Georgia-Pacific ToughRock Gypsum Board User Manual
ToughRock® Wallworks Guide
Your Guide to Planning, Applying, Installing, Finishing and
Repairing Your Walls and Ceilings with ToughRock Gypsum Board
Plan
1. Sketch
A little planning before the job begins can save you a
lot of time and materials later on.
• Sketch out the area you want to cover with gypsum
board. Use the sketch as a guide to determine how
much wallboard you’ll need.
• Remember to plan for the board to be installed
across (perpendicular to) joists and/or studs.
• Try to avoid end joints wherever possible. To do
that, you may want to buy 128 (3,658 mm) gypsum
board, instead of 88 (2,438 mm), depending on your
room size.
• If end joints can’t be avoided, stagger them so they
all don’t fall at one end of the room.
Your gypsum board should be stored flat, indoors,
away from moisture and temperature extremes, until
you’re ready to use it. As soon as possible after joint
treatment is thoroughly dry, all surfaces should be
sealed or primed with a vinyl or oil base primer/sealer.
2. Estimate
Once you’ve determined how much wallboard you’ll
need, you can use the charts on the next page to
estimate for nails, joint compound and tape.
If you choose the adhesive/nail-on method for wall
installation (see installation instructions), you’ll also
need some gypsum board adhesive. Use 8 quart-sized
(7.6 liters) tubes for each 1,000 sq. ft. (93 m
wallboard (1 tube to 4, 48 x 88 [1,220 mm x 2,438 mm]
sheets; 1 tube to 2
sheets).
Note: If you’re applying wallboard to masonry walls,
see ‘‘Masonry’’ section for additional materials.
How Much Board Do You Need?
First, figure out the wall and ceiling areas.
Width of the room x Length of the room = Ceiling area
(Width + Length) x 2 x Height of the room = Wall area
2
For example: a 128 x 168 x 88 (3,658 mm x 4,877 mm x 2,438 mm)
room has a wall/ceiling area of 640 sq. ft. (59 m
12 x 16 = 192; Wall area: (12 + 16) x 2 x 8 = 448; 192 + 448 = 640.)
1
⁄2, 48 x 128 [1,220 mm x 3,658 mm]
2
) of
2
) (Ceiling area:
Look at the Room Measurement Table for a quick
reference. Measure door and windows area and subtract
their square footage from the total square footage to
obtain net room area. Then refer to the Panel Coverage
Table to locate the number of wallboard panels required
for the room. Be sure to allow 10% to 15% overage for
cutting and piecing.
Room Measurement Table
48 58 68 78 88 98 108 118 128 138 148 158 168
88 224 248 272 296 320 334 368 392 416 440 464 488 512
98 244 269 294 319 344 369 394 419 444 469 494 519 544
108 264 290 316 342 368 394 420 446 472 498 524 550 576
118 284 311 338 365 392 419 446 473 500 527 554 581 608
128 304 332 360 388 416 444 472 500 528 556 584 612 640
138 324 353 382 411 440 469 498 527 556 585 614 643 672
148 344 374 404 434 464 494 524 554 584 614 644 674 704
158 364 395 426 457 488 519 550 581 612 643 674 705 736
168 384 416 448 480 512 544 576 608 640 672 704 736 768
Panel Coverage Table (in sq. ft. of wall area)
1 2 3 4 5 6
Panel Panels Panels Panels Panels Panels
4* x 8* Panel 32 64 96 128 160 192
4* x 9* Panel 36 72 108 144 180 216
4* x 10* Panel 40 80 120 160 200 240
4* x 12* Panel 48 96 144 192 240 288
4* x 14* Panel 56 112 168 224 280 336
4* x 16* Panel 64 128 192 256 320 384
Besides standard 48 (1,220 mm) widths, ToughRock®
®
Stretch 54
gypsum board is also available in a 549
(1,370 mm) width that eliminates the need for gap filler
boards in horizontal applications when walls are 98
(2,743 mm) high (see illustration). Using ToughRock
Stretch 54 gypsum board when you have 98 (2,743 mm)
ceilings reduces the number of seams you’ll need to
finish and cuts waste.
www.gpgypsum.com
®
ORANGE
Plan/Apply
29
Estimating Gypsum Board Fasteners
Approx. Number of
Type of Wallboard Length of Fasteners per
Fastener Thickness Fastener 1000 sq. ft. of Wallboard
Nail 1⁄29 (12.7 mm) 13⁄89 (35 mm) 2000
Nail 5⁄89 (15.9 mm) 11⁄29 (38 mm) 2000
Screw 1⁄29 (12.7 mm) 11⁄89 (28 mm) 1250
Screw 5⁄89 (15.9 mm) 11⁄49 (32 mm) 1250
Estimating Joint Compound and Tape
ToughRock® Estimated Amount
Wallboard All-Purpose of
Sq. Ft. Joint Compound Wallboard Tape
100-200 sq. ft. 12 lb. Pail two 60* rolls
(9-18 m2) (5.4 kg) (18.3 m)
500 sq. ft. 48 lb. Ctn. one 250* roll
(46 m2) (21.8 kg) (76.2 m)
800 sq. ft. 61.7 lb. Pail two 250* rolls
(74 m2) (28 kg) (76.2 m)
Tools
The basic tools you’ll need are:
1. Wallboard knife with heavy-duty blade
2. Wallboard hammer or regular crown-headed
carpenter’s claw hammer
3. 4* (1,220 mm) T-square or steel straightedge
4. Steel tape measure
5. Keyhole or utility saw
6. Joint finishing knives
7. Plastic pan for joint compound
8. Sandpaper, medium texture (80 to 100 grit) and
sanding block for joint finishing
9. Damp sponge
10. Caulking gun
11. Pencil
12. Safety glasses
13. Dust mask for sanding
CAUTION: When working with tools, always wear approved
safety glasses and other equipment recommended by the
manufacturer. Always read and follow manufacturer’s
instructions when using adhesives. Dust and fibers produced
during the handling and installation of gypsum board may
cause skin, eye and respiratory tract irritation. Avoid breathing
3
dust and minimize contact with skin and eyes. Wear long
sleeve shirts, long pants and eye protection. Always maintain
adequate ventilation. Use a dust mask or NIOSH/MSHA
approved respirator as appropriate in dusty or poorly
ventilated areas.
—
59 (127 mm) and 109 (254 mm) blades
4 5 6
3
2
1
2 3 4 5 6 7 8 9
6 5 4 3 2
7
9 8
10 11 12 13
14 151 6
17 18 19 20
32 33 34 35 36 37 38 39 40 41 42 43 44 45 464 7
21 22 23 24 25 26 27 28
22 23 24 25 26 27 28 29 30 31
Cut
Using your T-square or straightedge and wallboard
knife, score the gypsum board completely through the
face paper. Then use firm, even pressure to snap the
board along the cut. Fold back the board, and use the
knife to cut the back paper. Smooth rough edges.
Receptacle Openings, Etc.
Carefully measure openings for receptacles, switches,
etc. from the edge and end of the board, and mark
guidelines on the face paper. Use a keyhole saw to cut
the openings. Make sure your measurements and cuts
are accurate, or the cover plate you install later on will
not conceal the hole.
Want help calculating the amount of materials
you’ll need for your project? Check out the
ToughRock® Calculator at www.toughrock.com.
Select a product, click the installation tab and
enter the measurements of your room.
www.gpgypsum.com
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