Lightweight composite panels including an inorganic foam core, compositions used to make lightweight composite panels, and methods for manufacturing lightweight composite panels. The lightweight composite panels include a lightweight inorganic foam core sandwiched between thin protective
layers selected from
fiber mesh reinforced cementitious layer, thermoset
polymer layer, e.g.,
polyurea or
polyaspartic, or facer layer. The lightweight composite panels can be used in place of conventional wallboards and panels, including for various uses such as interior
drywall, backer boards for tile and other interior finishes, including those exposed to
moisture, exterior sheathing, floor underlayment, soffits, roofing decks, shaft liners, and the like. The lightweight composite panels can be
cut, drilled, and screwed onto structural elements of buildings, such as wall frames comprising wooden or
metal studs, roof frames comprising boards, studs, or trusses, floor joists, concrete floors, foundations, and the like. Exterior sheathing panels can include a drainage layer and / or a factory installed finish.