AU2009201848A1 - Structure and Production Method of Cement Board - Google Patents

Structure and Production Method of Cement Board Download PDF

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Publication number
AU2009201848A1
AU2009201848A1 AU2009201848A AU2009201848A AU2009201848A1 AU 2009201848 A1 AU2009201848 A1 AU 2009201848A1 AU 2009201848 A AU2009201848 A AU 2009201848A AU 2009201848 A AU2009201848 A AU 2009201848A AU 2009201848 A1 AU2009201848 A1 AU 2009201848A1
Authority
AU
Australia
Prior art keywords
fiber
cement
cement board
carrier
curing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
AU2009201848A
Inventor
Chien-An Lin
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Shih Chia Feng Mr
Original Assignee
CHIA FENG SHIH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by CHIA FENG SHIH filed Critical CHIA FENG SHIH
Priority to AU2009201848A priority Critical patent/AU2009201848A1/en
Publication of AU2009201848A1 publication Critical patent/AU2009201848A1/en
Abandoned legal-status Critical Current

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/06Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres reinforced
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00Producing shaped prefabricated articles from the material
    • B28B1/50Producing shaped prefabricated articles from the material specially adapted for producing articles of expanded material, e.g. cellular concrete
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/04Portland cements
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/30Nailable or sawable materials
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/52Sound-insulating materials

