Abstract: In general, the present invention is directed to the use of particular phosphorus containing compounds for making a gypsum board. The phosphorus containing compound may be a phosphite or a phosphate having a certain formula. In this regard, the present invention is directed to a slurry for making a gypsum board wherein the slurry includes such phosphorus containing compound. The present invention is also directed to a method of making a gypsum board from the slurry as well as a resulting gypsum board.

Abstract: A system and method for introducing a slurry mixture for making gypsum board is disclosed. The system includes a mixer for mixing slurry and directing it to an exit gate, a foam injector for injecting foam into the slurry, and a canister connected to the mixer for inducing swirl to the slurry. The system also includes an elongated hose and an optional adapter for depositing the slurry onto paper to form the board. Ends of the elongated hose are coupled to the canister and to the inlet of the adapter. Slurry is directed from the canister, through the hose, and into the adapter for exiting its outlet. Optionally, a mixing boot and/or elbow joints may be included. Use of the hose and adapter enhances the flexibility of the system, including moving the mixer offline or adjacent to the paper or belt, and improves foam blending in the slurry mixture.

Abstract: Gypsum panels and methods of making the same are provided. A method of making a gypsum panel includes forming a first gypsum slurry by combining stucco, water, a siliconate, and a phosphate salt or polymer, and setting the first gypsum slurry to form at least part of a core of the gypsum panel, wherein the gypsum panel displays a 2-hour water absorption test weight increase of at least 10 weight percent less than an otherwise identical comparative panel containing no phosphate salt or polymer in its core.

Abstract: A ready-mixed setting type joint compound in which formation of gypsum seeds has been inhibited. A method for controlling a setting reaction by mixing a ready-mixed setting type joint compound with one or more metal ion control agents comprising aminopolycarboxylic acid and/or a salt thereof, and further mixing the setting type joint compound with one or more non-calcium phosphate compounds. The method may further comprise mixing the setting type joint compound with a set activator obtained by blending together a first set activator including a cadmium compound, lead compound and/or zinc compound and a second set activator including a ferrous compound, aluminum compound and/or manganese compound.

Abstract: A method of cementing may include preparing a cement composition comprising water, a hydraulic cement, and an agglomerated zeolite catalyst; placing the cement composition in a wellbore.

Abstract: The present invention relates to the use of sacrificial agents to counteract the deleterious impact of gypsum contaminants on the effectiveness of certain stucco additives, particularly, water reducing agents and foaming agents, in a stucco slurry used to make gypsum wallboard.

Abstract: A hydraulically binding composition can be used to produce an inorganic fire-protection and/or insulation foam. The composition includes: (i) a hydraulic binder, (ii) a blowing-agent mixture, (iii) a thermally expandable compound, and (iv) optionally a foam stabilizer, where the at least one thermally expandable compound, depending on a particle size thereof and an adjusted density of a foamed composition, is present in a quantity such that a foam structure of the foamed composition is not destroyed by expansion thereof during heating of the composition above an onset temperature thereof.

Abstract: The present invention relates to the use of sacrificial agents to counteract the deleterious impact of gypsum contaminants on the effectiveness of certain stucco additives, particularly, water reducing agents and foaming agents, in a stucco slurry used to make gypsum wallboard.

Abstract: Solid alkali metal salts of organosilanols and/or their hydrolysis/condensation products are prepared by hydrolysis of organosilanes in water and in the presence of a basic alkali metal salt. The products contain predominately methyl and ethyl organic groups, and C4 or higher hydrocarbon groups as well. The solid salts effectively hydrophobe building materials, while being easily mixed with water.

Abstract: The present invention relates to a new mineral matter particle hydrophobization agent and to its various uses for the surface treatment of mineral matter particles.

Abstract: Body-hydrophobing of mineral building compositions prepared from water curable mineral materials such as cement and plaster are obtained by admixing into the curable composition an organosilicon compound prepared by reacting a hydrocarbylhalosilane or hydrocarbylhydrocarbyloxysilane with a gylcol or polyglycol in a mol ratio of halo or hydrocarbyloxy radicals to hydroxyl radicals of 0.3 to 1.3. The organosilicon compounds are solid at 20° C.

