Abstract: A composite backer board for wet space construction is disclosed, along with a method of producing the backer board. The board includes a rigid foam core of a suitable thickness for wet space construction. A first fabric layer is fixed to at least one face of the rigid foam core with a polymeric adhesive. A first polymer layer is on the first fabric layer in which the polymer layer is dimensionally stable parallel to the face of the rigid foam core. A second fabric layer is on the first polymer layer opposite the first fabric layer and forms a first face that is amenable to thin set mortar and related compositions in wet space construction.

Abstract: A wallboard panel is provided, including a sheet of face paper, a first layer of gypsum composition having a first density, a web of mesh associated with the first layer of gypsum composition, a second layer of gypsum composition having a second density, the second density being lower than the first density, and a layer of backing paper. An associated method includes providing a sheet of face paper and laying same upon a moving conveyor belt, applying a first layer of gypsum composition slurry upon the sheet of face paper, applying a web of mesh upon the first layer of gypsum composition slurry, applying a second layer of gypsum composition slurry upon the web of mesh, and applying a sheet of backing paper upon the second layer of gypsum composition slurry.

Abstract: A method of manufacturing a composite concrete article comprising forming a textile structure, removing material from regions of the textile structure to create voids in the textile structure and incorporating the textile structure into a body of wet uncured concrete such that the concrete flows into the voids created in the textile structure, embedding the textile structure into the concrete, whereby the textile structure defines at least a portion of a surface of the cured concrete article.

Abstract: Various embodiments of the present invention provide composite materials and methods of making the same. In some embodiments, the composite materials comprise high temperature resistant composite materials and methods of making high temperature resistant composite materials. In some embodiments, high temperature resistant composite materials of the present invention can be fabricated into landing pads, components used in landing pads to provide a structure to support the take-off and landing of aircraft, roadways or similar travel paths for heavy equipment, and/or components used in roadways or similar travel paths for heavy equipment.

Abstract: The present invention has for its object a prefabricated sealing membrane formed by a support, coated on at least one surface, and preferably impregnated throughout, with a modified bitumen base composition, characterized in that the thermoplastic bituminous composition for coating and/or impregnation is a bituminous binder modified by a thermoplastic polyurethane having the following weight proportion: 40 to 90% bitumen, 10 to 50% thermoplastic polyurethane, 0 to 10% aromatic oil, 0 to 50% filler, 0 to 0.5% catalyst.

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: The present invention is a backerboard having a fiberglass mesh on one side, and a 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: A corrosion-resistant lath is provided for use in exterior finishing systems, such as stucco systems and exterior insulation and finish systems (“EIFS”). The lath includes in a first embodiment an open, woven fabric comprising weft and warp yarns containing non-metallic fibers, such as glass fibers. A portion of the weft yarns are undulated, resulting in an increased thickness for the fabric. The fabric is coated with a polymeric resin for substantially binding the weft yarns in the undulated condition. This invention also includes methods for making an exterior finish system and building wall including an exterior finish system using such a lath.

Abstract: A noise control flooring system is presented herein for reducing noise transmission in a building structure that contains the system. The system comprises a solid substrate layer, a compressible layer overlying at least a portion of the substrate layer, and an entangled net layer that overlies at least a portion of the compressible layer, wherein the net layer is comprised of multiple polymer filaments and air, together forming a void space. A separation layer overlies at least a portion of the entangled net layer. The separation layer carries a floating solid substrate layer thereupon. This solid substrate layer provides loading for causing the compressible layer to compress into the overlying entangled net layer.

Abstract: A building panel structure is disclosed, in which composite building panels are used to form a structure. A composite building panel is disclosed which includes a core and a coating applied over the core. In some embodiments the core consists of a frame and one or more than one insulating structural block. The insulating structural blocks can be encapsulated polystyrene (EPS) foam blocks. In some embodiments the coating includes an inner scratch layer and an outer main brown layer. The inner scratch layer can be formed of at least two layers. The outer main brown layer can include a fiberglass mesh embedded into the outer main brown layer. A method of forming a building panel structure is disclosed which includes forming a core using a frame and one or more than block, applying an inner scratch layer to the core, and applying an outer main brown layer over the inner scratch layer.

