Lightweight plaster with polystyrene beads

Abstract

Disclosed herein are dry-mix and wet-mix compositions for lightweight plasters, kits for preparing lightweight plasters, lightweight plasters, and methods of making lightweight plasters. A dry-mix composition comprises a hydratable binder and polymer beads, the polymer beads having a mean equivalent particle diameter of no greater than 2.5 mm. A kit for preparing lightweight plasters comprises the dry mix composition and an accelerator composition. A method for preparing a plaster comprises mixing the dry-mix composition with water to prepare a wet mix composition, applying the wet mix composition to a surface of a substrate, and allowing the wet mix composition to dry to form a plaster.

Description

LIGHTWEIGHT PLASTER WITH POLYSTYRENE BEADSTECHNICAL FIELDThe present invention relates to dry -mix and wet-mix compositions for lightweight plasters, kits for preparing lightweight plasters, lightweight plasters, and methods of making lightweight plasters.Lightweight plasters are common construction materials used for coating or treating the surfaces or walls of buildings or other constructions. Known lightweight plasters typically include lightweight fillers such as shredded polystyrene or exfoliated vermiculite, dispersed within a hydratable binder such as dehydrated gypsum (calcium sulfate hemihydrate) or Portland cement.Exemplary plasters including shredded polystyrene are described in US Patent No. US 5,352,390, 4,751,024, 3,719,573, and 3,839,059. Unfortunately, shredded polystyrene tends to have fine particles that can clump into undesirable aggregates. Further, the large particle size range within batches of shredded polystyrene can be undesirable. Lastly, the shredding step can be energy intensive.Already formed polystyrene beads can provide an excellent alternative to shredded polystyrene and other common lightweight fillers for lightweight plaster. The inventors have found polystyrene beads of a particular shape and size provide for plasters with excellent process ability, mechanics, homogeneity, and pumpability.SUMMARYIn an aspect, the present invention relates to a dry-mix composition which comprises a hydratable binder and polymer beads, the polymer beads having a mean equivalent particle diameter of no greater than 2.5 mm.The dry-mix composition can be mixed with water to form a wet-mix composition. The present invention also relates to such wet-mix composition. The wet-mix can be applied to a substrate and allowed to dry to form a plaster.The present invention also relates to a kit comprises a dry-mix as defined herein and an accelerator composition.The present invention also relates to a plaster which comprises a binder and polymer beads, the polymer beads having a mean equivalent particle diameter of no greater than 2.5 mm.The present invention also relates to a method of preparing a plaster, where said method comprises preparing a dry-mix composition as defined herein (and more particularly,a dry-mix composition comprising a hydratable binder and polymer beads, the polymer beads having a mean equivalent particle diameter of no greater than 2.5 mm. The method further comprises mixing the dry-mix composition with water to prepare a wet-mix composition, applying the wet-mix composition to a surface of a substrate, allowing the wet-mix composition to dry to form a plaster.The present invention also relates to a plaster made by a method as defined herein. The present invention also relates to a plaster formed from a dry-mix composition as defined herein. The plaster may exhibit a Mean Max Z peak-Valley Profile of at least 500 pm and no greater than 1505 pm, as measured using X-ray tomography. The plaster may exhibit an Amplitude Max Z peak-Valley Profile of at least 500 pm no greater than 1550 pm, as measured busing X-ray tomography. The plaster may exhibit a Mean Max Z peak-Valley waviness of at least 500 pm and no greater than 950 pm. The plaster may exhibit a surface hardness of at least 3.2 mm and no greater than 50, as measured according to EN-13279-2. The plaster may exhibit a shore C hardness of at least 16 and no greater than 100, as measured according to EN 102042:2014. The plaster may exhibit a flexural strength of at least 0.073 KN and no greater than 1 KN, as measured according to EN-13279-2.BRIEF DESCRIPTION OF THE DRAWINGSThe present disclosure may be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings.FIG. 1 displays a Scanning Electron Microscopy (SEM) image of an exemplary nonshredded expanded polystyrene bead according to an embodiment of the present invention.FIG. 2 displays an SEM image of an exemplary shredded expanded polystyrene.FIG. 3 shows an exemplary process for preparing a lightweight plaster according to an embodiment of the present invention.DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)In an aspect of the invention, disclosed herein is a dry-mix composition comprising a hydratable binder and polymer beads having a mean equivalent particle diameter of no greater than 2.5 mm, according to various embodiments of the present invention.In an embodiment of the dry -mix composition, the polymer beads can have any suitable composition. In an embodiment the polymer beads can comprise an expanded polymer, a non-expanded polymer, or a combination thereof. In an embodiment, the polymer beads comprise polystyrene. In another embodiment, the polymer beads comprise anexpanded polystyrene, a non-expanded polystyrene, or a combination thereof. In an embodiment, the polymer beads substantially consist of expanded polystyrene. As used herein, substantially refers to at least 99.9% by weight or volume (e.g., a composition substantially consisting of component Y comprises at least 99.9 wt.% component Y or 99.9 vol. % of component Y; a composition substantially free of component X comprises no greater than 0.01 wt.% of component X or 0.01 vol. % component X). Hence, polymer beads substantially consisting of expanded polystyrene refers to polymer beads comprising at least 99.9% by weight of polystyrene. In another embodiment, the polymer beads can consist of polystyrene. In an embodiment, the polymer beads comprise a non-shredded polymer bead. In another embodiment, the polymer beads can comprise a non-shredded polystyrene bead. In yet another embodiment, the polymer beads can comprise or consist of a non-shredded expanded polystyrene bead. In some embodiments, the polymer beads can comprise a non- shredded unexpanded polystyrene bead. In some other embodiments, the polymer beads can comprise a mixture of non-shredded expanded and unexpanded polystyrene beads.The polymer beads can have a particular mean equivalent particle diameter. The mean equivalent particle diameter, as used herein, can be determined according to the following process. Particles are scanned with 2D Scanner and analyzed with Image software like Image J. The equivalent particle diameter d of each particle is calculated as d = 2^ with A being the surface area of the particle, calculated from the image with the image analysis software. It represents the diameter of a perfect circle having the same surface area as the 2D image of the particle. The mean equivalent diameter is based on the particle count, i.e., they are not weighted by particle volume or mass.In an embodiment, the polymer beads can have a mean equivalent particle diameter of no greater than 2.5 mm or no greater than 2.4 mm or no greater than 2.3 mm or no greater than 2.2 mm or no greater than 2.1 mm or no greater than 2.0 mm or no greater than 1.9 mm or no greater than 1.8 mm. In another embodiment, the polymer beads can have a mean equivalent particle diameter of at least 0.001 mm or at least 0.01 mm or at least 0.1 mm or at least 1.0 mm or at least 1.1 mm or at least 1.2 mm or at least 1.3 mm or at least 1.4 mm or at least 1.5 mm. It will be appreciated that the mean equivalent particle diameter can be in between any of the minimum and maximum values noted above, including for example, but not limited to, at least 0.001 mm and no greater than 2.5 mm or at least 1.0 mm and no greater than 2.1 mm.In an embodiment, the polymer beads can have a particular standard deviation in the equivalent particle diameter distribution. In an embodiment, the polymer beads can have a standard deviation in the equivalent particle diameter distribution of no greater than 0.3 mm or no greater than 0.28 mm or no greater than 0.26 mm or no greater than 0.24 mm or no greater than 0.22 mm or no greater than 0.20 mm or no greater than 0.18 mm. In another embodiment, the polymer beads can have a standard deviation in the equivalent particle diameter distribution of at least 0.001 mm or at least 0.01 mm or at least 0.1 mm. It will be appreciated that the standard deviation in the equivalent particle diameter distribution can be in between any of the minimum and maximum values noted above, including for example, but not limited to, at least 0.001 mm and no greater than 0.24 mm or at least 0.01 mm and no greater than 0.18 mm.In an embodiment, the polymer beads can have a particular length (L), width (W), and aspect ratio. As used herein, the length refers to the longest measurable dimension of a bead, the thickness refers to the shortest measurable dimension measured orthogonally from the length, and the aspect ratio refers to the ratio of the length: width (L: W). In an embodiment, the aspect ratio of the polymer beads can be no greater than 5: 1 or no greater than 4: 1 or no greater than 3: 1 or no greater than 2: 1 or no greater than 1.5: 1 or no greater than 1.3: 1 or no greater than 1.1 : 1 or no greater than 1.05: 1 or no greater than 1.01 : 1. In an embodiment, the polymer beads can have an aspect ratio of at least 1 : 1.In an embodiment, the polymer beads can have a particular mean circularity. In an embodiment, the polymer beads can have a mean circularity of at least 0.85 or at least 0.86 or at least 0.87 or at least 0.88 or at least 0.89. In an embodiment, the polymer beads can have a mean circularity of no greater than or equal to 1 or no greater than 1.In an embodiment, the polymer beads can have any suitable open cell content. In an embodiment, the polymer beads can have an open cell content of no greater than 50% or no greater than 45% or no greater than 40% or no greater than 35% or no greater than 30% or no greater than 25% or no greater than 20% or no greater than 15% or no greater than 10% or no greater than 5% or substantially no open cell content. An SEM image of the surface of an exemplary expanded polystyrene bead having no open cell content can be seen in FIG. 1. An SEM image of a shredded expanded polystyrene bead with open cell content can be seen in FIG. 2.In an embodiment, the polymer beads have a packing density of at least 10 g / L or at least 11 g / L or at least 12 g / L or at least 13 g / L. In an embodiment, the polymer beads have apacking density of no greater than 100 g / L or no greater than 90 g / L or no greater than 80 g / L or no greater than 70 g / L or no greater than 60 g / L.In an embodiment, the dry-mix composition comprises at least 0.001 wt.