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TTL PLC, National Control Centre. DN6 7HH

Specialist PAS 109 Gypsum Testing from Waste Plasterboard

The Testing Lab PLC (TTL) provides PAS 109 gypsum testing services to support the production of reprocessed gypsum from waste plasterboard across England, Scotland and Wales.

Specialist PAS 109 Gypsum Testing from Waste Plasterboard

The Testing Lab PLC (TTL) provides PAS 109 gypsum testing services to support the production of reprocessed gypsum from waste plasterboard across England, Scotland and Wales.

PAS 109 Gypsum Testing Across England, Scotland & Wales

PAS 109 sets out a quality framework for producing reprocessed gypsum from waste plasterboard, ensuring that the recovered material is safe, consistent, and suitable for use in manufacturing new plasterboard or other gypsum-based products. Testing plays a central role in PAS 109 because gypsum recycling carries risks related to contamination, moisture, particle size, and chemical composition, all of which affect product performance and safety.

Purpose of PAS 109 Testing

Testing under PAS 109 helps ensure that:

  • Waste plasterboard is suitable for processing

  • The recycling process is controlled and consistent

  • The final gypsum product meets defined quality specifications

  • Contaminants are identified and managed

  • Reprocessed gypsum is fit for reintroduction into manufacturing supply chains

Key Testing Requirements in PAS 109

  • 1. Input Material Testing

    Before processing, incoming waste plasterboard must be assessed to ensure it is acceptable. Testing and inspection typically include:

    Visual and physical checks

    • Identification of non-gypsum contaminants (e.g., wood, insulation, plastics, metals)

    • Detection of wet, mouldy, or degraded plasterboard

    • Confirmation that waste is plasterboard-based and not other gypsum products

    Chemical considerations

    • Screening for hazardous substances where relevant (e.g., legacy additives, adhesives)

    • Ensuring no prohibited waste streams are included

    These checks help prevent unsuitable material entering the recycling process.

  • 2. Process Control Testing

    PAS 109 requires operators to maintain a controlled recycling process. Testing during processing may include:

    Particle size monitoring

    • Ensuring the crushed gypsum meets required granularity

    • Verifying consistency across batches

    Moisture content

    • Regular measurement of moisture to prevent clumping, reduced product quality, and microbial growth

    Contamination control

    • Monitoring for paper fibre content, foreign materials, and oversized particles

    These tests help ensure the process is stable and outputs remain within specification.

  • 3. Output Material Testing (Reprocessed Gypsum)

    This is the most critical testing stage. PAS 109 defines quality criteria for the final gypsum product, including:

    Chemical composition

    • Purity of calcium sulfate

    • Absence of harmful contaminants

    • Acceptable levels of paper fibre

    Physical properties

    • Particle size distribution

    • Bulk density

    • Moisture content

    Contamination limits
    Testing must confirm that reprocessed gypsum is free from:

    • Plastics

    • Metals

    • Wood

    • Insulation fibres

    • Excessive paper content

    Sampling and frequency
    PAS 109 requires routine sampling, representative batch testing, documented sampling plans, and defined acceptance criteria—supporting traceability and consistent quality.

Documentation and Traceability Requirements

Testing under PAS 109 must be supported by robust documentation, including:

  • Test records for each batch

  • Calibration records for testing equipment

  • Non-conformance reports

  • Corrective action logs

  • Batch traceability from input to output

This documentation is essential for audits and customer assurance.

Contact our PAS 109 gypsum testing team

To discuss PAS 109 gypsum testing for reprocessed gypsum from waste plasterboard across England, Scotland and Wales, or to request a quotation, please contact our experienced and dedicated team:

Tel: 0800 177 7264
Email: [email protected]

Or please complete our online call back form by clicking on the “Call Me” button, and we’ll respond promptly.

Health, Safety, and Environmental Monitoring

Although not always laboratory-based, PAS 109 also expects monitoring of:

  • Dust levels and airborne particulates

  • Safe handling of gypsum fines

  • Environmental controls for storage and transport

These checks support safe operation and compliance with environmental regulations.

Why PAS 109 Testing Matters

Testing is fundamental to PAS 109 because it:

  • Protects manufacturers from receiving substandard gypsum
  • Ensures recycled gypsum performs reliably in new products
  • Reduces environmental impact by enabling safe, high-quality recycling
  • Builds confidence in the recycled gypsum supply chain

WHY CHOOSE THE TESTING LAB PLC FOR PAS 109 GYPSUM TESTING?

Specialist testing provider
Support for PAS 109 testing requirements, helping you demonstrate control of input quality, process consistency, and output specification across England, Scotland and Wales.

Clear, practical reporting
Straightforward reporting that supports batch release decisions, customer assurance, and audit requirements—without unnecessary complexity.

Support for controlled recycling processes
From input checks and process control testing through to output verification, sampling plans, and traceability documentation.

Independent. Nationwide.
Supporting clients across England, Scotland & Wales from our National Control Centre.

