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Abstract: This paper presents an expert system designed to support the inspection and diagnosis of gypsum plaster coatings applied to
partition walls and ceilings [interior gypsum plaster (IGP)]. It includes a classification of the defects that may affect IGP and their probable
causes, the correlation matrices amongst defects and between defects and probable causes, and a classification of diagnostic methods and
repair techniques suitable for each type of IGP defect. This inspection system was validated through standard IGP inspections undertaken on
119 walls or ceilings in 23 buildings located throughout Portugal. A statistical analysis of the results of the inspection is given that provides
details on, in particular, the pathological problems related to the action of water on IGP because the presence of moisture within or on the
surface of IGP coatings was shown to affect the severity of the problems of inspected samples. The characteristics and frequency of
occurrence of dampness, biodeterioration, and efflorescence and cryptoflorescence are presented, together with the primary causes for their
presence in the sample. The most suitable diagnostic methods, preventive measures, and repair solutions prescribed for these defects are also
analyzed, in detail. DOI: 10.1061/(ASCE)CF.1943-5509.0000258. © 2012 American Society of Civil Engineers.
CE Database subject headings: Defects; Diagnosis; Expert systems; Gypsum; Coating; Moisture; Rehabilitation; Walls.
Author keywords: Defects; Diagnostic methods; Expert systems; Gypsum plaster; Moisture; Plaster coatings; Rehabilitation methods;
Walls.
Introduction causes of defects and appropriate repair solutions. This is true even
on mainland Portugal but especially in coastal areas where damp
Gypsum-based plasters are typically produced in a factory and conditions are much more prevalent as compared to the national
sold ready-mixed, and accordingly to the European standard EN average [World Health Organization (WHO) 2009)].
13279-1, are referred to as gypsum plasters, a standard that deals The proposed inspection system for IGPs , described in detail in
with gypsum binders and plasters. This is the plaster coating most Pereira et al. (2011), was validated through a program of inspection
usually applied to interior partition walls and ceilings [interior that included the pathological characterization of IGP that was
gypsum plasters (IGPs) of homes located on mainland Portugal applied to over 100 walls or ceilings in 23 buildings located
and in most of Europe and the Americas.] Gypsum plasters, how- throughout Portugal. A detailed statistical analysis of the results
ever, are used less frequently in the Portuguese Azores Islands of the program is presented in this paper, which also covers the
because of the overwhelmingly wet climate and the well-known pathological problems related to the action of water on IGP. No
susceptibility of this coating to the action of moisture. The leading similar research work was found in any of the specialized literature,
role ascribed to dampness as a cause of defects to gypsum plasters with the exception of the work of Gaião et al. (2010a, b), in which a
is caused by its ability to stimulate the action of other deteriorating similar inspection system for IGP and specific to gypsum plaster-
agents. For example: gaseous pollutants become deleterious when board is described. However, the work carried out by Gaião et al.
dissolved in water; efflorescence depends on the migration of salts (2010a, b) is not as broad as the study described in this paper, nor
dissolved in water; and biological growth requires damp condi- does it provide a statistical analysis of results, as was done in this
tions. Therefore, knowledge of the patterns of behavior of damp- study. The statistical analysis that was carried out is both innovative
ness and the direct or indirect effect of dampness on gypsum plaster and scientifically validated and reveals statistically significant
is an essential source of information for the diagnosis of defects, the information on defects of IGPs.