% polymer beads at least 0.01 wt.% polymer beads or at least 0.1 wt.% polymer beads or at least 0.5 wt.% polymer beads or at least 1 wt.% polymer beads or at least 1.5 wt.% polymer beads or at least 2 wt.% polymer beads or at least 2.5 wt.% polymer beads or at least 3 wt.% polymer beads, based on a total weight of the dry -mix composition. In an embodiment, the dry-mix composition comprises no greater than 50 wt.% polymer beads or no greater than 40 wt.% polymer beads or no greater than 30 wt.% polymer beads or no greater than 20 wt.% polymer beads or no greater than 15 wt.% polymer beads or no greater than 10 wt.% polymer beads or no greater than 7 wt.% polymer beards, based on a total weight of the dry-mix composition. It will be appreciated that the polymer bead content of the dry -mix composition may be between any of the minimum and maximum values noted above, including for example, but not limited to, at least 0.1 wt.% and no greater than 50 wt.% polymer beads or at least 2 wt.% and not greater than 20 wt.% polymer beads, based on a total weight of the dry-mix composition.In an embodiment, the hydratable binder can have any suitable composition. In an embodiment, the dry-mix hydratable binder comprises dehydrated gypsum (calcium sulfate hemihydrate), cement (e.g., Portland cements, Calcium Aluminate cements, Calcium Sulfoaluminate cements, belite cements), lime, or a combination thereof. In an embodiment, the hydratable binder may comprise no greater than 5 wt.% cement or no greater than 4 wt.% cement, or no greater than 3 wt.% cement, or no greater than 2 wt.% cement, or no greater than 1 wt.% cement, or no greater than 0.5 wt.% cement, or no greater than 0.1 wt.% cement, based on a total weight of the dry-mix composition. In an embodiment, the hydratable binder does not include cement.In an embodiment, the dry-mix composition comprises at least 70 wt.% hydratable binder or at least 72 wt.% hydratable binder or at least 74 wt.% hydratable binder or at least 76 wt.% hydratable binder or at least 78 wt.% hydratable binder or at least 80 wt.% hydratable binder or at least 82 wt.% hydratable binder or at least 84 wt.% hydratable binder or at least 85 wt.% hydratable binder, based on a total weight of the dry-mix composition. In an embodiment, the dry-mix composition comprises no greater than 99 wt.% hydratable binder or no greater than 95 wt.% hydratable binder, based on a total weight of the dry-mix composition. It will be appreciated that the hydratable binder content of the dry-mix composition may be between any of the minimum and maximum values noted above,including for example, but not limited to, at least 72 wt.% and no greater than 99 wt.% hydratable binder or at least 72 wt.% and not greater than 95 wt.% hydratable binder, based on a total weight of the dry -mix composition.In an embodiment, the dry-mix composition can further comprise a fibrous component. In an embodiment, the fibrous component comprises cellulose fibers, glass fibers, or a combination thereof. In an embodiment, the fibrous component can comprise 0-20 wt.% cellulose or 4-20 wt.% cellulose, based on a total weight of the fibrous component composition. In an embodiment, the fibrous component can comprise 0-2 wt.% glass fibers, based on a total weight of the fibrous component composition.In an embodiment, the dry-mix composition can also comprise a foaming agent. In an embodiment, the foaming agent can comprise sodium alpha olefin sulfonates, sulfonated monoglycerides, sodium alkyl aryl sulfonate, sodium laurel sulfate, or a combination thereof. In an embodiment, the dry-mix composition can comprise 0.1-5% by wt. foaming agent, based on the total weight of the dry-mix composition.In an embodiment, the dry-mix composition can comprise a clay. In an embodiment, the clay can comprise attapulgite, sepiolite, bentonite, illite, or a combination thereof. In an embodiment the dry-mix composition comprises 1 to 12 wt.% clay or 4 to 8 wt.% clay, based on a total weight of the dry -mix composition.In an embodiment, the dry-mix composition can comprise reactive filler. In an embodiment, the reactive filler can be calcium carbonate or sodium bicarbonate or a combination thereof. In an embodiment, the reactive filler can have a particle size (based on max sieve size) of 1 to 500 pm. In an embodiment, the reactive filler can have a particle size (based on max sieve size) of 10 to 20 pm.In an embodiment, the dry-mix composition can comprise 1-10 wt.% reactive filler. In an alternative embodiment, the dry -mix composition can comprise 3-5 wt.% reactive filler, based on a total weight of the dry-mix composition.In an embodiment, the dry-mix composition can comprise a lightweight filler in addition to the polymer beads. In an embodiment, the lightweight filler can comprise expanded perlite, expanded vermiculite, shredded expanded polystyrene, stone wool, expanded glass beads, cenospheres, micronized rubber, or a combination thereof. In an embodiment, the dry-mix can contain no greater than 5 wt.% lightweight filler other than polystyrene beads, or no greater than 4 wt.% lightweight filler, or no greater than 3 wt.% lightweight filler, or no greater than 2 wt.% lightweight filler, or no greater than 1 wt.% lightweight filler, or no greater than 0.5 wt.% lightweight filler, or no greater than 0.1 wt.%lightweight filler, based on a total weight of the dry -mix composition. In an alternative embodiment, the dry-mix may contain no lightweight fillers besides polymer or polystyrene beads.In an embodiment, the dry-mix composition can comprise an inert filler in addition to the polymer beads and optional lightweight filler. In an embodiment, the filler can comprise dolomite, limestone, sand, silica, bauxite, or a combination thereof. In an alternative embodiment, the dry-mix may contain no fillers besides polymer or polystyrene beads.In an embodiment, the dry-mix composition can comprise an additive. In an embodiment, the additive can comprise fire resistive aggregates, flake mica, a super absorbent polymer, or a combination thereof. In an embodiment, the dry-mix can contain no greater than 5 wt.% aggregates other than polystyrene beads, or no greater than 4 wt.% aggregates, or no greater than 3 wt.% aggregates, or no greater than 2 wt.% aggregates, or no greater than 1 wt.% aggregates, or no greater than 0.5 wt.% aggregates, or no greater than 0.1 wt.% aggregates, based on a total weight of the dry-mix composition. Aggregates, as used herein, refers to inert materials such as fillers (e.g. limestone and / or dolomitic fillers; inert minerals under 63 pm (based on max sieve size)) or sands (between 63 pm and 4 mm (based on max sieve size)) including the lightweight fillers in the above paragraphs.In an embodiment, the dry-mix composition can contain no greater than 5 wt.% inert filler other than polystyrene beads, or no greater than 4 wt.% inert filler, or no greater than 3 wt.% inert filler, or no greater than 2 wt.% inert filler, or no greater than 1 wt.% inert filler, or no greater than 0.5 wt.% inert filler, or no greater than 0.1 wt.% inert filler other than polystyrene beads, based on a total weight of the dry -mix composition.In an embodiment, the dry-mix composition can contain no greater than 5 wt.% sand, or no greater than 4 wt.% sand, or no greater than 3 wt.% sand, or no greater than 2 wt.% sand, or no greater than 1 wt.% sand, or no greater than 0.5 wt.% sand, or no greater than 0.1 wt.% sand, based on a total weight of the dry-mix composition.In an embodiment, the dry-mix composition can have a particular dry bulk density. In an embodiment, the dry-mix can have a dry bulk density of 15 to 16 lb. / ft3.In another aspect, there is a process for preparing a lightweight plaster as shown in FIG. 3. Process 100 begins with step 101, providing a dry-mix composition according to embodiments of the present invention, as disclosed hereinabove. Process 100 can continue with step 102, mixing the dry -mix composition with water to provide a wet-mix composition.In an embodiment, the wet-mix can comprise 0.6 to 1.75 water per weight of dry -mix or 1.25 to 1.75 weight per weight of dry-mix.When hydrated, the hydratable binder of the dry -mix can be altered in one or more of composition and properties. For example, dehydrated gypsum (calcium sulphate hemihydrate), when hydrated, is converted into calcium sulphate dihydrate.The process can continue with step 103, of applying the wet-mix composition to a substrate. The wet-mix can be spray applied or applied by hand. The substrate can be metal, steel, concrete, polystyrene, wood, or a composite.The wet-mix can be mixed with an accelerator composition, just prior to applying, or during the application process. The accelerator can comprise a low viscosity (20-40 cP) fluid. The accelerator can comprise aluminum sulphate powder mixed with water.In another aspect, a kit comprises any of the aforementioned dry-mix compositions, and an accelerator composition as per paragraph

