Abstract: A construction board is formed from a composition comprising one or more of the following ingredients: 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® brand plaster wallboard.

Abstract: A multi-threat panel includes two first layers of polyurea mix, for at least one of reflecting and attenuating blast pressure and restricting ballistic penetration of the panel, and a layer of a concrete mix, including a ceramic aggregate, for increasing resistance to blast pressure and ballistic penetration of the panel. The first layers coat the concrete layer.

Abstract: Facing material useful in the manufacture of gypsum wallboard is surfaced treated in order to adhere an amount of seed crystals to improve the adhering affinity of the facing material for wet plaster thereby permitting the manufacture of gypsum wallboard with little or no added starch and reduced amounts of water. Various means for adhering the seed crystals to the facing material are described as well as, a method of converting the facing material and wallboards containing the facing material are also described.

Abstract: This invention relates to a gypsum board coating comprising cardboard with a water-repellent treatment, containing a treatment agent which prevents the growth of micro-organisms. This invention also relates to a gypsum board comprising such a coating and a method for producing the cardboard-coated gypsum board.

Abstract: Provided is a coated glass mat having enhanced flame and fire resistance properties. The glass mat comprises nonwoven glass fibers and a coating comprised of a silicate. The coated glass mat is particularly useful as a facer in the building industry.

Abstract: The object of the present invention is to provide an inorganic board whose dimensional stability, anti-freezing and fusing properties, and the like are much improved. To attain this object, an inorganic board is manufactured using a method comprising: preparing a raw material slurry by the dispersing of a cementitious material, silica-containing material, woody reinforcement, and mica in water, forming a papered mat by sheet forming the raw material slurry, pressing the papered mat, and curing the pressed papered mat in an autoclave at a temperature higher than 150° C., wherein the mass ratio of the cementitious inorganic material and silica-containing material is set to be in the range of between 35:65 and 45:55, to promote the curing reaction of the inorganic board and improve its dimensional stability and anti-freezing and fusing properties.

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: IR reflective cementitious systems comprising one or more IR reflective pigments are provided. The cementitious systems of the invention may be in the form of mixtures which increase the total solar reflectivity (TSR or albedo) and the Solar Reflectance Index (SRI) of concrete are provided. The cementitious systems are infrared reflective and may be toppings mixed with water for application to existing concrete surfaces, or dry-shake hardeners for application to freshly-placed plastic concrete. The formulations of the invention utilize one or more of cementitious binder(s), graded aggregates, super-plasticizers, one or more pigments selected for improving infrared reflectivity and color composition, and/or optionally other additives, such as dry redispersible polymers or fillers to provide decorative and LEED compliant, highly durable (sustainable) concrete hardscapes and other decorative concrete.

Abstract: A prefabricated cover board has a high-density polymer or predominantly polymer material core layer having a density between 4 lbs/ft3 and 25 lbs/ft3. A prefabricated roofing panel composite includes the cover board and an insulation board that has a low-density polymer or predominantly polymer material foam core layer preferably having a density less than 2.5 lbs/ft3. The cover board may have a waterproofing membrane forming the top major surface of the cover board. When making the roofing panel composite, the low-density foam core layer of the insulation board may be formed with the high-density core layer of the cover board being currently or subsequently formed over and bonded to a top major surface of the low-density foam core layer in the same operation or preformed insulation boards may be fed into a production line with the high-density core layer of the cover board being formed over and bonded to top major surfaces of the low-density foam core layers of the insulation boards.

Abstract: Polymerization of siloxane is improved using a gypsum-based slurry that includes stucco, Class C fly ash, magnesium oxide and an emulsion of siloxane and water. This slurry is used in a method of making water-resistant gypsum articles that includes making an emulsion of siloxane and water, then combining the slurry with a dry mixture of stucco, magnesium oxide and Class C fly ash. The slurry is then shaped as desired and the stucco is allowed to set and the siloxane polymerizes. The resulting product is useful for making a water-resistant gypsum panel having a core that includes interwoven matrices of calcium sulfate dihydrate crystals and a silicone resin, where the interwoven matrices have dispersed throughout them a catalyst comprising magnesium oxide and components from a Class C fly ash.