Abstract: A gypsum slurry is provided that includes calcium sulfate hemihydrate; water; a dispersant component comprising at least one of the following a comb-branched polymer with polyether side chains, naphthalene sulfonate-formaldehyde condensate or melamine sulfonate-formaldehyde condensate; a foaming agent; and a polycondensation component with three polycondensation repeating units. Also provided is a method for making a gypsum slurry with a foaming agent in which the ratio between the dispersant component and the polycondensation component is adjusted to control for the size of foam bubbles in the gypsum slurry. Gypsum products made from the gypsum slurry are provided and methods for making the products are provided as well.

Abstract: Water-resistant gypsum boards and compositions and methods for their manufacture are provided. The methods include forming a mixture of water, hydroxide, and siliconate, adding siloxane to the mixture, adding calcium sulfate hemi-hydrate to the mixture to form an aqueous slurry, curing the aqueous slurry under heat, drying the aqueous slurry, and forming a water-resistant gypsum board.

Abstract: Surfactant-coated hemihydrate gypsum which is coated with 0.01 to 1 part by weight of a surfactant based on 100 parts by weight of hemihydrate gypsum, wherein the residual rate of the surfactant when the surfactant-coated hemihydrate gypsum is heated up to 300° C. is not less than 40 wt % of the amount of the surfactant before heating.

Abstract: A hydraulic binder containing 25 to 85 wt % of cement clinker, 0 to 7 wt % of CaSO4, a mineral additive(s), and 1 to 10 wt % of a dual setting control system that includes an activator and a retarder, in a weight ratio of activator to retarder, based on the dry substance selected to be greater than 85:15, in particular greater than 90:10, more particularly greater than 95:5, and, in particular, greater than 98:2.

Abstract: Disclosed is a dry gypsum composition containing hemihydrate gypsum, at least one pigment and a crystal habit modifier. The crystal habit modifier is at least one compound selected from the group consisting of sulfate salts, carboxylate salts, carbonate salts and inorganic chlorides, and a content of the at least one compound is in a range of 0.1 to 5 parts by mass per 100 parts by mass of the hemihydrate gypsum, whereby upon hydration of the hemihydrate gypsum into dihydrate gypsum, the dihydrate gypsum is controlled to become plate crystals having an aspect ratio of 1 to 9. A gypsum-based coating formulation making use of the dry gypsum composition is also disclosed.

Abstract: A non-aqueous drywall compound being the combination of a first component mixture of acetone, a non-aqueous liquid adhesive containing ethyl cyanoacrylate, and a powder containing calcium sulfate hemihydrate (plaster of Paris), the mixture being a pliable putty capable of adhering to gypsum wallboard or similar work surfaces. The second component of the drywall compound is an accelerator or activator containing acetone and toluene. The first component is applied to a defect in a work surface using a spreading tool and the second component is then applied to the exposed surface of the first component, such as by spraying or brushing, whereupon the drywall compound cures, hardens or sets within less than ten minutes to a state capable of being sanded into a smooth, hard surface and painted.

Abstract: An adhesion bond strength enhancer for cementitious adhesive mortar is disclosed. The adhesion enhancer improves bond strength between the mortar and relatively hydrophobic plastic material, such as extruded polystyrene boards and expanded polystyrene boards of the type generally employed in Exterior Insulation Finishing Systems (“EIFS”). Preparation of non-caking, free-flowing, solid dialkyl sulfosuccinate compositions for use as the adhesion enhancer is also disclosed. The adhesion enhancer is attractive for large-scale application in mineral mortar dry-mixes or other solid construction materials. The invention can be used to improve the strength of an adhesive bond between a) gypsum based plaster or stucco and concrete or bricks, b) tile adhesives and concrete, and c) mineral mortars on polystyrene boards, among others.

Abstract: Solid alkali metal salts of organosilanols and/or their hydrolysis/condensation products are prepared by hydrolysis of organosilanes in water and in the presence of a basic alkali metal salt. The products contain predominately methyl and ethyl organic groups, and C4 or higher hydrocarbon groups as well. The solid salts effectively hydrophobe building materials, while being easily mixed with water.

