The manufacturing process starts with a naturally occurring ore called magnesite, which is magnesium carbonate in composition. Magnesite is one of the most abundant natural minerals in the world with mining operations found on all inhabited continents, including North America. Once mined, raw minerals are calcined (heat-treated) in a furnace to produce magnesium oxide (MgO), which is a non-combustible compound ideal for manufacturing fire-rated construction materials.
Production Process Overview:
- Raw Materials: MgO powder is blended with chloride or sulfate solutions to form a slurry that will eventually cure into MgO cement phase. Prior to curing, reinforcing fibers (usually fiberglass mesh) and mineral fillers like perlite and wood flour may be added to the wet mix to provide enhanced properties in the final panels.
- Panel Forming: The wet mixture is cast into flat sheets of uniform thickness with fiberglass reinforcement and allowed to cure into the final panel.
- Curing: Most panels undergo a two-stage curing process – initial curing (~24 hours), followed by secondary curing over several weeks to ensure moisture stability.
- Finishing: Once cured, edges are trimmed and panels are packaged for shipment.
Although most MgO panels have historically been imported – primarily from China – 2025 marks a turning point. One major manufacturer is already producing MgO panels in the U.S. while several companies are developing plans to launch domestic manufacturing plants, some of which with North American-sourced raw materials. North American capacity is expected to expand rapidly in the coming years.
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