Making Gypsum Board

Author: GE

Dec. 02, 2024

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Making Gypsum Board

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ASTM standards govern the manufacture of gypsum board and set strict criteria for strength, water resistance, and other characteristics. To produce gypsum board, crushed natural gypsum or synthetic gypsum is heated or calcined to dehydrate the feedstock. Next the calcined gypsum is mixed with water and additives to form a slurry which is fed between continuous layers of recycled paper on a long board machine.

As the board moves down a conveyer line, the calcium sulfate recrystallizes or rehydrates, reverting to its original rock state. The paper becomes chemically and mechanically bonded to the core. The board is then cut to length and conveyed through dryers to remove any free moisture.

End tapes are applied that identify manufacturer, facility, production line, date and time of manufacture as well as country of origin are applied per GA- Identification of Gypsum Board. Ready for installation, the panels are stored and distributed on risers of uniform height to ensure the gypsum panel products are supported evenly. More information on handling and storage of gypsum panels can be found in GA-801- Handling and Storage of Gypsum Panel Products: A Guide for Distributors, Retailers, and Contractors.

Five stages of gypsum production process

Gypsum

Gypsum is a useful mineral material. It is extensively applied as construction material, most of which is produced as plaster for painting walls or

making decorative material in buildings. Some gypsum ore deposits contain about 80% gypsum, which is excellent for producing plaster.
Raw gypsum ore could be processed into a variety of products such as a portland cement additive,soil conditioner, industrial and building plasters, and gypsum wallboard.

Gypsum production process

Gypsum ore, from quarries and underground mines, is crushed and stockpiled near a plant. Asneeded, the stockpiled ore is further crushed and screened to about 50 millimeters (2 inches) in diameter. If the moisture content of the mined ore is greater than about 0.5 weight percent, the ore must be dried in a rotary dryer or a heated roller mill. Ore dried in a rotary dryer is conveyed to a roller mill, where it is ground to the extent that 90 percent of it is less 149 micrometers (µm)(100 mesh). The ground gypsum exits the mill in a gas stream and is collected in a product cyclone. Ore is sometimes dried in the roller mill by heating the gas stream, so that drying and grinding are accomplished simultaneously and no rotary dryer is needed. The finely ground gypsum ore is known as landplaster, which may be used as a soil conditioner.

Five stages of gypsum production line

Gypsum processing equipment differs significantly in scale and level of technology. some plants produce one or two tonnes per day using low-cost manual technologies, some other plants of a thousand tonnes per day that are highly mechanized and capable of producing different types and grades of gypsum plaster or plaster boards.

There are five basic stages in gypsum processing:

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Waste sorting

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Excavation is sometimes carried out by digging out an area of ground where the gypsum is located using open-cast techniques. To reach deeper deposits drift or shaft mines may be needed. The drilling and digging equipment is applied to dig out the gypsum ore in excavation stages.
Crushing the gypsum rock is advisable before processing further, especially if subsequent heating is to be done in a pan rather than a shaft kiln. Crushing should reduce the gypsum to grains of less than a few millimetres across. Jaw crusher is the most popular crushing plant for size reduction of big massive material, impact crusher and cone crusher will also be used for fine crushing.
Screening with a sieve will remove large grains which have not been crushed properly and which may contain impurities.
Grinding, for example in a ball, rod, or hammer mill, is necessary if the gypsum is to be used for high quality plasterwork or for moulding, medical, or industrial applications. Unlike with other cements, such as lime and Ordinary Portland Cement, special mills for mineral grinding may not be required and the relatively soft gypsum could be pulverised in agricultural mills.
Heating may be done in a number of ways involving a range of technology levels and costs. rotary dryer will be applied to dewatering the materials, and cyclone collector will gather the final gypsum powder for final application.

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Making Gypsum Board