liapor industry.pdf

7/27/2019 liapor industry.pdf

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powered by rohrbach technology

LIAPOR | lightweight aggregate plants


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MERTEC engineering within MERTEC group

process

engineering products maintenance machinery

construction

divisions

businessunits

technology

solutions

customer

service

refractory

service

machinery

solutions

project

managemen

t

product

solutions

mechanical

service

machinery

service

MERTEC TECHNOLOGY GROUP

providing turn-key solutions for LIAPOR production plants of

lightweight expanded clay aggregate

process powered y ROHRbACH TECHNOLOGY

experience competence qualityThe Rohrach Technology developed the process to manufacture high quality lightweight expanded

clay aggregate under the rand name LIAPOR some 40 years ago. MERTEC technology group in

collaoration with Rohrach Technology provides the technology of the production process with the

respective plant design and realization capailities.

our services:

Consulting:

Overall engineering including all specific Know-How for the Implementation of a Liapor-LWA-Plant

Raw material investigation

Setting up tender documents for all mechanical and electrical equipment to e used in the process

Managing idding and ordering process and for implementation and commissioning of the plant

Training of key manufacturing personnel

We provide all specific Know-How for the Implementation of a plant to the equipment manufacturer

Contracting:

General Contractor for turn key plant solutions if requested

Support in interface control of the different assemly sections


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technology solutions - bridging your visions into reality


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Identifica-

tion and

validation

of

customers

usiness

potential.

Definition

of possile

solutions.

Joint

definition.

Project

planning

and plant

design of

selected

approach.

Elaoration

of

contracting

plan and

project

timing.Definition

of sequen-

ces for the

installation

process.

Production

and pro-

curement of

assets

according

to QA/QC

program.

Allocation

of goods

according

to time

schedule

to construc-

tion site.

Erection,

assemly

and installa-

tion of

machinery

and compo-

nents to the

integrated

plant

system.

QA/QC of

constructionwork.

Review and

verification

of achieved

plant

perfor-

mance and

conclusion

of further

improve-

ment

potential.

Testing, trial

operation

until

reaching

normal

operation

conditions.

Demonstra-

tion of plant

perfor-

mance.

Provisionalaccaptance.

beneftevaluation

In order to achieve a fully functional operating unit, MERTEC incorporates the overall scope of competences:

Solutions provision, tailored to the individual requirements of the production process

Field-proven components, selected y MERTEC from renowned manufacturers, fulfilling highest quality requirements.

Extensive process know-how, with the aility to optimise each stage to ensure the client maximum profitaility.

MERTEC provides the skills and competence to optimise and orchestrate the interplay of these essential elements,

creating the asis for successful projects and maximum results.

commissio

ning

constructio

n

transport

fabrication

engineerin

g

solutionpr

oposal

opportunity

evaluation

Designated project methodology, seamlessly joins the projects eight phases:

production plant


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project management

project management

Project execution with MERTEC means the close

collaoration with the customer and following a synchronised

project methodology.

On regular times the project coordination with the customer

forms the asis for a transparent review, control and

follow-up with conclusive measures for design, planning,

faricating, supplying, constructing and commissioning.

The MERTEC project management division assures a

professional implementation of projects and applies their

expertise, to the design and optimization of the productionprocess.

MERTEC has the capaility to develop usiness

opportunities and apply synchronised project management

methodology to any project type and execution mode.

venture developmentPlant auditing focused on process performance,

costs and organisation enchmarking

Opportunity and feasiility studiesPlant master, action & investment plans

Appraisal of manufacturing performance

project: turnkey expanded clay plant with rotary kilnsproject coordination at site

project management focusProject implementation control

Timely direct and relevent communication on the project

status and planning

QA / QC supervision system during engineering,

farication and construction

Realization of cost cutting measures during project

planning and project implementation with the aim

of reducing investment and production costs striving for

maximum return on investment

Project control through strict adherence of the agreedproject time and cost frame

project typesUpgrade & retrofit projects

Plant extensions

Plant conversions

Green-field plants

Modernizations & modifications

project execution modesFull- & semi turn key contracting (EPCC)

Package contracting

Full- & semi detail contracting


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lightweight aggregate concrete in constructionLightweight aggregate concrete (LAC) comines all the enefits of ordinary concrete construction in addition to the fact of

having low weight material. In LAC the lightweight aggregate replaces gravel and natural sand in order to decrease the

specific weight of the concrete while retaining concrete strength.

