H-ABUSE BRAND H-IMPACT BRAND GYPSUM WALLBOARD

09250/NGC

HI-ABUSE®BRAND

HI-IMPACT®BRAND

GYPSUM WALLBOARD

2

Only The Strong Survive!It’s a tough world out there. But, National Gypsum has thewallboard that can take it. Our Hi-Abuse Brand and Hi-Impact Brand Gypsum Wallboard’s are specificallydesigned to stand up to the bumps, scrapes and bangs socommon in places like schools, health care facilities, cor-rectional institutions, public corridors, and many othertough places.

Tough And Practical!National Gypsum Hi-Abuse Brand and Hi-Impact BrandWallboard may be tough, but they’re also good looking,lightweight, and cost-efficient.

In the weight category, Hi-Abuse Brand and Hi-ImpactBrand partition systems are just a fraction of the weight of concrete block (6 lbs./sq. ft. versus 27 lbs./sq. ft.).

That means easier, more efficient handling and lighterstructural and foundation requirements.

While specific cost comparisons will depend on specificinstallations, you can nevertheless save from 23% to28% per square foot in most typical installations overconcrete block.

Estimated Partition Costs*

5/8" Type X Drywall $3.51Hi-Abuse Brand $3.87Hi-Impact Brand $4.318" unfilled concrete block $5.70

*Estimated partition costs: 1) Partition construction is 3-5/8" 20 gauge stud 16"o.c. with above listed finishing material both sides of the wall. 2) Constructioncosts from the 2000 Means Cost Construction Guide and actual contractordata. Actual cost may vary based on local labor rates and material costs.3) The total installed cost estimate includes profit and overhead.

So Strong It Will ChangeYour Idea About Wallboard.

Prison walls have to be strong. And, with Hi-Impact Brand Wallboard, strong walls can be installed as easily as regular gypsum wallboard.

Quick And Easy!Since Hi-Abuse Brand and Hi-Impact Brand Wallboardare installed just like regular drywall in a single layer,installation goes quickly and easily with fewer tradesinvolved and a lot less extra material, such as plywood,metal security mesh and sheet metal. Like regular wall-board, finishing is easy with the same array of choices youwould normally have for conventional walls.

Did We Say Tough?Of course, although Hi-Abuse Brand and Hi-Impact BrandWallboard have all the advantages of cost-efficient instal-lation and an attractive appearance, their biggest advan-tage is sheer toughness. These walls have the abrasion andimpact resistance needed to stand up to tough situations,and that strength means long-term savings on repair andreplacement costs.

Before You Write The Spec, Make the Call.Hi-Abuse Brand and Hi-Impact Brand Wallboard havebeen specified and installed in countless facilities acrossthe country. Their track record of proven performance is

unmatched. So, if you’re facing a tough situation, makethe call to National Gypsum Company. After all, only thestrong survive: Hi-Abuse Brand and Hi-Impact BrandGypsum Wallboard.

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Across the country, builders and specifiers have learned that Hi-Abuse Brand and Hi-Impact Brand Wallboard can stand up to any school’s hard knocks.

In hospitals, Hi-Abuse Brand and Hi-Impact Brand Wallboard resistinjuries and accidents that can cripple conventional wallboard.

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Hi-Abuse® Brand Wallboard

Hi-Abuse Brand Wallboard is a superbly suited for wall and ceil-ing assemblies in high traffic, high activity areas, such as class-rooms, corridors, dormitories, cafeterias, day care centers, cor-rectional facilities and public housing, as well as industrial andcommercial environments. Hi-Abuse Brand Kal-Kore PlasterBase offers the same advantages as a base for veneer plasterfinishes.

Hi-Abuse Brand Wallboard panels consist of a fire resistant gyp-sum core encased in heavy smooth white abrasion resistant fin-ish paper on the face side and heavy liner paper on the backside. Hi-Abuse Wallboard panels feature a specially formulatedcore to provide greater resistance to surface indentation andimpact than fiber-reinforced gypsum panels. Long edges of thepanels are tapered to allow joints to be reinforced and con-cealed with joint tape and joint treatment compounds. Hi-Abuse 5/8" Fire-Shield® Wallboard features a type X core toprovide fire resistance ratings when used in tested systems.

Hi-Abuse® Brand Kal-Kore® Plaster Base

Hi-Abuse Brand Kal-Kore Fire-Shield type X Plaster Base panelsconsist of a fire resistive type X gypsum core encased in aheavy, blue absorptive face paper designed to permit rapidtrowel application and strong bond of Uni-Kal veneer plasterand strong liner paper on the back side. Hi-Abuse Brand Kal-Kore Fire-Shield type X plaster base features a specially formu-lated core to provide fire resistance ratings when used in testedsystems as well as greater resistance to surface indentation.Long edges of the panels are tapered to allow joints to be rein-forced and concealed with Kal-Mesh Tape and Uni-Kal Plaster.

� Provides greater resistanceto surface abuse, indenta-tion and impact than fiber-reinforced gypsum panels.The Hi-Abuse Brand’ssmooth, white face paper ishighly resistant to scuffingwhen sanding wallboardjoints and fasteners provid-ing a superior surface fordecoration.

� Hi-Abuse Brand Wallboardand Hi-Abuse Brand Kal-Kore Plaster Base are easilyscored and snapped forquick installation. Openingsand outlet boxes are cut outin the same manner as regu-lar wallboard.

