MANUFACTURING PROCESS OF FIBER-CEMENT COMPOSITE MATERIALS USING PORTLAND CEMENT REINFORCED WITH INORGANIC FIBERS CHEMICALLY MODIFIED BY ORGANOSELANES

摘要

An innovative method for manufacturing fiber-reinforced building products based on fiber-cement composites using inorganic fibers, with or without natural or synthetic polymeric fibers as supplementary reinforcing materials is provided. This invention discloses the formulation, the method of manufacturing and the final fiber-cement products using thermo-chemically treated and stabilized inorganic slag glassy fibers from iron blast furnace plants or derived, but not limited to these, with silane coupling agents, additives, and catalyzers, for reinforcing Portland cement composites. The process can be shortly described by the following steps: a) Mixing and agitation of glassy blast furnace slag fibers in an alcoholic aqueous solution until the fibers are well dispersed and suspended in the solution; b) Thermo-chemical treatment with dewaxing agents and hydrophilization process under stirring; c) Thermo- chemical treatment based on organosilanes and oxidants, dispersants and cross- linking agents at 20-500C; d) Cross-linking surface reactions and fibers drying at 80-1500C for 1-4 hours; e) Preparation of a well mixed slurry with treated fibers, cement, aggregates, supplementary materials, additives, and water; f) Composite production by Hatschek process through deposition of the aqueous fiber-cement slurry on a porous fabric belt positioned on a series of support rolls. The slurry is conveyed by the fabric belt over and through a series of rollers to flatten and shape the slurry; g) Moisture is mostly drained off by the application of vacuum to the slurry and product final shape and dimensions are obtained. This invention discloses an original method for modify blast furnace slag fibers or derived, but not limited to these, in order to improve their alkaline resistance to Portland cement matrix with supplementary cementitious materials. This fibers were used in the manufacturing of fiber-cement composites such as flat and corrugated sheets, shingles, panels, and several others fiber-cement commercial products for architectural and construction applications.