Aquamag®Multipurpose, High Performance Magnesium Oxide Board
AQUAMAG® is a registered trademark. Copyright © 2019 - 2021. All rights reserved.
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Handling and Fixing Guide
Ideal new age multi-purpose magnesium oxide board.
02
Aquamag® Handling and Fixing GuideIndex
Content
1. Handling guidelines
2. Cutting
3. Fixation
4. Screw fixing
5. Forming holes
6. Jointing
7. Painting
8. Self support
Page No.
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Handling Guidelines
The following guidelines and recommendations arebased on our best knowledge and experience.Nothing in these guidelines shall create or bedeemed to create any obligation on the part ofAquamag®. It remains the responsibility of the userto check the product and its use meets locallegislation and regulatory requirements.
Specific application and/or installation detailsmentioned in classification documents, assessmentsand other approvals as well as in Aquamag®technical data sheets must be followed.
Loading and unloading boardsAquamag® boards are supplied on pallets suitable forfork lift unloading by fork lift. If off-loading by craneand slings is envisaged, care should be taken to avoiddamaging the edges of the boards. All pallets andcrates can be safely handled by using a fork lift orhoisting equipment and straps. Steel cables or chainsshould not be used as they will damage both thepallet and the boards. Where crates are removed froma box container, care should be taken not to subjectcrates and pallets to any impact shock, as this couldresult in cracking of the boards.
Always drive the delivery vehicle as close as possibleto where the boards are to be used. Whentransporting the boards, it is essential to secure thepallets to prevent sliding. If the boards aresubsequently moved around the site, they should beplaced on a rigid base suitable for lifting by forklift.Aquamag® boards should always be stored on a rigidbase.
StorageAll Aquamag® boards are supplied with a protectiveplastic sheet wrap. This protection should not beremoved until the boards are ready for use.
In general, the following steps should be taken toensure that the boards remain in good conditionduring storage. All Aquamag® boards should bestored on covered and dry level ground, away fromthe working area or mechanical plant.
Pallets should be stored safely on firm level ground.If two or more pallets are stacked, the followingguidance as well as local legislation and regulationsmust be observed. The number of pallets per stack ismainly determined by site conditions such as groundconditions, flatness and load capacity of the ground.
Maximum number of pallets stacked one above theother under warehouse conditions: All boards –maximum 5 pallets, recommended < 4 pallets. Allboards must be protected from inclement weather.Cover protection is essential for stacked boards. Allboards must be stored under cover. Completeprotection for stacked and covered boards in storage.
The following recommendations must always betaken into account when handling all Aquamag®boards:
Wherever possible, always lift boards from the stackrather than slide board on board. This will preventdamage or scratches occurring to the face of thelower boards.
Always carry the boards on edge but do not store onedge.
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Aquamag® Handling and Fixing GuideHandling
04
Aquamag® Handling and Fixing GuideCutting
CuttingAll Aquamag® boards can be worked withconventional woodworking equipment although theuse of hand saws with hardened teeth isrecommended. Boards greater than 6 mm in thicknessmay be more easily cut using a circular saw with aTungsten Carbide tipped blade, or a jigsaw. For roughcutting, 6 mm sheets can be deeply scribed andbroken over a straight edge.
Aquamag® recommends that all cutting should becarried out in well ventilated spaces and using dustextraction facilities. Operators should wear theappropriate protective masks at all times (refer to therelevant safety information sheet).
Aquamag® do not recommend cutting different typesof material using the same saw blade. If the sameblade is used to cut Aquamag® boards, followed bytimber and then Aquamag® boards, the result will bepoor quality cuts and a much reduced blade life.Keeping a single saw blade for Aquamag® boardswill ensure a good quality cut and a long blade life.For a small project and where using a hand saw,Aquamag® recommend the use of a disposable sawwith hardened teeth.
There are a wide variety of applications and fixingmethods possible with all Aquamag® boards. Themethod to be used is dependent on a number offactors, including:
The shape of the board´s final application, i.e. square,rectangular, circular or other forms.
The location where the work is to be carried out, i.e.industrial, commercial, on or off site, etc.
