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Drywall
From Wikipedia, the free encyclopedia
Panels are also known as gypsum board, wallboard, plasterboard (USA, UK, Ireland, Australia),
Gibraltar board or GIB wall and ceiling linings (in New Zealand, trademark of Winstone Wallboards
[2]
), rock lath,[3] Sheetrock (a trademark of USG Corporation), rigips (Germany and Central Europe,
after the Rigips brand), alçıpan in Turkey, placoplatre (France) and pladur (Spain).
Contents
■ 1 History
■ 2 Manufacture
■ 3 Specifications
■ 3.1 USA and Canada
■ 3.2 Europe
■ 4 Construction techniques
■ 5 Water damage and mold
■ 6 Fire resistance
■ 7 North American market
■ 7.1 Waste
■ 8 Types available in the USA and Canada
■ 9 Common drywall tools
■ 10 Levels of finish
■ 10.1 Level 0
■ 10.2 Level 1
■ 10.3 Level 2
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■ 10.4 Level 3
■ 10.5 Level 4
■ 10.6 Level 5
■ 11 Defective Chinese imports
■ 12 See also
■ 13 References
■ 14 External links
History
“Sackett Board” was invented in 1894 by Augustine Sackett. It was made by layering plaster within
four plies of wool felt paper. Sheets were 36" x 36" x 1/4" thick with open (untaped) edges."[4]
"Gypsum Board" evolved between 1910 and 1930 beginning with wrapped board edges, and
elimination of the two inner layers of felt paper in favor of paper-based facings. Later air entrainment
technology made boards lighter and less brittle, then joint treatment materials and systems also evolved.
"[4]
"Rock Lath" was an early substrate for plaster. An alternative to traditional wood or metal lath, it was a
panel made up of compressed gypsum plaster board that was sometimes grooved or punched with holes
to allow wet plaster to key into its surface. As it evolved, it was faced with paper impregnated with
gypsum crystals that bonded with the applied facing layer of plaster.[3]
Manufacture
A wallboard panel is made of a paper liner wrapped around an inner core made primarily from gypsum
plaster, the semi-hydrous form of calcium sulfate (CaSO4·½ H2O). The raw gypsum, CaSO4·2 H2O,
(mined or obtained from flue gas desulfurization (FGD)) must be calcined before use. Kettle or Flash
calciners typically use natural gas today. The plaster is mixed with fiber (typically paper and/or
fiberglass), plasticizer, foaming agent, finely ground gypsum crystal as an accelerator, EDTA, starch or
other chelate as a retarder, various additives that increase mildew and fire resistance (fiberglass or
vermiculite), wax emulsion for lower water absorption and water. This is then formed by sandwiching a
core of wet gypsum between two sheets of heavy paper or fiberglass mats. When the core sets and is
dried in a large drying chamber, the sandwich becomes rigid and strong enough for use as a building
material.[5]
Drying chambers typically use natural gas today. To dry 1 MSF (1,000 square feet) of wallboard,
between 1.75 and 2.49 million BTU is required. Organic dispersants/plasticisers are used mainly to
reduce the amount of water, hence reduce the eventual drying time, needed to produce gypsum slurry
flow during wallboard manufacture.[6]
Specifications
USA and Canada
Drywall panels are manufactured in 48 inches (120 cm) wide panels in varying lengths to suit the
application. Common panel thicknesses are 1/2" (13 mm) and 5/8" (16 mm), with panels also available
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in 1/4" (6 mm) and 3/8" (10 mm). Both 1/2" (13 mm) and 5/8" (16 mm) panels of TYPE 'X' (a gypsum
board with special core additives to increase the natural fire resistance of regular gypsum board[7]) are
used where a fire-resistance rating is desired. Regular 5/8" (16 mm) panels are used (with or without
light gauge resilient metal channels) where additional mass is needed for the reduction of sound
transmission.[citation needed]
Drywall provides a thermal resistance R-value of 0.32 for 3/8" board, 0.45 for 1/2", 0.56 for 5/8", and
0.83 for 1" board. In addition to increased R-value, thicker drywall has a higher sound transmission
class.[citation needed]
Europe
In the UK and Europe, plasterboard is manufactured in metric sizes, with the common sizes being
corollaries of old imperial sizes.
Most plasterboard is made in 120 cm wide sheets, though 90 cm wide sheets are also made. 120 cm
wide plasterboard is most commonly made in 240 cm lengths, though 270 cm and 300 cm length sheets
are also commonly available.
