A composite board is formed from binding a cover layer to a base layer, wherein the base layer has a composition comprising one or more of the following ingredients: magnesium oxide, recycled magnesium oxide, fibrous chips, wood chips, bamboo chips, chemical additive and water. A method of manufacturing the composite board includes providing the base layer, which includes preparing a semi-arid mixture of the above ingredients, and pouring the mixture through a funnel onto a conveyor belt. The conveyor belt passes the mixture through a series of rollers to remove excess liquid. The layer is cut into panels, which are heat before being sprayed with dried magnesium oxide. A binding agent is applied to one side of the base layer. The cover layer has a bottom surface which is then aligned and bonded to one side of the base layer.

A composite board is formed from binding a cover layer to a base layer, wherein the base layer has a composition comprising one or more of the following ingredients: magnesium oxide, recycled magnesium oxide, fibrous chips, wood chips, bamboo chips, chemical additive and water. A method of manufacturing the composite board includes providing the base layer, which includes preparing a semi-arid mixture of the above ingredients, and pouring the mixture through a funnel onto a conveyor belt. The conveyor belt passes the mixture through a series of rollers to remove excess liquid. The layer is cut into panels, which are heat before being sprayed with dried magnesium oxide. A binding agent is applied to one side of the base layer. The cover layer has a bottom surface which is then aligned and bonded to one side of the base layer.

Stucco support structures and stucco wall systems incorporating the stucco support structures are provided. The stucco support structure includes a structural layer of composite material. The composite material includes a homogenous matrix of a gypsum material and a polymer resin material, and wet-use chopped strand fibers that are filamentized within the homogenous matrix. The stucco support structure also includes a stucco adhesion member interfaced with the structural layer that is configured to receive and bond a stucco material to the structural layer. The stucco support structure eliminates the need for sheathing and wire mesh lath conventionally used in stucco applications.

Stucco support structures and stucco wall systems incorporating the stucco support structures are provided. The stucco support structure includes a structural layer of composite material. The composite material includes a homogenous matrix of a gypsum material and a polymer resin material, and wet-use chopped strand fibers that are filamentized within the homogenous matrix. The stucco support structure also includes a stucco adhesion member interfaced with the structural layer that is configured to receive and bond a stucco material to the structural layer. The stucco support structure eliminates the need for sheathing and wire mesh lath conventionally used in stucco applications.

A reinforced water-resistant board includes a cover board with a reinforced water-resistant membrane applied to a surface of the cover board. The reinforced water-resistant membrane includes a primer layer, a reinforced membrane, a traffic coat, and a sealing layer. The primer layer is applied over the surface of the cover board. The reinforced membrane includes fleece soaked in a liquid resin and is applied over the primer layer. The traffic coat is boned to the reinforced member. The sealing layer is applied over the traffic coat.

A reinforced water-resistant board includes a cover board with a reinforced water-resistant membrane applied to a surface of the cover board. The reinforced water-resistant membrane includes a primer layer, a reinforced membrane, a traffic coat, and a sealing layer. The primer layer is applied over the surface of the cover board. The reinforced membrane includes fleece soaked in a liquid resin and is applied over the primer layer. The traffic coat is boned to the reinforced member. The sealing layer is applied over the traffic coat.

Gypsum panels, sheathing systems, and methods of making and using the same are provided. A gypsum panel includes a gypsum core associated with a first fiberglass mat having a continuous barrier coating, the coating penetrating a portion of the first fiberglass mat opposite the gypsum core, wherein gypsum penetrates a remaining fibrous portion of the first fiberglass mat such that voids in the first fiberglass mat are substantially eliminated. A building sheathing system includes at least two gypsum panels and a seaming component to provide a seam at an interface between the gypsum panels.

Gypsum panels, sheathing systems, and methods of making and using the same are provided. A gypsum panel includes a gypsum core associated with a first fiberglass mat having a continuous barrier coating, the coating penetrating a portion of the first fiberglass mat opposite the gypsum core, wherein gypsum penetrates a remaining fibrous portion of the first fiberglass mat such that voids in the first fiberglass mat are substantially eliminated. A building sheathing system includes at least two gypsum panels and a seaming component to provide a seam at an interface between the gypsum panels.

A fire-resistant construction panel (10) includes a structural panel (12) as the web component of an I-joist (24) having an exposed surface (14) and a magnesium oxide board (18) covering the exposed surface (14). Alternately, the fire-resistant construction panel (10′) includes a load-resistant magnesium oxide board (30) being a structural element as the web of an I-joist (24′).

A fire-resistant construction panel (10) includes a structural panel (12) as the web component of an I-joist (24) having an exposed surface (14) and a magnesium oxide board (18) covering the exposed surface (14). Alternately, the fire-resistant construction panel (10′) includes a load-resistant magnesium oxide board (30) being a structural element as the web of an I-joist (24′).