A PROCESS FOR THE MANUFACTURE OF AUTOCLAVED FIBRE-REINFORCED SHAPED ARTICLES

Abstract: In a process for the manufacture of autoclaved fibre-­ reinforced shaped articles having a density of at least 600 kg per m³, e.g. flat or corrugated boards, sheets and panels, with a matrix of cured calcium silicate binder, there is initially prepared an aqueous slurry of 5-30% fibres, including at least 5% cellulose fibres, 15-50% ultra fine silica dust with a specific surface area of 5-200 m²/g and a particle average diameter less than 0.5 µm, 20-80% lime and/or lime-containing mater­ ial and 0-40% additive (calculated on a dry weight basis); subsequently green shaped articles are formed by dewatering the slurry; and finally the green shaped articles are auto­ claved, possible after pressing and precuring. The autoclaved shaped articles thus manufactured exhibit high strength (par­ ticularly in relation to their density), low permeability, high frost resistance and high flexibility.

Description: A PROCESS FOR-THE MANUFACTURE OF AUTOCLAVED FIBRE-REINFORCED SHAPED ARTICLES The present invention relates to a process for the manufacture of autoclaved fibre-reinforced shaped articles having a density of at least 600 kg per m3 with a matrix of cured calcium silicate binder, comprising the steps of initially preparing an aqueous slurry of fibres, silica, lime and/or lime-containing material and possibly other additives and containing an excess of water in relation to the amount necessary to secure curing of the calcium silicate binder, and subsequently forming green shaped articles by dewatering the slurry, and finally autoclaving the green shaped articles, possibly after pressing and precuring. By the term "lime" is meant CaO and/or Ca(OH)2. By "lime-containing material" is understood material which contains lime, and material which liberates lime in the presence of water such as cement, in particular hydraulic cement, e.g. Portland cement. By "autoclaving" is meant heat treatment in the presence of saturated steam at superatmospheric pressure. Processes of this kind are known in connection with the manufacture of asbestos fibre-reinforced autoclaved products, such as flat or corrugated panels, sheets and boards used for e.g. roofing and exterior and interior cladding of buildings. A typical example is mentioned in US-A-3 501 323, which mentions a typical mixture of 15 weight percent asbestos fibres, 51 weight percent Portland cement (as lime-containing material) and 34 weight percent ground sand (as silica). A free-flowing aqueous slurry is prepared from this mixture, whereafter green sheets are prepared by dewatering said slurry. These sheets are pressed and autoclaved, typically at 1700C for 8 hours. Similar processes using hydrated- lime, Portland cement or mixtures thereof as lime and/or lime-containing material; ground quartz, silica sand, diatomite or fly ash as silica, typically having a specific surface area within the range -2 1000-12000 cm /g, preferably within the range 3000-5000 cm /g; and fibres of asbestos, silica, glass, cellulose and/or organic polymers, are also mentioned in US-A-3 501 323. Another process of the same kind for the production of asbestos-free products using e.g. 12 weight percent cellulose fibres, 15 weight percent Portland cement, 31.8 weight percent lime, 29.2 weight percent ground quartz and 12 weight percent mica is known from the specification of US-A-4 101 335, and a similar process using 40-60 weight percent cement, 30-40 weight percent ground quartz and 5-15 weight percent cellulose fibres is also known from the specification of EP-A-68741. The object of the present invention consists in providing a process of the above kind for the manufacture of products, such as flat or corrugated panels, sheets and boards used e.g. for roof-ing and exterior and interior cladding of buildings and as interior building elements in ships, having a particularly hgh strength relative to their density, low permeability, high frost resistance and high flexibility. it has now surprisingly been found that the object can be achieved by a process for the manufacture of autoclaved fibre-reinforced shaped articles having a density of at least 600 kg per m3 with a matrix of cured calcium silicate binder comprising the steps of initially preparing an aqueous slurry of fibres, silica, lime and/or lime-containing material and possibly other additives and containing an excess of water in relation to the amount necessary to secure curing of the