Handbook on Gypsum and Gypsum Based Products

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Introduction
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Gypsum is a soft sulfate mineral composed of calcium sulfate dehydrate,
with the chemical formula CaSO4·2H2O. It is widely mined and is used as a
fertilizer and as the main constituent in many forms of plaster,
blackboard/sidewalk chalk, and drywall. A massive fine-grained white or
lightly tinted variety of gypsum, called alabaster, has been used for
sculpture by many cultures including Ancient Egypt, Mesopotamia, Ancient
Rome, the Byzantine Empire, and the Nottingham alabasters of Medieval
England. Gypsum also crystallizes as translucent crystals of selenite. It
forms as an evaporate mineral and as a hydration product of anhydrite.
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Gypsum is chemically known as calcium sulfate dihydrate and it contains
calcium and sulfur, which is bound to oxygen and water. Gypsum is an
abundant mineral and takes various forms including alabaster, which is a
material, used in decoration and construction. This is a non-toxic mineral
and it can be helpful to humans, animals, plant life, and the environment.
The majority of gypsum produced is used to manufacture gypsum board or
building plasters and it is used in many other ways.
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Gypsum products are used in dentistry, medicine, homes, and industry. In
homes, gypsum plaster is used to make walls; in industry, it is used to
make molds. Three types of gypsum products are plaster, stone, and high-
strength or improved stone. The Gypsum and the Gypsum products are
used for construction purposes. It is also used in industry for making
pottery, moulds etc. It is used by orthopedics to make plaster casts and
helps the dentist for the cast preparation, models and dies, impression
material, investment material, mounting of Casts, as a mold material for
processing of complete dentures etc.
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Gypsum Is Used In A Wide Variety Of Applications:
Gypsum board is primarily used as a finish for walls and ceilings, and is
known in construction as drywall, wallboard, sheetrock or plasterboard.
Gypsum blocks are used like concrete blocks in building construction.
Gypsum mortar is an ancient mortar used in building construction.
Plaster ingredients are used in surgical splints, casting moulds and
modeling
Fertilizer and soil conditioner: In the late 18th and early 19th centuries,
Nova Scotia gypsum, often referred to as plaster, was a highly sought
fertilizer for wheat fields in the United States. It is also used in ameliorating
high-sodium soils.
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Used for reclamation of saline soils: when gypsum is added to sodic and
acidic soil the highly soluble form of boron (sodium meteorite) is converted
to the less soluble calcium meteorite and exchangeable sodium percentage
is also reduced by gypsum application.
A binder in fast-dry tennis court clay.
As alabaster, a material for sculpture, it was used especially in the ancient
world before steel was developed, when its relative softness made it much
easier to carve.
A wood substitute in the ancient world: For example, when wood became
scarce due to deforestation on Bronze Age Crete, gypsum was employed in
building construction at locations where wood was previously used.
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A tofu (soy bean curd) coagulant, making it ultimately a major source of
dietary calcium, especially in Asian cultures, which traditionally use few
dairy products.
Adding hardness to water used for brewing.
Used in baking as a dough conditioner, reducing stickiness, and as a
baked-goods source of dietary calcium. The primary component of mineral
yeast food.
A component of Portland cement used to prevent flash setting of concrete.
Soil/water potential monitoring (soil moisture).
A common ingredient in making mead.
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In the medieval period, scribes and illuminators mixed it with lead
carbonate (powdered white lead) to make gesso, which was applied to
illuminated letters and gilded with gold in illuminated manuscripts.
In foot creams, shampoos and many other hair products.
Impression plasters in dentistry.
Used in mushroom cultivation to stop grains from clumping together
Tests have shown that gypsum can be used to remove pollutants such as
lead. or arsenic from contaminated waters.
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Market of Gypsum
The global gypsum board market size is anticipated to exhibit a CAGR of
11.9% in terms of revenue. Increasing utilization of gypsum boards in
decorative and partitioning applications in residential constructions is
anticipated to drive the market. The demand for gypsum boards is driven
by the residential sector, where the product is widely used in multi-family
constructions for room partitioning. Durability and lightweight coupled
with easy handling of the product are some of the factors anticipated to
propel the demand.
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Growing demand from the residential construction sector coupled with
increasing consumer spending on advanced construction materials is
expected to drive growth. Accelerating the growth of the construction
industry across the major economies, such as China, India, Brazil, Mexico,
South Africa, and Russia is expected to support market growth. In addition,
growing innovative construction applications of gypsum board are likely to
provide growth opportunities. Increasing demand from cement, gypsum
board, and ceramic industries; the Indian gypsum market is set to grow
significantly in the following years. The industry is also being assisted by
the government in the form of 100% foreign direct investment (FDI) for
gypsum products. The FDI inflows in the Indian gypsum market have
recorded significant growth in the past few years.
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Gypsum is widely used in the manufacture of wallboard, plaster of Paris,
cement, and as a hardening retarder used in Portland cement. Its use as a
soil conditioner also is expected to rise, as famers look for effective methods
of improving fertility and crop yield. Increasing adoption of digital solutions
and spending on technological advancements has been driving the
construction sector. As a direct outcome of to this, cement and drywall
production has surged, boosting scope for gypsum application.
Infrastructural construction is not one-time investment, renovation and
remodeling tailgate this sector. Thus, the gypsum board market has
immense opportunities to capitalize on such resurfacing avenues. Time
efficient, economical construction techniques and labor saving replacements
are forecast to stroke the gypsum board market with abundant demand and
establish it as a contemporary asset in the flourishing construction sector.
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Demand for better infrastructures at low cost are to support the future
endeavors of gypsum board market.
The major contents of the book are Mining, Processing, Transportation,
Handling & Storage, Gypsum Board, Plaster of Paris for gypsum, Plant
Layout, Process Flow Chart and Diagram, Plant & Machinery Suppliers and
Photographs of Machineries.
This book is one-stop guide to one of the fastest growing sector of the
Gypsum and Gypsum based Products, where opportunities abound for
manufacturers, retailers, and entrepreneurs. This is the only complete
handbook on gypsum and gypsum based Products. It serves up a feast of
how-to information, from concept to purchasing equipment.
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Table of Contents
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1. INTRODUCTION
Chemical Identification and Analysis
Gypsum
Plaster of Paris
Calcium Sulfate
Physical-Chemical Properties
History of Gypsum
Gypsum Moulds
Gypsum Credentials
1. Unequalled as a Material for Interiors
2. Gypsum Products’ Unique Properties
Fire Properties
Fire Resistant
Non-Combustible

