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Edition 11: 11 October, 2007
Edition 12 : 31 August, 2011.
AN
INTRODUCTION TO "GYPSUM COMPOSITES"
Click here for some
more notes on the preparation of gypsum composites products.
"The use of gypsum composites begins where plaster stops and
synthetic materials begin"
Gypsum
composites form an innovative, advanced building material. Gypsum composites
begin where plaster stops and synthetic materials begin. The special general
technical specifications are comparable with those of unsaturated filled
polyester resin. Gypsum composites form an environmentally friendly building
material. It can be recycled. Its re-use is warmly recommended. Waste and rest
materials can be reconditioned and the material used again for the same or
another purpose.
Reasons for using gypsum composites.
To those with
many years of experience with synthetic materials it becomes apparent that there is a need
to find and produce alternative environmentally friendly, raw building
materials technically and mechanically comparable with existing synthetic
materials and which in some cases can replace them.
The advantages of gypsum composites.
They offer a
higher economic return.
They require less capital-, and inventory investment/outlays.
They are environmentally friendly , since rest materials can be 100% recycled.
They are non-critical and require little energy for manufacture.
They can be technically and mechanically comparable with some existing
synthetic materials.
They are widely available as natural raw material.
They are easily be adapted to innumerable uses and applications.
They can be simply be integrated with existing machinery and working methods.
They produce no deformation or expansion.
They have eminent colour properties.
They require no special, expensive moulds.
They are easy to finish and easy to repair.
They require no high pre-investment or production costs.
They are competitive in price with synthetic materials.
They can be re-used.
They accept various production-techniques as it is mouldable including
"curtain-systems") and can be pressed, extruded, sprayed, as rolled
using the "hand-lay-up" method.
They can easily be sawn, drilled, sandblasted, glued, ground, painted,
polished, etc.
Applicable regulations
The work
safety and storage regulations are the same as those applied to
plaster/concrete.
Some applications of gypsum composites.
Sheet-materials
Building
construction materials for ceilings, walls and floors (offering FIRE-Resistant,
sound proofing, temperature and insulation possibilities), cast plate linings
for external walls, injection mortar. Methods of production: open moulds,
extrusion.
Furniture
Marble
casting, decorative articles, table tops, work surfaces, table legs, doors,
furniture ornamentation, wood and image carving and sculpturing (no special
problems with regard to stain). Methods of production: open or closed moulds.
Small quantities (300 pieces.) are already economic.
Plaster work
Exterior and
interior, ceilings and walls (* seamless-ceilings system), ornamentation,
frames, panelling, casting and modelling. Interior and exterior repairs, *
seamless repairs to cracked ceilings and surfaces, artificial marble
fireplaces. Methods of production: as for furniture.
Construction
Joists and
trusses (composite structures) (e.g. gauze, fibrous material). Methods of
production: open moulds. Small quantities are already economic.
Metal work
*Shells for
casting by the "lost-wax-method"( "cire-perdu") in
precision metal foundries
Buildings
Floors,
*system building bricks (earthquake resistant), window frames*, roof tiles.
Toys, Models, Architects
Boxes of
bricks, do-it-yourself casting boxes + silicone moulds, silicone
matrixes/moulds, relief painting.
Arts & Crafts
Interior and
exterior, statues and ornaments, relief-art, pedestals, business gifts,
interior decorations, garden ornaments, garden gates*.
Cars
Environmentally
friendly Body filler*.
Rural Water Supply in Developing Countries
Water storage
tanks, well linings, pump-stands, washing places.
Sanitation projects in Developing Countries
San-plat
systems; structures for toilets.
Pipes
Ecological
and hygienic water pipe-lines.
*For
this purpose special systems and applications, together with accessory moulding
systems, have been developed (economic for small quantities). These systems can
be obtained under licence either in part or as a whole (subject to due
observance of the industrial ownership and payment of royalties, etc.)
General Technical Specifications of appropriate gypsum composites.
-Great
strength, variable strength depending on whether glass-fibre, tawron, kevlar,
etc. is added.
-Weatherproof: either for interior or exterior use.
-Scratch solidity/surface hardness: greater than acryl, less than glass,
comparable with marble (1 moh's 3.5).
-Specific mass/weight: 0.7 - 3 (can be further increased by use of additional
material), standard 1 1.2.
-Hardening/setting & removal (from the mould): after 1 - 180 minutes or
more, adjustable, depending on application and preparation.
-(Colour) shade: mat, silk or high gloss, marble-effect, depending on
preparation and finishing effect: marble (polish), terrazzo, onyx, etc.
-Surface texture: relief, e,g, (rush-mat) woven effect, stone structure,
slate/schist structure, etc.
Why use gypsum composites.
-They behave
like granite, marble and alabaster (Gypsum composites. AB quality).
-Their viscosity and properties can be adapted to a given application.
-They can be polished, sandblasted, drilled, sawn, etc.
-Their degree of polish, colour and marble-colouring can be adapted as
required.
-They can be made weatherproof .
-They are environmentally friendly, waste products can be re-used.
-Their specific mass/weight can be adapted as required.
Recommendations for working with gypsum composites.
Tools and
containers must be immediately cleaned with water after use.
The material is mechanically weak after removal from the mould, but stronger
than concrete after 24 hours. Test material after 24 hours.
Invisible and fast repairs can be carefully carried out immediately after
removal from the mould. Take a test.
Very special attention must be paid to prevent the formation of air bubbles.
Take a test.
A clean working environment and conscientious working is essential at all
times.
Preparation of products made from gypsum composites.
SOME RECOMMENDED TECHNOLOGIES
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