Gypsum & Gypsum Products: Their Science & Technology

Cover
Half Title
Title Page
Copyright Page
Table of Contents
Preface
Acknowledgements
1. About Gypsum
1.1 The History of Gypsum and Gypsum Plaster
1.1.1 Minoans to the Romans
1.1.2 Gypsum in the Middle Ages
1.1.3 The Gypsum Plaster in Baroque and Rococo Period
1.1.4 Gypsum in Modern Times
1.2 The CaSO4.H2O Crystal System
1.2.1 Phases
1.2.2 Laboratory Synthesis
1.2.3 Industrial Dehydration of Gypsum
1.2.4 Energy Aspects
1.2.5 Structure, Isomorphism, Mixed Compounds and Solubility Structure
1.3 Calcium Sulfate
1.4 Adducts
1.5 Solubility
1.6 Occurrence and Raw Materials
1.6.1 Gypsum and Anhydrite Availability
1.6.2 Gypsum in India
1.7 By-Product Gypsum
1.8 Flue-Gas Gypsum
1.8.1 Phosphogypsum
1.8.2 Fluorogypsum/Fluoroanhydrite
1.8.3 Other Variety of By-product Gypsum
1.9 Production
1.9.1 Natural Gypsum to Calcined Products
References
2. Production of Calcined Gypsum or Gypsum Plaster
2.1 Historic Background of Use of Gypsum Plaster
2.1.1 Conservation and Rehabilitation of Structures with Plaster
2.2 β-Hemi hydrate Plasters
2.2.1 Rotary Kiln Process
2.2.2 Kettle Process
2.2.3 Continuous Type Gypsum Kettles (Horizontal/Conical Kettle Types)
2.3 Anhydrous and Multiphase Plasters
2.3.1 Alpha Hemihydrate
2.3.2 Process Control Parameters
2.4 Calcined Products from By-product Gypsum
2.4.1 β-Hemihydrate and Multiphase Plasters
2.4.2 Methods of α-Hemihydrate Plaster
2.5 Z-Gypsum Plaster
2.6 Anhydrite Plaster
2.7 Medical Plasters
2.7.1 Dental Plaster
2.7.2 Bandage Plaster
2.7.3 Surgical Plaster
2.8 Plaster of Paris for Ceramic Industries
2.9 Properties of Gypsum Plasters and Products and Anhydrite Plasters
2.9.1 Hydration, Setting and Hardening
2.9.2 The Assessment of Plaster
References
3. By-Product Gypsum
3.1 By-Product Gypsum
3.1.1 Waste Phosphogypsum
3.1.2 Fluoroanhydrite/Fluorogypsum
3.1.3 By-product Gypsum from Different Sources
3.2 Details of Phosphogypsum
3.2.1 Characterization of Phosphogypsum
3.2.2 Beneficiation of Phosphogypsum
3.3 Role of Phosphogypsum Impurities on Compressive Strength and Microstructure of ß-Hemihydrate/Selenite Plaster
3.3.1 Morphology and Physical Characteristics of Selenite and Phosphogypsum Plasters
3.3.2 Combined Effect of Phosphatic Compounds with and without Organic Matter on the Selenite Plaster
References
4. Gypsum in Cement Industry
4.1 Manufacture of Cement
4.2 Effect of Phosphogypsum (Unprocessed) on the Properties of Portland Cement
4.2.1 Effect of Phosphates, Fluorides and Organic Matter
4.2.2 Retarding Mechanism of Water-Soluble Phosphates and Fluorides
4.2.3 Effect of Phosphates, Fluorides, and Organic Matter on the Compressive Strength of Cement
4.2.4 Effect of Beneficiated Phosphogypsum on Properties of Portland Cement
4.2.5 Studies on Heat of Hydration
4.3 Effect of By-product Gypsum on Hydration and Strength of Blended Cements
4.4 Influence of Blended Gypsum on the Properties of Portland Cement and Portland Slag cement
4.4.1 Energy Saving
References
5. Use of By-Product Gypsum in the Production of Super Sulphated Cement
5.1 Raw Materials
5.1.1 Phosphoanhydrite
5.1.2 Granulated Blast Furnace Slag
5.1.3 Cement Clinker
5.2 Preparation of Super-sulphated Cement, Concrete and its Assessment
5.2.1 Concrete Making Properties of SSC
5.2.2 Effect of Temperature on Hydration of SSC
