- What is GML
- How plaster metal panels are mounted
- Where are gypsum panels used
- How much does gypsum metal cost
The article tells about a new finishing material – gypsum metal panels (GMP). You will learn what this cladding is, where it is used and how it is installed..
Modern building standards are periodically reviewed and tightened. Naturally, finishing materials must meet changing requirements, therefore, in addition to improving known technologies, new technological solutions are regularly promoted to the market. Practice shows that literally according to all characteristics, the most successful materials are those with a complex structure, in which different layers bring unique properties to the product, help to perform one or another additional function. One of these innovative materials is gypsum metal used for the production of clean rooms..
What is GML
Gypsum sheet or panel (GML or GMP) is a flat multi-layer cassette plate, consisting of a front metal shell and a core made of familiar to all drywall. This material is used as a finishing cladding for walls and ceilings indoors. The GMF cladding is an example of absolutely dry construction, since it does not require any spackling, painting or priming after installation. They are quickly, without the formation of a large amount of garbage, collected, can also be easily dismantled. Below we will tell you more about the installation in more detail, while we talk about the design of GM panels.
Sheet metal with a thickness of about 0.55–0.7 mm in this case plays the role of a protective shell (it protects the drywall from damage, for example, upon impact), as well as the basis for the finishing polymer coating. For these purposes, use:
- galvanized steel (grades FePo3G, 08 Yu, 08 KP – with a zinc layer of at least 20 microns);
- sheet aluminum rolling;
- stainless steel (grades AISI 304, 430).
Stainless steel can be used in its pure form, and zinc and aluminum in most cases are covered with several technological layers on both sides: on top – a passivation layer, primer, polymer coating, self-adhesive protective film; bottom – passivation layer, primer, protective varnish / paint.
One of the following options is used as a material for creating a topcoat:
- pural, plastisol, polyester varnish, polyester;
- vinyl layer 0.5 mm thick;
- stainless steel sheet 0.5 mm thick.
The most common is polyester spraying with a thickness of 25 microns, as well as thermal painting with a mixture of polyester and epoxy resins with a thickness of about 130 microns. At high temperatures, polymer particles are sintered and polymerized on the surface of a metal workpiece (many are familiar with the so-called powder coating). Fused powder coating has good adhesion to metals, it can withstand abrasion, shock and bending effects; does not collapse under the influence of ultraviolet radiation and high / low temperatures (from -60 to +120 degrees). This coating is extremely resistant to corrosion..
The color of the coating can be any according to the international RAL catalog, but RAL 9002 and RAL 9003 are considered standard. As a rule, you can choose a matt, semi-matt or glossy surface.
The core of the gypsum board is made of plasterboard, which acts as a form-forming base and gives the product spatial rigidity and geometry stability. Depending on the specific tasks set, manufacturers use not only standard wall sheets – moisture-resistant, fire-resistant, perforated acoustic drywall, gypsum fiber (GVL) are enclosed in a metal wrapper. To create GML ceiling cassettes, lightweight plasterboard with a thickness of 9.5 mm is used. In accordance with the traditional dimensions of gypsum plasterboard sheets, the dimensions of gypsum metal panels are obtained:
- width – from 600 mm to 1200 mm;
- length – from 600 mm to 4000 mm (usually 600, 900, 1200, 2500, 3000 mm);
- thickness – about 10 mm and 13-13.5 mm.
Within these limits, gypsum metal manufacturers can make panels of arbitrary sizes to order..
The metal sheet is glued to the drywall with a special moisture-resistant glue, which provides greater bond strength, it is much more reliable than the drywall itself if you try to delaminate it. Note that a GML can be made to order, which will also be protected by metal from the back plane..
A sheet of metal covers the front of the panel and, with a radius of approximately 1.5 mm, bends around the edge of the drywall pasted over with cardboard. On the one hand, it forms a flange for mounting.
In another design, there is a slightly smaller spike-lug (about 10 mm) on both sides, these are panels with an independent type of fastening.
