Abstract: An impact resistant exterior sheathing gypsum building panel with an integrated impact resistant woven mesh which protects against impact from projectiles such as those conveyed by hurricane force winds is provided. Methods for manufacturing these exterior sheathing gypsum building panels with an integrated impact resistant woven mesh are also provided. An exterior sheathing system employing the exterior sheathing cementitious building panel is provided.

Abstract: The present invention provides composite materials comprising a population of cellulose fibers complexed with an activator, and an additive comprising synthetic fibers complexed with a tethering agent, wherein the tethering agent has an affinity for the activator, and wherein an interaction between the tethering agent and the activator attaches the synthetic fibers to the cellulose fibers to form the composite material. The present invention also provides methods of manufacture for such composite materials, and methods for their use, for example in forming gypsum board composites.

Abstract: Exemplary embodiments provide a transaction card that may have multiple layers contained therein. The layers may include a metal sub-assembly core. The transaction card may be engraved, prior to providing to a cardholder, with a replica of the cardholder's actual signature. Additional items may be personalized upon the transaction card. The transaction card may also be incorporated into a system whereupon the transaction card may be triggered to perform an action such as emitting an audible tone or an electronic communication being sent to the cardholder.

Abstract: A cementitious board system which is reinforced on its opposed surfaces by an improved glass fiber mesh scrim with thicker yarn and larger mesh openings to provide a cementitious board with improved handling properties while retaining tensile strength and long term durability. The fabric is constructed as a mesh of high modulus strands of bundled glass fibers encapsulated by alkali and water resistant material, e.g. a thermoplastic material. The composite fabric also has suitable physical characteristics for embedment within the cement matrix of the panels or boards closely adjacent the opposed faces thereof. The fabric provides a board system with long-lasting, high strength tensile reinforcement and improved handling properties regardless of their spatial orientation during handling. Included as part of the invention are methods for making the reinforced board.

Abstract: Disclosed is a system and method for constructing fibrous mats. In accordance with the disclosure, continuous lengths of filament are pre-coated with a liquefied thermoplastic. The pre-coated filaments are then laid down upon a belt to forum a fibrous mat. The filaments can be laid down in continuous lengths or they can be chopped into discontinuous lengths. The filaments are heated after they have been laid down in order to re-liquefy the thermoplastic and facilitate bonding between intersecting fibers. The disclosure further relates to a system and method for incorporating constructed fibrous mats into a composite building board.

Abstract: The invention generally provides gypsum-containing slurries including stucco, naphthalenesulfonate dispersant, and pregelatinized starch. The naphthalenesulfonate dispersant is present in an amount of about 0.1%-3.0% by weight based on the weight of dry stucco. The pregelatinized starch is present in an amount of at least about 0.5% by weight up to about 10% by weight of pregelatinized starch by weight based on the weight of dry stucco in the formulation. Other slurry additives can include trimetaphosphate salts, accelerators, binders, paper fiber, glass fiber, and other known ingredients. The invention also comprises the gypsum-containing products made with such slurries, for example, gypsum wallboard, and a method of making gypsum wallboard.

Abstract: The present invention is a method of making a backerboard having a fiberglass mesh on one side, and an impervious reinforcement membrane on the other side. The backerboard incorporates a low density, high compressive strength concrete core having an upper principal surface and a lower principal surface. The upper principal surface of the core is covered by a fiberglass mesh reinforcement layer, itself covered and bonded to the core by a thin layer of Portland cement. The lower principal surface of the backerboard is covered with a high tensile strength, impervious reinforcement membrane.

Abstract: The invention provides a lightweight cement panel which achieves light weight, high strength, and durability, is free of degraded strength or deformation due to water absorption or fluctuation of ambient temperature, etc., provides satisfactory processing capabilities including nailing, etc. and can be used as a concrete formwork panel, floor material, wall material, ceiling material, and others of architectural structures. A panel proper 2 is formed by a porous compact 8 produced by filling, curing, and solidifying a mixture prepared by kneading cement, water, reinforcing fibers, and foam obtained by prefoaming a foaming agent in a hermetically sealed cement form block block, contains the reinforcing fibers 7 and foam in a dispersion state in the compact 8, and provides the specific gravity within the range between 0.5 and 1.0.

