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Gypsum 101

Mundise MortimerNational Gypsum Company2001 Rexford RoadCharlotte, NC 28211704-365-7494

MMortimer@nationalgypsum.com www.nationalgypsum.com

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

An AIA Continuing Education Program

Course Number: NGC09G

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An American Institute of Architects (AIA)An American Institute of Architects (AIA)Continuing EducationContinuing Education ProgramProgram

Approved Promotional Statement:

Ron Blank & Associates, Inc. is a registered provider with The American

Insti tute 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 atron an .com o rece ve cre

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

o an ng, us ng, str ut ng, or ea ng n any mater a or pro uct.

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An American Institute of Architects (AIA)An American Institute of Architects (AIA)Continuing Education ProgramContinuing Education Program

Course Format: This is a structured, web-based, self study course with a

final exam.ourse re t: ea t a ety e are earn ng n t

Completion Certificate: A confirmation is sent to you by email and you canprint one upon successful completion of a course or from your

. .your Certificate please send requests to carol@ronblank.com

Design professionals, please remember to print or save your certificate of.

confirmations will be sent to the email address you have provided in yourRonBlank.com account.

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Copyright

This presentation is protected by U.S.

and International co ri ht laws.Reproduction, distribution, display and

use of the presentation without written

perm ss on o Ron Blank & Associates, Inc. 2007

and

National Gypsum Company 2007is prohibited.

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Learning Objectives

Upon Completion of this course the Design

Professional will be able to:

Describe the history of gypsum board

Ex lain the manufacturin rocess and distribution

methods for Gypsum

Explain the Attributes and Applications for Exterior

Products

Explain the Attributes and Applications for InteriorProducts

List the uses and applications for Specialty Gypsum

pro uc s

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History of Gypsum Board

Gypsum rock was first mined

.

It was sold and shipped by local

.

e rs gypsum oar was

patented in 1917.

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What are the two types

of gypsum?

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Natural Gypsum

Natural gypsum is a common

quarried. It is generally found close

to the surface of the earth.

Gypsum deposits are found all overthe 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

, , ,Texas, and California.

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Synthetic Gypsum

Synthetic Gypsum is a by-product

coal burning power plants.

When the coal burns Sulfur Dioxide

(SO2) is captured in the coal stacks soit is not released into the environment.

By chemically combining a slurry of

limestone (calcium carbonate) andwa er w e 2, g pur y

gypsum is formed.

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How is gypsum board

manufactured?

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Manufacturing

Gypsum rock is mined, crushed, dried and

ground to a fine powder.

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Manufacturing Manufacturing

Gypsum rock is mined, crushed, dried and

ground to a fine powder.

The powder is calcined to drive off theremaining chemically combined water.

s pro uces a pro uc common y ca e plaster of Paris or stucco. )

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Manufacturing Manufacturing

Gypsum rock is mined, crushed, dried and

ground to a fine powder.

The powder is calcined to drive off theremaining chemically combined water. (Thispro uces a pro uc common y ca e p as er of Paris or stucco.)

The calcined gypsum is mixed with waterand other ingredients to form a slurrywhich is fed between two continuous rol lsof paper.

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Manufacturing Manufacturing

Gypsum rock is mined, crushed, dried and

ground to a fine powder.

The powder is calcined to drive off theremaining chemically combined water. (Thispro uces a pro uc common y ca e p as er of Paris or stucco.)

The calcined gypsum is mixed with water andother ingredients to form a slurry which is fedbetween two continuous rolls of paper.

As the paper slurry sandwich moves down,

and returns to its original rock state.

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Manufacturing Manufacturing

Gypsum rock is mined, crushed, dried andground to a fine powder.

The powder is calcined to drive off theremaining chemically combined water. (Thisproduces a product commonly called plaster

.

The calcined gypsum is mixed with water and

between two continuous rolls of paper.

conveyor line, the gypsum rehydrates andreturns to its original rock state.

The board is cut to the desired length anddried further before shipping.

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Manufacturing Diagram

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Gypsum Board is Shipped in

1. Truck

.

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Gypsum Board is Shipped in

2. Rail Car

.

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What are the common

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Common Gypsum Board Ingredients

Re ular G sum Wallboard In redients

as er o ar s s ucco arc a er

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Gypsum Board Product MatrixThis matrix helps to show the evolution of gypsum board. This product has evolved from aninterior onl roduct to and exterior and now s ecialt roduct which the A&D communit

Shaftlineria

lty

has relied on for higher performance systems.

Cement BoardCement Board

mpac res s an

Abuse resistantSpec

Mold resistantHigh Flex

Soffit board

Gypsum sheathing

High strength ceiling board

Moisture resistantGlass mat sheathing

Gypsum fiberboard

Plaster base board

Regular board

Fire rated board

ExteriorInteriorBasi

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Exterior Sheathings

Gypsum Board

Gypsum soffit board

pec a y ea ng Cement board

Gypsum sheathing and Gypsum soffit board can be used for.

properties which allows the product to weather the elements

for a short period of time. Some of the specialty sheathing

nc u e cemen ac er oar an er re n orce s ea ngs.

