Fiber reinforced cement composition and products and manufacturing process

A fiber reinforced cement composition comprising the following raw material composition:

• not less than 28% by mass and not more than 32% by mass of portland cement as a 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 a siliceous material;
• 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;
• 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 polyvinyl alcohol resin, wherein
• the mass ratio of CaO to SiO2, in the hydraulic inorganic material and the siliceous material is in a range of from 30:70 to 40:60,
• the amount of the silica fume is not less than 3% by mass and not more than 7% by mass of the total amount of the fly ash and the silica fume,
• the fly ash contains 50-70% by mass of SiO2 component,
• the silica fume contains not less than 97% by mass of SiO2 component,
• the amount of the used paper 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 needle-leaves-tree bleached kraft pulp and used newspaper.

A fiber reinforced cement composition comprising the following raw material composition:

• not less than 28% by mass and not more than 32% by mass of portland cement as a 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 a siliceous material,
• 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,
• 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 polyvinyl alcohol resin, wherein
• the mass ratio of CaO to SiO2 in the hydraulic inorganic material and the siliceous material is in a range of from 50:50 to 60:40,
• the amount of the silica fume is not less than 5% by mass and not more than 20% by mass of total amount of the blast furnace slag and the silica fume,
• the blast furnace slag contains 20-40% by mass of SiO2 component,
• the silica fume contains not less than 97% by mass of SiO2 component, and
• the amount of the used paper is not less than 20% by mass and not more than 50% by mass of the total amount of the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp and the used newspaper.

A fiber reinforced cement composition comprising the following raw material composition:

• not less than 28% by mass and not more than 32% by mass of portland cement as a hydraulic inorganic material,
• not less than 54% by mass and not more than 58% by mass in total of fly ash and blast furnace slag as a siliceous material,
• 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, and
• not less than 0.5% by mass and not more than 1.25% by mass of a polyvinyl alcohol resin, wherein
• the mass ratio of CaO to SiO2 in the hydraulic inorganic material and the siliceous material is in a range of from 40:60 to 60:40,
• the fly ash contains 50-70% by mass of SiO2 component,
• the blast furnace slag contains 20-40% by mass of SiO2 component,
• the amount of the fly ash is not less than 30% by mass and not more than 70% by mass of total amount of the fly ash and the blast furnace slag, and
• the amount of the used paper 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, not less than 2% by mass and not more than 5% by mass of mica.

A fiber reinforced cement composition comprising the following raw material composition:

• not less than 28% by mass and not more than 32% by mass of portland cement as a hydraulic inorganic material,
• not less than 54% by mass and not more than 58% by mass in total of silica sand and silica fume as a siliceous material,
• 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,
• 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 polyvinyl alcohol resin, wherein
• the mass ratio of CaO to SiO2 in the hydraulic inorganic material and the siliceous material is in a range of from 23:77 to 35:65,
• the silica sand contains not less than 98% by mass of SiO2 component,
• the silica fume contains not less than 97% by mass of SiO2 component, and
• the amount of the used paper is not less than 20% by mass and not more than 50% by mass of total amount of the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp and the used newspaper.

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

• dispersing in water a raw material composition comprising as main raw materials a hydraulic inorganic material, a siliceous material, a woody reinforcement, mica, and a polyvinyl alcohol resin mixed in a mass ratio of CaO to SiO2 contained in the hydraulic inorganic material and the siliceous material in the raw materials in a range of from 23:77 to 60:40 to give a slurry of the raw materials;
• forming a green mat from 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 hydraulic inorganic material is a portland cement,
• the siliceous material is silica sand and/or silica fume and/or fly ash and/or blast furnace slag and/or perlite powder and/or glass powder,
• a woody reinforcement is needle-leaves-tree unbleached kraft pulp and/or needle-leaves-tree bleached kraft pulp and used newspaper.

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 a woody reinforcement;
• not less than 1% by mass and not more than 7% by mass of a mica;
• and
• not less than 0.25% by mass and not more than 1.5% by mass of a polyvinyl alcohol resin, wherein
• the mass ratio of CaO to SiO2 (CaO :
• SiO2) contained in the hydraulic inorganic material and the siliceous material in the raw materials is in a range of from 23:77 to 60:40,
• the hydraulic inorganic material is a portland cement,
• the siliceous material is silica sand and/or silica fume and/or fly ash and/or blast furnace slag and/or perlite powder and/or glass powder,
• a woody reinforcement is needle-leaves-tree unbleached kraft pulp and/or needle-leaves-tree bleached kraft pulp and used newspaper.

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 a 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 a siliceous material;
• 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;
• 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 polyvinyl alcohol resin, wherein
• the mass ratio of CaO to SiO2 in the hydraulic inorganic material and the siliceous material is in a range of from 30:70 to 40:60,
• the amount of the silica fume is not less than 3% by mass and not more than 7% by mass of the total amount of the fly ash and the silica fume,
• the fly ash contains 50-70% by mass of SiO2 component,
• the silica fume contains not less than 97% by mass of SiO2 component,
• the amount of the used paper 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 needle-leaves-tree bleached kraft pulp and used newspaper.

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 a 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 a siliceous material,
• 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,
• 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 polyvinyl alcohol resin, wherein
• the mass ratio of CaO to SiO2 in the hydraulic inorganic material and the siliceous material is in a range of from 50:50 to 60:40,
• the amount of the silica fume is not less than 5% by mass and not more than 20% by mass of total amount of the blast furnace slag and the silica fume,
• the blast furnace slag contains 20-40% by mass of SiO2 component,
• the silica fume contains not less than 97% by mass of SiO2 component, and
• the amount of the used paper is not less than 20% by mass and not more than 50% by mass of the total amount of the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp and the used newspaper.

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 a hydraulic inorganic material,
• not less than 54% by mass and not more than 58% by mass in total of fly ash and blast furnace slag as a siliceous material,
• 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, and
• not less than 0.5% by mass and not more than 1.25% by mass of a polyvinyl alcohol resin, wherein
• the mass ratio of CaO to SiO2 in the hydraulic inorganic material and the siliceous material is in a range of from 40:60 to 60:40,
• the fly ash contains 50-70% by mass of SiO2 component,
• the blast furnace slag contains 20-40% by mass of SiO2 component,
• the amount of the fly ash is not less than 30% by mass and not more than 70% by mass of total amount of the fly ash and the blast furnace slag, and
• the amount of the used paper 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, not less than 2% by mass and not more than 5% by mass of mica.

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 a hydraulic inorganic material,
• not less than 54% by mass and not more than 58% by mass in total of silica sand and silica fume as a siliceous material,
• 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,
• 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 polyvinyl alcohol resin, wherein
• the mass ratio of CaO to SiO2 in the hydraulic inorganic material and the siliceous material is in a range of from 23:77 to 35:65,
• the silica sand contains not less than 98% by mass of SiO2 component,
• the silica fume contains not less than 97% by mass of SiO2 component, and
• the amount of the used paper is not less than 20% by mass and not more than 50% by mass of total amount of the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp and the used newspaper.