How plaster metal panels are mounted
Gypsum sheets are installed on main walls and ceilings, and are also used for cladding frame partitions. As a rule, GMFs are mounted on metal subsystems, but it should be noted that they can also be fixed on a solid wooden or plastered wall. If the fixing is made on a mineral base, then it must be perfectly aligned, fixing is done using expansion dowels with a diameter of 6 mm.
A frame for walls made of GMF is assembled from a galvanized profile CD and UD (wall thickness 0.5–0.7 mm), using straight hangers. The rules for organizing the frame are fundamentally no different from those that are used when working with traditional GCR. The main technological nuances can be found in the article “Plasterboard Walls”. Just note that it makes no sense to place the racks more often than 600 mm along the axes. In addition, horizontal arrangement of CD carriers with the same pitch is allowed. It is not necessary to place frame profiles under all the joints of the sheets – that is, no jumpers are needed.
Fastening of panels to posts or planes can be carried out in one of two ways, depending on the type of flanging of the edges of the metal sheet:
In any case, all fasteners are hidden in the seam area. No self-tapping screws with sweat, which are recessed into the body of the panel, are not used here.
With an independent installation method, each panel can be quickly dismantled separately. In this case, on each side of the gypsum sheet there are sides, during installation they are joined or superimposed on each other (then the fastener, screw or dowel, double metal passes). A distinctive feature of this method is a large gap, which is closed with a special elastic profile.
When using a stationary fastening method, the plane is assembled according to the thorn-groove principle, like a lining. First, metal locks are attached to the sidewall of the panels, which are also painted with a powder composition. For wall panels, 2 pieces are used per linear meter, for ceiling panels, 3-4 locks are installed per meter of seam. Fixation of the lock to the end of the GML is performed with self-tapping screws for metal (or holes are drilled and blind rivets are used).
Then the plane is assembled in the same way as a plastic lining: the groove-lock petals are fixed on the supporting base (self-tapping screw, rivet or dowel), the spike of the next panel is inserted into the groove of the previous one and everything is repeated.
Whatever installation method is used, the joints of the panels must be sealed. A large gap of 8–10 mm, which is formed with independent fasteners, is closed with a shaped sealing profile made of medical silicone. Thinner joints (2–5 mm) remaining during permanent installation are filled flush with the plane with one-component silicone sealants. The sealant should be neutral vulcanized, sometimes containing fungicidal additives.
Gypsum sheets intended for ceiling cladding can also be fixed to the profiles with rivets or self-tapping screws, but more often they use installation without mechanical fasteners in order to have quick access to the inter-ceiling space where utilities are laid. Some models of GML ceiling cassettes have an enlarged flange perpendicular to the face plane, which snaps into a special frame element. It is called a stringer comb. Vacuum cups are used to pull the cassette out of these clamping profiles..
Ceiling panels with sides 600×600 or 600×1200 can be embedded in a subsystem with T-shaped profiles (Armstrong type).
Internal and external corners, adjoining walls and ceilings, adjoining walls to the floor, end end of the slab – all these areas are covered with framing elements. In order to exclude places in which cleaning and disinfection may be difficult, internal and sharp corners are completely excluded from the structure, therefore the extensions have a rounded section. The rounding radius is usually in the order of 70 mm. The framing elements are supplied in lengths of 3 meters, as a rule, they are made of aluminum, powder-painted. Some manufacturers offer additional elements made of rigid non-toxic PVC, which are co-extruded (they have an outer colored layer).
Where are gypsum panels used
Walls and ceilings made of gypsum metal in their technical and operational characteristics differ significantly from all other finishing options, therefore the scope of application of the GML is more specific. Let’s first outline the main features of the material..
The planes lined with gypsum sheets are completely sealed. As a result: the air masses of the room do not come into contact with the materials of the rough walls and ceilings, there is no diffusion of substances through the body of the panels. There are no leaks and overflows if the pressure inside the room jumps sharply (for example, if the doors of a clean room are opened with excess pressure).
Matte and semi-matt walls and ceilings do not create glare even in strong side lighting, so they do not interfere with staff when working.
