SLURRY DISTRIBUTOR, SYSTEM, AND METHOD FOR USING SAME

A slurry distributor includes a feed conduit and a distribution conduit in fluid communication therewith. The feed conduit includes an entry segment with a feed inlet and a feed entry outlet in fluid communication therewith and extending along a first feed flow axis. The feed conduit includes a shaped duct having a bulb portion in fluid communication with the feed entry outlet. The feed conduit includes a transition segment in fluid communication with the bulb portion and extending along a second feed flow axis in non-parallel relationship with the first feed flow axis. The bulb portion has an area of expansion with a cross-sectional flow area that is greater than a cross-sectional flow area of an adjacent area upstream from the area of expansion. The shaped duct has a convex interior surface in confronting relationship with the feed entry outlet of the entry segment. 1. A slurry distributor comprising:a feed conduit including an entry segment with a feed inlet and a feed entry outlet in fluid communication with the feed inlet, the entry segment extending along a first feed flow axis, the feed conduit including a shaped duct having a bulb portion in fluid communication with the feed entry outlet of the entry segment, the feed conduit including a transition segment in fluid communication with the bulb portion, the transition segment extending along a second feed flow axis, the second feed flow axis being in non-parallel relationship with the first feed flow axis; anda distribution conduit extending generally along a longitudinal axis and including an entry portion and a distribution outlet in fluid communication with the entry portion, the entry portion in fluid communication with the feed inlet of the feed conduit, the distribution outlet extending a predetermined distance along a transverse axis, the transverse axis being substantially perpendicular to the longitudinal axis;wherein the bulb portion has an area of expansion with a cross-sectional flow area that is ...

PLASTICIZER DEDUSTING AGENTS FOR JOINT COMPOUNDS

A joint compound including calcium sulfate hemihydrate and/or at least one filler, wherein a total amount of the at least one filler and/or calcium sulfate hemihydrate is at least about 50 wt % of the joint compound on a dry (water-free) basis, preferably the filler comprises calcium carbonate, calcium sulfate dihydrate, or calcium sulfate anhydrite, or a mixture thereof; binder at up to about 15 wt % of the joint compound on a dry basis; polymer thickener at up to about 3 wt % of the joint compound on a dry basis; plasticizer dedusting agent at about 0.01 to about 3 wt % of the joint compound on a dry (water free) basis; and an additive up to about 10 wt % of the joint compound on a dry basis. 21. The joint compound of claim , wherein the plasticizer dedusting agent is about 0.05 to about 2 wt % of the joint compound on a dry (water free) basis.31. The joint compound of claim , wherein the joint compound is drying-type joint compound comprising the filler ,wherein the filler comprises a primary filler at about 50 to about 98 wt % of the joint compound on a dry basis and a secondary filler at 0 to about 25 wt % of the joint compound on a dry basis,wherein the primary filler comprises any of calcium carbonate, calcium sulfate dihydrate, calcium sulfate anhydrite, or a mixture thereof, andwherein the plasticizer dedusting agent is about 0.5 to 3 wt %, of the joint compound on a dry basis.41. The joint compound of claim , wherein the joint compound is drying-type joint compound comprising joint compound components and water ,wherein the joint compound components comprise the filler, the binder, the polymer thickener, the plasticizer dedusting agent, and the additive, the filler comprises a primary filler at about 50 to about 98 wt % of the drying-type joint compound on a dry basis, wherein the primary filler comprises one selected from the group consisting of calcium carbonate, calcium sulfate dihydrate, and calcium sulfate anhydrite, and a mixture thereof;', 'the ...