HI-ABUSE®BRAND WALLBOARD &

HI-ABUSE®BRAND KAL-KORE® PLASTER BASE

DESCRIPTION

APPLICATIONS

FEATURES/BENEFITS

Heavy White Abrasion-Resistant Face Paper

Enhanced Core Heavy Liner Paper

Hi-Abuse Brand Wallboardand Hi-Abuse Brand Kal-Kore Plaster Base are ideallysuited for areas where sur-face durability and impactresistance are major con-cerns. For example:

� Classrooms

� Corridors

� Dormitories

� Day care centers

� High traffic areas.

Abrasion-Resistant Uni-Kal Veneer Plaster

Enhanced Core Heavy Liner Paper

� Hi-Abuse Brand Wallboardis a lightweight, cost-effi-cient material that readilyaccepts a wide range ofdecorative finishes.

� Hi-Abuse Brand Kal-Koreprovides the appearanceand surface of conventionalplaster at a lower cost thanregular plastering.

� Hi-Abuse Brand Kal-Kore,when used with Uni-Kalveneer plaster, provides anexcellent base over whichpaints and other finishescan be applied.

� The gypsum core will notsupport combustion ortransmit temperatures great-ly in excess of 2120F (1000C)until completely calcined, aslow process.

� Expansion and contractionunder normal atmosphericchanges is negligible.

� 5/8" Fire-Shield Hi-AbuseBrand panels may be usedwhere type X gypsum pan-els are specified in fire-ratedwall and floor-ceilingassemblies (i.e., UL U300,U400, V400 and L500series.)

Walls and ceilings in school corridors and cafeterias are ideal appli-cations for Hi-Abuse Brand Wallboard.

-0.045

-0.040

-0.035

-0.030

-0.025

-0.020

-0.015

-0.010

-0.005

-0.000

0 40 60 80 100

5

TECHNICAL DATA

As illustrated above, Hi-Abuse Brand Wallboard scores and snaps clean, unlike fiber reinforced gypsum panels and cement/gypsum compositepanels. Since Hi-Abuse Brand Wallboard installs like regular drywall, there is no additional labor required in scoring or making cutouts forelectrical and plumbing fixtures. Hi-Abuse Brand Wallboard also finishes like regular drywall which provides a better finished wall than fiberreinforced gypsum panels or cement/gypsum composite panels.

5/8" NGC HI-ABUSE BRAND WALLBOARD 5/8" FIBER REINFORCED GYPSUM PANEL 5/8" FIBER-CEMENT/GYPSUM COMPOSITE PANEL

SOFT BODY IMPACT RESISTANCEModified ASTM E 695

Number Cumulative 5/8" NGC 5/8" Fiber 5/8" Fiber-Of Impact Hi-Abuse Reinforced Cement/Gypsum

Impacts Force Brand Gypsum Compositeft-lbs. Wallboard Panel Panel

40 916 -0.019 -0.032 -0.03360 1374 -0.019 -0.037 -0.03380 1832 -0.019 -0.040 -0.033100 2290 -0.020 -0.042 -0.033

Procedure Summary – Soft body impactor (leather bag 29 "x 9") filledwith sand to a gross weight of 50 lbs. The bag is supported as a pendulum,striking the panel midway between stud and mid height of test wall. Valuesrepresent deflection in inches.

This test measures the ability to withstand soft impact, such a person’sbody impacting the wall.

Defle

ctio

n In

Inch

es

� 5/8" NGC Hi-Abuse Brand Wallboard � 5/8" Fiber Reinforced Gypsum Panel � 5/8" Fiber-Cement/Gypsum Composite PanelNumber Of Impacts

Less Is Better

050

100150200250300350400450500

INDENTATION RESISTANCE (HARDNESS)Modified ASTM D 1037

5/8" NGC 5/8" Fiber 5/8" Fiber-Hi-Abuse Reinforced Cement/Gypsum

Brand Gypsum CompositeWallboard Panel Panel

Load, lbs @ 0.100" 232 177 231Load, lbs @ 0.200" 469 266 381

Procedure Summary – To measure surface indentation, a load wasapplied to a steel ball (diameter 0.438"), at a rate of 0.25"/minute to anindentation depth of 0.100" and 0.200".

This test measures surface hardness and the ability to withstand dents,scuffs and indentations.

Load

, Lbs

.

@ 0.200"

More Is Better

� 5/8" NGC Hi-Abuse Brand Wallboard � 5/8" Fiber Reinforced Gypsum Panel � 5/8" Fiber-Cement/Gypsum Composite Panel

0

10

20

30

40

50

60

70

0

10

20

30

40

50

60

70

0

20

40

60

80

100

120

140

6

5/8" NGC 5/8" Fiber 5/8" Fiber-Hi-Abuse Reinforced Cement/Gypsum

Brand Gypsum CompositeWallboard Panel Panel

Impact/Penetration 60 24 24Rating (ft.-lbs.)

Impact/penetration ratings indicate the maximum force in foot-poundsresisted in a single drop without penetration through the board. Whenimpacted by a 24- pound 5-1/2" diameter, hemispherical steel projectile,5/8" Fire-Shield type X Hi-Abuse Brand Wallboard applied vertically to 20gauge 3-5/8" steel studs spaced 16" o.c. with 1-1/4" long, type S screwsspaced 8" o.c. along edges and 12" o.c. in the field of the board will resistan impact force of 60 foot-pounds without penetration.

This test measures the ability to withstand the impact of a large object suchas a hospital gurney or utility cart.


Number Of Cycles

5/8" NGC Hi-Abuse Brand Wallboard 125

5/8" Fiber Reinforced Gypsum Panel 125

5/8" Fiber-Cement.Gypsum Composite Panel 125

Number of cycles performed without abrasion depth exceeding .01".

