Abstract: The present disclosure relates generally to evaluating the surfaces of a building. The present disclosure relates more particularly to a method of characterizing a surface texture of a building surface. The method includes illuminating a first area of the building surface from a single direction and capturing an image of the first area using a camera while the first area is illuminated. The first image includes a first group of digital pixel values. The method further includes calculating a first set of values that characterize a first surface texture of the first area based on a first group of digital pixel values of the image, and comparing the first set of values to a second set of values that characterize a second surface texture, so as to produce a comparator value.

Abstract: The present disclosure relates generally to building surface joint supports, for example, configured to bridge and support the seam between two building surface panels. The present disclosure relates more particularly to a joint support configured to support a joint between building surface panels. The joint support includes a longitudinal support strip including a first end, a second end, a first side edge, a second side edge, an inner surface, and an outer surface. An inner layer of adhesive is distributed over the inner surface of the longitudinal support strip and is configured to bond with a joint compound. The adhesive of the inner layer includes a polysaccharide.

Abstract: Disclosed is a building board construction that provides enhanced acoustical properties. In one possible embodiment, the board is a gypsum board with opposing facing sheets and an intermediate set gypsum core. An opened celled polymeric sheet is formed within the gypsum core and gives the resulting board enhanced sound absorption. In an alternative embodiment, individual pieces of polymeric foam are used in stead of the polymeric sheet. Also disclosed are various manufacturing methods whereby boards with enhanced acoustical properties can be formed in an continuous process. The various components of the present disclosure, and the manner in which they interrelate, are described in greater detail hereinafter.

Abstract: The present disclosure relates generally to building surface products, for example, suitable for forming a building surface. The present disclosure relates more particularly to a building surface product including a panel having a front surface, a rear surface, and a gypsum body between the front surface and rear surface. A first attachment clip is secured to the rear surface of the panel and includes a first leg extending outward from the rear surface of the panel. A retaining flange is coupled to the first leg and extends over the rear surface in a first direction. The retaining flange includes a slot that is configured to receive a post so as to secure the building surface product to a support structure. A first fastener that penetrates the rear surface of the panel is attached to the first leg so as to secure the attachment clip to the panel.

Abstract: Disclosed herein are plaster boards having a first surface and an opposing second surface, and a first edge and an opposing second edge that bound the first surface and the second surface. The first surface includes a first section and a second section, the first section being raised compared to the second section, the second section abutting the second edge. The second surface includes a first section and a second section that are separated by a boundary between the first edge and the second edge. The first section of the second surface is substantially parallel to the first section of the first surface. The second section of the second surface slopes toward the first surface from the boundary toward the second edge. Methods for making the plaster boards involve forming wet plaster material and drying the wet plaster material such that the wet plaster material hardens into a plasterboard.

Abstract: The present disclosure relates a joint support that includes a support strip having first and second elongate flanges, the first and second elongate flanges having an inside surface, an outside surface, an inner edge, and an outer edge. The joint support further includes a first auxiliary flap including an inner portion attached to the inside surface of the first elongate flange and an outer portion that extends laterally beyond the outer edge of the first elongate flange. The joint support further includes a second auxiliary flap including an inner portion attached to the inside surface of the second elongate flange and an outer portion that extends laterally beyond the outer edge of the second elongate flange. The joint support further includes a pressure sensitive adhesive substance disposed on at least a first portion of an inside surface of each of the first auxiliary flap and the second auxiliary flap.

Abstract: The present disclosure relates generally to wallboards, for example, suitable for use in constructing internal walls. The present disclosure relates more particularly to a wallboard and a method that provides simplified high-quality surface finishing. The wallboard includes a wall panel having a front surface and a rear surface. A sandable coating is disposed on the front surface of the wall panel. The method includes positioning wallboards adjacent to one another, applying sandable joint compound over joint formed between the wallboards, and sanding the joint compound and the sandable coating of the wallboards.

Abstract: Disclosed is a building board construction with increased surface strength. More specifically, increased nail pull strength is achieved via the application of an external surface coating. The surface coating is ideally applied to a paper faced gypsum building board. In one possible embodiment, the coating is formed from a water soluble polymer.

Abstract: The present invention relates to a system and method for the production of gypsum board using starch pellets. In accordance with the present disclosure, the starch necessary for board formation is provided in the form of starch pellets. These pellets are mixed with a gypsum slurry in a mixer. The pellets are initially insoluble and do not dissolve. However, during subsequent drying stages, the pellets become soluble and dissolve into the gypsum phase. This both provides the desired starch component and also results in the formation of voids within the set gypsum.

Abstract: The present disclosure relates generally to building surface products, for example, panels suitable for forming a building surface. The present disclosure relates more particularly to a building surface product including a gypsum panel with an upper edge that overlaps a lower edge of a neighboring gypsum panel.

Abstract: The present disclosure relates generally to building surface joint supports, for example, suitable for covering a seam between two building surface panels. In certain aspects, the disclosure provides joint supports that include an elongate layered structure having inside and outside surfaces, the elongate layered structure including a support strip that includes first and second elongate flanges. In certain embodiments, the elongate layered structure also includes an inner facing sheet disposed on the inside surface of the support strip; and an outer facing sheet disposed on the outside surface of the support strip, wherein the each of the inner facing sheet and the outer facing sheet is formed from a fibrous polymer material.