calcium silicate binder, and subsequently forming green shaped articles by dewatering the slurry, and finally autoclaving the green shaped articles, possibly after pressing and precuring, which is characterized in that the aqueous slurry, calculated on a dry weight basis, contains 5-30%, preferably 8-20%, in particular 12-16% fibres, including at least 5%, preferably at least 8% cellulose fibres; ; 15-50%, preferably 18-35%, in particular 18-25% silica in the form of ultra fine silica dust with a specific surface area of 5-200 m2 /g and a particle average diameter less than about O.5jw', 20-80%, preferably 30-70%, in particular 45-65% 'lime and/or lime containing material; and 0-40% additives. The shaped articles formed by the process according to the invention exhibit particularly high strengths relative to their density. This is probably due partly to the unusually high fibre content and partly to the fact that the use of the ultra fine silica dust having an extremely high specific surface area as silica leads to an unusually high reactivity of the starting material and also to a particularly dense packing of the starting material in the green sheets, resulting in a matrix in the autoclaved product which is unusually compact as compared with a matrix--obtained by use of coarser silica, such as diatomite- or ground quartz. The high reactivity of the starting material also offers the possibility of performing autoclaving at low temperatures, if desired. The high concentration of fibres, including at least 5%, preferably at least 8% cellulose fibres is of crucial importance to ensure fair filtration conditions and high homogeneity of the green shaped articles, which is necessary for the production of a satisfactory end product. By the process according to the invention it is thus possible to manufacture flat boards with a MOR (defined below) of 20-60 MPa at densities of 0.9-1.6 g/cm . Preferred fibres are: synthetic inorganic fibres, such as mineral wool, glass, carbon and steel fibres; synthetic organic fibres, such as polyester, polyvinyl, polyvinylalcohol, polyethylene, polypropylene, polyacrylonitrile and polyacrylamide fibres; and natural organic fibres, such as cellulose fibres. As mentioned above, the aqueous slurry must contain at least 5%, preferably at least 8%, calculated on a dry weight basis, cellulose fibres. These are preferably selected from: wood fibres of e.g. birch, pine and spruce; seed and fruit hair fibres of e.g. coir and cotton; and leaf and/or bast fibres of e.g. sisal, abaca, flax, hemp and jute. The fibres serve partly to reinforce the autoclaved product, partly as filtration and retention aids at the dewatering step. Particularly satisfactory filtration and retention are obtained when at least a part of the cellulose fibres is refined to a degree of freeness of 20-600 SR and/or when the fibres include highly fibrillated polyethylene or polypropylene fibres. Very favourable results can be obtained if the fibres are exclusively cellulose fibres. A particularly preferred embodiment is characterized in that the aqueous slurry, calculated on a dry weight basis, contains 8-20, preferably 12-168 cellulose fibres, and that up to 50% of these cellulose fibres are refined to a degree of freeness of 20-60 SR, particularly 35-500 SR. The ultra fine silica dust is preferably fine filter dust from electrothermal production of -silicon or ferro-silicon with a specific surface area of about 25 m2/g and an average particle diameter of about O.lt. The lime and/or lime-containing material may be hydrated lime, hydraulic cement such as Portland cement, e.g. of the type I-V, according to ASTM standard C 150, and mixtures thereof. The additives (if present) may be selected from: fillers including mica, vermiculite, kieselgur, perlite, expanded clay, diatomite and ground quartz, silica sand and fly -ash; colouring agents; water sealing agents; setting and hardening accelerators including calcium chloride and aluminium sulphate; flocculants and dispersants; filtering agents including.acicular Wollastonite crystals; and organic and inorganic plasticising and fibre dispersion agents, including colloidal hydrophilic inorganic particles, e.g. hydrophilic silica particles with a specific surface. area larger than 100 mê/g and refined and unrefined colloidal clay particles. The autoclaving is preferably performed at temperatures between 100 and 2400C, preferably within the interval 130-190 C. The aqueous slurry can be prepared in a manner