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CertainTeed Academy of Continuing Education
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INNOVATIONS IN RESIDENTIAL CONSTRUCTION USING ADVANCED GYPSUM PRODUCTSCOURSE NUMBER: BSS077
MITCHELL SCHITTLER - LEED AP® BD+C
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Questions related to specific materials, methods, and services will be addressed at the conclusion of this presentation.
AIA-Approved provider
3 / Presentation Title
CERTAINTEED IS A REGISTERED PROVIDER WITH THE AMERICAN INSTITUTE OF ARCHITECTS CONTINUING EDUCATION SYSTEM.
Credit(s) earned upon completion of this program will be reported to AIA CES for AIA members.
Certificates of Completion for both AIA members and non-AIA members are available at the CertainTeed Academy of Continuing Education.
This course is registered with AIA CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using, distributing, or dealing in any material product., METHODS, AND SERVICES WILL BE ADDRESSED AT THE CONCLUSION OF THIS PRESENTATION.
This course qualifies for HSW credit.
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4 / Presentation Title
1
USGBC-Approved provider
1
CertainTeed Corporation
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Copyright
This presentation is protected by U.S. and international copyright laws. Reproduction and distribution of this presentation without written permission of the sponsor is prohibited. CertainTeed Corp.
5 / Presentation Title
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Course Description
6 /
The majority of homes today use gypsum boards, panels, and compounds in a
multitude of ways. While gypsum has a long history of use in American
construction, changes in building codes and design, programs such as
USGBC’s LEED, and construction practices have generated a need for a suite of
specialized solutions. Participants who complete this course will be able to
identify the environmental human and health considerations related to the
selection of gypsum solutions, the types of gypsum boards available today and
where they are intended for use, how the level of gypsum finishing is evaluated
and communicated, as well as identify emerging IEQ technologies.
Continuing Education Course
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Learning ObjectivesAfter completing this presentation you should be able to:
1. Review the history of gypsum as a natural material and how it has become so widely used in residential construction.
2. Identify the manufacturing process of both natural and synthetic gypsum products and the sustainable attributes of the manufacturing process.
3. Investigate the full range of high performance gypsum products and the different finish levels that can all help contribute to green building design.
4. Assess the functional performance of gypsum products as they contribute to green and sustainable design in any residential building or project.
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A Rich History
GYPSUM - A SHORT HISTORYCaSO4 2H2O
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Ancient Egypt
A Rich History
Pyramid of Cheops
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1700sAncient Egypt
A Rich History
Ancient Egyptians used gypsum rock to create a plaster
of Paris-type mixture that was
used on the interior of the
pyramids due to its strength and
smooth finish.
Pyramid of Cheops
Plaster of Paris discovered
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17-1800sAncient Egypt
A Rich History
Ancient Egyptians used gypsum rock to
create a plaster of Paris-type mixture
that was used on the interior of the
pyramids due to its strength and smooth
finish.
The Plaster of Paris begins to be used as abuilding
material after being discovered by
French chemist Antoine Laurent
Lavoisier
Benjamin Franklin brings
to AmericaPyramid of
Cheops
Plaster of Paris
discovered
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1900s17-1800sAncient Egypt
A Rich History
Ancient Egyptians used gypsum rock to
create a plaster of Paris-type mixture
that was used on the interior of the
pyramids due to its strength and smooth
finish.
The Plaster of Paris begins to be used as abuilding
material after being discovered by
French chemist Antoine Laurent
Lavoisier
Benjamin Franklin picked up a French farming method of using gypsum as a
soil additive for better crop yields. Large deposits of
natural gypsum were also discovered in
America.
Pyramid of Cheops
Plaster of Paris discovered
Benjamin Franklin brings
to America
Sackett Board introduced
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WWI1900s17-1800sAncient Egypt
A Rich History
Ancient Egyptians used gypsum rock to
create a plaster of Paris-type mixture
that was used on the interior of the
pyramids due to its strength and smooth
finish.
The Plaster of Paris begins to be used as abuilding
material after being discovered by
French chemist Antoine Laurent
Lavoisier
Benjamin Franklin picked up a French farming method of using gypsum as a
soil additive for better crop yields. Large deposits of
natural gypsum were also discovered in
America.
Augustine Sackett patented “Sackett
Board,” layers of thin plaster of Paris
placed between wool felt paper. By the
1919 it is developed to the point of
resembling today’s gypsum board.
