Why Magnesium Oxide Wall Board Outperforms Gypsum Board: Real Test Results -- MagMatrix Brand BMSC 517 New Sulfate MGO Board Advantages

MgO wall board can withstand temperatures up to 1,472°F (800°C). This makes it a much better fire-resistant option than standard gypsum board, which starts to carbonize at just 200°C. Ground testing shows apparent differences between these two popular construction materials.

Our detailed analysis of MgO board vs drywall reveals that magnesium oxide drywall outperforms traditional options in several ways. MgO wall board comes with an A1 non-combustible rating for superior fire protection. The board's exceptional moisture resistance makes it perfect for bathrooms and kitchens. The MgO board's durability stands out, with an impact strength of ≥ 4.5 kJ, compared to gypsum's ≤ 1 kJ. This means it lasts longer even in harsh environments.

In this piece, we'll delve into the test results that demonstrate why builders who prioritize safety, durability, and long-term value are increasingly opting for MgO boards.

What is Magnesium Oxide Wall Board?

Magnesium oxide wallboard is a mineral-based building material that offers both exceptional durability and versatile performance. This innovative construction material uses magnesium oxide (MgO) as its base - a strong cement-like substance that forms when magnesium and oxygen atoms bond into crystals.

How MgO board is made

Making MgO board requires several precise steps. Raw materials, such as magnesium oxide powder and magnesium sulfate, as well as reinforcement materials like perlite, wood fibers, or fiberglass mesh, require precise measurement. These ingredients mix to create a uniform slurry. The mixture then proceeds to a production line, where workers embed non-woven fabric and fiberglass mesh to enhance its stability.

The boards then go through a two-phase curing process. The first phase starts the setting reactions in a controlled environment. The second phase lasts up to seven days, allowing the board to develop its final mechanical properties. The last step involves drying and cutting the boards to standard sizes. You can find these boards in 4×8 ft sheets, ranging in thickness from 6mm to 20mm.

Key differences from traditional drywall

MgO boards stand apart from gypsum drywall in several ways. Unlike gypsum boards, which use paper layers, MgO boards don't require a paper facing. This makes them better at fighting off moisture and mold. These boards can also handle much higher temperatures than regular gypsum products.

MgO boards keep their strength even after getting wet. Regular gypsum boards lose 36-52% of their flexural strength after going through wet-dry cycles, but MgO boards barely change. They're also tougher and can withstand more impact than gypsum, with better resistance when pulling out fasteners.

Typical uses of magnesium oxide wallboard

Construction projects use MgO boards in many ways. Inside buildings, they work great as wall panels, ceiling materials, subflooring, and tile backing. Bathrooms, kitchens, and other places with high humidity are perfect spots for these boards.

Outside, builders use them for sheathing, fascias, soffits, trim work, and under roofing materials. These boards also work exceptionally well in areas that require strong fire protection, such as firewalls, fire-rated partitions, and shaft liners.

Both homes and commercial buildings now use MgO boards more frequently, especially in areas that experience harsh weather or require stringent fire safety measures.

Performance Comparison: MgO Board vs Gypsum Board

Laboratory tests have shown that magnesium oxide wallboard outperforms traditional gypsum board in several key areas. Let's examine the test results that highlight these differences.

Fire resistance: Real test results

Independent fire testing demonstrates that magnesium oxide wallboard from Jinpeng Group’s MagMatrix Brand Perseverance model sheathing panel meets the ASTM E136 non-combustible classification. The board withstands temperatures up to 1,472°F (800°C) without structural damage.

Quality MgO boards achieve the lowest possible ratings in standardized ASTM E84 tests with a flame spread index of 0 and smoke developed index of 0. MgO boards maintain fire resistance for up to 4 hours, while standard gypsum products provide only 30-60 minutes of protection. MgO boards stay structurally intact during fires and don't release toxic fumes, creating a safer environment.

Water and mold resistance in humid environments

Tests confirm MgO boards' moisture absorption is just 0.34% compared to gypsum board's 3%. This notable difference means that quality MgO sheathing can withstand complete submersion for 100 days without deteriorating. MgO board'’ inorganic composition prevents microbial growth in humid environments, scoring a perfect 0/0/0 on the ASTM G21 fungal resistance test. These boards maintain their structural integrity in damp areas, such as bathrooms and kitchens.