[0042] ,The process can continue with step 104, of drying the wet-mix to form a plaster, converting the hydrated binder into a binder.In an embodiment, the applied wet-mix can have a particular setting time. The setting time can be between 10-20 hours.In an embodiment the plaster can have a particular sprayed dry density. In an embodiment the spray dry density of the plaster may be 15 to 22 lb. / ft3.In an embodiment, the plaster can be a fire-resistant plaster. Fire resistance can be measured according to EN 13381-4: Test Methods for Determining the Contribution of Structural Elements to Fire Resistance - Part 4: Passive Protection Applied to Steel Elements; or ANSI / UL 263, the Standard for Safety of Fire Tests of Building Construction Materials; or ASTM El 19, Standard Test Methods for Fire Tests of Building Construction and Materials; or CAN / ULC-S101 Standard, Standard Methods of Fire Endurance Tests of Building Construction and Materials.In an embodiment, the plaster may exhibit certain surface features indicative of a smooth appearance. Such an appearance may be desirable due to its visible appearance.In an embodiment the plaster may exhibit a particular Mean Max Z peak-Valley Profile that may facilitate improved performance and / or manufacturing of the plaster. In an embodiment the Mean Max Z peak-Valley Profile may be no greater than 1505 pm or no greater than 1500 pm or no greater than 1495 pm. In an embodiment the Mean Max Z peak- Valley Profile may be at least 500 pm or at least 1000 pm or at least 1250 pm or at least 1400 pm. It will be appreciated that the Mean Max Z peak-Valley Profile may be between any of the minimum and maximum values noted above, including for example, but not limited to, at least 500 pm and not greater than 1505 pm or at least 1000 pm and not greater than 1500 pm.In an embodiment the plaster may exhibit a particular Amplitude Max Z peak-Valley Profile, as measured using X-ray tomography, which may facilitate improved performance and / or manufacturing of the plaster. In an embodiment the Amplitude Max Z peak-Valley Profile may be no greater than 1550 pm or no greater than 1525 pm or no greater than 1500 pm or no greater than 1475 pm or no greater than 1450 pm or no greater than 1425 pm or no greater than 1400 pm. In an embodiment the Amplitude Max Z peak-Valley Profile may be at least 500 pm or at least 750 pm or at least 1000 pm or at least 1200 pm. It will be appreciated that the Amplitude Max Z peak-Valley Profile may be between any of the minimum and maximum values noted above, including for example, but not limited to, at least 500 pm and not greater than 1550 pm or at least 1000 pm and not greater than 1500 pm.In an embodiment the plaster may exhibit a particular Mean Max Z peak-Valley Waviness, as measured using X-ray tomography, which may facilitate improved performance and / or manufacturing of the plaster. In an embodiment the Mean Max Z peak-Valley Waviness may be no greater than 950 pm or no greater than 925 pm or no greater than 900 pm or no greater than 875 pm. In an embodiment the Mean Max Z peak-Valley Waviness may be at least 500 pm or at least 600 pm or at least 700 pm or at least 800 pm. It will be appreciated that the Mean Max Z peak-Valley Waviness may be between any of the minimum and maximum values noted above, including for example, but not limited to, at least 500 pm and not greater than 900 pm or at least 600 pm and not greater than 950 pm.In an embodiment the plaster may exhibit a particular surface hardness that may facilitate improved performance and / or manufacturing of the plaster. Surface hardness may be measured according to EN- 13279-2. In an embodiment the surface hardness may be at least 3.2 mm or at least 3.4 mm or at least 3.6 mm or at least 3.8 mm or at least 4.0 mm or at least 4.2 mm or at least 4.4 mm or at least 4.6 mm or at least 4.8 mm. In an embodiment the surface hardness may be no greater than 50 mm or no greater than 20 mm or no greater than 10 mm. It will be appreciated that surface hardness may be between any of the minimum and maximum values noted above, including for example, but not limited to, at least 3.2 mm and not greater than 20 mm or at least 3.5 mm and not greater than 100 mm.In an embodiment the plaster may exhibit a particular shore C hardness that may facilitate improved performance and / or manufacturing of the plaster. Shore C hardness may be measured according to EN 102042:2014. In an embodiment the shore C hardness may be at least 16 or at least 17 or at least 18 or at least 19 or at least 20 or at least 21 or at least 22 or at least 23 or at least 24 or at least 25 or at least 26. In an embodiment the shore C hardness may be no greater than 100 or no greater than 75 or no greater than 50. It will be appreciatedthat shore C hardness may be between any of the minimum and maximum values noted above, including for example, but not limited to, at least 16 and no greater than 100 or at least 20 and no greater than 50.In an embodiment the plaster may exhibit a particular flexural strength that may facilitate improved performance and / or manufacturing of the plaster. Flexural strength may be measured according to EN- 13279-2. In an embodiment the flexural strength may be at least 0.073 KN or at least 0.074 KN or at least 0.075 KN or at least 0.076 KN or at least 0.077 KN or at least 0.078 KN or at least 0.079 KN or at least 0.080 KN or at least 0.081 KN or at least 0.082 KN or at least 0.083 KN or at least 0.084 KN. In an embodiment the flexural strength may be no greater than 1 KN or at least 0.5 KN or at least 0.25 KN or at least 0.10 KN. It will be appreciated that flexural strength may be between any of the minimum and maximum values noted above, including for example, but not limited to, at least 0.072 KN and no greater than 1 KN or at least 0.075 KN and no greater than 0.5 KN. EMBODIMENTSEmbodiment 1. A dry -mix composition comprising a hydratable binder and polymer beads, the polymer beads having a mean equivalent particle diameter of no greater than 2.5 mm.Embodiment 2. The dry-mix composition of Embodiment 1, wherein the polymer beads comprise an expanded polymer, a non-expanded polymer, or a combination thereof.Embodiment 3. The dry-mix composition of Embodiment 1 or Embodiment 2, wherein the polymer beads comprise an expanded polymer.Embodiment 4. The dry-mix composition of any one of Embodiments 1-3, wherein the polymer beads comprise polystyrene.Embodiment 5. The dry-mix composition of any one of Embodiments 1-4, wherein the polymer beads comprise an expanded polystyrene.Embodiment 6. The dry-mix composition of any one of Embodiments 1-5, wherein the polymer beads substantially consist of polystyrene.Embodiment 7. The dry-mix composition of any one of Embodiments 1-6, wherein the polymer beads consist of polystyrene.Embodiment 8. The dry-mix composition of any one of Embodiments 1-7, wherein the polymer beads comprise a non-shredded polymer.Embodiment 9. The dry-mix composition of any one of Embodiments 1-8, wherein the polymer beads have a mean equivalent particle diameter of no greater than 2.4 mm or nogreater than 2.3 mm or no greater than 2.2 mm or no greater than 2.1 mm or no greater than 2.0 mm or no greater than 1.9 mm or no greater than 1.8 mm.Embodiment 10. The dry-mix composition of any one of Embodiments 1-9, wherein the polymer beads have a mean equivalent particle diameter of at least 0.001 mm or at least 0.01 mm or at least 0.1 mm or at least 1.0 mm or at least 1.1 mm or at least 1.2 mm or at least 1.3 mm or at least 1.4 mm or at least 1.5 mm.Embodiment 11. The dry-mix composition of any one of Embodiments 1-10, wherein the polymer beads have a standard deviation in the equivalent particle diameter distribution of no greater than 0.3 mm or no greater than 0.28 mm or no greater than 0.26 mm or no greater than 0.24 mm or no greater than 0.22 mm or no greater than 0.20 mm or no greater than 0.18 mm.Embodiment 12. The dry-mix composition of any one of Embodiments 1-11, wherein the polymer beads have a standard deviation in the equivalent particle diameter distribution of at least 0.001 mm or at least 0.01 mm or at least 0.1 mm.Embodiment 13. The dry-mix composition of any one of Embodiments 1-12, wherein the polymer beads have a mean circularity of at least 0.85 or at least 0.86 or at least 0.87 or at least 0.88 or at least 0.89.Embodiment 14. The dry-mix composition of any one of Embodiments 1-13, wherein the polymer beads have a mean circularity of no greater than or equal to 1 or no greater than 1.Embodiment 15. The dry-mix composition of any one of Embodiments 1-14, wherein the polymer beads have an aspect ratio of no greater than 5: 1 or no greater than 4: 1 or no greater than 3: 1 or no greater than 2: 1 or no greater than 1.5: 1 or no greater than 1.3: 1 or no greater than 1.1 : 1.Embodiment 16. The dry-mix composition of any one of Embodiments 1-15, wherein the polymer beads have an open cell content of no greater than 50% or no greater than 45% or no greater than 40% or no greater than 35% or no greater than 30% or no greater than 25% or no greater than 20% or no greater than 15% or no greater than 10% or no greater than 5% or substantially no open cell content.Embodiment 17. The dry-mix composition of any one of Embodiments 1-16, wherein the polymer beads have a packing density of at least 10 g / L or at least 11 g / L or at least 12 g / L or at least 13 g / L.Embodiment 18. The dry-mix composition of any one of Embodiments 1-17, wherein the polymer beads have a packing density of no greater than 100 g / L or no greater than 90 g / L or no greater than 80 g / L or no greater than 70 g / L or no greater than 60 g / L.Embodiment 19. The dry-mix composition of any one of Embodiments 1-18, wherein the dry-mix composition comprises polymer beads in an amount of at least 0.001 wt.% or at least 0.01 wt.% or at least 0.1 wt.% or at least 0.5 wt.% or at least 1 wt.% or at least 1.5 wt.% or at least 2 wt.% or at least 2.5 wt.% or at least 3 wt.%, based on a total weight of the drymix composition.Embodiment 20. The dry-mix composition of any one of Embodiments 1-19, wherein the dry-mix composition comprises polymer beads in an amount of no greater than 50 wt.% or no greater than 40 wt.% or no greater than 30 wt.% or no greater than 20 wt.% or no greater than 15 wt.% or no greater than 10 wt.% polymer beads or no greater than 7 wt.%, based on a total weight of the dry-mix composition.Embodiment 21. The dry-mix composition of any one of Embodiments 1-20, wherein the hydratable binder comprises calcium sulfate hemihydrate, cement, lime, or a combination thereof.Embodiment 22. The dry-mix composition of any one of Embodiments 1-21, wherein the hydratable binder comprises a cement in an amount of no greater than 5 wt.% or no greater than 4 wt.%, or no greater than 3 wt.%, or no greater than 2 wt.%, or no greater than 1 wt.%, or no greater than 0.5 wt.%, or no greater than 0.1 wt.%, based on a total weight of the dry-mix composition.Embodiment 23. The dry-mix composition of any one of Embodiments 1-22, wherein the hydratable binder does not comprise cement.Embodiment 24. The dry-mix composition of any one of Embodiments 1-23, wherein the dry-mix composition comprises a hydratable binder in an amount of at least 70 wt.% or at least 72 wt.% or at least 74 wt.% or at least 76 wt.% or at least 78 wt.% or at least 80 wt.% or at least 82 wt.% or at least 84 wt.% hydratable binder or at least 85 wt.%, based on a total weight of the dry-mix composition.Embodiment 25. The dry-mix composition of any one of Embodiments 1-24, wherein the dry-mix composition comprises a hydratable binder in an amount of no greater than 99 wt.% or no greater than 95 wt.%, based on a total weight of the dry-mix composition.Embodiment 26. The dry-mix composition of any one of Embodiments 1-25, wherein the dry-mix composition further comprises a fibrous component.Embodiment 27. The dry-mix composition of Embodiment 26, wherein the fibrous component comprises cellulose fibers, glass fibers, or a combination thereof.Embodiment 28. The dry-mix composition of Embodiment 26 or Embodiment 27, wherein the fibrous component comprises 0-20 wt.% cellulose or 4-20 wt.% cellulose, based on a total weight of the fibrous component.Embodiment 29. The dry-mix composition of any one of Embodiments 26-28, wherein the dry-mix composition comprises 0-2 wt.