known per se by pulping and stirring the fibres in water and subsequently admixing the remaining materials, possibly adding more water to reach a suitable water/solid ratio. When pulping cellulose fibres it has, however, been found particularly advantageous initially to disperse the ultra fine silica dust in water having -a pH-vlue exceeding 8, subsequently stirring the fibres in this aqueous silica dispersion and finally admixing the remaining materials and, if necessary, additional water. Hereby is ensured a particularly homogeneous slurry of the fibres with a reduced tendency to lump formation, presumably because the ultra fine silica dust in a basic environment will coat.the surface of the individual cellulose fibres, providing an increased dispersibility of the cellulose fibres. The preparation of the green shaped articles by dewatering the slurry takes place in a manner.known per se, e.g. using the Hatschek,-Magnani, Head Box, injection or Fourdrinier method. The green shaped articles can, for example, be shaped as beams, blocks, pipes and flat or corrugated panels, boards and sheets which, if desired, can be subjected to compression, typically at a pressure of 10-100 kgf/cmê, and precuring, typically at 20-1000C for 6-24 hours and a relative humidity of 60-100%, before the autoclaving. When shaping the green shaped articles plasticity is a particularly desirable property. It has been found that excellent plasticity is obtained by the process according to the invention due to the use of the ultra fine silica dust as silica, and that the plasticity of the material increases with addition of lime. The invention is further illustrated in the Examples. The materials, used in the examples were as follows: Fibres: AO cellulose : Cellulose fibres (Pinus) (Kraft cellulose) length: less than 4 mm, diameter: about 35 m. BO cellulose : Bleached cellulose fibres (Betula) having a degree of freeness about 43-50 .SR, length: about 1.3 mm, diameter: about 30 m. EO cellulose : Bleached cellulose fibres (Eucalyptus grandis and Eucalyptus urophylla) having a degree of freeness of about 200 SR, length: about 1.0 mm, diameter: about 20 m. Abaca : Cellulose fibres (Musa), length: about 6 mm, diameter: about 30 m. Flax : Cellulose fibres (Linum) having a degree of freeness of about 350 SR, length: about 6 mm, diameter: about 1 5. Silica: ACE sand : Silica sand containing at least 90% SiO2, specific surface (Blaine): about 3000 cm /go Silica-dust : Ultra fine' filter dust from electro-thermal production of metallic silicon or ferrosilicon, SiO2-content: 80-100%, specific surface (BET): 2 about 25 m2/g, average particle diameter: about 0.1 Fly ash : Fly ash from power plant, specific surface (Blaine): about 3500 2 cm /g. Lime/lime-containing material Hydrated lime : 95% CaO, average particle size about 5 , specific surface (BET): about 15 m2/g. E cement : A special coarse Portland cement, specific surface 2 (Blaine) about 2600 cm /g. LSC cement : A sulphate-resistant Portland cement having a low alkali content (max. 0.60%) (type V), specific surface (Blaine): about 3000 cm Çg, C3A content: about 1.5%. White cement: A low-alkali white Portland cement, specific .surface (Blaine): about 4400 cm /g, C3A content: about 3%. Additives: Attagel 150 : A commercial colloidal, acicular attapulgus clay product, specifc surface: 210 mê/g. NYAD G : Acicular Wollastonite crystals, 80% having a size corresponding to a spherical diameter less than 4 rn, and 20% having a size corresponding to a spherical diameter less than Attagel and NYAD are Trade Marks. Fibre reinforced sheets were prepared in the laboratory at bench scale and on Hatschek and Magnani machines at full industrial, scale. Bench scale experiments: Production Procedure. Pulp preparation: A solution saturated at 200C was prepared of Ca(OH)2 and CaS04.2H20 in deionized water. A portion of this solution together with the desired amount of ultra fine silica dust were introduced into a British Pulp Evaluation Apparatus, and the silica was dispersed for 3 min. at 3000 r.p.m. Then the fibres were added to the dispersion, and the mixture was pulped fpr 15 min. at 3000 r.p.m. Slurry preparation: The resulting fibre pulp along with an additional portion of the above saturated solution were transferred to the vessel of a Diaf mixer, and the slurry was prepared by adding lime and/or lime-containing material and optional additives in an amount corresponding to a weight ratio water to total solid material equal to 10. The