Abstract: A corrosion-resistant lath is provided for use in exterior finishing systems, such as stucco systems and exterior insulation and finish systems (“EIFS”). The lath includes in a first embodiment an open, woven fabric comprising weft and warp yarns containing non-metallic fibers, such as glass fibers. A portion of the weft yarns are undulated, resulting in an increased thickness for the fabric. The fabric is coated with a polymeric resin for substantially binding the weft yarns in the undulated condition. This invention also includes methods for making an exterior finish system and building wall including an exterior finish system using such a lath.

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: A corrosion-resistant lath is provided for use in exterior finishing systems, such as stucco systems and exterior insulation and finish systems (“EIFS”). The lath includes in a first embodiment an open, woven fabric comprising weft and warp yarns containing non-metallic fibers, such as glass fibers. A portion of the weft yarns are undulated, resulting in an increased thickness for the fabric. The fabric is coated with a polymeric resin for substantially binding the weft yarns in the undulated condition. This invention also includes methods for making an exterior finish system and building wall including an exterior finish system using such a lath.

Abstract: A fillet is disclosed for enhancing the appearance of a frame or mat and comprises a flexible material, an elastomeric cord and an adhesive securing the fabric to the cord. The flexible material may have one or more flairs which may have a tape adhesive which adheres the flairs to the frame, the matt, or parts of both of the frame and the mat. The fillet is flexible and may be bent to various geometries.

Abstract: The present invention provides glass fiber fabric reinforcements, cement boards, and glass fiber coatings for such reinforcements. The glass fiber fabric reinforcement includes a glass fabric containing multiple yarns containing glass filaments and a polymeric coating disposed onto the multiple yarns to form a coated glass fabric. The polymeric coating comprises a polyolefin based copolymer composition whereby the glass fabric has a Gurley Stiffness measurement of about 100-3000 mg and an ASTM D 638 (2% Secant) modulus of compression of about 1-100 MPa. The reinforcement is sufficiently drapable and lacking in shape memory so as to be curved around the edge of a cement board during the manufacture of same.

Abstract: The present invention provides thickened fabrics and reinforcements for use as a spacer or reinforcement for a matrix system. The fabric includes in a first embodiment a woven fabric comprising weft and warp yarns containing glass fibers. A portion of the weft yarns are undulated, resulting in an increased thickness for the fabric. The fabric is coated with a polymeric resin or bonding agent, for substantially binding the weft yarns in the undulated condition. This invention also includes methods for making such fabric by increasing the thickness of a woven or non-woven material by such methods as applying tension during weaving operations, or using unbalanced yarns.

Abstract: A composite geotextile or construction product for reinforcing a stratum of concrete or of bitumen comprises at least one reinforcing grid consisting of yarns which are mechanically strong in the warp and/or weft directions. It further comprises at least one layer of an openwork textile produced by weaving or knitting, the openwork textile having openings that are smaller than those of the meshes of the grid, the openwork textile being knitted with the grid by means of at least one knitting yarn, in order to obtain a substantial miscibility of the concrete or the bitumen in the composite textile product.

Abstract: A corrosion-resistant lath is provided for use in exterior finishing systems, such as stucco systems and exterior insulation and finish systems (“EIFS”). The lath includes in a first embodiment an open, woven fabric comprising weft and warp yarns containing non-metallic fibers, such as glass fibers. A portion of the weft yarns are undulated, resulting in an increased thickness for the fabric. The fabric is coated with a polymeric resin for substantially binding the weft yarns in the undulated condition. This invention also includes methods for making an exterior finish system and building wall including an exterior finish system using such a lath.

