AU5338900A - Composite building material - Google Patents

Description

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT (Original) APPLICATION NO:

LODGED:

COMPLETE SPECIFICATION LODGED:

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PUBLISHED:

RELATED ART: NAME OF APPLICANT: ACTUAL INVENTOR(S): ADDRESS FOR SERVICE: AZMAN BIN HJ ZAHARI AZMAN BIN HJ ZAHARI LORD COMPANY Patent Trade Mark Attorneys 4 Douro Place West Perth, Western Australia, 6005

AUSTRALIA.

"COMPOSITE BUILDING MATERIAL" INVENTION TITLE: DETAILS OF ASSOCIATED PROVISIONAL APPLICATION NO'S: Malaysian Patent Application Number PI 20001258 filed on March 29, 2000 in Malaysia.

The following Statement is a full description of this invention including the best method of performing it known to me/us: TITLE OF THE INVENTION "COMPOSITE BUILDING MATERIAL" TECHNICAL FIELD The present invention relates to a composite material consisting of laterite, cellulosic materials, cement, fluids, preferably water, and optional preferably non-toxic waterproofing and anti-fungal additives and a process of manufacturing the same as an inexpensive alternative to conventional materials for, inter alia, constructing furniture, building structures, floors, walls, partitions, cladding and as an in-fill grout.

BACKGROUND ART It is known that conventional materials such as concrete, stone, brick, block, steel, timber and conventional boards such as plaster boards, woodchip boards, plywood and the like are used in the building industry to construct building structures, floors, walls, partitions, cladding and for making furniture. Each conventional material has stood the test of time but for whatever positive attributes they have, there are negative attributes. Although their initial costs are inexpensive, with time, due to rising costs of production and increasingly relatively high demand against supply, the costs of'the said conventional building materials are ever increasing.

Concrete, stone, bricks and blocks are dense, have high compressive strength, are durable and fire resistant in nature, each to a varying degree. However, they all have to be cast and or set in place. Until they are set and cured sufficiently, they cannot support their working load. Thus, the construction progress for buildings of this nature is relatively slow, being impeded by the setting and curing period, and thus it is particularly marked in multi-storey construction.

Conventional materials necessitate wet phases that form critical points on the work programme. These wet phases are critical activities because until they set, other works cannot proceed.

To overcome this delay, pre-cast modular construction was introduced. Success was limited however, being impeded by its relatively high cost and by the dense and heavy nature of the cast modular components.

Steel structures are lighter by comparison with poured and pre-cast modular concrete construction. Steel has high tensile, compressive and flexural strength. The construction of buildings with steel is not impeded by a setting and curing process, they are faster to build. However, in many parts of the world, they are relatively expensive and the skills required to erect them are much higher. When exposed to S-fire, they weaken in strength, thus, have to be fire-rated by encasing them back in concrete or coating cladding them with an insulating material.

*e Furthermore, steel rusts. To overcome this, the steel members are encased in S concrete, galvanized or attached to a sacrificial zinc anode, further enhancing its cost disadvantage.

The main advantage of timber is its high strength to weight ratio. It has good aesthetic appeal, may be easily sawed (even with precision on site), easily drilled and easily takes direct fixing, that is, it can be directly screwed or nailed to a surface.

However, due to its very destructive extraction process and scarcity of timbered areas, the timber industry is increasingly seen to be environmentally unfriendly.

Thus, timber has become a very expensive material except possibly, for where it is still abundant. In addition, if left untreated, timber is easily combustible, prone to attack from vermin such as termites, rot from fungus and other bio-elements.

Plaster boards, woodchip boards, plywood and the like are very light and fast to erect. Being light, they allow for a flexible internal layouts as they can be erected anywhere on an open floor space without the need for a beam or column underneath to carry its load, unlike brickwork. Plaster boards, woodchip boards, plywood and 4 the like when used with steel or timber stud flaming, are primarily used for internal partitions and ceilings, as most boards disintegrate when wet. They have low fire rating due to their hollow construction and the combustible nature of wood. In parts of the world where the raw materials are scarce, these boards are expensive. In some countries, buildings of this method of construction are perceived to be of low quality due to its hollow nature.

Malaysian Patent No. MY-100875-A discloses lightweight insulating boards and process for manufacturing the same. The invention comprises a composite material including cement, cellulose fibres, an alkali-resistant fibre material, mica, a light S: filler and hydrated lime. The composite is shaped into boards for internal structural

S.

*"use.

