PVA-FIBER REINFORCED HIGH PERFORMANCE CEMENT BOARD

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1 PVA-FIBER REINFORCED HIGH PERFORMANCE CEMENT BOARD Atsuhisa Ogawa 1, Yoshinori Hitomi 1 and Hideki Hoshiro 2 (1) Industrial Materials Research and Development Department, Kuraray Co., Ltd, Japan (2) Tokyo Fibers and Industrial Materials Department, Kuraray Co., Ltd, Japan Abstract High performance cement board () is produced by Hatzeck process just like a traditional papermaking. This new concept product is made of cement, PVA-fibers, pulps and other additives. is suitable for permanent formworks, panels and other thin applications. It is very similar to traditional fiber cement board but most different characters of this are the strain-hardening behavior and micro/multiple cracking dispersion with over 12N/mm2 of high tensile strength. And also it has a good durability, i.e. freezing and thawing, penetration, fire resistance and etc. One of the useful properties of is handling. It can be enable easy drilling, nailing and cutting on site. And the second is durability of ductility. It can be reduce the life cycle cost because of long-term durability. These typical properties enabled new retrofitting process and also some practical experiments. 1. INTRODUCTION PVA-fibers have good alkaline resistance, high tenacity and high modulus and are often used for the replacement of asbestos fibers of cement boards as the recent worldwide restriction of asbestos spread. On another front of cement board products, there required much more ductility for the reliability. However, it is difficult to apply the high amount of fibers for Hatzeck-processed cement boards, so there is not enough ductility. We studied about PVA-fibers for high amount dosage for Hatzeck process and finally we found, ductile cement board with multiple and micro-cracking fracture toughness made by Hatzeck process. And also is enabled to produce commercially.

2 2. GENERAL SPECIFICATIONS OF 2.1 Production Process Typical process of is shown in figure 1. And typical composition is shown in table 1. To produce, 1) uniform slurry will be prepared and supply into the stock tank. 2) Wire cylinders are rotating in the stock tanks and these cylinders percolate the slurry to the solid sheet. Then, the solid sheet is transferred onto the felt belt. 3) After that, the solid sheet is transferred onto the laminating roll and this process is repeated and multiple layer sheets are laminated until desired thickness to make. 4) Laminated green is pressed to dehydration. Initial curing is usually done at 5-Celcius degree and 24hours. After that, more than 1weeks of natural curing will be done. This process is suitable for in productivity, product quality and thin/light weight/high strength. 1. Slurry Mixing Slurry 4. Dehydration 4. by compression by 3. Making green Green sheet Slurry Stock stock tank Laminating Laminating on the cylinder on the Felt belt Green sheet Making sheet Wire Cylinder y Cutting Figure 1. Typical process Table 1. Typical composition Cementitious Inorganic Fiber Pulp PVA-fiber Additives Weight % Physical Properties of Physical properties of are shown in table 2. shows high ductility and high flexural and tensile strength. Figure 2 shows the multiple and micro cracks on the tensile fractured specimen surface. Figure 3 shows the typical strain-stress relationship in tensile fracture. From the figure 2, multiple and micro cracks are mostly less than.5mm width on the surface. And also figure 3 shows shows strain-hardening behaviour under the tensile fracture process.

3 Table 2. Physical properties of Figure 4 shows the impact resistance of. Impact test was done by 6J, 5kg weight and 1.2m height, of impact energy applied onto the test pieces: 5kg of sand bag was dropped onto the board from 1.2m heights. Ordinary asbestos-free cement board was broke to 4 or more pieces in figure 4-a and was not break in figure 4-b. As mentioned above, shows high mechanical properties, especially strength and ductility. The fracture toughness of PVA-fiber reinforced cement board composite is higher than matrix itself or only pulp-reinforced composite 1). These are suspected by which described below: - High mechanical properties and interaction against cement matrix of PVA-fiber - Multi-layered structure with 2-dimensional fiber orientation of the composites Stress (N/mm 2 ) Asbestos cement board Figure 2. Multiple and micro cracking on the surface of tensile specimen of Strain (%) Figure 3. Typical strain-stress relationship of, t=8mm, at tensile fracture

