High solids, sprayable setting type joint compound

A sprayable ready-mixed setting-type joint compound comprising a blend of

• (A) a joint compound mixture comprising:
• (a) joint compound mixture ingredients comprising in weight percent on a dry basis:
• about 75 to about 99 wt. % calcium sulfate hemihydrate in an alpha morphological form having blocky cubic crystal microstructure with a D50 average particle size of about 15 to 50 microns, and
• said calcium sulfate hemihydrate having a consistency of 31-36 cc water per 100 g said calcium sulfate hemihydrate,
• about 0-4 wt. % thickening agent,
• about 0-2 wt. % set retarder,
• about 0.05-5 wt. % chelating agent, wherein the chelating agent is selected from tetra sodium pyrophosphate or tetra potassium pyrophosphate,
• about 0-2 wt. % preservative,
• optionally about 0-5 wt. % second chelating agent,
• optionally about 0-80 wt. % filler, and
• optionally about 0-5 wt. % binder, and
• (b) joint compound mixture water, wherein weight ratio of the joint compound mixture ingredients to the joint compound mixture water is within a range of 3:1 to 1.5, and
• (B) an activator mixture, wherein the activator mixture comprises:
• (a) activator mixture ingredients comprising in weight percent on a dry basis:
• inert filler, wherein the inert filler comprises calcium carbonate at about 50 to 95 wt. % of the activator mixture ingredients,
• set accelerator at 5-50 wt. % of the activator mixture ingredients,
• thickening agent at about 0-4 wt. % of the activator mixture ingredients,
• preservative at about 0-2 wt. % of the activator mixture ingredients, and
• (b) activator mixture water, wherein weight ratio of the activator mixture ingredients to the activator mixture water is within a range of 3:1 to 1.5:1,
• wherein the composition has an absence of Portland cement,
• wherein a weight ratio of joint compound mixture:activator mixture is 1:1 to 10:1,
• wherein the activator mixture viscosity is the same as the joint compound mixture viscosity plus or minus 20%,
• wherein the joint compound mixture viscosity is 2,500-5600 cps,
• wherein the activator mixture viscosity is 2,500-5600 cps,
• wherein the joint compound viscosity is between 2,500-5600 cps, and
• wherein the joint compound mixture has about 60 to about 88 wt. % solids,
• wherein the activator mixture has about 60 to about 88 wt. % solids, and
• wherein the sprayable ready-mixed setting-type joint compound has a spray viscosity which is substantially the same as the joint compound mixture viscosity.