The invention disclosed by this said patent does not require the use of laterite because the purpose of this lightweight insulating board is for internal insulation only and is not suitable as a composite that could be used to construct a building because the board is not constituted to do so.

For example, it cannot provide sufficient structural strength or deadweight to the building, cannot withstand external use and is not weather-resistant.

The filler material required for this said patent is porous in order to trap air and primarily addresses an environmental issue of replacing asbestos with other suitable material and to dispense with the use of an autoclave for hardening the board.

British Patent No. 2802641A (as cited in the Malaysian patent above) relates to nonasbestos compression moulded heat-resistant load bearing board block having a matrix of cured hydraulic cement which is reinforced by both synthetic inorganic fibres and organic web-forming fibres and incorporates a micaceous material.

These patents are not targeted to be used as alternatives to known conventional materials for constructing a building per se but forms part of the insulation requirements for the building only.

The present invention is designed to cover a much wider scope of materials and is intended to be an economical and durable building material and to be utilised as panelling walls or composite structural members including columns, beams and floors, partitions, cladding, as an in-fill grout and even to make furniture.

Thus, the present invention addresses a much wider scope of problems arising out of the use of known conventional construction materials currently existing in the building industry.

DISCLOSURE AND OBJECTS OF THE INVENTION The present invention addresses the problems inherent with the conventional building materials today, primarily with regards to cost, speed and ease of .construction and ideal attributes.

The cost of conventional building materials are ever increasing due to the scarcity of supply in relation to demand and rising cost of production. Thus, with regards to cost, the objective of the present invention is to utilise bulk materials that are abundantly available in the world which are commonly discarded or disregarded wherein by today's standards, the same are inexpensive and in finding a new use for it, would contribute positively to environmental preservation.

With regard to the speed ease of construction and ideal attributes, the ideal attributes of conventional building materials were to be replicated as much as possible to produce a material having combined characteristics between wood and concrete insofar as the same would be light but not as light as wood, dense but not as dense as concrete, having the ability to be easily sawed, easily drilled, easily take direct fixes like wood and yet nonetheless, is able to be cast, moulded, extruded and injected, have good sound and thermal insulation, good compressive, tensile and 6 flexural strength, is durable, waterproof water-resistant, fire-resistant retardant, vermin and rot resistant and in having all these properties is yet environmentally friendly and can also be utilised modularly.

These ideal attributes are created when laterite, cellulosic materials, cement and fluids, preferably water, are combined in prescribed proportions.

The function of laterite is multiple in that it is naturally cohesive and plastic. Its cohesivity assists in binding. It crystallizes with the hydraulic binding agent to set hard. Its natural plasticizing qualities renders the composite workable without the need for further plasticizing agent such as lime.

The composite's plasticity may be varied to different degrees of firmness by varying the proportion of laterite and water (as disclosed in the Detailed Description of the 15 Preferred Embodiments below). For example, the composite may be made to range from a soft gel-like paste to a firm plastic material and this is the composite's key attribute which enables it to be cast, moulded, extruded and injected.

Laterite, in addition, acts as a bulk filler that provides density to the composite as 20 laterite is naturally a dense material, thus providing essential deadweight to the building. Density is also essential to provide good rebound properties to sound waves to insulate against air-borne noise.

oo,•• Laterite's inherent variety in granular sizes and impurities renders it coarser than, for example, clay or the like. Clay, due to its much more consistently fine make up, is not ideally suitable as clay would be too cohesive and lumpy to melange readily and easily in the composite's aqueous suspension.

The inherent coarse impurities in laterite assist further in providing compressive strength upon setting and hardening with a hydraulic binding agent.

Aggregates and sand on the other hand are of molecular sizes that are consistently too coarse and would make the composite too grainy and compromise its wood-like attribute to easily take direct fixes and ability to be easily drilled and sawed.

Further, laterite assists in insulating the organic fibers against oxidation when burnt and hence retards the burning process of the composite and provides an acceptable standard of fire-rating.

The function of cellulosic materials are also multiple in that it acts as the light bulk filler that provides the lightweight cells in the composite that reduces the .*.composite's overall density and provides for good thermal insulation. Cellulosic materials further provide for the wood-like attributes to the composite. The interlacing web that it creates acts as a reinforcement and assists in providing the 15 composite's tensile and flexural strength.

