Fifteen-Years-of-Focus-on-One-Board1

Fifteen Years of Focus on One Board

1.Overview

Magnesium oxide board is a high-quality, high-performance, fireproof mineral-based building material widely used to replace plywood, fiber cement panels, OSB, and gypsum wallboards. This material exhibits exceptional versatility in both interior and exterior construction. It primarily consists of a sturdy substance formed through the chemical reaction of elements like magnesium and oxygen, resembling cement. This compound has been historically utilized in world-renowned structures such as the Great Wall of China, the Pantheon in Rome, and Taipei 101.

Rich deposits of magnesium oxide are found in China, Europe, and Canada. For instance, the Great White Mountains in China are estimated to contain enough natural MgO to last another 800 years at the current rate of extraction. Magnesium oxide board is a broadly applicable building material, suitable for everything from subflooring to tile backing, ceilings, walls, and exterior surfaces. It requires a protective coating or treatment when used outdoors.

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Compared to gypsum board, magnesium oxide board is harder and more durable, offering excellent fire resistance, pest resistance, mold resistance, and corrosion resistance. It also provides good sound insulation, impact resistance, and insulation properties. It is noncombustible, non-toxic, has a receptive bonding surface, and does not contain hazardous toxins found in other building materials. Additionally, magnesium oxide board is lightweight yet extremely strong, allowing for thinner materials to replace thicker ones in many applications. Its excellent moisture resistance also contributes to its long lifespan, as exemplified by the Great Wall of China.

Furthermore, magnesium oxide board is easy to process and can be sawed, drilled, router-shaped, scored and snapped, nailed, and painted. Its uses in the construction industry are extensive, including as fireproof materials for ceilings and walls in various buildings like apartment complexes, theaters, airports, and hospitals.

Magnesium oxide board is not only powerful but also environmentally friendly. It contains no ammonia, formaldehyde, benzene, silica, or asbestos, and is completely safe for human use. As a fully recyclable natural product, it leaves minimal carbon footprint and has a negligible environmental impact.

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2.Manufacturing Process

Understanding the Production of Magnesium Oxide Boards

The success of a magnesium oxide (MgO) board hinges critically on the purity of raw materials and the precise ratio of these materials. For magnesium sulfate boards, for example, the proportion of magnesium oxide to magnesium sulfate must reach the correct molar ratio to ensure a complete chemical reaction. This reaction forms a new crystalline structure that solidifies the internal structure of the board, minimizing any residual raw materials and thus stabilizing the final product.

An excess of magnesium oxide can lead to surplus material that, due to its high reactivity, generates significant heat during the reaction. This heat can cause the boards to overheat during curing, leading to rapid moisture loss and resultant deformation. Conversely, if the magnesium oxide content is too low, there may not be enough material to react with the magnesium sulfate, compromising the structural integrity of the board.

It is particularly critical with magnesium chloride boards where excess chloride ions can be disastrous. Improper balance between magnesium oxide and magnesium chloride leads to excess chloride ions, which may precipitate on the surface of the board. The corrosive liquid formed, commonly referred to as efflorescence, results in what is known as 'weeping boards.' Therefore, controlling the purity and ratio of raw materials during the batching process is essential to ensure the board's structural integrity and prevent efflorescence.

Once the raw materials are thoroughly mixed, the process moves to forming, where four layers of mesh are used to ensure adequate toughness. We also incorporate wood dust to enhance the board's toughness further. The materials are segregated into three layers using four layers of mesh, creating customized spaces as required. Notably, when producing laminated boards, the side that will be laminated is densified to enhance the adhesion of the decorative film and ensure it does not deform under tensile stress from the laminating surface.

Adjustments to the formula can be made based on client specifications to achieve different molar ratios, especially important when the board is moved to the curing chamber. The time spent in the curing chamber is crucial. If not properly cured, the boards may overheat, damaging the molds or causing the boards to deform. Conversely, if the boards are too cold, the necessary moisture may not evaporate in time, complicating demolding and increasing time and labor costs. It could even result in the board being scrapped if the moisture cannot be adequately removed.

Our factory is one of the few that has temperature monitoring in the curing chambers. We can monitor the temperature in real-time via mobile devices and receive alerts if there are any discrepancies, allowing our staff to adjust the conditions immediately. After leaving the curing chamber, the boards undergo about a week of natural curing. This stage is crucial to evaporate any remaining moisture thoroughly. For thicker boards, gaps are maintained between the boards to enhance moisture evaporation. If the curing time is insufficient and the boards are shipped too early, any residual moisture trapped due to premature contact between the boards can lead to significant issues once the boards are installed. Before shipment, we ensure that as much of the necessary moisture as possible has evaporated, allowing for worry-free installation.

This optimized content provides a comprehensive look at the careful process involved in producing high-quality magnesium oxide boards, emphasizing the importance of precision in material handling and curing.

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3.Advantages

Gooban MgO Board Advantages

1. **Superior Fire Resistance**
- Achieving A1 fire rating, Gooban MgO boards offer exceptional fire resistance with a tolerance over 1200℃, enhancing structural integrity under high temperatures.

