Effective use of dispersants in wallboard containing foam results from a
method where stucco is mixed with a first dispersant and a first quantity
of water to form a gypsum slurry. A soap is blended with a second
dispersant and a second quantity of water to make a foam. Subsequently,
the foam is combined with the slurry. Choice of different first and
second dispersants and their relative amounts allows control of the size
distribution of the foam bubbles in the slurry and the resulting voids in
the gypsum core. Use of the same dispersant in both the mixer and the
foam water provides a boost in efficacy of the dispersant.