Installation guide ROCKFON System Mono® Acoustic ROCKFON System Mono® Acoustic – Installation Guide Contents Introduction System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Job site conditions during installation . . . . . . . . . . . . . . . 3 ROCKFON System Mono® Acoustic components Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ROCKFON System Mono Acoustic panels . . . . . . . . . . . . 5 Fastening washers and screws . . . . . . . . . . . . . . . . . . . . . . . 5 Mono intersection bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Tape and Mono Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ROCKFON System Mono Ready-Mix . . . . . . . . . . . . . . . . . 5 ROCKFON System Mono Acoustic inspection hatches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ROCKFON System Mono Acoustic Flecto . . . . . . . . . . . . . 6 System installation Grid installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Chicago Metallic Monolithic (1200x600). . . . . . . . . . . . . . 8 Chicago Metallic Monolithic (1200x900). . . . . . . . . . . . . . 9 Assembly of panels (1200x1200) . . . . . . . . . . . . . . . . . . . 10 Assembly of panels (1800x1200) . . . . . . . . . . . . . . . . . . . 11 Assembly of panels (1800x1200) . . . . . . . . . . . . . . . . . . . 12 Assembly of panels (900x1200) . . . . . . . . . . . . . . . . . . . . 13 Tape and filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Joint check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Sanding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Perimeter finish and site masking . . . . . . . . . . . . . . . . . . 17 Render . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-19 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2 Introduction Recommendations + System overview The use of a fan convector unit, ventilator and dehumidifier is recommended if the natural conditions of the site do not allow suitable temperatures and humidity levels. The use of these devices allows the drying time to be significantly reduced. Description Mono Acoustic is an aesthetically pleasing seamless ceiling offering excellent sound absorption properties (up to αw = 1,00, Class A). ROCKFON offers three different ROCKFON System Mono Acoustic ceiling panels for different installation purposes; • ROCKFON System Mono Acoustic • ROCKFON System Mono Acoustic Direct • ROCKFON System Mono Acoustic Flecto ROCKFON System Mono Acoustic is meant for installation on a grid (suspended mounting) and has an αw = 0,90. ROCKFON System Mono Acoustic Direct is meant only for installation directly underneath an existing ceiling or against the soffit and has an αw = 1,00. ROCKFON System Mono Acoustic Flecto is developed for vaulted installation of Mono and has an αw = 0,90 (similar to our standard ROCKFON System Mono Acoustic panels). Once installed, all the components form a seamless ceiling, requiring neither paint nor any additional structural elements. With the exception of the fastening screws, all products are made specifically for the Mono Acoustic system. Installers must use only the items described herein. – However, ROCKFON advises against using a hot air blower that is too powerful, produces excessive heat or that could result in too fast drying, as this may cause cracking. This type of device may only be used within a safe distance from the Mono Acoustic ceiling as the goal is to heat the air rather than the ceiling directly. The installation must be completed in accordance with the Mono Acoustic system installation guide. To conserve fire- and acoustical properties of the ROCKFON System Mono Acoustic ceiling, ROCKFON recommends that the installation is done by a certified Mono installer. Installation order 1. Installing the Chicago Metallic Monolithic grid system 2. Installing Mono Acoustic panels 3. Filling the joints with ROCKFON System Mono Acoustic Tape and Mono Filler 4. Sanding of joints 5. Protective masking of the room: walls, floors as well as furniture 6. Spraying the Mono Ready-Mix render Technical data Suspension depth Module size Module thickness Minimum suspension depth 900x1200 1200x1200 1800x1200 40mm 40mm with direct installation 90mm with 50mm plenum System weight per m 2 Panel Direct installation Installation on a grid system (200mm plenum) 6,0 kg 7,5 kg 8,5 kg System load-bearing capacity Maximum evenly-distributed load capacity Maximum point load capacity 2,0 kg/m2 1,5 kg When the system is installed to bear load, ROCKFON recommends to fix the panel with two screws in the middle instead of one (<1,5 kg point load) or with twoscrews + profile reinforcement (>1,5 kg point load or >2 kg/m2 evenly distributed load). Job site conditions during installation Temperature and humidity A Mono Acoustic ceiling must be installed in a closed and covered location. The air temperature in the location must be at least 15°C and the relative humidity must be between 40% and 60%. Non-compliance with these conditions significantly prolongs drying time. Handling For an optimised work environment, we recommend installers always observe common work practices and follow the installation advise as shown on our packaging. Planning Mono Acoustic is a finished ceiling. No paint or other treatment should be added after spraying the Mono Ready-Mix. It is important to avoid producing dust during and after the installation of the ceiling. The monolithic nature of the ceiling means it is non-demountable, so careful sequencing of the construction work is essential along with the installation of hatches if access is required. Incident light It is recommended to avoid incident/side light on suspended ceilings. Extreme floodlight might cause visible joints. 