Method for making a lightweight gypsum composition with internally generated foam and products made from same

A method comprising:

• filling a cavity with a first foamed gypsum slurry to a first fill vertical distance within the cavity of about 6 inches to about 10 feet, wherein the first foamed gypsum slurry is produced by the method of any one of the preceding claims;
• allowing the first foamed gypsum slurry in the cavity to expand and gain significant green strength harden to create a green foamed gypsum product;
• making a second foamed gypsum slurry according to the method of any one of the preceding claims;
• filling the cavity with the second foamed gypsum slurry on top of the green foamed gypsum product to a second fill vertical distance within the cavity of about 6 inches to about 10 feet;
• and
• allowing the second foamed gypsum slurry in the cavity to expand, harden and dry.

A method comprising:

• filling a cavity with a first foamed gypsum slurry to a first fill vertical distance within the cavity of about 6 inches to about 10 feet;
• allowing the first foamed gypsum slurry in the cavity to expand and gain significant green strength harden to create a green foamed gypsum product;
• making a second foamed gypsum slurry;
• filling the cavity with the second foamed gypsum slurry on top of the green foamed gypsum product to a second fill vertical distance within the cavity of about 6 inches to about 10 feet;
• wherein the first and second foamed gypsum slurries independently comprising water, 50 to 98 wt. % calcium sulfate hemihydrate on a dry basis, 1 to 50 wt. % calcium carbonate on a dry basis, and 0.1 to 10 wt. % cellulose thickener on a dry basis and have 15 to 90 volume percent gas bubbles;
• and
• allowing the second foamed gypsum slurry in the cavity to expand, harden and dry.