Abstract: Method of making foamed gypsum slurry having 15 to 90 volume percent gas bubbles including: passing first slurry including water and on dry basis 50 to 98 wt. % calcium sulfate hemihydrate, 1 to 50 wt. % calcium carbonate, and 0.1 to 10 wt. % cellulose thickener via a first hose to a Wye connector conduit first inlet opening at Rate C and passing alum solution via a second hose to a second inlet opening of the conduit at Rate D to create combined mixed stream passing from the conduit to a static mixer for mixing for Time 3 to activate at least a portion of the calcium carbonate and alum to generate CO2 and create the foamed gypsum slurry; transferring the slurry from the mixer to a cavity between two wall boards via a third hose. Allowing the slurry in the cavity to expand, harden and dry.

Abstract: Method of making foamed gypsum slurry having 15 to 90 volume percent gas bubbles including: passing first slurry including water and on dry basis 50 to 98 wt. % calcium sulfate hemihydrate, 1 to 50 wt. % calcium carbonate, and 0.1 to 10 wt. % cellulose thickener via a first hose to a Wye connector conduit first inlet opening at Rate C and passing alum solution via a second hose to a second inlet opening of the conduit at Rate D to create combined mixed stream passing from the conduit to a static mixer for mixing for Time 3 to activate at least a portion of the calcium carbonate and alum to generate CO2 and create the foamed gypsum slurry; transferring the slurry from the mixer to a cavity between two wall boards via a third hose. Allowing the slurry in the cavity to expand, harden and dry.