3 Attention ! In swimming pools ROCKFON advises to install the system in the following way; The grid and suspension system used should be corrosion resistant. The ventilation in the swimming pool and the plenum should be optimal to avoid condensation issues. ROCKFON recommends to install the ROCKFON System Mono Acoustic not completely against the wall but to leave an opening so that the air can circulate in the room/ plenum. ROCKFON recommends to create a similar climate (temperature and humidity) in the room and plenum. The ceiling should be at a certain height in order to overcome water splashing against the ceiling (this might lead to spots on the ROCKFON System Mono Acoustic surface). For usage of ROCKFON System Mono Acoustic in a swimming pool, please contact your local ROCKFON technical support for more information. ROCKFON System Mono® Acoustic components Grid The grid system ROCKFON recommends is the Chicago Metallic Monolithic grid. Additional alternative grid systems may be appropriate. Consult with ROCKFON to discuss suitability. Chicago Metallic Monolithic grid Prohibited – Regardless of the type of grid chosen, ROCKFON prohibits the use of any wire, quick hanger or other hanger that does not guarantee against up-lift. This grid system has a T-shaped main runner and an omega-shaped cross tee, typically known as “furring channel”, with a 35mm wide table. The main runner is available with a slot distance of 200mm and 225mm. Recommendations + To avoid uplift, ROCKFON recommends the use of rigid hangers. + A perimeter trim installed around the room will enhance the stability and rigidity of the ceiling. + To fix the omega-shaped cross tee in the perimeter trim ROCKFON recommends the use of the following clip ref. no. AX087X500P. 4 ROCKFON System Mono® Acoustic components ROCKFON System Mono Acoustic panels ROCKFON System Mono Acoustic panels are made from high-density stone wool. They are finished with a white fleece on the visible side and an anti-ageing, high performance membrane on the reverse. ROCKFON System Mono Acoustic panels have tapered edges on all four sides which allows for optimum jointing. Prohibited – With the exception of the standard 55mm long screws, all other accessories are specially developed to guarantee a perfect aesthetic and acoustic result with the Mono Acoustic panel. ROCKFON prohibits the use of accessories other than those sold for that purpose. ROCKFON System Mono Acoustic Direct panels are made from high-density stone wool and are also finished with a white fleece on the visible side. The reverse is not provided with an anti-ageing, high performance membrane since the panel is mounted directly to the soffit. This panel may under no circumstances be used for suspended solutions! ROCKFON System Mono Acoustic Flecto panels are made of high-density stone wool. They are finished with a white fleece on the visible side and an anti-ageing, high performance membrane on the reverse. The panel has tapered edges on all four sides for optimal jointing and the backside has grooves to allow for vaulted installation. Fastening washers and screws Combined with standard screws (55mm) positioned every 300mm, ROCKFON System Mono Acoustic Washers allow for the installation of panels to the Chicago Metallic Monolithic grid on the perimeter and in the middle of the tiles. The fastening washers increase the bearing surface of the screw head. Their specially designed bowl shape allows the screw heads to be recessed into the panel. Attention ! The joint filler and render must be stored at a temperature above 0°C. If kept in their original unopened packaging, they have a shelf life of 18 months. ROCKFON ROCKFON System Mono Acoustic Flecto panels should be handled with extra care. Due to the grooves in the backside the tiles are more difficult to handle than standard ROCKFON System Mono Acoustic panels. Mono intersection bracket The Mono intersection bracket allows for the installation of panels to the Chicago Metallic Monolithic grid at the intersection of ROCKFON System Mono Acoustic panels. It is designed in such a way that it can be pushed into the panel (four small teeth), providing that the installer has its hands free to fix the bracket. Question Tape and Mono Filler The 40mm wide tape and ready-mixed Mono Filler are specially designed to ensure strong, optimal joints between the ROCKFON System Mono Acoustic panels. Each tape roll is 150m, and the filler is packaged in a 20 kg tub. ROCKFON System Mono Ready-Mix (white or colour) Manufactured in white as standard, Mono Ready-Mix (render) can also be supplied in colours upon request. In this case, a colour reference (e.g. NCS code, RAL code) should be sent to ROCKFON and a sample of the requested colour will be created. The manufacturing time for a colour sample is around 10 working days. The colour finish render is subject to a minimum quantity of 20 kg. The render is packaged in 20 kg tubs. ? Are colour finishes available? Yes! 1. Send ROCKFON your required colour reference (NCS code or RAL code). 2. ROCKFON produces and sends colour samples. 