Abstract:
A ready-mixed composition, which sets when mixed with an activator for the reaction of calcined gypsum with water to form set gypsum, is disclosed. The composition comprises water and calcined gypsum in a weight ratio of water to calcined gypsum of from about 0.15 to about 0.5, as well as a set preventer comprising a polyacrylic acid and/or a salt thereof. The composition has a viscosity of from about 5,000 centipoise to about 48,000 centipoise. Also disclosed is a kit that comprises separately packaged components. One of the components is a composition comprising calcined gypsum and a polyacrylic acid and/or a salt thereof, and, optionally, water. Another component of the kit comprises an activator which, when mixed with the composition, permits the composition to set.
Abstract:
An about 5/8 inch to 3/4 inch thick low weight, low density gypsum panel with fire resistance capabilities sufficient to provide a Thermal Insulation Index of at least 17.0 minutes which when subjected to U419 test procedures will not fail for at least 30 minutes and, in selected embodiments, also has outstanding water resistance properties.
Abstract:
A method of continuously forming a multilayer panel includes making a gypsum slurry, then dividing the gypsum slurry into at least a primary gypsum slurry and a secondary gypsum slurry. An additive slurry having water and an intumescent material is created, then added to the secondary gypsum slurry to make an expandable layer slurry that is spread over at least a portion of a facing material. The primary gypsum slurry is distributed over the secondary gypsum slurry over the facing material and the expanding layer slurry to form a core. Optionally, another layer, an edge coating, is applied to the expanding layer for additional fire protection. The edge coating includes a second intumescent material. During a fire, the expanding layer expands to increase the thickness of the fire exposed gypsum panel and the edge coating expands to seal the gap between adjoining gypsum panels.
Abstract:
A composition and method for treating a set gypsum-containing material are disclosed. The composition is formed from at least water at least one trimetaphosphate salt, at least one monobasic phosphate salt, and at least one acyclic polyphosphate salt having at least three phosphate units. The method comprises applying to a set gypsum material at least two of the following inorganic phosphates: at least one monobasic phosphate salt, at least one trimetaphosphate salt, and at least one acyclic polyphosphate salt having at least three phosphate units. The method can be for inhibiting re-calcination of a set gypsum containing material, and/or for enhancing the strength, surface hardness, paintability, abrasion resistance, and/or water erosion resistance of a set gypsum-containing material. Also disclosed is a method of making a set gypsum-containing material.
Abstract:
The invention generally provides gypsum-containing slurries including stucco, naphthalenesulfonate dispersant, and pregelatinized starch. The naphthalenesulfonate dispersant is present in an amount of about 0.1% - 3.0% by weight based on the weight of dry stucco. The pregelatinized starch is present in an amount of at least about 0.5% by weight up to about 10% by weight of pregelatinized starch by weight based on the weight of dry stucco in the formulation. Other slurry additives can include trimetaphosphate salts, accelerators, binders, paper fiber, glass fiber, and other known ingredients. The invention also comprises the gypsum-containing products made with such slurries, for example, gypsum wallboard, and a method of making gypsum wallboard.
Abstract:
A composition comprising a mixture of a calcium sulfate material, water, and a tetrametaphosphate compound is disclosed. Desirably, the inclusion of the tetrametaphosphate compound (e.g., salt or ion) in a pre-set treatment of a calcium sulfate material enhances the resistance to permanent deformation (e.g., sag), dimensional stability, and/or compressive strength of the composition while also preferably avoiding any significant retardive effect on the rate of hydration of calcined gypsum to calcium sulfate dihydrate. A set gypsum-containing product and a method for producing a set gypsum-containing product having increased resistance to permanent deformation are also disclosed.