Abstract: A cementitious board system which is reinforced on its opposed surfaces by an improved glass fiber mesh scrim with thicker yarn and larger mesh openings to provide a cementitious board with improved handling properties while retaining tensile strength and long term durability. The fabric is constructed as a mesh of high modulus strands of bundled glass fibers encapsulated by alkali and water resistant material, e.g. a thermoplastic material. The composite fabric also has suitable physical characteristics for embedment within the cement matrix of the panels or boards closely adjacent the opposed faces thereof. The fabric provides a board system with long-lasting, high strength tensile reinforcement and improved handling properties regardless of their spatial orientation during handling. Included as part of the invention are methods for making the reinforced board.

Abstract: A process for making a fiber reinforced cementitious product such as a panel which hardens to an ultra-high compressive strength composite for use in making panels with ballistic and blast resistant properties. The panel has a continuous phase resulting from curing an aqueous mixture, in the absence of silica flour, of inorganic cement binder, inorganic mineral filler having a particle size of about 150-450 microns, pozzolanic mineral filler, and polycarboxylate based superplasticizer self-leveling agent, and water. The mixture may also include alkanolamine and acid or acid salt. The continuous phase may be reinforced with fiber distributed in the continuous phase before curing to form a panel. The panel may be reinforced with a fiber reinforced skin attached to at least one surface of the core, e.g., by lamination with an adhesive, e.g., epoxy, to form a ballistic and blast resistant cementitious armor panel.

Abstract: Emulsions are provided which are useful in imparting water-resistance to gypsum wood fiber products. In one embodiment, the emulsions comprise a wax or a combination of waxes, an alkyl phenol, at least one surfactant, Polynaphthalenesulfonic acid, and an alkali metal hydroxide. In another embodiment, the emulsions comprise a wax or a combination of waxes, an alkyl phenol, at least one surfactant, polynaphthalenesulfonic acid, an alkali metal hydroxide, and a complexed starch.

Abstract: A vibrating flexible smoothing sheet or shroud disposed transversely of a direction of travel of a formed fiber panel including gypsum-cementitious slurry and embedded chopped fibers. The sheet is used to smooth the surface of the panel as it exits a fiber embedment station of a structural cementitious panel production line to remove grooves and other non-uniform surface imperfections to reduce the need for costly finishing after the panels are cured and cut to size. The flexible sheet is designed to float over the surface of the formed panel without tearing or otherwise damaging the surface of the heavily fiber reinforced surface layers of the panel. The vibrating sheet is pivotally mounted on the side dams of the web production line so it can float over the panel surface during use, but be raised off the line when not in use.

Abstract: The present invention describes a fire resistant building material composition, useful for example as a fire door core and to a method of making this composition where the building material of the present invention is prepared from an aqueous slurry of calcined gypsum, paper fibers, a water insoluble organic binder, fiber reinforcement and a set retarder.

Abstract: An energy efficient method for making a gypsum cellulose fiberboard comprising adding a first portion of cellulose fiber to gypsum before the gypsum and cellulose fiber are co-calcined in a reactor, adding a second portion of cellulose fiber to the slurry after it leaves the reactor to form a second slurry, depositing the slurry to form a mat, dewatering the mat, rehydrating the mat and then finishing the mat to form a final gypsum cellulose fiberboard. A reduction of up to about 40% to 50% of steam energy used can be achieved when the second portion of added cellulose fiber is 50% or more of the total cellulose fiber used in the final board compared to gypsum cellulose board made with the same ingredients but when all of the fiber is added to the gypsum prior to the reactor.

Abstract: An impact resistant gypsum wallboard and method of making the same are disclosed that utilizes a woven scrim to improve upon the warping of the wallboard and to allow for a stronger bond to form between the facing material and gypsum core of the wallboard.

Abstract: Methods and a reinforcement fabric are disclosed for making a reinforced smooth cementitious board having a cement skin adjacent to an outer face, by depositing a reinforcement fabric and a layer of hydraulic cementitious material, one on the other, wherein the reinforcement fabric comprises an open mesh united with a thin, porous nonwoven web.

Abstract: A method of producing a paperless gypsum/fiber board from a mixture including reinforcing material particles, calcined gypsum and water. A headbox feeds the mixture into a panel forming area (forming pond) over the upper surface of a continuous forming fabric to form a panel mat. Also, a reinforcing mesh is fed over a transverse member, located over a portion of the forming fabric, and into the forming pond to embed the mesh in the mixture. At least a portion of a downstream end of the transverse member is under a downstream portion of the headbox or downstream of the headbox. Then the panel mat is pressed, the calcined gypsum of the pressed panel mat is rehydrated, and the resulting board is dried.

