How Chloride-Free MgO Boards Are Made Step by Step

05 Jul How Chloride-Free MgO Boards Are Made Step by Step

Chloride-free magnesium oxide board making uses a special process. This process mixes a secret, chloride-free formula with careful checks at every step. The steps make sure the boards have very low chlorate left over. The average amount is just 0.0183 mg/kg. The boards also keep safe levels of spore-forming bacteria. This shows the cleaning method works well.

The chloride free mgo board guide says each board is strong and steady. This makes these boards different from other boards.

Key Takeaways

• Chloride-free MgO boards use special materials. Careful mixing makes the boards strong, safe, and water-resistant.
• Additives and reinforcements like fiberglass mesh stop cracks. They help the boards last longer in hard conditions.
• The production process uses careful measuring, molding, pressing, curing, and drying. This makes sure each board is high quality and strong.
• Chloride-free boards fight mold, rust, and fire better than chloride-based boards. This makes them great for wet or dangerous places.
• Quality checks happen at every step. These checks make sure the boards stay strong, safe, and easy to install in homes and buildings.

Materials

MgO and Fillers

Mgo board makers pick their materials very carefully. They do not use magnesium chloride. Instead, they choose sulfate-based binders. This makes each board last longer and stay safer. Research shows sulfate-based binders, like magnesium sulfate, stop rust and water harm. These binders also help block carbonation and keep out chloride.

The main part of the board is mgo. It comes from natural rocks. Mgo gives the board its strength and stops fires. It can handle heat up to 1200ºC. It does not melt or make dangerous gases. This keeps the magnesium oxide board safe in places with fire risk.

Fillers are important for how the boards work and feel. Some common fillers are perlite, vermiculite, and wood fibers. Perlite and vermiculite make the board lighter and warmer. Wood fibers help the board bend and stay strong. Some boards have fiberglass mesh inside the mgo. This mesh helps stop cracks and breaks when the board is under pressure.

Note: Every time mgo and fillers are used, they get checked. Quality teams look at how pure they are, their size, and how wet they are. This makes sure each board is strong, safe, and lasts a long time.

Tests show these boards fight water, mold, and mildew better than drywall or plywood. The mgo and fillers work together to keep the board steady in wet places. This makes the boards great for bathrooms, kitchens, and other damp rooms.

Additives and Reinforcements

Additives and reinforcements help mgo boards work better. Makers use different additives to give the board special features. Flame retardants help stop fires. UV stabilizers protect the board from sun damage. Lubricants and other helpers make the mgo mix easy to shape. Antioxidants help the board last longer outside.

Reinforcements like fiberglass mesh, carbon fibers, and mineral fillers make the board stronger. Glass fibers soak up energy and stop cracks from getting bigger. This makes the boards tougher and harder to break. Some boards use nanoparticles to make them even stronger and keep their shape.

Additives and reinforcements help in many ways:

• They make the board stronger and stop small cracks.
• They help the board keep its shape when it gets hot or cold.
• They help the board stand up to chemicals and bad weather.
• They make the boards lighter and easier to move.

Industry rules say to pick additives based on what the mgo board needs. Makers think about how strong, stable, and cheap the board should be. New ideas include using recycled and plant-based additives to help the planet.

Tip: The right mix of mgo, fillers, and additives makes sure every board is safe and works well. This careful picking means the boards are non-toxic, good for people with allergies, and safe to use inside.

Mixing

Precise Batching

Making mgo boards starts with careful measuring. Every ingredient, like mgo powder, fillers, and additives, must be weighed exactly. Machines help control the recipe and watch each step. These machines use systems called PLC and SCADA. Workers follow strict recipes to make sure every board is the same.

Workers check the measuring in many ways. The table below lists some ways they check the process:

The process also uses electronic records and golden batch checks. These tools help track each batch and make sure boards are made right. Workers can change the recipe if the weather or room changes. This keeps the process steady and safe.

