Recent advances in gypsum technology for construction

A review of gypsum sources and standards classification, plaster manufacturing, high‑performance mixes, PCM integration, 3D printing, acoustic/thermal enhancement, fibre reinforcement, and self‑healing concepts.

The article synthesizes how gypsum-based systems can be advanced through formulation engineering and hybridization (e.g., fibres, additives, mineral co-binders) to improve functional performance while supporting sustainability-oriented construction practices

Standards-based gypsum classification

Functional performance upgrades (thermal/acoustic)

Additive-enabled innovation (PCM, fibres, self‑healing)

Background and objective

The article positions gypsum as a widely used construction mineral and frames recent interest around improving functional performance and operational efficiency in building systems. It highlights a shift toward innovative accoutrements and improved material performance, while keeping the foundational chemistry of gypsum intact. The review aims to summarize technology directions and practical routes by which gypsum materials can contribute to sustainable construction outcomes.

Sources/grades and manufacturing of gypsum plaster

Gypsum is classified into distinct source categories aligned with Indian Standards, including natural/mineral gypsum, by‑product gypsum, and marine gypsum. A manufacturing overview for gypsum plaster is presented in terms of comminution and processing steps that yield final powder suitable for downstream use. The material description emphasizes gypsum as calcium sulfate dihydrate and notes the existence of multiple calcium sulfate phases dependent on temperature history.

Source-based gypsum categories (standards context)

Natural/Mineral gypsum Conforms with IS 1290:1973

By‑product gypsum Conforms with IS 12679:2023

Marine gypsum Conforms with IS 4256:1967

Core function Establishes standards-linked classification for material sourcing and specification.

Gypsum phase framework (temperature-dependent forms)

Key idea Calcium sulfate exists in multiple phases with temperature-dependent formation

Implication Processing history can influence downstream performance and compatibility

Core function: Links thermal history to phase constitution and material behavior.

Gypsum plaster manufacturing (process overview)

Process elements shown Crushing/grinding and staged size reduction leading to final powder

Design intent Produce consistent particle form for plaster processing and application

Core function: Provides a process-level map from raw gypsum to usable plaster powder.

High-performance gypsum mixes (additive strategy)

Approach described Incorporate performance-enhancing additives (e.g., PCMs) post-hydration or as non-interfering additions

Use contexts cited Sanitary walls, kitchens, bathrooms

Core function Frames high-performance mixes as application-specific formulations tuned for functional outcomes.

Thermal management and PCM integration in gypsum matrices

The review describes phase change materials (PCMs) as a route to improve thermal functionality, while noting compatibility constraints. It distinguishes organic PCMs (e.g., paraffins, fatty acids) from inorganic salt-hydrate PCMs and emphasizes that encapsulation/micro-encapsulation can enable physical incorporation into gypsum. Potential challenges include phase separation, bonding disruption, salt–gypsum interactions, ion migration, efflorescence, volumetric instability, and hygroscopic moisture uptake altering mechanical behavior.

3D printing and performance-oriented gypsum boards

3D printing is discussed as a pathway enabling prefabricated gypsum structures with complex geometries and improved construction efficiency, thereby expanding gypsum’s role in modern building operations. The article also highlights acoustic and thermal advances in gypsum boards, framing improved soundproofing and temperature moderation as drivers for adoption in performance-critical spaces. Fibre reinforcement is presented as an additional mechanism to improve mechanical integrity and functional behavior, with multiple fibre families described.

Organic PCM integration (compatibility framing)

Examples cited Paraffins and fatty-acid PCMs

Integration mode Encapsulated or micro-encapsulated inclusion within gypsum

Constraint Hydrophobicity may impair bonding or cause phase separation

Core function Adds thermal buffering while creating interfacial/bonding design challenges.

Inorganic salt-hydrate PCMs (reaction and stability concerns)

Examples cited Sodium sulfate decahydrate; calcium chloride hexahydrate

Observed risks Ion exchange, salt precipitation/efflorescence, volumetric instability

Moisture issue Hygroscopic salts may draw moisture and modify mechanical properties

Core function Provides thermal storage potential but imposes chemical and moisture-stability constraints.

3D printing with gypsum (fabrication pathway)

Functional claim Supports prefabricated structures and complex designs with improved effectiveness

Operational framing Expands gypsum processing routes beyond conventional board/plaster workflows

Core function: Enables manufacturing of complex, repeatable architectural elements.

Acoustic/thermal boards and fibre reinforcement (performance route)

Acoustic framing Enhanced soundproofing for theatres, recording environments, and hospitals

Thermal framing Moderates interior temperature and reduces energy demand (quantified below)

Reinforcement families cited Glass fibres; PP/PE fibres; natural fibres (straw/hemp/jute/sisal); basalt fibres

Core function Combines microstructural reinforcement and board engineering to enhance durability and functional performance.

Self‑healing and additive‑enabled reaction pathways: constraints and feasibility

The article characterizes gypsum as generally non-reactive in most self-healing systems unless paired with additional mineral phases (e.g., aluminates or cement constituents). This implies that gypsum alone does not typically provide the chemical environment required for common self-healing mechanisms.

Gypsum as chemically passive in self‑healing concepts

Many self-healing systems rely on calcium hydroxide formation and subsequent carbonation (Ca(OH)₂ + CO₂ → CaCO₃ + H₂O) to seal microcracks. The review emphasizes that gypsum does not intrinsically provide Ca(OH)₂ in the way hydrated cement systems do, limiting carbonation-based self-healing unless composite mineral additions are present.

Carbonation-based healing requires Ca(OH)₂ availability

The review describes silicate-based additives (e.g., sodium silicate) that can react with Ca(OH)₂ to form C–S–H type products. It reiterates that gypsum-only systems do not supply Ca(OH)₂; therefore, such pathways remain conditional on composite formulations (e.g., gypsum combined with cement/minerals).

Silicate additive pathways depend on calcium hydroxide sources

If calcium aluminate phases are present and sulfate is available from gypsum, ettringite formation may occur and can seal microcracks through crystal growth. However, the review notes that uncontrolled ettringite formation can introduce expansion-related risks, implying the need for careful control of phase availability and reaction conditions.

Sulfate-based ettringite healing: opportunity and risk

Gypsum boards and interior linings

Construction boards for interior partitions and finishing.

Acoustic panels

Soundproofing in theatres, recording workrooms, and hospitals.

Thermal-performance interiors

Assemblies targeting improved thermal comfort and energy moderation.

Sanitary and wet-area applications

Kitchens, bathrooms, and sanitary wall contexts for high-performance mixes.

Prefabrication and complex geometries

3D printed gypsum elements and prefabricated structures.

Composite systems for enhanced performance

Gypsum–mineral hybrids enabling advanced functions (e.g., healing pathways).

Quantitative anchors explicitly stated

Heating/cooling savings

Enhanced gypsum-board assemblies are described as reducing heating and cooling costs by approximately 20–30% through improved thermal moderation (context-specific claim).

Standards classification

Gypsum sources are categorized with cited Indian Standards for natural/mineral, by‑product, and marine gypsum, respectively.

Composite-enabled self‑healing

Healing mechanisms discussed (carbonation, silicate-driven products, ettringite growth, biogenic CaCO₃) are presented as conditional on composite chemistry and reaction control.

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