Thesis--Technical University of Denmark. / Bibliography: p. 157-[159].

The replacement of asbestos fibres with cellulose fibres in producing corrugated fibre reinforced cement sheets by the Hatschek process resulted in edge cracking for stacked sheets. This was due to the hydrophilic nature of cellulose, which increases its tendency for exchanging water with the surroundings. The drying process of corrugated sheets, in a stack, resulted in shrinkage hence edge cracking along the sheet. To reduce the magnitude of drying shrinkage and edge cracking potential, several mitigation strategies were proposed including the surface treatment of cellulose fibres, incorporation of wollastonite microfibres, addition of admixtures and superplasticizers, kaolin inclusion as partial replacement of cement and different exposure conditions. A fundamental understanding in mechanisms behind volume changes and how cracks form was crucial for optimization of the mitigation strategies. This thesis initially used a review approach to understand the mechanisms involved in different types of shrinkage and the role of different mitigation techniques. The ultimate goal was to achieve lower drying shrinkage and cracking risks in corrugated sheets along with reducing its economic impact. As a result, surface treatment of cellulose fibres, based on transforming the hydrophilic nature of cellulose to hydrophobic state, was investigated. Furthermore, inclusion of wollastonite/ kaolin as partial replacement of cement, were evaluated. Also, the potential of adding admixtures/ superplasticizers was explored. Finally, investigation on development of edge cracks in stacked corrugated fibrecement sheets was conducted under different exposure conditions. The results and findings of this research showed no significant improvement in permeability with cellulose surface treatment. Wollastonite microfibres promoted pore discontinuity hence significant reduction in permeability thus lower drying shrinkage. However, the resultant sheets were brittle. By reducing water content with addition of superplasticizers, density was enhanced thus reducing volume change from drying and wetting. Kaolin acted as internal restraint for shrinkage, refining the microstructure at the interfacial transition zone thus increasing density and its pozzolanic reaction enhanced mechanical properties. The inclusion of kaolin in the fibrecement mix in conjunction with controlling exposure conditions managed to eliminate edge cracking.

A Research Report submitted to the Faculty of Architecture, University of the Witwatersrand, Johannesburg, in fulfilment of the requirements for the degree of Master of Science in Building. / Environmental and health considerations have led to the substitution of cellulosic fibres for asbestos fibres in many cement-based products. Inevitably, the substitution has required modifications to the manufacturing process. Certain production techniques associated with the switch to cellulosic fibres and other additives needed elucidation. It is possible that to ensure the required concentration of certalr additives in the final product, an excess is being used in the process because of uncertainties about the quantitative balance of the process. My intention was to examine the potential tole for Fourier Transform Infrared (FTtR) Spectroscopy in the investigation of the materials constituting fibre-reinforced cement boards. I was able to show that qualitative and quantitative determination of certain of the components in the final product are possible with adequate precision and reproducibility to be of value to the manufacturer, I also showed that care taken in the preparation of standard and analytical samples was essential for the success of such analyses. / Andrew Chakane 2018

A Research Report submitted to the Faculty of Architecture, University of the Witwatersrand, Johannesburg, in fulfilment of the requirements for the degree of Master of Science in Building. / Environmental and health considerations have led to the substitution of cellulosic fibres for asbestos fibres in many cement-based products. Inevitably, the substitution has required modifications to the manufacturing process. Certain production techniques associated with the switch to cellulosic fibres and other additives needed elucidation. It is possible that to ensure the required concentration of certaln additives in the final product, an excess is being used in the process because of uncertainties about the quantitative balance of the process. / Andrew Chakane 2019