Abstract: A system and method of making a plaster panel to use in the construction of a wall of a building in a relatively faster, easier, more efficient, and more precise manner for either interior or exterior walls is disclosed. The created plaster panels may include a slab of cementitious composition including a mixture of sizes of cut expanded polystyrene, a quantity of monofilament fiber, and a binding agent. At least one layer of a mesh may surround the slab, wherein the resulting panel is light in weight, flexible and strong. Such panels may be fixed in place to a building frame by suitable fasteners such as nails or screws, while causing little or no fracturing of the panel.

Abstract: A cementitious board and a reinforcement sheet for the board includes, a water vapor porous layer of glass fibers bonded together by a cured binder, and a hydrophilic coating material being mobile in slurry water to wet the binder coated glass fibers and spread a slurry of a cementitious compound, and the hydrophilic coating material being volatile to dissipate by evaporation at an elevated temperature at which the cementitious compound dries to form a dried cementitious board having both the cementitious compound and the binder coated glass fibers essentially free of the hydrophilic coating material.

Abstract: A gypsum board comprises a set gypsum layer having a first face and a second face. A fibrous mat is affixed to at least one of the faces. The mat comprises a non-woven web bonded together with a resinous binder. The web comprises a blend of a major portion composed of chopped continuous glass fibers having an average fiber diameter ranging from about 8 to 17 ?m and a minor portion composed of fine staple fibers having an average fiber diameter of less than about 5.5 ?m, the minor portion comprising about 1-30 percent of the dry weight of the web. The board is exceedingly durable. It has a smooth surface that is readily finished in an aesthetically pleasing way, using paint or other wall covering systems.

Abstract: A method of continuously forming a multilayer panel includes making a gypsum slurry, then dividing the gypsum slurry into at least a primary gypsum slurry and a secondary gypsum slurry. An additive slurry having water and an intumescent material is created, then added to the secondary gypsum slurry to make an expandable layer slurry that is spread over at least a portion of a facing material. The primary gypsum slurry is distributed over the secondary gypsum slurry over the facing material and the expanding layer slurry to form a core. Optionally, another layer, an edge coating, is applied to the expanding layer for additional fire protection. The edge coating includes a second intumescent material. During a fire, the expanding layer expands to increase the thickness of the fire exposed gypsum panel and the edge coating expands to seal the gap between adjoining gypsum panels.

Abstract: A method of forming a gypsum-based panel product including the steps of: mixing calcined gypsum, water, a foaming agent and a core strengthening agent to form a foamed slurry; depositing the slurry; shaping the slurry to form a board having a core and core surfaces, optionally sandwiched between sheets of liner; and allowing the core to set, and drying the board, wherein the strengthening agent is dextrin, used in an amount not less than 0.1% by weight, based on the amount of calcined gypsum, so that, after drying, there is provided a strengthening dispersion of dextrin throughout the core. Less than 5% dextrin in preferred.

Abstract: The present invention relates to an apparatus and method for selectively dispensing reinforcement material into a concrete component. The apparatus is capable of providing, positioning and embedding any form of rolled reinforcement materials into both prefabricated concrete components and cast-in-place concrete components which can be operated by a minimal number of personnel in a timely and economical manner, and which can be used to mass produce concrete components.

Abstract: A vibrating flexible smoothing sheet or shroud disposed transversely of a direction of travel of a formed fiber panel including gypsum-cementitious slurry and embedded chopped fibers. The sheet is used to smooth the surface of the panel as it exits a fiber embedment station of a structural cementitious panel production line to remove grooves and other non-uniform surface imperfections to reduce the need for costly finishing after the panels are cured and cut to size. The flexible sheet is designed to float over the surface of the formed panel without tearing or otherwise damaging the surface of the heavily fiber reinforced surface layers of the panel. The vibrating sheet is pivotally mounted on the side dams of the web production line so it can float over the panel surface during use, but be raised off the line when not in use.

Abstract: Methods and systems are provided for preparing a heat resistance accelerator (HRA) slurry. Also provided are methods and systems for introducing a HRA slurry to an aqueous dispersion of calcined gypsum in a discharge apparatus downstream of a stucco mixer in which the dispersion was prepared. These methods and systems are useful in the production of various gypsum products such as board including wallboard and ceiling tiles.

Abstract: A process for producing fiber-reinforced structural cementitious panels made of at least one layer of fiber reinforced cementitious slurry, the process for each such layer of slurry including providing a moving web; depositing a first layer of individual, loose fibers upon the web; depositing a layer of settable slurry upon the deposited first layer of individual, loose fibers; depositing a second layer of individual, loose fibers upon the deposited layer of settable slurry; and actively embedding both layers of individual, loose fibers into the layer of slurry to distribute the fibers throughout the slurry.

