Abstract: An engineered composite building material, such as fiber cement, having one or more engineered sub-surface regions designed to provide the building material with improved moisture ingress resistance, paint adhesion, and other mechanical properties is provided. The sub-surface region has a cement-polymer matrix formed by introducing an impregnating agent into the pores of the substrate. The composite building material may be formed by applying impregnating agents to the subsurface regions of the substrate to form chemical and/or mechanical bonds with the matrix of the building material, the reinforcement fibers, and/or the surface coatings applied to the material. The thickness of the sub-surface regions may be controlled by varying the viscosity and porosity of the building material substrate. The cement-polymer building material has enhanced durability, weather resistance, strength, and stiffness.

Abstract: A fiber-reinforced building material in one embodiment incorporates cellulose fibers that are chemically treated with a dispersant to impart improved dispersibility to the fibers. The fibers are treated with a dispersant which deactivates the hydroxyl sites of the fiber surfaces and in some cases, making the fiber surface more hydrophobic. The dispersant inhibits the hydroxyl groups on the cellulose fiber surface from bonding with hydroxyl groups of other fibers and from bonding with hydroxyl groups of the same fiber, thereby significantly reducing inter-fiber and intra-fiber hydrogen bonding. The treated fibers can be readily dispersed and uniformly distributed throughout a mixture without re-clustering or reclumping once the mechanical mixing action stops.

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 coated substrate is configured with one or more cross-linked interfacial zones provided to improve the adhesion between the coating and substrate of the article or between adjacent coating layers. The coating composition contains molecules having at least two reactive functional groups capable of reacting with cross-linking molecules in the substrate and/or molecules in adjacent coating layers. The cross-linked interfacial zones improve the adhesion between coatings and the substrate and between adjacent coating layers.

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 low-VOC silanol additive is provided for a wide range of silane treatment operations, including treating cellulose fibers in fiber cement applications. The silanol additive is made by hydrolyzing silane at the presence of a catalyst and then removing substantially all of the VOCs, such as alcohol, that are released by the hydrolysis reaction to produce a low-VOC and/or substantially alcohol-free silanol additive. The low-VOC silanol additive can be used in various industrial processes without increasing the VOC emission at the manufacturing facility. The silanol additive can be directly applied to the treated surface so as to eliminate the reaction time needed for hydrolyzing silane in most conventional silane treatment processes. The silanol additive can be added to a solution containing the treated substrate or directly applied as a surface treatment.

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 building article incorporating a biocidal agent, such as copper oxine, that inhibits the growth of mold, fungi, algae, mildew, bacteria, lichen, and other undesirable biological growth is provided. The biocidal agent can be a biocide, fungicide, germicide, insecticide, mildewcide, or the like. The biocidal agent can be interspersed throughout the matrix of the article; applied as a surface treatment to the article; or applied as a treatment to the fibers reinforcing the article. The building article can include tile backer boards, decks, soffits, trims, decking, fencing, roofing, cladding, sheathing, and other products. The building article can also include a variety of different composite materials such as cement, gypsum, wood, and wood/polymer composites.

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 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: 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: 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: 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 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: A fiber-reinforced building material in one embodiment incorporates cellulose fibers that are chemically treated with a dispersant to impart improved dispersibility to the fibers. The fibers are treated with a dispersant which deactivates the hydroxyl sites of the fiber surfaces and in some cases, making the fiber surface more hydrophobic. The dispersant inhibits the hydroxyl groups on the cellulose fiber surface from bonding with hydroxyl groups of other fibers and from bonding with hydroxyl groups of the same fiber, thereby significantly reducing inter-fiber and intra-fiber hydrogen bonding. The treated fibers can be readily dispersed and uniformly distributed throughout a mixture without re-clustering or reclumping once the mechanical mixing action stops.

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: 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 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.