Across the wall and ceiling industry in Australia, many installers still follow a very common “traditional” jointing process:

• Tape the joint

• Let it dry

• Run an 8-inch box for Base Coat

• Run 10-inch and 12-inch Top Coats

It seems reasonable and familiar—
but this process is non-compliant from the very first step.
It does not meet the requirements of AS/NZS 2589.

More importantly—

⚠️ Manufacturers’ technical teams have repeatedly stated:

If the first coat does not correctly fill the recessed edge,
any future quality issue will result in warranty denial.

This is not a suggestion;
it is an established rule within manufacturer warranty policies.

❌ The Most Common Incorrect Method in the Industry

1. Apply a small amount of mud and embed paper tape

2. Fail to immediately fill the Recessed Edge with a 6-inch knife

3. Tape has mud underneath but sits hollow on top

4. After drying, run 8”, 10”, 12” passes

5. Many believe this completes a “three-coat system”

But in reality:

❗ This method is wrong from the start and is the cause of 80% of hump, shadow and rework issues.

🔍 The Critical Problem: The Tape Dries “Hollow”

The standard clearly states:

“First fill the recess edge.”
The first coat must fill the Recess completely, fully embedding the tape in compound.

But the incorrect method is:
A thin coat under the tape → hollow space above → left to dry → structural defect formed

This leads to:

• Humps

• Butt joint bulges

• Shadow lines

• Wave effects

• Topping that keeps building out

• Impossible sanding

• Higher risk of cracking over time

This is not a material issue—it is a first-coat issue.

✔ The Correct Three-Coat System (The ONLY Compliant Method)

① After embedding tape → Immediately fill the Recess with a 6-inch knife (critical step)

• Tape must sit inside the compound

• Not floating in a hollow recess

• Not left to dry before filling

• The Recess must be filled while compound is still wet

👉 This is the structural layer. It determines the quality of the entire joint.

② Once dry → Apply Base Coat with an 8-inch knife (structural shaping)

• Creates the radius

• Establishes the transition

• Levels the surface

• This is not for fixing mistakes; it’s part of the structural build-up

③ Final Coat → 12-inch Topping (finish layer)

• Smooth light transition

• Visual flatness

• Correct total width

Topping is for finishing, not fixing.

🧨 Why do some installers say “I’ve done it wrong for years and had no issues”?

Because:

❗ Problems don’t appear immediately.

But they will reveal themselves through:

• Building movement

• Seasonal humidity

• Frame deflection

• Compound shrinkage

• Light direction and angles

• Thermal expansion and contraction

Once the builder or homeowner raises a warranty claim,
if manufacturer technicians inspect and find the first coat was not filled:

→ Warranty is immediately denied.

🚫 Manufacturers’ Technical Position (Consistent Across Brands)

If the first coat does not fill the Recess, it is an Installation Fault.
Installation Faults are not covered by any manufacturer’s warranty.

In short:
If work is not carried out according to the standard,
the installer bears all responsibility.

📣 Final Conclusion (Please Share With Your Team & Colleagues)

✔ If the first coat isn’t filled, nothing done afterward matters.

✔ “Looks fine” simply means the problem hasn’t appeared yet.

✔ Once it appears, warranty will be rejected without exception.

To avoid rework, disputes, and warranty failures,
there is only ONE correct process:

Tape → Fill Immediately (6-inch) → Dry → 8-inch Base Coat → 12-inch Topping

🏗️ Final Words: Standards Don’t Limit Us—They Protect Us

Working to standard isn’t about adding complexity.
It’s about:

• More stable workmanship

• Clearer warranty protection

• Stronger trust from builders

• A more professional team

• Better industry reputation

• More competitive pricing with confidence

An industry improves not because one person does it right,
but because we all do it right together.

We hope this article becomes a useful reference for your team.
Let’s continue learning, sharing and improving as an industry—
and together make the Australian wall and ceiling trade
more professional, more consistent and more respected.

Authorised by AWCI Australia

Disclaimer: AWCI Australia will provide information in English to the group moderator who is a member and is responsible for translating it into relevant languages for the audience of the group. AWCI Australia is not responsible for the translated version of its information.