A set control composition for cementitious systems comprises (a) an amine-glyoxylic acid condensate, and (b) at least one of (i) a borate source and (ii) a carbonate source. The carbonate source is selected from inorganic carbonates having an aqueous solubility of 0.1 gL.sup.−1 or more, and organic carbonates. The set control composition improves workability of cementitious systems for prolonged periods of time without compromising early compressive strength. Due to the retarding action of the set control composition, the dosage of dispersant(s) necessary to obtain a desired flowability of the cementitious system can be reduced.

Method of making foamed gypsum slurry having 15 to 90 volume percent gas bubbles including: passing first slurry including water and on dry basis 50 to 98 wt. % calcium sulfate hemihydrate, 1 to 50 wt. % calcium carbonate, and 0.1 to 10 wt. % cellulose thickener via a first hose to a Wye connector conduit first inlet opening at Rate C and passing alum solution via a second hose to a second inlet opening of the conduit at Rate D to create combined mixed stream passing from the conduit to a static mixer for mixing for Time 3 to activate at least a portion of the calcium carbonate and alum to generate CO.sub.2 and create the foamed gypsum slurry; transferring the slurry from the mixer to a cavity between two wall boards via a third hose. Allowing the slurry in the cavity to expand, harden and dry.

Method of making foamed gypsum slurry having 15 to 90 volume percent gas bubbles including: passing first slurry including water and on dry basis 50 to 98 wt. % calcium sulfate hemihydrate, 1 to 50 wt. % calcium carbonate, and 0.1 to 10 wt. % cellulose thickener via a first hose to a Wye connector conduit first inlet opening at Rate C and passing alum solution via a second hose to a second inlet opening of the conduit at Rate D to create combined mixed stream passing from the conduit to a static mixer for mixing for Time 3 to activate at least a portion of the calcium carbonate and alum to generate CO.sub.2 and create the foamed gypsum slurry; transferring the slurry from the mixer to a cavity between two wall boards via a third hose. Allowing the slurry in the cavity to expand, harden and dry.

This invention provides gypsum wallboards with a unique microstructure where the walls between voids are enhanced in thickness and strength to substantially improve the strength and handling properties of the wallboards. A method of making lightweight gypsum wallboards is also provided.

This invention provides gypsum wallboards with a unique microstructure where the walls between voids are enhanced in thickness and strength to substantially improve the strength and handling properties of the wallboards. A method of making lightweight gypsum wallboards is also provided.

A set control composition for cementitious systems comprises (a) an amine-glyoxylic acid condensate, and (b) at least one of (i) a borate source and (ii) a carbonate source. The carbonate source is selected from inorganic carbonates having an aqueous solubility of 0.1 gL.sup.−1 or more, and organic carbonates. The set control composition improves workability of cementitious systems for prolonged periods of time without compromising early compressive strength. Due to the retarding action of the set control composition, the dosage of dispersant(s) necessary to obtain a desired flowability of the cementitious system can be reduced.

A set control composition for cementitious systems comprises (a) an amine-glyoxylic acid condensate, and (b) at least one of (i) a borate source and (ii) a carbonate source. The carbonate source is selected from inorganic carbonates having an aqueous solubility of 0.1 gL.sup.−1 or more, and organic carbonates. The set control composition improves workability of cementitious systems for prolonged periods of time without compromising early compressive strength. Due to the retarding action of the set control composition, the dosage of dispersant(s) necessary to obtain a desired flowability of the cementitious system can be reduced.

This invention provides low dust low density gypsum wallboard products having high total core void volumes, corresponding to low densities in the range of about 10 to 30 pcf. The wallboards have a set gypsum core formed between two substantially parallel cover sheets, the set gypsum core preferably having a total void volume from about 80% to about 92%, and made from a slurry including stucco, pregelatinized starch, and a naphthalenesulfonate dispersant. The combination of the pregelatinized starch and the naphthalenesulfonate dispersant also provides a glue-like effect in binding the set gypsum crystals together. The wallboard formulation, along with small air bubble voids (and water voids) provides dust control during cutting, sawing, routing, snapping, nailing or screwing down, or drilling of the gypsum-containing products. This invention also provides a method of making the low dust low density gypsum products including the introduction of soap foam in an amount sufficient to form a total void volume, including air voids, preferably from about 80% to about 92% in the set gypsum core, corresponding to a set gypsum core density from about 10 pcf to about 30 pcf. The wallboards produced by the method generate significantly less dust during working.

This invention provides low dust low density gypsum wallboard products having high total core void volumes, corresponding to low densities in the range of about 10 to 30 pcf. The wallboards have a set gypsum core formed between two substantially parallel cover sheets, the set gypsum core preferably having a total void volume from about 80% to about 92%, and made from a slurry including stucco, pregelatinized starch, and a naphthalenesulfonate dispersant. The combination of the pregelatinized starch and the naphthalenesulfonate dispersant also provides a glue-like effect in binding the set gypsum crystals together. The wallboard formulation, along with small air bubble voids (and water voids) provides dust control during cutting, sawing, routing, snapping, nailing or screwing down, or drilling of the gypsum-containing products. This invention also provides a method of making the low dust low density gypsum products including the introduction of soap foam in an amount sufficient to form a total void volume, including air voids, preferably from about 80% to about 92% in the set gypsum core, corresponding to a set gypsum core density from about 10 pcf to about 30 pcf. The wallboards produced by the method generate significantly less dust during working.

A heat resistant countertop or a heat resistant three dimensional shape product comprising a composition comprising at least one aggregate, at least one cement, at least one fine material, at least one dispersant, and at least one viscosity modifier, and optionally at least one set retarder, and optionally at least one set accelerator. A heat resistant countertop or a heat resistant three dimensional shape product comprising a calcium aluminate cement hydraulic binder and matrix is provided.