A fiber cement gypsum composite formulation comprising a binder, reinforcing fibers and a pozzolanic material wherein the binder comprises a gypsum-hydraulic cement mix, wherein gypsum is calcium sulfate dihydrate and the hydraulic cement is Portland cement.

A composition of matter as well as a protective coating or article manufactured from the composition produced by preparing a non-flammable mixture by mixing (I) at least one water-soluble alkali metal silicate selected from the group consisting of sodium silicate, potassium silicate, and combinations thereof; (II) sodium aluminosilicate, which, in the process of interacting with a soluble alkali metal silicate under heat and/or fire, substantially expands and produces foam, which provides heat/fire protection for surfaces, (III) at least one chemical selected from the group consisting of silica, mica, talc, microspheres, glass, ceramic, chopped fibers, plaster of Paris, sodium bicarbonate, cement, perlite, zinc oxide, zeolite, wollastonite, vermiculate, clay, borax and alumina, which, in the process of interacting with a soluble alkali metal silicate and sodium aluminosilicate, accelerates the processes of interaction and improves the mechanical, physical and thermal properties including providing stability of the mixture.

A new and innovative fireproof coating is provided. The fireproof coating exhibits high heat insulation combined with a low flame spread and low smoke density. The fireproof coating can be applied to any suitable structure for which fireproofing is beneficial. An advantage of the fireproof coating is low weight and high flexibility compared to conventional fireproofing technologies while still providing equivalent or better fireproofing properties. The provided fireproof coating has a low thermal conductivity and high emissivity, each of which provide the coating with desirable fireproofing properties. The fireproof coating also demonstrates its advantageous fireproofing properties over a wide range of temperatures and adds minimal thickness to the structures on which it is applied while still providing equivalent or better fireproofing properties as other, thicker fireproof materials.

A hydraulically binding composition can be used to produce an inorganic fire-protection and/or insulation foam. The composition includes: (i) a hydraulic binder, (ii) a blowing-agent mixture, (iii) a thermally expandable compound, and (iv) optionally a foam stabilizer, where the at least one thermally expandable compound, depending on a particle size thereof and an adjusted density of a foamed composition, is present in a quantity such that a foam structure of the foamed composition is not destroyed by expansion thereof during heating of the composition above an onset temperature thereof.

Disclosed are a gypsum board, and related slurries and methods. The gypsum board comprises a gypsum layer disposed between two cover sheets. The gypsum layer comprises a crystalline matrix of set gypsum and expandable graphite. The expandable graphite exhibits volume expansion at high temperatures. Optionally, unexpanded vermiculite can also be included in the gypsum layer to provide an expansion component at even higher temperatures. Because of synergy between the expandable graphite and unexpanded vermiculite in accordance with some embodiments, less vermiculite can be included in the board than in conventional board that contained vermiculite. The board desirably can pass one or more fire-related tests, and is a fire-rated board in some embodiments.

Disclosed is a building board with increased heat and fire resistance. Boards constructed in accordance with this disclosure have lower densities while at the same time containing larger amounts of anti-shrinkage materials. In one embodiment, a board was constructed with a density of less than 1,750 lbs/msf while at the same time including anti-shrinkage additives in amounts greater than 14% by weight of the core material. The inventors have discovered that beneficial, and heretofore unexpected, levels of fire resistance can be achieved by using increased amounts of anti-shrinkage additives in lower density building boards.

The present disclosure relates generally to methods for characterizing unexpanded perlite, e.g., with respect to its expandability as well as articles containing expandable perlite, such as gypsum materials, fire-resistant building boards and other fire-resistant materials, and methods for making the same. The present inventors have determined thermogravimetric methods for characterizing unexpanded perlite with high predictive power for the selection of highly-expandable perlites. The disclosure also relates to materials including unexpanded perlites that meet certain threshold values with respect to these characterization methods.

The present invention is directed to gypsum panels with controlled intumescence and a method of making such gypsum panels. In one embodiment, the gypsum panel comprises a gypsum core, a first facing material, and a second facing material. The gypsum panel comprises a fire resistance composition. The fire resistance composition and/or any components thereof may be milled. The methods of the present invention are directed to making the aforementioned gypsum panels.

Gypsum panels exhibiting improved fire-resistance properties are provided. The gypsum panels comprise a first additive package, having intumescent properties, and a second additive package, exhibiting structural integrity at high temperatures. Methods of making such gypsum panels, and compositions used to prepare such gypsum panels are also provided.

The present invention is directed to gypsum panels containing an intercalated additive and a method of making such gypsum panels. In one embodiment, the gypsum panel comprises a gypsum core, a first facing material, and a second facing material. The gypsum panel comprises a fire resistance composition including an intercalated additive.