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INDEX

Raw Material Type and Manufacturing Process of Expanded Clay

Expanded Clay Properties

Expanded Clay: Main Applications

Light Concretes

Other Applications

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INDEX



Light Concretes

Other Applications



THE MONTMOR I L LON ITA is a mineral of the

group of silicates, phyllosilicates subgroup and belonging

to the so-called clays. It’s a magnesium and aluminum

hidroxisilicate with other possible elements. It’s

characterized by a variable chemical composition. Is

soluble in acids and expands upon contact with water.

Montmorillonita and illita are two types of soil that are not

advisable to carry out works such as roads and motor

roads. With similar composition and geometry they are

formed by a unity of gibbsite by two of silicon

superimposed indefinitely. The interaction (union) between

two layers of silicon is weak, allowing an easy penetration

of water between these “cells”. Therefore a soil with this

composition tends to be unstable in the presence of water

and is resistant only when it is dry. In the presence of

moisture, has a variation of volume, giving rising to an

“accordion effect” (expansion and contraction) between

the dry and the wet. The foundations of buildings in one of

the areas that one should take extra care because of its

expansive character.

Chemical Analysis(Example)

% Typicall

Al2O3 18

SiO2 64

Fe2O3 6,5

TiO2 0,9

MgO 2,5

CaO 2,0

K2O 3,5

Na2O 0,7

C L A Y P R E P A R AT I O N

The clay preparation starts in a

box feeder, fed by a charging

shovel and next is conveyed to

a toothed-roller crusher.

Further, the clay are processing

sequentially in machines

designed for the processing of

clay in order to obtain a

homogeneous and well-mixed

material.

After preparing, by the system

of belts conveyor, the clay

goes to storage zone.

E X P L O R AT I O N

Before introducing a clay to

the manufacturing process, it

places in layers, into cones of

homogenization and aging.

Storage of raw materials has

the following main objectives:

• retrieving a persistent

composition of initial of raw

materials and its supplies to

the plant from constant

characteristics;

• ensuring maturing of clay

using natural processes

(snow, rain, sun, wind,

biological processes, etc.);

• provision a stock of raw.

MANUFACTURING PROCESS OF EXPANDED

CLAY


1 2 3

S HA P I NG AND

CU T T I NG

From the stock the prepared

clay is feeding to the box

feeder from witch begins the

shaping line.

Between the box feeder and

the extruder, the clay pass

different machines to obtain

the desired grading and

plasticity.

In the extruder, the clay is

compressed. Then is passed

through perforate dies,

cutting by the rotary cutter in

the form of cylinders and

transported for especial drum

for be rounded.


E X P ANS I O N

The firing (expansion) of

aggregates has in rotary kiln.

Our rotary kiln is composted of

two metallic drums with

different diameters. The drum

diameter smaller has a pre-

heater where the green clay

aggregates are heated up to

600-800ºC. The other drum has

a expansion, where the

aggregates are expanded and

take final shape. The firing

temperature is between 1170-

1200ºC.

After firing expanded

aggregates fall into the outlet

chamber, before being fed to

the subsequent process step.

4 S TO RAG E AND

S I E V I NG

Hot expanded clay granules

from the outlet chamber enter

into a cooler with a ventilation

system. In the cooler cools the

granules from 1000 º C to a

temperature of 45-60 º C.

For even filling of product,

intermediate storage is

equipped with the mobile belt

conveyor.

The sieving section is equipped

with set of belt conveyor, that

distribute product between

sieving screens, that fill the

bunker type silos. From silos

product is fed on the

conveyors for supply of the

product for shipping or

packaging.

5 E X P ED I T I O N

The supply of the final product

is variable depending on the

customer’s wishes and can be

made as follows: in bulk on a

truck; in big bags; or in smaller

bags of 50l or other capacity,

in case of retail sale.

6

Raw Material Type and Manufacturing Process of Expanded Clay

Expanded clay properties


Light Concretes

Other Applications


T H E E X P E N D E D C L A Y S have great

future. They have ceramic, light and resistant

materials that afford a good thermic and a

sound insulation and represent a very

interesting alternative regarding other

construction materials.

The expended clays are obtained by

submitting special clays to a temperature of

1200º C centigrade degrees in big rotary kilns.

70% lighter than the conventional aggregates

Fire resistant

Noise and heat insulation

Microspores, non-corrosive and stable

Environment friend

Several applications in the building construction industry and others

P R O P E R T I E S C L A S S I F I C A T I O N


L I G H T N E S S

This in the main property ofthe light arid materials theexpansion at its biggest levelachieve 5 times the initialvolume, that means a density5 times lower.That is to say, a density of1500 kg/m3 of natural claypass to a density of 300kg/m3 in the lighterexpanded clay

T H E R M A L I N SU L A T I O N

The air at rest is the bestknown insulating material.The fine reticular of theexpanded clay conformsseveral microscopicchambers of air that conferto the expanded clay itsinsulating capacity withconductivities up to 0,099W/m2 K

Concrete with lightaggregates is accordinglyused worldwide to improvethe thermal insulation ofbuildings.