As telhas de cimento-amianto são utilizadas mundialmente nas construções comerciais, residenciais e industriais. O amianto foi a primeira aplicação de fibra natural em escala industrial. Esta fibra foi incorporada na forma do mineral (asbesto) como reforço de matrizes à base do cimento. O processo de fabricação de telhas de cimento-amianto mais utilizado mundialmente foi patenteado em 1900 por Ludwig Hatschek, recebendo o mesmo nome. O objetivo deste trabalho foi a melhoria do processo industrial (Hatschek) de fabricação de telha de cimento-amianto, com o uso de métodos estatísticos. Inicialmente as variáveis mais influentes no processo foram identificadas empregando-se o teste de correlação de Pearson e o Cp de Mallows que permitiu a escolha do melhor subconjunto da regressão (R², R²ajustado, Cp de Mallows e o desvio padrão do modelo). A seleção dessas variáveis permitiu a construção de modelos de regressão para o processo, para as respostas resistência mecânica e densidade da telha. Devido à análise de duas respostas, foi realizada uma otimização numérica por meio da função desejabilidade (desirability function), que é baseada na idéia de que a qualidade de um produto ou processo que tem múltiplas respostas depende de encontrar as variações do processo que atendem a todas as restrições impostas, sejam elas econômicas ou normas aplicáveis ao produto final. Com o resultado da otimização estabeleceram-se faixas de variação das variáveis mais influentes, que permitissem a operação do processo sob controle. Também, pode ser concluído que para a densidade de ambas as telhas (5 mm e 6 mm) encontraram-se modelos coerentes para serem usados mesmo após alguma modificação na máquina, enquanto que para a resistência os parâmetros dos modelos devem ser reajustados sempre que houver alguma modificação durante a parada da máquina. / Roofing tiles of the asbestos cement composites are used world-wide in the commercial, residential and industrial constructions. Asbestos was the first natural fiber application in industrial scale. This fiber was incorporated into the cimentitious matrices to overcome this weakness. The manufacturing process of asbestos-cement tiles most commonly used worldwide was patented in 1900 by Ludwig Hatschek, which gave his own name to this procedure. Considering that, this study aimed to improve the manufacturing process of roofing tiles of the asbestos cement composites, using several statistical methods. Firstly, the most influent variables were identified using the Pearson Correlation test and the Mallows Cp test, which provided the choice of the best subsets regression (R ², R ² adjusted, Mallows Cp and the standard deviation of this empirical model). The selection of these variables allowed the construction of regression models for the mechanical resistance and tile density responses. In order to fulfill the requirement of an appropriate analysis for two responses, a numerical optimization by means of desirability function was applied. This optimization is based on the premise that a product quality or process having multiple responses depends on finding all the variations that fulfill the imposed constraints. Even if these constraints were economic or norms applied to the final product. The optimization results established ranges of variation including the most influents variables, i.e., the ones that allow the process to run under control. Also, we conclude that for the density of both tiles (5 mm and 6 mm) were found consistent models to be used even after some eventual change in machine. For the resistance, however, the parameters of the models must be readjusted whenever it has some modification during the shutdown of the machine.

As telhas de cimento-amianto são utilizadas mundialmente nas construções comerciais, residenciais e industriais. O amianto foi a primeira aplicação de fibra natural em escala industrial. Esta fibra foi incorporada na forma do mineral (asbesto) como reforço de matrizes à base do cimento. O processo de fabricação de telhas de cimento-amianto mais utilizado mundialmente foi patenteado em 1900 por Ludwig Hatschek, recebendo o mesmo nome. O objetivo deste trabalho foi a melhoria do processo industrial (Hatschek) de fabricação de telha de cimento-amianto, com o uso de métodos estatísticos. Inicialmente as variáveis mais influentes no processo foram identificadas empregando-se o teste de correlação de Pearson e o Cp de Mallows que permitiu a escolha do melhor subconjunto da regressão (R², R²ajustado, Cp de Mallows e o desvio padrão do modelo). A seleção dessas variáveis permitiu a construção de modelos de regressão para o processo, para as respostas resistência mecânica e densidade da telha. Devido à análise de duas respostas, foi realizada uma otimização numérica por meio da função desejabilidade (desirability function), que é baseada na idéia de que a qualidade de um produto ou processo que tem múltiplas respostas depende de encontrar as variações do processo que atendem a todas as restrições impostas, sejam elas econômicas ou normas aplicáveis ao produto final. Com o resultado da otimização estabeleceram-se faixas de variação das variáveis mais influentes, que permitissem a operação do processo sob controle. Também, pode ser concluído que para a densidade de ambas as telhas (5 mm e 6 mm) encontraram-se modelos coerentes para serem usados mesmo após alguma modificação na máquina, enquanto que para a resistência os parâmetros dos modelos devem ser reajustados sempre que houver alguma modificação durante a parada da máquina. / Roofing tiles of the asbestos cement composites are used world-wide in the commercial, residential and industrial constructions. Asbestos was the first natural fiber application in industrial scale. This fiber was incorporated into the cimentitious matrices to overcome this weakness. The manufacturing process of asbestos-cement tiles most commonly used worldwide was patented in 1900 by Ludwig Hatschek, which gave his own name to this procedure. Considering that, this study aimed to improve the manufacturing process of roofing tiles of the asbestos cement composites, using several statistical methods. Firstly, the most influent variables were identified using the Pearson Correlation test and the Mallows Cp test, which provided the choice of the best subsets regression (R ², R ² adjusted, Mallows Cp and the standard deviation of this empirical model). The selection of these variables allowed the construction of regression models for the mechanical resistance and tile density responses. In order to fulfill the requirement of an appropriate analysis for two responses, a numerical optimization by means of desirability function was applied. This optimization is based on the premise that a product quality or process having multiple responses depends on finding all the variations that fulfill the imposed constraints. Even if these constraints were economic or norms applied to the final product. The optimization results established ranges of variation including the most influents variables, i.e., the ones that allow the process to run under control. Also, we conclude that for the density of both tiles (5 mm and 6 mm) were found consistent models to be used even after some eventual change in machine. For the resistance, however, the parameters of the models must be readjusted whenever it has some modification during the shutdown of the machine.