% glass fibers, based on a total weight of the fibrous component.Embodiment 30. The dry-mix composition of any one of Embodiments 1-29, wherein the compositon further comprises a foaming agent.Embodiment 31. The dry-mix composition of Embodiment 30, wherein the foaming agent comprises sodium alpha olefin sulfonates, sulfonated monoglycerides, sodium alkyl aryl sulfonate, sodium laurel sulfate, or a combination thereof.Embodiment 32. The dry-mix composition of Embodiment 30 or Embodiment 31, wherein the dry-mix composition comprises 0.1-5% by wt. foaming agent, based on a total weight of the dry-mix composition.Embodiment 33. The dry-mix composition of any one of Embodiments 1-32, wherein the dry-mix composition further comprises an accelerator.Embodiment 34. The dry-mix composition of any one of Embodiments 1-33, wherein the dry-mix compositon further comprises a clay.Embodiment 35. The dry-mix composition of Embodiment 34, wherein the clay comprises attapulgite, sepiolite, bentonite, illite, or a combination thereof.Embodiment 36. The dry-mix composition of Embodiment 34 or Embodiment 35, wherein the dry-mix composition comprises a clay in an amount of 1 to 12 wt.% or 4 to 8 wt.%, based on a total weight of the dry-mix composition.Embodiment 37. The dry-mix composition of any one of Embodiments 1-36, wherein the compositon further comprises a reactive filler.Embodiment 38. The dry-mix composition of Embodiment 37, wherein the reactive filler comprises calcium carbonate, sodium bicarbonate, or a combination thereof.Embodiment 39. The dry-mix composition of Embodiment 37 or Embodiment 38, wherein the reactive filler comprises a particle size of 1 to 500 pm or 10 to 20 pm.Embodiment 40. The dry-mix composition of any one of Embodiments 37-39, wherein the dry-mix composition comrpises 1-10 wt.% reactive filler or 3-5 wt.% reactive filler based on a total weight of the dry -mix composition.Embodiment 41. The dry-mix composition of any one of Embodiments 1-40, wherein the dry-mix compositon further comprises a lightweight filler.Embodiment 42. The dry-mix composition of Embodiment 41, wherein the lightweight filler comprises expanded perlite, expanded vermiculite, shredded expanded polystyrene, stone wool, expanded glass beads, cenospheres, micronized rubber, or a combination thereof.Embodiment 43. The dry-mix composition of Embodiment 41 or Embodiment 42, wherein the dry-mix composition comprises a lightweight filler other than polystyrene beads in an amount of no greater than 5 wt.% , or no greater than 4 wt.%, or no greater than 3 wt.%, or no greater than 2 wt.% , or no greater than 1 wt.%, or no greater than 0.5 wt.%, or no greater than 0.1 wt.%, based on a total weight of the dry -mix composition.Embodiment 44. The dry-mix composition of any one of Embodiments 1-43, wherein the dry-mix composition compries no lightweight fillers other than polymer or polystyrene beads.Embodiment 45. The dry -mix composition of any one of Embodiments 1-44, wherein the dry-mix compositon further comprises an inert filler.Embodiment 46. The dry-mix composition of Embodiment 45, wherein the inert filler comprises dolomite, limestone, sand, silica, bauxite or a combination thereof.Embodiment 47. The dry-mix composition of Embodiment 45 or Embodiment 46, wherein the dry-mix composition comprises an inert filler other than polystyrene beads in an amount of no greater than 5 wt.% i, or no greater than 4 wt.%, or no greater than 3 wt.%, or no greater than 2 wt.%, or no greater than 1 wt.% i, or no greater than 0.5 wt.%, or no greater than 0.1 wt.% , based on a total weight of the dry-mix composition.Embodiment 48. The dry -mix composition of any one of Embodiments 1-47, wherein the dry-mix comprises no inert fillers other than polymer or polystyrene beads.Embodiment 49. The dry-mix composition of any one of Embodiments 1-48, wherein the dry-mix composition comprises aggregates other than polystyrene beads in an amount of no greater than 5 wt.%, or no greater than 4 wt.%, or no greater than 3 wt.%, or no greater than 2 wt.%, or no greater than 1 wt.%, or no greater than 0.5 wt.%, or no greater than 0.1 wt.% based on a total weight of the dry-mix composition.Embodiment 50. The dry-mix composition of any one of Embodiments 1-49, wherein the dry-mix composition comprises a sand in an amount of no greater than 5 wt.%, or no greater than 4 wt.%, or no greater than 3 wt.%, or no greater than 2 wt.%, or no greater than 1wt.%, or no greater than 0.5 wt.%, or no greater than 0.1 wt.%, based on a total weight of the dry-mix composition.Embodiment 51. The dry-mix composition of any one of Embodiments 1-50, wherein the dry-mix comprises no aggregates other than polymer or polystyrene beads.Embodiment 52. The dry-mix composition of any one of Embodiments 1-51, further comprising an additive.Embodiment 53. The dry-mix composition of Embodiment 52, wherein the additive comprises fire resistive aggregates, flake mica, a super absorbent polymer, or a combination thereof.Embodiment 54. The dry-mix composition of any one of Embodiments 1-53, wherein the dry-mix composition has a dry bulk density of 15 to 16 lb / ft3.Embodiment 55. A kit comprising the dry-mix composition of any one of Embodiments 1-54 and an accelerator composition.Embodiment 56. The kit of Embodiment 55, wherein the accelerator composition comprises a fluid having viscosity in a range of 20-40 cP.Embodiment 57. The kit of Embodiment 55 or Embodiment 56, wherein the accelerator composition comprises aluminum sulphate and water.Embodiment 58. A wet-mix composition comprising the dry-mix composition of any one of Embodiments 1-54 and water.Embodiment 59. The wet-mix composition of Embodiment 58, wherein the wet-mix comprises water in an amount of 0.6 to 1.75 by weight per total weight of dry-mix or 1.25 to 1.75 by weight per total weight of dry-mix or 1.25 to 1.75 by weight per total weight of drymix.Embodiment 60. The wet-mix composition of Embodiment 58, wherein the wet-mix has a setting time of 10 to 20 hours.Embodiment 61. A method of preparing a plaster comprising: mixing the dry-mix composition of any one of Embodiments 1-54 with water to prepare a wet-mix composition, applying the wet-mix composition to a surface of a substrate, and allowing the wet-mix composition to dry to form a plaster.Embodiment 62. The method of Embodiment 61, wherein the wet-mix composition has a setting time of 10 to 20 hours.Embodiment 63. The method of Embodiment 61 or Embodiment 62, wherein the wet-mix composition comprises the wet-mix composition of any one of Embodiments 58-60.Embodiment 64. The method of any one of Embodiments 61-63, wherein the wet-mix composition is mixed with an accelerator composition prior to or during application of the wet-mix to the surface of the substrate.Embodiment 65. The method of Embodiment 64, wherein the accelerator composition comprises a fluid having viscosity in a range of 20-40 cP.Embodiment 66. The method of Embodiment 64 or Embodiment 65, wherein the accelerator composition comprises aluminum sulphate and water.Embodiment 67. The method of any one of Embodiments 61-66, wherein the step of applying the wet-mix composition to a surface of a substrate comprises applying the wet-mix composition to a surface of the substrate by hand or spraying the wet-mix composition to a surface of the substrate, or a combination thereof.Embodiment 68. The method of any one of Embodiments 61-67, wherein the substrate comprises metal, steel, concrete, polystyrene, wood, or a composite.Embodiment 69. A plaster having a composition comprising a binder and polymer beads, the polymer beads having a mean equivalent particle diameter of no greater than 2.5 mm.Embodiment 70. The plaster of Embodiment 69, wherein the polymer beads comprise an expanded polymer, a non-expanded polymer, or a combination thereof.Embodiment 71. The plaster of Embodiment 69 or Embodiment 70, wherein the polymer beads comprise an expanded polymer.Embodiment 72. The plaster of any one of Embodiments 69-71, wherein the polymer beads comprise polystyrene.Embodiment 73. The plaster of any one of Embodiments 69-72, wherein the polymer beads comprise expanded polystyrene.Embodiment 74. The plaster of any one of Embodiments 69-73, wherein the polymer beads substantially consist of polystyrene.Embodiment 75. The plaster of any one of Embodiments 69-74, wherein the polymer beads consist of polystyrene.Embodiment 76. The plaster of any one of Embodiments 69-75, wherein the polymer beads comprise a non-shredded polymer.Embodiment 77. The plaster of any one of Embodiments 69-76, wherein the polymer beads have a mean equivalent particle diameter of no greater than 2.4 mm or no greater than 2.3 mm or no greater than 2.2 mm or no greater than 2.1 mm or no greater than 2.0 mm or no greater than 1.9 mm or no greater than 1.8 mm.Embodiment 78. The plaster of any one of Embodiments 69-77, wherein the polymer beads have a mean equivalent particle diameter of at least 0.001 mm or at least 0.01 mm or at least 0.1 mm or at least 1.0 mm or at least 1.1 mm or at least 1.2 mm or at least 1.3 mm or at least 1.4 mm or at least 1.5 mm.Embodiment 79. The plaster of any one of Embodiments 69-78, wherein the polymer beads have a standard deviation in the equivalent particle diameter distribution of no greater than 0.3 mm or no greater than 0.28 mm or no greater than 0.26 mm or no greater than 0.24 mm or no greater than 0.22 mm or no greater than 0.20 mm or no greater than 0.18 mm.Embodiment 80. The plaster of any one of Embodiments 69-79, wherein the polymer beads have a standard deviation in the equivalent particle diameter distribution of at least 0.001 mm or at least 0.01 mm or at least 0.1 mm.Embodiment 81. The plaster of any one of Embodiments 69-80, wherein the polymer beads have a mean circularity of at least 0.85 or at least 0.86 or at least 0.87 or at least 0.88 or at least 0.89.Embodiment 82. The plaster of any one of Embodiments 69-81, wherein the polymer beads have a mean circularity of no greater than or equal to 1 or no greater than 1.Embodiment 83. The plaster of any one of Embodiments 69-82, wherein the polymer beads have a primary aspect ratio of no greater than 5: 1 or no greater than 4: 1 or no greater than 3: 1 or no greater than 2: 1 or no greater than 1.5: 1 or no greater than 1.3: 1 or no greater than 1.1 : 1.Embodiment 84. The plaster of any one of Embodiments 69-83, wherein the polymer beads have an open cell content of no greater than no greater than 50% or no greater than 45% or no greater than 40% or no greater than 35% or no greater than 30% or no greater than 25% or no greater than 20% or no greater than 15% or no greater than 10% or no greater than 5% or substantially no open cell content.Embodiment 85. The plaster of any one of Embodiments 69-84, wherein the polymer beads have a packing density of at least 10 g / L or at least 11 g / L or at least 12 g / L or at least 13 g / L.Embodiment 86. The plaster of any one of Embodiments 69-85, wherein the polymer beads have a packing density of 100 g / L or no greater than 90 g / L or no greater than 80 g / L or no greater than 70 g / L or no greater than 60 g / L.Embodiment 87. The plaster of any one of Embodiments 69-86, wherein the plaster comprises polymer beads in an amount of at least 0.001 wt.% or at least 0.01 wt.% or at least0.1 wt.% or at least 0.5 wt.% p or at least 1 wt.% or at least 1.5 wt.% or at least 2 wt.% or at least 2.5 wt.% or at least 3 wt.% p, based on a total weight of the plaster.Embodiment 88. The plaster of any one of Embodiments 69-87, wherein the plaster comprises polymer beads in an amount of no greater than 50 wt.% or no greater than 40 wt.% or no greater than 30 wt.% or no greater than 20 wt.% or no greater than 15 wt.% or no greater than 10 wt.% or no greater than 7 wt.%, based on a total weight of the plaster.Embodiment 89. The plaster of any one of Embodiments 69-88, wherein the plaster comprises the binder in an amount of at least 70 wt.% or at least 72 wt.% or at least 74 wt.% or at least 76 wt.% or at least 78 wt.% or at least 80 wt.% or at least 82 wt.% or at least 84 wt.% or at least 85 wt.%, based on a total weight of the plaster.Embodiment 90. The plaster of any one of Embodiments 69-89, wherein the plaster comprises the binder in an amount of no greater than 99 wt.% or no greater than 95 wt.%, based on a total weight of the plaster.Embodiment 91. The plaster of any one of Embodiments 69-90, wherein the binder comprises calcium sulfate hemihydrate, cement, lime, or a combination thereof.Embodiment 92. The plaster of any one of Embodiments 69-91, wherein the binder comprises cement in an amount of no greater than 5 wt.