LAC is produced in different categories, corresponding to the specific needs of constructions.

structural LACIn standard categories with specific densities etween 1000 and 1800 kg/m3 (normal concrete approx. 2300 kg/m3) for

reinforced, load earing concrete structures of high compressive strength for constructions such as:

multi-storey office uildings, apartments, uildings, etc.industrial uildings

ridges and fly-over

low-density LACLow-fines concrete with specific densities etween 600 and 1000 kg/m3 is especially suited for thermal insulation and Ioad-

earing concretes such as masonry locks large size and large-size wall elements in:

private housing

office uildings

school uildingspulicuildings

with technology to aggregatefrom nature


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liapor-LWA and liapor-LAC

liapor-LWA (lightweight aggregate)offers many advantages such as:

produced in any desired ulk density and grain size

suitale for LWA concrete at almost any

density for any strength requirement

produced with high uniformity, superior to international

standard requirements

high compressive particle strength at low specific weight

ideal spherical shape for easy concrete compaction

liapor-LAC (lightweight aggregate concrete)offers a maximum of creative freedom in design to

architects and engineers such as:

reduction in weight of uilding structures and

load-earing elements

high thermal insulation and temperature retention

properties

noise asorption properties

increased fire resistance

good duraility in sea water atmosphereresistance to water penetration like normal concrete

numerous advantages in seismic areas

cost savingsLiapor LAC offers extensive construction cost savings in:

foundations

reinforcing steel

concrete mass reduction

design of facade and wall thickness

material transport

construction time and laour

Other areas of Liapor-LWA application are:

drainage and aeration of soil

filter media for sewage treatment

hydroculture

animal housing

Liapor-LWA for fill in is used for flat-roof insulation, in ground

slas, etween floor joints, in concrete sufloors, as insulat-

ing fill for pipe ducts etc.

lightweight aggregate

specifc products diverse projectscontrolled aggregates


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Liapor production started in 1967. The Liapor technology has een applied in numerous plants in Europe. by the year 2009,

more than 40 million cuic meters have een produced on the asis of this technology.

Liapor LWA plants have een uilt up to a capacity of 400,000 cuic meters per year and production line.

innovative technology:Liapor production plants comprise innovative technology:process different clays composition to high quality LWA

run with high availaility and are operated under support of modern electronic control device

produce uniform, predetermined grain sizes of pellets within small ulk densities ranges

operate with low thermal energy consumption

operate with any type of fuel such as heavy oil, coal,

natural gas and even rice hulls

raw material:The raw material used for the production of expanded LWA y the Liapor process may e plastic or solid clay. Recommenda-

tions for raw material selection are given y our form (on demand). Suitaility will e checked in our laoratory.

raw material preparation:The raw material preparation will e performed either y dry preparation process for solid clay or y plastic preparation proc-

ess for plastic and wet clay. In any case, pellets within a small particle sizes range are formed and fed into the rotary kiln.

urning and expanding:The heart of the Liapor process is its two stage rotary kiln, with two separate, doule fired preheater and expansion kilns

and as a third element the rotary cooler. Through a separately controlled preheating process, the pellets go through an

ideal preconditioning efore entering the expansion kiln where the pellet expansion is precisely controlled in order to get a

finished product with very uniform ulk density.

The dedusting system of the kiln exhaust gases will meet strict environmental regulatory requirements.

liapor production


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aggregate production

liapor production plant, aleksin russia

1 Preheater kiln

2 Expansion kiln

3 Rotary cooler

The heart of the Liapor production Process is the 3-stage-

rotary-kiln.

