Abstract: A lightweight cementitious panel formed from a core mix is disclosed. The lightweight cementitious panel comprises one or more lightweight aggregate filler in the amount of 0.5 to 5 weight percent of the core mix, one or more binders in the amount of 35 to 75 weight percent of the core mix, rheological admixture in the amount of about 0.5 to 5 weight percent of the core mix, surfactant in the amount of 0 to 0.1 weight percent of the core mix, one or more normal weight aggregate filler in the amount of 5 to 50 weight percent of the core mix, and water in the amount of 5 to 20 weight percent of the core mix.

Abstract: A slurry for manufacturing gypsum board is disclosed. The slurry comprises calcined gypsum, water, a foaming agent, and a thickening agent. The thickening agent of the present disclosure acts to improve the cohesiveness of the slurry without adversely affecting the setting time of the slurry, the paper-to-core bond (wet and dry), or the head of the slurry by acting as a defoaming agent or coalescing agent. Examples of suitable thickening agents include cellulose ether and co-polymers containing varying degrees of polyacrylamide and acrylic acid. A gypsum board and method of forming the slurry and the gypsum board are also disclosed. The gypsum board comprises a gypsum layer formed from the slurry.

Abstract: The present disclosure embraces cementitious panels, and systems and methods of manufacturing cementitious panels. An exemplary cementitious panel includes a cementitious core material, a plurality of sheets of facing material surrounding the cementitious core material, and a radiation-cured adhesive. An exemplary method of manufacturing a cementitious panel includes conveying a slurry of cementitious core material and a plurality of sheets of facing material, applying a radiation-curable adhesive to at least one of the sheets of facing material, forming a continuous length of cementitious panel material, at least partly curing the radiation-curable adhesive with one or more beams of radiation emitting from one or more radiation-emitting devices, and cutting the continuous length of cementitious panel material laterally to a desired length, providing a cementitious panel.

Abstract: A sound damping wallboard and methods of forming a sound damping wallboard are disclosed. The sound damping wallboard includes a gypsum layer having a first side with a first gypsum surface, a first encasing layer at least partially covering the first gypsum surface to form a first encasing layer portion, and a sound damping layer on the first side covering at least part of the first encasing layer portion.

Abstract: Processes are disclosed for producing gypsum-based products from a gypsum slurry. Additives or combinations of additives for improving compressive strength, fluidity and/or set time of the gypsum product are mixed in intimate contact with raw gypsum prior to or during grinding and/or flash calcination to form stucco. The stucco is used to prepare a gypsum slurry which is shaped and sets to form the gypsum product.

Abstract: A process for controlling the embedding depth of reinforcing mesh to a cementitious board is disclosed. The process comprises applying a pressure from a plate to a reinforcing mesh on a core mix moving downstream on a conveyor, wherein the plate vibrates at a rate that assists in embedding the reinforcing mesh at a depth within the core mix such that the reinforcing mesh is barely visible.

Abstract: A sound damping wallboard and methods of forming a sound damping wallboard are disclosed. The sound damping wallboard includes a gypsum layer having a first side with a first gypsum surface, a first encasing layer at least partially covering the first gypsum surface to form a first encasing layer portion, and a sound damping layer on the first side covering at least part of the first encasing layer portion.

Abstract: Compositions for gypsum board are disclosed, comprising a mixture of a gypsum slurry and a pre-generated foam and a coalescing agent. The coalescing agent comprises one or more coalescing agents that are added to the composition singly, separately or in combination to change the size and distribution of the air bubbles in the foamed gypsum slurry. The resulting gypsum cores have increased nail pull resistance and an improved facer/gypsum core bond.

Abstract: A liquid accelerator composition for accelerating the setting reaction of calcium sulfate hemihydrate and water and methods of forming a liquid gypsum accelerator are provided. The liquid accelerator composition includes a liquid media in which calcium sulfate dihydrate is less than fully soluble and a ground product of a mill grinding of a mixture comprising calcium sulfate dihydrate.

Abstract: A process for the formation of highly durable cementitious board using lightweight aggregate is disclosed. The process comprises pouring a core mix onto a conveyor, wherein the core mix is comprised of one or more lightweight aggregate filler in the amount of 0.5 to 5 weight percent of the core mix, one or more binders in the amount of 35 to 75 weight percent of the core mix, rheological admixture in the amount of about 0.5 to 5 weight percent of the core mix, surfactant in the amount of 0 to 0.1 weight percent of the core mix, one or more normal weight aggregate filler in the amount of 5 to 50 weight percent of the core mix, and water in the amount of 5 to 20 weight percent of the core mix. The process further comprises passing the core mix under a screed roller to flatten the core mix to produce an extruding board with a desired thickness.