Procedure Summary - A Taber Abraser with two rubber wheels fittedwith S-42 sand paper was activated and after every 25 cycles the surface erosion was measured.

This test measures resistance to surface abrasion caused by a rough object. Num

ber O

f Cyc

les


TABER SURFACE ABRASION RESISTANCE (ABRASER - SAND PAPER)Modified ASTM D 4060

Impa

ct In

Ft.-

Lbs.

IMPACT/PENETRATION RESISTANCE RATINGModified ASTM D 2394

Impact Force In Ft.-Lbs.



5/8" Fiber-Cement/Gypsum Composite Panel 60

Procedure Summary - A 2'x2' test wall is securely clamped to a rigid testframe and impacted with a ram mounted on a pendulum which is faced witha nominal 2 1/2" pipe cap. The maximum impact force that the samplecan withstand without penetration through the face of the sample is reportedin foot-pounds.

This test measures the ability to withstand the impact of a small, hard objectsuch as a hammer or heel of a boot. Im

pact

For

ce In

Ft.-

Lbs.


SMALL PROJECTILE IMPACT TEST

More Is Better

More Is Better

05

101520253035404550

0

50

100

150

200

250

300

7

Number Of Cycles




Number of cycles performed without abrasion depth exceeding .001".

Procedure Summary - A 3M Granule Embedding Test Machine with wirebrush was activated and after every 50 cycles (50 forward and 50 backstrokes) the surface erosion was measured.

This test measures resistance to surface abrasion caused by a wire brush. Num

ber O

f Cyc

les


3M SURFACE ABRASION RESISTANCE (ABRASER - WIRE BRUSH)Modified ASTM D 4977

TECHNICAL DATA

Sizes & types

Width: 4’ (1219 mm)

Lengths: 8’ through 12’(2438 mm-3658 mm)

Thickness: 5/8" type X (15.9mm), 1/2” (12.7 mm) (Hi-Abuse Brand WallboardOnly)

Edges: Tapered

Surface Burning Characteristics(Wallboard & Plaster Base)

ASTM E 84

Flame spread: 15

Smoke developed: 0

Absorption In Grams

5/8" NGC Hi-Abuse Brand Wallboard 1.37

5/8" Fiber Reinforced Gypsum Panel 45.04

5/8" Fiber-Cement/gypsum Composite Panel 6.34

Procedure Summary - To measure water absorption, a Cobb Ring wasclamped to the panel surface, filled with a 1" head of 700 F water for 1 hourand the moisture absorption calculated by weight difference.

This test measures surface absorption which effects the ability to withstandmoisture on jobsite conditions and provides an indication of the amount ofpaint required to finish the surface to an acceptable level. Ab

sorp

tion

In G

ram

s


MOISTURE ABSORPTIONModified ASTM D 3285

Less Is Better

Fire resistance ratings repre-sent the results of tests onassemblies made up of spe-cific materials in a specificconfiguration. When select-ing construction designs tomeet certain fire resistancerequirements, caution mustbe used to insure that eachcomponent of the assemblyis the one specified in thetest. Further, precautionshould be taken that assem-bly procedures are in accordance withthose of the tested assem-bly. (For copies of specific tests, call 1-800-NATIONAL.)

5/8" Fire-Shield Hi-AbuseBrand panels may be usedwhere type X gypsum panels are specified in fire-rated wall and floor-ceilingassemblies (i.e., UL U300,U400, V400 and L500series.)

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Hi-Abuse Brand Wallboard

Installation of Hi-Abuse BrandWallboard should be consis-tent with methods describedin Applicable Standards. Forbest impact performance,use vertical application.

� For best painting results, allsurfaces, including jointcompound, should be clean,dust-free and not glossy. Toimprove fastener and jointconcealment, a coat of aquality drywall primer isrecommended to equalizethe porosities between sur-face paper and joint com-pound. The selection of apaint to give the specified ordesired finished characteris-tics is the responsibility ofthe architect or contractor.Hi-Abuse Brand wallboardthat is to have a wall cover-ing applied to it should beprepared and primed asdescribed for painting.

� Gypsum Association GA-214, RecommendedSpecification for Levels ofGypsum Board Finish,should be referred to inorder to determine the levelof finishing needed to assurea surface properly preparedto accept the desired deco-ration.

INSTALLATION


ASTM C 840

National Gypsum Co.Gypsum Construction Guide

Hi-Abuse Brand Kal-KorePlaster Base

ASTM C 843

ASTM C 844


APPLICABLE STANDARDS

LIMITATIONS


� Exposure to excessive orcontinuous moisture andextreme temperaturesshould be avoided.

� Not recommended where itwill be exposed to tempera-tures exceeding 1250F (520C)for extended periods oftime.

� Should not be used as a basefor tile or wall panels in tuband shower enclosures.

� Must be stored off theground and under cover.Sufficient risers must beused to assure support forthe entire length of the wall-board to prevent sagging.

Hi-Abuse Brand Kal-Kore

� Veneer plaster systems are tobe installed with maximumdeflection criteria of L/240.

� When Uni-Kal veneer plas-ter is applied, do not installHi-Abuse Brand Kal-KorePlaster Base too far inadvance of the plastering,since the bond can beadversely affected if the faceof the panels becomes fadedfrom light. If Hi-Abuse Kal-Kore has been faded, applyKal-Kote Base Plaster or abonding agent to obtain agood bond.