Abstract: The present invention relates to a container packing structure, characterized in that it comprises a crystalline phase containing 55 to 97% by weight of xonotlite crystallites and 3 to 45% by weight of tobermorite crystallites. It also relates to a method for fabricating such a packing structure, and the container containing same, and its use for storing fluids such as gases.

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: A lightweight cementitious composition containing from 22 to 90 volume percent of a cement composition and from 10 to 78 volume percent of particles having an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.03 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3, where after the lightweight cementitious composition is set it has a compressive strength of at least 1700 psi as tested according to ASTM C39. The cementitious composition can be used to make concrete masonry units, construction panels, road beds and other articles and can be included as a layer on wall panels and floor panels and can be used in insulated concrete forms. Aspects of the lightweight cementitious composition can be used to make lightweight structural units.

Abstract: A gypsum slurry includes water, a hydraulic component including stucco and a polycarboxylate dispersant. The dispersant has two repeating units wherein the first repeating unit is an olefinic unsaturated mono-carboxylic acid repeating unit or an ester or salt, and the second repeating unit is a vinyl or allyl group bound to a polyether by an ether linkage. The slurry can be made into a gypsum panel.

Abstract: Sandwich plate-like construction and method for making such a construction, wherein the construction comprises a steel plate, a contact layer and an inorganic layer, said inorganic layer at least comprises ultra fine particles and a binder. This type of construction is especially suitable as bridge decks, on oil platforms, ship decks, windmill foundations or towers, outdoor furniture, balconies and other tough and exposed applications.

Abstract: A gypsum slurry includes water, a hydraulic component including stucco and a polycarboxylate dispersant. The dispersant has two repeating units wherein the first repeating unit is an olefinic unsaturated mono-carboxylic acid repeating unit or an ester or salt, and the second repeating unit is a vinyl or allyl group bound to a polyether by an ether linkage. The slurry can be made into a gypsum panel.

Abstract: The invention provides gypsum wallboard, made from gypsum-containing slurries having outstanding hydration rate characteristics comprising alpha-hemihydrate ground to a particular particle size distribution range and having a Blaine surface area in the range from about 3100 cm2/g to about 9000 cm2/g, alone or in combination with beta-hemihydrate.

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 invention pertains to a coating composition, a coated material formed therewith, and a method for coating the material with the coating composition.

Abstract: A cementitious veneer and laminate composition is provided. The cementitious laminate composition includes a substrate, a primer layer applied to the substrate, the primer layer comprising a mixture of polyvinyl alcohol catalyst, Portland cement, and sand; and a cementitious veneer layer applied to the primer layer, the veneer layer comprising a mixture of magnesium sulfate, filler, magnesium oxide, gypsum cement, and polyvinyl alcohol catalyst. The polyvinyl alcohol catalyst comprises a mixture of polyvinyl alcohol fibers dissolved in water and mixed with butylene carbonate. The veneer layer is applied to the substrate and primer layer by means including spraying and manual spreading. The veneer layer can be ornamentally manipulated either before or after curing of the veneer layer. The veneer composition can be formed into laminated tiles or panels for use in building applications.

Abstract: The invention provides a light weight composite gypsum board including a foamed low density set gypsum core, a top non-foamed (or reduced-foamed) bonding high density layer and a bottom non-foamed (or reduced-foamed) bonding high density layer, a top cover sheet bonded to the foamed low density set gypsum core by the top non-foamed (or reduced-foamed) bonding high density layer, and a bottom cover sheet bonded to the foamed low density set gypsum core by the bottom non-foamed (or reduced-foamed) bonding high density layer. The foamed low density set gypsum core is prepared having a density of less than about 30 pcf using soap foam in the gypsum-containing slurry. The combination of components provide a composite gypsum board having light weight and high strength.