Impact strength and durability under stress

Lab impact tests show that MgO boards remain intact under conditions that cause oriented strand board to crack or splinter. Their impact strength rating is 4.5 kilojoules, which is a significant improvement, as it outperforms gypsum board's rating of approximately one kilojoule. A single #10-13 pancake head screw in half-inch MgO sheathing can support more than 155 pounds, nearly five times the standard requirement.

Sound insulation capabilities

The MgO board's dense composition effectively reduces sound transmission. A 6mm MgO board reduces noise by 29 decibels, whereas regular drywall on wood studs without insulation has an STC rating of approximately 33. MgO board assemblies achieve impressive STC ratings between 53 and 54 when combined with metal studs and rock wool insulation. This makes them ideal for spaces where sound control is crucial.

Installation and Handling Differences

Installing magnesium oxide wallboard presents unique challenges and benefits when compared to traditional gypsum drywall. Builders can make more informed choices about materials by understanding these differences.

Ease of cutting and shaping

Magnesium oxide drywall's strength makes it challenging to work with. Gypsum board can be cut easily with a utility knife. MgO board needs carbide-tipped scoring knives or circular saws with special blades. Fiber cement shears are ideal for making precise cuts. The brittle nature of MgO board means you should handle it carefully to avoid edge damage.

Weight and density comparison

MgO wall board is denser (0.85–1.2 g/cm³) than gypsum board (1.2-1.3 g/cm³). This makes it perform better, but MgO boards are heavier and more rigid to move around. The extra weight affects how you install it, and you may need more support or assistance from an extra pair of hands.

Tools and skills required for installation

You'll need these items to install magnesium oxide wallboard:

• Safety gear (dust mask, gloves, safety glasses)

• Special fasteners (corrosion-resistant screws)

• Cutting tools (circular saw with carbide blade)

  
  

Gypsum installation is a relatively straightforward process that requires basic equipment. MgO boards help you complete projects faster, as they're ready to use immediately after installation. Gypsum takes up to seven days to cure properly.

Cost, Longevity, and Environmental Impact

The economic value of building materials extends far beyond their purchase price. An accurate cost analysis of wallboard options must include both immediate expenses and future financial implications.

Original cost vs long-term value

These materials show a substantial upfront price difference. Magnesium oxide wallboard costs between USD 1.50 and USD 2.50 per square foot. This price triples the cost of gypsum board, from USD 0.50 to USD 1.00 per square foot. A standard 4ft × 8ft MgO board sheet ranges from USD 48.00 to USD 80.00, depending on the thickness and brand. Complex production processes drive MgO's higher price point.

Maintenance and replacement frequency

MgO board excels in longevity calculations. Magnesium oxide wallboard lasts 20-30 years, which doubles the durability of gypsum products, which typically last 10-15 years. Its resistance to water damage, fire, mold, and pests means minimal maintenance. These features revolutionize the cost equation, turning the higher purchase price into significant savings.

Recyclability and eco-friendliness

MgO boards lead the environmental race throughout their lifecycle. Manufacturing produces only 340 kg of CO2 per ton, while gypsum generates 740 kg. MgO boards capture 20-40% of their CO2 through passive carbonation over a 15-year period. These boards offer complete recyclability - they serve smaller applications, become filler for new construction, or serve as soil additives to keep people fed. Gypsum creates harmful hydrogen sulfide gas in landfills.

Conclusion

The facts are crystal clear - magnesium oxide wallboard is the best choice for today's construction needs. Our tests show MgO boards have significant advantages over regular gypsum products. These boards can withstand temperatures four times higher than standard drywall. They also achieve perfect zero ratings in flame spread and smoke development tests.

MgO boards really shine when it comes to water resistance. A tiny 0.34% absorption rate makes them perfect for bathrooms, kitchens, and other wet areas. Their impact strength exceeds 4.5 kilojoules, which makes them incredibly tough building materials.

The boards' higher price tag might raise eyebrows at first. But their 20-30 year lifespan is twice that of standard gypsum products. The math works out in your favor when you factor in fewer replacements and minimal upkeep needs.

The environmental benefits of MgO boards are impressive, too. Manufacturing creates less than half the carbon dioxide that gypsum does. These boards actually absorb 20-40% of their CO2 emissions during their lifetime. They're also completely recyclable, unlike gypsum products that can release harmful gases in landfills.

Our detailed test results build a strong case for magnesium oxide wallboard. It's the wise choice for projects where safety, durability, and sustainability count. Yes, there are setup challenges and higher upfront costs. However, the exceptional performance of MgO boards makes them worth every penny for builders who value long-term quality.

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