GYPSUM BOARD & GYPSUM WALL PUTTY
[CODE NO. 3713]
Gypsum Plaster Boards are constructional sheets composed of concined Gypsum with about 15% fibre. Its outstanding contributes are fire resistance, dimensional stability, easy workability and low cost fibres are added to provide crack resistance and for fire resistance water repellent chemicals may be added to the board core.
The various sources of gypsum in India when developed will yield in addition to high grade gypsum. According to the present knowledge the latter has prospect of economic use as building materials, namely plaster, plaster boards and block. Gypsum plaster boards can be used as covering for walls ceilings and partition in normally by environments and under controlled conditions of humidity and temperature in buildings.
Gypsum plaster boards are selected for use according to their type, size, thickeners and edge profit. The Boards may be used for example to provided dry lining finishes to masonry walls, to ceilings, to steel or timber framed partitions, or as claddings to structural steel columns and beams, or in the manufacture of pre-fabricated partition panels.
The boards may be fixed by nailing, screwing, or sticking with gypsum based or other adhesives. They may also be inserted in lay-in grids and/or secured by clips.
The manufacture of gypsum wall board originated in vision the early 1800's and has science spread to all highly industrialized Engineers of the work. The earliest Gypsum Board was known to the trade as plaster boards because it was intended or use as a base for plastering. In the 1820's gypsum board in large sheets and with an improved surface finish was brought to market, permitting direct application of decorative finishes without plastering.
COST ESTIMATION
Land & Building (3500 sq.mt.) Rs. 9.78 Cr
Plant & Machinery Rs. 8.30 Cr
Working Capital for 1 Month Rs. 2.80 Cr
Total Capital Investment Rs. 21.13 Cr
Rate of Return 30%
Break Even Point 51%
INTRODUCTION
WALL PUTTY
USES AND APPLICATION OF GYPSUM BOARD
USES AND APPLICATION OF WALL PUTTY
SPECIFICATIONS OF GYPSUM BOARD
SCOPE
TERMINOLOGY
TYPES
MATERIALS
MANUFACTURE OF GYPSUM PLASTER BOARD
EDGE AND END PROFILES
REQUIREMENTS
DIMENSIONS OF GYPSUM PLASTER BOARDS
TOLERANCE
THE TOLERANCE ON DIMENSIONS SHALL BE AS GIVEN BELOW:-
TRANSVERSE STRENGTH
WATER ABSORPTION
TESTS
BREAKING LOAD OF GYPSUM PLASTER BOARDS
MEASUREMENT OF TAPER PROFILE
TAPER WIDTH
TAPER DEPTH
SAMPLING AND CRITERIA FOR CONFORMITY
SALE OF SAMPLING
FINISH
PACKING AND MARKING
MAIN CONFIGURATION
TYPICAL PROCESS OF MANUFACTURING GYPSUM BOARD
1. RAW MATERIALS
2. CRUSHER
3. GRINDING MILL
4. CALCINE SYSTEM
5. STUCCO HOLDING TANK
6. MIXER
7. FORMING STATION
8. BOARD LINE
9. CUT-OFF KNIFE
10. TRANSFER TABLE
11. KILN
12. BUNDLER AND STACKER
PROCESSING CHART
DOSING SECTION
FORMING SECTION
CUTTING AND DRYING SECTION
EDGE TRIMMING AND STACKING SECTION
GYPSUM BOARD PRODUCTION LINE PICTURES
FORMING DEVICE
RUBBER BELT CONVEYOR AND DRYING ROOM
BLANK ROLLER CONVEYOR AND PRINTER
TRANSFERRING CONVEYOR
DISTRIBUTOR
AIR BLOWER
ELECTRICAL CABINET
B. I. S. SPECIFICATIONS
OVERVIEW OF INDIAN CONSTRUCTION INDUSTRY
STRONG GROWTH FOR INDIAN CONSTRUCTION INDUSTRY
MARKET SURVEY
EXPORT DATA OF GYPSUM BOARD
IMPORT DATA OF GYPSUM BOARD
IMPORT DATA OF WALL PUTTY
PRODUCTION OF GYPSUM BOARD
ESTIMATED DEMAND
MARKET OVERVIEW OF GYPSUM BOARD IN INDIA
CONSTRUCTION DEVELOPMENT FDI INFLOW IN USD BILLION IN
INDIA (2013-2018)
GLOBAL MARKET OF GYPSUM BOARD
U.S. GYPSUM BOARD MARKET REVENUE BY PRODUCT, 2014 - 2025
(USD MILLION)
MAURITANIA EXPORTED 100,000T OF GYPSUM IN 2017
GICA IN TALKS TO EXPORT GYPSUM FROM ALGERIA
GLOBAL WALL PUTTY MARKET
RAW MATERIALS
1. ALBASTER
2. SELENITE
3. SATIN SPAR
4. ANHIDRITE
5. GYPSITE
CHEMISTRY OF THE PROCESS & PHYSICAL PROPERTIES
STEP 1 - PLASTER OF PARIS MANUFACTURE
STEP 2 - REHYDRATION
SOME OF THESE ADDITIVES ARE LISTED IN TABLE 1.
PLASTER BOARD PRODUCTION
STEP 3 - SETTING
ROLE OF THE LABORATORY
ENVIRONMENTAL IMPLICATIONS
PRESENT MANUFACTURERS/EXPORTERS OF GYPSUM BOARD
OFFICE OF THE DEVELOPMENT COMMISSIONER (SSI)
SEQUENCES IN GYPSUM BOARD MAKING
MANUFACTURING PROCESS OF GYPSUM BOARD
FOLLOWING ARE THE MAJOR STAGES IN PRODUCTION GYPSUM
PLASTER BOARDS.
1. PREPARATION OF RAW MATERIALS
2. CALCINING OF GYPSUM
3. PREPARATION OF PASTE
4. MOULDING IN THE FORM OF BOARDS
5. DRYING OF BOARDS
PROCESS FLOW SHEET
FORMULATION OF GYPSUM WALL PUTTY
FORMULATION OF GYPSUM BOARD
DETAILS OF GYPSUM PROCESSING
MANUFACTURING PROCESS OF DRY WELL
BLENDING OF ADDITIVES
MAKING THE SANDWICH
FINISHING THE EDGES
CUTTING THE PANELS
THE DRYING PROCESS
THE FINISHED PRODUCT
MIXING METHOD OF WALL PUTTY
MANUFACTURING PROCESS OF GYPSUM WALL PUTTY
PROCESS FLOW DIAGRAM OF GYPSUM WALL PUTTY
LIGHTWEIGHT GYPSUM BOARD
CONTINUOUS PRODUCTION OF GYPSUM BOARD
A. PRODUCTION OF FIBROUS STUCCO
PLANT LAYOUT
RAW MATERIALS CALCULATION FOR GYPSUM BOARD CAP: 5000 NOS/DAY
RAW MATERIALS CALCULATION FOR GYPSUM PUTTY
CAP: 20 MT/DAY
SUPPLIERS OF RAW MATERIALS
GYPSUM
FOAMING AGENT
ACCELERATORS
COMPLETE PLANT SUPPLIERS ON TURNKEY BASIS
SUPPLIERS OF PLANT AND MACHINERY (INDIAN)
CONVEYOR BELT
BUCKET ELEVATOR
VERTICAL SHAFT KILNS
BOILERS
STORAGE TANKS
BALL MILL SUPPLIERS
SUPPLIERS OF PLANT AND MACHINERY (FOREIGN
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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