High temperature sag resistant gypsum panel
A fire-resistant gypsum panel comprises: a gypsum core layer comprising set gypsum and a high temperature sag-resistant material including mineral wool in an amount between 0.2% and 3.0% by weight of gypsum.
1. A fire-resistant gypsum panel comprising:
a gypsum core layer comprising set gypsum and mineral wool in an amount of between greater than 0.9% and less than or equal to and 3.0% by weight of stucco, wherein the mineral wool includes spun or drawn mineral rock material, and wherein the gypsum panel at a temperature of 1600° F. has a sag reduction of at least 10% compared to a gypsum panel that includes glass fiber in place of the mineral wool but is otherwise likewise configured.
2. The gypsum panel of claim 1 , further comprising:
a facing material.
3. The gypsum panel of claim 1 , wherein the gypsum core further comprises a shrinkage-resistant material.
4. The gypsum panel of claim 1 , wherein the gypsum core further comprises one or more of a starch, a binder, a set accelerator, a dispersant, a set retarder, or a reinforcing fiber.
5. The gypsum panel of claim 1 , wherein the gypsum core has a chloride level of 300 ppm or greater.
6. The gypsum panel of claim 1 , wherein the gypsum core does not include glass fiber.
7. The gypsum panel of claim 1 , wherein the set gypsum core has a density between about 15 pcf and about 60 pcf.
8. The gypsum panel of claim 1 , wherein the gypsum panel comprises ceiling board, wallboard, or surface board.
9. A set gypsum core for a gypsum panel comprising:
a. set gypsum; and
b. a mineral wool in an amount greater than 0.9% and less than or equal to 3.0% by weight of the stucco, wherein the mineral wool includes spun or drawn mineral rock material,
wherein the gypsum panel at a temperature of 1600° F. has a sag reduction of at least 10% compared to a gypsum panel that includes glass fiber in place of the mineral wool but is otherwise likewise configured.
10. The set gypsum core of claim 9 , further comprising:
a shrinkage-resistant material.
11. The set gypsum core of claim 9 , wherein the gypsum core does not include glass fiber.
12. The set gypsum core of claim 9 , wherein the gypsum core has a chloride level of 300 ppm or greater.
13. A composition for forming a gypsum core for a gypsum panel comprising:
a. water;
b. stucco; and
c. mineral wool in an amount greater than 0.9% and less than or equal to and 3.0% by weight of the stucco, wherein the mineral wool includes spun or drawn mineral rock material;
wherein the gypsum panel at a temperature at 1600° F. has a sag reduction of at least 10% compared to a gypsum panel that includes glass fiber in place of the mineral wool but is otherwise likewise configured.
14. The composition of claim 13 , further comprising:
a shrinkage-resistant material.
15. The composition of claim 13 , further comprising:
a starch.
16. The composition of claim 13 , wherein the composition does not include glass fiber.
17. The set gypsum core of claim 16 , wherein the gypsum panel is a ceiling board.
18. The composition of claim 13 , wherein the gypsum panel is a ceiling board.
19. The composition of claim 13 , wherein the gypsum core has a chloride level of 300 ppm or greater.
20. A method for making a gypsum panel comprising:
a. preparing a slurry comprising water, stucco, and mineral wool in an amount greater than 0.9% and less than or equal to 3.0% by weight of the stucco, and wherein the mineral wool includes spun or drawn mineral rock material;
b. combining the prepared slurry with aqueous foam to provide an air-foamed slurry;
c. forming a gypsum core from the air-foamed slurry;
d. allowing the formed gypsum core to set; and
e. drying the gypsum core,
wherein the gypsum panel at a temperature at 1600° F. has a sag reduction of at least 10% compared to a gypsum panel that includes glass fiber in place of the mineral wool but is otherwise likewise configured.
21. The method of claim 20 , wherein the slurry further comprises a shrinkage-resistant material.
22. The method of claim 20 , wherein said forming a gypsum core comprises depositing the air-foamed slurry over a facing material.
23. The method of claim 20 , further comprising:
providing a facing material over the deposited air-foamed slurry.
24. The method of claim 20 , further comprising:
forming a densified layer on the gypsum core; and
providing the facing material over the densified layer.
25. The method of claim 20 , further comprising:
cutting the gypsum core into one or more panels.
26. The method of claim 25 , wherein the gypsum panels comprise ceiling boards, wallboards, or surface boards.
27. The method of claim 20 , further comprising:
applying the gypsum panel to a ceiling of a structure.
28. The method of claim 20 , wherein the gypsum core has a chloride level of 300 ppm or greater.