Abstract: A system for making wallboard or backerboard sheets may include a mixer for mixing materials for making aerated concrete, at least one face layer supply, and a former downstream from the mixer. The former is for forming core material having opposing first and second major surfaces and comprising aerated concrete, and for securing at least one face layer from the at least one face layer supply onto at least one of the first and second major surfaces of the core material. The system may also include a cutter downstream from the former for cutting the core material and at least one face layer secured thereto into a plurality of wallboard or backerboard sheets. The provision of aerated concrete for the core provides many key advantages over conventional gypsum wallboard sheets, and/or conventional backerboard sheets, such as gypsum greenboard or cementitious backerboard, for example.

Abstract: A backerboard sheet is for moist areas and includes a core having opposing first and second major surfaces, at least one moisture-resistant face layer on at least one of the first and second major surfaces of the core; and wherein the core includes aerated concrete. The provision of aerated concrete for the core provides many key advantages over conventional backerboard sheets, such as gypsum greenboard or cementitious backerboard, for example. The at least one moisture-resistant face layer may include fibers, such as arranged in a woven mesh. The fibers may include at least one of glass, plastic, and metal. In addition, the at least one moisture-resistant face layer may further include a moisture-resistant material incorporating the fibers, such as a suitable resin, for example.

Abstract: A method for making wallboard or backerboard sheets which are relatively lightweight, strong, and which have good fire resistance, thermal insulation, and sound absorbing properties includes forming core material having opposing first and second major surfaces and comprising aerated concrete, securing at least one face layer on at least one of the first and second major surfaces of the core material, and cutting the core material and at least one face layer secured thereto into a plurality of wallboard or backerboard sheets. The provision of aerated concrete for the core provides many key advantages over conventional gypsum wallboard sheets, and/or conventional backerboard sheets, such as gypsum greenboard or cementitious backerboard, for example. In one class of embodiments, the method may further include curing the core material prior to securing the at least one face layer thereto. In another class, the method may further include curing the core material after securing the at least one face layer thereto.

Abstract: A method for making wallboard or backerboard sheets which are relatively lightweight, strong, and which have good fire resistance, thermal insulation, and sound absorbing properties includes forming core material having opposing first and second major surfaces and comprising aerated concrete, securing at least one face layer on at least one of the first and second major surfaces of the core material, and cutting the core material and at least one face layer secured thereto into a plurality of wallboard or backerboard sheets. The provision of aerated concrete for the core provides many key advantages over conventional gypsum wallboard sheets, and/or conventional backerboard sheets, such as gypsum greenboard or cementitious backerboard, for example. In one class of embodiments, the method may further include curing the core material prior to securing the at least one face layer thereto. In another class, the method may further include curing the core material after securing the at least one face layer thereto.

Abstract: A method for making wallboard or backerboard sheets which are relatively lightweight, strong, and which have good fire resistance, thermal insulation, and sound absorbing properties includes forming core material having opposing first and second major surfaces and comprising aerated concrete, securing at least one face layer on at least one of the first and second major surfaces of the core material, and cutting the core material and at least one face layer secured thereto into a plurality of wallboard or backerboard sheets. The provision of aerated concrete for the core provides many key advantages over conventional gypsum wallboard sheets, and/or conventional backerboard sheets, such as gypsum greenboard or cementitious backerboard, for example. In one class of embodiments, the method may further include curing the core material prior to securing the at least one face layer thereto. In another class, the method may further include curing the core material after securing the at least one face layer thereto.

Abstract: A wallboard sheet includes a core having opposing first and second major surfaces, at least one face layer on at least one of the first and second major surfaces of the core, and wherein the core includes aerated concrete. The provision of aerated concrete for the core provides many key advantages over conventional wallboard sheets, such as gypsum wallboard, for example. The at least one face layer may include first and second face layers on respective first and second major surfaces of the core. The one or more face layers may include paper. The core may have a generally rectangular shape defining a pair of opposing side edges and a pair of opposing end edges. The first major surface may have beveled portions adjacent respective opposing side edges in some embodiments. The at least one face layer may extend around the opposing side edges. In addition, the opposing end edges of the core may be exposed.

Abstract: A system for making wallboard or backerboard sheets may include a mixer for mixing materials for making aerated concrete, at least one face layer supply, and a former downstream from the mixer. The former is for forming core material having opposing first and second major surfaces and comprising aerated concrete, and for securing at least one face layer from the at least one face layer supply onto at least one of the first and second major surfaces of the core material. The system may also include a cutter downstream from the former for cutting the core material and at least one face layer secured thereto into a plurality of wallboard or backerboard sheets. The provision of aerated concrete for the core provides many key advantages over conventional gypsum wallboard sheets, and/or conventional backerboard sheets, such as gypsum greenboard or cementitious backerboard, for example.

Abstract: A system for making wallboard or backerboard sheets may include a mixer for mixing materials for making aerated concrete, at least one face layer supply, and a former downstream from the mixer. The former is for forming core material having opposing first and second major surfaces and comprising aerated concrete, and for securing at least one face layer from the at least one face layer supply onto at least one of the first and second major surfaces of the core material. The system may also include a cutter downstream from the former for cutting the core material and at least one face layer secured thereto into a plurality of wallboard or backerboard sheets. The provision of aerated concrete for the core provides many key advantages over conventional gypsum wallboard sheets, and/or conventional backerboard sheets, such as gypsum greenboard or cementitious backerboard, for example.

Abstract: A method for making wallboard or backerboard sheets which are relatively lightweight, strong, and which have good fire resistance, thermal insulation, and sound absorbing properties includes forming core material having opposing first and second major surfaces and comprising aerated concrete, securing at least one face layer on at least one of the first and second major surfaces of the core material, and cutting the core material and at least one face layer secured thereto into a plurality of wallboard or backerboard sheets. The provision of aerated concrete for the core provides many key advantages over conventional gypsum wallboard sheets, and/or conventional backerboard sheets, such as gypsum greenboard or cementitious backerboard, for example. In one class of embodiments, the method may further include curing the core material prior to securing the at least one face layer thereto. In another class, the method may further include curing the core material after securing the at least one face layer thereto.