IOP Con e ence Se ies: Ma e ials Science and Enginee ing
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Me hods o es ing he p ope ies o ib e-cemen
composi es
To ci e his a icle: L Bodna o a e al 2018 IOP Con . Se .: Ma e . Sci. Eng. 385 012005
View he a icle online o upda es and enhancemen s.
Rela ed con en
Delamina ion ini ia ed by a de ec
A Biel and H To egaa d
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In luence o ca bona ion and eeze- haw
on mac o-p ope ies o conc e e
M J Rao, Y Dong, H Q Yang e al.
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Subs an ia ion o Re e ence Me hod Fo
De e mining Conc e e's F eeze-Thaw
Resis ance
S Nikolskiy and O Pe se a
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Me hods o es ing he p ope ies o ib e-cemen composi es
L Bodna o a1, M Hosko2 and P Ma inec2
1 Ins i u e o Technology o Building Ma e ials and Componen s, Facul y o Ci il Enginee ing,
B no Uni e si y o Technology, Ve e i 95, 602 00 B no, Czech Republic
2 Cemb i a.s., Plan Sumpe k, P icna 26, 787 55 Sumpe k, Czech Republic
Abs ac . The pape deals wi h p ocess o manu ac u ing he ib e-cemen ma e ials and
me hods o es ing hei clima ic pe o mance. Basic aw ma e ials o p oduc ion ib e-cemen
shee s a e cemen , cellulose ibe s, ein o cing ibe s - poly inyl alcohol (PVA) ibe s, ille ,
addi i es and wa e . P oduc ion ollows he modi ied Ha schek's echnology. The pape
desc ibed he mos impo an es s o clima ic pe o mance: F eeze- haw es and Hea ain
es . The ib e-cemen p o iled shee s we e es ed. The F eeze- haw es includes assessmen o
os esis ance, p ecipi a ed sal s e lo escence on he ace-side su ace, peeling o he coa ing
on he edges, peeling o he coa ing on he ace-side su ace, longi udinal c acks in he a ious
loca ions on he ace-side, ans e se c acks in he a ious loca ions on he ace-side, shape
de o ma ion, swelling wa e be ween he laye s o coa ing and ma e ial delamina ion on he
edges. The os esis ance RL o ib e-cemen p o iled shee s a e 100 eeze- haw cycles
was 0.95, when min. RL = 0.70. The ib e-cemen p o iled shee s we e es ed o 50 hea - ain
cycles. A e 50 cycles, he samples we e checked o c acking (longi udinal, ans e se and a
he ixing poin s), delamina ion and o he isible de ec s (especially he p esence o o med
d ops on he unde side o co uga ed shee s). The es ed modi ied ecipe o ib e-cemen
p o iled shee me he Hea ain es equi emen s.
1. In oduc ion
Asbes os cemen p oduc s ha e been p oduced in Bohemia and Mo a ia since 1910. Own pa en o
he p oduc ion o his co e ing was iled by Ludwig Ha schek in 1901. Ludwik Ha schek himsel
called he p oduc s "E e ni ", meaning "e e las ing". The co e ing me wi h g ea success ela i ely
quickly, because i was ligh and i was possible o use i e en in ha sh clima es, whe e i was no
possible o use bu n oo ing. Asbes os was used o p oduce hese shee s un il he nine ies. Asbes os
ibe s ha e been epo ed as ha m ul o heal h, he e o e asbes os has been eplaced by cellulose
ibe s, syn he ic ibe s and o he addi i es. This has esul ed in c ea ion o an ecologically clean
p oduc . Since 1996 asbes os-cemen echnology has been being eplaced by ib e-cemen echnology
- no asbes os [1].
2. Composi ion o ib e-cemen composi es
Basic aw ma e ials o p oduc ion ib e-cemen shee s a e cemen , cellulose, ein o cing ibe s, ille ,
addi i es and wa e . P oduc ion ollows he modi ied Ha schek's echnology.
2.1. Cemen
As he name sugges s, he main aw ma e ial is cemen . Choosing he kind o cemen depends on he
ype o inal p oduc , on he cu ing p ocess, on manu ac u ing acili ies, and in some cases on wa e
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IOP Con . Se ies: Ma e ials Science and Enginee ing 385 (2018) 012005 doi:10.1088/1757-899X/385/1/012005
empe a u e. A ailabili y and economical aspec bo h also play impo an oles in choosing he ype o
cemen . P ope ies impo an when choosing ype o cemen :
• De elopmen o hyd a ion hea
• Beginning and he end o he cemen ha dening
• Pa icle size (Blaine)
• Final s eng h p ope ies.
