In the present disclosure, a method of forming a gypsum panel is disclosed. The method comprises: providing a first facing material, forming a starch slurry by combining starch and water at a shear rate of 3,000 rpm or more, providing the starch slurry onto the first facing material, depositing a gypsum slurry comprising stucco and water onto the starch slurry on the first facing material, providing a second facing material on the gypsum slurry, and allowing the stucco to convert to calcium sulfate dihydrate.

Disclosed is a composite gypsum board comprising a board core and a concentrated layer of substantial thickness (e.g., at least about 0.02 inches). The concentrated layer includes a higher weight percentage of an enhancing additive than the board core. The board core has a thickness greater than the thickness of the concentrated layer and forms the bulk of the board volume. The concentrated layer has a higher density (e.g., at least about 1.1 times greater) than the density of the board core. Also disclosed is a method of preparing a composite gypsum board.

An artificial stone building tile and method. Disclosed is an artificial stone building tile and a method of making the building tile. The building tile has a low density and significant flexibility, and is nailable without cracking. It is made by layers of cement formulations separated by layers of metal mesh. Color batches of cement are prepared and placed in the bottom of a mold, with the color batches becoming the visible face of the building tile.

A foaming agent for foaming a binder glue or a binding material slurry for producing air pore containing building materials, particularly filling, lightweight construction and insulating materials, consists of the following: a) 0.1 to 65.0 wt. % ionic, preferably anionic, foam-forming surfactant; b) 0.05 to 9.0 wt. %, preferably 1.0 to 7.0 wt. %, particularly preferably 2.0 to 6.0 wt. %, of at least one compound ELF-RG which is solid at room temperature, selected from the group consisting of ethoxylated long-chain fatty alcohols, ethoxylated natural resins, ethoxylated artificial resins and ethoxylated glycols; c) 0 to 9.0 wt. % fatty alcohol having a chain length of C10 to C18, preferably of C12 to C16; d) 0.1 to 60.0 wt. % of solvent selected from the group of vicinal diols having from 1 to 6 carbon atoms, diethylene glycol, triethylene glycol and diethylene glycol ethers; e) 0 to 20 wt. % of organic additives; f) 0 to 20 wt. % of pH regulators; g) from 0 to 99.75 wt. % of water,
wherein the mixture yields a total of 100 wt. %.

Disclosed is a composite gypsum board comprising a board core and a concentrated layer of substantial thickness (e.g., at least about 0.02 inches). The concentrated layer includes a higher weight percentage of an enhancing additive than the board core. The board core has a thickness greater than the thickness of the concentrated layer and forms the bulk of the board volume. The concentrated layer has a higher density (e.g., at least about 1.1 times greater) than the density of the board core. Also disclosed is a method of preparing a composite gypsum board.

Disclosed is a composite gypsum board comprising a hoard core and a concentrated layer of substantial thickness (e.g., at least about 0.02 inches). The concentrated layer includes a higher weight percentage of an enhancing additive than the board core. The board core has a thickness greater than the thickness of the concentrated layer and forms the bulk of the board volume. The concentrated layer has a higher density (e.g., at least about 1.1 times greater) than the density of the board core. Also disclosed is a method of preparing a composite gypsum board.

A cementitious composition, including for the molding of relatively light-weight, heat-insulative, nailable, structural units such as bricks, blocks, roof decking, etc. The composition may include an inorganic cementitious settable admixture within which is incorporated a significant proportion of waste industrial products, such as concrete, blacktop, windmill blades, brick chips, plastics, cordierite, tires, stack dust and/or fly ash, ceramics, clays, metals and plastics. The waste industrial products may be incorporated into the composition in various proportions.

Disclosed are cementitious articles with hydrophobic finish. In some embodiments, the article is a waterproof gypsum panel that is surface reinforced with inorganic mineral fibers that face a flexible and hydrophobic cementitious finish possessing beneficial waterproofing properties. The waterproof gypsum panels of the invention are useful in many applications, such as, for example, tilebacker board in wet or dry areas of buildings, exterior weather barrier panel for use as exterior sheathing, and roof cover board having superior water durability and extremely low surface absorption. The flexible and hydrophobic cementitious finish of the invention can include Class C fly ash, film-forming polymer, silane compound (e.g., alkyl alkoxysilane), and other optional additives.

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.

An artificial stone building tile and method. Disclosed is an artificial stone building tile and a method of making the building tile. The building tile has a low density and significant flexibility, and is nailable without cracking. It is made by layers of cement formulations separated by layers of metal mesh. Color batches of cement are prepared and placed in the bottom of a mold, with the color batches becoming the visible face of the building tile.