Hatcheck Procedure of Fibre Cement Sheets - Research Paper Example

Hatcheck Procedure of Fibre Cement Sheets Name of Student Institutional affiliation Date Hatschek procedure description Hatchek is a procedure of manufacturing fibre cement; fibre cement is a flexible building material. The product is shaped into different dimensions and is an Australia building material. The procedure of hydration ensures more potency to the material being produced. The benefits are that the Australia can help save on costs as compared to the costs involved in the extraction of stones. Transportation of Australia is easier to the site. Fibre cements are easier and fast to install and require less energy in the production procedure. Ludwig Hatchek from Australia invented this procedure of hatcheck, in the period of 7 years carrying out his experiments; he added water to cellulose, cement and reinforcing fibres. The ‘slurry' was channelled to a machine used for making paper; the solids are put on the sieve that on each rotation attracts the layer of solids and moves the layer into a continuous belt. The layers are made of different thickness and removed if they are not going to be compressed. The procedure patent name is Eternit procedure (Torgal 2011, P 56). Hatschek procedure in manufacturing of construction materials in current industry In hatschek procedure, the combination of sand, water, cement and fibres is done. The hatschek procedure forms the mixture into wet sheets; the mixture is then dried under pressure in an autoclave for 28days. Tolerance is ensured by trimming the product at the edges, the sheets then coated with hydrophobic products and packed for shipping. The product can be manufactured in any shape, but mainly export materials are moulded into panels for wall fittings. The product can be mounted and cut into different dimensions, easy to drill holes for other penetrations and has other design characteristics (Torgal 2011, P 57) Fibre cement materials have many uses, roofing, building boards, ceiling and flooring. This is because Australia should be a consideration in modern day constructions. High-density fibre cement product has a density of 1650gr/m³. The major difference between the high density and the low-density fibre cement products is the durability, water resistance and dimensional tolerance. The Eternit procedure has been the same for the last 100 years. The only slight improvement is the fine-tuning and addition of some ingredients used in the manufacturing procedure. The fist hatcheck machine was made in 1890 to produce asbestos cement; the machine has the same use as of today. However, the modern ones are more productive than the early models due to the improvements made to adjust the production rate and the quantities produced (Li 2011, p 78) The following schematic diagram shows the principal components of a Hatschek machine http://www.engineeredassemblies.com/media/1169/why_does_fibre_cement_matter_v6.pdf The crucial part of the Hatschek machine comprises of a vat where a cylinder sieve revolves and is exposed to dilute water-based slurry fibres that form a filtering film and materials of mineral nature that includes Portland cement. The sieve cylinder is placed on an axle and moved by a continuous felt wrapped around the top part of the sieve by a couch roller. Accumulation roller is pushed into hard contact by the drive or anvil roller (Torgal 2011, P 56) Hatschek machine forms sheets as follows; water from the slurry moves through the sieve as the clean sieve is pulled in the vat under the slurry. The water deposits a porous film that is soft and the cement on the sieve surface. The film exiting the vat is carried by the sieve and is brought together with the felt stretched across the sieve tightly. More water is eliminated by forcing it again through the film by the procedure. On this layer of water, the film that is solid in nature floats and is moved to the felt partially. This is due to the water removal and because the felt has more attraction for the film than the sieve (Li 2011, P 80) The following diagram indicates primary dewatering of the film on elimination from the sieve http://www.engineeredassemblies.com/media/1169/why_does_fibre_cement_matter_v6.pdf The film is moved to the felt on an accumulator roll to which it is transferred by more water removal under high pressure. Various desired number of films are rounded on the accumulator roll to create a sheet of chosen thickness. The pile if films are removed from the roller and then placed flat to form a sheet. The steps of removing water from successive films that are in contact with each other by pressure are enough to combine the