Advanced and Innovative Aerated Concrete Technology … · H LithoPore® Advanced and Innovative Aerated Concrete Technology by Luca Industries International GmbH LithoPore Aerated

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LithoPore®Advanced and Innovative Aerated Concrete Technology

by Luca Industries International GmbH

LithoPore Aerated Concrete (LPAC)

Insulation Construction Materials

© Luca Industries International GmbH 2017, Version 1.02

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LithoPore® Technology - Aerated Concrete

Applications

1 Luca Industries International inside

Technical Properties and Product Keydata

Economical View

6 Investment Options

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History


Incorporation of Dr. Lucà & Partner Ingenieurkontor GmbHBiotechnological additives for the textile industry and LithoPore Aerated Concrete

New focus: LithoPore Aerated Concrete (Manufacturing of machines, plant solutions, engineering)

1991

2003

2005

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History


Incorporation Dr. Luca Bioengineering and Services Pvt. Ltd. (India)

Cooperation HeidelbergCement (Heidelberger Beton Group)

Cooperation Masa GroupDevelopment of LithoPore©100-150 insulating board (polystyrene substitution)

2009

2010

2011/12

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History


Cooperation Knauf Gips KGJoint development of an aerated gypsum board

Cooperation Wienerberger, Schlagmann PorotonDevelopment of an aerated burned clay brick toachieve better insulation results

Cooperation Vicat Group, France

2012/13

2013

2014

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History / Business Model


Global Uniform Branding – Establishment of LithoPore

Aerated Concrete Brand - LPAC

Basic business model for plant customers

• Sales Contract for plant machinery

• Longterm Supply Contract for biotechnological additives

• License Contract (granting a license for a certain application,

time period and region, no license fees)

2015

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Company key data


Employees: 60 worldwide

Production capacity biochemical additives: 2500 mtons/year

Group turn over 2015: 8 Mio EUR

Customers: 250 in 40 countries

Key markets: Europe, India, South East Asia, Middle East, USA

Certifications: ISO 9001:2008 since 2005 through DQS

Registered brands

LithoPore (end product/aerated concrete )

LithoFoam (biochemical additives)

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Economical View


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• Raw materials

– Cement, filler (sand, fly ash, calcium carbonate, stone dust, etc.) waterand a foaming compound

• Production Methodology

– Specialized mixers, foaming equipment, and ordinary moulds.

– Steam cured or water spray-cured under ambient conditions

• Light Weight

– Foam creates millions of tiny voids, hence the name aerated concrete.

• Environment

– Eco-friendly and cost effective

LithoPore© Aerated Concrete - Introduction

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Production of LithoPore® aerated concrete

NetworkformerLithoFoam NWF S

1000 l IBC additive pump

Additive scale

Water

Foaming agent LithoFoam SL 200-L200 l barrel or 1000 l IBC, 20 °C tempered

Foam

Foam generator FG 4 II IND

1000 l IBC with agitator and pump

Stabilizer + water (micro fibre)LithoFoam MRF 2000-S


Cement, fillerscale

SlurryMixer

Water scale

Water

Primary Mixer

Ready mixedLitho Pore©

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LithoPore® vs. ordinary aerated concrete


201

2011

LithoPore® ordinary aerated

concrete

Foaming agent type

synthetic protein

(artificial) using

Molecular

Engineered Protein

extracted protein or

tensid based

Further additivesNetworkformer,

Stabilizernone

Foaming systemlow pressured

(energy saving)

compressed air

system

Density area 100-1800 kg/cbm 400-1800 kg/cbm

Compressive strength (600 kg/cbm) 3-4 mPa 1-2 mPa

Stability high low

Equipment complete system incomplete system

Local raw material qualitywill be considered

individually

is not respected

sufficiently

LithoPore® = advanced complete technology with innovative applications

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Foaming Agent

• LithoFoam® SL 200-L

Networkformer

• LithoFoam® NWF S

• LithoFoam® NWF NT

Stabilizer

• LithoFoam® MRF 2000-S

Accelerators

• LithoFoam® CC


Chemical Additives

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LithoFoam® SL 200-L

MEP – Molecular Engineered Protein

• Worldwide Unique

• Artificial Protein

• Compound not only Foaming Agent


Foaming Agent

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LithoFoam® NWF S

• Strength increasing agent

• Chemical reaction between NWF S with cement and foam

• Faster hardening

• LithoPore® density: ≥ 200 kg/m³

LithoFoam® NWF OAS

• Strength increasing agent

• Chemical reaction between NWF OAS with cement


LithoFoam® NWF NT

• Fills gaps between cement particles

• Shrinkage reducing agent

• Reduces pore structure



Networkformer

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LithoPore® Technology – Aerated Concrete

