CA2427799A1 - Fiber reinforced mineral-based materials and methods of making the same - Google Patents
Fiber reinforced mineral-based materials and methods of making the same Download PDFInfo
- Publication number
- CA2427799A1 CA2427799A1 CA 2427799 CA2427799A CA2427799A1 CA 2427799 A1 CA2427799 A1 CA 2427799A1 CA 2427799 CA2427799 CA 2427799 CA 2427799 A CA2427799 A CA 2427799A CA 2427799 A1 CA2427799 A1 CA 2427799A1
- Authority
- CA
- Canada
- Prior art keywords
- fiber
- mineral
- based material
- fibers
- 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.)
- Abandoned
Links
- 239000000463 material Substances 0.000 title claims abstract description 199
- 229910052500 inorganic mineral Inorganic materials 0.000 title claims abstract description 147
- 239000011707 mineral Substances 0.000 title claims abstract description 147
- 238000000034 method Methods 0.000 title claims abstract description 54
- 239000000835 fiber Substances 0.000 title claims description 234
- 239000004568 cement Substances 0.000 claims abstract description 45
- 239000002657 fibrous material Substances 0.000 claims abstract description 43
- 230000003014 reinforcing effect Effects 0.000 claims abstract description 6
- 235000010755 mineral Nutrition 0.000 claims description 144
- 239000010881 fly ash Substances 0.000 claims description 37
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 25
- 239000004567 concrete Substances 0.000 claims description 23
- 239000004570 mortar (masonry) Substances 0.000 claims description 16
- VTYYLEPIZMXCLO-UHFFFAOYSA-L calcium carbonate Substances [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 15
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 15
- 239000011122 softwood Substances 0.000 claims description 12
- 239000004927 clay Substances 0.000 claims description 10
- 239000011121 hardwood Substances 0.000 claims description 9
- 239000000377 silicon dioxide Substances 0.000 claims description 8
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- 229920001131 Pulp (paper) Polymers 0.000 claims description 6
- 235000010216 calcium carbonate Nutrition 0.000 claims description 6
- 238000005336 cracking Methods 0.000 claims description 6
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 4
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- 229920006317 cationic polymer Polymers 0.000 claims description 4
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- 235000017166 Bambusa arundinacea Nutrition 0.000 claims description 3
- 235000017491 Bambusa tulda Nutrition 0.000 claims description 3
- 235000018185 Betula X alpestris Nutrition 0.000 claims description 3
- 235000018212 Betula X uliginosa Nutrition 0.000 claims description 3
- 240000008564 Boehmeria nivea Species 0.000 claims description 3
- 244000025254 Cannabis sativa Species 0.000 claims description 3
- 235000012766 Cannabis sativa ssp. sativa var. sativa Nutrition 0.000 claims description 3
- 235000012765 Cannabis sativa ssp. sativa var. spontanea Nutrition 0.000 claims description 3
- 240000000491 Corchorus aestuans Species 0.000 claims description 3
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- 229920000742 Cotton Polymers 0.000 claims description 3
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- 240000000731 Fagus sylvatica Species 0.000 claims description 3
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- 240000000797 Hibiscus cannabinus Species 0.000 claims description 3
- 240000006240 Linum usitatissimum Species 0.000 claims description 3
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- 240000000907 Musa textilis Species 0.000 claims description 3
- 240000008790 Musa x paradisiaca Species 0.000 claims description 3
- 235000018290 Musa x paradisiaca Nutrition 0.000 claims description 3
- 240000007594 Oryza sativa Species 0.000 claims description 3
- 235000007164 Oryza sativa Nutrition 0.000 claims description 3
- 244000082204 Phyllostachys viridis Species 0.000 claims description 3
- 235000015334 Phyllostachys viridis Nutrition 0.000 claims description 3
- 235000008124 Picea excelsa Nutrition 0.000 claims description 3
- 240000000020 Picea glauca Species 0.000 claims description 3
- 235000008127 Picea glauca Nutrition 0.000 claims description 3
- 235000008331 Pinus X rigitaeda Nutrition 0.000 claims description 3
- 241000218680 Pinus banksiana Species 0.000 claims description 3
- 235000008565 Pinus banksiana Nutrition 0.000 claims description 3
- 241000018646 Pinus brutia Species 0.000 claims description 3
- 235000011613 Pinus brutia Nutrition 0.000 claims description 3
- 241000142776 Pinus elliottii Species 0.000 claims description 3
- 235000011334 Pinus elliottii Nutrition 0.000 claims description 3
- 241000183024 Populus tremula Species 0.000 claims description 3
- 240000001416 Pseudotsuga menziesii Species 0.000 claims description 3
- 235000005386 Pseudotsuga menziesii var menziesii Nutrition 0.000 claims description 3
- 229920002472 Starch Polymers 0.000 claims description 3
- 229910000831 Steel Inorganic materials 0.000 claims description 3
- 235000021307 Triticum Nutrition 0.000 claims description 3
- 244000098338 Triticum aestivum Species 0.000 claims description 3
- 229940037003 alum Drugs 0.000 claims description 3
- 229910000323 aluminium silicate Inorganic materials 0.000 claims description 3
- DIZPMCHEQGEION-UHFFFAOYSA-H aluminium sulfate (anhydrous) Chemical compound [Al+3].[Al+3].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O DIZPMCHEQGEION-UHFFFAOYSA-H 0.000 claims description 3
- 229920006318 anionic polymer Polymers 0.000 claims description 3
- 239000010426 asphalt Substances 0.000 claims description 3
- 239000010905 bagasse Substances 0.000 claims description 3
- 239000011425 bamboo Substances 0.000 claims description 3
- 229910000019 calcium carbonate Inorganic materials 0.000 claims description 3
- 235000009120 camo Nutrition 0.000 claims description 3
- 125000002091 cationic group Chemical group 0.000 claims description 3
- 239000000919 ceramic Substances 0.000 claims description 3
- 235000005607 chanvre indien Nutrition 0.000 claims description 3
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 claims description 3
- 239000000428 dust Substances 0.000 claims description 3
- 239000011440 grout Substances 0.000 claims description 3
- 239000011487 hemp Substances 0.000 claims description 3
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims description 3
- 229920000642 polymer Polymers 0.000 claims description 3
- 229940088417 precipitated calcium carbonate Drugs 0.000 claims description 3
- 235000003499 redwood Nutrition 0.000 claims description 3
- 235000009566 rice Nutrition 0.000 claims description 3
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- 239000010959 steel Substances 0.000 claims description 3
- 239000000454 talc Substances 0.000 claims description 3
- 229910052623 talc Inorganic materials 0.000 claims description 3
- 239000010803 wood ash Substances 0.000 claims description 3
- QTBSBXVTEAMEQO-UHFFFAOYSA-M Acetate Chemical compound CC([O-])=O QTBSBXVTEAMEQO-UHFFFAOYSA-M 0.000 claims description 2
- 229920002972 Acrylic fiber Polymers 0.000 claims description 2
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims description 2
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 2
- 229920000914 Metallic fiber Polymers 0.000 claims description 2
- 239000004698 Polyethylene Substances 0.000 claims description 2
- 239000004743 Polypropylene Substances 0.000 claims description 2
- 239000004793 Polystyrene Substances 0.000 claims description 2
- 229920000297 Rayon Polymers 0.000 claims description 2
- 229920006231 aramid fiber Polymers 0.000 claims description 2
- 229910052796 boron Inorganic materials 0.000 claims description 2
- 239000004917 carbon fiber Substances 0.000 claims description 2
- 229920002301 cellulose acetate Polymers 0.000 claims description 2
- 239000003365 glass fiber Substances 0.000 claims description 2
- 229920001778 nylon Polymers 0.000 claims description 2
- 229920002401 polyacrylamide Polymers 0.000 claims description 2
- 229920000728 polyester Polymers 0.000 claims description 2
- 229920000573 polyethylene Polymers 0.000 claims description 2
- 229920001155 polypropylene Polymers 0.000 claims description 2
- 229920002223 polystyrene Polymers 0.000 claims description 2
- 239000002964 rayon Substances 0.000 claims description 2
- 150000001875 compounds Chemical class 0.000 claims 11
- 238000001723 curing Methods 0.000 description 35
- 239000011398 Portland cement Substances 0.000 description 24
- 239000006185 dispersion Substances 0.000 description 19
- 238000012360 testing method Methods 0.000 description 16
- 239000002131 composite material Substances 0.000 description 14
- 239000000203 mixture Substances 0.000 description 13
- 239000011159 matrix material Substances 0.000 description 11
- 241000196324 Embryophyta Species 0.000 description 10
- 238000002156 mixing Methods 0.000 description 9
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 8
- 230000000694 effects Effects 0.000 description 8
- 239000000126 substance Substances 0.000 description 7
- QAOWNCQODCNURD-UHFFFAOYSA-L Sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 description 6
- 238000010009 beating Methods 0.000 description 6
- 229910052739 hydrogen Inorganic materials 0.000 description 6
- 239000001257 hydrogen Substances 0.000 description 6
- 230000036571 hydration Effects 0.000 description 5
- 238000006703 hydration reaction Methods 0.000 description 5
- 230000008569 process Effects 0.000 description 5
- 239000002994 raw material Substances 0.000 description 5
- 229910052791 calcium Inorganic materials 0.000 description 4
- 239000011575 calcium Substances 0.000 description 4
- 229920002678 cellulose Polymers 0.000 description 4
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- 230000000052 comparative effect Effects 0.000 description 4
- 239000011405 expansive cement Substances 0.000 description 4
- 229910052742 iron Inorganic materials 0.000 description 4
- 239000002245 particle Substances 0.000 description 4
- 230000009467 reduction Effects 0.000 description 4
- 238000007670 refining Methods 0.000 description 4
- 239000004575 stone Substances 0.000 description 4
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 3
- 230000009471 action Effects 0.000 description 3
- 239000010425 asbestos Substances 0.000 description 3
- 206010061592 cardiac fibrillation Diseases 0.000 description 3
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- 238000009826 distribution Methods 0.000 description 3
- 238000001035 drying Methods 0.000 description 3
- 230000002600 fibrillogenic effect Effects 0.000 description 3
- 239000011396 hydraulic cement Substances 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 239000000843 powder Substances 0.000 description 3
- 229910052895 riebeckite Inorganic materials 0.000 description 3
- 239000002002 slurry Substances 0.000 description 3
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 2
- 229920001410 Microfiber Polymers 0.000 description 2
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 2
- 239000011400 blast furnace cement Substances 0.000 description 2
- 235000012241 calcium silicate Nutrition 0.000 description 2
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 2
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- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 2
- 230000000670 limiting effect Effects 0.000 description 2
- 239000003658 microfiber Substances 0.000 description 2
- 210000001724 microfibril Anatomy 0.000 description 2
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- 238000012545 processing Methods 0.000 description 2
- 230000002787 reinforcement Effects 0.000 description 2
- 239000012783 reinforcing fiber Substances 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- 229910052710 silicon Inorganic materials 0.000 description 2
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- 230000008961 swelling Effects 0.000 description 2
- 239000002023 wood Substances 0.000 description 2
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- 235000008733 Citrus aurantifolia Nutrition 0.000 description 1
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- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
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- 239000000378 calcium silicate Substances 0.000 description 1
- 229910052918 calcium silicate Inorganic materials 0.000 description 1
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 description 1
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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
-
- 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
-
- 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
- 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
- C04B2111/00663—Uses not provided for elsewhere in C04B2111/00 as filling material for cavities or the like
-
- 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
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24752—Laterally noncoextensive components
- Y10T428/24769—Cellulosic
-
- 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
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
- Y10T428/249962—Void-containing component has a continuous matrix of fibers only [e.g., porous paper, etc.]
