Gypsum compositions and related methods

A set gypsum composition prepared by a method comprising:

• preparing a mixture formed from at least calcined gypsum and water, wherein the weight ratio of water to calcined gypsum used to prepare the mixture is at least about 4.5:1;
• and
• maintaining the mixture under conditions sufficient for the calcined gypsum to form an interlocking matrix of set gypsum.

A set gypsum composition prepared by a method comprising:

• preparing a mixture formed from at least calcined gypsum, water, and an enhancing material selected from the group consisting of a trimetaphosphate compound, an ammonium polyphosphate having 500-3000 repeating phosphate units, a polycarboxylic compound, a surfactant, and combinations thereof wherein the weight ratio of water to calcined gypsum present in the mixture is at least about 3:1;
• and
• maintaining the mixture under conditions sufficient for the calcined gypsum to form an interlocking matrix of set gypsum.

A set gypsum composition comprising a continuous phase of interlocking set gypsum matrix, the matrix including gypsum and evaporated water voids, wherein the evaporated water voids volume of the matrix is at least about 69% according to the evaporated water voids volume test, and wherein said set gypsum composition is formed from at least water and calcined gypsum comprising at least 30 wt. % of non-fibrous calcined gypsum.

A set gypsum composition comprising:

• a continuous phase of interlocking set gypsum matrix, wherein the matrix includes gypsum and evaporated water voids and wherein the evaporated water voids volume of the matrix is at least about 69% according to the evaporated water voids volume test;
• and
• wherein said set gypsum composition is formed from a mixture comprising calcined gypsum, water, and an enhancing material selected from the group consisting of a trimetaphosphate compound, an ammonium polyphosphate having 500-3000 repeating phosphate units, a polycarboxylic compound, a surfactant, and combinations thereof.

A set gypsum composition comprising a continuous phase of interlocking set gypsum matrix, wherein the matrix includes gypsum and evaporated water voids, and wherein the evaporated water voids volume of the matrix is at least about 80% according to the evaporated water voids volume test.

A method of preparing a set gypsum composition comprising:

• preparing a mixture formed from at least calcined gypsum and water, wherein the ratio of water to calcined gypsum used to prepare the mixture is at least about 4.5:1;
• and
• maintaining the mixture under conditions sufficient for the calcined gypsum to form a set gypsum matrix.

A method of preparing a set gypsum composition comprising:

• preparing a mixture formed from at least calcined gypsum and water, wherein at least 30 wt. % of said calcined gypsum is non-fibrous calcined gypsum, and the ratio of water to calcined gypsum used to prepare the mixture is at least about 3:1;
• and
• maintaining the mixture under conditions sufficient for the calcined gypsum to form a set gypsum matrix.

A method of preparing a set gypsum composition comprising:

• preparing a mixture formed from at least calcined gypsum, water, and an enhancing material selected from the group consisting of a trimetaphosphate compound, an ammonium polyphosphate having 500-3000 repeating phosphate units, a polycarboxylic compound, a surfactant, and combinations thereof, and wherein the ratio of water to calcined gypsum used to prepare the mixture is at least about 3:1;
• and
• maintaining the mixture under conditions sufficient for the calcined gypsum to form a set gypsum matrix.

A set gypsum composition comprising a continuous phase of interlocking set gypsum matrix, wherein the matrix includes gypsum, a trimetaphosphate compound, and evaporated water voids, and wherein the evaporated water voids volume of the matrix is at least about 69% according to the evaporated water voids volume test.