Abstract: A method for making the core of a door of autoclaved aerated concrete (AAC). A billet of AAC is provided from which slabs are cut to the approximate dimensions of the door core. A reinforcing band is secured about the perimeter of a slab or a pair of slabs sandwiching a reinforcing panel. The thickness of the slab, or the pair of slabs and reinforcing panel, is then sized for the door core as by sanding. The door is finished by applying skins to the core surfaces and trim to the reinforcing band.

Abstract: A gypsum board comprises a set gypsum layer having a first face and a second face. An uncoated fibrous mat is affixed to at least one of the faces. The mat comprises a non-woven web bonded together with a resinous binder. The web comprises glass fiber consisting essentially of a major portion composed of chopped continuous glass fibers having an average fiber diameter ranging from about 8 to 25 ?m and optionally a minor portion consisting essentially of at least one of small diameter glass fibers having a fiber diameter of at most about 13 ?m and microfibers having an average fiber diameter ranging from about 0.05 to about 6.5 ?m. The board is exceedingly durable and has a high resistance to water absorption, rendering it particularly useful for exterior insulation systems.

Abstract: An energy efficient method for making a gypsum cellulose fiberboard comprising adding a first portion of cellulose fiber to gypsum before the gypsum and cellulose fiber are co-calcined in a reactor, adding a second portion of cellulose fiber to the slurry after it leaves the reactor to form a second slurry, depositing the slurry to form a mat dewatering the mat, rehydrating the mat and then finishing the mat to form a final gypsum cellulose fiberboard. A reduction of up to about 40% to 50% of steam energy used can be achieved when the second portion of added cellulose fiber is 50% or more of the total cellulose fiber used in the final board compared to gypsum cellulose board made with the same ingredients but when all of the fiber is added to the gypsum prior to the reactor.

Abstract: A manufactured construction board is formed from a composition that may include magnesium oxide, magnesium chloride, a binding agent (e.g., perlite), wood shavings, recycled board scraps, and water. The construction board further includes fiberglass and polyester paper sheets on opposite sides of the construction board. A method of fabricating the construction board is also disclosed to include mixing magnesium chloride with water to form a solution, mixing the solution with magnesium oxide, perlite and a binding agent to form a paste, and pouring the paste onto a mold to form a construction board. The paste is poured onto a mold which is then passed through a series of rollers to spread out the paste evenly across the mold and to form the paste into the desired thickness. The resulting construction board is fire and water resistant and much more durable than conventional sheetrock.

Abstract: A manufactured construction board is formed from a composition that may include magnesium oxide, magnesium chloride, a binding agent (e.g., perlite), wood shavings, recycled board scraps, and water. The construction board further includes fiberglass and polyester paper sheets on opposite sides of the construction board. A method of fabricating the construction board is also disclosed to include mixing magnesium chloride with water to form a solution, mixing the solution with magnesium oxide, perlite and a binding agent to form a paste, and pouring the paste onto a mold to form a construction board. The paste is poured onto a mold which is then passed through a series of rollers to spread out the paste evenly across the mold and to form the paste into the desired thickness. The resulting construction board is fire and water resistant and much more durable than conventional sheetrock.

Abstract: A multi-layer process for producing structural cementitious panels, includes, a. providing a moving web; b. one of depositing a first layer of loose fibers upon the web and c. depositing a layer of settable slurry upon the web; d. depositing a second layer of loose fibers upon the slurry; e. embedding said second layer of fibers into the slurry; and f. repeating steps c. through e. until the desired number of layers of settable fiber-enhanced slurry in the panel is obtained. Also provided are a structural panel produced by the present process, an apparatus suitable for producing structural cementitious panels according to the present process, and a structural cementitious panel having multiple layers, each layer created by depositing a layer of settable slurry upon a moving web, depositing fibers upon the slurry and embedding the fibers into the slurry such that each layer is integrally formed with the adjacent layers.

Abstract: A cementitious board and methods of making the same are disclosed by a cementitious board including a cementitious core, a plurality of warp yarns and weft yarns and a coating applied to produce a coating weight distribution ratio of less than about 2.0:1, based upon the weight of the resinous coating of the weft yarns, over the weight of the resinous coating on the warp yarns.

