EP3484834A1 - Tôles de toiture ondulées en fibrociment sans amiante légères et à haute résistance fabriquées selon un procédé d'autoclavage - Google Patents

Tôles de toiture ondulées en fibrociment sans amiante légères et à haute résistance fabriquées selon un procédé d'autoclavage

Info

Publication number
EP3484834A1
EP3484834A1 EP17838080.4A EP17838080A EP3484834A1 EP 3484834 A1 EP3484834 A1 EP 3484834A1 EP 17838080 A EP17838080 A EP 17838080A EP 3484834 A1 EP3484834 A1 EP 3484834A1
Authority
EP
European Patent Office
Prior art keywords
fibers
high strength
asbestos
light weight
fiber cement
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.)
Withdrawn
Application number
EP17838080.4A
Other languages
German (de)
English (en)
Inventor
D. Satyanarayana
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.)
Hil Ltd (formerly Hyderabad Industries Limited)
Original Assignee
Hil Ltd (formerly Hyderabad Industries Limited)
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 Hil Ltd (formerly Hyderabad Industries Limited) filed Critical Hil Ltd (formerly Hyderabad Industries Limited)
Publication of EP3484834A1 publication Critical patent/EP3484834A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions 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
    • C04B28/04—Portland cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00586—Roofing materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/40—Porous or lightweight materials
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • the present invention relates to light weight & high strength non-asbestos corrugated fiber cement roofing sheets manufactured by autoclave method.
  • asbestos-cement compositions have been formed into products such as flat sheets, corrugated sheets, boards, panels and the like. These sheets generally contained Portland cement in the amount of 43 to 55%, siliceous material and / or filter in the amount of about 30 to 35% and asbestos fibres in the amount of about 10 to 12%.
  • the products had many desirable qualities, including high strength, exterior durability and easy application. Asbestos is a naturally occurring mining product. But day by day the availability of quality fibers is reduced tremendously. Hence it is essential to develop corrugated sheeting product with alternative fibers with similar strength of asbestos based and cost effective.
  • the wood pulp and synthetic fibers such as Poly vinyl alcohol and modified poly propylene fibers has been used as an alternate to asbestos due to its unique characteristic of good dispersion in cementicious / water slurry because of its hydrophilic nature.
  • These sheets generally contained Portland cement in the amount of 70 to 80%, siliceous material and / or filler in the amount of about 10 to 20% and synthetic fibers like poly vinyl alcohol, modified poly propylene and wood pulp in an amount of about 4 to 8%.
  • Indian Patent application 6305/CHE/2015 describes the manufacturing of non- asbestos corrugated sheet by auto clave method.
  • Asbestos fibers were replaced with cotton pulp, modified or unmodified wollastonite and modified PET fiber.
  • the part quantity of cement was replaced with GGBS slag and fly ash. in addition to this microsilica and additives are used.
  • US 4377415 relates to a cement-wollastonite product consisting essentially of Portland cement binder in an amount of between about 40% and 90% by weight, and wollastonite in an amount of between about 10% and 60% by weight.
  • the product may contain fibers in an amount of between about 1% and 15% by weight. If the product contains fibers other than asbestos and is to be formed on a Hatschek or other type of wet forming machine, it may contain clay in an amount of between about 2% and 15% by weight, and poly(ethylene oxide) homopolymer in an amount of between about 0.03% and 0.5% by weight.
  • the product may also contain silica and/or filler in an amount of between about 10% and 40% by weight for replacing part of the wollastonite.
  • the filler may be waste fiber-cement product or inert filler material.
  • US8293003B1 teaches us a cement product incorporating nanocrystalline cellulose and cellulose fiber throughout the product and a method of making the product.
  • US5122550 relates to a non-asbestos friction material composition suitable for use as a friction element includes: a binder; a reinforcing material; and a structural integrity imparting amount of cellulose ester fibrils.
  • US6284815B1 teaches us a non-asbestos friction material, which comprises a non-asbestos fibrous reinforcement, a thermosetting resin binder, and a filler as the main components, wherein the fibrous reinforcement is a combination of plural kinds of non-asbestos fibers and contains sepiolite fibers, cellulose fibers, and an acryl pulp as the fibrous reinforcement.
  • the friction material of the present invention is excellent in fade characteristics, stability of effectiveness, etc., and low in cost.
  • US Patent 8182606B2 describes the manufacturing of low density fiber cement building materials by using low density additives such as hollow ceramic microspheres, volcanic ash (density : 2-25 Ibs/cu.ft) and other low density additives either alone or in combination.
  • low density additives such as hollow ceramic microspheres, volcanic ash (density : 2-25 Ibs/cu.ft) and other low density additives either alone or in combination.
  • Australian patent 2008348271 A1 illustrates the manufacturing of structural fiber cement building materials with density less than 1 .25 g/cc & thickness less than 19 mm by using microspheres, calsil, polymeric beads, expanded vermiculite/perlite/shale and their combinations.
  • Indian Patent 279236 describes the manufacturing of light weight cementicious cellulose fiber reinforced building material without using any low density additives.
  • flat fiber cement boards are manufactured by using bauxite and wood pulp by autoclave method.
  • PET fibers with alternative fibers like mineral fiber, sepiolite, Jute fiber, bamboo fiber etc.
  • GGBS slag has been replaced with fly ash to reduce density and make the sheet lighter.
  • micro silica has been replaced with high surface area fly ash for cost reduction and addressing the processing problems by maintaining cone and sieve filtrate solids.
  • a product replacing asbestos fibres and PVA fibers, si!ica and partly replacing cement with suitable materials makes it unique Green product in many ways.
  • the present invention provides the method to manufacture of Light weight and high strength Non asbestos fiber cement corrugated sheet comprising of the processing reinforced fibers such as herein described
  • An object of the present invention is to propose Light weight & high strength non- asbestos corrugated fiber cement roofing sheets manufactured by autoclave method. Another object of the present invention is to replace asbestos fibers, wood pulp, PVA, modified Poly propylene fibers, micro silica and part replacement of cement to make it light weight and high strength Non Asbestos fiber cement corrugated roofing sheets.
