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Midstream quality control in drywall production using a quantitative phase analysis of stucco

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Abstract

At the midstream of drywall production, gypsum raw material is calcinated to make stucco, which contains not only calcium sulfate hemihydrate (the desired constituent), but also gypsum (under-calcinated), soluble calcium sulfate (over-calcinated), and insoluble phases. Here, we propose a quantitative phase analysis that measures the amount of all calcium sulfate phases in the stucco mix. The phase content was calculated using calcination mass loss and hydration mass gain of original, semi-hydrated, and fully hydrated samples. The proposed uncomplicated sample preparation and conventional measurement routines make it an excellent on-site quality control measure in an industrial setting.

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Abbreviations

AI, AII:

Insoluble calcium sulfate anhydrites

AIII:

Soluble calcium sulfate anhydrite

DH:

Calcium sulfate dehydrate

FM:

Free moisture

GA:

Gravimetric analysis

GPA:

Gravimetric phase analysis

HH:

Calcium sulfate hemihydrate

HUM:

Sample made by conditioning stucco in a humidity chamber

HYD:

Sample made by full hydration of the stucco

IN:

Inert phases

ORG:

Stucco sample taken from the stucco mix without any modification

RMSE:

Root mean squared error

TA:

Thermal analysis

TGA:

Thermogravimetric analysis

TGPA:

Thermogravimetric phase analysis

XRD:

X-ray diffraction

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Acknowledgements

This work was financially supported by the Mitacs Accelerate Project (IT14541) and CertainTeed Gypsum, Inc. The authors would like to thank CertainTeed Gypsum, Inc. for providing industrial stucco samples. The authors would also like to acknowledge Anirban Y. Ghosh and Remi Lespiat from the CertainTeed Gypsum, Inc. for valuable discussions and insightful proofreading.

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Authors and Affiliations

  1. Department of Chemical and Materials Engineering, University of Alberta, Edmonton, Canada

    Mohammad Khalkhali, Yi Lu, Hanrui Zheng & Qingxia Liu

  2. CertainTeed Gypsum Inc., Palatka, FL, USA

    Roger Jones

Authors
  1. Mohammad Khalkhali
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  2. Yi Lu
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  3. Hanrui Zheng
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  4. Roger Jones
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  5. Qingxia Liu
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Contributions

MK: conceptualization, methodology, formal analysis, investigation, writing—original draft preparation, visualization. YL: methodology, formal analysis, investigation, data curation, writing—original draft preparation, writing—review and editing, visualization, supervision. HZ: formal analysis, investigation. RJ: resources, writing—review and editing, supervision, project administration. QL: resources, writing—review and editing, supervision, project administration, funding acquisition. All authors have read and agreed to the published version of the manuscript.

Corresponding author

Correspondence to Qingxia Liu.

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Khalkhali, M., Lu, Y., Zheng, H. et al. Midstream quality control in drywall production using a quantitative phase analysis of stucco. J Therm Anal Calorim 148, 3201–3211 (2023). https://doi.org/10.1007/s10973-022-11872-w

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  • DOI: https://doi.org/10.1007/s10973-022-11872-w

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