LIAPOR | lightweight aggregate plants

powered by rohrbach technology

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.

experience competence quality

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

construction products maintenance mechanical service machinery

engineering project management

technology solutions

MERTEC engineering within MERTEC group

machinery solutions

refractory service

customer service

product solutions

machinery service

divisions

technology solutions - bridging your visions into reality

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.

Designated project methodology, seamlessly joins the projects eight phases:

opportunity evaluation

benefit evaluation

solution proposal

Identification and validation of customers business potential.

Definition of possible solutions. Joint definition.

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.

Production and procurement of assets according to QA/QC program.

Allocation of goods according to time schedule to construction site.

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 coordination at site

project: turnkey expanded clay plant with rotary kilns

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.

project management focus

 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 

project execution modes

 ull- & semi turn key contracting (EPCC) F Package contracting  Full- & semi detail contracting 

from nature

with technology

to aggregate

lightweight aggregate concrete in construction

Lightweight aggregate concrete (LAC) combines all the benefits 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 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 and liapor-LAC

(lightweight aggregate) offers many advantages such as: produced in any desired bulk density and grain size suitable 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 (lightweight aggregate concrete) offers a maximum of creative freedom in design to architects and engineers such as: reduction in weight of building structures and load-bearing elements high thermal insulation and temperature retention properties noise absorption properties increased fire resistance good durability in sea water atmosphere resistance to water penetration like normal concrete numerous advantages in seismic areas

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.

raw material preparation: burning and expanding:

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

liapor production plant, aleksin russia

the liapor production process

1

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.

1 Preheater kiln 2 Expansion kiln 3 Rotary cooler

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

kg/m3 Liapor Natural CEM I kg/m3

324 * 42,5 R 420 * *

320 * 42,5 R 350

400 * * 42,5 R 350

510 * 42,5 R 350

610 *

610

720 *

720

720

810

810 *

* 42,5 R 350 42,5 R 350 42,5 R 350

* 42,5 R 350

* 52,5 R 380

* 52,5 R 380

* 52,5 R 400 +

kg/m3 kg/m kg/m

3

1059

1310 1290 1260

1350 1320 1310 1160

1430 1400 1380 1230

1480 1460 1440 1260

1710 1670 1650 1520

1620 1600 1550 1390

1840 1830 1800 1610

1820 1790 1750 1580

1890 1880 1860 1720

1760

kg/m3
3

900

1110

1570 27 51

Compressive Strength

12,4 14,4 16,7

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

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

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

saw cut through liapor LAC

structural lapor LAC, dense, waterproof, up to high compressive strength

low fines liapor LAC, porous and thermal insulating

structural liapor LAC, different mix design

60 Compressive strength, cube [MPa] 50 with Liapor Sand 40 30 with Natural Sand 20 10 0.8 1.0 1.2 1.4 1.6 1.8 Concrete density, dry [kg/dm]

Liapor 33 Liapor Liapor 44 Liapor

Liapor Liapor 55 Liapor Liapor 66 Liapor Liapor 77 Liapor Liapor 88

liapor masonry blocks

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 of walls with liapor masonry blocks

Heat transfer values to be calculated in W/mK according to DIN 4108

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

0,5 0,23 0,29

0,6 0,26 0,32

0,7 0,29 0,35

0,8 0,33 0,39

Density rating of block With low dens. mortar LM 21 With low dens. mortar LM 36 With normal mortar

0,6 0,13 0,21 0,21

0,7 0,16 0,24 0,27

water absorption test of different masonry blocks

liapor block

liapor plant tuningen, germany

Liapor Plant Tuningen, Layout

aggregate plants

liapor LWA plant at pautzfeld, germany

one of 6 canalbridges in the netherlands

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

concrete projects

stovset bridge norway

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

oil drilling platform heidrun norway

bmw motor car, office building munich

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

Lift slab system 41 Mpa 1.530 kg/m3 6.000 t

concrete applications

precast liapor LAC

floor slabs with structural liapor LAC

wall elements with low fines liapor LAC

liapor LAC masonry apartment houses

liapor LAC masonry single family homes

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 engineering@mertec.ch products@mertec.ch

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 maintenance@mertec.ch machinery@mertec.ch

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

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