Cement board with water-resistant additive
In the present disclosure, a cement board is disclosed. The cement board comprises a core having a first surface and a second surface opposite the first surface and a binder including a pozzolan material and a water-resistant additive, wherein the water-resistant additive is present in an amount of less than 5 wt. % based on the weight of the pozzolan material.
1 . A cement board, comprising:
a core having a first surface and a second surface opposite the first surface and a binder including a cement, a water-resistant additive comprising a metal salt of a fatty acid including a backbone carbon chain having from 12 to 60 carbon atoms, wherein the water-resistant additive is present in an amount of less than 5 wt. % to 0.3 wt. % or more based on the weight of the core, and a lightweight aggregate comprising expanded shale, expanded clay, expanded vermiculite, expanded perlite, expanded pumice, expanded glass, expanded polystyrene, polyurethane, hollow spheres, or a mixture thereof;
wherein the cement board exhibits a compressive strength of from 250 psi to 4,000 psi as determined in accordance with ASTM D2394.
2 . The cement board of claim 1 , wherein the cement comprises Portland cement, magnesia cement, alumina cement, calcium sulphoaluminate cement, or a mixture thereof.
3 . The cement board of claim 1 , wherein the binder further comprises a pozzolan material.
4 . The cement board of claim 3 , wherein the pozzolan material comprises fly ash, blast furnace slag, metakaolin, silica fume, microsilica, or a mixture thereof.
5 . The cement board of claim 1 , wherein the core further comprises a normal weight aggregate.
6 . The cement board of claim 5 , wherein the normal weight aggregate comprises sand, limestone, stone, shale, clay, granite, or a mixture thereof.
7 . The cement board of claim 1 , wherein the lightweight aggregate comprises expanded shale, expanded clay, expanded vermiculite, expanded perlite, expanded pumice, or a mixture thereof.
8 . The cement board of claim 1 , wherein the lightweight aggregate comprises expanded polystyrene beads.
9 . The cement board of claim 8 , wherein the expanded polystyrene beads have a bimodal particle size distribution.
10 . The cement board of claim 1 , wherein the core further comprises a retarder, an accelerator, or a mixture thereof.
11 . The cement board of claim 1 , wherein the core further comprises a sulfonate, a cellulose polymer derivative, a polysaccharide, a galactomannan, or a mixture thereof.
12 . The cement board of claim 1 , wherein the water-resistant additive is present in an amount of from 0.5 wt. % or more to 2 wt. % or less based on the weight of the core.
13 . The cement board of claim 1 , wherein the fatty acid comprises from 12 to 24 carbon atoms.
14 . The cement board of claim 1 , wherein the fatty acid comprises myristic acid, palmitic acid, arachidonic acid, montanic acid, octadecanoic acid, parinaric acid, or a mixture thereof.
15 . The cement board of claim 1 , wherein the fatty acid comprises stearic acid.
16 . The cement board of claim 1 , wherein the metal comprises an alkaline earth metal.
17 . The cement board of claim 1 , wherein the cement board indicates a water penetration having an area of 0.2 in 2 or less as determined in accordance with ANSI A118.10 and ASTM D4068, Annex A2.
18 . The cement board of claim 1 , wherein the cement board exhibits a water absorption of 8 wt. % or less as determined in accordance with ASTM C473.
19 . The cement board of claim 1 , wherein the cement board exhibits a water vapor permeance of 10 Perms or more as determined in accordance with ASTM E 96/E96M-16, Procedure B.
20 . The cement board of claim 1 , wherein the cement board exhibits a fastener hold of from 50 lb f to 200 lb f as determined in accordance with ASTM C1396 and ASTM C473.
21 . The cement board of claim 1 , wherein the cement board exhibits a modulus of rupture of from 500 psi to 2,000 psi as determined in accordance with ASTM C78.
22 . The cement board of claim 1 , wherein the cement board exhibits a compressive strength of from 500 psi to 3,000 psi as determined in accordance with ASTM D2394.
23 . The cement board of claim 1 , wherein the cement board exhibits a compressive strength of from 700 psi to 2,000 psi as determined in accordance with ASTM D2394.
24 . The cement board of claim 1 , wherein the cement board exhibits a compressive strength of from 900 psi to 1,500 psi as determined in accordance with ASTM D2394.
25 . A cement board, comprising:
a core having a first surface and a second surface opposite the first surface and a binder including a cement and a water-resistant additive comprising a metal salt of a fatty acid including a backbone carbon chain having from 12 to 24 carbon atoms, wherein the water-resistant additive is present in an amount of less than 2 wt. % to 0.3 wt. % or more based on the weight of the core;
wherein the cement board exhibits a compressive strength of from 500 psi to 2,500 psi as determined in accordance with ASTM D2394.