The composite created from the combination of laterite and cellulosic materials is ,ooe relatively light in weight but yet has the requisite dense properties for effective air- S. .borne sound insulation.

c Ordinary cement functions as an overall hydraulic binder which enhances the composite's structural strength. Other types of cement such as rapid hardening cement, extra rapid hardening cement, low heat cement, sulphate resisting cement, blast furnace cement, white cement, pozzolana cement, supersulphated cement and high alumina cement may be used as and when the situation requires the same.

A liquid medium, preferably water, functions as the setting agent to enable reaction with cement which causes setting and hardening. Water allows the components to melange evenly and acts as a lubricant that assists laterite in providing the composite's plasticity.

8 Preferably non-toxic concrete waterproofing additives maybe added as recommended by the manufacturer to improve the composite's water resistance in weather-exposed conditions.

Preferably non-toxic fungalcides maybe added as recommended by the manufacturer to improve the composite's fungal resistance in weather-exposed conditions.

The present invention, therefore, achieves the following: 1) Economic by the use of abundant and readily available cheap substances The present invention preferably uses cellulosic materials such as straw, paddy barley stalks, corn plants, grass, hay and the like which are commonly discarded and in the case oflaterite, usually disregarded.

15 By using abundant and readily available substances such as laterite and cellulosic materials from the abovementioned sources, the present invention is economical.

2) Environmental Friendliness The present invention also seeks to minimise the use of timber and reduce the felling 20 of trees. The present invention utilises bulk materials that are abundantly available which are commonly discarded or disregarded and in finding a new use for such materials, would contribute positively to environmental preservation.

3) Simplified and efficient manufacturing process The manufacturing process is exceedingly simple as described in Detailed Description and Preferred Embodiments below which also allows for flexibility of on-site and off-site manufacturing.

The composite can also be pre-mixed and pre-packed into dry ready mixes for the respective four examples (see below) to cut down the manufacturing time and allow for different geographical locations of the various manufacturing processes to 9 take advantage of the local region's economic edge.

4) Creating a more efficient construction programme by permitting overlapping of critical activities in the programme The composite permits easy and economical employment of construction techniques that facilitate rapid erection of a building by permitting the setting curing period (which often forms part of the critical activities of the work programme) to be easily overlapped.

0 By way of example, when using the composite as factory pre-cast self-centering floor panels, the idle setting period normally required for concrete cast in-situ floors eliminated because after laying the composite's pre-cast self-centering floor panels, other works, for example, the walls, can immediately be effected.

0.0 The composite's relatively lower cost permits employing this rapid technique of construction economically for low-cost dwellings. The less dense nature of the composite permits for easier transporting, lifting and manhandling, and thus, expedites erection of multi-storey structures.

Another example of the efficiency of the composite is as an in-fill grout for injecting into cavities. The plastic nature of the composite permits an economic gel- S° like grout paste to be injected to fill and make solid rapidly erected hollow stud frame partitions. Such partitions can also be made of the same composite. The said grout can then set independently, whilst other work such as wall finishes can be effected immediately. This then permits for rapid erection of solid walls economically. In addition, whilst the in-fill sets, other works around that affected work area can proceed immediately.

The overlapping of these various works allow for valuable time and cost-saving as the idling periods usually required for conventional materials to set cure are significantly minimised.

Wood Concrete attributes The present invention possesses some combined qualities.of both wood and concrete which would be revolutionary to the building industry, inter alia, having the attributes of wood-like flexibility, durability, acceptable fire-rating standards, thermal and sound insulation, lightweight, deadweight, structural strength, variable plasticity which permits moulding, casting and injecting utility.

The invention has middle-ground characteristics of wood and concrete, in that it is not as heavy as concrete but yet not as light as wood. For example, the invention emulates wood in that it can be easily sawed or easily drilled and easily take direct fixes and is thus more flexible than concrete.

The invention is on the other hand also like concrete, in that it is durable, may be 15 cast moulded, has good sound insulation, is fire-resistant, vermin and rot resistant.

6) Flexible forms of and uses for the composite The present invention can be produced into four examples for different uses according to the user's requirements as disclosed in the "Detailed Description of the Preferred Embodiments" below, namely a) Boards and Panels b) Filler Grout c) Reinforced Components d) Composite with Firm Plastic Consistency DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS In accordance with one aspect of the invention, there is provided a composite material characterised by a compounding a quantity of a fluid setting agent to: from between 10% to 75% by dry weight of a hydraulic binding agent; from between 0% to 25% by dry weight of cellulosic materials; and from between 15% to 90% by dry weight of laterite.

The percentages for and will vary depending on what level of consistency and strength is required of the resultant material.