resulting mixture was stirred at 4000 r.p.m. for 6 min. Preparation of green sheets: A portion of the slurry corresponding to 109 g solid material was dewatered in a filtration apparatus, suction pressure 200 mm Hg. The resulting filter cakes we-re pressed to green sheets in a Johns-Manville sheet forming press. Preparation of hardened sheets: The green sheets were cured to hardened sheets in the following way: The green sheets were placed on a glass plate and kept in a humidity box for 24 hours, relative humidity: about 95%, temperature 250C. Thereafter the sheets were autoclaved with a heating up time of 2.5 hours, held for 16 hours and a cooling time of 2.5 hours. The physical properties of the slurry and the hardened sheets were measured as--described below: Testing Procedure: Filtration time: A portion of slurry corresponding to 109 g of solid material was dewatered in a filtration apparatus at a suction pressure equal to 200 mm Hg A sudden drop in suction pressure indicates the end of the filtration period. The filtration time is defined as the period of time from start of suction to pressure drop. Loss of solids: The particle retention properties of the slurry were measured in the following way: 3 times 440 g portions of slurry were dewatered in a filtration apparatus provided with a 40 mesh sieve, suction pressure:. 30 mm Hg. The content of solid material in the filtrate was filtered out from the filtrate and the weight thereof determined. Loss of solids is defined as the percentage by weight of solid material in the filtrate compared with total amount of solids. MOR dry and wet: The autoclaved sheets were subjected to bending tests in which the curvature of the specimens was determined as a function of the load --A -ZW-ICK 1454 testing machine with 4-point load with a support distance of 190 mm and a 35 mm arm of momentum was used. Force/deformation curves were registered. MOR, modulus of rupture, designates the maximum tensile stress in bending at maximum load. - Attribution "wet" designates that measurements were made on watersoaked sheets which had been submerged in water for 48 hours, and "dry" designates that measurements were made on sheets which had been dried at 1100C for 48 hours. Example 1. Comparison between sheets prepared according oto.the invention and sheets prepared according to the known art Three series of experiments were performed with production of sheets according to the Production Procedure. In experiment 1 sheets based on ultra fine silica dust were produced according to the invention. The green sheets were pressed at 15, 100 and 50 kgf/cm2 and autoclaved at 1400cm 140 C and 180 0C, respectively. By way of comparison sheets were produced in experiments 2 and 3 according to the known art in which ACE sand and fly ash, respectively, was used as silica. The green sheets were presed at 50 kgf/cm2 and autoclaved at 18O0C. Compositions, calculated in percent by weight of total solid material, and test results are shown in Table I. It is evident that the sheets produced according to the invention exhibit extremely superior strength properties. Further, it is seen that the strength properties improve with increasing compression pressure. Example 2. Incorporation of fly ash as a component in the binder Seven series of experiments were carried out with production of sheets according to the Production Procedure. In experiment 4 fly ash-free sheets were produced based on ultra fine silica dust. In experiment 5 part of the ultra fine silica dust was replaced by fly ash, while in experiment 6 there were produced sheets according to the known art in which fly ash exclusively was used as silica. Compositions, in weight percet calculated on total solid material, compression pressure and test results are shown in Table II. The autoclaving temperature was 140 0C. It is evident that the sheets produced according to the invention exhibit extremely superior strength properties. Further, it is seen that partial replacement of ultra fine silica by fly ash leads to impaired strength properties. In experiments 7-10 the amount of ultra fine silica dust used in experiment 4 was maintained, whereas the cement was replaced by increasing amounts of fly ash and lime hydrate. Compositions,- compression pressure and test results are shown in Table II. The autoclaving temperature was -1400C. Comparison of the results of experiments 4 and 7-10 shows that a high silica content ensures excellent strength properties - also when, considerable