Fiber-cement/gypsum laminate composite building material

Abstract

A building material ( 40 ) is provided comprising fiber-cement ( 10 ) laminated to gypsum ( 20 ) to form a single piece laminate composite. This single piece laminate composite exhibits improved fire resistance and surface abuse and impact resistance, but achieves these properties without the excessive weight and thickness of two piece systems. Additionally, because of the reduced thickness, the preferred laminate building material is easier to cut and is quicker and easier to install than two piece systems. Furthermore, forming the fiber-cement and gypsum into a single piece laminate eliminates the need to install two separate pieces of building material, thereby simplifying installation. In one embodiment, a ⅝″ thick laminate composite is provided comprising a ½″ thick gypsum panel laminated to a ⅛″ thick fiber-cement sheet, the laminate composite having a fire resistance rating of 1 hour when measured in accordance with ASTM E119.

What is claimed is:  
     
         1 . A method of installing a composite building material, comprising: 
 positioning a composite building material adjacent a supporting frame, wherein the composite building material has two layers, the first layer comprises gypsum and the second layer comprises fiber cement, wherein the gypsum-containing layer is positioned against the supporting frame while the fiber cement-containing layer faces outwardly from the supporting frame; and    attaching the building material to the supporting frame.    
     
     
         2 . The method of  claim 1 , wherein the building material is attached to a metal supporting frame.  
     
     
         3 . The method of  claim 1 , wherein the building material comprises a composite panel having a thickness of about ⅝ inch.  
     
     
         4 . A method of installing a building material, comprising: 
 attaching a gypsum panel to a supporting frame, wherein the gypsum panel is about ½ inch thick; and    attaching a fiber-cement panel to an outer surface of the gypsum panel, wherein the fiber-cement panel is about ⅛ inch thick.    
     
     
         5 . The method of  claim 4 , wherein the fiber-cement panel is attached to the gypsum panel by an adhesive.  
     
     
         6 . The method of  claim 4 , wherein the building material is installed as an interior wallboard, wherein the fiber-cement panel is positioned to face outward to the interior of a room.  
     
     
         7 . A method of installing interior wallboards in a building structure, comprising: 
 positioning a first interior wallboard adjacent a first side of a support frame, wherein a first layer of the interior wallboard comprises gypsum and a second layer of the interior wallboard comprises fiber cement, wherein the second layer of the wallboard faces outward away from the first side of the support frame; and    attaching the interior wallboard to the support frame.    
     
     
         8 . The method of  claim 7 , wherein the. interior wallboard is-about ⅝ inch thick.  
     
     
         9 . The method of  claim 7 , further comprising positioning a second interior wallboard adjacent a second side of the support frame, wherein a first layer of the interior wallboard comprises gypsum and a second layer of the interior wallboard comprises fiber cement, wherein the second layer of the wallboard faces outward away from the second side of the frame; and 
 attaching the second interior wallboard to the second side of the support frame.    
     
     
         10 . The method of  claim 7 , wherein the support frame comprises load bearing wood studs.  
     
     
         11 . The method of  claim 7 , wherein attaching the interior wallboard to the frame comprises nailing the wallboard to the frame.