Description

Patent Application with Complete Specification The following statement is a full description of this invention, including the best method of performing it 5 known to me. [ Title ] Structure and Production Method of Cement Board 10 [ Abstract] This invention describes the structure and its production method for a cement board. The structure of this cement board is formed by stirring the mixture of water, cement, expandable Polystyrene (EPS), polypropylene (PP) fiber, 15 and emulsion resin; which follows grouting, coagulating and mold release processes for shaping. The production includes a platform mixer for material preparation; a first carrier that carries and places the horizontal mold at the outlet of the platform mixer as the formation step; 20 the concrete is poured into the horizontal mold as the grouting procedure; initial setting is performed for the concrete to form into a cement board; after the completion of the initial setting the cement board is separated from the horizontal mold on the first carrier 1 as the mold release process; the cement board is then placed onto the second carrier and at the same time the first carrier returns to formation step; the second carrier is placed in the steam curing room to proceed 5 with curing; after curing the cement board is sent to the cutting area for cutting. By above, the structure of the cement board is enhanced to stronger which has the functions of fireproofing, sound insulating, and easy to be nailed by using standard nails or hooks without 10 fracture. [ Field of Technology] This invention is related to the structure and its production method of a cement board, which especially 15 describe the enhancement of the structure of this cement board. This invention enables the cement board to have the functions of fireproofing, sound insulating, and easy to be nailed by using standard nails or hooks without fracture. 20 [ Existing techniques] According to IPC patent no. B32B-013/02 "A process for producing a woody cement sound-insulating plank and the woody cement sound-insulating plank prepared by 2 the process", the production of conventional cement boards include the following manufacturing procedures: (i) Immerse the flake-shape wooden material in the water; 5 (ii) Remove the immersed wooden material and place it into a container. During stirring, sequentially add the surface-active agent, cement powder, and hardener to mix homogeneously; of the above during adding of the surface-active agent 10 and hardener, simultaneously adding appropriate amount of water; (iii) After initial setting of the mixture, stir and pour it into the mold and then pressurization for forming. 15 (iv) Pre-setting is done before or after mold release; and (v) Steam curing according to the situation and then oven-dry or air-dry. Although previously mentioned woody cement 20 sound-insulating plank can indeed achieve sound insulating performance, however it is not fireproofing; furthermore according to IPC patent no. E04C-002/04 "Fiber-cement/gypsum laminate composite building material" (Please refer to Figure 4), it must at least 3 include: a fiber cement board 90; and a gypsum board 91; the fiber cement board 90 is laid on the gypsum board 91 to form a individual laminate composite board 9, which conform to ASTM E119 specification with the 5 fire rating of at least 1 hour. Although the above has fireproofing performance, however it does not possess sound insulating function. Thus, both previously mentioned conventional cement boards do not concurrently possess both fireproofing and 10 sound insulating capabilities. In addition, if a nail is directly nailed onto the board, fracture is caused to the cement board. To avoid the fracture we need to use IPC patent no. E04D-003/365 "Improved nail structure used in fixing coated corrugated board (or Calcium Silicate 15 Board)" (Please refer to Figure 5). The nailing body 92 is composed of board 93, which the front end of the board 93 forms a sharp angle end 94. In addition, the middle part of the board 93 is installed with several crossed corresponding barbs 95. The rear end of the board 93 20 has a vertical fixed end 96; on the fixed end 96 there is a fixed surface and an impact surface 97. The impact surface corresponds to the firing pin of a nail gun. Thus for those two previously mentioned type of cement boards, not only can they concurrently possess the 4 functions of fireproofing and sound insulating, but also a special structured nail is to be used. Ordinary nails cannot be used. Therefore, conventional techniques are not suitable for practical requirements. 5 [Content of the invention] The main purpose of this invention is to solve the defects above, this invention can enhanced the structure of the cement board, and to enable the cement board 10 has the capabilities of fireproofing, sound insulating, and easy to be nailed by using standard nails or hooks without fracture. To achieve the above purpose, this invention is a cement board production method. The structure of the cement 15 board is the mixture of water, cement, polystyrene (EPS), polypropylene (PP) fiber, and emulsion resin; by stirring, grouting, coagulating and mold release processes for shaping. This method is sequentially done by adding water, self-curing materials, injection molding foam, 20 filling materials, and water-base structural materials into a platform mixer, and make them homogenized by