Disclosed are a composite gypsum board and a method of preparing composite gypsum board. The board contains a set gypsum core sandwiched between two cover sheets. The core is formed from a slurry containing stucco, water, and optional ingredients such as foaming agent, accelerator, retarder, polyphosphate, starch, and dispersant, and core intumescent material. The board also contains at least one skim coat and/or hard edges. A face skim coat layer can be included on one side of the core, facing a face cover sheet. A back skim coat layer can be included on the other side of the core, facing a back cover sheet. Hard edges are known in the art and can be formed, e.g., continuously from a stucco slurry for forming the face and/or back skim coats. Preferably, the back skim coat layer and/or the hard edges are formed from a slurry containing stucco, water, skim coat or edge intumescent material (which have the same desired characteristics), and other optional additives as desired. The skim coat or edge intumescent material can be composed of the same material as the core intumescent material, if desired, but the skim coat and/or edge intumescent material is present in a higher relative concentration in its respective slurry than the amount of core intumescent material in the core slurry. Examples of suitable intumescent materials include expandable vermiculite (e.g., No. 4 or No. 5 according to the US naming system, or combinations thereof), expandable graphite, perlite, or any combination thereof.

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.

The invention concerns an apparatus for furnishing a liner with a layer of stucco slurry, comprising at least: a conveying device (24) for conveying a liner (7), said conveyor device defining a transport direction (31); a stucco slurry feeder device (26) for casting stucco slurry onto the liner (7); a stucco slurry distribution device (27) for distributing stucco slurry cast onto the liner (7); and at least one stripper device (28) for stripping stucco slurry from lateral portions of the liner.

The invention further concerns a method for furnishing a liner with a layer of stucco slurry of defined width and a method for producing a gypsum plasterboard.

Disclosed is a method and system for blending a foam modifier with foaming agent on-line, e.g., as may be particularly useful for gypsum or cement slurries. The foam modifier comprises a fatty alcohol that is added to a gypsum or cement slurry that includes foaming agent, such as an alkyl sulfate surfactant. The fatty alcohol can be a C.sub.6-C.sub.16 fatty alcohol in some embodiments. The use of such a foam modifier can be used, for example, to stabilize the foam, reduce waste of foaming agent, improve void size control in the final product, and improve the gypsum board manufacturing process.

A method for making a gypsum board including: combining a first plurality of particles including at least about 50 wt. % calcium sulfate dihydrate and about 0.05 wt. % to about 10 wt. % hydrophobic material and having a D50 particle size of about 200 μm to about 800 μm with a second plurality of particles including calcium sulfate hemihydrate to form a combined mixture of calcium sulfate; adding water to the combined mixture of calcium sulfate to make an aqueous gypsum slurry; depositing a core layer including the aqueous gypsum slurry over a forming surface; and allowing the core layer to set, thereby forming a set gypsum core.

In the present disclosure, a method of forming a gypsum panel is disclosed. The method comprises: providing a first facing material, forming a starch slurry by combining starch and water at a shear rate of 3,000 rpm or more, providing the starch slurry onto the first facing material, depositing a gypsum slurry comprising stucco and water onto the starch slurry on the first facing material, providing a second facing material on the gypsum slurry, and allowing the stucco to convert to calcium sulfate dihydrate.

The present invention is a thermal and acoustic insulating sphere that has an evacuated hollow interior. The spheres are constructed of insulating materials, and the inner and outer surfaces of each sphere have highly reflective coatings evenly applied to them. The coatings applied to the inner and outer surfaces reduce the transmission of heat by conduction, convection, and radiation. Additionally, the spheres provide superior acoustic insulation due to the inability of sound to travel through the interior vacuum. The spheres can be used to produce insulating materials, for example, by embedding or positioning them within or between other materials, to provide thermal and acoustic insulation.

A sampling apparatus is provided, which includes a pressing-up unit configured to press up a sheet piece that is being conveyed by a conveying unit, from a lower side of a conveyance course of the sheet piece to above the conveyance course; and a holding unit configured to hold the sheet piece pressed up by the pressing-up unit.

A system for making a cementitious composite includes a cementitious material supply system for dispensing a powdered cementitious material or a semi-powdered cementitious material into a receiving material. The receiving material includes a structural layer and a sealing layer. The structural layer includes an open continuous volume extending from a first side to a second side opposite the first side. The sealing layer is coupled to the first side. The cementitious material supply system is configured to dispense the powdered cementitious material or the semi-powdered cementitious material into the open continuous volume to fill the open continuous volume.

Concrete Picket Fence Replacement is an innovative upgrade to designer and durable fencing, comprising the strength of concrete, steel, and stone to create a series of interlocking panels, capable of resisting the destructive forces of wind, water, fire, and deterioration from insects and animals. In preferred embodiments, a strong matrix of Concrete Picket Fence boards are adhered vertically along a horizontal metal pipe by welding metal points of contact, creating a solid fence panel anchored to the ground by metal fence posts secured by concrete. To date, concrete and steel have not been combined in such fashion. The return will be a conservation of trees and lower costs due to loss, theft, and replacement cost.