Further characteristics are:

Separately fired preheater and expansion kiln secure

optimal controlled product density with minimal variation.

The Liapor production Process operates with excellent

fuel efficiency. Oil, natural gas, coal and even rice hulls

can e used as fuel.

Clays or shales as raw materials will e processedaccording to their specific raw material properties in

order to get high quality Liapor LWA.

Kiln and other exhaust gases will e cleaned in order to

meet environmental regulatory requirements.

the liapor production process1

2

3


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LWA bulk Dens. kg/m3 324 320 400 510 610 610 720 720 720 810 810

Type of Sand Liapor * * * * * * *

Natural * * * * * *

Type of Cement CEM I 42,5 R 42,5 R 42,5 R 42,5 R 42,5 R 42,5 R 42,5 R 42,5 R 52,5 R 52,5 R 52,5 R

Cement portion kg/m3 420 350 350 350 350 350 350 350 380 380 400

Microsilica SPP * +

foam additive *

Concrete Unit Weight

fresh kg/m3 1059 1310 1350 1430 1480 1710 1620 1840 1820 1890 1760

7 days kg/m3 1290 1320 1400 1460 1670 1600 1830 1790 1880

28 days kg/m3 1260 1310 1380 1440 1650 1550 1800 1750 1860

dry kg/m3 900 1110 1160 1230 1260 1520 1390 1610 1580 1720 1570

Compressive Strength

1 day 273 days 51

7 days N/mm2 12,4 15 20 30 34 36 34 38 44,8 57 53

28 days N/mm2 14,4 19 22 33 40 41 41,4 47 54 68 70

56 days N/mm2 16,7 76

Three Point bending Test

28 days N/mm2 5 5 5,7 5,8 5,4 5,4 5,6 5,5 6,3

Type of Liapor Particle Size Bulk Density Tolerance Particle Gravity

mm kg/m3 kg/m3 kg/litre

Liapor 3 4 to 8 and 8 to 16 325 + -25 0,60

Liapor 4 4 to 8 and 8 to 16 400 + -25 0,75

Liapor 5 4 to 8 and 8 to 16 500 + -25 0,95

Liapor 6 4 to 8 and 8 to 16 600 + -25 1,10

Liapor 7 4 to 8 and 8 to 16 700 + -25 1,30

Liapor 8 4 to 8 and 8 to 16 800 + -25 1,50

Liapor Sand 0 to 4 700 + -25 1,60

liapor-lightweight-aggregate-concrete

liapor-manufacturing-program

Test Results (compressive strength on 20 x 20 x 20 cm cues


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concrete characteristics

Lia

Lia

Lia

Lia

Lia

Lia

low fnes liapor LAC, porous and thermal insulatingstructural lapor LAC, dense, waterproof, up to high

compressive strength

saw cut through liapor LAC

structural liapor LAC, different mix design

with Liapor Sand

Compressivestrength,cube[MP

a]

Concrete density, dry [kg/dm]

60

50

40

30

20

10

0.8 1.0 1.2 1.4 1.6 1.8

Liapor 3

Liapor 4

Liapor 5

Liapor 6

Liapor 7

Liapor 8with Natural Sand


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liapor masonry locks

The Liapor masonry locks have a wide range of

different types and provides several advantages:

Good thermal insulation

Good air noise asorption

Frost resistant

Easy workaility

Low mortar consumption

Rough surface for rendering

Good humidity transfer

Good fire resistance


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heat transfer of walls with liapor masonry locks

Density rating of lock 0,6 0,7

With low dens. mortar LM 21 0,13 0,16

With low dens. mortar LM 36 0,21 0,24

With normal mortar 0,21 0,27

Density rating of lock 0,5 0,6 0,7 0,8

With low dens. Mortar LM 36 0,23 0,26 0,29 0,33

With normal mortar 0,29 0,32 0,35 0,39

Heat transfer values toe calculated in W/mK

according to DIN 4108

Heat transfer valuesto e calculated in W/

mK according to decree

Z-17.1-451 of German

Institute of Construction

liapor lock

water asorption test of different masonry locks

concrete blocks


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Liapor Plant Tuningen, Layout

liapor plant tuningen, germany


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aggregate plants

liapor LWA plant at pautzfeld, germany


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concrete characteristics:

