Extruded fiber reinforced cementitious products having stone-like properties and methods of making the same

Abstract

A cementitious composite product that can function as a substitute for stone and solid surface materials, such as granite, marble, and engineered stone is provided. Furthermore methods for manufacturing the cementitious composite product using an extrudable cementitious composition that can be extruded or otherwise shaped into stone-like building products that can be used as a substitute for many known stone products is disclosed. In one embodiment, the cementitious composite products can be manufactured more cheaply to be as tough or tougher and more durable than stone and solid surface materials.

Description

BACKGROUND OF THE DISCLOSURE[0001]The present disclosure relates generally to cementitious building products that contain high amounts of reinforcing fibers and more particularly, to extrudable compositions for use in making ultra-high strength cementitious composite building products having stone-like properties.[0002]The success of the building and construction industry is in large part determined by the properties available for use in construction. Many materials have been used historically and currently but each has one or more significant limitations, as further described in the following chart.Specific ValueFlexuralBulkInstalled(FlexuralBuildingStrengthDensityCost / kgStrength / InstalledBrittlenessGoodMaterials[MPa][g / cm3][US$ / kg]Cost / kg)[Y / N]AestheticsWood750.5418.75NYEternit101.442.5NNSteel4007.92020NNConcrete32.30.1323.08YNGranite / Marble182.563.0YYFiber301.3-2.30.5060NYreinforcedcementitiousproduct[0003]As the availability of high quality natural occurring materials such as st...

AI Technical Summary

Benefits of technology

[0008]The present disclosure relates to cementitious composite products (also referred to as building products or cementitious composite building products) that can function as a substitute for stone and solid surface materials. Specifically, the disclosed compositions and manufacturing processes have an increased flexural and tensile strength by more than 10 times as compared to conventional products. The products provide for easy molding and shaping for a wide variety of usable construction materials or products. Further, the compositions and processes make cementious building materials that are highly aesthetically pleasing at a much reduced cost and weight. These cementious materials are not brittle and do not chip or crack like natural synthetic stone commonly used in construction. Additionally, they have all the advantages of standard Portland Cement Concrete but are 10 times stronger and 100 times tougher at ⅓ less weight. The products are non flammable, highly durable and can be manufactured locally. A final advantage of these materials is that they obtain all required strength for use within 24 to 48 hours and do not need the typical 28 day period of other cementitious materials peak performance requirement.

Problems solved by technology

Furthermore, although concrete has historically been recognized as having high compressive strength, the compressive strength of concrete is not usable.

Previous attempts to use fiber reinforcing concrete have been generally limited by many factors.

One factor is the difficulty of uniformly mixing and distributing fibers more than 3% by volume throughout a high strength water cement ratio composition.

The second factor is the rapid reduction in rheology of the concrete makes the shaping and placing of the concrete material much more difficult.

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