Gypsum concrete blocks – main characteristics and areas of application

Due to their ease of use and versatility, Gypsum concrete blocks are becoming a popular choice in modern construction. These blocks are ideal for a variety of building applications because they combine the strength of concrete with the light weight and flexibility of gypsum.

Gypsum concrete blocks provide a practical and efficient solution for building external walls, interior partitions, or even decorative features. They are renowned for their superior fire resistance, superior acoustic and thermal insulation, and ecologically friendly makeup.

In this post, we’ll go over the essential features of gypsum concrete blocks and talk about when and how to use them in building projects. When organizing your next building project, having a thorough understanding of these factors will help you make wise choices.

Main Characteristics Areas of Application
Lightweight and strong Internal and external walls
Good thermal insulation Energy-efficient buildings
Fire-resistant Fireproof construction
Soundproofing Partitions and sound barriers
Eco-friendly Residential and commercial buildings

Main characteristics of gypsum concrete

This concrete is referred to as gypsum concrete because gypsum serves as the primary binder in its production, and the end products made from it are gypsum concrete panels or blocks.

Although they are not very strong, their low weight and excellent heat and sound insulation make them popular for use in interior partition construction.

The molding mass in the manufacture of gypsum concrete products is diluted with various fillers of organic and inorganic origin. This results in lower consumption of the main gypsum binder and reduces the deformation of blocks during drying.

Fillers weaken the mechanical strength of gypsum concrete blocks and slabs, which is why they are typically used as internal partition structures and as a heat-insulating material in situations where there is no particular load.

Organic fillers

The following materials are suitable for use as an organic filler inside the body:

  1. Wood shavings;
  2. Wood wool;
  3. Sawdust;
  4. Cellulose;
  5. Straw;
  6. Shives;
  7. Peat;
  8. Straw;
  9. Reed.

When compared to inorganic filler, gypsum concrete products with organic filler have substantially less mechanical strength under compressive loads. The thermal performance is better, though.

The elasticity and impact resistance indicators are much higher when wool, paper, or shavings are used. These materials take a lot longer to dry and don’t have soundproof properties that make them appropriate for use in interior partition construction.

Inorganic fillers

Inorganic filler-filled blocks are stronger:

  1. Sand;
  2. Ash;
  3. Slag;
  4. Pumice;
  5. Tuff;
  6. Expanded clay crushed stone;
  7. Expanded clay gravel.

These gypsum concrete products have better mechanical and physical qualities. The addition of inorganic fillers to gypsum concrete improves its resistance to weathering while marginally lowering its mechanical strength.

Because using crushed stone or gravel as a filler can result in fragile products with poor heat-insulating qualities, fillers with rough surfaces—such as slag, pumice, tuff, and expanded clay—are used to improve the adhesion of the gypsum binder in the production of gypsum concrete blocks and panels.

  1. Fuel slag for the production of high-quality gypsum concrete products should not contain impurities (earth, stones, chips, quicklime) and be clean. Unburned coal particles should not be more than 20% of the slag volume. Before using slag for gypsum concrete production, it is kept outdoors for 2 months or more.

The dimensions of the manufactured product determine the size of the filler particles. The primary requirement is that the substance’s fragments be entirely submerged in the solution.

Slag is prepared by removing dust and particles smaller than 2 mm that contain coal particles that haven’t burned. It is considered that the proportion of slag particles smaller than 5 mm should not be more than 30% of the filler volume overall;

  1. High-quality gypsum concrete products are obtained using such a filler as pumice.

Because of the filler’s high porosity and lack of harmful impurities, gypsum concrete has enhanced thermal insulation properties and is considered an environmentally friendly material.

  1. When adding volcanic tuff filler, gypsum concrete products acquire a higher volumetric weight.

The table in the image below illustrates the general makeup of gypsum concrete.

The molding method is used to produce gypsum concrete products.

The mass that is utilized to produce gypsum concrete products can have the following consistency:

Products can be molded in a number of ways:

  1. The casting method is typical for products consisting of pure gypsum material of liquid consistency. Its distinctive feature is high productivity and low labor intensity;

  1. The vibration molding method is based on rigid and semi-rigid pure gypsum masses or those with slag filler. This method is the most cost-effective, since there is an economical consumption of the binder, and its drying requires less fuel;
  2. The pressing molding method is characterized by the use of a mass with a small amount of moisture in its composition;
  3. The clotting molding method allows for the production of more durable gypsum concrete products than with the casting method.

