GYPSUM BOARD AND GYPSUM POWDER

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Gypsum has been known for centuries and is one of the oldest building materials in the world. For centuries now, gypsum has played a crucial role in construction. Today, all over the world’ principal interior wall material is gypsum wallboard. Often also referred to as drywall, rock, plasterboard, gyp-board, or by the trade names Sheetrock or Gyp-roc, gypsum drywall is a sheet of gypsum with a paper facing and backing with following composition: • The wallboard is approximately 92% gypsum (calcium sulfate dehydrate CaSO4 2H2O). • 7% paper, and 1% impurities and additives. Gypsum is found in every continent of the world and is one of the most widely used minerals. The chemistry of Gypsum board: Pure gypsum is a white to transparent mineral, but sometimes impurities color it grey, brown, or pink. Its chemical name is calcium sulphate dihydrate, and its chemical formula is CaSO4•2H2O. When gypsum is heated, it loses about three quarters of its water and becomes hemihydrate gypsum (CaSO4•½H2O), which is soft and can be easily ground to a powder called hemihydrate gypsum plaster or Plaster of Paris. If this powder is then mixed with water to form a paste or slurry, then it will dry and set rock hard. The chemically combined water, previously driven off by heating, will recombine, and the material will revert to the original chemical composition of gypsum. While the hemihydrate gypsum plaster is in slurry form, it can be poured between two paper layers to make wallboard, used to fill cracks and crevices, or poured into a mold. Plaster of Paris is a building material. Plaster of Paris is raw gypsum that is chemically altered by heat to remove much of the water contained in the gypsum molecule and then hydrated to make it useable as a plastering material. It remains a viable product to this day. Gypsum board is the technical product name used by manufacturers to define a specific gypsum-core board material that is typically installed on the walls and ceilings of the interior or exterior of a residential or non-residential structure. The product is defined by the ASTM C11 standard as “the generic name for a family of sheet products consisting of a noncombustible core primarily of gypsum with paper surfacing.” Drywall and plasterboard are non-technical synonyms for gypsum board. Gypsum board manufacturing companies also manufacture gypsum sheets products that do not have a paper facing. These products are called gypsum panel products and are defined by the ASTM C11 standard as “a family of sheet products consisting essentially of gypsum.” Glass mat-faced panels and panels manufactured without a facing that have a gypsum core are examples of gypsum panel products. The commonality between the board and the panel definitions is the gypsum core. The core often contains additives, but to be considered a gypsum board or panel, and be regarded as drywall, the core must be predominantly gypsum.

