Poor Installation of a One-Hour Fire-Resisting Wall
Poor installation practices were identified around an opening within a one-hour fire-resisting plasterboard wall. The boards have damaged and broken edges, irregular joints, narrow infill pieces, inconsistent fixing positions and visible gaps around the metal frame. The joints and interfaces do not appear to have been completed in accordance with a tested wall-system detail.
These defects could reduce the wall’s ability to provide the required 60 minutes of fire resistance and should be assessed and remediated in accordance with the approved manufacturer’s system.
- NCQLE reference
- NCQLE-2026-00035
- Quality topic
- Installation quality
- Lesson type
- Failure
- Evidence rating
- Experience
- Published
- 3 August 2026
- Last reviewed
- 3 August 2026
Evidence basis: Supported by relevant professional experience. This learning is provided for professional consideration and does not replace project-specific competent advice, statutory duties or contractual requirements.
Context
The issue was identified during construction of an internal plasterboard wall intended to provide 60 minutes of fire resistance. The defects were concentrated around a framed opening, where accurate board cutting, suitable framing support and correct joint formation are essential. The wall had not yet been fully finished, allowing the workmanship concerns to be identified before final decoration and concealment. Poor workmanship was observed in the construction of a one-hour fire-resisting plasterboard wall around a framed opening. The installation included damaged board edges, poorly cut and narrow infill pieces, open and irregular joints, inadequate finishing around the frame and fixings positioned inconsistently or too close to board edges. The opening did not appear to have been formed in accordance with a tested and approved wall-system detail.
The transferable lesson
Fire-resisting plasterboard walls must be installed as complete tested systems, not assembled from improvised pieces. Board type, thickness and layers, joint positions, framing, fixing centres, edge distances and treatment around openings must all follow the manufacturer’s approved detail. Poor cutting, damaged boards, narrow infill strips and unsealed joints can undermine the performance of the entire wall. Work should therefore be inspected at key stages before joints and framing are concealed.
Recommended action
Another project should brief installers on the approved fire-wall specification before work begins and provide the manufacturer’s installation details at the workface. Use full, undamaged boards wherever possible, form openings accurately and maintain the specified board layout, joints, fixings, edge distances and framing supports. Introduce hold-point inspections before joint treatment and concealment. Any damaged boards, unsupported edges, narrow infill pieces, excessive gaps or incorrect fixings should be rejected and replaced. Record the completed work with photographs, inspection results and product details for the project’s fire-safety records.
Limitations and application
The assessment is based on the visible face of the wall only. The board type, thickness and number of layers, internal framing, insulation, concealed fixings, opposite face and head-of-wall construction could not be verified. The intended 60-minute performance must be confirmed against the approved design and manufacturer’s tested system. Remediation should not rely on cosmetic filling alone. The affected area may need to be opened up and reconstructed where concealed components or board integrity cannot be verified.