The quality of workmanship and the equipmentrequired.
Local legislation, regulations and safety informationguidelines must be observed.
All Aquamag® boards can be cut on site with relativeease. However, if a large number of boards are to becut, it is recommended that cutting is carried out offsite under controlled conditions as much as possible,to ensure good quality of finished edges and surface.If you do not have a high quality saw, ask your localAquamag® partner company for recommendations ofan approved cutting partner or Aquamag® workshop.
A few general rules that should be observed whenworking with boards:
For workshop cutting and to extend the cuttinglife of tools, working with diamond tipped saws isrecommended.
Experience shows that tools with Tungsten Carbideteeth (TCT) provide a more than adequate cut for on-site activities.
High speed electric tools generate very fine dust.Inhaling fine dust can be harmful to health. Thus, dustextraction equipment is necessary, as the alternativetechnology of wet cutting cannot be recommended.Although Aquamag® boards contain no harmfulfibres, inhalation of excessive nuisance dust can bedetrimental to health. It is also recommended thatwhen cutting or processing any Aquamag® products,appropriate face masks and personal protectionequipment (PPE) should be worn.
The speed of the cutting is best determined by:• Thickness of the board• Hardness of the board• Condition of the blade
Boards must be held securely during cutting avoidingslippage and vibration which can lead to chipping ofthe board edges.
The choice of the most appropriate tool for use willdepend on custom, practice and local regulations.
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Aquamag® Handling and Fixing GuideCutting
Cutting with hand circular sawsThe use of a Tungsten Carbide-tipped saw blade isrecommend. The cutting is carried out in a dry stateso dust extraction is essential. The Tungsten Carbideteeth of the saw have a shorter life span thandiamond tipped blades but they can be sharpened bya skilled professional.
The riving knife adjustment and fixing must bechecked and if necessary adjusted. Set the intendeddepth of cut, the saw blade protruding some 15 mmbelow the material - an optimal setting guaranteeslong life of the circular sawing blade.
Recommendations for cutting tool:• Diameter of the blade 180 mm but depending on
the tool• Speed approximately 3000 rpm• Number of teeth: 36 – 56 per blade• Feed speed: the saw is to be pushed evenly
without stopping and without forcing the sawforward. If movement is stopped, the saw shouldbe lifted. Cutting should to be continuedperpendicular to the cutting surface, lower thesaw and proceed with the cut at a uniform feedspeed.
Static circular sawsIndustrial machines are used for continuous cuttingover long periods of time, for large quantities and forimproved efficiency. We recommend the use of lowspeed motors with diamond based tipped blades forthe cutting of Aquamag® boards. There are manysuppliers of professional sawing machines, yourAquamag® support team will guide you in makingthe right decision of equipment.
Recommendations for the cutting blades:• Diameter of the blade 300 – 400 mm depending
on the tool
• Speed approximately 500 – 1000 rpm• Number of teeth: 36 – 56 per blade
On-site machinesSawing machines work with a Tungsten Carbidetipped saw blade with a low speed electric motor andmounted to move over a fixed working table, is atypical machine for occasional use on site andproduces very good results.
A vacuum cleaner is recommended for use whilecutting especially when using power saws. As anadditional precaution, always wear eye, ear and dustprotection when using power tools of any type.
While working with power saws, the followingimportant points should be observed:
Ensure that the boards to be cut are continuously andwell supported on either side of the cut;
A straight edge should be clamped in position toguide the cutting operation;
Care must be taken to ensure the tool remainsagainst the straight edge during the cuttingoperation;
The cutting rate should be such that the blade is notlaboring or over heating. Feed speed for calciumsilicate boards is slower than for timber if you wish toprolong the life of the blade and achieve a good cut.
JigsawThis tool is applicable for panels up to 25 mm thick.Panels can be easily cut with a jigsaw to form variousshapes. Blades with special hardened teeth areavailable for cutting Aquamag® boards.
As with all power tools, care should be taken to cutwithin the capacity of the tool and blade. Do not forcethe cutting speed.
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Aquamag® Handling and Fixing GuideFixation
Rasp / SurformA rasp or surform can be used for edge finishingwhere necessary in order to trim away rough cutting.For optimum edge finishing, dress the edges with fineglass paper.
