GYPSUM PRODUCT

By: Swati Pawar

PG 1ST Year
 Contents:
 Introduction
 History
 Application
 Supplied as
 Setting reaction
 Classification
 Manufacture
 Factors affecting
 Specialized form
 Introduction
 Gypsum is a soft sulphate mineral composed of
calcium sulphate dihydrate with chemical formula
Caso4.2H2O.

 It is widely mined and used as a fertilizer.

 As the main component in many forms of

plaster, blackboard / sidewalk chalk, and drywall.
 A massive fine-grained white or lightly tinted
variety of gypsum called alabaster, has been used
for sculpture .
 Gypsum is also present as translucent form of
crystals known as selenite.
  It also forms as an evaporate mineral and as a 
hydration product of anhydrite.
 History
 The word gypsum is derived from the greek
word gypsos which means “plaster”.

 Gypsum in form of Calcium sulphate

dihydrate (Caso4.2H2O.) is mineral mined in
various parts of world.

 It was mainly found in mines around the city of

paris so called as “ plaster of paris”.
 Gypsum was known in Old English as, "spear
stone", referring to its crystalline projections.

 In mid 18th century German cleryman and

agriculturalist Johnn friedrich Mayer used
gypsum as fertiliser.
 It was also produced as a by- product of flue gas
desulfurization in some coal – fired electric power plants.

 In 19th Century it was called lime sulpate or sulphate of

lime.
 Application in dentistry

 Gypsum is widely used in dentistry as auxiliary

dental material.
 Impression plaster was extensively used for
impressions of mouth and face.
 Various types of plaster are used to make
moulds , casts, dies over which dental prostheses
and restoration are made.

Study model Cast made with die

stone
Mounting plaster for A plaster mould for denture
mounting of cast on construction
articulator
 Supplied as
Powders of various colors

 In small preweighed sachets.

 In medium size containers and bags
 In large bags , sacks or bins .
 Manufacture of gypsum

 The gypsum is produced by calcining calcium

sulphate dihydrate.

 Commercially , the gypsum is ground and

subjected to temperature of 110 0 C to 130 0 C in
open container to drive off part of water of
crystallization.
 On further heating , remaining water is lost.

 First , hexagonal anhydrite is formed at

temperature between 1300 C to 2000 C .

 Later , orthorhombic anhydrite is formed at

temperature between 2000 C to 10000 C .
 Calcination
Calcination is process of removing the water of
crystallization from the dihydrate.

OR

The process of heating gypsum for the manufacture

of plaster is known as calcination.
Calcination reaction
 Alpha and beta Hemihydrate
Depending upon calcination various forms
of hemihydrates:
CaSo4.2H2o / Dihydrate

CaSo4.1/2H2O/
CaSo4.1/2H2O/ CaSo4.1/2H2O/
α hemihydrate
β hemihydrate α hemihydrate (modified}
 Manufacture of dental plaster
Gypsum is ground and heated in an open kettle on kiln at
temperature 110 0 C to 130 0 C.

The process is called as dry calcination .

CaSo4.2H2o 110 0 C to 130 0 C CaSo4.1/2H2O

 Microscopically fibrous aggregates are fine
crystals with capillary pores.
 They breakup as needle like stuctures .
 It improves packing.
 Manufacture of dental stone

 Gypsum is steamed under pressure in an

autoclave at 1200C to 1300C at 17lbs/sq. inch
for 5 to 7 hours .

 Thus product obtained is so stronger.

 Cleavage fragments and crystals in form of rods
and prism present microscopically.
 Manufacture of high strength
(α hemihydrate) stone

 The gypsum is calcined by boiling it in 30%

calcium chloride solution .

 The chlorides are then washed away or

autoclaved in presence of sodium succinate 0.5%.
 These particles are densest of all.

 Microscopically these are cuboidal in shape.

 Setting reaction

 When gypsum is mixed with water it takes up

one and half molecules of water , i.e. ,it regains
its water of crystallization and becomes calcium
sulphate dihydrate.

 This unique property of gypsum leads to its wide

applications in many fields.
 The reaction is exothermic.
 Comparison between dental
plaster and dental stone
properties plaster stone
Manufacture Dry calcination Wet calcination
Size particles Large, irregular, porous Smaller, regular, dense
W/P ratio Requires more water Requires less water
Porosity Porous More dense
Properties Low strength and hardness High strength and hardness
Applications Used when strength is not Used when strength is
required(diagnostic cast) required(dies, master
cast)
Classification
 Type 1
Dental plaster ,
Type 5 impression
Dental stone,
High strength ,
High expansion

Type 2
Dental plaster,
model

Type 4
Dental stone,
High strength,
Low expansion

Type 3
Dental stone,
model
 Type 1 or Dental plaster,
impression
 It was earliest impression material

 Because of rigidity , it often had to be fractured to

remove it from undercuts areas in mouth.