US Military housing uses
gypsumPyramid of
Cheops
Plaster of Paris discovered
Benjamin Franklin brings
to America
Sackett Board introduced
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1950sWWI1900s17-1800sAncient Egypt
A Rich History
Ancient Egyptians used gypsum rock to
create a plaster of Paris-type mixture
that was used on the interior of the
pyramids due to its strength and smooth
finish.
The Plaster of Paris begins to be used as abuilding
material after being discovered by
French chemist Antoine Laurent
Lavoisier
Benjamin Franklin picked up a French farming method of using gypsum as a
soil additive for better crop yields. Large deposits of
natural gypsum were also discovered in
America.
In response to World War I, the U.S.
Military starts rapidly building military housing units, dramatically
increasing the demand for gypsum board. This led to more streamlined manufacturing.
Gypsum board continued to increase in
popularity during WW2. With the post-
war economic boom of the 1950s,
nearly half of all new American
homes were built with gypsum wallboard.
Pyramid of Cheops
Plaster of Paris discovered
Benjamin Franklin brings
to America
Sackett Board introduced
US military housing uses
gypsum
Post WWII Housing Boom
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1960/70s1950sWWI1900s17-1800sAncient Egypt
A Rich History
Ancient Egyptians used gypsum rock to
create a plaster of Paris-type mixture
that was used on the interior of the
pyramids due to its strength and smooth
finish.
The Plaster of Paris begins to be used as abuilding
material after being discovered by
French chemist Antoine Laurent
Lavoisier
Benjamin Franklin picked up a French farming method of using gypsum as a
soil additive for better crop yields. Large deposits of
natural gypsum were also discovered in
America.
In response to World War I, the U.S.
Military starts rapidly building military housing units, dramatically
increasing the demand for gypsum board. This led to more streamlined manufacturing.
Gypsum board continued to increase in popularity during
WW2. With the post-war economic boom of the 1950s, nearly
half of all new American homes
were built with gypsum wallboard.
As cities began to build upwards in
the form of skyscrapers and
high rise buildings, lightweight gypsum
wallboards were preferred over
heavy masonry and concrete
counterparts.
Pyramid of Cheops
Plaster of Paris discovered
Benjamin Franklin brings
to America
Sackett Board introduced
Military housing uses gypsum
Gypsum expanded into
high rise commercial construction
Post WWII housing boom
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1980s1960/70s1950sWWI1900s17-1800sAncient Egypt
A Rich History
Ancient Egyptians used gypsum rock to
create a plaster of Paris-type mixture
that was used on the interior of the
pyramids due to its strength and smooth
finish.
The Plaster of Paris begins to be used as abuilding
material after being discovered by
French chemist Antoine Laurent
Lavoisier
Benjamin Franklin picked up a French farming method of using gypsum as a
soil additive for better crop yields. Large deposits of
natural gypsum were also discovered in
America.
Augustine Sackett patented “Sackett
Board,” layers of thin plaster of Paris
placed between wool felt paper. By the
1919 it is developed to the point of
resembling today’s gypsum board.
Gypsum board continued to increase in popularity during
WW2. With the post-war economic boom of the 1950s, nearly
half of all new American homes
were built with gypsum wallboard.
Lightweight gypsum
introduced
Paperless gypsum
developed
Pyramid of Cheops
Plaster of Paris discovered
Benjamin Franklin brings
to America
Sackett Board introduced
Military housing uses gypsum
Post WWII housing boom
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1990s1980s1960/70s1950sWWI1900s17-1800sAncient Egypt
A Rich History
Ancient Egyptians used gypsum rock to
create a plaster of Paris-type mixture
that was used on the interior of the
pyramids due to its strength and smooth
finish.
The Plaster of Paris begins to be used as abuilding
material after being discovered by
French chemist Antoine Laurent
Lavoisier
Benjamin Franklin picked up a French farming method of using gypsum as a
soil additive for better crop yields. Large deposits of
natural gypsum were also discovered in
America.
Augustine Sackett patented “Sackett
Board,” layers of thin plaster of Paris
placed between wool felt paper. By the
1919 it is developed to the point of
resembling today’s gypsum board.
Gypsum board continued to increase in popularity during
WW2. With the post-war economic boom of the 1950s, nearly
half of all new American homes
were built with gypsum wallboard.
