Eternit is a registered trademark for a brand of fibre cement currently owned by the Belgian company Etex . Fibre is often applied in building and construction materials , mainly in roofing and facade products.
55-591: The term " cement " originates from the Latin word " Caementum ", which signifies chopped stone. Cement describes a binding substance, which will react chemically with water and develop into a material as hard as stone. In fibre cement, there is a fibre reinforcement , which contributes to making the fibre-cement material even stronger and to better withstand tension . Together with a carefully planned production process, fibre cement makes it possible to develop strong and long-lasting construction materials. Today fibre cement
110-554: A chemical reaction between the dry ingredients and water. The chemical reaction results in mineral hydrates that are not very water-soluble. This allows setting in wet conditions or under water and further protects the hardened material from chemical attack. The chemical process for hydraulic cement was found by ancient Romans who used volcanic ash ( pozzolana ) with added lime (calcium oxide). Non-hydraulic cement (less common) does not set in wet conditions or under water. Rather, it sets as it dries and reacts with carbon dioxide in
165-558: A mortar made of sand and roughly burnt gypsum (CaSO 4 · 2H 2 O), which is plaster of Paris, which often contained calcium carbonate (CaCO 3 ), Lime (calcium oxide) was used on Crete and by the Ancient Greeks . There is evidence that the Minoans of Crete used crushed potsherds as an artificial pozzolan for hydraulic cement. Nobody knows who first discovered that a combination of hydrated non-hydraulic lime and
220-401: A controlled bond with masonry blocks. Expansive cements contain, in addition to Portland clinker, expansive clinkers (usually sulfoaluminate clinkers), and are designed to offset the effects of drying shrinkage normally encountered in hydraulic cements. This cement can make concrete for floor slabs (up to 60 m square) without contraction joints. Inorganic An inorganic compound
275-432: A fine powder. This product, made into a mortar with sand, set in 5–15 minutes. The success of "Roman cement" led other manufacturers to develop rival products by burning artificial hydraulic lime cements of clay and chalk . Roman cement quickly became popular but was largely replaced by Portland cement in the 1850s. Apparently unaware of Smeaton's work, the same principle was identified by Frenchman Louis Vicat in
330-461: A form of lung cancer , years after professional or occasional exposure ( asbestosis ). Starting from the seventies, asbestos use became progressively prohibited; however, in several countries, it is still used for building materials. Safer fibre alternatives, based on e.g. cellulose fibers were developed in the eighties and applied to secure the widely known strength of fibre cement. In countries where asbestos use has been phased out, fibre cement
385-432: A form of hydraulic cement, is by far the most common type of cement in general use around the world. This cement is made by heating limestone (calcium carbonate) with other materials (such as clay ) to 1,450 °C (2,640 °F) in a kiln , in a process known as calcination that liberates a molecule of carbon dioxide from the calcium carbonate to form calcium oxide , or quicklime, which then chemically combines with
440-678: A half-century. Technologies of waste cementation have been developed and deployed at industrial scale in many countries. Cementitious wasteforms require a careful selection and design process adapted to each specific type of waste to satisfy the strict waste acceptance criteria for long-term storage and disposal. Modern development of hydraulic cement began with the start of the Industrial Revolution (around 1800), driven by three main needs: Modern cements are often Portland cement or Portland cement blends, but other cement blends are used in some industrial settings. Portland cement,
495-787: A market for use in concrete. The use of concrete in construction grew rapidly from 1850 onward, and was soon the dominant use for cements. Thus Portland cement began its predominant role. Isaac Charles Johnson further refined the production of meso-Portland cement (middle stage of development) and claimed he was the real father of Portland cement. Setting time and "early strength" are important characteristics of cements. Hydraulic limes, "natural" cements, and "artificial" cements all rely on their belite (2 CaO · SiO 2 , abbreviated as C 2 S) content for strength development. Belite develops strength slowly. Because they were burned at temperatures below 1,250 °C (2,280 °F), they contained no alite (3 CaO · SiO 2 , abbreviated as C 3 S), which
550-413: A month for Rosendale cement made it unpopular for constructing highways and bridges, and many states and construction firms turned to Portland cement. Because of the switch to Portland cement, by the end of the 1920s only one of the 15 Rosendale cement companies had survived. But in the early 1930s, builders discovered that, while Portland cement set faster, it was not as durable, especially for highways—to
