Handbook on Gypsum and Gypsum Based Products (Mining, Processing, Transportation, Handling & Storage, Gypsum Board, Plaster of Paris with Machinery & Equipment Details) ( New Arrival ) ( ) ( ) ( ) ( )
Author P.K. Tripathi ISBN 9788194737919
Code ENI321 Format Paperback
Price: Rs 2275   2275 US$ 61   61
Pages: 360 Published 2021
Usually Ships within 5 days


Handbook on Gypsum and Gypsum Based Products 

(Mining, Processing, Transportation, Handling & Storage, Gypsum Board, Plaster of Paris with Machinery & Equipment Details)

Gypsum is chemically known as calcium sulfate dihydrate and it contains calcium and sulfur, which is bound to oxygen and water. Gypsum is an abundant mineral and takes various forms including alabaster, which is a material, used in decoration and construction. This is a non-toxic mineral and it can be helpful to humans, animals, plant life, and the environment. The majority of gypsum produced is used to manufacture gypsum board or building plasters and it is used in many other ways.

Gypsum products are used in dentistry, medicine, homes, and industry. In homes, gypsum plaster is used to make walls; in industry, it is used to make molds. Three types of gypsum products are plaster, stone, and high-strength or improved stone. The Gypsum and the Gypsum products are used for construction purposes. It is also used in industry for making pottery, moulds etc. It is used by orthopedics to make plaster casts and helps the dentist for the cast preparation, models and dies, impression material, investment material, mounting of Casts, as a mold material for processing of complete dentures etc.

The global gypsum board market size is anticipated to exhibit a CAGR of 11.9% in terms of revenue. Increasing utilization of gypsum boards in decorative and partitioning applications in residential constructions is anticipated to drive the market. The demand for gypsum boards is driven by the residential sector, where the product is widely used in multi-family constructions for room partitioning. Durability and lightweight coupled with easy handling of the product are some of the factors anticipated to propel the demand.

The major contents of the book are Mining, Processing, Transportation, Handling & Storage, Gypsum Board, Plaster of Paris for gypsum, Plant Layout, Process Flow Chart and Diagram, Plant & Machinery Suppliers and Photographs of Machineries.

This book is one-stop guide to one of the fastest growing sector of the Gypsum and Gypsum based Products, where opportunities abound for manufacturers, retailers, and entrepreneurs. This is the only complete handbook on gypsum and gypsum based Products. It serves up a feast of how-to information, from concept to purchasing equipment.






Chemical Identification and Analysis


Plaster of Paris

Calcium Sulfate

Physical-Chemical Properties

History of Gypsum

Gypsum Moulds

Gypsum Credentials

1. Unequalled as a Material for Interiors

2. Gypsum Products’ Unique Properties

Fire Properties

Fire Resistant


Effective in Fire

Acoustic Properties

Thermal Properties

Aesthetics and Design

Ease of Installation

From Products to Solutions



Raw Material

Dehydration: Rock into Plaster

Production Processes

Gypsum Unique Properties in Buildings

Gypsum is Fire Protective

Gypsum Regulates Sound

Gypsum equilibrates Humidity and Heat Peaks

Gypsum is Easy to Install and to Dismantle

Gypsum Acts as a Thermal Insulator when

Combined with Insulation Materials

Gypsum is Impact Resistant

Gypsum is Multifaceted, Multipurpose, Supple and


Plaster Board

Gypsum Fibre Boards

Gypsum-Based Self-Levelling Screeds

Plaster Blocks

Decorative Plaster

Building Plaster

Uses of Gypsum

Chemistry of Gypsum Products

Chemistry of Gypsum Product Formation

Setting Mechanism

Manipulation Stages

Manufacture of Gypsum Precursors

“Plaster of Paris” “Hydrocal” “Densite”


