Title of Invention	A COMPOSITION FOR THE MANUFACTURE OF FLYASH BASED RIGID SHEET USEFUL AS AN ALTERNATIVE FOR ASBESTOS SHEET
Abstract	The present invention provides a novel composition for the manufacture of flyash -based rigid sheets useful as an alternative for asbestos sheets which poses potential health hazard. The asbestos free synergistic composition consists of flyash, an industrial waste product, natural fibrous material, such as agricultural waste like paddy rind or straw, and unsaturated resins. The novel asbestos free synergistic composition is for manufacturing of rigid sheets having water and heat resistant properties, there is no rusting effect and is useful as an alternative for asbestos sheet and are usable as roofing material particularly in rural areas.

Title of Invention

A COMPOSITION FOR THE MANUFACTURE OF FLYASH BASED RIGID SHEET USEFUL AS AN ALTERNATIVE FOR ASBESTOS SHEET

Abstract

The present invention provides a novel composition for the manufacture of flyash -based rigid sheets useful as an alternative for asbestos sheets which poses potential health hazard. The asbestos free synergistic composition consists of flyash, an industrial waste product, natural fibrous material, such as agricultural waste like paddy rind or straw, and unsaturated resins. The novel asbestos free synergistic composition is for manufacturing of rigid sheets having water and heat resistant properties, there is no rusting effect and is useful as an alternative for asbestos sheet and are usable as roofing material particularly in rural areas.

