Gypsum 101

Mundise Mortimer National Gypsum Company 2001 Rexford Road Charlotte, NC 28211 704-365-7494 MMortimer@nationalgypsum.com

www.nationalgypsum.com

Please note: you will need to complete the conclusion quiz online at ronblank.com to receive credit

An AIA Continuing Education Program

Credit for this course is 1 AIA/CES HSW Learning Unit Course Number: NGC09G

An American Institute of Architects (AIA) Continuing Education Program

Approved Promotional Statement: g provider p with The American Ron Blank & Associates, Inc. is a registered Institute of Architects Continuing Education System. Credit earned upon completion of this program will be reported to CES Records for AIA members. Certificates of Completion are available for all course participants upon completion of the course conclusion quiz with +80%.
Please note: you will need to complete the conclusion quiz online at ronblank.com bl k to t receive i credit dit

This program is registered with the AIA/CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA or Ron Blank & Associates, Inc. of any material of construction or any method or manner of f handling, h dli using, i distributing, di t ib ti or dealing d li in i any material t i l or product. d t

An American Institute of Architects (AIA) Continuing Education Program

Course Format: This is a structured, web-based, self study course with a final exam. C Course C Credit: dit 1 H Health lth S Safety f t &W Welfare lf (HSW) L Learning i U Unit it (LU) Completion Certificate: A confirmation is sent to you by email and you can print one upon successful completion of a course or from your RonBlank com transcript. RonBlank.com transcript If you have any difficulties printing or receiving your Certificate please send requests to carol@ronblank.com

Design professionals, please remember to print or save your certificate of completion after successfully completing a course conclusion quiz quiz. Email confirmations will be sent to the email address you have provided in your RonBlank.com account.

Copyright
This presentation is protected by U.S. py g laws. and International copyright Reproduction, distribution, display and use of the presentation without written permission i i of f Ron Blank & Associates, Inc. 2007 and National Gypsum Company 2007 is prohibited.

Learning Objectives
Upon Completion of this course the Design Professional will be able to: Describe the history of gypsum board Explain p the manufacturing gp process and distribution methods for Gypsum Explain the Attributes and Applications for Exterior Products Explain the Attributes and Applications for Interior Products List the uses and applications for Specialty Gypsum products d t

History of Gypsum Board

Gypsum rock was first mined in 1770. 1770
It was sold and shipped by local traders to be used as fertilizer fertilizer.

Th The first fi t gypsum board b d was patented in 1917.

What are the two types of gypsum?

Natural Gypsum
Natural gypsum is a common mineral that is easily mined or quarried. It is generally found close to the surface of the earth.
Gypsum deposits are found all over the world. Experts believe that they are a result of seas which once covered the land. States with the largest quantity of gypsum deposits in the United States are: New York York, Michigan Michigan, Iowa Iowa, Texas, and California.

Synthetic Gypsum
Synthetic Gypsum is a by-product of cleaning the emissions of the coal burning power plants.
When the coal burns, Sulfur Dioxide (SO2) is captured in the coal stacks so it is not released into the environment. By chemically combining a slurry of limestone (calcium carbonate) and water t with ith th the SO2, high hi h purity it gypsum is formed.

How is gypsum board manufactured?

Manufacturing
Gypsum rock is mined, crushed, dried and ground to a fine powder.

Manufacturing Manufacturing
Gypsum rock is mined, crushed, dried and ground to a fine powder. The powder is calcined to drive off the remaining chemically combined water. (Thi produces (This d a product d t commonly l called ll d plaster of Paris or stucco.)

Manufacturing Manufacturing
Gypsum rock is mined, crushed, dried and ground to a fine powder. The powder is calcined to drive off the remaining chemically combined water. (This produces d a product d t commonly l called ll d plaster l t of Paris or stucco.) The calcined gypsum is mixed with water and other ingredients to form a slurry which is fed between two continuous rolls of paper.

Manufacturing Manufacturing
Gypsum rock is mined, crushed, dried and ground to a fine powder. The powder is calcined to drive off the remaining chemically combined water. (This produces d a product d t commonly l called ll d plaster l t of Paris or stucco.) The calcined gypsum is mixed with water and other ingredients to form a slurry which is fed between two continuous rolls of paper. As the paper slurry sandwich moves down the conveyor line, the gypsum rehydrates and returns to its original rock state.

