Abstract: A building composite panel including a core of a continuous phase comprising hydraulic binder. The core has first and second opposed longitudinal edge faces, and opposed first and second major faces, each major face adjoining the first and second opposed longitudinal edge faces. A slurry-permeable reinforcing material is attached to the first major face. A non-woven polymer fabric laminate facing material, that is different from the reinforcing material, covering and attached to and traversing the first major face and covering and attached to the opposed longitudinal edges of the core. The facing material includes a plurality of bonded laminas, wherein the plurality includes a first and second water-permeable laminas on opposed outer sides of the facing material, and a water-impermeable lamina between the first and second water-permeable laminas. The first water-permeable lamina attached to the core. A method for making the panel is also provided.

Abstract: A rapid setting, water durable binder composition includes a mixture of: a reactive powder including cement, at about 10-40 wt. % of the reactive powder, ?-stucco at about 30-75 wt. % of the reactive powder, and pozzolanic material at about 5-30 wt. % of the reactive powder; a plasticizer in an amount equal to about 0.05-3 wt. %, preferably 0.1-3 wt. %, of the reactive powder, and water.

Abstract: An exterior sheathing cementitious panel which prevents water penetration and air leakage is provided. Methods for manufacturing exterior sheathing cementitious panels with a highly efficient integrated air/water barrier sheet are also provided. An exterior sheathing system employing the exterior sheathing cementitious panel is provided.

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: Aqueous cementitious slurries including predominantly Type I Portland cement containing an aluminate additive. The aluminate additive is an aluminate salt other than calcium aluminate or calcium sulfoaluminate, preferably sodium aluminate. Cementitious reactive powders of the slurry include the Type I Portland cement and 0.1-10 wt. % of the aluminate additive as an accelerator. The slurries may have a set time of about 10 minutes or less. Due to the short set time, the cementitious reactive powders may facilitate cement board fabrication by continuous manufacturing processes. Methods for making cement boards may include disposing the aqueous cementitious slurry including the cementitious reactive powders in a continuous layer, preferably upon a porous support, and setting the aqueous cementitious slurry with a set time of about 10 minutes or less.

Abstract: A gypsum tile backer panel with a pre-impregnated or pre-coated nonwoven fiber face mat. Methods for manufacturing these gypsum tile backer panel which include applying a gypsum slurry to a pre-impregnated or pre-coated nonwoven fiber face mat are also provided. A gypsum tile backer panel system employing the gypsum tile backer panel is also provided.

Abstract: Embodiments of a system and a method for manufacturing a cementitious panel can be used to produce a cementitious panel having a multi-layer air/water barrier membrane assembly. The layers of the membrane can be built up via a series of applicator stations applying a fluid composition using roll coating, for example. Between applicator stations the applied layer of fluid composition can be subjected to drying conditions via infrared heating. To help protect from the deleterious effects of infrared heating, the cementitious panel can be conveyed through a cooling tunnel after each drying section.

Abstract: Disclosed are hydrophobic finish compositions and cementitious articles made with the hydrophobic finish compositions. In some embodiments, the article is a waterproof gypsum panel surface reinforced with inorganic mineral fibers that face a flexible and hydrophobic cementitious finish possessing beneficial waterproofing properties. The waterproof gypsum panels of the invention have many uses, such as, tilebacker board in wet or dry areas of buildings, exterior weather barrier panel for use as exterior sheathing, and roof cover board having water durability and low surface absorption. The flexible and hydrophobic cementitious finish can include fly ash, film-forming polymer, silane compound (e.g., alkyl alkoxysilane), an extended flow time retention agent including either one or more carboxylic acids, salts of carboxylic acids, or mixtures thereof, and other optional additives.

Abstract: Aqueous cementitious slurries including predominantly Type I Portland cement containing an aluminate additive. The aluminate additive is an aluminate salt other than calcium aluminate or calcium sulfoaluminate, preferably sodium aluminate. Cementitious reactive powders of the slurry include the Type I Portland cement and 0.1-10 wt. % of the aluminate additive as an accelerator. The slurries may have a set time of about 10 minutes or less. Due to the short set time, the cementitious reactive powders may facilitate cement board fabrication by continuous manufacturing processes. Methods for making cement boards may include disposing the aqueous cementitious slurry including the cementitious reactive powders in a continuous layer, preferably upon a porous support, and setting the aqueous cementitious slurry with a set time of about 10 minutes or less.

Abstract: An exterior sheathing cementitious panel which prevents water penetration and air leakage is provided. Methods for manufacturing exterior sheathing cementitious panels with a highly efficient integrated air/water barrier sheet are also provided. An exterior sheathing system employing the exterior sheathing cementitious panel is provided.

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: Disclosed are hydrophobic finish compositions and cementitious articles made with the hydrophobic finish compositions. In some embodiments, the article is a waterproof gypsum panel surface reinforced with inorganic mineral fibers that face a flexible and hydrophobic cementitious finish possessing beneficial waterproofing properties. These waterproof gypsum panels have many uses, such as, tile backer board in wet or dry areas of buildings, exterior weather barrier panel for use as exterior sheathing, interior wall and ceiling, and roof cover board having water durability and low surface absorption. The flexible and hydrophobic cementitious finish can include fly ash, film-forming polymer, preferably silane compound (e.g., alkyl alkoxysilane), an extended flow time retention agent including either one or more carboxylic acids, salts of carboxylic acids, or mixtures thereof, and other optional additives.