DrillingDrilling can be carried out either by hand drill or anyconventional power drill with or without dustextraction. For best results the boards should befirmly supported behind the location of the holes.Generally when working with Aquamag® boards theuse of drills with point angles of 60° to 80° ratherthan the more usual 120° type, are preferable andmore efficient.
Aquamag® strongly recommend an underlyingsupport to avoid break out as the drill passesthrough the back face of the board.
FixationTested and approved fastening systems can be foundin the assessment and classification reports as well asin the Aquamag® technical data sheets.
Aquamag® boards are easy to handle and work usingconventional tools. However basic standard safetyprecautions should be used at all times duringinstallation. The following pages highlight somegeneral guidance notes for reference when fixingboard systems.
Drywall screwUsed to fix boards in metal studs
Sleeve boltUsed to fix boards or supporting structures in masonry or concrete substrates
Through boltUsed to fix boards or supporting structures in masonry or concrete substrates
Shell boltUsed to fix boards or supporting structures in masonry or concrete substrates
Premium nailsUsed to fix boards or supporting structures in steel, masonry or concrete substrates
Hex head self drillingUsed to fix boards in heavier gauge steel structures
Knock-in-anchorUsed to fix boards directly in masonry or concrete substrates
Metal anchorUsed to fix suspension systems in masonry or concrete substrates
Flat head self drillingscrewUsed to fix Aquamag boards to supporting substrates.
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Aquamag® Handling and Fixing GuideFixation
Fixing & InstallationTested and approved fixing systems can be found inassessment and classification reports as well as inAquamag® technical data sheets.
The type of fixings used when installing Aquamag®boards are important as they may determine thestability of a structure and its fire performance. Ingeneral, a fixing should meet the followingrequirements:
Corrosion resistant.Galvanised nails are recommended for timberframing. Stainless steel nails can be used if preferred.Do not use screws when the board forms part ofstructural bracing, unless the system was tested withsuch fixings. If stainless steel screws are fixed ingalvanised steel structures, the threat of corrosionunder humid conditions must be considered. Allinstallations should be regularly checked forcorrosion.
Zinc or other plated self-drilling screws arerecommended for steel framing. Stainless steelscrews can also be used.
Fixing points should be located at least 12 mm fromany board edge and 50 mm from board corners.Fixing centres are generally 200 mm but should be inaccordance with the appropriate Aquamag®specification. All relevant system details arereferenced in Aquamag® technical literature andsupporting documents.
Nailing, staplingThe most economical method of fastening is to usepneumatic nailing or stapling equipment. When fixingAquamag® boards using nails, the following shouldbe noted:
Do not drive the fixings too deep beneath the surfaceof the boards, as this may reduce the holding capacityof the fixing and damage the boards.
Fixings should be driven straight into the boardand at best embedded no more than 0,5 mmbelow the surface of the board. Depending on theapplication equipment, the length of the nails andstaples, we recommend a working pressureof 8 – 9 bars for 12 up to 20mm Aquamag® Board.5 – 6 bars for 6 up to 10mm Aquamag® Board.
Do not damage the board around the fixing or at theedges of the boards. Where boards are crackedaround fixings, the boards must be replaced.
Nails can be driven directly through these boards intotimber framing, without predrilling, provided theyare at least 12 mm from the edge of the board andthe back face of the board is fully supported whilefixing.
For use in areas of high humidity, galvanised nailsshould be used. Panel pins, oval or lost head nailsshould not be used. Wire or clout nails are acceptable.
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Aquamag® Handling and Fixing GuideScrew fixing
Screw fixingWhen fixing Aquamag® boards, especially to lightguage steel frames, the following should be noted:
For best results, pre-drill fixing holes unless usingspecially designed self-drilling screws suitable forfixing cement based boards to steel.
Use a high torque, variable speed screw gun,preferably fitted with a depth gauge.
Do not over drive the fixing, as this may reduce theholding capacity of the screw. Reduce the speedof the drill as the screw pulls the board against theframing.
