Disclosed is a method and system for blending a foam modifier with foaming agent online, e.g., as may be particularly useful for gypsum or cement slurries. The foam modifier comprises a fatty alcohol that is added to a gypsum or cement slurry that includes foaming agent, such as an alkyl sulfate surfactant. The fatty alcohol can be a C.sub.6-C.sub.16 fatty alcohol in some embodiments. The use of such a foam modifier can be used, for example, to stabilize the foam, reduce waste of foaming agent, improve void size control in the final product, and improve the gypsum board manufacturing process.

Disclosed is a method and system for blending a foam modifier with foaming agent online, e.g., as may be particularly useful for gypsum or cement slurries. The foam modifier comprises a fatty alcohol that is added to a gypsum or cement slurry that includes foaming agent, such as an alkyl sulfate surfactant. The fatty alcohol can be a C.sub.6-C.sub.16 fatty alcohol in some embodiments. The use of such a foam modifier can be used, for example, to stabilize the foam, reduce waste of foaming agent, improve void size control in the final product, and improve the gypsum board manufacturing process.

A process for the production of a mineral foam suitable for its use as refractory material includes (i) separately preparing a slurry of cement and an aqueous foam, wherein the cement slurry comprises water (W), an aluminate cement (C) and a lithium salt; (ii) contacting the slurry of cement with the aqueous foam to obtain a slurry of foamed cement; (iii) adding lithium salt during or after stage (ii); (iv) casting the slurry of foamed cement and leaving it to set.

Provided is a gypsum-based board producing apparatus including: a mixer configured to prepare a gypsum slurry; a foaming apparatus; and a pump configured to convey foam generated by the foaming apparatus to the mixer, wherein the pump is a positive displacement pump.

Provided is a gypsum-based board producing apparatus including: a mixer configured to prepare a gypsum slurry; a foaming apparatus; and a pump configured to convey foam generated by the foaming apparatus to the mixer, wherein the pump is a positive displacement pump.

A method of making a composition material comparable to strength with regular concrete but with a lower weight and thermal conductivity is provided. The process includes forming a first composition from a foam admixture of a first cementitious slurry and foam. This first composition is set and then pulverized to a fine dust. The fine dust is then added to a second cementitious slurry, producing a lightweight and insulative composition material for construction applications.

A method of making a composition material comparable to strength with regular concrete but with a lower weight and thermal conductivity is provided. The process includes forming a first composition from a foam admixture of a first cementitious slurry and foam. This first composition is set and then pulverized to a fine dust. The fine dust is then added to a second cementitious slurry, producing a lightweight and insulative composition material for construction applications.

The present invention is concerned with plasterboards including at least two layers A and B of different composition, wherein layer A includes a calcium sulfate binder and a synthetic polymer foam and the layer B includes a calcium sulfate binder and a surfactant foam and wherein the at least one layer A is a surface layer. Improved nail pull resistance can be achieved in lightweight plasterboards, if foamed synthetic polymer is present in a surface layer. The present invention further concerns a method for the production of corresponding products, an apparatus for the production of such products as well as the use of synthetic polymer foam in a surface layer to produce plasterboards with high nail pull resistance at a minimal amount of synthetic polymer.

A method of manufacturing a lightweight thermal insulating cellular cement-based material and a lightweight thermal insulating cellular cement-based board made thereof are disclosed. A binder, an activator, and a blowing agent are mixed to obtain a mixture. The mixture is homogenized to form a cement slurry, which is poured into a mold afterwards. With the help of the activator and an increased temperature of the mold, the cement slurry in the mold will be activated and start foaming and curing to form a cellular cement-based material. The cellular structure is constructed by decomposition of the blowing agent to form a plurality of closed-cell bubbles, which are fixed in the cement slurry during the curing. After the formation, the mold is removed to obtain the cellular cement-based material. The material exhibits high integrity fire resistance and extraordinary insulation fire resistance.

This invention relates to water-resistant gypsum products manufactured with water-based emulsions comprising polymerizable siloxane compound and an anionic polyacrylamide; and methods for making a water-resistant gypsum product, comprising a step of preparing a water-based siloxane emulsion in a turbine emulsifier.