Lightweight gypsum
introduced
Paperless gypsum
developed
Pyramid of Cheops
Plaster of Paris discovered
Benjamin Franklin brings
to America
Sackett Board introduced
Military housing uses gypsum
Post WWII housing boom
Synthetic gypsum begins
production
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A Rich History
HISTORY WORTH REPEATING
GYPSUM MANUFACTURINGNatural and Synthetic
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19 /
Rock is crushed into a powder is heated to about 350° F in a
process called calcining
Calcined gypsum is mixed with water and additives to form a
slurry that is fed between continuous layers of paper
Calcium sulfate recrystallizes back to its original rock state -
board is cut to length and conveyed through dryers
Natural Gypsum
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20 /
Flue-gas from power plants can be purified and refined into
gypsum using a process called flue-gas desulfurization (FGD)
Sulfur dioxide is passed through limestone in an air pollution control
scrubber tower with forced oxidation turning it into hardened calcium sulfate –
same compound as natural gypsum
Contributes to cleaner air and repurposes and diverts an otherwise useless material from landfills
Synthetic Gypsum
Synthetic gypsum used for gypsum wall board is non-toxic and safe, does not use fly ash or bottom ash and must meet stringent quality control standards.
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Today’s Standard Gypsum Board Products
21 /
The average home in the United States uses about 200 sheets of 4 feet by 12 feet board for walls and ceilings (approx. 8,500 – 9,000 square feet)
Regular ½”• Regular gypsum core• ¾ hour fire rating
Type X 5/8”• Added fiberglass increases natural fire
resistance• 1 hour fire resistance
Type C (5/8”)• Specially formulated core• Vermiculite minimizes shrinkage• 1 hour+ fire resistance
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Standard Boards with Enhanced Fire Protection
22 / Continuing Education Course
• Testing is not applicable to individual products
• Fire-resistance ratings apply to assemblies
• Assemblies: generic v. proprietary
• Type C can be substituted for Type X, but not Type X for Type C
• Type C assemblies are proprietary to manufacturers
• GA-600-2015: 6 assembly categories
Type X Type C
5/8” Thickness ½” or 5/8” thickness
1 hour fire rating Enhanced fire protection over Type X
Contains glass fibers Contain more glass fibers than Type X to remain more stable
Generic assemblies Proprietary Assemblies
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Specialty Gypsum Boards
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Moisture/Mold Resistant Gypsum Boards
24 /
• Used in bathrooms, basements, or where moisture resistance is needed
• Engineered with a chemistry to provide greater water resistance
• Core is moisture resistant
• A water resistant paper is used to prevent moisture from penetrating
• Additives are used to prevent the paper from being food for the growth of mold or mildew
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Glass-Mat Tile Backer
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• Protects the gypsum from deterioration and offers even greater resistance to mold and mildew
• Reinforced with a fiberglass mat instead of a paper facing
• Used in areas of high humidity, not for use in direct water exposure
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Acoustic Control Gypsum Board
26 /
• Two layers of gypsum board with a layer of "viscoelastic polymer"
• Use wherever there is a need to reduce noise in residence or between residences
• Outperforms other solutions: double-layer drywall, resilient channel, and insulation alone
According to the World Health Organization, excessive noise disturbs sleep, causes cardio-vascular disease and psychophysiological effects such as reduced performance, elevated irritability and changes in social behavior.
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Indoor Air Quality Gypsum Board
27 /
• There is now a gypsum board available that can capture formaldehyde in the air, break it down and remove from the environment
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Enhanced Durability Gypsum Board
28 /
Different manufacturers offer varying degrees of performance levels based on various ASTM tests Levels range from 1-3 with 3 being the highest level
Abuse Resistant Drywall• Designed to resist abrasion resulting from
the scraping of objects across the wall surface.
• Face paper is scuff and tear resistant
Impact Resistant Drywall• Built to handle impact from heavy objects
that could potentially puncture the surface of the wall.