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Effective in Fire
Acoustic Properties
Thermal Properties
Aesthetics and Design
Ease of Installation
From Products to Solutions
2. MANUFACTURING PROCESS
Raw Material
Dehydration: Rock into Plaster
Production Processes
Gypsum Unique Properties in Buildings
Gypsum is Fire Protective
Gypsum Regulates Sound
Gypsum equilibrates Humidity and Heat Peaks
Gypsum is Easy to Install and to Dismantle
Gypsum Acts as a Thermal Insulator when
Combined with Insulation Materials
Gypsum is Impact Resistant

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Gypsum is Multifaceted, Multipurpose, Supple and
Aesthetic
Plaster Board
Gypsum Fibre Boards
Gypsum-Based Self-Levelling Screeds
Plaster Blocks
Decorative Plaster
Building Plaster
Uses of Gypsum
Chemistry of Gypsum Products
Chemistry of Gypsum Product Formation
Setting Mechanism
Manipulation Stages
Manufacture of Gypsum Precursors
“Plaster of Paris” “Hydrocal” “Densite”

Properties
Variables influencing Properties
Manufacturing Variables
User’s Variables
Effects of Increases in Variables on Final Properties
Occurrence of Gypsum
Gypsum Physical Properties
Agricultural Gypsum Uses
1. Gypsum Improves Soil Texture and Compacted
Soils
2. Gypsum Decreases Bulk Density of Soil
3. Gypsum Stops Water Runoff, Erosion and Soil
Crusting
4. Gypsum Improves Swelling Clays
5. Gypsum Increases Value of Organics
6. Gypsum Counteracts Subsoil Acidity
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7. Gypsum Helps Reclaim Sodic Soils
8. Gypsum Decreased ph of Sodic Soils
9. Gypsum Enhances Water Use Efficiency
10. Gypsum Makes it Possible to Use Low Quality
Irrigation Water
11. Gypsum Replaces Harmful Salts
12. An Excellent Fertilizer Source for Calcium and
Sulfur
13. Gypsum Helps with High Bicarbonate
Irrigation Water
14. Gypsum Makes Slightly Wet Soils Easier to Till
15. Gypsum Prevents Water Logging of Soil
16. Gypsum Helps Earthworms to Flourish

