gyprock hole repair tips




Hole in gyprock to be repaired
gyprock with hole repair

Gyprock Hole Repair Tips
Gyprock Tool Use Instructions

Gyprock Repair Instructions.
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Gyprock Properties

Gyprock is a strong durable product, and usually only requires painting from time to time. Over time the wall gets bumped with heavy furniture, causing dents and holes. Water leaks also cause damage to the gyprock. Holes are sometimes made to find or place wires. These holes need to be repaired, and damaged gyprock needs to be replaced. This article will assist you in making the repairs.


Gyprock Hole Repair Instructions

1/ Before applying tape or gyprock compound, remove all high spots. Use a carpenter knife, or utility knife with a sharp blade to cut away the high spots, and loose material. Use a hammer to lightly drive in nails that have popped out.
Low spots can be easily filled to look normal, high spots never look normal, and may not be sandable.

2/Remove all loose material around the repair area, loose material ends up in the gyprock compound, which causes streaks, as the trowel is drawn over the surface of the repair area.

3/ Groove the edge of the repair joints to about 1/4 of an inch deep, at 45 degrees. This provides space for the gyprock compound to enter and bond firmly with the gyprock.


4/ Apply light coats of gyprock compound, and allowed to dry. Knock off any high spots, before applying the next coat of compound.
Load the trowel with gyprock compound from the bottom front edge, of the gyprock hawk ( see bottom of page for picture and information about loading the hawk). Place the trowel over the gyprock compound on the hawk, press down gently and draw the trowel towards yourself. Clean off the trowel each time before re-loading.


 Working with Gyprock Repair Compound

Gyprock compound can be purchased unmixed or premixed. If you decide to use premixed compound, mix it gently before using, vigorous mixing adds air into the compound. When the compound dries, tiny holes appear on the wall, from the dried up bubbles.
For small to medium jobs, premixed compound is the best choice.
Apply sticky fiberglass tape over the repair area, followed with a quick thin coat of gyprock compound, the compound bonds the tape firmly to the wall.
Leave the repair area for a day to dry thoroughly, before applying more compound.
I find a three inch gyprock trowel comfortable to work with, when appling the first coat of gyprock compound.


Apply enough coats of compound, to allow for sanding, and to keep the fiberglass mesh tape from being exposed. Apply two or three light coats, one coat at a time, allow enough time for each layer to dry before placing the next layer. Apply the gyprock compound four to six inches pass the edge of the patch area, as this spreads out the height of the patch over a greater distance which makes the patch less noticeable when finished.

Run the trowel over each new layer after it has dried, to knock off any burrs and high spots, and then apply additional coats
Place portable lighting beside the wall to show any imperfections in the wall.


 Sanding Gyprock Compound

Use a common disposable dust mask when sanding.
Sand the dried gyprock compound with medium grit sandpaper, use very little pressure. Use a light circular motion to finish up.
First use 120-grit sandpaper to remove the material faster, then finish with 150-grit sandpaper.
Sanding helps texture the dried gyprock compound to match the texture of the existing gyprock wall.
After sanding, prime the area with gyprock undercoat primer paint. Gyprock primer helps the patch area to look normal, reducing the too smooth look.
The wall is ready for painting.


 Patching a Small Hole in Gyprock

To Patch small holes like nail and screw holes, cut away lumps along the edge of the hole with a knife.,
A hole can be filled, but protruding bumps are much harder to deal with.
Apply a small amount of gyprock compound over the hole, and scrape away the excess. This is done one or two times, as there is a little shrinkage when compound dries each time.
On the final coat, leave it to dry for a day, then lightly sand smooth and it is ready for painting.
Tip
If you have a very tiny nail hole, a very quick solution is to apply a little compound with your finger directly into the hole, it will do the job.


 Patching a Medium Size Hole in Gyprock

To patch a medium size hole, cut away any lumps or bumps with a sharp utility knife. Cover the hole over with fiberglass tape in a criss-cross fashion. Extend the fiberglass a couple of inches past the hole. Apply the first thin coat of gyprock compound over the tape, and let dry. When the compound is dry, run the trowel across the patch area, to knock off any bumps. Apply another coat of compound, then let dry. Continue this process until the hole is covered over, creating a flat surface.
Lightly sand the area before painting.