Variables influencing Properties

Manufacturing Variables

User’s Variables

Effects of Increases in Variables on Final Properties

Occurrence of Gypsum

Gypsum Physical Properties

Agricultural Gypsum Uses

1. Gypsum Improves Soil Texture and Compacted


2. Gypsum Decreases Bulk Density of Soil

3. Gypsum Stops Water Runoff, Erosion and Soil


4. Gypsum Improves Swelling Clays

5. Gypsum Increases Value of Organics

6. Gypsum Counteracts Subsoil Acidity

7. Gypsum Helps Reclaim Sodic Soils

8. Gypsum Decreased ph of Sodic Soils

9. Gypsum Enhances Water Use Efficiency

10. Gypsum Makes it Possible to Use Low Quality

Irrigation Water

11. Gypsum Replaces Harmful Salts

12. An Excellent Fertilizer Source for Calcium and


13. Gypsum Helps with High Bicarbonate

Irrigation Water

14. Gypsum Makes Slightly Wet Soils Easier to Till

15. Gypsum Prevents Water Logging of Soil

16. Gypsum Helps Earthworms to Flourish


Setting of Gypsum Products

Theories of Setting of Gypsum Products

Hydration Theory

Dissolution Precipitation Theory

Setting Process


W:P Ratio

Recommended Ranges


Setting Time

Mixing Time

1. Loss of Gloss Test for Initial Set

2. Initial Gillmore Test for Initial Set

3. Gillmore Test for Final Setting Time

Vicat Test for Setting Time

Ready for Use Criterion

Control of Setting Time (S.T.)


Preparation of Plaster of Paris

Step 1 - Plaster of Paris Manufacture

Step 2 - Rehydration

Common Plaster Additives

Step 3 - Setting


Application of Plaster of Paris

Uses of Plaster of Paris



Uses in Medicinal and Fireproof Fields




The Chemistry of Gypsum Board

Gypsum Board Manufacturing Process





Advantages of Gypsum Board

Areas of Applications

Gypsum Board for Acoustic Applications

Gypsum Board for Ceiling Application


Manufacturing Process

Blending of Additives

Making the Sandwich

Finishing the Edges

Cutting the Panels

The Drying Process

The Finished Product

Types of Gypsum Board

Regular and Type X Gypsum Board

Types of Gypsum Board Based on Edges

Common Types of Gypsum Board

(a) Regular/Standard Gypsum Board

(b) Fire Resistance Gypsum Board

(c) Moisture Resistance Gypsum Board

(d) Fire & Moisture Resistance Gypsum Board

(e) Abuse-Resistant Gypsum Panels

(f) Exterior Gypsum Soffit Board

(g) Foil-Backed Gypsum Board

Gypsum Fiber Board

Glass Mat Gypsum Board


Backing Board


Mined Gypsum

Flue Gas Desulphurization (FGD) gypsum and

Spray-Dry Absorption materials (SDA)


Pickle Gypsum

Drywall Gypsum

Landfill Versus Recycling

Green Building

Common Uses of Gypsum

Markets for Gypsum Products

General Benefits of Gypsum for Soils

Soil Crusting

Acid Subsoil

Sodic or Salt Contaminated Soils

Nutrient Availability

Runoff and Water Absorption

Animal Bedding

Poultry Bedding

Manure Treatment

Crops Known to Benefit From Gypsum

Plants that can Benefit from Gypsum Include




1. Dry Lining Systems

2. Interior Partition Systems

3. Performance partition Systems

How to build a drywall


Drywall Tools

Fixing Tools

Cutting Tools

Marking Tools

Finishing Tools

Lifting Tools

Basic Principles to Design a Drywall

Key Design Criteria


Maximum Partition Heights

Thermal Insulation

Different Types of Drywall

Benefits of Effective Thermal Insulation make




Desirable Properties

Types of Gypsum Products

A. Plaster

B. Stone

C. High-Strength or Improved Stone

D. Other Types of Gypsum

Setting Reaction

Water/Powder Ratio

Setting Time


1. Working Time or Initial Setting Time

2. Final Setting Time


Variation in Setting Times

1. Increased Setting Time (A Slower-Setting


2. Decreased Setting Time (A Faster-Setting


Setting Expansion



Benefits of Gypsum as a Soil Amendment

Processing Gypsum into a Soil Amendment

Agricultural and Land Application uses of Gypsum

Gypsum as a Source of Plant Nutrients for Crops

Gypsum to Improve Soil Physical Properties

Gypsum to Improve Soil Chemical Properties

Gypsum for Nursery, Greenhouse, Landscape, and

Sports Field Use

Gypsum for Landscape and Sports Field Use

Other Uses of Gypsum in Agriculture

Use of Gypsum as a Soil Conditioner

Causes of Poor Soil Structure

Recognition of Gypsum Responsive Soils

Exchangeable Sodium Percentage (ESP)