stirring to form into concrete prior to grouting process; the horizontal mold on the first carrier is placed at the outlet of the platform mixer, and the concrete is poured 5 into the horizontal mold; and the first carrier along with the horizontal mold and concrete is placed in a warm house for initial setting, after the completion of initial setting the concrete in the horizontal mold become a 5 cement board; after mold release the cement board in the horizontal mold on the first carrier is placed onto the second carrier and the first carrier returns to formation step; the cement board on the second carrier is then placed to the steam curing room; after steam 10 curing the cement board is sent to cutting area to proceed with cutting procedure, which the second carrier returns to mold release step. [Performing Method] 15 Please refer to Figure 1, structure illustration of the cement board of this invention. As shown in the figure: the structure of the cement board 1 was formed by stirring the mixture of water, cement 11, polystyrene (EPS) 12, polypropylene fiber (PP) 13, and emulsion 20 resin, and to coagulate for shaping; so that the structure of the cement board was enhanced with the functions of fireproofing, sound insulation, and easy to be nailed by using standard nails or hooks without fracture. 6 Please refer to Figure 2 & 3, the production flow chart of the invention. As shown in the figure: the invention describes the structure of a cement board and its production method, the method includes the steps at 5 least of material preparation 2, formation 3, grouting 4, initial setting 5, mold release 6, curing 7, and cutting 8; Descriptions of those steps above are as follows: a. Material preparation 2: Pour sequentially into the platform mixer 21 a determined amount of water, two 10 packs of self-curing materials, determined amount of injection molding foam, stuffing material, and water-base structural material, and then the concrete is formed by proceed with stirring, and at last to perform material preparation prior to grouting 15 procedure. Among of above, the self-curing material is cement, which the cement can be standard Portland cement Type I, Type II, Type III and Type V, or can be Portland blast-furnace slag cement Type IS; The injection molding foam is a light weight 20 particulate material, which can be natural pumice or artificial polystyrene (EPS). This foam is shaped by steam via steam boiler; The stuffing material can be an inorganic particulate filler (including hollow particles), this filler can be a siliceous material (such 7 as silica powder and clay), carbon black basic alkaline earth metal carbonate (such as calcium carbonate and magnesium carbonate), inorganic oxides (such as aluminum dioxide, aluminum oxide, 5 titanium dioxide, and zirconium dioxide), inorganic hydroxides (such as calcium hydroxide, magnesium hydroxide, and aluminum hydroxide); The stuffing material can be an inorganic particulate filler (such as spherical silicon); The stuffing material can be a 10 fiber filler, and this fiber filler includes inorganic fiber filling materials (such as aluminum oxide fiber, alkali proof glass fiber, carbon fiber, silicon carbide fiber, asbestos, asbestos wool and slag) and organic fiber filling materials (such as nylon fiber, ethylene 15 fiber and polypropylene fiber); the filler can be a metal fiber (such as steel fiber and stainless steel fiber ); The water-base structural material is emulsion resin, which the emulsion resin can be epoxy and polyester. 20 b. Formation 3: Place the first carrier 31 which contains the horizontal mold 32 at the outlet site of the platform mixer 22. c. Grouting 4: Pour the concrete 23 in the platform mixer 22 into the horizontal mold 32 on the first 8 carrier. d. Initial setting 5: Place the first carrier 31 (which includes the horizontal mold 32 and concrete 23) in a warm room to proceed with coagulation for 6 hours. 5 The temperature of this room is controlled at 25~30C; so that the concrete 23 in the horizontal mold 32 shall form into cement board 51. e. Mold release 6: After the completion of the initial setting, the cement board 51 is separated from the 10 horizontal mold 32 on the first carrier 31, and then the cement board 51 is placed onto the second carrier 61. The first carrier 31 returns to formation 3 step. f. Curing 7: After the cement board 51 is placed on the 15 second carrier 61 the second carrier is then placed in a curing room 71 to proceed with steam curing for 8 hours, which the temperature is controlled at 60-70'C g. Cutting 8: After curing the cement board 51 will move to cutting area 81 to perform with cutting 20 procedure. The structure of the cement board 1 is shown in Figure 1. A dust collector is installed in cutting area 81 to remove the dust/particles generated during cutting. The second carrier 61 returns to mold release step. 9 From above, structure of the cement board and its production method in this invention can effectively improve the defects of the conventional laminate composite boards, the structure of the cement board is 5 enhanced to stronger which has the capabilities of fireproofing, sound insulating, and easy to be nailed by using standard nails or hooks without fracture. This invention is more improved, more applicable, and to better meet user's needs. This invention has indeed met 10 all the criteria for registration as a patent, so we propose a patent application under official regulations of the authorities. The description above is just the best known methods of carrying out in this invention, it should not be limited to 15 the application scope of this invention; Therefore, according to the contents and descriptions of this patent specification, any simple changes or modifications with equivalent functions, which should all be included within the patent scope of this invention. 