The present invention is directed to a gypsum panel and a method of making such gypsum panel. For instance, in one embodiment, the gypsum panel comprises a gypsum core and a first facing material and a second facing material sandwiching the gypsum core, wherein the gypsum core includes gypsum and one or more chloride ion mitigating additives. The methods of the present invention are directed to making the aforementioned gypsum panels by providing the first facing material, providing a gypsum slurry comprising gypsum, water, and the respective additive onto the first facing material, and providing a second facing material on the gypsum slurry.

A joint compound system includes a set-inhibited, pre-wetted, setting-type, ready-mix joint compound and a set initiator. The set-inhibited, pre-wetted, setting-type joint compound includes a ready-mixed, setting-type joint compound base with a calcium-free phosphate set preventing agent that impedes chemical hydration of a gypsum component of the setting-type joint compound. The joint compound base is free of calcium carbonate. The set initiator includes alum to reinitiate the chemical hydration reactions.

A joint compound system includes a set-inhibited, pre-wetted, setting-type, ready-mix joint compound and a set initiator. The set-inhibited, pre-wetted, setting-type joint compound includes a ready-mixed, setting-type joint compound base with a calcium-free phosphate set preventing agent that impedes chemical hydration of a gypsum component of the setting-type joint compound. The joint compound base is free of calcium carbonate. The set initiator includes alum to reinitiate the chemical hydration reactions.

Printable cementitious compositions for additive manufacturing are provided, that have a fresh state and a hardened state. In fresh state, the composition is flowable and extrudable in the additive manufacturing process. In the hardened state, the composition exhibits strain hardening. In one variation, the strain hardening is represented by a uniaxial tensile strength of ?about 2.5 MPa, a tensile strain capacity of ?about 1%, and a compressive strength at 100 hours of ?about 20 MPa. In other variations, the composition includes Portland cement, a calcium aluminate cement, a fine aggregate, water, a high range water reducing agent (HRWRA), and a polymeric fiber, as well as one or more optional components selected from: fly ash, silica flour, microsilica, attapulgite nanoclay, and/or hydroxypropylmethyl cellulose (HPMC). Methods of additive manufacturing with such compositions are also provided.

Printable cementitious compositions for additive manufacturing are provided, that have a fresh state and a hardened state. In fresh state, the composition is flowable and extrudable in the additive manufacturing process. In the hardened state, the composition exhibits strain hardening. In one variation, the strain hardening is represented by a uniaxial tensile strength of ?about 2.5 MPa, a tensile strain capacity of ?about 1%, and a compressive strength at 100 hours of ?about 20 MPa. In other variations, the composition includes Portland cement, a calcium aluminate cement, a fine aggregate, water, a high range water reducing agent (HRWRA), and a polymeric fiber, as well as one or more optional components selected from: fly ash, silica flour, microsilica, attapulgite nanoclay, and/or hydroxypropylmethyl cellulose (HPMC). Methods of additive manufacturing with such compositions are also provided.

According to the present invention, there is provided a filler compound, the filler compound comprising filler particles and a binder, wherein the filler particles comprise particles of at least one glassy material, and the particles of glassy material are at least 10 wt. % of the dry mass of the filler compound, and wherein at least 30 wt. % of the filler particles have a diameter between 50 and 100 microns inclusive. Use of a filler compound in the erection of a structure is also described.

According to the present invention, there is provided a filler compound, the filler compound comprising filler particles and a binder, wherein the filler particles comprise particles of at least one glassy material, and the particles of glassy material are at least 10 wt. % of the dry mass of the filler compound, and wherein at least 30 wt. % of the filler particles have a diameter between 50 and 100 microns inclusive. Use of a filler compound in the erection of a structure is also described.

Perlite-free, lightweight setting-type joint compounds which comprise calcium sulfate hemihydrate with a dry density of less than 50 lb/ft.sup.3, a foaming agent having a HLB value of at least 10 and preferably comprising an alkylbenzene sulfonic acid having a linear alkyl chain containing 8 to 14 carbons and/or a salt thereof, and a combination of rheology modifiers. Methods for building wallboard assemblies and methods for wall patch and repair projects that include applying the perlite-free, lightweight setting-type joint compounds to a substrate.

Spackling and joint compounds with lower shrinkage, better sanding, and fast drying. Methods for repairing walls and ceiling in which the present spackling compound is applied to a variety of substrates, including wallboard, plaster and/or wood. Methods for finishing seams in wall construction in which the spackling/joint compound is used for finishing the seams.

Spackling and joint compounds with lower shrinkage, better sanding, and fast drying. Methods for repairing walls and ceiling in which the present spackling compound is applied to a variety of substrates, including wallboard, plaster and/or wood. Methods for finishing seams in wall construction in which the spackling/joint compound is used for finishing the seams.