Full Text	This invention relates to a composition for the manufacture of flyash based rigid sheet useful as an alternative for asbestos sheet. The present invention particularly provides asbestos free composition for the manufacture of rigid sheets. The asbestos free composition of the present invention more particularly provides flyash, an industrial waste product, based binder compositions made from unsaturated resins and natural fibrous material, such as agricultural waste like paddy rind or straw for manufacturing of rigid sheets useful as an alternative for asbestos sheets. The flyash, an industrial waste product, based rigid sheet manufactured from the composition of the present invention will find wide spread use as an alternative to asbestos sheet in particular and as an alternative to roofing sheets such as asbestos sheets, corrugated tin sheets in general. Asbestos sheet of cement is widely used as roof covering, specially as roofing material of in rural areas. The cement asbestos sheet poses a potential health hazard and hence, is not a recommended material. Corrugated-iron sheet is also used as roof covering, but this sheet is uncomfortable in summer and cold seasons. Further, the drawbacks of asbestos are given below: Inhalation of the fine asbestos dust may cause the disease known as "asbestosis", which is a scarring of the lung tissues. Asbestos fibers, if they become airborne and are inhaled can be hazardous to health. Therefore, to remove the risk of health hazard, the product made the use of asbestos in construction products virtually impossible as per government regulations during 1980s and early 1990s. Reference may be made to the website: www.professionalroofinq.net/past/oct2000/tech.asp. This brought about the search for substitutes of asbestos fibres used in fibres cement roofing products. Reference may be made to: Northern Territory, work Health Authority and series Work Health Information Bulletin; Bui 66 , website: www.nohsc.gov.au/OHSInformation/Databases/PracticalGuidanceMaterial/w/003 598.htm .regarding working with asbestos cement (A-C) sheet. Further reference may be made to: Tasmania: Department of Employment, Industrial Relations and Training. Occupational Health and Safety branch (www.nohsc.qov.au/OHSInformation/Databases/PracticalGuidancelvlaterial/0028 OO.htm) regarding asbestos-health precautions. Regulation concerning the use of asbestos in work places generally issued in industrial safety, health and welfare (Administrative General) regulation 1979: Inhalation of the fine asbestos dust may cause the disease known as asbestosis, which is a scarring of the lung tissues. Cancer in other body sites have been attributed to asbestos dust. An uncommon form of cancer (methothelima) may occur in the chest or abdomen due to inhalation of asbestos dust over a long period. Reference may be made to technical report "Development of a pilot scale commercial facility for fabrication and marketing of light weight coal combination by products based artificial support for mine use" Chugh et al, Southern Illinois University at Carbonate, USA (1996). The work on the utilization of flyash as support material in laboratory provides a non-polymerized material product. The support was prepared with the help of cement, thus the product has brittleness. Reference may be made to the proceedings of "International conference of flyash disposal & utilization, 20-22 January 1998", for making flyash bricks by using flyash, lime, gypsum, sand and water. Further reference may be made to ACI Mater, M48, 1991, V. M. Malhotra, G. G. Carette and A. Bilodean, wherein use has been made of polypropylene fibers with flyash. The strength of the product is found to be low. Reference may be made to an US Patent No. 4,011,195 dated March 8, 1977 entitled " Polymerizable compositions containing unsaturated polymer resins and aqueous alkali metal silicate, method of preparing shaped articles form such compositions and thermoset products thereof wherein polymerizable unsaturated polyester resin syrup can be extended with aqueous alkali metal silicate in compositions. The compositions further can be extended; a) by the addition of reactive fillers such as metal oxides or hydrated metallic salts; b) by the addition of inertfiller such as clay, silica glass-fibers, perlite and c) by the addition of both a) and b). The composition can be employed in coatings, laminates, cast articles, molded articles and other shaped articles. The polymerized products are resistant to combustion have low fuel content, low flame spread and are useful thermal insulating materials. The products furthermore have a low smoke content. When exposed to fire, the organic content of these materials is burned and the residual inorganic content is converted to refractory ceramic material, which resists further thermal deterioration and functions as a thermal insulator to resist thermal transfer. The drawback is that use has been made of inorganic compounds such as SiC>2 There is no use of flyash and natural fiber for changing the molecular structure of the unsaturated polyester resin. Reference may be made to an US Patent No. 5, 439, 578 dated August 8, 1995 titled "Flyash based composition" wherein a composition of lime containing flyash with water has been described. The developed compositions are only provided for floor underlayment, road patch and exterior statuary applications. Reference may be made to an US patent No. 5, 852, 077 dated December 22, 1998 titled "lightweight, waterproof, insulating, cementitious compositions and methods for forming and using such compositions" wherein noncementitious filler, Portland cement, bentonite, diatomaceous earth and lime have used as composition. The noncementatious filler may be sawdust, rubber chips, flyash or combinations of two or more of these ingredients. The developed product may be used for electrically nonconductive posts and can be used to absorb and contain liquid contaminants in a vessel. Reference may