The level of consistency and strength will in turn depend on which Example (see (1) to below) is sought to be produced.

The cellulosic materials are preferably from sources such as straw, paddy barley stalks, corn plants, grass, hay or a mixture thereof and are mechanically shredded and sized to include lengths of up to and including 30 mm only to come through.

.*...Preferably, the laterite is dried before use, then crushed and sized to provide a homogenous product. Preferably, the homogenous product excludes granules/particles exceeding 10mm in diameter.

It is preferred that the hydraulic binding agent is ordinary cement, rapid hardening cement, extra rapid hardening cement, low heat cement, sulphate resisting cement, blast furnace cement, white cement, pozzolana cement, supersulphated cement, high **alumina cement or a mixture thereof The hydraulic binding agent, cellulosic materials and laterite (as prepared into the homogenous product described above) are combined to achieve a substantially homogenous dry mixture.

The resultant dry mixture may then be packed wherein a fluid setting agent can be added later to delay the set.

The percentage of the fluid setting agent, preferably water, to be added to the dry mixture is guided by two objectives. Firstly, to enable reaction with the hydraulic binding agent to complete the setting and hardening process.

Secondly, the fluid setting agent acts as a lubricant to render the composite material to be sufficiently plastic and workable as required by the manufacturing process for placing, compacting or injecting the composite as the case may be (that is, having the right consistency as required depending on which Examples to below is sought to be produced).

More fluid can be added to render the composite material more plastic and workable although this will weaken the composite's compressive strength, as the excess fluid evaporates leaving voids in the composite. This feature may be advantageous where good thermal insulation is desired in lieu of compressive strength.

It will be understood that the composite material may include preferably non-toxic 0 fungalcides and or water-proofing additives according to the manufacturer's recommendation if the composite is to remain in weather-exposed conditions.

o.

Sand aggregate may be added to the composite up to and including 30 parts by 0 15 weight of sand aggregate to 100 parts by dry weight of the dry mixture to enhance the structural compressive strength of the composite if such strength is so required.

••o Clay kaolin may be added to the composite up to and including 35 parts by weight of clay kaolin to 100 parts by dry weight of the dry mixture to enhance the fine 0 20 consistency of the composite if such fine consistency is so required.

Curing can generally be expedited in an autoclave if so required.

o In the subsequent Examples, typical embodiments and the process for preparing the same are described below EXAMPLE BOARDS PANELS One example of a typical embodiment is boards or panels characterised in that said boards and or panels can be produced by compounding in a quantity of a fluid setting agent to: 13 from between 25% to 50% by dry weight of a hydraulic binding agent; from between 5% to 20% by dry weight of cellulosic materials; and from between 35% to 65% by dry weight of laterite.

The cellulosic materials should preferably be shredded and sized in lengths of up to and including The hydraulic binding agent cellulosic materials and laterite (as prepared into the homogenous product described above) are combined to achieve a substantially homogenous dry mixture.

Preferably up to and including 100 parts by weight of a fluid setting agent, preferably water, to 100 parts by dry weight of the dry mixture is gradually combined in a mechanical mixer to produce a slurry or suspension.

S Fungalcides and or water-proofing additives may be added according to the manufacturer's recommendation if the said boards panels are to remain in weatherexposed conditions.

Sand aggregate may be added to the composite up to and including 15 parts by weight of sand aggregate to 100 parts by dry weight of the dry mixture to enhance "the structural compressive strength of the composite if such strength is so required.

Clay kaolin may be added to the composite up to and including 18 parts by weight of clay kaolin to 100 parts by dry weight of the dry mixture to enhance the fine consistency of the composite if such fine consistency is so required.

The resultant slurry or suspension is shaped into boards or panels and the superfluous liquid may be separated by way of using filter press manner, cast and winding machines, centrifugal machines or other known methods.

14 Other known methods of manufacturing boards or panels may also be employed.

After dehydration, the said boards or panels (preferably with varied thickness between 5mm to 150mm) is allowed to cure at room temperature in humid conditions for at least 14 days, preferably 28 days. Curing can be expedited by steam-curing.

EXAMPLE FILLER GROUT Another example of a typical embodiment is a filler grout characterised in that said filler grout can be produced by compounding in a quantity of a fluid setting agent to from between 15% to 60% by dry weight of a hydraulic binding agent; from between 5% to 20% by dry weight of cellulosic materials; and from between 20% to 80% by dry weight of laterite.