3. TYPES OF GYPSUM PRODUCTS
Setting of Gypsum Products
Theories of Setting of Gypsum Products
Hydration Theory
Dissolution Precipitation Theory
Setting Process
Stages
W:P Ratio
Recommended Ranges
Properties
Setting Time
Mixing Time
1. Loss of Gloss Test for Initial Set
2. Initial Gillmore Test for Initial Set
3. Gillmore Test for Final Setting Time
Vicat Test for Setting Time
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Ready for Use Criterion
Control of Setting Time (S.T.)
4. PLASTER OF PARIS
Preparation of Plaster of Paris
Step 1 - Plaster of Paris Manufacture
Step 2 - Rehydration
Common Plaster Additives
Step 3 - Setting
Properties
Application of Plaster of Paris
Uses of Plaster of Paris
Architecture
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Art
Uses in Medicinal and Fireproof Fields
Medicinal
Fireproof
5. GYPSUM BOARD
The Chemistry of Gypsum Board
Gypsum Board Manufacturing Process
Step-1
Step-2
Step-3
Step-4
Advantages of Gypsum Board
Areas of Applications
Gypsum Board for Acoustic Applications
Gypsum Board for Ceiling Application
Drywall
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Manufacturing Process
Blending of Additives
Making the Sandwich
Finishing the Edges
Cutting the Panels
The Drying Process
The Finished Product
Types of Gypsum Board
Regular and Type X Gypsum Board
Types of Gypsum Board Based on Edges
Common Types of Gypsum Board
(a) Regular/Standard Gypsum Board
(b) Fire Resistance Gypsum Board
(c) Moisture Resistance Gypsum Board
(d) Fire & Moisture Resistance Gypsum Board
(e) Abuse-Resistant Gypsum Panels
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(f) Exterior Gypsum Soffit Board
(g) Foil-Backed Gypsum Board
Gypsum Fiber Board
Glass Mat Gypsum Board
Sheathing
Backing Board
6. TYPES AND SOURCES OF GYPSUM
Mined Gypsum
Flue Gas Desulphurization (FGD) gypsum and
Spray-Dry Absorption materials (SDA)
Phosphogypsum
Pickle Gypsum
Drywall Gypsum
Landfill Versus Recycling

Green Building
Common Uses of Gypsum
Markets for Gypsum Products
General Benefits of Gypsum for Soils
Soil Crusting
Acid Subsoil
Sodic or Salt Contaminated Soils
Nutrient Availability
Runoff and Water Absorption
Animal Bedding
Poultry Bedding
Manure Treatment
Crops Known to Benefit From Gypsum
Plants that can Benefit from Gypsum Include
Animals
Application
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7. DIFFERENT TYPES OF DRYWALL
1. Dry Lining Systems
2. Interior Partition Systems
3. Performance partition Systems
How to build a drywall
Installation
Drywall Tools
Fixing Tools
Cutting Tools
Marking Tools
Finishing Tools
Lifting Tools
Basic Principles to Design a Drywall
Key Design Criteria
Height
Maximum Partition Heights
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Thermal Insulation
Different Types of Drywall
Benefits of Effective Thermal Insulation make
Building
8. GYPSUM PRODUCTS IN DENTISTRY: TYPES,
USES, PROPERTIES
Desirable Properties
Types of Gypsum Products
A. Plaster
B. Stone
C. High-Strength or Improved Stone
D. Other Types of Gypsum
Setting Reaction
Water/Powder Ratio
Setting Time

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Definitions
1. Working Time or Initial Setting Time
2. Final Setting Time
Measurement
Variation in Setting Times
1. Increased Setting Time (A Slower-Setting
Product)
2. Decreased Setting Time (A Faster-Setting
Product)
Setting Expans
Strength

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9. GYPSUM AS AN AGRICULTURAL PRODUCT
Benefits of Gypsum as a Soil Amendment
Processing Gypsum into a Soil Amendment
Agricultural and Land Application uses of Gypsum
Gypsum as a Source of Plant Nutrients for Crops
Gypsum to Improve Soil Physical Properties
Gypsum to Improve Soil Chemical Properties
Gypsum for Nursery, Greenhouse, Landscape, and
Sports Field Use
Gypsum for Landscape and Sports Field Use
Other Uses of Gypsum in Agriculture
Use of Gypsum as a Soil Conditioner
Causes of Poor Soil Structure
Recognition of Gypsum Responsive Soils
Exchangeable Sodium Percentage (ESP)

