According to statistics from the construction industry, the UK uses around 4 million tonnes of gypsum each year. This comes from domestic production as well as net imports. The UK does have natural gypsum but it also manufactures a synthetic version of it too. This level is increasing in Great Britain. In , the value of new work construction increased to a record high. The increase was 15.8%, which amounted to almost £133,000 million. The growth in was driven by private and public sector growth alike.
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Gypsum is a hydrated form of calcium sulphate, otherwise called calcium sulphate dihydrate. It is a soft sulphate mineral with the chemical formula CaSO4.2H2O. This means it is made up of water, oxygen, sulphur and calcium. The substance is used widely as the main constituent in lots of forms of plaster, chalk (for blackboards or pavements), drywall and fertiliser.
Naturally, gypsum is created due to seawater evaporation. It occurs as nodular masses or as beds that can be several metres thick. It occurs within layers of sedimentary rock. Gypsum, as opposed to anhydrite, which is the anhydrous form of calcium sulphate, forms near the surface. Typically, when you get to 40 to 50 metres below the surface, you get anhydrite instead.
Gypsum occurs naturally around the world and is mined in places like Thailand, Brazil, Russia, the US and the UK. The substance is soft and white or grey in colour and is extracted with surface mining. After extraction, it is crushed inside industrial machines and then sorted into pieces of different sizes depending on their intended commercial use.
Synthetic gypsum is often produced as a by-product in some industrial processes. This includes the FGD (flue gas desulphurisation) process. This is purer (around 96%) compared to natural gypsum, which is about 80% pure usually.
Gypsum is widely used in construction and for many different reasons. Generally, it is used to improve the structural properties of a building. Here are some examples:
The construction industry generally uses gypsum in powder form. When it is heated in its natural solid form, it loses its water molecules and becomes a powder. This is known as plaster in the construction industry. Applying different amounts of heat to the gypsum will give you different types of plaster.
By adding water to gypsum powder, it will set and turn solid once more. This means it can be easily moulded and smoothed for surfaces.
When it is ground and heated to between 150°C and 165°C around 75% of its water is removed. This product is known as plaster of Paris.
Gypsum’s properties mean it is an especially useful product in construction. It has been used in construction for centuries. Ancient civilisations used alabaster, which is gypsum in solid form, to make sculptures. Powdered gypsum was also used to construct the pyramids of Giza.
Here are some of the ways it is used in construction these days:
This also goes by the name of gypsum board and drywall. It has a gypsum core that is sandwiched between two facers, which is essentially thick paper. The core will often contain other additives that improve its structure.
Plasterboard has excellent soundproofing and fire-resistant properties. It is also light, cheap and easy to install. Plasterboard’s main uses are in interior wall structures and ceilings. The majority of UK residential and commercial properties will contain gypsum in this form.
Synthetic gypsum is used widely in the manufacturing of plasterboard. Demand for gypsum is heavily driven by plasterboard manufacturing.
Gypsum in the form of plaster of Paris is used for casts, models and moulds for decorating in construction. This is also crack- and shrink-resistant when it’s dry—and it dries quickly too.
This is like plasterboard. It is used to line roofs, floors, ceilings and walls. It is shock-resistant and also resistant to humidity. Fibreboard is also good for soundproofing.
This is the plaster that you use to skim walls and ceilings. It is easy to use and will set quickly. Natural gypsum is favoured for building plaster because it contains natural clays that make it more workable.
Gypsum-based screed is used for floors in buildings as it is self-levelling. It is strong and thermally stable.
When you add gypsum to cement, it does increase how long it takes to harden and dry. However, the concrete is more stable.
These tiles are used to make building partitions and ceilings. They are fire-resistant.
Gypsum has many features that make it useful for building. It contains crystal water and is non-combustible. This means it can stop fires from spreading within buildings. It also has low thermal conductivity, which means it can keep heat within rooms, lowering bills.
Besides its fire-resistant properties, gypsum offers soundproofing. When plasterboard is used, there is an additional sound barrier in the room. What’s more, it is impact-resistant. This means that it can be used in places where strong walls are needed like corridors in busy buildings like hospitals or schools.
Another thing that’s great about this material is that it’s sustainable and can be recycled. It is easy to use but also easy to disassemble.