films to create a solid sheet that is contiguous (Girard 2013, P 40). Cycles of Hatcheck procedure in cement sheets production Asbestos became more popular among manufacturers and contractors in the 19th century due to its sound absorption and potency. Also due to its heat resistance property and durability, electrical and compound damage increased its popularity. According to the outcomes of study that have been done in the world, other fibres are not able, without further changes in the formulation. Thus providing a comparatively high drainage period, of forming required filter mat from the slurry and many shortcomings during production (Girard 2013, P 46). Much concentration has been moved to the utilization of cellulose and synthetic fibres in cement amalgamated board. It has also been noticed that some synthetic fibres, including polyethene, polypropylene, etc. Some natural fibres cannot be used alone instead of asbestos because they will not disperse in the right way in the slurry solution. These fibres float to the top of the slurry since they have lower specific gravity compared to aqueous cement solution. Therefore, They will not create a homogeneous mat on the cylinder of a wet creating machine (Girard 2013, P 40). A substance for supporting cement sheet products containing fibres other than asbestos, clay and thickener have been introduced. (Edgerton 2011, P 230) Cellulosic fibres have been seen to be useful as support in fibre cement building products. Albeit, linked with various problems like swelling in high alkaline cement matrix and result of climatic changes. The long-lasting property of cellulose fibres cement compound is correlated with the fibre nature, fibre substance, matrix nature and ageing procedure. However, study has indicated that cellulose fibres at amounts ranging from 0.06% to 0.5% significantly decrease controlled drying shrinkage cracking in materials with cement (Geological Survey 2013, P 232) An enhanced procedure for creating a polymer-modified fibre-cement compound that exhibits enhanced the presentation in at slightest one of resistance to water, freeze-thaw constancy, compound resistance, collision potency. Additionally, scratch resistance, flexural potency, tensile potency, and pull at failure, dimensional steadiness, bond potency, and fibre to medium bond potency relative to a corresponding compound missing the polymer. Additionally, polymer change may allow a compound with a condensed intensity of fibres, beneficial since fibre is characteristically more costly than cement, to give presentation equivalent to an unchanged compound. Polymer change may also let equivalent performance from a thinner and lighter fibre-cement panel, which assists in moving, usage and fitting (Girard 2013, P 40). The Kraft procedure is the common used compound pulping technique and this procedure entails the cooking of wood chips with a blend of caustic soda and sodium sulphide. This is in a digester to break the inside layer that is in the fibre. The pulp obtained from this procedure is usually used to produce high-grade papers and other elevated eminence materials. For instance, the softwood unbleached Kraft are the mainly broadly used wood fibres in cement compound due to their characteristic of potency, accessibility and price (Evans 2002, P 126). The outcome of potassium silicate, sodium silicate and silane treatment on broadsheet and unbleached Kraft fibre cement compound compared to the raw wood fibre cement compound has also been accounted. Mutually, both wood fibres were mixed and treated with the aqueous solution. They accomplished that aqueous compound treatments improved the mechanical properties of the treated wood fibre-cement compounds (Kalia 2011, P 186). The winning substitute for asbestos in many of the European countries has been a mixture of PVA fibres and cellulose fibres and cement using the Hatcheck procedure. Also in some instances, fillers such as silica or limestone powder are applied (about 5-20%). , curing of this type of produce is in the air since PVA fibres are not steady in the autoclave. Normally PVA fibres can't be refined whereas cellulose fibres can be. The mainly significant function of cellulose fibre in this procedure is aiding to structure the network on the sieve cylinders that catches the concrete particles in the dewatering step. This product has a high-quality biological toughness due to its elevated density and non-biological degradable PVA fibres. The vast drawback of these products is a very large augmentin substance and manufacturing procedure costs. At current, the price for cellulose is on £300 per tonne and PVA fibre is on £2500 per tonne (Evans 