A high toughness inorganic composite artificial stone panel and preparation method are disclosed. The panel includes a surface layer, an intermediate metal fiber toughening layer and a substrate toughening layer. The surface layer includes the following components: 40-70 parts of quartz sand, 10-30 parts of quartz powder, 20-45 parts of inorganic active powder, 0.5-4 parts of pigment, 0.3-1 part of water reducer and 3-10 parts of water. The intermediate metal fiber toughening layer includes the following components: 40-60 parts of inorganic active powder, 45-65 parts of sand, 0.8-1.5 parts of water reducer, 6-14 parts of water and 4-8 parts of metal fiber. The substrate toughening layer includes the following components: 30-50 parts of inorganic active powder, 30-55 parts of quartz sand, 15-20 parts of quartz powder, 0.5-1.2 parts of water reducer, 4-8 parts of water and 0.8-2.5 parts of toughening agent.

The invention relates to a panel and a method for producing a panel. The panel is in particular a floor, wall or ceiling panel, and comprises at least one core layer, the core layer comprising an upper core surface and a lower core surface and at least one pair of opposite side edges; wherein the core layer comprises magnesium oxide cement; wherein the core has a density which is substantially homogenous over its entire volume, and wherein at least one decorative top layer is attached to an upper core surface of the core layer.

A panel and a method of making a panel are provided. The panel comprises a cured polymeric foam layer that is formed by application of a foam composition to an edge surface of the panel and then shaped and cured. The panel comprises man-made vitreous fibre or wood wool cement.

Gypsum panels and methods of making gypsum panels are provided. Methods of making gypsum panels include: depositing a first gypsum slurry onto a first surface of a first fiberglass mat; allowing the first gypsum slurry to set to form at least a portion of a gypsum core; and applying a substantially continuous barrier coating comprising a polymer binder to a second surface, opposite the first surface, of the first fiberglass mat, in an amount of from about 1 lb/MSF to about 40 lb/MSF, such that the substantially continuous barrier coating has an average thickness of from about 1 micron to about 100 microns, wherein the substantially continuous barrier coating eliminates at least 99 percent of pin holes present in the exposed second surface of the first fiberglass mat.

Various cement-containing compositions are disclosed, including insulating cement, forms, and prefabricated building materials produced from cement-containing compositions with insulating properties. Some of the preferred embodiments include expanded polystyrene and an acrylic component to provide enhanced insulating properties, or have a lower density, lighter weight, and increased insulating R-value in comparison with other cement-containing compositions.

A method of setting tile includes constructing a floor panel and a plurality of wall panels and attaching each of the plurality of wall panels to either the floor panel or one of the other wall panels with a waterproof caulk. Each of the wall panels includes a first rigid layer, a second rigid layer attached to the first rigid layer by a thinset mortar, and a waterproofing layer formed of a flexible material and attached to the second rigid layer by the thinset mortar.

A prefabricated wall panel defines a panel plane and a peripheral edge includes a plurality of material layers parallel to the panel plane and superimposed on one another, including a load-bearing layer made of reinforced cement, a protective layer distanced from the load-bearing layer, and a heat-insulating layer formed on a side of the load-bearing layer opposite to the protective layer. An air circulation gap is formed between two layers of the material layers so as to separate the two layers from each other. The air circulation gap is open on the entire peripheral edge. A plurality of spacer connectors extends in a direction transversal to the panel plane through the air circulation gap, each spacer connector having a first anchoring end fixed in the protective layer and a second anchoring end fixed in the load-bearing layer.

A prefabricated wall panel defines a panel plane and a peripheral edge includes a plurality of material layers parallel to the panel plane and superimposed on one another, including a load-bearing layer made of reinforced cement, a protective layer distanced from the load-bearing layer, and a heat-insulating layer formed on a side of the load-bearing layer opposite to the protective layer. An air circulation gap is formed between two layers of the material layers so as to separate the two layers from each other. The air circulation gap is open on the entire peripheral edge. A plurality of spacer connectors extends in a direction transversal to the panel plane through the air circulation gap, each spacer connector having a first anchoring end fixed in the protective layer and a second anchoring end fixed in the load-bearing layer.

A method of installing a binder-based overlay system may include contacting a layer of geotextile fabric to a surface of a substrate and applying a primer layer to a surface of the geotextile fabric. Two or more binder layers including infill particles may be applied over the primer layer. A resurfacer layer followed by one or more color layers may be applied over the two or more binder layers. The primer layer, one or more binder layers, resurfacer layer, and two or more color layers may cure upon application to form a monolithic layer upon the substrate.

A method of installing a binder-based overlay system may include contacting a layer of geotextile fabric to a surface of a substrate and applying a primer layer to a surface of the geotextile fabric. Two or more binder layers including infill particles may be applied over the primer layer. A resurfacer layer followed by one or more color layers may be applied over the two or more binder layers. The primer layer, one or more binder layers, resurfacer layer, and two or more color layers may cure upon application to form a monolithic layer upon the substrate.