be made to an US Patent No. 6,485,561 dated Nov. 26, 2002 titled "Low density cellular concrete with accelerators for rapid hardening" wherein a composition have been described and claimed. The composition of the above patent was cement, water, a surfactant to create foam and an accelerator such as sodium carbonate. An additional embodiment includes using a byproduct such as flyash in the composition to further reduce costs and make an environmentally product. The drawbacks of the prior art as referred above are that the end-products are for use in the field of floor underlayment, road patch, exterior statuary applications and electrically non-conductive ports. In all the above prior art the authors were using flyash with cement in the compositions. These compositions may also increase the density of the products. Reference may be made to an US Patent No. 6,596,789 dated August July 22, 2003 titled "Non-asbestos friction materials" wherein a composition has been described and claimed. The developed composition was suitable for disc pads, brake linings, clutch facings and the like in automobiles, heavy duty trucks, railroad cars, and various types of industrial equipment. Disposal of flyash generated from thermal power plants is a great problem. The dispersion of flyash in environment leads to pollution and increasing health hazards to human, animals and decreasing the fertility of nearby agriculture land. The constructive use of industrial waste materials like flyash and agricultural waste such as paddy rind and straw will help to reduce environmental pollution. Thus, there is a definite requirement to develop asbestos free roof covering sheet for rural areas with the help of waste material like flyash, paddy rind and straw with polymer having high compressive and tensile strength and good shelf life. This will solve the ground control problem and also facilitate flyash disposal. The main object of the present invention to provide a composition for the manufacture of flyash based rigid sheet useful as an alternative for asbestos sheet, which obviates the above noted drawbacks. Another object of the present invention is to provide a composition for the manufacture of asbestos free flyash based sheet suitable for rural development such as roof covering. Yet another object of the present invention is to provide an asbestos free composition for the manufacture of rigid asbestos free sheet other than cement asbestos sheet, which are suitable for use as alternative of cement asbestos sheet for using in rural areas. Still another object of the present invention is to provide a composition, which primarily consists of flyash, an industrial waste product and agricultural waste such as paddy rind or straw. A further object of the present invention is to provide a composition for the manufacture of flyash based rigid sheet which is not a health hazard. A still further object of the present invention is to provide a composition for the manufacture of flyash based rigid sheet which has no moisture and does not have rusting effect. The present invention provides a novel composition for the manufacture of flyash based rigid sheets useful as an alternative for asbestos sheets which poses potential health hazard. The asbestos free synergistic composition consists of flyash, an industrial waste product, natural fibrous material, such as agricultural waste like paddy rind or straw, and unsaturated resins. The novel asbestos free synergistic composition is for manufacturing of rigid sheets having water and heat resistant properties, there is no rusting effect and is useful as an alternative for asbestos sheet and are usable as roofing material particularly in rural areas. Accordingly, the present invention provides a composition for the manufacture of the flyash based rigid sheet useful as an alternative for asbestos sheet, which comprises: Flyash 53.00 to 55.00 wt% Natural fibrous material, 6.50 to 10.50 wt % such as agricultural waste like paddy rind or straw Unsaturated resin 33.50 to 35.50 wt % Methyl ethyl ketone peroxide 1.00 to 2.00wt % Cobalt 1.00 to 2.00 wt % In an embodiment of the present invention the flyash used is an industrial waste product consisting of fine particles generated from thermal power plant and collected from electrostatic precipitator (ESP). In another embodiment of the present invention the flyash used is having Si of the order of 56.63%, Al of the order of 19.86%, Fe of the order of 13.99% and Ca of the order of 1.82%. In still another embodiment of the present invention the unsaturated resins used is unsaturated polymer resin of commercial grade. In yet another embodiment of the present invention the unsaturated resins have straw colour, viscosity of the order of 175 sec/cps, acid value of the order of 24.6 mg/KOH/gms, volatile content of the order of 27%, peak exotherm of the order of 164°C. In a further embodiment of the present invention a mixture of methyl ethyl ketone peroxide and cobalt is used as an additive in a 1:1 ratio. The composition of the present invention is not a mere admixture but a synergistic mixture having properties which are distinct and different from the mere aggregated properties of the individual ingredients. In the present invention there is provided a novel asbestos free synergistic composition for the manufacture of rigid sheets useful as an alternative for asbestos sheets which poses potential health hazard. The novel asbestos free composition of the present invention has been made possible by the non-obvious inventive steps of providing a synergistic composition consisting of flyash, an industrial waste product, natural fibrous material, such as agricultural waste like paddy rind or straw, and unsaturated resins. The novel asbestos free synergistic composition is for manufacturing of rigid sheets having water and heat resistant properties, there is no rusting effect and is useful as an alternative for asbestos sheet and are usable as roofing material particularly in rural