The evolution of gypsum in construction
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Gypsum plaster has been in use for over 7,000 years. Ancient Egyptians used it as mortar between blocks in the pyramids and as a smooth coating for the interiors, some of which still exist today.
In the late s, Augustine Sackett discovered a method for controlling the setting time of plaster. This advancement led Sackett to patent a precursor to modern-day gypsum board in , which consisted of alternating layers of wool felt and plaster, known as &#;Sackett Board.&#;
The first product standard for gypsum board, ASTM C36, Standard Specification for Gypsum Wallboard, was introduced in .
Gypsum board gained widespread popularity during the postwar building boom in the United States as a cost-effective and efficient alternative to plaster. Commonly known as &#;drywall&#; because it avoided the humid environments and wet applications of plaster, gypsum board could be installed faster and with less skilled labor, providing jobs and homes for returning veterans.
In , the first wall assembly to achieve a 1-hour fire rating was constructed, and in the s, Type X drywall was defined in ASTM C36.
Over the years, additional standards were created as more gypsum products were developed, such as moisture-resistant products, soffit boards and shaftliner panels. In , these various standards were consolidated into ASTM C, Standard Specification for Gypsum Board, the current standard for all paper-faced gypsum board products.
While modern drywall products provide valuable benefits, such as sound control and mold resistance, the fire resistance of gypsum is what continues to make it the premier choice for the construction industry.
How does drywall achieve fire ratings?
Type X gypsum board has special additives that give it increased fire resistance. Glass fibers, for example, are added to the gypsum slurry during the manufacturing process to reinforce the gypsum core as it calcines. Gypsum board assemblies are tested in accordance with ASTM E119, Standard Test Methods for Fire Tests of Building Construction and Materials.
To pass ASTM E119, the assembly must achieve the following:
Resource Alert: Learn more about the testing standard for fire-rated assemblies, modifications permitted to those assemblies and the most common questions about fire-rated assemblies.
NOTE: If you are builder or specifier please go here for specific building codes requirements.
You're building a new home or maybe you're adding an addition or a garage, remodeling a kitchen or a family room. What precautions do you need to take for fire safety?
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What if you live in an adjoined condo or an apartment building? Do you need to be concerned if your untrained neighbor imagines himself a Top Chef?
Just what exactly do we need to know when it comes to fire safety in our homes? In this article we review frequently asked questions related to fire safety in residential construction. Understanding what you need to know is an important part of any project.
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A: A certification process determines the fire-rating of a wall system. It is the wall system, not specific products, that are tested and certified. For example, a fire-rated drywall board is approved for use as part of a certified wall system. A basic wall system could include a drywall board, insulation, light gauge steel stud followed by another drywall board.
A: Both drywall Type X and Type C are approved for use in a 60-minute rated design. The wall systems they are approved for are different, however. Type C fire-rated drywall has more glass fiber reinforcement and other ingredients in the gypsum core that makes its fire-resistive properties superior to Type X.
A: A 60 minute fire rating is a measure of the amount of time the wall system can withstand fire resistance in a fire-rating performance test. More than one hour is achieved by adding additional layers of boards to extend protection or by adding other elements to the system to make it more robust.
A: Fire-rated products are not typically used in single-family residential construction except for garages. These products are primarily used in commercial construction (high rises, office buildings, industrial, institutional) and any space requiring an area separation wall such as a hotel or multi-family home.
A: The purpose of fire-rated products is to delay the spread of a fire and extend the time a person has to leave the building. In a single family home, getting out is easier. There are fewer floors and multiple exits so the code focuses more on prevention. You will see requirements around electrical wiring, for example, to prevent fire risks caused by faulty wiring.
A: First, fire-rated systems are only required if the garage shares a wall or a ceiling with the home. If you are doing repairs in the garage you should replace with like materials, but remember it is the wall system that is fire rated not the product itself. So if it's more than a patch job or you're repairing in an area that overlaps with the main living space, it's probably best to contact a professional.
A: Yes, any space requiring an area separation wall (a wall separating adjacent living units) like apartments, condos and townhouses, uses a fire-rated system. They are also required in any egress area in the apartment building.
A: Drywall Type X and Type C are the industry standards for this type of construction and are used on all exterior-facing and joining walls. Interior walls are traditionally non-fire-rated ½" drywall.
A: Fire safety is part of the building code. It spells out the necessary requirements for this type of construction. In addition to construction requirements the building code also specifies things such as automatic sprinkler systems, emergency and exit lighting, emergency power supplies and fire alarm systems. In general renters/owners will likely have little say in what construction materials are used per unit but you can request information on system maintenance and notify the facilities department if a fire alarm has been disabled.
A: No, in residential construction fire-rated assemblies are only specified for garages and most homeowners with attached garages are probably not aware of the fire-rating for that wall. Same can probably be said for occupants of multi-family homes with separation walls, and (unless you are replacing the drywall in an attached garage) there really is no need to be aware. The required fire-rating is specified in the building code. Your builder, your architect, your contractor, they need to be aware.
A: Definitely. First, if you are doing home repairs have all work checked by a building inspector. It may seem like a tedious step at times but it's important to making sure your family is safe. Second, this one is simple but critical. Make sure you have all your necessary smoke detectors and the batteries in them are working properly.
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