In many applications, gypsum replaced asbestos as a safer alternative. It has now substituted the use of asbestos in many construction materials where non-toxic and fire-resistant products are needed. For instance, plasterboard, fireproofing, insulation and ceiling tiles would have once been manufactured using asbestos but have now been replaced with gypsum.
No. Gypsum products do not contain asbestos. However, the Health and Safety Executive does say that when gypsum-based plasterboard is used and its dust becomes airborne, its dust could contain fibres of asbestos. As such, some people wrongly believe gypsum contains asbestos.
Back in the s, both asbestos and gypsum were gaining in popularity as building materials. No one realised just how terrible asbestos was for health, nor the dangers that came with ingesting it or inhaling its fibres. Asbestos was simply thought of as useful for insulating and strengthening building work. It also had soundproofing properties and was heat-resistant.
Nowadays, plasterboard doesn’t contain asbestos but it used to. As such, buildings constructed between the s and s might have plasterboard that contains asbestos. However, when asbestos-containing plasterboard is painted, the fibres are sealed inside. Therefore, the risk of harm is reduced significantly. But, if the plasterboard is disturbed, the fibres can become dangerous as they could become airborne.
The construction industry commonly recycles old plasterboard for environmental reasons. However, this now needs to be tested for asbestos because it is illegal to use asbestos in building materials nowadays.
Gypsum and asbestos, though they share similar properties, are distinct materials that have different compositions.
Firstly, gypsum is a soft sulphate material that’s found in formations of sedimentary rocks. Asbestos, on the other hand, is a naturally occurring mineral (or a group of such minerals) that are thin, fibrous crystals. Types of asbestos include tremolite, actinolite, anthophyllite, crocidolite, amosite and chrysotile.
The physical properties of the two also differ. Gypsum is soft. It has a Mohs hardness score of 2. This means it can be scratched easily with a fingernail. It is not fibrous and isn’t as heat-resistant as asbestos. Asbestos is fibrous and is much better than gypsum at retaining heat and insulating. It is resistant to fire, corrosion by chemicals and electricity.
Both products have been used in the construction industry, though asbestos is now banned due to its association with serious health problems like lung diseases and cancer. Asbestos was used commonly in fireproofing materials and insulation due to its properties. Gypsum isn’t best known for these properties but it also doesn’t have hidden dangers like cancer, specifically mesothelioma.
Comparatively, gypsum is considered safe to use in construction. It poses minimal risks to health. Asbestos has been outlawed since due to its health risks.
Although gypsum doesn’t contain asbestos, some building materials could have been contaminated with asbestos if they were made before the use of asbestos was made illegal in . In these cases, it is the asbestos fibres and not the gypsum that is a risk to your health.
Asbestos is the biggest causal factor of occupational disease in the construction industry, despite the product being illegal for over 20 years. However, because many buildings still contain older materials, construction workers need to take particular care when working.
Gypsum itself is non-toxic. However, any dust that is inhaled or ingested on a regular basis can cause harm. Workers will use gypsum with control measures in place. The Control of Substances Hazardous to Health (COSHH) Regulations outline the limits of how much dust workers can be exposed to. PPE should be worn, for example.
Understanding the environmental impact of gypsum is important as we seek to promote sustainable building practices.
The material is sourced primarily from mining in a range of regions worldwide. Its extraction involves surface mining, which means we need to consider the environmental impact. Land rehabilitation, sustainable mining practices and adherence to environmental regulations are essential to responsible gypsum sourcing.
When synthetic gypsum is produced, it is actually a by-product of other processes. This means that it reduces waste produced in industry by repurposing something that otherwise would go to landfill.
Thankfully, gypsum has noteworthy recyclability. The construction industry recycles gypsum-based materials commonly, which reduces the demand for raw materials and minimises waste. It is common practice to recycle old plasterboard, although this does require testing for asbestos and asbestos contamination before it can be used again.
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Gypsum is inherently sustainable. This is because it is non-combustible and is a fire inhibitor. Its low thermal conductivity also means that it helps rooms to retain heat, which contributes to lower heating bills and energy efficiency. Its soundproofing qualities also mean it offers acoustic insulation.
