Fiber reinforced cement composition and products and manufacturing process

The fiber reinforced cement composition having the following raw material composition:

• not less than 28% by mass and not more than 32% by mass of Portland cement as hydraulic inorganic material;
• not less than 54% by mass and not more than 58% by mass in total of fly ash and silica fume as an amorphous siliceous material;
• not less than 2% by mass and not more than 5% by mass of mica;
• and
• not less than 0.5% by mass and not more than 1.25% by mass of a water-soluble resin, wherein
• the amount of the silica fume is not less than 3% by mass and not more than 7% by mass of the whole amorphous siliceous material consisting of the fly ash and the silica fume, not less than 8% by mass and not more than 12% by mass in total of needle-leaves-tree unbleached kraft pulp and/or needle-leaves-tree bleached kraft pulp and used newspaper as a woody reinforcement, wherein the amount of the used newspaper is not less than 20% by mass and not more than 50% by mass of the whole woody reinforcement consisting of the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp and the used newspaper,
• the fly ash contains 50-70% by mass of SiO2,
• the silica fume contains 97% by mass or more of and
• the water-soluble resin is a polyvinyl alcohol resin.

The fiber reinforced cement composition having the following raw material composition:

• not less than 28% by mass and not more than 32% by mass of Portland cement as hydraulic inorganic material;
• not less than 54% by mass and not more than 58% by mass in total of blast furnace slag and silica fume as an amorphous siliceous material;
• not less than 2% by mass and not more than 5% by mass of mica;
• and
• not less than 0.5% by mass and not more than 1.25% by mass of a water-soluble resin, wherein
• the amount of the silica fume is not less than 5% by mass and not more than 20% by mass of the whole amorphous siliceous material consisting of the blast furnace slag and the silica fume, not less than 8% by mass and not more than 12% by mass in total of needle-leaves-tree unbleached kraft pulp and/or needle-leaves-tree bleached kraft pulp and used newspaper as a woody reinforcement, wherein the amount of the used newspaper is not less than 20% by mass and not more than 50% by mass of the whole woody reinforcement consisting of the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp and the used newspaper,
• the blast furnace slag contains 20-40% by mass of SiO2,
• the silica fume contains 97% by mass or more of SiO2, and
• the water-soluble resin is a polyvinyl alcohol resin.

The fiber reinforced cement composition having the following raw material composition:

• not less than 28% by mass and not more than 32% by mass of Portland cement as hydraulic inorganic material;
• not less than 54% by mass and not more than 58% by mass in total of blast furnace slag and fly ash as an amorphous siliceous material;
• not less than 2% by mass and not more than 5% by mass of mica;
• and
• not less than 0.5% by mass and not more than 1.25% by mass of a water-soluble resin, wherein
• the amount of the fly ash is not less than 30% by mass and not more than 70% by mass of the whole amorphous siliceous material consisting of the blast furnace slag and the fly ash, not less than 8% by mass and not more than 12% by mass in total of needle-leaves-tree unbleached kraft pulp and/or needle-leaves-tree bleached kraft pulp and used newspaper as a woody reinforcement, wherein the amount of the used newspaper is not less than 20% by mass and not more than 50% by mass of the whole woody reinforcement consisting of the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp and the used newspaper,
• the fly ash contains 50-70% by mass of SiO2,
• the blast furnace slag contains 20-40% by mass of SiO2, and
• the water-soluble resin is a polyvinyl alcohol resin.

A process for manufacturing a fiber reinforced cement product comprising the steps of:

• dispersing in water a raw material composition to give a slurry of the raw materials;
• forming a green mat by forming the slurry;
• and
• pressing the green mat by press molding and thereafter curing the mat in an autoclave at a temperature not lower than 150° C., wherein
• the raw material composition comprises:
• not less than 25% by mass and not more than 45% by mass of a hydraulic inorganic material;
• not less than 50% by mass and not more than 65% by mass of a siliceous material;
• not less than 5% by mass and not more than 12% by mass of woody reinforcement;
• not less than 1% by mass and not more than 7% by mass of mica;
• and
• not less than 0.25% by mass and not more than 1.5% by mass of a water-soluble resin, wherein
• the hydraulic inorganic material is a Portland cement,
• the siliceous material is amorphous material, and is fly ash and/or silica fume and/or blast furnace slag and/or perlite powder and/or glass powder,
• the woody reinforcement is needle-leaves-tree unbleached kraft pulp and/or needle-leaves-tree bleached kraft pulp and used newspaper, and
• the water-soluble resin is a polyvinyl alcohol resin.