- Y10T428/249964—Fibers of defined composition
- Y10T428/249965—Cellulosic
-
- 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
-
- 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
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- 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
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/699—Including particulate material other than strand or fiber material
Abstract
The present invention relates to a method for reinforcing mineral-based materials using reinforced fiber material. More particularly, the present invention relates a method for more uniformly dispensing a fiber material with a mineral-based material, such as cement paste.
Description
FIBER REINFORCED MINERAL-BASED MATERIALS
AND METHODS OF MAKING THE SAME
DESCRIPTION OF THE INVENTION
Field of the Invention [001 ] The present invention relates to a method for reinforcing mineral-based materials using reinforced fiber material. More particularly, the present invention relates a method for more uniformly dispersing a fiber material within a mineral-based material, such as cement pasfe.
Background of the Invention [002] With an annual production of twelve billion tons, concrete has emerged as the material of choice for modern infrastructure construction. Portland cement concrete, a mineral-based material, is a composite material produced from proportioned mixtures of water, Portland cement, fine and coarse aggregates, and in some cases, mineral admixtures, chemical admixtures, and fibers. The products of cement hydration bind the aggregate particles together. Inherent in the microstructure of concrete are voids and cracks, ranging in size from microscale to macroscale. These voids and cracks can influence the mechanical behavior of the product. The presence of such flaws coupled with the generally brittle nature of concrete cause the tensile strength of concrete to be only 1/8 to 1/12 its compressive strength.
AND METHODS OF MAKING THE SAME
DESCRIPTION OF THE INVENTION
Field of the Invention [001 ] The present invention relates to a method for reinforcing mineral-based materials using reinforced fiber material. More particularly, the present invention relates a method for more uniformly dispersing a fiber material within a mineral-based material, such as cement pasfe.
Background of the Invention [002] With an annual production of twelve billion tons, concrete has emerged as the material of choice for modern infrastructure construction. Portland cement concrete, a mineral-based material, is a composite material produced from proportioned mixtures of water, Portland cement, fine and coarse aggregates, and in some cases, mineral admixtures, chemical admixtures, and fibers. The products of cement hydration bind the aggregate particles together. Inherent in the microstructure of concrete are voids and cracks, ranging in size from microscale to macroscale. These voids and cracks can influence the mechanical behavior of the product. The presence of such flaws coupled with the generally brittle nature of concrete cause the tensile strength of concrete to be only 1/8 to 1/12 its compressive strength.
[003] In order to enhance the properties, fibers have been used in various cement-based materials, including mortar, concrete, and fiber-cement products.
Fibers conventionally used in concrete construction generally range from 30-60 mm in length. While randomly distributed fibers of this size can improve certain mechanical properties of coricrete, mixing and dispersion are typically more demanding because of the likelihood of fiber "balling" or flocculation and non-uniform dispersion. Finishing is also challenging because "fuzzing" of fibers at the concrete surface can occur. These difficulties in mixing and dispersing the fiber limit the fiber volume that may be practically incorporated in concrete to 2% or less by volume. In addition, to non-uniform dispersion, steel, glass, and synthetic polymer fibers may increase the cost of concrete by 10-50%, rendering their use less cost effective.
Fibers conventionally used in concrete construction generally range from 30-60 mm in length. While randomly distributed fibers of this size can improve certain mechanical properties of coricrete, mixing and dispersion are typically more demanding because of the likelihood of fiber "balling" or flocculation and non-uniform dispersion. Finishing is also challenging because "fuzzing" of fibers at the concrete surface can occur. These difficulties in mixing and dispersing the fiber limit the fiber volume that may be practically incorporated in concrete to 2% or less by volume. In addition, to non-uniform dispersion, steel, glass, and synthetic polymer fibers may increase the cost of concrete by 10-50%, rendering their use less cost effective.
[004] Another source of fiber used for reinforcing mineral-based materials is asbestos fibers. However, the use of these fibers is hazardous and requires the provision of safety measures. In addition, due to their nature, asbestos fibers have a tendency to form clusters and bundles. For these reasons, asbestos have generally been replaced by other wood-based fibers.
[005] Wood-based fibers, which range from 1 to 4 mm in length and are tens of microns in diameter, are similar to other types of microfibers previously investigated for concrete reinforcement. Also the tensile strength and elastic modulus of microfibers vary with material type. Wood pulp fibers were found to be comparable to the other types of fibers. The hydrophilic surfaces of cellulose fibers may facilitate their dispersion and bonding to the cement paste. Since fibers have a very large aspect ratio of length to width, and they are very flexible, the fibers tend to be entangled forming flocs, which are very difficult to break up into individual fibers.
The fibers in the dry pulp are bonded strongly by hydrogen bonds. When the dry pulp is wetted, water breaks most of the hydrogen bonds, however mechanical entanglement still remains and makes the dispersion of the fibers very difficult.
Strong shear force is required to disperse the entangled fibers. Therefore, if well dispersed, the relatively high surface area and the close spacing of pulp fibers, when combined with their desirable mechanical characteristics, make them effective in suppression and stabilization of microcracks in a concrete matrix.
The fibers in the dry pulp are bonded strongly by hydrogen bonds. When the dry pulp is wetted, water breaks most of the hydrogen bonds, however mechanical entanglement still remains and makes the dispersion of the fibers very difficult.
Strong shear force is required to disperse the entangled fibers. Therefore, if well dispersed, the relatively high surface area and the close spacing of pulp fibers, when combined with their desirable mechanical characteristics, make them effective in suppression and stabilization of microcracks in a concrete matrix.
[006] The dispersion of pulp fibers are effective when used in small quantities or volume fractions, like 0.1 % or less, but higher fiber contents may cause the balling and poor distribution throughout the cement paste matrix. Rather than improving the properties of a mineral-based material, fibers which are not well distributed through the cement paste matrix act instead as defects, creating points of weakness in the composite. Balling or clumping of poorly distributed fibers may cause a decrease in the mechanical characteristics and the durability of the bulk composite.
[007] A major challenge to the introduction of pulp fibers to the cement-based matrix is the uniform dispersion of the fibers throughout the matrix.
The pulp fibers in their original form are very difficult to disperse in an inorganic binder, such as a cement paste matrix.
The pulp fibers in their original form are very difficult to disperse in an inorganic binder, such as a cement paste matrix.
[008] The Inventors have developed a method for effectively reinforced mineral-based materials. The Inventors have developed a method that improves the dispersion of reinforcing fibers into the mineral-based materials. The Inventors have further developed a low-cost method, to improve dispersion and bonding of fibers in mineral-based materials, resulting in composite materials with enhanced performance for a variety of applications such reduction of early age cracking and reduction of shrinkage cracking.
SUMMARY OF THE INVENTION
SUMMARY OF THE INVENTION
[009] According to the present invention there is disclosed a method for reinforcing mineral-based material comprising contacting at least one mineral-based material with at least one reinforced fiber material. The present invention discloses a composition comprising at least one mineral-based material and at least one reinforced fiber material.
[010] The present invention can provide improvement in one or more of the following properties: compressive strength, volume stability, crack resistance, toughness, ductility, durability, reduces of shrinkage, fire performance, post peak loading behavior, improved tensile strength, paintability, workability, flowability, and finishability.
BRIEF DESCRIPTION OF THE DRAWINGS
BRIEF DESCRIPTION OF THE DRAWINGS
[011] Figure 1 illustrates the flocculation and distribution of untreated softwood pulp fibers in Portland cement mortar.
[012] Figure 2 illustrates the relationship between cationic starch and fly ash or silica fume and absorption on to the fiber surface.
[013] Figure 3 illustrates dispersion of treated softwood fibers in Portland cement mortars according to the present invention.
[014] Figure 4 compares load vs. deflection for unreinforced mortar and mortar reinforced with treated softwood pulp fiber according to the present invention.
[p15] Figure 5 illustrates load vs. deflection for unreinforced mortar and mortar reinforced with treated hardwood fiber and treated softwood fiber according to the present invention.
[016] Figure 6 illustrates comparative data of the compressive strength of mineral-based materials, cured for a period of seven days, according to the present invention.
[017] Figure 7 illustrates comparative data of the compressive strength of mineral-based materials, cured for a period of twenty-eight days, according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[018] It has been discovered that reinforcement of mineral-based materials can be achieved by incorporating reinforced fiber materials into the mineral-based materials. Therefore, in one embodiment of the invention, we provide a method of reinforcing mineral-based materials using reinforced fiber materials.
[019] According to the present invention mineral-based material is any material for any solid mineral based material particularly for use in environments where strength is an issue, non-limiting examples, include buildings, bridges, pavements, sidewalks, precast concrete products, floors, roads, drainage, stones, bricks, siding, roofing. Non-limiting examples of mineral-based materials are cement based material, clay-based material, asphalt-based material, mortar, concrete, ceramic tile, grout, and terrazzo. Cement-based material generally comprise at least one of lime, alumina, silica, calcium silicates, calcium, silicon, aluminum, iron, iron oxide, sulfate, gypsum, calcium sulfate, calcium aluminates, and calcium sulfoaluminates. Examples of cement based materials are aluminous cement, blast furnace cement, Type I portland cement, Type IA portland cement, Type II
portland cement, Type IIA portland cement, Type III portland cement, Type IIIA, Type IV
portland cement, Type V portland cement, hydraulic cement such as white cement, gray cement, blended hydraulic cement, Type IS-portland blast-furnace slag cement, Type IP and Type P-portland-pozzolan cement, Type S-slag cement, Type I (PM)-pozzolan modified portland cement, and Type I (SM)-slag modified portland cement, Type GU-blended hydraulic cement, Type HE-high-early-strength cement, Type MS-moderate sulfate resistant cement, Type HS-high sulfate resistant cement, Type MH-moderate heat of hydration cement, Type LH-low heat of hydration cement, Type K expansive cement, Type O expansive cement, Type M expansive cement, Typse S expansive cement, regulated set cement, very high early strength cement, high iron cement, and oil-well cement, further concrete fiber cement deposits and any composite material including any of the above listed cement.
~020~ The different types of cement may be characterized by The American Society for Testing and Materials (ASTM) Specification C-150. For example, Type I
portland cement is a normal, general-purpose cement suitable for all uses. It is used in general construction projects such as buildings, bridges, floors, pavements, and other precast concrete products. Type IA portland cement is similar to Type I
with the addition of air-entraining properties. Type II Portland cement generates less heat at a slower rate and has a moderate resistance to sulfate attack. Type lIA
Portland cement is identical to Type II and produces air-entrained concrete. Type III
Portland cement is a high-early-strength cement and causes .concrete to set and gain strength rapidly. Type III is chemically and physically similar to Type I, except that its particles have been ground finer. Type IIIA is an air-entraining, high-early-strength cement. Type IV portland cement has a low heat of hydration and develops strength at a slower rate than other cement types, making it ideal for use in dams and other massive concrete structures where there is little chance for heat to escape. Type V portland cement is used only in concrete structures that will be exposed to severe sulfate action, principally where concrete is exposed to soil and groundwater with a high sulfate content.
~027~ The mineral-based material may be made in any method known to those skilled in the arts. For example, Portland cement, the fundamental ingredient in concrete, is a calcium silicate cement made with a combination of calcium, silicon, aluminum, and iron. Portland cement generally comprises a combination of limestone, shells or chalk, and shale, clay, sand, and/or iron ore. The raw materials are then reduced in size by means of, for example, a crusher. The materials are proportioned to create a cement with a specific chemical composition. Two different methods, dry and wet, can be used to manufacture portland cement. In the dry process, dry raw materials are proportioned, ground to a powder, blended together and fed to the kiln in a dry state. In the wet process, a slurry is formed by adding water to the properly proportioned raw materials. The grinding and blending operations are then completed with the materials in slurry form. After blending, the mixture of raw materials is fed into the upper end of a tilted rotating, cylindrical kiln.
