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Expert M. Expert has long experience in the selection of material and proportions of cellulose fiber reinforced cement composites. The most commonly used of these composites are manufactured on modified paper machinery in the Hatschek process. This combines wood pulp and Portland cement and other ingredients depending on the method chosen to cure the cement. Where such composites are cured at low temperatures (100C or less) then they usually include synthetic fibers compatible with cement (such as PVA fibers) and small amounts of filler such as ground limestone, clay etc. The cellulose fibers allow the manufacture of the composites on Hatschek machinery while the PVA fibers produce the required strength in the final composite. If the composite is to be autoclave cured (at temperatures around 180C) then synthetic fibers cannot be used as they are destroyed by the alkalinity of the cement and the high temperatures and ground silica sand is added to the cement along with other minerals reactive to the cement to form the matrix. The cellulose fiber in the autoclaved mixes provides the strength of the final composite and allows it to be manufactured on the paper machinery. Expert developed the original formulations for autoclaved cellulose fiber cement and has considerable experience in evaluation of their long-term performance in external environments. He has contributed to the development of coatings for use with fiber cements.

Expert has some 30 years’ experience with Portland cement and concrete products. He has worked in the manufacture of concrete roof tiles, concrete masonry bricks and blocks, concrete pipes, precast concrete, cement based coatings and patterning and in the manufacture of Portland cement itself. His experience has been directed to problem solving in the manufacturing processes, field performance of the products, and testing and product standards. He has considerable experience in the management of production for a variety of concrete products.

Expert has been involved in all aspects of manufacture of cellulose fiber cement composites. This experience has included commissioning of a new fiber cement production plant to manufacture 200 million square feet per year capacity. He was involved from the start of construction of the plant to its commissioning and daily running. He developed the commissioning plan, was a major contributor to the training of operators and set up the quality assurance and testing. He also was involved with the negotiation with suppliers of raw materials and consumables. The plant had commercial grade product within six weeks of the first runs of product from the Hatschek machine. Expert has also been involved with the construction and commissioning of a plant to manufacture sawdust cement blocks and extruded panels.

Expert has been involved with the development of special wood pulp fibers for cellulose fiber cement. He was instrumental in the development of the specifications for softwood pulps for cellulose fiber cement and has worked with pulp suppliers in North America, New Zealand, and Russia.


Expert provided assistance with the review of a test program to develop fiber for fiber cement composites. He assisted a paper and pulp company to set up and interpret the results of an evaluation program to select softwood pulp for fiber cement composites. This included providing advice on the chemistry of cement hydration in autoclave when ground silica is present in the mix and the effect of the presence of wood pulp on these reactions, advice on appropriate specimen manufacturing methods and test methods, assistance in training operators, technical evaluation, and interpretation of the results of the testing. Expert prepared documentation to assist the relocation of a office equipment factory. He spent 10 weeks in documenting all of the manufacturing procedures for the manufacture of wire basket and shelves prior to the removal of the production facility to remote location. All of the drawings were checked for accuracy and the operating procedures for the manufacture of various components were observed, photographed, and written down in a form such that it would have been quite easy to adopt an ISO 9000 quality system. Expert is assisting with the conversion of an asbestos cement manufacturing facility to autoclaved cellulose cement. He is providing technical advice to the contractor undertaking the conversion. This includes advice on the principles of operation of an autoclaved plant, selection of raw materials and materials processing within the facility, layout of plant to provide efficient operation of the factory, detailed process design and evaluation of equipment, selection and purchase of major items of equipment including autoclaving, commissioning of the plant, provision of operating procedures, and quality control measures.He gave expert advice in a patent litigation. He provided advice on prior art on a patent for cutting of fiber cement. The advice resulted in the denial of a patent and the dropping of a lawsuit around that patent. Expert provided technical advice to a housing association. He served as a paid member of a housing association technical committee and acted as the representative on Australian standards on behalf of the association. Advice covered all matters relating to building materials, building products such as boards, bricks and blocks, concrete, and coatings.