Applications



Economical View


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Application – Cast at site / frame work filling


Major countries: Africa, South East AsiaDry density target: 1000-1600 kg/cbm

End product trade name: LithoPore®1000-1600

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Application – Roof insulation


Major countries: India, Middle EastDry density target: 400-800 kg/cbm


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Application – Panel production (at site or precast)


Major countries: USA, Australia, ItalyDry density target: 800-1400 kg/cbm


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Application – Lightweight floor screeds


Major countries: East and South Europe, TurkeyDry density target: 400-800 kg/cbm


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Application – Blocks


Major countries: India, South East AsiaDry density target: 400-800 kg/cbm


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Innovations - Heat insulating compensation layer below floorscreed


Major countries: Germany, DenmarkDry density target: 200-300 kg/cbm


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Innovations - Heat insulating compensation layer below floorscreed


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LithoPore® – advantages at a glance

Low density area of 75-100 kg/cbm

Manufacturing of aerated lightweight mortar without any EPS beads (polystyrene)

Constant and safe adjustment of fresh density

Transportation in truck mixers for 2 hours

Ready to use product ex works

Simple logistics

Realisation of smaller consignments

Fire protection class A1 (no organic ingredients) instead of B1

In case of future renovations: only ordinary recycable construction waste


worldwide unique

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Innovations – pre cast insulating board


Masa-LithoPore®-TechnologyLithoPore75-150

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Innovations – pre cast insulating board Applications


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Innovations – pre cast insulating boardTechnical properties


• Non-inflammable

• Totally inorganic construction material based on cement

• Similar insulating properties as mineral/rock wool

• excellent steam diffusion

• fully recycable

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Standard product typeLithoPore75 LithoPore150

Dry density DIN EN 1602 [2] ρ105 °C 75-85 kg/m3 140-155 kg/m3

Moisture absorption DIN EN ISO 12571 [3] Δm, 23/80 ≤ 19 M.-% ≤ 19 M.-%

Thermal conductivity DIN EN 12667 [13] λ10, tr ≤ 0,0398 W/m*K ≤ 0,0518 W/m*K

Thermal conductivity DIN EN 12667 [13] λ 0,046 W/m*K 0,060 W/m*K

Compressive Strength DIN EN 826 [4] σ10% ≥ 40 kPa ≥ 220 kPa

Tensile strength perpendicular to faces DIN EN 1607 [5] σmt ≥ 10 kPa ≥ 20 kPa

Bending strength DIN EN 12089 Methode B [6] σb ≥ 10 kPa ≥ 60 kPa

Behaviour under point load at 1mm NPD ≥ 1400 N

DIN EN 12430 [8] εFp

Water absorption DIN EN 1609 [9]Wp, 24h ≤ 3,5 kg/m2 ≤ 4,5 kg/m2

Fire behaviour DIN EN 13501 Class A1 Class A1

Steam diffusion DIN EN ISO 12572 [10] μ ≤ 3,0 ≤ 4,0

Dimensions stability DIN EN 1604 [11] ≤ 0,1 % ≤ 0,1 %

Hydrophobic product typeLithoPore75H LithoPore150H

All values as for standard product, however:

Water absoprtion DIN EN 1609 [9]Wp, 10s ≤ 0,7 kg/m2 ≤ 0,7 kg/m2

Wp, 24h ≤ 0,9 kg/m2 ≤ 0,9 kg/m2


Innovations – pre cast insulating boardTechnical properties

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Economical View


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• Can be produced in a range of densities (75 – 1600 Kg/m3)– The lower density range of 75-600 kg/m3 is most suitable for use as insulation

over roofs, prefabricated insulation panels or as filling in sunken areas of floors– The mid-range density of 600-1000 kg/m3 is excellent for making non-load-

bearing cladding panels or pre-cast blocks for non-structural filler wallmasonry

– The higher density range of 1,200-1,600 kg/m3 is used in structural elements,either as reinforced components or in the form of block-work for load bearingmasonry wall.

• Closed cellular structure– The intrinsic structure of the aerated concrete consists of very small sized

unconnected individual air bubbles, uniformly spaced over the body of thematerial

– Due to absence of coarse aggregate (gravel), aerated concrete flows by itselfinto the moulds, shuttering and any cavities, thereby avoiding the necessity ofcompaction or vibration.