% or no greater than 4 wt.%, or no greater than 3 wt.%, or no greater than 2 wt.%, or no greater than 1 wt.%, or no greater than 0.5 wt.%, or no greater than 0.1 wt.%, based on a total weight of the plaster.Embodiment 93. The plaster of any one of Embodiments 69-92, wherein the binder does not comprise cement.Embodiment 94. The plaster of any one of Embodiments 69-93, wherein the plaster further comprises a fibrous component.Embodiment 95. The plaster of Embodiment 94, wherein the fibrous component comprises cellulose fibers, glass fibers, or a combination thereof.Embodiment 96. The plaster of Embodiment 94 or Embodiment 95, wherein the fibrous component comprises 0-20 wt.% cellulose or 4-20 wt.% cellulose, based on a total weight of the fibrous component.Embodiment 97. The plaster of any one of Embodiments 94-96, wherein the fibrous component comprises 0-2 wt.% glass fibers, based on a total weight of the fibrous component.Embodiment 98. The plaster of any one of Embodiments 69-97, wherein the plaster further comprises an accelerator.Embodiment 99. The plaster of any one of Embodiments 69-98, wherein the plaster further comprises a clay.Embodiment 100. The plaster of Embodiment 99, wherein the clay comprises attapulgite, sepiolite, bentonite, illite, or a combination thereof.Embodiment 101. The plaster of Embodiment 99 or Embodiment 100, wherein the plaster comprises 1 to 12 wt.% clay or 4 to 8 wt.% clay, based on a total weight of the plaster.Embodiment 102. The plaster of any one of Embodiments 69-101, wherein the compositon further comprises a reactive filler.Embodiment 103. The plaster of Embodiment 102, wherein the reactive filler comprises calcium carbonate, sodium bicarbonate, or a combination thereof.Embodiment 104. The plaster of Embodiment 102 or Embodiment 103, wherein the reactive filler comprises a particle size of 1 to 500 pm or 10 to 20 pm.Embodiment 105. The plaster of any one of Embodiments 102-104, wherein the plaster composition comrpises 1-10 wt.% reactive filler or 3-5 wt.% reactive filler, based on a total weight of the plaster.Embodiment 106. The plaster of any one of Embodiments 69-105, wherein the plaster compositon further comprises a lightweight filler.Embodiment 107. The plaster of Embodiment 106, wherein the lightweight filler comprises expanded perlite, expanded vermiculite, shredded expanded polystyrene, stone wool, expanded glass beads, cenospheres, micronized rubber, or a combination thereof.Embodiment 108. The plaster of Embodiment 106 or Embodiment 107, wherein the plaster composition comprises the lightweight filler other than polystyrene beads in an amount of no greater than 5 wt.%, or no greater than 4 wt.%, or no greater than 3 wt.% 1, or no greater than 2 wt.%, or no greater than 1 wt.%, or no greater than 0.5 wt.%, or no greater than 0.1 wt.%, based on a total weight of the plaster composition.Embodiment 109. The plaster of any one of Embodiments 69-108, wherein the plaster composition complies no lightweight fillers other than polymer or polystyrene beads.Embodiment 110. The plaster of any one of Embodiments 69-109, wherein the plaster compositon further comprises an inert filler.Embodiment 111. The plaster of Embodiment 110, wherein the inert filler comprises dolomite, limestone, sand, silica, bauxite, or a combination thereof.Embodiment 112. The plaster of Embodiment 110 or Embodiment 111, wherein the plaster composition comprises the inert filler other than polystyrene beads in an amount of no greater than 5 wt.%, or no greater than 4 wt.%, or no greater than 3 wt.%, or no greater than 2wt.%, or no greater than 1 wt.%, or no greater than 0.5 wt.%, or no greater than 0.1 wt.%, based on a total weight of the plaster composition.Embodiment 113. The plaster of any one of Embodiments 69-112, wherein the plaster comprises no inert fillers other than polymer or polystyrene beads.Embodiment 114. The plaster of any one of Embodiments 69-113, wherein the plaster composition comprises aggregates other than polystyrene beads in an amount of no greater than 5 wt.% , or no greater than 4 wt.%, or no greater than 3 wt.%, or no greater than 2 wt.%, or no greater than 1 wt.%, or no greater than 0.5 wt.% aggregates, or no greater than 0.1 wt.%, based on a total weight of the plaster.Embodiment 115. The plaster of any one of Embodiments 69-114, wherein the plaster composition comprises a sand in an amound of no greater than 5 wt.%, or no greater than 4 wt.%, or no greater than 3 wt.%, or no greater than 2 wt.%, or no greater than 1 wt.%, or no greater than 0.5 wt.%, or no greater than 0.1 wt.%, based on a total weight of the plaster.Embodiment 116. The plaster of any one of Embodiments 69-115, wherein the plaster comprises no aggregates other than polymer or polystyrene beads.Embodiment 117. The plaster of any one of Embodiments 69-116, further comprises an additive.Embodiment 118. The plaster of Embodiment 117, wherein the additive comprises fire resistive aggregates, flake mica, a super absorbent polymer, or a combination thereof.Embodiment 119. The plaster of any one of Embodiments 69-118, further comprising aluminum sulphate.Embodiment 120. The plaster of any one of Embodiments 69-119, wherein the plaster is a fire-resistant plaster.Embodiment 121. The plaster of any one of Embodiments 69-120, wherein the plaster exhibits a Mean Max Z peak-Valley Profile of no greater than 1505 pm or no greater than 1500 pm or no greater than 1495 pm as measured using X-ray tomography.Embodiment 122. The plaster of any one of Embodiments 69-121, wherein the plaster exhibits a Mean Max Z peak-Valley Profile of at least 500 pm or at least 1000 pm or at least 1250 pm or at least 1400 pm, as measured using X-ray tomography.Embodiment 123. The plaster of any one of Embodiments 69-122, wherein the plaster exhibits an Amplitude Max Z peak-Valley Profile of no greater than 1550 pm or no greater than 1525 pm or no greater than 1500 pm or no greater than 1475 pm or no greaterthan 1450 m or no greater than 1425 pm or no greater than 1400 pm, as measured using X- ray tomography.Embodiment 124. The plaster of any one of Embodiments 69-123, wherein the plaster exhibits an Amplitude Max Z peak-Valley Profile of at least 500 pm or at least 750 pm or at least 1000 pm or at least 1200 pm as measured using X-ray tomography.Embodiment 125. The plaster of any one of Embodiments 69-124, wherein the plaster exhibits a Mean Max Z peak-Valley waviness of no greater than 950 pm or no greater than 925 pm or no greater than 900 pm or no greater than 875 pm, as measured using X-ray tomography.Embodiment 126. The plaster of any one of Embodiments 69-125, wherein the plaster exhibits a Mean Max Z peak-Valley waviness of at least 500 pm or at least 600 pm or at least 700 pm or at least 800 pm, as measured using X-ray tomography.Embodiment 127. The plaster of any one of Embodiments 69-126, wherein the plaster exhibits a surface hardness of at least 3.2 mm or at least 3.4 mm or at least 3.6 mm or at least 3.8 mm or at least 4.0 mm or at least 4.2 mm or at least 4.4 mm or at least 4.6 mm or at least 4.8 mm, as measured according to EN- 13279-2.Embodiment 128. The plaster of any one of Embodiments 69-127, wherein the plaster exhibits a surface hardness of no greater than 50 mm or no greater than 20 mm or no greater than 10 mm, as measured according to EN- 13279-2.Embodiment 129. The plaster of any one of Embodiments 69-128, wherein the plaster exhibits a shore C hardness of at least 16 or at least 17 or at least 18 or at least 19 or at least 20 or at least 21 or at least 22 or at least 23 or at least 24 or at least 25 or at least 26, as measured according to EN 102042:2014.Embodiment 130. The plaster of any one of Embodiments 69-129, wherein the plaster exhibits a shore C hardness no greater than 100 or no greater than 75 or no greater than 50, as measured according to EN 102042:2014.Embodiment 131. The plaster of any one of Embodiments 69-130, wherein the plaster exhibits a flexural strength of at least 0.073 KN or at least 0.074 KN or at least 0.075 KN or at least 0.076 KN or at least 0.077 KN or at least 0.078 KN or at least 0.079 KN or at least 0.080 KN or at least 0.081 KN or at least 0.082 KN or at least 0.083 KN or at least 0.084 KN, as measured according to EN-13279-2.Embodiment 132. The plaster of any one of Embodiments 69-130, wherein the plaster exhibits a flexural strength of no greater than 1 KN or at least 0.5 KN or at least 0.25 KN or at least 0.10 KN, as measured according to EN-13279-2.Embodiment 133. The plaster of any one of Embodiments 70-133, which is obtained by a method as defined in any one of Embodiments 61-68.EXAMPLESExample 1 - Large vs small beads Dry -mix compositions for samples SI, comparative sample CS1, and commercial sample CMS1 were prepared according to Table 1 below.Table 1Properties of the polystyrene beads can be seen below in Table 2.Table 2Sample SI and comparative sample CS1 were mixed with 0.68 weight water per weight dry-mix untill the wet-mix was hydrated and homogenous. Commercial samples CMS were mixed with 0.89 weight water per weight dry-mix untill the wet-mix was hydrated and homogenous.All samples were spray applied to a substrate. However, smaple CS1 was unable to flow consistently through the sprayer.Example 2 - Vicat testing.Dry -mix compositions for samples SI, comparative sample CS1, and commercial sample CMS1 were prepared according to Table 3 below.Table 3All samples and comparative samples were mixed with 1.3 weight water per weight dry -mix in a Putzmeister mixer and pump untill the wet-mix was hydrated and homogenous to prepare wet-mix compositions. Wet-mix compositions were vicat tested according to a modified ASTM C472Physical Testing of Gypsum, Gypsum Plasters and Concrete. A 5 oz dixie cup was filled completely with the wet-mix and placed under a Vicat Cone Penetrometer (a modified Vicat Apparatus with a 50 gram cone weight (50 grams = weight of cone + weight of Vicat shaft + weight of pointer and thumbscrew). Humbolt Mfg. Co. Catalog #H-3137 or equivalent). Vicat results for each mix were recorded as shown below in Table 4.Each wet-mix composition was also sprayed via the putzmeister mixer and pump. The sprayed wet-mix samples were collected and used to fill additional 5 oz dixie cups for spray Vicat testing. Results can be seen below in Table 4.Table 4Example 3 - Plaster PropertiesSample plasters SI A, S2B, CS1A , and CS1B were prepared according to SI and CS1 in example 1 above and shaped into rectangular prisms having dimensions 160x100x15mm. Plasters SI A, S2B, CS1A , and CS1B were measured using X-ray tomography and a voxel size of 80 micrometers. Tomographic slices were processed and evaluated for a number of surface features including surface profile and waviness. A surface profile is the measured contour of a surface that shows the variations at the resolution acquisition; specifically, over80pm variation in height along a based line under the surface of the sample. The waviness refers to waviness profile refers to the medium-scale surface irregularities on the material (specifically, between 0.3mm and 1mm), measured along a median line on the surface. The 'MeanMax Z peak-valley (pm) - Profile' metric represents the average of the maximum peak heights extracted from the surface profile of each tomographic slice. The 'Amplitude Max Z peak-valley (pm) - Profile' metric represents the average of the maximum peak-to-valley height differences computed across all tomographic slices based on the surface profile. The 'MeanMax Z peak-valley (pm) - Waviness' metric represents the average of the maximum peak heights extracted from the waviness profile of each tomographic slice. Results can be found below in table 5.Table 5Notably, Samples SI A and SIB had more even surfaces as compared to CS1A and CS1B resulting in an improved visually aesthetic appearance by naked eye.Plasters SIC and CS1C were prepared according to SI and CS1 in example 1 above and shaped into rectangular prisms having dimensions 160x40x40mm. Samples SIC and CS1C were evaluated for surface hardness, shore c hardness and flexural strength. Flexural strength and surface hardness were measured according to EN- 13279-2. Shore C hardness was measured according to EN 102042:2014. Results may be found below in table 6.Table 6