3. After validation, ROCKFON produces the colour render with a minimum quantity of 20 kg. System components and brute consumption guide per m² Mono Acoustic panels in module 1800x1200mm 0,46 Round washer (250 pcs/box) 0,46 pcs (excl. perimeter fixation) Mono intersection Mono Ready-Mix - low Mono Ready-Mix bracket Mono Acoustic Tape Fast-drying ready-mix pressure application - high pressure (150 pcs/box) R40//150 Mono Filler (20 kg/tub) (20 kg/tub) application (20 kg/tub) 4,17 pcs 1,4 lm 1,00 - 1,20 kg * In critical light conditions or depending on the co lours, higher consumption may be required. ** For colour render it is recommend to prime the joints with mono primer. Please note that the quantity of accessories, tape and Mono Filler required depends on the panel module size. 5 White 1,0-1,2 kg * Colour 1,2-1,4 kg * White 1,2-1,4 kg * Colour 1,3-1,5 kg * ROCKFON System Mono® Acoustic components ROCKFON System Mono Acoustic inspection hatches To provide access towards the plenum ROCKFON has developed three standard inspection hatches. Two sizes of square hatches made out of an aluminum frame with an integrated ROCKFON System Mono Acoustic panel, which can be sprayed with ROCKFON System Mono ReadyMix render to create a similar surface as the rest of the seamless ceiling. And one round white pre-coated metal hatch which can be installed either over sprayed with ROCKFON System Mono Ready-Mix render or used in its original state without over spraying. Dimensions square hatches: 400x400mm 600x600mm Dimension round hatch: Ø700mm Consult with your local technical support in order to get more information about our ROCKFON System Mono Acoustic inspection hatches. Details of the ROCKFON System Mono Acoustic inspection hatches can be found in the ROCKFON System Mono Acoustic solution library. This hatch requires a void space of 10cm. For opening, lift the total hatch 5cm and slide it (above the grid) a few centimeters to the side, then rotate the opposite side of the hatch downwards. This hatch requires no void space. For opening, lift the total hatch 1cm and rotate. ROCKFON System Mono Acoustic Flecto ROCKFON System Mono Acoustic Flecto ceiling panels allow for installation to concave or convex surfaces with a radius of 1500mm minimum. A ROCKFON System Mono Acoustic Flecto ceiling should be fitted to a curved solid structure. The “shell” serves as a support for the fastening screws and the ROCKFON System Mono Acoustic Flecto panels. 6 ROCKFON does not recommend using timber panels for supporting structures or shells. Examples and details of the ROCKFON System Mono Acoustic Flecto can be found in the ROCKFON System Mono Acoustic solution library. System installation Grid installation Tools required • Metre rule • Laser level • Worksite light Recommendations • Utility knife • Drill • Scaffolding + • Pencil • Power screwdriver • Scissors Installation guideline The installer must consider the dimensions of the room, the presence of service elements to be integrated (lights, air-conditioning, etc.) and arrange the ceiling so there are no whole panels against the walls. For grid installation, ROCKFON recommends the use of suitable scaffolding and additional lighting apparatus under all circumstances. + ROCKFON also recommends the use of a laser level to guarantee optimum results. Regardless of the grid system, the installer should always install a perimeter trim. This component should be fastened to all vertical junctions with the ceiling such as walls, partitions, columns, upstands, etc. A perimeter trim installed around the room enhances the stability and rigidity of the ceiling. Regardless of the grid system, the installer should always suspend the grid using rigid hangers (threaded rods, nonius hangers, fixed brackets, metal fixing clips, metal angle, etc.) for stability and rigidity. ROCKFON prohibits the use of any wire or other hanger that does not provide stability and rigidity. All fitting elements involving a space reservation in the ceiling, such as ventilation grating, lighting apparatus or an access hatch, need a crosshead. To install the crosshead, the installer should choose the profile most appropriate to the situation: Omega-shaped cross tee,T35 main runner or the C-shaped wall angle. 7 Caution !! The ROCKFON System Mono Acoustic system can maximally bear the direct load of service elements (HVAC, Lighting, etc.) as described on page 3 of this installation guide. System installation Chicago Metallic Monolithic system in 1200x600mm. Recommendations Tile dimensions 1800x1200mm and 1200x1200mm. + Suspente rigide Hangers Perimeter trim Coulisse de rive Cross tee T 40 Entretoise During and after grid installation, it is recommended that the flatness and the level of the grid be checked. In a 1200x600mm installation, it is recommended that the angles between the main runners and cross tees also be checked for squareness. This can be easily done by comparing the measurements of the two diagonals. Concrete soffit Support plafond Check ! The maximum surface flatness tolerance is 2mm over one metre and 5mm over five metres. This tolerance is valid for all directions. Main runner Porteur T 40 Caution • T35 main runners with slot distance 200mm main runners positioned at 1200mm centres ! • Omega cross tees installed every 600mm between main runners When used for large dimension ceilings, ROCKFON System Mono Acoustic ceilings must be installed with a movement joint. The maximum surface area between