Fiber Cement Products Research Articles

Green Manufacturing Excellence in Fiber Cement Production: Leveraging Green SCOR and AHP for Enhanced Environmental PerformanceTimes

Green manufacturing has become key strategy in improving environmental sustainability and operational performance in industry. This research evaluates the implementation and performance of green manufacturing activities in the Fiber Cement industry, using the Green SCOR framework integrated with AHP. This method allows for an in-depth assessment of the effectiveness of existing practices and provides a foundation for the development of targeted improvement strategies. The results indicated that the company was in the unsatisfactory performance category, with a score of 58.6. Of the 12 KPIs evaluated, there were 5 that required significant improvement, including the addition of a water pool, waste reduction, improved order management, additional labor, and training on green production. This research contributes to the green manufacturing literature by providing valuable insights for companies to evaluate their performancein improving green manufacturing practices specific to the Fiber Cement industry.

Novel surface functionalization of cellulose fibers with polyurethane prepolymers in fiber cement composites: Impact on final properties and potential benefits for the production process

The objective of this research was to perform a deep exploration of cellulose polyurethane (PU) fibers used in fiber cement boards for usage in building applications. Grafting treatment was performed on cellulose fibers with PU-pre-polymers, through a synthesis method using propylene carbonate solvent medium, followed by a cleaning step. Fiber cement boards were prepared thorough cement and limestone dispersion followed by a dewatering process, to roughly mimic the Hatschek production process. The experiments confirmed that grafted cellulose fibers can present lower water absorption (∼10 %) and greater fiber preservation, when embedded in alkaline matrix. Although the mechanical performance of fiber cement composites prepared with cellulose-PU fibers were not appreciably different, superior ability to drain water from the green cement sheet was demonstrated, which can provide great benefits during the production process. It’s worth mentioning that cellulose fiber is added in the air cured fiber cement formulation as a process aid agent to retain fine aggregates, and mechanical reinforcement is mainly carried out by the synthetic fibers. From the fiber cement production perspective, the reduced water retention showed in the green sheet can be beneficial in different production processes, e.g. the Hatschek or flow-on, in two ways: First, by possibly reducing the number of stops, as a lighter green sheet would be less prone to drop from the machine, and second, due to lower vacuum applied, possibly avoiding segregation and producing more homogeneous boards.

Use of Alternative Raw Materials for the Production of Fiber Cement Products

The paper deals with the production of fiber cement and the use of alternative raw materials in its production. The paper describes the basic technologies used for the production of fiber cement with a description of their advantages and disadvantages for the given type of product. The paper also describes the most commonly used types of fillers and their impact on the final fiber cement products. The paper also describes selected alternative raw materials used for the production of fiber cement and their impact on the final products. The paper describes the possible use of waste dust from facade fiber cement boards in the production of corrugated sheets. Trial recipes were designed with partial replacement of original raw materials with waste dust. The fiber-cement corrugated sheets were produced with using Hatchesk technology. Mainly was investigated the influence of the addition of waste dust on the strength characteristics and the volume weight of the final products. The produced sheets were tested according to EN 494+A1: 2016 Fibre-cement profiled sheets and fittings - Product specification and test methods. The tested samples with waste dust reached comparable results like sheets produced according to standard recipe. No negative effect was proven of the addition of waste dust on the strength characteristics of final products.

Passive of CRFS Technology in Soil-Cement Application

In Brazil, with the ban on the production, sale, and use of chrysotile asbestos, the sector’s industry opted to replace asbestos with CRFS Technology—Cement Reinforced with Synthetic Wire (fiber cement); that is, another product to be disposed of in landfills. This work aimed to determine a composite based on clay, fiber cement powder, and cement that meets the technical specifications of Brazilian soil–cement application standards to contribute to a more sustainable treatment of the future disposal of fiber cement products. With the characterization analysis of the materials, we identified that the clay granulometry is heterogeneous and distributed from 0.1 µm to 25 µm. In comparison, 75% of the fiber cement powder has grains greater than 10 µm. For clay, the liquidity limit is 39.67%, the plasticity limit is 25.01%, and the plasticity index is 14.66%. In the semiquantitative chemical analysis, silicon oxide (SiO2) and calcium oxide (CaO) stood out as the main oxides found, reflected in the mineralogy as quartz and calcium silicate. Therefore, we identified the percentage of organic matter in clay at 2%, using the result of the thermogravimetric analysis. The results described met the normative parameters foreseen for soil–cement applications. That said, the technological characterization was carried out by tests of linear retraction, water absorption, and simple mechanical compression on the specimens made under an axial pressure of 31.2 Mpa in the formulations defined in this work. The formulations with 10% cement and 20% and 30% fiber cement powder are suitable for use in soil–cement bricks, as they have volumetric shrinkage percentages from 2% to 2.5%, water absorption ranging from 18.66% to 19.39%, and simple compressions from 4.25 Mpa to 6.88 Mpa, meeting the requirements of Brazilian standards for soil–cement applications. It is concluded that the results showed that it is possible to produce soil–cement bricks with passive fiber cement products converted into powder, avoiding improper disposal and unwanted environmental impacts.