2.2. Cellulose ibe s
Cellulose ibe s a e used as p ocedu al ibe s. These ibe s abso b cemen and o he addi i es on he
su ace. Fo he p oduc ion o ib e-cemen shee s 2 ypes o cellulosic ibe s a e used. Bleached o
unbleached pine ibe s and sulpha e ibe s - high pe o mance ibe s. When ib e-cemen shee s a e
manu ac u ed, he dis ibu ion o cellulose ibe s in wa e is impo an . This di ision is usually
pe o med in he pulpe du ing he pulping con olled ime. P ope ies o he pulp ibe s a e molded in
he disc mills. The e he speci ic su ace ibe s and he echnological pa ame e s o he p ocedu al
ibe s a e imp o ed. When modi ying he p ope ies o he pulp ibe s, he ibe s a e la ge , ibe s a e
mo e lexible and ibe s ha e la ge ex e nal su ace a ea o he ibe . Ex e nal s uc u e o ibe s
becomes b oken and he ibe su ace becomes hai y [1,2].
2.3. Poly inyl alcohol ibe s
Poly inyl alcohol ibe s (PVA) a e used as ein o cing ibe s. When using he PVA ibe s in a
conc e e o cemen composi es se e al ad an ages o e compe ing ibe s o o he ma e ials can be
obse ed. PVA ibe s ha e high ensile s eng h, ela i ely high modulus o elas ici y, good chemical
compa ibili y wi h Po land cemen , a good a ini y wi h wa e and PVA ibe s a e wi hou any heal h
isks [3]. PVA ibe o a hickness o 0.014 mm wi h a ensile s eng h o 1600 MPa, modulus o
elas ici y 37 GPa and possible elonga ion o 7% a e used o ib e-cemen p oduc s. G owing conce n
abou he dange s o asbes os inhala ion b ough he PVA ibe s in o he limeligh as a subs i u e o
asbes os ibe s. S udies show ha PVA ibe s ep esen less isk han ch yso ile ibe s because hey a e
oo big o b ea he in. PVA ibe s do no cause any issue eac ions [4].
2.4. Fille s
The mos commonly used ille s in he p oduc ion o ib e-cemen shee s a e mic o silica (speci ic
su ace a ea o 15000 - 35000 m2/kg), g ound limes one (speci ic su ace a ea 300-400 m2/kg) o
ano he sui able mic onized ille . [1] Besides applica ions o mic opa icles a e es ed nanopa icles
wi h he use o in cemen composi es wi h cellulose ibe s o in luence he p ope ies o he cemen
composi es [5]. The cha below shows he p opo ional ep esen a ion o he a ious componen s o
ib e-cemen composi es.
Figu e 1. The p opo ional ep esen a ion o he a ious componen s o ib e-cemen composi es.
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3. Technology o p oduc ion ib e-cemen composi es
The modi ied Ha schek's echnology is used o he p oduc ion o ib e-cemen shee s. Ha schek
machine o he p oduc ion o ib e-cemen was i s de eloped in 1890 and i was logged on a he
pa en o ice by Ludwig Ha schek. The machine has been used in he same basic o m ill oday,
hough mode n Ha schek machines a e much mo e p oduc i e, han he models a he s a o he
p oduc ion. Ha schek p ocess is pa icula ly sui able o making la and p o iled shee s. This p ocess
is he p ocess o il e ing based on he d ainage o he suspension o dilu ed h ough he cylind ical
sie e. Thus, he p ima y laye consis ing o ibe s, cemen , addi i es and ille s is sepa a ed on he
sie e, and his laye is ans e ed o he endless il e ca pe [6].
The ib ous componen is mixed wi h cemen and o he addi i es in a u bomixe . F om he e i
goes in o he homogenize whe e i egula es he densi y o he slu y. The suspension is anspo ed
in o he p oduc ion machine a s. In he a s, he e a e o a ing sie es cylinde s ha ans e he ibe
cemen on a con inuous laye . I is e y impo an o main ain he cons an and igh le el o
suspension in he a . I he le el o he slu y mo es, i could a ec he hickness o each laye , and
hus he inal p oduc . The Ha schek p oduc ion machine has no mally 3 o 4 manu ac u ing a s and
con ibu ion o each a is abou 0.3 mm. The indi idual laye s a e piled on he o ma olle , un il he
desi ed hickness o he p oduc is eached.