SHAFTWALL SYSTEM USING FOLDED PANELS, AND PANEL

A panel for a shaftwall system includes a panel body with a core and at least one outer facing layer and an opposite backing surface. A score line is formed in the facing layer, defining two folded panel portions. The panel is folded along the score line to form a folded edge, and the folded panel portions are arranged so that the backing surfaces of the panel portions contact each other. A companion shaftwall building structure system is provided, including a plurality of the panels defining an enclosure, each panel being a ½-inch thick wallboard panel having a “V”-shaped score line defining a pair of panel portions, the score line forms a tapered edge of the folded panel. A plurality of brackets is provided, each bracket defining a panel track dimensioned for slidingly accommodating the folded panel and retaining the panel in place without the use of fasteners. 1. A panel for a shaftwall system , comprising:a panel body with a core and an outer facing layer and a backing surface opposite said facing layer;a score line in said facing layer, defining two folded panel portions;said panel being folded along said score line to form a folded edge, and the folded panel portions arranged so that said backing surfaces of said panel portions are in contact with each other.2. The panel of claim 1 , wherein said score line defines a beveled shape having a general “V”-configuration claim 1 , with a wide end and an opposite narrow end.3. The panel of claim 2 , wherein said score line extends approximately one half a thickness of said panel.4. The panel of claim 3 , wherein a region of said panel between a tip of said score line and said backing surface forms an outer portion of said folded edge.5. The panel of claim 1 , wherein said folded edge defines a generally tapered shape when viewed from the side.6. The panel of claim 1 , wherein said backing surfaces of said panel portions are in contact with each other about a total periphery of said respective portions.7. The panel of ...

ONE HOUR FIRE RATED WOODEN FRAME MEMBERS USING LIGHTWEIGHT GYPSUM WALLBOARD

A combined wooden frame support and ceiling system is provided, each support including upper and lower wooden chords and a wooden structure connecting the lower chord to the upper chord for weight bearing purposes. A gypsum wallboard batten strip is attached to the lower chord, and defining a ledge extending from each side of the lower chord. A single thickness of gypsum wallboard panels is used to create a ceiling attached to the support, each panel used to create the ceiling is made from a slurry composition including less than 5% by weight of Grade 4 vermiculite. Upon the support being assembled in the ceiling system, with a plurality of the supports, and having lengths of insulation supported by the ledges of the adjacent supports, the ceiling system resists charring by fire for at least one hour. 1. A combined wooden frame support with enhanced fire resistance compared to conventional open-web wooden trusses , and a ceiling system including a plurality of said supports mounted in spaced parallel relation to each other , each said support comprising:an upper wooden chord extending along a longitudinal axis;a lower wooden chord disposed below the upper chord and extending along an axis vertically displaced and parallel relative to said longitudinal axis, a wooden structure connecting said lower chord to said upper chord for weight bearing purposes; andat least one gypsum wallboard batten strip attached directly to an underside of said lower chord, said strip being dimensioned to have a width in a range of 6-8 inches to define a ledge extending from each side of said lower chord, such that a space is defined between ledges of adjacent supports, and enhanced fire resistance is provided by said batten strip being attached to said lower chord;said batten strip being a separate component from a single thickness of gypsum wallboard panels used to create a ceiling attached to said support;each said gypsum wallboard panel used to create said ceiling being made from a ...

FIRE RESISTANT GYPSUM BOARD COMPRISING EXPANDABLE GRAPHITE AND RELATED METHODS AND SLURRIES

Disclosed are a gypsum board, and related slurries and methods. The gypsum board comprises a gypsum layer disposed between two cover sheets. The gypsum layer comprises a crystalline matrix of set gypsum and expandable graphite. The expandable graphite exhibits volume expansion at high temperatures. Optionally, unexpanded vermiculite can also be included in the gypsum layer to provide an expansion component at even higher temperatures. Because of synergy between the expandable graphite and unexpanded vermiculite in accordance with some embodiments, less vermiculite can be included in the board than in conventional board that contained vermiculite. The board desirably can pass one or more fire-related tests, and is a fire-rated board in some embodiments. 1. A gypsum board comprising a gypsum layer disposed between two cover sheets , the gypsum layer comprising a crystalline matrix of set gypsum and expandable graphite wherein the gypsum board has a High Temperature Shrinkage (S) of about 10% or less in the z direction when heated to about 1560° F. (850° C.) , according to ASTM C1795-15.2. The gypsum board of claim 1 , wherein the gypsum layer is further formed from an unexpanded vermiculite.3. The gypsum board of claim 2 , wherein the unexpanded vermiculite is present in an amount of from about 0% to about 20% by weight of the stucco.4. The gypsum board of claim 2 , wherein the weight ratio of expandable graphite to unexpanded vermiculite is from about 10:90 to about 70:30.5. The gypsum board of claim 1 , wherein the expandable graphite is present in an amount of from about 0.1% to about 10% by weight of the stucco.6. The gypsum board of claim 1 , wherein the expandable graphite has an expansion onset temperature of from about 250° F. (120° C.) to about 750° F. (400° C.).7. The gypsum board of claim 1 , wherein the expandable graphite has a particle size of from about 5 mesh to about 400 mesh.8. The gypsum board of claim 1 , wherein the expandable graphite has a ...