  • Still another object of the present invention is to use more quantity of Cellulose fibers and high aspect ratio Wollastonite/modified wollastonite to replace asbestos fibers, Modified poly propylene and PVA fibers.
  • Further object of the present invention is to use sepiolite, mineral fibers, jute fiber and bamboo fiber to replace part quantity or full quantity of modified PET fibers.
  • Still further object of the present invention is to use modified rock wool fiber to part replacement of cotton rag pulp.
  • One more object of the present invention is to maintain cone and sieve filtrate solids to address the process problems by replacing micro silica with high surface area fly ash, rice husk ash and fine ground silica.
  • Another object of the present invention is the effective utilization of fine particle in the form of floccs by adding anionic poly acrylamide flocculent.
  • Yet another object of the present invention is to reduce drying shrinkage of corrugated sheets produced by hydrothermal (Autoclaving) curing.
  • Another object of the present invention is to propose a method of manufacturing building product with improved strength and other properties to the product manufacturing non-Asbestos fiber cement roofing sheet by autoclave method.
  • fibrous reinforcing material is a combination of plurality of fibers having 8 to 20% of cellulose fiber, 0 to 3% of modified PET fibers, and 0 to 6% other fibers optionally containing fibers mineral selected from wollastonite modified or unmodified, sepiolite and mineral fiber.
  • a process for manufacturing light weight and high strength non-asbestos corrugated fiber cement roofing sheets comprising; preparing a slurry; subjecting the said slurry to the step of forming thin films, applying the said thin films on accumulator rolls, pre curing and curing in autoclave to produce the product.
  • the present invention relates to Non asbestos cement roofing fiber product by autoclave method which does not contains asbestos, PVA and virgin wood pulp, GGBS, and micro silica powder but which contains other fibers either alone in the combination of Cellulose, Modified PET Fibers, wollastonite/modified wollastonite, sepiolite, mineral fiber, jute fiber, bamboo fiber along with cement and siliceous material such as fly ash, fine ground silica and rice husk ash so as to permit satisfactory production thereof on a machine in which a slurry is formed on a screen and subsequently vacuum-filtered through a screen and or felt.
  • cellulose pulp which is obtained by mechanical pulping of waste jeans cotton rags or other natural cotton in loose or cloth form.
  • Modified PET Fibers are having high molecular weight with good water dispersion and compatible with cement.
  • Wollastonite is natural occurring mineral fiber having very good aspect ratio to attain strength and durability by reducing moisture movement.
  • the wollastonite is optionally modified with using additives such as Vinyl silane, Amino silane, glycidoxy silane and Vinyl acetoxy silane either alone or in combination. Due to this invention we have achieved the strength similar to asbestos based fiber cement sheets with light weight.
  • Sepiolite is naturally occurring soft white clay mineral. Fibers texture of sepiolite makes it suitable for reinforcement. Jute and bamboo fiber are obtained from natural plants which are processed to suitable for fiber cement application. Mineral fibers is naturally occurring mining product.
  • fly ash means the fly ash generated during the combustion of pulverized coal in the thermal power plant.
  • Rice husk ash is an ash produced by controlled burning of grounded rice husk which contains amorphous silica.
  • Bentonite is also naturally occurring clay mineral which have very good swelling properties used to achieve the bonding between the layers.
  • Non-asbestos fiber cement sheets that is the new and invented non-asbestos fiber cement sheets which are environment friendly products as is described in the present claim invention.
  • the said reinforcing fibers essentially included Cellulose Pulp having fiber opening Deg.SR 12 - 50 used in an amount of 8-20%, modified PET fibers 0 to 3% and wollastonite/modified wollastonite is having the aspect ratio 5 to 40 in an amount of 0.25 to 10%, sepiolite 0-5%, mineral fibers 0-5%, jute fibers 0-5%, bamboo fibers 0-5%, modified rock wool fiber 0-5%, Portland cement in an amount of 20 to 55%, Siliceous material in the binder essentially pulverized fly ash having surface area of 2000-4000 cm 2 /gm used in an amount of 15 - 55%, fine fly ash having surface area of above 4000 cm 2 /gm used in an amount of 20 - 60%, rice husk ash having surface area of greater than 5000 cm 2 /gm used in an amount of 0-20%, fine ground silica used in an amount of 0 to 25% and bentonite used in an amount of 1-5% and fillers
  • Mixing/holding system ensured that solids are not separated from the aqueous solution, i.e. solids do not settle so that the lamination having uniform distribution of the binder and the reinforcing fibers is obtained in the process.
  • the recipe thus obtained in respect of the above formulations were independently run on pilot plant and plant sheet forming machine such as HATSCHECK MACHINE where thin films are picked up and superimposed on accumulator roll.
  • the composite is cut upon after building up to desired thickness and laid flat and or conveyed for corrugation and stacking before pre curing. Over a period of time and at predetermined temperature, the initial curing in the composite make it strong and acquire enough strength for demoulding.
  • STEP 3 CURING THE ARRANGED PRODUCT.
  • Demoulded corrugated sheets are then arranged on a trolley and cured under Autoclave maintaining the steam pressure for 90 to 130psi and duration of 5 to 15 hours. After curing is over, cured material in the trolleys is pulled out and stacked in ambient condition for further inspection and dispatch.
  • Carbonization test The carbonization each cycle is 24 hours which is consist of following: 9 hrs immersion in water at ambient, 1 hr dry in ventilated oven at 60°C, 5hrs purging C02 at ambient temperature, 8 hours dry in ventilated oven at 60°C and cooling to ambient temperature within 1 hour time. The specimens are subjected to expose for 50 cycles. No visual defect cracks are observed. Table 2. Present invention - pilot plant trials
  • Rock wool fibers are used in example 5 for part replacing jeans cotton rag pulp.
  • Rice husk ash and ground fine silica are used as a part replacement for pulverized fly ash in Example 6 and 7 respectively.
  • Sepiolite, mineral fiber, jute/bamboo fibers are used as part or full replacement of modified PET fibers in examples 8,9 and 10 respectively.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Abstract

