Abstract: A method of making a gypsum panel comprises sandwiching a gypsum slurry between two moving sheets of facing material, one of said sheets comprising a fibrous facing material, curing and drying the gypsum slurry to form a set gypsum panel, applying a coating of a radiation curable formulation, which is essentially free of any unreactive components, onto the fibrous facing material of the set gypsum panel, applying a surface coating of an aggregate material onto the coating of the radiation curable formulation, and curing the coating of the radiation curable formulation with high energy radiation, wherein the radiation curable formulation comprises a high energy radiation curable polymer comprising ethylenically unsaturated double bonds.

Abstract: The present invention describes an improved building material composition, useful for example as a fire door core. The building material of the present invention is prepared by compressing an aqueous mixture of expanded perlite and a fast setting, cementitious composition consisting essentially of a hydraulic cement, preferably Portland cement, and a pozzolan additive selected from the group consisting of metakaolin, VCAS and mixtures thereof, and preferably also includes an organic binder and a fibrous reinforcement.

Abstract: A laminated structure comprises a first external layer and a second external layer; an internal layer disposed between the first and the second external layers; a first adhesive layer disposed between the first external layer and the internal layer, wherein the first adhesive layer is patterned to cover only a first portion of the internal layer; and a second adhesive layer disposed between the second external layer and the internal layer, wherein the second adhesive layer is patterned to cover only a second portion of the internal layer on a side opposite the first adhesive layer, and wherein the first portion is different than the second portion.

Abstract: A gypsum wallboard suitable for Level 4 finishing having a coated non-woven glass fiber mat facing material where the glass fiber mat has a majority of fibers of a fiber diameter between 8 and 11 microns and a fiber length between ¼ and ¾ inch and preferably between ¼ and ½ inch and preferably has a basis weight between about 0.8 lb./100 ft.2 and about 2.2 lb./100, and wherein the fibers in the non-woven glass fiber are bound together with an acrylic adhesive binder and wherein the non-woven glass mat has a coating of a dried aqueous mixture of (i) a mineral pigment, (ii) a polymer latex adhesive binder and optionally (iii) an inorganic adhesive binder such that the coated non-woven glass mat facing material has a porosity which allows water to evaporate through said coated mat from the gypsum core during preparation of the wallboard.

Abstract: A gypsum board which comprises a set gypsum core sandwiched between and faced with fibrous mats, wherein a free surface of one of said mats is pre-coated with a combination of a mineral pigment, optionally an inorganic adhesive binder and an organic binder, preferably a hydrophobic, UV resistant polymer latex adhesive binder applied to said surface as an aqueous coating composition, said aqueous coating composition upon drying and setting providing a pre-coated mat satisfying certain morphology requirements.

Abstract: The present invention describes a fire resistant building material composition, useful for example as a fire door core and to a method of making this composition where the building material of the present invention is prepared from an aqueous slurry of calcined gypsum, paper fibers, a water insoluble organic binder, fiber reinforcement and a set retarder.

Abstract: A gypsum wallboard suitable for Level 4 finishing having a coated non-woven first glass fiber mat facing material on one major surface and an optionally coated second glass fiber mat where on the other major surface. The first glass fiber mat has a majority of fibers of a nominal fiber diameter between 8 and 11 microns and a fiber length between ¼ and ¾ inch and has a basis weight between about 1.7 lb./100 ft.2 and about 2.0 lb./100; the second glass fiber mat has a majority of fibers of a nominal fiber diameter of at least 13 microns but no greater than about 16 microns and a fiber length between ¾ and 1 inch and has a basis weight between about 1.8 lb./100 ft.2 and about 2.2 lb./100, and wherein the fibers in both of the non-woven glass fiber mats are bound together with an acrylic-type adhesive binder.

Abstract: A gypsum board which comprises a set gypsum core sandwiched between and faced with fibrous mats, wherein a free surface of one of said mats is pre-coated with a combination of a mineral pigment, optionally an inorganic adhesive binder and an organic binder, preferably a hydrophobic, UV resistant polymer latex adhesive binder applied to said surface as an aqueous coating composition, said aqueous coating composition upon drying and setting providing a pre-coated mat satisfying certain morphology requirements.

Abstract: A gypsum board which comprises a set gypsum core sandwiched between and faced with fibrous mats, wherein a free surface of one of said mats is pre-coated with a combination of a mineral pigment, optionally an inorganic adhesive binder and an organic binder, preferably a hydrophobic, UV resistant polymer latex adhesive binder applied to said surface as an aqueous coating composition, said aqueous coating composition upon drying and setting providing a pre-coated mat satisfying certain morphology requirements.

