A surfactant composition is disclosed comprising branched alkyl sulfate having 8 to 12 carbon atoms; optionally a linear alkyl sulfate having 8 to 12 carbon atoms; and optionally an alkyl ether sulfate having 8 to 13 carbon atoms. A gypsum slurry or gypsum board core is disclosed comprising gypsum, water, and a surfactant composition as described above. The foam voids in the core have a greater median diameter than foam voids made with corresponding linear alkyl sulfate. A method of controlling the median foam void diameter in a gypsum board is disclosed. A first foam water composition is provided comprising a linear alkyl sulfate surfactant. A second foam water composition is also provided comprising a branched alkyl sulfate surfactant. The proportions of the first and second foam water compositions employed in a gypsum composition are selected, or if desired changed, to provide the desired median foam void diameter.

An ultra-light, pourable, self-drying cementitious product with improved density control and ultra-low water demand is provided. Compositions and methods for making the products are provided as well, including compositions and methods with ultra-low water demand.

A foam concrete has constituents that include a cement, a sand, a coarse aggregate having a density in a range of 1400-1600 kg/m.sup.3, a water, and a foam solution. The foam solution includes a foaming agent and a foaming water. The foam concrete has a compressive strength of at least 20 MPa, a thermal conductivity of less than 0.40 W/mK and a maximum dry weight of 2000 kg/m.sup.3.

A foam concrete has constituents that include a cement, a sand, a coarse aggregate having a density in a range of 1400-1600 kg/m.sup.3, a water, and a foam solution. The foam solution includes a foaming agent and a foaming water. The foam concrete has a compressive strength of at least 20 MPa, a thermal conductivity of less than 0.40 W/mK and a maximum dry weight of 2000 kg/m.sup.3.

An insulation panel comprising an outer shell formed of thermoplastic material and an inner space inside the outer shell, wherein the inner space is at least partially filled with a foamed inorganic material comprising at least one mineral binder and optionally at least one synthetic organic polymer, wherein the foamed inorganic material has a density of not more than 500 g/l. The invention is also directed to a method for producing an insulation panel.

An insulation panel comprising an outer shell formed of thermoplastic material and an inner space inside the outer shell, wherein the inner space is at least partially filled with a foamed inorganic material comprising at least one mineral binder and optionally at least one synthetic organic polymer, wherein the foamed inorganic material has a density of not more than 500 g/l. The invention is also directed to a method for producing an insulation panel.

In some embodiments, a method may include preparing building forms including at least some cementitious materials. The method for preparing forms may include mixing substantially dry cementitious material particles with closed cell foam particles to form a substantially dry composition. In some embodiment, at least some of the cementitious material particles may adhere to at least some surface deformations on the surface of the closed cell foam particles. In some embodiments, the method may include mixing a second portion of water with the substantially dry composition for a second period of time to form a partially wet composition. In some embodiments, a method may include forming a building form including at least some cementitious materials from the partially wet composition. In some embodiments, the closed cell foam particles may include expanded polystyrene. In some embodiments, a ratio of the water to cementitious material particles may range from 0.20 to 0.40.

A liquid accelerator composition for accelerating the setting reaction of calcium sulfate hemihydrate and water and methods of forming a liquid gypsum accelerator are provided. The liquid accelerator composition includes a liquid media in which calcium sulfate dihydrate is less than fully soluble and a ground product of a mill grinding of a mixture comprising calcium sulfate dihydrate.

A liquid accelerator composition for accelerating the setting reaction of calcium sulfate hemihydrate and water and methods of forming a liquid gypsum accelerator are provided. The liquid accelerator composition includes a liquid media in which calcium sulfate dihydrate is less than fully soluble and a ground product of a mill grinding of a mixture comprising calcium sulfate dihydrate.

Disclosed is a foamed cementitious composition which limits or eliminates aggregate, especially porous lightweight aggregate and uses a lower than usual water to cementitious composition weight ratio. The stable cementitious foam mixtures may be employed to make cement boards and other cement products. The foamed cementitious composition was made with additions of PVOH foaming stabilizer and surfactant foaming agents to make foam water or by entrain air into cementitious slurry mixtures. The cementitious mixtures have a limited amount or preferably no perlite and no lightweight aggregate. The resulting foamed mixture had foam bubbles with size in the range of 50 to 200 m. After setting the foamed cementitious composition the resulting set board has air cells with size in the range of 50 to 200 m.