Abstract: A method of making a setting type compound by injecting an activator compound into a plaster compound wherein the activator compound tube is coaxial and within the plaster compound tube, each at the same flowrate, the same pressure and the same viscosity. The cross sectional transverse areas of an annulus containing the plaster compound and the hole in the annulus containing the activator compound are the same.

Abstract: Gypsum boards formed from synthetic gypsum and other gypsum sources having high chloride salt concentrations. Gypsum boards may include a board core including set gypsum between a front cover sheet and a back cover sheet. A total concentration of the chloride anion in the board core ranges from about 150 to 4000 parts by weight (pbw) chloride, typically about 300 to about 3000 pbw, more typically from about 400 to about 2000 pbw, further typically from about 1000 to about 2000 pbw, and further typically from about 600 to about 1000 pbw, per 1,000,000 pbw calcium sulfate dihydrate. A polymer layer contacts an inner surface of the back cover sheet. A densified gypsum layer contacts an inner surface of the front cover sheet. Methods of making the gypsum board, and a wall system for employing the gypsum boards, are also provided.

Abstract: A high solids, sprayable, fast drying, ready-mixed setting-type joint compound comprising a blend of a joint compound mixture comprising: joint compound mixture ingredients comprising: calcium sulfate hemihydrate (e.g. US Gypsum's HYDROCAL C-Base), a chelating agent, and water; and an activator mixture, wherein the activator mixture comprises: activator mixture ingredients comprising: inert filler, set accelerator, and water, wherein a weight ratio of joint compound mixture:activator mixture is 1:1 to 100:1, wherein the activator mixture viscosity is the same as the joint compound mixture viscosity plus or minus 50 percent, and wherein the joint compound has about 55 to about 80 wt. % solids and a viscosity of 2,500-28,000 cps.

Abstract: Mat-faced cementitious board including: (a) a cementitious core; (b) a fibrous mat having an inner first surface facing at least one face of the cementitious core, and an outer second surface, wherein the inner first surface and the outer second surface are opposed; (c) a hydrophobic, non-setting coating resulting from applying to the outer second surface of the fibrous mat a layer of hydrophobic finish composition including: (i) about 50 to about 80 weight % non-setting, inorganic filler having a mean particle diameter of about 12 microns to about 35 microns, (ii) about 20% to about 50 weight % an aqueous dispersion of a film-forming polymer, (iii) 0% to about 30 weight % additional water; (iv) an absence of fly ash, (v) an absence of pozzolanic material, (vi) an absence of hydraulic cement, (vii) an absence of calcium sulfate hemihydrate, and (viii) an absence of calcium sulfate anhydrite.

Abstract: Spackling and joint compounds with lower shrinkage, better sanding, and fast drying. Methods for repairing walls and ceiling in which the present spackling compound is applied to a variety of substrates, including wallboard, plaster and/or wood. Methods for finishing seams in wall construction in which the spackling/joint compound is used for finishing the seams.

Abstract: A formulation for an acoustically transparent coating for use on an acoustical substrate comprising a water dispersible binder and relatively large filler particles, and characterized by a high pigment to volume concentration, high viscosity, high shear thinning, and fast drying to enable the formulation to be sprayed in droplets that retain their identity when in mutual contact and in a dry coating can be efficiently sanded flat.

Abstract: A prefill tool for finishing wallboard joints is provided for finishing a wallboard joint, and includes a box assembly defining a hopper, having a top wall and a front wall constructed and arranged for engaging the wallboard joint. The front wall partially defines a gate dimensioned for dispensing joint compound stored in the hopper. Also, the gate is located on a skid plate mounted on the front wall, the skid plate having a main portion, and a gate portion partially defining the gate being displaced from a plane defined by the main portion.

Abstract: Mat-faced cementitious board including: (a) a cementitious core; (b) a fibrous mat having an inner first surface facing at least one face of the cementitious core, and an outer second surface, wherein the inner first surface and the outer second surface are opposed; (c) a hydrophobic, non-setting coating resulting from applying to the outer second surface of the fibrous mat a layer of hydrophobic finish composition including: (i) about 50 to about 80 weight % non-setting, inorganic filler having a mean particle diameter of about 12 microns to about 35 microns, (ii) about 20% to about 50 weight % an aqueous dispersion of a film-forming polymer, (iii) 0% to about 30 weight % additional water; (iv) an absence of fly ash, (v) an absence of pozzolanic material, (vi) an absence of hydraulic cement, (vii) an absence of calcium sulfate hemihydrate, and (viii) an absence of calcium sulfate anhydrite.