Due to the fact that the joints of the panels are sealed with a sealant, the fasteners are hidden, and all the corners are rounded – dust, moisture, various kinds of dirt have nowhere to accumulate.
The seams remain flexible, so the system can be used correctly even in seismic areas. For the same reason, this cladding withstands well the vibrations generated by the equipment, as well as the excess pressure that is generated inside the “clean rooms” in order to maintain the stability of the air composition..
The outer polymer coating of the GMF does not release any aerosol particles into the air, it can withstand regular exposure to disinfectants such as, for example, alcohol, 6% hydrogen peroxide and 3% chloramine. Most importantly, it is devoid of porosity or significant roughness that could trap moisture, microbiological and chemical contamination. Such characteristics of the polymer coating fully comply with the requirements of GOST R ISO 14644–4–2002 “Cleanrooms and associated controlled environments. Part 4. Design, construction and commissioning ”. Thanks to the precious metals (silver ions) contained in epoxy-polyester powder, the finish coat has a pronounced antibacterial effect on many pathogens of hospital infections that can settle and grow even on flat surfaces.
GMF cladding systems can be easily integrated with all components of cleanrooms (pass windows, doors, locks, lighting and ventilation devices, internal and external communications). Overhead and built-in wiring accessories are easily mounted and sealed on gypsum metal, technological openings and openings are organized, for example, for installing exhaust or heating grilles.
Flammability, flammability, smoke-generating ability, toxicity – gypsum metal tolerates fires very worthily, significantly increases the chances for people to leave the building on time (classes G1, B1, D1, T1, respectively).
So, clean rooms are where the gypsum cladding reveals itself in all its glory. Clean rooms are called rooms with strict environmental control when it is necessary to minimize the amount of foreign and harmful particles: anaerobic bacteria, dust, inert chemical and aerosol vapors. In addition, in such environments, pressure, humidity, temperature can still be regulated..
Most often this is the medical industry – the organization of birth, intensive care, operating units. Naturally, you cannot do without a stable environment in research laboratories. Also, a clean room lined with gypsum metal is used in several dozen industries, where foreign substances can significantly affect the quality of products. For example, it is believed that up to 70 percent of cleanrooms are used to create pharmaceutical and microbiological products, electronic components (especially semiconductors), and micromechanical devices. Increasingly, GMF can be found at food processing enterprises.
In fact, these panels are not only suitable for clean rooms. Due to its high strength characteristics and excellent moisture resistance, gypsum metal is successfully used for finishing garages, car washes, warehouses and workshops. Connoisseurs of the laconicism of the high-tech style immediately noticed this material, especially since, in addition to RAL colors, it became possible to create a coating “imitating a tree”, “marbled”, “metallic”, etc. centers, clubs, restaurants and even used in apartments and cottages.
How much does gypsum metal cost
The main elements of such systems are manufactured in Russia using European equipment, so the GMP is a fairly economical solution, and the delivery times for ordered products are minimal. The price for gypsum panels starts at 700 rubles per square meter. The price will increase by about 10% if you want to order a custom color. The price tag will change if special requirements are imposed on the panels. For example, increased fire resistance, sound insulation or moisture resistance will require the use of other types of drywall as a core. Then the cost of the GML square also changes – 800, 1500, 1800 rubles per m2 respectively.
It seems that this is more than other finishes are worth, but it should be borne in mind that gypsum panels are completely ready for use, and they are very easy and quick to install. If you calculate the cost of a multi-layer cake that you have to create when finishing surfaces with many traditional materials, as well as the money that must be paid to the contractor for the work (usually each operation is taken into account), then the GMF is often even more profitable..
As for the finishing of clean rooms, there are very few competitors for gypsum systems. Somewhere on a similar level in terms of practicality and efficiency are HPL panels made of high-pressure laminated plastic, but the cost per square meter starts from one and a half thousand rubles. Tiles, latex painting of plastered walls, gypsum vinyl cladding – these finishes do not compete with GMF in terms of functionality and performance and cannot be used in high-cleanliness rooms, therefore it is useless to compare them.