Case Studies Of Magnesium Oxide Board In Modular Construction

06 Sep Case Studies Of Magnesium Oxide Board In Modular Construction

Modular construction teams use magnesium oxide boards a lot. These boards are good because they stop fires, keep out water, and last a long time. Industry surveys say magnesium oxide board has many good points:

• Sustainability and eco-friendliness help meet green building rules.

• Strong fire resistance and durability give safety and trust.

• Moisture resistance and mold prevention make them good for wet places.

• Lightweight panels are easy to put in and help block sound.

But magnesium oxide boards also have some problems. They cost more and not everyone knows about them. This can make people use them less in some places. Still, more people notice magnesium oxide. Designers and builders want safer and greener buildings.

Key Takeaways

• Magnesium oxide boards are very good at stopping fires. They also protect against water and mold. They last a long time. This helps buildings stay safe and healthy. These boards do not weigh much. You can put them in place with normal tools. This makes building faster and easier. If you handle and install the boards the right way, they work better. Using the right fasteners stops cracks, rust, and wet spots. This helps the boards stay strong. Magnesium oxide boards help the environment. They use materials that are good for nature. They also lower carbon emissions. Picking boards that are certified and high quality is important. Builders should follow the best steps. This makes buildings safer, stronger, and better for the planet.

Magnesium Oxide Board Overview

Key Properties

Magnesium oxide boards are special in modular construction. They have unique chemical and physical features. The table below shows important properties and why they matter:

Magnesium oxide boards keep their fire resistance even when it is humid or hot. Sometimes the surface gets white as it ages, but the inside stays strong. Builders can make them last longer by adding coatings that resist water. These boards do not scratch, dent, or crack easily. They do not soak up water or let mold grow.

Intended Benefits

Magnesium oxide boards have many good points for modular construction. They protect against fire, so they are used in schools and hospitals. Their water resistance keeps them strong in bathrooms and kitchens. They are also good for green buildings because they do not have harmful chemicals and can be recycled.

Note: Magnesium oxide panels help save money on repairs. They do not get damaged by water, mold, or bumps. This makes them a smart choice for homes and businesses.

Magnesium oxide boards are stronger and last longer than regular building materials. They keep working well even after getting wet and drying out many times. Builders like them because they are easy to put in, which saves time. These boards help make buildings safer, stronger, and better for the planet.

Case Studies in Modular Construction

Residential Projects

Many homes use magnesium oxide panels. Builders pick them for fire safety and to stop water damage. These panels are strong and last a long time. People use them in houses, apartments, and modular homes. Projects in Europe and Australia show both good and bad sides of these panels.

Small cracks can show up in magnesium oxide panels. This happens when buildings move or the weather changes. Water can also make the panels expand and crack. When a house settles, tiny cracks may form. Builders can help by letting panels get used to the room air before putting them in. They leave small spaces between panels. They use flexible caulk and paint that keeps out water. Keeping the air and temperature steady in the house helps stop cracks.

Some homes have had problems with dampness and rust. A study in Denmark found that wet panels can leak salty water. This salty water can rust metal and hurt wood parts. Fixing this can cost a lot of money. In the UK and Australia, some companies stopped using these panels in new homes because of these issues. Even with these problems, many builders still use magnesium oxide panels. They like them for fire safety and stopping mold, especially in bathrooms and kitchens.

Note: Good installation and keeping the air right are important for magnesium oxide panels to work well in homes.

Commercial Projects

Offices, schools, and hospitals use magnesium oxide panels. These panels are strong and safe. They work well in busy places and meet tough building rules. Many offices use them for walls and ceilings. They help stop fires and help buildings get green awards.

• Builders like that these panels do not crack or bend easily.

• Schools and hospitals use them because they stop mold and keep people healthy.

• Stores and offices like that the panels last long and need little care.

• The panels are used as floors in busy places and hold up well.

• Their fire safety makes them a top pick for walls in crowded spots.

One school used magnesium oxide panels to make the building safer from fire. The panels also made the air inside better. In a tall apartment near the sea, the panels stopped water and mold. This kept the building and people safe. These stories show that magnesium oxide panels work well in many types of buildings.