1
IST—Technical Univ. of Lisbon, Av. Rovisco Pais, 1049-001, Lisbon,
Portugal. E-mail: fpalha@gmail.com Inspection Program
2
IST—Technical Univ. of Lisbon, Av. Rovisco Pais, 1049-001, Lisbon,
Portugal. E-mail: ap.cascais@clix.pt A program of inspection was designed for buildings in which IGP
3
Full Professor, Dept. of Civil Engineering and Architecture, Section of coatings were used; this permitted validating the inspection system
Construction, IST—Technical Univ. of Lisbon, Av. Rovisco Pais, 1049- and related inspection procedures. The inspection plan included the
001, Lisbon, Portugal (corresponding author). E-mail: jb@civil.ist.utl.pt pathological characterization of 119 IGP coatings applied to walls
4
Ph.D. Student, Assistant Lecturer, Dept. of Civil Engineering and (75) or ceilings (44) of 87 rooms in 23 buildings (22 residential
Architecture, Section of Construction, IST—Technical Univ. of Lisbon, and one office building), 83% of which are in the Lisbon area
Av. Rovisco Pais, 1049-001, Lisbon, Portugal. E-mail: jds@civil.ist.utl.pt
in Portugal. The buildings were primarily constructed in the
Note. This manuscript was submitted on February 1, 2011; approved on
June 14, 2011; published online on June 16, 2011. Discussion period open 1990s (43%) but 9% of these date from the 1950s and 1960s.
until January 1, 2013; separate discussions must be submitted for individual The average age of these buildings is 18 years and the oldest were
papers. This paper is part of the Journal of Performance of Constructed built in 1945 (Pereira 2008; Palha 2008). The pathologies found
Facilities, Vol. 26, No. 4, August 1, 2012. ©ASCE, ISSN 0887-3828/2012/ and the repair techniques prescribed were quite different from those
4-424–432/$25.00. for gypsum plasters applied in older buildings (Silveira et al. 2007;
Pathology Fig. 2. Stain caused by too much water within an IGP applied to a
ceiling (Pereira 2008)
The IGP was inspected by using a system previously built up and
described, in detail, in Pereira et al. (2011); it includes a system to
classify defects in IGP and their causes. The defect classification
system includes pathological problems of physical, chemical, and
mechanical nature that can affect IGP, totaling 12 individual de-
fects, which were defined after studying referenced pathological
processes of wall coatings [Dias 2007; National Gypsum (NG)
2008; Rodrigues et al. 2005; Vergès-Belmin 2005]. Of these de-
fects, 31% of those identified are related to the action of water
Fig. 3. Stain caused by too much water within an IGP applied to a wall
Fig. 1. Relative incidence of the inspected rooms (Pereira 2008) (Pereira 2008)
amount of water on or inside the materials is the most important door air quality); in new buildings, the means to comply with
trigger of the growth of microorganisms. Water can also appear this need should be taken into account in the design stage by
in walls if a pipe bursts, water leaks, or there is flooding (Henriques following the national standard related with the “Energetic
1992; WHO 2009). and interior air quality certification” [e.g., European Commis-
Most condensation inside buildings results from water vapor sion (EC) 2002].
generated within the work or habitable space (Fig. 4) and primarily The persistence of condensation on IGP coated walls or ceilings
occurs on IGP surfaces that are cooler than the surrounding air may also result in the growth of mold and fungus (Fig. 4) or the
and where the temperatures are below the dew point of the air. formation of stains, efflorescence, or cryptoflorescence phenomena
Therefore, condensation can be prevented by (WHO 2009) (Henriques 1992).
• Heating indoor air (e.g., when air at a temperature of 15°C and a The IGP is a material that has an open porosity, and this eases
relative humidity of 75% is heated to a temperature of 20°C, its the percolation of water through its microstructure and exposes it to
relative humidity decreases to 58%), hygroscopic movements (Petković et al. 2010). If this water trans-
• Increasing the insulation of the external walls (over the entire ports soluble salts (such as calcium sulfate) that already exist within
surface or over thermal bridges) and windows and preventing construction materials, the consequent pathological phenomena can
be particularly severe. These salts can crystallize under or within
the IGP, thus producing cryptoflorescence that, in turn, lowers the
mechanical resistance of the coating that may thereafter result in a
total loss of its cohesion (Fig. 5) (Henriques 1992; Pühringer 1983;
Arnold and Zehnder 1987; Goudie and Viles 1997). If these salts
crystallize on the outer surface of the IGP, they result in efflores-
cence, but they also indicate that a significant amount of water has
made its way within the IGP and as a consequence, damaged part of
its chemical and physical structure.