The mixture passes through the kiln at a rate controlled by the slope and rotational speed of the kiln. Burning fuel consisting of powdered coal or natural gas is forced into the lower end of the kiln. Inside the kiln, raw materials reach temperatures of 2600°F to 3000°F (1430°C to 1650°C). At 2700°F (1480°C), a series of chemical reactions cause the materials to fuse and create cement clinker-grayish-black pellets, often the size of marbles. Clinker is discharged red-hot from the lower end of the kiln and transferred to various types of coolers to lower the clinker to handling temperatures. Cooled clinker is combined with gypsum and ground into a fine gray powder. The clinker is ground so fine that nearly all of it passes through a No. 200 mesh (75 micron) sieve. This fine gray powder is portland cement.
[022] Other methods for obtaining mineral-based materials may also be used for the present invention. Mineral-based material may be in any form known to those or ordinary skilled in the art. For example, mineral-based material may be in a ready mixed form, wherein it is batched at local plants. Another example form of mineral-based material may be precast mineral-based products such as concrete bricks, paving stones, bridge girders, structural components, and panels for cladding. Yet another example of mineral-based material form is mineral masonry such as roofing tiles, shake shingles, lap siding, and countertops.
[023] Aggregates as used herein, unless otherwise stated, refer to granular materials such as sand, gravel, or crushed stone. Aggregates may be divided into two distinct categories such as fine and coarse. An example of fine aggregates includes natural sand or crushed stone with most particles passing through a inch (9.5-mm) sieve. An example of coarse aggregates includes particles greater than 0.19 inch (4.75 mm), but generally range between 3l8 and 1.5 inches (9.5 mm to 37.5 mm) in diameter, e.g., gravel. Aggregates such as natural gravel and sand may be dug or dredged from a pit, river, lake, or seabed. Crushed aggregate may be produced by crushing quarry rock, boulders, cobbles, or large-size gravel.
Another example of aggregates may be recycled mineral-based material such as concrete.
[024] Chemical admixtures as used herein, unless otherwise stated, refers to any compositions for the use in air-entraining, water-reducing, retarding, accelerating, plasticizing, corrosion inhibition, shrinkage reduction, alkali-silica reactivity reduction, workability enhancement, bonding, damp proofing, or coloring for mineral-based material.
[025] Fiber materials, according to the present invention, are chosen from at least one of cellulosic fibers, recycled fibers, mechanical pulp such as mechanical pulp such as thermomechanical pulp, and synthetic fibers. Cellulosic fibers are derived from plants. Examples of cellulosic fibers are woody fiber such as hardwood fiber such as fibers on broad leaf trees such as oak, aspen, birch, and beech, and softwood fiber such as fibers from coniferous trees such as slash pine, jack pine, white spruce, logepole pine, redwood, or douglas fir, and non-woody fibers, such as hemp flax, bagasse, mailla, cotton, ramie, jute abaca, banana, kenaf, sisal hemp, wheat, rice, bamboo, and pineapple. Recycled fiber are derived from paper products, such as, for example old corrugated container, old magazine grade, old newsprint, mixed office waste, tissue, or napkin. Synthetic fibers, according to the present invention, are any fibers non-naturally occurring. Examples of synthetic fibers include, but are not limited to glass fiber, metallic fiber such as steel fiber, which includes boron fiber and aluminum fiber, acrylic fiber, nylon fiber, rayon fiber, polyester fiber, polystyrene fiber, cellulose acetate fiber, acetate base fiber, polypropylene fiber, polyacrylamide fiber, polyethylene fiber, carbon fiber, and aramid fiber. According to one embodiment of the present invention, the fiber materials according to the present invention can be from about 0.01 mm to about 80 mm in length. Further, the fiber can range from about 30 mm to about 60 mm in length. Still further, the fiber range can be from 1 mm to about 4 mm in length.
[026] Yet another embodiment of the present invention, provides a method for creating reinforced, fiber materials. Reinforced fiber materials according to the present invention provide improved product properties when dispersed in mineral-based materials. The fiber material according to the present invention may be wet or dry. The mixture may be dried according to any method known in the art. For example, the mixture may be subjected to filtration, vacuum, or flash drying.
[027] Reinforced fiber material comprises either at least one fiber material as described above, and at least one coordinating material or a treated fiber material capable of dispersion or bonding within the mineral-based material.
Coordinating materials are any material that 1 ) allows separation or dispersion of fiber materials which results in improved dispersion when mixed with a mineral-based material;
or 2) that improves bonding between the fibers and the mineral-based material.
Examples of coordinating materials include, but are not limited to silica-rich materials such as fly ash and silica fume; slag; aluminosilicate such as heat-treated clay, metakaolin, clay; fines from crushed rock; fine sand; silica gel; talc;
calcium carbonates such as precipitated calcium carbonate and grounded calcium carbonate; aluminum sulfate as known as alum; wood ash; polymers that can adsorb or bond to fiber materials such as anionic polymers and cationic polymers such as potato starch and corn starch; surfactants; water; and saw dust.
[028] Improved dispersion and/or improved bonding of fiber based materials to mineral-based materials results in a composite material having enhanced performance for a variety of applications. For example, by improving dispersion and/or bonding, fiber materials may be incorporated into mineral-based materials at demonstrated volume fractions, but with improved workability, affording improved strengths and more efficient construction or production. In addition, higher fiber volume fractions may be incorporated into mineral-based materials, without requiring any additional machinery or technology, such as extruders or specialized ' mixing tools. Products having higher volume fractions can maintain improved workability and strength. Strengthening the bond between the fiber and the surrounding matrix also can allow for more efficient transfer of tensile stress to the fiber.
[029] To improve.the distribution and/or the bonding of fiber based materials with the mineral-based material matrix, such as cement, the fibers, such as plant fibers, may be treated using any art recognized method including mechanical or chemical treatment or a combination of both. Without being bound by theory, the inherent chemical characteristics of plant fibers affect their dispersion in water, and, hence, in cement-based materials. First, plant fiber is hydrophilic, and as a result, the ability of the plant fiber to adsorb water is high. This can adversely affect the workability, placement, and compaction of cement composites resulting in higher void contents and lower strength. Second, because the plant fibers are composed primarily of cellulose (60-80%, depending upon processing), drying of the fibers can cause an increase in the number and strength of hydrogen bonds in the cellulose.
When fibers are introduced to water, the typical chemical behavior includes the polar attraction of the water molecules to each other and to the hydroxyl groups covering the cellulose surface. As the water is evaporated, the hydroxyl groups of cellulose surface ultimately link together by means of hydrogen bonding. Mechanical action may aid in fiber separation. If the plant fiber is allowed to flocculate together or "ball", the properties of reinforced mineral-based material will be negatively affected.
Instead of acting to improve the mechanical properties of the mineral-based material, poorly dispersed or clumped plant fiber can act as a weak point inside the composite. Cement material can hardly penetrate into the flocculated fibers.
In addition, swelling of the fiber clumps, in response to moisture fluctuations, may be more disruptive to the matrix than swelling of well-dispersed fibers.
[030] Mechanical bonding between the fibers and the mineral-based material may be improved by beating the plant fibers. Fiber beating,. fiber refining, or fibrillation is a common mechanical process in the papermaking industry.
According to one embodiment of the present invention, two operations are involved in this mechanical treatment. The first is called pulping or dispersion. In this stage, the dry pulp is dispersed in water to form a slurry. The second operation is beating.
The major effects of the beating process are: removing the primary wall of the fibers, penetration of the water into the fiber cell wall, breaking some of the intra-fiber hydrogen bonding, and replacing it with water-fiber hydrogen bond, external fibrillation by peeling some of the microfibrils in the S1 layer of the fibers, and fiber shortening. According to one embodiment of the present invention, beating refers to the mechanical action of fibrillating the fiber surface, essentially creating many "branches" or extensions from the fiber surface to improve the bonding effect between the fiber and the matrix of the mineral based material.
[031] Fibrillation or fiber refining can be achieved by any art recognized methods such as for example disc refiner, conical refiner, and valley beater.
The degree of refining is measured by the Canadian Standard Freeness (CSF) test.
The CSF is defined as "the number of milliliters of water collected from the side orifice of the standard tester when pulp drains through an perforated plate at 0.30 consistency and 20°-C"(G. A. Smook 1982). Refining is preferably selected to fibrillate the external surface of the fiber to increase the surface area for better bonding with the mineral based material and/or coordinating material. The fibrillated surface also is advantageous for capturing mineral-based material and/or coordinating material. Beating may give better flexural performance.
[032] Chemical treatment of the fiber material may also improve fiber dispersion. Fibers can be introduced to coordinating materials to improve dispersion and/or bonding between the fiber and the matrix of the mineral-based material.
Coordinating materials have been found to separate fiber materials from one another and/or improve bonding with the surrounding mineral-based material paste. In addition, coordinating materials on the surface of the fiber materials may make it difficult for the microfibrils to collapse back to the fiber surface.
X033] By introducing a coordinating materials to the fibers during processing, the coordinating materials may contain positively charged side groups that may become strongly attracted to the negatively-charged sites on the fibers.
Because these coordinating materials can contain a cationic site or sites, they are capable of bonding with the negatively charged fiber, thereby making the surface of the fiber neutral or positively charged fiber surfaces advantageous for capturing negatively charged coordinating material.
[034], The mixing of the mineral-based material and reinforced fiber materials can be carried out in any manner known in the art. For example, the fiber material may be introduced with the coordinating materials, and then the combined mixture may be introduced to the mineral-based material. Another example of the mixing procedure may be to introduce the fiber material, coordinating material, and mineral-based material simultaneously. A further example may be to contact the mineral-based material with the coordinating material and then combine the mixture with the fiber material. An even further example of the mixing procedure may be to contact the fiber material with the mineral based material and then combine the mixture with the coordinating material. Additionally, the fiber material and the mineral based material may be mixed without the addition of the coordinating material, resulting in somewhat decreased binding of the mineral to the fiber.
Still further, the reinforced fiber may be added with the mineral-based material.
The fiber material can range from about 0.001 % to about 50% of the total volume of the reinforced fiber and the coordinating material (hereinafter referred to as composite).
Further the fiber material can range from about 0.1 % to about 8% of the total volume of the composite. Still further the fiber material can range from about 0.6%
to about 3% of the total volume of the composite. The coordinating material can range from about 0.01 % to about 70% of the total volume of the composite. Still further the coordinating material can range from about to about 1 % to about 50% of the total volume of the composite.
[035] The combination of mineral-based material and reinforcing fibers mixtures may be mixed with any tools known to those in the art such as mechanical mixers, manual mixing, or specialized processes such as the hatschek process.
[036] The mineral-based material may be cured according to any method known to those in the art. The curing method should be chosen to provide the desired properties of the hardened mineral-based material, such as, durability, strength, water tightness, fire performance, abrasion resistance, volume stability, and resistance to freezing and thawing and deicer salts. The method chosen for curing should also provide surface strength development in the mineral-based material. Curing methods should assist in the chemical reaction called hydration.
An example temperature range may be from 40° F to 75° F. When desired, other curing methods such as steam curing or autoclaving may be used. Steam curing may be performed at atmospheric pressures, where temperatures may be from about 40°F to about 200°F at various periods in the process.
During autoclaving, curing may be performed under any pressure known in the art and generally at high temperature as known in the art.
[037] The reinforced mineral based material may be tested according to any known method in the art. The mineral based material may be tested in the hardened state or in the freshly mixed state. For example the mineral-based material may be subjected to a slump, flow, air-content, unit weight, compressive strength tests, tensile strength, dimensional stability, and flexure tests.