portions of the cement are replaced by fly ash. It was further observed that the addition of lime-hydrate had an advantageous plasticising effect on the green sheets. Example 3. Addition of various types of cellulose fibres Three series of experiments were performed with production of sheets according to the invention, Experiment 11 is identical with experiment 4. In experiments 12 and 13 the fibres used in experiment 11 were replaced by other fibre combinations. Compositions, in weight percent calculated on total solid material, compression pressure and test results are shown in table III. The autoclaving temperature was 14O0C. It is evident that the products produced in all the series of experiments have excellent strength properties. Example 4. Use of various kinds of cement. Three series of experiments were performed with production of sheets according to the invention. Experiment 14 is identical with experiment 4. In experiments 15 and 16 the LSC cement used in experiment 14 was replaced by other types of cement. Compositions, in.weight percent calculated on total solid material, compression pressure and test results are shown in Table IV. The autoclaving vemperature was 14O0C. It is evident that the products produced in all the series of experiments have excellent strength properties. Example 5. Effect of incorporation of Wollastonite crystals. Two series of experiments were performed with production of sheets according to--the-invention, experiment 17 without - experiment 18 with addition of Wollastonite crystals. Compositions, in weight percent calculated on total solid material., compression pressure and test results are shown in Table V. The autoclaving temperature was 140 C. The test results show that the incorporation of Wollastonite crystals results in considerable reduction in the filtration time and in the solid material loss with substantially unchanged strength properties. Example 6. The effect of fibre concentration on strength properties. Eight series of experiments were performed with production of sheets according to the Production Procedure. In experiment 19 sheets were produced with a fibre content of 4%, i.e. lower than the minimum claimed in Claim 1. In experiments 20 and 21 sheets were produced according to the invention with 12 and 15% fibres, respectively. These sheets were pressed 2 at 15kgf/cm and autoclaved at 140 C. In experiments 22-26 sheets were produced with cellulose fibre contents increasing from 5 to 30%. Compositions, in weight percent calculated on total solid material, compression pressure, autoclaving tempe.rature and test-results' are shown in Table VI. The test results show that a high cellulose fibre content is necessary in order to obtain excellent strength properties (for products having a rather low density) and fair filtration conditions. It is further seen that the optimal cellulose fibre content is within the range 10-20%. Example 7. Effect of silica concentration on strength properties. Six series of experiments were performed with production of sheets according to the invention. In experiments 27-32 sheets were produced with a content of ultra fine silica dust increasing from 20-40%. Compositions, in weight percent calculated on total solid material, compression pressure, autoclaving temperature and test results are shown in Table VII. The test results show that a favourable combination of excellent strength properties and acceptable filtration times are obtained when the content of ultra fine silica dust lies within the range 18-358. Industrial experiments. Example 8. Experiment on a full scale Hatschek machine Experiment Hl. 178 kg BO cellulose were pulped for 10 min. with 3200 litres of water in a 6m3 Solvo hydro pulper. The resulting pulp was refined in a Black Clawson disc refiner to a degree of freeness of 450 SR. 550 kg ultra fine silica dust were dispersed in 4000 litres of water for 10 min. Thereafter 204 kg AO cellulose were added, and the mixture was pulped for 20 min. 4754 kg of this pulp were mixed with the first pulp and further water was added to a total weight of 8600 kg. 1845 kg of the resulting pulp were mixed with 300 kg LSC cement for 10 min. Thereafter water was added in order to obtain a water to solid material ratio equal to about 10. The resulting slurry was in known manner processed into flat boards on a Hatschek machine. The flat boards were pressed for 45-60 min. The pressed boards which had a thickness of 6 mm were cured in a curing channel at 600C for 8 