Claims

WHAT IS CLAIMED IS:

1. A dry -mix composition comprising a hydratable binder and polymer beads, the polymer beads having a mean equivalent particle diameter of no greater than 2.5 mm.

2. The dry-mix composition of claim 1, wherein the polymer beads comprise an expanded polymer, a non-expanded polymer, or a combination thereof.

3. The dry-mix composition of claim 1 or claim 2, wherein the polymer beads comprise an expanded polymer.

4. The dry-mix composition of any one of claims 1-3, wherein the polymer beads comprise polystyrene.

5. The dry-mix composition of any one of claims 1-4, wherein the polymer beads comprise an expanded polystyrene.

6. The dry-mix composition of any one of claims 1-5, wherein the polymer beads substantially consist of polystyrene.

7. The dry-mix composition of any one of claims 1-6, wherein the polymer beads consist of polystyrene.

8. The dry-mix composition of any one of claims 1-7, wherein the polymer beads comprise a non-shredded polymer.

9. The dry-mix composition of any one of claims 1-8, wherein the polymer beads have a mean equivalent particle diameter of no greater than 2.4 mm or no greater than 2.3 mm or no greater than 2.2 mm or no greater than 2.1 mm or no greater than 2.0 mm or no greater than 1.9 mm or no greater than 1.8 mm.

10. The dry-mix composition of any one of claims 1-9, wherein the polymer beads have a mean equivalent particle diameter of at least 0.001 mm or at least 0.01 mm or at least 0.1 mm or at least 1.0 mm or at least 1.1 mm or at least 1.2 mm or at least 1.3 mm or at least 1.4 mm or at least 1.5 mm.

11. The dry -mix composition of any one of claims 1-10, wherein the polymer beads have a standard deviation in the equivalent particle diameter distribution of no greater than 0.3 mm or no greater than 0.28 mm or no greater than 0.26 mm or no greater than 0.24 mm or no greater than 0.22 mm or no greater than 0.20 mm or no greater than 0.18 mm.

12. The dry-mix composition of any one of claims 1-11, wherein the polymer beads have a standard deviation in the equivalent particle diameter distribution of at least 0.001 mm or at least 0.01 mm or at least 0.1 mm.

13. The dry -mix composition of any one of claims 1-12, wherein the polymer beads have a mean circularity of at least 0.85 or at least 0.86 or at least 0.87 or at least 0.88 or at least 0.89.

14. The dry-mix composition of any one of claims 1-13, wherein the polymer beads have a mean circularity of no greater than or equal to 1 or no greater than 1.

15. The dry -mix composition of any one of claims 1-14, wherein the polymer beads have an aspect ratio of no greater than 5: 1 or no greater than 4: 1 or no greater than 3: 1 or no greater than 2:1 or no greater than 1.5: 1 or no greater than 1.3: 1 or no greater than 1.1 : 1.

16. The dry -mix composition of any one of claims 1-15, wherein the polymer beads have an open cell content of no greater than 50% or no greater than 45% or no greater than 40% or no greater than 35% or no greater than 30% or no greater than 25% or no greater than 20% or no greater than 15% or no greater than 10% or no greater than 5% or substantially no open cell content.

17. The dry -mix composition of any one of claims 1-16, wherein the polymer beads have a packing density of at least 10 g / L or at least 11 g / L or at least 12 g / L or at least 13 g / L.

18. The dry -mix composition of any one of claims 1-17, wherein the polymer beads have a packing density of no greater than 100 g / L or no greater than 90 g / L or no greater than 80 g / L or no greater than 70 g / L or no greater than 60 g / L.

19. The dry -mix composition of any one of claims 1-18, wherein the dry-mix composition comprises polymer beads in an amount of at least 0.001 wt.% or at least 0.01 wt.% or at least 0.1 wt.% or at least 0.5 wt.% or at least 1 wt.% or at least 1.5 wt.% or at least 2 wt.% or at least 2.5 wt.% or at least 3 wt.%, based on a total weight of the dry-mix composition.

20. The dry -mix composition of any one of claims 1-19, wherein the dry-mix composition comprises polymer beads in an amount of no greater than 50 wt.% or no greater than 40 wt.% or no greater than 30 wt.% or no greater than 20 wt.% or no greater than 15 wt.% or no greater than 10 wt.% polymer beads or no greater than 7 wt.%, based on a total weight of the dry-mix composition.

21. The dry -mix composition of any one of claims 1-20, wherein the hydratable binder comprises calcium sulfate hemihydrate, cement, lime, or a combination thereof.

22. The dry -mix composition of any one of claims 1-21, wherein the hydratable binder comprises a cement in an amount of no greater than 5 wt.% or no greater than 4 wt.%, or no greater than 3 wt.%, or no greater than 2 wt.%, or no greater than 1 wt.%, or no greater than 0.5 wt.%, or no greater than 0.1 wt.%, based on a total weight of the dry -mix composition.

23. The dry -mix composition of any one of claims 1-22, wherein the hydratable binder does not comprise cement.

24. The dry-mix composition of any one of claims 1-23, wherein the dry-mix composition comprises a hydratable binder in an amount of at least 70 wt.% or at least 72 wt.% or at least74 wt.% or at least 76 wt.% or at least 78 wt.% or at least 80 wt.% or at least 82 wt.% or at least 84 wt.% hydratable binder or at least 85 wt.%, based on a total weight of the dry-mix composition.