areas. The following examples are given by way of illustration and should not be construed to limit the scope of the present invention. Example 1 The flyash, which was used for making the sheet, was having Si = 56.63%, Al = 19.86%, Fe = 13.99% and Ca = 1.82% . The unsaturated resins was straw in colour and of viscosity =175 sec/cps, acid value = 24.6 mg/KOH/gms, volatile content = 27%, peak exotherm = 164°C. Sr. No. Ingredients Percentage (g/100) 1. Flyash 55.00 2. Paddy rind 6.50 3. Unsaturated Resin 35.50 4. Methyl ethyl ketone peroxide 1.50 5. Cobalt 1.50 Flyash, polymer resin and reinforced materials were mixed well in the above said proportions and filled in a wax lined steel mould. The cast in the mould was kept for curing at room temperature for 3 hours. Properties of flyash based sheet with paddy rind, as obtained in example -1: Sr. No. Length of Water Failure Load Strength Sheet (mm) resistance (Kg) Compressive Tensile property Strength (Kg/cm2) Strength (Kg/cm2) 1. 180 Excellent 1150 110.77 30.04 2. 190 Excellent 1248 112.31 32.00 3. 200 Excellent 1350 117.42 35.21 4. 210 Excellent 1600 120.58 40.29 The flyash based sheet with paddy rind was found to have excellent water resistant properties. The load failure of the sheet was found to be in the range of 1150 to 1600 Kg in different length of sheet. The compressive and tensile strength was in the range of 110.77 to 120.58 Kg/cm2 and 30.04 to 40.29 Kg/cm2 respectively. Example 2 The flyash, which was used for making the sheet, was having Si = 56.63%, Al = 19.86%, Fe = 13.99% and Ca = 1.82%. The unsaturated resins was straw in colour and of viscosity = 175 sec/cps, acid value = 24.6 mg/KOH/gms, volatile content = 27%, peak exotherm = 164°C. Sr. No. Ingredients Percentage (g/100) 1. Flyash 53.00 2. Straw 10.50 3. Unsaturated Resin 33.50 4. Methyl ethyl ketone peroxide 1.50 4. Cobalt 1.50 Flyash, polymer resin and straw were mixed well in the above said pre-decided ratio and put on the surface of steel well lined on outer side by waxpol. The casted mould was kept for curing at room temperature for about three hours. Properties of flyash based rigid sheet with straw, as obtained in example - 2: Sr. No. Length of Sheet (mm) Water resistance Failure Load Strength Compressive Tensile property (Kg/cm2) Strength (Kg/cm2) strength (Kg/cm2) 1. 180 Excellent 1050 95.24 23.29 2. 190 Excellent 1120 100.21 26.12 3. 200 Excellent 1238 102.31 28.31 4. 210 Excellent 1405 103.82 31.29 The flyash based sheet with straw was found to have excellent water resistant properties. The load failure of the sheet was found to be in the range of 1050 to 1405 Kg in different length of sheet. The compressive and tensile strength was in the range of 95.24 to 103.82 Kg/cm2 and 23.29 to 31.29 Kg/cm2 respectively. The characteristic properties of flyash-based sheets obtained using the composition of the present invention are: Sr. No. Length of Sheet (mm) Water resistance Property Failure Load (Kg) Strength Compressive Strength (Kg/cm2) Tensile Strength (Kg/cm2) 1. 2. 3. 4. 180 190 200 210 Excellent Excellent Excellent Excellent 1050-1150 1120-1248 1238-1350 1405 -1600 95.24 -110.77 100.21-112.31 102.31-117.42 103.82-120.58 23.29-30.04 26.12-32.00 28.31 -35.21 31.29-40.29 The compressive and tensile strength of the cement asbestos sheet tested by universal testing machine in CMRI is as follows: Types of test Length (mm) Breadth (mm) Thickness (mm) Failure Load (Kg) Strength (Kg/cm2) Compressive Strength 136.93 58.19 7.44 1340 309 Tensile Strength 300 40 7.44 160 56 The weight of asbestos sheet (length: 13.7cm, Breath: 5.7cm and thickness 7.44mm) was 75gm whereas The weight of flyash based sheet (length: 13.7cm, 5.7cm and thickness 7.44mm) was 80gm. The prepared flyash based sheets have excellent water resistance properties, failure load in the range of 1050 to 1600 Kg. The compressive and tensile strength of the developed sheet were in the range of 95.24 to 120.58Kg/Cm2 and 23.29 to 40.29 Kg/Cm2 respectively. The main advantages of the present invention are: 1. The failure load, compressive strength and tensile strength of developed flyash base asbestos free sheet are comparable to asbestos sheet of cement. 2. The flyash-based sheet is not a health hazard because it contains natural fibres whereas the asbestos sheet poses health hazard. 3. There is no moisture and rusting effect in the flyash base roof support. 4. Flyash, an industrial waste, constructively used to reduce environmental pollution. 5. Paddy rind or straw, agricultural waste constructively used. We Claim: 1. A composition for the manufacture of the flyash based rigid sheet useful as an alternative for asbestos sheet, which comprises: Flyash 53.00 to 55.00 w t% Natural fibrous material, 6.50 to 10.50 wt% such as agricultural waste like paddy rind or straw Unsaturated resin 33.50 to 35.50 wt % Methyl ethyl ketone peroxide 1.00 to 2.00wt % Cobalt 1.00 to 2.00 wt % 2. A composition as claimed in claim 1 wherein, the flyash used is an industrial waste product consisting of fine particles generated from thermal power plant and collected from electrostatic precipitator (ESP). 3. A composition as claimed in claim 1-2 wherein, the flyash used is having Si of the order of 56.63%, Al of the order of 19.86%, Fe of the order of 13.99% and Ca of the order of 1.82%. 4. A composition as claimed in claim 1-3 wherein, the unsaturated resin used is unsaturated polymer resin of commercial grade. 5. A composition as claimed in claim 1-4 wherein, the unsaturated resins have straw colour, viscosity of the order of 175 sec/cps, acid value of the order of 24.6 mg/KOH/gms, volatile content of the order of 27%, peak exotherm of the order of 164°C. 6. A composition as claimed in claim 1-5 wherein, a mixture of methyl ethyl ketone peroxide and cobalt is used as an additive in a 1:1 ratio. 7. A composition for the manufacture of the flyash based rigid sheet useful as an alternative for asbestos sheet, substantially as herein described with reference to the examples.

