MATERIAL COMPOSITION FOR USE IN CONSTRUCTION AND METHODS OF APPLYING THE SAME
A material composition for use in construction includes calcium sulfate hemihydrate (CSH), calcium carbonate (CC) powder, hydrophobic dispersible polymer, and a retarder comprising modified amino acid. Further, a method of using material composition in one or more construction activities includes adding the material composition to water in a mixer, the material composition comprises calcium sulfate hemihydrate (CSH), calcium carbonate (CC) powder, hydrophobic dispersible polymer, and a retarder comprising modified amino acid. The method further includes blending the material composition with water in the mixer for a predetermined amount of time to produce a jointing compound having a predetermined consistency and workability.
1 . A material composition for use in construction, comprising:
calcium sulfate hemihydrate (CSH);
calcium carbonate (CC) powder;
a hydrophobic dispersible polymer; and
a retarder comprising modified amino acid.
2 . The material composition of claim 1 , wherein the hydrophobic dispersible polymer is based on a flexible terpolymer of vinyl chloride, ethylene, and vinyl laurate.
3 . The material composition of claim 1 , wherein amounts of one or more of: the CSH, the CC powder, the hydrophobic dispersible polymer, and the retarder correspond to a water absorption rate of the material composition, and wherein the water absorption rate corresponds to a ratio of a weight of water absorbed to a weight of the material composition in dry form.
4 . The material composition of claim 3 , wherein the water absorption rate of the material composition is less than 5%.
5 . The material composition of claim 1 , further comprising a silane emulsion coating for application on the surface of the material composition, wherein the silane emulsion coating includes a solventless emulsion based on a mixture of silane and siloxane.
6 . The material composition of claim 5 , wherein the silane emulsion coating is formulated to reduce a capillary water absorption rate of the material composition, and wherein the capillary water absorption rate corresponds to a rate of water absorption into the material composition by capillary suction.
7 . The material composition of claim 5 , wherein the silane emulsion coating includes a water re-dispersible silicone-based water repellent powder mixed with water in a ratio between 1:4 and 1:9.
8 . The material composition of claim 1 , wherein a grain size of the material composition is 75 um or less.
9 . The material composition of claim 1 , further comprising water in an amount such that a flowable consistency of the material composition is within a predetermined range.
10 . The material composition of claim 1 , wherein the material composition is cement-free.
11 . The material composition of claim 1 , wherein the material composition forms one or more of: gypsum board joint filler, interior and exterior ceilings coating, gypsum board lamination, dry and wet interior coating, exterior coating, and a skim coat for concrete, block, and brick wall substrates.
12 . The material composition of claim 1 , wherein:
a quantity of the CSH is between 50%-80% of the material composition by weight;
a quantity of the CC powder is between 20%-50% of the material composition by weight;
a quantity of the hydrophobic dispersible polymer is between 2%-3% of the material composition by weight; and
a quantity of the retarder is between 0.01%-0.011% of the material composition by weight.
13 . A method of using material composition in one or more construction activities, the method comprising:
adding the material composition to water in a mixer, wherein the material composition comprises calcium sulfate hemihydrate (CSH), calcium carbonate (CC) powder, a hydrophobic dispersible polymer, and a retarder comprising modified amino acid; and
blending the material composition with water in the mixer for a predetermined amount of time to produce a jointing compound having a predetermined consistency and workability.
14 . The method of claim 13 , further comprising applying a coat of a predetermined thickness of the jointing compound to a substrate.
15 . The method of claim 14 , wherein the predetermined thickness is 5 mm or less.
16 . The method of claim 13 , further comprising applying a silane emulsion coating on a surface of the jointing compound, wherein the silane emulsion coating includes a solventless emulsion based on a mixture of silane and siloxane.
17 . The method of claim 16 , wherein applying the silane emulsion coating includes mixing a water re-dispersible silicone-based water repellent powder with water in a ratio between 1:4 and 1:9.
18 . The method of claim 13 , wherein amounts of one or more of: the CSH, the CC powder, the hydrophobic dispersible polymer, and the retarder correspond to a water absorption rate of the material composition, and wherein the water absorption rate corresponds to a ratio of a weight of water absorbed to a weight of the material composition in dry form.
19 . The method composition of claim 18 , wherein the water absorption rate of the material composition is less than 5%.
20 . The method of claim 13 , wherein the material composition comprises:
a quantity of the CSH is between 50%-80% of the material composition by weight;
a quantity of the CC powder is between 20%-50% of the material composition by weight;
a quantity of the hydrophobic dispersible polymer is between 2%-3% of the material composition by weight; and
a quantity of the retarder is between 0.01%-0.011% of the material composition by weight.