20 [ Brief description of the figures] Figure 1, illustration of the cement board structure in this invention. Figure 2, production block diagram of this invention. 10 Figure 3, production flow chart of this invention. Figure 4, illustration of conventional laminate composite boards. Figure 5 & 6, illustration of conventional nailing body. 5 [ Description of the main component] (For part of this invention) Cement board 1 Cement 11 10 Polystyrene 12 Polypropylene fiber 13 Material preparation 2 Platform mixer 21 Concrete 23 15 Formation 3 First carrier 31 Horizontal mold 32 Grouting 4 Initial setting 5 20 Cement board 51 Mold release 6 Second carrier 61 Curing 7 Steam curing room 71 11 Cutting 8 Cutting area 81 (For part of conventional design) Laminate composite boards 9 5 Fiber cement board 90 Gypsum board 91 Nailing body 92 Board 93 Sharp angle end 94 10 Barbs 95 Fixed end 96 Impact surface 97 [The claims defining the invention are as follows] 15 1. A cement board structure. The structure of this cement board is formed by stirring the mixture of water, cement, expandable Polystyrene (EPS), polypropylene (PP) fiber, and emulsion resin; which follows grouting, coagulating and mold release 20 processes for shaping. 2. A production method of a cement board, which includes at least the following steps: a. Material preparation: Sequentially pour the water, self-curing materials, injection molding foam, 12 stuffing material, and water-base structural material into the platform mixer 21 and then the concrete is formed by stirring; b. Formation: The horizontal mold on the first 5 carrier is placed at the outlet of the platform mixer; c. Grouting: The concrete is poured into the horizontal mold on the platform mixer as the grouting procedure; 10 d. Initial setting: The concrete in the horizontal mold on the first carrier is placed in a warm room to proceed with initial setting, after the completion of initial setting the concrete become a cement board; 15 e. Mold release: After the completion of the initial coagulation the cement board is separated from the horizontal mold on the first carrier. Place the cement board onto the second carrier, and the first carrier returns to formation step; 20 f. Curing: After the cement board is placed on the second carrier, it is placed in a steam curing room to proceed with curing; g. Cutting: After curing the cement board will move to cutting area to perform with cutting procedure. 13 The second carrier returns to mold ejection step. 3. According to claim 2, which the self-curing material is cement. The cement could be of standard Portland cement Type I, Type II, Type III, and Type V. 5 4. According to claim 2, which the self-curing material is cement. The cement could be of Portland blast-furnace slag cement Type IS. 5. According claim 2, which the injection molding foam is a light weight particulate material. 10 6. According to claim 5, which the light weight particulate material could be of natural pumice, or artificial products of polystyrene (EPS) 7. According to claim 2, The stuffing material can be an inorganic particulate filler (including hollow 15 particles) 8. According to claim 7, the inorganic particulate filler can be a siliceous material (such as silica powder and clay), carbon black basic alkaline earth metal carbonate (such as calcium carbonate and 20 magnesium carbonate), inorganic oxides (such as aluminum dioxide, aluminum oxide, titanium dioxide, and zirconium dioxide), inorganic hydroxides (such as calcium hydroxide, magnesium hydroxide, and aluminum hydroxide); 14 9. According to claim 7, the inorganic particulate filler can be spherical silicon. 10. According to claim 2, the stuffing material can be a fiber filler, and this fiber filler includes inorganic 5 fiber filling materials and organic fiber filling materials; 11. According to claim 10, which the inorganic fiber filling materials could be aluminum oxide fiber, alkali proof glass fiber, carbon fiber, silicon carbide fiber, 10 asbestos, asbestos wool and slag; 12. According to claim 10, which the organic fiber filling materials could be Nylon fiber, ethylene fiber, and PP fiber. 13. According to claim 2, the filler can be a metal fiber; 15 14. According to claim 14, which the metal fiber could be steel fiber and stainless steel fiber; 15.According to claim 2, the water-base structural material is emulsion resin, which the emulsion resin can be epoxy and polyester. 20 16. According to claim 2, which the room temperature of the warm room is between 25~30'C. 17. According to claim 2, which the initial setting time is 6 hours. 18. According to claim 2, which the temperature inside 15 the steam curing room is between 60~70C 19. According to claim 2, which the steam curing duration time is 8 hours. 20. According to claim 2, which a dust collector is 5 installed in the cutting area, the purpose is to remove the dust/particles generated during cutting the cement board. 10 The illustration figures are shown in the following pages. 16