5.2.3 Grind-ability of Slag and Cement Clinker
5.2.4 Heat of Hydration
5.3 Phosphoanhydrite
5.4 Granulated Blast-Furnace Slag
5.4.1 Bulk Density, Glass Content and Refractive Index of Slags
5.4.2 Cement Clinker
5.5 Evaluation of Super-sulphated Cement
5.5.1 Properties of Super-sulphated Cement
5.5.2 Concrete Making Properties
5.5.3 Effect of Temperature on Hydration of SSC
5.5.4 Grind-ability of Slag and Clinker
5.5.5 Heat of Hydration
5.6 Use of Fluorogypsum in Making Super-sulphated Cement
5.6.1 Materials and Methods
5.6.2 Preparation of Super-Sulphated Cement, Concrete and its Assessment
5.6.3 Concrete Making Properties of SSC
5.6.4 Effect of Temperature on Hydration of SSC
5.6.5 Properties of Super-Sulphated Cement
5.6.6 Concrete Making Properties
5.6.7 Effect of Temperature on Hydration of SSC
5.6.8 Heat of Hydration
5.7 Super-sulphated Cement through Activation of β-Hemi-hydrate Plaster (CaSO4.½ H2O)
5.7.1 Raw Materials
5.7.2 Preparation of Super-sulphated Cement (SSC)
5.7.3 Properties of SSC
References
6. Gypsum Building Products
6.1 Water-Resistant Gypsum Binder
6.1.1 Production and Properties of Gypsum Binder
6.1.2 Hydration Mechanism of Water-Resistant Gypsum Binder
6.2 Durability of Gypsum Binder
6.2.1 Effect of Outside Exposure on the Gypsum Binder
6.2.2 Performance of the Gypsum Binder in High Atmospheric Temperature and High Humidity
6.2.3 Water Absorption of Gypsum Binder
6.2.4 Efflorescence Studies on Gypsum Binder
6.3 Suitability of Gypsum Binder for Masonry Mortars
6.3.1 Compressive Strength
6.3.2 Bond Strength
6.3.3 Water Retaining Capacity
6.3.4 Predesign, Cost Estimates for the Production of Gypsum Binder
6.4 Masonry Cement from Phosphogypsum
6.5 Gypsum Plaster Boards
6.5.1 Production of Fibrous Gypsum Plaster Boards
6.5.2 Raw Materials
6.5.3 Properties of Fibrous Plaster Boards
6.5.4 Thermal Conductivity
6.5.5 Predesign, Cost Estimates for the Production of Fibrous Gypsum Plaster Boards
6.5.6 Casting of Large Size Plaster Boards
6.6 Glass Reinforced Gypsum Binder Composites
6.6.1 Microstructure at the Interface
6.6.2 Durability of Glass Fibre
6.6.3 Gypsum Fibre Board
6.7 Gypsum Bonded Particle Board
6.7.1 End-use Characteristics and Applications for Gypsum Bonded Particle Boards
6.7.2 Gypsum Door Shutters
6.8 Gypsum Blocks
6.8.1 Casting of Large Size Blocks
6.8.2 Gypsum Bricks
6.8.3 Prefabricated Gypsum Building Components
6.8.4 Water Proof Gypsum Cabinet
6.8.5 Polymerized Gypsum
6.9 New Plaster Compositions from Gypsum
6.9.1 Development of Multiphase Plaster
6.9.2 Applications of Multiphase Plaster
6.9.3 Waste Gypsum from Intermediate Dye Industries
References
7. Anhydrite Plaster Based Building Products
7.1 Preparation of Phosphonahydrite
7.1.1 Properties of Anhydrite Plaster
7.1.2 Physical Testing and Evaluation of Anhydrite Cement/Plaster
7.1.3 Assessment of Anhydrite Plaster
7.1.4 Hydration Mechanism of Anhydrite
7.1.5 Microstructure of Hydrated Anhydrite
7.1.6 Effect of Temperature
7.1.7 Uses of Phosphogypsum Anhydrite in Construction Works
7.2 Polymerised Anhydrite Plaster for Use in Flooring Composition
7.2.1 Methodology
7.2.2 Production of Anhydrite from Phosphogypsum
7.2.3 Preparation of Flooring Tiles
7.2.4 Properties of Phosphoanhydrite and Its Hydration
7.2.5 Hydration of Anhydrite in Presence of Polymer
7.2.6 Properties of Flooring Tiles
