mcgrace environmental friendly gypsum blocks

McGrace Automation & Projects Pvt. Ltd.

1305, CIRCULAR ROAD, CIVIL LINES SOUTH, MUZAFFARNAGAR - 251002, UP, INDIA

ENVIRONMENTAL · FRIENDLY GYPSUM BLOCKS

(A Substitute or Replacement of Concrete Blocks)

INTRODUCTION

Gypsum Blocks are flat rectangular in shape, with vertical & horizontal edges respectively tongue and groove,divided into two categories - Solid Blocks and Hollow Blocks.

According to international standards, gypsum block length should not exceed 700 mm, and block area shouldmeet not less than 0.25 M2 with a thickness ranging from 60 to 150 mm.

Recommended Block Size is Length - 666 mm, Height - 500 mm and Thickness - 80 mm (Solid Block), 100, 120& 150 mm (Hollow Block). 100 mm thick hollow blocks are mostly used as internal partition wall.

APPLICATIONGypsum Block is used for main frame and other structural construction of the non-load bearing walls, but, canbear utilities loads such as Kitchen Cabinets, Water Heaters, and Bathroom Appliances etc. with specialadditives, the gypsum blocks can be used in the bathroom, toilet and at wet places.

Corporate Identity Number: U72300UP2012PTC053988, TEL: +91-131-2620120



ENVIRONMENTFRIENDLY(GreenProduct)Gypsum is a noncombustible material by nature used as binder, which, compared with other material as Limeand Cement, can be considered much less aggressive to the ENVIRONMENT. During process of production,Cement and Lime emits C02 whereas Gypsum emits molecules of water in the atmosphere. Also Production ofCement and Lime requires a very high temperature compared to Gypsum (only 150 degree C).

Gypsum Blocks being light in weight with properties like fire safety, seismic, thermal insulation, soundinsulation, regulating indoor humidity and 100% recyclable leads to environmental protection and energyconservation, which makes it a GREEN PR0DUCT.

COSTSAVINGADVANTAGES

• Easy Construction

• Dry Construction

) Water consumption is reduced by more than 70% compared to Concrete Blocks masonry.

• Reduced Work Time & Man Power Cost

) Plastering is not required, painted directly.

) Quick installation

) Work flexibility is enhanced as can be hand sawn at site makes easy for electrical and waterconduits laying.

) Clean site - Reduced manpower for housekeeping.

• Light Weight

) Dead load is reduced, therefore, Less Reinforcement.


) Bulk density 600 - 900 Kg per M3 compared to concrete blocks (2000 Kg per M3).

Concrete Blocks (13 Blocks per M2)

) Tongue and Grooved Gypsum Blocks with 3 Block per M2 allow quick installation compared to



PERFORMANCEADVANTAGES

• Fire Proof

) 3 Hrs Passive Fire Protection compared with Concrete Blocks (1 Hr PFR).

) Does not release any harmful volatile organic compound matters.

• Thermal Resistance

) Small thermal conductivity (0.109WImk), therefore, Energy saving building material comparedwith Concrete Blocks.

• Acoustic Resistance

) Average acoustic resistance for single layer is 41 dB STC, using double layer of 80 mm thickgypsum block with 40 mm mineral wool the sound insulation index can reach up to 55dB.

• High Strength

) Compressive strength as 5 MPa, able to withstand crushing of 30 Kg sandbag from a height of

0.5 mtrs for min 3 times.

• Respiration

) Absorbs moisture under wet room condition and releases moisture under dry condition,therefore, maintains suitable humidity for living which is not possible with Concrete Blocks.

• Electric - Magnetic Radiance Absorbance

) Absorbs radiance produced from electrical appliances and does not generate any staticelectricity.




PERFORMANCE SPECIFICATION

S/N Description Properties & Performance1 Format 666 mm x 500 mm (3 blocks = 1 m2 )2 Thickness 80 mm Solid & 80, 100, 120 & 150 mm Hollow3 Dimensions Tolerance Length : ± 3 mm, Height : ± 2mm, Width : ± 1 mm

4 Weight80 mm - 68 kgIm2 ± 2 kg100 mm - 85 kg I m2 ± 2 kg120 mm - 102 kg I m2 ± 2 kg150 mm - 127 kg I m2 ± 2 kg

5 Color White

6 Surface Appearance Smooth : Tolerance ± 1 mm (No plastering and slimcoat required on the gypsum block wall)

7 Physical Appearance Rectangular solid 8lock8 Construction Joint All 4 Side with Tongue & Groove

9 Fire Rating - (8S476-part22) 180 MIN. FRP

10Sound Insulation8S EN ISO 140-3:1995 41d8 STC

11Crowd Pressure8S5234 - Part 2:1992 2 kNIm

12Impact Energy8S5234 - Part 2:1992

120 Nm

13Anchor Pull Down8S5234 - Part 2:1992

250 N OR >2.36 kN

15Anchor Pull Out8S5234 - Part 2:1992 >1.4 kN

16Compressive StrengthCS1 : 1990 Section 15 (AMD 1201, 1203, 1205) 5 MPa

17Transverse Strength8S6073 - Part 1:1981 (AMD 4462) > 1.5 N I mm2

18 Max. Partition Height 5 MTR

19 Bonding Agent Gypsum based adhesive

CONSTRUCTION OF PARTITIONS FROM GYPSUMTONGUE-AND-GROOVE BLOCKS.