25. The dry -mix composition of any one of claims 1-24, wherein the dry-mix composition comprises a hydratable binder in an amount of no greater than 99 wt.% or no greater than 95 wt.%, based on a total weight of the dry-mix composition.

26. The dry -mix composition of any one of claims 1-25, wherein the dry-mix composition further comprises a fibrous component.

27. The dry-mix composition of claim 26, wherein the fibrous component comprises cellulose fibers, glass fibers, or a combination thereof.

28. The dry -mix composition of claim 26 or claim 27, wherein the fibrous component comprises 0-20 wt.% cellulose or 4-20 wt.% cellulose, based on a total weight of the fibrous component.

29. The dry-mix composition of any one of claims 26-28, wherein the dry-mix composition comprises 0-2 wt.% glass fibers, based on a total weight of the fibrous component.

30. The dry-mix composition of any one of claims 1-29, wherein the compositon further comprises a foaming agent.

31. The dry -mix composition of claim 30, wherein the foaming agent comprises sodium alpha olefin sulfonates, sulfonated monoglycerides, sodium alkyl aryl sulfonate, sodium laurel sulfate, or a combination thereof.

32. The dry-mix composition of claim 30 or claim 31, wherein the dry-mix composition comprises 0.1-5% by wt. foaming agent, based on a total weight of the dry-mix composition.

33. The dry-mix composition of any one of claims 1-32, wherein the dry-mix composition further comprises an accelerator.

34. The dry-mix composition of any one of claims 1-33, wherein the dry-mix compositon further comprises a clay.

35. The dry -mix composition of claim 34, wherein the clay comprises attapulgite, sepiolite, bentonite, illite, or a combination thereof.

36. The dry-mix composition of claim 34 or claim 35, wherein the dry-mix composition comprises a clay in an amount of 1 to 12 wt.% or 4 to 8 wt.%, based on a total weight of the dry-mix composition.

37. The dry-mix composition of any one of claims 1-36, wherein the compositon further comprises a reactive filler.

38. The dry-mix composition of claim 37, wherein the reactive filler comprises calcium carbonate, sodium bicarbonate, or a combination thereof.

39. The dry-mix composition of claim 37 or claim 38, wherein the reactive filler comprises a particle size of 1 to 500 pm or 10 to 20 pm.

40. The dry-mix composition of any one of claims 37-39, wherein the dry-mix composition comrpises 1-10 wt.% reactive filler or 3-5 wt.% reactive filler based on a total weight of the dry-mix composition.

41. The dry -mix composition of any one of claims 1-40, wherein the dry-mix compositon further comprises a lightweight filler.

42. The dry-mix composition of claim 41, wherein the lightweight filler comprises expanded perlite, expanded vermiculite, shredded expanded polystyrene, stone wool, expanded glass beads, cenospheres, micronized rubber, or a combination thereof.

43. The dry -mix composition of claim 41 or claim 42, wherein the dry-mix composition comprises a lightweight filler other than polystyrene beads in an amount of no greater than 5 wt.% , or no greater than 4 wt.%, or no greater than 3 wt.%, or no greater than 2 wt.% , or no greater than 1 wt.%, or no greater than 0.5 wt.%, or no greater than 0.1 wt.%, based on a total weight of the dry-mix composition.

44. The dry-mix composition of any one of claims 1-43, wherein the dry-mix composition compries no lightweight fillers other than polymer or polystyrene beads.

45. The dry -mix composition of any one of claims 1-44, wherein the dry-mix compositon further comprises an inert filler.

46. The dry -mix composition of claim 45, wherein the inert filler comprises dolomite, limestone, sand, silica, bauxite or a combination thereof.

47. The dry-mix composition of claim 45 or claim 46, wherein the dry-mix composition comprises an inert filler other than polystyrene beads in an amount of no greater than 5 wt.% i, or no greater than 4 wt.%, or no greater than 3 wt.%, or no greater than 2 wt.%, or no greater than 1 wt.% i, or no greater than 0.5 wt.%, or no greater than 0.1 wt.% , based on a total weight of the dry-mix composition.

48. The dry-mix composition of any one of claims 1-47, wherein the dry-mix comprises no inert fillers other than polymer or polystyrene beads.

49. The dry -mix composition of any one of claims 1-48, wherein the dry-mix composition comprises aggregates other than polystyrene beads in an amount of no greater than 5 wt.%, or no greater than 4 wt.%, or no greater than 3 wt.%, or no greater than 2 wt.%, or no greaterthan 1 wt.%, or no greater than 0.5 wt.%, or no greater than 0.1 wt.% based on a total weight of the dry-mix composition.

50. The dry -mix composition of any one of claims 1-49, wherein the dry-mix composition comprises a sand in an amount of no greater than 5 wt.%, or no greater than 4 wt.%, or no greater than 3 wt.%, or no greater than 2 wt.%, or no greater than 1 wt.%, or no greater than 0.5 wt.%, or no greater than 0.1 wt.%, based on a total weight of the dry -mix composition.

51. The dry-mix composition of any one of claims 1-50, wherein the dry-mix comprises no aggregates other than polymer or polystyrene beads.

52. The dry-mix composition of any one of claims 1-51, further comprising an additive.

53. The dry -mix composition of claim 52, wherein the additive comprises fire resistive aggregates, flake mica, a super absorbent polymer, or a combination thereof.

54. The dry-mix composition of any one of claims 1-53, wherein the dry-mix composition has a dry bulk density of 15 to 16 lb / ft3.

55. A kit comprising the dry-mix composition of any one of claims 1-54 and an accelerator composition.

56. The kit of claim 55, wherein the accelerator composition comprises a fluid having viscosity in a range of 20-40 cP.

57. The kit of claim 55 or claim 56, wherein the accelerator composition comprises aluminum sulphate and water.

58. A wet-mix composition comprising the dry -mix composition of any one of claims 1-54 and water.

59. The wet-mix composition of claim 58, wherein the wet-mix comprises water in an amount of 0.6 to 1.75 by weight per total weight of dry-mix or 1.25 to 1.75 by weight per total weight of dry -mix or 1.25 to 1.75 by weight per total weight of dry -mix.

60. The wet-mix composition of claim 58, wherein the wet-mix has a setting time of 10 to 20 hours.

61. A method of preparing a plaster comprising: mixing the dry-mix composition of any one of claims 1-54 with water to prepare a wet-mix composition, applying the wet-mix composition to a surface of a substrate, and allowing the wet-mix composition to dry to form a plaster.

62. The method of claim 61, wherein the wet-mix composition has a setting time of 10 to 20 hours.

63. The method of claim 61 or claim 62, wherein the wet-mix composition comprises the wet-mix composition of any one of claims 58-60.

64. The method of any one of claims 61-63, wherein the wet-mix composition is mixed with an accelerator composition prior to or during application of the wet-mix to the surface of the substrate.

65. The method of claim 64, wherein the accelerator composition comprises a fluid having viscosity in a range of 20-40 cP.

66. The method of claim 64 or claim 65, wherein the accelerator composition comprises aluminum sulphate and water.

67. The method of any one of claims 61-66, wherein the step of applying the wet-mix composition to a surface of a substrate comprises applying the wet-mix composition to a surface of the substrate by hand or spraying the wet-mix composition to a surface of the substrate, or a combination thereof.

68. The method of any one of claims 61-67, wherein the substrate comprises metal, steel, concrete, polystyrene, wood, or a composite.

69. A plaster having a composition comprising a binder and polymer beads, the polymer beads having a mean equivalent particle diameter of no greater than 2.5 mm.

70. The plaster of claim 69, wherein the polymer beads comprise an expanded polymer, a non-expanded polymer, or a combination thereof.

71. The plaster of claim 69 or claim 70, wherein the polymer beads comprise an expanded polymer.

72. The plaster of any one of claims 69-71, wherein the polymer beads comprise polystyrene.

73. The plaster of any one of claims 69-72, wherein the polymer beads comprise expanded polystyrene.

74. The plaster of any one of claims 69-73, wherein the polymer beads substantially consist of polystyrene.

75. The plaster of any one of claims 69-74, wherein the polymer beads consist of polystyrene.

76. The plaster of any one of claims 69-75, wherein the polymer beads comprise a nonshredded polymer.

77. The plaster of any one of claims 69-76, wherein the polymer beads have a mean equivalent particle diameter of no greater than 2.4 mm or no greater than 2.3 mm or no greater than 2.2 mm or no greater than 2.1 mm or no greater than 2.0 mm or no greater than 1.9 mm or no greater than 1.8 mm.

78. The plaster of any one of claims 69-77, wherein the polymer beads have a mean equivalent particle diameter of at least 0.001 mm or at least 0.01 mm or at least 0.1 mm or at least 1.0 mm or at least 1.1 mm or at least 1.2 mm or at least 1.3 mm or at least 1.4 mm or at least 1.5 mm.

79. The plaster of any one of claims 69-78, wherein the polymer beads have a standard deviation in the equivalent particle diameter distribution of no greater than 0.3 mm or no greater than 0.28 mm or no greater than 0.26 mm or no greater than 0.24 mm or no greater than 0.22 mm or no greater than 0.20 mm or no greater than 0.18 mm.

80. The plaster of any one of claims 69-79, wherein the polymer beads have a standard deviation in the equivalent particle diameter distribution of at least 0.001 mm or at least 0.01 mm or at least 0.1 mm.

81. The plaster of any one of claims 69-80, wherein the polymer beads have a mean circularity of at least 0.85 or at least 0.86 or at least 0.87 or at least 0.88 or at least 0.89.

82. The plaster of any one of claims 69-81, wherein the polymer beads have a mean circularity of no greater than or equal to 1 or no greater than 1.

83. The plaster of any one of claims 69-82, wherein the polymer beads have a primary aspect ratio of no greater than 5: 1 or no greater than 4: 1 or no greater than 3: 1 or no greater than 2: 1 or no greater than 1.5: 1 or no greater than 1.3:1 or no greater than 1.1 : 1.

