CA2424744A1 - Fiber cement composite material using biocide treated durable cellulose fibers - Google Patents

Fiber cement composite material using biocide treated durable cellulose fibers Download PDF

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Publication number
CA2424744A1
CA2424744A1 CA 2424744 CA2424744A CA2424744A1 CA 2424744 A1 CA2424744 A1 CA 2424744A1 CA 2424744 CA2424744 CA 2424744 CA 2424744 A CA2424744 A CA 2424744A CA 2424744 A1 CA2424744 A1 CA 2424744A1
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Canada
Prior art keywords
fibers
formulation
treated
building material
cellulose fibers
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Granted
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CA 2424744
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French (fr)
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CA2424744C (en
Inventor
Donald J. Merkley
Caidian Luo
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James Hardie Technology Ltd
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Individual
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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
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04—Waste materials; Refuse
    • C04B18/18—Waste materials; Refuse organic
    • C04B18/24—Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper, cork
    • C04B18/241—Paper, e.g. waste paper; Paper pulp
    • 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
    • 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
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04—Waste materials; Refuse
    • C04B18/18—Waste materials; Refuse organic
    • C04B18/24—Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper, cork
    • 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
    • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/10—Coating or impregnating
    • C04B20/1051—Organo-metallic compounds; Organo-silicon compounds, e.g. bentone
    • 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
    • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/10—Coating or impregnating
    • C04B20/1055—Coating or impregnating with inorganic materials
    • C04B20/107—Acids or salts thereof
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
    • D21H21/14—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by function or properties in or on the paper
    • D21H21/16—Sizing or water-repelling agents
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/03—Non-macromolecular organic compounds
    • D21H17/05—Non-macromolecular organic compounds containing elements other than carbon and hydrogen only
    • D21H17/13—Silicon-containing compounds
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/20—Macromolecular organic compounds
    • D21H17/33—Synthetic macromolecular compounds
    • D21H17/46—Synthetic macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H17/59—Synthetic macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon
    • 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
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S428/00—Stock material or miscellaneous articles
    • Y10S428/907—Resistant against plant or animal attack
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/249932—Fiber embedded in a layer derived from a water-settable material [e.g., cement, gypsum, etc.]
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
    • Y10T428/253—Cellulosic [e.g., wood, paper, cork, rayon, etc.]
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2927—Rod, strand, filament or fiber including structurally defined particulate matter
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/298—Physical dimension
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31971—Of carbohydrate
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31971—Of carbohydrate
    • Y10T428/31989—Of wood
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31971—Of carbohydrate
    • Y10T428/31993—Of paper

Abstract

A fiber cement composite material providing improved rot resistance and durability, the composite material incorporating biocide treated fibrous pul ps to resist microorganism attacks. The biocide treated fibers have biocides attached to inner and outer surfaces of individualized fibers to protect the fibers from fungi, bacteria, mold and algae attacks. The biocides selected have strong affinity to cellulose and do not interfere with cement hydration reactions. This invention also discloses the formulation, the method of manufacturing and the final fiber cement products using the biocide treated fibers.

Claims (73)

