foam concrete, clc | luca industries international …...bearing cladding panels or pre-cast blocks...
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LithoPore®
advanced and innovative foamed conrete technologyby Luca Industries International GmbH
Cellular Lightweight Concrete (CLC)
Insulation Construction Materials
© Luca Industries International GmbH 2015, Version 2.01
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© Luca Industries International GmbH 2015, Version 2.01
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LithoPore® Technology - Cellular Lightweight Concrete
Applications
1 Luca Industries International inside
Technical Properties and Product Keydata
Economical View
6 Investment Options
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History
© Luca Industries International GmbH 2015, Version 2.01
Incorporation of Dr. Lucà & Partner Ingenieurkontor GmbHBiotechnological additives for the textil industry and cellular lightweight concrete
New focus: Cellular lightweight concrete (Manufacturing of machines, plant solutions, engineering)
1991
2003
2005
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History
© Luca Industries International GmbH 2015, Version 2.01
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)
2007
2010
2011/12c
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History
© Luca Industries International GmbH 2015, Version 2.01
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
© Luca Industries International GmbH 2015, Version 2.01
2015: Global Uniform Branding
Step 1: Cooperation agreement for 1-2 yearsStep 2: Franchise agreement after 1 or 2 years
Luca Industries International GmbH
2013
Luca Industries USA Luca Industries Region X
EC1 USA EC2 USAEC1
Region X
EC2Region X
Cooperationagreement
LongtermSupply
ContractLithoFoam©
Additives
LicenceAgreement
to useLithoPore© CLC brand
2013SalesContracts
2013SalesContracts
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Company key data
© Luca Industries International GmbH 2015, Version 2.01
Employees: 60 worldwide
Production capacity biochemical additives: 2500 mtons/year
Group turn over 2014: 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/cellular lightweight concrete )
LithoFoam (biochemical additives)
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© Luca Industries International GmbH 2015, Version 2.01
2
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LithoPore® Technology - Cellular Lightweight Concrete
Applications
1 Luca Industries International inside
Technical Properties and Product Keydata
Economical View
6 Investment Options
Luca In
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© Luca Industries International GmbH 2015, Version 1.01
• 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 cellular concrete.
• Environment
– Eco-friendly and cost effective
LithoPore© foamed concrete - Introduction
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Production of LithoPore® foamed 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
© Luca Industries International GmbH 2015, Version 2.01
Cement, fillerscale
SlurryMixer
Water scale
Water
Primary Mixer
Ready mixedLitho Pore©
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LithoPore® vs. ordinary foamed concrete
© Luca Industries International GmbH 2015, Version 2.01
201
2011
LithoPore® ordinary foamed
concrete
Foaming agent typesynthetic protein
(artificial)
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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© Luca Industries International GmbH 2015, Version 2.01
2
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LithoPore® Technology - Cellular Lightweight Concrete
Applications
1 Luca Industries International inside
Technical Properties and Product Keydata
Economical View
6 Investment Options
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Application – Cast at site / frame work filling
© Luca Industries International GmbH 2015, Version 2.01
Major countries: Africa, South East AsiaDry density target: 1000-1600 kg/cbm
Endproduct trade name: LithoPore®1000-1600
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Application – Roof insulation
© Luca Industries International GmbH 2015, Version 2.01
Major countries: India, Middle EastDry density target: 400-800 kg/cbm
Endproduct trade name: LithoPore®400-800
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Application – Panel production (at site or precast)
© Luca Industries International GmbH 2015, Version 2.01
Major countries: USA, Australia, ItalyDry density target: 800-1400 kg/cbm
Endproduct trade name: LithoPore®800-1400
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Application – Lightweight floor screeds
© Luca Industries International GmbH 2015, Version 2.01
Major countries: East and South Europe, TurkeyDry density target: 400-800 kg/cbm
Endproduct trade name: LithoPore®400-800
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Application – Blocks
© Luca Industries International GmbH 2015, Version 2.01
Major countries: India, South East AsiaDry density target: 400-800 kg/cbm
Endproduct trade name: LithoPore®400-800
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Innovations - Heat insulating compensation layer below floorscreed
© Luca Industries International GmbH 2015, Version 2.01
Major countries: Germany, DenmarkDry density target: 200-300 kg/cbm
Endproduct trade name: LithoPore®200-300
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Innovations - Heat insulating compensation layer below floorscreed
© Luca Industries International GmbH 2015, Version 2.01
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LithoPore® – advantages at a glance
Low density aerea of 200-300 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 ingrediences) instead of B1
In case of future renovations: only ordinary recycable construction waste
© Dr. Lucà & Partner 2011, Version 1.01
worldwide unique
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Innovations – pre cast insulating board
© Luca Industries International GmbH 2015, Version 2.01
Masa-LithoPore®-TechnologyLithoPore75-150
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Innovations – pre cast insulating board Applications
© Luca Industries International GmbH 2015, Version 2.01
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Innovations – pre cast insulating boardReady to market...