HIGH SOLIDS, SPRAYABLE SETTING TYPE JOINT COMPOUND

A high solids, sprayable, fast drying, ready-mixed setting-type joint compound comprising a blend of a joint compound mixture comprising: joint compound mixture ingredients comprising: calcium sulfate hemihydrate (e.g. US Gypsum's HYDROCAL C-Base), a chelating agent, and water; and an activator mixture, wherein the activator mixture comprises: activator mixture ingredients comprising: inert filler, set accelerator, and water, wherein a weight ratio of joint compound mixture:activator mixture is 1:1 to 100:1, wherein the activator mixture viscosity is the same as the joint compound mixture viscosity plus or minus 50 percent, and wherein the joint compound has about 55 to about 80 wt. % solids and a viscosity of 2,500-28,000 cps. 1. A sprayable ready-mixed setting-type joint compound comprising a blend of [ about 20 to about 99 wt. % calcium sulfate hemihydrate in an alpha morphological form having blocky cubic crystal microstructure with a D50 average particle size of about 15 to 50 microns, for example 15 to 20 microns or 20 to 50 microns,', 'about 0-4 wt. % thickening agent,', 'about 0-2 wt. % set retarder,', 'about 0.05-5 wt. % chelating agent, wherein the chelating agent is selected from tetra sodium pyrophosphate or tetra potassium pyrophosphate,', 'about 0-2 wt. % preservative,', 'optionally about 0-5 wt. % second chelating agent,', 'optionally about 0-80 wt. % filler, and', 'optionally about 0-5 wt. % binder,, '(a) joint compound mixture ingredients comprising in weight percent on a dry basis, 'and', '(b) joint compound mixture water, wherein weight ratio of the joint compound mixture ingredients to the joint compound mixture water is within a range of 9:1 to 3:2, and, '(A) a joint compound mixture comprising [ inert filler at about 0-95 wt. % of the activator mixture ingredients, set accelerator at about 5-99 wt. % of the activator mixture ingredients,', 'thickening agent at about 0-4 wt. % of the activator mixture ingredients,', 'preservative at about 0-2 wt ...

SETTING TYPE JOINT COMPOUND COMPOSITIONS WITH REDUCED PLASTER

A snap-setting joint compound with reduced calcium sulfate hemihydrate and improved sandability, as well as methods for building wall assemblies and repairing walls with the joint compound. 1. A dry-powder setting-type joint compound , the setting-type joint compound comprising: calcium sulfate hemihydrate in an amount from 28 wt % to 50 wt %; calcium carbonate in an amount such that the total amount of calcium sulfate hemihydrate and calcium carbonate is 80 wt % to 95 wt %; a starch binder; a redispersible latex binder; one or more of kaolin clay , sepiolite , bentonite , montmorillonite clay , attapulgite clay , or any mixture thereof; a rheological modifier; a cellulosic thickener; a set retarder; and a set accelerator.2. The dry-powder setting-type joint compound of claim 1 , wherein calcium sulfate hemihydrate is in the amount from 34 wt % to 46 wt %.3. The dry-powder setting-type joint compound of claim 1 , wherein calcium sulfate hemihydrate does not comprise beta calcium sulfate hemihydrate.4. The dry-powder setting-type joint compound of claim 1 , wherein calcium sulfate hemihydrate does not comprise alpha calcium sulfate hemihydrate.5. The dry-powder setting-type joint compound of claim 1 , wherein the redispersible latex binder includes one or more of the following: vinyl acetate ethylene (VAE) copolymers claim 1 , vinyl acetate/vinyl ester of versatic acid (VAE-VeoVa) copolymers claim 1 , styrene butadiene claim 1 , acrylic powder claim 1 , polyvinyl alcohol claim 1 , or any combination thereof.6. The dry-powder setting-type joint compound of claim 1 , wherein the starch binder is pregelatinized.7. The dry-powder setting-type joint compound of claim 1 , wherein the setting-type joint compound further comprises one or more of the following: perlite claim 1 , resin microspheres claim 1 , hollow microspheres claim 1 , or any combination thereof.8. The dry-powder setting-type joint compound of claim 1 , wherein the setting-type joint compound comprises from ...

