Abstract: In one embodiment, a reinforced fiber cement article comprising a fiber cement piece and a reinforcing fixture bonded to a portion of the fiber cement piece for improving the performance, strength and durability of the fiber cement piece. The reinforcing fiber cement article could be used as or in conjunction with a siding plank assembly, which further comprises an interlocking feature that allows the siding plank to be stacked with other siding planks in a manner such that a uniform and deep shadow line is created. The interlocking feature sets the gauge of the exposed plank face and allows for leveling of the plank during installation. The reinforcing fixture could also serve as a thick butt piece or a plastic spline that produces a deep shadow line. A cementitious adhesive is used to bond the reinforcing fixture to the fiber cement piece.

Abstract: A cementitious product and method of modifying the properties of a low or medium density FRC product by providing a predetermined pore size distribution. The pore size distribution is obtained such that in critical zones of the distribution, the pore volume is substantially equivalent to or less than the pore volume in a respective critical zone of a conventional high density FRC product. The resultant material provides improved properties over conventional medium density FRC products, in particular improved freeze/thaw durability and/or improved workability.

Abstract: A fiber cement composite material that incorporates a blend of bleached and unbleached cellulose fibers as a partial or complete substitute for premium grade cellulose pulp is provided. Bleached standard grade cellulose fibers are used in conjunction with unbleached, standard grade cellulose fibers to provide a fiber cement composite product having substantially equal or even superior flexibility and strength as an equivalent fiber cement composite material reinforced by premium grade, unbleached cellulose fibers. A synergistic combination of bleached and unbleached standard grade cellulose fibers to produce a composite material with the desired properties previously achievable only through the use of premium grade cellulose pulp.

Abstract: Protected prefinished fiber cement products are manufactured by applying a protective layer on the finished surface of a fiber cement product. The protective layer protects the finish layer of the prefinished fiber cement product during handling, storage, and transport. Removing the protective layer leaves no adhesive residue on the finish layer, does not damage the finish layer, and does not substantially tear the protective layer. Protected prefinished fiber cement products are typically stacked on pallets for storage and transport. Optionally, spacers may be placed between the stacked protected prefinished fiber cement products.

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: Protected prefinished fiber cement articles are manufactured by applying a protective layer on the finished surface of a fiber cement article. The protective layer protects the finish layer of the prefinished fiber cement article during handling, storage, and transport. Removing the protective layer leaves no residue on the finish layer, does not damage the finish layer, and does not substantially tear the protective layer. Protected prefinished fiber cement article are typically stacked on pallets for storage and transport. Optionally, spacers may be placed between the stacked protected prefinished fiber cement article.

Abstract: A method of manufacturing high purity fiber cement grades of cellulose fibers is described. Additional washing steps, coupled with an elevated temperature, are used in the process to extensively wash the pulps and remove substantially all COD components remaining in the pulps. The pulps are counter-currently washed by diffusion and dewatering at elevated temperatures following the brown stock washer systems. During the additional washing steps, the pulps are soaked in counter-current heated water for a pre-determined time and some chemicals may be introduced to chemically break down the COD components in the pulps and to make them more soluble in the aqueous solution. The additional washing steps can be performed using existing equipment at conventional pulp mills.

Abstract: A method of manufacturing high purity fiber cement grades of cellulose fibers is described. Additional washing steps, coupled with an elevated temperature, are used in the process to extensively wash the pulps and remove substantially all COD components remaining in the pulps. The pulps are counter-currently washed by diffusion and dewatering at elevated temperatures following the brown stock washer systems. During the additional washing steps, the pulps are soaked in counter-current heated water for a pre-determined time and some chemicals may be introduced to chemically break down the COD components in the pulps and to make them more soluble in the aqueous solution. The additional washing steps can be performed using existing equipment at conventional pulp mills.

Abstract: The invention relates to a building section including a sub-structure and a cladding member connected in fixed relation relative to the sub-structure. A multi-function elongate, flexible insulating element is disposed between the sub-structure and the cladding member for damping energy transfer between the cladding member and the sub-structure, facilitating alignment of the cladding, and creating a rainscreen configured to drive out moisture from the wall cavities. In some implementations, the insulating element has at least one insulating layer which is substantially incompressible and which has a substantially constant density in the range of 200 kg/m3 to 300 kg/m3. In certain preferred implementations, the insulating element can be formed of a foam material such as foam tape or thermal break tape.