of materials, which may also lead to the pollution of indoor air. haps confirms a trend for improved construction methods, in which
However, the health risks derived from biological contaminants there is an enhanced performance and resistance of construction
of indoor air can be addressed by considering dampness as a risk materials that contribute to the reduction in rate of natural aging
indicator (WHO 2009). and to a significant decrease in the number of defects. Dampness,
The second group of defects comprises those caused by chemi- however, occurs in all rooms in buildings from having been built
cal phenomena. The first defect results in the growth of molds or between 1990 and 1999, which also reveals the need for important
bacteria on the coating, known as biodeterioration. Microbial repair interventions in the buildings constructed in this period.
growth may result in more spores, cell fragments, and allergens Correlation matrices are the backbone of the IGP inspection
present in the indoor air, and an excessive level of any of these system. They provide a link between the defects observed in situ
agents in the indoor environment is a potential health hazard to their probable causes, and this assists in the diagnosis of the
(Kildeso et al. 2003; WHO 2009). The second defect arises from problem and thereafter the prescription for repair solutions (Pereira
the volumetric expansion of salts within the coating-substrate inter- et al. 2011). The inspection program also permitted a means to
face that results in efflorescence and perhaps cryptoflorescence validate these correlation matrices.
phenomena (Pereira et al. 2011). A defect in the IGP may be confined to a small area or occur
In the sample set of 119 IGP coatings, 331 defects were iden- throughout the IGP surface. The interdefect correlation index
tified, in which only one occurrence per defect type was recorded provides a list of the simultaneous occurrence of defects and thus,
for each IGP; this generated an average of 2.78 defect types per is a useful tool that permits establishing the likelihood of occur-
IGP. Fig. 6 presents the relative incidence of the defects (i.e., num- rence of other defects once a single defect is detected. This index
ber of defects observed divided by the number of IGPs inspected) was based on a correlation matrix for defects and probable causes
for dampness, biodeterioration, and efflorescence or cryptoflores- of defects developed by Pereira et al. (2011) using the method
cence. The information provided in Fig. 6 shows that dampness is
clearly the defect most often found in IGPs, with an incidence of
occurrence of 50% in this sample set. Biodeterioration (incidence
of 26%) is also very likely to be found when inspecting IGPs in this
location.
Of the 331 IGP defects identified of the buildings inspected, 231
(70%) of these defects effected walls, whereas the other 100 (30%)
were identified in ceilings. Of course, more walls than ceilings were
inspected (75 to 44); however, the proportion of defects for walls
was greater than that for ceilings. This may be because the walls in
each room account for a larger overall surface area, even discount-
ing the area attributable to windows and doors, as compared with
the surface area of ceilings and perhaps because the walls are more
readily exposed to human action. The area of external walls, exter-
nal walls exposed to the infiltration of rainwater, is also greater than
the area of external ceilings; as a consequence, this may also affect
the total number of defects attributable to walls than ceilings. If one Fig. 7. Absolute incidence of dampness, biodeterioration, and efflor-
considers the absolute value of the incidence of defects detected in escence/cryptoflorescence in walls and ceilings
Fig. 6. Relative incidence of dampness, biodeterioration, and efflores- Fig. 8. Average number of defects of each type in the rooms in each
cence/cryptoflorescence age group
represents [75;100]%. During the course of the program of inspection described in this
paper, 3,154 probable causes were identified, which gives an aver-
described by Silvestre and de Brito (2009). The basis of the devel- age of 9.5 causes for every IGP defect type. The inspections
opment of the matrix is straightforward; the probability of occur- consisted solely of a visual examination of the IGP (time and cost
rence of defect j (column j) is estimated when defect k (row k) limitations prevented in situ or perfomance of laboratory tests) and
occurs (Table 1). The information provided in Table 1 confirms were documented in standard inspection and validation files. This
the strong correlation that exists between the three defects under explains the large average number of probable causes per defect.
study (i.e., probability of simultaneous occurrence between 50% This would likely decrease if a diagnosis procedure were put into
and 75%). In fact when dampness is detected, only the probability practice that facilitated the detection of the actual cause of defects
of occurrence of efflorescence and cryptoflorescence lies within a identified during inspection.