 Preparing Surfaces for Gyprock

Standard size gyprock sheets are 1/2 inch thick, it contours to the surface beneath it. If the wall studs are not level, the studs show in the finished wall. It is very important to carefully prepare walls before applying the gyprock sheets. Use a string to check walls for bows. To straighten a wall before gyprocking, cut away bows that jut into the room, and add material to the studs that bow inward.
Tip
In preparation to gyprock a wall, measure the position of the wall studs, record this information on a sheet of paper for future reference. Mark each stud position on the floor and ceiling where possible. This also shows where the studs are located behind the gyprock.



 Cutting Out a Electrical Box Placement in Gyprock

Coat the outer lip of the electrical box with soft chalk or lipstick. Slide the drywall sheet into place at the correct height, press the sheet against the electric box, and lightly tap around the electrical box area with the end of the hammer handle. This leaves an accurate impression of the electrical box onto the gyprock. Cut outside the line to create a bit of clearance for easy installation.


 Installing Gyprock Sheets

Use the larger piece of gyprock first. If a mistake is made in the measurement, the larger sheet of gyprock can be cut down in size and used where a smaller piece is required. This procedure reduces waste.


 Cleanup Tip

When cleaning up your tools, don't wash a lot of gyprock compound down the drain, compound can clog
up your drainpipes. First wipe down the gyprock tools with wet paper towel to remove most of the compound,
then finish up under the tap.
Dry the tools to prevent rust from forming.

Clean up any spilled gyprock compound while wet. Scoop up what you can
and finish cleaning up with a damp rag.


 Cutting Gyprock Information

A utility knife (carpenter knife, sheetrock knife) is used to cut a gyprock sheet. A sharp blade is required, dull blades tear the paper and make a mess.
After the measurement is taken, draw a pencil line where the cut will be made. Lay the gyprock sheet face up on a flat surface, place a two foot carpenter square or straight edge against the line, run the knife against the square, or flat edge, until the cut made is about half way through the gyprock.
Stand the gyprock sheet up up onto its edge, and tap along the backside of the cut, with the handle of the knife, the full length of the cut, to insure a good clean cut. Bend the section of the gyprock into a right angle. While holding the portion to be cut off, run the knife from the bottom to the top of the sheet, cutting, along the fold.
Any intricate cuts can be made with a key hole saw, or handsaw.

When cutting out material for a light or electrical outlet, a gyprock tapered blade handsaw is used. To start the cut, place the point of the saw at one of the corners of the area to be cut out, gently rock the saw back and forth while appling inward pressure until the blade is through the material. Do this with all four corners and saw along the lines, until the hole is cut out.


 Gyprock Dust Cleanup

Tip

Gyprock dust creates a real mess that can be tracked all over the place. The dust is so fine it floats all over the room. The best way to deal with dust, is to trap as much as possible as you are sanding. Place a drop sheet on the floor below the area you are sanding, then gently sand. When the sanding is completed, carefully wrap up the drop sheet, take it out side, and give it a good shake. Use a damp cloth to wipe up any small bits left around the room.
Finish up with a vacuum cleaner. A regular vacuum will tolerate a bit of gyprock dust, a large amount of gyprock dust will destroy your household vacuum cleaner.
The dust plugs up the bag and prevents air from cooling the motor, which will cause the vacuum motor to overheat. If the vacuum cleaner uses a disposable bag, or vacuum cup, when the job is completed, replace with a new bag or clean cup.
A wet dry vacuum is best to use to clean up gyprock dust.


 Popped Nails or Screws in Gyprock

Popped nails/screws occur anytime there is a space between the stud in the wall and the drywall. Studs which are not dried properly before installing, causes nails or screws to pop as the wood dries.
To repair this problem, drive the popped nails or screws below the level of the wallboard. Place another nail or screw above and below the popped nail and tightened down. Finish up with gyprock compound, sand and paint.


 Water Damaged Gyprock

Extreme water damaged gyprock cannot be repaired because the outside paper it bond with the interior material which has swelled and crumbled. Any strength of the gyprock is gone, the only solution is to remove the water damaged gyprock and replace with new gyprock sheets.