The cellulosic materials should preferably be shredded and sized in lengths of up to o 20 and including The hydraulic binding agent, cellulosic materials and laterite (as prepared into the homogenous product described above) are combined to achieve a substantially homogenous dry mixture.

Preferably in the proportion of up to and including 90 parts by weight of the fluid setting agent, preferably water, to 100 parts by dry weight of the dry mixture above is gradually combined in a mechanical mixer to produce a workable slurry.

Fungalcides and or water-proofing additives may be added according to the manufacturer's recommendation if it is to remain in weather-exposed conditions.

Sand aggregate may be added to the composite up to and including 5 parts by weight of sand aggregate to 100 parts by dry weight of the dry mixture if there is a need for the grout to possess structural compressive strength.

Clay kaolin may be added to the composite up to and including 6 parts by weight of clay kaolin to 100 parts by dry weight of the dry mixture to enhance the fine consistency of the composite if such fine consistency is so required.

The resultant slurry is immediately ready for use by way of hydraulic injection into cavities and can be left to cure naturally at room temperature and humidity. Working strength set would be achieved in 14 days, preferably 28 days.

EXAMPLE REINFORCED COMPONENTS 0 15 Another example of a typical embodiment is reinforced components characterised in that said reinforced components can be produced by compounding in a quantity of a fluid setting agent to: 0 from between 30% to 60% by dry weight of a hydraulic binding agent; 0 from between 0% to 15% by dry weight of cellulosic materials; and from between 30% to 60% by dry weight of laterite.

The cellulosic materials should preferably be shredded and sized in lengths of up to and including The hydraulic binding agent, cellulosic materials and laterite (as prepared into the homogenous product described above) are combined to achieve a substantially homogenous dry mixture.

Preferably in the proportion of up to and including 85 parts by weight of a fluid setting agent, preferably water, to 100 parts by dry weight of the dry mixture above, is gradually combined in a mechanical mixer to produce a workable slurry.

16 Water proofing and or anti-fungal additives may also be added to the composite according to the manufacturer's instructions if the composite is to remain exposed to the elements for prolonged periods.

Sand aggregate may be added to the composite up to and including 25 parts by weight of sand aggregate to 100 parts by dry weight of the dry mixture to enhance the structural compressive strength of the composite if such strength is so required.

Clay kaolin may be added to the composite up to and including 30 parts by weight of clay kaolin to 100 parts by dry weight of the dry mixture to enhance the fine consistency of the composite if such fine consistency is so required.

A die-cast mould or prefabricated permanent formwork mould (which, apart from conventional materials, can be fabricated from boards as Example above) is then 15 prepared. Steel reinforcement (for example, in the form of reinforcement bars, structural steel sections, pressed sheet steel sections, expanded metal lathing sections, etc) or natural reinforcements such as bamboo or rattan (for example, in the form of bars, lattice grid strips or woven fabric) is set in place in the formwork on spacers to give adequate cover.

The slurry is then applied (for example, by way of pouring or injecting into the above mould) and allowed to cure at room temperature in humid conditions for at least 14 days, preferably 28 days.

Where appropriate, curing can be expedited by way of steam-curing.

EXAMPLE COMPOSITE WITH FIRM PLASTIC

CONSISTENCY

An example of a typical embodiment a composite with firm plastic consistency 17 characterised in that said composite can be produced by compounding in a quantity of a fluid setting agent to: from between 20% to 60% by dry weight of a hydraulic binding agent; from between 5% to 20% by dry weight of cellulosic materials; and from between 25% to 75% by dry weight oflaterite.

The cellulosic materials should preferably be shredded and sized in lengths of up to and including 30mm. The hydraulic binding agent, cellulosic materials and laterite (as prepared into the homogenous product described above) are combined to achieve a substantially homogenous dry mixture.

.i Preferably in the proportion of up to and including 80 parts by weight of the fluid setting agent, preferably water, to 100 parts by dry weight of the dry mixture above, is gradually combined in a mechanical mixer to produce a thick and firm workable 15 paste.

oo•• The resultant paste is of a consistency that enables the composite to be worked upon clay-like for example, by way of being press-moulded, extruded or sculptured to produce building blocks, modular panels, putty or items that require sculpting S 20 aesthetic application. While still green, the composite may be etched, carved or embossed.

•Water proofing and or anti-fungal additives can be added to the composite according to the manufacturer's instructions if the composite is to remain exposed to the elements for prolonged periods Up to and including 25 parts by weight of sand aggregate to 100 parts by dry weight of the dry mix above may be added to the composite to enhance the structural compressive strength of the composite if such strength is so required.

