etc.

2.1.3. G.R.G panel’s installation and finishing are similar as plasterboard under AS/NZS 2589:2007. When tiling to plasterboard fixed to timber or steel framework, ensure that additional supports are installed to carry the additional weight of the G.R.G panels if necessary. Our panels loading weight must be passed to frame designers or architects.

2.1.4. G.R.G panels are able to make a seamless surface. However, surface imperfections may still be apparent in a Level 4 surface finish in critical lighting conditions or glossy, semi-glossy or deep tone paints are applied. For some complex pattern, we suggest minimum gaps will be necessary.

2.2. Exposure to Excessive Heat Our GRG panels are not suitable for elevated temperatures. i.e fireplace flues or chimneys, but they can be used as the mantels and surrounds in safe distance from heater. According to AS/NZS 2589:2007, gypsum linings must not be exposed to temperature above 52°C for prolonged periods, even if the chemical reaction may start at around 80°C. Please refer the heat generating appliances installation instructions and BCA requirements for the correct distances between gypsum linings and heating appliances.

2.3. Exposure to High Humidity Our GRG panels are not suitable for high relative humidity (above 90%) for prolonged period. i.e indoor swimming pools, sauna room and bath rooms etc.

2.4. Wet Area Our GRG panels are not suitable for wet area if optional additive was not added. The fixing must be mechanism and GRG panels can’t take place of any substrates.

3. SITE CONDITION

Environment condition should be near to 16-29°C, no more than 70% relative humidity. Bring them goods 24 hours before the installation. In line with AS/NZS 2589:2007, sufficient area shall be made available and the area should be protected from the weather and dry. Treat G.R.G panels as normal plasterboard installation site requirement.

3.1. Delivery and handling

3.1.1. All G.R.G. panels should be placed in the crates and pallet, protected from damage, rain and warp.

3.1.2. Lift and support pieces carefully and slowly.

3.2. Storage

3.2.1. Material should be stored in weather protected site in the crates with proper covers. Keep a prolonged safe temperature and humidity until finish.

3.2.2. Do not stacking the G.R.G panels without protection as possible as you can.

3.3. Permanent lighting To start the seam finishing, the permanent project lighting should be installed. To avoid the individual panels highlighted, the light should run across the waves pattern if possible

4. PRE-INSTALLATION

4.1. Pre-Installation Meeting

4.1.1. Hold a meeting for Owner, Architect, General Contractor, Builders (Erecter, Finisher and Painter) onsite 2 weeks before the installation.

4.1.2. Examine substrates upon which paneling will be affixed to make sure it is not overloaded by manufacturers instruction. Review all of the tools including screws, anchors, cutting tools, caulking, joint compound filler, primers, sealant and paints etc.

4.1.3. Keep minutes of meeting for respective responsibilities.

4.1.4. Good trade practice will be followed and the installer requires minimum three years experience in carpentry/ plaster/painter.

4.2. Substrates and Framing

4.2.1. Our G.R.G panels will not take place of any substrate for their construction purpose. They must be installed on the acceptable flat and even substrates, i.e, plasterboard, cement board and concrete (must be no less than 28 days old and sealed properly).

4.2.2. All substrates should be installed under Building Code of Australia. If it is plasterboard, they must be installed under AS/NZS 2589:2007 and follow the manufacturer manual for the safe loading requirement. Our installation can be referred to the recommendation of the heavy tiles installation in the manufacturer manual. Our G.R.G panels’ average weight is as followed:

(Tolerance ±1%)

4.2.3. The wood or steel frame designer should consider the substrates weight, our GRG panels weight, adhesive weight etc to decide the stud width, board thickness, screws type, length and toggles. The plasterboard thickness should be above 13mm .The maximum loading limitation information should be provided by the plasterboard and frame manufacturers manual.

4.2.4. The substrate needs to be at least level 3 finished before the G.R.G panel’s installation.

4.2.5. For painted surface, you need to affix our G.R.G panels to the substrate (Gauge 6 or above, drywall screws, embedded 30mm into timber frame) by screws in addition of adhesive.

4.2.6. For concrete surface, it must be dry and sealed. Apply 4/5mm diameter nylon wall anchor and fix the panels in the concrete in additional of adhesive.

