Presentation Foamed Concrete 2009

Building materials industryLithoPore™ – Foamed concrete system

a DIN EN ISO 9001:2000 company

Foaming agents and other biotechnological additivesFoam generators

Foamed concrete machinesSawing machines

Foamed concrete plantsTechnical supportKnow how transfer

GERMAN QUALITY



Dr. Lucà & Partner inside

GERMAN QUALITY

Corporate Overview

● The company of Dr. Lucà & Partner Ingenieurkontor GmbH came into being through the merging of Dr. Lucà & Sohn GbR (founded in 1991) and the Department for Technical Biochemistry of the Institute for Experimentation, Training and the Manufacturing of Spirit and Fermentation Technology (VLSF, founded in 1857) a long-standing experimental and training establishment with a rich tradition in fermentation technology and the manufacturing of spirit at the Institute for Fermentation and Biotechnology (IfGB). (IfGB).

● Own Research & Development department.

● Two production sites with an overall yearly capacity of more than 5,000 tons of liquid products and 2,500 tons of solid products.

● Branches in India and Turkey

● Partners in Iran, Brazil, Vietnam, China, Egypt, Saudi Arabia, Syria

© Dr. Lucà & Partner 2010 Email: [email protected] / www.dr-luca.com / phone: +49-30-457989-681

Our certificates - your quality warrantyQuality management DIN EN ISO 9001:2000


● Testing of locally available materials (cement, sand, flyash, …)● Training in Berlin (free service for our customers)● Local training at site● Turn key foamed concrete plants

Our outstanding services

● Turn key foamed concrete plants● Variable foamed concrete system (components can be integrated into current systems)● Support for necessary local approval● Issuing of test certificates regarding characteristics of foamed concrete● Everything out of one hand…● True Technology: LithoPore™ is granting the user a w orld wide unique end

product quality in opposite to all competitor produ cts




Foamed concrete

GERMAN QUALITY

● Cost reduction for raw materials: By adding air, enclosed in LithoFoam bubbles, the volume of concrete can be increased at very low cost.

● Energy savings / environmentally friendly: Opposite to autoclaved aerated concrete (AAC / gas concrete) incase of foamed concrete air curing is possible. This saves up to 9 cbm of gas for curing one cubic meter of AACand therefore protects our environment.

● Weight Reduction: Less steel reinforcements required.

Advantages of foamed concrete

● Cost reduction for transportation and storage: Less raw materials, very efficient LithoFoam concentrate.

● Improved thermal insulation: Foam concrete can reach the same insulation results as normal concrete with only20 % weight and 10 % raw materials.

● Improved fire protection: A wall of 13 cm thickness and 1250 kg/cbm can withstand a fire for 5 hours. A wall of 10 cm thickness and only 400 kg/cbm achieves the same result, due to the air enclosed in the cellular concrete.

● Easy to use/produce/handle

● Low investment: Just one simple machine required.

● High flowing capability: Can fill hollow spaces.

● Low water absorption : Only 10-15 %, if specific foaming agents are being used in combination with silicon oil in the cement slurry the water absorption rate can be decreased to only 1 %


Industrial buildingsApplication of LithoPore™ - Blocks

Residential buildings


Foam concrete is very useful as additional layer in floors. Not only does it even out the floor level, it also reduces considerably the subsonic noises.

Application of LithoPore™– Flooring


Especially in southern countries foamed concrete is used for flat roofs mainly for insulation purposes.

Application of LithoPore™– Roofing


LithoPore™ can be used also for direct wall fills into a frame work system. In opposite to competitor products for LithoPore™ no sedimentation appears during the fill and curing time for wall heights up to 2,4 meters. Therefore the final density is uniform and homogenous.

Application of LithoPore™– Cast in Situ Walls


Equipment / components

LithoPore Station all in one machine by Dr. Lucà & Pa rtnerSawing machine (only for block production)Block-Moulds (only for block production)Framing System (only for cast in situ walls)Mould conveying systems, package systems, sand mill ing stations, etc.

LithoPore™ - Equipment and raw materials

Mould conveying systems, package systems, sand mill ing stations, etc.

Raw materials

● Water●Cement● Sand● Optional aggregates: Fly ash, slack, pumice, perlite● Foaming agent (LithoFoam SL 200-L), optional also networkformer (LithoFoam

NWF S), optional also stabilizer (LithoFoam MRF 2000-S)


1. Pour water into the mixer according to mix design2. Add cement afterwards3. Mix water with cement4. Add networkformer and stabilizer (optional)

Manufacturing process of LithoPore™ foamed concrete

4. Add networkformer and stabilizer (optional)5. Add the sand or fly ash6. Mix water, cement and sand or fly ash7. Add in foam (produced out of foaming agent, water, air)8. Mix water, cement, sand or fly ash, foam and other additives9. Pump the material to the desired place




Foaming agents and other biotechnological additives

GERMAN QUALITY

LithoFoam ™ – world wide unique foaming agents and other biotechnological additives

