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Abstract

A method of making a foamed building board or the like from the following components: (a) a major amount by weight of an inorganic base material selected from the group consisting of a calcium sulphate hemi-hydrate, magnesium oxychloride, magnesium oxysulphate and a hydraulic cement; (b) a suitable amount by weight of the inorganic base material of a thermosetting resin which is miscible, soluble or dispersable in water; (c) a suitable amount of a catalyst for the thermosetting resin; (d) water in an amount sufficient to rehydrate the inorganic base material with the water present in the other components; (e) a suitable amount of a plasticizer such as a melamine formaldehyde condensate; (f) a suitable amount of a polyvinyl alcohol; (g) a suitable amount of a retarder for the setting time of the inorganic base material; (h) a suitable amount of a fibrous reinforcing material; and (i) a suitable amount by weight of a foam or a foaming agent; which comprises the steps of: (1) mixing together components (a), (b), (c), (d), (e), (f) and (g); (2) adding component (h) into the mixture of step (1); (3) adding component (i) into the mixture of step (2) with stirring to give a foamed product; (4) forming the product of step (3) into a building: board; and (5) allowing rehydration of the inorganic base material to occur and curing of the thermosetting resin to occur.

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