605-695: A pozzolan produces a hydraulic mixture (see also: Pozzolanic reaction ), but such concrete was used by the Greeks, specifically the Ancient Macedonians , and three centuries later on a large scale by Roman engineers . There is... a kind of powder which from natural causes produces astonishing results. It is found in the neighborhood of Baiae and in the country belonging to the towns round about Mount Vesuvius . This substance when mixed with lime and rubble not only lends strength to buildings of other kinds but even when piers of it are constructed in
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#1732790491784660-741: A very advanced civilisation in El Tajin near Mexico City, in Mexico. A detailed study of the composition of the aggregate and binder show that the aggregate was pumice and the binder was a pozzolanic cement made with volcanic ash and lime. Any preservation of this knowledge in literature from the Middle Ages is unknown, but medieval masons and some military engineers actively used hydraulic cement in structures such as canals , fortresses, harbors , and shipbuilding facilities . A mixture of lime mortar and aggregate with brick or stone facing material
715-422: Is hydraulic cement , which hardens by hydration of the clinker minerals when water is added. Hydraulic cements (such as Portland cement) are made of a mixture of silicates and oxides, the four main mineral phases of the clinker, abbreviated in the cement chemist notation , being: The silicates are responsible for the cement's mechanical properties — the tricalcium aluminate and brownmillerite are essential for
770-512: Is pozzolanic , so that ultimate strength is maintained. Because fly ash addition allows a lower concrete water content, early strength can also be maintained. Where good quality cheap fly ash is available, this can be an economic alternative to ordinary Portland cement. Portland pozzolan cement includes fly ash cement, since fly ash is a pozzolan , but also includes cements made from other natural or artificial pozzolans. In countries where volcanic ashes are available (e.g., Italy, Chile, Mexico,
825-403: Is a binder , a chemical substance used for construction that sets , hardens, and adheres to other materials to bind them together. Cement is seldom used on its own, but rather to bind sand and gravel ( aggregate ) together. Cement mixed with fine aggregate produces mortar for masonry, or with sand and gravel , produces concrete . Concrete is the most widely used material in existence and
880-493: Is a main component of long-lasting building materials . The main application areas are roofing and cladding . The list below gives some common applications. Internal cladding: External cladding: Roofing: Fibre-cement products have found wide usage in various sectors of construction: industrial, agricultural, domestic and residential buildings, mainly in roofing and cladding applications, for new constructions and refurbishment projects. Cement A cement
935-520: Is a major emitter of global carbon dioxide emissions . The lime reacts with silicon dioxide to produce dicalcium silicate and tricalcium silicate. The lime also reacts with aluminium oxide to form tricalcium aluminate. In the last step, calcium oxide, aluminium oxide, and ferric oxide react together to form brownmillerite. A less common form of cement is non-hydraulic cement , such as slaked lime ( calcium oxide mixed with water), which hardens by carbonation in contact with carbon dioxide , which
990-573: Is about 4.4 billion tonnes per year (2021, estimation), of which about half is made in China, followed by India and Vietnam. The cement production process is responsible for nearly 8% (2018) of global CO 2 emissions, which includes heating raw materials in a cement kiln by fuel combustion and release of CO 2 stored in the calcium carbonate (calcination process). Its hydrated products, such as concrete, gradually reabsorb atmospheric CO 2 (carbonation process), compensating for approximately 30% of
1045-424: Is behind only water as the planet's most-consumed resource. Cements used in construction are usually inorganic , often lime - or calcium silicate -based, and are either hydraulic or less commonly non-hydraulic , depending on the ability of the cement to set in the presence of water (see hydraulic and non-hydraulic lime plaster ). Hydraulic cements (e.g., Portland cement ) set and become adhesive through
1100-417: Is completely evaporated (this process is technically called setting ), the carbonation starts: This reaction is slow, because the partial pressure of carbon dioxide in the air is low (~ 0.4 millibar). The carbonation reaction requires that the dry cement be exposed to air, so the slaked lime is a non-hydraulic cement and cannot be used under water. This process is called the lime cycle . Perhaps
1155-686: Is considered a material physically suited for construction products such as cladding and roofing. Fibre-reinforced cement products were invented in the late 19th century by the Austrian Ludwig Hatschek . Principally he mixed 90% Portland cement and 10% asbestos fibres with water and ran it through a cardboard machine. Originally, the fibres were of asbestos and the material was commonly used as siding in house buildings due to its low cost, fire-resistance , water tightness, lightweight, and other useful properties. Asbestos turned out to be harmful to health and produces mesothelioma ,