Abstract: A coating for preparing a floor underlayment to receive an adhesive includes a water-soluble, latex polymer, a defoamer and a dual-function surface enhancing agent. The surface enhancing agent includes a set accelerator that also functions to cross link the adhesive, hardening the surface of the underlayment using at least two mechanisms. One embodiment of the invention is a dry mixture that forms a coating when added to water. The dry mixture includes from about 10% to about 50% of the redispersible polymer by weight based on the mixture, from about 50% to about 90% of the surface enhancing agent and from about 0.15% to about 0.25% of the defoamer by weight based on the mixture. Other embodiments describe a liquid coating formed by adding from about 1 to about 8 parts water to 1 part of the dry mixture by volume based on the mixture.

Abstract: Provided is a fiber reinforced cement board having good installation properties such as nail performance, flexibility performance and handling performance, as well as other favorable physical properties. The board has an absolute dry specific gravity of not less than 1.20 and not more than 1.30 and comprises as raw materials not less than 28% by mass and not more than 32% by mass of a hydraulic inorganic material, not less than 54% by mass and not more than 58% by mass of a siliceous material, not less than 8% by mass and not more than 12% by mass of a woody reinforcement, not less than 2% by mass and not more than 5% by mass of mica, and not less than 0.5% by mass and not more than 1.25% by mass of a water-soluble resin.

Abstract: A prefabricated cover board has a high-density polymer or predominantly polymer material core layer having a density between 6 lbs/ft3 and 25 lbs/ft3. A prefabricated roofing panel composite includes the cover board and an insulation board that has a low-density polymer or predominantly polymer material foam core layer having a density less than 6 lbs/ft3. The cover board may have a waterproofing membrane forming the top major surface of the cover board. When making the roofing panel composite, the low-density foam core layer of the insulation board may be formed with the high-density core layer of the cover board being currently or subsequently formed over and bonded to a top major surface of the low-density foam core layer in the same operation or preformed insulation boards may be fed into a production line with the high-density core layer of the cover board being formed over and bonded to top major surfaces of the low-density foam core layers of the insulation boards.

Abstract: A building or construction material comprises a fluorinated polymer system. The fluorinated polymer system is heat weldable and waterproofing, which shows improved adhesion properties and has a wide range of applications in building and construction industries.

Abstract: The invention relates to a new plasterboard having a facer comprising two plies, and uses of such plasterboards in EIS or EFS.

Abstract: A composition which provides stain resistance and soil resistance to substrates comprising a copolymer of Formula 1 wherein D is at least one vinyl monomer selected from the group consisting of aryl olefin, vinyl ether, allyl ether, alpha olefin and diene; each M is independently H, NH4, Ca, Mg, Al, or a Group I metal; R is H, a C1-C16 alkyl group, or an arylalkyl group; Rf is a fully fluorinated straight or branched C2 to C20 aliphatic radical, or mixture thereof, which is optionally interrupted by at least one oxygen atom; x is 1 to about 10, or a mixture thereof; k and h are each independently a positive integer; i and j are each independently zero or a positive integer, provided that i and j are not both simultaneously zero; the molar ratio of k to (h+i+j) is from about 3:1 to about 1:3, and the molar ratio of h to (i+j) is from about 1:99 to about 22:78 is disclosed.

Abstract: A method of producing a foamed plaster comprises the following steps: (a) mixing plaster of Paris and calcium carbonate; (b) supplying water, and (c) adding phosphoric acid. The phosphoric acid reacts with the calcium carbonate to release gaseous carbon dioxide. It also reacts with any steel present to form an insoluble iron phosphate coating.

Abstract: The present invention relates to the use of quaternary ammonium compounds in the remediation of microbial growth such as mold, funguses, and mildew.