As we’ve seen, gypsum is popular as a building material in the construction industry. Let’s look at its advantages and disadvantages together:
Gypsum, whether natural or synthetic, is commonly preferred for interior construction like walls and ceilings. Its sound absorption, fire resistance and workability mean it is great for both residential and commercial purposes. It is also a sustainable product, provided that natural gypsum is mined considerately. However, it is not the best material for heavy industrial applications or for moist environments. In these cases, cement board or plastics might be better. Importantly, gypsum isn’t dangerous to health like asbestos. However, care should still be taken when demolishing old walls with plasterboard as asbestos wasn’t banned until .
Gypsum, the naturally occurring mineral that makes up 90% of the drywall manufactured around the country, is getting a new lease on life, thanks to the growing popularity of drywall recycling. Reclaimed gypsum can be used in the production of new drywall, which means less new gypsum needs to be mined, saving our natural resources. However, there are many ways to use recycled gypsum that are far more significant.
Here are just some of the ways recycled gypsum is being used to improve crops, protect our environment, improve animal living conditions, revitalize contaminated industrial sites, and much more.
Gypsum has been used as a fertilizer to improve agricultural soil for more than 250 years, providing a moderately soluble source of calcium and sulfur that are essential to overall plant growth and increased crop yield.
Now, with the availability of recycled gypsum, it’s less expensive and more environmentally friendly than ever to use this valuable, naturally occurring mineral.
“Because gypsum solubilizes rather slowly, gypsum can provide continual release of sulfur to the soil for more than just the year it is applied. Use of gypsum as a sulfur fertilizer to enhance crop production in sulfur deficient soils has been proved for many crops such as corn, soybean, canola, and alfalfa.” – Gypsum as an Agricultural Amendment – Bulletin 945
Gypsum also provides beneficial calcium that improves crop production and prevents disease in many plants such as peanuts, watermelon, tomatoes and apples.
In addition to improving plant growth and increasing crop yields, recycled gypsum can also be used to condition the soil to improve conditions for optimal growth.
For example, sub-soil acidity can prevent plant roots from utilizing available nutrients and water in the soil, adversely affecting plant growth. Agricultural lime is often used to correct soil acidity and lower soil pH. But calcitic lime’s effectiveness is limited to the zone of incorporation.
Gypsum is often a better alternative to calcitic lime, since its solubility promotes greater penetration of the calcium throughout the soil, controlling acidic soil more effectively.
“Soil scientists note that this material [gypsum] is not only important as a source of sulfur and calcium, but it also may promote changes in soil structure that facilitates better water management and plant growth.” – Journal of ASFMRA
One of the biggest sources of pollution to our waterways and critical drinking water resources is nutrient runoff from agricultural fields. Nitrogen and phosphorous, commonly found in fertilizers and animal manure used to supply vital nutrients to crops, adversely affect the environment and threaten wildlife when they enter rivers, lakes and streams.
This environmental damage can be clearly seen, particularly in watershed areas such as the Maumee River watershed in Indiana and Ohio, where annual algae blooms have become the norm on Lake Erie. These conditions kill wildlife, introduce toxins into drinking water and disrupt economic growth in the surrounding areas.
While it is necessary to sustain fruitful and reliable agriculture, the need to safeguard our water resources is also a pressing problem that threatens our future. Fortunately, promising research is underway that could turn the tide, allowing farmers to continue supporting their livelihoods, while acting as responsible stewards of the land and the water.
A study is being conducted at Ohio State University to test the effects of using recycled gypsum as a soil amendment in the Maumee River watershed area in an effort to reduce the levels soluble reactive phosphorus (SRP) in the runoff water that enters area waterways.
The earliest results have shown a 55% reduction of SRP in runoff water in gypsum-treated plots of land, when compared with untreated plots. These findings show a significant potential to improve water quality in agricultural areas around the country from the Great Lakes to the Gulf of Mexico.
Data collected from drainage tiles on multiple farms in the Maumee River watershed
While recycled gypsum is already being used to improve soil quality on many farms, this research demonstrates the added environmental benefits of using gypsum to reduce SRP levels and preserve waterways and aquatic life, as well.
While gypsum’s solubility makes it the perfect mineral for increasing crop yields, conditioning soil and preventing toxic run-off, gypsum’s absorbency also makes it a great additive for animal bedding.
Organic materials, such as sawdust, shavings, straw and corn fodder are widely used as bedding materials for dairy cows. However, these materials often support conditions such as moisture, nutrients, and rich pH, which are ideal for pathogenic growth. Adding gypsum additives to dairy bedding keeps bedding dryer, while decreasing teat end exposure to environmental mastitis pathogens and reducing somatic cell counts. The result is healthier cows and safer milk production.