Abstract: A gypsum cellulose fiber composite board having a cellulosic fiber layer on at least one surface layer of the composite material is disclosed. A continuous method for preparing the composite board is described wherein a cellulosic fiber first slurry is deposited on a traveling web from a head box to form a first cellulosic layer and a co-calcined gypsum and cellulosic fiber second slurry is deposited to form a co-calcined gypsum and cellulosic fiber second layer on the cellulosic first layer. If desired a cellulosic fiber third layer is deposited or coated on top of the co-calcined gypsum and cellulosic fiber second layer. A method including laminating a layer of wallboard paper to at least one surface of a co-calcined gypsum and cellulosic fiber composite panel is also disclosed.

Abstract: A gypsum-containing panel and a method of making it are disclosed including at least one facing layer having a first polymer that is reinforced with reinforcing fibers and a gypsum core that has a second polymer in a second polymer matrix interwoven with a gypsum matrix. The first polymer in the facing layer and said second polymer matrix in said gypsum core form a continuous polymer matrix.

Abstract: The invention provides a lightweight cement panel which achieves light weight, high strength, and durability, is free of degraded strength or deformation due to water absorption or fluctuation of ambient temperature, etc., provides satisfactory processing capabilities including nailing, etc. and can be used as a concrete formwork panel, floor material, wall material, ceiling material, and others of architectural structures. A panel proper 2 is formed by a porous compact 8 produced by filling, curing, and solidifying a mixture prepared by kneading cement, water, reinforcing fibers, and foam obtained by prefoaming a foaming agent in a hermetically sealed cement form block block, contains the reinforcing fibers 7 and foam in a dispersion state in the compact 8, and provides the specific gravity within the range between 0.5 and 1.0.

Abstract: A method for making the core of a door of autoclaved aerated concrete (AAC). A billet of AAC is provided from which slabs are cut to the approximate dimensions of the door core. A reinforcing band is secured about the perimeter of a slab. The thickness of the slab is then sized for the door core as by sanding. The door is finished by applying skins to the core surfaces and trim to the reinforcing band.

Abstract: A multiple layer fiber reinforced material and method of constructing the same including the provision of a first layer of a roll lofted glass material. Optional variants include the pre-application of plywood, OSB or fiber reinforced cement board materials prior to the first glass layer. A layer of a rolled fiber reinforced material is applied over the rolled glass material, with or without backing board material, and at least a second layer of the roll lofted glass material is applied over the rolled fiber reinforced material. A layer of a second rolled glass material is applied over the subsequent layer of the first glass material and a urethane resin syrup is intermixed with said layers of glass material and the fiber reinforced material. An application of heat and pressure results in the formation of the reinforced material. A flexural, closed cell foam material may also be applied to provide acoustical insulating properties to the multi-layer fiber material.

Abstract: In some embodiments, alternate sources of aluminum or calcium are provided in various ways including the desired compounds. The further object of the present invention contemplate in situ creation of the compound in interest in fresh concrete and as a slurry which can be employed in remediation of existing concrete structures. A method of resisting corrosion in concrete containing metal elements is provided. It includes introducing into fresh concrete, containing metal elements, at least one compound capable of sequestering chloride ions. The method may also involve employing a compound which is capable of establishing a corrosion resistant oxide layer on the metal reinforcing elements. The invention also includes certain compounds which may be employed in the method as well as concrete structures containing the compounds.

Abstract: A moisture-tolerant structural panel comprising a gypsum board which comprises a set gypsum core sandwiched between and faced with fibrous mats, wherein a free surface of one of said mats is pre-coated with a combination of a mineral pigment, optionally an inorganic adhesive binder and a hydrophobic, UV resistant polymer latex adhesive binder applied to said surface as an aqueous coating composition, said aqueous coating composition upon drying and setting, covering said mat to the extent that substantially none of the fibers of said mat can be seen protruding from said coating.

Abstract: In some embodiments, alternate sources of aluminum or calcium are provided in various ways including the desired compounds. The further object of the present invention contemplate in situ creation of the compound in interest in fresh concrete and as a slurry which can be employed in remediation of existing concrete structures. A method of resisting corrosion in concrete containing metal elements is provided. It includes introducing into fresh concrete, containing metal elements, at least one compound capable of sequestering chloride ions. The method may also involve employing a compound which is capable of establishing a corrosion resistant oxide layer on the metal reinforcing elements. The invention also includes certain compounds which may be employed in the method as well as concrete structures containing the compounds.

