Clayworks Clay Panels

1. OVERVIEW

Clayworks Clay Panels are vapour diffusion open, clay plaster dry-lining boards. They are the only clay panel systems with a sandwich construction, consisting of a soft fibreboard (DIN EN 18986), clay plaster and glass fibre reinforcing mesh. All four edges are tapered. 

The panels are designed to be finished with Clayworks Clay Plasters (base coat and topcoat) and have all of the Health, Sustainability and Performance benefits of clay when used as an internal building material: breathability, no VOCs, no toxins, no off-gassing, humidity control, thermal and acoustic properties.

The composition results in a consistent and reliable product with an extremely small deviation in the boards’ thickness compared to other systems. 

2. DIMENSIONS & KEY DATA

• Dimensions: 1150 x 625 x 31mm

• Surface area: 0.72 m²

• Weight: 15 kg

• Density: 6.7 · 10² kg / m³ (average)

• Water vapour diffusion resistance: μges <7 

3. BENEFITS

Easy to work with:

• The panel can be easily cut to size with a circular saw or hand saw.

• Increased speed of installation if boards are glued to the substrate with a mineral adhesive.

• The panel can be directly screwed or stapled to timber studs. 

Performance

• The insulation part of the panel is a 17mm wood fibreboard panel.

• High inherent stability – excellent for stud constructions.

• Humidity regulation: the clay helps to keep room humidity at between 40% and 70%, the level at which the majority of adverse health effects are kept at bay including asthma. At these levels the likelihood for airborne infectious bacteria and virus to survive is the lowest.

• Absorbs and stores indoor air pollution.

• Absorbs and stores odours and ionises the air, contributing to a feeling of fresh internal air.

• Thermal mass – the panels store warmth during the day and release it slowly in the night.

• Extremely low levels of primary operational energy are used in manufacturing.

• Sustainable materials primarily used in construction – wood and clay.

• Clay works clay panels are highly sustainable due to the low energy required during production and the raw materials used. Clayworks clay boards can be 95% recycled.

• Acoustics: excellent sound insulation.

4. THERMAL CONDUCTIVITY OF CLAYWORKS CLAY PANELS

λges =0.073 W/(m · K); s(d)=0.031m

Based on panel buildup of 17mm wood fibre board within a 14mm clay sandwich.

Overall panel thickness is 31mm. 

5. RANGE OF USE

Anywhere within a building except for areas where there is running or standing water. The panels are especially suitable for bathrooms as the clay system absorbs humidity, however they cannot be used within shower enclosures or directly behind a sink as a splash back.

In a kitchen, clay plaster significantly decreases the build-up of grease, which tends to occur over time in all kitchens.

6. INSTALLATION

• Fixed with staggered joints on OSB clad walls or timber/metal studs (w = 60mm) studs at 625mm centres. For masonry and stone we would recommend a soft wood subframe which allows for even spacing of screws to fix the boards. The subframe also creates a space to run services.

• Can also be fixed to a solid substrate i.e. masonry, concrete or stone using a mineral based adhesive.

• On ceilings or to the underside of rafters, fixed at 312mm centres.

• Fixing materials: drywall screws (4 x 45mm) or galvanised staples (length 50mm or longer, width 10mm or more, wire gauge 1.4mm or more).

• Fixing distance: approx. 150mm apart on all tapered edges. On ceilings or the underside of rafters, an additional row through the middle of the length of the board is required.

Installation overview

We strongly recommend that you contract with an approved installer. The following guidelines are for design and construction planning purposes.

Backing boards behind the panels

Wood fibre boards can be used for extra stability and added acoustic and thermal performance. The panels can be glued to any flat solid surface such as concrete walls and ceilings but for masonry we would recommend a soft wood subframe which allows for even spacing of screws to fix the boards. The subframe also creates a space to run services.

Installation instructions

1. Cut the clay panel with a circular saw or hand saw.

2. Mount the panel to the wall: the panels are either screwed, stapled or glued to the substrate.

3. Staple 100mm wide mesh over the joints to avoid cracks between the joints of the panels.

4. Wet the joints: it is easier to fill up the joints with clay plaster when the joints are wet.

5. Fill up the joints.

6. Apply Clayworks clay base coat (approximately 8mm) whilst integrating reinforcing mesh. Thickness of base coat depends on which fixing method is used and which topcoat plaster is selected.

7. Apply Clayworks clay topcoat plaster. 

7. SERVICES

Wiring within the panels is not possible, but drilling through them for lights, sockets and so on is. We recommend running any services behind the panels and marking out locations of any fittings prior to applying the Clayworks clay base coat and topcoat plaster.

Fixings

In the same way you would for any plastered wall, you can put nails and screws in the wall. For heavier items such as built in floating cabinet or shelves, we recommend plywood backing, but we can look at the project in detail and advise.

8. FIRE RATING

Clayworks Clay Panels are not yet fire rated. The clay plaster itself is BRE Class 1 fire rated (also fulfilling the requirements for Class 0 as outlined in the Building Regulations).