Characteristics of LithoPore© aerated concrete I

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• Ease of production– Aerated concrete may be cast into pre-cast blocks or pre-cast reinforced

panels for walling, roofing etc. or poured in-situ, into appropriately reinforced dwelling units or specific structural elements in a building

– It can also be easily produced in hilly areas or in deserts since it has limited requirements for the materials

• Lower water absorption– As a consequence of the closed cellular structure of the material, the water

absorption of aerated concrete is in the range of 5% to 25%, depending on density thus, lower than that of Aerated Autoclaved Concrete (AAC) blocks which is in the range of 45%.

– As a result, aerated concrete provides excellent protection of the reinforcing steel and does not require to pre-coat steel bars in reinforced elements. When using AAC, because of its high absorption, it is mandatory to pre-coat the reinforcing steel.


Characteristics of LithoPore© aerated concrete II

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Characteristics of LithoPore© aerated concrete IIIWater absorption

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Characteristics of LithoPore© aerated concrete IVCompressive Strength (average values)

1,9

3,7

5,8

8

10,5

13,5

0,7

2

3,7

5,5

7,4

9,5

0

2

4

6

8

10

12

14

16

400 600 800 1000 1200 1400

Ave

rage

Co

mp

ress

ive

Stre

ngt

h in

MP

a

Dry desity of LithoPore® Aereted Concrete in kg/m3

Cement + Fine Sized Filler (Fly Ash, Calciumcarbonate, 50-200 micron Sand, etc) + Additives Cement + 0-2mm Sand + Additives

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Characteristics of LithoPore© aerated concrete VFire Resistance

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Durability

• Sound insulation

• Thermal insulation

• Fire resistant

Workability

• Drilling

• Cutting and installing

• Nailing

• Sawing

Characteristics of LithoPore© aerated concrete VI

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Overall technical data at a glance


LithoPore® 200 LithoPore® 400 LithoPore® 600 LithoPore® 1000 LithoPore® 1400

Dry Density in kg/cbm and

(lb/cu.ft)200 (12.5) 400 (25.0) 600 (37.5) 1000 (62.5) 1400 (87.5)

Compressive strength in

mPa and (PSI)

0.25-0.45

(37-66)

1.5-2.5

(220-368)

2.5-4.0

(368-588)

5.0-7.0

(735-1029)

8.0-11.0

(1176-1617)

Thermal conductivity

W/(m*K)0.06-0.065 0.10-0.11 0.17-0.19 0.30-0.33 0.44-0.47

U-Value W/(m2*K)

100 mm / 4´´ thick material 0.60-0.65 1.00-1.10 1.70-1.90 3.00-3.30 4.40-4.70

R-Value per inch 2.22-2.40 1.31-1.44 0.76-0.85 0.44-0.48 0.31-0.33

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Economical View


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Technology overview by application


Market entrance

Technology Masa-LithoPore®-Technology

LithoPore®-Technology

Product (density) LithoPore®75-150 LithoPore®200-300 LithoPore®400-600

LithoPore®600-1600

Block production X

Pre cast panel production X

Filling of hollow blocks (burned clay and concrete) x

Pre cast insulating board x

Heat insulation layer below floor screed X

Cast in place wall filling X

Lightweight floor screed X

Lightweight concrete X

Flat roof insulation X X

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Technology overview by capacity


Market entrance

Technology Masa-LithoPore®-Technology

LithoPore®-Technology

Product (density) LithoPore®75-150 LithoPore®200-300 LithoPore®400-600

LithoPore®600-1600

less than 100 cubic meters daily production x x x

100 up to 400 cubic meters daily production(semi automatic)

x x

above 400 cubic meters daily production(fully automatic)

x x

Summary: with the Masa-LithoPore-Technology fly ash blocks and cementitious insulating boards can be manufactured with the same fully automated plant

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Economical Details


For further economical details (involved costs into machinery or average costs per cubic meter of LithoPore® aerated concrete) please contact us. We will assist you with a detailedcost break down.

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LithoPore® Technology - Cellular Lightweight Concrete

Applications



Economical View

6 Investment options

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Mobile Systems

• LithoPore® Foam Generator FG4 II IND

• LithoPore® Station

• LithoPore® Pump 800/1200

Semi-Automatic Plants

• LithoPore® Station (Plant version)

• LithoPore® Silos and Sand Bunkers

• LithoPore® Cuttingmachine SM25/SM50/SM100

• Steam Curing Chamber

• Accessories (Moulds, Rails, Turntables etc.)

