A wallboard panel is provided, including a sheet of face paper, a first layer of gypsum composition having a first density, a web of mesh associated with the first layer of gypsum composition, a second layer of gypsum composition having a second density, the second density being lower than the first density, and a layer of backing paper. An associated method includes providing a sheet of face paper and laying same upon a moving conveyor belt, applying a first layer of gypsum composition slurry upon the sheet of face paper, applying a web of mesh upon the first layer of gypsum composition slurry, applying a second layer of gypsum composition slurry upon the web of mesh, and applying a sheet of backing paper upon the second layer of gypsum composition slurry.

A wall panel may have a veneer layer, a middle layer made from magnesium oxide and an insulation layer made from a two-part rigid urethane pour foam. The insulation layer maybe chemically bonded to the middle layer. The veneer layer may include a poured substrate made from polyurethane or plastic. The veneer layer may further include aesthetic elements embedded in and bonded to the poured substrate. The aesthetic elements may include one or more of brick, ceramic tile, porcelain tile, natural stone, engineered stone, wood, ceramic, plastic, or vinyl. A finished surface of the aesthetic elements may extend above a top surface of the poured substrate. The poured substrate may include sand causing the top surface of the poured substrate to have an appearance of mortar.

A composite structure having a solid-phase concrete base-substrate component; a fibrous component that is a plurality of polypropylene fibers, at least a portion of which are embedded into and thereby mechanically attached to the solid-phase concrete base-substrate component, wherein at least a portion of the fibers extend from within the concrete base-substrate component and out of the concrete base-substrate component through an exterior surface of the concrete base-substrate component; and a polyvinylchloride-adhesive layer component having a first and second surface, wherein the polyvinylchloride-adhesive layer component first surface is in contact with and adhesively attached to the fibrous component, and wherein the polyvinylchloride-adhesive layer second surface is in contact with and adhesively attached to a first surface of a polyvinylchloride or polyvinylchloride-containing-alloy exterior sheet.

Disclosed are composite building boards and associated manufacturing methods. The composite boards may include, for example, one or more slurry layers with embedded fibrous mats. An exterior plastic coating is mechanically adhered to the underlying slurry layer. The plastic layer chemically bonds and cross-links with polymer additives within the slurry layer. The result is an integrated polymer matrix with greatly improved durability and surface strength.

A wall panel may have a veneer layer, a middle layer made from magnesium oxide and an insulation layer made from a two-part rigid urethane pour foam. The insulation layer maybe chemically bonded to the middle layer. The veneer layer may include a poured substrate made from polyurethane or plastic. The veneer layer may further include aesthetic elements embedded in and bonded to the poured substrate. The aesthetic elements may include one or more of brick, ceramic tile, porcelain tile, natural stone, engineered stone, wood, ceramic, plastic, or vinyl. A finished surface of the aesthetic elements may extend above a top surface of the poured substrate. The poured substrate may include sand causing the top surface of the poured substrate to have an appearance of mortar.

A cementitious composite for in-situ hydration includes a first layer, a second layer spaced from the first layer, and a cementitious mixture disposed between the first layer and the second layer. The cementitious mixture includes cementitious materials. The cementitious mixture is configured to absorb a mass of water that provides a maximum 28 day compressive strength of the cementitious composite upon curing which is represented by M.sub.w=x.Math.M.sub.c. M.sub.w is the mass of the water per unit area of the cementitious composite. M.sub.c is a mass of the cementitious materials of the cementitious mixture per unit area of the cementitious composite. x is a ratio of the mass of the water relative to the mass of the cementitious materials of the cementitious mixture per unit area of the cementitious composite that provides the maximum 28 day compressive strength of the cementitious composite. x is between 0.25 and 0.55.

A dual-walled ceramic matrix composite (CMC) component comprises: a CMC core having a hollow shape enclosing at least one interior channel; and a CMC outer layer overlying and spaced apart from the CMC core by a ceramic slurry-cast architecture positioned therebetween. Each of the CMC core and the CMC outer layer comprises ceramic fibers in a ceramic matrix. The CMC core further includes a plurality of through-thickness inner cooling holes in fluid communication with the at least one interior channel. The ceramic slurry-cast architecture defines a cooling fluid path over an outer surface of the CMC core that connects the interior channel(s) to an external environment of the dual-walled CMC component. The CMC outer layer may also include a plurality of through-thickness outer cooling holes in fluid communication with the cooling fluid path, thereby extending the cooling fluid path through the CMC outer layer.

Disclosed are composite building boards and associated manufacturing methods. The composite boards may include, for example, one or more slurry layers with embedded fibrous mats. An exterior plastic coating is mechanically adhered to the underlying slurry layer. The plastic layer chemically bonds and cross-links with polymer additives within the slurry layer. The result is an integrated polymer matrix with greatly improved durability and surface strength.

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 composite structure for use in tiling surfaces is disclosed. The composite structure can include a fiber matrix impregnated with a water-activated setting material. The composite structure can be wet and then compressed between a tile and an application surface. The composite structure can cure to provide a support surface for the tile.