Abstract: Gypsum plaster compositions with improved adhesion to plastic surfaces and metal surfaces comprise from 10 to 90% by weight of gypsum plaster, based on the total weight of the composition, and also, where appropriate, other additives, and a combination of: a) one or more water-redispersible polymer powders based on one or more vinyl ester, (meth)acrylate, vinylaromatic, olefin, 1,3-diene, or vinyl halides monomers, and optionally other monomers copolymerizable therewith; and b) one or more alkali metal and/or alkaline earth metal salts of short-chain fatty acids having from 1 to 4 carbon atoms in the hydrocarbon skeleton and from 1 to 4 carboxy groups, and which contain no OH groups.

Abstract: Improved sprayable gypsum-based fireproofing composition comprising a lightweight aggregate and a set retarding agent in an amount effective to delay the setting of said composition for at least 24 hours and preferably for at least 72-96 hours without causing the composition to swell or shrink or to cause a salt layer to form on the composition when it is spray-applied. The fireproofing composition can retain fluidity in conventional spray hoses overnight and yet is capable of being injected with a set accelerator, such as aluminum sulfate, on the next day or on a successive day when spray-applied onto a substrate.

Abstract: A set gypsum composition and methods for the preparation thereof are disclosed. The set gypsum composition comprises a continuous phase of interlocking set gypsum matrix having an enhanced water voids volume and/or is prepared from a mixture (e.g., slurry) comprising an elevated ratio of water to calcined gypsum. Also disclosed is an article comprising the set gypsum composition.

Abstract: A porous paste, especially a plaster paste or slurry for producing sandwich-type plasterboard, is made in a disk-shaped mixer having a rotor rotatable in a mixing chamber by introducing compressed air or other pressurizable gas through a wall or bottom segment directly into the chamber so that the incoming pressurized gas meets the mixture with a shearing action along the wall or bottom.

Abstract: A novel wallboard composition is disclosed comprising a unique combination of synthetic binders selected for their ability to establish a strengthened permanent bond in the final dry state for use in a wallboard composition comprising primarily gypsum, and in a wallboard composition comprising an expanded mineral such as Perlite which largely reduces the amount of gypsum over current gypsum wallboard formulations, thus reducing the weight while maintaining the strength of the wallboard structure. In a preferred embodiment, the lightweight, strengthened wallboard of the present invention also comprises an optional covering veneer that is applied to the top ply of the face paper to provide increased strength, moisture resistance, and fire retardency, and the back paper top ply is treated to provide increased flexural strength.

Abstract: A novel wallboard composition is disclosed comprising a unique combination of synthetic binders selected for their ability to establish a strengthened permanent bond in the final dry state for use in a wallboard composition comprising primarily gypsum, and in a wallboard composition comprising an expanded mineral such as Perlite which largely reduces the amount of gypsum over current gypsum wallboard formulations, thus reducing the weight while maintaining the strength of the wallboard structure. In a preferred embodiment, the lightweight, strengthened wallboard of the present invention also comprises an optional covering veneer that is applied to the top ply of the face paper to provide increased strength, moisture resistance, and fire retardency, and the back paper top ply is treated to provide increased flexural strength.

Abstract: A lightweight insulating concrete composition includes a cementitious forming material and a lightweight aggregate combination of expanded vermiculite and expanded perlite, the weight ratio of one to the other not exceeding about 2:1. Preferably, the composition is about 4 parts by weight cementitious forming material and about 1 part by weight lightweight aggregate. The cementitious forming material may be a hydraulic binder and accelerator combination, and may be Portland cement, plaster of Paris, and terra alba, in a weight ratio of about 5:4:1, or calcium aluminate cement, and plaster of Paris, in a weight ratio of about 11:5. The composition may further include an air entraining admixture in an amount between about 0.5 and about 2.0 percent of the total weight of the mixture, where neutralized vinsol resin and alpha olefin sulfonate are acceptable, and a surfactant in an amount between about 0.3 and about 1.

