CONTENTS

1. INTRODUCTION

Chemical Identification and Analysis

Gypsum

Plaster of Paris

Calcium Sulfate

Physical-Chemical Properties

History of Gypsum

Gypsum Moulds

Gypsum Credentials

1. Unequalled as a Material for Interiors

2. Gypsum Products’ Unique Properties

Fire Properties

Fire Resistant

Non-Combustible

Effective in Fire

Acoustic Properties

Thermal Properties

Aesthetics and Design

Ease of Installation

From Products to Solutions

2. MANUFACTURING PROCESS

Raw Material

Dehydration: Rock into Plaster

Production Processes

Gypsum Unique Properties in Buildings

Gypsum is Fire Protective

Gypsum Regulates Sound

Gypsum equilibrates Humidity and Heat Peaks

Gypsum is Easy to Install and to Dismantle

Gypsum Acts as a Thermal Insulator when

Combined with Insulation Materials

Gypsum is Impact Resistant

Gypsum is Multifaceted, Multipurpose, Supple and

Aesthetic

Plaster Board

Gypsum Fibre Boards

Gypsum-Based Self-Levelling Screeds

Plaster Blocks

Decorative Plaster

Building Plaster

Uses of Gypsum

Chemistry of Gypsum Products

Chemistry of Gypsum Product Formation

Setting Mechanism

Manipulation Stages

Manufacture of Gypsum Precursors

“Plaster of Paris” “Hydrocal” “Densite”

Properties

Variables influencing Properties

Manufacturing Variables

User’s Variables

Effects of Increases in Variables on Final Properties

Occurrence of Gypsum

Gypsum Physical Properties

Agricultural Gypsum Uses

1. Gypsum Improves Soil Texture and Compacted

Soils

2. Gypsum Decreases Bulk Density of Soil

3. Gypsum Stops Water Runoff, Erosion and Soil

Crusting

4. Gypsum Improves Swelling Clays

5. Gypsum Increases Value of Organics

6. Gypsum Counteracts Subsoil Acidity

7. Gypsum Helps Reclaim Sodic Soils

8. Gypsum Decreased ph of Sodic Soils

9. Gypsum Enhances Water Use Efficiency

10. Gypsum Makes it Possible to Use Low Quality

Irrigation Water

11. Gypsum Replaces Harmful Salts

12. An Excellent Fertilizer Source for Calcium and

Sulfur

13. Gypsum Helps with High Bicarbonate

Irrigation Water

14. Gypsum Makes Slightly Wet Soils Easier to Till

15. Gypsum Prevents Water Logging of Soil

16. Gypsum Helps Earthworms to Flourish

3. TYPES OF GYPSUM PRODUCTS

Setting of Gypsum Products

Theories of Setting of Gypsum Products

Hydration Theory

Dissolution Precipitation Theory

Setting Process

Stages

W:P Ratio

Recommended Ranges

Properties

Setting Time

Mixing Time

1. Loss of Gloss Test for Initial Set

2. Initial Gillmore Test for Initial Set

3. Gillmore Test for Final Setting Time

Vicat Test for Setting Time

Ready for Use Criterion

Control of Setting Time (S.T.)