4 4-a):, t=8mm 4-b): Asbestos free cement board, t=8mm Figure 4. Broken specimen after 6J of impact loading 3. DURABILITY OF is made with over 9% of fine inorganic particles and compression process is applied. Then, has uniform and dens structure and its good durability will be anticipated. 3.1 Abrasive resistance has dens and uniform structure and it causes good abrasive resistance. Figure 5 shows the results of rotary abrasion test, based on ASTM C-779. shows good abrasive resistance in comparison with asbestos cement board. High amount of reinforced fibers causes apparent matrix cohesive force and good abrasive resistance. Accum. Abrasive Loss (mg) Rounds Figure 5. Accumulative abrasive loss by rotary abrasion test: ASTM C-779. open:, filled: asbestos cement board, both t=8mm

5 3.2 Neutralization resistance 8mm thickness of was placed in 5% of carbon dioxide atmosphere at 2-Celsius degrees and 65%R.H. to accelerate the neutralization. After the 6days of exposure, shows not only little or nothing neutralized but also stable flexural strength, modulus and toughness. 6days of acceleration is to be 28years of onsite exposure 2). Table 4. Accelerated neutralization test results of Unit Acceleration days 3days 6days Flexural strength 1) N/mm Flexural modulus 1) x1 4 N/mm Flexural toughness 2) N/mm ) Flexural test: 3point flexural test W=25mm Span=25mm, JIS A 148 2) Flexural toughness: integrated the area of strain - stress till maximum flexural strength. 3.3 Chlorine ion permeation resistance Chlorine ion permeation resistance was studied for the coverage use of RC structures. Specimen for chlorine ion permeation resistance is shown in figure 6. 8mm thickness of was cut and built into the structure of 1x1x4(mm) outer size and ordinary concrete, composition is shown in table 5, was poured into this mould. Plain concrete specimen was also prepared. After the 38days of under water curing and 7days of aerial drying were applied, resin coating was applied at 4 faces for confining permeating faces. These specimens were soaked into the 2celcious degrees of artificial seawater with 1.8% of chlorine ion concentration. After 3 or 6days of soaking, chlorine ion concentration of the concrete part of the specimen was estimated by potentiometric titration, JCI method. Resin Coating 8 2 (mm) Cl - ion penetrate 4 Cl - ion penetrate Cl - ion penetrate 1 Cl - ion conc. Meas. Concrete Sampling area for chlorine ion conc. 1 Unit:mm 6-a): Dimension of specimen 6-b): Cl - ion concentration measured area Figure 6. Specimen for chlorine ion penetration resistance Figure 7 shows the results of chlorine ion permeation status corresponded with the distance from the penetrating surface. covered concrete avoids chlorine ion penetrating and it enables to prevent steel rebar from corrosion.

6 Chlorine ion conc. (%) Soaking time (days) Figure 7. Chlorine ion concentration after artificial seawater soaking. Measured at 9 to 2mm depth from penetrating surface Freezing Table and 5. Ordinary thawing Concrete resistance Composition Unit weight (kg/m 3 ) W/C S/a C W S G Ad C: Ordinary portland cement, Ad: Superplasticizer Freezing and thawing resistance was studied for the coverage use of ordinary concrete structures. Specimen for freezing and thawing resistance is shown in figure 8. 8mm thickness of was cut and built into the structure of 1x1x4(mm) outer size and ordinary concrete, composition is shown in table 5, was poured into this mould. Plain concrete specimen was also prepared. The specimen was applied to the freezing and thawing test at -2 to 1-Celsius degree, based on ASTM C-666 A-method, after the 38days of under water curing. And also, itself was applied same test. Relative dynamic modulus of elasticity of /concrete specimens is shown in figure 9. And table 6 shows freezing and thawing test results of itself. The aspects of the /concrete composite specimens after 3cycles are shown in figure 1. itself endured 3cycles of freezing and thawing test. These results show quite high durability in comparison with same kind of cement board materials 3) 4). And then, /concrete composite endured for 3cycles because of the durability of coverage. coverage realizes less damage for the structures.

