TREA

Fiber reinforced cement composition and products and manufacturing process

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Information

  • Patent Application
  • 20070186822
  • Publication Number
    20070186822
  • Date Filed
    February 15, 2006
    18 years ago
  • Date Published
    August 16, 2007
    17 years ago
Information
Abstract
A fiber reinforced cement composition having the following raw material composition is provided to manufacture a fiber reinforced cement product which is excellent in bending strength, dimension stability, handling property, flexibility performance, and processability such as nail performance, as well as to provide a process for manufacturing the product.
Description
Claims
  • 1. A fiber reinforced cement composition comprising the following raw materials: a hydraulic inorganic material, a siliceous material and a woody reinforcement, 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.
  • 2. The fiber reinforced cement composition according to claim 1, wherein the hydraulic inorganic material is a portland cement.
  • 3. The fiber reinforced cement composition according to claim 1, wherein the hydraulic inorganic material is a portland cement having the following chemical composition: SiO2: not less than 18.0% by mass and not more than 23.0% by mass,Al2O3: not less than 2.0% by mass and not more than 6.0% by mass,Fe2O3: not less than 1.0% by mass and not more than 6.0% by mass,CaO: not less than 60.0% by mass and not more than 65.0% by mass,MgO: not more than 6.0% by mass,SO3: not more than 3.0% by mass,Na2O: not more than 0.3% by mass, andK2O: not more than 0.7% by mass.
  • 4. The fiber reinforced cement composition according to claim 1, wherein the hydraulic inorganic material is a portland cement having the following mineral composition: C3S: not less than 60.0% by mass and not more than 65.0% by mass,C2S: not less than 9.0% by mass and not more than 13.0% by mass,C3A: not less than 5.0% by mass and not more than 9.0% by mass, andC4AF: not less than 6.0% by mass and not more than 10.0% by mass.
  • 5. The fiber reinforced cement composition according to claim 1, wherein 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.
  • 6. The fiber reinforced cement composition according to claim 1, wherein the siliceous material is silica sand which contains not less than 98% by mass of SiO2 component.
  • 7. The fiber reinforced cement composition according to claim 1, wherein the siliceous material is silica fume which contains not less than 97% by mass of SiO2 component.
  • 8. The fiber reinforced cement composition according to claim 1, wherein the siliceous material is fly ash which contains not less than 50% by mass and not more than 70% by mass of SiO2 component.
  • 9. The fiber reinforced cement composition according to claim 1, wherein the siliceous material is blast furnace slag which contains not less than 20% by mass and not more than 40% by mass of SiO2 component.
  • 10. The fiber reinforced cement composition according to claim 1, wherein the woody reinforcement is NUKP and/or NBKP having a Canadian standard freeness of not more than 500 ml.
  • 11. The fiber reinforced cement composition according to claim 1, wherein the woody reinforcement is a used paper having a fiber length of not less than 0.5 mm and not more than 3.0 mm, a fiber diameter of not less than 10 μm and not more than 100 μm, and a Canadian standard freeness of not more than 350 ml.
  • 12. The fiber reinforced cement composition according to claim 1, wherein the woody reinforcement is a mixture of two kinds of woody reinforcement.
  • 13. The fiber reinforced cement composition according to claim 1, wherein the woody reinforcement is a mixture of NUKP and/or NBKP and used paper in a ratio of the NUKP and/or NBKP to the used paper in a range of from 1:4 to 4:1.
  • 14. The fiber reinforced cement composition according to claim 1 comprising the following raw material composition: not less than 25% by mass and not more than 45% by mass of the hydraulic inorganic material, not less than 50% by mass and not more than 65% by mass of the siliceous material, and not less than 5% by mass and not more than 12% by mass of the woody reinforcement.
  • 15. The fiber reinforced cement composition according to claim 14, additionally comprising mica in an amount of not less than 1% by mass and not more than 7% by mass of the composition.
  • 16. The fiber reinforced cement composition according to claim 14, additionally comprising a water-soluble resin in an amount of not less than 0.25% by mass and not more than 1.5% by mass of the composition.
  • 17. The fiber reinforced cement composition according to claim 14, additionally comprising mica in an amount of not less than 1% by mass and not more than 7% by mass and a water-soluble resin in an amount of not less than 0.25% by mass and not more than 1.5% by mass based on the composition.
  • 18. A 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 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, wherein the amount of the silica fume is not less than 3% by mass and not more than 7% by mass of the whole 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 NUKP and/or NBKP and used paper as a woody reinforcement, wherein 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 NUKP and/or NBKP and the used paper, 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 mass ratio of CaO to SiO2 in the raw materials consisting of the hydraulic inorganic material and the siliceous material is in a range of from 30:70 to 40:60.
  • 19. A 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 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, wherein the amount of the silica fume is not less than 5% by mass and not more than 20% by mass of the whole 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 NUKP and/or NBKP and used paper as a woody reinforcement, wherein 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 NUKP and/or NBKP and the used paper, 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 mass ratio of CaO to SiO2 in the raw materials consisting of the hydraulic inorganic material and the siliceous material is in a range of from 50:50 to 60:40.
  • 20. A 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 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, wherein the amount of the fly ash is not less than 30% by mass and not more than 70% by mass of the whole siliceous material consisting of the fly ash and the blast furnace slag, not less than 8% by mass and not more than 12% by mass in total of NUKP and/or NBKP and used paper as a woody reinforcement, wherein 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 NUKP and/or NBKP and the used paper, 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 mass ratio of CaO to SiO2 in the raw materials consisting of the hydraulic inorganic material and the siliceous material is in a range of from 40:60 to 60:40.
  • 21. A 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 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 NUKP and/or NBKP and used paper as a woody reinforcement, wherein 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 NUKP and/or NBKP and the used paper, 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 mass ratio of CaO to SiO2 in the raw materials consisting of the hydraulic inorganic material and the siliceous material is in a range of from 23:77 to 35:65.
  • 22. A fiber reinforced cement product manufactured from the fiber reinforced cement composition according to any of claims 18 to 21.
  • 23. 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 and a woody reinforcement 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.