[038] Slump and flow are both measures of consistency, or relative ability of the mineral-based material to flow and compact. If the mineral-based material cannot flow because the consistency or slump is too low, there are potential problems with proper consolidation. If the mineral-based material will not stop flowing because the slump is too high, there are potential problems with mortar loss through the formwork, excessive formwork pressures, finishing delays and segregation. Air content measures the total air content in a sample of fresh mineral-based material mix, but does not indicate what the final in-place air content will be, because a certain amount of air is lost in transportation, consolidating, placement and finishing. Three field tests are widely specified: the pressure meter and volumetric method are ASTM standards and the Chace Indicator is an AASHTO
procedure. Unit weight measures the weight of a known volume of fresh mineral-based material. Compressive strength is tested by pouring cylinders or cubes of fresh mineral based material and measuring the force needed to break the mineral-based material cylinders at proscribed intervals as they harden. Tensile strength may be measured indirectly by applying a compressive load along the length of a cylindrical sample of mineral based material, inducing a tensile stress.
Dimensional stability can be measured by monitoring change in length of mineral-based materials fitted with rigid gauge studs.
[039] The test data are seen in Figures 4, 5, 6, and 7. Figure 4 shows load vs. deflection curves for unreinforced mortar and mortar reinforced with treated softwood pulp fiber at volume fraction (per total sample volume) of 0.6% and 1.2%.
The fiber reinforced samples show significantly improved toughness, when compared to the unreinforced sample. In addition, flexural strength is retained, showing that the fibers enhance properties of the composite and do not act as inclusions or stress-raisers.
[040] Figure 5 shows load vs. deflection data for unreinforced mortar and mortar reinforced with treated hardwood fiber and treated softwood fiber, both at 0.6% fiber volume fraction. The hardwood fiber reinforced sample also shows improved toughness, while retaining flexural strength. However, the softwood fibers tend to improve toughness more than the hardwood fibers. Without being bound by theory, this is believed to be due to the greater length of the softwood fibers which are typically 4-6 mm in length, while hardwood fibers are typically ~1 mm in length.
[041] Figure 6 illustrates comparative data of the compressive,strength of mineral-based materials for a period of seven days according to the present invention. The data shows that the reinforced fiber material increases the compressive strength of the mineral-based material.
[042] Figure 7 illustrates comparative data of the compressive strength of mineral-based materials for a period of twenty-eight days according to the present invention. Again, the data shows that the reinforced fiber material increases the compressive strength of the mineral-based material.
[043] The present invention will now be described by way of example. The examples are not limiting of the invention as claimed.
Examples:
Example 1: Effect of Fiber Treatment on the Compressive Strength at Fiber Volume Fraction 2.0 % for Seven Days Table 1 Sample VfAge Load Strength Fly Ash No. Dim. (1b) (psi) (in) Control 0 3 2*2*2 10470 2617 0 Control 0 3 2*2*2 10360 2590 0 Control 0 3 2*2*2 10050 2512 0 Control 0 3 2*2*2 10293 2573 0 Avr Control 0 7 2*2*2 15100 3775 0 Control 0 7 2*2*2 16530 4132 0 Control 0 7 2*2*2 16440 4110 0 Control ~ 7 2*2*2 16023 4005 0 Avr ~
[044] Table 1 shows the compressive strength of mineral-based materials without any fiber volume fraction for a three and seven day period. Vf represents fiber volume fraction in percent. Age represents the number of days of curing.
The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 2 Sample Strength I I
No. Vf Age Dim. Load (psi) Fly Ash (in) (1b) 3 2 7 2*2*2 11330 2832 0 3 2 7 2*2*2 12120 3030 0 3 2 7 2*2*2 11640 2910 0 3 Avr 2 7 2*2*2 11696 2924 0 [045] Table 2 shows the compressive strength of mineral-based material with 2% fiber volume fraction after a curing period of seven days without any fiber treatment. Vf represents fiber volume fraction -in percent. Age represents the number of days of curing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b), The strength is measured in pounds per square inch (psi).
Table 3 Sample Dim. ~ Strength No. Vf Age (in) Load (1b)(psi) Fly Ash 23 2 7 2*2*2 14390 3597 40 23 2 7 2*2*2 15420 3855 40 23 2 7 2*2*2 15420 3855 40 23 Avr 2 7 2*2*2 15076 3769 40 [046] Table 3 shows the compressive strength of mineral-based material with 2% fiber volume fraction after a curing period of seven days. The fibers are treated with fly ash represented in percentage, Vf represents fiber volume fraction in percent. Age represents the number of days curing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (!b). The strength is measured in pounds per square inch (psi).
Table 4 Sample Dim. Strength No. Vf Age (ink- Load (Ib)-(psi) Fly Ash 19 2 7 2*2*2 14320 3580 49 19 2 7 2*2*2 13610 3402 49 19 2 7 2*2*2 14670 3667 49 19 Avr 2 7 2*2*2 14200 3550 49 ~
[047] Table 4 shows the compressive strength of mineral-based material with 2% fiber volume fraction after a curing period of seven days. The fibers are treated with fly ash represented in percentage by mass. Vf represents fiber volume fraction in percent. Age represents the number of days curing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 5 Vf FI Ash % Load Ib Stren th si [048] Table 5 shows a comparison of the compressive strength of the mineral-based material after a seven day curing period. The table shows that the mineral-based materials treated with fly ash has an improved strength when compared with fibers not treated with fly ash.
Example 2: Effect of Fiber Treatment on the Compressive Strength at Fiber Volume Fraction 1.2 % for Seven Days Table 6 Sam 1e VfA Load Stren th FI Ash No. a Ib si Dim.
in Control 0 3 2*2*2 10470 2617 0 Control 0 3 2*2*2 10360 2590 0 Control 0 3 2*2*2 10050 2512 0 Control 0 3 2*2*2 10293 2573 0 Avr Control 0 7 2*2*2 15100 3775 0 Control 0 7 2*2*2 16530 4132 0 Control 0 7 2*2*2 16440 4110 0 Control 0 7 2*2*2 16023 4005 0 Avr [049] Table 6 shows the compressive strength of mineral-based materials without any fiber volume fraction cured for either a three and seven day period. Vf represents fiber volume fraction in percent. Age represents the number of days of curing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b).
The strength is measured in pounds per square inch (psi).
Table 7 Sample ~ ~ Dim. Load Strength Fly Ash No Age(in) (1b) (psi) 3 1.2 7 2*2*2 14010 3502 0 3 1.2 7 2*2*2 12180 3045 0 3 1.2 7 2*2*2 14100 3525 0 r 3 Avr 1.2 ~ 2*2*2 13430 3357 ~ ' 0 [050] Table 7 shows the compressive strength of mineral-based material with 1.2% fiber volume fraction without any fiber treatment after curing for a period of seven days. Vf represents fiber volume fraction in percent. Age represents the number of days of curing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 8 Sample Vf ~ Dim. Load Strength Fly Ash No. Age (in) (1b) (psi) 23 1.27 2*2*2 18290 4572 40 23 1.27 2*2*2 17000 4250 40 23 1.27 2*2*2 17140 4285 40 23 Avr 1.27 2*2*2 17476 4369 40 [051 ] Table 8 shows the compressive strength of mineral-based material with 1.2% fiber volume fraction after curing for a period of seven days. The fibers are treated with fly ash represented in percentage. Vf represents fiber volume fraction in percent. Age represents the number of days of curing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 9 Sample Vf Age Dim. Load Strength Fly Ash No. (in) (1b) (psi) 19 1.27 2*2*2 16410 4102 49 19 1.27 2*2*2 15060 3765 49 19 1.27 2*2*2 14870 3717 49 19 Avr 1.27 2*2*2 15446 3861 ~9~
[052] Table 9 shows the compressive strength of mineral-based material with 1.2% fiber volume fraction after curing for a period of seven days. The fibers are treated with fly ash represented in percentage. Vf represents fiber volume fraction in percent. Age represents the number of days of curing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 10 Vf FI Ash % Load Ib , Strencth si 1.2 0 13430 3357 1.2 40 17476 4369 1.2 49 15446 3861 [053] Table 10 shows a comparison of the compressive strength of the mineral-based material, cured for a seven day period. The table shows that the mineral-based materials treated with fly ash has an improved strength when compared with fibers not treated with fly ash.
Example 3: Effect of Fiber Treatment on the Compressive Strength at Fiber Volume Fraction 0.6 % for Seven Days Table 11 Sample Vf~ Load Strength Fly Ash No. Age (1b) (psi) Dim.
(in) Control 0 3 2*2*2 10470 2617 0 Control 0 3 2*2*2 10360 2590 0 Control 0 3 2*2*2 10050 2512 0 Control O ~ 2*2*2 10293 2573 0 Av~ 3 Control 0 7 2*2*2 15100 3775 0 Control 0 7 2*2*2 16530 4132 0 Control 0 7 2*2*2 16440 4110 0 Control 0 ~ 2*2*2 16023 4005 0 Avr 7 [054] Table 11 shows the compressive strength of mineral-based materials without any fiber volume fraction cured for periods of either three or seven days. Vf represents fiber volume fraction in percent. Age represents the number of days of curing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b).
The strength is measured in pounds per square inch (psi).
Table 12 Sam 1e No. Vf A a Dim. in Load Ib Stren th si FI Ash 3 0.6 7 2*2*2 16370 4092 0 3 0.6 7 2*2*2 15930 3982 3 0.6 7 2*2*2 16380 4095 0 3 Avr 0.6 7 2*2*2 16226 4056 0 [055] Table 12 shows the compressive strength of mineral-based material with 0.6% fiber volume fraction without any fiber treatment cured for a period of seven dayst. Vf represents fiber volume fraction in percent. Age represents the number of days of curing prior to testing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 13 Sample Vf ~ Dim, Load Strength Fly Ash No. Age(in) (1b) (psi) 23 0.6 7 2*2*2 15270 3817 40 23 0.6 7 2*2*2 18630 4657 40 23 0.6 7 2*2*2 17210 4302 40 23 Avr 0.6 7 2*2*2 17036 4259 40 [056] Table 13 shows the compressive strength of mineral-based material with 0.6% fiber volume fraction cured for a period of seven days. The fibers are treated with fly ash represented in percentage. Vf represents fiber volume fraction in percent. Age represents the number of days of curing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 14 Sam 1e Vf A Dim. Load Stren th FI Ash No. a in Ib si 19 0.67 2*2*2 17730 4432 49 19 0.67 2*2*2 17310 4327 49 19 0.67 2*2*2 18850 4712 49 19 Avr 0.67 2*2*2 17963 4490 49 [057] Table 14 shows the compressive strength of mineral-based material with 0.6% fiber volume fractiori cured for a period of seven days. The fibers are treated with fly ash represented in percentage. Vf represents fiber volume fraction in percent. Age represents the number of days of curing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 15 Vf FI Ash % Load Ib Stren th si 0.6 0 16226 4056 0.6 40.36 17036 4259 0.6 49.7 17963 4490 [058] Table 15 shows a comparison of the compressive strength of the mineral-based material cured for a seven day period prior to testing. The table shows that the mineral-based materials treated with fly ash has an improved strength when compared with fibers not treated with fly ash.
Example 4: Effect of Fiber Treatment on the Compressive Strength at Fiber Volume Fraction 2 °l° for Twent r-~Ei, hq t Days Table 16 Sam 1e Vf A Dim. Load Stren th FI Ash No. a in Ib si 3 2 28 2*2*2 16760 4190 0 3 2 28 2*2*2 17470 4367 0 3 2 28 2*2*2 16810 4202 0 3 Avr 2 28 2*2*2 17013 4253 0 [059] Table 16 shows the compressive strength of mineral-based material with 2% fiber volume fraction without any fiber treatment cured for a period of twenty eight days. Vf represents fiber volume fraction in percent. Age represents the number of days of curing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 17 Sample Vf ~ Dim. Load Strength Fly Ash No. Age (in) (1b) (psi) 23 2 28 2*2*2 20270 5067 40 23 2 28 2*2*2 21140 5285 40 23 2 28 2*2*2 21810 5452 40 23 Avr 2 ~ ~ 2*2*221073 5268 40 ~ 28 [060] Table 17 shows the compressive strength of mineral-based material with 2% fiber volume fraction cured for a period of twenty eight days. Vf represents fiber volume fraction in percent. Age represents the number of days of curing before testing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b).
