INTRODUCTION

• Gypsum is a non-hydraulic binder occurring naturally as a soft crystalline rock or sand.

• Pure gypsum is a white translucent crystalline mineral and is so soft that it can be scratched by a finger nail.
• When heated to 205°C, pure gypsum loses its luster and its specific gravity is increased from 2.3 to 2.95 due
to the loss of water of crystallization.
• Gypsum has a unique property of moulding. When heated it gives up combined water and easily turns into
powder. On adding water to the powder it can easily be shaped and moulded, and in a short time it
• hardens again and becomes similar to what it was in its natural state
GYPSUM BOARD
1. It is a gypsum product of recent origin made of thin layers of card board or wood cemented together with wall plaster, used
for lining walls and ceiling of buildings. The boards may be strengthened by incorporating fibres as fibrous gypsum plaster
boards. Sissal or coconut fibres are generally used. The weight of plaster in the later variety is 10 kg/m2 of board and that
of fibre is 250 g/m2 of board.
2. They are very light weight and have high fire resisting properties.
3. Gypsum plaster boards can be sawn to desired size and shape.
4. They are available in widths 400, 600, 800, 900, 1200 mm; in length 1200, 1500, 1800, to 3600 mm in steps of 100 mm
and; in
5. thickness 9.5 to 15 mm.
They are classified as
I. It has a face to which decoration may be applied.
II. These boards have additives in the core and/or the paper liners to reduce water absorpation rate.
III. These boards have mineral fibres and/or other additives in the gypsum core to improve core cohesion at high
temperature.
IV. These have a face suitable for direct direction.
V. These boards have a face suitable to receive gypsum plaster and may be perforated during
VI. primary manufacturing. It is a combination of the above two.
VII. These boards have cores containing special mineral materials.
MANUFACTURING PROCESS OF CALCINED GYPSUM
1. The ra w m ate r i a l gypsum is s o r t e d a n d washed w i t h wate r f o r re m ova l o f s a n d
a n d o t h e r impuriti es.
2. The lum ps t h u s o b ta i n e d a r e t h e n d r i e d a n d p o wd e re d in p u l v e r i ze r.
3. The d r i e d gypsum p o wd e r is ca l c i n e d in a r o t a r y d r u m c a l c i n e r
4. a t a te m p e rat u r e o f 1 6 0 º C t o 1 8 0 º C .
5. The p r o c e s s o f c a l c i n a ti o n is d o n e o v e r a p e r i o d o f a b o u t 2 h o u r s . t h e
te m p e rat u re s o t h a t one a n d h a l f m o l e c u l e s o f wate r is removed t o c o n v e r t t h e
gypsum (CaSo4 2 H2O ) i n t o p l a s t e r o f Pa r i s (CaSo4 ½ H2 O).
6. A ft e r c o o l i n g t h e p r o d u c t ( p l a s t e r o f Paris) is f u r t h e r p u l ve r i ze d t o a fi n e n e s s o f
1 5 0 mesh a n d packed in a i r ti g h t p o l y t h e n e l i n e d g u n ny bag s t o avoid t h e p l a s t e r o f
Pa r i s f r o m a b s o r p ti o n o f m o i st u re .

Water
crushing 160ºC t o 180ºC
was h e d

Raw ma t e r i a l Calcination POP

about 2 hrs.
HISTORY
Gypsum is a r o c k l i ke m i n e ra l commonly f o u n d in t h e e a r t h ’s c r u s t , e x t r a c t e d , p ro c e s s e d
a n d u s e d by Man in c o n s t r u c ti o n o r d e c o r a ti o n in t h e f o r m o f p l a s t e r a n d a l a b a s t e r
since 9 0 0 0 B.C.. P l a s t e r was d i s co v e r e d in C ata l- Hu y u k in Asia in a n u n d e r g r o u n d f r e s c o ,
a n d in I s r a e l Gypsum fl o o r s c r e e d s were f o u n d f r o m 7 0 0 0 B.C. D u r i n g t h e ti me o f t h e
P h a ra o h s , Gypsum was u s e d a s m o r t a r in t h e c o n s t r u c ti o n o f t h e Cheops Pyramid ( 3 0 0 0
B.C.). I n t h e M i d d l e Ages a n d t h e Renaissance, d e c o r a ti o n s a n d a r ti s ti c c r e a ti o n s were
made o f p l a s t e r. Since t h e n , t h e ra n g e o f c o n s t r u c ti o n - r e l a t e d u s e s have c o n ti n u e d t o
m u l ti p l y.
 MANUFACTURE OF GYPSUM board
Raw material
1.High-quality gypsum ro c k is ex t ra cte d at qu arri e s
o r mine
2.Large ro c ks are c r us he d i nto s m a l l pieces
Grinding mill
3.The m i l l reduces s m a l l ro c ks t o a very fi ne, chalk-
like powder c a l l e d l a n d p l a ste r .
Crusher
Calcine system
4.The l a n d p l a s t e r is heated in l a r g e ke tt l e s t o remove
most o f the water f ro m t he p l a st e r
Stucco holding tank
5.Calcined l a n d p l a s t e r, c a l l e d stucco , is fe d f ro m a
h o l d i n g bin t o the mixer by a screw conveyor.
Mixer
6. In he mixer, water is added back t o the st u cco
t o fo r m a s l u r r y, and foam is added t o t he s l u r r y t o
make t he w a l l b o a rd more lightweight.
.
Board line
8 . the b o a rd t rave l s down a
l o n g conveyor li ne in a single conti nuous piece. During
t hi s t ri p, water re hydrate s t he st ucco, causing i t t o
harden.
Cut –of knife
9 . t he end o f t he line, a bl a de c u t s t he hardened b o a rd
i nto various l e n gt h s .
11. K i l n
The b o a rd k i l n completes t he dryi ng process, leaving t he
gypsum b o a rd v i r t u a l l y moisture-free.
Transfer table
10. H ere t he c u t l e n gt h s are t u r n e d face-side up t o
p r o t e c t the face paper o r mat, t hen f e d i nt o the ki l n .
Type of gypsum:-
1. N a t u r a l gypsum o r ,

