EcoRock
Contents |
Material analysis
MasterFormat Number: 09 10 00
Definition
EcoRock is a new gypsum-free alternative drywall material. It is the first premium drywall material designed for sustainable buildings. It contains 80% recycled content and requires 80% less energy to produce. It hangs and finishes like regular drywall, and contributes more potential LEED credits than any other drywall. The product launched in the summer of 2009 and will be released to the market around late spring in 2010. It is claimed to be "the only true green alternative to gypsum drywall. 5X more environmentally friendly than Gypsum." [1]
Manufacturing process
The fly ash, slag, kiln dust and fillers — 85% of which are industrial by-products — react chemically when mixed with water and bind together into a paste that’s poured into sheets. The oven-free process uses just 20 percent of the energy of the typical method. [2]
Cost analysis
- $14 - $20 per 4' X 8' sheet
comparable to current high-end drywall, but expects the price to come down as production and demand increases. [3]
Material properties
Primary structural use
- In place of traditional gypsum drywall in buildings
Material performance
- Meets 100% of ASTM C1396 physical drywall properties
- Used just like gypsum drywall
- Cleaner, smoother score & snap
- Generates less dust than gypsum drywall
- 50% more mold resistant face (fiberglass) and core
- Termite resistant face and core
- Mold-proof, scoring 10 on a 10 point ASTM D3273 rating scale
- Impact resistant
- Ceiling sag resistant
- Tile backer board qualified
Dimension
Available in 1/2" thick and 5/8" thick sheets that measure 8' x 4'
Surfacing
Coated glass mat on face and back
Acoustic property
- Testing in progress - result will be released in late spring 2010
Environmental impact
- Use 80% less energy to produce than gypsum drywall
- Naturally cured and dried, EcoRock eliminates the energy-intensive, high-C02 generating calcining and oven-drying found in gypsum drywall production.
- Made of 80% recycled materials
- EcoRock is made using 80% post-industrial recycled waste, including waste from steel and cement plants—with no gypsum.
- Earned MBDC Cradle to Cradle Gold certification. It is engineered to be completely recycled and designed to be fully reutilized at end of life
- EcoRock can be used as a pH additive for soils and can be returned to the production of EcoRock and other building materials as a valuable raw material. Unlike gypsum, EcoRock may be safely disposed of in landfills if necessary, whereas many landfills will not accept gypsum, making disposal of it problematic.
- The most mold-resistant and lowest emitting drywall
- EcoRock outperforms all other mold resistant drywall by 50%. EcoRock scores the highest ASTM D3273 rating of 10 out of 10, showing zero mold growth over a six week period, (other published tests go only four weeks). No harsh anti-fungal chemicals are used on its surface or within its core. This makes it a much healthier building material in the home.
- Reduces the quantity of indoor air contaminants drastically over any other drywall
- EcoRock generates 60% less dust according to ASTM F0025-04 test, and presents no negative effects of airborne mercury often generated during wallboard production using FGD (recycled) gypsum from coal plants.
- Generates no mercury in production
LEED
Can contribute up to 8 LEED credits in the areas of recycled content, regional materials, low-emitting materials, and innovation in design. See potential credits under LEED 2009 in this spec sheet.
Life Safety & Rating Standards
Flammability rating
- Surface burning characteristics (per ASTM E84): Class A
- Fire rating: ASTM E119, 1 Hour (Type X) for 5/8" EcoRock; None rated for 1/2" EcoRock
References
Notes
- ↑ http://www.seriousmaterials.com/html/ecorock.html
- ↑ http://www.ecolect.net/materials/view/ecorock
- ↑ http://www.inhabitat.com/2008/11/24/ecorock-drywall-by-serious-materials/
Student contributions
- Grace Chen, Spring 2010
Similar materials
External links
Additional resources
- http://www.seriousmaterials.com/html/ecorock.html
- http://www.seriousmaterials.com/EcoRock_Claims.pdf
- http://www.seriousmaterials.com/ecorock_dsheet.pdf
- http://www.astm.org/index.shtml
