Abstract: A composite product comprising a substrate layer and one or more functional layers applied thereto. The slurry is applied to the substrate layer to form a functional layer and the functional layer dewatered through the substrate layer. The functional layers can be repeated to build up a laminated composite product. Functional additives may be included in each layer to provide desired properties to that layer and indeed to the subsequent composite product.

Abstract: An additive for use in the preparation of lightweight concrete, said additive including a blend of from around 40% to 99% of organic polymeric material and from 1% to around 60% of an air entraining agent. The additive is particularly suitable for the preparation of lightweight concrete which uses polystyrene aggregate. It provides for excellent dispersion of the polystyrene aggregate and improved bond between the polystyrene aggregate and surrounding cementitious binder. The resultant lightweight concrete formulation may be pumped and is particularly suitable for sandwich wall construction.

Abstract: This invention discloses a new technology related to cellulose fiber reinforced cement composite materials using the loaded cellulose fibers. This invention discloses four aspects of the technology: fiber treatment, formulation, method and final product. This technology advantageously provides fiber cement building materials with the desirable characteristics of reduced water absorption, reduced rate of water absorption, lower water migration, and lower water permeability. This invention also impart the final products improved freeze-thaw resistance, reduced efflorescence, reduced chemical dissolution and re-deposition, and improved rot and fire resistances, compared to conventional fiber cement products. These improved attributes are gained without loss in dimensional stability, strength, strain or toughness.

Abstract: A method for forming a laminated sheet material from a slurry having a liquid component. The method comprising the steps of: applying the slurry to a substrate in successive layers to form a wet sheet of predetermined thickness; applying at least one of the layers by spattering; removing the wet sheet from the substrate; and drying or curing the wet sheet so as to remove at least a substantial proportion of the liquid component and thereby forming the sheet material.

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

Abstract: The present invention involves building sheets with a plurality of grooves indented into a surface of the building sheet to provide a guide for cutting the building sheet along the grooves. Preferably, the grooves are arranged in a regularly repeating pattern and are spaced apart by a standard unit of measurement in order for a cutter to accurately size the building sheet to a precise dimension. A simple scoring knife is preferably used to score the sheet along the grooves, without the need for a straight edge, and the sheet is broken by simply bending the sheet of along the score mark. The grooves are preferably provided at a depth into the surface the sheet such that they do not substantially decrease the strength of the sheet or affect off-groove scoring. Thus, a score mark can be made between or across grooves without deflection of the mark into a groove and without breakage of the sheet along a groove when the sheet is bent.

Abstract: A suspended concrete flooring system (100) comprising a plurality of spaced-apart load-bearing members (110) or supporting walls that support a plurality of joists (122) having opposing sides and arranged substantially at right-angles to the load-bearing members. The joists have a support shelf (127) running the length of each opposing side for the purpose of supporting a plurality of fiber cement corrugated sheets (130) that span the space between the joists. A shrinkage control mesh (140) is arranged atop the corrugated sheets and is oriented generally in the direction of the load-bearing members and the joists. A thin layer of concrete (150) is formed over the corrugated sheets and the shrinkage control mesh, to form a flat, horizontal floor surface (151). The load-bearing members and the joists are made of strong, lightweight materials, such as steel.

Abstract: A method for coating a building product in which a coating formulation is provided which includes an hydraulic binder and a quantity of dewatering agent. A slurry is produced from said formulation and applied to the product to be coated. The resultant coating is then dewatered through said product. Dewatering can be accomplished with or without vacuum assistance. The method is suitable for producing a composite product which comprises a base structural layer with the coating thereon.

Abstract: A building material having a durable exterior finish comprising a fiber cement substrate laminated with a fluorohydrocarbon protective film. The protective film provides the fiber cement substrate with resistance to weathering and maintains the surface texture of the underlying fiber cement substrate while providing an aesthetically pleasing and uniform pre-finish on the exterior surface. The protective film is bonded to the fiber cement substrate using an adhesive composition comprised of a one-component moisture cure polyurethane or polyurea adhesive composition having a reactive isocyanate compound or a two component polyurethane or polyurea composition.

Abstract: An apparatus (1) for applying a slurry to a substrate (2). The apparatus includes a delivery drum (4) incorporating a delivery surface (5) disposed to support a layer of slurry. A spattering roller (8) is positioned closely adjacent the delivery drum and is rotatable so as to spatter the slurry from the delivery surface onto the substrate. Regulation means selectively vary or interrupt the flow of slurry from the delivery surface onto the substrate.

Abstract: This invention relates generally to a pre-finished, moisture resistant and durable building material that is able to diffuse stress caused by variations in temperature and climate. One preferred embodiment of the building material includes a fiber cement substrate, at least one resin impregnated paper, and a stress-relieving elastomeric film between the fiber cement substrate and the resin impregnated paper, wherein the elastomeric film acts as a stress relaxer between the fiber cement substrate and the one resin impregnated paper.

