Structural fire- and water-resistant panels, and manufacturing methods therefor

A structural, fire-resistant, water-resistant panel, comprising:

• at least one structural layer having structural-strength, fire-resistance, water-resistance properties, the structural layer including a cementitious material that provides the structural-strength and fire-resistance properties and a hydrophobic agent that provides the water-resistance properties;
• a water-resistant layer on the structural layer having water-resistance properties, wherein the water-resistant layer includes a fiber-based carrier layer with an outward-facing surface and an opposite inward-facing surface, wherein the inward-facing surface of the fiber-based carrier layer is uncoated to form an open backer with loose fiber strands extending therefrom, and wherein the loose fiber strands are embedded into the structural layer during curing of the cementitious material to secure the water-resistant layer to the structural layer without using an adhesive;
• and
• a weather barrier including a hydrophobic treatment on the outward-facing surface of the fiber-based carrier layer.

A structural, fire-resistant, water-resistant panel, comprising:

• a core layer having structural-strength and fire-resistance properties, the core layer including a cementitious material and an aggregate material, the cementitious material including magnesium oxide, and the aggregate material including biomaterial, perlite, glass fibers, expanded clay, or a combination thereof, wherein the core layer is structural;
• an intermediate layer having structural-strength, fire-resistance, and water-repellency properties, the intermediate layer including a cementitious material and a hydrophobic additive, the cementitious material including magnesium oxide, and the hydrophobic additive including silicone, siloxane, or another inorganic or polymer-based material;
• a divider layer positioned between the core and intermediate layers to form a physical barrier that prevents cross-migration of the aggregate material and the hydrophobic additive between the between the core and intermediate layers, wherein the divider layer is made of a sheet of non-woven or woven material including a polymer and having a density that prevents passage through it of the aggregate material from the core layer to the intermediate layer to prevent the aggregate material from lessening the water-repellency properties of the intermediate layer and that prevents passage through it of the hydrophobic material from the intermediate layer to the core layer to prevent the hydrophobic additive from lessening the structural-strength properties of the core layer;
• and
• a water-resistant layer providing water-resistance properties and positioned on the intermediate layer opposite the core layer, the water-resistant layer including a fiber-based carrier layer with an outward-facing surface and an opposite inward-facing surface, and the inward-facing surface of the fiber-based carrier layer being uncoated to form an open backer with loose fiber strands extending therefrom, wherein the loose fiber strands are embedded into the intermediate layer during curing of the cementitious material to secure the water-resistant layer to the intermediate layer without using an adhesive, wherein the loose fiber strands are secured to the intermediate layer by the cured cementitious material binding to the strands without using an adhesive.