18 compressive strength of the composite if such strength is so required.

Clay kaolin can be added to the composite up to and including 30 parts by weight of clay kaolin to 100 parts by dry weight of the above dry mix to enhance the fine consistency of the composite if such fine consistency is so required. The resultant product can be left to cure naturally at room temperature in humid conditions, working strength would be achieved in 14 days, preferably 28 days.

Curing can be expedited by way of steam-curing.

It will of course be realised that whilst the above has been given by way of illustrative examples of the invention, all such other modifications and variations thereto, as would be apparent to persons skilled in the art, are deemed to fall within the broad scope and ambit of the invention as claimed herein.

o o.

o Soo

Claims (56)

1. A composite material characterised by compounding in a quantity of a fluid setting agent a dry mixture comprising: (a)from between 10% to 75% by dry weight of a hydraulic binding agent; (b)from between 0% to 25% by dry weight of cellulosic materials; and (c)from between 15% to 90% by dry weight of laterite.

2. Composite material according to Claim 1, characterised in that the cellulosic materials include lengths of up to and including .o 3. Composite material according to Claim 1 or Claim 2, characterised in that .5 laterite excludes particles exceeding 10mm in diameter. 0° 15 4. Composite material according to any one of Claims 1 to 3, characterised in that the hydraulic binding agent is preferably selected from a group comprising ordinary cement, rapid hardening cement, extra rapid hardening cement, low heat cement, sulphate resisting cement, blast furnace cement, white cement, pozzolana cement, supersulphated cement, high alumina 20 cement or a mixture thereof.

5. Composite material according to any one of Claims 1 to 4, characterised in that the cellulosic materials are preferably selected from a group comprising straw, paddy and barley stalks, corn plants, grass, hay, other like vegetable matter or a mixture thereof

6. Composite material according to any one of Claims 1 to 5, characterised in that said composite material includes waterproofing additives to improve weather resistance.

7. Composite material according to any one of Claims 1 to 6, characterised in that said composite material includes fungalcides to improve fungal resistance.

8. Composite material according to any one of Claims 1 to 7, characterised in that said composite material includes sand and/or aggregate.

9. Composite material according to any one of Claims 1 to 8, characterised in that said composite material includes clay and/or kaolin.

10. Composite material according to any one of Claims 1 to 9, characterised in that the fluid setting agent used is preferably water.

11. Boards and/or panels formed from a composite material characterised in that said boards and or panels can be produced by compounding in a quantity of a fluid setting agent a dry mixture comprising: (a)from between 25% to 50% by dry weight of a hydraulic binding agent; (b)from between 5% to 20% by dry weight of cellulosic materials; and (c)from between 3 5% to 65% by dry weight of laterite.

12. Boards and/or panels as claimed in Claim 11, characterised in that the cellulosic materials preferably include lengths of up to and including

13. Boards and or panels as claimed in Claim 11 or Claim 12 characterised in that up to and including 15 parts by weight of sand and/or aggregate can be added to 100 parts by dry weight of said composite material.

14. Boards and/or panels as claimed in any one of Claims 11 to 13, characterised in that up to and including 18 parts by weight of clay and/or kaolin can be added to 100 parts by dry weight of said composite material. 21 Boards and/or panels as claimed in any one of Claims 11 to 14, characterised in that the quantity of the fluid setting agent added is preferably in the proportion of up to and including 100 parts by weight of the fluid setting agent to 100 parts by dry weight of said hydraulic binding agent, cellulosic materials and laterite.

16. Boards and or panels as claimed in any one of Claims 11 to characterised in that resultant boards and or panels are preferably 5mm to 150mm in thickness.

17. Filler grout formed from a composite material characterised in that a filler grout can be produced by compounding in a quantity of a fluid setting agent a dry mixture comprising: (a)from between 15% to 60% by dry weight of a hydraulic binding agent; (b)from between 5% to 20% by dry weight of cellulosic materials; and (c)from between 20% to 80% by dry weight of laterite.

18. Filler grout as claimed in Claim 17, characterised in that the cellulosic materials preferably includes lengths of up to and including

19. Filler grout as claimed in Claim 17 or 18, characterised in that up to and ~including 5 parts by weight of sand and/or aggregate can be added to 100 parts by dry weight of said composite material.

20. Filler grout as claimed in any one of Claims 17 to 19, characterised in that up to and including 6 parts by weight of clay and/or kaolin can be added to 100 parts by dry weight of said composite material.