Abstract: The invention relates to additives for hydraulic binders and systems produced from them, such as concrete and mortar. In particular, the present invention relates to a setting and hardening accelerator for hydraulic binders produced by means of reaction of a calcium compound CV with a silicon compound SV and addition of a phosphonic acid derivative, as well as its production.

Abstract: An aqueous gypsum plaster-cement composition comprises a hydraulic binder consisting of calcined gypsum and hydraulic cement in a weight ratio of from about 4:1 to about 2:1, an aggregate which comprises sand, a foam, a perlite, rice hulls or a mixture thereof, a superplasticizer comprising an air entraining agent, a retarder, and water in an amount of from about 0.4 to about 0.75 parts by weight per part of binder, with the proviso that the gypsum plaster-cement composition contains essentially neither a pozzolana nor lime. The use thereof, a method of constructing buildings using this composition and the buildings obtainable in this way are also described.

Abstract: A panel is provided that includes stucco, water and a dispersant component having dispersing properties and comprising a comb-branched polymer with polyether side chains, naphthalene sulfonate-formaldehyde condensate or melamine sulfonate-formaldehyde condensate. A polycondensation component is also included in the slurry that includes three repeating units. A method of making the gypsum panel includes combining stucco, water and a first dosage of a first dispersant to form a slurry, the first. A second dosage of a second dispersant is added to the slurry. Properties of the gypsum slurry are tested and it is formed into a product. The product sets and properties of the product are identified. The first dosage or the second dosage is changed based on the properties of the slurry or product.

Abstract: The present invention relates to construction materials comprising at least one binder, at least one oil-containing filler and at least one metallate additive according to formula (1): (RO)m-M-(Oa—Xb—R?c—Yd)n??(1) wherein M is one of titanium and zirconium. The present invention also relates to methods of preparing and using the inventive construction materials. The inventive construction material compositions are capable of utilizing oil-containing fillers in which the oil is stable in the final composition and the desired mechanical properties of the construction material are maintained or improved.

Abstract: The present invention relates to a plaster-based material which includes an agent capable of trapping formaldehyde, in particular a plasterboard intended for the interior fittings of residential buildings. The agent capable of trapping formaldehyde is chosen from ethylene urea and its derivatives, compounds comprising active methylene(s), sulphites, tannins and their mixtures. Another subject-matter of the invention is the use of the said material for reducing the amount of formaldehyde present in the atmosphere inside residential buildings.

Abstract: An adhesion bond strength enhancer for cementitious adhesive mortar is disclosed. The adhesion enhancer improves bond strength between the mortar and relatively hydrophobic plastic material, such as extruded polystyrene boards and expanded polystyrene boards of the type generally employed in Exterior Insulation Finishing Systems (“EIFS”). Preparation of non-caking, free-flowing, solid dialkyl sulfosuccinate compositions for use as the adhesion enhancer is also disclosed. The adhesion enhancer is attractive for large-scale application in mineral mortar dry-mixes or other solid construction materials. The invention can be used to improve the strength of an adhesive bond between a) gypsum based plaster or stucco and concrete or bricks, b) tile adhesives and concrete, and c) mineral mortars on polystyrene boards, among others.

Abstract: A dry composition including at least one binder and at least one silicone oil with the following formula (I): in which: Z1 and Z2, identical or different, independently represent a terminal group selected from the group consisting of a hydrogen atom; a hydroxyl; a linear or branched, optionally substituted C1 to C12 alkyl; a linear or branched, optionally substituted C2 to C12 alkenyl radical; a linear or branched, optionally substituted C1 to C12 heteroalkyl; an optionally substituted C5 to C10 cycloalkyl radical; and an optionally substituted C6 to C18 aryl radical; R1 and R2, identical or different, independently represent a hydrogen atom; a hydroxyl; a linear or branched, optionally substituted C1 to C12 alkyl; a linear or branched, optionally substituted C2 to C12 alkenyl radical; a linear or branched, optionally substituted C1 to C12 heteroalkyl; an optionally substituted C5 to C10 cycloalkyl radical; or an optionally substituted C6 to C18 aryl radical; m and n, identical or different, independen