 Impression plaster sometimes contain potato starch

to make it soluble.

 After the cast hardened , the impression and cast are

put in hot water.
 The starch swells and the impression
disintegrates, making it easy to separate.

 This type is often called as soluble plaster

 Uses:
 For making impression incomplete dentures and maxillofacial
prosthesis.
( not currently used).

 Bite registration material.

Composition

Dental plaster + k2So4 + borax +coloring and flavoring

agent.
 Type 2 or Dental plaster, model

 Synonyms: Model plaster,

laboratory plaster.

Composed of
Beta hemihydrate and modifiers.
 Requirement of ideal cast
material
 It should set rapidly but give adequate
manipulation time.
 It should set very hard and strong mass.
 It should flow in all part to reproduce minor
surface details.
 It should neither contract nor expand while
setting.
 It should not lose its strength when subjected to
moulding or curing procedures.
 uses

 For making study cast and models.

 To make molds for curing dentures.
 For mounting casts on articulators.
 Type 3 Dental stone, Model

 Also known as class I stone or Hydrocal.

Used for
Preparing master casts and to make
molds.
 Composition

 Alpha hemihydrate
 2 - 3% coloring agent
 k2So4 - Accelerator
 Borax - Retarder

 Compressive strength - 3000 to 5000 psi

 Setting expansion – 0.06% to 0.12%
 Hardness 82 RHN
 Type 4 or Dental stone , Die,
High strength , Low expansion
 Also known as – Class II stone
Die stone
Densite
Improved stone

Uses

For making dies, inlay , crown, bridge

And wax pattern
 Advantages:

 Strongest and hardest variety amongst gypsum.

 Abrasion resistance
 Minimum setting expansion
 Type 5 or Dental stone, Die,
High strength , High expansion
 Compressive strength higher than type 4
 Can lower W/P ratio to attain good strength.
 Setting expansion increases by 0.10- 0.13%
 Can compensate for shrinkage in base metal
alloy during solidification.
 Theories of setting

Three theories has been proposed:

 Colloidal theory

 Hydration theory

 Dissolution – precipitation theory

 Colloidal theory

 The theory proposes when mixed with water ,

plaster enters into colloidal state through sol- gel
mechanism.

 In sol state hemihydrate combines with water to

form dihydrate.

 As the water is consumed the mass turns to “solid

gel”.
 Hydration theory

 The hydration theory suggest that

rehydrated plaster particles join together
through hydrogen sulphate bond to form
the set material.
 Dissolution precipitation theory:

 Most widely excepted theory

 According to this theory , plaster dissolves and
react to form gypsum crystals which interlocks to
form the set gel.
 This suggest that hemihydrates are four times
more soluble than dihydrates.
 When hemihydrate is mixed in water it forms a
fluid workable suspension.
 Hemihydrate dissolves until it forms a saturated
solution.
 Some dihydrate is formed due to reaction.
 Saturated hemihydrate is supersaturated with
respect to dihydrate.
 All supersaturated hemihydrates are unstable .

 So precipitation of dihydrate crystals occur.

 As dihydrates precipitates, there is no longer

saturation on hemihydrates.

 So reaction , continues until no further dihydrate

precipitates out from solution.
 Manipulation

Water / powder ratio

 The water/powder ratio is an important factor in
deciding physical and chemical properties of
final product.
 Higher the water / powder ratio longer the setting
time and weaker will be the product.
Water requirement can be affected by:

 Shape and compactness of crystals

 Particle size distribution

“Water powder ratio is defined as amount of water

that is required for 100g of powder.”
 Water powder ratio of gypsum
products

Material Water / Powder ratio

Impression plaster 0.50 to 0.70
Dental plaster 0.45 to 0.50
Dental stone 0.28 to 0.38
Die stone, Type 4 0.22 to 0.24
Die stone, Type 5 0.18 to 0.22
 Hand mixing

Material required for hand mixing are:

 Flexible rubber bowl
 Stiff bladed spatula
 procedure

 Water is taken first, this to prevent adherence of

powder to the sides of bowl.

 Allow it for 30 sec to minimize air entrapment.

 Mix vigorously, periodically wipe to ensure

wetting of powder .
 Continue to get creamy mix .
 Spatulation should be completed by 45-60 sec.
 Vibrate the mix to prevent air entrapment.
 Mechanical mixing

 Mechanical mixing under vaccum gives

stronger and denser cast.