Climate Adaptability

Magnesium oxide panels work well in many places. They do well in wet, coastal, and very hot or cold areas. These panels stop water, mold, and mildew. This makes them great for bathrooms, kitchens, basements, and homes near the sea. Builders in wet places use them because they do not swell or rot like wood. The panels also stop salt from hurting metal parts.

• The panels stay strong in hard weather, like heavy rain and high humidity.

• They make a good base for tiles, even when the weather changes.

• Magnesium oxide panels are light, easy to put in, and fire-safe. This saves money on repairs.

Studies show magnesium oxide panels stay flat and strong in heat or cold. They do not bend or warp like some other boards. This is good for homes that face bad weather. The panels stop fire, mold, and water, so they are used in hurricane areas and other tough places.

Tip: Do not use magnesium oxide panels where it is always very humid, above 93%.

These stories and studies show that magnesium oxide panels work well in many buildings and climates. They are used in homes, offices, and more.

Noncombustibility and Fire Safety

Fire Resistance Performance

Noncombustibility is very important for keeping people safe in modular buildings. Magnesium oxide boards are known for not burning. They do not catch fire or help flames spread, even when it gets very hot. MagPanel® MgO boards have a zero flame spread rating. They stay strong during a fire. This helps buildings like hospitals, schools, and offices follow strict safety rules.

The table below shows how well some magnesium oxide products resist fire:

Magnesium oxide boards can handle heat up to 1200°C. They do not burn for up to four hours. Plywood and OSB fail fast in fire, but these boards do not. They do not make toxic smoke or gases. They let out water vapor in a fire, which cools things down and slows the flames. This makes them great for fire-safe walls, ceilings, and floors in modular buildings.

Certifications and Test Results

Manufacturers must prove their boards do not burn by doing tough tests. These tests include ASTM E119, UL 723 (ASTM E84), and EN 13501-1. The tests show that magnesium oxide boards get top ratings like A1 or Class A. They do not let flames or smoke spread.

• MgO boards stay strong even above 1000°F.

• They pass tough tests, so they can be used in very safe places.

• Lab tests and real fires show they really do not burn.

• Testing makes sure they follow building rules around the world.

• These boards help people get out safely by stopping smoke and fire.

Note: Third-party testing is needed to make sure the boards really do not burn and keep people safe in modular buildings.

Moisture and Durability Issues

Moisture Resistance

Magnesium oxide boards work well in wet places. Their mineral makeup stops mold and mildew from growing. This makes them a good pick for bathrooms, kitchens, basements, and pool areas. Drywall and plywood soak up water and can swell. Magnesium oxide boards do not do this. Builders choose these boards when they need water resistance.

Tip: Magnesium oxide boards work best if you use vapor barriers and seal the joints. This keeps water and mold out of the walls.

Moisture problems happen if the boards have untreated magnesium chloride. These boards can take in water from the air. This can cause salt to leak out, which is called “crying boards.” Salt can rust metal fasteners and steel frames, especially in cold or wet places. Boards made with magnesium sulfate or treated magnesium chloride do not have these problems. Good sealing and vapor barriers help stop moisture issues.

Corrosion and Cracking

Corrosion and cracking are still problems in modular buildings. Old magnesium oxide boards with magnesium chloride can rust steel frames and fasteners. MagPanel® boards use magnesium sulfate, which stops rust and keeps the structure safe. Rust often happens because of chloride and using the wrong fasteners. Builders should use stainless steel or ceramic-coated fasteners for old boards. For MagPanel® boards, use bi-metal drywall screws. Putting a barrier between the board and steel frame helps stop reactions.

Tiny cracks can form if the building moves, the temperature changes, or the board gets wet. Letting boards get used to the room and leaving small gaps helps stop cracks. Using flexible sealants also helps. Keeping the inside air steady helps the boards stay strong.

• Rust links to chloride boards and wrong fasteners.

• Tiny cracks come from changes in the building or weather.

• Using the right fasteners and good methods makes boards last longer.

MagPanel® boards are very tough. They do not break in freeze or thaw, and they resist mold, bugs, and bumps. They keep their shape and strength even after being wet for a long time. This makes them good for busy places that get a lot of use.