smaller interval [i.e., (25; 50)%]. Execution errors were the most important group of causes of
The information related to each type of defect is summarized in defects in the sample set representing almost 40% of all those
the inspection system through individual defect files. The damp- causes identified of the 119 IGP coatings inspected. These defect
ness defect file included in Pereira et al. (2011), is comprised of causes can be related to substrate preparation (e.g., excessive water-
the probable causes of defects, possible consequences, diagnostic proofing or lack of humidity) or to incorrect execution of some
methods to be applied in situ to characterize the extent of defects, coating components (e.g., waterproofing barriers, ventilation sys-
the severity and stability of the defect, and the prescribed repair tems, air gaps, and drainage holes). In this group, the most frequent
solutions for the defect. As well, every defect detected from inspec- causes were incorrect or lack of installation of waterproofing
tions was rated in the urgency for repair, in which the following barriers and protection profiles specified in the design and incorrect
actions could be selected: or lack of installation of ventilation system. The high incidence of
• 0- Action required immediately or in the short-term (6 months); both causes can be explained by the direct relationship between the
• 1- Action required in the medium-term (12 months); or presence of water and early deterioration and the occurrence of
• 2- Action required in the long-term (reassessment in next most of the defects in IGP.
routine inspection). Of environmental actions, which comprised 8% of all the defect
Considering the data collected in the inspection and validation causes in the inspection program, the most important was excessive
files, the incidence of each ranking of the defects related with the humidity for reasons already stated. Finally, within the causes
action of water is presented in Fig. 9. This graph shows that damp- related to maintenance errors, insufficient ventilation had a high
ness, biodeterioration, and efflorescence and cryptoflorescence number of occurrences, especially in defects found in water closets
have a severity and urgency for repair of greater than 33%. This and kitchens because of its relationship to poor design and execu-
result is related to the progressive deterioration characteristics tion errors in these systems or improper use of the room by users.
typical of these types of defects.
Correlation between Probable Causes and Defects
Incidence of Probable Causes The causes of defects in IGPs were correlated with defects by using
As stated, many of the pathological problems evident of IGPs are a classification system. After the defects were identified and linked
caused by the presence of water, which can occur for various rea- with their probable causes, a matrix was then produced by using a
sons. However the isolated occurrence of each type of defect under correlation index for these two items. The correlation matrix en-
study in this paper is, in fact, an ideal occurrence and not one that abled identifying the probable cause(s) of each defect and thereafter
typically occurs in service conditions. Usually, two or all three rated each defect cause with a number according to its degree of
defects occur simultaneously because their causes are similar or correlation (0, 1 for indirect causes or 2 for direct causes); the com-
correlated. Therefore, it is essential to identify and analyze each plete set of values for the correlation matrix can be found in Pereira
et al. (2011). The theoretical correlation matrix for IGP defects and
their probable causes, which is on the basis of the experience of the
authors and on specialized literature, was validated through the use
of the inspection program. The correlation between defects and
their causes taken from the sample set obtained in this study is
analyzed subsequently and the results are discussed.
Fig. 10 presents the main probable causes of dampness defect
(incidence above 66 ). This defect was found in 59 of the 119 IGP
coatings and was associated with 621 probable causes; the average
number of causes for this defect was thus 10.5. The information
provided in Fig. 10 shows that the defect is caused by excessive
humidity in almost every instance (90%). This results from a strong
relationship between the defect and faults in the waterproofing or
Fig. 9. Repair urgency of each defect in the sample
ventilation systems of the rooms, which is evident from the high
incidence of incorrect design and detailing of waterproofing system 66%. This defect was found in 31 IGP coatings with a total of 365
(design error 71%), and incorrect or lack of installation of water- probable causes, thus representing an average of 11.8 probable
proofing barriers and protection profiles specified in the design causes per occurrence. A comparison between Figs. 10 and 11
(execution error 69%). These directly contribute to the presence helps confirm the similarity of causes of both defects. This was
of high humidity in the spaces that were inspected, even if the expected because the presence of dampness encourages the devel-
humidity was caused by water vapor. Insufficient supervision opment of microorganisms.
