Liapor Industry PDF
Liapor Industry PDF
Liapor Industry PDF
MERTEC TECHNOLOGY GROUP providing turn-key solutions for LIAPOR production plants of lightweight expanded clay aggregate process powered by rohrbach technology
The Rohrbach Technology developed the process to manufacture high quality lightweight expanded clay aggregate under the brand name LIAPOR some 40 years ago. MERTEC technology group in collaboration with Rohrbach Technology provides the technology of the production process with the respective plant design and realization capabilities.
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 be used in the process Managing bidding 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 assembly sections
process
business units
technology solutions
machinery solutions
refractory service
customer service
product solutions
machinery service
divisions
production plant
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 by MERTEC from renowned manufacturers, fulfilling highest quality requirements. E xtensive process know-how, with the ability to optimise each stage to ensure the client maximum profitability. MERTEC provides the skills and competence to optimise and orchestrate the interplay of these essential elements, creating the basis for successful projects and maximum results.
opportunity evaluation
benefit evaluation
solution proposal
commissioning
construction
engineering
fabrication
transport
Project planning and plant design of selected approach. Elaboration of contracting plan and project timing. Definition of sequences for the installation process.
Erection, assembly and installation of machinery and components to the integrated plant system. QA/QC of construction work.
Testing, trial operation until reaching normal operation conditions. Demonstration of plant performance. Provisional accaptance.
Review and verification of achieved plant performance and conclusion of further improvement potential.
project management
project management
Project execution with MERTEC means the close collaboration with the customer and following a synchronised project methodology. On regular times the project coordination with the customer forms the basis for a transparent review, control and follow-up with conclusive measures for design, planning, fabricating, 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 production process. MERTEC has the capability to develop business opportunities and apply synchronised project management methodology to any project type and execution mode.
roject implementation control P Timely direct and relevent communication on the project status and planning Q A / QC supervision system during engineering, fabrication 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 agreed project time and cost frame
project types
venture development
pgrade & retrofit projects U Plant extensions Plant conversions Green-field plants Modernizations & modifications
lant auditing focused on process performance, P costs and organisation benchmarking Opportunity and feasibility studies Plant master, action & investment plans A ppraisal of manufacturing performance
ull- & semi turn key contracting (EPCC) F Package contracting Full- & semi detail contracting
from nature
with technology
to aggregate
structural LAC
In standard categories with specific densities between 1000 and 1800 kg/m3 (normal concrete approx. 2300 kg/m3) for reinforced, load bearing concrete structures of high compressive strength for constructions such as: multi-storey office buildings, apartments, buildings, etc. industrial buildings bridges and fly-over
low-density LAC
Low-fines concrete with specific densities between 600 and 1000 kg/m3 is especially suited for thermal insulation and Ioadbearing concretes such as masonry blocks large size and large-size wall elements in: private housing office buildings school buildings publicbuildings
lightweight aggregate
controlled aggregates
specific products
diverse projects
liapor-LWA
cost savings
Liapor LAC offers extensive construction cost savings in: foundations reinforcing steel concrete mass reduction design of facade and wall thickness material transport construction time and labour 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 slabs, between floor joints, in concrete subfloors, as insulating fill for pipe ducts etc.
liapor-LAC
liapor production
Liapor production started in 1967. The Liapor technology has been applied in numerous plants in Europe. By the year 2009, more than 40 million cubic meters have been produced on the basis of this technology. Liapor LWA plants have been built up to a capacity of 400,000 cubic 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 availability and are operated under support of modern electronic control device produce uniform, predetermined grain sizes of pellets within small bulk 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 by the Liapor process may be plastic or solid clay. Recommendations for raw material selection are given by our form (on demand). Suitability will be checked in our laboratory.
The raw material preparation will be performed either by dry preparation process for solid clay or by plastic preparation process for plastic and wet clay. In any case, pellets within a small particle sizes range are formed and fed into the rotary kiln.