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Exterior Gypsum Sheathing

Used to keep core of building dry

Gypsum sheathing (paper faced)

Glass-mat (fiberglass faced) Fiber cellulose (fiber wood

composite)

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Gypsum Sheathing Attributes

Treated facings

,

and long edges

ow cost Easy to apply

Readily available

with ASTM C 79/ C 1396

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Gypsum Sheathing Applications

Wood and steel stud framing

exterior insulation systems

re rate exter or wall assemblies

5/8 Type X

4 x 8 9 10

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Soffit Board Attributesand A lications

Exterior Soffit Board

Extra resistant to moisture and

sagg ng n ou oor con ons

Setting compounds must be used to

rea o n s

Gypsum board is painted as finaln s

This product should comply with

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Cement Board Sheathings

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Cement Board Attributes

Cement board should have less

than

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Cement BoardExterior A lications

Sheathing and soffit areas incement board stucco systems

Tile and/or stone substrate

Swimming pool areas

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CBS System ComponentsThe most important past of a cement board stucco system is the

moisture barrier, cement board, and flashing.

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Flexible Cement Board

thick

Uniform curved surface

m n mum ra us or corners

Innovative and creative applications

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Interior GypsumBoard A lications

Walls

Ceilings

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Interior ProductsThere are five types of gypsum board product that are considered standard (left).

Innovation has created several new products now available (right).

Regular core Interior ceiling board

Specialty Gypsum Boardtan ar ypsum oar

Flexible board T e X- fire resistant

Mold andmoisture resistant

Moisture resistant Shaftliner

Abuse resistant Impact resistant

ASTM C 1396 (new standard)

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Edge Configurations

Tapered (market preference)

Round (specialty edge)

eve e s a ner

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Regular Core

and flex

, , ,

54 wide board - has become verypopular in residential applications.This product helps to eliminatebelly bands and other unwanted

difficult to finish.

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Fire Rated

Type C (enhanced Type X)

Type C (enhanced Type X)

a ner

Look for UL stamp on all fire

res s an pro uc s.

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Moisture Resistant

Commonly called Green Board

ASTM C 630 / C 1396 Core is treated to

withstand moisture

a er repe an paper on e ace,back, and edges

Type X and Type C

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Moisture Resistant Applications

Residential bath areas with limitedexposure to moisture

ase or ceram c e

Not for direct exposure to water orhi h humidit

Not for saunas, steam rooms, gangshowers or pool enclosures

2006. This change indicates that no

gypsum based product can be used ina we area un er s res en a co e.

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Who has adopted the IRC & IBC?The IRC/IBC now recommends a cement backer board ofALL wet areas.

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Plaster Base Board

Commonly called Blue Board

plaster systems

Typically square and tapered edge

ne coa or wo coa sys ems

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Specialty Gypsum Board

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Mold and Mildew

1 Shaftliner

and Type X mold

resistant board

Abuse resistant gypsum board

Impact resistant gypsum board

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ASTM D 3273ASTM D 3273 is mold and mildew test that is run for 28 days. At the endof the test a score is assigned to the product. A product that scores 8 or

greater is considered acceptable mold resistance.

*

per ASTM D3273 ("Standard Test Methodfor Resistance to Growth of Mold on the Surfaceof Interior Coatings in an Environmental Chamber"),

pro uc s ac eve an averagepanel score of 10 out of a possible

high score of 10.

* Standard board scores a 0 to 3 on ASTM D3273

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Mold and Mildewes s an a ner

Commercial cavity

Residential/commercial area

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I Stud Shaftwall System

Lightweight 10 lbs. per square foot

ns a a on Installed from one side

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

Fire Ratings

, , ,

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I Stud Shaftwall System

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H Stud Cavity System

Non load bearing

Built betweenv ng un s

Built up to

Use mold resistant or MR on the faceso an ng wawood framing

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Paper Faced Mold and Moisture

Mold resistant

Moisture resistant

Standard application and

installation methods Standard finishing and

decorating techniques

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Mold and Mildewes s an ypsum oar

Residential

Remodel

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Mold Resistant Gypsum Board Applications

Cementoar or

wet area Mold resistantgypsum boardor um area

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Definitions

Abuse Resistance = Designed for

surface abrasion is a concern

Surface of the board

=

use where abuse and impact

resistance is neededIntrusion into the wall cavity

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Abuse Resistantypsum oar pp ca ons

Resistant to scuffin , scratchin ,surface indentation

Schools

Airports

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Impact Resistantypsum oar pp ca ons

Alternative to CMU, OSB orsecurity mesh

Prevent enetration throu h the

wall cavity Ps chiatric areas

Correctional facilities

Schools and Universities

erv ce areas

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ASTM C 1629 Industry Standard for

There are four standards for testing abuse and impact resistant

boards. They are ASTM D 4977, ASTM D 5420, ASTM E 695, and

Hard bod Im act.

ASTM D 4977 ASTM D 5420

ASTM E 695 Hard Body Impact

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Learning Objectives

The Design Professional wil l now be able to:

Explain the manufacturing process and distribution

methods for G sum

Explain the Attributes and Applications for ExteriorProducts

Explain the Attributes and Applications for Interior

Products List the uses and applications for Specialty Gypsum

products

Gypsum 101

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Mundise MortimerNational Gypsum Company2001 Rexford RoadCharlotte, NC 28211704-365-7494MMortimer@nationalgypsum.com www.nationalgypsum.com

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

An AIA Continuing Education Program

Course Number: NGC09G