SO U N D I N SU L A T I O N

• Expanded clay has amagnificent behavior as

sound insulating materialespecially on the impact

noise propagated byvibrations at low frequency.

• The porous structure ofexpanded clay mortar weak

the vibrations removing theacoustic energy.

• Example: with 5 cm/esp. weachieve to reduce 25 dB(A).

The sound absorption

coefficient is a value foracoustic comfort in the

transmitting space. The lessabsotion, the more reflection,

the longer the reverberationtime.

F I R E -R E S I S T AN C E

The expanded clay is aceramic and refractorymaterial. It has a meltingpoints superior to 1200ºC andthe absence of organicmaterial in its composition (asit evaporates during themanufacturing process) theemission of toxic gases athigh temperatures cancel.

Structural lightweightconcrete has better fire-resistance than heavyconcrete. These highervalues are attributable to itslow thermal conductivity andits low coefficient of thermalexpansion. The insulatingproperty of lightweightconcrete gives betterprotection to the concretereinforcement than heavyconcrete (between 5 and20% less depending on therequired concrete density).


Raw material type and Manufacturing Process of Expanded Clay


Expanded Clay: Applications

Light Concretes

Other Applications


P R E F A B R I C A T E D C O N S T R U C T I O N S

One of the most important applications of the expanded

clays are the light prefabricated blocks which provide a

reduction of approximate 35% in construction time,

properties of thermal and sound insulation.

1

FARMING INDUSTRY AND HORTICULTURE

Due to the properties of the expanded clays they canbe used in hydroponic crops, also known as cropswithout soil, manures, gardening in general, etc. Theycan de added directly to the soil, allowing its airing andthe maintenance of its moistures.

2

G E O T E C H N I C A L A P P L I C A T I O N S

The expanded clays are an efficient cost alternative forthe filling of lands in geotechnical applications, due toits low weight which is 50% lower than the traditionalfillings and the expanded clays also reduce the lateralpressures, so more economical retaining walls can bebuilt.

4 C I V I L W O R K S

The expanded clays as filling in the structural concretes,

give rise to a reduction of approx. 30% of the total

weight of the structure without affecting the resistance,

which allow making estimations of structural sections

lower than with heavy aggregates, saving raw material

and obtaining lower foundations costs.

The biggest volume of charge by lorry represents a

considerable saving in freights. Great facility in the

transport in work, both in aggregates and in fresh

concrete. Saving in time and wages. Significant saving

in the final cost of the work.

3


– Textile thermal insulating materials

– Thermo acoustic insulating material for ship

building

– Stock and fire proof packing

– Filtering element

– Cold chamber insulating material

– Load in fibreglass formulation

– Block and refractory ceramics

– Oil absorption, pesticides and heavy metals

– Mould lining for iron and aluminium foundry

– Lubricant of joints during the thermic adjustment

– Component at lubricating greases

– Charge in paints and in fire proof greases for walls,

ceilings and doorways.

– Rockwool

– Thermal and sound insulating material

– Insides of divisions and fire-guard doors

– Light aggregate for concrete

– Concrete blocks and light bricks for construction

– Protection moulds of metallic structures, delaying the

fire in = 40 minutes

– Sheet and wall insulating material

– Waterproof in covering sheets

– Fire and sound proof chambers

Elaboration of chemical, organic and mineral formulas due

to the high capacity of cathodical change and water absorption

Asbestos replacement

Density controllers and regulation

In mixtures with resins

Hulls of boats and canoes

Source of nutrients Ca, K, Mg, during the low water period

Inhibitor of leaching of micro and macro fertilizers

Retainers of water in gardening and agriculture

Germination of seeds

Conditioner of acid and clay soils

Vehicle for insecticides, herbicides, fungicides and fumigants

EXPANDED CLAY APPLICATIONS ACCORDING TO ITS CHARACTERISTICS

Civil works

Chemestry

Shipbuil-ding

Farming &horticulture

Industry


L IGHT AND INSULATING FLOORING

D O S I N G

1.100 litres of F-3

expanded clay

150 kg of cement

120 litres of water

T H E R M A L I N S U L A T I O N

According to the present CTE norm (recently

approved) the U maximum thermal transmission

allowed to an horizontal closing is: U < 1,20 W/m2 °K

With 4 cm of HL-20 expanded clay a U=1,12 W/m2ºK

is achieved, i.e., we’ll have a thermal insulation

enough to fulfil the norm:

U=1,12 W/m2 °K < 1,20 W/m2 °K

M A I N R E A S O N S

Levelling of flooring base

Allowing the passage of electrical and water

installations, etc.

Increase the flooring measure according to

project needs

Insulate thermal and acoustically the flooring and

prove its fire resistance

T H E R M A L I N S U L A T I O N

According to the present CTE norm (recently

approved) the U maximum thermic transmission

allowed to a building covering is:

U < 0,49 W/m2°K

With 16 cm of HL-20 expanded clay a U=0,49 W/m2ºK

is achieved, i.e., we’ll have thermic insulation enough

to fulfill the norm.