Abstract: Multi-layer concrete forms are provided that can include outer layers having a scrim layer there between. The forms may include a form section having four edges, wherein at least two of the edges are configured to abut one another; and a flange section extending from at least one of the other four edges. Processes for constructing a concrete form are provided with the process including providing a substantially flat section of form to a construction site, with the section having four edges; substantially abutting at least two of the edges to create a tubular form; and heat sealing the edges.

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 gypsum or foam facer is formed by the direct in-line or off-line coating of a pre-impregnated, fibrous network matting with a secondary binder system. The pre-impregnated fibrous network is preferably formed of a randomly oriented wet use chop strand fiber material impregnated with a modified urea-formaldehyde binder system. The secondary binder system preferably consists of low glass transition acrylic or styrene-butadiene-rubber resin filled predominantly with fillers combined with a plate like reinforcement or fibrous reinforcement. In an alternative embodiment, a low basis secondary veil is layered onto the fibrous network matting with or without the secondary binder system to improve softness and decorative appearance of the formed gypsum board. In another preferred alternative embodiment, a plurality of high aspect ratio particles may be introduced to the binder prior to introduction of an optional secondary binder resin to also improve the softness and decorative appearance of gypsum board.

Abstract: A bituminous water vapor retarder is disclosed of the type which can be used under concrete slabs in contact with soil or granular fill. The vapor barrier is a multi-ply weather coated permanently bonded semi-flexible bituminous core board composed of the homogeneous high melt point bituminous material in combination with an exclusive core suspended midpoint in the board. This core is sealed under heat and pressure between liners of asphalt and impregnated felt and a glass mat liner. An asphalt weather coat is applied to the glass mat liner and covered with a polyethylene anti-stick sheet.

Abstract: A composite fabric for use in reinforcement, particularly tensile reinforcement, of cementitious boards and similar prefabricated building wall panels. The fabric is constructed as a mesh of continuously coated, high modulus of elasticity strands. The high modulus strands 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 fabric provides long-lasting, high strength tensile reinforcement of the panels or boards regardless of their spatial orientation during handling. The reinforcement also enhances the impact resistance of the boards after installation. Included as part of the invention are methods for making the reinforcement, cementitious boards and panels including the reinforcement, and methods for manufacturing such boards and panels.

Abstract: Cement wallboards and methods for their preparation are disclosed. The wallboards comprise two scrim layers and one mat layer. The wallboards have a smooth surface, are strong, lightweight, and easy to score and snap. Tiles can be readily adhered to the boards. The wallboards can be used in general commercial and residential construction, and are particularly attractive for use in high water/moisture areas such as bathrooms and shower enclosures.

Abstract: One aspect of the present invention is a casting article comprised of a water-curable Plaster of Paris (PP) article having a first side and a second side and having a substrate and PP material and a polyisocyanate material being applied to at least one of the first and second sides of the water-curable PP to obtain a water-curable hybrid plaster-polyisocyanate (HPP) casting article.

Abstract: There is provided a facing sheet for cement boards comprising a scrim and polymer film. The scrim has a plurality of intersecting yarns defining an open mesh pattern with an inner face defining a grid profile for mechanical interaction with the cementitious composition of the cement board. The polymer film is joined to an outer face of the scrim and defines a repeating pattern of openings. The polymer film facilitates the mechanical interaction between the grid profile of the scrim and the cementitious composition and allows the passage of moisture from the cementitious composition during hardening of the cement board. The scrim may include glass fibers yarns and the polymer film may be formed by a gravure rolling process. A cement board may include a second facing sheet on a surface opposite the first facing sheet.

Abstract: A reinforced membrane, particularly Well suited for use as a membrane in a single ply roofing membrane system, includes first and second thermoplastic olefin (“TPO”) sheets and a polypropylene reinforcing mesh or scrim intermediate the first and second thermoplastic olefin sheets and bonded to the first and second thermoplastic olefin sheets.