ACCESSORIES


� Fasteners: drywall screws

� Joint tape

� Joint compound

� Cornerbead

� Trims

� Casing beads

� Furring channels

� E-Z Strip control joints

� .093 zinc control joint

Hi-Abuse Brand Kal-Kore Plaster Base

� Kal-Mesh to reinforce jointsand interior angles

� Kal-Korner Bead

� Expanded VeneerCornerbead

� Veneer L Trim Casing Bead

� Veneer J Trim Casing Bead

� E-Z Strip Control Joint

� Fasteners: type S Screws - 1-1/4" for single layer and 1-5/8" for outer layer in two-ply application to 3-5/8", 20gauge screw studs.

Hi-Abuse Brand Kal-Kore Plaster Base

Installation of Hi-Abuse Kal-Kore Plaster Base should beconsistent with methodsdescribed in ApplicableStandards.

� Plaster base job site condi-tions of temperature andhumidity, mineral content ofwater and variances inaggregates often cause shad-ing discolorations in theplaster. Therefore, theveneer plaster should not beconsidered a finished prod-uct. Plaster should be paint-ed or decorated in someother manner. Paint manu-facturers should be consult-ed as to compatible prod-ucts. National Gypsum rec-ommends alkali-resistantprimers formulated for useover new plaster. Highbuild, heavy duty and spe-cial purpose coatings suchas Epoxy are not recom-mended over veneer or jobgauged lime putty finishes.

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SPECIFICATIONS

The following paragraphs arefor insertion into sections ofgeneric specifications orgeneric/proprietary specifi-cations covering gypsumwallboard products. TheNational Gypsum productname follows the genericdescription in parentheses.

PART 2 PRODUCTS

A. Fire/Abuse-ResistantGypsum Board: A gypsumcore wall panel with addi-tives to enhance fire resis-tance, surface indentationresistance, and impact resis-tance of the core and sur-faced with abrasion-resistantpaper on front and longedges with heavy linerpaper bonded to the backside; and complying withASTM C 36/C 1396, type X(Hi-Abuse Brand Fire-Shieldtype X Wallboard)

1. Thickness: 5/8 in.

2. Width: 4 ft.

3. Length: 8 ft. through 12 ft.

4. Edges: tapered

5. Impact Resistance: No fail-ures after 100 impacts whentested in accordance withASTM E 695, modified.

6. Indentation Resistance: Notless than the following loadsto produce the indicateddepth of the surface indenta-tion when produced inaccordance with ASTM D1037, modified;

a. 0.100 in.: 232 lbs

b. 0.200 in.: 469 lbs.

7. 3M Surface AbrasionResistance: Not greater than0.001 in. when tested at 250cycles in accordance withASTM D 4977, modified.

8. Taber Surface AbrasionResistance: Not greater than0.010 in. when tested at 125cycles in accordance withASTM D 4060, modified.

9. Impact/PenetrationResistance Rating: Not lessthan 60 ft.-lbs. when testedin accordance with ASTM D2394, modified.

Hi-Abuse Brand Wallboard provides the perfect solution for high traffic areas such as hallways and corridors.

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HI-IMPACT®BRAND WALLBOARD &

HI-IMPACT®BRAND KAL-KORE® PLASTER BASE

DESCRIPTION

This is one tough wallboard. By combining the surface tough-ness of Hi-Abuse Brand Wallboard with the strength ofLexan,®* National Gypsum has created a wallboard that canreally stand up to scrapes and hard knocks. The newlyimproved Hi-Impact Brand Fire-Shield type X Wallboard pro-vides the maximum combination of abrasion resistance andimpact/penetration resistance for those areas faced withexceptionally high levels of wear and tear. Here’s a wallboardthat can go in places you never dreamed gypsum wallboardcould go before.

Hi-Impact Brand Wallboard

As strong and tough as it is, Hi-Impact Brand Wallboard is aseasy to use and install as regular gypsum wallboard. Lessexpensive and labor intensive than concrete block and fiber-reinforced gypsum panels, the original Hi-Impact BrandWallboard has quickly become the preferred choice of archi-tects and contractors. Now, that original is even better andtougher with the addition of improved surface abrasion resis-tance. Thus, improved Hi-Impact Brand Fire-Shield type XWallboard is superbly suited for all those really tough jobs,such as schools, correctional facilities, dormitories, hospitals,mass transit facilities, public housing, common areas andretail separation walls.

Hi-Impact Brand Wallboard panels are backed with Lexan substrate and are available in four increasingly higher levelsof impact resistance:

1. Hi-Impact Brand 1000 with a 0.010" Lexan substrate



4. Hi-Impact Brand 8000** with a 0.080" Lexan substrate

** Hi-Impact Brand 8000 is manufactured with heavy natural-finish paper on the face side.

And, just like regular wallboard, Hi-Impact Brand Wallboard canbe cut and installed quickly; so painting, other decoration andthe installation of most metal and wood trim can begin almostimmediately.

With Hi-Impact Brand Wallboard, now tough walls can still begood looking.

Each 5/8" panel consists of a fire resistive type X gypsum coreencased in heavy, smooth, white abrasion-resistant paper onthe face side and strong liner paper on the back side. Lexansubstrate is bonded to the back side of the panel to provideadditional impact/penetration resistance. Long edges of thepanels are tapered to allow joints to be reinforced and con-cealed with National Gypsum Joint Tape and Joint TreatmentCompounds.

Hi-Impact Brand Kal-Kore Fire-Shield type X Plaster Base

For those applications where the look and feel of veneer plasteris preferred, Hi-Impact Brand Kal-Kore Fire-Shield type XPlaster Base provides comparable impact/penetration resis-tance. Each panel consists of a fire resistive type X gypsumcore encased in a heavy blue absorptive face paper designedto permit rapid trowel application and a strong bond of Uni-Kal veneer plaster. Like Hi-Impact Brand Wallboard, it too isbacked with Lexan substrate to the back paper.