Full Text

This invention relates to a composition for the manufacture of flyash based rigid sheet useful as an alternative for asbestos sheet. The present invention particularly provides asbestos free composition for the manufacture of rigid sheets. The asbestos free composition of the present invention more particularly provides flyash, an industrial waste product, based binder compositions made from unsaturated resins and natural fibrous material, such as agricultural waste like paddy rind or straw for manufacturing of rigid sheets useful as an alternative for asbestos sheets.
The flyash, an industrial waste product, based rigid sheet manufactured from the composition of the present invention will find wide spread use as an alternative to asbestos sheet in particular and as an alternative to roofing sheets such as asbestos sheets, corrugated tin sheets in general.
Asbestos sheet of cement is widely used as roof covering, specially as roofing material of in rural areas. The cement asbestos sheet poses a potential health hazard and hence, is not a recommended material. Corrugated-iron sheet is also used as roof covering, but this sheet is uncomfortable in summer and cold seasons.
Further, the drawbacks of asbestos are given below:
Inhalation of the fine asbestos dust may cause the disease known as "asbestosis", which is a scarring of the lung tissues. Asbestos fibers, if they become airborne and are inhaled can be hazardous to health. Therefore, to remove the risk of health hazard, the product made the use of asbestos in construction products virtually impossible as per government regulations during 1980s and early 1990s. Reference may be made to the website: www.professionalroofinq.net/past/oct2000/tech.asp. This brought about the search for substitutes of asbestos fibres used in fibres cement roofing products.
Reference may be made to: Northern Territory, work Health Authority and series Work Health Information Bulletin; Bui 66 , website:
www.nohsc.gov.au/OHSInformation/Databases/PracticalGuidanceMaterial/w/003 598.htm .regarding working with asbestos cement (A-C) sheet.
Further reference may be made to: Tasmania: Department of Employment, Industrial Relations and Training. Occupational Health and Safety branch (www.nohsc.qov.au/OHSInformation/Databases/PracticalGuidancelvlaterial/0028 OO.htm) regarding asbestos-health precautions.
Regulation concerning the use of asbestos in work places generally issued in industrial safety, health and welfare (Administrative General) regulation 1979: Inhalation of the fine asbestos dust may cause the disease known as asbestosis, which is a scarring of the lung tissues. Cancer in other body sites have been attributed to asbestos dust. An uncommon form of cancer (methothelima) may occur in the chest or abdomen due to inhalation of asbestos dust over a long period.
Reference may be made to technical report "Development of a pilot scale commercial facility for fabrication and marketing of light weight coal combination by products based artificial support for mine use" Chugh et al, Southern Illinois University at Carbonate, USA (1996). The work on the utilization of flyash as support material in laboratory provides a non-polymerized material product. The support was prepared with the help of cement, thus the product has brittleness.
Reference may be made to the proceedings of "International conference of flyash disposal & utilization, 20-22 January 1998", for making flyash bricks by using flyash, lime, gypsum, sand and water.
Further reference may be made to ACI Mater, M48, 1991, V. M. Malhotra, G. G. Carette and A. Bilodean, wherein use has been made of polypropylene fibers with flyash. The strength of the product is found to be low.
Reference may be made to an US Patent No. 4,011,195 dated March 8, 1977 entitled " Polymerizable compositions containing unsaturated polymer resins and aqueous alkali metal silicate, method of preparing shaped articles form such compositions and thermoset products thereof wherein polymerizable unsaturated polyester resin syrup can be extended with aqueous alkali metal silicate in compositions. The compositions further can be extended; a) by the addition of reactive fillers such as metal oxides or hydrated metallic salts; b) by the addition of inertfiller such as clay, silica glass-fibers, perlite and c) by the addition of both a) and b). The composition can be employed in coatings, laminates, cast articles, molded articles and other shaped articles. The polymerized products are resistant to combustion have low fuel content, low flame spread and are useful thermal insulating materials. The products furthermore have a low smoke content. When exposed to fire, the organic content of these materials is burned and the residual inorganic content is converted to refractory ceramic material, which resists further thermal deterioration and functions as a thermal insulator to resist thermal transfer. The drawback is that use has been made of inorganic compounds such as SiC>2 There is no use of flyash and natural fiber for changing the molecular structure of the unsaturated polyester resin.
Reference may be made to an US Patent No. 5, 439, 578 dated August 8, 1995 titled "Flyash based composition" wherein a composition of lime containing flyash with water has been described. The developed compositions are only provided for floor underlayment, road patch and exterior statuary applications.
Reference may be made to an US patent No. 5, 852, 077 dated December 22, 1998 titled "lightweight, waterproof, insulating, cementitious compositions and
methods for forming and using such compositions" wherein noncementitious filler, Portland cement, bentonite, diatomaceous earth and lime have used as composition. The noncementatious filler may be sawdust, rubber chips, flyash or combinations of two or more of these ingredients. The developed product may be used for electrically nonconductive posts and can be used to absorb and contain liquid contaminants in a vessel.