2. **Eco-Friendly Low Carbon**
- As a new type of low-carbon inorganic gel material, Gooban MgO boards significantly reduce energy consumption throughout their production and transportation, supporting sustainable practices.

3. **Lightweight and High Strength**
- Low density yet high strength, with bending resistance 2-3 times greater than common Portland cement, along with excellent impact resistance and toughness.

4. **Water and Moisture Resistance**
- Technologically enhanced for superior water resistance, suitable for various humid environments, maintaining high integrity even after 180 days of immersion.

5. **Insect and Decay Resistance**
- Inorganic composition prevents damage from harmful insects and termites, ideal for high-corrosion environments.

6. **Easy to Process**
- Can be nailed, sawed, and drilled, facilitating quick and easy onsite installation.

7. **Wide Applications**
- Suitable for both interior and exterior decorations and fireproof sheathing in steel structures, meeting diverse architectural needs.

8. **Customizable**
- Offers customization of physical properties to meet specific requirements of different scenarios.

9. **Durable**
- Proven durability through rigorous testing, including 25 wet-dry cycles and 50 freeze-thaw cycles, ensuring long-lasting performance.

3.Advantages
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4.Environmental and Sustainability

Low Carbon Footprint:
Gooban MgO board is a new type of low-carbon inorganic gel material. It significantly reduces total energy consumption and carbon emissions from raw material extraction to production and transportation compared to traditional fireproof materials like gypsum and Portland cement.

Regarding carbon emission factors, traditional cement emits 740 kg CO2eq/t, natural gypsum emits 65 kg CO2eq/t, and Gooban MgO board only 70 kg CO2eq/t.

Here are specific energy and carbon emission comparison data:
- See table for details on formation processes, calcination temperatures, energy consumption, etc.
- Relative to Portland cement, Gooban MgO board consumes about half the energy and emits significantly less CO2.

Carbon Absorption Capability:
Global CO2 emissions from the traditional cement industry account for 5%. Gooban MgO boards have the capability to absorb significant amounts of CO2 from the air, converting it into magnesium carbonate and other carbonates, which helps reduce greenhouse gas emissions. This supports environmental protection and aids in achieving global dual carbon goals.

Eco-Friendliness and Non-Toxicity:

- Asbestos-Free: Contains no forms of asbestos materials.

- Formaldehyde-Free: Tested according to ASTM D6007-14 standards, resulting in zero formaldehyde emissions.

- VOC-Free: Meets ASTM D5116-10 standards, free from benzene and other harmful volatile substances.

- Non-Radioactive:Complies with the non-radioactive nuclide limits set by GB 6566.

Heavy Metal-Free:Free from lead, chromium, arsenic, and other harmful heavy metals.

Solid Waste Utilization: Gooban MgO boards can absorb about 30% of industrial, mining, and construction waste, supporting solid waste recycling. The production process generates no waste, aligning with the development of zero-waste cities.

5.Application

Broad Applications of Magnesium Oxide Boards

Magnesium Oxide Boards (MagPanel® MgO) are becoming increasingly significant in the construction industry, especially given the challenges of skilled labor shortages and rising labor costs. This efficient, multifunctional building material is favored for modern construction due to its significant construction efficiency and cost savings.

1. Indoor Applications:

  • Partitions and Ceilings: MgO boards offer excellent sound insulation and fire resistance, making them ideal for creating safe, quiet living and working environments. Their lightweight nature also makes installation quicker and reduces structural load.
  • Floor Underlay: As an underlay in flooring systems, MgO boards provide additional sound and thermal insulation, enhance the load-bearing capacity and stability of floors, and extend their lifespan.
  • Decorative Panels: MgO boards can be treated with various finishes, including wood and stone textures or paints, combining practicality and aesthetics to meet diverse interior design needs.
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2. Outdoor Applications:

  • Exterior Wall Systems: The weather resistance and moisture resistance of MgO boards make them ideal for exterior wall systems, especially in humid climates. They effectively block moisture ingress, safeguarding the structural integrity.
  • Roof Underlay: When used as roof underlay, MgO boards not only provide additional insulation but also significantly enhance the building's safety due to their fire-resistant properties.
  • Fencing and Outdoor Furniture: Due to their corrosion resistance and insect resistance, MgO boards are suitable for making fences and outdoor furniture that are exposed to the elements, offering ease of maintenance and longevity.

3. Functional Applications:

  • Acoustic Improvement: In venues requiring acoustic management, such as theaters, concert halls, and recording studios, MgO boards serve as acoustic panels, effectively improving sound quality and propagation.
  • Fire Barriers: In environments that demand high fire safety, such as subway stations and tunnels, MgO boards are widely used due to their excellent fire resistance, serving as fire barriers and protecting structures.

These application examples demonstrate the versatility and cost-effectiveness of MgO boards in the modern building materials market, securing their place in the field of construction materials.