FIRE RESISTANT GYPSUM BOARD AND RELATED METHODS

Disclosed are a composite gypsum board and a method of preparing composite gypsum board. The board contains a set gypsum core sandwiched between two cover sheets. The core is formed from a slurry containing stucco, water, and optional ingredients such as foaming agent, accelerator, retarder, polyphosphate, starch, and dispersant, and core intumescent material. The board also contains at least one skim coat and/or hard edges. A face skim coat layer can be included on one side of the core, facing a face cover sheet. A back skim coat layer can be included on the other side of the core, facing a back cover sheet. Hard edges are known in the art and can be formed, e.g., continuously from a stucco slurry for forming the face and/or back skim coats. Preferably, the back skim coat layer and/or the hard edges are formed from a slurry containing stucco, water, skim coat or edge intumescent material (which have the same desired characteristics), and other optional additives as desired. The skim coat or edge intumescent material can be composed of the same material as the core intumescent material, if desired, but the skim coat and/or edge intumescent material is present in a higher relative concentration in its respective slurry than the amount of core intumescent material in the core slurry. Examples of suitable intumescent materials include expandable vermiculite (e.g., No. 4 or No. 5 according to the US naming system, or combinations thereof), expandable graphite, perlite, or any combination thereof. 1. A gypsum board comprising:(a) face and back cover sheets;(b) a board core disposed between the face and back cover sheets, the core comprising set gypsum formed from a core slurry comprising water and stucco;(c) a back skim coat layer defining first and second skim coat faces, the back skim coat formed from a back skim coat slurry comprising water, stucco, and a skim coat intumescent material, the back skim coat disposed in bonding relation to the core, the first face of the ...

Fire resistant gypsum board comprising expandable graphite and related methods and slurries

Disclosed are a gypsum board, and related slurries and methods. The gypsum board comprises a gypsum layer disposed between two cover sheets. The gypsum layer comprises a crystalline matrix of set gypsum and expandable graphite. The expandable graphite exhibits volume expansion at high temperatures. Optionally, unexpanded vermiculite can also be included in the gypsum layer to provide an expansion component at even higher temperatures. Because of synergy between the expandable graphite and unexpanded vermiculite in accordance with some embodiments, less vermiculite can be included in the board than in conventional board that contained vermiculite. The board desirably can pass one or more fire-related tests, and is a fire-rated board in some embodiments.

Slurry distributor, system, and method for using same

Light-weight fast-dry self-leveling cementitious gypsum underlayment with particle fillers

Stucco-cement compositions with a shortened drying time, lighter weight, high strength and reduced expansion, the compositions comprising expanded perlite and preferably also calcium aluminate cement and/or calcium sulfoaluminate cement, and methods for making and using these compositions, including pourable and/or pumpable floor underlayment slurries and methods for forming high strength underlayment on different substrates.

Method of making a sprayable setting type compound

A method of making a setting type compound by injecting an activator compound into a plaster compound wherein the activator compound tube is coaxial and within the plaster compound tube, each at the same flowrate, the same pressure and the same viscosity. The cross sectional transverse areas of an annulus containing the plaster compound and the hole in the annulus containing the activator compound are the same.

Light-weight fast-dry self-leveling cementitious gypsum underlayment with particle fillers

Stucco-cement compositions with a shortened drying time, lighter weight, high strength and reduced expansion, the compositions comprising expanded perlite and preferably also calcium aluminate cement and/or calcium sulfoaluminate cement, and methods for making and using these compositions, including pourable and/or pumpable floor underlayment slurries and methods for forming high strength underlayment on different substrates.

Method of making a sprayable setting type compound

A method of making a setting type compound by injecting an activator compound into a plaster compound wherein the activator compound tube is coaxial and within the plaster compound tube, each at the same flowrate, the same pressure and the same viscosity. The cross sectional transverse areas of an annulus containing the plaster compound and the hole in the annulus containing the activator compound are the same.