Liapor 6 (600 kg/m3)

Natural sand (1.400 kg/m3)

Concrete density (fresh):

1.750 1.800 kg/m3

Concrete strength (28 days):

40 54 Mpa

building owner:

Rijkswaterstraat, Netherlands

one of 6 canalridges in the netherlands


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Liapor 8 (800 kg/m3): 750 litre/m3

Natural sand (1.400 kg/m3): 490 litre/m3

Cement (HS 65): 425 kg/m3

Silicafume: 30 kg/m3

Superplastisizer: 4,5 kg/m3

Air-entraining admixture: 1,5 kg/m3

Concrete density (dry): 1.775 kg/m3

Concrete strength (28 days): 64.5 MPa

contractor:

Selmer AS

stovset ridge norway

concrete projects


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design system

20 floors, suspended

Construction: Lift sla system

Concrete strength: 41 Mpa

Concrete density dry: 1.530 kg/m3

Total weight savings: 6.000 t

contractors:

Dyckerhoff & Wiedmann

Hochtief AG

Philip Holzmann AGSiemens bauunion


Liapor 8 (800 kg/m3): 704 litre/m3

Natural sand (1.400 kg/m3): 514 litre/m3

Cement (HS 65): 420 kg/m3

Silicafume: 20 kg/m3

Superplastisizer: 6 to 9 kg/m3

Air-entraining admixture: 1 to 3 kg/m3

Concrete density (fresh): 1.885 kg/m3

Concrete density (28 days): 1.943* kg/m3

Concrete strength (28 days): 79 MPa

* Density measured on water stored cuesTotal LAC poured: 60.000 m3

contractors:

Norwegian Contractors AS

oil drilling platform heidrunnorway

mw motor car, office uildingmunich


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liapor LAC masonry apartment houses

precast liapor LAC

liapor LAC masonry single family homes

wall elements with low fnes liapor LACoor slabs with structural liapor LAC

concrete applications


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susidiaries

MERTEC SWITZERLAND AG

P.O. box

CH-8475 Ossingen

Switzerland

Tel: +41 52 304 34 00

Fax: +41 52 304 34 01

MERTEC SWITZERLAND AG

Construction/brokk

Vorderschlundstrasse 5

CH-6010 Kriens

Switzerland

Tel: +41 41 755 39 77

Fax: +41 41 755 39 78

MERTEC ENGINEERING AG

P.O. boxCH-8475 Ossingen

Switzerland

Tel: +41 52 304 34 80

Fax: +41 52 304 34 81

group

MERTEC AG

P.O. box

CH-8475 Ossingen

Switzerland

Tel: +41 52 304 34 30

Fax: +41 52 304 34 03

www.mertec.ch

MERTEC INTERNATIONAL FZE

RAKFTZ/P.O. box

Ras Al Khaimah

United Ara Emirates

Tel: +971 7 207 72 43

Fax: +971 7 227 45 53

MERTEC MIDDLE EAST LLC

P.O. box 35412

Work Street

Ras Al Khaimah

United Ara Emirates

Tel: +971 7 227 45 54

Fax: +971 7 227 45 53

MERTEC RUSSIA

Representative OfficeKozhevnicheskaya Street 1

building 1, Off ice 418

115114 Moscow

Russian Federation

Tel: +7 499 235 34 86

Fax: +7 499 235 34 86

Your trusted partner for engineering solut ions

contactsengineering products maintenance machinery

Tel: +41 52 304 34 80 Tel: +41 52 304 34 00 Tel: +41 52 304 34 70 Tel: +41 52 304 34 50

Fax: +41 52 304 34 81 Fax: +41 52 304 34 01 Fax: +41 52 304 34 71 Fax: +41 52 304 34 51

[email protected] [email protected] [email protected] [email protected]

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liapor industry.pdf