APPLICATION

FEATURES/BENEFITS

Hi-Impact Brand Wallboard is ideally suited for those areaswhere both surface durability and resistance to impacts andpenetrations are a vital concern.

� Schools

� Hospitals

� Detention Centers

� Prisons

� Lightweight, cost-efficient material that readily accepts a widerange of decorative finishes.

� Resistance to abrasion, indentation and penetration superiorto fiber-reinforced gypsum panels.

� Hi-Impact Brand Fire-Shield Wallboard is easily cut for quickinstallation, permitting painting or other decoration and theinstallation of most metal or wood trim almost immediately.

� The gypsum core will not support combustion or transmittemperatures greatly in excess of 2120F (1000C) until com-pletely calcined, a slow process.

� Expansion and contraction under normal atmosphericchanges is negligible.

� Resists scuffing during installation for a superior surface fordecoration.

� Cuts and scores like regular wallboard.

Heavy White Abrasion-Resistant Face Paper

Enhanced Core Lexan® Substrate

Abrasion-Resistant Uni-Kal® Veneer Plaster

Enhanced Core Lexan® Substrate

*

11

LIMITATIONS


� Exposure to excessive orcontinuous moisture andextreme temperaturesshould be avoided. Hi-Impact Brand products arenot recommended wherethey will be exposed totemperatures exceeding1250 F (520 C) for extendedperiods of time.

� Should not be used as a basefor tile or wall panels in tuband shower enclosures.

� Not recommended for useon the interior side of exteri-

or walls in hot, humid cli-mates such as the SouthernAtlantic and Gulf Coast areas.

� Listed impact/penetrationratings apply to walls con-structed with Hi-ImpactBrand Wallboard appliedwith long edges parallel toand centered over minimum20 gauge framing membersspaced a maximum of 16”o.c.

� Not recommended to beused over kraft-faced insula-tion or other vapor retarders.

� Must be stored off theground and under cover.Sufficient risers must beused to assure support for

the entire length of the wall-board to prevent sagging.

� When using Hi-ImpactBrand 8000 Wallboard spe-cial consideration should begiven when ordering doorframes to allow for the addi-tional width of the wall sys-tem due to the 0.080" Lexanbacking.

Hi-Impact Brand Kal-Kore Plaster Base

� Veneer plaster systems are tobe installed with maximumdeflection criteria of L/240.

INDENTATION RESISTANCE (HARDNESS)Modified ASTM D 1037

5/8" NGC 5/8" FiberHi-Impact Reinforced

Brand GypsumWallboard Panel

Load, lbs @ 0.100" 232 177Load, lbs @ 0.200" 469 266

Procedure Summary – To measure surface indentation, a load wasapplied to steel ball (diameter 0.438"), at a rate of 0.25"/minute to an inden-tation depth of 0.100" and 0.200".

This test measures surface hardness and the ability to withstand dents, scuffs and indentations.

Load

, Lbs

.

050

100150200250300350400450500

@ 0.200"

More Is Better

� 5/8" NGC Hi-impact Brand Wallboard � 5/8" Fiber Reinforced Gypsum Panel

TECHNICAL DATA

� When Uni-Kal veneer plas-ter is applied, do not installHi-Impact Brand Kal-KorePlaster Base too far inadvance of the plastering,since the bond can beadversely affected if the faceof the panels becomes fadedfrom light. If Hi-Impact Kal-Kore has been faded, applyKal-Kore Base Plaster or abonding agent to obtain agood bond.

0

50

100

150

200

250

300Number Of Cycles

5/8" NGC Hi-Impact Brand Wallboard 250


Numbers of cycles performed without abrasion depth exceeding .001".

Procedure Summary - A 3M Granule Embedding Test Machine withwire brush was activated and after every 50 cycles (50 forward and 50 backstrokes) the surface erosion was measured.

This test measures resistance to surface abrasion caused by a wire brush.

Num

ber O

f Cyc

les

� 5/8" NGC Hi-Impact Brand Wallboard � 5/8" Fiber Reinforced Gypsum Panel

3M SURFACE ABRASION RESISTANCE (ABRASER - WIRE BRUSH)Modified ASTM D 4977

05

101520253035404550

155

160

165

170

175

180

185

0

20

40

60

80

100

120

140

12

Number Of Cycles

5/8" NGC Hi-Impact Brand Wallboard 125


Numbers of cycles performed without abrasion depth exceeding .01".

Procedure Summary - A Taber Abraser with two rubber wheels fittedwith S-42 sand paper was activated and after every 25 cycles the surface erosion was measured.

This test measures resistance to surface abrasion caused by a rough object.

Num

ber O

f Cyc

les


TABER SURFACE ABRASION RESISTANCE (ABRASER - SAND PAPER)Modified ASTM D 4060

Absorption In Grams

5/8" NGC Hi-Impact Brand Wallboard 1.37

5/8" Fiber Reinforced Gypsum Panel 45.04

Procedure Summary - To measure water absorption, a Cobb Ring wasclamped to the panel surface, filled with a 1" head of 700 F water for 1 hourand the moisture absorption was calculated by weight difference.

This test measures surface absorption which effects the ability to withstandmoisture on jobsite conditions and provides an indication of the amount ofpaint required to finish the surface to an acceptable level.

Abso

rptio

n In

Gra

ms


MOISTURE ABSORPTIONModified ASTM D 3285

Less Is Better

Impact Force In Ft.-Lbs.