Study on the use of mining waste as raw material for extruded fiber cement production

This study aimed to evaluate the effect of replacing agricultural limestone (AL) with mining waste (IOT) on the physical, mechanical, and durability properties of extruded fiber cement. The experimental results showed that replacing AL with IOT either improved or maintained the technological properties seen on conventional fiber cement, highlighting the 25% IOT formulations replacing AL. The 100% IOT formulations replacing AL showed the technical feasibility of use and may assist in reducing the amount of waste disposed of in containment dams and, consequently, the environmental disasters related to the ruptures of such dams.

Effect of fiber type and content on the performance of extruded wood fiber cement products

This study presents the physical, mechanical, and durability characteristics of the extruded cement fiber products manufactured with various types of wood fibers. Four types of wood fiber cement products, one each produced with softwood, hardwood, recycled wood, and a blend of hard/softwood fibers were investigated in the experimental program. For each type of fiber mixtures, the effect of fiber content (fiber to cement ratio) was investigated at 5%, 10%, and 15% levels. These products were tested in unaged and aged conditions after exposure to accelerated aging effects. Test results showed decrease in bulk specific gravity and increase in water absorption capacity of the wood fiber cement composites with increase in fiber content. Considerable increase in flexural toughness was recorded with increase in fiber content for the softwood fiber products. After exposure to accelerated aging conditions comprising of freeze-thaw cycles, wet-dry cycles, saturation, and warm water exposure, the softwood fibers-based cement composite provided the highest level of flexural strength and stiffness. Furthermore, fiber cement composites having 10% fiber content retained a target flexural strength of 8–10 MPa besides showing good flexural stiffness after aging. Test results of this study help in identifying wood fiber reinforcement conditions which yield extruded fiber cement products with the balance of physical, mechanical, and durability characteristics suiting different building applications.

Evaluation of refined cement-based matrix systems for extrusion of wood fiber cement

Different cementitious matrix formulations incorporating various chemical, polymeric and mineral additives were evaluated for use in extruded fiber cement products. These alternative formulations were designed to enhance the end product performance characteristics under aging conditions and to facilitate the extrusion process. The impact of different matrix formulations on mechanical, durability and physical characteristics of extruded cellulose fiber cement products were compared. Test results show that most of the additives lowered the bulk specific gravity but increased the moisture absorption capacity of extruded fiber cement products when compared with the basic mix formulation. Generally, the additives caused drop in flexural strength but did not significantly affect the flexural toughness of the matrix formulations. Upon saturation the frictional pull-out of swollen fibers increased the ductility (deformation) capacity of extruded cellulose fiber cement products. These results provide further insight into performance characteristics of extruded cellulose fiber cement products, and help with selection of matrix mix formulations to meet performance requirements of a particular application.

К вопросу о безопасном применении фиброцементных материалов в зданиях и сооружениях

Fiber cement finishing materials are widely used in the construction of industrial buildings and structures due to the complex of valuable operational properties. In the Russian market there are fiber-cement panels with a variety of design solutions for their coloring and application of protective coatings. Fiber cement board is a strong and moisture-resistant composite material made from a cement-sand mixture, reinforcing cellulose fibers and special additives. Not being a non-combustible material, the fiber cement boards in accordance with the current mandatory requirements, as a decorative, finishing and facing material for walls and ceilings have restrictions on their use. Existing domestic requirements regarding the methodology for assessing the combustibility of fiber cement products largely narrow the field of using these materials. Therefore, it is advisable to develop the proposals for amending the test methods and the regulatory framework governing their fire-safe extended scope. In the course of this work execution, the main provisions of the regulatory and methodological framework that establish the requirements for the fire-safe use of fiber cement materials are analyzed. Experimental complex studies of fire hazard properties of various types of samples of the fiber cement finishing panels and slabs were carried out. It is established that fiber-cement materials belong to the class of the least fire-hazardous materials. Advisability is determined concerning the introduction to the national regulatory practice of GOST R «Building materials. Test method for fire hazard under thermal exposure with a single burner (SBI)». Classification parameters of the group of non-combustible materials NG2 were established to amend GOST R 57270—2016 (method 1). Classification parameters of the group of non-combustible materials NG2 for making changes in GOST R 57270—2016 (method 1) are established. Proposals were developed to expand the scope of application of the materials and products made of fiber cement as enclosing structures, partitions, and decorative finishes (cladding) in the buildings and structures.