these joints is limited to 300m2, and the largest dimension must not exceed 25m1. Movement joints in a ROCKFON System Mono Acoustic ceiling must coincide with the Movement joints in the building. • Perimeter trims fixed to the vertical surfaces (walls, columns, etc.) every 400mm • Hangers installed every 1200mm along the main runners F A A G C E D B D D Distance overview (mm) A Hanger distance 1200 B Main runner distance 1200 C Max. distance to the first main runner 400 D Distance between cross tees 600 E Max. distance to the first cross tee 400 F Max. distance to the first hanger 400 G Distance between fixing points perimeter trim 400 8 System installation Chicago Metallic Monolithic system in 1200x900mm. Recommendations Tile dimensions 1800x1200mm and 1200x900mm. + Suspente rigide Hangers Perimeter trim Coulisse de rive Cross tee T 40 Entretoise During and after grid installation, it is recommended that the flatness and the level of the grid be checked. In a 1200x900mm installation, it is recommended that the angles between the main runners and cross tees also be checked for squareness. This can be easily done by comparing the measurements of the two diagonals. Concrete soffit Support plafond Check ! The maximum surface flatness tolerance is 2mm over one metre and 5mm over five metres. This tolerance is valid for all directions. Main runner Porteur T 40 Caution • T35 main runners with slot distance 200mm main runners positioned at 1200mm centres ! • Omega cross tees installed every 900mm between main runners When used for large dimension ceilings, ROCKFON System Mono Acoustic ceilings must be installed with a movement joint. The maximum surface area between these joints is limited to 300m2, and the largest dimension must not exceed 25m1. Movement joints in a ROCKFON System Mono Acoustic ceiling must coincide with the Movement joints in the building. • Perimeter trims fixed to the vertical surfaces (walls, columns, etc.) every 400mm • Hangers installed every 1200mm along the main runners F A A G C E D B D D Distance overview (mm) A Hanger distance 1200 B Main runner distance 1200 C Max. distance to the first main runner 400 D Distance between cross tees 900 E Max. distance to the first cross tee 400 F Max. distance to the first hanger 400 G Distance between fixing points perimeter trim 400 9 System installation Assembly of panels 1200x1200mm Installation Guide • Each Mono Acoustic panel is fastened with a plasterboard screw (length 55mm) combined with a Mono Acoustic washer or a ROCKFON System Mono Acoustic intersection bracket. • The round washers are used for fixation of the panels at the centre and at the perimeter trim. The spacing between the round washers is 300mm. • The Mono intersection brackets are fastened on the intersection of panels. The spacing between the Mono intersection brackets is 300mm (along the main runner) and 400mm (along the cross tees) as shown in the drawing below. • Minimum one round washer connection should be placed at the centre of each panel. If the system is bearing load, according to the maximum capacities as displayed on page 3 of this guide, ROCKFON recommends to place two round washers at the centre of the panel (400mm distance between the washers). Cutting and fastening at perimeters • The edge cuts must be no more than 2mm shorter than the actual dimension in order to guarantee optimum perimeter finish. • The fastening of panels is done with the round washers with a maximum spacing as described above. 300 custom x 300 300 Check ! During and after installation of the panels, it is recommended that the surface level and flatness of the ceiling be checked. The maximum tolerance is 2mm over one metre and 5mm over five metres. This tolerance is valid for all directions. Caution !! If an edge cut is too long, the installer will have to force the panel in, which can result in damage to the fleece. Conversely, if an edge cut is too short it can leave a gap that is too large to guarantee an optimum and quick finish during installation of the acrylic filler. 300 custom x 1200 custom custom x 1200 300 1200 x 1200 300 600 600 300 1200 x 1200 !! When installing the fasteners, it is recommended that they be controlled. If they are screwed in too deep, the panels will deform resulting in surface flatness problems and excess use of filler and reduction in sound absorption properties. custom x 1200 300 Recommendations + 1200 x 1200 ROCKFON recommends a staggered installation of the panels. 400 400 400 + An aligned installation of the panels is possible. : Washer : Mono Intersection Bracket 10 System installation Assembly of panels 1800x1200mm Installation Guide • Each Mono Acoustic panel is fastened with a plasterboard screw (length 55mm) combined with a Mono Acoustic washer or a ROCKFON System Mono Acoustic intersection bracket. • The round washers are used for fixation of the panels at the centre and at the perimeter trim. The spacing between the round washers is 300mm. • The Mono intersection brackets are fastened on the intersection of panels. The spacing between the Mono intersection brackets is 300mm (along the main runner) and 400mm (along the cross tees) as shown in the drawing below. • Two round washers should be placed at the centre of each panel. If the system is bearing load, according to the maximum capacities as displayed on page 3 of this guide, ROCKFON recommends to place extra round washers at the centre of the panel (400mm distance between the washers). Cutting and fastening at perimeters • The edge cuts must be no more than 2mm shorter than the actual dimension in order to guarantee optimum perimeter finish. • The fastening of panels is done with the round washers with a maximum spacing as described above. 