The heart of the Liapor process is its two stage rotary kiln, with two separate, double 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 before entering the expansion kiln where the pellet expansion is precisely controlled in order to get a finished product with very uniform bulk density. The dedusting system of the kiln exhaust gases will meet strict environmental regulatory requirements.
aggregate production
2 3
The heart of the Liapor production Process is the 3-stagerotary-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 be used as fuel. Clays or shales as raw materials will be processed according to their specific raw material properties in order to get high quality Liapor LWA. Kiln and other exhaust gases will be cleaned in order to meet environmental regulatory requirements.
liapor-lightweight-aggregate-concrete
LWA Bulk Dens. Type of Sand Type of Cement Cement portion Microsilica SPP foam additive Concrete Unit Weight fresh 7 days 28 days dry 1 day 3 days 7 days 28 days 56 days N/mm2 N/mm
2
610 *
610
720 *
720
720
810
810 *
* 42,5 R 350
* 52,5 R 380
* 52,5 R 380
* 52,5 R 400 +
1059
1760
kg/m3
3
900
1110
1570 27 51
Compressive Strength
15 19
20 22
30 33
34 40
36 41
34 41,4
38 47
44,8 54
57 68
53 70 76
N/mm2
Three Point Bending Test 28 days N/mm2 5 5 5,7 5,8 5,4 5,4 5,6 5,5 6,3
liapor-manufacturing-program
Type of Liapor Particle Size mm Liapor 3 Liapor 4 Liapor 5 Liapor 6 Liapor 7 Liapor 8 Liapor Sand 4 to 8 and 8 to 16 4 to 8 and 8 to 16 4 to 8 and 8 to 16 4 to 8 and 8 to 16 4 to 8 and 8 to 16 4 to 8 and 8 to 16 0 to 4 Bulk Density kg/m3 325 400 500 600 700 800 700 Tolerance kg/m3 + -25 + -25 + -25 + -25 + -25 + -25 + -25 Particle Gravity kg/litre 0,60 0,75 0,95 1,10 1,30 1,50 1,60
concrete characteristics
The Liapor masonry blocks have a wide range of different types and provides several advantages:
Good thermal insulation Good air noise absorption Frost resistant Easy workability Low mortar consumption Rough surface for rendering Good humidity transfer Good fire resistance
concrete blocks
Heat transfer values to be calculated in W/ mK according to decree Z-17.1-451 of German Institute of Construction
Density rating of block With low dens. Mortar LM 36 With normal mortar
Density rating of block With low dens. mortar LM 21 With low dens. mortar LM 36 With normal mortar
liapor block
aggregate plants
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
concrete projects
concrete characteristics: 750 litre/m3 Liapor 8 (800 kg/m3): 3 Natural sand (1.400 kg/m ): 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
concrete characteristics: Liapor 8 (800 kg/m3): Natural sand (1.400 kg/m3): Cement (HS 65): Silicafume: Superplastisizer: Air-entraining admixture: Concrete density (fresh): Concrete density (28 days): Concrete strength (28 days): * Density measured on water stored cubes Total LAC poured: contractors: Norwegian Contractors AS 704 litre/m3 514 litre/m3 420 kg/m3 20 kg/m3 6 to 9 kg/m3 1 to 3 kg/m3 1.885 kg/m3 1.943* kg/m3 79 MPa 60.000 m3
design system 20 floors, suspended Construction: Concrete strength: Concrete density dry: Total weight savings: contractors: Dyckerhoff & Wiedmann Hochtief AG Philip Holzmann AG Siemens Bauunion
concrete applications
contacts engineering products Tel: +41 52 304 34 80 Tel: +41 52 304 34 00 Fax: +41 52 304 34 81 Fax: +41 52 304 34 01 [email protected] [email protected]
maintenance machinery Tel: +41 52 304 34 70 Tel: +41 52 304 34 50 Fax: +41 52 304 34 71 Fax: +41 52 304 34 51 [email protected] [email protected]
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
subsidiaries 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. Box CH-8475 Ossingen Switzerland Tel: +41 52 304 34 80 Fax: +41 52 304 34 81 MERTEC INTERNATIONAL FZE RAKFTZ/P.O. Box Ras Al Khaimah United Arab 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 Arab Emirates Tel: +971 7 227 45 54 Fax: +971 7 227 45 53 MERTEC RUSSIA Representative Office Kozhevnicheskaya Street 1 Building 1, Office 418 115114 Moscow Russian Federation Tel: +7 499 235 34 86 Fax: +7 499 235 34 86