An impact resistant exterior sheathing gypsum building panel with an integrated impact resistant woven mesh which protects against impact from projectiles such as those conveyed by hurricane force winds is provided. Methods for manufacturing these exterior sheathing gypsum building panels with an integrated impact resistant woven mesh are also provided. An exterior sheathing system employing the exterior sheathing cementitious building panel is provided.

An exterior sheathing cementitious panel which prevents water penetration and air leakage is provided. Methods for manufacturing exterior sheathing cementitious panels with a highly efficient integrated air/water barrier sheet are also provided. An exterior sheathing system employing the exterior sheathing cementitious panel is provided.

A method for making an accessory cladding element for use in architecture and design. The method provides preparing an elastically deformable support element, including a first outer surface, in particular a decorated surface, a second outer surface and a plurality of spacer elements placed between the two surfaces. An impermeable and removable layer is applied on the first outer surface to protect at least a part thereof. Then a fluid cement mixture is prepared and introduced into the support element to obtain a cement-based composite structure in a deformable state. The excess fluid cement mixture is removed from the support element. The cement-based composite structure in the deformable state is positioned in a forming device which gives it the desired shape. The composite structure is solidified and after the removable layer is removed.

A method of installing a binder-based overlay system may include contacting a layer of geotextile fabric to a surface of a substrate and applying a primer layer to a surface of the geotextile fabric. Two or more binder layers including infill particles may be applied over the primer layer. A resurfacer layer followed by one or more color layers may be applied over the two or more binder layers. The primer layer, one or more binder layers, resurfacer layer, and two or more color layers may cure upon application to form a monolithic layer upon the substrate.

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.

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 distributed throughout. Also disclosed herein are air entrainment systems and methods for manufacturing aerated low density fiber cement panels or sheets with consistent air void content and uniform air void distribution. Also disclosed herein are air entrainment technologies adapted to work in conjunction with the Hatschek process to produce aerated fiber cement articles having controlled air void content and distribution.

A method for waterproofing a substrate includes steps of: attaching a separation sheet to the surface of the substrate; and attaching a waterproofing membrane sheet to a surface of the separation sheet by a plurality of adhesive elements having a first and second major adhesive surface, wherein the separation sheet is a non-woven fabric sheet, or an embossed polyolefin membrane sheet and each adhesive element includes an adhesive layer composed of a pressure sensitive adhesive.

Composite panels and methods of use and manufacturing are described herein. The composite panels may comprise a foam composite and one or more layers of a facing material. The foam composite may have a density less than or equal to 20 pcf, and the layer(s) of facing material, e.g., inorganic facing material, may have a thickness of 1/16 inch to 1 inch covering at least the front surface of the foam composite.

A high toughness inorganic composite artificial stone panel and preparation method are disclosed. The panel includes a surface layer, an intermediate metal fiber toughening layer and a substrate toughening layer. The surface layer includes the following components: 40-70 parts of quartz sand, 10-30 parts of quartz powder, 20-45 parts of inorganic active powder, 0.5-4 parts of pigment, 0.3-1 part of water reducer and 3-10 parts of water. The intermediate metal fiber toughening layer includes the following components: 40-60 parts of inorganic active powder, 45-65 parts of sand, 0.8-1.5 parts of water reducer, 6-14 parts of water and 4-8 parts of metal fiber. The substrate toughening layer includes the following components: 30-50 parts of inorganic active powder, 30-55 parts of quartz sand, 15-20 parts of quartz powder, 0.5-1.2 parts of water reducer, 4-8 parts of water and 0.8-2.5 parts of toughening agent.

A process for making a layered multi-material structural element having controlled mechanical failure characteristics. The process includes the steps of: supplying a cementitious layer and forming a polymer layer on the cementitious layer by additive manufacture such that the polymer layer has a first thickness and the cementitious layer has a second thickness, wherein the polymer layer comprises a polymer and the cementitious layer comprises a cementitious material; and allowing the polymer from the polymer layer to suffuse into the cementitious layer for a period of time to obtain a suffused zone in the cementitious layer such that the suffused zone has a third thickness that is less than half the second thickness.