Abstract: Gypsum board is formed into a continuous sheet by depositing an aqueous slurry of calcium sulfate hemihydrate, including conventional additives, between two paper cover sheets on a moving conveyor. After the slurry has reached the initial stiffening degree of set and before the slurry has reached a final or temperature rise set, and in the preferred form before it has reached a Vicat set, the moving sheet is transversely cut into individual boards by means of a high pressure and velocity fluid cutting jet. Since the cutting may be carried out before the Vicat set is reached, the board line may be operated at an increased velocity, thereby enabling a particular board line materially to increase its production within a given period of time and to use conveying equipment which is shorter in length.

Abstract: A pallet comprising a generally flat top sheet and a generally flat bottom sheet spaced from the top sheet. A plurality of sills constructed from elongate generally flat rehydrated gypsum strips are sandwiched between the top and bottom sheets. A water-impervious cover is closely positioned over the sheets and over the edges of the sills.

Abstract: A predecorated wall panel is disclosed for use in forming walls in which the joints between the panels are not to be finished. The panel includes a rigid core of green hydrated gypsum with a layer of resilient deformable material along at least one edge thereof being adhesively affixed thereto and a decorative sheet covering the front surface and side edge surface of the panel with a decorative sheet being under tension in the vicinity of one edge surface thereby partially compressing the deformable material and enabling two or more panels to be positioned with a core edge surface adjacent to each other thereby presenting an attractive appearance.