Building on Reliability

In 1916, Chicago-based United States Gypsum Co. invented drywall as an alternative to the time-consuming lathe and plaster method of constructing walls. The product failed to catch on at first. However, the housing boom and manpower shortage that followed World War II created a demand for the ease and efficiency offered by drywall. What was considered a perfect product remained largely unchanged for nearly 100 years.

Drywall, also known as gypsum board, is a panel made of gypsum plaster pressed between two thick sheets of paper. It is used to make interior walls and ceilings. Cement board is a wallboard option that combines cement and reinforcing fibers, and is used as a backing board for interior tile or as a base for exterior plaster.

Homeowners’ recent interest in eco-friendly products has spurred manufacturers to offer modern-day enhancements to what always has been considered a reliable product. Today’s consumers not only are demanding wallboard that is mold-resistant, but they also are seeking products that improve indoor air quality, or IAQ, by reducing volatile organic compounds, or VOCs, in the home; have high recycled content; and minimize sound between rooms.

“This is an exciting time to be in the construction industry,” says Amy Lee, manager of marketing communications for CertainTeed Gypsum, Valley Forge, Pa. “Forecasts indicate the economy is slowly rebounding, and, overall, we are finding that homeowners are looking for innovative ways to make their homes more green and eco-friendly.” The drywall industry is accomplishing these objectives by developing sustainable products that meet traditional expectations. 

The Green Movement

According to the Hyattsville, Md.-based Gypsum Association, in 2007 alone, the gypsum industry’s use of recycled paper kept more than 3.5 million cubic yards of material out of landfills. Gypsum-board manufacturers also utilize synthetic gypsum as an alternative to natural gypsum. Synthetic gypsum, which has an identical chemical composition to natural gypsum, is a byproduct from the desulfurization of flue gases in fossil-fueled power plants. In 2007, U.S. gypsum wallboard manufacturers used about 8.3 million short tons of byproduct gypsum, accounting for approximately 28 percent of all the gypsum used by Gypsum Association members that year.

In addition to utilizing synthetic gypsum, modern manufacturing techniques allow panel manufacturers to use “re-grind” or production overrun material in their products. Although demolition and remodeling waste cannot be recycled into new product because of the possibility of contaminants, like lead and asbestos, independent recycling firms can pick up and transport clean gypsum panel construction waste. The scrap gypsum board can be ground and used as a soil conditioner or animal bedding.

In addition to recycled content, IAQ is an important aspect of the green movement. We all are subjected to pollutants in the air every day, but we don’t often consider that our indoor air may be just as toxic—if not more toxic—than the outdoor air. To mitigate this issue, manufacturers are developing products that contain fewer chemicals and do not offgas.

Several drywall and finishing products carry the GREENGUARD Environmental Institute label. The third-party certification company tests many types of building products for chemical emissions.

"A contractor’s business is built on his reputation, so the way to make sure that reputation is high is to make sure the products used are truly moisture-resistant.”

Moisture Resistance

Most wallboard manufacturers offer mold- and moisture-resistant products. Lee says, “In regard to moisture and mold protection, there are gypsum-board products with specialized facings and core formulations that resist moisture and protect against the formation of mold.”