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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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concrete characteristics:
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
concrete characteristics:
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]