300 custom x 300 300 Check ! During and after installation of the panels, it is recommended that the surface level and flatness of the ceiling be checked. The maximum tolerance is 2mm over one metre and 5mm over five metres. This tolerance is valid for all directions. Caution !! If an edge cut is too long, the installer will have to force the panel in, which can result in damage to the fleece. Conversely, if an edge cut is too short it can leave a gap that is too large to guarantee an optimum and quick finish during installation of the acrylic filler. 300 custom x 1200 custom custom x 1200 300 300 600 600 400 400 400 custom 300 !! When installing the fasteners, it is recommended that they be controlled. If they are screwed in too deep, the panels will deform resulting in surface flatness problems and excess use of filler and reduction in sound absorption properties. 300 x 1800 1200 x 1800 Recommendations 1200 x 1800 + ROCKFON recommends a staggered installation of the panels. + An aligned installation of the panels is possible. : Washer : Mono Intersection Bracket 11 System installation Assembly of panels 1800x1200mm Installation Guide • Each Mono Acoustic panel is fastened with a plasterboard screw (length 55mm) combined with a Mono Acoustic washer or a ROCKFON System Mono Acoustic intersection bracket. • The round washers are used for fixation of the panels at the centre and at the perimeter trim. The spacing between the round washers is 300mm. • The Mono intersection brackets are fastened on the intersection of panels. The spacing between the Mono intersection brackets is 300mm (along the main runner) and 400mm (along the cross tees) as shown in the drawing below. • Minimum one round washer connection should be placed at the centre of each panel. If the system is bearing load, according to the maximum capacities as displayed on page 3 of this guide, ROCKFON recommends to place two round washers at the centre of the panel (400mm distance between the washers). custom x 300 300 ! During and after installation of the panels, it is recommended that the surface level and flatness of the ceiling be checked. The maximum tolerance is 2mm over one metre and 5mm over five metres. This tolerance is valid for all directions. Caution Cutting and fastening at perimeters • The edge cuts must be no more than 2mm shorter than the actual dimension in order to guarantee optimum perimeter finish. • The fastening of panels is done with the round washers with a maximum spacing as described above. 300 Check !! If an edge cut is too long, the installer will have to force the panel in, which can result in damage to the fleece. Conversely, if an edge cut is too short it can leave a gap that is too large to guarantee an optimum and quick finish during installation of the acrylic filler. 300 custom x 1200 custom custom x 1200 300 300 600 600 custom 300 400 x 1800 1200 x 1800 400 400 300 !! When installing the fasteners, it is recommended that they be controlled. If they are screwed in too deep, the panels will deform resulting in surface flatness problems and excess use of filler and reduction in sound absorption properties. Recommendations + 1200 x 1800 ROCKFON recommends a staggered installation of the panels. + An aligned installation of the panels is possible. : Washer : Mono Intersection Bracket 12 System installation Assembly of panels 900x1200mm Installation Guide • Each Mono Acoustic panel is fastened with a plasterboard screw (length 55mm) combined with a Mono Acoustic washer or a ROCKFON System Mono Acoustic intersection bracket. • The round washers are used for fixation of the panels at the centre and at the perimeter trim. The spacing between the round washers is 300mm. • The Mono intersection brackets are fastened on the intersection of panels. The spacing between the Mono intersection brackets is 225mm (along the main runner) and 400mm (along the cross tees) as shown in the drawing below. • Minimum one round washer connection should be placed at the centre of each panel. If the system is bearing load, according to the maximum capacities as displayed on page 3 of this guide, ROCKFON recommends to place extra round washers at the centre of the panel (400mm distance between the washers). custom x 300 300 ! During and after installation of the panels, it is recommended that the surface level and flatness of the ceiling be checked. The maximum tolerance is 2mm over one metre and 5mm over five metres. This tolerance is valid for all directions. Caution Cutting and fastening at perimeters • The edge cuts must be no more than 2mm shorter than the actual dimension in order to guarantee optimum perimeter finish. • The fastening of panels is done with the round washers with a maximum spacing as described above. 300 Check !! If an edge cut is too long, the installer will have to force the panel in, which can result in damage to the fleece. Conversely, if an edge cut is too short it can leave a gap that is too large to guarantee an optimum and quick finish during installation of the acrylic filler. 