Cement sheets and coatings for building construction

A process for manufacturing a continuous flexible cement sheet roll for coating construction elements, the process comprising

• i) preparing a cement mortar mixture by homogenizing hydraulic cement, sand, water, 5-15% polymeric binder added to the mixture with a solvent as a fine dispersion, and up to 10% additives comprising agents selected from plasticizers, superplasticizers, antifoams, thickeners, fillers, dispersants, and viscosity adjusting agents;
• ii) layering said cement mortar mixture onto a heat-resistant surface of a conveyor, the surface optionally covered by a polymeric foil, thereby forming a wet cement mortar layer of a thickness of from 0.5 to 5 mm;
• iii) optionally embedding in said wet cement mortar layer a reinforcing layer of a thickness lower than the thickness of said wet cement mortar layer, selected from a film of a nonwoven fabric, a layer of organic or inorganic fibers, a polymer web, chop strand mat, and fiberglass mat;
• iv) moving said heat resistant surface, optionally with said polymeric foil, bearing said wet cement mortar mixture, optionally with said reinforcing layer, through an oven set at 110-140° C. in which said wet cement mixture sets, thereby forming a flexible solid layer;
• v) peeling said flexible solid layer, optionally with said polymeric foil attached to said flexible layer and lining said flexible layer, from said heat resistant surface, thereby obtaining said continuous flexible cement sheet;
• and
• vi) rolling said flexible cement sheet up, thereby obtaining a roll of readymade continuous separate cement sheet for immediate or future use in coating construction elements, wherein
• the continuous sheet is strong and flexible enough to be unfolded and glued on at least one surface of said construction elements, the elements including foamed or extruded slabs, polystyrene or polyurethane panels, carton slabs, slabs comprising mineral or organic fibers, and metal columns or beams.

A process for manufacturing a construction composite panel comprising a polymer slab core and a cement coat at least on one side of the slab, the process comprising:

• i) preparing a cement mortar mixture by homogenizing hydraulic cement, sand, water, 5-15% polymeric binder added to the mixture as a fine dispersion, and up to 10% additives comprising agents selected from plasticizers, superplasticizers, antifoams, thickeners, fillers, dispersants, and viscosity adjusting agents;
• ii) casting said cement mortar mixture onto a heat-resistant surface of a conveyor, the surface optionally covered by a polymeric foil, thereby forming a wet cement mortar layer of a thickness of from 0.5 to 5 mm;
• iii) optionally embedding a reinforcing layer of a thickness lower than the thickness of said wet cement mortar layer, selected from a film of a nonwoven fabric, a layer of organic or inorganic fibers, a polymer web, chop strand mat, and fiberglass mat, in said wet cement mortar layer;
• iv) setting cement mortar layer by exposing it to a temperature of 110-140° C., in a continuous or in a batch manner, thereby providing a solid and flexible cement layer;
• v) peeling said flexible cement layer, optionally with said polymeric foil, thereby obtaining a continuous flexible cement sheet;
• vi) folding the sheet to provide a roll of separate readymade flexible cement sheet;
• vii) applying glue on one side of said slab core or on one side of said flexible cement sheet after unfolding from the coil, and pressing said cement sheet onto said core, thereby obtaining a composite panel coated on one side;
• viii) optionally gluing said flexible cement sheet on the second side of said slab, thereby obtaining a sandwich building composite panel;
• and
• ix) clearing and cutting the coated slab to desired shape and size;
• thereby obtaining structure elements coated on one or two sides, including sandwich-structured polystyrene panels coated on both sides.