Claims (16)

  1. 2. A production method of a cement board, which includes at least the following steps: a. Material preparation: Sequentially pour the water, self-curing materials, injection molding foam, 15 stuffing material, and water-base structural material into the platform mixer 21 and then the concrete is formed by stirring; b. Formation: The horizontal mold on the first carrier is placed at the outlet of the platform 20 mixer; c. Grouting: The concrete is poured into the horizontal mold on the platform mixer as the grouting procedure; d. Initial setting: The concrete in the horizontal 1 mold on the first carrier is placed in a warm room to proceed with initial setting, after the completion of initial setting the concrete become a cement board; 5 e. Mold release: After the completion of the initial coagulation the cement board is separated from the horizontal mold on the first carrier. Place the cement board onto the second carrier, and the first carrier returns to formation step; 10 f. Curing: After the cement board is placed on the second carrier, it is placed in a steam curing room to proceed with curing; g. Cutting: After curing the cement board will move to cutting area to perform with cutting procedure. 15 The second carrier returns to mold ejection step.
  2. 3. According to claim 2, which the self-curing material is cement. The cement could be of standard Portland cement Type I, Type II, Type III, and Type V.
  3. 4. According to claim 2, which the self-curing material 20 is cement. The cement could be of Portland blast-furnace slag cement Type IS.
  4. 5. According claim 2, which the injection molding foam is a light weight particulate material.
  5. 6. According to claim 5, which the light weight 2 particulate material could be of natural pumice, or artificial products of polystyrene (EPS)
  6. 7. According to claim 2, The stuffing material can be an inorganic particulate filler (including hollow 5 particles)
  7. 8. According to claim 7, the inorganic particulate filler can be a siliceous material (such as silica powder and clay), carbon black basic alkaline earth metal carbonate (such as calcium carbonate and 10 magnesium carbonate), inorganic oxides (such as aluminum dioxide, aluminum oxide, titanium dioxide, and zirconium dioxide), inorganic hydroxides (such as calcium hydroxide, magnesium hydroxide, and aluminum hydroxide); 15 9. According to claim 7, the inorganic particulate filler can be spherical silicon.
  8. 10. According to claim 2, the stuffing material can be a fiber filler, and this fiber filler includes inorganic fiber filling materials and organic fiber filling 20 materials;
  9. 11. According to claim 10, which the inorganic fiber filling materials could be aluminum oxide fiber, alkali proof glass fiber, carbon fiber, silicon carbide fiber, asbestos, asbestos wool and slag; 3
  10. 12. According to claim 10, which the organic fiber filling materials could be Nylon fiber, ethylene fiber, and PP fiber.
  11. 13. According to claim 2, the filler can be a metal fiber; 5 14. According to claim 14, which the metal fiber could be steel fiber and stainless steel fiber;
  12. 15. According to claim 2, the water-base structural material is emulsion resin, which the emulsion resin can be epoxy and polyester. 10 16. According to claim 2, which the room temperature of the warm room is between 25~30C.
  13. 17. According to claim 2, which the initial setting time is 6 hours.
  14. 18. According to claim 2, which the temperature inside 15 the steam curing room is between 60~70C
  15. 19. According to claim 2, which the steam curing duration time is 8 hours.
  16. 20. According to claim 2, which a dust collector is installed in the cutting area, the purpose is to 20 remove the dust/particles generated during cutting the cement board. END 4
AU2009201848A 2009-05-06 2009-05-06 Structure and Production Method of Cement Board Abandoned AU2009201848A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
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Application Number Priority Date Filing Date Title
AU2009201848A AU2009201848A1 (en) 2009-05-06 2009-05-06 Structure and Production Method of Cement Board

Publications (1)

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2480807A (en) * 2010-05-27 2011-12-07 John Parry A low density construction material
CN109176829A (en) * 2018-09-30 2019-01-11 潮州市联源陶瓷制作有限公司 It is a kind of to be molded into pulp grinder for the folded of household porcelain production
CN114804793A (en) * 2022-05-27 2022-07-29 江西龙正科技发展有限公司 Industrial slag solid waste light fireproof partition plate
CN115403329A (en) * 2022-08-16 2022-11-29 东至丰达混凝土有限公司 Concrete based on solid waste recycling and preparation method thereof
CN115475780A (en) * 2022-09-26 2022-12-16 金海龙 Preparation process of PP composite material

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2480807A (en) * 2010-05-27 2011-12-07 John Parry A low density construction material
CN109176829A (en) * 2018-09-30 2019-01-11 潮州市联源陶瓷制作有限公司 It is a kind of to be molded into pulp grinder for the folded of household porcelain production
CN114804793A (en) * 2022-05-27 2022-07-29 江西龙正科技发展有限公司 Industrial slag solid waste light fireproof partition plate
CN115403329A (en) * 2022-08-16 2022-11-29 东至丰达混凝土有限公司 Concrete based on solid waste recycling and preparation method thereof
CN115475780A (en) * 2022-09-26 2022-12-16 金海龙 Preparation process of PP composite material
CN115475780B (en) * 2022-09-26 2023-09-26 广州市文逸通讯设备有限公司 Preparation process of PP composite material

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