21. Filler grout as claimed in any one of Claims 17 to 20, characterised in that the quantity of the fluid setting agent added is preferably in the proportion of up to and including 90 parts by weight of the fluid setting agent to 100 parts 22 by dry weight of said hydraulic binding agent, cellulosic materials and laterite.

22. Reinforced components formed from a composite material characterised in that said reinforced components can be produced by compounding in a quantity of a fluid setting agent a dry mixture comprising: (a)from between 30% to 60% by dry weight of a hydraulic binding agent; (b)from between 0% to 15% by dry weight of cellulosic materials; and (c)from between 30% to 60% by dry weight of laterite.

23. Reinforced components as claimed in Claim 22 characterised in that the cellulosic materials preferably include lengths of up to and including

24. Reinforced components as claimed in Claim 22 or Claim 23, characterised in that said components are cast and or moulded. Reinforced components as claimed in any one of Claims 22 to 24, characterised in that the quantity of the fluid setting agent added is preferably in the proportion of up to and including 85 parts by weight of the fluid setting agent to 100 parts by dry weight of said hydraulic binding agent, cellulosic materials and laterite.

26. Composite with firm plastic consistency formed from a composite material characterised in that said composite with firm plastic consistency can be produced by compounding in a quantity of a fluid setting agent a dry mixture comprising: (a)from between 20% to 60% by dry weight of a hydraulic binding agent; (b)from between 5% to 20% by dry weight of cellulosic materials; and (c)from between 25% to 75% by dry weight of laterite.

27. Composite as claimed in Claim 26, characterised in that the cellulosic 23 materials preferably include lengths of up to and including

28. Composite as claimed in Claim 26 or 27, characterised in that laterite preferably excludes particles exceeding 10 mm in diameter.

29. Composite as claimed in any one of Claims 26 to 28, characterised in that up to and including 25 parts by weight of sand and/or aggregate can be added to 100 parts by dry weight of said composite material.

30. Composite as claimed in any one of Claims 26 to 29, characterised in that up to and including 30 parts by weight of clay and/or kaolin can be added to 100 parts by dry weight of said composite material.

31. Composite as claimed in any one of Claims 26 to 30, characterised in that the quantity of the fluid setting agent added is preferably in the proportion of up to and including 80 parts by weight of the fluid setting agent to 100 parts by weight of said hydraulic binding agent, cellulosic materials and laterite.

32. A fluid setting agent as claimed in any one of Claims 1 to 31, characterised in that said fluid setting agent used is preferably water.

33. Interior structural members formed from said composite material of any one of the above preceding claims.

34. Exterior structural members formed from said composite material of any one of the preceding claims. Furniture formed from said composite material of any one of the preceding claims.

36. A method for producing a composite material characterised in that said method preferably includes 24 (a)mixing together between 10% to 75% by dry weight of a hydraulic binding agent, between 0% to 25% by dry weight of cellulosic materials and between 15 to 90% by dry weight of laterite in a quantity of a fluid setting agent; (b)curing the said mixture.

37. A method as claimed in Claim 36, characterised in that the cellulosic materials preferably include lengths of up to and including 30 mm and are shredded.

38. A method according to Claim 36 or Claim 37, characterised in that the cellulosic materials are preferably selected from a group comprising straw, paddy and barley stalks, corn plants, grass, hay, other like vegetable matter a mixture thereof

39. A method according to any one of Claims 36 to 38, characterised in that the laterite excludes particles exceeding 10mm in diameter. A method according to any one of Claims 36 to 39, characterised in that the hydraulic binding agent is preferably selected from a group comprising ordinary cement, rapid hardening cement, extra rapid hardening cement, low heat cement, sulphate resisting cement, blast furnace cement, white cement, pozzolana cement, supersulphated cement, high alumina cement or a mixture thereof

41. A method according to any one of Claims 36 to 40, characterised in that said composite material includes waterproofing additives to improve weather resistance.

42. A method according to any one of Claims 36 to 41, characterised in that said composite material includes fungalcides to improve fungal resistance.

43. A method according to any one of Claims 36 to 42, characterised in that said composite material includes sand and/or aggregate.

44. A method according to any one of Claims 36 to 43, characterised in that said composite material includes clay and/or kaolin. A method for producing boards and panels characterised by (a)mixing together between 25% to 50% by dry weight of a hydraulic binding agent; between 5% to 20% by dry weight of cellulosic materials and between 35% to 65% by dry weight of laterite in a quantity of a fluid setting agent to form a slurry; (b)removing superfluous liquid from the slurry; (c)shaping the slurry from into boards and/or panels; and curing the boards and/or panels.