Abstract: High odor eliminating property is provided to a building material for interiors by compounding a hydrazide compound. Additionally, the odor eliminating property of the building material for interiors is improved and hygroscopicity and size stability at the time of use are provided by adding and compounding an organic carbide, an inorganic hygroscopic material, and a water repellent. Also, an interior structure in which these building materials for interiors are employed is provided.

Abstract: A gypsum-based building material containing from 1 to 25% by weight of zeolites.

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, and can be the same polymer material.

Abstract: Laminated structures for use in building construction are fabricated by a manufacturing process such that the laminating steps to not require elevated drying temperatures or an extended dwell time at any point. The process employs stock materials that simultaneously reduce cost and improve performance. This is accomplished using a specially formulated viscoelastic glue and ambient temperature drying apparatus. As a result, the production capacity of the manufacturing facility, cost of goods, and delivered performance are greatly improved over existing methods.

Abstract: An improved gypsum slurry that includes water, calcium sulfate hemihydrate, a polycarboxylate dispersant and a modifier. The modifier is chemically configured to improve the efficacy of the polycarboxylate dispersant. Preferred modifiers include cement, lime, slaked lime, soda ash, carbonates, silicates and phosphates.

Abstract: An aluminum nitride ceramic including aluminum nitride grains and grain boundary phases comprises a grain boundary phase-rich layer including more amount of the grain boundary phases in a surface layer of the aluminum nitride ceramic than in an inside of the aluminum nitride ceramic. The grain boundary phases in the grain boundary phase-rich layer include at least one of rare earth element and alkali earth element.

Abstract: The invention is a product, comprising a substrate and a film that limits the transmission of water vapor comprising a polymer derived from one or more nonionic monomers polymerized in the presence of at least one nonionic surfactant and in the absence of ionic surfactants. The cloud temperature of the at least one nonionic surfactant is preferably less than the polymerization temperature. The nonionic surfactant is preferably an alkylene oxide adduct of an alkyl alcohol, alkylbenzene alcohol or dialkylbenzene alcohol, wherein the number of alkylene oxide groups is less than or equal to 14.

Abstract: Curing blanket having a clear, transparent or opaque first layer and a second layer that is airlaid on the first layer. Another embodiment has a first layer, a second layer that is airlaid on the first layer, and a third layer disposed on the said second layer, with the second layer interposed between the first layer and the third layer. The first layer and said second layer are thermally bonded and/or latex bonded. The third layer includes a polymer release agent composed of bi-component fibers.

Abstract: A new roofing tile with enhanced surface durability and processes for manufacturing the same. The abstract of the disclosure is submitted herewith as required by 37 C.F.R. §1.72(b). As stated in 37 C.F.R. §1.72(b): A brief abstract of the technical disclosure in the specification must commence on a separate sheet, preferably following the claims, under the heading “Abstract of the Disclosure.” The purpose of the abstract is to enable the Patent and Trademark Office and the public generally to determine quickly from a cursory inspection the nature and gist of the technical disclosure. The abstract shall not be used for interpreting the scope of the claims. Therefore, any statements made relating to the abstract are not intended to limit the claims in any manner and should not be interpreted as limiting the claims in any manner.

Abstract: A fire protection coating 10 includes insulation layer 20 including at least 20% free moisture. Insulation layer 20, preferably a vermiculite/gypsum mixture 26, is applied such as by spraying a water slurry of the mineral particles to structural member 85. Before the free moisture can evaporate, diffusion barrier 40, such as artificial stone formulation 44, is applied over the moist vermiculite/gypsum mixture 26. Moisture is retained within vermiculite/gypsum mixture 26 indefinitely and is released in the event of a fire to help cool and prolong the efficacy of fire protection coating 10.