2002, P 125). In Australia, one of the mainly successful replacements for asbestos has been the use of unbleached cellulose fibres (usually Kraft fibres). Through cement (on 35%), and fine ground silica (about 55%) in the Hatcheck procedure. Some of the pertinent patents concerning this type of cement panel are Australian Patent No. 515151 along with U.S. Pat. No. 6,030,447. As the cellulose, fibre is steady in the autoclave, the majority of this type of product cures in the autoclave. Also, the European expertise uses augmented material and mechanised costs through their eminence and durability. Alongside ecological condition and biological attacks are further than the products that have been made of merely cellulose fibres lacking pressing step in fabrication line. It means cellulose fibre cement compound board may have a number of disadvantages due to absorbent and higher vulnerability to biological attacks. These are poorer rot resistance and poorer long-standing durability compared to the products that use PVA fibres and pressing step in manufacturing (Haigh 2005, P 67). Techniques of hatcheck procedure The slurry with cement that is discharged to the exterior of the revolving cylindrical dewatering sieve encompasses synthetic and natural reinforcing fibres. Mutually autoclaved and air-cured fibre toughened cement sheets can be produced according to the formula of the current discovery. Natural fibres are characteristically cellulose fibres, more possibly compound wood pulp. They are used as reinforcing and process fibres. Cellulose fibres created by the Kraft or sulphate procedure are predominantly preferred. Good results are obtained with bleached or unbleached roughage fibres from softwood or hardwood (Mukherjee 2011, P 106). Cellulose fibres characterised by a Kappa number in the array from 14 to 40, more predominantly in the range from 25 degrees to 30 degrees are especially preferred. While cellulose fibres refined to a °SR in the range from 35 to 70, more predominantly in the assortment from 40 to 65, are possibly used for the manufacture of air-cured fibre cement sheets. The second consist of preferably, except cellulose fibres, other reinforcing fibres, such as synthetic polymeric fibres. Examples of synthetic polymeric reinforcing fibres that can be used in air-cured fibre cement sheets are polypropylene, polyethene, polyvinyl alcohol and polyacrylonitrile. A number of monolayers can be superposed on the surface of the revolving cylindrical dewatering sieve. Every monolayer is corresponding to the discharge of the fibre cement slurry by a device with a slot shaped outlet (Haigh 2005, P 67). Prices of the sheets produced in AUD$ including the material of the sheets (Bunning’s Warehouse) Product Description Image Price (AUD) James Hardie 2400* 1200* 4.5mm 2.88sqm 23.14 BGC 2400*600*4.5mm Dura sheet FC Lining 11.07 BGC Durasheet 2400*1200*4.5mm Fibre cement Cladding 21.95 BGC 2400*450*4.5mm Durasheet FC Lining 8.31 James Hardie 1800*900*4.5mm 1.62sqm 14.31 BGC Duratex 2725*1200*7.55mm Fibre cement 36.69 BGC Duragroove 3000 x 1200 x 9mm Smooth Wide Fibre Cement Sheet 100 BGC Duraplank 4200 x 300 x 7.5mm Woodgrain Fibre Cement Weatherboard 21.88 BGC Durascape 2450 x 1200 x 9mm Fibre Cement Sheet 62.86 BGC Durascape 3000 x 1200 x 9mm Fibre Cement Sheet 76.96 BGC Nuline 4200 x 205 x 14mm Fibre Cement Bullnose Weatherboard 31.54 BGC Fibre Cement 2400 x 150 x 4.5mm Infill Durasheet 10.02 Fibre cement sheet 18mm thick x 1.2m wide x 2.4m long 100 Hatschek procedure and current construction materials production in Australia Australia, construction and building products, mean lightweight building frames that need lower embodied energy resources to sustain the building structures. This too means lighter concrete fundamentals and thinner gauge steel or wood sections to sustain the upper-storey structure. Australia building materials use an abridged amount of energy to move to the site and are much faster to inaugurate. In brief, Australia building, which can be achieved by using modern building products, it assists to attain a general smaller carbon trace. Just the correct size Minimizing and recycling ravage can have an important societal, financial and ecological benefits (Mukherjee 2011, P 106). With this intelligence, designers and installers ought to set a greater importance of choosing building equipment and product sizes that reduce waste. Abridged maintenance means you will need to paint less often, better environmental sustainability above the life of a structure. Durability, Some of the concealed factors that decide the true ecological effect of a creation is its serviceable life, preservation and discarding