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Magnesium Oxide Board vs Fire Rated Gypsum Board

Magnesium oxide (MgO) board and gypsum board are both popular materials used in construction, but they differ significantly in terms of properties, performance, and applications. Here's a comparison:


Composition and Manufacturing


MgO Board: Made from magnesium oxide, an eco-friendly mineral, along with other non-organic materials, water, and fibers. It is cured at body-high temperatures.


Fire Rated Gypsum Board: Made primarily from gypsum (calcium sulfate dihydrate), sandwiched between paper layers. It often contains additives for fire resistance.





Fire Resistance


MgO Board: Naturally fire-resistant, offering superior fire protection without additional chemicals. It is non-combustible and often has fire ratings as high as 4 hours, making it ideal for fire-rated assemblies.


Fire Rated Gypsum Board: Fire-rated gypsum (Type X) is treated with additives to increase fire resistance, but standard gypsum boards offer less protection. Fire ratings typically range from 30 minutes to 1 hour.


Moisture and Mold Resistance


MgO Board: Highly resistant to moisture, mold, and mildew, which makes it suitable for humid or wet environments. It does not degrade when exposed to water.


Fire Rated Gypsum Board: Regular gypsum boards are susceptible to moisture, leading to mold growth and deterioration. Moisture-resistant versions (greenboard) are available but still perform poorly compared to MgO in wet conditions.


Strength and Durability


MgO Board: Stronger and more impact-resistant than gypsum. It can withstand higher shear forces, making it suitable for structural applications.


Fire Rated Gypsum Board: Less impact-resistant, and it tends to crumble or break under pressure. It's mostly used in non-structural applications like partition walls and ceilings.


Weight and Handling


MgO Board: Slightly heavier but generally easier to handle and install because it requires fewer layers to achieve fire and moisture protection.


Fire Rated Gypsum Board: Lighter but may require multiple layers to meet fire code requirements, increasing labor time and material costs.


Environmental Impact


MgO Board: Has a lower carbon footprint due to a cleaner manufacturing process and abundant, non-toxic raw materials. It is considered a more sustainable option.


Fire Rated Gypsum Board: Gypsum extraction and processing are more energy-intensive. The cutting and handling of gypsum boards may release dust, which can be harmful, especially if the board contains fly ash toxins.


Indoor Air Quality


MgO Board: Contains no harmful chemicals like formaldehyde, silica, or asbestos, making it a safer choice for indoor air quality. It’s also mold-resistant, contributing to healthier interiors.


Fire Rated Gypsum Board: While it generally does not contain harmful chemicals, it can still contribute to poor indoor air quality in case of moisture infiltration, which leads to mold growth.


Applications


MgO Board: Ideal for high-performance construction, including fire-rated walls, floors, roofs, and structural sheathing. It’s commonly used in exterior wall assemblies, humid environments, and where higher durability is needed.


Fire Rated Gypsum Board: Widely used for interior partition walls and ceilings in residential and commercial construction. It’s more common in drywall applications.


Cost


MgO Board: Generally more expensive upfront due to its superior performance characteristics but may save costs in the long run by eliminating the need for extra layers or repair costs from water or fire damage.


Fire Rated Gypsum Board: Typically cheaper in initial cost, making it a popular choice for budget-conscious projects, though additional layers may be needed for fire and moisture resistance.


Summary


MgO board is superior to gypsum board in terms of fire resistance, moisture resistance, strength, and sustainability. It’s ideal for projects requiring higher performance, especially in fire-rated or wet environments. Gypsum board, on the other hand, is a cost-effective and lightweight option commonly used for interior walls and ceilings in less demanding environments.


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