1. A composite building material, comprising:
a cementitious matrix; and individualized cellulose fibers incorporated into the cementitious matrix, wherein the cellulose fibers are at least partially treated with a biocide chemical that inhibits microorganism growth inside the fibers.
2. The composite building material of Claim 1, wherein the biocide chemical is attached to inner and outer surfaces of the individualized fibers.
3. The composite building material of Claim 1, wherein the chemical is selected from the group consisting of fungicides, algaecides, mold and termite preservatives, and mixtures thereof.
4. The composite building material of Claim 1, wherein the chemical comprises inorganic compounds.
5. The composite building material of Claim 4, wherein the inorganic compounds are selected from the group consisting of sodium, potassium, calcium, zinc, copper, and barium salts of carbonate, silicate, sulfate, halide, and borate;
zinc carboxylates; boric acids; sodium dichromate; copper oxene; copper chrome arsenate (CCA); chromated copper borate (CBC); ammoniacal copper arsenate (ACA);
ammoniacal copper zinc arsenate (ACZA); copper chromium fluoride (CFK); copper chromium fluoroborate (CCFB); and copper chromium phosphorous (CCP), and combinations thereof.
6. The composite building material of Claim 1, wherein the chemical comprises organic compounds.
7. The composite building material of Claim 6, wherein the organic compounds are selected from the group consisting of propiconazole, tebuconazole, organochloride, quaternary ammonium compounds (AAC), tri-n-butyltin oxide (TBTO), tri-n-butyltin naphthenate (TBTN), didecyldimethylammonium bromide (DDAB), didecyldimethylammonium chloride (DDAC), and mixtures thereof.
8. The composite building material of Claim 1, wherein the chemical comprises about 0.01% to 20% of the dry weight of the treated cellulose fibers.
9. The composite building material of Claim 1, wherein the cellulose fibers are made from cellulose pulps of a lignocellulosic material by a pulping process.
10. The composite building material of Claim 9, wherein the fiber lengths are between about 0.2 and 7 mm.
11. The composite building material of Claim 10, wherein the fiber lengths are between about 0.6 and 4 mm.
12. The composite building material of Claim 1, wherein the treated fibers comprise about 0.5%-20% by weight of the matrix.
13. The composite building material of Claim 1, further comprising untreated cellulose fibers.
14. The composite building material of Claim 1, further comprising natural inorganic and synthetic fibers.
15. The composite building material of Claim 1, wherein the cementitious matrix and the individualized cellulose fibers are autoclaved.
16. The composite building material of Claim 15, further comprising an aggregate.
17. The composite building material of Claim 16, wherein the aggregate is ground silica.
18. The composite building material of Claim 1, comprising about 10-80%
cement by weight.
19. A material formulation used to form a composite building material, comprising:
a cementitious binder; and cellulose fibers, wherein the cellulose fibers have been individualized and wherein at least some of the cellulose fibers are treated with a chemical to inhibit microorganism growth in the fibers.
20. The formulation of Claim 19, wherein the chemical comprises barium borate.
21. The formulation of Claim 19, wherein the chemical comprises copper oxene.
22. The formulation of Claim 19, wherein the chemical comprises propiconazole.
23. The formulation of Claim 19, wherein the chemical comprises copper and zinc in a salt form.
24. The formulation of Claim 19, comprising about 10%-80% cement by weight.
25. The formulation of Claim 19, wherein the cementitious binder has a surface area of about 250 to 400 m2/kg.
26. The formulation of Claim 19, wherein the cementitious binder comprises Portland cement.
27. The formulation of Claim 19, wherein the cementitious binder comprises high alumina cement, lime, ground granulated blast furnace slag cement, and high phosphate cement, and mixtures thereof.
28. The formulation of Claim 19, further comprising an aggregate.
29. The formulation of Claim 28, wherein the aggregate is approximately 30%-70% of the formulation by weight.
30. The formulation of Claim 28, wherein the aggregate comprises silica having a surface area of about 300-450 m2/kg.
31. The formulation of Claim 28, wherein the aggregate comprises ground silica.
32. The formulation of Claim 28, wherein the aggregate is selected from the group consisting of amorphous silica, micro silica, geothermal silica, diatomaceous earth, coal combustion fly and bottom ashes, rice hull ash, blast furnace slag, granulated slag, steel slag, mineral oxides, mineral hydroxides, clays, magnasite or dolomite, metal oxides and hydroxides, polymeric beads, and mixtures thereof.
33. The formulation of Claim 19, wherein the treated cellulose fibers comprise about 0.5%-20% of the formulation by weight.
34. The formulation of Claim 19, wherein the treated cellulose fibers are blended with untreated cellulose fibers.
35. The formulation of Claim 19, further comprising a density modifier.
36. The formulation of Claim 35, wherein the density modifier is about 0%-50%
of the formulation.
37. The formulation of Claim 35, wherein the density modifier comprises natural or synthetic lightweight materials selected from the group consisting of plastic material, expanded polystyrene, other foamed polymer materials, glass and ceramic material, calcium silicate hydrates, microspheres, volcano ashes including perlite, pumice, shirasu basalt, and zeolites in expanded forms, and mixtures thereof.
38. The formulation of Claim 19, further comprising additives.
39. The formulation of Claim 38, wherein the additives are about 0%-10% of the formulation.
40. The formulation of Claim 38, wherein the additives are selected from the group consisting of viscosity modifiers, fire retardants, waterproofing agents, silica fume, geothermal silica, pigments, colorants, plasticisers, dispersants, forming agents, flocculent, drainage aids, wet and dry strength aids, silicone materials, aluminum powder, clay, kaolin, bentonite, alumina trihydrate, zeolite, mica, metakaolin, calcium carbonate, wollastonite, polymeric resin emulsion, and mixtures thereof.
41. The formulation of Claim 19, wherein the treated cellulose fibers decrease the average fiber loss in the composite building material by more than about 5% as compared to a building material made from an equivalent formulation without treated cellulose fibers after 9 months of exposure in a high humidity and rot prone environment.