L'invention concerne des tôles de toiture ondulées en fibrociment sans amiante légères et à haute résistance fabriquées selon un procédé d'autoclavage. Une tôle de toiture ondulée en fibrociment sans amiante légère et à haute résistance comprend : du ciment Portland, un matériau pouzzolanique, un matériau de renforcement fibreux, de l'argile bentonite et des additifs, ledit matériau de renforcement fibreux étant une combinaison de plusieurs fibres comprenant de 8 à 20 % de fibre de cellulose, de 0 à 3 % de fibres de PET modifiées et de 0 à 6 % d'autres fibres contenant éventuellement de 0 à 3 % de laine de roche/laine de roche modifiée, une fibre organique comme le jute, le bambou et des fibres minérales choisies parmi la wollastonite modifiée ou non modifiée, la sépiolite et une fibre minérale.
EP17838080.4A 2017-10-05 2017-11-20 Tôles de toiture ondulées en fibrociment sans amiante légères et à haute résistance fabriquées selon un procédé d'autoclavage Withdrawn EP3484834A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN201741035233 2017-10-05
PCT/IN2017/050541 WO2019069315A1 (fr) 2017-10-05 2017-11-20 Tôles de toiture ondulées en fibrociment sans amiante légères et à haute résistance fabriquées selon un procédé d'autoclavage