4. PLASTER OF PARIS

Preparation of Plaster of Paris

Step 1 - Plaster of Paris Manufacture

Step 2 - Rehydration

Common Plaster Additives

Step 3 - Setting

Properties

Application of Plaster of Paris

Uses of Plaster of Paris

Architecture

Art

Uses in Medicinal and Fireproof Fields

Medicinal

Fireproof

5. GYPSUM BOARD

The Chemistry of Gypsum Board

Gypsum Board Manufacturing Process

Step-1

Step-2

Step-3

Step-4

Advantages of Gypsum Board

Areas of Applications

Gypsum Board for Acoustic Applications

Gypsum Board for Ceiling Application

Drywall

Manufacturing Process

Blending of Additives

Making the Sandwich

Finishing the Edges

Cutting the Panels

The Drying Process

The Finished Product

Types of Gypsum Board

Regular and Type X Gypsum Board

Types of Gypsum Board Based on Edges

Common Types of Gypsum Board

(a) Regular/Standard Gypsum Board

(b) Fire Resistance Gypsum Board

(c) Moisture Resistance Gypsum Board

(d) Fire & Moisture Resistance Gypsum Board

(e) Abuse-Resistant Gypsum Panels

(f) Exterior Gypsum Soffit Board

(g) Foil-Backed Gypsum Board

Gypsum Fiber Board

Glass Mat Gypsum Board

Sheathing

Backing Board

6. TYPES AND SOURCES OF GYPSUM

Mined Gypsum

Flue Gas Desulphurization (FGD) gypsum and

Spray-Dry Absorption materials (SDA)

Phosphogypsum

Pickle Gypsum

Drywall Gypsum

Landfill Versus Recycling

Green Building

Common Uses of Gypsum

Markets for Gypsum Products

General Benefits of Gypsum for Soils

Soil Crusting

Acid Subsoil

Sodic or Salt Contaminated Soils

Nutrient Availability

Runoff and Water Absorption

Animal Bedding

Poultry Bedding

Manure Treatment

Crops Known to Benefit From Gypsum

Plants that can Benefit from Gypsum Include

Animals

Application

7. DIFFERENT TYPES OF DRYWALL

1. Dry Lining Systems

2. Interior Partition Systems

3. Performance partition Systems

How to build a drywall

Installation

Drywall Tools

Fixing Tools

Cutting Tools

Marking Tools

Finishing Tools

Lifting Tools

Basic Principles to Design a Drywall

Key Design Criteria

Height

Maximum Partition Heights

Thermal Insulation

Different Types of Drywall

Benefits of Effective Thermal Insulation make

Building

8. GYPSUM PRODUCTS IN DENTISTRY: TYPES,

USES, PROPERTIES

Desirable Properties

Types of Gypsum Products

A. Plaster

B. Stone

C. High-Strength or Improved Stone

D. Other Types of Gypsum

Setting Reaction

Water/Powder Ratio

Setting Time

Definitions

1. Working Time or Initial Setting Time

2. Final Setting Time

Measurement

Variation in Setting Times

1. Increased Setting Time (A Slower-Setting

Product)

2. Decreased Setting Time (A Faster-Setting

Product)

Setting Expansion

Strength

9. GYPSUM AS AN AGRICULTURAL PRODUCT

Benefits of Gypsum as a Soil Amendment

Processing Gypsum into a Soil Amendment

Agricultural and Land Application uses of Gypsum

Gypsum as a Source of Plant Nutrients for Crops

Gypsum to Improve Soil Physical Properties

Gypsum to Improve Soil Chemical Properties

Gypsum for Nursery, Greenhouse, Landscape, and

Sports Field Use

Gypsum for Landscape and Sports Field Use

Other Uses of Gypsum in Agriculture

Use of Gypsum as a Soil Conditioner

Causes of Poor Soil Structure

Recognition of Gypsum Responsive Soils

Exchangeable Sodium Percentage (ESP)

Exchangeable Magnesium Percentage (EMgP)

Calcium: Magnesium Ratio (Ca:Mg)