300 custom x 1200 custom 225 custom x 1200 900 x 1200 225 225 600 600 900 x 1200 !! When installing the fasteners, it is recommended that they be controlled. If they are screwed in too deep, the panels will deform resulting in surface flatness problems and excess use of filler and reduction in sound absorption properties. 225 custom x 900 Recommendations 900 x 1200 + ROCKFON recommends a staggered installation of the panels. 400 400 400 + An aligned installation of the panels is possible. : Washer : Mono Intersection Bracket 13 System installation Tape and filler Tools required • Soft finishing knife (150mm) • Soft finishing knife (240mm) • Scaffolding Recommendations • Mixer • Ventilator • Site light • Rotating blades for mixing filler • Dehumidifier (optional) • Fan convector unit (optional) + For the finishing phase, ROCKFON recommends the use of suitable scaffolding and additional lighting apparatus in all circumstances. A scaffolding platform adjusted to the correct height and appropriate lighting will be more comfortable for the installer and result in faster, quality installation of the joints. Affixing the tape and applying the first coat of filler + ROCKFON recommends mixing the Mono Filler before use. This ensures homogenity and achieves a better slide off the finishing knife. 1. Lay the filler on the joints 2. W hile the filler is still wet, position the tape on the joints Check ! Keep the specific design/layout of the project in mind when calculating the amount to be used. ! 3. Load the thinned edge with filler 4. O nce the first coat dries*, apply a second coat of filler to all joints and fasteners to guarantee good overall evenness Consumption The filler will cover approximately 1,0 kg/m². The maximum width of the filler is 200mm. Attention: this usage amount is theoretical. It is calculated for a flat ceiling and does not take into account the specific layout of the worksite. The presence of downstands, light troughs, floating edges (island zone) or an unusual room shape may result in additional consumption. For example, the treatment of a plasterboard bulkhead connected to a Mono Acoustic ceiling using reinforced tape leads to additional consumption of the joint finish by approximately 1,0 kg per linear metre of level change. *Drying time The drying time depends on the conditions of the site. For the first coat, the general drying time is between 10 and 16 hours. For the second coat, the general drying time is between 6 and 10 hours. During this phase, it is recommended that the amount of filler applied is carefully checked to guarantee evenness of the joint after drying. Attention ! The second coat of filler can only be done when the first coat is completely dry. Non-compliance with this will result in serious defects in the quality of the joint. Caution !! Tape that is not properly stuck or pressed into the joint can result in serious joint quality defects. 14 System installation Joint check 1. Light up the area to check: Position a high-power lamp in front of the ceiling area to be checked. Attention ! A clean 350mm finishing knife and a high-power lamp are required in order to adequately check the quality of the joints. 2. Position the finishing knife: It must be a perfectly clean 350mm knife, and should be placed vertically under the sanded joints. Check - Negative result: The presence of a beam of light will indicate a lack of quality on the joint. This will need to be rectified in order to attain the quality expected of a Mono Acoustic joint. ! In order to check the quality of a joint, a knife must be used to show surface level and flatness defects or bumps. Follow the checking instructions shown opposite. Question - Positive result: The absence of a beam of light indicates perfect evenness of the joint. It is ready to be sanded. 15 ? I s it possible to correct a joint defect if the ceiling is finished? YES! It is always possible to correct it but the work is more difficult. It is much easier to correct a joint before spraying the finishing coat. System installation Sanding Tools required • Protective mask • Scaffolding • Site light Recommendations • Sanding block (120x70mm) • Sanding handle (230x110mm) • Long-neck sander with rigid flat surface • Safety goggles • Sandpaper (80 and 100 grain) • Connected vacuuming system + For the sanding phase, ROCKFON recommends the use of suitable scaffolding and additional lighting apparatus in all circumstances. A scaffolding platform adjusted to the correct height and appropriate lighting will be more comfortable for the installer and facilitate faster, better quality sanding. + It is strongly recommended to connect the long-reach sander to a dedicated vacuum system to provide maximum cleanliness and offer maximum protection. Attention ! ROCKFON recommends the use of a long-reach sander equipped with a rigid sanding platform (ref. no. 495 168) such as FESTOOL PLANEX LHS 225 EQ-PLUS or equivalent. ! Sanding techniques To guarantee quality sanding, the installer must use the long-neck sander for large surfaces. The sanding block and handle are reserved for perimeter sanding work and for small retouches. The chosen sandpaper must have 80 or 100 grade grit. Repeat joint check A final joint check is highly recommended before applying the final render. Although it is always possible to correct unevenness, the work is more difficult once render has been applied. It is much easier to correct a joint before spraying the