Trade Name Description Specific effect Application

LithoFoam SL 200-L foaming agent higher compressive strength than ordinaryfoaming agents in

all applications

for advanced quality


foaming agents in combination with the LithoPore™ foaming system

for advanced quality compared to competitors

LithoFoam NWF S networkformer •higher compressive strength

•faster curing time•quicker demoulding

all applications

for higher quality and increased capacity

LithoFoam MRF 2000-S stabilizer •higher compressive strength

•less shrinkage•crack controll

Cast in situ wall

for highest quality



Technical and economical comparison

GERMAN QUALITY

Technical comparison to competitor systems: compressive strength


Technical comparison: Structure


Ytong, Siporex (AAC)

LithoPore™ LithoPore™ PRO

Raw material cost calculation for 600 kg/cbm (infiel d blocks)*Cement OPC 42.5: 350 kg at 85 EUR/ton = EUR 29.75 (80.4 %)Water: 150 kg at 5 EUR/cbm = EUR 0.75 (2.0 %)Sand: 175 kg at 20 EUR/ton = EUR 3.50 (9.5 %)Foam: 50 kg (~625 litres at 80 g/l)Foaming Agent (3% of foam): 1.5 kg at 1.99 EUR/kg = EUR 2.99 (8.1 %)

Average cost calculation

Total: = EUR 36.99 (100 %)

Raw material cost calculation for 1200 kg/cbm (struc tural walls)*Cement OPC 42.5: 350 kg at 85 EUR/ton = EUR 29.75 (62.0 %)Water: 170 kg at 5 EUR/cbm = EUR 0.85 (1.8 %)Sand: 760 kg at 20 EUR/ton = EUR 15.20 (31.7 %)Foam: 37 kg (~460 litres at 80 g/l)Foaming Agent (3% of foam): 1.1 kg at 1.99 EUR/kg = EUR 2.19 (4.5 %)Total: = EUR 47.99 (100 %)

*calculation with local German prices, cement quantity can be also reduced or substituted with fly ash or further aggregates,final mix design varies with regards to different types of used local raw material


Cost comparison to competitor systemsIngredients for 600 kg/cbm

Competitor products

Equivalent LithoPore™(low quality)

LithoPore™(medium quality)

LithoPore™(high quality)

LithoPore™PRO

Avarage compressive strength in MPa (N/mm2)

1 MPa 1 MPa 1.5-2 MPa 2.0-2.5 MPa 3-4.5 MPa

Water 150 kg/cbmat 5 EUR/ton0.75 EUR/cbm

150 kg/cbmat 5 EUR/ton0.75 EUR/cbm




Cement 350 kg/cbmat 85 EUR/ton

250 kg/cbmat 85 EUR/ton





at 85 EUR/ton29.50 EUR/cbm





Sand or Fly Ash 150 kg/cbmat 20 EUR/ton3.00 EUR/cbm





Lime None None None 18 kg/cbmat 50 EUR/ton0.90 EUR

18 kg/cbmat 50 EUR/ton0.90 EUR

Foaming agent 1.5 kg at 1 EUR/kg1.50 EUR

1.5 kg at 1.99 EUR/kg2.99 EUR



1.5 kg at 1.99 EUR/kg2.99 EUR/cbm

Networkformer none none none 5 kgat 1.34 EUR/kg6.70 EUR

5 kgat 1.34 EUR/kg6.70 EUR/cbm

Stabilizer none none None None 0.65 kgat 2.95 EUR/kg1.92 EUR/cbm

Total Sum 34.75 EUR/cbm 30.49 EUR/cbm 36.49 EUR/cbm 43 .73 EUR/cbm 45.65 EUR/cbm



Equipment

GERMAN QUALITY

For small scale production and the first start20-40 cubic meters per shift

CS MP 500 PRO 1.4• 500 Liter mixer including pump and scales• Pumping distance: horizontally 60 m, vertically

30 m30 m

Foam Generator FG 4 II• Foam output: 300-500 l/min


For medium scale production60-80 cubic meters per shift

High precision complete foamed concrete machine„Mixer, pump, foam generator, scale and computer all in one...“

● Volume usable: 1000 l ● Dimensions: 1950 x 1450 mm,● Dimensions: 1950 x 1450 mm,

Height: 1220 mm● Weight: ~900 kg● Pumping distance:

horizontally 60 m, vertically 30 m● Power: ~14 kW● Foam output: 300-500 l/min


For high scale production80-560 cubic meters per shift LithoPore™ Plants for block and panel production

● automatic dosage out of silos and sand bunkers

● automatic mix design control● automatic finishing (cutting process)● automatic finishing (cutting process)● moulds● local assemblage● local commissioning


ContactCompany address GERMANY: Dr. Lucà & Partner Ingenieurkontor GmbH Potsdamerstrasse 12-13 14163 Berlin Germany

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

Email: [email protected]: [email protected]

Company address INDIA: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: [email protected]


Documents

Presentation Foamed Concrete 2009