hours. Then the boards were autoclaved at 14006 for 16 hours, preceded-by a heating up time of 4 hours and followed by a cooling time of 4 hours. Testing. Two values of the MOR of the boards were measured: MOR 1 (with rupture parallel to the direction of production). MOR t (with rupture perpendicular to the direction of production). The designations "wet" and "dry" are the same as stated above, "stock" refers to the fact thatthe boards after the autoclaving have been conditioned for about 1 month under atmospheric conditions prior to measurement. Compositions, in weight percent calculated on total solid material, compression pressure and test results are shown in Table VIII. Experiment S2* Analogously sheets according to the invention were prepared with a binder based on' hydrated limey Composition, in weight percent calculated on total solid material, compression pressure and test results are shown in Table VIII. The boards were tested for water permeability, and the results demonstrated a reduction in permeability by a factor of approximately 10 compared with ordinary asbestos cement. Further the boards were subjected to frost/thaw tests and here again the results were significantly better than for ordinary asbestos cement. After exposure for 1 hot:r in water and subsequently 23 hours at 60 n dry heat with 50 repetitions the strength properties of the boards remained unchanged. The ability of the boards to protect flammable material behind them against fire was demonstrated as being equal to that of asbestos cement. Experiment H3 and 114. Analogously sheets according to the invention were prepared with binders based on LSC cement containing flax cellulose and AO cellulose, respectively. Compositions, in weight percent calculated on total solid materials, composition pressure and test results appear from Table VIII. Experiment H5 Corrugated sheets were produced at full industrial scale in the following way: A slurry having the same composition as in Experiment H4 was prepared and processed into flat boards on a Hatschek machine as described in Experiment Hl. The flat boards were subsequently corrugated in a conventional corrugation machine producing corrugated boards having a pitch (i.e. wave length) of 177 mm and a height (i.e. distance from upper part of wave trough to upper part of wave crest) of 51 mm (plate thickness 6 mm). The boards were cured and autoclaved as described in Experiment Hl. Some boards were pressed for 45-80 min. at 100 kgf/cmê before curing. Test coupons were cut from the autoclaved boards and two values of the modulus of rupture were measured for each coupon, namely MOR 1 (with rupture parallel to the corrugations) and MOR t (with rupture perpendicular to the corrugations). The designations "1", "t", "wet" and "-stock" are the same as stated above. The followihg test results were found: Unpressed boards: Density: 1.04 g/cm3; MOR 1 wet: 7.6 MPa; MOR t wet: lO'.7 MPa; MOR i stock: 12.1 MPa; MOR t stock 16.8 MPa. Pressed boards: Density: 1.34 g/cm ; MOR 1 wet: 12.6 MPa; MOR t wetr 17.8 MPa; MOR 1 stock 27.4 MPa; MOR t stock: 29.4 MPa. The boards exhibited excellent frost resistance and water-t ghtness. Example 9. Experiment on a full scale Magnani machine. An aqueous slurry having a water/solid ratio equal to about 2 and containing 12 parts by weight cellulose fibres, 20 parts by weight ultra fine silica dust, 16 parts by weight fly ash and 52 parts by weight LSC cement was prepared as described in Example 8. The slurry was pumped into a Magnani machine where it was dewatered to corrugated boards (pitch: 147 mm, height: 48 mm, thickness: 6-7 mm). The unpressed boards were cured and autoclaved as described in Example 8. Test coupons were cut from the autoclaved boards and two values of the modulus of rupture were measured for each coupon, namely MOR 1 and MOR t. The designations "1", "t", "wet" and "stock" are as defined in Experiment 115. The following test results were found: Density within the range 1.04-1.13 g/cm ; MOR 1 wet within the range 7.5-12 MPa; MOR t wet within the range 9-14 NPa; NOR 1 stock within the range 13-20 NPa; NOR t stock within the range 16-22 MPa. It is seen that excellent strength properties are obtained with varying cellulose fibre combinations. TABLE I Experiment No. 1 2 3 AO cellulose 3.3 3.3 3.0 BO cellulose 6.7 6.7 5.0 ACE sand - 30.3 Fly ash - - 31.0 Silica dust 30.3 - - Hydrated lime 28.1 28.1 28.7 Attagel 150 2.0 2.0 2.0 Nyad G 29.6 29.6 30.3 Filtration time (sec.) 815 34 27 Solid