Fire resistant gypsum board and related methods

Disclosed are a composite gypsum board and a method of preparing composite gypsum board. The board contains a set gypsum core sandwiched between two cover sheets. The core is formed from a slurry containing stucco, water, and optional ingredients such as foaming agent, accelerator, retarder, polyphosphate, starch, and dispersant, and core intumescent material. The board also contains at least one skim coat and/or hard edges. A face skim coat layer can be included on one side of the core, facing a face cover sheet. A back skim coat layer can be included on the other side of the core, facing a back cover sheet. Hard edges are known in the art and can be formed, e.g., continuously from a stucco slurry for forming the face and/or back skim coats. Preferably, the back skim coat layer and/or the hard edges are formed from a slurry containing stucco, water, skim coat or edge intumescent material (which have the same desired characteristics), and other optional additives as desired. The skim coat or edge intumescent material can be composed of the same material as the core intumescent material, if desired, but the skim coat and/or edge intumescent material is present in a higher relative concentration in its respective slurry than the amount of core intumescent material in the core slurry. Examples of suitable intumescent materials include expandable vermiculite (e.g., No. 4 or No. 5 according to the US naming system, or combinations thereof), expandable graphite, perlite, or any combination thereof.

Composiciones de compuestos para juntas del tipo fraguado con yeso reducido.

Un compuesto para juntas de fraguado instantáneo con sulfato de calcio hemihidrato reducido y capacidad de lijado mejorada, así como también métodos para construir ensamblajes de paredes y reparar paredes con el compuesto para juntas.

Perlite-free, lightweight setting-type joint compound compositions

Perlite-free, lightweight setting-type joint compounds which comprise calcium sulfate hemihydrate with a dry density of less than 50 lb/ft 3 , a foaming agent having a HLB value of at least 10 and preferably comprising an alkylbenzene sulfonic acid having a linear alkyl chain containing 8 to 14 carbons and/or a salt thereof, and a combination of rheology modifiers. Methods for building wallboard assemblies and methods for wall patch and repair projects that include applying the perlite-free, lightweight setting-type joint compounds to a substrate.

Perlite-free, lightweight setting-type joint compound compositions

Perlite-free, lightweight setting-type joint compounds which comprise calcium sulfate hemihydrate with a dry density of less than 50 lb/ft 3 , a foaming agent having a HLB value of at least 10 and preferably comprising an alkylbenzene sulfonic acid having a linear alkyl chain containing 8 to 14 carbons and/or a salt thereof, and a combination of rheology modifiers. Methods for building wallboard assemblies and methods for wall patch and repair projects that include applying the perlite-free, lightweight setting-type joint compounds to a substrate.

Compuesto para juntas de tipo fraguado pulverizable con alto contenido de solidos.

Un compuesto para juntas de tipo fraguado premezclado, de secado rápido, pulverizable, con alto contenido de sólidos que comprende una combinación de una mezcla de compuestos para juntas que comprende: ingredientes de la mezcla de compuestos para juntas que comprenden: hemihidrato de sulfato de calcio (por ejemplo, HYDROCAL C-Base de US Gypsum), un agente quelante y agua; y una mezcla activadora, en donde la mezcla activadora comprende: ingredientes de la mezcla activadora que comprenden: agente de relleno inerte, acelerador de fraguado y agua, en donde una relación en peso de mezcla de compuestos para juntas:mezcla activadora es 1:1 a 100:1, en donde la viscosidad de la mezcla activadora es la misma que la viscosidad de la mezcla de compuestos para juntas más o menos 50 por ciento, y en donde el compuesto para juntas tiene aproximadamente 55 a aproximadamente 80 % en peso de sólidos y una viscosidad de 2500-28,000 ops.

Plasticizer dedusting agents for joint compounds

A joint compound including calcium sulfate hemihydrate and/or at least one filler, wherein a total amount of the at least one filler and/or calcium sulfate hemihydrate is at least about 50 wt % of the joint compound on a dry (water-free) basis, preferably the filler comprises calcium carbonate, calcium sulfate dihydrate, or calcium sulfate anhydrite, or a mixture thereof; binder at up to about 15 wt % of the joint compound on a dry basis; polymer thickener at up to about 3 wt % of the joint compound on a dry basis; plasticizer dedusting agent at about 0.01 to about 3 wt % of the joint compound on a dry (water free) basis; and an additive up to about 10 wt % of the joint compound on a dry basis.