Fully-Automated Plants

• Machinery made by MASA


Equipment

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LithoPore® Foam Generator FG4 II IND

• Stand-Alone Machine e.g. for RMC Concrete Plants

• High output

• Remote controlled


Mobile Systems

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LithoPore® Station

• All-in-One Machine

• Including LithoPore® Foam Generator FG4 II IND

• Unique mixing arm design to mix slurry and Foam

• Suitable for start-up projects, small plants (SM25)

• Precise weighing scale included


Mobile Systems

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LithoPore® Pump 800/1200

• Special designed Pump for Pumping LithoPore®


Mobile Systems

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Fully Automatic Mixing Tower and Cutting Machine.

Only mould handling is by hand.

• Up to 400m³ per day/shift

• All inclusive – from raw-material storage to package

• Upgradeable 100-200-400m³


Semi-Automatic Plants

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Semi-Automatic PlantsBlock Plant 50 Block Plant 100 Block Plant 200 Block Plant 400

Capacity [m³/day] 50 100 200 400

Water [m³/day] 15 30 60 120

Voltage [V] 400/230 400/230 400/230 400/230

Total Current [A] 52,5 205 225 312,5

Total Current with Sand Bunker [A] 135 287,5 307,5 395

Total Power [kW] 21 82 90 125

Total Power with Sand Bunker [kW] 54 115 123 158

Molds [pce.] 30 60 120 240

Mold Basements [pce.] 30 60 120 240

Space requirements [m²] 1375 1450 1750 3024

Assemblage / Commissioning time [days, min] 7/7 21/10 21/14 28/14

Recommended days of production supervision 7 14 21 28

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Masa-LithoPore®-Technology (fully automatic plant line)for block production with fly ash and for insulating boards


Hardening of cut material Waiting area before cutting

Mixing area with cement storage

Cutting machine

Foaming systemPackage area

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Masa-LithoPore®-Technology (fully automatic plant line)for block production with fly ash and for insulating boards


Overall Data

Capacity per hour: 24-72 cbm

Batch size mixer: 6000 liters

Moulds size: approx. 6 cubic meter

Power: 500 kW, 400 V, 50/60 Hz

Staff: 6-12

Characteristics

Fully automatic dosage and mixing

Fully automatic cutting

Fully automatic handling

Fully automatic package

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Contact


Company address GERMANY: Luca Industries International GmbH Potsdamerstrasse 12-13 14163 Berlin Germany

Telefon: +49-(0)30-457989-680 Telefax: +49-(0)30-457989-689

Email: [email protected]: www.luca-industries.com

mailto:[email protected]

http://www.luca-industries.com/

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Contact – Luca Industries worldwide


Country Person Contact details Status

Balkan Mr. Marijan Rados Dr. Lucà & Partner Ingenieurkontor GmbH Potsdamerstrasse 12-13 14163 Berlin Germany Telephone: +49 - 234 3387745Mobile: +49 - 176 57288773Telefax: +49-30-457989-689 [email protected]

Country Manager

India Mr. Sivaram Kumar Dr. Luca Bioengineering and Services Pvt. Ltd. Plot No. 127, Perungudi Industrial Estate, Old Mahabalipuram Road / IT Expressway, Perungudi, Chennai - 600 096 India Telefon: +91-44-42154667, +91 - 97909 27126 Telefax: +91-44-42154668 [email protected]

Subsidiary

Middle East Eng. Mohamed SallamMadkour

No.17, Ismael RaafatSafeer squareCairo 11361Egypt

Telephone: +49-30-457989-680Mobile: +20-1119111559Telefax: [email protected]

Country Manager(Convertion into Franchisee)

Philippines Mr. Lothar Ulmer Tel: +63 [email protected]

Country Manager

Turkey Mr. Berkay Denge Tel: +90 [email protected]


USA Mr. Michael Baron LithoPore USA LLC,PO Box 24334Santa Fe, New Mexico,87502 USA

Telephone: +1-505-983-2160Mobile: +1-719-588-1772Telefax: [email protected]








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Documents

Advanced and Innovative Aerated Concrete Technology … · H LithoPore® Advanced and Innovative Aerated Concrete Technology by Luca Industries International GmbH LithoPore Aerated