Commonly used thicknesses of plasterboard available are 12.5 mm (modern equivalent of half an inch),
typically used for walls, and 9.5 mm (modern equivalent of three-eights of an inch), typically used for
ceilings. 15 mm thick board is commonly available, and other thicknesses are also produced.[citation needed]
Plasterboard is commonly made with one of two different edge treatments—tapered edge, where the
long edges of the board are tapered with a wide bevel at the front to allow for jointing materials to be
finished flush with the main board face, and plain edge, used where the whole surface will receive a thin
coating (skim coat) of finishing plaster.
Construction techniques
As opposed to a week-long plaster application, an entire house
can be drywalled in one or two days by two experienced
drywallers, and drywall is easy enough to use that it can be
installed by many amateur home carpenters. In large-scale
commercial construction, the work of installing and finishing
drywall is often split between the drywall mechanics, or hangers,
who install the wallboard, and the tapers and mudmen, or float
crew, who finish the joints and cover the nailheads with drywall
compound.[citation needed]
Drywall is delivered to a building Drywall is cut to size, using a large T-square, by scoring the
site on a flatbed truck and unloaded paper on the front side (usually white) with a utility knife,
with a forked material handler breaking the sheet along the cut, scoring the paper backing, and
crane. The bulk drywall sheets are finally breaking the sheet in the opposite direction. Small
unloaded directly to upper floors viafeatures such as holes for outlets and light switches are usually
a window or exterior doorway. cut using a keyhole saw or a small high-speed bit in a rotary tool.
Drywall is then fixed to the wall structure with nails, glue, or
more commonly in recent years, the now-ubiquitous drywall screws.
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Drywall fasteners, also referred to as drywall clips or stops, are gaining popularity in both residential
and commercial construction. Drywall fasteners are used for supporting interior drywall corners and
replacing the non-structural wood or metal blocking that traditionally was used to install drywall. Their
function serves to save on material and labour expenses; to minimise call backs due to truss uplift; to
increase energy efficiency; and to make plumbing and electrical installation simpler.
Drywall screws heads have a curved taper allowing them to self-pilot and install
rapidly without punching through the paper cover. These screws are set slightly into
the drywall. When drywall is hung on wood framing, screws having an acute point
and widely spaced threads are used. When drywall is hung on light-gauge steel
framing, screws having an acute point and finely spaced threads are used. If the Drywall screws
steel framing is heavier than 20-gauge, self-tapping screws with finely spaced are designed to
be self-tapping.
threads must be used. In some applications, the drywall may be attached to the wall
with adhesives.
After the sheets are secured to the wall studs or ceiling joists, the
seams between drywall sheets are concealed using joint tape and
several layers of joint compound (sometimes called mud). This
compound is also applied to any screw holes or defects. The
compound is allowed to air dry then typically sanded smooth
before painting. Alternatively, for a better finish, the entire wall
may be given a skim coat, a thin layer (about 1 mm or 1/16 inch)
of finishing compound, to minimise the visual differences
between the paper and mudded areas after painting.
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Fire resistance
When used as a component in fire barriers, drywall is a passive fire protection item. In its natural state,
gypsum contains the water of crystallization bound in the form of hydrates. When exposed to heat or
fire, this water is vapourised, retarding heat transfer. Therefore, a fire in one room that is separated from
an adjacent room by a fire-resistance rated drywall assembly will not cause this adjacent room to get any
warmer than the boiling point(100°C) until the water in the gypsum is gone. This makes drywall an
ablative material because as the hydrates sublime, a crumbly dust is left behind, which, along with the
paper, is sacrificial. Generally, the more layers of Type X drywall one adds, the more one increases the
fire-resistance of the assembly, be it horizontal or vertical. Evidence of this can be found both in
publicly available design catalogues, including, but not limited to DIN4102 Part 4 and the Canadian
Building Code on the topic, as well as common certification listings, including but not limited to
certification listings provided by Underwriters Laboratories and Underwriters Laboratories of Canada
(ULC). "Type X" drywall is formulated by adding glass fibers to the gypsum, to increase the resistance
to fires, especially once the hydrates are spent, which leaves the gypsum in powder form. Type X is
typically the material chosen to construct walls and ceilings that are required to have a fire-resistance
rating.
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The "I-was-there-first"
scenario, resulting in
improper drywall
firestops with plastic
piping.