The strength is measured in pounds per square inch (psi).
Table 18 Sample ~Vf~ Dim. Load Strength Fly Ash No. Age (in) (1b) (psi) ~
19 2 28 2*2*2 18260 4565 49 19 2 28 2*2*2 21680 5420 49 19 2 28 2*2*2 20010 5002 49 19 Avr 2 ~ 2*2*2 19983 4995 49 ~
[061] Table 18 shows the compressive strength of mineral-based material with 2°/o fiber volume fraction cured for a period of twenty eight days. Vf represents fiber volume fraction in percent. Age represents the number of days of curing prior to testing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b).
The strength is measured in pounds per square inch (psi).
Table 19 Vf Fly Ash % Load Ib Stren th si 2 _ 0 , 17013 14253 [062] Table 19 shows a comparison of the compressive strength of the mineral-based material cured for a twenty-eight day period. The table shows that the mineral-based materials treated with fly ash has an improved strength when compared with fibers not treated with fly ash.
Example 5: Effect of Fiber Treatment on the Compressive Strength at Fiber Volume Fraction 1.2 % for Twenty-Eiaht Days Table 20 Sam 1e Vf A Dim. Load Stren th FI Ash No. a in Ib si 3 1.228 2*2*2 20050 5012 0 3 1.228 2*2*2 19610 4902 0 3 1.228 2*2*2 18380 4595 0 3 Avr 1.228 2*2*2 19346 4836 0 [063] Table 20 shows the compressive strength of mineral-based material with 1.2% fiber volume fraction without any fiber treatment cured for a period of twenty eight days. Vf represents fiber volume fraction in percent. Age represents the number of days of curing prior to testing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 21 Sample Vf AgeDim. Load Strength Fly Ash No. (in) (1b) (psi) 23 1.2 28 2*2*2 24120 6030 40 23 1.2 28 2*2*2 23980 5995 40 23 1.2 28 2*2*2 23110 5777 40 23 Avr 1.2 28 2*2*2 23736 5934 40 (064] Table 21 shows the compressive strength of mineral-based material with 1.2% fiber volume fraction cured for a period of twenty eight days. Vf represents fiber volume fraction in percent. Age represents the number of days of curing prior to testing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 22 Sam 1e Vf A Dim. Load Stren th FI Ash No. a in Ib si 19 1.228 2*2*2 20100 5025 49 19 1.228 2*2*2 25200 6300 49 19 1.228 2*2*2 22410 5602 49 19 Avr 1.2~8 ~ 2*2*222570 5642 ~ 49 , [065] Table 22 shows the compressive strength of mineral-based material with 1.2% fiber volume fraction cured for a period of twenty eight days. Vf represents fiber volume fraction in percent. Age represents the number of days of curing prior to testing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 23 Vf Fl Ash % Load Ib Stren th si 1.2 0 19346 4836 1.2 40 23736 5934 1.2 49 22570 5642.5 [066] Table 23 shows a comparison of the compressive strength of the mineral-based material cured for a twenty-eight day period. The table shows that the mineral-based materials treated with fly ash has an improved strength when compared with fibers not treated with fly ash.
Example 6: Effect of Fiber Treatment on the Compressive Strength at Fiber Volume Fraction 0.6 % for Twenty-Eight Days Table 24 Sam 1e Vf A Dim. Load Stren th FI Ash No. a in Ib si 3 0.628 2*2*2 21540 5385 0 3 0.628 2*2*2 23030 5757 0 3 0,628 2*2*2 23530 5882 0 3 Avr 0.628 2*2*2 22700 5675 0 [067] Table 24 shows the compressive strength of mineral-based material with 0.6% fiber volume fraction without any fiber treatment cured for a period of twenty eight days. Vf represents fiber volume fraction in percent. Age represents the number of days of curing prior to testing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (Ib)~ The strength is measured in pounds per square inch (psi).
Table 25 Sam 1e Vf A Dim. Load Stren th FI Ash No. a in Ib si 23 0.628 2*2*2 27920 6980 40 23 0.628 2*2*2 24430 6107 40 23 0.628 2*2*2 27750 6937 40 23 Avr 0.628 2*2*2 26700 6675 40 [068] Table 25 shows the compressive strength of mineral-based material with 0.6% fiber volume fraction cured for a period of twenty eight days. Vf represents fiber volume fraction in percent. Age represents the number of days of curing prior to testing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 26 Sam 1e Vf A Dim. Load Stren th FI Ash No. a in Ib si 19 0.628 2*2*2 25500 6375 49 19 0.628 2*2*2 28570 7142 49 19 0.628 2*2*2 27600 6900 49 19 Avr ~ 28 2*2*2 27223 6805 49 0.6~
[069] Table 26 shows the compressive strength of mineral-based material with 0.6% fiber volume fraction cured for a period of twenty-eight days. Vf represents fiber volume fraction in percent. Age represents the number of days of curing prior to testing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 27 Vf FI Ash % Load Ib Stren th si 0.6 0 22700 5675 0.6 40 26700 6675 0.6 4 27223 6805 [070] Table 27 shows a comparison of the compressive strength of the mineral-based material cured for a twenty-eight day period. The table shows that the mineral-based materials treated with fly ash has an improved strength when compared with fibers not treated with fly ash.
[071 ] Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.
[p15] Figure 5 illustrates load vs. deflection for unreinforced mortar and mortar reinforced with treated hardwood fiber and treated softwood fiber according to the present invention.
[016] Figure 6 illustrates comparative data of the compressive strength of mineral-based materials, cured for a period of seven days, according to the present invention.
[017] Figure 7 illustrates comparative data of the compressive strength of mineral-based materials, cured for a period of twenty-eight days, according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[018] It has been discovered that reinforcement of mineral-based materials can be achieved by incorporating reinforced fiber materials into the mineral-based materials. Therefore, in one embodiment of the invention, we provide a method of reinforcing mineral-based materials using reinforced fiber materials.
[019] According to the present invention mineral-based material is any material for any solid mineral based material particularly for use in environments where strength is an issue, non-limiting examples, include buildings, bridges, pavements, sidewalks, precast concrete products, floors, roads, drainage, stones, bricks, siding, roofing. Non-limiting examples of mineral-based materials are cement based material, clay-based material, asphalt-based material, mortar, concrete, ceramic tile, grout, and terrazzo. Cement-based material generally comprise at least one of lime, alumina, silica, calcium silicates, calcium, silicon, aluminum, iron, iron oxide, sulfate, gypsum, calcium sulfate, calcium aluminates, and calcium sulfoaluminates. Examples of cement based materials are aluminous cement, blast furnace cement, Type I portland cement, Type IA portland cement, Type II
portland cement, Type IIA portland cement, Type III portland cement, Type IIIA, Type IV
portland cement, Type V portland cement, hydraulic cement such as white cement, gray cement, blended hydraulic cement, Type IS-portland blast-furnace slag cement, Type IP and Type P-portland-pozzolan cement, Type S-slag cement, Type I (PM)-pozzolan modified portland cement, and Type I (SM)-slag modified portland cement, Type GU-blended hydraulic cement, Type HE-high-early-strength cement, Type MS-moderate sulfate resistant cement, Type HS-high sulfate resistant cement, Type MH-moderate heat of hydration cement, Type LH-low heat of hydration cement, Type K expansive cement, Type O expansive cement, Type M expansive cement, Typse S expansive cement, regulated set cement, very high early strength cement, high iron cement, and oil-well cement, further concrete fiber cement deposits and any composite material including any of the above listed cement.
~020~ The different types of cement may be characterized by The American Society for Testing and Materials (ASTM) Specification C-150. For example, Type I
portland cement is a normal, general-purpose cement suitable for all uses. It is used in general construction projects such as buildings, bridges, floors, pavements, and other precast concrete products. Type IA portland cement is similar to Type I
with the addition of air-entraining properties. Type II Portland cement generates less heat at a slower rate and has a moderate resistance to sulfate attack. Type lIA
Portland cement is identical to Type II and produces air-entrained concrete. Type III
Portland cement is a high-early-strength cement and causes .concrete to set and gain strength rapidly. Type III is chemically and physically similar to Type I, except that its particles have been ground finer. Type IIIA is an air-entraining, high-early-strength cement. Type IV portland cement has a low heat of hydration and develops strength at a slower rate than other cement types, making it ideal for use in dams and other massive concrete structures where there is little chance for heat to escape. Type V portland cement is used only in concrete structures that will be exposed to severe sulfate action, principally where concrete is exposed to soil and groundwater with a high sulfate content.
~027~ The mineral-based material may be made in any method known to those skilled in the arts. For example, Portland cement, the fundamental ingredient in concrete, is a calcium silicate cement made with a combination of calcium, silicon, aluminum, and iron. Portland cement generally comprises a combination of limestone, shells or chalk, and shale, clay, sand, and/or iron ore. The raw materials are then reduced in size by means of, for example, a crusher. The materials are proportioned to create a cement with a specific chemical composition. Two different methods, dry and wet, can be used to manufacture portland cement. In the dry process, dry raw materials are proportioned, ground to a powder, blended together and fed to the kiln in a dry state. In the wet process, a slurry is formed by adding water to the properly proportioned raw materials. The grinding and blending operations are then completed with the materials in slurry form. After blending, the mixture of raw materials is fed into the upper end of a tilted rotating, cylindrical kiln.
The mixture passes through the kiln at a rate controlled by the slope and rotational speed of the kiln. Burning fuel consisting of powdered coal or natural gas is forced into the lower end of the kiln. Inside the kiln, raw materials reach temperatures of 2600°F to 3000°F (1430°C to 1650°C). At 2700°F (1480°C), a series of chemical reactions cause the materials to fuse and create cement clinker-grayish-black pellets, often the size of marbles. Clinker is discharged red-hot from the lower end of the kiln and transferred to various types of coolers to lower the clinker to handling temperatures. Cooled clinker is combined with gypsum and ground into a fine gray powder. The clinker is ground so fine that nearly all of it passes through a No. 200 mesh (75 micron) sieve. This fine gray powder is portland cement.
[022] Other methods for obtaining mineral-based materials may also be used for the present invention. Mineral-based material may be in any form known to those or ordinary skilled in the art. For example, mineral-based material may be in a ready mixed form, wherein it is batched at local plants. Another example form of mineral-based material may be precast mineral-based products such as concrete bricks, paving stones, bridge girders, structural components, and panels for cladding. Yet another example of mineral-based material form is mineral masonry such as roofing tiles, shake shingles, lap siding, and countertops.
[023] Aggregates as used herein, unless otherwise stated, refer to granular materials such as sand, gravel, or crushed stone. Aggregates may be divided into two distinct categories such as fine and coarse. An example of fine aggregates includes natural sand or crushed stone with most particles passing through a inch (9.5-mm) sieve. An example of coarse aggregates includes particles greater than 0.19 inch (4.75 mm), but generally range between 3l8 and 1.5 inches (9.5 mm to 37.5 mm) in diameter, e.g., gravel. Aggregates such as natural gravel and sand may be dug or dredged from a pit, river, lake, or seabed. Crushed aggregate may be produced by crushing quarry rock, boulders, cobbles, or large-size gravel.
Another example of aggregates may be recycled mineral-based material such as concrete.
[024] Chemical admixtures as used herein, unless otherwise stated, refers to any compositions for the use in air-entraining, water-reducing, retarding, accelerating, plasticizing, corrosion inhibition, shrinkage reduction, alkali-silica reactivity reduction, workability enhancement, bonding, damp proofing, or coloring for mineral-based material.