Abstract: A method of reducing the curing time of drywall joint compound, and thereby reducing the time required to finish drywall joints or to repair plaster walls, includes adding a predetermined amount of a drying agent to a conventional ready-mixed drywall joint compound. The drying agent preferably comprises at least one compound selected from the group of compounds consisting of plaster of Paris, calcium carbonate, gypsum, crystallized silicon dioxide (quartz), Portland cement, perlite, lime, hydroxy ethyl ether of cellulose, polyvinyl alcohol, starch, wood fiber, potassium naphthalene sulfon, aluminum sulfate, sodium citrate, ammonium tartrate, hydrolyzed protein, monosodium phosphate, sodium naphthalene sulfonate, potassium sulfate and various trace materials, or mixtures thereof A sufficient amount of water is added to the drying agent to facilitate mixing the drying agent with the drywall joint compound to form a joint compound mixture.

Abstract: A composition of matter comprising (a) gypsum (CaSO4 . 2H2O); (b) one or more naturally occurring or synthetic latex polymers; and (c) one or more nonionic surfactants; wherein said composition of matter has a density less than 0.64 g/cm3 and wherein wallboard produced from said composition of matter satisfies the criteria of ASTM Methods C-36 and C-473 is provided.

Abstract: Improved sprayable gypsum-based fireproofing composition comprising a lightweight aggregate and a set retarding agent in an amount effective to delay the setting of said composition for at least 24 hours and preferably for at least 72-96 hours without causing the composition to swell or shrink or to cause a salt layer to form on the composition when it is spray-applied. The fireproofing composition can retain fluidity in conventional spray hoses overnight and yet is capable of being injected with a set accelerator, such as aluminum sulfate, on the next day or on a successive day when spray-applied onto a substrate.

Abstract: A composition for producing light plaster contains as main constitutive elements particles of plaster in anhydride or hemihydrate form and at least one foaming agent. The composition is characterized in that the foaming agent generates gas after a delay of 1 minute to 24 hours and constitutes 0.1 to 50% by weight of the total dry mixture. Also disclosed is the use of said composition to produce in-situ cellular plastic and low density plaster moldings.

Abstract: Disclosed is a process of making foamed compositions of water, gypsum, and either or both of alpha-olefin sulfonates and/or amphoteric surfactants of formula (a) or (b)R.sup.4 --(OC.sub.3 H.sub.6).sub.0-1 --(C(O)NH(CH.sub.2).sub.1-3).sub.0-1 --N(Z.sup.1) (Z.sup.2).sub.0-1 --ZCOOX (a)R.sup.4 --(OC.sub.3 H.sub.6).sub.0-1 --(C(O)NH(CH.sub.2).sub.1-3).sub.0-1 --N(Z.sup.1) (Z.sup.2).sub.0-1 --ZSO.sub.3 X (b)wherein X is --H, a sodium, calcium, potassium, lithium or ammonium cation, or an amine of the formula --N.sup.+ H(C.sub.1-20 alkyl).sub.2 or --N.sup.+ H.sub.2 (C.sub.1-20 alkyl); or when a Z.sup.2 group is present there is no X group on --ZCOOX; R.sup.4 is straight or branched alkyl or alkylene, or cyclic or heterocyclic aromatic which is optionally substituted with alkyl, and contains 4 to 40 carbon atoms and 0-5 carbon-carbon double bonds; Z.sup.1 and Z.sup.2 are independently of each other H, C.sub.f H.sub.2f+1 or C.sub.f H.sub.2f OH wherein f is 1 to 6 and preferably 1, 2 or 3 or, in formula (a), one of Z.