5/8" NGC Hi-Impact Brand 1000 Wallboard 180

5/8" Fiber Reinforced Gypsum Panel With Embedded Fiberglass Scrim 165

Procedure Summary - A 2'x2' test wall is securely clamped to a rigidtest frame and impacted with a ram mounted on a pendulum which is facedwith a nominal 2-1/2" pipe cap. The maximum impact force that the sample can withstand without penetration through the face of the sample isreported in foot-pounds.

This test measures the ability to withstand the impact of a small, hard objectsuch as a hammer or heel of a boot. Im

pact

For

ce In

Ft.-

Lbs.

� 5/8" NGC Hi-Impact Brand 1000 Wallboard � 5/8" Fiber Reinforced Gypsum Panel With Embedded Fiberglass Scrim

SMALL PROJECTILE IMPACT TEST

More Is Better

0

500

1000

1500

2000

2500

13

Impact/Penetration Product Resistance (Ft.-Lbs.)

5/8" Fire-Shield Type X Hi-Impact Brand 1000 (Substrate – (0.010" Lexan)* 264



5/8" Fire-Shield Type X Hi-Impact Brand 8000 (Substrate – (0.080" Lexan)* >2188

1/2" Fiber-Reinforced Gypsum Panel (single layer) 24

5/8" Fiber-Reinforced Gypsum Panel (single layer) 24

5/8" Fiber-Reinforced Gypsum Panel (double layer) 168

5/8" Fiber-Reinforced Gypsum Panel With Fiberglass Scrim 144


1/2" Regular Wallboard (single layer) 36

5/8" Type X Wallboard (single layer) 60

5/8" Type X Wallboard (double layer) 72

1/2" Exterior Grade Plywood 216

7/16" OSB With 1/2" Regular Wallboard 144

8" CMU Unreinforced – Single Block (at hollow) 12

8" Unreinforced Single Block (at rib) 72

*Testing certified by ITS/Warnock Hersey Laboratories.

Footnotes:1.Impact rating indicates the maximum force in foot-pounds resisted in a single drop without penetration into the wall.2. When impacted by a 5-1/2" diameter, hemispherical projectile, 5/8" Fire-Shield type X Hi-Impact Brand Wallboard

applied vertically to 20 gauge 3-5/8" studs spaced 16" o.c. with 1-1/4" long, type S screws spaced 8" o.c. along edgesand 12" o.c. in the field of the board will resist an impact force of 264 foot-pounds (Hi-Impact Brand 1000), 846 foot-pounds (Hi-Impact Brand 2000), 1450 foot-pounds (Hi-Impact Brand 3000), and > 2188 foot-pounds (Hi-ImpactBrand 8000) without penetration.

3. With the exception of the concrete block, all products were tested on metal framing consisting of 3-5/8", 20 gaugestuds and track. Products were attached with 1-1/4" type S screws 8" o.c. along the perimeter and 12" o.c. in the field.

IMPACT / PENETRATION RESISTANCE RATINGPer ASTM D 2394 Modified*

TECHNICAL DATA

Sizes & Types

� Width: 4' (1219mm)

� Lengths: 8' (2438mm)through 12' (3658mm)

� Thickness: 5/8" (15.9mm)

� Edge: Tapered

Surface Burning Characteristics

ASTM E 84

Flame spread (Face): 15

Flame spread (Back): 50 or less

NONCOMBUSTIBLE

Hi-Impact Brand Fire-ShieldWallboard and Hi-ImpactBrand Kal-Kore Plaster Basemeet the definition of “non-

combustible” as stated insection 215 of the 1997Uniform Building Code, sec-tion 202 of the 1999Standard Building Code,and are accepted as non-combustible in accordancewith section 704.4.1.2 ofthe 1999 BOCA NationalBuilding Code.

In addition, Hi-Impact BrandFire-Shield Wallboard andHi-Impact Brand Kal-KorePlaster Base meet the defini-tion of “Limited-Combustible” as stated insection 3.3.118 of NFPA 101Life Safety Code, 2000 edi-tion, and chapter 2 of NFPA220 Types of BuildingConstruction, 1999 edition.

POTENTIAL HEAT VALUE

Potential Heat Values perNFPA 259 are as follows:

Hi-Impact Brand 1000 - 488 BTU/lb.

Hi-Impact Brand 2000 - 771 BTU/lb.

Hi-Impact Brand 3000 -1086 BTU/lb.

WATER VAPOR PERMEABILITY

In tests conducted according toASTM test method E 96(desiccant method), Hi-Impact Brand Fire-ShieldWallboard showed a perfor-mance of less than 0.3perm.

FIRE ENDURANCE

1 Hour Rating: 5/8" Hi-ImpactBrand Fire-Shield type XWallboard screw attachedvertically to both sides of 20gauge 3-5/8" studs spaced16" o.c. with 1-1/4" long,type S screws spaced 8" o.c.along edges and 12” o.c. inthe field of the board.Wallboard joints staggered.

