Abstract: In the present disclosure, a cement board is disclosed. The cement board comprises a cement core having a first surface and a second surface opposite the first surface. The cement core comprises a binder, a lightweight aggregate, and a combustible additive, wherein the combustible additive is present in an amount of greater than 0 wt. % to less than 0.5 wt. % based on the weight of the cement core. The cement board passes CAN/ULC-S114:2018 and/or ASTM E136-19a.

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 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 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 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 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 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 process for expanding small diameter polystyrene beads is disclosed. The process comprises applying a steam pressure of about three to seven pounds per square inch at a temperature of about two hundred twenty degrees Fahrenheit to two hundred forty degrees Fahrenheit to a plurality of expandable polystyrene beads until each of the plurality of expandable polystyrene beads has expanded to a diameter of about 0.030 inches to 0.125 inches, wherein each of the plurality of expandable polystyrene beads has an unexpanded diameter of about 0.015 inches to about 0.028 inches.

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 cementitious panel with a low density core that can include at least one lightweight particulate aggregate filler, at least one binder, and at least one air entraining agent. The core of the cementitious panel can further comprise a rheological admixture, a standard weight aggregate filler, and/or synthetic and/or natural fibers. The method of forming such a cementitious panel involves forming a cementitious slurry, covering a reinforcing mesh with a portion of the cementitious slurry, forming a core by mixing together at least one lightweight particulate aggregate filler, and at least one air entraining agent, and introducing the core on top of the slurry covered mesh.