Abstract: A lightweight gypsum board is provided, including, by dry weight, gypsum as the largest single ingredient, perlite as the second largest single ingredient, and starch as a minor ingredient, in the board. The starch may be pre-cooked prior to mixing, and is dispersed in the core of the board to act as a binder for binding the gypsum to the perlite. Gypsum board made according to the invention is lighter in weight, yet has a comparable nail pull value to conventional wallboard.

Abstract: Cementitious binders include calcium sulfate beta-hemihydrate, a cement component comprising Portland cement, and either silica fume or rice-husk ash. The silica fume or rice-husk ash component is at least about 92 wt % amorphous silica and has an alumina content of about 0.6 wt % or less.

Abstract: The invention relates to an improved sound absorbing cementitious composition and method of making involving a preformed foam solution made from a surfactant, such as an ammonium salt of a sulfated linear alcohol ethoxylate surfactant, preblended with water at a dilution ratio in a range of water to surfactant of from about 40:1 to 10:1. Thereafter, the preformed foam solution is combined with components including cement(s), aggregate(s), water and optional additives. The composition provides for an open cellular surface capable of absorbing sound.

Abstract: A process in which the conventional sulfate components in an aerated concrete mixture, such as gypsum, semihydrate or anhydrite, are replaced at least in part by calcium aluminum sulfates and/or calcium aluminate sulfate hydrates. As a result, agglomeration of the lime, retardation of the lime hydration, and aftergrowth of the cut aerated concrete cakes are reduced or even ruled out. In addition, the number of molds used can be reduced with the process in accordance with the invention, whereby the use of one single mold is achievable.

Abstract: A cementitious composition useful for water-resistant construction materials, including floor underlayments, backing boards, self-leveling floor materials, road patching materials, fiberboard, fire-proofing sprays, and fire-stopping materials includes about 20 wt. % to about 75 wt. % calcium sulfate beta-hemihydrate, about 10 wt. % to about 50 wt. % Portland cement, about 4 wt. % to about 20 wt. % silica fume and about 1 wt. % to about 50 wt. % pozzolanic aggregate. The Portland cement component may also be a blend of Portland cement with fly ash and/or ground blast slag.

Abstract: Surfactants containing a mixture of alkyl sulfate and alkyl ether sulfate in specific ratios are provided. Preferred compositions are blends of alkyl sulfate with narrow range alkoxylated alcohols are sulfonated. These compositions are used as improved foaming agent compositions and exhibit desirable foaming characteristics for use in the manufacture of gypsum board and concrete and in oil field applications.

Abstract: A cementitious composition useful for water-resistant construction materials, including floor underlayments, backing boards, self-leveling floor materials, road patching materials, fiberboard, fire-proofing sprays, and fire-stopping materials includes about 20 wt. % to about 75 wt. % calcium sulfate beta-hemihydrate, about 10 wt. % to about 50 wt. % Portland cement, about 4 wt. % to about 20 wt. % silica fume and about 1 wt. % to about 50 wt. % pozzolanic aggregate. The Portland cement component may also be a blend of Portland cement with fly ash and/or ground blast slag.

Abstract: Process for protecting articles from shock comprising encasing such articles in a plurality of molded blocks of a composition capable of progressively and irreversibly deforming in response to such shocks, said composition comprising cellulosic fibers dispersed in a matrix of at least one non-hydrated hydraulic binder, wherein from 2.5 to 75 parts by weight of the cellulosic fibers are dispersed per 100 parts by weight of said binder, said composition, upon curing and drying, exhibiting a density between 0.15 and 0.60.

Abstract: The invention provides a method of making gypsum products such as plasterboard from foamed gypsum plaster slurry. The method uses a first mixing chamber 10 containing a high speed rotor 14 and inlets 18, 19 for gypsum plaster and water. The initial dispersion of gypsum plaster and water foamed in the first chamber passes directly and continuously into a second chamber 25 containing a low speed rotor 29. Preformed foam is introduced into the second chamber through an inlet 33, and the foamed slurry product leaves the second chamber through an outlet 34, to be formed into plasterboard.