Placa de yeso resistente al fuego y metodos relacionados.

Un panel de yeso que tiene láminas de cubierta frontal y posterior, un núcleo de tablero dispuesto entre las láminas de cubierta frontal y posterior, el núcleo tiene yeso fraguado formado a partir de una lechada de agua y estuco en el núcleo, una capa posterior de capa delgada que define la primera y la segunda cara de capa delgada, la capa de enlucido posterior formada a partir de una suspensión de capa de enlucido posterior de agua, estuco y un material intumescente de capa de enlucido, la capa de enlucido posterior dispuesta en relación de unión con el núcleo, la primera cara de la capa de enlucido mirando hacia la hoja de cubierta posterior, y la segunda cara de la capa de capa delgada que mira hacia el núcleo del panel, y el panel de yeso tiene una contracción a alta temperatura (S) de aproximadamente 10 % o menos en la dirección z cuando se calienta a aproximadamente 1560 °F (850 °C), de acuerdo con ASTM C1795-15.

Fire resistant gypsum board and related methods

A gypsum board having face and back cover sheets, a board core disposed between the face and back cover sheets, the core having set gypsum formed from a core slurry of water and stucco, a back skim coat layer defining first and second skim coat faces, the back skim coat formed from a back skim coat slurry of water, stucco, and a skim coat intumescent material, the back skim coat disposed in bonding relation to the core, the first face of the skim coat layer facing the back cover sheet, and the second face of the skim coat layer facing the board core, and the gypsum board having a High Temperature Shrinkage (S) of about 10% or less in the z direction when heated to about 1560 °F (850 °C), according to ASTM C1795-15.

Perlite-free, lightweight setting-type joint compound compositions

Perlite-free, lightweight setting-type joint compounds which comprise calcium sulfate hemihydrate with a dry density of less than 50 lb/ft3, a foaming agent having a HLB value of at least 10 and preferably comprising an alkylbenzene sulfonic acid having a linear alkyl chain containing 8 to 14 carbons and/or a salt thereof, and a combination of rheology modifiers. Methods for building wallboard assemblies and methods for wall patch and repair projects that include applying the perlite-free, lightweight setting-type joint compounds to a substrate.

Agentes desempolvadores plastificantes para compuestos para juntas.

Un compuesto para juntas que incluye sulfato de calcio hemihidrato y/o al menos un agente de relleno, en donde una cantidad total del al menos un agente de relleno y/o sulfato de calcio hemihidrato es de al menos aproximadamente 50 % en peso del compuesto para juntas en base seca (sin agua), preferiblemente el agente de relleno comprende carbonato de calcio, sulfato de calcio dihidrato o anhidrita de sulfato de calcio, o una mezcla de estos; aglutinante en hasta aproximadamente 15 % en peso del compuesto para juntas en base seca; espesante polimérico en hasta aproximadamente 3 % en peso del compuesto para juntas en base seca; agente desempolvador plastificante en de aproximadamente 0.01 a aproximadamente 3 % en peso del compuesto para juntas en base seca (sin agua); y un aditivo en hasta aproximadamente 10 % en peso del compuesto para juntas en base seca.

High solids, sprayable setting type joint compound

A high solids, sprayable, fast drying, ready-mixed setting-type joint compound comprising a blend of a joint compound mixture comprising: joint compound mixture ingredients comprising: calcium sulfate hemihydrate (e.g. US Gypsum's HYDROCAL C-Base), a chelating agent, and water; and an activator mixture, wherein the activator mixture comprises: activator mixture ingredients comprising: inert filler, set accelerator, and water, wherein a weight ratio of joint compound mixture : activator mixture is 1:1 to 100:1, wherein the activator mixture viscosity is the same as the joint compound mixture viscosity plus or minus 50 percent, and wherein the joint compound has about 55 to about 80 wt. % solids and a viscosity of 2,500-28,000 ops.