Fiber reinforced cement composition and products and manufacturing process
The problems to be solved by the invention are to provide a fiber reinforced cement composition for obtaining a fiber reinforced cement product which is inexpensive and economical, and to provide pushing forward disposal of defective products. Namely, the fiber reinforced cement composition comprises a hydraulic inorganic material, a siliceous material, a woody reinforcement and a finely dividing fiber reinforced cement product which is produced by said raw materials and cured in an autoclave.
1. A fiber reinforced cement composition comprising the following raw materials:
a hydraulic inorganic material;
a siliceous material;
a woody reinforcement;
fiber reinforced cement particles having average particle size of 15-50 μm;
mica; and
polyvinyl alcohol resin, wherein
the amount of the woody reinforcement is not less than 6% by mass and not more than 12% by mass;
the woody reinforcement comprises needle-leaves-tree unbleached kraft pulp and/or needle-leaves-tree bleached kraft pulp and used newspaper,
the amount of the used newspaper is not less than 1% by mass and not more than 20% by mass of the whole woody reinforcement consisting of the used newspaper and the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp,
the amount of the fiber reinforced cement particles is not less than 5% by mass and not more than 20% by mass, and
the fiber reinforced cement particles are obtained by grinding and/or milling a fiber reinforced cement product which is obtained by curing raw materials comprising a hydraulic inorganic material, a siliceous material and a woody reinforcement in an autoclave.
2. The fiber reinforced cement composition according to claim 1 , wherein
the hydraulic inorganic material is Portland cement, and
the siliceous material is pearlstone and/or fly ash.
3. A fiber reinforced cement composition comprising the following raw materials:
not less than 27% by mass and not more than 35% by mass of a hydraulic inorganic material;
not less than 36% by mass and not more than 60% by mass of a siliceous material;
not less than 6% by mass and not more than 12% by mass of a woody reinforcement;
not less than 5% by mass and not more than 20% by mass of fiber reinforced cement particles having average particle size of 15-50 μm;
not less than 1% by mass and not more than 7% by mass of mica;
not less than 0.25% by mass and not more than 1.25% by mass of a polyvinyl alcohol resin, wherein
the woody reinforcement comprises needle-leaves-tree unbleached kraft pulp and/or needle-leaves-tree bleached kraft pulp and used newspaper,
the amount of the used newspaper is not less than 1% by mass and not more than 20% by mass of the whole woody reinforcement consisting of the used newspaper and the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp, and
the fiber reinforced cement particles are obtained by grinding and/or milling a fiber reinforced cement product which is obtained by curing raw materials comprising a hydraulic inorganic material, a siliceous material and a woody reinforcement in an autoclave.
4. The fiber reinforced cement composition according to claim 3 , wherein
the hydraulic inorganic material is Portland cement, and
the siliceous material is pearlstone and/or fly ash.
5. A fiber reinforced cement product comprising the following raw materials:
not less than 27% by mass and not more than 35% by mass of a hydraulic inorganic material;
not less than 36% by mass and not more than 60% by mass of a siliceous material;
not less than 6% by mass and not more than 12% by mass of a woody reinforcement;
not less than 5% by mass and not more than 20% by mass of fiber reinforced cement particles having average particle size of 15-50 μm;
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 1.25% by mass of a polyvinyl alcohol resin, wherein
the woody reinforcement comprises needle-leaves-tree unbleached kraft pulp and/or needle-leaves-tree bleached kraft pulp and used newspaper,
the amount of the used newspaper is not less than 1% by mass and not more than 20% by mass of the whole woody reinforcement consisting of the used newspaper and the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp, and
the fiber reinforced cement particles are obtained by grinding and/or milling a fiber reinforced cement product which is obtained by curing raw materials comprising a hydraulic inorganic material, a siliceous material and a woody reinforcement in an autoclave.
6. The fiber reinforced cement product according to claim 5 , wherein
the hydraulic inorganic material is Portland cement, and
the siliceous material is pearlstone and/or fly ash.
7. The fiber reinforced cement composition according to claim 1 , wherein the polyvinyl alcohol resin is a powdery polyvinyl alcohol resin having a saponification value 98 mol % or higher.
8. The fiber reinforced cement composition according to claim 7 , wherein
the amount of the hydraulic inorganic material is not less than 27% by mass and not more than 35% by mass;
the amount of siliceous material is not less than 36% by mass and not more than 60% by mass; and
the amount of mica is not less than 1% by mass and not more than 7% by mass of mica.
9. The fiber reinforced cement composition according to claim 7 , wherein
the hydraulic inorganic material is Portland cement, and
the siliceous material is pearlstone and/or fly ash.