Abstract: Disclosed is a dry gypsum composition containing hemihydrate gypsum, at least one pigment and a crystal habit modifier. The crystal habit modifier is at least one compound selected from the group consisting of sulfate salts, carboxylate salts, carbonate salts and inorganic chlorides, and a content of the at least one compound is in a range of 0.1 to 5 parts by mass per 100 parts by mass of the hemihydrate gypsum, whereby upon hydration of the hemihydrate gypsum into dihydrate gypsum, the dihydrate gypsum is controlled to become plate crystals having an aspect ratio of 1 to 9. A gypsum-based coating formulation making use of the dry gypsum composition is also disclosed.

Abstract: Aqueous silane formulations for treatment of an article or material such as wood, concrete, drywall, cotton fabric or wool fabric, and methods of treating the article or material with the formulation. The aqueous medium comprises an alkoxysilane or a combination of a halosilane a high concentration of a salt component. Optionally, the silane formulation may include a boron-containing component. Integrated processes for producing hydrophobic paper, gypsum, drywall, and concrete by pre-mixing components with alkoxysilane are also disclosed. Further disclosed are combinations of a silane component and a salt component, e.g., in a premixture or in a kit, co-pack or co-shipment. Novel treated products, including recreational equipment, are also disclosed.

Abstract: The present application relates to compositions comprising at least one siloxane and at least one superplasticizer based on polycarboxylate ethers or sulphonates of lignin, melamine or naphthalene or of resins thereof, and to the use of such compositions as or in building-product mixtures or building products, especially mortar mixtures or concrete mixtures.

Abstract: Provided herein are mixtures, emulsions and other additives for use in manufacturing gypsum wallboard. The mixtures and emulsions may be wax-based emulsions or wax-free mixtures or emulsions, with wax-based emulsions including water, at least one wax, a dispersant which may include sulfur or a sulfur-containing group, and an additive comprising an organic titanium compound or organic zirconium compound. Mixtures may also be prepared including water, a dispersant; and an additive comprising an organic titanium compound or organic zirconium compound. Gypsum slurries may be prepared using such emulsions and mixtures and/or through addition of an organic titanium compound or organic zirconium compound.

Abstract: Methods comprising providing a dry, solid particulate material comprising a cementitious material, a non-cementitious material, or a combination thereof and having a flow enhancing additive absorbed thereon. The flow enhancing additive comprises a flow inducing chemical, ethylene glycol, and water. The coated, dry, solid material is then mixed with a sufficient amount of water to form a pumpable slurry and then the slurry may be placed in a subterranean formation. In some cases the dry, solid particulate material comprising a cementitious material, a non-cementitious material, or a combination thereof and having a flow enhancing additive absorbed thereon may be stored for a period of time before the slurry is formed.

Abstract: A method of manufacturing a water-resistant gypsum article, comprising sonicating a water-resistance additive in water to form a emulsion; combining the emulsion, calcined gypsum, and gauging water to form a slurry; and forming and setting the slurry to form the water-resistant gypsum article.

Abstract: The application relates to a reactive ceramic binder suitable for producing ceramic products from ceramic powder, characterized in that the reactive ceramic binder represents hydroxyl compounds which carry reactive silyl groups and can be additionally (poly)siloxane-substituted.

Abstract: The present invention relates to the use of a solid comprising at least one organosilane and a carrier material to hydrophobise mortars, wherein the organosilane has the formula R1Si(OR?)3 or R1R2Si(OR?)2 wherein R1 and R2 are the same or different and are a linear or branched C1- to C4-alkyl and/or alkenyl group, OR? is an acetoxy, a C1- to C4- alkoxy and/or a C2- to C6-methoxyalkoxy and/or ethoxyalkoxy group, and the carrier material is a solid at room temperature. The amount of cement in the final formulation is zero or less than 5 wt.-%, based on the total weight of the final formulation in the dry and uncured form. Claimed are also a powder comprising the silane and a carrier with the carrier being a water-soluble polymer, dry mortar formulations containing no or less than 5 wt.-% cement, based on the dry weight of the uncured mortar formulation, as well as processes to manufacture the formulations and/or compounds.