Abstract: A gypsum board which comprises a set gypsum core sandwiched between and faced with fibrous mats, wherein a free surface of one of said mats is pre-coated with a combination of a mineral pigment, optionally an inorganic adhesive binder and an organic binder, preferably a hydrophobic, UV resistant polymer latex adhesive binder applied to said surface as an aqueous coating composition, said aqueous coating composition upon drying and setting providing a pre-coated mat satisfying certain morphology requirements.

Abstract: A gypsum board which comprises a set gypsum core sandwiched between and faced with fibrous mats, wherein a free surface of one of said mats is pre-coated with a combination of a mineral pigment, optionally an inorganic adhesive binder and an organic binder, preferably a hydrophobic, UV resistant polymer latex adhesive binder applied to said surface as an aqueous coating composition, said aqueous coating composition upon drying and setting providing a pre-coated mat satisfying certain morphology requirements.

Abstract: A drying type, low VOC filler or joint composition that when mixed with water to produce a wet, paste-like mixture, can be spread easily to fill wallboard joints and other wallboard surface defects and imperfections; dries to a solid mass and can be sanded to a smooth finish.

Abstract: A composition for the manufacture of a gypsum board comprising hydrated pregelatinized starch and stucco with 0.4 to 3 wt. % of starch based on the stucco weight is disclosed. The composition provides enhanced strength in the absence of other strengthening agents.

Abstract: A gypsum wallboard suitable for Level 4 finishing having a coated non-woven first glass fiber mat facing material on one major surface and an optionally coated second glass fiber mat where on the other major surface. The first glass fiber mat has a majority of fibers of a nominal fiber diameter between 8 and 11 microns and a fiber length between ¼ and ¾ inch and has a basis weight between about 1.7 lb./100 ft.2 and about 2.0 lb./100; the second glass fiber mat has a majority of fibers of a nominal fiber diameter of at least 13 microns but no greater than about 16 microns and a fiber length between ¾ and 1 inch and has a basis weight between about 1.8 lb./100 ft.2 and about 2.2 lb./100, and wherein the fibers in both of the non-woven glass fiber mats are bound together with an acrylic-type adhesive binder.

Abstract: A flooring composition for mixing with water to produce a self-leveling slurry that quickly hydrates to form a high strength floor underlayment comprising a dry mixture of (1) beta gypsum produced by a continuous method; (2) Class C fly ash; (3) a conventional water reducing aid such as sulfonated melamines, sulfonated naphthalenes and their related formaldehyde condensates, and (4) a conventional set retarder.

Abstract: A gypsum wallboard suitable for Level 4 finishing having a coated non-woven first glass fiber mat facing material on one major surface and an optionally coated second glass fiber mat where on the other major surface. The first glass fiber mat has a majority of fibers of a nominal fiber diameter between 8 and 11 microns and a fiber length between ¼ and ¾ inch and has a basis weight between about 1.7 lb./100 ft.2 and about 2.0 lb./100; the second glass fiber mat has a majority of fibers of a nominal fiber diameter of at least 13 microns but no greater than about 16 microns and a fiber length between ¾ and 1 inch and has a basis weight between about 1.8 lb./100 ft.2 and about 2.2 lb./100, and wherein the fibers in both of the non-woven glass fiber mats are bound together with an acrylic-type adhesive binder.

Abstract: A floor patching composition for mixing with water to produce a self-leveling slurry that quickly hydrates to form an acceptable patch comprising a dry mixture of (1) Class C fly ash, (2) a calcium aluminate cement, (3) an organic binder along with (4) a cellulose ether, in part to facilitate mixing of the dry ingredients and preferably (5) an antimicrobial preservative and (6) metakaolin clay.

Abstract: A gypsum board which comprises a set gypsum core sandwiched between and faced with fibrous mats, wherein a free surface of one of said mats is pre-coated with a combination of a mineral pigment, optionally an inorganic adhesive binder and an organic binder, preferably a hydrophobic, UV resistant polymer latex adhesive binder applied to said surface as an aqueous coating composition, said aqueous coating composition upon drying and setting providing a pre-coated mat satisfying certain morphology requirements.

Abstract: A flooring composition for mixing with water to produce a self-leveling slurry that quickly hydrates to form a high strength floor underlayment comprising a dry mixture of (1) beta gypsum produced by a continuous method; (2) Class C fly ash; (3) a conventional water reducing aid such as sulfonated melamines, sulfonated naphthalenes and their related formaldehyde condensates, and (4) a conventional set retarder.

Abstract: A fibrous mat faced gypsum panel having on at least one of the facing sheets a moisture resistant, cured coating of a radiation curable, e.g., UV curable, polymer.