Abstract: A building material (40) is provided comprising fiber-cement (10) laminated to gypsum (20) 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 ?? thick laminate composite is provided comprising a ½? thick gypsum panel laminated to a ?? thick fiber-cement sheet, the laminate composite having a fire resistance rating of 1 hour when measured in accordance with ASTM E119.

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: Abstract of the Disclosure A building material (40) is provided comprising fiber-cement (10) laminated to gypsum (20) 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 5/8” thick laminate composite is provided comprising a ½” thick gypsum panel laminated to a 1/8” thick fiber-cement sheet, the laminate composite having a fire resistance rating of 1 hour when measured in accordance with ASTM E119.

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 composite building article is configured with one or more subsurface interfacial zones provided to improve the durability of the article. Each subsurface interfacial zone is made of a matrix of fiber cement and radiation curable material. The radiation curable material forms an interlocking network with the fiber cement to provide a interfacial zone against ingress of environmental agents that can degrade the article. The number, configuration and distribution of the subsurface interfacial zones can vary dependent on the desired characteristics of the final product. The subsurface interfacial zones also improves the adhesion between exterior coatings and the substrate as the interfacial zones can be integrally formed with the substrate as well as exterior coating layer.

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: 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.