• Before erection of the partition it is necessary to remove dust and dirt from the wallsFloor and ceiling. Make the markings of the designed partition on the floor.

• By means plumb, transfer the marking on the ceiling and walls, mark theposition of the doorways. If the floor has humps or pits, should be appliedleveling layer of the Gypsum mortar. Finally will be obtained planehorizontal surface.




• To prepare the gypsum mortar. Ready mortar powder dissolve in the water while Mixing.Leave for some time for few minutes and mix to achieve a consistence of the "thick cream".

• Apply gypsum mortar on the floor and walls.There are two methods of contiguity to thebuilding Envelope, rigid and elastic. In case ofrigid continuity the gypsum blocks are to befixed to the building Envelope directly throughgypsum mortar.

• In case of flexible contiguity between partitionand main walls it should be applied elastic pad forsound Insulation. The elastic pad must be fixed onthe Contiguity joints with gypsum mortar (glue). Toregulate Horizontality of the elastic pad by meansof regulating the mortar thickness under pad. Leavethe mortar to dry and begin the partition erection.

Before the wall is erected, a cement sand curb is placed on concrete floor for the erection. Thereason for that is if the wall is directly sitting on the concrete floor, it will absorb water duringconstruction stage thus becoming soft.




•Gypsum blocks may be installed as the groove upnot as the tongue up. Always the preferable installationis the groove up, because in Grooves the gypsummortar (Glue) is evenly distributed in the joint and toreach this it is necessary to remove the tongue of theblock to make it a flat surface at the bottom for properinstallation.

• Glue used for the block work should be themortar of the gypsum base - hemihydrates and causticLime with retarder & additives. The same mortar isalso used for joint covering. The blocks of the first rowshall be installed on the cork or elastic pad coveredwith gypsum mortar. By means of level, first andsubsequent rows must be leveled correctly.

• During installation of the upper row gypsummortar (glue) is to be applied into the groove of theLower row. Additionally the gypsum mortar (glue) Shouldbe applied into the vertical groove

• Every block should be stabilized with rubber hummer.

• The mortar (glue) coming out from the joints must beremoved. Recommended thickness of the joints is 2 mm.




• Every row should be controlled with level in order tokeep verticality and planarity of the partition.

• The alternation of the vertical joints is to be respected.Joint alteration in block work gives a partition maximalrigidity. The gypsum blocks are very easy to cut by means ofhandsaw with big cogs or by means of electric cutter or saw.

• The last row blocks adjoined to the ceiling must bechamfered. In case of necessity it is possible to cut offthe blocks accordingly with configuration of the ceiling.Normally the blocks must be installed horizontally (onthe bigger side), but the Blocks of the last row may beinstalled vertically in order to minimize waste. Thevertical joints between blocks must be alternated.

The gap between blocks and ceiling or walls is to be filledup with gypsum basis putty (glue).




• In case of flexible contiguity, the blocks must be fixed to the building envelope bymeans special clamps with certain interval between clamps. The clamps are to beinstalled into the groove of the Block and fixed by means self-tapping screw to theblock and by means anchors to the building envelope.

• At the corners and intersections between partitions, the joints must be alternated. Thealternated joints stiffen partitions. (For altered joints check the pic. below)




• If by any reason the partition has concavity or lumps finishing is necessary. The con-caves must be covered with gypsum based putty by means of 20-30 cm wide spattle.Lumps are simply removed by means of smoothing plane. After the drying of the puttythe joints and all surface is to be smoothed. Finally will be obtained a plane and perfectsurface without any concavity or lumps.




• This is a loading test. Two screws which are fixed at the joint of the wall are hanginga bag of cement of 50 Kg weight for 10 days and the wall remains intact after 10 daysafter the end of the test.

McGrace Automation & Projects Pvt. Ltd.1305, CIRCULAR ROAD, CIVIL LINES SOUTH, MUZAFFARNAGAR ‐251002, UP. INDIATel: +91‐131-2620120, +973-33100178.Email: [email protected], [email protected]: www.mcgraceprojects.com


mcgrace environmental friendly gypsum blocks

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