A superhydrophobic coating is provided and contains organosilane, an inorganic nanomaterial, and an emulsifying agent. A mass proportion of the components is controlled, so that the superhydrophobic coating can form a micro-nano mixed microstructure inside foam concrete. The organosilane first forms dense hydrophobic surface layers on the surface and in inner pores of the foam concrete, and the nanomaterial forms uniformly distributed nano-bulges on the hydrophobic surface layers formed by the silane. The superhydrophobic performance of the foam concrete can be effectively improved by combining the two microstructures. The foam concrete exhibits excellent superhydrophobic performance.

A superhydrophobic coating is provided and contains organosilane, an inorganic nanomaterial, and an emulsifying agent. A mass proportion of the components is controlled, so that the superhydrophobic coating can form a micro-nano mixed microstructure inside foam concrete. The organosilane first forms dense hydrophobic surface layers on the surface and in inner pores of the foam concrete, and the nanomaterial forms uniformly distributed nano-bulges on the hydrophobic surface layers formed by the silane. The superhydrophobic performance of the foam concrete can be effectively improved by combining the two microstructures. The foam concrete exhibits excellent superhydrophobic performance.

Gypsum panels and methods of making gypsum panels are provided. Methods of making gypsum panels include: depositing a first gypsum slurry onto a first surface of a first fiberglass mat; allowing the first gypsum slurry to set to form at least a portion of a gypsum core; and applying a substantially continuous barrier coating comprising a polymer binder to a second surface, opposite the first surface, of the first fiberglass mat, in an amount of from about 1 lb/MSF to about 40 lb/MSF, such that the substantially continuous barrier coating has an average thickness of from about 1 micron to about 100 microns, wherein the substantially continuous barrier coating eliminates at least 99 percent of pin holes present in the exposed second surface of the first fiberglass mat.

Gypsum panels and methods of making gypsum panels are provided. Methods of making gypsum panels include: depositing a first gypsum slurry onto a first surface of a first fiberglass mat; allowing the first gypsum slurry to set to form at least a portion of a gypsum core; and applying a substantially continuous barrier coating comprising a polymer binder to a second surface, opposite the first surface, of the first fiberglass mat, in an amount of from about 1 lb/MSF to about 40 lb/MSF, such that the substantially continuous barrier coating has an average thickness of from about 1 micron to about 100 microns, wherein the substantially continuous barrier coating eliminates at least 99 percent of pin holes present in the exposed second surface of the first fiberglass mat.

Methods of treating inorganic surfaces are provided. The methods include a step of applying an aqueous-based composition to the inorganic surface, in which the aqueous-based composition includes at least one transesterified alkoxy silane. The methods impart water resistance to the inorganic surface. After application, a treated inorganic surface may exhibit a long term water repellant property due to the formation of a hydrophobic layer upon drying of the aqueous-based composition

Methods of treating inorganic surfaces are provided. The methods include a step of applying an aqueous-based composition to the inorganic surface, in which the aqueous-based composition includes at least one transesterified alkoxy silane. The methods impart water resistance to the inorganic surface. After application, a treated inorganic surface may exhibit a long term water repellant property due to the formation of a hydrophobic layer upon drying of the aqueous-based composition

Mat-faced cementitious board including: (a) a cementitious core; (b) a fibrous mat having an inner first surface facing at least one face of the cementitious core, and an outer second surface, wherein the inner first surface and the outer second surface are opposed; (c) a hydrophobic, non-setting coating resulting from applying to the outer second surface of the fibrous mat a layer of hydrophobic finish composition including: (i) about 50 to about 80 weight % non-setting, inorganic filler having a mean particle diameter of about 12 microns to about 35 microns, (ii) about 20% to about 50 weight % an aqueous dispersion of a film-forming polymer, (iii) 0% to about 30 weight % additional water; (iv) an absence of fly ash, (v) an absence of pozzolanic material, (vi) an absence of hydraulic cement, (vii) an absence of calcium sulfate hemihydrate, and (viii) an absence of calcium sulfate anhydrite.

Mat-faced cementitious board including: (a) a cementitious core; (b) a fibrous mat having an inner first surface facing at least one face of the cementitious core, and an outer second surface, wherein the inner first surface and the outer second surface are opposed; (c) a hydrophobic, non-setting coating resulting from applying to the outer second surface of the fibrous mat a layer of hydrophobic finish composition including: (i) about 50 to about 80 weight % non-setting, inorganic filler having a mean particle diameter of about 12 microns to about 35 microns, (ii) about 20% to about 50 weight % an aqueous dispersion of a film-forming polymer, (iii) 0% to about 30 weight % additional water; (iv) an absence of fly ash, (v) an absence of pozzolanic material, (vi) an absence of hydraulic cement, (vii) an absence of calcium sulfate hemihydrate, and (viii) an absence of calcium sulfate anhydrite.

A method and device for modifying a building panel. The building panel including a first surface comprising a facing paper and a second surface comprising a backing paper with a core of calcium sulfate hemihydrate arranged between the facing paper and the backing paper. The method including applying a solution to a predetermined portion of the facing paper, the backing paper, or the facing and backing paper to sufficiently hydrate at least a predetermined portion of the hemihydrate core to convert it to deformable calcium sulfate dihydrate. The solution including at least one alcohol and water. A predetermined force is applied to the deformable portion of the building panel. The predetermined force causing a desired deformation of the predetermined hydrated portion of the building panel. The device for modifying a building panel according to the method includes a building panel mounting structure, a liquid applicator, and a force applicator.

A method and device for modifying a building panel. The building panel including a first surface comprising a facing paper and a second surface comprising a backing paper with a core of calcium sulfate hemihydrate arranged between the facing paper and the backing paper. The method including applying a solution to a predetermined portion of the facing paper, the backing paper, or the facing and backing paper to sufficiently hydrate at least a predetermined portion of the hemihydrate core to convert it to deformable calcium sulfate dihydrate. The solution including at least one alcohol and water. A predetermined force is applied to the deformable portion of the building panel. The predetermined force causing a desired deformation of the predetermined hydrated portion of the building panel. The device for modifying a building panel according to the method includes a building panel mounting structure, a liquid applicator, and a force applicator.