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Exchangeable Magnesium Percentage (EMgP)
Calcium: Magnesium Ratio (Ca:Mg)
Clay Dispersion Index
10. MINING TECHNOLOGY
Exploration Techniques
Stratigraphy
Topography
Vegetation
Hydrology
Deposit Evaluation
Drilling and Sampling
Testing Procedures

11. PREPARATION OF OTHER GYPSUM AND
ANHYDRITE
Phosphogypsum
Titanogypsum
Insoluble Anhydrite
Calcination Methods
Batch Kettle
Continuous Kettles
Submerged Combustion Kettles
Conical Kettle
Rotary Kilns
Impact Mill Calciner
Ring Ball and Roller Mills
Calcidyne Unit
Anhydrous and Multiphase Plaster
Hemihydrate Plasters
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12. ROLE OF GYPSUM IN CEMENT
The Effect of Gypsum on Setting of Cement
The Effect of Gypsum Solubility
Optimum Gypsum Content
Strength and Volume Stability
Effects of Gypsum on Cement
13. TECHNOLOGY OF GYPSUM AND GYPSUM
PLASTERS
14. GYPSUM TRANSPORTATION
Power Station to Plaster Board Factory
Packaging
Transportation
Truck
Rail
Barge
Ship
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15. GYPSUM HANDLING AND STORAGE
Handling and Transportation
Gypsum Storage
Gypsum Panel Products
Safety Tips for Handling
Handling and Storage of Gypsum Panel Products:
A guide for distributors, Retailers, and
Contractors
Storage
Support Risers
Preventing Sagging Gypsum Panel Products
Preventing Sagging Gypsum Panel Products, cont.
Manual Handling
Mechanical Handling
Use of Wedges
Stocking Gypsum Panel Products on Job Sites
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Loading Gypsum Panel Products
Open Top Rail Flatcars
Flatbed Trucks
Guidelines for Carriers, Drivers and Trailer
Loading Personnel
16. GYPSUM BOARD WASTE MANAGEMENT
Gypsum and Gypsum Board
Sustainability Imperative
Gypsum Board Waste and the Management
Recycling Process and Technology
Policy Instruments for Promoting Recycling
Action on Gypsum Board Waste
CRD Waste Management in Europe

17. GRINDING AND CALCINING OF GYPSUM
18. CRYSTALLISTAION AND DISSOLUTION OF
GYPSUM
Introduction
Background Information
Mineralogy
Crystal Nucleation: The Classical Nucleation
Theory
The Induction Period and the Surface Free Energy
Crystallization of Gypsum
Gypsum Nucleation Kinetics
Gypsum Nucleation Induction Period and the
Surface Free Energy
Inhibition of Gypsum Crystallization
Dissolution of Gypsum
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Gypsum Dissolution Kinetics
Surface Behavior of Gypsum during Dissolution
19. GYPSUM PELLETIZING
Gypsum Waste
Recycled Gypsum Products
Agricultural Products
New Drywall
Cement
Paper Products
Composting
Flow Diagram of Typical Gypsum Pelletizing
Process
Gypsum Pelletizing
Pelletizing Gypsum for Use as a Soil Conditioner
Benefits of Pelletizing Gypsum

The Basics of Pelletizing Gypsum
Disc Pelletizer
Rotary Dryer
Important Gypsum Pelletizing Elements
Binder
Equipment
Drying Gypsum
Drying Mined Gypsum
Beneficiation
Drying Gypsum for Use in Wallboard
Benefits to Drying Pelletized Gypsum
Improved Product Handling
Product Consistency
The Benefits of Adding a Pin Mixer to a Gypsum
Pelletizing System

Improved Blending
De-Dusting
Improved Productivity
Reduced Binder Usage
20. BIS SPECIFICATIONS
21. PROCESS FLOW SHEET
22. PLANT LAYOUT
23. PHOTOGRAPHS OF MACHINERY WITH
SUPPLIER’S CONTACT DETAILS
Gypsum Board Making Machine
Plaster of Paris Making Machine
Rotary Kiln
Gypsum Cutting Machine
Storage Tank
Conveyors

Gypsum Rotary Dryer
Blower
Crusher
Scrubber
Hammer Mill
Coarse Grain Silos
Mixer
Gypsum Plaster Spraying Machine
Pulveriser
Automatic Corrugated Board Making Machine
Corrugated Board Making Machine
Rotary Calciner
Rotary Die Cutting Machine
Die Cutting Creasing