requirements. Australia construction products contain demonstrated durability trace. All products developed are exposed to excessive weather conditions they will encounter throughout their lifetime. Such as waterless to wet conditions, moist, warm and cold temperatures in order to assess their performance (Thukral 2006, P 157). The subsequent tests are carried out on Australia manufacturers' products of fibre cement products to test their long-term performance in real life situations. Water penetration – checking weather resistance of an exterior product Heat rain – checking the product performance in different dry or wet circumstances Soak dry – checking potency after protracted wetting Resistance to frost – checking for potency after introduction to freeze and thaw circumstances. Additionally, they are suitable where the Australia Building Code (Thukral 2006, P 159) requires non-combustible materials. This is predominantly pertinent when construction products are indispensable close to a margin. Frequently maintained, Australia manufacturer's products will not only meet the lowest durability requirements of ASBC, but will also meet the 50-year serviceable life obligation for a fibre cement building (Lang 2012, P 256). Absolute products made from these supplies have improved freeze-thaw resistance, abridged efflorescence, abridged suspension and re-deposition of water-soluble matrix apparatus in natural weathering. It is possible, with the right fibre placing, to improve other product properties, for instance, corrosion and blaze resistances, in comparison to usual fibre cement products. It has been established, startlingly, that these enhanced qualities are acquired without loss in dimensional firmness, potency, tension or toughness. Even more surprisingly, potency, tension and stiffness may even be improved with less cellulose being applied than conventional cellulose fibre cement composite materials (Kogel 2006, P 125). More principally in Australia, the applicant has established that by occupying, or partially filling the interior hollow places of cellulose fibres with unsolvable inorganic and organic materials. An engineered fibre can be created that, when applied to cement compounds, still has the benefits of regular cellulose fibres of refining, autoclaving, and manufacture without pressing. However, the resultant fibre cement material also approaches or exceeds the performance advantages of artificial fibres such as PVA. What is more astonishing is that fewer quantities of fibres may be used, so that the cost of loading or partially loading the fibre can be offset by the lower usage of the fibre in products. This is Without a reduction in the important physical properties of the material, such as potency and toughness (Lang 2012, P 256). Specifically, certain favoured epitomes demonstrate that when used as a part of details regular of autoclaved cellulose-based fibre bond. The rate of water ingestion and the measure of water assimilation are incredibly abbreviated in the compound item. Hence diminishing the propensity to efflorescence, or to restore mixes inside the item (Krause 2007, P 125). The strands may be refined to go about as a catch medium in the Hatschek technique, they may be autoclaved without extreme fibre degradation, and they make items satisfactory in intensity without squeezing. Also, most surprisingly, even with lower measures of real cellulose fibre, the favoured exemplifications encounter no diminishment in key physical properties. For example, strength, solidness, sturdiness and movement of moisture, and may, indeed, enhance some of these properties, particularly durability (Ward Harvey 2009, P 66). Hence, the application of designed stacked strands bestows to the compound material these upgraded properties and accordingly constitutes an enhanced innovation. When completely executed, it can enhance mechanical properties and the workability of the material in building and development. While enhancing the solidness of the items in different situations including particularly those that include cyclic wetting and drying, fire. It also plays a part in solidifying and defrosting, and presentation to the environment, paying little heed to the method for production. They are especially suitable for the Hatschek method that obliges a refinable fibre and to the autoclave curing cycle. This permits the supplanting of concrete with fine ground silica. This is in spite of the fact that they might be useful noticeable all around cured items, in conjunction with PVA, to lessen the need for the costly strategy (Arratia 2003, P 98) Appropriately, the favoured embodiments of the present creation identify