Disclosed herein are low density fiber cement articles, such as fiber cement building panels and sheets, comprised of multiple overlaying fiber cement substrate layers having small and uniform entrained air pockets and low density fillers distributed throughout. The combination of entrained air pockets and low density fillers provide a low density fiber cement matrix with physical and mechanical properties similar to comparable low density fiber cement matrix without entrained air pockets.

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.

The invention relates to a non-flammable panel with real wood veneer and a method for manufacturing such a panel. The non-flammable panel is characterized by a non-flammable carrier board and a thin real wood veneer which was laminated onto the carrier board by means of a mineral glue.

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.

Disclosed herein are low density fiber cement articles, such as fiber cement building panels and sheets, comprised of multiple overlaying fiber cement substrate layers having small and uniform entrained air pockets distributed throughout. Also disclosed herein are air entrainment systems and methods for manufacturing aerated low density fiber cement panels or sheets with consistent air void content and uniform air void distribution. Also disclosed herein are air entrainment technologies adapted to work in conjunction with the Hatschek process to produce aerated fiber cement articles having controlled air void content and distribution.

Disclosed herein are low density fiber cement articles, such as fiber cement building panels and sheets, comprised of multiple overlaying fiber cement substrate layers having small and uniform entrained air pockets distributed throughout. Also disclosed herein are air entrainment systems and methods for manufacturing aerated low density fiber cement panels or sheets with consistent air void content and uniform air void distribution. Also disclosed herein are air entrainment technologies adapted to work in conjunction with the Hatschek process to produce aerated fiber cement articles having controlled air void content and distribution.

A pre-fabricated construction panel (100) for use on an external surface and/or as part of a building or construction is provided. The panel comprises at least a first layer (110) which is at least partially provided from thermally insulating material having a first surface, said panel comprising at least a second layer (120), said at least second layer being provided from fiber cement board, said second layer having a second surface facing said first surface, said first and second layers being connected one to the other by a spacing means located between and adhering to said first and said second surface, which spacing means provides at least one interspace (140) between the first and second surface, said at least one interspace having at least two openings to the external of said panel for enabling air to flow into and out of the interspace towards the external of said panel. The thermally insulating material means material has a thermal conductivity (lambda) less than or equal to 0.05 W/mK.

A pre-fabricated construction panel (100) for use on an external surface and/or as part of a building or construction is provided. The panel comprises at least a first layer (110) which is at least partially provided from thermally insulating material having a first surface, said panel comprising at least a second layer (120), said at least second layer being provided from fiber cement board, said second layer having a second surface facing said first surface, said first and second layers being connected one to the other by a spacing means located between and adhering to said first and said second surface, which spacing means provides at least one interspace (140) between the first and second surface, said at least one interspace having at least two openings to the external of said panel for enabling air to flow into and out of the interspace towards the external of said panel. The thermally insulating material means material has a thermal conductivity (lambda) less than or equal to 0.05 W/mK.

Gypsum based compositions, processes for making same, and articles made therefrom. In one example, the gypsum based composition can include about 1.5 wt % to about 3 wt % of a starch, about 11 wt % to about 14 wt % of a paper, about 0.7 wt % to about 2.3 wt % of vermiculite, about 1.3 wt % to about 3 wt % of a plurality of reinforcing fibers, about 7 wt % to about 10 wt % of a binding agent, about 2 wt % to about 4 wt % of perlite, and about 65 wt % to about 75 wt % of a calcium sulfate, where all weight percent values are based on a combined weight of the starch, paper, vermiculite, plurality of reinforcing fibers, binding agent, perlite, and calcium sulfate.