• Fiberglass reinforcement provides resistance to soft and hard body impact
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Fun Facts
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Fun Facts
Mold and Moisture Resistant Drywall
BATHROOM
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Fun Facts
Acoustic Control Drywall
HOME OFFICE
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Fun Facts
Indoor Air Quality Drywall
NURSERY
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Fun Facts
Enhanced Durability Drywall
GARAGE
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Recommended Applications for SpecialtyGypsum Products
Room Recommendation Featured Product Additional Attribute
Bedroom, kitchen, living room and bathroom
Mold Resistant GypsumIndoor Air Quality GypsumGlass-Mat Tile Backer
Healthy Home
Bedroom, home office, media room and nursery Acoustic Control Gypsum Noise Control Solutions
Basements, garage and utility rooms
Type X & C Fire Resistant GypsumImpact ResistantAbuse ResistantHigh Impact Corners
Durability
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A Rich History
HISTORY WORTH REPEATINGINSTALLING AND FINISHING GYPSUM
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Industry Standards
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Level 0 Finish No tape, joint compound, corner bead or any other accessories.
Level 2 FinishTape is embedded in a layer of joint compound and then tooled with an additional thin layer of
joint compound.
Level 1 Finish Tape is embedded in a single layer of joint compound at all joints and
interior corners.
Level
0Finish
Level
1Finish
Level
2Finish
Level 0 - 2
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Level 3 - 5
Level 3 FinishTape is embedded and tooled with
an additional thin layer of joint compound (Level 2).
An additional coat of joint compound is then applied.
Level 4 FinishUsed where flat paints and lightweight wall
coverings will be applied over the wall surface. All tape, joints and fasteners and accessories shall be covered with three
layers of joint compound.
Level 5 FinishHighest level of finish and is used where semi-gloss, gloss, or other
non-textured paints are used and a thin skim coat of joint compound is applied to the entire surface of
the wall.
Level
3Finish
Level
4Finish
Level
5Finish
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A Rich History
HISTORY WORTH REPEATINGSUSTAINABILITY BENEFITS OF GYPSUM
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Sustainable Product Life Cycle
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Manufacturing• Gypsum core made up of 90 to 95 percent recycled or reclaimed gypsum• Paper facings are 100 percent recycled content
• More than 40 million cubic yards of paper diverted from landfills annuallyShipping• Products require minimal packaging reducing shipping waste and weightInstallation and Use• During installation, gypsum scrap can be collected, reused or recycled • Abrasion and impact resistant gypsum board and durability enhanced
corners helps extend useful lifeEnd of Life• Gypsum products can be recycled into new products or used as an agricultural
soil conditioner or concrete additive
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Synthetic Gypsum: A Cleaner Environment
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• Synthetic gypsum promotes the continued use of scrubber towers to keep the air clean
• Repurposes an otherwise useless material that would occupy landfills
• U.S. gypsum industry has diverted almost 8 million tons a year
• Currently, almost half of all of the gypsum used in the United States is synthetic FGD gypsum
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Indoor Environmental Quality
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• Sustainable programs seek to protect human health in indoor environments
• Materials and products that contain no, or low levels of, indoor air pollutants or toxic chemicals are preferred
• GREENGUARD and DECLARE look at materials and provide ratings
• Home owners and builders can request Health Product Declarations (HPDs) on products they install
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Green Building Certification Labels
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Transparency Documents: EPDs and HPDs
Environmental Product Declaration
Health Product Declaration
HPDs cover the human health impact of those same compounds and chemicals, but do not go into the manufacturing aspect.
EPDs describe the environmental impact of a product, and what compounds comprise that product.
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Indoor Environmental Quality Matters
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Healthy Home Solutions
Sound ControlSolutions
Gypsum has a long and proven history of contributing to green and sustainable construction
DurabilitySolutions
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Conclusions
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Gypsum products have evolved to include a full array of standard and high
performance offerings.
Building on its long history, gypsum is an integral part of most residential construction in North America.
Continuing Education Course
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Conclusions
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1. Design objectives can be met2. Construction can be enhanced3. Green building objectives can
be achieved4. Budgets can be controlled5. The quality of life for people
who reside in these buildings can improve.
By selecting products with the multi-attribute performance capabilities presented:
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Thank you for your participation
49 / Presentation Title
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50 / Presentation Title
Credit information
Your certificate of completion will be available at the CertainTeed Academy of Continuing Education continuinged.certainteed.com
You will receive an email with a link to access your certificate
If applicable, update your profile with your AIA number for reporting. Reporting is uploaded to AIA once a week.
Thank you for your attendance!
This concludes The American Institute Architects Continuing Education systems course
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