[025] Fiber materials, according to the present invention, are chosen from at least one of cellulosic fibers, recycled fibers, mechanical pulp such as mechanical pulp such as thermomechanical pulp, and synthetic fibers. Cellulosic fibers are derived from plants. Examples of cellulosic fibers are woody fiber such as hardwood fiber such as fibers on broad leaf trees such as oak, aspen, birch, and beech, and softwood fiber such as fibers from coniferous trees such as slash pine, jack pine, white spruce, logepole pine, redwood, or douglas fir, and non-woody fibers, such as hemp flax, bagasse, mailla, cotton, ramie, jute abaca, banana, kenaf, sisal hemp, wheat, rice, bamboo, and pineapple. Recycled fiber are derived from paper products, such as, for example old corrugated container, old magazine grade, old newsprint, mixed office waste, tissue, or napkin. Synthetic fibers, according to the present invention, are any fibers non-naturally occurring. Examples of synthetic fibers include, but are not limited to glass fiber, metallic fiber such as steel fiber, which includes boron fiber and aluminum fiber, acrylic fiber, nylon fiber, rayon fiber, polyester fiber, polystyrene fiber, cellulose acetate fiber, acetate base fiber, polypropylene fiber, polyacrylamide fiber, polyethylene fiber, carbon fiber, and aramid fiber. According to one embodiment of the present invention, the fiber materials according to the present invention can be from about 0.01 mm to about 80 mm in length. Further, the fiber can range from about 30 mm to about 60 mm in length. Still further, the fiber range can be from 1 mm to about 4 mm in length.
[026] Yet another embodiment of the present invention, provides a method for creating reinforced, fiber materials. Reinforced fiber materials according to the present invention provide improved product properties when dispersed in mineral-based materials. The fiber material according to the present invention may be wet or dry. The mixture may be dried according to any method known in the art. For example, the mixture may be subjected to filtration, vacuum, or flash drying.
[027] Reinforced fiber material comprises either at least one fiber material as described above, and at least one coordinating material or a treated fiber material capable of dispersion or bonding within the mineral-based material.
Coordinating materials are any material that 1 ) allows separation or dispersion of fiber materials which results in improved dispersion when mixed with a mineral-based material;
or 2) that improves bonding between the fibers and the mineral-based material.
Examples of coordinating materials include, but are not limited to silica-rich materials such as fly ash and silica fume; slag; aluminosilicate such as heat-treated clay, metakaolin, clay; fines from crushed rock; fine sand; silica gel; talc;
calcium carbonates such as precipitated calcium carbonate and grounded calcium carbonate; aluminum sulfate as known as alum; wood ash; polymers that can adsorb or bond to fiber materials such as anionic polymers and cationic polymers such as potato starch and corn starch; surfactants; water; and saw dust.
[028] Improved dispersion and/or improved bonding of fiber based materials to mineral-based materials results in a composite material having enhanced performance for a variety of applications. For example, by improving dispersion and/or bonding, fiber materials may be incorporated into mineral-based materials at demonstrated volume fractions, but with improved workability, affording improved strengths and more efficient construction or production. In addition, higher fiber volume fractions may be incorporated into mineral-based materials, without requiring any additional machinery or technology, such as extruders or specialized ' mixing tools. Products having higher volume fractions can maintain improved workability and strength. Strengthening the bond between the fiber and the surrounding matrix also can allow for more efficient transfer of tensile stress to the fiber.
[029] To improve.the distribution and/or the bonding of fiber based materials with the mineral-based material matrix, such as cement, the fibers, such as plant fibers, may be treated using any art recognized method including mechanical or chemical treatment or a combination of both. Without being bound by theory, the inherent chemical characteristics of plant fibers affect their dispersion in water, and, hence, in cement-based materials. First, plant fiber is hydrophilic, and as a result, the ability of the plant fiber to adsorb water is high. This can adversely affect the workability, placement, and compaction of cement composites resulting in higher void contents and lower strength. Second, because the plant fibers are composed primarily of cellulose (60-80%, depending upon processing), drying of the fibers can cause an increase in the number and strength of hydrogen bonds in the cellulose.
When fibers are introduced to water, the typical chemical behavior includes the polar attraction of the water molecules to each other and to the hydroxyl groups covering the cellulose surface. As the water is evaporated, the hydroxyl groups of cellulose surface ultimately link together by means of hydrogen bonding. Mechanical action may aid in fiber separation. If the plant fiber is allowed to flocculate together or "ball", the properties of reinforced mineral-based material will be negatively affected.
Instead of acting to improve the mechanical properties of the mineral-based material, poorly dispersed or clumped plant fiber can act as a weak point inside the composite. Cement material can hardly penetrate into the flocculated fibers.
In addition, swelling of the fiber clumps, in response to moisture fluctuations, may be more disruptive to the matrix than swelling of well-dispersed fibers.
[030] Mechanical bonding between the fibers and the mineral-based material may be improved by beating the plant fibers. Fiber beating,. fiber refining, or fibrillation is a common mechanical process in the papermaking industry.
According to one embodiment of the present invention, two operations are involved in this mechanical treatment. The first is called pulping or dispersion. In this stage, the dry pulp is dispersed in water to form a slurry. The second operation is beating.
The major effects of the beating process are: removing the primary wall of the fibers, penetration of the water into the fiber cell wall, breaking some of the intra-fiber hydrogen bonding, and replacing it with water-fiber hydrogen bond, external fibrillation by peeling some of the microfibrils in the S1 layer of the fibers, and fiber shortening. According to one embodiment of the present invention, beating refers to the mechanical action of fibrillating the fiber surface, essentially creating many "branches" or extensions from the fiber surface to improve the bonding effect between the fiber and the matrix of the mineral based material.
[031] Fibrillation or fiber refining can be achieved by any art recognized methods such as for example disc refiner, conical refiner, and valley beater.
The degree of refining is measured by the Canadian Standard Freeness (CSF) test.
The CSF is defined as "the number of milliliters of water collected from the side orifice of the standard tester when pulp drains through an perforated plate at 0.30 consistency and 20°-C"(G. A. Smook 1982). Refining is preferably selected to fibrillate the external surface of the fiber to increase the surface area for better bonding with the mineral based material and/or coordinating material. The fibrillated surface also is advantageous for capturing mineral-based material and/or coordinating material. Beating may give better flexural performance.
[032] Chemical treatment of the fiber material may also improve fiber dispersion. Fibers can be introduced to coordinating materials to improve dispersion and/or bonding between the fiber and the matrix of the mineral-based material.
Coordinating materials have been found to separate fiber materials from one another and/or improve bonding with the surrounding mineral-based material paste. In addition, coordinating materials on the surface of the fiber materials may make it difficult for the microfibrils to collapse back to the fiber surface.
X033] By introducing a coordinating materials to the fibers during processing, the coordinating materials may contain positively charged side groups that may become strongly attracted to the negatively-charged sites on the fibers.
Because these coordinating materials can contain a cationic site or sites, they are capable of bonding with the negatively charged fiber, thereby making the surface of the fiber neutral or positively charged fiber surfaces advantageous for capturing negatively charged coordinating material.
[034], The mixing of the mineral-based material and reinforced fiber materials can be carried out in any manner known in the art. For example, the fiber material may be introduced with the coordinating materials, and then the combined mixture may be introduced to the mineral-based material. Another example of the mixing procedure may be to introduce the fiber material, coordinating material, and mineral-based material simultaneously. A further example may be to contact the mineral-based material with the coordinating material and then combine the mixture with the fiber material. An even further example of the mixing procedure may be to contact the fiber material with the mineral based material and then combine the mixture with the coordinating material. Additionally, the fiber material and the mineral based material may be mixed without the addition of the coordinating material, resulting in somewhat decreased binding of the mineral to the fiber.
Still further, the reinforced fiber may be added with the mineral-based material.
The fiber material can range from about 0.001 % to about 50% of the total volume of the reinforced fiber and the coordinating material (hereinafter referred to as composite).
Further the fiber material can range from about 0.1 % to about 8% of the total volume of the composite. Still further the fiber material can range from about 0.6%
to about 3% of the total volume of the composite. The coordinating material can range from about 0.01 % to about 70% of the total volume of the composite. Still further the coordinating material can range from about to about 1 % to about 50% of the total volume of the composite.
[035] The combination of mineral-based material and reinforcing fibers mixtures may be mixed with any tools known to those in the art such as mechanical mixers, manual mixing, or specialized processes such as the hatschek process.
[036] The mineral-based material may be cured according to any method known to those in the art. The curing method should be chosen to provide the desired properties of the hardened mineral-based material, such as, durability, strength, water tightness, fire performance, abrasion resistance, volume stability, and resistance to freezing and thawing and deicer salts. The method chosen for curing should also provide surface strength development in the mineral-based material. Curing methods should assist in the chemical reaction called hydration.
An example temperature range may be from 40° F to 75° F. When desired, other curing methods such as steam curing or autoclaving may be used. Steam curing may be performed at atmospheric pressures, where temperatures may be from about 40°F to about 200°F at various periods in the process.
During autoclaving, curing may be performed under any pressure known in the art and generally at high temperature as known in the art.
[037] The reinforced mineral based material may be tested according to any known method in the art. The mineral based material may be tested in the hardened state or in the freshly mixed state. For example the mineral-based material may be subjected to a slump, flow, air-content, unit weight, compressive strength tests, tensile strength, dimensional stability, and flexure tests.
[038] Slump and flow are both measures of consistency, or relative ability of the mineral-based material to flow and compact. If the mineral-based material cannot flow because the consistency or slump is too low, there are potential problems with proper consolidation. If the mineral-based material will not stop flowing because the slump is too high, there are potential problems with mortar loss through the formwork, excessive formwork pressures, finishing delays and segregation. Air content measures the total air content in a sample of fresh mineral-based material mix, but does not indicate what the final in-place air content will be, because a certain amount of air is lost in transportation, consolidating, placement and finishing. Three field tests are widely specified: the pressure meter and volumetric method are ASTM standards and the Chace Indicator is an AASHTO
procedure. Unit weight measures the weight of a known volume of fresh mineral-based material. Compressive strength is tested by pouring cylinders or cubes of fresh mineral based material and measuring the force needed to break the mineral-based material cylinders at proscribed intervals as they harden. Tensile strength may be measured indirectly by applying a compressive load along the length of a cylindrical sample of mineral based material, inducing a tensile stress.
Dimensional stability can be measured by monitoring change in length of mineral-based materials fitted with rigid gauge studs.
[039] The test data are seen in Figures 4, 5, 6, and 7. Figure 4 shows load vs. deflection curves for unreinforced mortar and mortar reinforced with treated softwood pulp fiber at volume fraction (per total sample volume) of 0.6% and 1.2%.
The fiber reinforced samples show significantly improved toughness, when compared to the unreinforced sample. In addition, flexural strength is retained, showing that the fibers enhance properties of the composite and do not act as inclusions or stress-raisers.
[040] Figure 5 shows load vs. deflection data for unreinforced mortar and mortar reinforced with treated hardwood fiber and treated softwood fiber, both at 0.6% fiber volume fraction. The hardwood fiber reinforced sample also shows improved toughness, while retaining flexural strength. However, the softwood fibers tend to improve toughness more than the hardwood fibers. Without being bound by theory, this is believed to be due to the greater length of the softwood fibers which are typically 4-6 mm in length, while hardwood fibers are typically ~1 mm in length.
[041] Figure 6 illustrates comparative data of the compressive,strength of mineral-based materials for a period of seven days according to the present invention. The data shows that the reinforced fiber material increases the compressive strength of the mineral-based material.
[042] Figure 7 illustrates comparative data of the compressive strength of mineral-based materials for a period of twenty-eight days according to the present invention. Again, the data shows that the reinforced fiber material increases the compressive strength of the mineral-based material.