U= 0,49 W/m2°K < 0,49 W/m2°K

M A I N R E A S O N S A N D A D V A N T A G E S

High compression resistance

Continuous insulating material without thermic

variations

Thermic and sound insulator

Durability, it doesn’t deteriorate with time and

bears the sun exposition and high temperatures

FLOORING COVERING

Conductivity(Kcal/h.m.ºC)

Resistance(kp/cm2)

Weight(kg/m2)

Extruded Polystyrene 0,028 2-4 0

G-3 Expanded clay 0,073 10-12 35

Expanded clay concrete 0,10 25 55

Cellular concrete 0,25 1-2 35

Mortar 1,2 40 200

• Corporation between different base materials


Raw material type and Manufacturing Process of Expanded Clay



Light concretes

Other Applications


L IGHT CONCRETES•The structural light concrete can be

used to manufacture any element

of concrete, mortar or reinforced,

on site or prefabricated and, in

general, any type of structure that

can be made with the concretes of

normal use.

•It’s specially indicated for works

of rehabilitation and, specially, in

those cases that require a

density lower than the usual

(reductions up to 40%) or with

insulating qualities.

•The density of light concrete charges

between 500 y 1900 kg/m3 depending

of the dosing

•A low density of concrete represents

a proportional in crease of the

surcharge that a structural element

can support this affects directly the

drawing and the economy of the

structure

•With a light concrete we achieve

the same resistance that with a

traditional concrete, being

necessary to increase the

proportion of cement

•The light concrete achieve 80% of

its resistance within 7 days

• The light concrete has a bigger

elasticity than the conventional

one, thus having a bigger initial

retraction than the conventional

concrete with the same density

•Has a good adherence

aggregate-paste

•The light concretes are more

resistant to the effects of frost

and defrosting than the

conventional concretes

•The light concretes assure its

inalterability before the chemical

attacks


LIGHT CONCRETES•The thermic behaviour of

light concretes is directly

connected to its density.

The entered air in its porous

structure reduces

considerably the

conductivity

•In the Spanish and

European norm the light

concretes are considered

as insulating concretes

•Due to its porous structure, the light concrete has a

good behaviour regarding the air and impact noise

•The expanded clay is a material made at 1200ºC,

thus it keeps steady up to achieve this temperature.

The light concrete protects the framework and

keeps its resistant capacity during longer periods

than the conventional concrete in case of fire.

SPECIFIC APPLICATION

– Great saving in frameworks, quick, hardening,

handling in transport and work

– Come to have more light with a material saving

(framework

– Stability before the high temperatures with a

reduced fissuring and thermic conductivity

– Ideal for running the refractoryRecommended dosing table


Raw Material Type And Manufacturing Process Of Expanded Clay



Light Concretes

Pr-fabricated and Other applications


LIGHT FILLINGS

Fillings in Covered up Structures Underground Parking

Natural rounds Lines and satiation of metro False tunnel

Some Works

Tunnel filling of M-50 Madrid

Light rampart in the new Avenida

Filling in false tunnel of Boadilla M-50, Madrid.

Radiales UTE (ACS, FCC, OHL et SACYR). 100.000 m3


Filling in false tunnel of Villafranca del Bierzo,

Autovía A-6. ACS-NECSO, 5.500 m3

Record work in Spain and second at European level

Roof Gardens, Water Management and Infiltration


A roof gardens creates green space and also provides insulation for houses, commercial

and public buildings and other structures, making it cooler on the inside in hot seasons,

warmer during cool months. In addition to improved insulation, other valuable benefits

include naturally enhanced visual impact and significant reduction in environmental noise.

There two main types of roof gardens: the intensive and the extensive. The intensive roof

garden can be compared with a “classic” garden on the ground floor. The extensive

garden is a thin lightweight substrate allowing the protective grown of succulents, moss

and herbs on elevated roof structures.

Buffer and filtration basins created using expanded clay granules actually retain

the water and slow down drainage. A multitude of opportunities opens up when

choosing expanded clay. The benefits of the aggregates are mainly due to its

hollow cavities: 45% between pellets and 43% inside them. Rapid processing with

tankers, full use excavation, unlimited life span and reusability of the aggregates

make their the most cost-effective solution for water buffer and filtration basins.

The biological portion of the filter utilizes an expanded clay media which provides a large

surface area to attract naturally occurring bacteria.

Expanded clay granules are 100% natural, inert, rot-free and very durable, providing the

ideal biological filtering solution for pools, ponds or waste water. Several studies

demonstrate that it is totally unnecessary to sterilize the water with chemicals and that it is

better to use biological slow filtering methods which using less energy, too.

IPIAC NERYCtra. Villaviciosa a Pinto, Km 15,500Apdo. Correos, 3FUENLABRADA - Madrid (España)

Telfs. + 34 91- 690 75 48 / + 34 91-690 76 49Fax: 34 91 –690 75 98e-mail: [email protected]

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