Curved Plasterboard Case Study – Aspire Dental

Curved plasterboard walls look effortless once finished, but tight radii, changing heights and complex junctions are far from simple to produce accurately.

For this project, we reviewed the design information, engineered and 3D modelled the curved wall arrangement, then divided the geometry into practical sections that we could manufacture offsite.

As a result, each component was prepared to the agreed geometry, giving the installation team a controlled route to positioning, installing and finishing the complex forms.

Overall, the completed curves, textured surfaces and carefully positioned lighting show how closely the finished interior follows the original design intent.

Project Snapshot: Curved Plasterboard Walls

Complex curved wall components for a high-end dental surgery and training environment

Drylining contractor: Dentons
End client: Aspire Dental
Application: Dental surgery and training environment
What we supplied: Geometry review and offsite-manufactured full-height and low-level curved plasterboard wall components

Curved Plasterboard Wall and Ceiling Details

How Curved Plasterboard Walls Shaped the Interior

Because a visit to the dentist can feel daunting, the Aspire Dental interior was designed to create a warm and reassuring experience.

For example, curved walls helped remove the hard lines normally associated with a clinical setting. They also allowed the rooms and surrounding spaces to flow naturally.

In addition, lighting was carefully positioned around the curved features. As a result, this emphasised the geometry and helped create a softer atmosphere throughout the practice.

The Challenge of Forming Curved Plasterboard Walls on Site

However, curved plasterboard walls can be difficult and time-consuming to form accurately on site.

Above all, each radius needed to flow smoothly into the surrounding construction. The finished walls also needed to provide a consistent base for the specialist textured finish.

Lighting would highlight the completed curves, so any variation in the underlying geometry could become visible.

What the Installation Team Needed on Site

For this reason, the installation team needed accurately prepared components that would help them achieve the design without unnecessary cutting and forming on site. In short, the more work we could complete in the workshop, the more time the dryliners could spend on positioning and finishing the curves.

“Seeing the completed Aspire Dental project on my birthday was a real ‘wow’ moment. The curved plasterboard walls, lighting and finished space looked fantastic. Sadly, our photographs do not do it justice.”

Tony Baccarini
Technical Director, Innovate at SA

Our Offsite Curved Plasterboard Walls Solution

First, we reviewed the project drawings and developed a 3D model of the curved plasterboard walls.

This allowed us to see each detail in context, check how the radiuses connected with the surrounding construction and value engineer the solution before manufacturing began.

Using the agreed 3D geometry, we then divided the design into practical sections that could be manufactured, transported and installed on site.

Next, each component was cut and prepared within our workshop to follow the required geometry.

Curved Plasterboard Walls: The Finished Result

Of course, offsite manufacturing did not replace the skill and experience of the dryliner. Instead, it gave the installation team accurately prepared components that were easier to understand, position and install.

As a result, this reduced the repeated setting out, cutting, forming and adjustment required on site, allowing the team to concentrate on installing and finishing the curved walls.

In short, the consistent geometry provided a controlled base for the specialist textured finish and carefully positioned lighting, helping the completed interior follow the original design intent.

You can see more examples of this approach across our offsite plasterboard case studies.

FAQs

What did Innovate at SA manufacture for Aspire Dental?

We manufactured curved plasterboard wall components based on the agreed project geometry. In addition, the sections were prepared within our workshop and supplied ready for positioning, installation and finishing on site.

How did 3D modelling help develop the curved walls?

First, we developed a 3D model to examine each radius and understand how the curves connected with the surrounding construction. As a result, we could value engineer the detail into practical sections for manufacture, transport and installation.

Why were the curved plasterboard sections manufactured offsite?

Offsite manufacturing moved much of the repeated setting out, cutting, forming and adjustment away from site. It also gave us greater control over the curved geometry and repeated components.

How did the offsite preparation help the site team?

Consistent components based on the agreed geometry allowed the team to concentrate on positioning, installing and finishing the curved walls. Therefore, this reduced uncertainty and provided a controlled base for the specialist finish and lighting.

Can you manufacture curved plasterboard walls to our drawings and required radiuses?

Yes. We can work from construction drawings, dimensions or an early sketch. We review the required radiuses, board specification and surrounding details before developing a practical manufacturing solution.

How do we get started with a curved plasterboard project?

Send us your drawings, dimensions or even a sketch. We will review the detail in context, develop a 3D model where needed and work with you to create a practical, value-engineered solution for offsite manufacture and installation.