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#17327904917841210-566: Is constantly fed into a rotary kiln, it allowed a continuous manufacturing process to replace lower capacity batch production processes. Calcium aluminate cements were patented in 1908 in France by Jules Bied for better resistance to sulfates. Also in 1908, Thomas Edison experimented with pre-cast concrete in houses in Union, N.J. In the US, after World War One, the long curing time of at least
1265-674: Is more usually added to Portland cement at the concrete mixer. Masonry cements are used for preparing bricklaying mortars and stuccos , and must not be used in concrete. They are usually complex proprietary formulations containing Portland clinker and a number of other ingredients that may include limestone, hydrated lime, air entrainers, retarders, waterproofers, and coloring agents. They are formulated to yield workable mortars that allow rapid and consistent masonry work. Subtle variations of masonry cement in North America are plastic cements and stucco cements. These are designed to produce
1320-403: Is present in the air (~ 412 vol. ppm ≃ 0.04 vol. %). First calcium oxide (lime) is produced from calcium carbonate ( limestone or chalk ) by calcination at temperatures above 825 °C (1,517 °F) for about 10 hours at atmospheric pressure : The calcium oxide is then spent (slaked) by mixing it with water to make slaked lime ( calcium hydroxide ): Once the excess water
1375-483: Is responsible for early strength in modern cements. The first cement to consistently contain alite was made by William Aspdin in the early 1840s: This was what we call today "modern" Portland cement. Because of the air of mystery with which William Aspdin surrounded his product, others ( e.g., Vicat and Johnson) have claimed precedence in this invention, but recent analysis of both his concrete and raw cement have shown that William Aspdin's product made at Northfleet , Kent
1430-438: Is to make concrete. Portland cement may be grey or white . Portland cement blends are often available as inter-ground mixtures from cement producers, but similar formulations are often also mixed from the ground components at the concrete mixing plant. Portland blast-furnace slag cement , or blast furnace cement (ASTM C595 and EN 197-1 nomenclature respectively), contains up to 95% ground granulated blast furnace slag , with
1485-590: Is typically a chemical compound that lacks carbon–hydrogen bonds — that is, a compound that is not an organic compound . The study of inorganic compounds is a subfield of chemistry known as inorganic chemistry . Inorganic compounds comprise most of the Earth's crust , although the compositions of the deep mantle remain active areas of investigation. All allotropes (structurally different pure forms of an element) and some simple carbon compounds are often considered inorganic. Examples include
1540-478: The Isle of Portland , Dorset, England. However, Aspdins' cement was nothing like modern Portland cement but was a first step in its development, called a proto-Portland cement . Joseph Aspdins' son William Aspdin had left his father's company and in his cement manufacturing apparently accidentally produced calcium silicates in the 1840s, a middle step in the development of Portland cement. William Aspdin's innovation
1595-523: The Art to Prepare a Good Mortar published in St. Petersburg . A few years later in 1825, he published another book, which described various methods of making cement and concrete, and the benefits of cement in the construction of buildings and embankments. Portland cement , the most common type of cement in general use around the world as a basic ingredient of concrete, mortar , stucco , and non-speciality grout ,
1650-543: The New York Commissioner of Highways to construct an experimental section of highway near New Paltz, New York , using one sack of Rosendale to six sacks of Portland cement. It was a success, and for decades the Rosendale-Portland cement blend was used in concrete highway and concrete bridge construction. Cementitious materials have been used as a nuclear waste immobilizing matrix for more than
1705-463: The Philippines), these cements are often the most common form in use. The maximum replacement ratios are generally defined as for Portland-fly ash cement. Portland silica fume cement. Addition of silica fume can yield exceptionally high strengths, and cements containing 5–20% silica fume are occasionally produced, with 10% being the maximum allowed addition under EN 197–1. However, silica fume
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1760-616: The absence of pozzolanic ash, the Romans used powdered brick or pottery as a substitute and they may have used crushed tiles for this purpose before discovering natural sources near Rome. The huge dome of the Pantheon in Rome and the massive Baths of Caracalla are examples of ancient structures made from these concretes, many of which still stand. The vast system of Roman aqueducts also made extensive use of hydraulic cement. Roman concrete