Fire testing of drywall assemblies for the purpose of expanding national catalogues, such as the National
Building Code of Canada, Germany's Part 4 of DIN4102 and its British cousin BS476, are a matter of
routine research and development work in more than one nation and can be sponsored jointly by national
authorities and representatives of the drywall industry. For example, the National Research Council of
Canada routinely publishes such findings.[8] The results are printed as approved designs in the back of
the building code. Generally, exposure of drywall on a panel furnace removes the water and calcines the
exposed drywall and also heats the studs and fasteners holding the drywall. This typically results in
deflection of the assembly towards the fire, as that is the location where the sublimation occurs, which
weakens the assembly, due to the fire influence.
When tests are cosponsored, resulting in code recognised designs with assigned fire-resistance ratings,
the resulting designs become part of the code and are not limited to use by any one manufacturer,
provided the material used in the field configuration can be demonstrated to meet the minimum
requirements of Type X drywall (such as an entry in the appropriate category of the UL Building
Materials Directory) and that sufficient layers and thicknesses are used. Fire test reports for such unique
third party tests are confidential.
Deflection of drywall assemblies is important to consider to maintain the integrity of drywall assemblies
in order to preserve their ratings. The deflection of drywall assemblies can vary somewhat from one test
to another. Importantly, penetrants do not follow the deflection movement of the drywall assemblies
they penetrate. For example, see cable tray movement in a German test. It is, therefore, important to test
firestops in full scale wall panel tests, so that the deflection of each applicable assembly can be taken
into account. The size of the test wall assembly alone is not the only consideration for firestop tests. If
the penetrants are mounted to and hung off the drywall assembly itself during the test, this does not
constitute a realistic deflection exposure insofar as the firestop is concerned. In reality, on a construction
site, penetrants are hung off the ceiling above. Penetrants may increase in length, push and pull as a
result of operational temperature changes (e.g., hot and cold water in a pipe), particularly in a fire, but it
is a physical impossibility to have the penetrants follow the movement of drywall assemblies that they
penetrate, since they are not mounted to the drywalls in a building. It is, therefore, counterproductive to
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suspend penetrants from the drywall assembly during a fire test. As downward deflection of the drywall
assembly and buckling towards the fire occurs, the top of the firestop is squeezed and the bottom of the
firestop is pulled, and this is motion over and above that, which is caused by the expansion of metallic
penetrants, due to heat exposure in a fire. Both types of motion occur in reality, because metal first
expands in a fire and then softens once the critical temperature has been reached, as is explained under
structural steel. To simulate the drywall deflection effect, one can simply mount the penetrants to the
steel frame holding the test assembly. The operational and fire induced motion of the penetrants, which
is independent of the assemblies penetrated, can be separately arranged.
The introduction in March 2005 of the Clean Air Interstate Rule by the United States Environmental
Protection Agency requires power plants to "cut sulfur dioxide emissions by 73%" by 2018.[11] The
Clean Air Interstate Rule also requested that the power plants install new scrubbers (industrial pollution
control devices) to remove sulfur dioxide present in the output waste gas. Scrubbers use the technique of
flue gas desulfurization (FGD), which produces synthetic gypsum as a usable by-product. In response to
the new supply of this raw material, the gypsum board market was predicted to shift significantly.
However, issues such as mercury release during calcining need to be resolved.[12]
Waste
Because up to 17% of drywall is wasted during the manufacturing and installation processes[citation needed]
and the drywall material is frequently not re-used, disposal can become a problem. Some landfill sites
have banned the dumping of drywall. Some manufacturers take back waste wallboard from construction
sites and recycle it into new wallboard. Recycled paper is typically used during manufacturing. More
recently, recycling at the construction site itself is being investigated. There is potential for using
crushed drywall to amend certain soils at building sites, such as clay and silt mixtures (bay mud), as well
as using it in compost.[13]
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■ Soundboard is made from wood fibers to increase the sound rating (STC)
■ Soundproof drywall is a laminated drywall made with gypsum, other materials, and damping
polymers to significantly increase the STC[citation needed]
■ Mold-resistant, paperless drywall[citation needed]
■ Enviroboard, a board made from recycled agricultural materials
■ Lead-lined drywall, a drywall used around radiological equipment[citation needed]
■ Foil-backed drywall to control moisture in a building or room[citation needed]
■ Controlled density (CD), also called ceiling board, which is available only in 1/2" thickness and is
significantly stiffer than regular white board.