Reference may be made to an US Patent No. 6,485,561 dated Nov. 26, 2002 titled "Low density cellular concrete with accelerators for rapid hardening" wherein a composition have been described and claimed. The composition of the above patent was cement, water, a surfactant to create foam and an accelerator such as sodium carbonate. An additional embodiment includes using a byproduct such as flyash in the composition to further reduce costs and make an environmentally product.
The drawbacks of the prior art as referred above are that the end-products are for use in the field of floor underlayment, road patch, exterior statuary applications and electrically non-conductive ports. In all the above prior art the authors were using flyash with cement in the compositions. These compositions may also increase the density of the products.
Reference may be made to an US Patent No. 6,596,789 dated August July 22, 2003 titled "Non-asbestos friction materials" wherein a composition has been described and claimed. The developed composition was suitable for disc pads, brake linings, clutch facings and the like in automobiles, heavy duty trucks, railroad cars, and various types of industrial equipment.
Disposal of flyash generated from thermal power plants is a great problem. The dispersion of flyash in environment leads to pollution and increasing health hazards to human, animals and decreasing the fertility of nearby agriculture land.
The constructive use of industrial waste materials like flyash and agricultural waste such as paddy rind and straw will help to reduce environmental pollution.
Thus, there is a definite requirement to develop asbestos free roof covering sheet for rural areas with the help of waste material like flyash, paddy rind and straw with polymer having high compressive and tensile strength and good shelf life. This will solve the ground control problem and also facilitate flyash disposal.
The main object of the present invention to provide a composition for the manufacture of flyash based rigid sheet useful as an alternative for asbestos sheet, which obviates the above noted drawbacks.
Another object of the present invention is to provide a composition for the manufacture of asbestos free flyash based sheet suitable for rural development such as roof covering.
Yet another object of the present invention is to provide an asbestos free composition for the manufacture of rigid asbestos free sheet other than cement asbestos sheet, which are suitable for use as alternative of cement asbestos sheet for using in rural areas.
Still another object of the present invention is to provide a composition, which primarily consists of flyash, an industrial waste product and agricultural waste such as paddy rind or straw.
A further object of the present invention is to provide a composition for the manufacture of flyash based rigid sheet which is not a health hazard.
A still further object of the present invention is to provide a composition for the manufacture of flyash based rigid sheet which has no moisture and does not have rusting effect.
The present invention provides a novel composition for the manufacture of flyash based rigid sheets useful as an alternative for asbestos sheets which poses potential health hazard. The asbestos free synergistic composition consists of flyash, an industrial waste product, natural fibrous material, such as agricultural waste like paddy rind or straw, and unsaturated resins. The novel asbestos free synergistic composition is for manufacturing of rigid sheets having water and heat resistant properties, there is no rusting effect and is useful as an alternative for asbestos sheet and are usable as roofing material particularly in rural areas.
Accordingly, the present invention provides a composition for the manufacture of the flyash based rigid sheet useful as an alternative for asbestos sheet, which comprises:
Flyash 53.00 to 55.00 wt%
Natural fibrous material, 6.50 to 10.50 wt %
such as agricultural waste
like paddy rind or straw
Unsaturated resin 33.50 to 35.50 wt %
Methyl ethyl ketone peroxide 1.00 to 2.00wt %
Cobalt 1.00 to 2.00 wt %
In an embodiment of the present invention the flyash used is an industrial waste product consisting of fine particles generated from thermal power plant and collected from electrostatic precipitator (ESP).
In another embodiment of the present invention the flyash used is having Si of the order of 56.63%, Al of the order of 19.86%, Fe of the order of 13.99% and Ca of the order of 1.82%.
In still another embodiment of the present invention the unsaturated resins used is unsaturated polymer resin of commercial grade.
In yet another embodiment of the present invention the unsaturated resins have straw colour, viscosity of the order of 175 sec/cps, acid value of the order of 24.6 mg/KOH/gms, volatile content of the order of 27%, peak exotherm of the order of 164°C.
In a further embodiment of the present invention a mixture of methyl ethyl ketone peroxide and cobalt is used as an additive in a 1:1 ratio.
The composition of the present invention is not a mere admixture but a synergistic mixture having properties which are distinct and different from the mere aggregated properties of the individual ingredients.
In the present invention there is provided a novel asbestos free synergistic composition for the manufacture of rigid sheets useful as an alternative for asbestos sheets which poses potential health hazard. The novel asbestos free composition of the present invention has been made possible by the non-obvious inventive steps of providing a synergistic composition consisting of flyash, an industrial waste product, natural fibrous material, such as agricultural waste like paddy rind or straw, and unsaturated resins. The novel asbestos free synergistic composition is for manufacturing of rigid sheets having water and heat resistant properties, there is no rusting effect and is useful as an alternative for asbestos sheet and are usable as roofing material particularly in rural areas.
The following examples are given by way of illustration and should not be construed to limit the scope of the present invention.
Example 1
The flyash, which was used for making the sheet, was having Si = 56.63%, Al = 19.86%, Fe = 13.99% and Ca = 1.82% .
The unsaturated resins was straw in colour and of viscosity =175 sec/cps, acid value = 24.6 mg/KOH/gms, volatile content = 27%, peak exotherm = 164°C.

