The present invention relates to a process for the manufacture of a cable employing the impregnation of a non-woven fibrous material with a liquid geopolymer composition and the addition of at least one precursor composition of a gel to the liquid geopolymer composition.

Exterior wall structures or roofing decks include an exterior wall or roof frame and lightweight composite sheathing panels fastened thereto by screws, other mechanical fasteners, and/or construction adhesive. Lightweight composite sheathing panels include a foam core and protective layers formed over and covering the foam core. The foam core may include extruded polystyrene (XPS), other polymer foam material, or inorganic foam material. The protective layers may include a fiber mesh reinforced cementitious composition, a thermoset polymer, or other rigid material. Joints between adjacent composite sheathing panels are sealed using sealing tape, polyurethane foam, and/or other sealant Lightweight composite sheathing panels can be fastened to studs or trusses suing screws, nails, adhesives, and other fasteners known in the art. The exterior wall structure or roofing deck is waterproof, fire-resistant, resists water damage, and facilitates application of finishes such as stucco, brick veneers, stone and masonry, shingles, roofing tiles, and metal cladding.

Lightweight composite panels, compositions used to make lightweight composite panels, and methods for manufacturing lightweight composite panels. The lightweight composite panels include a lightweight foam core sandwiched between thin protective layers selected from fiber mesh reinforced cementitious layer and thermoset polymer layer, e.g., polyurea or polyaspartic. The lightweight composite panels can be used in place of conventional wallboards and panels, including for various uses such as interior drywall, backer boards for tile and other interior finishes, including those exposed to moisture, exterior sheathing, floor underlayment, soffits, roofing decks, shaft liners, and the like. The lightweight composite panels can be cut, drilled, and screwed onto structural elements of buildings, such as wall frames comprising wooden or metal studs, roof frames comprising boards, studs, or trusses, floor joists, concrete floors, foundations, and the like. Exterior sheathing panels can include a drainage layer and/or a factory installed finish.

Exterior wall structures include exterior walls and lightweight composite panels to which an exterior finish is applied. Exterior wall structures may include wooden or metal studs to which sheathing (e.g., OSB panels or composite sheathing panels) are fastened. A drainage layer can be positioned between sheathing and lightweight composite panels to which an exterior finish is applied. Lightweight composite panels are fastened to sheathing and/or studs by screws, nails, rivets, other mechanical fasteners, and/or adhesive. Lightweight composite panels can include a polymer foam core with interior and exterior surfaces and fiber mesh reinforced cementitious layers formed over and covering the foam core surfaces. Joints between adjacent lightweight composite panels can be sealed using sealing tape, mesh tape and a seam coat, polyurethane foam, and/or other sealants. The exterior wall structure is waterproof, fire-resistant, and facilitates application of different finishes, such as stucco, tiles, or stone, masonry, or brick veneers.

Lightweight composite building panels with incorporated drainage layer that facilitates moisture removal and methods of manufacturing and using lightweight composite building panels with incorporated drainage layer. The lightweight composite building panels with incorporated drainage layer can be used to applied a desired finish to exterior wall and roof structures. The lightweight composite building panels include a core composite panel structure and a drainage layer attached or bonded thereto. The core composite panel structure includes a foam core sandwiched between first and second protective layers, such as a fiber mesh reinforced cementitious composition and/or cured thermoset resin or other rigid material. The drainage layer is designed to face an exterior wall or roof structure to facilitate removal of moisture between the panels and underlying wall or roof structure. The building panels can be cut, drilled, and screwed, nailed, or glued to structural elements of buildings, such as OSB sheathing.

Composite plaster panels, compositions used to make composite plaster panels, and methods for manufacturing composite plaster panels. Composite plaster panels include a core composite panel structure and a plaster layer applied to and at least partially covering at least one side of the core composite panel structure. The core composite panel structure includes a foam core sandwiched between thin protective layers (e.g., fiber mesh reinforced cementitious layer or thermoset polymer layer). The plaster layer includes reaction products of water, Portland cement, preferably, white cement, calcium carbonate, aluminum oxide, silicon dioxide, cellulose ether, and latex. The composite plaster panels can be used to replace gypsum drywall panels and are advantageously lighter weight, have beveled edges, and can have a smooth or textured plastic layer. The composite plaster panels can be cut, drilled, and screwed onto structural elements of buildings, such as wall frames comprising wooden or metal studs or ceiling joists.

A continuous process of forming a magnesium oxide-based product. The process includes preparing a feedstock, transferring the feedstock to a continuous curing process occurring at elevated temperatures and pressures, and drying the product of the continuous curing process. The process can further include lamination processes occurring after drying or in conjunction with curing. The continuous process reduces costs and times associated with traditional processes.

The present invention is directed to a method of making such gypsum panel. For instance, the method comprises: providing a first facing material; providing a gypsum slurry including calcium sulfate hemihydrate, water, and a silicon containing compound onto the first facing material; providing a second facing material onto the gypsum slurry to form a continuous gypsum sheet; allowing the calcium sulfate hemihydrate to hydrate to form calcium sulfate dihydrate; cutting the continuous gypsum sheet to form a gypsum panel; supplying the gypsum panel to a heating or drying device; and providing a gaseous mixture from the heating or drying device to a regenerative thermal oxidizer.

A board consisting at least of a substrate formed at least of a gypsum-based and/or cement-based basic material layer. The board is provided with a chamfer extending through the basic material layer.

The invention relates to a potting paste composition for honeycomb reinforcement having improved fire retardancy characteristics. The potting paste composition comprises (a) a curable polymer; (b) a curing agent for the curable polymer; (c) a fire retardant comprising an ammonium polyphosphate in combination with an ingredient selected from the group consisting of metal hydroxides, expandable graphites, liquid phosphate esters, phosphorous organic compounds or salts thereof, and zeolites; and (d) a filler selected from the group consisting of polymeric microspheres, hollow glass microspheres, and thixotropic fillers; wherein the potting paste has an uncured density determined by the method according to EN ISO 1183 of not more than 0.7100 g/cm.sup.3, preferably of at most 0.680 g/cm.sup.3, more preferably of at most 0.673 g/cm.sup.3, still more preferably of at most 0.660 g/cm.sup.3, even more preferably of at most 0.658 g/cm.sup.3, yet more preferably of at most 0.653 g/cm.sup.3 and in particular of at most 0.620 g/cm.sup.3; and wherein the total content of the fire retardant is at least 5.0 wt.-%, preferably at least 10 wt.-%, more preferably at least 15 wt.-%, relative to the total weight of the potting paste composition.