Abstract: A wet-formed permeable mat composed of wet use chopped strands (WUCS), chopped roving, and potentially unidirectional roving coupled with an alkaline resistant binder are combined to create an randomly oriented open mat structure with a high degree of openness that can be used in cement backerboard applications. The cement backerboard that is subsequently formed from the wet-formed permeable mat has lower binder content, superior decorative finish, and better permeability control than known glass scrim systems and can be produced in a single continuous step.

Abstract: A cement panel that is reinforced with a fabric made of carbon fibers. The cement panel includes a core layer that is made of a lightweight cement composition. This core layer is covered with a layer of reinforcing carbon fabric on the top and on the bottom, each bonded to the core with a coating of cementitious material on the top and on the bottom of the core layer. On the edges of the cement panels, the fabric layers are overlapped so as to augment the strength of these edges.

Abstract: A new method of applying fire protection coating to structures results in a new type of fire protection coating 10. 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 epoxy intumescent coating 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 intumescent coating 44.

Abstract: A backerboard sheet is for moist areas and includes a core having opposing first and second major surfaces, at least one moisture-resistant face layer on at least one of the first and second major surfaces of the core; and wherein the core includes aerated concrete. The provision of aerated concrete for the core provides many key advantages over conventional backerboard sheets, such as gypsum greenboard or cementitious backerboard, for example. The at least one moisture-resistant face layer may include fibers, such as arranged in a woven mesh. The fibers may include at least one of glass, plastic, and metal. In addition, the at least one moisture-resistant face layer may further include a moisture-resistant material incorporating the fibers, such as a suitable resin, for example.

Abstract: A novel gypsum wallboard having a textile reinforcing material embedded within a gypsum core together with randomly oriented chopped glass fibers, as well as a novel process for constructing such gypsum wallboards.

Abstract: A wallboard includes a set cementitious core, and (ii) at least a composite facing material on at least one of the faces of the core, the facing material including: (a) a synthetic scrim, and adhered thereto, (b) a synthetic non-woven; the scrim being completely embedded in the core while the synthetic non-woven is at most partially embedded in the core. A process for making such a wall board, in which the viscosity of the cementitious slurry is controlled on the facing material such that the scrim is completely embedded in the core while the synthetic non-woven is at most partially embedded in the core.

Abstract: A composite board for use as backerboard for tile, the board including a mesh layer with a mesh fabric, a mat layer with a mat fabric and a polystyrene layer disposed between the two portions where a non-shrinking cement compound saturates and connects the two outer portions with the polystyrene substrate. The composite board's mesh layer incorporates a stretchable mesh which in conjunction with the polystyrene substrate and the non-shrinking cement compound supports standard fasteners used in the home-building industry along with providing a suitable tile adhesion surface. The mat layer incorporates a fiberglass mat which provides high rigidity as well as being suitable for contact with an inner wall or studs. The combination of materials provides a backerboard that is light weight, rigid, economical and easy to build with.

Abstract: A reinforced plasterboard has a first layer of paper having at least two sides, wherein the sides are folded to form a trough. A layer of cementitious slurry is disposed within the trough formed by the first layer of paper. A layer of reinforcing mesh is disposed within the cementitious slurry.

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 cementitious panel having a basalt fiber-containing reinforcing web embedded in at least one major surface, preferably both major surfaces, of the panel. The basalt fibers-containing reinforcing webs preferably are in the form of a mesh or scrim comprising spaced basalt fiber strands in both the warp and fill directions, each strand made from a plurality of aligned, continuous basalt fibers. The basalt fiber reinforcing webs also can be in the form of woven or non-woven fabrics of basalt fibers, having aligned or randomly oriented staple and/or micro fibers, so long as the fabrics have sufficient void area to permit a cementitious core material to penetrate the fabric when the fabric is embedded in one or both major surfaces of the cementitious panel before the cementitious core material hardens.

