Conventional Plaster
Plasterers often use gypsum to simulate the appearance of surfaces of wood, stone, or metal, on movie and theatrical sets for example
Gypsum plaster (plaster of Paris)
Gypsum plaster, or plaster of Paris, is produced by heating gypsum to about 300°F (150 °C):[1]
CaSO4·2H2O + Heat → CaSO4·½H2O + 1½ H2O (released as steam).
When the dry plaster powder is mixed with water, it re-forms into gypsum. The setting of unmodified plaster starts about 10 minutes after mixing and is complete in about 45 minutes; but not fully set for 72 hours.[2] If plaster or gypsum is heated above 392°F (200°C), anhydrite is formed, which will also re-form as gypsum if mixed with water.[3]
A large gypsum deposit at Montmartre in Paris led gypsum plaster to be commonly known as “plaster of Paris”.[4]
Plasterers often use gypsum to simulate the appearance of surfaces of wood, stone, or metal, on movie and theatrical sets for example. Nowadays, theatrical plasterers often use expanded polystyrene, although the job title remains unchanged.
Plaster of Paris can be used to impregnate gauze bandages to make a sculpting material called modroc. It is used similarly to clay, as it is easily shaped when wet, yet sets into a resilient and lightweight structure. This is the material which was (and sometimes still is) used to make classic plaster orthopedic casts to protect limbs with broken bones. Set modroc is an early example of a composite material.Lime plasterMain article: Lime plaster.
Lime plaster is a mixture of calcium hydroxide and sand (or other inert fillers). Carbon dioxide in the atmosphere causes the plaster to set by transforming the calcium hydroxide into calcium carbonate (limestone). Whitewash is based on the same chemistry.
To make lime plaster, limestone (calcium carbonate) is heated to produce quicklime (calcium oxide). Water is then added to produce slaked lime (calcium hydroxide), which is sold as a wet putty or a white powder. Additional water is added to form a paste prior to use. The paste may be stored in air-tight containers. Once exposed to the atmosphere, the calcium hydroxide turns back into calcium carbonate, causing the plaster to set
Lime plaster was a common building material for wall surfaces in a process known as lath and plaster, whereby a series of wooden strips on a studwork frame was covered with a semi-dry plaster that hardened into a surface. The plaster used in most lath and plaster construction was mainly lime plaster, with a cure time of about a month. To stabilize the lime plaster during curing, small amounts of plaster of Paris were incorporated into the mix. Because plaster of Paris sets quickly, “retardants” were used to slow setting time enough to allow workers to mix large working quantities of lime putty plaster. A modern form of this method uses expanded metal mesh over wood or metal structures, which allows a great freedom of design as it is adaptable to both simple and compound curves. Today this building method has been partly replaced with drywall, also composed mostly of gypsum plaster. In both these methods a primary advantage of the material is that it is resistant to a fire within a room and so can assist in reducing or eliminating structural damage or destruction provided the fire is promptly extinguished.
Lime plaster is used for true frescoes. Pigments, diluted in water, are applied to the still wet plaster.Cement plasterSee also: Cement render.
Cement plaster is a mixture of suitable plaster, sand, portland cement and water which is normally applied to masonry interiors and exteriors to achieve a smooth surface. Interior surfaces sometimes receive a final layer of gypsum plaster. Walls constructed with stock bricks are normally plastered while face brick walls are not plastered. Various cement-based plasters are also used as proprietary spray fireproofing products. These usually use vermiculite as lightweight aggregate. Heavy versions of such plasters are also in use for exterior fireproofing, to protect LPG vessels, pipe bridges and vessel skirts.