Gypsum 101. An AIA Continuing Education Program. Mundise Mortimer National Gypsum Company

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1 Gypsum 101 Mundise Mortimer National Gypsum Company 2001 Rexford Road Charlotte, NC 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 Credit for this course is 1 AIA/CES HSW Learning Unit Course Number: NGC09G

2 An American Institute of Architects (AIA) Continuing Education Program Approved Promotional Statement: Ron Blank & Associates, Inc. is a registered provider with The American 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 to receive credit 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 handling, using, distributing, ib ti or dealing in any material or product.

3 An American Institute of Architects (AIA) Continuing Education Program Course Format: This is a structured, web-based, self study course with a final exam. Course Credit: 1 Health Safety & Welfare (HSW) Learning Unit (LU) Completion Certificate: A confirmation is sent to you by and you can print one upon successful completion of a course or from your RonBlank.com transcript. If you have any difficulties printing or receiving your Certificate please send requests to Design professionals, please remember to print or save your certificate of completion after successfully completing a course conclusion quiz. confirmations will be sent to the address you have provided in your RonBlank.com account.

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

5 Learning Objectives Upon Completion of this course the Design Professional will be able to: Describe the history of gypsum board Explain the manufacturing 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

6 History of Gypsum Board Gypsum rock was first mined in It was sold and shipped by local traders to be used as fertilizer. Th fi t b d The first gypsum board was patented in 1917.

7 What are the two types of gypsum?

8 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, Michigan, Iowa, Texas, and California.

9 Synthetic Gypsum Synthetic Gypsum is a by-product of cleaning the emissions of the coal burning power plants. When the coal burns, Sulfur Dioxide (SO 2 ) 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 with the SO 2, high h purity gypsum is formed.

10 How is gypsum board manufactured?

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

12 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 or stucco. )

13 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 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.

14 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 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.

15 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 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.

16 Manufacturing Diagram

17 Gypsum Board is Shipped in Two forms of Transportation. 1. Truck

18 Gypsum Board is Shipped in Two forms of Transportation. 2. Rail Car

19 What are the common ingredients in gypsum board?

20 Common Gypsum Board Ingredients Regular Gypsum Wallboard Ingredients Plaster of Paris (stucco) Starch Water

21 Gypsum Board Product Matrix This matrix helps to show the evolution of gypsum board. This product has evolved from an interior only yproduct to and exterior and now specialty yproduct which the A&D community has relied on for higher performance systems. Speci ialty Basic Shaftliner Impact resistant t Abuse resistant Mold resistant High Flex High strength ceiling board Moisture resistant Plaster base board Regular board Fire rated board Interior Cement Board Soffit board Gypsum sheathing Glass mat sheathing Gypsum fiberboard Exterior

22 Gypsum Board Gypsum sheathing Gypsum soffit board Specialty Sheathing Cement board Exterior Sheathings Gypsum sheathing and Gypsum soffit board can be used for exterior 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.

23 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)

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

25 Gypsum Sheathing Applications Wood and steel stud framing Curtain wall systems and exterior insulation systems Fire rated exterior wall assemblies 5/8 Type X 4 x 8, 9, 10

26 Soffit Board Attributes and Applications Exterior Soffit Board Fire resistant gypsum board Extra resistant to moisture and sagging in outdoor conditions Setting compounds must be used to treat t joints Gypsum board is painted as final finishi This product should comply with ASTM C 931 / C 1396

27 Cement Board Sheathings

28 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

29 Cement Board Exterior Applications Sheathing and soffit areas in cement board stucco systems Tile and/or stone substrate Swimming pool areas Residential and light commercial

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

31 ½ thick Flexible Cement Board Available in a 4 x8 sheet Uniform curved surface 6 minimum i radius for 90 º corners Innovative and creative applications

32 Interior Gypsum Board Applications Walls Ceilings

33 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 d Gypsum Board Regular core Flexible board Type X - fire resistant Moisture resistant Plaster baseboard Specialty Gypsum Board Interior ceiling board Mold and moisture resistant Shaftliner Abuse resistant Impact resistant ASTM C 1396 (new standard)

34 Edge Configurations Tapered (market preference) Square (sheathing and plaster base) Round (specialty edge) Beveled (shaftliner)

35 Regular Core ¼ and ¼ flex ⅜ ½ Sizes: 4 x8,9,10,12 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.

36 Fire Rated ½ Type C (enhanced Type X ) ⅝ Type X ⅝ Type C (enhanced Type X ) 1 Shaftliner Look for UL stamp on all fire resistant t products.

37 Moisture Resistant Commonly called Green Board ASTM C 630 / C 1396 Core is treated to withstand moisture Water repellant paper on the face, back, and edges ½ regular ⅝ Type X and Type C

38 Moisture Resistant Applications Residential bath areas with limited exposure to moisture Base for ceramic tile Not for direct exposure to water or high humidity Not for saunas, steam rooms, gang showers or pool enclosures There is a new IRC code change in This change indicates that no gypsum based product can be used in a wet area under this residential code.

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

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

41 Specialty Gypsum Board High Performance Systems

42 Mold and Mildew Resistant Gypsum Boards 1 Shaftliner ½ and ⅝ Type X mold resistant board Abuse resistant gypsum board Impact resistant gypsum board

43 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 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 achieved an average panel score of 10 out of a possible high score of 10. * Standard board scores a 0 to 3 on ASTM D3273

44 Mold and Mildew Resistant t Shaftliner Mold resistant 1 shaftliner panel Commercial cavity shaftwall systems Residential/commercial area separation wall systems

45 I Stud Shaftwall System Lightweight 10 lbs. per square foot Installation 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 hour ratings

46 I Stud Shaftwall System

47 H Stud Cavity System Non load bearing Built between living i units Built up to four stories Use mold resistant or ½ MR on the faces of flanking wall wood framing

48 Paper Faced Mold and Moisture Resistant Gypsum Board Mold resistant Moisture resistant Standard application and installation methods Standard finishing and decorating techniques

49 Mold and Mildew Resistant t Gypsum Board Commercial construction Residential New Remodel

50 Mold Resistant Gypsum Board Applications Cement board for wet area Mold resistant gypsum board for humid area

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

52 Abuse Resistant Gypsum Board Applications Resistant to scuffing, scratching, surface indentation High traffic areas Schools Healthcare Airports

53 Impact Resistant Gypsum Board Applications Alternative to CMU, OSB or security mesh Prevent penetration through the wall cavity Psychiatric areas Correctional facilities Sporting facilities Schools and Universities Service areas

54 ASTM C 1629 Industry Standard for Abuse and Impact Resistance 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 D 4977 ASTM D 5420 ASTM E 695 Hard Body Impact

55 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 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

56 Gypsum 101 Mundise Mortimer National Gypsum Company 2001 Rexford Road Charlotte, NC 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 Credit for this course is 1 AIA/CES HSW Learning Unit Course Number: NGC09G

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