Low embodied energy wallboards and methods of making same

A wallboard with a size of at least 16 square feet with an outer layer of paper on at least 1 side, comprising:

• a binder of one or more of magnesium oxide (MgO,) calcium oxide, calcium hydroxide, iron oxide (Hematite or Magnetite);
• one or more alkali phosphate salts selected from the group consisting of sodium phosphate, potassium phosphate, monopotassium phosphate, tripotassium phosphate, triple super phosphate or dipotassium phosphate;
• and
• water less than or equal to approximately 50% by weight of the wallboard.

A wallboard with a size of at least 16 square feet, with an average thickness between 0.1″ and 1.0″, comprising:

• a binder of one or more of magnesium oxide (MgO,) calcium oxide, calcium hydroxide, iron oxide (hematite or magnetite);
• one or more alkali phosphate salts selected from the group consisting of sodium phosphate, potassium phosphate, monopotassium phosphate, tripotassium phosphate, triple super phosphate or dipotassium phosphate);
• water equal to or less than approximately 50% by weight of the wallboard;
• and;
• an outer layer of paper on at least one (1) side of the wallboard.

A wallboard with a size of at least 16 square feet, with an average thickness between 0.1″ and 1.0″, comprising:

• a binder comprising one or more of magnesium oxide (MgO,) calcium oxide, calcium hydroxide, iron oxide (hematite or magnetite);
• alkali phosphate salt or salts selected from the group consisting of sodium phosphate, potassium phosphate, monopotassium phosphate, tripotassium phosphate, triple super phosphate or dipotassium phosphate;
• water less than 50% by weight of the initial slurry;
• and
• an outer layer of fiberglass matt on at least one (1) side.

A wallboard with a size of at least 16 square feet, with an average thickness between 0.1″ and 1.0″ comprising:

• a binder of one or more of magnesium oxide (MgO,) calcium oxide, calcium hydroxide, iron oxide (hematite or magnetite);
• an alkali phosphate salt;
• a filler of calcium carbonate where said calcium carbonate makes up greater than 30% of the weight of the wallboard, and;
• an outer layer of paper on at least one (1) side.

A method of fabricating a wallboard, comprising:

• forming a slurry comprising:
• a binder comprising one or more of magnesium oxide (MgO,) calcium oxide, calcium hydroxide and iron oxide (hematite or magnetite);
• and
• at least one alkali phosphate salt;
• and
• allowing the slurry to set.