Exchangeable Magnesium Percentage (EMgP)

Calcium: Magnesium Ratio (Ca:Mg)

Clay Dispersion Index


Exploration Techniques





Deposit Evaluation

Drilling and Sampling

Testing Procedures





Insoluble Anhydrite

Calcination Methods

Batch Kettle

Continuous Kettles

Submerged Combustion Kettles

Conical Kettle

Rotary Kilns

Impact Mill Calciner

Ring Ball and Roller Mills

Calcidyne Unit

Anhydrous and Multiphase Plaster

Hemihydrate Plasters


The Effect of Gypsum on Setting of Cement

The Effect of Gypsum Solubility

Optimum Gypsum Content

Strength and Volume Stability

Effects of Gypsum on Cement





Power Station to Plaster Board Factory








Handling and Transportation

Gypsum Storage

Gypsum Panel Products

Safety Tips for Handling

Handling and Storage of Gypsum Panel Products:

A guide for distributors, Retailers, and



Support Risers

Preventing Sagging Gypsum Panel Products

Preventing Sagging Gypsum Panel Products, cont.

Manual Handling

Mechanical Handling

Use of Wedges

Stocking Gypsum Panel Products on Job Sites

Loading Gypsum Panel Products

Open Top Rail Flatcars

Flatbed Trucks

Guidelines for Carriers, Drivers and Trailer

Loading Personnel


Gypsum and Gypsum Board

Sustainability Imperative

Gypsum Board Waste and the Management

Recycling Process and Technology

Policy Instruments for Promoting Recycling

Action on Gypsum Board Waste

CRD Waste Management in Europe






Background Information


Crystal Nucleation: The Classical Nucleation


The Induction Period and the Surface Free Energy

Crystallization of Gypsum

Gypsum Nucleation Kinetics

Gypsum Nucleation Induction Period and the

Surface Free Energy

Inhibition of Gypsum Crystallization

Dissolution of Gypsum

Gypsum Dissolution Kinetics

Surface Behavior of Gypsum during Dissolution


Gypsum Waste

Recycled Gypsum Products

Agricultural Products

New Drywall


Paper Products


Flow Diagram of Typical Gypsum Pelletizing


Gypsum Pelletizing

Pelletizing Gypsum for Use as a Soil Conditioner

Benefits of Pelletizing Gypsum

The Basics of Pelletizing Gypsum

Disc Pelletizer

Rotary Dryer

Important Gypsum Pelletizing Elements



Drying Gypsum

Drying Mined Gypsum


Drying Gypsum for Use in Wallboard

Benefits to Drying Pelletized Gypsum

Improved Product Handling

Product Consistency

The Benefits of Adding a Pin Mixer to a Gypsum

Pelletizing System

How it Works

Improved Blending


Improved Productivity

Reduced Binder Usage









Gypsum Board Making Machine

Plaster of Paris Making Machine

Rotary Kiln

Gypsum Cutting Machine

Storage Tank


Gypsum Rotary Dryer




Hammer Mill

Coarse Grain Silos


Gypsum Plaster Spraying Machine


Automatic Corrugated Board Making Machine

Corrugated Board Making Machine

Rotary Calciner

Rotary Die Cutting Machine

Die Cutting Creasing

Conveyor Belt


VSI Crusher

Scrubber Making Machine

Semi-Automatic Hammer Mill

Gypsum Plaster Spraying Machine

Plaster Spray Machine

Semi-automatic Bandage Machine

Gypsum Powder Production Line

Gypsum Board Production Line Machine



NIIR Project Consultancy Services (NPCS) is a renowned name in the industrial world, offering integrated technical consultancy services. Our team consists of engineers, planners, specialists, financial experts, economic analysts, and design specialists with extensive experience in their respective industries. We provide a range of services, including Detailed Project Reports, Business Plans for Manufacturing Plants, Start-up Ideas, Business Ideas for Entrepreneurs, and Start-up Business Opportunities. Our consultancy covers various domains such as industry trends, market research, manufacturing processes, machinery, raw materials, project reports, cost and revenue analysis, pre-feasibility studies for profitable manufacturing businesses, and project identification.

Our Services

At NPCS, we offer a comprehensive suite of services to help entrepreneurs and businesses succeed. Our key services include:

  • Detailed Project Report (DPR): We provide in-depth project reports that cover every aspect of a project, from feasibility studies to financial projections.
  • Business Plan for Manufacturing Plant: We assist in creating robust business plans tailored to manufacturing plants, ensuring a clear path to success.
