Described herein is a composite board and a method of producing a composite board, the board having increased fire endurance. The board comprises a sheet having a thickness greater than about 0.014 inches, and a thermal conductivity of about 0.1 w/(m.k.) or less. The composite board can be part of a
Described herein is a composite board and a method of producing a composite board, the board having increased fire endurance. The board comprises a sheet having a thickness greater than about 0.014 inches, and a thermal conductivity of about 0.1 w/(m.k.) or less. The composite board can be part of a wall assembly comprising two boards defining an interior cavity, the sheet facing the interior cavity.
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1. A composite gypsum board comprising: a core comprising set gypsum formed from at least water and stucco, the core having a substantially flat shape and a generally uniform thickness, the core defining first and second board faces in opposing relation;a sheet disposed in bonding relation along the
1. A composite gypsum board comprising: a core comprising set gypsum formed from at least water and stucco, the core having a substantially flat shape and a generally uniform thickness, the core defining first and second board faces in opposing relation;a sheet disposed in bonding relation along the first board face, the sheet made of a material that has a thickness greater than about 0.014 inches, possesses a thermal conductivity that is less than about 0.1 w/(m.k.), and is applied to a back side of the composite gypsum board; andthe composite gypsum board having a dry weight of less than about 2000 lbs/1000 ft2 when at a thickness of about ⅝ inch. 2. The composite gypsum board of claim 1, wherein the sheet has a thickness from about 0.017 inches to about 0.023 inches. 3. The composite gypsum board of claim 1, wherein the sheet comprises cellulosic fiber. 4. The composite gypsum board of claim 1, wherein the sheet comprises cellulosic fiber, glass fiber, mineral wool, ceramic fiber, or a mixture thereof. 5. The composite gypsum board of claim 1, wherein the sheet further comprises an inorganic compound or a mixture of inorganic compounds with high crystallized water content. 6. The composite gypsum board of claim 5, wherein the inorganic compound is about 0.1% to about 30% by the total weight of the sheet. 7. The composite gypsum board of claim 5, wherein the inorganic compound is aluminum trihydrate. 8. The composite gypsum board of claim 7, wherein an amount of aluminum trihydrate is from about 5% to about 30% by total weight of the sheet. 9. The composite gypsum board of claim 5, wherein the inorganic compound is magnesium hydroxide. 10. The composite gypsum board of claim 1, wherein an additional sheet is laminated on the sheet using an adhesive. 11. The composite gypsum board of claim 1, wherein the composite gypsum board has a dry weight of less than about 1750 lbs/1000 ft2 when at a thickness of about % inch. 12. The composite gypsum board of claim 1, wherein the composite gypsum board has a Fire Endurance Index (FEI) greater than 52 minutes and at least 3 minutes greater than a board comprising at least one cover sheet having a thickness less than about 0.014 inches. 13. The composite gypsum board of claim 1, wherein the composite gypsum board has a Fire Endurance Index (FEI) greater than 52 minutes and at least 4 minutes greater than a board comprising at least one cover sheet having a thickness less than about 0.014 inches. 14. The composite gypsum board of claim 1, wherein the composite gypsum board is built into a test assembly in accordance to UL U305, and has a fire rating of at least about 55 minutes when heated in accordance with the time-temperature curve of ASTM standard E119-09. 15. The composite gypsum board of claim 1, wherein the composite gypsum board is built into a test assembly in accordance to UL U305, and has a fire rating of at least about 60 minutes when heated in accordance with the time-temperature curve of ASTM standard E119-09. 16. The composite gypsum board of claim 1, wherein the composite gypsum board is built into a test assembly in accordance to UL U419 with fiberglass insulation, and has a fire rating of at least about 60 minutes when heated in accordance with the time-temperature curve of ASTM standard E119-09. 17. A method for making a composite gypsum board comprising a core comprising: forming a mixture of at least stucco and water to make stucco slurry,disposing the stucco slurry between two cover sheets and forming a flat, relatively uniform layer to create a continuous board preform,cutting the continuous board preform into the composite gypsum board of predetermined dimensions after the stucco slurry has hardened sufficiently for cutting, anddrying the composite gypsum board;wherein at least one of the two cover sheets has a thickness greater than about 0.014 inches, and a thermal conductivity lower than about 0.1 w/(m.k.);the composite gypsum board having a dry weight of less than about 2000 lbs/1000 ft2 when at a thickness of about ⅝ inch. 18. The method of claim 17, wherein at least one of the two cover sheets comprises cellulosic fiber. 19. The method of claim 17, wherein at least one of the two cover sheets comprises an inorganic compound or a mixture of inorganic compounds. 20. The method of claim 19, wherein the inorganic compound is aluminum trihydrate. 21. A composite gypsum board comprising: a set gypsum core disposed between first and second cover sheets;the second cover sheet having a thickness greater than about 0.014 inches, and a thermal conductivity of about 0.1 w/(m.k.) or less;the composite gypsum board having a dry weight of less than about 2000 lbs/1000 ft2 when at a thickness of about ⅝ inch;such that when the composite gypsum board is disposed in a fire endurance index test apparatus having a heat source and the second cover sheet faces away from the heat source of the fire endurance index test apparatus, a Fire Endurance Index (FEI) of the composite gypsum board is greater than about 50 minutes. 22. A method for making a board, the method comprising: forming a mixture of at least stucco and water to make a slurry,disposing the slurry between two cover sheets to form a board preform,cutting the board preform into a board of predetermined dimensions after the slurry has hardened sufficiently for cutting, anddrying the board;at least one of the two cover sheets having a thickness greater than about 0.014 inches and a thermal conductivity of about 0.1 w/(m.k.) or less;the board having a dry weight of less than about 2000 lbs/1000 ft2 when at a thickness of about ⅝ inch;such that when the board is disposed in a fire endurance index test apparatus having a heat source, and at least one of the two cover sheets having a thickness greater than about 0.014 inches and a thermal conductivity of about 0.1 w/(m.k.) or less faces away from the heat source, the board has a Fire Endurance Index (FEI) greater than about 50 minutes. 23. A wall assembly comprising: a first board comprising a set gypsum core disposed between first and second cover sheets, the first and second cover sheets defining first and second board faces in opposing relation, the second cover sheet having a thickness greater than about 0.014 inches, and a thermal conductivity of about 0.1 w/(m.k.) or less;the first board having a dry weight of less than about 2000 lbs/1000 ft2 when at a thickness of about ⅝ inch;a second board comprising a set gypsum core, the set gypsum core defining third and fourth board faces in opposing relation, the third and fourth board faces each optionally in association with a cover sheet; andthe first and second boards defining an interior cavity of the wall assembly, the interior cavity between the first and second boards such that the second cover sheet faces the interior cavity.
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