Abstract: A modified sulfur binder capable of implementing a physical property of being re-melted at a temperature less than 100° C., by mixing sulfur with a heterocyclicamine or alkylamine-based modifier and a dicyclopentadiene-based modifier, and a fabrication method thereof. A hydraulic modified sulfur material composition capable of being mixed with water by adding a surfactant to the modified sulfur binder, and obtained by mixing aggregate and a hydraulic material to the modified sulfur binder, and a fabrication method thereof. A hydraulic modified sulfur material obtained by molding the hydraulic modified sulfur material composition, and a fabrication method thereof. A combustible modified sulfur material composition obtained by adding aggregate to the modified sulfur binder, and by selectively adding a filler to the modified sulfur binder, and a fabrication method thereof.

Abstract: The present invention relates to a setting retarder for compounds that set hydraulically, containing at least one at least simple adduct and/or condensate, the retarder being produced by the reaction of at least one protein hydrolysate, one pure amino acid, amino acid mixture, and/or the hydrochlorides thereof having at least one mono-, di-, oligo- and/or polycarboxylic acid which is not derived from an amino acid, and/or a carboxylic acid derivative derived therefrom, wherein the carboxylic acid is selected from a group including carboxylic acid anhydrides, carboxylic acid halogenides, and/or carboxylic acid active esters.

Abstract: A mold material castable to provide a mass reduced work piece machinable to produced a mold and methods of utilizing such mold material to cast mass reduced work pieces machinable to produce a mold.

Abstract: A hydraulic cement for biomedical applications. The cement sets in-situ, hardening when exposed to water to produce nano-dispersed composite of calcium-silicate-hydrate gel mixed with hydroxyapatite. In comparison with prior cements, the composition provides high biocompatibility, high bioactivity and high biomechanical strength, due to the composite structure of the calcium silicate hydrate reinforced with co-precipitated particles of hydroxyapatite. Biocompatibility is also increased due to an absence of aluminum and magnesium in the composition. The cement is suitable for variety of applications, including dental implants, bone fixation, and bone repair.

Abstract: A composition is disclosed for a mixture to be used in conjunction with water for preparing a slurry that hydrates to form a high strength flooring compound. The mixture includes from about 50% to about 98% by weight calcium sulfate hemihydrate. A three repeating unit polycarboxylate dispersant is included in the mixture in amounts from about 0.2% to about 10% by weight. The repeating units include a polyether repeating unit, an acrylic acid-type repeating unit and a maleic acid-type repeating unit. A modifier that enhances the efficacy of the dispersant is also a component of the mixture. When combined with recommended amounts of water, a slurry is formed that is useful as a flooring composition.

Abstract: Emulsions are provided which are useful in imparting water-resistance to lignocellulosic composite products. In one embodiment, the emulsions comprise at least one wax, an alkyl phenol, a salt of polynaphthalenesulfonic acid, and a complexed starch. Emulsions of this embodiment may be added to hot, even boiling, water without the emulsion separating or curdling. The emulsions of the present invention are stable for extended periods of time when stored at room temperature, do not require the addition of a bactericide, and are pourable liquids at room temperature.

Abstract: Emulsions are provided which are useful in imparting water-resistance to gypsum products. In one embodiment, the emulsions comprise at least one wax, an alkyl phenol, a salt of polynaphthalenesulfonic acid, and a complexed starch. Emulsions of this embodiment may be added to hot, even boiling, water without the emulsion separating or curdling. The emulsions of the present invention are stable for extended periods of time when stored at room temperature and do not require the addition of a bactericide. The emulsions of the present invention are pourable liquids at room temperature.