1815-630: The air. It is resistant to attack by chemicals after setting. The word "cement" can be traced back to the Ancient Roman term opus caementicium , used to describe masonry resembling modern concrete that was made from crushed rock with burnt lime as binder. The volcanic ash and pulverized brick supplements that were added to the burnt lime, to obtain a hydraulic binder , were later referred to as cementum , cimentum , cäment , and cement . In modern times, organic polymers are sometimes used as cements in concrete. World production of cement
1870-541: The allotropes of carbon ( graphite , diamond , buckminsterfullerene , graphene , etc.), carbon monoxide CO , carbon dioxide CO 2 , carbides , and salts of inorganic anions such as carbonates , cyanides , cyanates , thiocyanates , isothiocyanates , etc. Many of these are normal parts of mostly organic systems, including organisms ; describing a chemical as inorganic does not necessarily mean that it cannot occur within living things. Friedrich Wöhler 's conversion of ammonium cyanate into urea in 1828
1925-530: The available hydraulic limes, visiting their production sites, and noted that the "hydraulicity" of the lime was directly related to the clay content of the limestone used to make it. Smeaton was a civil engineer by profession, and took the idea no further. In the South Atlantic seaboard of the United States, tabby relying on the oyster-shell middens of earlier Native American populations
1980-420: The development of new cements. Most famous was Parker's " Roman cement ". This was developed by James Parker in the 1780s, and finally patented in 1796. It was, in fact, nothing like material used by the Romans, but was a "natural cement" made by burning septaria – nodules that are found in certain clay deposits, and that contain both clay minerals and calcium carbonate . The burnt nodules were ground to
2035-607: The earliest known occurrence of cement is from twelve million years ago. A deposit of cement was formed after an occurrence of oil shale located adjacent to a bed of limestone burned by natural causes. These ancient deposits were investigated in the 1960s and 1970s. Cement, chemically speaking, is a product that includes lime as the primary binding ingredient, but is far from the first material used for cementation. The Babylonians and Assyrians used bitumen (asphalt or pitch ) to bind together burnt brick or alabaster slabs. In Ancient Egypt , stone blocks were cemented together with
2090-461: The first decade of the nineteenth century. Vicat went on to devise a method of combining chalk and clay into an intimate mixture, and, burning this, produced an "artificial cement" in 1817 considered the "principal forerunner" of Portland cement and "...Edgar Dobbs of Southwark patented a cement of this kind in 1811." In Russia, Egor Cheliev created a new binder by mixing lime and clay. His results were published in 1822 in his book A Treatise on
2145-402: The formation of the liquid phase during the sintering ( firing ) process of clinker at high temperature in the kiln . The chemistry of these reactions is not completely clear and is still the object of research. First, the limestone (calcium carbonate) is burned to remove its carbon, producing lime (calcium oxide) in what is known as a calcination reaction. This single chemical reaction
2200-426: The initial CO 2 emissions. Cement materials can be classified into two distinct categories: hydraulic cements and non-hydraulic cements according to their respective setting and hardening mechanisms. Hydraulic cement setting and hardening involves hydration reactions and therefore requires water, while non-hydraulic cements only react with a gas and can directly set under air. By far the most common type of cement
2255-404: The low pH (8.5–9.5) of its pore water) limited its use as reinforced concrete for building construction. The next development in the manufacture of Portland cement was the introduction of the rotary kiln . It produced a clinker mixture that was both stronger, because more alite (C 3 S) is formed at the higher temperature it achieved (1450 °C), and more homogeneous. Because raw material
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2310-509: The objects made of fibre-cement and by long-term erosion of the materials exposed to atmospheric weathering and wind when cement degrades . Occupational health concerns and the protection of workers in the fibre-cement factories have finally led to the progressive elimination of asbestos from these products. For health reasons, it is recommended that existing fibre-cement products that are in good condition are left undisturbed and possibly encapsulated, to prevent fibre release. Fibre cement
2365-465: The other materials in the mix to form calcium silicates and other cementitious compounds. The resulting hard substance, called 'clinker', is then ground with a small amount of gypsum ( CaSO 4 ·2H 2 O ) into a powder to make ordinary Portland cement , the most commonly used type of cement (often referred to as OPC). Portland cement is a basic ingredient of concrete , mortar , and most non-specialty grout . The most common use for Portland cement
2420-474: The point that some states stopped building highways and roads with cement. Bertrain H. Wait, an engineer whose company had helped construct the New York City's Catskill Aqueduct , was impressed with the durability of Rosendale cement, and came up with a blend of both Rosendale and Portland cements that had the good attributes of both. It was highly durable and had a much faster setting time. Wait convinced