Die Cutting Creasing
Conveyor Belt
Blower
VSI Crusher
Scrubber Making Machine
Semi-Automatic Hammer Mill
Gypsum Plaster Spraying Machine
Plaster Spray Machine
Semi-automatic Bandage Machine
Gypsum Powder Production Line
Gypsum Board Production Line Machine

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o Medical Plastics, Disposables Plastic Syringe, Blood
Bags
o Organic Farming, Neem Products Etc.
www.niir.org

o Paints, Pigments, Varnish & Lacquer
o Paper And Paper Board, Paper Recycling Projects
o Printing Inks
o Packaging Based Projects
o Perfumes, Cosmetics And Flavours
o Power Generation Based Projects & Renewable Energy
Based Projects
o Pharmaceuticals And Drugs
o Plantations, Farming And Cultivations
o Plastic Film, Plastic Waste And Plastic Compounds
o Plastic, PVC, PET, HDPE, LDPE Etc.
www.niir.org

o Potato And Potato Based Projects
o Printing And Packaging
o Real Estate, Leisure And Hospitality
o Rubber And Rubber Products
o Soaps And Detergents
o Stationary Products
o Spices And Snacks Food
o Steel & Steel Products
o Textile Auxiliary And Chemicals
www.niir.org

o Township & Residential Complex
o Textiles And Readymade Garments
o Waste Management & Recycling
o Wood & Wood Products
o Water Industry(Packaged Drinking Water & Mineral
Water)
o Wire & Cable
www.niir.org

www.niir.org

To get a detailed scenario of the industry along with
its structure and classification
To provide a comprehensive analysis of the industry
by covering aspects like:
Growth drivers of the industry
Latest market trends
Insights on regulatory framework
SWOT Analysis
Demand-Supply Situation
Foreign Trade
Porters 5 Forces Analysis
www.niir.org

To provide forecasts of key parameters which helps to
anticipate the industry performance
To help chart growth trajectory of a business by detailing
the factors that affect the industry growth
To help an entrepreneur/manager in keeping abreast with
the changes in the industry
To evaluate the competitive landscape of the industry by
detailing:
Key players with their market shares
Financial comparison of present players
www.niir.org

Venturist/Capitalists
Entrepreneur/Companies
Industry Researchers
Investment Funds
Foreign Investors, NRI’s
Project Consultants/Chartered Accountants
Banks
Corporates
Click here for list
www.niir.org

Online Research
Industry Journals
Secondary
Research
Primary
Research
Industry Experts
Industry Industry
Sources Associations
Companies
Surveys
One-on-one
Interactions
Databases
www.niir.org

Present Status
(Indian &
Global)
Macro Environment
Indian Market
Outlook & Forecasts
(5Years)
Demand Assessment
SWOT & Porters
Analysis
Internal Market
Analysis
www.niir.org

Our research team comprises of experts from
various financial fields:
MBA’s
Industry Researchers
Financial Planners
Research veterans with decades of experience
www.niir.org

•1. Overview
•2. Market Analysis
2.1Growth Drivers
2.2Emerging Trends in the Industry
2.3Regulatory Framework
2.4SWOT Analysis
2.5Herfindahl–Hirschman Index (HHI)
•3. Market Forecasts
•4. Key Players
www.niir.org

5. Key Financials and Analysis
5.1 Contact Information
5.2 Key Financials
5.3 Financial comparison
6. Industry Size & Outlook
www.niir.org

Take a look at
SERVICES on #Street View
www.niir.org

Contact us
106-E, Kamla Nagar, Opp. Mall ST,
New Delhi-110007, India.
Email: npcs.ei@gmail.com , info@entrepreneurindia.co
Tel: +91-11-23843955, 23845654, 23845886
Mobile: +91-9097075054, 8800733955
Fax: +91-11-23845886
Website : www.entrepreneurindia.co , www.niir.org
Take a look at NIIR PROJECT CONSULTANCY SERVICES on #StreetView

https://www.linkedin.com/company/niir-project-
consultancy-services
https://www.facebook.com/NIIR.ORG
https://www.youtube.com/user/NIIRproject
https://twitter.com/npcs_in
 https://www.pinterest.com/npcsindia/
Follow us
www.niir.org

For more information, visit us at:
www.niir.org
www.niir.org

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