Formation of cementitious board with lightweight aggregate

1. A process for the formation of highly durable cementitious board using lightweight aggregate, the process comprising:

pouring a core mix onto a conveyor, wherein the core mix is comprised of:

a lightweight aggregate filler in an amount of 0.5 to 5 weight percent of the core mix, the lightweight aggregate filler comprising a first plurality of expanded closed-cell polystyrene beads at a first quantity having an expanded diameter of 0.030 inches to 0.080 inches and a second plurality of expanded closed-cell polystyrene beads at a second quantity having an expanded diameter of 0.100 inches to 0.130 inches, the second quantity being between 25 percent and 50 percent of the first quantity;

one or more binders in an amount of 35 to 75 weight percent of the core mix;

rheological admixture in an amount of about 0.5 to 5 weight percent of the core mix;

surfactant in an amount of 0 to 0.1 weight percent of the core mix;

one or more normal weight aggregate filler in an amount of 5 to 50 weight percent of the core mix, the one or more normal weight aggregate filler being a single use or a combination use of sand, stone, crushed stone, limestone, shale, clay, recycled concrete, and granite; and

water in an amount of 5 to 20 weight percent of the core mix;

passing the core mix under a screed roller to flatten the core mix to produce an extruding board with a desired thickness;

wherein a forming wire is adjacent to the screed roller, the forming wire having a predetermined diameter such that it prevents accumulation of the core mix on the screed roller and wherein the forming wire is located above the extruding board such that it assists in smoothing the extruding board.

2. The process of claim 1 , wherein the forming wire is made of steel.

3. The process of claim 1 , wherein the forming wire has the predetermined diameter between 0.020 inches to 0.030 inches.

4. The process of claim 1 , wherein the conveyor has a conveying direction and the forming wire is zero to two inches downstream on the conveyor of the screed roller in the conveying direction.

5. The process of claim 1 , wherein the forming wire touches the screed roller.

6. A process for the formation of highly durable cementitious board using lightweight aggregate, the process comprising:

pouring a core mix onto a conveyor, wherein the core mix is comprised of a plurality of lightweight aggregate filler in an amount of 0.5 to 5 weight percent of the core mix, the plurality of lightweight aggregate filler comprising a first plurality of expanded closed-cell polystyrene beads at a first quantity having an expanded diameter of 0.030 inches to 0.080 inches and a second plurality of expanded closed-cell polystyrene beads at a second quantity having an expanded diameter of 0.100 inches to 0.130 inches, the second quantity being between 25 percent and 50 percent of the first quantity;

passing the core mix under a screed roller to flatten the core mix to produce an extruding board with a desired thickness;

wherein a forming wire is adjacent to the screed roller, the forming wire having a predetermined diameter such that it prevents accumulation of the core mix on the screed roller and wherein the forming wire is located above the extruding board such that it assists in smoothing the extruding board.

7. The process of claim 6 , wherein the forming wire is made of steel.

8. The process of claim 7 , wherein the forming wire has the predetermined diameter between 0.020 inches to 0.040 inches.

9. The process of claim 8 , wherein the conveyor has a conveying direction and the forming wire is between zero to two inches downstream of the screed roller in the conveying direction.

10. The process of claim 9 , wherein the forming wire touches the screed roller.

11. A process for the formation of highly durable cementitious board using lightweight aggregate, the process comprising:

pouring a core mix onto a conveyor, wherein the core mix is comprised of:

a plurality of lightweight aggregate filler in an amount of 0.5 to 5 weight percent of the core mix, the plurality of lightweight aggregate filler comprising a first plurality of expanded closed-cell polystyrene beads at a first quantity having an expanded diameter of 0.030 inches to 0.080 inches and a second plurality of expanded closed-cell polystyrene beads at a second quantity having an expanded diameter of 0.100 inches to 0.130 inches, the second quantity being between 25 percent and 50 percent of the first quantity;

one or more binders in an amount of 35 to 75 weight percent of the core mix; rheological admixture in an amount of about 0.5 to 5 weight percent of the core surfactant in an amount of 0 to 0.1 weight percent of the core mix;

one or more normal weight aggregate filler in an amount of 5 to 50 weight percent of the core mix, the one or more normal weight aggregate filler being a single use or a combination use of sand, stone, crushed stone, limestone, shale, clay, recycled concrete, and granite; and

water in an amount of 5 to 20 weight percent of the core mix;

passing the core mix under a screed roller to flatten the core mix to produce an extruding board with a desired thickness;

wherein a rotating rod is adjacent to the screed roller on a downstream side thereof having a desired thickness such that it prevents accumulation of the core mix on the screed roller by rolling with the screed roller wherein the diameter of the rotating rod is smaller than the diameter of the screed roller.