© Luca Industries International GmbH 2015, Version 2.01
Initial product under laboratory style 2010
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Innovations – pre cast insulating boardReady to market...
© Luca Industries International GmbH 2015, Version 2.01
First industrial test with 1 cubic meter batching volume in 2011
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Innovations – pre cast insulating boardReady to market...
© Luca Industries International GmbH 2015, Version 2.01
First industrial test in existing German Masa AAC plant in 2012
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© Luca Industries International GmbH 2015, Version 2.01
2
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LithoPore® Technology - Cellular Lightweight Concrete
Applications
1 Luca Industries International inside
Technical Properties and Product Keydata
Economical View
6 Investment Options
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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 foam concrete consists of very small sized
unconnected individual air bubbles, uniformly spaced over the body of thematerial
– Due to absence of coarse aggregate (gravel), foam concrete flows by itself intothe moulds, shuttering and any cavities, thereby avoiding the necessity ofcompaction or vibration.
© Luca Industries International GmbH 2015, Version 1.01
Characteristics of LithoPore© foamed concrete I
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• Ease of production– Foam 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 foam 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, foam 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.
© Luca Industries International GmbH 2015, Version 1.01
Characteristics of LithoPore© foamed concrete II
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© Luca Industries International GmbH 2015, Version 1.01
Characteristics of LithoPore© foamed concrete IIIWater absorption
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© Luca Industries International GmbH 2015, Version 1.01
Characteristics of LithoPore© foamed concrete IVCompressive Strength (average values)
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© Luca Industries International GmbH 2015, Version 1.01
Characteristics of LithoPore© foamed concrete VFire Resistance
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© Luca Industries International GmbH 2015, Version 1.01
Durability
• Sound insulation
• Thermal insulation
• Fire resistant
Workability
• Drilling
• Cutting and installing
• Nailing
• Sawing
Characteristics of LithoPore© foamed concrete VI
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Overall technical data at a glance
© Luca Industries International GmbH 2015, Version 2.01
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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Innovations – pre cast insulating boardTechnical properties
© Luca Industries International GmbH 2015, Version 2.01
• 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
© Luca Industries International GmbH 2015, Version 2.01
Innovations – pre cast insulating boardTechnical properties
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© Luca Industries International GmbH 2015, Version 2.01
2
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LithoPore® Technology - Cellular Lightweight Concrete
Applications
1 Luca Industries International inside
Technical Properties and Product Keydata
Economical View
6 Investment Options
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Technology overview by application
© Luca Industries International GmbH 2015, Version 2.01
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
© Luca Industries International GmbH 2015, Version 2.01
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
© Luca Industries International GmbH 2015, Version 2.01
For further economical details (involved costs into machineryor average costs per cubic meter of LithoPore® foamedconcrete) please contact us. We will assist you with a detailedcost break down.
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© Luca Industries International GmbH 2015, Version 2.01
2
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LithoPore® Technology - Cellular Lightweight Concrete
Applications
1 Luca Industries International inside
Technical Properties and Product Keydata
Economical View
6 Investment options
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Starter Kit for block production
© Luca Industries International GmbH 2015, Version 2.01
Components
LithoPore® Station (all-in-one-machine)
Cutting System SM100
Moulds
Overall Data
Capacity per hour: 6.0-8.0 cbm
Batch size mixer: 1000 liters
Moulds size: approx. 1 cubic meter
Power: 50 kW, 400 V, 50/60 Hz
Staff: 6-8
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LithoPore® Block Plant 400 (semi automatic plant line)for block production
© Luca Industries International GmbH 2015, Version 2.01
Overall Data
Capacity per hour: 18-20 cbm
Batch size mixer: 1500 liters
Moulds size: approx. 1 cubic meter
Power: 150 kW, 400 V, 50/60 Hz
Staff: 11-29
Characteristics
Fully automatic dosage and mixing
Fully automatic cutting
Mould handling by forklifts
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Masa-LithoPore®-Technology (fully automatic plant line)for block production with fly ash and for insulating boards
© Luca Industries International GmbH 2015, Version 2.01
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
© Luca Industries International GmbH 2015, Version 2.01
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
© Luca Industries International GmbH 2015, Version 2.01
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
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Contact – Luca Industries worldwide
© Luca Industries International GmbH 2015, Version 2.01
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]
Sudsidiary
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]
Country Manager(Convertion into Franchisee)
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]
Country Manager(Convertion into Franchisee)
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Thank you for your attention...
© Luca Industries International GmbH 2015, Version 2.01