Abstract: A method for making a gypsum board including: combining a first plurality of particles including at least about 50 wt. % calcium sulfate dihydrate and about 0.05 wt. % to about 10 wt. % hydrophobic material and having a D50 particle size of about 200 ?m to about 800 ?m with a second plurality of particles including calcium sulfate hemihydrate to form a combined mixture of calcium sulfate; adding water to the combined mixture of calcium sulfate to make an aqueous gypsum slurry; depositing a core layer including the aqueous gypsum slurry over a forming surface; and allowing the core layer to set, thereby forming a set gypsum core.

Abstract: A foam injection system for use in the manufacture of cementitious products includes a foam injection body and first and second port inserts. The foam injection body defines a slurry passageway and a port passageway having a port opening in fluid communication with the slurry passageway. The first and second port inserts respectively define first and second foam passageways having first and second orifice sizes. The first and second orifice sizes are different. The first and second port inserts are adapted to removably mount to the foam injection body such that the respective foam passageway is in fluid communication with the slurry passageway via the port opening of the port passageway. One port insert can be replaced with another to readily vary the pressure of the foam passing through the particular port insert and injected into a cementitious slurry traveling through the slurry passageway.

Abstract: A slurry distributor includes a feed conduit and a distribution conduit in fluid communication therewith. The feed conduit includes an entry segment with a feed inlet and a feed entry outlet in fluid communication therewith and extending along a first feed flow axis. The feed conduit includes a shaped duct having a bulb portion in fluid communication with the feed entry outlet. The feed conduit includes a transition segment in fluid communication with the bulb portion and extending along a second feed flow axis in non-parallel relationship with the first feed flow axis. The bulb portion has an area of expansion with a cross-sectional flow area that is greater than a cross-sectional flow area of an adjacent area upstream from the area of expansion. The shaped duct has a convex interior surface in confronting relationship with the feed entry outlet of the entry segment.

Abstract: A foam injection system for use in the manufacture of cementitious products includes a foam injection body and first and second port inserts. The foam injection body defines a slurry passageway and a port passageway having a port opening in fluid communication with the slurry passageway. The first and second port inserts respectively define first and second foam passageways having first and second orifice sizes. The first and second orifice sizes are different. The first and second port inserts are adapted to removably mount to the foam injection body such that the respective foam passageway is in fluid communication with the slurry passageway via the port opening of the port passageway. One port insert can be replaced with another to readily vary the pressure of the foam passing through the particular port insert and injected into a cementitious slurry traveling through the slurry passageway.

Abstract: A slurry distributor includes a feed conduit and a distribution conduit in fluid communication therewith. The feed conduit includes an entry segment with a feed inlet and a feed entry outlet in fluid communication therewith and extending along a first feed flow axis. The feed conduit includes a shaped duct having a bulb portion in fluid communication with the feed entry outlet. The feed conduit includes a transition segment in fluid communication with the bulb portion and extending along a second feed flow axis in non-parallel relationship with the first feed flow axis. The bulb portion has an area of expansion with a cross-sectional flow area that is greater than a cross-sectional flow area of an adjacent area upstream from the area of expansion. The shaped duct has a convex interior surface in confronting relationship with the feed entry outlet of the entry segment.