A lightweight gypsum wallboard having a foamed gypsum core reinforced with pre-gelatinized, e.g., pre-gelled, starch and prepared by mixing an aqueous foam into a gypsum slurry comprising a source of calcined gypsum (commonly known as plaster of Paris), pre-gelled starch and a lignosulfonate dispersant; allowing the so-formed gypsum slurry to set, and then drying the set gypsum core.

The process of the invention presents a simple, effective and continuous process for producing slabs and panels from compositions free from ceramic components or ceramic binders.

Compositions and a method for making self consolidating grouts containing fly ash, ground granulated blast furnace slag, and lime are described. No polymeric admixtures are utilized, and the 28 day cure strength of the cured gouts exceeds the minimum ASTM standards. The uncured grout exhibits slump flows between 24 and 30 without visible segregation of the components.

Hexagonal Boron Nitride (hBN) is a synthetic material that may be used in several applications due to its chemical inertness, thermal stability, and other beneficial properties. hBN composite materials and method for making such composites are described here. In particular composite materials including both functionalized hBN and cement or cementitious materials and methods for making the same are discussed. Such materials may be useful for construction, well cementing (both primary and remedial cementing), nuclear industry, 3D printing of advanced multifunctional composites, and refractory materials.

A method can include: hot milling a mixture comprising calcium sulfate dihydrate and about 5% to about 25% sucrose by weight of the calcium sulfate dihydrate at a temperature of about 150 F. (66 C.) to about 250 F. (121 C.) to produce a climate stabilizing accelerator (CSA). The CSA produced from this method is dispersed in water and optionally aged for at least 1 minute before use in forming gypsum-fiber composite boards.

A cementitious composite and cured masonry block made from the cementitious composite. The cementitious composite contains a cement, a non-rubber aggregate, a crumb rubber and at least one of cement kiln dust and limestone powder. The crumb rubber aggregate is extracted from scrap tires after being processed and then mixed in specified percentages with the aggregate, the cement and water, then cured in forms to make the masonry blocks. In the present disclosure sand, which is used in conventional masonry blocks, is at least partially replaced with crumb rubber to produce a sand-free or sand-reduced masonry block that contains crumb rubber. The crumb rubber masonry blocks satisfy the ASTM non-load bearing requirements. The use of crumb rubber decreases the unit weight and increases thermal resistance of the masonry blocks. The use of cement kiln dust or limestone as a partial replacement of cement will lead to decrease in the cost. The use of industrial waste materials, such as crumb rubber, limestone powder and cement kiln dust, will lead to economic and environmental benefits.

There is provided a gypsum composition for a drying type coating material, the gypsum composition, when made into a gypsum-based coating material by addition of water, capable of forming a coating film in which color unevenness is suppressed even though the coating film is thin and smooth. This gypsum composition for a drying type coating material contains hemihydrate gypsum having a mean particle diameter of 50 m or less, calcium carbonate having a mean particle diameter of 50 m or less, and a setting retarder, wherein the gypsum composition has a content of calcium carbonate of 100 to 400 parts by mass and a content of the setting retarder of 0.1 parts by mass or more each based on 100 parts by mass of the hemihydrate gypsum.

The invention is directed to a fly ash containing construction material having improved strength and water resistance. The fly ash containing material includes fly ash, an alkali solution comprising sodium hydroxide, and water. The invention further provides a geopolymerization method of forming a fly ash containing material.

A composition for additive manufacturing of an article may include a base material, a functional particulate having at least one of an acicular morphology and a platy morphology, and binder. The functional particulate may increase a strength property of the article manufactured with the composition as compared to the strength property of the article manufactured with the composition being devoid of the functional particulate. A method of manufacturing an article via additive manufacturing may include providing a first layer of a powder composition. The powder composition may include a base material, a functional particulate, and binder. The method may also include binding the first layer of powder composition in a predetermined pattern to form a hardened two-dimensional shape including the powder composition, and successively providing additional layers of the powder composition and binding the respective layers to form the article.

Described herein are compositions and methods for waste-to-energy ash in engineered aggregate in road construction.