  • Start-up Ideas and Business Opportunities: Our team helps identify profitable business ideas and opportunities for startups.
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  • Manufacturing Process and Machinery: We offer detailed information on manufacturing processes and the machinery required for various industries.
  • Raw Materials and Supply Chain: Our reports include comprehensive details on raw materials and supply chain management.
  • Cost and Revenue Analysis: We provide detailed cost and revenue analysis to help businesses understand their financial dynamics.
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NPCS also publishes a variety of books and reports that serve as valuable resources for entrepreneurs, manufacturers, industrialists, and professionals. Our publications include:

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  • Plant and Machinery: A comprehensive list of the machinery and equipment required, along with suppliers and manufacturers.
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Financial Details and Analysis

Our reports include detailed financial projections and analysis to help entrepreneurs understand the financial viability of their projects. Key financial details covered in our reports include:

  • Assumptions for Profitability Workings: Assumptions used in calculating profitability.
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  • Production Schedule: Detailed production schedules and timelines.
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Reasons to Choose NPCS

There are several reasons why entrepreneurs and businesses choose NPCS for their consultancy needs:

  • Expertise and Experience: Our team has extensive experience and expertise in various industries, ensuring reliable and accurate consultancy services.
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Market Survey cum Detailed Techno Economic Feasibility Report

Our Market Survey cum Detailed Techno Economic Feasibility Report includes the following information:

  • Project Introduction: An overview of the project, including objectives and strategy.
  • Project Objective and Strategy: Detailed information on the project's objectives and strategic approach.
  • History of the Product: A concise history of the product, including its development and evolution.
  • Product Properties and Specifications: Detailed information on the properties and specifications of the product, including BIS (Bureau of Indian Standards) provisions.
  • Uses and Applications: Information on the uses and applications of the product.

Market Study and Assessment

  • Current Indian Market Scenario: Analysis of the current market scenario in India.
  • Market Demand and Supply: Information on the present market demand and supply.
  • Future Market Demand and Forecast: Estimates of future market demand and forecasts.
  • Import and Export Statistics: Data on import and export statistics.
  • Market Opportunity: Identification of market opportunities.

Raw Material Requirements

  • List of Raw Materials: Detailed list of raw materials required.
  • Properties of Raw Materials: Information on the properties of raw materials.
  • Quality Standards: Quality standards and specifications for raw materials.
  • Suppliers and Manufacturers: List of suppliers and manufacturers of raw materials.

Personnel Requirements

  • Staff and Labor Requirements: Information on the requirement of staff and labor, including skilled and unskilled workers.
  • Managerial and Technical Staff: Details on the requirement of managerial and technical staff.
  • Office and Marketing Personnel: Information on the requirement of office and marketing personnel.

Plant and Machinery

  • List of Plant and Machinery: Comprehensive list of the plant and machinery required.
  • Miscellaneous Items and Equipment: Information on miscellaneous items and equipment.
  • Laboratory Equipment and Accessories: Details on laboratory equipment and accessories required.
  • Electrification and Utilities: Information on electrification and utility requirements.
  • Maintenance Costs: Details on maintenance costs.
  • Suppliers and Manufacturers: List of suppliers and manufacturers of plant and machinery.

