History and Manufacture
– First plasterboard plant in the UK opened in 1888 in Rochester, Kent
– Sackett Board invented in 1894 by Augustine Sackett and Fred Kane
– Gypsum board evolved between 1910 and 1930
– United States Gypsum Corporation bought Sackett Plaster Board Company in 1910
– Gypsum lath was an early substrate for plaster
– Wallboard panel consists of gypsum plaster sandwiched between two layers of paper
– Raw gypsum is heated and rehydrated to produce calcium sulfate hemihydrate
– Fiber, plasticizer, foaming agent, and additives are mixed with plaster
– Core of wet mixture is sandwiched between paper or fiberglass mats
– Drying chambers use natural gas to dry the board
Specifications and Usage in Australia, New Zealand, Canada, and the United States
– Australia and New Zealand use the term ‘plasterboard’
– Australia’s largest plasterboard manufacturer is called Gyprock
– In New Zealand, it is also called Gibraltar or Gib board
– AquaGib is a specific type for wet conditions
– Plasterboard is commonly used in renovating old buildings
– Drywall panels are made in widths of 48, 54, and 96 inches in Canada and the United States
– Lengths up to 16 feet are common
– Common thicknesses are 12 and 5/8 inch
– Drywall is commonly referred to as Gyproc in many parts of Canada
– 54-inch-wide panels are becoming more popular
Construction Techniques and Drywall Installation
– Drywall can be installed by experienced drywallers or amateur home carpenters
– Installation and finishing are often split between hangers and tapers
– Drywall can be finished from level 0 to level 5
– Priming and painting of drywall are recommended
– Drywall is cut to size and fixed to the structure with nails or screws
– Drywall sheets are secured to wall studs or ceiling joists using screws or adhesives
– Bugle head screws are used to avoid tearing the drywall surface
– Self-drilling screws with finely spaced threads are used for heavier steel framing
– Joint tape or fiber mesh is used to conceal seams between drywall sheets
– Layers of joint compound, also known as mud, are applied to the seams and screw holes
Sound Control, Water Damage and Mold, Other Damage
– Thicker drywall can reduce sound transmission, but multiple layers of drywall are recommended
– Construction details such as steel studs and insulation also help reduce sound transmission
– Sound transmission class (STC) ratings can be increased by using double 12-inch drywall with resilient channels and insulation
– Drywall is highly vulnerable to moisture due to its composition of gypsum, paper, and organic additives
– Exposure to moisture can cause drywall to soften, turn into a gooey paste, and promote mold growth
– Water damage can lead to separation of drywall tape, sagging, and collapse
– Termites can eat the paper facings of drywall, causing it to crumble and requiring replacement
– Honeybees can chew out foam insulation and gypsum in drywall to enlarge their nest area, causing damage
– Defective drywall imported from China caused foul odors, health effects, and metal corrosion in US homes
– Volatile sulfur compounds emitted from the drywall were linked to health problems
– Fire-resistant drywall, also known as Type X, is used for fire barrier walls as a passive fire protection measure
Types of Drywall, Environmental Impact, and Other Facts
– Type X drywall contains special glass fibers to improve fire resistance
– Type C drywall has a higher density of glass fibers and vermiculite for stronger fire resistance
– Regular drywall is suitable for most interior applications
– Moisture-resistant drywall is used in areas with high humidity
– Soundproof drywall reduces noise transmission between rooms
– Impact-resistant drywall is more durable and can withstand accidental impacts
– Gypsum, the main component of drywall, is mined from natural deposits
– Drywall production consumes significant amounts of energy and water
– Efforts are being made to develop more sustainable and eco-friendly alternatives to traditional drywall
– Up to 12% of drywall is wasted during manufacturing and installation processes
– Disposal of drywall can be problematic, with some landfill sites banning its dumping
– Gypsum board is also known as plasterboard or drywall
– The use of synthetic gypsum as a by-product of flue-gas desulfurization has impacted the market
– Drywall installation is a profession with a positive employment outlook
– North America is one of the largest users of gypsum board in the world
– The introduction of the Clean Air Interstate Rule has impacted the gypsum board market Source: https://en.wikipedia.org/wiki/Drywall
Drywall (also called plasterboard, dry lining, wallboard, sheet rock, gib board, gypsum board, buster board, turtles board, slap board, custard board, and gypsum panel) is a panel made of calcium sulfate dihydrate (gypsum), with or without additives, typically extruded between thick sheets of facer and backer paper, used in the construction of interior walls and ceilings. The plaster is mixed with fiber (typically paper, glass wool, or a combination of these materials); plasticizer, foaming agent; and additives that can reduce mildew, flammability, and water absorption.
In the mid-20th century, drywall construction became prevalent in North America as a time- and labor-saving alternative to lath and plaster.
