A panel has a gypsum matrix, in which the following additives are embedded: glass fibre in an amount greater than 1 wt % relative to the gypsum and a synthetic polymeric binder in an amount greater than 2.5 wt % relative to the gypsum. The glass fibre and synthetic polymeric binder are present in a weight ratio of at least 2 parts binder to one part fibre. The amount of sand present in the gypsum matrix lies in the range 0-0.5 wt % relative to the gypsum. The amount of cellulosic fibre present in the gypsum matrix lies in the range 0-2 wt % relative to the gypsum.

A gypsum product with improved elasticity and increased nail-pull strength is provided, the product made with a glass fiber mat in which glass fibers are cross-linked with a polymeric resin. Further embodiments provide methods for making the glass fiber mats and gypsum products.

A method of making a concrete panel board is provided. The method includes the steps of: (a) providing a substrate; (b) applying a primer layer to the substrate; (c) drying the board after step b; (d) applying a thinset mortar layer to the primer layer; (e) drying the board after step d; (f) applying a plaster layer to the thinset mortar layer; (g) drying the board after step f; and (h) applying a sealant layer to the plaster layer.

Building panels, assemblies of building panels, and associated methods are provided. A building panel includes a structural core, such as a set gypsum core, at least one filamentous scrim associated with the core, and a nonwoven mat facer.

This disclosure relates to using polyester films on building boards to enable improved surface coatings. The polyester film is preferably applied to a glass mat via an adhesive to form a laminate. This laminate is then bonded to the exterior surface of a gypsum board. The polyester film is advantageous because it allows for exterior surface coatings to be applied. In one embodiment, an exterior acrylic coating is applied to the polyester film. Boards constructed in accordance with this disclosure allow for exterior finishings to be achieved without the need for excessive finishing materials or steps.

A method of forming a coating layer on a fibrous mat to make a coated article includes depositing a coating composition on a carrier material and at least partially embedding a first major surface of a fibrous mat in the coating composition, the fibrous mat including a plurality of mat fibers. The coating composition is at least partially hardened to form a coating layer at the first major surface of the fibrous mat. A second major surface of the fibrous mat opposite the first major surface includes an uncoated portion of the plurality of mat fibers.

A plasterboard comprises a gypsum matrix having particles of agglomerated fibres embedded therein in an amount of at least 1 wt % relative to the gypsum, the gypsum matrix further comprising a polymeric additive, the polymeric additive being present in an amount of at least 1 wt % relative to the gypsum.

A gypsum product has a first polymeric additive and a second polymeric additive distributed therein, wherein the first polymeric additive is a synthetic polymer and the second polymeric additive is starch. It has been found that the combination of starch and a synthetic polymer may result in one or more of the following advantages in the manufacture and performance of gypsum products: —increased strength; —greater ease of manufacturing due to the increased fluidity of stucco slurries containing both additives; and —increased resistance to hygroscopic expansion.

Disclosed is an improved facer mat for use as a cover sheet for gypsum board. Also disclosed are gypsum boards containing such mat facers on one or both major surfaces of the board (face and back sides when installed), a method of manufacturing such board, and a method of making the mat. The mat can comprise glass, thermoplastic, and/or thermoset fiber. In preferred embodiments, binder is included with the fiber. The mat has outer and inner surfaces. The mat comprises a first region adjacent to the outer surface defined along a horizontal plane of the mat, the first region having a first substantial thickness, and a second region adjacent to the inner surface defined along a horizontal plane of the mat, the second region having a second substantial thickness. The first region has (a) more hydrophilicity than the second region, (b) more wettability than the second region, and/or (c) less density than the second region.

A building assembly can include a substrate and a water barrier coating film. The water barrier coating film can include a thermoplastic polymer and microporous particles, such as microporous glass beads. The water barrier coating film can provide a good protection towards liquid water but may allow water vapor flow from the substrate through the coating film. The water vapor permeability of the water barrier coating film can be at least 2 US perms as tested according to ASTM E96 (2014) at 21° C. and 50% average relative humidity.