Abstract: A process is provided for creating a gypsum wallboard slurry with enhanced strength. The process includes providing a gypsum wallboard slurry mixer, providing suitable amounts of calcined gypsum and water in the mixer to create a slurry, agitating the slurry in the mixer, extracting a portion of the slurry in the mixer, reintroducing the extracted portion into the mixer for further mixing, and dispensing the mixed slurry from an outlet of the mixer.

Abstract: Provided are a gypsum set accelerator wherein the gypsum set accelerator is a dry-milled mixture comprising calcium sulfate dihydrate co-ground with one or more of the following: a polycarboxylic ether (PCE) and/or a sulfonated melamine polycondensate (SMP), gypsum slurries formulated with the gypsum set accelerator and methods for producing the gypsum set accelerator and manufacturing gypsum products with the gypsum set accelerator.

Abstract: The disclosure provides a coating composition for improving the sag resistance of a fibrous panel, the composition including 10 to 100 wt. % inorganic binder, based on the total weight of the dry coating, wherein the inorganic binder includes a borate salt and at least one of an alkali metal silicate or an alkaline earth metal silicate, and the inorganic binder is water soluble. Further provided are fibrous panels having a backing side and an opposing facing side including the coating of the disclosure, and methods of preparing same.

Abstract: Disclosed are an organic binder-based coating; a composite gypsum board containing face and back cover sheets, an outside surface of the back cover sheet bearing the coating; and a method of preparing composite board where the back cover sheet contains the coating on its outer surface. The coating is formed from a composition comprising an alkaline silicate, a solid filler, and optionally, a borate. An enhancing layer can also be applied to the back cover sheet.

Abstract: The disclosure provides a ceiling tile including a curable coating composition including 10-50 vol. % inorganic binder, based on the total volume of solids in the dry coating composition, wherein the inorganic binder is an alkali metal silicate or an alkaline earth metal silicate and 50-90 vol. % inorganic filler, based on the total volume of solids in the coating composition, wherein the binder and the filler are not the same and the coating is substantially free of an organic polymeric binder. The ceiling tiles have a backing side and an opposing facing side, and a cured coating layer disposed on the backing side of the panel, the backing side being directed to a plenum above the fibrous panel in a suspended ceiling tile, the cured coating layer including the curable coating composition of the disclosure.

Abstract: Disclosed are an organic binder-based coating; a composite gypsum board containing face and back cover sheets, an outside surface of the back cover sheet bearing the coating; and a method of preparing composite board where the back cover sheet contains the coating on its outer surface. The coating is formed from a composition comprising an alkaline silicate, a solid filler, and optionally, a borate. An enhancing layer can also be applied to the back cover sheet.

Abstract: The disclosure provides a coating composition for improving the sag resistance of a fibrous panel, the composition including 10 to 100 wt. % inorganic binder, based on the total weight of the dry coating, wherein the inorganic binder includes a borate salt and at least one of an alkali metal silicate or an alkaline earth metal silicate, and the inorganic binder is water soluble. Further provided are fibrous panels having a backing side and an opposing facing side including the coating of the disclosure, and methods of preparing same.

Abstract: A gypsum product with a fortified glass fiber mat is provided in which the glass fiber mat is strengthened by crystallization of salt crystals on the glass fiber mat prior to the glass fiber mat use in the gypsum product. Methods for making a glass fiber mat saturated with salt crystals and gypsum products with the glass fiber mats are provided as well.

Abstract: Methods for making a gypsum board provided with a latex polymer coating layer having a sufficiently low glass transition temperature, a less dense gypsum core layer, and a relatively denser layer of gypsum between the less dense gypsum core layer and the latex polymer coating layer and a gypsum board made by the method.

Abstract: The disclosure provides a curable coating composition including 10-50 vol. % inorganic binder, based on the total volume of solids in the dry coating composition, wherein the inorganic binder is an alkali metal silicate or an alkaline earth metal silicate and 50-90 vol. % inorganic filler, based on the total volume of solids in the coating composition, wherein the binder and the filler are not the same and the coating is substantially free of an organic polymeric binder. Further provided are ceiling tiles having a backing side and an opposing facing side, and a cured coating layer supported by the backing side of the panel, the cured coating layer including the curable coating composition of the disclosure and methods of preparing same.

Abstract: Methods for making a gypsum board provided with a latex polymer coating layer having a sufficiently low glass transition temperature, a less dense gypsum core layer, and a relatively denser layer of gypsum between the less dense gypsum core layer and the latex polymer coating layer and a gypsum board made by the method.

Abstract: Disclosed are cementitious product, as well as cementitious slurry, and method of forming the product. To reduce density in the cementitious product, foam is included in the slurry and in the method of forming the product. The slurry includes cementitious particles, water, and air bubbles such as from compressed air. Instead of using detergent chemistry at the gas/water interface of bubbles, the present invention uses a surface modifying agent for the cementitious particles in the slurry. The modified particles act to produce stable foam in the slurry. As an example mode of introduction, the surface modifier can be added (e.g., as solid or solution) directly into a bulk cementitious slurry that forms the product. As another example, the surface modifier can be added in a separate solution with water, air bubbles, and cementitious particles that serve as additive to the main cementitious slurry, where the separate solution is then added to the main cementitious slurry.

Abstract: A gypsum product with a fortified glass fiber mat is provided in which the glass fiber mat is strengthened by crystallization of salt crystals on the glass fiber mat prior to the glass fiber mat use in the gypsum product. Methods for making a glass fiber mat saturated with salt crystals and gypsum products with the glass fiber mats are provided as well.

Abstract: Disclosed are cementitious product, as well as cementitious slurry, and method of forming the product. To reduce density in the cementitious product, foam is included in the slurry and in the method of forming the product. The slurry includes cementitious particles, water, and air bubbles such as from compressed air. Instead of using detergent chemistry at the gas/water interface of bubbles, the present invention uses a surface modifying agent for the cementitious particles in the slurry. The modified particles act to produce stable foam in the slurry. As an example mode of introduction, the surface modifier can be added (e.g., as solid or solution) directly into a bulk cementitious slurry that forms the product. As another example, the surface modifier can be added in a separate solution with water, air bubbles, and cementitious particles that serve as additive to the main cementitious slurry, where the separate solution is then added to the main cementitious slurry.