Abstract: A method of construction of partitions (1) including the steps of erecting a structural steel frame from spaced apart frame members (2, 3), the frame members having boxed mounting flanges (4, 6) and being formed from a metal having a relatively high tensile strength, applying at least one layer of sheet material (11) to at least one side of the frame, and securing the layer of sheet material (11) to the frame by means of self-piercing impact fasteners (12). In one preferred form, staples (51) are used to secure cladding sheets (52) to boxed flange frame members for various dry wall constructions. In another preferred embodiment, staples (51) or nails (12) are similarly used to secure layers of sheet material (11, 52) to opposing sides of the frame to define an intermediate cavity which is subsequently filled with cementitious material to form a solid partition.

Abstract: This invention discloses a new technology related to cellulose fiber reinforced cement composite materials using cellulose fibers that are treated with inorganic and/or organic resins to make the fibers more hydrophobic, as well as other chemical treatments. This invention discloses four aspects of the technology: fiber treatment, formulations, methods and the final product. This technology advantageously provides fiber cement building materials with the desirable characteristics of reduced water absorption, reduced rate of water absorption, lower water migration, and lower water permeability. This invention also impart the final products improved freeze-thaw resistance, reduced efflorescence, and improved rot and UV resistances, compared to conventional fiber cement products. These improved attributes are gained without loss in dimensional stability, strength, strain or toughness. In some cases the physical and mechanical properties are improved.

Abstract: This invention discloses a new technology related to cellulose fiber reinforced cement composite materials using the loaded cellulose fibers. This invention discloses four aspects of the technology: fiber treatment, formulation, method and final product. This technology advantageously provides fiber cement building materials with the desirable characteristics of reduced water absorption, reduced rate of water absorption, lower water migration, and lower water permeability. This invention also impart the final products improved freeze-thaw resistance, reduced efflorescence, reduced chemical dissolution and re-deposition, and improved rot and fire resistances, compared to conventional fiber cement products. These improved attributes are gained without loss in dimensional stability, strength, strain or toughness.

Abstract: This invention relates to a formulation with the addition of low density additives of volcanic ash, hollow ceramic microspheres or a combination of microspheres and volcanic ash or other low density additives into cementitious cellulose fiber reinforced building materials. This formulation is advantageously lightweight or low density compared as compared to current fiber cement products without the increased moisture expansion and freeze-thaw degradation usually associated with the addition of lightweight inorganic materials to fiber cement mixes. The low density additives also give the material improved thermal dimensional stability.

Abstract: A building material is provided in which fiber-cement is laminated to gypsum to form a single piece laminate composite. This single piece laminate composite exhibits improved fire resistance and surface abuse and impact resistance, but achieves these properties without the excessive weight and thickness of two piece systems. Additionally, because of the reduced thickness, the preferred laminate building material is easier to cut and is quicker and easier to install than two piece systems. Furthermore, forming the fiber-cement and gypsum into a single piece laminate eliminates the need to install two separate pieces of building material, thereby simplifying installation. In one embodiment, a ⅝″ thick laminate composite is provided in which a ½″ thick gypsum panel laminated to a ⅛″ thick fiber-cement sheet, the laminate composite having a fire resistance rating of 1 hour when measured in accordance with ASTM E119-98.

Abstract: The present invention involves building sheets with a plurality of grooves indented into a surface of the building sheet to provide a guide for cutting the building sheet along the grooves. Preferably, the grooves are arranged in a regularly repeating pattern and are spaced apart by a standard unit of measurement in order for a cutter to accurately size the building sheet to a precise dimension. A simple scoring knife is preferably used to score the sheet along the grooves, without the need for a straight edge, and the sheet is broken by simply bending the sheet of along the score mark. The grooves are preferably provided at a depth into the surface the sheet such that they do not substantially decrease the strength of the sheet or affect off-groove scoring. Thus, a score mark can be made between or across grooves without deflection of the mark into a groove and without breakage of the sheet along a groove when the sheet is bent.

Abstract: A process for constructing a wall, floor or ceiling in situ. The process includes the steps of erecting a substantially rigid frame (10) and attaching fiber reinforced cementitious sheets (50) to the front and rear faces of the frame to form a void (60) therebetween. This void (60) is then filled with a lightweight aggregate concrete slurry and allowed to cure. The sheets are adapted to absorb sufficient moisture from the lightweight aggregate slurry to provide natural adherence of the concrete slurry to the sheets without substantially losing their structural integrity during setting and curing of the concrete slurry.

Abstract: A formulation for preparing a cementitious product comprising a cementitious material, a siliceous material, and a low bulk density material being substantially calcium silicate hydrate and including unreacted siliceous reactant. A method of forming a cementitious product comprises adding a cementitious material, a siliceous material and a low bulk density material to water to form a slurry, forming a green shaped article from the slurry and curing the article in an autoclave, wherein the low bulk density material is substantially calcium silicate hydrate and includes unreacted siliceous reactant.

Abstract: A formulation for preparing a cementitious product comprising a cementitious material, a siliceous material, and a low bulk density material being substantially calcium silicate hydrate and including unreacted siliceous reactant. A method of forming a cementitious product comprises adding a cementitious material, a siliceous material and a low bulk density material to water to form a slurry, forming a green shaped article from the slurry and curing the article in an autoclave, wherein the low bulk density material is substantially calcium silicate hydrate and includes unreacted siliceous reactant.