■ EcoRock, a drywall which uses a combination of 20 materials including recycled fly ash, slag,
kiln dust and fillers and no starch cellulose; it is advertised as being environmentally-friendly due
to the use of recycled materials and an energy efficient process.[14]
Levels of finish
"In 1990, four major trade associations, the Association of Wall and Ceiling Industries International
(AWCI), the Ceilings and Interior Systems Construction Association (CISCA), the Gypsum Association
(GA), and the Painting and Decorating Contractors of America (PDCA), presented the consensus
document Levels of Gypsum Board Finish. The document was created to "precisely describe" the
desired finish of walls and ceilings prior to final decoration. This precise description enables contractors
to better understand the requirements of architects and building owners in order to enhance the
satisfaction of the client. Specifications that include the Levels of Gypsum Board Finish also promote
competitive bidding that allows the bidder to consider the correct labor and materials to finish the wall
suitably for its final decoration." [3]
(http://www.nationalgypsum.com/resources/techtalk/revisiting.aspx)
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The official document (summarized below) is known as GA-214-96 "Recommended Levels of Gypsum
Board Finish" (http://www.nationalgypsum.com/literature/GA-214-96.pdf) .
Level 0
No taping, finishing, or accessories required.
Level 1
All joints and interior angles shall have tape set in joint compound. Surface shall be free of excess joint
compound. Tool marks and ridges are acceptable.
Usage: Above false ceilings or other areas that are out of public view where a degree of fire and noise
resistance is required.
Level 2
All joints and interior angles shall have tape embedded in joint compound and wiped with a joint knife
leaving a thin coating of joint compound over all joints and interior angles. Fastener heads and
accessories shall be covered with a coat of joint compound. Surface shall be free of excess joint
compound. Tool marks and ridges are acceptable. Joint compound applied over the body of the tape at
the time of tape embedment shall be considered a separate coat of joint compound and shall satisfy the
conditions of this level.
Usage: As a substrate for tile walls and ceilings as well as in garages, warehouses, and other places
where appearance is not a primary concern.
Level 3
All joints and interior angles shall have tape embedded in joint compound and one additional coat of
joint compound applied over all joints and interior angles. Fastener heads and accessories shall be
covered with two separate coats of joint compound. All joint compound shall be smooth and free of tool
marks and ridges. It is recommended that the prepared surface be coated with a drywall primer prior to
the application of final finishes.
Usage: Suitable base for heavy-medium textured paint or other thick finishes.
Level 4
All joints and interior angles shall have tape embedded in joint compound and two separate coats of
joint compound applied over all flat joints and one separate coat of joint compound applied over interior
angles. Fastener heads and accessories shall be covered with three separate coats of joint compound. All
joint compound shall be smooth and free of tool marks and ridges. It is recommended that the prepared
surface be coated with a drywall primer prior to the application of final finishes.
Usage: "Standard" household and office walls. Used with light or non-textured finishes. Not suitable for
harsh lighting conditions, which may highlight minor imperfections
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Level 5
All joints and interior angles shall have tape embedded in joint compound and two separate coats of
joint compound applied over all flat joints and one separate coat of joint compound applied over interior
angles. Fastener heads and accessories shall be covered with three separate coats of joint compound. A
thin skim coat of joint compound, or a material manufactured especially for this purpose, shall be
applied to the entire surface. The surface shall be smooth and free of tool marks and ridges. It is
recommended that the prepared surface be coated with a drywall primer prior to the application of finish
paint. The skim coat is a final leveling agent suitable to smooth out a surface to be used under the
harshest lighting conditions that may otherwise highlight any imperfections under the finished surface.