When fixing to steel framing, always fix to the openside of the flange first. This maintains a flush outsideface.
Pilot holes should be predrilled not less than 12mmfrom the edge of the boards and countersunk ifrequired. Use self-drilling or self-tapping screwswhen securing boards to steel. For all other situations,drywall screws are generally suitable.
Boards with a thickness of 15 mm or more can befixed face to edge with great care. The correct screwsare detailed in the technical data sheet for therelevant application. We recommend the use SPAX –screws.
Pilot holes should be predrilled not less than half theboard thickness from the edge of the board andcountersunk if required. Screws should have a deepthread (e.g. Hilo or drywall type) when securing oneboard to another. Self-drilling or self-tapping screwsare also suitable. Screws at corners should bepositioned at a distance equal to the board thicknessfrom the corner, or a minimum of 50 mm, whichever isgreater. Care has to be taken not to over tightenscrews.
INCORRECT sequence of fixing to steel stud
CORRECT sequence of fixing to steel stud
Stapling machines forstaples up to a lengthof 90 mm
Nailing machines forstaples up to a lengthof 90 mm
Screw machine
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Aquamag® Handling and Fixing GuideForming holes
Forming holesApertures often need to be cut within a board to allow for penetration of services such as switchboxes, lights, access panels etc. The following procedures therefore serve as general guidance only. Any method that allows for cutting of holes without damaging the board is acceptable.
For smooth, clean cut circular holes:
Mark the centre of the hole on the board;Predrill a hole to be used as a guide;Cut the hole to the required diameter using a hole saw fitted to a heavy duty electric drill where the central bit is inserted into the predrilled hole or use a jigsaw.
For small irregular holes:
Small rectangular apertures can be achieved by forming a serious of small holes (using a drill) around the perimeter of the opening;Carefully tap out the waste piece from the panel face. Make sure that the edges are properly supported in order to avoid damage to boards;Rough edges can be cleaned with a rasp or a 40 grit glass paper.
For larger openings or apertures:
Score deeply around the perimeter of the opening using a sharp tool (thin boards only); Form a large round hole in the centre using the method previously described;Saw cut from the centre towards the corners of the opening;Tap waste pieces from the face side and if necessary clean rough edges with a rasp or with at least 40 grit sand paper. Radius corners with a half round rasp to eliminate any stress points.
NOTE:Never make holes by using heavy hammers, cold chisels or other "aggressive" methods. This will damage the underside of the boards and adversely effect the fire performance of the system.
Nailing and hammering for openings.
For larger openings or apertures
Apertures opening using alternative method
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Aquamag® Handling and Fixing GuideJointing
Seamless finishing between boardsSeamless finishing is applicable to most partition andceiling constructions. However, in some instances itmay also be applicable for external wallconstructions. Generally, installations of concealedframed ceiling and partition systems constructionsrequire crack-free flush jointing.
The method of constructing flush joints depends verymuch on the skills and expertise of the installer, aswell as the stability of the supporting construction.
It is recommended that the thickness of panels usedfor flush jointing should be at least 7 mm thick.Thinner boards are used only when they are to berendered with synthetic binders or textures at a laterstage.
Following are some guidelines for joint finishing thatwill help achieve the required professionalappearance.
To obtain a good flush joint, it is important that allpanels have bevelled or recessed edges at the sidewhere they abut other panels.
Note that when a panel is cut to size on site, thebevel or recessed edge is often cut away. For a flushfinish, a flush joint with a double trowel width(minimum 200 mm) is required unless the recess isre-applied.
When the boards are ready for joint treatments, thefollowing steps should be followed to obtain therequired finish.
After the installation of the boards, waitapproximately 24 to 48 hours to allow the board toequalise to the moisture content of the ambientatmosphere.
