This invention provides low dust
low density gypsum wallboard products having high total core void volumes, corresponding to low densities in the range of about 10 to 30 pcf. The wallboards have a set
gypsum core formed between two substantially parallel cover sheets, the set
gypsum core preferably having a total
void volume from about 80% to about 92%, and made from a
slurry including
stucco,
pregelatinized starch, and a
naphthalenesulfonate dispersant. The combination of the
pregelatinized starch and the
naphthalenesulfonate dispersant also provides a glue-like effect in binding the set gypsum crystals together. The wallboard formulation, along with small
air bubble voids (and water voids) provides
dust control during
cutting, sawing, routing, snapping, nailing or screwing down, or drilling of the gypsum-containing products. This invention also provides a method of making the low dust
low density gypsum products including the introduction of
soap foam in an amount sufficient to form a total
void volume, including
air voids, preferably from about 80% to about 92% in the set gypsum core, corresponding to a set gypsum core density from about 10 pcf to about 30 pcf. The wallboards produced by the method generate significantly less dust during working.