WHI Test No: 651-0489.01UL U495, V416

2 Hour Rating: Constructedwith a base layer of 5/8" Hi-Impact Brand Wallboardwith an additional layer of5/8" Fire-Shield type X wall-board screw attached verti-cally to both sides of 20gauge 3-5/8" studs spaced16” o.c. with joints stag-gered between face andbase layer. Base layerattached with 1-1/4" long

Products� 5/8" Fiber-Cement/Gypsum Composite Panel � 5/8" Fiber-Reinforced Gypsum Panel (single layer)� 5/8" Fiber-Reinforced Gypsum Panel With Fiberglass Scrim� 5/8" Fire-Shield Type X Hi-Impact Brand 1000 (Substrate – (0.010" Lexan)� 5/8" Fire-Shield Type X Hi-Impact Brand 2000 (Substrate – (0.020" Lexan)� 5/8" Fire-Shield Type X Hi-Impact Brand 3000 (Substrate – (0.030" Lexan)� 5/8" Fire-Shield Type X Hi-Impact Brand 8000 (Substrate – (0.080" Lexan)

Impa

ct/R

atin

gs (F

t.-L

bs.)

IMPACT / PENETRATION RESISTANCE RATING

>2188

14

type S screws spaced 8" o.c.along edges and 12” o.c. inthe field of the board. Outerlayer attached with 1-5/8"long type S screws spaced16" o.c. in the field andalong vertical edges and 12"o.c. to the floor and ceilingrunners.

UL U495

INSTALLATION


� Installation of 5/8" Hi-Impact Brand Fire-Shieldtype X Wallboard should beconsistent with methodsdescribed in ApplicableStandards (see page 15) withone exception - for bestresults, cutting and scoringof Hi-Impact Brand 1000,2000 and 3000 should befrom the back side of theboard. (Hi-Impact Brand8000 should be cut with acircular saw (face up) usinga carbide-tipped fine-toothed blade. For cuttingout minor penetrations, usea carbide-tipped router.)

� For best painting results, allsurfaces, including jointcompound, should be clean,dust-free and not glossy. Toimprove fastener and jointconcealment, a coat of aquality drywall primer isrecommended to equalizethe porosities between sur-face paper and joint com-pound. The selection of apaint to give the specified ordesired finished characteris-tics is the responsibility ofthe architect or contractor.Hi-Impact Brand wallboardthat is to have a wall cover-ing applied to it should beprepared and primed asdescribed for painting.

� Gypsum Association GA-214, RecommendedSpecification for Levels ofGypsum Board Finish,should be referred to inorder to determine the levelof finishing needed to assurea surface properly preparedto accept the desired deco-ration.

Hi-Impact Brand Kal-KorePlaster Base

� Hi-Impact Brand Kal-KorePlaster Base is installed inthe same manner as Hi-Impact Brand Wallboardnoted above.

ACCESSORIES

STRUCTURALCORNER SYSTEM


� Fasteners: drywall screws

� Joint tape

� Joint compound

� Cornerbead

� Trims

� Casing beads

� Furring channels

� E-Z Strip control joints

� .093 zinc control joint

Hi-Impact Brand Kal-Kore Plaster Base

� Kal-Mesh to reinforce jointsand interior angles

� Kal-Korner Bead

� Expanded VeneerCornerbead

� Veneer L Trim Casing Bead

� Veneer J Trim Casing Bead

� E-Z Strip Control Joint

� Fasteners: Type S Screws - 1-1/4" for single layer and 1-5/8" for outer layer in two-ply application to 3-5/8”, 20gauge screw studs.

No-Coat Drywall Corner System

� No-Coat® has engineered acorner system that actuallybecomes part of the struc-ture. The center membraneof each No-Coat StructuralDrywall Corner is made ofstrong, impact-resistant plas-tic. On the inner surface,joint tape permanentlybonds the entire flange tothe drywall corner with justa small amount of ProForm®

All Purpose joint compound.

� NAHB research Center testsdetermined that No-coatStructural Corners are eighttimes stronger than tradi-tional cornerbead.

� When used in combinationwith Hi-Impact Wallboard,No-Coat UltraCornerTM

Structural Corner provides asuperior system that is moreresistant to impact and surface abuse than conven-tional drywall systems.

� For more information, contact No-Coat atwww.no-coat.com.

Tapered plastic membranedelivers incredible strength.

Surface paper flapeliminates cracking.

48 sq. in. of joint tapeper foot ensures 100%bonding to drywall withProForm® Brand All Purpose Ready Mix.

Corner Product Height Of Level 1 FailureVinyl Standard 12"Vinyl Radius 12"Metal Crimp-On 12"Metal Radius 12"Paper-Face Metal 18"Metal Nail-On 24"No-Coat UltraCornerTM 96"

The chart above indicates at what drop height each corner type warranted repair.The No-Coat UltraCorner displayed significantly greater resistance to hard-bodied impact than the other corners tested.Procedure Summary - A steel cylinder, two inches in diameter with arounded head and weighing about two pounds, was used as the impact object.The cylinder was dropped down a guide tube at various heights, beginning atsix inches, to gauge the degree of impact each corner type could sustain.

NAHB RESULTS FROM IMPACT TESTING

No-Coat Structural Corner

15


ASTM C 840

Gypsum Association GA-216

Gypsum Association GA-214


Hi-Impact Kal-Kore BrandPlaster Base

ASTM C 843

ASTM C 844


APPLICABLE STANDARDS

SPECIFICATIONS

The following paragraphs arefor insertion into sections ofgeneric specifications orgeneric/proprietary specifi-cations covering gypsumwallboard products. TheNational Gypsum productname follows the genericdescription in parentheses.

PART 2 PRODUCTS

A. Fire and Impact/PenetrationResistant Gypsum Board: Agypsum core wall panelwith additives to enhancefire resistance, surfaceindentation resistance, and

impact resistance of the coreand surfaced with abrasion-resistant paper on front andlong edges, heavy linerpaper bonded to the backside, and a GE LexanSubstrate adhered toenhance impact/penetrationresistance and complyingwith ASTM C 36/C 1396type X Hi-Impact BrandGypsum Wallboard.