Manufacturing Manufacturing
Gypsum rock is mined, crushed, dried and ground to a fine powder. The powder is calcined to drive off the remaining chemically combined water. (This produces a product commonly called plaster of Paris Paris or stucco stucco.) ) The calcined gypsum is mixed with water and other ingredients to form a slurry which is fed between two continuous rolls of paper. As the paper slurry sandwich moves down the conveyor line, the gypsum rehydrates and returns to its original rock state. The board is cut to the desired length and dried further before shipping.

Manufacturing Diagram

Gypsum Board is Shipped in Two forms of Transportation. Transportation

1. Truck

Gypsum Board is Shipped in Two forms of Transportation. Transportation

2. Rail Car

What are the common ingredients in gypsum board?

Common Gypsum Board Ingredients

Regular g Gypsum yp Wallboard Ingredients g

Pl t of Plaster f Paris P i (stucco) ( t )

St h Starch

W t Water

This matrix helps to show the evolution of gypsum board. This product has evolved from an interior only yp product to and exterior and now specialty p yp product which the A&D community y has relied on for higher performance systems.

Gypsum Board Product Matrix

Speci ialty

Shaftliner I Impact t resistant i t t Abuse resistant Mold resistant High Flex High strength ceiling board Soffit board Moisture resistant Plaster base board Regular board Gypsum sheathing Glass mat sheathing Gypsum fiberboard
Exterior

Cement Board

Basic c

Fire rated board

Interior

Exterior Sheathings
Gypsum Board Gypsum sheathing Gypsum soffit board S Specialty i lt Sh Sheathing thi Cement board
Gypsum sheathing and Gypsum soffit board can be used for exterior applications applications. These product have moisture resistant properties which allows the product to weather the elements for a short period of time. Some of the specialty sheathing include cement backer board and fiber reinforced sheathings sheathings.

Exterior Gypsum Sheathing

Used to keep core of building dry Types of gypsum sheathing
Gypsum sheathing (paper faced) Glass-mat (fiberglass faced) Fiber cellulose (fiber wood composite)

Gypsum Sheathing Attributes

Treated facings Water resistant on front front, back and long edges Low L cost t Easy to apply Readily available These products must comply with ASTM C 79/ C 1396

Gypsum Sheathing Applications

Wood and steel stud framing Curtain wall systems and exterior insulation systems Fire Fi rated t d exterior t i wall assemblies 5/8 Type X 4 x 8, , 9, , 10

Soffit Board Attributes and a d Applications pp cat o s

Exterior Soffit Board
Fire resistant gypsum board Extra resistant to moisture and sagging i i in outdoor td conditions diti Setting compounds must be used to t t joints treat j i t Gypsum board is painted as final fi i h finish This product should comply with ASTM C 931 / C 1396

Cement Board Sheathings

Cement Board Attributes

Cement board should have less than <8% Water absorption per ASTM C 473 Cementicious core, fiberglass reinforced panel Complies with ANSI A118.9 & ASTM C1325 Impact and weather resistant Shear value between gypsum sheathing and structural wood panel

Cement Board pp Exterior Applications

Sheathing and soffit areas in cement board stucco systems Tile and/or stone substrate Swimming pool areas Residential and light commercial

CBS System Components

The most important p p past of a cement board stucco system y is the moisture barrier, cement board, and flashing.

Flexible Cement Board

thick Available in a 4 4 x8 8 sheet Uniform curved surface 6 minimum i i radius di f for 90 corners Innovative and creative applications

Interior Gypsum pp Board Applications

Walls Ceilings

Interior Products
There are five types of gypsum board product that are considered standard (left). Innovation has created several new products now available (right).

Standard St d d Gypsum G Board B d Regular core Flexible board yp X- fire resistant Type Moisture resistant Plaster baseboard

Specialty Gypsum Board Interior ceiling board Mold and moisture resistant Shaftliner Abuse resistant Impact resistant

ASTM C 1396 (new standard)

Edge Configurations
Tapered (market preference) Square (sheathing and plaster base) Round (specialty edge) B Beveled l d ( (shaftliner) h ftli )

Regular Core
and flex Sizes: 4 4 x 8 8,9 9,10 10,12 12 54 wide board - has become very popular in residential applications. This product helps to eliminate belly bands and other unwanted butt ends which are typically very difficult to finish.

