This disclosure relates to using polyester films on building boards to enable improved surface coatings. The polyester film is preferably applied to a glass mat via an adhesive to form a laminate. This laminate is then bonded to the exterior surface of a gypsum board. The polyester film is advantageous because it allows for exterior surface coatings to be applied. In one embodiment, an exterior acrylic coating is applied to the polyester film. Boards constructed in accordance with this disclosure allow for exterior finishings to be achieved without the need for excessive finishing materials or steps.

The invention concerns an apparatus for furnishing a liner with a layer of stucco slurry, comprising at least: a conveying device (24) for conveying a liner (7), said conveyor device defining a transport direction (31); a stucco slurry feeder device (26) for casting stucco slurry onto the liner (7); a stucco slurry distribution device (27) for distributing stucco slurry cast onto the liner (7); and at least one stripper device (28) for stripping stucco slurry from lateral portions of the liner.

The invention further concerns a method for furnishing a liner with a layer of stucco slurry of defined width and a method for producing a gypsum plasterboard.

The invention is a machine for producing decorative aggregate G-layer on top surfaces of claddings in cooperation with a cladding manufacturing machine. The G-layer production machine may be integrated into the cladding manufacturing machine or a standalone machine. In both options, the machines synchronize the overlaying of the top G-layer with the manufacturing process of the claddings to ensure continuous production of multi-layer claddings with a decorative aggregate layer. The overlaying itself is done under controlled condition to produce homogenous distribution of the aggregates on the top surface of the claddings to provide them an aesthetic look.

A method of fabricating a barrier layer on a substrate includes mixing gettering particles, diffusive particles, and matrix material in a carrier fluid to form a slurry; applying a layer of the slurry to the substrate; adjusting the surface of the layer of the slurry; and sintering the layer of the slurry to form a barrier layer. An article is also disclosed.

In the present disclosure, a method of forming a gypsum panel is disclosed. The method comprises: providing a first facing material, forming a starch slurry by combining starch and water at a shear rate of 3,000 rpm or more, providing the starch slurry onto the first facing material, depositing a gypsum slurry comprising stucco and water onto the starch slurry on the first facing material, providing a second facing material on the gypsum slurry, and allowing the stucco to convert to calcium sulfate dihydrate.

The appearance of natural rock faces are formed on planar panels or part portions thereof that disposed horizontally by stamping or texturizing a cementitious mixture of veneer material and then selectively applying colorant matter, which may include combinations of stains and mineral.

The appearance of natural rock faces are formed on planar panels or part portions thereof that disposed horizontally by stamping or texturizing a cementitious mixture of veneer material and then selectively applying colorant matter, which may include combinations of stains and mineral.

A precast concrete wall structure and method for forming a wall structure are disclosed. A frame is positioned within a casting bed. The frame comprises first and second spaced apart metal tracks which are interconnected by a plurality of metal studs. The casting bed has a plurality of surfaces defining a generally rectangular interior area. A forming member is placed above the frame, the forming member comprising a layer of insulating material defining a plurality of integrally-formed rectangular protrusions extending in a parallel and spaced-apart relationship to one another to define a plurality of rectangular-shaped channels therebetween. Uncured concrete is placed within the casting bed and allowed to cure.

A decorative concrete with a very uniform finish surface and a method of fabricating the same is disclosed. A concrete mixture is poured over a subgrade which defines an exposed surface. The exposed surface is finished with any of several techniques, and the surface is then worked with an abrasive material, and additional techniques are used to color and seal the concrete.

A system for making a cementitious composite includes a cementitious material supply system for dispensing a powdered cementitious material or a semi-powdered cementitious material into a receiving material. The receiving material includes a structural layer and a sealing layer. The structural layer includes an open continuous volume extending from a first side to a second side opposite the first side. The sealing layer is coupled to the first side. The cementitious material supply system is configured to dispense the powdered cementitious material or the semi-powdered cementitious material into the open continuous volume to fill the open continuous volume.