42. The formulation of Claim 19, wherein the treated cellulose fibers improve the rot resistance of the composite building material as compared to a building material made from an equivalent formulation without treated cellulose fibers.
43. The formulation of Claim 19, wherein the treated cellulose fibers improve the retention of modulus of rupture (MOR) of the composite building material after 18 months of exposure in high humidity and rot-prone environment by more than about 5% as compared to a building material made from an equivalent formulation without treated cellulose fibers.
44. The formulation of Claim 19, wherein the treated cellulose fibers improve the retention of modulus of elasticity (MOE) of the composite building material by more than about 5% after 18 months of exposure in lugh humidity and rot-prone environment as compared to a building material made from an equivalent formulation without treated cellulose fibers.
45. The formulation of Claim 19, wherein the treated cellulose fibers improve the retention of ultimate strain of the composite building material by more than about 5%
after 18 months of exposure in high humidity and rot-prone environment as compared to a building material made from an equivalent formulation without treated cellulose fibers.
46. The formulation of Claim 19, wherein the treated cellulose fibers improve the retention of toughness of the building product by more than about 5% after 18 months of exposure in high humidity and rot-prone environment as compared to a building material made from an equivalent formulation without treated cellulose fibers.
47. A method of manufacturing a fiber reinforced composite building material, comprising:
providing individualized cellulose fibers;
treating at least a portion of the cellulose fibers with a chemical, wherein the chemical inhibits microorganism growth in the treated cellulose fibers;
mixing the treated fibers with a cementitious binder to form a fiber cement mixture;
forming the fiber cement mixture into a fiber cement article of a pre-selected shape and size; and curing the fiber cement article so as to form the fiber reinforced composite building material.
48. The method of Claim 47, wherein providing individualized fibers comprises removing a majority of the lignin binding the cellulose fibers together.
49. The method of Claim 47, wherein providing individualized fibers comprises mechanically separating the fibers.
50. The method of Claim 47 wherein cellulose fibers are individualized by a chemical pulping method.
51. The method of Claim 47, wherein treating the fibers comprises physically and/or chemically bonding the biocide chemical to the outer and inner surface of the cellulose fibers.
52. The method of Claim 47, wherein treating the fibers comprises using a pressure impregnation technique.
53. The method of Claim 47, wherein treating the fibers comprises using a concentration diffusion technique.
54. The method of Claim 47, further comprising processing the treated fibers by dispersing the fibers at a pre-selected consistency range and then fibrillating the treated fibers to a pre-selected freeness range.
55. The method of Claim 47, wherein treating the fibers comprises chemically bonding a biocide to inner and outer surfaces of the cellulose fibers.
56. The method of Claim 47, wherein processing the treated fibers comprises dispersing the treated fibers at the consistency of about 1% - 6% in a hydra-pulper.
57. The method of Claim 47, further comprising processing the treated fibers by fibrillating the treated fibers to the freeness of 150 to 750 degrees of Canadian Standard Freeness.
58. The method of Claim 57, wherein processing the treated fibers comprises fibrillating the treated fibers to the freeness of 150 to 650 degrees of Canadian Standard Freeness.
59. The method of Claim 47, further comprising mixing the treated fibers with untreated cellulose fibers.
60. The method of Claim 47, further comprising mixing the treated fibers with synthetic fibers.
61. The method of Claim 47, wherein mixing the treated fibers with ingredients comprises mixing the treated fibers with an aggregate.
62. The method of Claim 47, wherein mixing the treated fibers with ingredients comprises mixing the treated fibers with additives.
63. The method of Claim 47, wherein mixing the treated fibers with ingredients comprises mixing the treated fibers with a density modifier.
64. The method of Claim 47, wherein mixing comprises directly adding biocides to the mixture.
65. The method of Claim 47, wherein forming the fiber cement article comprises forming the article using a process selected from the group consisting of a Hatschek sheet process, a Mazza pipe process, a Magnani process, injection molding, extrusion, hand lay-up, molding, casting, filter pressing, Fourdrinier forming, multi-wire forming, gap blade forming, gap roll/blade forming, Bel-Roll forming, and combinations thereof
66. The method of Claim 47, wherein curing the fiber cement article comprises pre-curing and curing.
67. The method of Claim 66, wherein the fiber cement article is pre-cured for up to 80 hours at ambient temperature.
68. The method of Claim 66, wherein the fiber cement article is pre-cured for up to 24 hours at ambient temperature.
69. The method of Claim 66, wherein the fiber cement article is cured in an autoclave.
70. The method of Claim 69, wherein the fiber cement article is autoclaved at an elevated temperature and pressure at about 60 to 200°C for about 3 to 30 hours.
71. The method of Claim 69, wherein the fiber cement article is autoclaved at an elevated temperature and pressure at about 60 to 200°C for about 24 hours or less.
72. The method of Claim 47, wherein curing the fiber cement article comprises air curing the formed article for up to 30 days.
73. A building material incorporating individualized reinforcing fibers, wherein at least a portion of the fibers are treated with a biocide to prevent microorganism growth within the fibers.
CA 2424744 2000-10-17 2001-09-25 Fiber cement composite material using biocide treated durable cellulose fibers Expired - Lifetime CA2424744C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US24121200P 2000-10-17 2000-10-17
US60/241,212 2000-10-17
PCT/US2001/042286 WO2002032830A2 (en) 2000-10-17 2001-09-25 Fiber cement composite material using biocide treated durable cellulose fibers