Environmental and Structural Impact

Sustainability

Magnesium oxide boards help make buildings greener. Factories use lots of natural magnesium to make these panels. This means they do not need to dig up as many materials that hurt nature. Making these panels uses less energy than making fiber cement boards. This helps lower the amount of carbon released into the air. When the panels dry, they can trap carbon dioxide. This makes the project even better for the planet.

These panels help buildings get green awards like LEED and BREEAM. They last a long time, so you do not need to replace them often. This means less trash over the years. The panels stop mold, mildew, and fire, so they are good for health inside buildings. They do not have harmful chemicals, so the air inside is cleaner. The panels are light and strong. This makes them easy to move and put in. It also helps finish building faster and lowers pollution.

Structural Strength

Magnesium oxide structural panels are important in modular buildings. These panels make walls, floors, and ceilings strong. Tests show magnesium oxide panels are stronger than wood and gypsum. They can hold heavy things without breaking. Fiberglass mesh inside makes the panels tougher. This stops them from cracking or bending when loaded.

• Structural panels hold heavy things and do not bend.

• They do not swell or warp when wet.

• The panels stay the same shape and do not crack.

• They last a long time and stand up to bad weather.

• The panels can take high heat, which helps stop fires.

• Builders like them because they are easy to put in and need little care.

• The panels keep buildings safe even after many years.

Studies show these panels are key for strong modular walls. They help the whole building stay safe and work well. Builders use these panels for safety and to save time. Their steady strength makes them a top pick for new buildings.

Standards and Manufacturing

Quality Variability

Manufacturers make magnesium oxide boards with different quality levels. Some boards have chloride salts or woodchip inside. These things can soak up water from the air or from touching water. Water can build up inside the boards and leak out. This can make metal parts rust and hurt building parts. Sometimes, problems stay hidden until something breaks. Studies in Denmark, Australia, and Canada show bad manufacturing causes rust and damage.

Experts say current tests do not always show how boards work in real buildings. Some warranty companies do not accept these boards in some places. The Centre for Window and Cladding Technology says to be careful with boards that do not have approvals. People are working to make better tests for these boards.

Problems in the supply chain also change board quality. Different ways of making boards can cause them to bend, crack, or break early. Without clear certifications, it is hard to compare boards and slows people from using them. High prices and not knowing the benefits make it hard for buyers to pick magnesium oxide boards.

Tip: Builders should look for certifications and ask for test results before using magnesium oxide boards in modular buildings.

Compliance and Certification

Certifications and standards help make sure magnesium oxide boards are safe and work well. The table below lists important grades and how they are used:

Boards with Class A1 fire rating under EN standards are very safe from fire. Green building awards like LEED and BREEAM notice magnesium oxide boards for being good for the planet and clean air inside. Different rules in different places can make boards cost more and take longer to get approved. Builders can have trouble getting boards because of tariffs, trade rules, or natural disasters. Many companies now try to buy boards locally and use different suppliers to keep costs down and finish projects on time.

Comparison with Alternatives

Fiber Cement Boards

Fiber cement boards are often used instead of magnesium oxide panels in modular buildings. Many builders pick fiber cement because it is cheap and easy to find. But magnesium oxide panels have some clear benefits:

• Magnesium oxide panels are lighter and bend more than fiber cement boards. Workers can carry and put them up more easily.

• You can cut and shape magnesium oxide panels with normal tools. Fiber cement boards need special tools because they are hard and break easily.

• Magnesium oxide panels do a better job stopping fire, water, and mold. This makes them safer and helps them last longer in many buildings.

• Fiber cement boards cost less at first. But they might need extra coatings or treatments to last as long as magnesium oxide panels.

• Magnesium oxide panels cost more at the start. But they save money later because they last longer and need less fixing.

Some places limit magnesium oxide panels because of water problems. Studies in the UK and Denmark found that some panels soaked up water. This caused rust and mold. Builders should check local rules and test panels before using them in modular buildings.

Other Sheathing Options

Builders also look at magnesium oxide panels compared to OSB panels and fire-rated OSB. The table below shows the main differences:

Tip: Magnesium oxide panels are best for safety and lasting a long time. OSB panels are good if you want to save money and install them quickly.