Abstract: A composition is disclosed for a mixture to be used in conjunction with water for preparing a slurry that hydrates to form a high strength flooring compound. The mixture includes from about 50% to about 98% by weight calcium sulfate hemihydrate. A three repeating unit polycarboxylate dispersant is included in the mixture in amounts from about 0.2% to about 10% by weight. The repeating units include a polyether repeating unit, an acrylic acid-type repeating unit and a maleic acid-type repeating unit. A modifier that enhances the efficacy of the dispersant is also a component of the mixture. When combined with recommended amounts of water, a slurry is formed that is useful as a flooring composition.

Abstract: A combination includes a composition providing corrosion resistance for application to a post-construction material, and a post-construction material, wherein the composition is applied to at least one surface of the post-construction material after the post-construction material has hardened. The composition may include an effective amount of a thinning agent, e.g., isopropyl alcohol, ethanol, xylene or similar composition. The composition may be an aqueous solution of a metal salt of a dioic acid. The post-construction material may be reinforced or unreinforced concrete. The post-construction material may be a concrete-containing structure, and the composition may be applied to an exterior surface thereof.

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: Wall and ceiling acrylic latex coating compositions having properties that prevent joints between adjacent wallboard panels from cracking during settling of new homes and during transportation of manufactured buildings, and otherwise prevents joint cracking from flexing, such as caused by extreme weather conditions or building settling. In another embodiment, the coating compositions can be applied directly over joints between adjacent square-edged wallboard panels to conceal the joint without using tape, wallboard “mud”, or other joint filling compositions.

Abstract: A description is given of a concrete molding which is coated with cement-bound mineral coating composition (cement slurry) and with a transparent varnish, the transparent varnish comprising as binder an aqueous polymer dispersion and also at least one anionic emulsifier containing at least one phosphate and/or phosphonate group. The concrete molding is distinguished by high gloss and can be used in particular as rooftile.

Abstract: A laminated structure appropriate for use in constructing walls, floors, ceilings or doors, has a selected area and in one embodiment comprises two external layers of one or more materials such as, but not limited to, gypsum, at least one internal constraining layer having less than said selected area, and two or more internal layers of a viscoelastic glue separated by said at least one internal constraining layer, wherein each of said layers of viscoelastic glue is patterned to cover a selected percentage, but not all, of said area of said laminated structure thereby to allow moisture to pass through said structure.

Abstract: The invention provides a method for preparing a gypsum composition containing a cross-linked polymer comprising the following steps: preparing a slurry of the gypsum composition by mixing the various constituents of the composition, or precursors thereof, with water, in a mixer; hydraulic setting; and drying and cross-linking in the presence of heat. The invention applies to the manufacture of gypsum boards. The invention further provides a composition of gypsum containing a cross-linked polymer, and further comprising a water resisting additive in an amount such that the water uptake is below 10%.

Abstract: Articles, including fiberboard, are made from a pumpable, flowable slurry including alpha-calcined calcium sulfate hemihydrate anchored in pores of host particles, alpha-calcined calcium sulfate hemihydrate, a silicone compound, magnesium oxide, and water. The magnesium oxide catalyzes the reaction of the silicone compound into a silicone resin. In a preferred method of making a water resistant fiberboard calcium sulfate dihydrate is combined with the host particles and water to form a slurry which is heated under pressure to calcine the calcium sulfate dihydrate to form alpha-calcined calcium sulfate hemihydrate. After relieving the pressure, a silicone compound and magnesium oxide are added to the slurry. The slurry is dewatered to form a filter cake, which is then formed into a desired shape and allowed to set.

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: The present invention relates to the addition of biocidal agents to colloidal silicate coating compositions, said compositions being useful for coating structures prepared from Portland cement compositions.

Abstract: A structural member such as a steel I-beam or column covered with a heat resistant coating for protection against high temperatures. The coating is sprayed onto the structural member after a reinforcing mesh has been applied. The coating is specially formulated to resist extremely high temperatures and includes cement, gypsum, perlite, a liquid catalyst that includes styrene acrylic, and water.