There are reports that a substantial amount of defective drywall was imported into the United States
from China and incorporated into tens of thousands of homes during rebuilding in 2006 and 2007
following Hurricane Katrina and in other places. Complaints include foul odor, health effects, and
corrosion of metal within the structure. The same drywall was sold in Asia without problems resulting,
but U.S. homes are much tighter than Asian homes. A number of lawsuits are underway in many
jurisdictions, but many of the sheets of drywall are simply marked, "Made in China", thus making
identification of the Chinese manufacturer difficult. An investigation by the Consumer Product Safety
Commission, CPSC, was underway in 2009.[15] In November 2009, the CPSC reported a "strong
association" between Chinese drywall and corrosion of pipes and wires reported by thousands of
homeowners in the United States. Further findings have shown that volatile sulfur compounds, including
hydrogen sulfide, have been detected as emissions from the imported drywall and may be linked to
health problems.[16] Volatile sulfur compounds are emitted from many different types of drywall, and at
least one investigation has pointed to high levels being emitted from drywalls manufactured in the
United States.[17]
See also
■ Ablation
■ Cement board
■ Certification mark
■ Compartmentalization
■ Construction
■ Endothermic
■ Fire protection
■ Firestop
■ Firewall (construction)
■ Gypsum
■ Homasote
■ Knockdown
■ Product certification
■ QuietRock
■ United States Gypsum
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References
1. ^ [1] (http://www.nps.gov/history/hps/TPS/briefs/brief21.htm#Historical%20Background)
2. ^ [2] (http://teaohou.natlib.govt.nz/journals/teaohou/image/Mao46TeA/Mao46TeA062.html)
3. ^ a b Repairing Historic Flat Plaster Walls and Ceilings By The Old House Web
(http://www.oldhouseweb.com/how-to-advice/repairing-historic-flat-plaster-walls-and-ceilings-
introduction.shtml)
4. ^ a b http://www.gypsum.org/mediaguide.html Gypsum Association History of Gypsum Board
5. ^ http://www.freepatentsonline.com/4222984.html
6. ^ Global Gypsum Magazine, January 2009, p. 18
7. ^ *Gypsum Association - Fire Resistance Design Manual (GA-600-2009) (http://www.gypsum.org/pdf/GA-
600-09_Print_7_Megs.pdf)
8. ^ Performance of wood stud shear walls exposed to fire (http://www.nrc-
cnrc.gc.ca/obj/irc/doc/pubs/nrcc41733/nrcc41733.pdf)
9. ^ Mineral Commodity Summaries, January 2006
(http://minerals.usgs.gov/minerals/pubs/commodity/gypsum/gypsumcs06.pdf)
10. ^ Donald W. Olson (2002) Gypsum
(http://minerals.usgs.gov/minerals/pubs/commodity/gypsum/gypsmyb01.pdf) History and production
11. ^ Clean Air Interstate Rule (http://www.epa.gov/cair/)
12. ^ Mercury Release from FGD Gypsum (http://www.flyash.info/2003/75heeb.pdf)
13. ^ Recycled Inerts (http://www.ciwmb.ca.gov/Markets/StatusRpts/Inerts.htm)
14. ^ Serious Materials EcoRock (http://www.popsci.com/bown/2008/product/serious-materials-ecorock) .
Popular Science.
15. ^ "Thousands of U.S. Homeowners Cite Drywall for
Ills" (http://www.nytimes.com/2009/10/08/business/08drywall.html) article by Leslie Wayne in The New
York Times October 7, 2009
16. ^ http://www.google.com/hostednews/ap/article/ALeqM5gD4avarflIqeq856bkEM8jMJRR_wD9C5HGRO0
17. ^ http://www.cbsnews.com/stories/2009/11/23/cbsnews_investigates/main5752469.shtml?
tag=cbsnewsTwoColUpperPromoArea
External links
■ Gypsum Association, an organization of manufacturers of gypsum board in the U.S. and Canada
(http://www.gypsum.org/)
■ Results of 22 tests run at National Research Council of Canada, M.A. Sultan and G.D. Lougheed,
some passed, some failed, determining influence of various factors in the design of drywall
assemblies. (http://nparc.cisti-icist.nrc-cnrc.gc.ca/npsi/ctrl?
action=rtdoc&an=5753664&article=17&lang=en)
■ Article on preventing mold growth in lightweight construction such as drywall
(http://www.ncma.org/resources/Marketing%20Resources/Articles%20for%20Print%20and%
20Radio/How%20to%20Prevent%20and%20Control%20mold%20in%20Your%
20Home/Mold.htm)
■ Fire Test Report per ASTM E119 on Drywall Assemblies with Hose Stream run immediately
following Fire Exposure, including pictures. (http://www.ncma.org/resources/Documents/Fire%
20Safety%20Materials/WallAssemblies.pdf)
■ Drywall Information Trust Fund (http://www.drywallca.com/)
Retrieved from "http://en.wikipedia.org/wiki/Drywall"
Categories: Composite materials | Building materials | Passive fire protection | Wallcoverings
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