A composite structure for use in tiling surfaces is disclosed. The composite structure can include a fiber matrix impregnated with a water-activated setting material. The composite structure can be wet and then compressed between a tile and an application surface. The composite structure can cure to provide a support surface for the tile.

Disclosed are cementitious product, as well as cementitious slurry, and method of forming the product. To reduce density in the cementitious product, foam is included in the slurry and in the method of forming the product. The slurry includes cementitious particles, water, and air bubbles such as from compressed air. Instead of using detergent chemistry at the gas/water interface of bubbles, the present invention uses a surface modifying agent for the cementitious particles in the slurry. The modified particles act to produce stable foam in the slurry. As an example mode of introduction, the surface modifier can be added (e.g., as solid or solution) directly into a bulk cementitious slurry that forms the product. As another example, the surface modifier can be added in a separate solution with water, air bubbles, and cementitious particles that serve as additive to the main cementitious slurry, where the separate solution is then added to the main cementitious slurry.

A gypsum-based construction material can include gypsum core including a stucco component, a siloxane component at a content of not greater than about 2.0 wt. % relative to a content of the stucco component, and a calcium hydroxide catalyst at a content of at least about 0.01 wt. % and not greater than about 0.1 wt. % relative to the content of the stucco component. The gypsum-based construction material can have a pH of at least about 7.5 and not greater than about 10.

A method for measuring the weights of phase components in a calcium sulphate material, e.g., gypsum or stucco, in particular for measuring the weights of DH, HH and AIII phases. The method includes (a) weighing a given amount of calcium sulphate material at ambient temperature; (b) placing the weighed calcium sulphate material in a moisture balance at ambient temperature; (c) drying the calcium sulphate material at temperature between 40 C. and 50 C.; (d) waiting until the weight is constant; (e) weighing the dried calcium sulphate material; (f) calculating the weight gain between (a) and (e), the weight gain being related to the amount of AIII phases in the calcium sulphate material.

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 present invention relates to a process and an apparatus to cool and heal calcined stucco particles. The process includes feeding stucco particles into an upper portion of a vessel, and feeding a gas comprising air and water into the lower portion of a vessel, wherein the gas cools and substantially fully encapsulates the stucco particles. The apparatus includes a vessel with a rotating spreader for homogenizing the stucco particles, for use in the process described.

A method of recovering desalinated activated alumina (AA) beads from a composition including salt laden (high salt absorbed) activated alumna (AA) beads and free anions and free cations, comprising the step of electrodialysis of the composition to reduce salt content of the activated alumina (AA) beads to produce a stream comprising the desalinated activated alumina (AA) beads.

Wasted gypsum boards are crushed and heated to convert semi-hydrated gypsum and/or anhydrous type III gypsum, and the obtained semi-hydrated gypsum and/or anhydrous type III gypsum is mixed with gypsum slurry. The gypsum slurry is solid/liquid separated by a filtration device into gypsum particles and filtrate which has passed through the filter cloth of the filtration device. The filtrate is returned into the gypsum slurry. The solid/liquid separation is performed such that the concentration of the suspended solid in the filtrate that has passed through the filter cloth and consists of gypsum granules and inorganic impurities derived from wasted gypsum boards is made 1000 to 8000 mass ppm. The clogging of the filter cloth is reduced.

The present disclosure relates to negative-carbon cement (NC2) production, which can be achieved by integrating carbon dioxide hydrogenation and methane pyrolysis into the cement manufacturing process, using hydrogen gas derived from methane pyrolysis as the fuel for heating, and converting any captured carbon dioxide into solid carbon. The solid carbon can be incorporated into building materials such as portland cement and gypsum boards, fixing the carbon to achieve cradle-to-gate emission reduction.

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.