 However , the equipment is to expensive.

 Setting time

 Time elapsing from the beginning of mixing to

until material sets is called as setting time.

Mixing time
 It’s the time from addition of powder to water
until mixing is done .
 It is 1 minute usually sufficient.
 Working time

 Time available to use a workable mix.

 Measured from the start of mixing to the point
where the consistency is no longer acceptable for
the product ‘s intended purpose.
 Generally 3 min working time is adequate.
 Tests for measurement of setting
time
 Loss of gloss test:
As reaction proceeds the gloss diappears from
surface of plaster mix.
 Exothermic reaction:
Rise is temperature is also an indicative for setting
reaction , as the setting reaction is exothermic.
 Penetration test:
By using phenometer.
 Types of phenometers

 Vicat needle
 Gilmore needle

Vicat needle
 Itweighs 300gms and diameter 1mm.
 The time elapsing from mixing till needle
does not penetrates to bottom of plaster is
setting time.
Vicat’s needle apparatus
 Gilmore needles
These are of two types:
 Small : ¼ lb weight
1/12 (2.12) mm diameter
 large: 1 lb weight
1/24 (1.06) mm diameter

Initial Gilmore: Time elapsing from start of

mixing until the point of ¼ needle is nolonger
penetrates the surface is initial setting time.
Final Gillmore:
 Time elapsing from start of mixing until the point
of 1lb Gillmore needle leaves only a barely mark
on surface is final setting time.
 Factors affecting setting time
Manufacturing process

 If calcination is incomplete and excess dihydrate is

present, material will set fast.

 If soluble anhydrate is present in excess , it will set

fast.

 If natural anhydrate is present , material will set slow.

mixing and spatulation:

 Within the limit longer and faster plaster is mixed

, fast it will set because nuclei of crystallization is
broken and well distributed.

 An increase in the amount of spatulation shortens

the setting time
 Water / powder ratio

 More the water longer the setting time as few

nuclei of crystallization present.

Modifiers
These are the chemical added in orders to
alter some properties and make it more
acceptable to dentist.
Accelerators
 It decreases the setting time.

 Finely powdered gypsum (upto1%) is added by

manufacturer to accelerate setting time.

 It act by providing extra nuclei for crystallization.

 In low concentration salts like sodium and

potassium act as accelerators.
 Retarders

 They increases the setting reaction.

 Act by forming a layer on hemihydrate making it
insoluble.
 Various retarders are: Borax
Acetates
Colloids such as
gelatin.
 Setting expansion

These are of two types:

 Normal setting expansion
 Hygroscopic setting expansion

Normal setting expansion is that which occurs when

gypsum or gypsum bonded investment set in
ambient air.
Factors affecting setting expansion are:

 Mechanical mixing reduces expansion as

compared to hand mix.
 Increase W/P ratio reduces expansion.
 Modifiers reduces setting expansion.
 Potassium sulphate 4% reduces setting
expansion.
 Sodium chloride and borax reduces setting
expansion.
 Hygroscopic setting expansion

 The expansion that occurs when gypsum or

gypsum bonded investment is immersed into
water.

 Magnitude is more than double as compared to

the setting expansion in air.

 Accepted reason is that the crystals grow more

freely in water as compared to air.
 Basic mechanism of crystal growth is the same.

 Reduced W/P ratio increases the hygroscopic

setting expansion.

 Increased spatulation increases the hygroscopic

setting expansion.
 Strength:

The strength increases material hardens

after the initial setting.

It is mainly affected by W/P ratio ,greater

the free water available less the strength.
Wet strength:

 It is the strength when free amount of

water is present in the set gypsum.

Dry strength:
 It is strength of gypsum when excess free
water is lost due to evaporation.
 It is two or more time greater than that of wet
strength.
 Specialized Gypsum products

 Dental casting investment

 Orthodontic stone
 Resin modified stones
 Mounting plaster
 Fast setting stone
 Gypsum in orthodontics

Orthodontic stone ( ADA type III)

 Also known as Orthokal.
 This is hard accurate stone with super white
color for optimal esthetics.
 Having W/P ratio 0.28 – 0.30
 Working time 5-7 min.
 Setting time 11 min.
 Gives a glossy surface when finished cast treated
with model glow or soap.
 Infection control
Increased cross contamination to dental
personnel's has been noticed.

Gypsum product may be disinfected by:

 Immersing cast in disinfectant like sodium
hypochlorite for 30 mins
 Addition of disinfectant into stone.
(e.g. Idophour)
 Autoclaving