Gypsum Doesn't Have To Come From A Mine. It Can Be Made Too.
The process of making American Gypsum's Synthetic Gypsum (FGD Gypsum) at our Georgetown, SC facility starts at our partner power plants, where SO2 gas (sulfur dioxide) is passed through limestone that is sprayed in the air pollution control scrubber stack. The resulting sludge is then subjected to forced air oxidation to produce Calcium Sulfate (Gypsum), which is washed and inspected to ensure all of the impurities have been removed.
This Synthetic Gypsum is tested by the power plant before it is sent to our facility. It is then tested again to make sure it meets every single specification we require to produce American Gypsum wallboard.
Synthetic gypsum, which comprises about 95%, by weight, of American Gypsum wallboard, is processed almost identically as you would natural gypsum rock:
- Dry and calcine Synthetic Gypsum into a stucco before mixing it with water and other setting and binding ingredients in a continuous mixer
- Place mixture between two sheets of moving paper
- Form into a long ribbon of wallboard
- Set and harden wallboard before cutting to appropriate length by a rotating knife
- Send through a dryer and run through finishing saws to get it to exact length
- Bundle and stack into units before sending it off to the warehouse
Typically, Synthetic Gypsum has lower trace metal content then what is typically found in residential soil standards. All of our synthetic gypsum wallboard products are just as safe as natural gypsum and are certified as low volatile organic compound (VOC) products by the GREENGUARD Environmental Institute.