Effect of Fiber Type and Content on the Performance of Extruded Wood Fiber Cement Products

Effect of Fiber Type and Content on the Performance of Extruded Wood Fiber Cement Products

Health promotion in the workplace: pneumoconiosis

Pneumoconiosis corresponds to a group of diseases that develop with a chronic fibrous reaction of the lungs due to the inhalation of dust. They are especially marked by loss of expandability, fibrosis and pigmentation and can be given several names depending on the dust inhaled. The multiplicity of industrial and extractive activities in Brazil results from a high number of workers exposed to the risk of developing pneumoconiosis. It is a professional disease (technopathy) triggered by the exercise of work peculiar to a certain activity. This category of disease can only be prevented by adopting control measures, especially engineering or environmental measures. In order to understand the magnitude of the problem and trigger surveillance actions, notification of the event to the Notifiable Diseases Information System (SINAN) is essential. In this work, data on pneumoconiosis in Brazil, reported to SINAN, between 2014 and 2018 were collected. An annual average of 161 cases was found, 2017 being the year in which the disease most occurred, representing 77% of the total. Pneumoconiosis usually affects men (94.03%), between 40 and 59 years of age (44.44%), illiterate (90.22%) and who are registered employees (85.90%). The occupation most frequently affected was that of a construction worker (41.63%). However, when the cases were classified according to economic activities, the most found was the manufacture of concrete, cement, fiber cement, plaster and stucco products (85.74%). Regarding the disease itself, 81.43% of cases were reported as pleural plaques, which represent the most frequent manifestation of exposure to asbestos. Asbestosis represented 5.31% of the cases and silicosis 5.14%. 89.39% of the total cases were reported by the Reference Centers in Occupational Health (Cerest). Pneumoconiosis are serious diseases that require intensive treatment and follow-up. Preventive measures and early diagnosis/treatment must be adopted through strict surveillance of workers' health and safety conditions.

Soil-cement bricks produced from local clay brick waste and soft sludge from fiber cement production

Soil-cement bricks were produced using local clay brick waste (CBW) and soft sludge (SS) from fiber-cement industries, preserving raw resources by substituting with industrial wastes. The control formula to produce soil-cement bricks, is 15 wt% Portland cement, 15 wt% sand, and 70 wt% laterite. Clay brick waste was added with values from 10 to 50 % of laterite weight in the control formula. For SS, 5 and 10 % was used to replace the total weight of the dry mixture in the control formula. The samples were shaped by using a manual brick making machine. The results showed that the compressive strength of all by-product bricks exceeded industry standards. The maximum compressive strength was attained for 10 % replacement of laterite by CBW. When using both SS and CBW, thermal conductivity and weight of the bricks were further reduced. However, the percentage of water absorption incorporated into the by-product bricks was higher than that of the control formula but still within permissible limit of the industrial standard for load-bearing applications. All by-product bricks showed lower thermal conductivity compared with the control formula. Soil-cement bricks produced with industry by-products have improved or provided similar properties to control formula soil-cement bricks. The utilization of CBW and SS content in the brick samples can save natural resources, decreasing fuel consumption, and reduce CO2 emissions during delivery.

Coconut fibers and quartzite wastes for fiber-cement production by extrusion

Brazil is worldwide known by production and commercialization of ornamental rocks and its characteristics of great agricultural production. However, along with these productions, tons of wastes are produced and incorrectly abandoned each year. In this sense, the use of these industrial or agricultural wastes in the construction sector is an environmentally correct and economically suitable option. The present study aimed to characterize quartzite wastes and coconut fibers (Cocos nucifera) to be used as reinforcement in cementitious matrix composites, in intention of reducing the fragility of these materials and improve its mechanical properties. The basic density and chemical characterization of the coconut fibers were performed. The Inhibition index of cement solidification, quartzite chemical composition and granulometry were also evaluated. The chemical analysis of the quartzite showed the high percentage of silicon, followed by zirconium and molybdenum, which depends on the region and temperature where it was generated. The granulometric analysis showed that the quartzite of this research was mostly powdered. The chemical analysis of the coconut fiber confirmed the low percentage of extractives (3.38%) what would be a positive factor low for production of composites besides the high content of lignin and cellulose, which could provide an increase in the mechanical properties of the fiber-cement. Coconut fiber showed low inhibition index (<10) of the cement, which could result in a good fiber/matrix interface. The insertion of coconut fibers and quartzite wastes in composites could be an option for more resistant and more sustainable fiber-cement.