The size o he holes on he sie e eaches alues a ound 0.4 mm (400 mic ons) and a non- ib ous
componen used in he p oduc ion a e much smalle han he hole o he sie e, and ha could cause
hei passage. Cap u ing he non- ib ous ma e ial he e o e depends on he o ma ion o he il a ion
laye o ibe s on he su ace o he sie e. Fil e laye o ibe s is c ea ed on he su ace o he sie e a
a sho dis ance om he imme sion o sie e, which is imme sed in o he suspension. Fo ma ion o he
ilm con inues on he sie e, bu now i con ains a lowe p opo ion o he ibe s and a highe
p opo ion o non- ib ous ma e ials. Subsequen ly, he ilm is dewa e ed and i is emo ed om he
sie e by plo ing on a con inuous bel . Main d ainage is pe o med by means o acuum chambe s,
which a e disposed on he uppe side o he s ip be ween he las p oduc ion a and a o ma cylinde .
A acuum chambe wi h a la ge amoun o wa e is used o clean he bel .
The ib e-cemen laye is ans e ed on he con inuous bel and he bel is ans e ed on a o ma
olle . A e winding he desi ed hickness he ma e ial is cu and mo es on he ow able. Winding he
desi ed hickness o ma e ial on he o ma olle a ies by p oduc ange in he ange o 5-7 mm.
Fib e-cemen ma e ial is cu o desi ed dimensions by s eel disks, o he e is cu ing shapes, including
holes and edges on he cu ing p ess. All he pa ings, which ep esen app oxima ely 10-20 % o o al
p oduc ion, go o he dissol e and a e eused in he p oduc ion. The cu ing ma e ial is ans e ed o
he co uga o head, whe e i is o med o he co uga ed oo ing.
The indi idual shee s a e loca ed on he s eel empla es which a e placed on ca iages. The
ca iages a e anspo ed o p e-hea ing unnel whe e hey a e hyd a ed o e a pe iod o 8-10 hou s a
abou 60 °C. The s eel empla es a e pa ly hea ed o p e en he low o hea om he shee s du ing
cu e and achie e he equi ed handling s eng h. Then he indi idual shee s a e sepa a ed om he
s eel empla e and a e s acked on wooden palle s. Each empla e is hen b ushed and sp ayed wi h a
hin laye o mine al oil in he oil machine. Applica ion o oil ensu es good sepa a ion o he s eel
pla es and ib e-cemen shee s a e cu ing. A e 10 hou s, he shee s a e mo ed on he wooden palle s
and he palle s a e anspo ed in o he ipening wa ehouse whe e he shee s unde con olled
condi ions ob ain inal p ope ies. Time o s o ing pla es in he ipening wa ehouse is a leas 7 days
[1].
4. Me hods o es ing he p ope ies o ib e-cemen composi es
Fib e-cemen is an ideal building ma e ial o p o ec ing he ex e nal shell o he building and i is used
o oo ing and acade cladding on new buildings and eno a ions. Today's ib e-cemen co e ing is
al eady incompa able wi h he one ha was p oduced 30 o 40 yea s ago, he en i onmen ally neu al
aw ma e ial such as cemen , wa e , g ound limes one, mic osilica, cellulose and syn he ic ibe s a e
used o p oduce ib e-cemen oo ing ma e ials. Combining hese ma e ials makes i possible o o m a
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non-combus ible building ma e ial which is sui able o any ype o building. Fib e-cemen ma e ial
combines he echnical p ope ies such as s eng h, du abili y, and wea he esis ance, easy
wo kabili y, e iciency and en i onmen al sa e y. I is esis an o wa e , os , o , co osion, and can
be p ocessed by con en ional ools on he cons uc ion si e [1].
The ollowing ex exp esses he mos impo an es s (F eeze- haw es and Hea ain es ) o
clima ic pe o mance. Du ing a p oposal o new o modi ied ecipe mus be e i ied he impac o
changes in he ecipe on he inal p ope ies o ib e-cemen shee s.
4.1. F eeze- haw es (EN 494+A1 Fib e-cemen p o iled shee s and i ings - P oduc speci ica ion
and es me hods)
The specimens we e longi udinally cu om he middle o a comple e shee , wi h wo comple e
co uga ions. Twen y specimens we e es ed. Specimens we e ans e sely cu o a leng h allowing a
span o 12 imes he heigh o co uga ion.
The specimens we e di ided a andom in o wo lo s o 10. The i s lo o 10 specimens was es ed
on he b eaking load es (o o he bending momen es o sho shee s). A he same ime, he
second lo o specimens was imme sed in wa e a ambien empe a u e (> 5 °C) o 48 hou s. Then
he second lo o specimens was subjec ed o 100 eeze- haw cycles:
 cooling ( eeze) in he eeze which each a empe a u e o (-20 ± 4) °C wi hin 1 hou o 2
hou and holding his empe a u e o a u he 1 hou
 hea ing ( hawing) in he wa e ba h which each a empe a u e o (20 ± 4) °C wi hin 1 hou o
2 hou and holding a his empe a u e o a u he 1hou .