Sr. No. Ingredients Percentage (g/100)
1. Flyash 55.00
2. Paddy rind 6.50
3. Unsaturated Resin 35.50
4. Methyl ethyl ketone peroxide 1.50
5. Cobalt 1.50
Flyash, polymer resin and reinforced materials were mixed well in the above said proportions and filled in a wax lined steel mould. The cast in the mould was kept for curing at room temperature for 3 hours.
Properties of flyash based sheet with paddy rind, as obtained in example -1:

Sr. No. Length of Water Failure Load Strength
Sheet (mm) resistance (Kg) Compressive Tensile
property Strength (Kg/cm2) Strength (Kg/cm2)
1. 180 Excellent 1150 110.77 30.04
2. 190 Excellent 1248 112.31 32.00
3. 200 Excellent 1350 117.42 35.21
4. 210 Excellent 1600 120.58 40.29
The flyash based sheet with paddy rind was found to have excellent water resistant properties. The load failure of the sheet was found to be in the range of 1150 to 1600 Kg in different length of sheet. The compressive and tensile strength was in the range of 110.77 to 120.58 Kg/cm2 and 30.04 to 40.29 Kg/cm2 respectively.
Example 2
The flyash, which was used for making the sheet, was having Si = 56.63%, Al = 19.86%, Fe = 13.99% and Ca = 1.82%.
The unsaturated resins was straw in colour and of viscosity = 175 sec/cps, acid value = 24.6 mg/KOH/gms, volatile content = 27%, peak exotherm = 164°C.

Sr. No. Ingredients Percentage (g/100)
1. Flyash 53.00
2. Straw 10.50
3. Unsaturated Resin 33.50
4. Methyl ethyl ketone peroxide 1.50
4. Cobalt 1.50
Flyash, polymer resin and straw were mixed well in the above said pre-decided ratio and put on the surface of steel well lined on outer side by waxpol. The casted mould was kept for curing at room temperature for about three hours.
Properties of flyash based rigid sheet with straw, as obtained in example - 2:

Sr. No. Length of Sheet (mm) Water resistance Failure Load Strength

Compressive Tensile
property (Kg/cm2) Strength (Kg/cm2) strength (Kg/cm2)
1. 180 Excellent 1050 95.24 23.29
2. 190 Excellent 1120 100.21 26.12
3. 200 Excellent 1238 102.31 28.31
4. 210 Excellent 1405 103.82 31.29
The flyash based sheet with straw was found to have excellent water resistant properties. The load failure of the sheet was found to be in the range of 1050 to 1405 Kg in different length of sheet. The compressive and tensile strength was in the range of 95.24 to 103.82 Kg/cm2 and 23.29 to 31.29 Kg/cm2 respectively.
The characteristic properties of flyash-based sheets obtained using the composition of the present invention are:

Sr. No. Length of Sheet (mm) Water
resistance
Property Failure Load (Kg) Strength

