High performance non-combustible gypsum-cement compositions with enhanced water durability and thermal stability for reinforced cementitious lightweight structural cement panels
First Claim
1. A non-combustible, fire resistant lightweight reinforced cementitious panel for resisting transverse and shear diaphragm loads having improved water durability and greater resistance to thermal transmission comprising:
- a continuous phase resulting from the curing of an aqueous mixture of;
a cementitious composition comprising, on a dry basis,50 to 95 wt % reactive powder,1 to 20 wt % of coated hydrophobic expanded perlite particles uniformly distributed as lightweight filler in said continuous phase, the coated hydrophobic perlite particles having a diameter in the range of about 1 to 500 microns (micrometers), a median diameter of 20 to 150 microns (micrometers) and an effective particle density (specific gravity) of less than about 0.50 g/cc,0 to 25 wt % hollow ceramic microspheres, and3 to 16 wt. % alkali-resistant glass fibers for uniformly reinforcing the continuous phase;
wherein said reactive powder comprises;
25 to 75 wt. % calcium sulfate alpha hemihydrate,10 to 75 wt. % hydraulic cement comprising Portland cement,0 to 3.5 wt. % lime, and5 to 30 wt. % of an active pozzolan; and
the panel having a density of 50 to 100 pounds per cubic foot.
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Accused Products
Abstract
Structural cement panel for resisting transverse and shear loads equal to transverse and shear loads provided by plywood and oriented strain board, when fastened to framing for use in shear walls, flooring and roofing systems. The panels provide reduced thermal transmission compared to other structural cement panels. The panels employ one or more layers of a continuous phase resulting from curing an aqueous mixture of calcium sulfate alpha hemihydrate, hydraulic cement, coated expanded perlite particles filler, optional additional fillers, active pozzolan and lime. The coated perlite has a particle size of 1-500 microns, a median diameter of 20-150 microns, and an effective particle density (specific gravity) of less than 0.50 g/cc. The panels are reinforced with fibers, for example alkali-resistant glass fibers. The preferred panel contains no intentionally added entrained air. A method of improving fire resistance in a building is also disclosed.
148 Citations
20 Claims
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1. A non-combustible, fire resistant lightweight reinforced cementitious panel for resisting transverse and shear diaphragm loads having improved water durability and greater resistance to thermal transmission comprising:
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a continuous phase resulting from the curing of an aqueous mixture of; a cementitious composition comprising, on a dry basis, 50 to 95 wt % reactive powder, 1 to 20 wt % of coated hydrophobic expanded perlite particles uniformly distributed as lightweight filler in said continuous phase, the coated hydrophobic perlite particles having a diameter in the range of about 1 to 500 microns (micrometers), a median diameter of 20 to 150 microns (micrometers) and an effective particle density (specific gravity) of less than about 0.50 g/cc, 0 to 25 wt % hollow ceramic microspheres, and 3 to 16 wt. % alkali-resistant glass fibers for uniformly reinforcing the continuous phase; wherein said reactive powder comprises; 25 to 75 wt. % calcium sulfate alpha hemihydrate, 10 to 75 wt. % hydraulic cement comprising Portland cement, 0 to 3.5 wt. % lime, and 5 to 30 wt. % of an active pozzolan; and the panel having a density of 50 to 100 pounds per cubic foot. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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20. A method for providing improved fire resistance for a shear diaphragm in a building by improving resistance to thermal transmission of a structural cement panel in a building structure comprising applying a first non-combustible, fire resistant lightweight reinforced cementitious panel for resisting transverse and shear diaphragm loads having improved water durability and greater resistance to thermal transmission, to a metal framing element for use as a shear diaphragm in shear bearing wall systems, flooring systems and/or roofing system in said building,
the first panel comprising: -
a continuous phase resulting from the curing of an aqueous mixture of; a cementitious composition comprising, on a dry basis, 50 to 95 wt % reactive powder, 1 to 20 wt % of coated hydrophobic expanded perlite particles uniformly distributed as lightweight filler in said continuous phase, the coated hydrophobic perlite particles having a diameter in the range of about 1 to 500 microns (micrometers), a median diameter of 20 to 150 microns (micrometers) and an effective particle density (specific gravity) of less than about 0.50 g/cc, 0 to 25 wt % hollow ceramic microspheres, and 3 to 16 wt. % alkali-resistant glass fibers for uniformly reinforcing the continuous phase; wherein said reactive powder comprises; 25 to 75 wt. % calcium sulfate alpha hemihydrate, 10 to 75 wt. % hydraulic cement comprising Portland cement, 0 to 3.5 wt. % lime, and 5 to 30 wt. % of an active pozzolan; and the first panel having a density of 50 to 100 pounds per cubic foot; wherein a time for thermal transmission in the first panel is delayed by about 10% % to 40% compared to a time for thermal transmission in a second panel having the same composition as the first panel except for comprising ceramic microspheres instead of coated hydrophobic expanded perlite particles.
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Specification