A process for manufacturing a fiber reinforced cement product comprising the steps of:

• dispersing in water a raw material composition to give a slurry of the raw materials;
• forming a green mat by forming the slurry;
• and
• pressing the green mat by press molding and thereafter curing the mat in an autoclave at a temperature not lower than 150° C., wherein
• the raw material composition comprises:
• not less than 28% by mass and not more than 32% by mass of Portland cement as hydraulic inorganic material;
• not less than 54% by mass and not more than 58% by mass in total of fly ash, and silica fume as an amorphous siliceous material;
• not less than 2% by mass and not more than 5% by mass of mica;
• and
• not less than 0.5% by mass and not more than 1.25% by mass of a water-soluble resin, wherein
• the amount of the silica fume is not less than 3% by mass and not more than 7% by mass of the whole amorphous siliceous material consisting of the fly ash and the silica fume, not less than 8% by mass and not more than 12% by mass in total of needle-leaves-tree unbleached kraft pulp and/or needle-leaves-tree bleached kraft pulp and used newspaper as a woody reinforcement, wherein the amount of the used newspaper is not less than 20% by mass and not more than 50% by mass of the whole woody reinforcement consisting of the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp and the used newspaper,
• the fly ash contains 50-70% by mass of SiO2,
• the silica fume contains 97% by mass or more of SiO2, and
• the water-soluble resin is a polyvinyl alcohol resin.

A process for manufacturing a fiber reinforced cement product comprising the steps of:

• dispersing in water a raw material composition to give a slurry of the raw materials;
• forming a green mat by forming the slurry;
• and
• pressing the green mat by press molding and thereafter curing the mat in an autoclave at a temperature not lower than 150° C., wherein
• the raw material composition comprises:
• not less than 28% by mass and not more than 32% by mass of Portland cement as hydraulic inorganic material;
• not less than 54% by mass and not more than 58% by mass in total of blast furnace slag and silica fume as an amorphous siliceous material;
• not less than 2% by mass and not more than 5% by mass of mica;
• and
• not less than 0.5% by mass and not more than 1.25% by mass of a water-soluble resin, wherein
• the amount of the silica fume is not less than 5% by mass and not more than 20% by mass of the whole amorphous siliceous material consisting of the blast furnace slag and the silica fume, not less than 8% by mass and not more than 12% by mass in total of needle-leaves-tree unbleached kraft pulp and/or needle-leaves-tree bleached kraft pulp and used newspaper as a woody reinforcement, wherein the amount of the used newspaper is not less than 20% by mass and not more than 50% by mass of the whole woody reinforcement consisting of the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp and the used newspaper,
• the blast furnace slag contains 20-40% by mass of SiO2,
• the silica fume contains 97% by mass or more of SiO2, and
• the water-soluble resin is a polyvinyl alcohol resin.

A process for manufacturing a fiber reinforced cement product comprising the steps of:

• dispersing in water a raw material composition to give a slurry of the raw materials;
• forming a green mat by forming the slurry;
• and
• pressing the green mat by press molding and thereafter curing the mat in an autoclave at a temperature not lower than 150° C., wherein
• the raw material composition comprises:
• not less than 28% by mass and not more than 32% by mass of Portland cement as hydraulic inorganic material;
• not less than 54% by mass and not more than 58% by mass in total of blast furnace slag and fly ash as an amorphous siliceous material;
• not less than 2% by mass and not more than 5% by mass of mica;
• and
• not less than 0.5% by mass and not more than 1.25% by mass of a water-soluble resin, wherein
• the amount of the fly ash is not less than 30% by mass and not more than 70% by mass of the whole amorphous siliceous material consisting of the blast furnace slag and the fly ash, not less than 8% by mass and not more than 12% by mass in total of needle-leaves-tree unbleached kraft pulp and/or needle-leaves-tree bleached kraft pulp and used newspaper as a woody reinforcement, wherein the amount of the used newspaper is not less than 20% by mass and not more than 50% by mass of the whole woody reinforcement consisting of the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp and the used newspaper,
• the fly ash contains 50-70% by mass of SiO2,
• the blast furnace slag contains 20-40% by mass of SiO2, and
• the water-soluble resin is a polyvinyl alcohol resin.