finishing coat. 16 System installation Perimeter finish and site masking Tools required • Adhesive masking tape • Sealant pump gun • Protection film e.g. polyethylene • Acrylic sealant cartridge Recommendations • Site light • Scaffolding + The necessity of masking will depend on the site progress. The need to protect the floor, furniture or walls will vary for each situation. This chapter only covers the installation of vertical protections against walls. Vertical protection installation Caution !! The placement of the adhesive masking tape determines the quality of the edge finish during the spray phase. If it is set too low, the installer risks spraying the wall. If it is set too high, the ceiling will not be completely protected. Prohibited – Never use silicone joints. These particular joints cannot be painted and prevent a perfect finish during the spray phases. Use acrylic sealant. Further information and details can be found in the ROCKFON System Mono Acoustic solution library. 17 System installation Render Tools required • Protective mask • Safety goggles • Mixer • Rotating blade for mixing the render • Spray machine for low pressure application (type Euromair MPE 80 or equivalent) or spray machine for high pressure application (type Euromair CP10 or equivalent) Check ! The only method of checking the render consumption is to count the boxes used as spraying progresses. This simple and efficient operation can become complex on large surfaces, hence dividing into sections is recommended. Consumption The nett consumption is 1,2 kg/m². To realize this consumption with low pressure application the brute amount of render applied is 1,2 kg/m² for the ROCKFON System Mono Ready-Mix white and 1,2 - 1,4 kg/m² for the ROCKFON System Mono Ready-Mix in colour. To realize this consumption with high pressure application (max. 3,5 bar) the brute amount of render applied is 1,2 - 1,4 kg/m² for the ROCKFON System Mono Ready-Mix white and 1,3 - 1,5 kg/m² for the ROCKFON System Mono ReadyMix in colour. For example, by dividing a 180 m² ceiling into three 60 m² sections, the theoretical consumption indicates a spray of 78 kg per section, or approximately 4 buckets. It is possible to apply the Mono Ready-Mix on surfaces other than the Mono Acoustic itself, such as plasterboard and concrete beams. However, once treated, these surfaces will not offer any acoustic benefit, but will provide the same finish as the Mono Acoustic to give a homogenous appearance. As the spray is done in three coats, it is recommended that a little more than one box be sprayed per coat and per 60 m² section. Stirring and mixing of ROCKFON System Mono Ready-Mix • Stir up the ROCKFON System Mono Ready-Mix in the tub • Empty the contents of the bucket into the mixing tank Check ! Take into account the specific layout/design of the project and the depth of the tank/pipe for the calculation. Depending on the machine type, the tank/pipe bottom corresponds to a certain loss of render finish associated with the initial filling. Treating a 500mm plasterboard downstand with the Mono Acoustic finish coat along a 30 m facade results in additional consumption of 20 kg, or one box of render. Attention ! Even if the Mono Ready-Mix has a pasty texture in the packaging, it is not necessarily ready to use. Whether white or in colour, it must be mixed in accordance with the directions outlined in this chapter. 18 System installation Render Recommendations Spraying • The nozzle must be 0,80 m from the ceiling. • Treat the peripheries by following a slow and linear motion along the perimeter of the room. + ROCKFON recommends the use of a spray machine such as EUROMAIR MPE 80 or CP but it is also possible to use equivalent machines. Airless spray equipment is not allowed. Please contact your local technical support for more info on the specifications of the machinery. • By regular rotations of the nozzle, apply a first coat of approximately 0,4 kg/m² onto the ceiling. • Progress in areas of about 0,6 m, depending on the diameter of rotation. The layers should cover each other to provide good coverage. • The drying time is approximately four hours per coat. • After the first spray coat has completely dried, repeat this procedure and apply a second coat of 0,4 kg/m². • A fter the second spray coat has completely dried, repeat this procedure and apply a final coat of 0,4 kg/m². + During the spray phases, the nozzle must be between 0,80 m from the surface to be sprayed. A scaffolding platform adjusted to the correct height and appropriate lighting will be more comfortable for the installer and facilitate a faster, quality spray finish. + If the surface to be sprayed is large, it is recommended that it be divided into sections in order to control the render consumption. The presence of columns, windows or beams can help with this division. Recommendations + It is recommended to wait for the final coat to dry completely to have a final rendering of the finished ceiling. The drying time depends on the conditions of the site. To learn what ROCKFON recommends, see page 3. 