Clay Dispersion Index

10. MINING TECHNOLOGY

Exploration Techniques

Stratigraphy

Topography

Vegetation

Hydrology

Deposit Evaluation

Drilling and Sampling

Testing Procedures

11. PREPARATION OF OTHER GYPSUM AND

ANHYDRITE

Phosphogypsum

Titanogypsum

Insoluble Anhydrite

Calcination Methods

Batch Kettle

Continuous Kettles

Submerged Combustion Kettles

Conical Kettle

Rotary Kilns

Impact Mill Calciner

Ring Ball and Roller Mills

Calcidyne Unit

Anhydrous and Multiphase Plaster

Hemihydrate Plasters

12. ROLE OF GYPSUM IN CEMENT

The Effect of Gypsum on Setting of Cement

The Effect of Gypsum Solubility

Optimum Gypsum Content

Strength and Volume Stability

Effects of Gypsum on Cement

13. TECHNOLOGY OF GYPSUM AND GYPSUM

PLASTERS

14. GYPSUM TRANSPORTATION

Power Station to Plaster Board Factory

Packaging

Transportation

Truck

Rail

Barge

Ship

15. GYPSUM HANDLING AND STORAGE

Handling and Transportation

Gypsum Storage

Gypsum Panel Products

Safety Tips for Handling

Handling and Storage of Gypsum Panel Products:

A guide for distributors, Retailers, and

Contractors

Storage

Support Risers

Preventing Sagging Gypsum Panel Products

Preventing Sagging Gypsum Panel Products, cont.

Manual Handling

Mechanical Handling

Use of Wedges

Stocking Gypsum Panel Products on Job Sites

Loading Gypsum Panel Products

Open Top Rail Flatcars

Flatbed Trucks

Guidelines for Carriers, Drivers and Trailer

Loading Personnel

16. GYPSUM BOARD WASTE MANAGEMENT

Gypsum and Gypsum Board

Sustainability Imperative

Gypsum Board Waste and the Management

Recycling Process and Technology

Policy Instruments for Promoting Recycling

Action on Gypsum Board Waste

CRD Waste Management in Europe

17. GRINDING AND CALCINING OF GYPSUM

18. CRYSTALLISTAION AND DISSOLUTION OF

GYPSUM

Introduction

Background Information

Mineralogy

Crystal Nucleation: The Classical Nucleation

Theory

The Induction Period and the Surface Free Energy

Crystallization of Gypsum

Gypsum Nucleation Kinetics

Gypsum Nucleation Induction Period and the

Surface Free Energy

Inhibition of Gypsum Crystallization

Dissolution of Gypsum

Gypsum Dissolution Kinetics

Surface Behavior of Gypsum during Dissolution

19. GYPSUM PELLETIZING

Gypsum Waste

Recycled Gypsum Products

Agricultural Products

New Drywall

Cement

Paper Products

Composting

Flow Diagram of Typical Gypsum Pelletizing

Process

Gypsum Pelletizing

Pelletizing Gypsum for Use as a Soil Conditioner

Benefits of Pelletizing Gypsum

The Basics of Pelletizing Gypsum

Disc Pelletizer

Rotary Dryer

Important Gypsum Pelletizing Elements

Binder

Equipment

Drying Gypsum

Drying Mined Gypsum

Beneficiation

Drying Gypsum for Use in Wallboard

Benefits to Drying Pelletized Gypsum

Improved Product Handling

Product Consistency

The Benefits of Adding a Pin Mixer to a Gypsum

Pelletizing System

How it Works

Improved Blending

De-Dusting

Improved Productivity

Reduced Binder Usage

20. BIS SPECIFICATIONS

21. PROCESS FLOW SHEET

22. PLANT LAYOUT

23. PHOTOGRAPHS OF MACHINERY WITH

SUPPLIER’S CONTACT DETAILS

Gypsum Board Making Machine

Plaster of Paris Making Machine

Rotary Kiln

Gypsum Cutting Machine

Storage Tank

Conveyors

Gypsum Rotary Dryer

Blower

Crusher

Scrubber

Hammer Mill

Coarse Grain Silos

Mixer

Gypsum Plaster Spraying Machine

Pulveriser

Automatic Corrugated Board Making Machine

Corrugated Board Making Machine

Rotary Calciner

Rotary Die Cutting Machine

Die Cutting Creasing

Conveyor Belt

Blower

VSI Crusher

Scrubber Making Machine

Semi-Automatic Hammer Mill

Gypsum Plaster Spraying Machine

Plaster Spray Machine

Semi-automatic Bandage Machine

Gypsum Powder Production Line

Gypsum Board Production Line Machine

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