Magnesium oxide panels are great at stopping fire and water. OSB panels cost less but might need more repairs later. Builders should pick the right sheathing for the project and the local weather.

Recommendations for Specifiers

Due Diligence

Specifiers are very important in modular construction projects. They need to be careful when picking magnesium oxide boards. Each board can act differently, so checking them closely is needed.

1. Identify the Product: Specifiers must know the brand and type of magnesium oxide board. Not all boards work the same way.

2. Assess Building Moisture: They should look at the building’s past for leaks or dampness. Too much water can make magnesium oxide boards soak up moisture. This can cause rust or stains.

3. Investigate Failures: If there were problems before, specifiers need to find out why. Problems can come from bad products, mistakes during installation, or outside reasons.

4. Check Chloride Content: Boards with lots of chloride can make rust worse, especially in wet places.

5. Onsite Inspections: Going to the site lets specifiers see how the boards work in real life.

6. Review Research and Claims: Specifiers should read independent studies. They should not trust ads without proof.

7. Avoid High-Humidity Exteriors: Magnesium oxide boards should not be used outside in places that are always very humid.

Tip: Always ask for recent, third-party test results for fire and moisture safety.

The table below shows the main due diligence steps and why they matter:

Best Practices

Following best practices helps magnesium oxide boards work well in modular buildings. Good handling, installing, and finishing stop many problems.

1. Handling and Storage: Carry boards on their side to keep edges safe. Stack them flat on wood, not on the ground. Do not put heavy things on top.

2. Acclimation: Take off the packaging and let boards get used to the room’s air for at least 48 hours before putting them in.

3. Placement and Spacing: Leave a 1/16″ gap between boards on steel frames and a 1/8″ gap on wood frames. This lets the boards expand and stops cracks.

4. Board Orientation: Use the smooth side for finished walls. The rough side is good as a backer.

5. Cutting and Tools: Use special knives or saws made for cement boards. Do not use power saws inside to keep dust down.

6. Framing and Support: Make sure frames are straight and level. Support board ends with joists and plan cuts so edges are at the room’s edge.

7. Fastening: Use screws that do not rust, like 316 stainless steel or ceramic-coated screws. Put screws 6″ apart at the edges and 12″ in the middle. Sink screws a little and do not put them near corners.

8. Joint Treatment and Finishing: Fill seams with polyurea or special epoxy. Use primers and paints that work with alkaline surfaces.

9. Safety Measures: Wear dust masks and safety glasses when cutting or sanding. Use wet cutting or HEPA vacuums to control dust.

10. Additional Precautions: Put a barrier in place when using galvanized steel frames to stop chemical reactions. Always follow local building codes.

Note: Careful planning and correct installation help magnesium oxide boards last longer and work better.

By following these tips, specifiers can lower risks and help modular construction projects succeed with magnesium oxide boards.

Case studies show magnesium oxide boards work well. They stop fires, keep out water, and last long. The table below shows what global projects learned:

Picking the right boards is important for safety. Teams should let boards get used to the room air. They need to use the right screws and follow local rules. Doing these things helps buildings stay safe and strong.

FAQ

What makes magnesium oxide boards different from drywall?

Magnesium oxide boards stop fire, water, and mold. Drywall soaks up water and can break fast. Builders pick magnesium oxide boards for safety and strength. These boards also help with green building rules.

Can magnesium oxide boards be used outside?

Some magnesium oxide boards are made for outdoor use. Builders need to check the board type and local weather. Boards with special coatings work best outside. Always follow what the maker says for putting them in.

Do magnesium oxide boards need special fasteners?

Installers should use stainless steel or ceramic-coated screws. These screws stop rust and keep boards strong. Using the right screws helps boards last longer and keeps buildings safe.

Are magnesium oxide boards safe for people with allergies?

Magnesium oxide boards do not have formaldehyde or bad chemicals. They stop mold and mildew. This makes them a good pick for people with allergies or asthma.

How should builders store magnesium oxide boards before installation?

Builders should keep boards dry and flat. Storing them off the ground stops water damage. Letting boards get used to room air for 48 hours helps stop cracks.