Publications (2)

Publication Number Publication Date
CA2424744A1 true CA2424744A1 (en) 2002-04-25
CA2424744C CA2424744C (en) 2011-05-10

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CA 2424744 Expired - Lifetime CA2424744C (en) 2000-10-17 2001-09-25 Fiber cement composite material using biocide treated durable cellulose fibers

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US (2) US6777103B2 (en)
EP (1) EP1334076B1 (en)
JP (1) JP5226925B2 (en)
KR (1) KR100817968B1 (en)
CN (1) CN1575264A (en)
AR (1) AR034162A1 (en)
AT (1) ATE337281T1 (en)
AU (1) AU1181602A (en)
BR (1) BR0114710A (en)
CA (1) CA2424744C (en)
CZ (1) CZ20031212A3 (en)
DE (1) DE60122561T2 (en)
MX (1) MXPA03003120A (en)
MY (1) MY130473A (en)
NZ (1) NZ525392A (en)
PL (1) PL201082B1 (en)
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WO2023280484A1 (en) * 2021-07-07 2023-01-12 Swisspearl Group Ag Fire resistant fibre cement compositions
US11884590B2 (en) 2021-07-07 2024-01-30 Swisspearl Group Ag Fire resistant fibre cement compositions

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CA2424744C (en) 2011-05-10
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US6777103B2 (en) 2004-08-17
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