Compressive
Strength
(Kg/cm2) Tensile
Strength
(Kg/cm2)
1. 2. 3. 4. 180 190 200 210 Excellent Excellent Excellent Excellent 1050-1150 1120-1248 1238-1350 1405 -1600 95.24 -110.77 100.21-112.31 102.31-117.42 103.82-120.58 23.29-30.04 26.12-32.00 28.31 -35.21 31.29-40.29
The compressive and tensile strength of the cement asbestos sheet tested by universal testing machine in CMRI is as follows:

Types of test Length (mm) Breadth (mm) Thickness (mm) Failure Load (Kg) Strength (Kg/cm2)
Compressive Strength 136.93 58.19 7.44 1340 309
Tensile Strength 300 40 7.44 160 56
The weight of asbestos sheet (length: 13.7cm, Breath: 5.7cm and thickness 7.44mm) was 75gm whereas The weight of flyash based sheet (length: 13.7cm, 5.7cm and thickness 7.44mm) was 80gm. The prepared flyash based sheets have excellent water resistance properties, failure load in the range of 1050 to
1600 Kg. The compressive and tensile strength of the developed sheet were in the range of 95.24 to 120.58Kg/Cm2 and 23.29 to 40.29 Kg/Cm2 respectively.
The main advantages of the present invention are:
1. The failure load, compressive strength and tensile strength of developed flyash base asbestos free sheet are comparable to asbestos sheet of cement.
2. The flyash-based sheet is not a health hazard because it contains natural fibres whereas the asbestos sheet poses health hazard.
3. There is no moisture and rusting effect in the flyash base roof support.
4. Flyash, an industrial waste, constructively used to reduce environmental pollution.
5. Paddy rind or straw, agricultural waste constructively used.

We Claim:
1. A composition for the manufacture of the flyash based rigid sheet useful as an alternative for asbestos sheet, which comprises:

Flyash 53.00 to 55.00 w t%
Natural fibrous material, 6.50 to 10.50 wt%
such as agricultural waste
like paddy rind or straw
Unsaturated resin 33.50 to 35.50 wt %
Methyl ethyl ketone peroxide 1.00 to 2.00wt %
Cobalt 1.00 to 2.00 wt %
2. A composition as claimed in claim 1 wherein, the flyash used is an industrial waste product consisting of fine particles generated from thermal power plant and collected from electrostatic precipitator (ESP).
3. A composition as claimed in claim 1-2 wherein, the flyash used is having Si of the order of 56.63%, Al of the order of 19.86%, Fe of the order of 13.99% and Ca of the order of 1.82%.
4. A composition as claimed in claim 1-3 wherein, the unsaturated resin used is unsaturated polymer resin of commercial grade.
5. A composition as claimed in claim 1-4 wherein, the unsaturated resins have straw colour, viscosity of the order of 175 sec/cps, acid value of the order of 24.6 mg/KOH/gms, volatile content of the order of 27%, peak exotherm of the order of 164°C.
6. A composition as claimed in claim 1-5 wherein, a mixture of methyl ethyl ketone peroxide and cobalt is used as an additive in a 1:1 ratio.
7. A composition for the manufacture of the flyash based rigid sheet useful as an alternative for asbestos sheet, substantially as herein described with reference to the examples.

Documents:

http://ipindiaonline.gov.in/patentsearch/GrantedSearch/viewdoc.aspx?id=eI+ugs4ATmJvc+Q/PI/rkg==&loc=+mN2fYxnTC4l0fUd8W4CAA==

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Patent Number

272142

Indian Patent Application Number

149/DEL/2004

PG Journal Number

13/2016

Publication Date

25-Mar-2016

Grant Date

18-Mar-2016

Date of Filing

30-Jan-2004

Name of Patentee

COUNCIL OF SCIENTIFIC AND INDUSTRIAL RESEARCH

Applicant Address

RAFI MARG, NEW DELHI-110 001, INDIA

Inventors:

#	Inventor's Name	Inventor's Address
1	NABIULLAH	CENTRAAL MINING RESEARCH INSTITUTE, BARWA ROAD, DHANBAD
2	BRAJ MOHAN PAT PINGUA	CENTRAAL MINING RESEARCH INSTITUTE, BARWA ROAD, DHANBAD
3	EMRANUZZAMAN	CENTRAAL MINING RESEARCH INSTITUTE, BARWA ROAD, DHANBAD
4	JAGDISH	CENTRAAL MINING RESEARCH INSTITUTE, BARWA ROAD, DHANBAD

PCT International Classification Number

E04C 2/00

PCT International Application Number

N/A

PCT International Filing date

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1			NA