Abstract: A formulation for an acoustically transparent coating for use on an acoustical substrate comprising a water dispersible binder and relatively large filler particles, and characterized by a high pigment to volume concentration, high viscosity, high shear thinning, and fast drying to enable the formulation to be sprayed in droplets that retain their identity when in mutual contact and in a dry coating can be efficiently sanded flat.

Abstract: A formulation for an acoustically transparent coating for use on an acoustical substrate comprising a water dispersible binder and relatively large filler particles, and characterized by a high pigment to volume concentration, high viscosity, high shear thinning, and fast drying to enable the formulation to be sprayed in droplets that retain their identity when in mutual contact and in a dry coating can be efficiently sanded flat.

Abstract: A formulation for an acoustically transparent coating for use on an acoustical substrate comprising a water dispersible binder and relatively large filler particles, and characterized by a high pigment to volume concentration, high viscosity, high shear thinning, and fast drying to enable the formulation to be sprayed in droplets that retain their identity when in mutual contact and in a dry coating can be efficiently sanded flat.

Abstract: A prefill tool for finishing wallboard joints is provided for finishing a wallboard joint, and includes a box assembly defining a hopper, having a top wall and a front wall constructed and arranged for engaging the wallboard joint. The front wall partially defines a gate dimensioned for dispensing joint compound stored in the hopper. Also, the gate is located on a skid plate mounted on the front wall, the skid plate having a main portion, and a gate portion partially defining the gate being displaced from a plane defined by the main portion.

Abstract: This invention provides flexible adhesive compositions which can be used instead of joint reinforcement tape for securing a joint seam between abutting panels. Methods using the compositions are provided as well.

Abstract: A construction adhesive composition comprises between about 10 weight percent (wt. %) and about 30 wt. % of a vinyl acrylic latex, between about 30 wt. % and about 65 wt. % of calcium carbonate, and a surfactant.

Abstract: A formulation for an acoustically transparent coating for use on an acoustical substrate comprising a water dispersible binder and relatively large filler particles, and characterized by a high pigment to volume concentration, high viscosity, high shear thinning, and fast drying to enable the formulation to be sprayed in droplets that retain their identity when in mutual contact.

Abstract: Provided is an adhesive composition suitable for fortifying panel joints in construction, the adhesive composition comprising a polymeric binder, filler and thickener, wherein the binder is selected from acrylic acid polymers, acrylic acid copolymers, alkyds, polyurethanes, polyesters, epoxies, and combinations thereof and wherein the viscosity of the composition is the range from 100 to 200 Brabender Units and density is in the range from about 7.5 lbs/gal to about 10 lbs/gal. Methods of using the adhesive composition in wall assembly are provided as well.

Abstract: This invention provides flexible adhesive compositions which can be used instead of joint reinforcement tape for securing a joint seam between abutting panels. Methods using the compositions are provided as well.

Abstract: Provided is an adhesive composition suitable for fortifying panel joints in construction, the adhesive composition comprising a polymeric binder, filler and thickener, wherein the binder is selected from acrylic acid polymers, acrylic acid copolymers, alkyds, polyurethanes, polyesters, epoxies, and combinations thereof and wherein the viscosity of the composition is the range from 100 to 200 Bradbender Units and density is in the range from about 7.5 lbs/gal to about 10 lbs/gal. Methods of using the adhesive composition in wall assembly are provided as well.

Abstract: Provided are compositions and methods for expeditious wall installation by spray-applying a joint compound comprising a polymeric binder and hollow spheres.

Abstract: Disclosed are aspects of board finishing systems. For example, in various aspects, disclosed are joint compound compositions, wall assemblies, methods of treating walls, and products related to any of the foregoing, including reinforcement trim, e.g., for protecting corners where boards meet, fasteners, and tape. The joint compound preferably is a drying type composition with reduced shrinkage property, and includes binder and hollow spheres, resulting in an ultra lightweight formulation in some embodiments. The joint compound composition can be applied in a one-coat treatment in preferred embodiments. Other aspects of board finishing system accommodate such a one-coat treatment to thusly allow a user to manipulate the compound closer to the plane of board as compared with conventional formulations. Joint tape and reinforcement trim can include non-swelling synthetic paper facing material in some embodiments.