Abstract: A composite fabric for use in reinforcement of cementitious boards and similar prefabricated building wall panels. The fabric includes an open mesh first component of continuously coated, high modulus of elasticity strands and a nonwoven second component fabricated from alkali resistant thermoplastic material. The high modulus strands of the first component are preferably bundled glass fibers encapsulated by alkali and water resistant thermoplastic material. The composite fabric also has suitable physical characteristics for embedment within the cement matrix of the panels or boards closely adjacent the opposed faces thereof. The reinforcement provides long-lasting, high strength tensile reinforcement and impact resistance for the panels or boards. The reinforcement also enables the boards to have smooth outer faces suitable for painting, papering, tiling or other finishing treatment.

Abstract: A composite facer material for use with cementitious wallboards, where the composite facer is embedded in a top and bottom face thereof. The composite facer material, in a most preferred embodiment, comprises two layers. The first layer is preferably a carded polyester nonwoven mat, which is bonded to a second layer comprising preferably a tri-directional laid scrim fabric reinforcement layer made of continuous glass fibers. The two layers are preferably bonded together using an acrylic adhesive, which offers superior adhesion between the layers as well as superior adhesion between the composite facing material and the cementitious core.

Abstract: The invention provides a set gypsum-containing product having increased resistance to permanent deformation and a method for preparing it comprising forming a mixture of a calcium sulfate material, water, and an appropriate amount of one or more enhancing materials chosen from condensed phosphoric acids, each of which comprises 2 or more phosphoric acid units; and salts or ions of condensed phosphates, each of which comprises 2 or more phosphate units. The mixture is then maintained under conditions sufficient for the calcium sulfate material to form a set gypsum material.

Abstract: The present invention is directed to a pad for carrying liquid having a piece of non-woven material wherein the piece of material is capable of absorbing an amount of the liquid at least about 1.5 times the weight of the piece of material, a first printed ink on a first surface of the material, and a second printed ink on either the first or a second surface of the material, and wherein the first ink is substantially in register with the second ink. The present invention is also directed to a method for making a printed pad for carrying a liquid including the steps of feeding a web of non-woven material into a rotogravure press, wherein the material is capable of absorbing at least about 1.5 times its own weight of the liquid, printing a first ink with the press on a first surface of the web, printing a second ink with the press substantially in register with the first ink on the first surface or a second surface of the web.

Abstract: A reinforced plasterboard has a first layer of paper, a core of a cementitious material, a mesh reinforcement and adjacent to that mesh reinforcement a further layer of paper. The mesh may be in contact with the paper layer.

Abstract: A gypsum/fiber board having improved impact resistance is produced by mixing predetermined amounts of fibers, calcined gypsum and water to form a mixture of wetted, loose fibers; laying out a reinforcing mesh over the upper surface of a forming belt; depositing said mixture on said mesh to form a layer of said mixture, said; and compressing said mesh together with said layer of mixture to embed said mesh in the lower surface of said layer to form a board composed of bonded fibers and gypsum with said mesh embedded in the surface thereof.

Abstract: A cementitious panel comprising a cementitious core which is fabric-reinforced at the surface thereof and whose longitudinal edges are reinforced by a network of fibers. A panel may be obtained wherein the surface edge reinforcement layers are relatively strong and hard such that a nail or screw may be driven through the edge of panel without pre-drilling and without breaking, even when nailed or screwed almost at the very limit of the edge of the panel. Such a panel may provide a long lasting substrate for humid or wet areas such as shower rooms and bath rooms.

Abstract: This invention relates to a process for making gypsum board comprising feeding a paper backing sheet and a fiberglass or plastic woven or non-woven scrim material in alignment to a board forming station, separating the paper and the scrim, feeding a high density calcium sulfate hemihydrate slurry into the trough formed between the paper and the scrim, and subsequently compressing the paper and the scrim into contact whereby the high density slurry is forced through the scrim, completely encapsulating the scrim in the high density slurry. As a result of this unique process, excellent bond is developed between the paper, the high density gypsum layer and the foamed gypsum core. The gypsum board has improved through-penetration strength.

Abstract: A gypsum/fiber board having improved impact resistance is produced by mixing predetermined amounts of fibers, calcined gypsum and water to form a mixture of wetted, loose fibers; laying out a reinforcing mesh over the upper surface of a forming belt; depositing said mixture on said mesh to form a layer of said mixture, said; and compressing said mesh together with said layer of mixture to embed said mesh in the lower surface of said layer to form a board composed of bonded fibers and gypsum with said mesh embedded in the surface thereof.