Abstract: A core for fire doors comprises hydrated gypsum occupying about 40% to 46% of the core volume and bubbles occupying almost all the core volume which is not gypsum. The bubbles preferably comprise about 31% to 38% by volume of larger bubbles of between 1 and 4 mm and about 17% to 25% of smaller bubbles between 0.01 mm and 0.25 mm. The larger bubbles are formed using styrene spheroids.

Abstract: The invention relates to a process for producing heat-insulating material from silicate-containing material, hydrated lime, water, foam and a reactive aluminates-containing quick-setting cement, from which a pourable raw mixture is produced which is poured into molds, the green moldings formed in the molds being demolded and autoclaved after sufficient setting. To achieve very low bulk densities, it is provided that, as silicate-containing material, a quartz powder with a specific surface area according to BET of at least approx. 3 m.sup.2 /g, in particular approx. 4 to 5 m.sup.2 /g, is used, the raw mixture is produced with a weight ratio of water/solids (excluding foam) of at least approx. 1.25 and an essentially stoichiometric amount, with respect to the virtually complete reaction of the quartz powder and the reactive aluminates, of hydrated lime with a surface area according to BET of at least approx. 15 m.sup.

Abstract: Lightweight concrete products, useful for example in blocks, wall panels, floor and roof slabs, in which zeolite is a major component, its content in the cementing material of the products exceeding 50 wt. %. Depending on application, zeolite may be non-treated or calcined at a temperature enabling the surface activation of the zeolite and resulting high surface energy. Zeolite thus treated will work as both pozzolanic material and bubble-generating agent. Strengthening agents are used to improve compressive strength of the products. Also, a binding material, useful for hazardous waste stabilization, comprising zeolite as a major component, is proposed.

Abstract: A foaming agent having improved foaming performance comprised of a mixture of alkyl sulfates and alkyl ether sulfates which have the general formula: R (CH.sub.2 CH.sub.2 O).sub.y --SO.sub.

Abstract: A foaming agent having improved foaming performance comprised of a mixture of alkyl sulfates and alkyl ether sulfates which have the general formula: R (CH.sub.2 CH.sub.2 O).sub.y --SO.sub.

Abstract: Glass fibre reinforced plasterboard comprising a gypsum matrix of high density with embedded staple glass fibres therewith forming a pressure resistant solid body frame in which are embedded a plurality of very small hollow spaces of 5-350 .mu.m diameter, produced by a fine-pore foam or at least partially by small particles of non-porous and non-water absorbing fillers. During the manufacturing process of such glass fibre reinforced gypsum board, the gypsum and the fibre pieces are given only so much water that the water/gypsum ratio does not exceed 0.6, whereafter a foam and/or pourable or free-flowing fillers are added in such quantities that the apparent density of the entire board is at least 20% smaller than the density of the bonding means component of the matrix and the paste are subjected while being formed, to a vibration.

Abstract: Narrow range alkoxylated alcohols are sulfonated and used as improved foaming agent compositions. These compositions exhibit desirable foaming characteristics for use in the manufacture of gypsum board and concrete and in oil field applications.

Abstract: A simple and inexpensive method of wetting a cement or gypsum-bonded fibrous mixture of building materials using water is characterized in that the water is added to the mixture of building materials at least partially in the form of a foam containing at least one foam forming surfactant and at least one foam stabilizer, or is added to the mixture of building materials in combination with at least one foam forming surfactant and at least one foam stabilizer prior to foam formation, and then at least partially foamed in situ, such that a sufficient quantity of water is present in the mixture to provide a final mixture exhibiting a powdery-crumbly consistency.

Abstract: A sprayable fireproofing composition comprising a hydratable cementitious binder, a porous aggregate, a fibrous material, an air-entraining agent and a rheopectic agent selected from granular attapulgite, sepiolite or mixture thereof having a major amount of particulate greater than 40 microns and water content less than 16 percent.