 Types of Gyprock Wallboard

Standard, Flexible, fire-resistant, moisture resistant, abuse resistant, foil-backed, decorative, blue board, high density, cellulose-fiber sound proofing and mold resistant.


 Gyprock Wallboard Strength

Gyprock wallboard has a grain that runs parallel to the length, giving panels more strength along the length, rather than across the width. For load bearing walls the gyprock should be applied horizontally.


 General Gyprock Wallboard Information

Gypsum a mineral, in the gyprock, contains 21 percent water in a crystallized form. A large percentage of gypsum is water. This ability to hold water makes it a very good fire resistant material. When gypsum is subject to extreme heat, water in the gypsum converts into steam, retarding any flames.

Gyprock wallboard is also great at deadening sound and the board is easy to repair. Gyprock wallboard can be painted, textured and wallpapered.

An 8 ft. sheet of gyprock wallboard weighs about 54 pounds. The sheets are shipped together in two's, but can be easily separated by removing the strip of paper which holds them together.

Gyprock drywall sheets come in lengths of 8, 9, 10, 12, 14 and 16 ft. They come in 1/4, 3/8, 1/2, and 5/8 inch thicknesses.

Drywall was developed in the late 1930's by United States Gypsum Company.
Before drywall, plaster was the popular choice.


 Gyprock Hawk Use Instructions

Work with a gyprock hawk, it reduces the effort. The hawk holds the gyprock repair compound, it provides a place to access and deposit compound, and it provides a place to clean off your trowel, and deposit grit laden compound. It saves you many steps, back and forth

Build your own gyprock hawk. For small repair jobs a 6 inch by 6 inch gyprock hawk will do the job. Use 1/4 inch plywood, 6 inches by 6 inches. Painted plywood is best as it can be washed off easier. Make a handle from 1 inch by 1 inch stock, cut it to 2 and 1/2 inches in length. Center it in the ply wood and nail in place from the top with two small nails.

gyprock hawk gyprock hawk gyprock hawk
The first picture shows gyprock hawk loaded with repair compound.

The second picture shows the correct way to remove gyprock compound off the gyprock hawk. Place the trowel into the compound at an angle and draw it towards yourself. Pick up just enough gyprock compound to work with. The compound is picked up on the bottom side. Don't worry, it will not drop off, if the compound is the right consistency.

The third pictures shows how to clean off the trowel, each time before re-loading. Scrape the trowel at an angle, downward along the edge of the gyprock hawk, and deposit unused compound, back onto the board. Each time you go to reload, clean off both sides of the trowel.

If you have picked up some lumps, or loose pieces off the wall while Appling compound, clean off the trowel on the far side of the gyprock hawk, this material to be discarded later. You do not want to add lumps to the fresh compound on the hawk.


 Nailing Framing Strips

When using powder-actuated mailer, to nail framing strips onto a cinder block, aim for the center of the block. Cinderblocks have a web in the center and ends, the rest is hollow.

If you are using masonry nails, drill pilot holes and drive the nails into the mortar joints.


 Example of Hole Repair

Thick 3/4 inch plywood covering hole in wall
plywood covering hole in gyprock to be repaired

Cover removed, shows hole in wall
abanded fireplace cleanout, fireplace was converted
cleanout no longer required
shows hole in wall

3/8 inch plywood installed into hole to support patch
plywood extends 2 inches past edges of hole
7/64 inch pilot holes drilled for gyprock screws
Notice temporary screws to hold onto while installing
plywood back support for gyprock repair

Patch in place and secured with gyprock screws
Screw heads are dimpled below gyprock
patch in gyprock for the gyprock repair

Fiberglass tape applied over gap and screws
fiberglass tape applied on the gyprock to be repaired

First coat of gyprock compound applied, and allowed to dry.
Three more coats were added, and sanded.
gyprock repair compound applied over patch area of the gyprock to be repaired


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Sanded and painted
painted gyprock


Texture a ceiling using a hopper and air pressure








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Gyprock Hole Repair and Tool Use Tips