and quality control is also an execution error that had a significant Fig. 12 shows the primary probable causes for the occurrence of
incidence (85%) and may help explain the inefficiency or lack of a efflorescence and cryptoflorescence in the sample set (incidence
ventilation system that resulted in humidity that was observed to more than 66%). This defect was observed in 13 IGP coatings with
occur on an IGP coating. The maintenance error related to lack a total of 180 probable causes, an average of 13.8 probable causes
of conservation and maintenance works was also prevalent (71% per occurrence. The high number of probable causes associated
of the sample set was represented by this type of error). with this defect was expected given the two main factors that
Fig. 11 shows the contribution of the main causes of the bio- can provoke it: the quantity of salts within materials and the fact
deterioration defect having an incidence of occurrence of more than that the presence of water often affects the surfaces of walls and
concentration of salt or that are chemically incompatible; the correlation matrix was therefore validated during the inspection
outcome will be destructive crystallization reactions under or on program and can be found in Pereira et al. (2011). The correlation
the IGPs. between the diagnostic methods and defects in the sample set is
In the second group of causes of this defect are problems related analyzed subsequently.
to the prolonged presence of water in the coating. These causes The inspections found that 1,010 methods were suitable for
include, from the group categorized as design errors, incorrect characterizing defects, representing an average of 3.1 methods
design and detailing of waterproofing system (92%) and incorrect per defect detected in IGP. In Fig. 13 the main diagnostic methods
application of mandatory construction rules or standards (85%), are presented that were considered suitable to characterize damp-
whereas from that categorized as execution errors include: incorrect ness and biodeterioration when they occurred in the sample set.
or lack of installation of waterproofing barriers and protection pro- The damp measurement (i.e., superficial and/or environmental-
files specified in the design (85%), insufficient supervision/quality humidity) and methods for the measurement of interior damp were
control (92%), and the environmental action excessive humidity used in more than 90% of all occurrences of these two defects be-
(92%). Finally, the group of causes relating to environmental cause they are directly related to measurement of the water content.
effects includes: chemical and biological attack (85%) and the Temperature measurement (i.e., surface and/or ambient) was also
maintenance error excessive or incorrect cleaning of IGP (92%); strongly correlated with biodeterioration because of the possibility
both these errors have a high incidence in the sample set. of identifying likely surfaces for condensation. Also, Infrared ther-
mography may be used to determine the extent of dampness in
an IGP.
Diagnosis In Fig. 14, the main diagnostic methods are given that were
Indicators of dampness and microbial growth include the presence considered suitable to characterize efflorescence and cryptoflores-
of condensation, visible mold, perceived moldy odor, and a history cence. Damp measurement (i.e., surface and/or ambient-humidity),
measurement of interior damp, salt identification, and percussion
test are the methods associated with all the occurrences of this
defect. The first three types of test methods enable characterization
of the causes of this defect, and the last method determines the
severity of degradation in the affected IGP coating.
Repair
The most effective way to avoid adverse health effects arising from
the action of water in IGP is to prevent or reduce persistent damp-
ness and from this, the presence of microbial growth on interior
surfaces and in building structures (WHO 2009). Repair techniques
were prescribed for defects identified from inspections, but they
Fig. 13. Relative incidence in the sample of the main diagnosis meth-
were not actually implemented because of time and cost con-
ods for dampness and biodeterioration
straints. Repair techniques were chosen from those in the proposed
Fig. 14. Relative incidence in the sample of the main diagnosis methods for efflorescence/cryptoflorescence
classification system as described in Pereira et al. (2011). Over dampness defect in almost 80% of all situations, whereas the ap-
the entire set of available repair techniques, 437 were considered plication of fungicide (58%) was considered the most appropriate
appropriate for the 331 defects observed, giving an average of 1.3 repair for biodeterioration. The IGP cleaning and application of
repair techniques per defect. This is an approximate figure because fungicide inside the IGP techniques had a usage incidence of
the corrective measures only cover the repair of the IGP, not nec- almost 50%. The suitability of these techniques depends on the
essarily the elimination of the causes, and they were reduced to the severity of each defect thus, highlighting the heterogeneity of
best one for each situation considering both the technical aspects the sample. The IGP replacement (85%) was considered the best
and those related to the cost of the repair technique. The choice for the efflorescence and cryptoflorescence defect, even though
of each repair solution, nevertheless, took into account the stabi-
the application of fungicide inside the IGP was also frequently
lized or nonstabilized nature of each defect. For example, if
recommended (nearly 77%). This was caused by the strong link
biodeterioration has stabilized and is only a superficial defect, then
between this defect and bioremediation.
