Abstract: An additive injection system can be a part of a cementitious slurry mixing and dispensing assembly. The additive injection system can be used to inject an additive into an auxiliary slurry discharge conduit carrying a secondary flow of cementitious slurry produced in the assembly such that the secondary slurry stream is different from a main slurry stream discharged from a main slurry discharge conduit.

Abstract: Disclosed is a composite gypsum board comprising a set gypsum core disposed between face (e.g., Manila) and back (e.g., Newsline) cover sheets. The set gypsum core is formed from a core slurry comprising stucco, water, and optional additives, such as foaming agent, migrating starch, accelerator, retarder, dispersant, etc. A dense layer formed from a dense layer slurry comprising stucco, water, fiber (e.g., paper fiber), and optionally, strength-enhancing starch, is disposed between the core and the face paper. The dense layer slurry contains a greater concentration of fiber, and optionally, strength-enhancing starch, than the core slurry, but the concentration of one or more other additives (e.g., accelerator, retarder, dispersant, or combinations thereof) is lower or the same in the dense slurry as compared with the core slurry. Also disclosed is a method of making board using one board mixer. In embodiments, paper fiber is added to water to form a suspension.

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 panel includes about 0.1% to about 95% by weight of a ground renewable component. In an embodiment, the panel has at least one core comprising: from about 0.1% to about 95% by weight of the ground renewable component; from about 0.1% to about 95% by weight of one or more fibers; and from about 1% to about 30% by weight of one or more binders, all based on dry panel weight. In an embodiment, the ground renewable component has a particle size distribution whereby less than 5% of the particles are retained by a mesh screen with openings of about 0.312 inches and less than 5% of the particles pass through a mesh screen with openings of about 0.059 inches. A method for manufacturing such panels is also provided.

Abstract: A panel includes about 0.1% to about 95% by weight of a renewable component. The panel has at least one of a CAC value of at least about 25, an NRC value of at least about 0.25 and an STC of at least about 25. A method for manufacturing such panels is also provided.

Abstract: A panel includes about 0.1% to about 95% by weight of a renewable component. The panel has at least one of a CAC value of at least about 25, an NRC value of at least about 0.25 and an STC of at least about 25. A method for manufacturing such panels is also provided.

Abstract: A panel includes about 0.1% to about 95% by weight of a renewable component. The panel has at least one of a CAC value of at least about 25, an NRC value of at least about 0.25 and an STC of at least about 25. A method for manufacturing such panels is also provided.

Abstract: A panel includes about 0.1% to about 95% by weight of a renewable component. The panel has at least one of a CAC value of at least about 25, an NRC value of at least about 0.25 and an STC of at least about 25. A method for manufacturing such panels is also provided.

Abstract: A panel includes about 0.1% to about 95% by weight of a ground renewable component. In an embodiment, the panel has at least one core comprising: from about 0.1% to about 95% by weight of the ground renewable component; from about 0.1% to about 95% by weight of one or more fibers; and from about 1% to about 30% by weight of one or more binders, all based on dry panel weight. In an embodiment, the ground renewable component has a particle size distribution whereby less than 5% of the particles are retained by a mesh screen with openings of about 0.312 inches and less than 5% of the particles pass through a mesh screen with openings of about 0.059 inches. A method for manufacturing such panels is also provided.