2475-447: The rest Portland clinker and a little gypsum. All compositions produce high ultimate strength, but as slag content is increased, early strength is reduced, while sulfate resistance increases and heat evolution diminishes. Used as an economic alternative to Portland sulfate-resisting and low-heat cements. Portland-fly ash cement contains up to 40% fly ash under ASTM standards (ASTM C595), or 35% under EN standards (EN 197–1). The fly ash
2530-407: The sea, they set hard underwater. The Greeks used volcanic tuff from the island of Thera as their pozzolan and the Romans used crushed volcanic ash (activated aluminium silicates ) with lime. This mixture could set under water, increasing its resistance to corrosion like rust. The material was called pozzolana from the town of Pozzuoli , west of Naples where volcanic ash was extracted. In
2585-444: Was a true alite-based cement. However, Aspdin's methods were "rule-of-thumb": Vicat is responsible for establishing the chemical basis of these cements, and Johnson established the importance of sintering the mix in the kiln . In the US the first large-scale use of cement was Rosendale cement , a natural cement mined from a massive deposit of dolomite discovered in the early 19th century near Rosendale, New York . Rosendale cement
2640-525: Was among the last remaining asbestos-containing materials on the market. The reason is that the asbestos fibres are intimately bound to the cement matrix and were first considered to be well immobilized in the cement and less prone to be released in the environment, suspended in the air, and inhaled in the lung than in other materials or applications such as thermal insulation or flocking in which bare asbestos fibres were used. However, asbestos fibres are inevitably released during machining operations of
2695-479: Was counterintuitive for manufacturers of "artificial cements", because they required more lime in the mix (a problem for his father), a much higher kiln temperature (and therefore more fuel), and the resulting clinker was very hard and rapidly wore down the millstones , which were the only available grinding technology of the time. Manufacturing costs were therefore considerably higher, but the product set reasonably slowly and developed strength quickly, thus opening up
2750-473: Was developed in England in the mid 19th century, and usually originates from limestone . James Frost produced what he called "British cement" in a similar manner around the same time, but did not obtain a patent until 1822. In 1824, Joseph Aspdin patented a similar material, which he called Portland cement , because the render made from it was in color similar to the prestigious Portland stone quarried on
2805-505: Was extremely popular for the foundation of buildings ( e.g. , Statue of Liberty , Capitol Building , Brooklyn Bridge ) and lining water pipes. Sorel cement , or magnesia-based cement, was patented in 1867 by the Frenchman Stanislas Sorel . It was stronger than Portland cement but its poor water resistance (leaching) and corrosive properties ( pitting corrosion due to the presence of leachable chloride anions and
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#17327904917842860-629: Was formalized by French and British engineers in the 18th century. John Smeaton made an important contribution to the development of cements while planning the construction of the third Eddystone Lighthouse (1755–59) in the English Channel now known as Smeaton's Tower . He needed a hydraulic mortar that would set and develop some strength in the twelve-hour period between successive high tides . He performed experiments with combinations of different limestones and additives including trass and pozzolanas and did exhaustive market research on
2915-405: Was rarely used on the outside of buildings. The normal technique was to use brick facing material as the formwork for an infill of mortar mixed with an aggregate of broken pieces of stone, brick, potsherds , recycled chunks of concrete, or other building rubble. Lightweight concrete was designed and used for the construction of structural elements by the pre-Columbian builders who lived in
2970-407: Was used in house construction from the 1730s to the 1860s. In Britain particularly, good quality building stone became ever more expensive during a period of rapid growth, and it became a common practice to construct prestige buildings from the new industrial bricks, and to finish them with a stucco to imitate stone. Hydraulic limes were favored for this, but the need for a fast set time encouraged
3025-748: Was used in the Eastern Roman Empire as well as in the West into the Gothic period . The German Rhineland continued to use hydraulic mortar throughout the Middle Ages, having local pozzolana deposits called trass . Tabby is a building material made from oyster shell lime, sand, and whole oyster shells to form a concrete. The Spanish introduced it to the Americas in the sixteenth century. The technical knowledge for making hydraulic cement
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