Plasterboard has taken the construction industry by storm as it offers superb lining solution to today’s modern buildings, office spaces and home interiors. What makes it special is its quality of being resistant to fire, sound, thermal, moisture and impact.
Want to explore more about it, here’s a guide on everything that you need to know about this amazing board.
Plasterboard- An all purpose board!
Also known as drywall, they are lightweight and easy to install that are used to make linings for walls and ceilings, lift shafts, stairwells, corridors and auditoria in hospitals, cinemas, schools, houses and other such buildings.
Plasterboards are basically sheets of gypsum (calcium sulfate dihydrate CaSO.2H2O) that are used to construct partition walls and false ceilings in an easy and hassle-free manner. These gypsum boards come under the umbrella of gypsum panel products as the core material used is gypsum. However, it may differ in the secondary material that includes paper or fiberglass. Plasterboards differ from other panel type building materials because of its non-combustible core and paper facers. These boards of gypsum form an even and continuous surface, once the joints and fastener heads are covered with joint compounds.
Manufacturing of plasterboard:
Plasterboard is manufactured by layering gypsum plaster between piles or sheets of paper. The manufacturing process of plasterboard is a simple yet interesting 4-step process. So let us see what are these steps.
- The raw gypsum is first heated to reduce any moisture or water contained in the product and then slightly re-hydrated. This is done to produce the hemihydrate form of calcium sulfate i.e. CaSO4.1/2H2
- Once the hemihydrate is formed, the plaster is then mixed with various additives to achieve some of the important properties like:
- To decrease the mildew and increase the fire-resistant properties: the wet plaster is mixed with fibre(paper or fibreglass), plasticizer, and a foaming agent. It is further mixed with finely grounded gypsum crystal that acts as an accelerator, and ethylenediaminetetraacetic acid(EDTA), starch or other chelate additives that acts as retarders.
- For lowering water absorption: wax emulsions or silanes are mixed to the plaster.
- Once these additives are mixed, the board is then formed by layering a core of the wet mixture between two sheets of heavy paper or fibreglass mats.
- After the core sets, the board is then dried in a large drying chamber making it right and strong enough for use.
Another product that can be used in the production of plasterboard is Synthetic Gypsum which is commonly known as Flue Gas Desulphurization(FGD) gypsum or Desulphurized(DSG) gypsum. This product is obtained primarily from coal-fired power stations that consist of scrubbers that remove sulphur from exhaust emissions. Synthetic Gypsum is mostly used in western countries whereas, in India, manufacturers prefer using natural gypsum.
Gypsum boards are manufactured in different dimensions and thickness throughout the world. Each panel has its own specification and you can select the panel board according to your requirements. Given below are some of the dimensions of drywall:
Canada and the US: Drywalls are manufactured in 48-inch, 54-inch, and 96-inch with a thickness of 13mm and 16mm primarily. The length of panel boards can vary between 8 feet(2.5m) to 16 feet(4.9m). You can also find plasterboards of 6.4mm, 9.5mm, 19mm, and 25mm for specific applications.
Europe: Plasterboards in Europe can be found in 60cm, 90cm, and 120 cm wide, with 120 cm X 240 cm being the most common dimension. The thickness of these boards can vary from 9.5mm to 25mm.
India: Gypsum boards in India are available in the standard thickness of 12.5mm weighing approximately 18kgs. The dimension followed for manufacturing plasterboards in India is 1830mmX1219mm.
These boards are an excellent building material resulting in a hassle-free and fast construction. Some of the benefits of using plasterboard are that they are highly durable, economical, and most importantly comes with fire and moisture resistant properties. If you are looking forward to constructing a new house, plasterboards are a must-have construction material in the list.
Keeping all the benefits and factors of production in mind, Kabco Ventures offers a robust yet flexible drywall Terra Gypsum Board. Available in suitable width and length, these gypsum boards are used in residential and commercial constructions. Kabco Ventures offers different types of plasterboards that are moisture resistant and fire resistant. In addition to this, Terra board also comes in a combination of both moisture and fire resistant properties.