2. S y n t h e ti c gypsum i s k / n a s f g d .

M a j o r varieti es o f gypsum
1. S a ti n s p a r 1. P e a r l y, fi b r o u s masses
1. Tr a n s p a r e n t a n d b l a d e d
1. Selenite crystals

1. Alabaster 1. F i n e - g ra i n e d , s l i g h t l y c o l o r e d

SATIN SPAR Selenite ALABASTER ALABASTER

USES O F GYPSUM
1. Gypsum c a n be u s e d :-

2. architecture.

3. Medical.

4. Agriculture.

5. Fine a r t .

6. Che mical i n d u s t r y .

7. j u i c e e x t r a c ti o n o f some f r u i t s a n d v e g e t a b l e s .

8. Co s meti c e t c .
USE O F GYPSUM IN B U I L D I N G
Gypsum building m ater ia ls a r e u s e d i n a l l c o n s t r u c ti o n types
( r e s i d e n ti a l , n o n - r e s i d e n ti a l , new o r r e f u r b i s h e d )

Pl a st e r bo a r d
P l a s t e r b o a r d i s u s e d f o r p a r ti ti o n s a n d t h e l i n i n g o f w a l l s ,
c e i l i n g s , r o o f s . The p r o p e r ti e s o f
p l a s t e r b o a r d c a n be m o d i fi e d t o meet s p e c i fi c r e q u i r e m e n t s
, s u c h a s fi r e r e s i s t a n c e , h u m i d i t y r e s i s t a n c e , s h o c k r e s i s t a n c e , e t c .
 Decorative P l a s t e r

P l a s t e r p o w d e r, mixed w i t h w a t e r, m a n ua ll y o r t h r o u g h t h e
use o f s i l o - s u p p l i e d s p r a y systems, a r e u s e d t o c r e a t e
an e ff e c t i v e a n d a e s t h e t i c a l l y - p l e a s i n g l i n i n g f o r b r i c k a n d
b l o c k w a l l s , and f o r ceilings.
 Building p l a s t e r

 Gypsum p l a s t e r is u s e d f o r w a l l s a n d c e i l i n g s .
 P l a s t e r blocks

Gypsum b l o c k s a r e u s e d f o r p a r t i t i o n s a n d Gypsum
t i l e s f o r ceilings .
 Gypsum Fibreboards

Gypsum f i b r e b o a r d is u s e d f o r p a r t i t i o n s a n d t h e l i n i n g o f
w a l l s , c e i l i n g s , r o o f s a n d f l o o r s . S t a n d a r d Gypsum
f i b r e b o a r d o f f e r s g o o d p e r f o r m a n c e when i t comes t o
s h o c k r e s i s t a n c e , s o u n d i n s u l a t i o n a n d humidity r e s is t an c e .
 GYPSUM
BOARD
1) Gypsum b o a r d i s t h e g e n e r i c name f o r a fa m i l y o f p a n e l p r o d u c t s t h a t
c o n s i s t o f a n o n - c o m b u s ti b l e c o r e .
2) A l l gypsum p a n e l p r o d u c t s c o n t a i n gypsum c o r e s ; h o w e v e r
3) , t h e y c a n be f a c e d w i t h a v a r i e t y o f d i ff e r e n t m a t e r i a l s , i n c l u d i n g
p a p e r a n d fi b e r g l a s s m at s .
4) Gypsum b o a r d i s o ft e n c a l l e d d r y w a l l , w a l l b o a r d , o r
plasterboard.
 Standard size o f
gypsum board
 S t a n d a r d size gypsum b o a r d s a r e 4 8 inches wide a n d 8,
10, 1 2 o r 1 4 feet long.

The 4 8 i n c h w i d t h is compatible w i t h s t a n d a r d f r a m i n g m et h o ds in
which s t u d s o r j o i s t s a r e spaced 1 6 inches a n d 2 4 inches.

o t h e r l e n g t h s a n d w i d t h s o f gypsum b o a r d a r e a v a i l a b l e f r o m
t h e m a n u f a c t u r e r o n s pe c ia l o r d e r.
 Gypsum is a l s o an i n d e fi n i t e l y r e c y c l a b l e r a w
material

You can always r e u s e Gypsum because t h e chemical composition

o f t h e r a w m a t e r i a l in t h e p r o d u c t s remains u n c h a n g e d
 t h e waste o f is u s e d t o make t h e same p r o d u c t again.
 Properties o f
gypsum

Gypsum is fi re protecti ve
• Gypsum is non-combusti ble and able t o delay a fi re’s
spread up t o 4 hours.

Gypsum regulates sound.

•Gypsum walls, ceilings and fl o o r s together with
insulati on materials create quiet zones in the house
o r business environment.
Gypsum is impact resistant.
•The Gypsum Industry provides plasterboards, gypsum
fi breboards and p l a ste r blocks with a degree o f hardne
 Advantage o f
gypsum board
Gypsum b o a r d w a l l s a n d c e i l i n g s have a number o f
o u t s t a n d i n g advant ages:
 Ease o f i n s t a l l a t i o n
 Fire r e s i s t a n c e
S o u n d i s o l a t i o n
D u r a b i l i t y
 Economy
 Ve r s a t i l i t y
 Edges o f
gypsum
board
1.

2.

3.

4.

5.