Gypsum Board Manufacturing


Gypsum board has been successfully manufactured since the 1950’s in plants with various levels of technology. Large modern plants operate at line speeds of as high as 500 ft/min (152 m/min) and can produce very lightweight boards as low as 1500 lb/msf (7.32 kg/m2).  Recently, North American manufacturers are pushing these limits even lower with "ultralight" gypsum board products.  The high speed factories that manufacture gypsum board can represent 100's of millions of dollars of installed manufacturing equipment and can supply vast cities and regions with gypsum board. Maintaining cost competitiveness in this commodity market is difficult without current manufacturing processes, good raw materials and a knowledgeable well-trained staff.

The Gypsum Board Manufacturing Process

The Gypsum Board Manufacturing Process - Training

Gypsum board, drywall or plasterboard is a building product used in modern construction for efficient, cost effective fire protection that can be easily installed and decorated.

Gypsum Board Core Structure by Computed X-Ray Tomography

Gypsum Board Core Structure by Computed X-Ray Tomography

The gypsum board industry is highly competitive with excess capacity, similar products and a very price sensitive market. As a result, quality improvement and cost control are of paramount importance. The manufacturing process is constantly tuned to give a satisfactory product at the lowest possible cost.

gypsum board nail pull 3d

Nail Pull Mechanism as Determined by Computed Tomography

As gypsum board weights continue to decrease in North America, a renewed focus on the microscopic elements of gypsum board production could save each plant upwards of US $1million/year.  It is well known in the gypsum industry that the ASTM C473 nail pull resistance test specification represents a significant barrier to further technology advancements in manufacturing cost reduction.

Gypsum Wallboard Core Structure & Effects on End User Performance

Gypsum Wallboard Core Structure & Effects on End User Performance - FREE DOWNLOAD

Interior grade gypsum wallboard products are manufactured by combining an aqueous pregenerated chemical foam with a plaster/water flowable slurry to form a porous lightweight core panel that contains many cellular air voids. Recent technology advances in foaming agent chemistry and manufacturing equipment have altered the traditional gypsum core structure to preferentially contain relatively large air voids as opposed to relatively small air voids.

Gypsum Board Survival Economics 2008

Survival Economics 2008

The gypsum board industry in North America has enjoyed an extended period of growth, resulting in record shipments and profits in 2005-2006. In the second half of 2006, however, the building industry entered a down cycle.



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