Gypsum panels, systems, and methods
Gypsum panels, sheathing systems, and methods of making and using the same are provided. A gypsum panel includes a gypsum core associated with a first fiberglass mat having a continuous barrier coating, the coating penetrating a portion of the first fiberglass mat opposite the gypsum core, wherein gypsum penetrates a remaining fibrous portion of the first fiberglass mat such that voids in the first fiberglass mat are substantially eliminated. A building sheathing system includes at least two gypsum panels and a seaming component to provide a seam at an interface between the gypsum panels.
1. A method of constructing a building sheathing system, comprising:
installing at least two gypsum panels having an interface therebetween to form an external building sheathing; and
applying a seaming component at the interface between the at least two gypsum panels,
wherein, in the absence of any externally applied barrier product, other than the seaming component:
the system passes a hydrostatic head test against water leakage, as measured by AATCC 127-2008,
the system displays no water leaks when measured according to ICC Evaluation Service Acceptance Criteria 212,
the system passes ICC Evaluation Service Acceptance Criteria 310, and/or
the system displays no water leaks when measured according to ASTM E331 wall assembly test,
wherein the at least two gypsum panels each comprise a gypsum core associated with a first fiberglass mat having a continuous barrier coating that comprises a plurality of pin holes that provide for water vapor transmission across the coating, the coating penetrating a portion of the first fiberglass mat opposite the gypsum core, wherein gypsum of the gypsum core penetrates a remaining fibrous portion of the first fiberglass mat such that voids in the first fiberglass mat are substantially eliminated, and
wherein the gypsum core of each gypsum panel comprises a first gypsum layer that at least partially penetrates the remaining fibrous portion of the first fiberglass mat, the first gypsum layer being formed by a gypsum slurry that comprises a wetting agent in an amount effective to bring a slurry surface tension of the first gypsum layer from about 30 dyne/cm to about 55 dyne/cm.
2. The method of claim 1 , wherein the gypsum core of each gypsum panel comprises a first gypsum layer that at least partially penetrates the remaining fibrous portion of the first fiberglass mat, the first gypsum layer having a slurry density of about 88 pcf to about 98 pcf.
3. The method of claim 1 , wherein the first gypsum layer is present in an amount from about 5 percent to about 20 percent, by weight, of the gypsum core.
4. The method of claim 1 , wherein the seaming component comprises tape or a bonding material.
5. The method of claim 4 , wherein the seaming component comprises a bonding material selected from the group consisting of synthetic stucco plasters, cement plasters, synthetic acrylics, sand-filled acrylics, solvent-based acrylics, solvent-based butyls, polysulfides, polyurethanes, silicones, silyl-modified polymers, water-based latexes, EVA latexes, and acrylic latexes.
6. The method of claim 1 , wherein the system passes AATCC hydrostatic head test method 127-2008 for a 22-inch head of water directly over the seaming component at the interface between the at least two gypsum panels, with no leaks after 5 hours.
7. The method of claim 1 , wherein the system has a water vapor permeance of at least 20 inch-pound units, as measured by ASTM E96 wet cup method.
8. The method of claim 1 , wherein the system displays an air leakage rate of less than 0.04 cfm/ft 2 at 1.57 lbs/ft 2 , when measured according to ASTM E2357.
9. The method of claim 1 , wherein the system is substantially free of any externally-applied fabric membrane, liquid coating, or self-adhered membrane.
10. A method of constructing a building sheathing system, comprising:
installing at least two gypsum panels having an interface therebetween to form an external building sheathing, each gypsum panel comprising a gypsum core associated with a first fiberglass mat having a continuous barrier coating that comprises a plurality of pin holes that provide for water vapor transmission across the coating, the coating penetrating a portion of the first fiberglass mat opposite the gypsum core, wherein gypsum of the gypsum core penetrates a remaining fibrous portion of the first fiberglass mat such that voids in the first fiberglass mat are substantially eliminated; and
applying a seaming component at the interface between the at least two gypsum panels,
wherein the system is substantially free of any externally-applied fabric membrane, liquid coating, or self-adhered membrane, and
wherein the gypsum core of each gypsum panel comprises a first gypsum layer that at least partially penetrates the remaining fibrous portion of the first fiberglass mat, the first gypsum layer being formed by a gypsum slurry that comprises a wetting agent in an amount effective to bring a slurry surface tension of the first gypsum layer from about 30 dyne/cm to about 55 dyne/cm.
11. The method of claim 10 , wherein the gypsum core of each gypsum panel comprises a first gypsum layer that at least partially penetrates the remaining fibrous portion of the first fiberglass mat, the first gypsum layer having a slurry density of about 88 pcf to about 98 pcf.
12. The method of claim 10 , wherein the first gypsum layer is present in an amount from about 5 percent to about 20 percent, by weight, of the gypsum core.
13. The method of claim 10 , wherein the seaming component comprises tape or a bonding material.
14. The method of claim 13 , wherein the seaming component comprises a bonding material selected from the group consisting of synthetic stucco plasters, cement plasters, synthetic acrylics, sand-filled acrylics, solvent-based acrylics, solvent-based butyls, polysulfides, polyurethanes, silicones, silyl-modified polymers, water-based latexes, EVA latexes, and acrylic latexes.
15. The method of claim 10 , wherein the system passes AATCC hydrostatic head test method 127-2008 for a 22-inch head of water directly over the seaming component at the interface between the at least two gypsum panels, with no leaks after 5 hours.
16. The method of claim 10 , wherein the system has a water vapor permeance of at least 20 inch-pound units, as measured by ASTM E96 wet cup method.
17. The method of claim 10 , wherein the system displays an air leakage rate of less than 0.04 cfm/ft 2 at 1.57 lbs/ft 2 , when measured according to ASTM E2357.