4.3. Tools May Be Required The tools will be similar requirement as installation of plasterboard under AS/NZS 2589:2007 and installation of heavy ceramic tiles. They include but not limited as followed:

4.3.1. Drill for different substrates---for metal, wood, drywall or masonry

4.3.2. Countersink drill bit with depth stop-collar--use for the panels for custom drilling

4.3.3. Screws--Dry wall screws-- stainless wood screw or self tapping screw for timber or steel frame stud, gauge and length depend on the plasterboard thickness(13mm above), G.R.G panel thickness( after countersink drilling, the depth will be about 4-8mm) and designing requirement, screws will be 30mm embedded into the wood studs

4.3.4. Stainless nylon anchors and cavity toggles--use for the masonry, concrete wall or plasterboard

4.3.5. Saw or tiles cutter--with diamond blade for masonry and ceramic tiles

4.3.6. Sanding paper--p200g to repair, p400g to finish and p800g to polish

4.3.7. Stud detector--laser detector to find the stud location

4.3.8. Others-- spacers , spreader, tapes, sanding tools, hand screw driver (Philip), level bar, pencil, mixing bucket, air sprayers, etc.

4.4. Materials May Be Required All materials must meet Australian Standard. They include but not limited as followed:

4.4.1. Dry wall joint compound-- easy sanding, humidity resistant, quick set time for gypsum dry wall joint, used for the patching and seaming

4.4.2. Caulking compound--high quality, flexible and paintable sealant for gypsum

4.4.3. Construction adhesive--- affix gypsum panels for different substrates, such as plasterboard, masonry, concrete or cement sheets. i.e. cornice bond, liquid nails etc Extra consideration will be attended for fire or acoustic requirement if any

4.4.4. Primer sealer--oil based pigmented sealer for drywall

4.4.5. Paints--depending on the requirement, low sheen paints preferred

5. INSTALLATION

Commencement of work by installer is acceptance of substrate and our G.R.G product conditions. Therefore no claim can be made to Newdecor Pty Ltd and manufacturers except the standard defect product warranty. This installation is aimed to our modular GRG panel products. For the custom panels or suspension ceilings, metal rod or bracket may be embedded in the plaster as designing requirement. In this case, please follow up the architect or designer instruction.

5.1. Substrate Surface Preparation Clear the substrate surface, free of dirt, oil, loose material, paints as required by adhesive manufacturer. We recommend leaving a 6mm gap at least around the perimeter of the panels to accommodate movement.

5.2. Wall and Ceiling Installation It is similar as the installation of plasterboard under AS/NZS 2589:2007 and installation of heavy ceramic tiles on the plasterboard. The laser detector needs to be used to find the drilling point on the stud. Draw grid lines by level lines and plumb lines. If necessary, install a temporary level batten and plumb batten on the wall surface bottom as a frame.

5.2.1. The first panel installation Start the first panel at the middle bottom intersection and work out on either side to make sure the ending cuts equal to both sides. Or if the panel pattern is continuous, you can start either left bottom or right bottom side. We recommend four corners or by 600mm center of the panels need to be fixed to the substrate structure by drywall screws (stainless wood screw embedded in the substrate with 30mm minimum in wood stud) The drilling holes can be pre-cast or customized. In addition, use liquid nail or a 10mm notch for the cornice bond on the back of the panels or on the wall.

5.2.2. Next Panels Place the second panels with gaps by a spacer. Then repeat installation for all of the panels. Patch the screw holes by the fillers, after fillers dry, sand and smooth them to make them match the pattern.

5.3. Finishing The panels, patching and caulking need to be properly sealed primed and painted as Level 4 or even Level 5 finish as AS/NZS 2589:2007 for critical lighting conditions or where glossy, semi-glossy and deep tone paints are not avoidable.

5.4. Notes:

5.4.1. Uneven surface. We suggest that apply a bead of caulking around the perimeter of the tiles to make the tiles floating.

5.4.2. Cutting. We suggest that apply diamond blade cutting saws(for cutting stones, ceramic tiles).

5.4.3. Smoothing surface. We suggest that use sand block for the smooth the edges.

5.4.4. Movement control joints. For the 6m maximum centre, the movement joints must be installed as per AS/NZS 2589:2007 .All movement joints must go from the substrate to the face of the tiling, sealed by flexible sealant with 10mm gaps.

5.4.5. More screws fixing points. We suggest the extra screws fixed on the substrate or studs if the panels size is more than 600X600mm, besides the four corner screw fixing and adhesive.

5.4.6. Do not place adhesive under fasteners to avoid popping up.

5.4.7. Over tightening. When tighten the panels on the substrate, use a hand screw driver or the slowest clutch to avoid cracking the panels.

5.4.8. Gaps. All gaps need to be filled by drywall filler.

6. WASTE MANAGEMENT

G.R.G panels are made of natural gypsum and fiber, no asbestos, which are suited to recycling. It should be placed in the waste bin for plasterboard.

7. WARRANTY

7.1.1. The manufacturer will provide the warranty for G.R.G panels against defect for one year after acceptance of the materials.

7.1.2. The manufacturer will, at his discretion, replace defective pieces subject to approval of architect. The installer will warrant their installation by respective warranty as agreed in the pre-installation meeting.

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