Then he b eaking load es (o o he bending momen es o sho shee s) was done. The
ollowing igu e 2 and igu e 3 show he esul s o eeze- haw es o he ib e-cemen p o iled shee s.
Figu e 2. Sample o ib e-cemen p o iled shee
be o e eeze- haw es .
Figu e 3. Sample o ib e-cemen p o iled shee
a e 100 cycles o eeze- haw.
Fo each o he wo lo s, he mean b eaking load o bending momen and he s anda d de ia ion a
he alue was calcula e. F om hese alues is subsequen ly de e mined RL a io (see equa ion (1) –
(3)). The a ion RL shall be no less han 0.70 a e 100 eeze- haw cycles [7]:
L2= X2− (0,58 × s2) (1)
Which is he lowe es ima ion o he mean b eaking load o bending momen a e eeze- haw
cycles a 95 % con idence le el (second lo ):
L1= X1+ (0,58 × s1) (2)
Which is he uppe es ima ion o he mean b eaking load o bending momen a 95 % con idence
le el o he e e ence lo ( i s lo ):
RL=L2
L1 (3)
The RL a io o ib e-cemen p o iled shee s (Cemb i , ype A5, A6.5, A6, B7, B8) is min. 0.70
a e 100 eeze- haw cycles [1]. To e alua e he es o os esis ance is no only RL a io bu also
he assessmen o ollowing p ope ies: P ecipi a ed sal s e lo escence on he ace-side su ace,
peeling o he coa ing – on he edges, peeling o he coa ing – on he ace-side su ace, longi udinal
c acks – in he a ious loca ions on he ace-side, ans e se c acks – in he a ious loca ions on he
ace-side, shape de o ma ion, swelling - wa e be ween he laye s o coa ing and ma e ial,

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delamina ion - on he edges [7]. The esul s o eeze- haw es a e o modi ied ecipe shown in he
able 1. Table 1. The esul s o he eeze- haw es o modi ied ecipe.
Re e ence
100 eeze- haw cycles
∆ b eaking load
(kN/m)
4.77
4.74
L1
4.82
-
L2
-
4.62
RL a io
0.95
Toge he wi h he assessmen o os esis ance (RL) on he samples he peeling o pain on edges
was assessed as i shown on he igu e 2 and igu e 3. In his es , he e shall be no c acks on he pain
leading o subsequen peeling o he su ace ea men . The occu ence o e lo escence on he sample
a e 100 cycles is no a majo p oblem because he main objec i e is o e i y he du abili y o he
su ace ea men .
4.2. Hea ain (acco ding o EN 494+A1 Fib e-cemen p o iled shee s and i ings - P oduc
speci ica ion and es me hods)
The specimens shall comp ise a minimum o one ull sized shee wi h he unde lapping and
o e lapping shee s/s ips su ounding i a minimum o ½ sized shee s. 12 specimens o shee s o
leng h equal o o less han 0.9 m o 9 specimens o longe shee s we e es ed. The specimens we e
s o ed o 7 days in a labo a o y a mosphe e. Each shee we e laid wi h o e laps a he ou edges. The
specimens we e ixed on he ame acco ding o egula ions o , i no egula ions exis , o
manu ac u e ’s ins uc ions. One ins alla ion sys em, which he manu ac u e ega ds as decisi e o
he shee s, shall be selec ed. The uppe ace o he shee s was es ed o 50 cycles wi hou in e up ion
in acco dance wi h able 2. Any isible c acks, delamina ion o o he de ec s in he ib e-cemen shee s
shall no be o such deg ee as o a ec hei pe o mance in use a e 50 hea - ain cycles [7].
Table 2. Hea - ain cycle
Cycles
Du a ion
We ing 2.5
l/(m2.min)
2 h 50 min
Pause
10 min
Hea ing (70 ± 50C)
2 h 50 min
Pause
10 min
To al cycle
6 h
The igu e 4 shows he compa ison o esul s o hea - ain es o he ib e-cemen p o iled shee s
a e 4 cycles. On he le in blue bo de is modi ied ecipe and on he igh in ed bo de is s anda d
ecipe. On he sample wi h modi ied ecipe we can see he longi udinal and ans e se mic oc acks,
esul ing in as e mois u e pene a ion. F om he igu e 4 he e is a clea di e ence in he a e o
de elopmen o mois u e aces. The e o e, i is impo an o assess no only he inal esul s bu also
con inuous esul s o indi idual samples. The p esence o we aces on samples is no a eason o
non-compliance, bu in no case shouldn' be o med d ops on he unde side o co uga ed shee s. A e
50 cycles, he samples a e checked o c acking (longi udinal, ans e se and a he ixing poin s),
delamina ion and o he isible de ec s [1].
