The formula and process of the new gypsum mortar

Creating a new gypsum mortar involves careful consideration of the desired properties and performance requirements. Here’s a general formula and process for developing a basic gypsum mortar:

Ingredients:

1. Gypsum: Gypsum is the primary binder in the mortar and provides the necessary adhesion and strength. It typically comes in the form of gypsum plaster or gypsum powder.
2. Aggregates: Aggregates such as sand or perlite may be added to improve the workability, bulk density, and mechanical properties of the mortar.
3. Water: Water is essential for hydrating the gypsum and forming a workable paste.

Additives (Optional):

1. Retarders: Retarders can be added to control the setting time of the mortar, allowing for longer working times.
2. Modifiers: Various modifiers such as cellulose ethers, polymers, or air-entraining agents may be incorporated to enhance specific properties like workability, water retention, or durability.
3. Accelerators: Accelerators may be included to speed up the setting and curing process, useful in cold weather or time-sensitive applications.
4. Fillers: Fillers such as lightweight aggregates or microspheres can be used to reduce the density and improve thermal or acoustic insulation properties.

Process:

1. Mixing:
   • Start by pre-measuring the required amounts of gypsum, aggregates, and additives according to the desired formulation.
   • Combine the dry ingredients (gypsum, aggregates, fillers) in a mixing vessel or mixer and mix thoroughly until homogeneous.
2. Adding Water:
   • Gradually add water to the dry mix while mixing continuously until a smooth, workable paste is formed.
   • The water-to-gypsum ratio should be carefully controlled to achieve the desired consistency and setting time.
3. Incorporating Additives:
   • If using additives such as retarders, accelerators, or modifiers, add them to the mix according to the manufacturer’s instructions.
   • Mix the mortar thoroughly to ensure uniform distribution of additives and consistent performance.
4. Testing and Adjusting:
   • Perform tests on the freshly prepared mortar to evaluate properties such as workability, setting time, strength development, and adhesion.
   • Adjust the formulation as needed based on test results and desired performance criteria.
5. Application:
   • Apply the gypsum mortar to the substrate using appropriate techniques such as troweling, spraying, or pouring.
   • Ensure proper surface preparation and substrate compatibility for optimal adhesion and performance.
6. Curing:
   • Allow the mortar to cure and set according to the specified timeframes, taking into account environmental conditions such as temperature and humidity.
   • Monitor the curing process and protect the mortar from premature drying or exposure to adverse conditions.
7. Quality Control:
   • Conduct quality control tests on the cured mortar to assess properties such as strength, durability, and dimensional stability.
   • Make any necessary adjustments to the formulation or application techniques based on quality control results.

By following this formula and process, you can develop a new gypsum mortar tailored to specific project requirements, ensuring optimal performance and durability. It’s essential to conduct thorough testing and quality control throughout the development process to achieve consistent results and meet industry standards.