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Description

PROJECT AT A GLANCE
INTRODUCTION
THE CHEMISTRY OF GYPSUM BOARD
DEFINITION AND CATEGORIES OF GYPSUM BOARD
PRODUCT RANGE
DETAILS OF GYPSUM BOARD
EDGE AND END PROFILES
REQUIREMENTS
TOLERANCE
TRANSVERSE STRENGTH
WATER ABSORPTION
TESTS
MEASUREMENT OF TAPER PROFILE
TAPER WIDTH
TAPER DEPTH
SAMPLING AND CRITERIA FOR CONFORMITY
SALE OF SAMPLING
FINISH
PACKING AND MARKING
ADVANTAGE AND APPLICATION
ADVANTAGES OF GYPSUM BOARD
AREAS OF APPLICATIONS
GYPSUM BOARD FOR ACOUSTIC APPLICATIONS
GYPSUM BOARD FOR CEILING APPLICATION
CONFIGURATION OF GYPSUM BOARD
TYPICAL PROCESS OF MANUFACTURING GYPSUM BOARD
1. RAW MATERIALS
2. CRUSHER
3. GRINDING MILL
4. CALCINE SYSTEM
5. STUCCO HOLDING TANK
6. MIXER
7. FORMING STATION
8. BOARD LINE
9. CUT-OFF KNIFE
10. TRANSFER TABLE
11. KILN
12. BUNDLER AND STACKER
PROCESSING CHART
DOSING SECTION
FORMING SECTION
CUTTING AND DRYING SECTION
EDGE TRIMMING AND STACKING SECTION
GYPSUM BOARD PRODUCTION LINE PICTURES
FORMING DEVICE
RUBBER BELT CONVEYOR AND DRYING ROOM
BLANK ROLLER CONVEYOR AND PRINTER
TRANSFERRING CONVEYOR
DISTRIBUTOR
AIR BLOWER
ELECTRICAL CABINET
AVAILABILITY OF GYPSUM
AVAILABILITY OF GYPSUM IN KILWA-TANZANIA
ANNUAL REQUIREMENT OF RAW MATERIALS
RECOMMENDED SOURCES OF RAW MATERIALS
MARKET OVERVIEW OF GYPSUM BOARD AND POWDER
GYPSUM BOARD – A PART REPLACEMENT TO WOOD
CONSTRUCTION MATERIAL – BASED ON INDIGENOUS RAW MATERIALS
GYPSUM BOARD – ENVIRONMENT FRIENDLY MATERIAL OF CONSTRUCTION
WORLD MARKET SCENARIO
MARKETS SCENARIO IN TANZANIA
COMPETITIVE STRENGTH OF GYPSUM BOARD PRODUCED IN TANZANIA
DEMAND FOR GYPSUM BOARDS IN TANZANIA & DEMAND SUPPLY GAP
EXPORTS PROSPECTS
FUTURE MARKET PROJECTIONS
TARGET MARKET AND MARKETING STRATEGY
BASIS
GLOBAL MARKET OVERVIEW OF GYPSUM BOARD
MANUFACTURERS OF GYPSUM BOARDS
MANUFACTURING PROCESS OF GYPSUM BOARD
TECHNOLOGY AND MANUFACTURING PROCESS
TECHNOLOGIES EMPLOYED FOR PRODUCTION OF GYPSUM BOARD
MANUFACTURING PROCESS
PROCESS FLOWCHART FOR GYPSUM BOARD
PLANT LOCATION & INFRASTRUCTURE 64
POTENTIAL LOCATIONS
SELECTION OF SUITABLE LOCATIONS
ENVIRONMENTAL ASPECT IN GYPSUM BOARD & POWDER MANUFACTURE
ENVIRONMENTAL ASPECT OF MANUFACTURING PROCESS
WASTE GENERATED AND MITIGATION MEASURES
WASTE GENERATED DURING CONSTRUCTION PHASE
RAW MATERIALS
1. ALBASTER
2. SELENITE
3. SATIN SPAR
4. ANHIDRITE
5. GYPSITE
CHEMISTRY OF THE PROCESS & PHYSICAL PROPERTIES
STEP 1 – PLASTER OF PARIS MANUFACTURE
STEP 2 – REHYDRATION
STEP 3 – SETTING
ROLE OF THE LABORATORY
ENVIRONMENTAL IMPLICATIONS
DETAILS OF MANUFACTURING PROCESS FOR GYPSUM BOARD
FOLLOWING ARE THE MAJOR STAGES IN PRODUCTION GYPSUM
PLASTER BOARDS.
1. PREPARATION OF RAW MATERIALS
2. CALCINING OF GYPSUM
3. PREPARATION OF PASTE
4. MOULDING IN THE FORM OF BOARDS
5. DRYING OF BOARDS
PROCESS FLOW SHEET
DETAILS OF GYPSUM PROCESSING
MANUFACTURE OF PLASTER OF PARIS
DETAILS OF DRYWALL MANUFACTURE
BLENDING OF ADDITIVES
MAKING THE SANDWICH
FINISHING THE EDGES
CUTTING THE PANELS
THE DRYING PROCESS
THE FINISHED PRODUCT
LIGHTWEIGHT GYPSUM BOARD
CONTINUOUS PRODUCTION OF GYPSUM BOARD
A. PRODUCTION OF FIBROUS STUCCO 101
SUPPLIERS OF RAW MATERIALS (INDIAN)
GYPSUM
FOAMING AGENT 5
SUPPLIERS OF PLANT AND MACHINERIES (GLOBAL)
COMPLETE PLANT SUPPLIERS ON TURNKEY BASIS

APPENDIX – A:

01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

Additional information

Plant Capacity

360 MT/Day
Land and Building

(4 Acres)
Plant & Machinery

US$.50000
Rate of Return

23%
Break Even Point

76%

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