Abstract: The present disclosure relates to plaster boards and methods for making them. For example, one aspect of the disclosure is a plaster board comprising one or more continuous layers of material disposed within a body of hardened plaster material, the first side and second side of each continuous layer of material being substantially covered by the hardened plaster material. In certain such embodiments, each continuous layer of material includes a polymer (e.g., a damping polymer) disposed on a carrier sheet. Another aspect of the disclosure relates to a method for making a plaster board that involves drying a wet body of plaster material while a continuous layer of material or precursor therefor is disposed within it.

Abstract: The present disclosure relates generally to evaluating the surfaces of a building. The present disclosure relates more particularly to a method of characterizing a surface texture of a building surface. The method includes illuminating a first area of the building surface from a single direction and capturing an image of the first area using a camera while the first area is illuminated. The first image includes a first group of digital pixel values. The method further includes calculating a first set of values that characterize a first surface texture of the first area based on a first group of digital pixel values of the image, and comparing the first set of values to a second set of values that characterize a second surface texture, so as to produce a comparator value.

Abstract: Disclosed herein are plaster boards that include first and second layers of hardened plaster material, a liner attached to the first layer of hardened plaster material, and a first material (e.g., a polymer material such as a viscoelastic polymer) adhered between the liner and the second layer of hardened plaster material. The liner includes one or more structurally weakened regions each extending substantially from a first edge to a second opposing edge of the plaster board. The structurally weakened regions of the liner may facilitate creation of a fissure that propagates substantially within a plane within the plaster board. Methods for making the plaster boards may involve drying wet plaster material while it is in contact with a liner having structurally weakened regions, processing a liner to form its structurally weakened regions while in contact with wet plaster material, or processing a liner to form its structurally weakened regions while in contact with hardened plaster material.

Abstract: An example plasterboard includes a layer of hardened plaster having a first surface and an opposed second surface, a layer of polymer material having particles of one or more cementitiously-active substances mixed therein, and a liner between the first surface of the layer of hardened plaster and the layer of polymer material. Another example is a method of forming such a plasterboard. The method includes loading an extruder with the polymer material having the particles of one or more cementitiously active substances mixed therein, extruding the polymer material through a die to form the layer of polymer material on a surface of the liner, contacting with a layer of wet plaster material, the liner having the polymer material applied thereon such that the surface of the liner faces away from the wet plaster material, and drying the layer of wet plaster material to form the layer of hardened plaster.

Abstract: The present disclosure relates generally to plaster wall panels, for example, suitable for covering interior wall frames. The present disclosure relates more particularly to a plaster wall panel including a first plaster layer, a second plaster layer, and a damping layer disposed between the first and second plaster layers. The first plaster layer has a first thickness and is composed of a first plaster material that has a first material property. The second plaster layer has a second thickness and is composed of a second plaster material that has a second material property. The first thickness is smaller than the second thickness, and the first and second material properties are different.

Abstract: Disclosed is a building board construction that provides enhanced acoustical properties. In one possible embodiment, the board is a gypsum board with opposing facing sheets and an intermediate set gypsum core. An opened celled polymeric sheet is formed within the gypsum core and gives the resulting board enhanced sound absorption. In an alternative embodiment, individual pieces of polymeric foam are used in stead of the polymeric sheet. Also disclosed are various manufacturing methods whereby boards with enhanced acoustical properties can be formed in an continuous process. The various components of the present disclosure, and the manner in which they interrelate, are described in greater detail hereinafter.

Abstract: An example plasterboard includes a layer of hardened plaster material having a first surface and an opposed second surface and a layer of molded material having a surface that faces away from the layer of hardened plaster material. The surface of the layer of molded material has one or more raised features. The plasterboard also includes a liner between the first surface of the layer of hardened plaster material and the layer of molded material. Other examples include a method of forming such plasterboards and a method for installing such plasterboards.

Abstract: The present disclosure relates generally to wallboards, for example, suitable for use in constructing internal walls. The present disclosure relates more particularly to a wallboard and a method that provides simplified high-quality surface finishing. The wallboard includes a wall panel having a front surface and a rear surface. A sandable coating is disposed on the front surface of the wall panel. The method includes positioning wallboards adjacent to one another, applying sandable joint compound over joint formed between the wallboards, and sanding the joint compound and the sandable coating of the wallboards.

Abstract: Disclosed herein are plaster boards having a first surface and an opposing second surface, and a first edge and an opposing second edge that bound the first surface and the second surface. The first surface includes a first section and a second section, the first section being raised compared to the second section, the second section abutting the second edge. The second surface includes a first section and a second section that are separated by a boundary between the first edge and the second edge. The first section of the second surface is substantially parallel to the first section of the first surface. The second section of the second surface slopes toward the first surface from the boundary toward the second edge. Methods for making the plaster boards involve forming wet plaster material and drying the wet plaster material such that the wet plaster material hardens into a plasterboard.