A manufacturing facility for gypsum concrete goods, comprising of the following: 1 dosing device, 2 gypsum concrete mixer, 3 receiving surface, 4 rolling mill, 5 waste removal unit, 6 overrunning roller table, and 7 edging product table

The primary technological requirement for any gypsum mass, whether it contains fillers or not, is that all of its constituent parts be thoroughly mixed with water.

  • During this process, gypsum particles are abundantly wetted with water, increasing their hydration (the process of adding water molecules to the molecules of the second substance), which improves the quality of enveloping the filler granules with a binder.
  • It is also an indispensable condition that after the gypsum sets when vibration or pressing is used, no loss of bonds occurs and the strength of the manufactured product does not drop, therefore the plasticity index of the mass must be sufficient at all stages of production.
  • The process of production of blocks and panels is accelerated by the rapid release of the molding equipment from the finished product, and this is possible with its rapid drying. To achieve this, special additives are added to the gypsum mass.

The internal reinforcement of products made of metal-reinforced gypsum concrete must always be treated with anti-corrosion materials, such as bitumen varnish. Another option for strengthening large-format panels is to use a coniferous wood (usually pine) wooden frame.

Technical and economic indicators

From an economic perspective, the use of gypsum concrete products in construction has been demonstrated. Gypsum concrete panels are two times less expensive to install than brick walls when compared in cost. They will have a 2.5 times lighter weight and a 2 times better thermal resistance.

The products’ unique applications result in a five-fold reduction in the amount of labor required on construction sites.

Building materials that are lightweight and adaptable, gypsum concrete blocks are well-known for their effective insulation against heat and sound. Because of their ease of use, they are perfect for use in non-load-bearing walls and partitions in both residential and commercial construction. Their eco-friendly composition and ability to withstand fires make them a popular option for sustainable building projects.

Advantages of gypsum concrete products

The following are some of the primary benefits of gypsum concrete blocks and other gypsum concrete products:

  1. All products and structures erected with their help are lightweight, which significantly facilitates their transportation. The cost of erecting buildings using gypsum concrete structures is reduced due to the insignificant load on the base, and therefore simplified requirements for organizing the strength of the foundation;
  2. Products on a gypsum binder are characterized by high soundproofing properties, which affects the increase in comfort of buildings of any purpose;
  3. The low cost of gypsum concrete products is due to the availability and low cost of the components;
  4. The use of gypsum concrete panels in the construction of partition structures occurs faster, due to their large size. And the presence of a tongue-and-groove fastening system facilitates and ensures the quality of the work performed;

  1. Due to the high degree of vapor permeability, the use of gypsum concrete products allows for optimal microclimatic indicators of residential premises, as well as increasing their thermal efficiency, due to the low thermal conductivity of the material;
  2. The versatility of gypsum concrete lies in the fact that it can be used to manufacture monolithic structures, walls and partitions, as well as to manufacture decorative facing bricks and panels for interior wall decoration.

One can identify the material’s high hydrophobicity as one of its drawbacks.

Types of gypsum concrete products

Numerous products are made with gypsum concrete, including:

  1. Gypsum concrete panels for partitions. These products are used when the air humidity does not exceed 60%. Using the continuous molding method, solid or with a doorway products are made, the dimensions of which correspond to the parameters of the room;
  2. Partition slabs are rectangular in shape. Can be produced with voids inside or solid.

  1. Floor base in the form of a gypsum concrete panel made according to the size of the room with a filler of expanded clay or sawdust. When laying such slabs on concrete floors, soundproofing gaskets are used;
  2. For mass construction, sanitary slabs are assembled from gypsum concrete slabs, the basis for which is a reinforced concrete slab covered with tiles;

  1. Ventilation blocks are volumetric products formed using vertical forms.

As you can see, the material known as gypsum concrete is quite adaptable. Gypsum concrete tongue-and-groove partition blocks have become particularly popular in private construction, allowing you to complete the job yourself.

Building materials with a blend of strength, insulation, and ease of use are gypsum concrete blocks. They can save time and labor on construction projects because of their lightweight nature, which also makes them easier to handle and install.

Because of their superior ability to insulate against heat and sound, these blocks are especially well-suited for interior walls and partitions. Additionally, they provide strong fire resistance, giving buildings an additional degree of security.

Gypsum concrete blocks have special qualities that make them a valuable option in many situations, even though they might not be the best choice for every construction need. When organizing your next project, having a clear understanding of their advantages and disadvantages will help you make wise choices.

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Dmitry Sokolov

Chief engineer in a large construction company. I have extensive experience in managing construction projects and implementing modern technologies.

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