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Du ing he 1s cycle: 75 minu es o sp inkling seq. – Fi s occu ence o mois u e aces on he le sample
( hickness 6.5 mm) mos p obably due o he loose sc ew (s ill no p oblem o he ib e-cemen ma e ial)
Du ing he 2nd cycle: Fi s occu ence o wa e soaked h ough ma e ial on he le sample (longi udinal c acks),
big spo is commen ed in he p e ious pic u e
Du ing he 4 h cycle: Fi s occu ence o ans e se c acks on he le sample (wi h combina ion o longi udinal
c acks also)
Figu e 4. The compa ison o he esul s o s anda d (le blue bo de ) and modi ied ( igh ed bo de )
ecipes a e 4 cycles.
5. Conclusion
Fib e-cemen p oduc s mus mee he high du abili y, aes he ic and u ili y equi emen s. To ul ill all
hese equi emen s, i is necessa y o use in he p oduc ion o ib e-cemen shee s sui able ma e ials,
which mus mee he s ic quali y equi emen s. Fib e-cemen p oduc s a e made exclusi ely om
na u al ma e ials en i onmen ally iendly. Using pu ely na u al ma e ials, he p oduc s a e ully
ecyclable (e.g. use in comminu ed s a e as an admix u e in conc e e, o use as pe manen o mwo k),
and in line wi h he end o sus ainable de elopmen . F om he iewpoin o achie ing he igh
du abili y o hese p oduc s is a key pa ame e he igh echnological p ocess o p oduc ion. The
pe ec manu ac u ing echnology is impo an o s eng h and du abili y o ib e-cemen shee s when
hin laye s o ib e-cemen a e w apping hemsel es and be o e inal ma u a ion a e exposed unde
in ense p essu e in he p ess. G ea - alue is he es ing he p ope ies o he ibe -cemen shee . We can
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IOP Con . Se ies: Ma e ials Science and Enginee ing 385 (2018) 012005 doi:10.1088/1757-899X/385/1/012005
assume he du abili y o hese ma e ials om he esul s o wa e abso p ion es s, eeze- haw es and
hea - ain es s. The combina ion o es s allows us o deduce u he ea u es such as esis ance o ain
and esis ance o lowing luids. To achie e he high and s able quali y o ibe cemen p oduc s, he
echnological p ocess o p oduc ion mus be ca e ully obse ed. The quali y o ibe cemen i ious
ma e ial can be in luenced by bo h he a iabili y o eeds ocks and he changes in cu e and aging.
Consis en con ol o key s ages o p oduc ion con ibu es o non-p oblem p oduc ion p ocess and
quali y o p oduced shee s.
Acknowledgemen s
This ou come has been achie ed wi h he inancial suppo o P ojec FAST-S-18-5410, suppo ed by
B no Uni e si y o Technology, and p ojec GACR 18-25035S S udy o e ec s o lowing luids on
cemen composi es wea and subsequen modelling o mechanical co osion, suppo ed by Czech
Science Founda ion.
Re e ences
[1] In e nal ma e ials p o ided by Cemb i 2018 h ps://www.cemb i .com/ (online)
[2] Bodna o a L, Kos elanská K, Jankech J 2014 Ad anced Ma e ials Resea ch 1054 85 - 89
[3] Noushini A, Samali B, Vessala K 2013 Cons . Build. Ma e . 49 374-383
[4] Ho ikoshi T, Ogawa A, Sai o T, Hoshi o H 2006 P ope ies o poly inylalcohol ibe as
ein o cing ma e ials o cemen i ious composi es In . Wo kshop on High Pe o mance Fibe
Rein o ced Cemen i ious Composi es in S uc u al Applica ions (Pa is: RILEM Publica ions)
pp 145 - 153
[5] San os S F, Rod igues J A, Denzin T, Gus a o H, e al. 2014 J. Ma . Sci. 49 7497-7506
[6] Cooke T 2002 P oc. In . Con . on Ino ganic-bonded wood and ibe composi e ma e ials (Sun
Valley) (Madison: Fo es P oduc s Resea ch Socie y) pp 231-246
[7] EN 494+A1: 2016 Fib e-cemen p o iled shee s and i ings - P oduc speci ica ion and es
me hods