Abstract: A joint compound or wall repair composition and the method of making the same is disclosed that reduces the amount of airborne dust emitted during traditional sanding processes. Generally, such a reduction can be achieved by combining a first binder that has a high glass transition temperature and a second binder that has a low glass transition temperature with conventional joint compound compositions.

Abstract: A coalescing additive is used in the manufacturing process for gypsum wallboard. Such an additive increases the surface area and density of the slurry at the paper to core interface by coalescing the foam cells away from the paper core interface. This permits a stronger paper to core bond to form and increases the compressive strength of the gypsum wallboard as compared to standard wallboards made from slurries with reduced water levels.

Abstract: A lightweight cementitious panel formed from a core mix is disclosed. The lightweight cementitious panel comprises one or more lightweight aggregate filler in the amount of 0.5 to 5 weight percent of the core mix, one or more binders in the amount of 35 to 75 weight percent of the core mix, rheological admixture in the amount of about 0.5 to 5 weight percent of the core mix, surfactant in the amount of 0 to 0.1 weight percent of the core mix, one or more normal weight aggregate filler in the amount of 5 to 50 weight percent of the core mix, and water in the amount of 5 to 20 weight percent of the core mix.

Abstract: A process and system for manufacturing gypsum wallboard that aerates, conditions, and cools a portion of the stucco used in the manufacturing process. This conditioning of the stucco reduces the amount of water needed to manufacture the gypsum wallboard which in turn reduces the amount of energy and cost needed to manufacture the wallboard. The stucco may also be pretreated with water. This process may be carried out using a conveyor that agitates a moving bed of stucco while the top surface of the bed is subject to a low pressure water spray.

Abstract: An insulated exterior wall assembly combining insulating material and reflective surface insulation coupled with an air gap. A wall assembly according to this invention includes wall support studs defining insulation cavities between them, sheathing boards facing the building exterior, an insulating material such as cellular plastic material or fibrous insulation applied from the exterior sheathing partly through the depth of the insulation cavities, a foil-backed gypsum-containing wallboard applied to the interior facing portions of the studs, with an air gap between the foil backing of the wallboards and the surface of the foam along the depth of the studs. The wall assembly according to this invention provides comparable thermal resistance compared to a deep layer of insulating material.

Abstract: A joint compound or wall repair composition and the method of making the same is disclosed that reduces the amount of airborne dust emitted during traditional sanding processes. Generally, such a reduction can be achieved by combining a first binder that has a high glass transition temperature and a second binder that has a low glass transition temperature with conventional joint compound compositions.

Abstract: A process and system for manufacturing gypsum wallboard that aerates, conditions, and cools a portion of the stucco used in the manufacturing process. This conditioning of the stucco reduces the amount of water needed to manufacture the gypsum wallboard which in turn reduces the amount of energy and cost needed to manufacture the wallboard. The stucco may also be pretreated with water. This process may be carried out using a conveyor that agitates a moving bed of stucco while the top surface of the bed is subject to a low pressure water spray.

Abstract: A slurry for manufacturing gypsum board is disclosed. The slurry comprises calcined gypsum, water, a foaming agent, and a thickening agent. The thickening agent of the present disclosure acts to improve the cohesiveness of the slurry without adversely affecting the setting time of the slurry, the paper-to-core bond (wet and dry), or the head of the slurry by acting as a defoaming agent or coalescing agent. Examples of suitable thickening agents include cellulose ether and co-polymers containing varying degrees of polyacrylamide and acrylic acid. A gypsum board and method of forming the slurry and the gypsum board are also disclosed. The gypsum board comprises a gypsum layer formed from the slurry.

Abstract: The subject invention relates to compositions and methods for the preparation of stucco slurry compositions. The compositions and methods involve replacing typically used starches with modified high amylose starches that can be used in the normal wallboard manufacturing process. The compositions and methods provide wallboards having increased core strength and increased paper-to-core bond integrity compared to standard wallboards made from slurries with reduced water levels.

Abstract: An insulated exterior wall assembly combining insulating material and reflective surface insulation coupled with an air gap. A wall assembly according to this invention includes wall support studs defining insulation cavities between them, sheathing boards facing the building exterior, an insulating material such as cellular plastic material or fibrous insulation applied from the exterior sheathing partly through the depth of the insulation cavities, a foil-backed gypsum-containing wallboard applied to the interior facing portions of the studs, with an air gap between the foil backing of the wallboards and the surface of the foam along the depth of the studs. The wall assembly according to this invention provides comparable thermal resistance compared to a deep layer of insulating material.