Abstract: A structural fiber cement sheet containing cementitious matrix and reinforcing cellulose fibers distributed throughout the matrix having a dry density less than 1.25 g/cm3, a thickness less than 0.7500 in, and able to withstand uniform loads of 200 psf or greater according to test method of Section 6.4.2.4 of PS2 and with a deflection of less than 0.067 inches at 60 psf when spaced on a span of 24 inches or less on center.

Abstract: Cementitious formulations and their products with enhanced reactivity are provided. Formulations in certain embodiments may include at least one calcium source, a reactant and a filler in a hydrated environment, wherein the reactant, in one form, is crystalline silica that has been modified for reactivity. Enhancement of a reactant may include one or more modifications to its content, grind and/or the cement to silica ratio, as well as addition of one or more additives in the formulation, additives in the form of at least one alumina source, defoamer, catalyst and/or a clay.

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: An exemplary composite product and method of manufacturing is provided. In one embodiment, the method includes dewatering a first slurry through a dewatering belt to form a first substrate layer, applying a first functional layer onto at least a portion of the first substrate layer, and dewatering a second slurry through the dewatering belt to form a second substrate layer. A first side of the second substrate layer may be overlayed onto the first functional layer, and the layers may be cured, and the layers bonded.

Abstract: Cementitious formulations and their products with enhanced reactivity are provided. Formulations in certain embodiments may include at least one calcium source, a reactant and a filler in a hydrated environment, wherein the reactant, in one form, is crystalline silica that has been modified for reactivity. Enhancement of a reactant may include one or more modifications to its content, grind and/or the cement to silica ratio, as well as addition of one or more additives in the formulation, additives in the form of at least one alumina source, defoamer, catalyst and/or a clay.

Abstract: A method of manufacturing high purity fiber cement grades of cellulose fibers is described. Additional washing steps, coupled with an elevated temperature, are used in the process to extensively wash the pulps and remove substantially all COD components remaining in the pulps. The pulps are counter-currently washed by diffusion and dewatering at elevated temperatures following the brown stock washer systems. During the additional washing steps, the pulps are soaked in counter-current heated water for a pre-determined time and some chemicals may be introduced to chemically break down the COD components in the pulps and to make them more soluble in the aqueous solution. The additional washing steps can be performed using existing equipment at conventional pulp mills. A formulation and a process of making fiber reinforced cement composite materials are also described using the low COD and high purity cellulose fibers.

Abstract: A process for manufacturing an elongated panel formed of synthetic materials including a polymer resin matrix, a filler and a fiber reinforcement. The process includes depositing the curable composition on a conveyor belt, distributing and leveling the curable composition prior to feeding the composition into a compression apparatus in which the curable composition is partially cured as it is compressed to form the panel. The machine for manufacturing the composite panel includes a mixer for the polymer system, filler and fiber reinforcement, a distribution apparatus that distributes the curable composition prior to feeding the composition into a compacting apparatus. The process and machine may be used to form a composite siding board that includes a grain pattern on at least one side.

Abstract: The present invention relates to methods for marking a substrate. In particular, the present invention relates to methods for applying visual indicia to a substantially cementitious substrate in the form of a cementitious building product. The method comprising the steps of: irradiating a surface of said substantially cementitious substrate for a sufficient time and with sufficient energy to at least partially vitrify said surface thereby marking said substrate.

Abstract: The present invention relates to methods for marking a coated substrate. In particular, the present invention relates to methods for marking a coated substantially cementitious substrate in the form of a cementitious building product. The method comprises the steps of treating at least a portion of an uncoated cementitious substrate to form indicia; and applying a surface coating on said cementitious substrate to at least partially cover said indicia such that a marking is formed.

Abstract: A cementitious product and method of modifying the properties of a low or medium density FRC product by providing a predetermined pore size distribution. The pore size distribution is obtained such that in critical zones of the distribution, the pore volume is substantially equivalent to or less than the pore volume in a respective critical zone of a conventional high density FRC product. The resultant material provides improved properties over conventional medium density FRC products, in particular improved freeze/thaw durability and/or improved workability.

Abstract: A cladding system based on a specially configured base sheet profiled to provide a ship lap expressed joint with an adjacent sheet, which is ideal for use with relatively low-build brushable or rollable texture coatings. The ship lap expressed joint includes within the visible portion of the joint between the outer surfaces of the base sheets, an interface line defined by an inner overlapping edge of one of the base sheets, whereby the interface line is set in from the outer surface of the base sheets. This arrangement enables coated walls, and in particular texture coated masonry look walls, to be created at a much lower cost and using less skilled operators, as it obviates the need to set and finish the joints between adjacent sheets and the problems associated with that process.