Reducing water absorption of fiber-cement composites for exterior applications by crystal modification method

The aim of this work was to reduce the water absorption of the fiber-cement composites, which is also known as fiber-cement products, by the crystal modification of cement matrix using the additives including polyurethane-based corn starch–lithium perchlorate (LiClO4), and acrylic resin emulsion-based chitosan-silicate hybrid compound. To prepare the samples, the mixtures consisting Portland cement Type I, sand, cellulose fibers from pine trees, gypsum, and additive were mixed with water. The percentages of additive in the mixtures before mixing with water were 0.03 to 0.17 wt%. The green sheets of samples were formed by filter-pressing method, air cured for 1 day, and then autoclaved at 8 bars and 140°C for 12 h. The experimental results indicated that the water absorption of the samples was reduced when polyurethane-based corn starch–lithium perchlorate (LiClO4) was used as the additive due to the crystallization of the small crystals within cement matrix, while their mechanical properties including modulus of rupture (MOR) and modulus of elasticity (MOE) of the samples using this additive conform industrial standard.

Influence of MFPSA on mechanical and hydrophobic behaviour of fiber cement products

The modified Fenton paper sludge ash (MFPSA) was employed to replace cement in different proportions to prepare fiber cement products. The mechanical and hydrophobic properties of the MFPSA/fiber cement and concrete were studied. When the calcination temperature is 800 °C and the dosage is 4%, the MFPSA increases 28d flexural strength of fiber cement by 11.5%, compressive strength by 5.7%, and decreases water absorption by 2.6%. The MFPSA also decreases the 28d capillary water absorption of fiber concrete by 31.9%. The XRD, SEM/EDS, FTIR were employed to reveal how the MFPSA affects the hydration mechanism, and microstructure of MFPSA/fiber cement products.

Lignocellulosic Materials for Fiber Cement Production

Among the products used in the construction industry, cement composites with lignocellulosic reinforcement have been highlighted in the research. These materials have advantageous characteristics, such as being lighter and more economical. This work aimed at evaluating the effect of different lignocellulosic materials use on the physical, mechanical, and durability properties of fiber cement. The composites were produced in laboratory scale by extrusion. The formulation consisted of 5% lignocellulosic material, 30% agricultural limestone, 1% hydroxypropylmethylcellulose, and 1% polyether carboxylic additive and the remainder of the material was Portland cement (CPV-ARI) to complete the formulation. The samples were cured for 2 days in a saturated environment and for 5 days in thermal curing. Fiber cement properties such as bulk density, water absorption, apparent porosity, modulus of elasticity, modulus of rupture, and tenacity after curing and after 200 and 400 aging cycles were evaluated. Eucalyptus, coffee husk, banana pseudostem and coconut shell particles could be used for fiber cement production since they met the marketing standards after the aging process.

Exploratory pre-industrial test linking FGM and Hatschek technologies for the manufacture of asbestos-free corrugated cementitious roof sheets

The concept of functionally graded materials (FGM) has been successfully applied in the development of many advanced cement-based composites. In the fiber-cement sector, however, little attention has been given to this approach. In this paper, the mechanical behavior of corrugated asbestos-free (AF) fiber-cement and asbestos-cement (AC) sheets are compared, and the FGM concept is used to improve the production cost and mechanical performance of corrugated asbestos-free (AF) fiber-cement products compared to asbestos-cement sheets. A loaded AF sheet was modeled using the finite element method to assess and develop strategies for improving its mechanical performance, leading to the linking of FGM and Hatschek technologies to locally address performance issues. Tensile tests indicated that the AF fiber-cement sheets initially crack at stresses about 50% lower than AC sheets. The FEM models, in turn, indicated that the flat regions between the crowns and valleys of the corrugated sheet are only subject to low intensity stresses under bending and wind loadings. In this work, instead, we propose the application of fibrous mixtures between layers of corrugated fiber-cement sheets as an alternative strategy for controlling the distribution of fibers along Hatschek-made corrugated sheets. In preliminary tests conducted on a pre-industrial scale, the application of extrudable fibrous cementitious mixtures between the layers of Hatschek-made AF fiber-cement sheets resulted in an approximately 10% increase in the limit of proportionality and modulus of rupture. The results indicate that the proposed technique presents an excellent potential to produce functionally graded corrugated sheets whose fiber contents and mechanical strengths are controlled locally.