Gypsum additives are also useful in chicken houses to promote healthier chickens.
“Ammonia concentration, litter moisture and pH were significantly lower in the gypsum treatment than the shavings treatment at both 21 and 40 day of age. No differences in broiler performance, livability or paw score were observed” – University of Georgia, Athens, GA
Horse boarding facilities and equine enthusiasts can also benefit from using a gypsum additive in their horse bedding. Gypsum additives absorb, neutralize and trap ammonia odors, extending bedding life. Unlike other bedding additives, like lime, gypsum will not burn or crack horse hooves. In fact, gypsum additives are natural, non-toxic and safe for humans and animals. Gypsum additives also aid in composting manure and improve manure value.
Another useful application for recycled gypsum is in the area of soil remediation or stabilization in industrial sites such as hard rock mining, coal mining, smelting and refining and construction and mixed-contaminant areas.
Gypsum, combined with other soil amendments, can address a variety of soil issues including:
Gypsum is a great choice for soil remediation because it is inexpensive, non-toxic, safe to handle and relatively soluble.
To minimize the release of harmful chemicals from industrial waste sites, liquid waste if often converted into solids for proper storage or disposal. Due to its absorbent properties, gypsum powder is an ideal choice to convert semi-solid slurries that represent a significant volume of most waste. Recycled gypsum, in particular, is more absorbent and provides superior solubility when compared to mined gypsum products, for faster waste cleanup and remediation.
Recycled gypsum can be successfully substituted in many products that have traditionally used mined gypsum products. Cement and specialty ready-mix concrete manufacturers have already begun using recycled gypsum in many of their products. Recycled gypsum is also used in a wide range of plastics, caulks, adhesives, sealants and specialty cements.
Due to its lack of abrasiveness and inert properties, recycled gypsum is also an ideal filler or diluent for a variety of products including:
Recycled gypsum also improves fire retardancy, tensile strength and translucency of polymers, particularly thermoplastics, thermosets and coatings, while reducing production costs at the same time.
Cloudy or muddy water in ponds is not aesthetically pleasing and can be potentially dangerous. Muddy water reduces sunlight penetration which can be detrimental to aquatic life, by limiting food production for game fish and other animals. Cloudy water can also interfere with the ability of many species of fish to see and capture prey. Cloudy water conditions can also promote the growth of undesirable blue-green algae and bacteria.
The most common cause of cloudy ponds and lakes is the presence of suspended particles, mainly clay. Soil erosion, rain runoff, animal activity and the food-seeking actions of bottom-feeding fish like carp and bullheads can all contribute to suspended clay particles in ponds and lakes.
The addition of gypsum into muddy ponds helps to clarify the water by attracting clay particles together to form clumps. As the clay particles clump together, their weight increases and the clumps settle to the bottom. Since gypsum is a neutral salt, adding it to the water will not affect the pH of the pond or lake.
Recycled gypsum is an all-natural way to enhance compost, whether you’re a backyard gardener or a commercial composter. Gypsum naturally reduces nitrogen losses which improves compost aeration, increases heat, enhances microbial growth and reduces unpleasant odors. The addition of a gypsum additive also provides calcium, sulfur, nitrogen and trace minerals to the basic compost, making it more valuable.
Everyone wants the rich, green lawns they see on TV. But many of the products on the market, such as weed and feed or garden fertilizers, may not produce results homeowners expect because poor soil quality is the real problem.
The key to lush, green grass and blooming gardens is proper soil conditioning. Just as farmers use recycled gypsum to enhance crop growth and improve agricultural soil, the same techniques can be applied to residential lawns and gardens. The addition of recycled gypsum soil amendments loosens clay soils, naturally aerating soil and improving water and air penetration. This encourages the production of early roots. Recycled gypsum can also improve acidic, sodic or erosion-prone soil conditions.
Recycled gypsum soil amendments are cost effective and safe for pets, people and plants.
When you consider all the beneficial uses for recycled gypsum, it’s no wonder that recycled gypsum production is on the rise. The use of recycled gypsum not only preserves natural resources by reducing the need for additional gypsum mining. It also keeps waste drywall out of landfills and provides many ways to safeguard our environment, sustain our crops, and revitalize contaminated sites to provide additional resources for the future.
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