Self-sealing fasteners and associated building panels, systems, and methods are provided. In one aspect, a fastener includes an elongated fastener body with an external surface extending between the first end and the second end, and a coating material disposed on at least a portion the external surface. In another aspect, a fastener includes an elongated fastener body with an external surface extending between the first end and the second end, and a polymer annulus surrounding at least a portion of the external surface of the of the elongated fastener body at or adjacent the head of the fastener.

A building panel structure is disclosed, in which building panels are used to form a structure. Roof panels and roof panel tiles are disclosed, which can be used to form the roof of the structure. The roof panels and the building panels include a core and a coating covering a portion of the core. In some embodiments the core consists of a frame and at least one insulating structural block. The insulating structural blocks can be encapsulated polystyrene (EPS) foam blocks. In some embodiments the coating includes ceramic material. In some embodiments the coating includes a first layer and a second layer. In some embodiments the coating is used to retrofit existing wall structures. The roof panel and the roof tile can be shaped, formed, and colored to look like traditional roof tiles such as shake roof tiles or Spanish roof tiles.

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.

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 protective fabric jacket for placement on an object to be protected from excessive heat includes a first layer; a second layer; and an intermediate spacer fabric layer that is disposed between the first layer and the second layer. The first and second layers are attached to the intermediate spacer fabric layer to form a layered structure. The intermediate spacer fabric layer comprises a flexible honeycomb or octagonal shaped spacer fabric that has a plurality of cells defined therein. The protective fabric jacket also includes a settable material that disposed within the cells and includes a cementitious mixture and one or more organic polymers and is settable to a hardened material.

A building board including a cementitious layer between two fiber mats. At least one fiber mat forms with a polymer film a fiber mat/polymer film laminate. The cementitious layer of the building board contains a reactive water-insoluble polymer which improves binding of the fiber mat/polymer film laminate to the cementitious layer. The building board has a low water absorption and a high level surface finish.

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 cementitious composite includes a first layer, a second layer, and a cementitious mixture disposed between the first layer and the second layer. The cementitious mixture includes (i) cementitious materials and (ii) a viscosity modifier and/or an accelerator. The cementitious materials provide a void fraction between 0.64 and 1.35. The void fraction is defined as the ratio of the volume of the voids within the cementitious mixture per unit area of the cementitious composite to the volume of the cementitious materials per unit area of the cementitious composite. The cementitious mixture is configured to absorb a mass of water that provides a maximum 28 day compressive strength of the cementitious composite. 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 is between 0.25 and 0.55.

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.