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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
IPIACNERY www.ipiac.com
INDEX
Expanded Clay Properties
Expanded Clay: Main Applications
Light Concretes
Other Applications
IPIACNERY www.ipiac.com
IPIACNERY www.ipiac.com
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
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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.
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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
Expanded Clay: Main Applications
Light Concretes
Other Applications
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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
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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).
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Raw material type and Manufacturing Process of Expanded Clay
Expanded Clay Properties
Expanded Clay: Applications
Light Concretes
Other Applications
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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
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– 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
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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
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Raw material type and Manufacturing Process of Expanded Clay
Expanded Clay Properties
Expanded Clay: Main Applications
Light concretes
Other Applications
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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
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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
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Raw Material Type And Manufacturing Process Of Expanded Clay
Expanded Clay Properties
Expanded Clay: Main Applications
Light Concretes
Pr-fabricated and Other applications
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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
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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
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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.
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