Characterization of Fiber-Cement Composites Reinforced with Alternate Cellulosic Fibers

The eucalyptus and araucaria fibers were used as alternatives to virgin cellulose common in fiber-cement production. Three different types of these virgin-cellulose replacements were utilized as main raw materials while the silica sand was the aggregate. Chemical and physical analyses were performed on the raw materials. In the experiments, the effect of various fiber types on the mechanical strength, water absorption and the density of fiber-cement mixture was studied for 8 wt% of these three fiber types. The excess water in homogeneous mixtures of these raw materials was first removed and then samples were pressed and baked in the autoclave. Physical and mechanical tests on these samples indicated that the fiber-cements produced with eucalyptus and araucaria cellulose were superior mechanically than those produced with virgin cellulose.

Utilization of vegetable fibers for production of reinforced cementitious materials

Vegetable fibers produced from agroindustrial resources in the macro, micro and nanometric scales have been used as reinforcement in cementitious materials. The cellulosic pulp, besides being used as the reinforcing element, is also the processing fiber that is responsible for the filtration system in the Hatcheck method. On the other hand, the nanofibrillated cellulose has the advantage of having good mechanical performance and high specific surface, which contributes to improve the adhesion between fiber and matrix. In the hybrid reinforcement, with micro and nanofibers, the cellulose performs bonding elements with the matrix and acts as stress transfer bridges in the micro and nano-cracking network with the corresponding strengthening and toughening of the cementitious composite. Some strategies are studied to mitigate the degradation of the vegetable fibers used in cost-effective and non-conventional fiber cement, as well as to reach a sustainable fiber cement production. As a practical example, the accelerated carbonation curing at early age is a developing technology to increase the durability of composite materials: it decreases porosity, promotes a higher density in the interface generating a good fiber–matrix adhesion and a better mechanical behavior. Thus, the vegetable fibers are potentially applicable to produce high mechanical performance and sustainable cementitious materials for use in the Civil Construction.

Feasibility Study of Using Basalt Fibers as the Reinforcement Phase in Fiber-Cement Products

The aim of this work was to study the feasibility of using basalt fibers as the reinforcement phase in fiber-cement products which was the fiber-reinforced construction materials used for roof, wall, ceiling, and floor applications. The feasibility study included (1) the alkaline resistant test of the basalt fibers by soaking the basalt fibers in 1 N Ca(OH)2up to 28 days, and (2) the mechanical test based on ASTM C1185 standard on the fiber-cement board that used basalt fibers as a reinforcement phase. Scanning electron microscope (SEM) and x-ray diffractometer (XRD) were used to characterize the basalt fibers after alkaline resistant test. The basalt-fiber reinforced cement board was produced on the industrial level by using Hatschek process.From the alkaline resistant test, basalt fibers had well alkaline resistant. From the mechanical test, the modulus of rupture (MOR) of basalt-fiber reinforced cement boards passed the requirement of TIS 1427-2540 and ASTM C1186 standard. Therefore, basalt fibers could be considered as a good candidate for using as a reinforcement phase in the fiber-cement products.

Study of the degradation of non-conventional MgO-SiO2 cement reinforced with lignocellulosic fibers

This paper assesses the use of low alkaline composites based on magnesium oxide and silica (MgO-SiO2) cement and reinforced with cellulose fibers for the production of thin elements to resist bending loads. The strategy adopted was to study the durability of lignocellulosic fibers in a lower pH environment than the ordinary Portland cement (OPC), by comparing the flexural performance of samples at 28 days and after 200 accelerated ageing cycles. Two types of vegetable fibers were used: eucalyptus and pine pulps. For both types of fibers, composites made out of MgO-SiO2 cement after ageing treatment show a better mechanical performance than OPC samples (modulus of rupture of ∼10.5 and 9 MPa respectively). When used in MgO-SiO2 cement matrices, eucalyptus fibers offer excellent specific energy (SE) values (∼5 kJ/m2) compared to OPC samples in which SE drastically decreases after ageing from 4.97 kJ/m2 to 0.14 kJ/m2. The preservation of the reinforcing capacity of the composite materials after ageing was also proved by SEM techniques. In the light of the results, the use of MgO-SiO2 cements is an effective way to apply cellulosic fibers as reinforcement in fiber-cement products since no signs of degradation were found, even improving flexural properties over time.