with another innovation of making fibre fortified concrete compound materials using stacked cellulose strands. This innovation incorporates details, fabricating procedures and last compound materials. These embodiments will lessen water penetrability, water retention, efflorescence, inner water disintegration and re-deposition of materials, and enhance toughness in freeze-thaw weathering situations (Arratia 2003, P 98). These can be completed while keeping up or enhancing key mechanical and physical properties, particularly sturdiness, surprisingly with less cellulose fibre than would be utilised as a part of the typical cellulose fibre bond. In addition, this innovation is likewise useful for taking care of one of the key issues of air-cured PVA fortified fibre bond. This is by wiping out the requirement for the costly system of hydraulic pressing of the shaped "green" body, to smash the cellulose strands and decrease water penetrability in completed products. In one feature of the current invention, a compound building substance is provided consisting cement containing medium and individualised cellulose fibres integrated into the cement containing medium. The cellulose fibres encompass voids that are at least partly filled with loading substances that restrain water from flowing through (Ward Harvey 2009, P 66). In another part of the present innovation, a material detailing used to frame a compound building material embodies a cement containing binding and cellulose filaments. Where the cellulose strands have been individualized and where at any rate a portion of the cellulose filaments are stacked with insoluble substances to repress water movement through the filaments. In one epitome, the building material detailing ideally contains around 10%-80% bond, around 20%-80% silica (total). Around 0%-50% thickness modifiers, around 0%-10% added substances, and around 0.5%-20% stacked individualized cellulose strands or a mix of stacked cellulose filaments. In addition, standard emptied filaments, and regular inorganic filaments, and engineered filaments. The materials from these plans can be autoclave cured or air-cured (Castle man 2004, P 43) In another exemplification, a building material definition is accommodated and not pressed, autoclaved, fibre concrete item. This plan embodies around 20-50% bond, all the more ideally around 35%, around 20-80% fine ground silica, even more ideally around 55%. Moreover, around 0-30% different added substances and thickness modifiers may be incorporated in the definition. The definition ideally incorporates around 0.5-20% strands, all the more ideally around 10% filaments. In which some division of the filaments is individualized cellulose filaments stacked with inorganic and natural materials that decrease water stream in the fibre pore space (Barker 2005, P 76) Retailers who deal in Hatschek machines and their specifications in Australia include Product Retailers Specifications 200 Hatschek Fibre Cement/Calcium Silicate Board Sheeting Machine James Hardie Automatic, Semi-automatic and manual Fibre Cement Sheeting Colour: Black Fibre Cement sheeting Machine Size: 3000 sqm work shop Brand: Australian Fibre Cement Board sheeting Machine strength: High quality 4 vats (flow -on) hatschek-Fibre cement board making machine BGM company 4 vats(flow -on) hatschek-Fibre cement board making machine  1.asbests free  2.use widely  3.high achieve  4.high quality  4 vats(flow -on) hatschek-Fibre cement board making machine Specification:   slab length:              1500mm-5000mm width:                900mm-1500mm JHJ Jaw Crusher CSR company Model Capacity(t/h) Power (kW) Machine Size(mm) (mm) HJ98 110-350 90-110 2470×2000×2180 HJ110 215-510 110-132 2875×2472×2530 Fibre Cement Board Machine Penny World Pty Ltd Brand Name: Fibre Cement Board Production line Model Number: Fibre Cement Board Machine Fibre Cement Production Line: European Standard Fibre Cement Board Steel: Clean Steel Fibre Cement Board Size: from 2400 mm to 3000 mm Fibre Cement Board Width: 600 mm to 1200 mm Fibre Cement Board Thickness: 4 mm to 18 mm Fibre Cement Board density: 1100 Kg m3 to 1600 kg m3 Fibre Cement Board Colour: Gray Fibre Cement Board Machine Size: 4000 sqm work shop Brand: Australian Fibre Cement Board Machine strength: High quality References TORGAL, F. 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R., & KLEIST, C. (2007). Fibre cement - technology and design. Basel, Birkhäuser. KALIA, S., KAITH, B. S., & INDERJEET KAUR. (2011). Cellulose fibres bio- and nano-polymer composites; green chemistry and technology. Berlin, Springer. http://public.eblib.com/choice/publicfullrecord.aspx?p=763222. Read More