material loss (%) 2.9 2.9 3.0 2 Compression pressure: 15 kgf/cm Density (g/cm ) 1.00 - MOR wet, (MPa) 13.1 MOR dry, (MPa) 20.6 - TABLE I (Cont) 2 Compression pressure: 100 kgf/cm Density (cm ) 1.23 - - MOR wet, (MPa) 18.0 - MOR dry, (MPa) 31.3 - - Compression pressure: 50 kgf/cm Density tg/cm ) 1.14 1.06 1.02 MOR dry, (MPa) 25.8 9.6 3.4 TABLE II Experiment No. 4 5 6 AO cellulose 8 8 8 BO cellulose 7 -7 7 Fly ash - 9 24 Silica dust 24 15 LSC cement 61 61 61 Filtration time (sec.) 271 115 32 Solid material loss (%) 3.3 3.6 2.5 Compression pressure: 15 kgf/cmZ Density (g/cm ) 1.21 1.19 0.95 MOR wet, (MPa) 22.6 16.4 6.2 MOR dry, (Mpa) 29.9 25.8 10.4 Compression pressure: 100 kgf/cmê Density (g/cm ) 1.45 1.39 1.09 MOR wet, (MPa) 33.9 24.6 9.0 MOR dry, (MPa) 35.2 30.0 13.6 TABLE II (Cont.) Experiment No. 7 8 9 10 AO cellulose 8 8 8 8 BO cellulose 7 7 7 7 Fly ash 5 10 15 25 Silica dust 24 24 24 24 Hydrated lime - 5 8 13 LSC cement 56 46 38 . 23 Filtration time (sec.) 263 223 240 234 Solid material loss (%) 3.8 3.5 3.9 3.5 Compression pressure: 15 kgf/cm Density (g/cm ) 1.22 1.14 1.10 1.01 MOR wet, (MPa) 19.0 18.9 17.7 15.0 MOR dry, (MPa) 26.9 25.4 24.6 23.0 Compression pressure: 100 kgf/cm Density (g/cm ) - 1.45 1.39 1.33 1.25 MOR wet, (MPa) 28.6 27.1 24.9 21.7 MOR dry, (MPa) 32.7 33.5 34.2 27.1 TABLE III Experiment No. 11 12 13 AO cellulose 8 - 8 BO cellulose 7 - Abaca -- g- ¯ EO cellulose - 7 7 Silica dust 24 .24 24 LSC cement 61 61 Filtration time (sec.) 271 131 174 Solid material loss (8) 3.3 3.6 4.1 Compression pressure: 15 kgf/cmê Density (g/cm ) 1.21 1.30 .1.28 MOR wet, (MPa) 22.6 25.1 22.0 MOR dry, (MPa) 29.9 28.8 29.8 Compression pressure: 100 kgf/cm Density (g/cm ) 1.45 1.51 1.52 MOR wet, (MPa) 33.9 33.8 31.6 MOR dry, (MPa) 35.2 36.9 37.9 TABLE IV Experiment No. 14 15 16 AO cellulose 8 8 8 BO cellulose 7 7 7 Silica dust 24 24 24 LSC cement 61 - -E cement - - 61 White cement - 61 - Filtration time (sec.) 271 259 242 Solid material loss (%) 3.3 2.8 3.3 Compression pressure: 15 kgf/cm Density (g/cm ) 1.21 1.19 1.20 MOR wet, (MPa) 22.6 17.1 21.8 MOR dry, (MPa) 29.9 26.5 26.0 Compression pressure: 100 kgf/cmê Density (g/cm3) 1.45 1.46 1.45 MOR wet, (MPa) 33.9 23.9 29.E MOR dry, (MPa) 35.2 32.6 29.7 TABLE V Experiment No. 17 18 AO cellulose 8 8 BO cellulose 7 7 Silica dust 24 24 E cement 61 51 Nyad G - 10 Filtration time (sec.) 242 180 Solid material loss (8) 3.3 2.9 Compression pressure: 15 kgf/cmê Density (g/cm ) 1.20 1.19 MOR wet, (MPa) 21.8 20.1 MOR dry, (MPa) 26.0 26.6 Compression pressure: 100 kgf/cmD Density (g/cm ) 1.45 1.43 MOR wet, (MPa) 29.6 29.7 MOR dry, (MPa) 29.7 34.9 TABLE VI Experiment No. 19 20 21 AO cellulose 4 8 8 BO cellulose - 4 7 Silica dust 24 24 24 LSC cement 72 64 61 Filtration time (sec.) 1500 427 271 Solid material loss (*) - 4.4 3.3 Compression pressure 2 (kgf/cm ) 15 15 15 Autoclaving temperature ( C) 140 140 140 Density (g/cm ) 1.55 1.31 1.21 MOR wet, (MPa) 13.9 18.8 22.6 TABLE VI (Cont) Experiment No. 22 23 24 25 26 AO cellulose 3 6 9 12 18 BO cellulose- 2 4 6 8 12 Silica dust 26.8 25.4 24 22.6 19.8 LSC cement 68.2 64.6 .61 57.4 50.2 Filtration time (sec.) 549 403 166 124 57 Solid material loss (%) 13.3 5.4 4.3 1.8 1.3 Compression pressure (kgf/cm2) 100 100 100 100 100 Autoclaving temperature: 14OOC Density (g/cm3) 1.73 1.59 1.48 1.33 1.15 MOR wet, (MPa) 14.6 24.5 24.2 20.6 15.8 Autoclaving temperature-: : 180 C Density (g/cm ) 1.74 1.58 1.46 1.26 1.14 MOR wet, (MPa) 11.4 17.8 22.8 22.6 18.8 TABLE VII Experiment No. 27 28 29 30 31 32 AO cellulose 8 8 8 8 8 8 BO cellulose 7 7 7 7 7 7 Silica dust 20 24 28 32 36 40 LSC cement 65 61 57 53 49 45 Filtration time (sec.) 189 221 301 227 302 349 Solid material loss (%) 3.2 2.3 4.2 2.4 2.7 2.4 Compression pressure (kgf/cmê) 100 100 100 100 100 100 Autoclaving temperature: 140 C Density (g/cm ) 1.45 1.48 1.49 1.41 1.39 1.35 MOR wet, (MPa) 23.4 24.3 28.7 27.4 25.5 24.2 Autoclaving -temperature: 180 C - Density (g/cm ) 1.45 1.45 1.47 1.43 1.41 1.39 MOR wet, (MPa) 19.1 22.3 25.6 29.1 29.2 27.5 TABLE VIII Experiment No. H1 H2 H3 H4 AO cellulose 8 3.2 - 6 HO cellulose 7 6.-4 4 4 Flax - - 6 Silica dust 24 30.3 20 20 Hydrated lime - 28.1 - LSC cement 61 - 60 60 Nyad G - 29.6 10 10 Attagel 150 - 2.4 - Compress ion pressure (kgf/cmê) 223 205 190 190 Density (g/cm ) 1.3 1.2 1.5 1.4 MOR 1 wet, (MPa) 22.5 17.2 20.4 24.4 MOR t wet, (MPa) 36.0 23.9 30.1 38.2 MOR 1 dry, (MPa) 26.6 26.0 27.6 33.8 MOR t dry, (MPa) 44.9 40.4 34.4 47.6 MOR 1 stock, (MPa) 30.9 21.8 25.3 28.8 MOR t stock, (MPa) 55.5 37.2 33.6 49.6