[043] The present invention will now be described by way of example. The examples are not limiting of the invention as claimed.
Examples:
Example 1: Effect of Fiber Treatment on the Compressive Strength at Fiber Volume Fraction 2.0 % for Seven Days Table 1 Sample VfAge Load Strength Fly Ash No. Dim. (1b) (psi) (in) Control 0 3 2*2*2 10470 2617 0 Control 0 3 2*2*2 10360 2590 0 Control 0 3 2*2*2 10050 2512 0 Control 0 3 2*2*2 10293 2573 0 Avr Control 0 7 2*2*2 15100 3775 0 Control 0 7 2*2*2 16530 4132 0 Control 0 7 2*2*2 16440 4110 0 Control ~ 7 2*2*2 16023 4005 0 Avr ~
[044] Table 1 shows the compressive strength of mineral-based materials without any fiber volume fraction for a three and seven day period. Vf represents fiber volume fraction in percent. Age represents the number of days of curing.
The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 2 Sample Strength I I
No. Vf Age Dim. Load (psi) Fly Ash (in) (1b) 3 2 7 2*2*2 11330 2832 0 3 2 7 2*2*2 12120 3030 0 3 2 7 2*2*2 11640 2910 0 3 Avr 2 7 2*2*2 11696 2924 0 [045] Table 2 shows the compressive strength of mineral-based material with 2% fiber volume fraction after a curing period of seven days without any fiber treatment. Vf represents fiber volume fraction -in percent. Age represents the number of days of curing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b), The strength is measured in pounds per square inch (psi).
Table 3 Sample Dim. ~ Strength No. Vf Age (in) Load (1b)(psi) Fly Ash 23 2 7 2*2*2 14390 3597 40 23 2 7 2*2*2 15420 3855 40 23 2 7 2*2*2 15420 3855 40 23 Avr 2 7 2*2*2 15076 3769 40 [046] Table 3 shows the compressive strength of mineral-based material with 2% fiber volume fraction after a curing period of seven days. The fibers are treated with fly ash represented in percentage, Vf represents fiber volume fraction in percent. Age represents the number of days curing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (!b). The strength is measured in pounds per square inch (psi).
Table 4 Sample Dim. Strength No. Vf Age (ink- Load (Ib)-(psi) Fly Ash 19 2 7 2*2*2 14320 3580 49 19 2 7 2*2*2 13610 3402 49 19 2 7 2*2*2 14670 3667 49 19 Avr 2 7 2*2*2 14200 3550 49 ~
[047] Table 4 shows the compressive strength of mineral-based material with 2% fiber volume fraction after a curing period of seven days. The fibers are treated with fly ash represented in percentage by mass. Vf represents fiber volume fraction in percent. Age represents the number of days curing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 5 Vf FI Ash % Load Ib Stren th si [048] Table 5 shows a comparison of the compressive strength of the mineral-based material after a seven day curing period. The table shows that the mineral-based materials treated with fly ash has an improved strength when compared with fibers not treated with fly ash.
Example 2: Effect of Fiber Treatment on the Compressive Strength at Fiber Volume Fraction 1.2 % for Seven Days Table 6 Sam 1e VfA Load Stren th FI Ash No. a Ib si Dim.
in Control 0 3 2*2*2 10470 2617 0 Control 0 3 2*2*2 10360 2590 0 Control 0 3 2*2*2 10050 2512 0 Control 0 3 2*2*2 10293 2573 0 Avr Control 0 7 2*2*2 15100 3775 0 Control 0 7 2*2*2 16530 4132 0 Control 0 7 2*2*2 16440 4110 0 Control 0 7 2*2*2 16023 4005 0 Avr [049] Table 6 shows the compressive strength of mineral-based materials without any fiber volume fraction cured for either a three and seven day period. Vf represents fiber volume fraction in percent. Age represents the number of days of curing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b).
The strength is measured in pounds per square inch (psi).
Table 7 Sample ~ ~ Dim. Load Strength Fly Ash No Age(in) (1b) (psi) 3 1.2 7 2*2*2 14010 3502 0 3 1.2 7 2*2*2 12180 3045 0 3 1.2 7 2*2*2 14100 3525 0 r 3 Avr 1.2 ~ 2*2*2 13430 3357 ~ ' 0 [050] Table 7 shows the compressive strength of mineral-based material with 1.2% fiber volume fraction without any fiber treatment after curing for a period of seven days. Vf represents fiber volume fraction in percent. Age represents the number of days of curing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 8 Sample Vf ~ Dim. Load Strength Fly Ash No. Age (in) (1b) (psi) 23 1.27 2*2*2 18290 4572 40 23 1.27 2*2*2 17000 4250 40 23 1.27 2*2*2 17140 4285 40 23 Avr 1.27 2*2*2 17476 4369 40 [051 ] Table 8 shows the compressive strength of mineral-based material with 1.2% fiber volume fraction after curing for a period of seven days. The fibers are treated with fly ash represented in percentage. Vf represents fiber volume fraction in percent. Age represents the number of days of curing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 9 Sample Vf Age Dim. Load Strength Fly Ash No. (in) (1b) (psi) 19 1.27 2*2*2 16410 4102 49 19 1.27 2*2*2 15060 3765 49 19 1.27 2*2*2 14870 3717 49 19 Avr 1.27 2*2*2 15446 3861 ~9~
[052] Table 9 shows the compressive strength of mineral-based material with 1.2% fiber volume fraction after curing for a period of seven days. The fibers are treated with fly ash represented in percentage. Vf represents fiber volume fraction in percent. Age represents the number of days of curing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 10 Vf FI Ash % Load Ib , Strencth si 1.2 0 13430 3357 1.2 40 17476 4369 1.2 49 15446 3861 [053] Table 10 shows a comparison of the compressive strength of the mineral-based material, cured for a seven day period. The table shows that the mineral-based materials treated with fly ash has an improved strength when compared with fibers not treated with fly ash.
Example 3: Effect of Fiber Treatment on the Compressive Strength at Fiber Volume Fraction 0.6 % for Seven Days Table 11 Sample Vf~ Load Strength Fly Ash No. Age (1b) (psi) Dim.
(in) Control 0 3 2*2*2 10470 2617 0 Control 0 3 2*2*2 10360 2590 0 Control 0 3 2*2*2 10050 2512 0 Control O ~ 2*2*2 10293 2573 0 Av~ 3 Control 0 7 2*2*2 15100 3775 0 Control 0 7 2*2*2 16530 4132 0 Control 0 7 2*2*2 16440 4110 0 Control 0 ~ 2*2*2 16023 4005 0 Avr 7 [054] Table 11 shows the compressive strength of mineral-based materials without any fiber volume fraction cured for periods of either three or seven days. Vf represents fiber volume fraction in percent. Age represents the number of days of curing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b).
The strength is measured in pounds per square inch (psi).
Table 12 Sam 1e No. Vf A a Dim. in Load Ib Stren th si FI Ash 3 0.6 7 2*2*2 16370 4092 0 3 0.6 7 2*2*2 15930 3982 3 0.6 7 2*2*2 16380 4095 0 3 Avr 0.6 7 2*2*2 16226 4056 0 [055] Table 12 shows the compressive strength of mineral-based material with 0.6% fiber volume fraction without any fiber treatment cured for a period of seven dayst. Vf represents fiber volume fraction in percent. Age represents the number of days of curing prior to testing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 13 Sample Vf ~ Dim, Load Strength Fly Ash No. Age(in) (1b) (psi) 23 0.6 7 2*2*2 15270 3817 40 23 0.6 7 2*2*2 18630 4657 40 23 0.6 7 2*2*2 17210 4302 40 23 Avr 0.6 7 2*2*2 17036 4259 40 [056] Table 13 shows the compressive strength of mineral-based material with 0.6% fiber volume fraction cured for a period of seven days. The fibers are treated with fly ash represented in percentage. Vf represents fiber volume fraction in percent. Age represents the number of days of curing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 14 Sam 1e Vf A Dim. Load Stren th FI Ash No. a in Ib si 19 0.67 2*2*2 17730 4432 49 19 0.67 2*2*2 17310 4327 49 19 0.67 2*2*2 18850 4712 49 19 Avr 0.67 2*2*2 17963 4490 49 [057] Table 14 shows the compressive strength of mineral-based material with 0.6% fiber volume fractiori cured for a period of seven days. The fibers are treated with fly ash represented in percentage. Vf represents fiber volume fraction in percent. Age represents the number of days of curing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 15 Vf FI Ash % Load Ib Stren th si 0.6 0 16226 4056 0.6 40.36 17036 4259 0.6 49.7 17963 4490 [058] Table 15 shows a comparison of the compressive strength of the mineral-based material cured for a seven day period prior to testing. The table shows that the mineral-based materials treated with fly ash has an improved strength when compared with fibers not treated with fly ash.
Example 4: Effect of Fiber Treatment on the Compressive Strength at Fiber Volume Fraction 2 °l° for Twent r-~Ei, hq t Days Table 16 Sam 1e Vf A Dim. Load Stren th FI Ash No. a in Ib si 3 2 28 2*2*2 16760 4190 0 3 2 28 2*2*2 17470 4367 0 3 2 28 2*2*2 16810 4202 0 3 Avr 2 28 2*2*2 17013 4253 0 [059] Table 16 shows the compressive strength of mineral-based material with 2% fiber volume fraction without any fiber treatment cured for a period of twenty eight days. Vf represents fiber volume fraction in percent. Age represents the number of days of curing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 17 Sample Vf ~ Dim. Load Strength Fly Ash No. Age (in) (1b) (psi) 23 2 28 2*2*2 20270 5067 40 23 2 28 2*2*2 21140 5285 40 23 2 28 2*2*2 21810 5452 40 23 Avr 2 ~ ~ 2*2*221073 5268 40 ~ 28 [060] Table 17 shows the compressive strength of mineral-based material with 2% fiber volume fraction cured for a period of twenty eight days. Vf represents fiber volume fraction in percent. Age represents the number of days of curing before testing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b).
The strength is measured in pounds per square inch (psi).
Table 18 Sample ~Vf~ Dim. Load Strength Fly Ash No. Age (in) (1b) (psi) ~
19 2 28 2*2*2 18260 4565 49 19 2 28 2*2*2 21680 5420 49 19 2 28 2*2*2 20010 5002 49 19 Avr 2 ~ 2*2*2 19983 4995 49 ~
[061] Table 18 shows the compressive strength of mineral-based material with 2°/o fiber volume fraction cured for a period of twenty eight days. Vf represents fiber volume fraction in percent. Age represents the number of days of curing prior to testing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b).
The strength is measured in pounds per square inch (psi).
Table 19 Vf Fly Ash % Load Ib Stren th si 2 _ 0 , 17013 14253 [062] Table 19 shows a comparison of the compressive strength of the mineral-based material cured for a twenty-eight day period. The table shows that the mineral-based materials treated with fly ash has an improved strength when compared with fibers not treated with fly ash.
