Premixing and dry fibration process

Abstract

The process is described for the dry mixing of fibers of different types and sizes with materials formulated with cementants or agglutinant components, granular aggregates and able to include or otherwise other additional ingredients. The principal characteristics of the process are to ensure a correct incorporation of the fibers with the rest of the materials, increase the mechanical fastening of same with the rest of the components and facilitate the use of formulas with high fiber content (over-fibration).

1 - 34 . (canceled) 
     
     
         35 . A cementitious product comprising a mixture of micro-structured components, comprising:
 fibers having thicknesses of from about 0.02 μm to about 5008 μm and lengths of from about 0.2 mm to about 100 mm;   cementants or agglutinant compounds selected from Portland cement or Puzolana cement, polymers, glass, clay, gum, elastomer, volcanic ash and combinations thereof; and   sandy granular materials having particle sizes from about 400 mesh (0.037 mm) to about 25 mm.   
     
     
         36 . The cementitious product in accordance with  claim 35 , wherein the fibers are organic, inorganic, mineral, non mineral, natural, synthetic or metallic, or mixtures thereof. 
     
     
         37 . The cementitious product in accordance with  claim 35 , wherein the fibers are of the same or different thicknesses and of the same or different lengths. 
     
     
         38 . The cementitious product in accordance with  claim 35 , wherein the fibers are monofilament or multifilament fibers having circular cross-sections or of other naturally occurring or synthetic forms. 
     
     
         39 . The cementitious product in accordance with  claim 36 , wherein the fibers are polymer fibers selected from the group consisting of polyethylene, polypropylene, polyester, polyamide, acrylic, polyvinyl and aramid fibers, and are in an amorphous-cylindrical state. 
     
     
         40 . The cementitious product in accordance with  claim 35 , wherein the fibers have thicknesses of from about 0.02 μm to about 600 μm. 
     
     
         41 . The cementitious product in accordance with  claim 40 , wherein the fibers have thicknesses of from about 100 μm to about 200 μm. 
     
     
         42 . The cementitious product in accordance with  claim 35 , wherein the fibers have lengths from about 3 mm to about 80 mm. 
     
     
         43 . The cementitious product in accordance with  claim 35 , wherein the cementant is Portland cement or Puzolana cement. 
     
     
         44 . The cementitious product in accordance with  claim 35 , wherein the sand granular materials have particle sizes from about 400 mesh to about 9.5 mm. 
     
     
         45 . The cementitious product in accordance with  claim 35 , wherein the sand granular materials have particle sizes from about 0.149 mm to about 9.5 mm. 
     
     
         46 . The cementitious product in accordance with  claim 35 , further comprising water, such that while setting the cementitious product can be formed to a desired shape without forms or molds. 
     
     
         47 . A cementitious product comprising a mixture of micro-structured components, prepared by:
 adding multiple stages of loads of sandy granular materials consisting of particle sizes from 0.149 mm to 9.5 mm and fibers to a mixer;   mixing each bad of said sandy granular materials and fibers for 5 to 10 seconds;   adding and mixing cementant materials to said mixer to form a dry premix product having an isotropic and homogeneous distribution of said fibers;   adding and mixing water; and   unloading said cementitious product from said mixer,   wherein while setting the cementitious product can be formed to a desired shape without forms or molds.   
     
     
         48 . The cementitious product in accordance with  claim 47 , wherein the fibers are organic, inorganic, mineral, non mineral, natural, synthetic or metallic, or mixtures thereof. 
     
     
         49 . The cementitious product in accordance with  claim 47 , wherein the fibers are of the same or different thicknesses and of the same or different lengths. 
     
     
         50 . The cementitious product in accordance with  claim 47 , wherein the fibers are monofilament or multifilament fibers having circular cross-sections or of other naturally occurring or synthetic forms. 
     
     
         51 . The cementitious product in accordance with  claim 50 , wherein the fibers are polymer fibers selected from the group consisting of polyethylene, polypropylene, polyester, polyamide, acrylic, polyvinyl and aramid fibers, and are in an amorphous-cylindrical state. 
     
     
         52 . The cementitious product in accordance with  claim 47 , wherein the fibers have thicknesses of from about 0.02 μm to about 600 μm. 
     
     
         53 . The cementitious product in accordance with  claim 52 , wherein the fibers have thicknesses of from about 100 μm to about 200 μm. 
     
     
         54 . The cementitious product in accordance with  claim 47 , wherein the fibers have lengths from about 3 mm to about 80 mm. 
     
     
         55 . The cementitious product in accordance with  claim 47 , wherein the cementant is Portland cement or Puzolana cement.