Homogeneous Slurry

After measuring, the next step is mixing everything into a smooth slurry. The goal is to make sure every part of the board is the same. Special mixers break up lumps and spread the mgo, fillers, and additives evenly.

Several checks help make sure the slurry is mixed well:

• Viscosity and yield stress show if the slurry is smooth.
• Workers check particle size and solids to keep them in range.
• Mixing can use hydrodynamic shear, ball-mill, or ultrasonic methods. Each way uses different speeds and times for the best mix.
• Workers use computer models to see how the slurry moves and mixes.

These steps help make sure the slurry is even. This makes every board strong, smooth, and ready for the next step.

Forming

Molding

Mgo board production moves to the molding stage after mixing. Workers pour the smooth slurry into flat molds. These molds shape the board to the right size and thickness. Each mold holds a layer of fiberglass mesh or other reinforcements. The mesh sits in the middle of the slurry. This step helps the board resist cracks and breaks.

The molding process must stay controlled. Workers check the mold temperature and how fast the slurry spreads. If the slurry spreads too fast or slow, the board may not form right. The mgo board production team uses special tools to keep the molds even. They also watch for air bubbles or gaps. These checks help every board stay strong and smooth.

Experimental flexural tests on composite panels show that the molding technique, with careful placement of glass-fiber mesh, gives boards high strength and flexibility. The tests also show that the right molding process improves fire resistance. Boards made with this method work well in modular panel systems.

Long-term studies on over 1000 samples confirm that the molding process, when paired with the right materials, makes boards that last. Boards made with magnesium oxysulfate cement do not show the ‘crying’ problem seen in other types. These boards stay strong and resist moisture, even after years in humid air.

Pressing

After molding, the mgo board production process uses pressing to finish the board shape. Workers place the filled molds under a press. The press flattens the slurry and removes extra air. This step makes the board dense and smooth. Pressing also helps the board stick to the mesh and other reinforcements.

The production process uses different pressures for different board types. Thicker boards need more pressure. The press time and force affect the final board strength. Workers check the thickness and surface after pressing. If the board does not meet the standards, they adjust the process.

Pressing is key for making sure each board has the right size and strength. It also helps the board surface stay flat and ready for the next steps. Good pressing means the boards will not warp or crack later.

Tip: Careful molding and pressing in mgo board production help create boards that are strong, safe, and ready for many uses.

Curing and Drying

Controlled Curing

Curing helps the MgO board get strong and safe. Workers put the boards in special rooms. They control the heat and wetness in these rooms. The temperature stays between 50°F and 75°F. The humidity stays between 80% and 90%. Boards stay in these rooms for 7 to 28 days. The time depends on the mix and project.

Workers use many tests to check curing:

• They test how much weight the board can hold at 7, 14, and 28 days.
• They use rebound hammer and sound wave tests.
• They check how hard it is to push into the board.
• They look for cracks or color changes.

These steps help the boards cure the right way. Workers use curing compounds to keep water in and dry the board slowly. These compounds also meet strict VOC rules. They test how much water stays in and how fast the board dries. This stops weak spots or damage on the surface. Careful curing makes the boards strong and safe.

Note: Good curing helps the board last longer and stay strong in wet or rough places.

Demolding

After curing, workers take the boards out of the molds. They do this carefully to stop cracks or damage. Studies show rough or sticky molds can hurt the boards. To fix this, workers use smooth molds and special coatings. These coatings stop the board from sticking. Some factories use spiral molds or soft materials. This makes it easier to take out the boards and keeps their shape.

Important things for safe demolding:

• Smooth molds lower friction.
• Special coatings help the board come out clean.
• Spiral and soft molds stop cracks.

These steps keep the boards strong and free from damage for the next step.

Final Drying

The last step is final drying. Workers move the boards to rooms with steady air and gentle heat. This takes out any water left inside. How long it takes depends on the board’s thickness and room conditions. Workers check the boards for water before they leave the factory. Dry boards do not get mold, stay strong, and are ready to ship or use.

