A gypsum board having roughened surface glass fiber reinforcement. The
roughened surface of glass fiber is created by incorporating nano or
micro particles of colloidal silica or clay or other inorganic particles
in a silane based sizing composition. The sizing coating is partially or
completely cured and incorporated in gypsum wet mix either as additions
of chopped fibers or as placement of roughened surface glass fiber mats
at selected locations within a cast gypsum sheet. The roughened surface
of glass fiber with nano or micro particles compliantly bonded with
silane polymer transfers load from gypsum to glass fibers providing
improved strength and flexure resistance of gypsum boards.