Plasterboard can be curved to create imaginative architectural drama and effects.

INTRODUCTION Installation Principles INSTALLATION Curved Ceiling & Wall

With proper framing methods and careful installation, curved walls and ceilings are possible. GypSorb panels can achieve tight and gentle curves with proper preparation.
All of the GypSorb plasterboard product range can be curved if required.

DESIGN AND SPECIFICATIONS
GypSorb Acoustic Panels are the perfect solution for combining unique interior design and acoustic performance. GypSorb can be curved on a ceiling or wall when built on a metal grid system and doesn’t have any visible joints. The curved ceiling and walls can be used in many different segments, like, schools, office buildings, health care facilities, library, lobbies and so on. The GypSorb panels are fully recyclable materials. Use of the Product

Size Availability
See GypSorb website for available sizes in Sonus / Strata / Stratum. www.gypsorb.com

Surfaces
GypSorb panels come in multiple perforation pattern options. Sonus / Strata / Stratum. The gypsum surface is intended to be painted after installation and not left unpainted. Paint must be applied with a short nap roller (1/4″ recommended). Do not spray paint panels as this will substantially degrade the panel’s acoustic performance. Joints should be taped, finished, and sanded. See page 5 #10, #11 and #12 for joint finishing.

Attachment
GypSorb panels are attached to radius track ceiling or wall framing systems consisting of a minimum of 1-3/4″ screw surface for adequate attachment.

Fire
ASTM E 1264 Classification: Type XII, Form 2, Pattern G, Fire Class A.

Load
Maximum point load is 2.2 pounds. If a higher load is needed, the elements should be independently suspended from the structure.

Stability
GypSorb should be installed and used in rooms with relative low humidity not exceeding 70% or temperatures that exceed 104˚ F. GypSorb can be curved (dry) to a maximum 10-foot radius and
curved (wet) to a maximum 5-foot radius.

Weight
1.80 PSF

Cleaning
GypSorb panels can be cleaned with a damp lint free cloth depending on the final surface treatment. The use of a mild detergent is recommended.

Maintenance
Individual GypSorb panels can be replaced as needed. Repainting should be done with a short nap roller and blended into neighboring panels. Panels must not be spray painted.

GypSorb panels should be installed in climate-controlled conditions.

Safety and Handling
When cutting product, eye protection and ear protection is recommended.

INSTALLATION FOR GYPSORB CURVED

Read the entire manual before installing

Make a plan of where you will place the hangers.
Fix the hangers using the appropriate fasteners.
Hanger center distance = 900 mm.
Main channel center distance = 1200 mm.

The first hanger should be placed with a maximum distance of no more than 200 mm from the wall.
The center distance for the main channels are 1200 mm.
The first main channel should be placed no more that 120 mm from the wall. See image 3 below.

Where there is a connection between the short edges of the GypSorb panel, it is important to place the cross channels with a center distance of 200 mm to secure a smooth curved transition between the GypSorb panels

GypSorb panel, dry curving
PolySorb has only taped edges on the long sides. On the short side/end, it is important to make a beveled edge with a knife or sanding pad so filler can be used in the connections between the panels.

The panel must be attached to the steel system with proper screws for application. All short edges must be supported by the steel grid system as well.

Installation of the panels on the grid system, must be done with an even amount of pressure applied slowly to the boards. Place the screws according to the fixing template on page 4. The dry panels must be curved along its length, not width. 

Fill all joints with an appropriate GypSorb Ready Mix filler along with sheet rock paper tape/strips. When the filler is dry, use fine sandpaper to make a smooth surface between the panels. Do not
overlap the sheet rock paper tape/strips.

To cover the screws, use GypSorb Ready Mix. Do not get filler in perforations. Repeat using filler and fine sandpaper until surface of the board is smooth and paint ready.

Paint GypSorb panels with a short napped roller. Prime the panel first and paint twice. Avoid getting paint in the perforation holes. Do NOT spray paint panels, because getting paint on the interior acoustic tissue will strongly reduce the acoustic panel performance.

GypSorb panel, dent on length, dry curving

Length bending can be done on a dry panels if the radius isn’t too extreme.

Fixing Template
Main channels o.c. 1200mm (48″)
and cross channels o.c. 300mm (12″)
(cross channels o.c. 150mm (6″)
at the short edges).

Screw Spacing:
Space screws equally to spread the load.
Do not set to close to the panel edges!

Wetting Curved Plasterboard
Hot, humid conditions are ideal for curving plasterboard. In cold, low-humidity conditions or if very tight curves are required, prepare the plasterboard as follows:
>Use a clean paint roller or sponge to apply a small amount of water to the plasterboard surface that will be in compression. Add a small amount of detergent to the water in very dry conditions to act as a wetting agent.
>Allow at least 15 minutes for the water to soak in before bending the plasterboard.

A Rondo Flexi-Track and stud system is recommended for framing curved walls or ceilings.
>Avoid joints parallel to studs in the curved section.
>Only the face layer needs to be jointed.
>The minimum curve radius is determined by the concave side.
>A minimum of two layers of GypSorb is recommended.

Framing
Maximum Frame Spacing And Minimum Curve Radius For GypSorb

MAXIMUM FRAME SPACING AND MINIMUM CURVE RADIUS FOR OTHER PLASTERBOARD

*GypSorb has a minimum curve radius of 5000mm

GypSorb panel, bent on width, wet curving

Make a buck/template to curve the wet GypSorb
panels in the desired curve radius – Radius from 9 feet to 5 feet use wet bending technic

Use clean warm water to soften the GypSorb panel.
Water must be applied on the sides of the GypSorb panels close to the center of the radius.

Place one panel on an even floor or table. Work a small amount of water at a time with a sponge on to
the panel. If needed, apply more water after 2-5 minutes (continue to apply water for 15-20 minutes in total). Avoid excessive water inside of the perforations.

2+ people carefully lift the wet panel and place it on  top of your buck/template. Lightly apply pressure on the edges with a straight, wooden or steel stud and fix the stud with clamps until the gypsum panel is 100% dry.

With 2+ people, carefully lift up the panel straight up when it is 100% dry and install no more than 2 hours after it is removed from the form.

GypSorb panels can be wet curved width-wise with the perforations inside or outside of the radius.
See pages 9 and 10.

GypSorb Panel Fixing

FIGURE 1
Concave Wall – Horizontal Curved lengthways

Dry versus wet depends on the radius severity

FIGURE 2
Concave Wall – Vertical Curved width ways

FIGURE 3
Convex Wall – Horizontal Curved lengthways

Dry versus wet depends on the radius severity

FIGURE 4
Convex Wall – Vertical Curved width ways

GypSorb panel, mounting good advice

GypSorb panels must be lifted straight up from the stack to avoid damage.

If a panel is slid off the stack, the acoustic tissue on the backside might get rolled off of the panel.
This might create some issues with the level between boards during the installation.

Checklist for installing GypSorb Panels on a Curve
Humidity must not exceed 70% during construction or when the room is in use.
Measure the room and lay out hangers properly, based off the dimensions of the space.
Place an extra cross channel with a center distance of 150 mm on each short side/end of a panel in order to make a smoother curve.
Make a small, beveled edge on the short side/end of the panel to obtain a smoother joint when applying filler.
Never place a screw in a corner of a board.
Place screws with a center distance of 100 mm, on the short side/ends of the board.
Never dry bend a GypSorb Stratum, to less than a radius of 9 feet.
Always prime the surface of the boards, before painting it twice.
Read this installation manual before commencing the installation work.