Tip: Careful drying helps the boards keep their shape and strength for a long time.

Finishing and Inspection

Cutting and Edges

After the boards dry, workers take them to be cut. Machines shape each board to the right size. Laser cutting is fast and very exact. It makes smooth edges without rough spots. Laser cutting also does not burn the board. For many boards, rotary die cutting is used. This way gives clean cuts every time. If a board needs a special shape, workers use die cutting or photochemical machining. These methods help keep the edges neat and strong.

Some ways to cut and finish edges are:

• Laser cutting for fast, exact work
• Rotary die cutting for lots of boards
• Die cutting for special shapes
• Slitting to make thin boards
• Laser Microjet cutting to stop heat damage

After cutting, workers check each board. They look for chips, cracks, or rough spots. If they find problems, they fix them right away. Smooth edges help the boards fit well in buildings. Good edges also make the boards stronger and last longer.

Quality Control

Quality control is very important before boards leave the factory. Workers test each board for free chloride, strength, and moisture. They use special tools to check how much chloride is left. Low chloride means the board will not rust or get water damage. Workers bend and press the board to test its strength. They also check if the board is dry enough to use safely.

Before shipping, supervisors watch workers load the boards. They make sure the boards are stacked safely. Every batch is written down and tracked. This helps keep the boards safe while moving. Careful checks and records help builders trust the boards will work well.

Chloride Free MgO Board Guide: Comparison

Chloride-Free vs. Chloride-Based

The chloride free mgo board guide points out big differences between the two types of boards. Chloride-free boards use a special mix that does not have magnesium chloride. This makes them better at stopping water and rust. Metal parts do not rust when these boards are used. Chloride-based boards soak up more water. This can make them swell, grow mold, or hurt other things nearby.

Chloride-free boards are also safer in fires. They do not let out bad gases when they get hot. Chloride-based boards can break down faster in a fire. They might give off smoke or harmful fumes. The chloride free mgo board guide says chloride-free boards keep their shape and strength even after being in heat or wet air for a long time.

Key Benefits

The chloride free mgo board guide lists many good things for builders and homeowners. Chloride-free boards last a long time and stay strong in wet, hot, or cold places. These boards do not let mold, mildew, or water hurt them. They also keep metal fasteners and frames from rusting.

Research shows chloride-free boards are better at handling heat and fire. They stay strong at high temperatures and do not fall apart quickly. Studies on other chloride-free things, like halogen-free PCBs, show they take in less water and handle heat better. This means they last longer and work well in tough places.

Main benefits of chloride-free boards:

• They stop water, mold, and rust.
• They are strong and safe in fires.
• They handle heat and fire better in hard places.
• They last a long time with less chance of damage.

Note: Builders trust the chloride free mgo board guide because it shows these boards are safer and work better than chloride-based boards. They pick these boards for jobs that need strength, safety, and protection from tough weather.

Chloride-free MgO boards are strong and safe. Every step, like mixing and checking, helps make tough boards. Quality checks make sure each board is made right. Builders and homeowners can use these boards in wet or risky places.

• The process is reliable
• These boards are safe for many jobs
• They last a long time

Picking chloride-free boards means you get more safety and value.

FAQ

What makes chloride-free MgO boards safer than regular MgO boards?

Chloride-free MgO boards do not contain magnesium chloride. This means they do not cause rust on metal parts. They also resist water and mold better. Builders trust these boards for safe and long-lasting projects.

Can people use chloride-free MgO boards in wet areas?

Yes, people can use these boards in bathrooms, kitchens, and basements. The boards resist water and do not swell or grow mold. Builders often pick them for places with lots of moisture.

How do chloride-free MgO boards compare to drywall?

Chloride-free MgO boards last longer and stay strong in tough conditions.

Are chloride-free MgO boards easy to install?

Most workers find these boards easy to cut and fasten. Standard tools work well. The boards stay flat and do not crack easily. Builders can use screws or nails for quick installation.