Claims: CLAIMS 1. A process for the manufacture of autoclaved fibre-reinforced shaped articles having a density of at least 600 kg per m with a matrix of cured calcium silicate binder comprising the steps of initially preparing an aqueous slurry of fibres, silica, lime and/or lime-containing material and possibly other additives and containing an excess of water- i-n relation to the amount necessary to secure curing of the calcium silicate binder, and subsequently forming green shaped articles by dewatering the slurry, and finally autoclaving the green shaped articles, possibly after pressing and precuring, characterized in that the aqueous slurry, calculated on a dry weight basis, contains 5-30%, preferably 8-20%, in particular 12-16% fibres, including at least 5%, preferably at least 8%, cellulose fibres; ; 15-50%, preferably 18-35%, in particular 18-25% silica in the form of ultra fine silica dust with a specific surface area of 5-200 mê/g and a particle average diameter less than about 0.5*m;20-80%, preferably 30-70%, in particular 45-65% lime and/or lime-containing material; and 0-40% additives. 2. A process according to Claim '1, characterized in that the fibres are selected from synthetic inorganic fibres, such as mineral wool, glass, carbon and steel fibres; synthetic organic fibres, such as polyester, polyvinyl, polyvinylalcohol, polyethylene, polypropylene, polyacrylonitrile and polyacrylamide fibres; and natural organic fibres, such as cellulose fibres. 3. A process according to Claim 1 or Claim 2 characterized in that the cellulose fibres are selected from wood fibres of e.g. birch, pine and spruce; seed and fruit hair fibres of e.g. coir and cotton; and leaf and/or bast fibres of e.g. sisal, abaca, flax, hemp and jute. 4. A process according to any of Claims 1 to 3 characterized in that-at least part of the cellulose fibres are refined to a degree of freeness of 20-60 SR. 5. A process according to any of Claims 1 to 4 characterized in that the fibres include highly fibrillated polyethylene or polypropylene fibres. 6. A process according to any of Claims 1 to 4 characterised in that the fibres are exclusively cellulose fibres. 7. A-process according to any of Claims 1 to 6 characterized in that the aqueous slurry, calculated on a dry weight basis, contains 8-20, preferably 12-16% cellulose fibres, and that up to 50% of these cellulose fibres are refined o a-degree of freeness of 20-60 SR, particularly 35-50 SR. 8. A process according to any of Claims 1 to 7 characterized in that the ultra fine silica dust is fine filter dust from electrothermal production of silicon or ferrosilicon with a specific surface area of about 25 m /g and an average particle diameter of about O.l 9. A process according to any of Claims 1 to 8. characterized in that the lime and/or lime-containing material is hydrated lime. 10. A process according to any of Claims 1 to 8 characterised in that the lime and/or lime-containing material is Portland cement. 11. A process according to any of Claims 1 to 8 characterised in that the lime and/or lime-containing material is a mixture of Portland cement and hydrated lime. 12. A process according to any of Claims 1 to 11 characterized in that the additives are selected from: fillers including mica, vermiculite, kieselgur, perlite, expanded clay, diatomite and ground quartz, silica sand and fly ash; colouring agents; water sealing agents; setting and hardening accelerators including calcium chloride and aluminium sulphate; flocculants and dispersants; filtering agents including adicular Wollastonite crystals; and organic and inorganic plasticising and fibre dispersion agents, including colloidal hydrophilic inorganic particles, e.g. hydrophilic silica particles with a specific surface area larger than 100 m2/g and refined and unrefined colloidal clay particles. 13. A process according to any of Claims 1 to 12 characterized in that the autoclaving is performed at temperatures between 100 and 240 C, preferably at 130-190 C. 14. A process according to any of Claims 1 to 13 characterized in that the aqueous slurry is prepared by initially dispersing the ultra fine. silica in water having a pH-value exceeding 8, subsequently stirring the fibres in this aqueous silica dispersion and finally admixing the remaining materials and, if desired, additional water.

Inventors: GREGERSEN, JENS CHRISTIAN
Applicants: DANSK ETERNIT-FABRIK A/S
Application year: 1984
Main classification: C04B28
IPC codes: C04B28