Publications (1)

Publication Number Publication Date
EP3484834A1 true EP3484834A1 (fr) 2019-05-22

Family

ID=61157251

Family Applications (1)

Application Number Title Priority Date Filing Date
EP17838080.4A Withdrawn EP3484834A1 (fr) 2017-10-05 2017-11-20 Tôles de toiture ondulées en fibrociment sans amiante légères et à haute résistance fabriquées selon un procédé d'autoclavage

Country Status (5)

Country Link
EP (1) EP3484834A1 (fr)
AU (1) AU2017401054C1 (fr)
SG (1) SG11201808677PA (fr)
TW (1) TW201915276A (fr)
WO (1) WO2019069315A1 (fr)

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110561648B (zh) * 2019-07-26 2021-10-15 中国航空工业集团公司济南特种结构研究所 一种非热压罐成型中温固化预浸料制备方法
CN111470811B (zh) * 2020-04-09 2022-02-11 唐山华纤科技有限公司 一种硅酸钙板及其制备方法
WO2021250684A1 (fr) * 2020-06-11 2021-12-16 Hil Limited (Formerly Hyderabad Industries Limited) Plaques ondulées en fibrociment sans amiante et leur procédé de fabrication
CN113831634B (zh) * 2020-06-24 2022-12-02 合肥杰事杰新材料股份有限公司 一种力学性能优异的隔音复合材料及其制备方法
CN112876204B (zh) * 2021-03-22 2022-04-12 乌鲁木齐胜达天利建材科技有限公司 一种改性聚酯纤维增强的硅钙材料及制备方法
US11884590B2 (en) 2021-07-07 2024-01-30 Swisspearl Group Ag Fire resistant fibre cement compositions
EP3957616A1 (fr) * 2021-07-07 2022-02-23 Swisspearl Group AG Compositions de ciment fibreux résistant au feu

Family Cites Families (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1588938A (en) * 1975-05-30 1981-04-29 Tac Construction Materials Ltd Fibrous cementitious artefacts
GB2045306B (en) * 1979-02-09 1983-02-02 Cape Boards & Panels Ltd Boards and sheets
US4377415A (en) 1981-02-11 1983-03-22 National Gypsum Company Reinforced cement sheet product containing wollastonite for reduced shrinkage
FI822075L (fi) * 1981-06-19 1982-12-20 Cape Universal Claddings Byggnadsskivor
US5122550A (en) 1990-11-21 1992-06-16 Hoechst Celanese Corporation Cellulose ester fibrils: a molding aid for friction materials
US5482550A (en) * 1991-12-27 1996-01-09 Strait; Mark C. Structural building unit and method of making the same
JPH108037A (ja) 1996-06-27 1998-01-13 Akebono Brake Ind Co Ltd 非石綿系摩擦材
NZ521491A (en) 2000-03-14 2004-06-25 James Hardie Res Pty Ltd Fiber cement building materials with low density additives and cellulose fibers
US8209927B2 (en) 2007-12-20 2012-07-03 James Hardie Technology Limited Structural fiber cement building materials
US8273174B2 (en) 2008-12-31 2012-09-25 Wyerhaeuser NR Company Method of making a fiber cement board with improved properties and the product

Also Published As

Publication number Publication date
AU2017401054B2 (en) 2020-04-16
TW201915276A (zh) 2019-04-16
AU2017401054C1 (en) 2020-10-08
AU2017401054A1 (en) 2019-05-02
SG11201808677PA (en) 2019-05-30
WO2019069315A1 (fr) 2019-04-11

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