Wallboards are produced by methods which use significantly reduced embodied energy, generating far less greenhouse gases when compared with the energy used to fabricate gypsum wallboard. Invented are:
A wallboard comprising:
- greater than 50% w/w of post-industrial waste products, wherein the post-industrial waste products is expanded perlite by-product; and
- at least one pH modifier.
A method of fabricating a wallboard, comprising:
- forming a dry mix comprising
(i) greater than about 50% w/w of post-industrial waste products, wherein the post-industrial waste products is expanded perlite by-product and
(ii) at least one pH modifier selected from the group consisting of calcium oxide, magnesium oxide, potassium hydroxide, sodium hydroxide, calcium hydroxide, calcium carbonate, potassium carbonate, sodium carbonate, sodium sesquicarbonate, sodium silicate, calcium silicate, magnesium silicate and calcium aluminate;
- adding water to said dry mix to form an initial slurry in a slurry line; and
- allowing the initial slurry to set.
The products include less than approximately 1% gypsum content.