Abstract: In general, the present invention is directed to a gypsum board comprising a gypsum core and a glass mat facing material including a coating. The coating comprises a resin including an acrylic resin, a siloxane rubber, or a mixture thereof and hydrophobic additive comprising an organosilane. The gypsum board passes at least one of the three air and water barrier tests specified in AC-212 wherein the tests comprise a water penetration barrier test as conducted in accordance with ASTM E331-00, a hydrostatic head test as conducted in accordance with AATCC 127-2008, or an air barrier test as conducted in accordance with ASTM E2357-11.

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: The present invention is directed to a gypsum board and a method of making such gypsum board. In one embodiment, the gypsum board comprises a gypsum core including a first gypsum core layer and a second gypsum core layer sandwiching a laminate layer. The laminate layer comprises two outer laminate layers sandwiching an inner laminate layer, wherein the two outer laminate layers have a higher elastic modulus than the inner laminate layer. The method of making the gypsum board includes steps of providing facing materials and corresponding gypsum slurries wherein the laminate layer is provided in-line during the manufacturing process of the gypsum board.

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: The present disclosure is directed to a method of manufacturing gypsum board as well as the resulting gypsum board. The method comprises providing a gypsum slurry with a shrinkage-reducing additive comprising a metal salt of an acid, a silica, or a mixture thereof. As a result, the gypsum board includes gypsum and a shrinkage-reducing additive comprising a metal salt of an acid, a silica, or a mixture thereof. The gypsum board exhibits an area shrinkage of less than 10%.

Abstract: The present invention is directed to a gypsum board and a method of making such gypsum board. For instance, the gypsum board comprises a gypsum core, a first facing material, and a second facing material wherein the first facing material and the second facing material sandwich the gypsum core. The gypsum core comprises a first gypsum core section and a second gypsum core section each comprising gypsum, wherein the first gypsum core section comprises a polyol compound and has a density higher than a density of the second gypsum core section.

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 is directed to a method of manufacturing gypsum board as well as the resulting gypsum board. The method comprises providing a gypsum slurry with a shrinkage-reducing additive comprising a metal salt of an acid, a silica, or a mixture thereof. As a result, the gypsum board includes gypsum and a shrinkage-reducing additive comprising a metal salt of an acid, a silica, or a mixture thereof. The gypsum board exhibits an area shrinkage of less than 10%.

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: In general, the present invention is directed to a building panel, such as a gypsum board, comprising a core having a first side and a second side opposing the first side and at least one facing material having a coating comprising at least one fungicide, at least one polymeric binder, and at least one pigment. The panel satisfies at least one of the following: the board exhibits a rating of 2 or less when tested in accordance to ASTM G21-15 or the board exhibits a rating of at least 8 when tested in accordance to ASTM D3273-16. The panel may also exhibit at least a Level 3 finish.

Abstract: The present invention is directed to an improved gypsum board, such as an improved sound damping gypsum board, and a method of making such gypsum board. For instance, the method comprises: providing a first encasing layer and a first sound damping layer on the first encasing layer wherein the sound damping layer includes at least 50 wt. % of a first sound damping polymer; depositing a gypsum slurry comprising stucco and water on the sound damping layer to form a gypsum core; providing a second encasing layer on the gypsum slurry; and allowing the stucco to convert to calcium sulfate dihydrate.

Abstract: In general, the present invention is directed to a building panel, such as a gypsum board, comprising a core having a first side and a second side opposing the first side and at least one facing material having a coating comprising at least one fungicide, at least one polymeric binder, and at least one pigment. The panel satisfies at least one of the following: the board exhibits a rating of 2 or less when tested in accordance to ASTM G21-15 or the board exhibits a rating of at least 8 when tested in accordance to ASTM D3273-16. The panel may also exhibit at least a Level 3 finish.

Abstract: Provided are wallboard panels that include a foam material layer and a core material, with one or more sheets of facer material and/or one or more sheets of backing material. The foam material layer may include one or more pores having an open pore geometry. Additionally, provided are methods of manufacturing such wallboard panels.

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: Provided are cementitious panel that include a swellable material within a core layer, a dense layer, and/or a sheet of facing material that make up a cementitious panel, as well as methods of manufacturing such cementitious panels that include a swellable material and methods of providing a moisture or water barrier in a cementitious panel.

Abstract: Provided are cementitious panels that include a cementitious core material and a plurality of sheets of facing material surrounding the cementitious core material, in which at least one of the plurality of sheets of facing material includes a polymeric-film. The polymeric film may include a thermoplastic composition that has a polymeric matrix including one or more polymeric materials. Additionally, the thermoplastic composition may optionally include a filler material. Additionally, provided are methods of manufacturing such cementitious panels.

Abstract: The present invention is directed to an improved gypsum board, such as an improved sound damping gypsum board. The gypsum board comprises a gypsum core including gypsum and a sound damping polymer. The gypsum core includes a first gypsum layer surface and a second gypsum layer surface opposing the first gypsum layer surface. In addition, a first encasing layer is disposed on the first gypsum layer surface and a second encasing layer is disposed on the second gypsum layer surface.

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: In general, the present invention is directed to a building panel, such as a gypsum board, comprising a core having a first side and a second side opposing the first side and at least one facing material having a coating comprising at least one fungicide, at least one polymeric binder, and at least one pigment. The panel satisfies at least one of the following: the board exhibits a rating of 2 or less when tested in accordance to ASTM G21-15 or the board exhibits a rating of at least 8 when tested in accordance to ASTM D3273-16. The panel may also exhibit at least a Level 3 finish.

Abstract: A sound damping wallboard for installation on an installed wallboard, a sound damping wallboard system, and a method of constructing a sound damping wallboard on a building structure are disclosed. The sound damping wallboard includes a gypsum layer having a gypsum layer inner surface and a gypsum layer outer surface, a first sound damping layer disposed at the gypsum layer inner surface and having a first sound damping layer inner surface opposite the gypsum layer inner surface, a first encasing layer disposed at the gypsum layer outer surface, a second encasing layer disposed at the first sound damping layer inner surface, and a second sound damping layer disposed at the second encasing layer opposite the first sound damping layer inner surface.