Example 5: Effect of Fiber Treatment on the Compressive Strength at Fiber Volume Fraction 1.2 % for Twenty-Eiaht Days Table 20 Sam 1e Vf A Dim. Load Stren th FI Ash No. a in Ib si 3 1.228 2*2*2 20050 5012 0 3 1.228 2*2*2 19610 4902 0 3 1.228 2*2*2 18380 4595 0 3 Avr 1.228 2*2*2 19346 4836 0 [063] Table 20 shows the compressive strength of mineral-based material with 1.2% fiber volume fraction without any fiber treatment cured for a period of twenty eight days. Vf represents fiber volume fraction in percent. Age represents the number of days of curing prior to testing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 21 Sample Vf AgeDim. Load Strength Fly Ash No. (in) (1b) (psi) 23 1.2 28 2*2*2 24120 6030 40 23 1.2 28 2*2*2 23980 5995 40 23 1.2 28 2*2*2 23110 5777 40 23 Avr 1.2 28 2*2*2 23736 5934 40 (064] Table 21 shows the compressive strength of mineral-based material with 1.2% fiber volume fraction cured for a period of twenty eight days. Vf represents fiber volume fraction in percent. Age represents the number of days of curing prior to testing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 22 Sam 1e Vf A Dim. Load Stren th FI Ash No. a in Ib si 19 1.228 2*2*2 20100 5025 49 19 1.228 2*2*2 25200 6300 49 19 1.228 2*2*2 22410 5602 49 19 Avr 1.2~8 ~ 2*2*222570 5642 ~ 49 , [065] Table 22 shows the compressive strength of mineral-based material with 1.2% fiber volume fraction cured for a period of twenty eight days. Vf represents fiber volume fraction in percent. Age represents the number of days of curing prior to testing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 23 Vf Fl Ash % Load Ib Stren th si 1.2 0 19346 4836 1.2 40 23736 5934 1.2 49 22570 5642.5 [066] Table 23 shows a comparison of the compressive strength of the mineral-based material cured for a twenty-eight day period. The table shows that the mineral-based materials treated with fly ash has an improved strength when compared with fibers not treated with fly ash.
Example 6: Effect of Fiber Treatment on the Compressive Strength at Fiber Volume Fraction 0.6 % for Twenty-Eight Days Table 24 Sam 1e Vf A Dim. Load Stren th FI Ash No. a in Ib si 3 0.628 2*2*2 21540 5385 0 3 0.628 2*2*2 23030 5757 0 3 0,628 2*2*2 23530 5882 0 3 Avr 0.628 2*2*2 22700 5675 0 [067] Table 24 shows the compressive strength of mineral-based material with 0.6% fiber volume fraction without any fiber treatment cured for a period of twenty eight days. Vf represents fiber volume fraction in percent. Age represents the number of days of curing prior to testing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (Ib)~ The strength is measured in pounds per square inch (psi).
Table 25 Sam 1e Vf A Dim. Load Stren th FI Ash No. a in Ib si 23 0.628 2*2*2 27920 6980 40 23 0.628 2*2*2 24430 6107 40 23 0.628 2*2*2 27750 6937 40 23 Avr 0.628 2*2*2 26700 6675 40 [068] Table 25 shows the compressive strength of mineral-based material with 0.6% fiber volume fraction cured for a period of twenty eight days. Vf represents fiber volume fraction in percent. Age represents the number of days of curing prior to testing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 26 Sam 1e Vf A Dim. Load Stren th FI Ash No. a in Ib si 19 0.628 2*2*2 25500 6375 49 19 0.628 2*2*2 28570 7142 49 19 0.628 2*2*2 27600 6900 49 19 Avr ~ 28 2*2*2 27223 6805 49 0.6~
[069] Table 26 shows the compressive strength of mineral-based material with 0.6% fiber volume fraction cured for a period of twenty-eight days. Vf represents fiber volume fraction in percent. Age represents the number of days of curing prior to testing. The dimensions of the mineral-based material is 2 inches in width by 2 inches in height by 2 inches in depth. The load is measured in pounds (1b). The strength is measured in pounds per square inch (psi).
Table 27 Vf FI Ash % Load Ib Stren th si 0.6 0 22700 5675 0.6 40 26700 6675 0.6 4 27223 6805 [070] Table 27 shows a comparison of the compressive strength of the mineral-based material cured for a twenty-eight day period. The table shows that the mineral-based materials treated with fly ash has an improved strength when compared with fibers not treated with fly ash.
[071 ] Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.
Claims (35)
1. A method for reinforcing mineral-based material comprising contacting at least one mineral-based material with at least one reinforced fiber material.
2. The method according to claim 1, wherein reinforced fiber material comprises of at least one coordinating material and at least one fiber material.
3. The method according to claim 2, wherein the coordinating material is chosen from at least one of silica-rich materials such as fly ash and silica fume; slag; aluminosilicate such as heat-treated clay, metakaolin, clay;
fines from crushed rock; fine sand; silica gel; talc; calcium carbonates such as precipitated calcium carbonate and grounded calcium carbonate;
aluminum sulfate as known as alum; wood ash; polymers that can adsorb or bond to fiber materials such as anionic polymers and cationic polymers such as potato starch and corn starch; surfactants; water; and saw dust.
fines from crushed rock; fine sand; silica gel; talc; calcium carbonates such as precipitated calcium carbonate and grounded calcium carbonate;
aluminum sulfate as known as alum; wood ash; polymers that can adsorb or bond to fiber materials such as anionic polymers and cationic polymers such as potato starch and corn starch; surfactants; water; and saw dust.
4. The method according to claim 3, wherein the silica-rich material is chosen from at least one of silica fume and fly ash.
5. The method according to claim 4, wherein the silica-rich material is silica fume.
6. The method according to claim 4, wherein the silica-rich material is fly ash.
7. The method according to claim 3, wherein the cationic polymer is chosen from at least one of starch and surfactant.
8. The method according to claim 7, wherein the cationic starch is chosen from at least one of potato starch and corn starch.
9. The method according to claim 2, wherein the fiber material is chosen from at least one of cellulosic fibers, recycled fibers, mechanical pulp, and synthetic fibers.
10. The method according to claim 9, wherein said cellulosic fiber is chosen from at least one woody fiber such as hardwood fiber such as fibers on broad leaf trees such as oak, aspen, birch, and beech, and softwood fiber such as fibers from coniferous trees such as slash pine, jack pine, white spruce, logepole pine, redwood, or douglas fir, and non-woody fibers, such as hemp flax, bagasse, mailla, cotton, ramie, jute abaca, banana, kenaf, sisal hemp, wheat, rice, bamboo, and pineapple.
11. The method according to claim 9, wherein cellulosic fiber is softwood fiber.
12. The method according to claim 9, wherein cellulosic fiber is hardwood fiber.
13. The method according to claim 9, wherein cellulosic fiber is recycled fiber.
14. The method according to claim 9, wherein cellulosic fiber is non-woody fiber.
15. The method according to claim 9, wherein recycled fiber is chosen from paper products.
16. The method according claim 9, wherein synthetic fiber is chosen from at least one of glass fiber, metallic fiber such as steel fiber, which includes boron fiber and aluminum fiber, acrylic fiber, nylon fiber, rayon fiber, polyester fiber, polystyrene fiber, cellulose acetate fiber, acetate base fiber, polypropylene fiber, polyacrylamide fiber, polyethylene fiber, carbon fiber, and aramid fiber.
17. The method according to claim 1, wherein the mineral-based material is chosen from at least one of cement. based material, clay-based material, asphalt-based material, mortar, concrete, ceramic tile, grout, and terrazzo.
18. The method according to claim 1, wherein the mineral-based material is cement based material.
19. The method according to claim 1, wherein the mineral-based material is mortar.
20. The method according to claim 1 for the use of reducing early-age cracking and shrinkage cracking of mineral-based material.
21. The method according to claim 1 for the use of improving ductility of mineral based material.
22. The method according to claim 1 for the use of improving toughness of mineral based material.
23. The method according to claim 1 wherein the reinforced mineral-based material is formed into fiber-cement panels.
24. The method according to claim 1 for the use of patching and repairing damaged mineral-based material.
25. A compound comprising at least one mineral-based material and at least one reinforced fiber material.
26. A compound according to claim 24, wherein the mineral-based material is chosen from at least one of cement based material, clay-based material, asphalt-based material, mortar, concrete, ceramic tile, grout, and terrazzo.
27. A compound according to claim 24, wherein the reinforced fiber material comprises a fiber material and a coordinating material.
28. A compound according to claim 26, wherein the fiber material is chosen from at least one of cellulosic fibers, recycled fibers, mechanical pulp, and synthetic fibers.
29. A compound according to claim 27, wherein the cellulosic fiber is from at least one of woody fiber such as hardwood fiber such as fibers on broad leaf trees such as oak, aspen, birch, and beech, and softwood fiber such as fibers from coniferous trees such as slash pine, jack pine, white spruce, logepole pine, redwood, or douglas fir, and non-woody fibers, such as hemp flax, bagasse, mailla, cotton, ramie, jute abaca, banana, kenaf, sisal hemp, wheat, rice, bamboo, and pineapple.
30. A compound according to claim 26, wherein the coordinating material is chosen from at least one of silica-rich materials such as fly ash and silica fume; slag; aluminosilicate such as heat-treated clay, metakaolin, clay;
fines from crushed rock; fine sand; silica gel; talc; calcium carbonates such as precipitated calcium carbonate and grounded calcium carbonate;
aluminum sulfate as known as alum; wood ash; polymers that can adsorb or bond to fiber materials such as anionic polymers and cationic polymers such as potato starch and corn starch; surfactants; water; and saw dust.
fines from crushed rock; fine sand; silica gel; talc; calcium carbonates such as precipitated calcium carbonate and grounded calcium carbonate;
aluminum sulfate as known as alum; wood ash; polymers that can adsorb or bond to fiber materials such as anionic polymers and cationic polymers such as potato starch and corn starch; surfactants; water; and saw dust.
31. The compound according to claim 24 for the use of reducing early-age cracking or shrinkage cracking of mineral-based material.
32. The compound according to claim 24 for the use of improving ductility of mineral-based material.
33. The compound according to claim 24 for the use of improving toughness of mineral-based material.
34. The compound according to claim 24 for the use as fiber-cement panels.
35. The compound according to claim 24 for the use of patching and repairing damaged mineral-based material.
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MXPA02008921A (en) | 2000-03-14 | 2004-10-15 | James Hardie Res Pty Ltd | Fiber cement building materials with low density additives. |
KR100855848B1 (en) * | 2000-10-04 | 2008-09-01 | 제임스 하디 인터내셔널 파이낸스 비.브이. | Fiber cement composite materials using sized cellulose fibers |
JP2004511675A (en) | 2000-10-17 | 2004-04-15 | ジェイムズ ハーディー リサーチ ピーティーワイ.リミテッド | Method and apparatus for reducing impurities in cellulosic fibers for the production of fiber reinforced cement composites |
ATE359245T1 (en) * | 2001-03-09 | 2007-05-15 | James Hardie Int Finance Bv | FIBER REINFORCED CEMENT MATERIALS USING CHEMICALLY MODIFIED FIBERS WITH IMPROVED MIXABILITY |
US6942726B2 (en) * | 2002-08-23 | 2005-09-13 | Bki Holding Corporation | Cementitious material reinforced with chemically treated cellulose fiber |
US20040140072A1 (en) * | 2002-09-10 | 2004-07-22 | Fibermark, Inc. | High temperature paper containing aramid component |
MXPA05003691A (en) | 2002-10-07 | 2005-11-17 | James Hardie Int Finance Bv | Durable medium-density fibre cement composite. |
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- 2001-11-06 CA CA 2427799 patent/CA2427799A1/en not_active Abandoned
- 2001-11-06 WO PCT/US2001/042979 patent/WO2002036517A2/en not_active Application Discontinuation
- 2001-11-06 JP JP2002539281A patent/JP2004525845A/en not_active Withdrawn
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- 2001-11-06 AU AU2002224483A patent/AU2002224483A1/en not_active Abandoned
- 2001-11-06 MX MXPA03003972A patent/MXPA03003972A/en unknown
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2004
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AU2002224483A1 (en) | 2002-05-15 |
US20050112981A1 (en) | 2005-05-26 |
EP1339650A2 (en) | 2003-09-03 |
US20020160174A1 (en) | 2002-10-31 |
WO2002036517A2 (en) | 2002-05-10 |
JP2004525845A (en) | 2004-08-26 |
MXPA03003972A (en) | 2004-09-10 |
WO2002036517A3 (en) | 2002-08-29 |
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