Accelerating the hydration of calcium sulfate hemihydrate via high energy mixing

High energy mixing of calcium sulfate hemihydrate/water slurries provides a means to accelerate the hydration leading to gypsum formation. Additional benefits associated with high energy mixing include enhanced strength of the resulting gypsum casts. In order to exploit the advantages of high energy mixing, an understanding of the relationship between mixing energy and set acceleration is needed. The present study investigated the relationship between a chemical accelerator and high energy mixing for the purpose of set acceleration. A mathematical model of this relationship allows calculation of the time to achieve 50% hydration given the added specific mixing energy, the percentage of added chemical accelerator by weight of stucco, and the water to stucco ratio for a given slurry. Use of this model along with experimental data allowed a comparison of the accelerative efficacy of mixing energy relative to chemical accelerator. The results show that the accelerative capacity of high energy mixing is rather modest compared to that of the chemical accelerator, with a ten-fold increase in mixing energy required to maintain the same time to achieve 50% hydration when the chemical accelerator loading is reduced by 0.03%.