only cleaning with a sterilizing product is required to remedy it.
Whereas, if it has not stabilized, perhaps because of the presence
of condensation, it would be better to choose application of fungi-
Conclusion
cide following the cleaning process. Finally, if biodeterioration
has already proliferated deep into the plaster, but it has definitely
An expert system to support the inspection and diagnosis of gyp-
stabilized, the best option is to replace the IGP. However, if this
sum plaster coatings applied to partition walls and ceilings (IGP)
problem has gone deep into the plaster but is not yet stabilized,
then a better option to the replacement of the IGP is to add an proposed in this paper was validated through standard inspections
application of fungicide inside the IGP. of IGP applied to 119 walls or ceilings in 23 buildings located
All techniques were similarly prescribed for walls and ceilings, throughout Portugal. No other work of this type has yet been pub-
with the exception of three, one of which was the application of lished that offers a scientifically validated and statistically signifi-
fungicide inside the IGP. As previously stated, this technique was cant analysis of IGP defects. The statistical analysis of the results of
used when biodeterioration had already propagated deep within the the program of inspection, i.e., the pathological problems related to
IGP and had not stabilized. This kind of problem was normally the action of water on IGP because of their significance and severity
associated with the ceilings of rooms, in which considerable water in the sample, included the characteristics and incidence of damp-
vapor was produced, and also, the ventilation in the room was poor. ness, biodeterioration, and efflorescence and cryptoflorescence,
Because vapor rises to a cooler ceiling surface, condensation occurs together with the primary causes of their occurrence, the most suit-
and prolonged dampness on the surface creates ideal conditions for able diagnosis methods, preventive measures, and repair solutions
the fixation and development of fungi and molds. Thus, the appli- prescribed for them in the sample set. The detailed characterization
cation of fungicide inside the IGP is better suited to ceilings when of the pathological process of these defects is important not only
the progress of biodeterioration is caused by high indoor humidity because IGP has a high tendency to deteriorate under the action of
levels. water but also because of the resulting deterioration that affects and
Regarding the distribution of repair techniques by area of coat- reduces the quality of indoor air to the extent that may lead to un-
ing effected, only the application of fungicide and application of
warranted respiratory ailments in occupants given what is already
fungicide inside the IGP were prescribed more for reentrant corners
known about the direct connection between healthiness of air and
than for regular areas. Typically these areas are less well-ventilated
respiratory problems (WHO 2009).
and favor the persistence of dampness and thereby defects, such as
The prevention of pathological problems in IGP is a cause of
biodeterioration, occur.
The repair techniques were also correlated with defects in IGP concern even in drier areas. It can include the application of a final
before the inspection program by using theoretical figures taken layer over the IGP to improve its resistance to the action of water.
from the literature. This correlation matrix was then validated from Maintenance of IGP should avoid cleaning with large amounts of
results derived from the inspection program (Pereira et al. 2011). water or with chemically aggressive products. Condensation must
However, only the correlation between the repair techniques and be prevented to avoid the persistence of water in or over the IGP. An
defects in the sample set is analyzed in this paper, as shown in antifungal product must be added to the IGP, or a coat of antifungal
Fig. 15, in which how often each repair technique was used per paint should be applied over it when it is used in a wet area or one
is given. The technique IGP cleaning was associated with the with poor or no ventilation.
Symp. of the Courtauld Institute of Art and the Getty Conservation and diagnosis system for gypsum plasters in partition walls and
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