7.2.7 Durability of Phosphogypsum Tiles
7.2.8 Techno-economic Feasibility
7.2.9 Newer Applications of Polymerised Gypsum
7.3 Phosphogypsum Based Water-Resistant Anhydrite Binder
7.3.1 Durability of Phospho Anhydrite Binder
7.4 Utilization of By-product Fluorogypsum
7.4.1 Beneficiation of Fluorogypsum
7.4.2 Preparation of Gypsum Binder/Plaster
7.4.3 Properties of Fluorogypsum Plaster/Binder
7.4.4 Water Absorption and Porosity of Fluorogypsum Binder/Plaster
7.4.5 Effect of Lime Sludge on the Fluorogypsum Binder Produced by Blending Activators
7.4.6 Development of Bricks from Fluorogypsum Binders
7.5 Fluorogypsum Based Cementitious Binders
7.5.1 Preparation of Cementitious Binders
7.5.2 Durability of Cementitious Binder
References
8. Rapid Wall Gypsum Panels/Gypcrete
8.1 Rapid Wall Panels for Buildings
8.2 Rapid Wall Panels
8.3 Residential Buildings Using Rapid Wall Panels
8.3.1 Low Cost Mass Housing
8.4 Manufacture of Wall Panels in India
8.4.1 Production of RWP
8.4.2 Manufacture of Gypsum Plaster
8.5 Characteristics of RWP
8.5.1 How Gypcrete buildings will be able to resist earthquakes better compared to conventional load bearing brick/concrete block construction?
8.5.2 Protection against Corrosion
8.6 Rapid Wall Panels for Use in Rapid Construction
8.6.1 Rapid Construction Method
8.6.2 Joints
8.6.3 Concrete Infill
8.6.4 Embedded RCC tie Beam All Around at Each Level Floor/Roof Slab
8.6.5 Rapid Wall for Floor/ Roof Slab in Combination with RCC
8.6.6 Finishing Work
8.7 Concluding Remarks
References
9. Radioactivity in Gypsum
9.1 European and National Regulations of Natural Radioactivity of Building Materials
9.2 Industrial By-products Incorporated in Building Materials
9.3 Radon Emanation from Building Materials and Regulations
9.4 Radiation in Waste Gypsum
9.4.1 Radiation Exposures in Phosphogypsum Disposal Environment
9.5 Dissolution Characteristics of 226Ra from Phosphogypsum
9.5.1 Collection of Phosphogypsum Samples and Methodology
9.5.2 Leaching Performance of Phosphogypsum
References
10. Market Potential Assessment of Gypsum Industry
10.1 Market Potential Assessment
10.2 Markets Trend and Consumption
10.2.1 Top Producers
10.2.2 Technology Trends
10.2.3 Products Trends
10.3 Chemical Gypsum
10.3.1 Phosphogypsum
10.4 Premixed Lightweight Gypsum Plasters
10.4.1 Vermiculite Plasters
10.5 Properties and Uses of Perlite
10.5.1 Perlite
10.5.2 Analysis of Perlite
10.5.3 Properties of Ready-Mix Gypsum - Perlite Plaster
10.5.4 Advantages
10.5.5 The Filling Compound for Dry Perlite Mixes
10.5.6 Advantages of Perlite Dry Mixtures
10.5.7 Heat-Insulating Mixes, Method of Application
10.5.8 Applications of Expanded Perlite in Gypsum Products
10.6 Agricultural Uses of Phosphogypsum and Gypsum
10.6.1 Phosphogypsum
References
11. Standardisation of Gypsum and Gypsum Products
11.1 Types of Gypsum
11.1.1 Mineral Gypsum
11.1.2 By-product Gypsum
11.2 Aims of Study
11.2.1 Standards Specifications for Gypsum
11.2.2 Indian Standards Specifications for Gypsum for Various Uses
11.3 Indian Standards Specifications for Plaster of Paris for Ceramic Industries (IS : 2333–1992)
11.4. Requirements of Gypsum Building Plaster (IS : 2547–1976)
11.5 American Standards Specifications
11.6 Specifications of Various Types of Gypsum Consumed in Cement Industry
11.7 Global Trends of Gypsum
References
Index