Once equilibrium moisture content is achieved,moisture induced movement will be lower, reducingthe risk of joint cracking;
Clean the surface of the joint and surrounding area(approximately 300 mm in width on each side ofjoint);
Always work with clean tools and containers;
The work should be carried out in an environmentwhere the ambient temperature is at least 5 °C orabove;
Prepare the joint filler as per instructions prescribedby the filler manufacturer. Always use clean water;
Fill the joint with sufficient joint filler;
Apply a layer of reinforcing fibre mesh tape over thefiller and with a spatula cover the complete surfaceof the tape with an excessive amount of well-embedded joint filler;
Allow to dry completely and sand the surface withfine grade sandpaper;
Apply a second layer of joint filler with wide trowel;
Wait until it is completely cured and sand the surfaceagain slightly with fine grade sandpaper;
Depending on the level of finish required, aneventual final layer of joint finisher can be appliedwith a 280 mm wide (preferably curved) trowel.
It is recommended that the areas to which the filler isto be applied are primed using a P.V.A. Sealer. Thisprevents moisture from the filler being absorbed toorapidly into the boards and reduces the risk ofcracking and/or delamination of the filler.
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Aquamag® Handling and Fixing GuideJointing
Fill joint with single, thin layer of plaster and thenoverlay reinforcing mesh
Apply subsequent covering of plaster compound tofinish
Final joint after finishing with trowel
WallpaperWhen papering Aquamag® calcium silicate boards,size the surface to seal against suction and improveslip, then hang papers or vinyls in the normal way.
Flush jointing with mesh tape.Legend:
1. Aquamag® fire protective board2. Rebate, 30 mm wide, 2 mm deep (creating a 60
mm wide joint)3. PVA Sealer4. Self adhesive, woven fibreglass, jointing scrim, 50
mm wide5. Aquamag® Moisture Resistant Ready-Mixed Joint
Filler6. Timber or steel stud support framework behind
all board joints7. Dry-wall self-tapping screws or nails
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Aquamag® Handling and Fixing GuideJointing
Flush jointing with paper tapeLegend:
1. Aquamag® fire protective board2. Tapered rebate, nominal 50 mm wide3. PVA Sealer4. 50mm wide paper jointing tape5. Gypsum based joint filler6. Timber or steel stud support framework behind
all board joints7. Dry-wall self-tapping screws or dry wall nails
PlasteringAquamag® boards have a high suction and thereforeit is generally difficult to apply gypsum plaster. Ifplastering is essential please consult the Aquamag®Technical Services Department.
It is recommended that a small test area is plasteredinitially to ensure that the boards have beenadequately sealed. It is advisable that a self-adhesiveglass or hessian scrim is applied over joints andinternal angles. Paper jointing tape is notrecommended.
If a skim coat is desired:
Apply a sealing coat of diluted universal primer /P.V.A. (1 part P.V.A. to 5 parts water).Sealing coat should be allowed to dry thoroughly(approximately 24 hours).Apply bonding coat (3 parts P.V.A. to 1 part water).Apply plaster skim (maximum 5mm thick) while thebonding coat is wet and tacky.
All Aquamag® boards have a high suction factor andwhile successful skim coats are relatively easy toobtain, some care is needed to retard the rapid dryingof plaster coats, especially in areas of high ambienttemperature. The bonding agent and plastermanufacturer´s recommendations must be followedat all times.
TilingAll Aquamag® boards can be tiled, provided dueconsideration is given to the installation of theboards and the requirements for additional framingprior to applying the tiles. It should be carefully notedthat Aquamag® systems are used for their fireresistance properties.
Placing additional weight on the structural system,such as ceramic or marble tiling for instance, can havea significant effect on the overall performance of thefire resistance. It is for this reason that additionalframing is required for partition systems etc. whichare to bear the additional weight and still maintaintheir fire performance.
Support centres and fixing centres may need to bereduced to allow for the weight of the tiles(maximum 30 kg/m²). Aquamag® recommend theboards are sealed on their back face prior toinstallation, additionally Aquamag® recommendusing minimum boards with a thickness of minimum9 mm with all board joints supported, support centresat 450 mm and screws centres at 200 mm.
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Aquamag® Handling and Fixing GuidePainting
PaintingAll coatings should be supplied by a reputablemanufacturer and their recommendations regardingsurface preparation, sealing and finish coating shouldbe followed at all times.
Surfaces should be dry, free of oil, loose surface layersand dust. If required, screw holes and board jointsmay be filled with Aquamag® Ready-mixed jointfiller and sanded accordingly.