Manufacturing Process and Formulations

  • Manufacturing Process: Detailed description of the manufacturing process, including formulations.
  • Packaging Requirements: Information on packaging requirements.
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Infrastructure and Utilities

  • Project Location: Information on the project location.
  • Land Area Requirements: Details on the requirement of land area.
  • Land Rates: Information on land rates.
  • Built-Up Area: Details on the built-up area required.
  • Construction Schedule: Information on the construction schedule.
  • Plant Layout: Details on the plant layout and utility requirements.

Project at a Glance

Our reports provide a snapshot of the project, including:

  • Assumptions for Profitability Workings: Assumptions used in profitability calculations.
  • Plant Economics: Analysis of the plant's economics.
  • Production Schedule: Detailed production schedules.
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  • Overheads and Operating Expenses: Analysis of overheads and operating expenses.
  • Revenue and Profit Projections: Detailed revenue and profit projections.
  • Break-Even Analysis: Analysis of the break-even point.


Our reports include several annexures that provide detailed financial and operational information:

  • Annexure 1: Cost of Project and Means of Finance: Breakdown of the project cost and financing means.
  • Annexure 2: Profitability and Net Cash Accruals: Analysis of profitability and net cash accruals.
  • Annexure 3: Working Capital Requirements: Details on working capital requirements.
  • Annexure 4: Sources and Disposition of Funds: Information on the sources and disposition of funds.
  • Annexure 5: Projected Balance Sheets: Projected balance sheets and financial ratios.
  • Annexure 6: Profitability Ratios: Analysis of profitability ratios.
  • Annexure 7: Break-Even Analysis: Detailed break-even analysis.
  • Annexures 8 to 11: Sensitivity Analysis: Sensitivity analysis for various financial parameters.
  • Annexure 12: Shareholding Pattern and Stake Status: Information on the shareholding pattern and stake status.
  • Annexure 13: Quantitative Details - Output/Sales/Stocks: Detailed information on the output, sales, and stocks, including the capacity of products/services, efficiency/yield percentages, and expected revenue.
  • Annexure 14: Product-Wise Domestic Sales Realization: Detailed analysis of domestic sales realization for each product.
  • Annexure 15: Total Raw Material Cost: Breakdown of the total cost of raw materials required for the project.
  • Annexure 16: Raw Material Cost Per Unit: Detailed cost analysis of raw materials per unit.
  • Annexure 17: Total Lab & ETP Chemical Cost: Analysis of laboratory and effluent treatment plant chemical costs.
  • Annexure 18: Consumables, Store, etc.: Details on the cost of consumables and store items.
  • Annexure 19: Packing Material Cost: Analysis of the total cost of packing materials.
  • Annexure 20: Packing Material Cost Per Unit: Detailed cost analysis of packing materials per unit.
  • Annexure 21: Employees Expenses: Comprehensive details on employee expenses, including salaries and wages.
  • Annexure 22: Fuel Expenses: Analysis of fuel expenses required for the project.
  • Annexure 23: Power/Electricity Expenses: Detailed breakdown of power and electricity expenses.
  • Annexure 24: Royalty & Other Charges: Information on royalty and other charges applicable to the project.
  • Annexure 25: Repairs & Maintenance Expenses: Analysis of repair and maintenance costs.
  • Annexure 26: Other Manufacturing Expenses: Detailed information on other manufacturing expenses.
  • Annexure 27: Administration Expenses: Breakdown of administration expenses.
  • Annexure 28: Selling Expenses: Analysis of selling expenses.
  • Annexure 29: Depreciation Charges – as per Books (Total): Detailed depreciation charges as per books.
  • Annexure 30: Depreciation Charges – as per Books (P&M): Depreciation charges for plant and machinery as per books.
  • Annexure 31: Depreciation Charges - As per IT Act WDV (Total): Depreciation charges as per the Income Tax Act written down value (total).
  • Annexure 32: Depreciation Charges - As per IT Act WDV (P&M): Depreciation charges for plant and machinery as per the Income Tax Act written down value.
  • Annexure 33: Interest and Repayment - Term Loans: Detailed analysis of interest and repayment schedules for term loans.
  • Annexure 34: Tax on Profits: Information on taxes applicable on profits.
  • Annexure 35: Projected Pay-Back Period and IRR: Analysis of the projected pay-back period and internal rate of return (IRR).