Areas we cover

From our National Control Centre, we provide PAS 109 gypsum testing services across:

We can support:

  • Plasterboard recyclers and transfer stations handling waste plasterboard

  • Operators producing reprocessed gypsum for reintroduction into manufacturing supply chains

  • Routine sampling and representative batch testing programmes

  • Defined sampling plans, acceptance criteria, and audit-ready documentation

  • Non-conformance investigation support and corrective action evidence

FREQUENTLY ASKED QUESTIONS ABOUT PAS 109 GYPSUM TESTING

  • Why is testing required under PAS 109?
    Because gypsum recycling can introduce risks from contamination, moisture, particle size variation, and chemical composition—testing helps ensure safe, consistent reprocessed gypsum.

  • What checks are carried out on incoming waste plasterboard?
    Incoming material is typically assessed for non-gypsum contaminants, wet or degraded loads, and confirmation that the waste stream is plasterboard-based.

  • What is process control testing in PAS 109?
    Process control testing helps maintain consistent output, typically including particle size monitoring, moisture checks, and contamination control (such as paper fibre and foreign materials).

  • What is tested on the final reprocessed gypsum output?
    Output testing focuses on chemical composition (including purity and absence of harmful contaminants) and physical properties such as particle size distribution, bulk density, and moisture content, as well as contamination limits.

  • Do you support sampling plans and batch documentation?
    Yes. PAS 109 expects routine sampling, representative batch testing, documented sampling plans, acceptance criteria, and traceability from input to output.

Our Accredited Testing Services

Asbestos Testing & Analysis
UKAS accredited for bulk materials, soils, and air.
Asbestos Consultancy
Expert support for CAR 2012 compliance, asbestos management and project oversight.
Legionella
LCA registered risk assessments, testing, and remedial works.
Geotechnical Laboratory Testing
UKAS accredited soil and material testing.
Water Management
Monitoring and trend data to optimise treatment and reduce risk.
Radon Testing
Externally accredited testing for waste and radon safety.
RAAC Testing
Identify and manage RAAC risks in buildings.
WAC Testing
Soil and waste samples tested for accurate, compliant landfill classification.
WM3 Testing
Testing and reporting to support WM3 waste classification and compliant disposal.
Mundic Block Testing
Specialist testing for concrete degradation.
Effluent Discharge Permit Monitoring
Effluent sampling, laboratory analysis and clear compliance reporting.
PAS 109 Gypsum Testing
Testing recycled gypsum from waste plasterboard, with clear reporting from our Doncaster lab.
XRD Analysis
Non-destructive X-Ray diffraction to identify phases and characterise crystalline materials.
XRF Analysis
Fast, non-destructive elemental analysis for materials and products.
BS 1881-124 Hardened Concrete Testing
Hardened concrete analysis for mix constituents, durability indicators and reporting.
BS 3882 Topsoil Testing
Topsoil testing for BS 3882:2015 classification, quality and suitability.
Coal Tar Testing
Testing reclaimed asphalt for coal tar and PAHs to support classification and compliant management.
HMRC LOI Fines Testing
HMRC-compliant LOI testing for waste fines to support landfill tax classification.
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Douglas
Lothian Hotels Ltd

Dear The Testing Lab PLC,

Many thanks for your prompt and professional asbestos survey report service, I would not hesitate to recommend your company in this regard.

 

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Poole Housing Partnership

This must be an absolute record for getting a report back, considering the surveyor arrived around 3pm – very well done!
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Anonymous
ECORE Construction

Thank you for the very quick response for the quote and scheduling the survey. There’s never any fuss, and always straight forward. Thanks again.

 

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Stuart Meadowcroft
MRICS

Thank you for offering such a prompt turnaround for ACM testing and for your courteous service in doing so – I had a nervous client to placate and knowing the report would be back with them in such a short time was very reassuring to them, and for no more than a basic service from the competition!

 

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Anonymous
ARW Specialist Building Contractors Limited

Bradley, thank you for your efforts at short notice today, please pass on our gratitude to your surveyor Tim who did your company proud!

 

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Pawel Juraszczyk
British Pepper & Spice
H&S Manager

Thank you very much for the air sampling results – and please accept our grateful thanks for resolving this issue so quickly and for the promptness of the report.

Your analyst, Lee, was very helpful and his suggestions and advice appreciated.

We would have no hesitation in recommending The Testing Lab and will be in touch soon with regards arrangements for a full asbestos survey for the rest of the site.

 

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Gary Collinson MCIOB
Hull City Council
Programme Manager

TTL have been working directly as my analyst for the last 12 months on a very complex asbestos removal scheme, they have achieved all of their KPI’s without fail and on a number of occasions surpassed their SLA in acting for us on planning issues associated with the demolition in regard to contamination which cannot be removed as part of the normal sequence of operation.

 

There reports are always issued within timescales and they have policed the reports by the Licensed asbestos contractor faultlessly sometimes in very difficult circumstances.

 

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