10. A fiber reinforced cement product comprising the following raw materials:
a hydraulic inorganic material;
a siliceous material;
a woody reinforcement;
fiber reinforced cement particles having average particle size of 15-50 μm;
mica; and
polyvinyl alcohol resin, wherein
the amount of the woody reinforcement is not less than 6% by mass and not more than 12% by mass;
the woody reinforcement comprises needle-leaves-tree unbleached kraft pulp and/or needle-leaves-tree bleached kraft pulp and used newspaper,
the amount of the used newspaper is not less than 1% by mass and not more than 20% by mass of the whole woody reinforcement consisting of the used newspaper and the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp,
the amount of the fiber reinforced cement particles is not less than 5% by mass and not more than 20% by mass, and
the fiber reinforced cement particles are obtained by grinding and/or milling a fiber reinforced cement product which is obtained by curing raw materials comprising a hydraulic inorganic material, a siliceous material and a woody reinforcement in an autoclave.
11. The fiber reinforced cement product according to claim 10 , wherein
the hydraulic inorganic material is Portland cement, and
the siliceous material is pearlstone and/or fly ash.
12. The fiber reinforced cement product according to claim 10 , wherein the polyvinyl alcohol resin is a powdery polyvinyl alcohol resin having a saponification value of 98 mol % or higher.
13. The fiber reinforced cement product according to claim 12 , wherein
the amount of the hydraulic inorganic material is not less than 27% by mass and not more than 35% by mass;
the amount of siliceous material is not less than 36% by mass and not more than 60% by mass; and
the amount of mica is not less than 1% by mass and not more than 7% by mass of mica.
14. The fiber reinforced cement product according to claim 12 , wherein
the hydraulic inorganic material is Portland cement, and
the siliceous material is pearlstone and/or fly ash.
15. A process for manufacturing a fiber reinforced cement product which comprises the following steps:
preparing a slurry by dispersing in water a mixture of the following raw materials:
a hydraulic inorganic material;
a siliceous material;
a woody reinforcement;
fiber reinforced cement particles having average particle size of 15-50 μm;
mica; and
polyvinyl alcohol resin, wherein
the amount of a woody reinforcement is not less than 6% by mass and not more than 12% by mass,
the woody reinforcement comprises needle-leaves-tree unbleached kraft pulp and/or needle-leaves-tree bleached kraft pulp and used newspaper,
the amount of the used newspaper is not less than 1% by mass and not more than 20% by mass of the whole woody reinforcement consisting of the used newspaper and the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp,
the amount of the fiber reinforced cement particles is not less than 5% by mass and not more than 20% by mass, and
the fiber reinforced cement particles are obtained by grinding and/or milling a fiber reinforced cement product which is obtained by curing raw materials comprising a hydraulic inorganic material, a siliceous material and a woody reinforcement in an autoclave;
forming a green mat by forming the slurry;
press-molding the green mat; and
curing the press mat in an autoclave.
16. The process for manufacturing the fiber reinforced cement product according to claim 15 , wherein
the hydraulic inorganic material is Portland cement, and
the siliceous material is pearlstone and/or fly ash.
17. The process for manufacturing the fiber reinforced cement product according to claim 15 , wherein the polyvinyl alcohol resin is a powdery polyvinyl alcohol resin having a saponification value of 98 mol % or higher.
18. The process for manufacturing the fiber reinforced cement product according to claim 17 , wherein
the amount of the hydraulic inorganic material is not less than 27% by mass and not more than 35% by mass;
the amount of siliceous material is not less than 36% by mass and not more than 60% by mass; and
the amount of mica is not less than 1% by mass and not more than 7% by mass of mica.
19. The process for manufacturing the fiber reinforced cement product according to claim 17 , wherein
the hydraulic inorganic material is Portland cement, and
the siliceous material is pearlstone and/or fly ash.
20. A process for manufacturing a fiber reinforced cement product which comprises the following steps:
preparing a slurry by dispersing in water a mixture of following raw materials:
not less than 27% by mass and not more than 35% by mass of a hydraulic inorganic material;
not less than 36% by mass and not more than 60% by mass of a siliceous material;
not less than 6% by mass and not more than 12% by mass of a woody reinforcement;
not less than 5% by mass and not more than 20% by mass of fiber reinforced cement particles having average particle size of 15-50 μm;
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 1.25% by mass of a polyvinyl alcohol resin, wherein
the woody reinforcement comprises needle-leaves-tree unbleached kraft pulp and/or needle-leaves-tree bleached kraft pulp and used newspaper,
the amount of the used newspaper is not less than 1% by mass and not more than 20% by mass of the whole woody reinforcement consisting of the used newspaper and the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp, and
the fiber reinforced cement particles are obtained by grinding and/or milling a fiber reinforced cement product which is obtained by curing raw materials comprising a hydraulic inorganic material, a siliceous material and a woody reinforcement in an autoclave;
forming a green mat by forming the slurry;
press-molding the green mat; and
curing the press mat in an autoclave.
21. The process for manufacturing the fiber reinforced cement product according to claim 20 , wherein
the hydraulic inorganic material is Portland cement,
the siliceous material is pearlstone and/or fly ash.