If corners of the encasement require protection,plastic or steel dry wall corner beading can be used.
When using water based paints, a first coat, typically50/50 mixed with clean water, is recommended. Foroil based paints a suitable alkali resisting primershould be used. Painted vapour barriers may beformed by the application of chlorinated rubber,epoxy resin or polyurethane paint (back sealing maybe required in certain instances).
These boards have an attractive, smooth finish but ifrequired can be painted with emulsion or oil basedpaint. With water based paints, a first coat should beused. For oil based paints, use a universal primer. Analkali resisting primer is not required.
Applying joint filler
Before painting make sure all joints are dry and clean
Water or oil based paints applied on pre installedAquamag® boards
Self supporting ducts
Kitchen extract ducts
For hygienic reasons and for the convenience ofcleaning it is recommended that a grease and fatresistant coating is applied to the board surfaceforming the internal face of the duct.
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Aquamag® Handling and Fixing GuideSelf support
Supply air ductsWhere it cannot be avoided, rain and snow may getinto the duct in the area of the fresh air intake. WhilstAquamag® boards are resistant against the effects ofmoisture, we recommend the application of a suitablewater proofing impregnation in the areas adjacent tothe intake openings for a minimum distance of 1m toreduce any water absorption. Ask a representative ofyour local Aquamag® company for appropriateproducts.
It is not recommended to coat the whole of the ductsystem with a waterproof coating, otherwise liquidwater will pool in the ducts.
The surface of Aquamag® boards may have a slightlayer of dust when first installed. In order to preventthe dust spreading through the ventilation system itis recommended to coat the Aquamag® – boards witha commercial silicate vapour permeable primer.
Self-supporting ductsAquamag® boards usually have one fair face and onenatural. For use as self-supporting ducts, the fair faceshould be positioned on the inside of the ventilationduct. This will ensure optimum air flow across theboards.
Self-supporting ducts – humidity controlArtifacts in museums and exhibitions can suffer fromhigh humidity. Especially in autumn and winter whenvisitors enter historical buildings with wet shoes andclothing, air conditioning can be overstrained by anaccumilation of moisture. Self-supporting ductsconstructed with Aquamag® boards can contribute tohumidity control as the boards are naturallybreathable and vapour permeable. Aquamag® boardsare able to absorb and release moisture dependingon the humidity of the ambient air.
Mould growthAquamag® boards do not support mould growth.There is insufficient organic material in the boardswith which a culture can form. This statement doesnot mean that the formation of moulds can beexcluded. Mould could start to grow with thepresence of high humidity and organic dust.
Exterior applicationsMost Aquamag® boards are moisture and humidityresistant, some boards are frost resistant. Despitethese properties we recommend Aquamag® boardsare protected form excessive humidity and weatherinfluences by:
ImpregnationAquamag® boards can be protected with a suitablewaterproof impregnation designed for exteriorapplications. Special attention should be paid toensure permanent closure of any joints. Penetrationof humidity through the joints is to be avoided.
CladdingThe entire construction can be protected by anovercladding system. Preferably a galvanised orAluzinc or stainless steel sheet should be used forcladding.
CoatingThe application of a commercial silicate coatingsystem will also provide a sufficient measure forweather protection. A reinforcing glass fabric iswrapped around the Aquamag® construction thenpainted with an appropriate coating systeme.g. Decothane. Thick film epoxy coatings or texturedexternal thin film coatings are also suitable.
AQUAMAG® is a registered trademark. Copyright © 2019 - 2021. All rights reserved. AQUAMAG® is a registered trademark. Copyright © 2019 - 2021. All rights reserved.
Corporate Office:P.O Box 126852 Prestige Tower-17 5th Floor, Suite 501 MBZ City, Abu Dhabi United Arab Emirates
Manufacturing Plant:No. 88, Yao Chi RoadHaian Industrial ZoneNantong, 226001 Jiangsu, China
Telephone:+971 4 244 3145
+971 50 297 1300
Email:[email protected]
Website:www.aquamag.ae
All information and data is correct at the time of going to print and we reserve the right to make technical changes at any time.