Abstract: Disclosed are cementitious articles with hydrophobic finish. In some embodiments, the article is a waterproof gypsum panel that is surface reinforced with inorganic mineral fibers that face a flexible and hydrophobic cementitious finish possessing beneficial waterproofing properties. The waterproof gypsum panels of the invention are useful in many applications, such as, for example, tilebacker board in wet or dry areas of buildings, exterior weather barrier panel for use as exterior sheathing, and roof cover board having superior water durability and extremely low surface absorption. The flexible and hydrophobic cementitious finish of the invention can include Class C fly ash, film-forming polymer, silane compound (e.g., alkyl alkoxysilane), and other optional additives.

Abstract: Disclosed are hydrophobic finish compositions and cementitious articles made with the hydrophobic finish compositions. In some embodiments, the article is a waterproof gypsum panel surface reinforced with inorganic mineral fibers that face a flexible and hydrophobic cementitious finish possessing beneficial waterproofing properties. The waterproof gypsum panels of the invention have many uses, such as, tilebacker board in wet or dry areas of buildings, exterior weather barrier panel for use as exterior sheathing, and roof cover board having water durability and low surface absorption. The flexible and hydrophobic cementitious finish can include fly ash, film-forming polymer, silane compound (e.g., alkyl alkoxysilane), an extended flow time retention agent including either one or more carboxylic acids, salts of carboxylic acids, or mixtures thereof, and other optional additives.

Abstract: Embodiments of a system and a method for manufacturing a cementitious panel can be used to produce a cementitious panel having a multi-layer air/water barrier membrane assembly. The layers of the membrane can be built up via a series of applicator stations applying a fluid composition using roll coating, for example. Between applicator stations the applied layer of fluid composition can be subjected to drying conditions via infrared heating. To help protect from the deleterious effects of infrared heating, the cementitious panel can be conveyed through a cooling tunnel after each drying section.

Abstract: Disclosed are hydrophobic finish compositions and cementitious articles made with the hydrophobic finish compositions. In some embodiments, the article is a waterproof gypsum panel surface reinforced with inorganic mineral fibers that face a flexible and hydrophobic cementitious finish possessing beneficial waterproofing properties. The waterproof gypsum panels of the invention have many uses, such as, tilebacker board in wet or dry areas of buildings, exterior weather barrier panel for use as exterior sheathing, and roof cover board having water durability and low surface absorption. The flexible and hydrophobic cementitious finish can include fly ash, film-forming polymer, silane compound (e.g., alkyl alkoxysilane), an extended flow time retention agent including either one or more carboxylic acids, salts of carboxylic acids, or mixtures thereof, and other optional additives.

Abstract: A water-resistant preformed polystyrene foam product with improved adhesive properties is provided. A water-resistant coating for preformed polystyrene products is also provided. The coating can be formulated as a sprayable composition and is easy to apply. Methods for making the coating formulations and water-resistant preformed polystyrene products are also provided.

Abstract: Disclosed are hydrophobic finish compositions and cementitious articles made with the hydrophobic finish compositions. In some embodiments, the article is a waterproof gypsum panel surface reinforced with inorganic mineral fibers that face a flexible and hydrophobic cementitious finish possessing beneficial waterproofing properties. These waterproof gypsum panels have many uses, such as, tile backer board in wet or dry areas of buildings, exterior weather barrier panel for use as exterior sheathing, interior wall and ceiling, and roof cover board having water durability and low surface absorption. The flexible and hydrophobic cementitious finish can include fly ash, film-forming polymer, preferably silane compound (e.g., alkyl alkoxysilane), an extended flow time retention agent including either one or more carboxylic acids, salts of carboxylic acids, or mixtures thereof, and other optional additives.

Abstract: Disclosed are hydrophobic finish compositions and cementitious articles made with the hydrophobic finish compositions. In some embodiments, the article is a waterproof gypsum panel surface reinforced with inorganic mineral fibers that face a flexible and hydrophobic cementitious finish possessing beneficial waterproofing properties. The waterproof gypsum panels of the invention have many uses, such as, tilebacker board in wet or dry areas of buildings, exterior weather barrier panel for use as exterior sheathing, and roof cover board having water durability and low surface absorption. The flexible and hydrophobic cementitious finish can include fly ash, film-forming polymer, silane compound (e.g., alkyl alkoxysilane), an extended flow time retention agent including either one or more carboxylic acids, salts of carboxylic acids, or mixtures thereof, and other optional additives.

Abstract: Disclosed are cementitious articles with hydrophobic finish. In some embodiments, the article is a waterproof gypsum panel that is surface reinforced with inorganic mineral fibers that face a flexible and hydrophobic cementitious finish possessing beneficial waterproofing properties. The waterproof gypsum panels of the invention are useful in many applications, such as, for example, tilebacker board in wet or dry areas of buildings, exterior weather barrier panel for use as exterior sheathing, and roof cover board having superior water durability and extremely low surface absorption. The flexible and hydrophobic cementitious finish of the invention can include Class C fly ash, film-forming polymer, silane compound (e.g., alkyl alkoxysilane), and otheroptional additives.