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 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,
wherein the gypsum panel passes a hydrostatic head test against water leakage, as measured by AATCC 127-2008,
wherein the gypsum core 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 from about 88 pcf to about 98 pcf, and
wherein the gypsum core comprises a second gypsum layer having a slurry density of from 76 pcf to 93 pcf.
2. The gypsum panel of claim 1 , wherein the first gypsum layer is 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 to from about 30 dyne/cm to about 55 dyne/cm.
3. The gypsum panel 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 gypsum panel of claim 1 , wherein the continuous barrier coating comprises a polymer binder and at least one inorganic filler.
5. The gypsum panel of claim 1 , wherein the gypsum panel has a water vapor permeance of at least 10 inch-pound units, as measured by ASTM E96 wet cup method.
6. The gypsum panel of claim 1 , wherein the gypsum panel has a water vapor permeance of at least 30-inch pound units, as measured by ASTM E96 wet cup method.
7. The gypsum panel of claim 1 , wherein the gypsum panel has a Type X designation, when measured according to ASTM E119.
8. The gypsum panel of claim 1 , wherein the gypsum panel has a level 0 flame spread index and smoke develop index, when measured according to ASTM E84.
9. The gypsum panel of claim 1 , wherein the continuous barrier boating comprises a binder material.
10. The gypsum panel of claim 1 , wherein no surfactant is present in the continuous barrier coating.