Abstract: Articles, including fiberboard, are made from a pumpable, flowable slurry including alpha-calcined calcium sulfate hemihydrate anchored in pores of host particles, alpha-calcined calcium sulfate hemihydrate, a silicone compound, magnesium oxide, and water. The magnesium oxide catalyzes the reaction of the silicone compound into a silicone resin. In a preferred method of making a water resistant fiberboard calcium sulfate dihydrate is combined with the host particles and water to form a slurry which is heated under pressure to calcine the calcium sulfate dihydrate to form alpha-calcined calcium sulfate hemihydrate. After relieving the pressure, a silicone compound and magnesium oxide are added to the slurry. The slurry is dewatered to form a filter cake, which is then formed into a desired shape and allowed to set.

Abstract: A cementitious material in powder form comprising cement, also comprises sufficient of a granulated hydrophobing additive, which comprises form 5 to 15 parts by weight of an organopolysiloxane component, form 10 to 50 parts by weight of a water-soluble or water-dispersible binder and from 50 to 90 parts by weight of a carrier particle, to give from 0.01 to 5% by weight of the organosiloxane component based on the weight of the cement. The cementitious material displays good hydrophobicity, which may improve upon subsequent wettings of the applied cementitious material to a substrate.

Abstract: An improved gypsum slurry that includes water, calcium sulfate hemihydrate, a naphthalene sulfonate dispersant and a modifier. The modifier is chemically configured to improve the efficacy of the naphthalene sulfonate dispersant. Preferred modifiers include cement, lime, slaked lime, soda ash, carbonates, silicates and phosphates.

Abstract: Emulsions, useful for imparting water resistance to gypsum products are disclosed. The emulsions of the invention include at least one wax, an alkyl phenol and a hydrophyllic metallic salt, preferably magnesium sulfate. The emulsions of the invention do not require the addition of a starch compound and therefore exhibit enhanced stability even at higher solids content then compared to prior art emulsions.

Abstract: A hydrophobic gypsum composition is provided which contains gypsum, a granulated hydrophobing additive and a pH effecting additive in an amount sufficient to maintain the pH of the composition in the range of 8 and 12.5, in the presence of water. The granule contains an organopolysiloxane having silicon bonded hydrogen, a water soluble or water dispersible binder, and a carrier, preferably gypsum or a stearate salt, in an amount sufficient to hydrophobe the gypsum. The pH effecting additive is preferably lime but may be any appropriate additive.

Abstract: An emulsion comprising water as the continuous phase, a wax as the discontinuous phase, an emulsifier and a preservative having the general structure: wherein R1 can be a heterocycle containing nitrogen and sulfur, such as thiazolyl, isothiazolyl, or thiadiazolyl, which can optionally be substituted with C1–C6 alkyl; R2 can be hydrogen or C1–C6 alkyl, specifically hydrogen; n is 0, 1, 2, or 3; each instance of R3 can independently be hydrogen, C1–C6 alkyl, phenoxy, C1–C6 alkoxy, halo, amino, C1–C6 alkylamino, di C1–C6 alkyl amino, imidazolyl, thiazolyl, isothiazolyl, thiadiazolyl, thienyl, furyl, pyrryl, naphthyl, phenyl, halophenyl, C1–C6 alkyl phenyl, or C1–C6 alkoxyphenyl. The preservative may be added to the emulsion after the emulsion is formed. The emulsion can be incorporated into a gypsum product such as gypsum board or gypsum wood fiber board. The gypsum product may be made by forming a slurry containing gypsum, water, and the emulsion into a solid product.

Abstract: In at least one embodiment, the present invention relates to a gypsum composition suitable for use in the manufacture of construction materials comprising a) gypsum, b) water, and c) a water repellancy composition comprising a hydroxy-based cellulose and a siliconate.

Abstract: Disulfonate salts of 2,4-pentanedione and methods for making such salts are described. The disulfonate salts are useful as cement dispersants. Cement compositions including such salts, methods for making cement compositions including such salts, and methods for performing cementing operations using such cement compositions are also described.

Abstract: Methods and cement compositions are provided for sealing a subterranean zone penetrated by a wellbore, wherein the cement composition comprises zeolite, cementitious material, and a mixing fluid.