Plaster

Plaster

Plaster is a building material used for the protective and/or decorative coating of walls and ceilings and for moulding and casting decorative elements. In English "plaster" usually means a material used for the interiors of buildings, while "render" commonly refers to external applications. Another imprecise term used for the material is stucco, which is also often used for plasterwork that is worked in some way to produce relief decoration, rather than flat surfaces.

The most common types of plaster mainly contain either gypsum, lime, or cement, but all work in a similar way. The plaster is manufactured as a dry powder and is mixed with water to form a stiff but workable paste immediately before it is applied to the surface. The reaction with water liberates heat through crystallization and the hydrated plaster then hardens.

Plaster can be relatively easily worked with metal tools or even sandpaper, and can be moulded, either on site or to make pre-formed sections in advance, which are put in place with adhesive. Plaster is not a strong material; it is suitable for finishing, rather than load-bearing, and when thickly applied for decoration may require a hidden supporting framework, usually in metal.

·      Gypsum plaster

Gypsum plaster, or plaster of Paris, is produced by heating gypsum to about 300 °F (150 °C):

CaSO₄·2H₂O + heat → CaSO₄·0.5H₂O + 1.5H₂O (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. If plaster or gypsum is heated above 266 °F (130 °C), hemihydrate is formed, which will also re-form as gypsum if mixed with water.

On heating to 180 °C, the nearly water-free form, called γ-anhydrite (CaSO₄·nH₂O where n = 0 to 0.05) is produced. γ-Anhydrite reacts slowly with water to return to the dihydrate state, a property exploited in some commercial desiccants. On heating above 250 °C, the completely anhydrous form called β-anhydrite or dead burned plaster is formed.

A large gypsum deposit at Montmartre in Paris led "calcined gypsum" (roasted gypsum or gypsum plaster) to be commonly known as "plaster of Paris".

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 plaster bandages. 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 that was (and sometimes still is) used to make classic plaster orthopediccasts to protect limbs with broken bones, the artistic use having been partly inspired by the medical use (see orthopediccast). Set Modroc is an early example of a composite material. The hydration of plaster of Paris relies on the reaction of water with the dehydrated or partially hydrated calcium sulfate present in the plaster.

·    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 above approximately 850 °C 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 airtight containers. When exposed to the atmosphere, the calcium hydroxide very slowly turns back into calcium carbonate through reaction with atmospheric carbon dioxide, causing the plaster to increase in strength.

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 frescoes, where pigments, diluted in water, are applied to the still wet plaster.

USA and Iran are the main plaster producers in the world.

·    Cement plaster

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.

Cement plaster was first introduced in America around 1909 and was often called by the generic name adamant plaster after a prominent manufacturer of the time. The advantages of cement plaster noted at that time were its strength, hardness, quick setting time and durability.

·      Heat resistant plaster

Heat resistant plaster is a building material used for coating walls and chimney breasts. Its purpose is to replace conventional gypsum plasters in cases where the temperature can get too high for gypsum plaster to stay on the wall. Heat resistant plaster should be used in cases where the wall is likely to exceed temperatures of 50 °C.

Ø  Uses:-

v   Architecture

Plaster may also be used to create complex detailing for use in room interiors. These may be geometric (simulating wood or stone) or naturalistic (simulating leaves, vines, and flowers). These are also often used to simulate wood or stone detailing found in more substantial buildings.

In modern days this material is also used for FalseCeiling. In this, the powder form is converted in a sheet form and the sheet is then attached to the basic ceiling with the help of fasteners. It is done in various designs containing various combinations of lights and colors. The common use of this plaster can be seen in the construction of houses. After the construction, direct painting is not possible, here comes the use of plaster. The walls are painted with the plaster which is nothing but calcium carbonate. After drying the calcium carbonate plaster turns white and then the wall is ready to be painted

v   Art

Many of the greatest mural paintings in Europe, like Michelangelo's Sistine Chapel ceiling, are executed in fresco, meaning they are painted on a thin layer of wet plaster, called intonaco; the pigments sink into this layer so that the plaster itself becomes the medium holding them, which accounts for the excellent durability of fresco. Additional work may be added a secco on top of the dry plaster, though this is generally less durable.

Plaster (often called stucco in this context) is a far easier material for making reliefs than stone or wood, and was widely used for large interior wall-reliefs in Egypt and the Near East from antiquity into Islamic times (latterly for architectural decoration, as at the Alhambra), Rome, and Europe from at least the Renaissance, as well as probably elsewhere. However, it needs very good conditions to survive long in unmaintained buildings – Roman decorative plasterwork is mainly known from Pompeii and other sites buried by ash from Mount Vesuvius.

·    Fire protection

Plasters have been in use in passive fire protection, as fireproofing products, for many decades.

The finished plaster releases water vapor when exposed to flame, acting to slow the spread of the fire, for as much as an hour or two depending on thickness. It also provides some insulation to retard heat flow into structural steel elements, that would otherwise lose their strength and collapse in a fire. Early versions of these plasters have used asbestos fibres, which have by now been outlawed in industrialized nations and have caused significant removal and re-coating work. More modern plasters fall into the following categories:

·        fibrous (including mineral wool and glass fiber)

·        cement mixtures either with mineral wool or with vermiculite

·        gypsum plasters, leavened with polystyrene beads, as well as chemical expansion agents to decrease the density of the finished produc.

Ø Plastering Deductions as per IS Code 1200

ü For small opening up to 0.5 m2 area, no deduction in plastering is made For opening of size 0.5m2 to 3m2 area, deduction is made on one face of the wall.

ü For openings of size above 3m2, deduction is made on both faces of the wall,but the area of sill, jamb and soffits of the opening is added.

ü There are many other clauses in IS Code such as:
1. If both sides of wall are plastered with a different mix
2. If only one side of the wall is plastered and other side is not