1. Thickness: 5/8 in. with0.010" Lexan substrate (Hi-Impact Brand Fire-Shieldtype X 1000);

5/8 in. with 0.020" Lexansubstrate (Hi-Impact BrandFire-Shield type X 2000);

5/8 in. with 0.030" Lexansubstrate (Hi-Impact BrandFire-Shield type X 3000);

5/8 in. with 0.080" Lexansubstrate (Hi-Impact BrandFire-Shield type X 8000*).

2. Width: 4 ft.

3. Length: 8 ft. through 12 ft.

4. Edges: square, tapered, orBeveled Tapered (Sta-Smooth Edge)

5. Impact Resistance: No fail-ures after 100 impacts whentested in accordance withASTM E 695, modified.

6. Indentation Resistance: Not less than 469 lbs. toproduce 0.200 in. depth ofthe surface indentationwhen produced in accor-dance with ASTM D 1037,modified.

7. 3M Surface AbrasionResistance: Not greater than0.001 in. when tested at 250cycles in accordance withASTM D 4977, modified.

8. Taber Surface AbrasionResistance: Not greater than0.010 in. when tested at 125cycles in accordance withASTM D 4060, modified.

9. Penetration Resistance:

264 ft.-lbs. without penetra-tion (Hi-Impact Brand Fire-Shield type X 1000); 846 ft.-lbs. without penetration (Hi-Impact Brand Fire-Shieldtype X 2000); 1,450 ft.-lbs. with-out penetration (Hi-ImpactBrand Fire-Shield type X 3000);>2188 ft-lbs. without pene-tration (Hi-Impact BrandFire-Shield type X 8000).

*Hi-Impact Brand 8000 ismanufactured with heavynatural-finish paper on theface side.

The Pepsi Center, home of the NBA Denver Nuggets and the NHL Colorado Avalanche, used Hi-ImpactBrand Wallboard throughout its high-traffic areas.

� Plaster base job site condi-tions of temperature andhumidity, mineral content ofwater and variances inaggregates often cause shad-ing discolorations in theplaster. Therefore, theveneer plaster should not beconsidered a finished prod-uct. Plaster should be paint-ed or decorated in someother manner. Paint manu-facturers should be consult-ed as to compatible prod-ucts. National Gypsum rec-ommends alkali-resistantprimers formulated for useover new plaster. Highbuild, heavy duty and spe-cial purpose coatings suchas Epoxy are not recom-mended over veneer or jobgauged lime putty finishes.

110793 Rev. 5/01

� Western AreaPhone: (800) 824-4227Fax: (800) 438-6266

� Midwest AreaPhone: (800) 323-1447Fax: (800) 443-1329

� Southwest AreaPhone: (800) 548-9396Fax: (800) 442-2793

� Gulf AreaPhone: (800) 343-4893Fax: (800) 442-2793

� Southeast AreaPhone: (800) 548-9394Fax: (800) 442-2793

� Atlantic AreaPhone: (800) 237-9167Fax: (800) 443-1329

� Central AreaPhone: (800) 252-1065Fax: (800) 443-1329

� Northeast AreaPhone: (800) 253-3161Fax: (800) 443-1329

National AccountsPhone: (800) 440-1230Fax: (800) 442-2793

Manufactured HousingPhone: (800) 455-3185Fax: (800) 639-1714

Technical InformationPhone: (800) NATIONAL

(800) 628-4662Fax: (800) FAX-NGC1

(800) 329-6421

Corporate HeadquartersNational Gypsum Company2001 Rexford RoadCharlotte, NC 28211 Phone: (704) 365-7300www.nationalgypsum.com

Limited Warranty and Remedies

Products manufactured and sold byNational Gypsum Company are war-ranted by National Gypsum Companyto its customers to be free from defectsin materials and workmanship at thetime of shipment. THIS EXPRESS WARRANTY IS THE ONLY WARRANTYAPPLICABLE TO SUCH PRODUCTS,AND IS IN LIEU OF AND EXCLUDES ALLOTHER EXPRESS ORAL OR WRITTENWARRANTIES AND ALL IMPLIED WARRANTIES, INCLUDING BUT NOTLIMITED TO THE IMPLIED WARRANTIESOF MERCHANTABILITY AND FITNESSFOR A PARTICULAR PURPOSE.

National Gypsum Company will notbe liable for any incidental, indirector consequential losses, damages orexpenses. The customer’s exclusiveremedy for any type of claim oraction for defective products will belimited to the replacement of theproducts (in the form originallyshipped) or, at National Gypsum’soption, to a payment or credit notgreater than the original purchaseprice of the products.

National Gypsum Company will notbe liable for products claimed to bedefective where the defect resultedfrom causes not within NationalGypsum’s control, or which arose oroccurred after shipment, including butnot limited to accidents, misuse, mis-handling, improper installation, conta-mination or adulteration by othermaterials or goods, or abnormal con-ditions of temperature, moisture, dirtor corrosive matter.

Any claim that products sold byNational Gypsum Company weredefective or otherwise did not conformto the contract of sale is waived unlessthe customer submits it in writing toNational Gypsum within thirty (30)days from the date the customer discovered or should have discoveredthe defect or nonconformance. Nolegal action or proceeding complainingof goods sold by National Gypsummay be brought by the customer morethan one year after the date the customer discovered or should havediscovered the defect or problem ofwhich it complains.

CUSTOMER SERVICE SALES AREAS

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H-ABUSE BRAND H-IMPACT BRAND GYPSUM WALLBOARD

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