46. A method as claimed in Claim 45, characterised in that the cellulosic materials should preferably include lengths of up to and including 30 mm.

47. A method as claimed in Claim 45 or 46, characterised in that the quantity of the fluid setting agent added is preferably in the proportion of up to and *including 100 parts by weight of the fluid setting agent to 100 parts by dry weight of said hydraulic binding agent, cellulosic materials and laterite.

48. A method as claimed in any one of Claims 45 to 47, characterised in that up to and including 15 parts by weight of sand and/or aggregate can be added to 100 parts by dry weight of said composite material.

49. A method as claimed in any one of Claims 45 to 48, characterised in that up to and including 18 parts by weight of clay and/or kaolin can be added to 100 parts by dry weight of said composite material. 26 A method as claimed in any one of Claims 45 to 50, characterised in that dehydration of the slurry is achieved by known filter press manner, cast and winding machines, centrifugal machines or other known methods of manufacturing boards and/or panels.

51. A method for producing a filler grout characterised by mixing together between 15% to 60% by dry weight of a hydraulic binding agent; between to 20% by dry weight of cellulosic materials and between 20% to by dry weight of laterite in a quantity of a fluid setting agent. :0.0 52. A method as claimed in Claim 51, characterised in that the cellulosic 0 materials should preferably include lengths of up to and including 10 mm.

53. A method as claimed in Claim 51 or 52, characterised in that the quantity of the fluid setting agent added is preferably in the proportion of up to and including 90 parts by weight of the fluid setting agent to 100 parts by dry .e weight of said hydraulic binding agent, cellulosic materials and laterite. A method as claimed in any one of Claims 51 to 53, characterised in that up to and including 5 parts by weight of sand and/or aggregate can be added to 100 parts by dry weight of said composite material. A method as claimed in any one of Claims 51 to 54, characterised in that up to and including 6 parts by weight of clay and/or kaolin can be added to 100 parts by dry weight of said composite material.

56. A method for producing reinforced components characterised by: (a)mixing together between 30% to 60% by dry weight of a hydraulic binding agent; between 0% to 15% by dry weight of cellulosic materials and between 30% to 60% by dry weight of laterite in a quantity of a fluid setting agent to form a slurry; 27 (b)wherein the slurry can be shaped or moulded into said components; and (c)the shaped or moulded components are allowed to cure.

57. A method as claimed in Claims 56, characterised in that the cellulosic materials should preferably include lengths of up to and including 25 mm.

58. A method as claimed in Claim 56 or 57, characterised in that the quantity of the fluid setting agent added is preferably in the proportion of up to and including 85 parts by weight of the fluid setting agent to 100 parts by dry weight of said hydraulic binding agent, cellulosic materials and laterite.

59. A method for producing a composite with firm plastic consistency characterised by: (a)mixing together between 20% to 60% by weight of a hydraulic binding agent; between 5% to 20% by weight of cellulosic materials and between 25% to 75% by weight of laterite with a quantity of a fluid setting agent to form a workable paste of thick consistency allowing the workable paste to cure.

60. A method as claimed in Claim 59, characterised in that the cellulosic materials should preferably include lengths of up to and including 30 mm.

61. A method as claimed in Claim 59 or 60, characterised in that the quantity of the fluid setting agent added is preferably in the proportion of up to and including 80 parts by weight of the fluid setting agent to 100 parts by dry weight of said hydraulic binding agent, cellulosic materials and laterite.

62. A method as claimed in any one of Claims 59 to 61, characterised in that up to and including 25 parts by weight of sand and/or aggregate can be added to 100 parts by dry weight of said composite material.

63. A method as claimed in any one of Claims 59 to 62, characterised in that up 28 to and including 30 parts by weight of clay and/ or kaolin can be added to 100 parts by dry weight of said composite material.

64. A method as claimed in any one of Claims 59 to 63, characterised in that the curing process can be expedited in by way of steam-curing. A method as claimed in any one of Claims 59 to 64, characterised in that the fluid setting agent is water.

66. A method as claimed in any one of Claims 59 to 65, characterised in that the laterite preferably excludes particles exceeding 10mm in diameter.

67. A method as claimed in any one of Claims 59 to 66, characterised in that the curing process preferably takes place at room temperature.

68. A method as claimed in any one of Claims 59 to 67, characterised in that the curing process preferably takes place under humid conditions. l*Ot