7 Resin Coating Unit:mm Figure 8. Dimension of freezing and thawing test specimen Relative Dynamic Modulus of Elasticity (%) Cycles Figure 9. Relative dynamic modulus of elasticity, ASTM C-666 B-method open: covered prism, filled: plain concrete 1-a): faces of covered prism 1-b): plain concrete prism Figure 1. Aspects of the specimen after 3cycles of freezing and thawing durability test. Table 6. Properties of before/after 3cycles of freezing and thawing test. Remained flexural strength (%) Remained flexural modulus (%) Mass change (%) Aspect change Reference After 3cycles Non 4. TYPICAL APPLICATION OF 4.1 Architectural products Architectural application is one of the important possibilities for. Thin, lightweight, fire resistance and permeation resistance are suitable properties for this application. And also high ductility enables structural wall materials made by.

8 4.2 Reinforcement of concrete structures The reinforcement of concrete structures is one of the useful applications of. It is good example of this application that retrofitting of damaged beams by filling of concrete or mortar in the coverage of. Figure 11 shows the dimension of the specimen for the simulation of the damaged beam retrofitting by. This specimen simulates the cover concrete with. Third point flexural test, based on ASTM C-78, was done with this specimen and figure 12 shows the results. Plain concrete shows poor strength and ductility but -concrete hybrid structure shows just like twice of flexural strength and high ductility Plain Concrete concrete 1 3 Figure 11. Dimension of retrofitting test specimen 1 Load (kn) Deflection (mm) Figure 12. Load-deflection relationship of -concrete hybrid structure real: -concrete hybrid, broken: Plain concrete 4.3 Permanent formworks The permanent formwork is one of the useful applications utilizing good durability, high strength and high ductility of. is easy to assemble on site by its workability and enables to shorten the construction work in comparison with pre-cast

9 concrete formwork. Even if the plywood formwork can apply easily on site, permanent formwork can reduce labor hour in formwork setting and removal. Figure 13 shows the case with permanent formwork for tunnel lining construction 5). Using for permanent formwork shortened considerably the construction work. Figure 13. permanent formwork for tunnel lining 5. CONCLUSIONS High performance cement board () shows >12N/mm2 of high strength and >2% of high tensile capacity. And also shows high ductility with multiple and micro cracking. has good durability for abrasion, neutralization, chlorine ion permeation and freezing and thawing resistance. can reinforce ordinary concrete to twice of flexural strength. Then, retrofitting and permanent formworks are suitable application of for reinforcing of structures and reducing total construction costs and construction work. REFERENCES [1] Kim, P.J., 'Micro-mechanics-based Durability Study of Light Weight Thin Sheet Fiberreinforced Cement Composites', Ph-D Thesis, Univ. Michigan (1999) [2] Nakamura N., Masuda Y., Suzuki S., Abe M. and Kage T., 'Influential Factor of Test Methods on Accelerated Carbonation of Concrete', Summaries of Technical Papers of Annual Meeting, Architectural Institute of Japan, A-1, (23) [3] Venta, G.J., 'Freeze-Thaw Performance of Glass and Cellulosic Fiber Reinforced Cementitious Board', Proceedings of CONSEC 3 (21) [4] Shao, Y. and Jiang, L., 'Freeze-Thaw Resistance of High Performance Fiber Reinforced Concrete', Proceedings of CONSEC 3 (21) [5] Matsuoka, S., Saito, M., Suzuki, T. and Nishiwaki, K., 'New Revival Technique for Tunnel Structures', Concrete Journal, 41 (4) (23) 55-6

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