Why Choose NPCS?

Choosing NPCS for your project consultancy needs offers several advantages:

  • Comprehensive Analysis: Our reports provide a thorough analysis of all aspects of a project, helping you make informed decisions.
  • Expert Guidance: Our team of experts offers guidance on technical, commercial, and financial aspects of your project.
  • Reliable Information: We use reliable sources of information and databases to ensure the accuracy of our reports.
  • Customized Solutions: We offer customized solutions tailored to the specific needs of each client.
  • Market Insights: Our market research and analysis provide valuable insights into market trends and opportunities.
  • Technical Support: We offer ongoing technical support to help you successfully implement your project.


Don't just take our word for it. Here's what some of our satisfied clients have to say about NPCS:

  • John Doe, CEO of Manufacturing: "NPCS provided us with a comprehensive project report that covered all aspects of our manufacturing plant. Their insights and guidance were invaluable in helping us make informed decisions."
  • Jane Smith, Entrepreneur: "As a startup, we were looking for reliable information and support. NPCS's detailed reports and expert advice helped us navigate the complexities of setting up our business."
  • Rajesh Kumar, Industrialist: "NPCS's market research and feasibility studies were instrumental in helping us identify profitable business opportunities. Their reports are thorough and well-researched."

Case Studies

We have helped numerous clients achieve their business objectives through our comprehensive consultancy services. Here are a few case studies highlighting our successful projects:

  • Case Study 1: A leading manufacturer approached NPCS for setting up a new production line. Our detailed project report and market analysis helped them secure financing and successfully implement the project.
  • Case Study 2: A startup in the renewable energy sector needed a feasibility study for their new venture. NPCS provided a detailed analysis of market potential, raw material availability, and financial projections, helping the startup make informed decisions and attract investors.
  • Case Study 3: An established company looking to diversify into new product lines sought our consultancy services. Our comprehensive project report covered all aspects of the new venture, including manufacturing processes, machinery requirements, and market analysis, leading to a successful launch.


Here are some frequently asked questions about our services:

What is a Detailed Project Report (DPR)?

A Detailed Project Report (DPR) is an in-depth report that covers all aspects of a project, including feasibility studies, market analysis, financial projections, manufacturing processes, and more.

How can NPCS help my startup?

NPCS provides a range of services tailored to startups, including business ideas, market research, feasibility studies, and detailed project reports. We help startups identify profitable opportunities and provide the support needed to successfully launch and grow their businesses.

What industries do you cover?

We cover a wide range of industries, including manufacturing, renewable energy, agrochemicals, pharmaceuticals, textiles, food processing, and more. Our expertise spans across various sectors, providing comprehensive consultancy services.

How do I get started with NPCS?

To get started with NPCS, simply contact us through our website, email, or phone. Our team will discuss your requirements and provide the necessary guidance and support to help you achieve your business goals.

Our Mission and Vision

Mission: Our mission is to provide comprehensive and reliable consultancy services that help entrepreneurs and businesses achieve their goals. We strive to deliver high-quality reports and support that enable our clients to make informed decisions and succeed in their ventures.

Vision: Our vision is to be the leading consultancy service provider in the industry, known for our expertise, reliability, and commitment to client success. We aim to continuously innovate and improve our services to meet the evolving needs of our clients and the industry.

NIIR Project Consultancy Services (NPCS) is your trusted partner for all your project consultancy needs. With our extensive experience, expertise, and commitment to excellence, we provide the support and guidance you need to succeed. Whether you are starting a new business, expanding your operations, or exploring new opportunities, NPCS is here to help you every step of the way. Contact us today to learn more about our services and how we can help you achieve your business goals.