84. The plaster of any one of claims 69-83, wherein the polymer beads have an open cell content of no greater than no greater than 50% or no greater than 45% or no greater than 40% or no greater than 35% or no greater than 30% or no greater than 25% or no greater than 20% or no greater than 15% or no greater than 10% or no greater than 5% or substantially no open cell content.

85. The plaster of any one of claims 69-84, wherein the polymer beads have a packing density of at least 10 g / L or at least 11 g / L or at least 12 g / L or at least 13 g / L.

86. The plaster of any one of claims 69-85, wherein the polymer beads have a packing density of 100 g / L or no greater than 90 g / L or no greater than 80 g / L or no greater than 70 g / L or no greater than 60 g / L.

87. The plaster of any one of claims 69-86, wherein the plaster comprises polymer beads in an amount of at least 0.001 wt.% or at least 0.01 wt.% or at least 0.1 wt.% or at least 0.5 wt.% p or at least 1 wt.% or at least 1.5 wt.% or at least 2 wt.% or at least 2.5 wt.% or at least 3 wt.% p, based on a total weight of the plaster.

88. The plaster of any one of claims 69-87, wherein the plaster comprises polymer beads in an amount of no greater than 50 wt.% or no greater than 40 wt.% or no greater than 30 wt.%or no greater than 20 wt.% or no greater than 15 wt.% or no greater than 10 wt.% or no greater than 7 wt.%, based on a total weight of the plaster.

89. The plaster of any one of claims 69-88, wherein the plaster comprises the binder in an amount of at least 70 wt.% or at least 72 wt.% or at least 74 wt.% or at least 76 wt.% or at least 78 wt.% or at least 80 wt.% or at least 82 wt.% or at least 84 wt.% or at least 85 wt.%, based on a total weight of the plaster.

90. The plaster of any one of claims 69-89, wherein the plaster comprises the binder in an amount of no greater than 99 wt.% or no greater than 95 wt.%, based on a total weight of the plaster.

91. The plaster of any one of claims 69-90, wherein the binder comprises calcium sulfate hemihydrate, cement, lime, or a combination thereof.

92. The plaster of any one of claims 69-91, wherein the binder comprises cement in an amount of no greater than 5 wt.% or no greater than 4 wt.%, or no greater than 3 wt.%, or no greater than 2 wt.%, or no greater than 1 wt.%, or no greater than 0.5 wt.%, or no greater than 0.1 wt.%, based on a total weight of the plaster.

93. The plaster of any one of claims 69-92, wherein the binder does not comprise cement.

94. The plaster of any one of claims 69-93, wherein the plaster further comprises a fibrous component.

95. The plaster of claim 94, wherein the fibrous component comprises cellulose fibers, glass fibers, or a combination thereof.

96. The plaster of claim 94 or claim 95, wherein the fibrous component comprises 0-20 wt.% cellulose or 4-20 wt.% cellulose, based on a total weight of the fibrous component.

97. The plaster of any one of claims 94-96, wherein the fibrous component comprises 0-2 wt.% glass fibers, based on a total weight of the fibrous component.

98. The plaster of any one of claims 69-97, wherein the plaster further comprises an accelerator.

99. The plaster of any one of claims 69-98, wherein the plaster further comprises a clay.

100. The plaster of claim 99, wherein the clay comprises attapulgite, sepiolite, bentonite, illite, or a combination thereof.

101. The plaster of claim 99 or claim 100, wherein the plaster comprises 1 to 12 wt.% clay or 4 to 8 wt.% clay, based on a total weight of the plaster.

102. The plaster of any one of claims 69-101, wherein the compositon further comprises a reactive filler.

103. The plaster of claim 102, wherein the reactive filler comprises calcium carbonate, sodium bicarbonate, or a combination thereof.

104. The plaster of claim 102 or claim 103, wherein the reactive filler comprises a particle size of 1 to 500 pm or 10 to 20 pm.

105. The plaster of any one of claims 102-104, wherein the plaster composition comrpises 1- 10 wt.% reactive filler or 3-5 wt.% reactive filler, based on a total weight of the plaster.

106. The plaster of any one of claims 69-105, wherein the plaster compositon further comprises a lightweight filler.

107. The plaster of claim 106, wherein the lightweight filler comprises expanded perlite, expanded vermiculite, shredded expanded polystyrene, stone wool, expanded glass beads, cenospheres, micronized rubber, or a combination thereof.

108. The plaster of claim 106 or claim 107, wherein the plaster composition comprises the lightweight filler other than polystyrene beads in an amount of no greater than 5 wt.%, or no greater than 4 wt.%, or no greater than 3 wt.% 1, or no greater than 2 wt.%, or no greater than 1 wt.%, or no greater than 0.5 wt.%, or no greater than 0.1 wt.%, based on a total weight of the plaster composition.

109. The plaster of any one of claims 69-108, wherein the plaster composition compries no lightweight fillers other than polymer or polystyrene beads.

110. The plaster of any one of claims 69-109, wherein the plaster compositon further comprises an inert filler.

111. The plaster of claim 110, wherein the inert filler comprises dolomite, limestone, sand, silica, bauxite, or a combination thereof.

112. The plaster of claim 110 or claim 111, wherein the plaster composition comprises the inert filler other than polystyrene beads in an amount of no greater than 5 wt.%, or no greater than 4 wt.%, or no greater than 3 wt.%, or no greater than 2 wt.%, or no greater than 1 wt.%, or no greater than 0.5 wt.%, or no greater than 0.1 wt.%, based on a total weight of the plaster composition.

113. The plaster of any one of claims 69-112, wherein the plaster comprises no inert fillers other than polymer or polystyrene beads.

114. The plaster of any one of claims 69-113, wherein the plaster composition comprises aggregates other than polystyrene beads in an amount of no greater than 5 wt.% , or no greater than 4 wt.%, or no greater than 3 wt.%, or no greater than 2 wt.%, or no greater than 1 wt.%, or no greater than 0.5 wt.% aggregates, or no greater than 0.1 wt.%, based on a total weight of the plaster.

115. The plaster of any one of claims 69-114, wherein the plaster composition comprises a sand in an amound of no greater than 5 wt.%, or no greater than 4 wt.%, or no greater than 3 wt.%, or no greater than 2 wt.%, or no greater than 1 wt.%, or no greater than 0.5 wt.%, or no greater than 0.1 wt.%, based on a total weight of the plaster.

116. The plaster of any one of claims 69-115, wherein the plaster comprises no aggregates other than polymer or polystyrene beads.

117. The plaster of any one of claims 69-116, further comprises an additive.

118. The plaster of claim 117, wherein the additive comprises fire resistive aggregates, flake mica, a super absorbent polymer, or a combination thereof.

119. The plaster of any one of claims 69-118, further comprising aluminum sulphate.

120. The plaster of any one of claims 69-119, wherein the plaster is a fire-resistant plaster.

121. The plaster of any one of claims 69-120, wherein the plaster exhibits a Mean Max Z peak-Valley Profile of no greater than 1505 pm or no greater than 1500 pm or no greater than 1495 pm as measured using X-ray tomography.

122. The plaster of any one of claims 69-121, wherein the plaster exhibits a Mean Max Z peak-Valley Profile of at least 500 pm or at least 1000 pm or at least 1250 pm or at least 1400 pm, as measured using X-ray tomography.

123. The plaster of any one of claims 69-122, wherein the plaster exhibits an Amplitude Max Z peak-Valley Profile of no greater than 1550 pm or no greater than 1525 pm or no greater than 1500 pm or no greater than 1475 pm or no greater than 1450 pm or no greater than 1425 pm or no greater than 1400 pm, as measured using X-ray tomography.

124. The plaster of any one of claims 69-123, wherein the plaster exhibits an Amplitude Max Z peak-Valley Profile of at least 500 pm or at least 750 pm or at least 1000 pm or at least 1200 pm as measured using X-ray tomography.

125. The plaster of any one of claims 69-124, wherein the plaster exhibits a Mean Max Z peak-Valley waviness of no greater than 950 pm or no greater than 925 pm or no greater than 900 pm or no greater than 875 pm, as measured using X-ray tomography.

126. The plaster of any one of claims 69-125, wherein the plaster exhibits a Mean Max Z peak-Valley waviness of at least 500 pm or at least 600 pm or at least 700 pm or at least 800 pm, as measured using X-ray tomography.

127. The plaster of any one of claims 69-126, wherein the plaster exhibits a surface hardness of at least 3.2 mm or at least 3.4 mm or at least 3.6 mm or at least 3.8 mm or at least 4.0 mm or at least 4.2 mm or at least 4.4 mm or at least 4.6 mm or at least 4.8 mm, as measured according to EN- 13279-2.

128. The plaster of any one of claims 69-127, wherein the plaster exhibits a surface hardness of no greater than 50 mm or no greater than 20 mm or no greater than 10 mm, as measured according to EN- 13279-2.

129. The plaster of any one of claims 69-128, wherein the plaster exhibits a shore C hardness of at least 16 or at least 17 or at least 18 or at least 19 or at least 20 or at least 21 or at least 22 or at least 23 or at least 24 or at least 25 or at least 26, as measured according to EN 102042:2014.

130. The plaster of any one of claims 69-129, wherein the plaster exhibits a shore C hardness no greater than 100 or no greater than 75 or no greater than 50, as measured according to EN 102042:2014.

131. The plaster of any one of claims 69-130, wherein the plaster exhibits a flexural strength of at least 0.073 KN or at least 0.074 KN or at least 0.075 KN or at least 0.076 KN or at least 0.077 KN or at least 0.078 KN or at least 0.079 KN or at least 0.080 KN or at least 0.081 KN or at least 0.082 KN or at least 0.083 KN or at least 0.084 KN, as measured according to EN- 13279-2.

132. The plaster of any one of claims 69-130, wherein the plaster exhibits a flexural strength of no greater than 1 KN or at least 0.5 KN or at least 0.25 KN or at least 0.10 KN, as measured according to EN- 13279-2.

133. The plaster of any one of claims 70-133, which is obtained by a method as defined in any one of claims 61-68.

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