Abstract: A sheet material is useful as a waterproof underlayment for a roof of a structure. The sheet material has upper and lower surfaces and comprises a web of reinforcing mat comprising fire-resistant fibers and a continuous non-porous matrix of water-resistant modified bitumen saturating the web of reinforcing mat, wherein the modified bitumen is self-adhesive.

Abstract: A plastering layer (2) of plastics material, having attached thereto a net reinforcing material (6) to be embedded in or underneath a plaster layer (12), in particular a plaster layer (12) on a thermal insulation (16) of a building wall (26), wherein said reinforcing material (6) is connected to said plastering fillet (2) by means of at least one plastics strand (8), with said reinforcing material (6) having been interposed between plastering fillet (2) and plastics strand (8) when the connection was made, and with a material-uniting connection being established between plastering fillet (2) and plastics strand (8).

Abstract: The present invention provides an article comprising a curable resin and a filler associated with the resin. The incorporation of fillers into the casting materials of the present invention adds substantially to the strength of the cured casting material as well as to the handling properties of the uncured casting tape or bandage. The incorporation of fillers into the casting materials of the present invention also imparts air and vapor porosity to the cured casting materials. If desired articles of the present invention may also incorporate fibers (either individually, bundled, or in the form of a light-weight scrim) to provide increased cohesiveness to the uncured article. Extremely moldable casting tapes are also provided which comprise a highly-filled composite material coated on a light-weight scrim. The casting tapes of this embodiment handle like traditional plaster of Paris casts yet cure to a weight-bearing cast in less than one hour.

Abstract: A method of making a multiple-layer article having a surface application material effectively bonded to an injection molded plastic member is provided along with a method for making same. At least a portion of an intermediary substratum is located inside a mold cavity during injection of a plastic injection material where the plastic injection material contacts and becomes partially absorbed into a first side of the intermediary substratum. The plastic member and the intermediary substratum are then removed from the mold cavity, and the surface application material is applied to a second side of the intermediary substratum where the surface application material becomes partially absorbed into the second side of the intermediary substratum.

Abstract: A patch for repair or finishing of surfaces, such as drywall or plaster walls and ceilings, wherein the patch includes a liquid-hardenable material (such as a water-hardenable material) coated on and/or impregnated in a substrate or carrier. The patch is wetted and then applied to the surface of the wall or ceiling and pressed against the surface. The liquid-hardenable material becomes gel-like and adheres the patch to the surface. Upon drying, it sets to a hard coating overlying a hole, crack, recess or joint in the wall or ceiling. If necessary, joint compound or the like can be applied to the edges of the patch to provide a smooth taper to the surrounding surface. The liquid-hardenable material can be a cement, plaster, resin or glass composition. The carrier can be paper, or a fabric comprised of natural or synthetic fibers.

Abstract: The invention relates to a method for encapsulating lead paint on a surface comprises the steps of applying a glass mesh to the surface containing the lead paint and applying an encapsulating mixture in a continuous layer over the glass mesh and to the encapsulated lead paint surface. The invention completely seals and encapsulates the lead paint and has significant structural integrity to prevent exposure to lead paint.

Abstract: The present invention has an object to provide a reinforcing fiber sheet which permits sufficient reinforcement of a concrete structure with a smaller number of layers than in the conventional cases, without causing fracture of the sheet within a range of yielding of reinforcing bars. The reinforcing fiber sheet 1 of the invention comprises high-elasticity and high-elongation carbon fibers 4 having a modulus of elasticity of at least 35 ton/mm.sup.2 and a fracture elongation of at least 0.9%, arranged in an amount of at least 250 g/m.sup.2 in one direction through an adhesive layer 3 on a substrate sheet 2. The object of the invention can be achieved by providing the carbon fibers 4 of the reinforcing fiber sheet 1 with the above-mentioned properties.