19 System maintenance Servicing ROCKFON System Mono Acoustic ceilings require only minor maintenance, and the amount will depend on the use of the room in which it is installed. Mono Acoustic ceilings should only be installed by authorised system installers. (Please contact ROCKFON for contact details of your nearest authorised installer or visit us at www.rockfon.com). Any small repairs and surface processing must be carried out exclusively by authorised installers. It is possible to apply the ROCKFON System Mono Ready-Mix on surfaces other than the Mono Acoustic panels, such as plasterboard and concrete beams. However, once treated, these surfaces will not offer any acoustic benefit, but will provide the same finish as the Mono Acoustic to give a homogenous appearance. Overview Cleaning Vacuum cleaner with soft brush at low power. Surface discolouration Apply a thin layer of render using the Mono trowel. Minor cracks and scratches Apply a small amount of ROCKFON System Mono Ready-Mix using a paintbrush or paint gun. Cracks and indentations Seal by using ROCKFON System Mono Acoustic Filler, then apply a small amount of ROCKFON System Mono Ready-Mix. Larger cracks and damage Fill the gap with a “plug” made of ROCKFON System Mono Acoustic panel, then cover the repaired spot with ROCKFON System Mono Ready-Mix. Maintenance Cleaning The Mono Acoustic ceiling is anti-static so it does not retain dust and can easily be kept clean. To clean the panels, use a vacuum cleaner with a soft brush operating at low power. Mono Acoustic ceilings must not be cleaned with water or wiped with a wet cloth, etc. Renovating Mono Acoustic ceilings can be renewed/refreshed by applying a new layer of ROCKFON System Mono Ready-Mix. For this, ROCKFON advises you to call the company that performed the initial works or a qualified Mono Acoustic installer. The sound absorption ratio decreases by approximately 10% with each additional layer of Mono Ready- Mix. Surface discolouration In the case of surface discolouration, apply one or more new, thin layers of ROCKFON System Mono Ready-Mix. If the discoloured spots are due to water action (or because of deposition or tobacco smoke) the surface should be thoroughly dried and sealed prior to commencement of repairs. Approximately 0,3 kg render per m2 should be applied by using dedicated Mono Acoustic equipment. In order to preserve the ceiling’s acoustic properties, the recommended amount of render should not be exceeded. The sound absorption ratio decreases by approximately 10% for each additional layer of ROCKFON System Mono Ready-Mix. 20 Prohibited – Do not use any paints or similar products that provide a total covering over the surface, since such products will reduce the ceiling’s acoustic properties. System maintenance Repairs Any damage to a Mono Acoustic ceiling can always be repaired. However, the base materials that the ceiling is made of must be used. For tile reparations during the ROCKFON System Mono Acoustic installation, please refer to your local technical support for more information. For damages that occur after the ceiling is installed, ROCKFON recommends calling upon the company that installed the original ceiling or a qualified ROCKFON System Mono Acoustic installer. Superficial damage - Minor cracks and scratches Superficial damage (screw holes, light impact) or minor cracks and scratches can be easily repaired using a small quantity of ROCKFON System Mono Ready-Mix applied with a paintbrush on the damaged parts. Alternatively, a thin layer of the render may be applied using a Mono Acoustic paint gun. Structural damage - Larger cracks and damage In the case of larger cracks, significant or structural damage (water damage, heavy impact) follow the procedure for replacement of entire panel fragments. In this case, the repair method is as follows: 1. Remove the damaged panel fragment by cutting it out with a knife at an angle of 60°. 2. Cut a matching “plug” out of a new Mono Acoustic panel and fasten the “plug” in the hole using the Mono Filler. 3. Sand the surface around the hole in order to remove the excess render. 4. Apply a new layer of the filler on the seam between the “plug” and the Mono Acoustic panel, following the instructions set out in the system installation guide. 5. Apply the ROCKFON System Mono Ready-Mix, following the instructions set out in the system installation guide. The render layer will become “toned” which will minimise the contrast between the elements. Alternatively, apply the render over the entire ceiling surface. 1. Removing damaged panels and sanding surrounding area 2. Installing new panels and filling edges 3. Sanding of dry joints and spraying of the area 4. Spraying and removal of masking protections of walls, floor etc. 21 Easy to install and durable, they protect people from noise and the spread of fire. They are our way of making a constructive contribution towards a sustainable future. Create and Protect is what drives us. It means putting people first, sharing success and maintaining trust. It’s our rock-solid promise to you. At ROCKFON, Create and Protect is what we do - and it’s inspired by you. ROCKFON (ROCKWOOL Finland) Pakkalankuja 6, PL78 FI-01511 Vantaa Finland Puh. (+358) 09 8563 5880 Faksi (+358) 09 8563 5889 www.rockfon.fi [email protected] 11.2015 | Kaikki värikoodit perustuvat NCS - Natural Colour System®© järjestelmään. Tekijänoikeus ja käytössä lisenssillä NCS Colour AB, Tukholma 2010. Oikeus muutoksiin pidätetään ilman erillistä ilmoitusta. ROCKFON ei vastaa painovirheistä. We believe our acoustic stone wool and metal solutions for ceilings and walls are a fast and simple way to create beautiful, comfortable and safe spaces.
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