Fire Rated
Type C (enhanced Type X) Type X X Type C (enhanced Type X) 1 Shaftliner Sh ftli Look for UL stamp on all fire resistant i t t products. d t

Moisture Resistant
Commonly called Green Board ASTM C 630 / C 1396 Core is treated to withstand moisture Water W t repellant ll t paper on the th face, f back, and edges regular Type X and Type C

Moisture Resistant Applications

Residential bath areas with limited exposure to moisture Base B for f ceramic i tile til Not for direct exposure to water or g humidity y high Not for saunas, steam rooms, gang showers or pool enclosures There is a new IRC code change in 2006. This change indicates that no gypsum based product can be used in a wet t area under d thi this residential id ti l code. d

The IRC/IBC now recommends a cement backer board of ALL wet areas.

Who has adopted the IRC & IBC?

Plaster Base Board

Commonly called Blue Board Veneer base used to apply plaster systems Highly absorptive face paper Typically square and tapered edge One O coat t or Two T coat t systems t

Specialty Gypsum Board

High Performance Systems

Mold and Mildew Resistant Gypsum Boards

1 Shaftliner and Type X mold resistant board Abuse resistant gypsum board Impact resistant gypsum board

ASTM D 3273
ASTM D 3273 is mold and mildew test that is run for 28 days. At the end of the test a score is assigned to the product. A product that scores 8 or greater is considered acceptable mold resistance.

*When When tested by an independent lab per ASTM D3273 ("Standard Test Method for Resistance to Growth of Mold on the Surface of Interior Coatings in an Environmental Chamber"), products d t achieved hi d an average panel score of 10 out of a possible high score of 10.

* Standard board scores a 0 to 3 on ASTM D3273

Mold and Mildew R i t t Shaftliner Resistant Sh ftli

Mold resistant 1 1 shaftliner panel Commercial cavity shaftwall systems Residential/commercial area separation wall systems

I Stud Shaftwall System

Lightweight
10 lbs. per square foot

Installation I t ll ti
Installed from one side

Limitations
Non load bearing Made with 25 gauge steel, and 20 gauge base steel

Fire Ratings
1,2,3,4 1 2 3 4 hour ratings

I Stud Shaftwall System

H Stud Cavity System

Non load bearing Built between li i units living it Built up to four stories Use mold resistant or MR on the faces of f flanking fl ki wall ll wood framing

Paper Faced Mold and Moisture Resistant Gypsum Board

Mold resistant Moisture resistant Standard application and installation methods Standard finishing and decorating techniques

Mold and Mildew R i t tG Resistant Gypsum Board B d

Commercial construction Residential
New Remodel

Mold Resistant Gypsum Board Applications

Cement b board df for wet area

Mold resistant gypsum board f h for humid id area

Definitions
Abuse Resistance = Designed for use in wall assembly areas where surface abrasion is a concern Surface of the board Impact Resistance = Designed for use where abuse and impact resistance is needed Intrusion into the wall cavity

Abuse Resistant G Gypsum Board B d Applications A li ti

Resistant to scuffing, g, scratching, g, surface indentation High traffic areas
Schools Healthcare Airports

Impact Resistant G Gypsum Board B d Applications A li ti

Alternative to CMU, OSB or security mesh penetration through g the Prevent p wall cavity Psychiatric areas Correctional facilities Sporting facilities Schools and Universities Service S i areas

There are four standards for testing abuse and impact resistant boards. They are ASTM D 4977, ASTM D 5420, ASTM E 695, and Hard body Impact.

ASTM C 1629 Industry Standard for Abuse and Impact Resistance

ASTM D 4977

ASTM D 5420

ASTM E 695

Hard Body Impact

Learning Objectives
The Design Professional will now be able to: Describe the history of gypsum board Explain the manufacturing process and distribution methods for Gypsum yp Explain the Attributes and Applications for Exterior Products Explain the Attributes and Applications for Interior Products List the uses and applications for Specialty Gypsum products

Gypsum 101
Mundise Mortimer National Gypsum Company 2001 Rexford Road Charlotte, NC 28211 704-365-7494 MMortimer@nationalgypsum.com

www.nationalgypsum.com

Please note: you will need to complete the conclusion quiz online at ronblank.com to receive credit

An AIA Continuing Education Program

Credit for this course is 1 AIA/CES HSW Learning Unit Course Number: NGC09G