Utilization of Ground Eco-Filler Actived by High-Speed Multi Level

Mill in Civil Engineering

with partners

• Recycling Lines: rubber granulate, concrete dust and stone sludge/dust.

• Technology: active rubber powder, concrete and stone powder science and applied research.

• Customer Service:

• Research center

• Service and spare part

• Consulting

• Design

• Optimalization

LAVARIS Ltd. company(Libčice near Prague, CZ)

Assembly Line

Variable layout, components according Recycling Line

Drying

Activation

Homogenization

Light-Weight Blocks

Mobile Version:

to requirements.

Stationary Version:

Key Component of the Recycling Lines

High-Speed Mill

ModelPower plant

[kW]Productivity

[t/hours]

SBD 251 2 × 15 0.25

SBD 401 1 × 10 0.15

SBD 600 2 × 30 0.80

SBD 800 2 × 55 3 – 5

SBD 1000 2 × 110 4 – 7

• Stationary Line

ModelPower plant

[kW]Productivity

[t/hours]

MBD 251 2 × 15 0.25

MBD 401 1 × 10 0.15

MBD 600 2 × 30 0.80

MBD 800 2 × 55 3 – 5

• Mobil Line

SBD 600

SBD 300

SBD 150

SBD 600

Screener

Design of Homogenizing Mill D550High-Speed Mill

Hammer Mill

Filtration – Polymer Nanofiber Textiles

High-Tech Technologies

Dust-Free Design

Anti-Vibration and Acoustic Barrier

Self-Supporting Power Unit – Photovoltaic Panel with Tracker

Photo: dynamix/sxc.hu

Recycled Rubber

West Bank of Jordan River and Egypt

Some Model Materials

Optical microscopy (80 ×)Electron microscopy (100 ×)

raw

mat

eri

alm

ille

d

Marble industry(http://mines.pajhwok.com)

Frakce 0 – 2 mmFrakce 2 – 4 mm Controlled grain-size distribution

Cement Sand 0 – 2 mm Stone sludge

Model Material (West Bank)

• variable layout,

• components according.

to requirements

Complete Building System

Reference house from recycled materials – student project.

Exterior Plasters

stone microfiller to 70 % wt

compressive strength > 6 MPa

optimized for low shrinkage

good adhesion

Masonry Block

low cement content

recycled material to 90 % wt.

compressive strength 12 MPa

heat accumulation

acoustic barrier

Bed-Joint Mortar

stone dust filler to 80 % wt.

cement 20 % wt.

compressive strength to 9 MPa

good adhesion

Interior Plasters

stone microfiller to 90 %

compressive strength > 4 MPa

optimized for low shrinkage

good adhesion

Controlled Modification of Utility Properties2D or 3D Nanohydrophobization

Light-Weight Blocks (no need for heating)

Experimental/Standard Testingon Nano/Micro/Macro Level

Application / Real Conditions

Use of Concrete MicrofillerDensity Specific surface

(kg.m-3) (m2kg-1)

Grinded concrete (KR) 2,432 3,737

Grinded concrete (DR) 2,547 3,884

Reference material (CEM I/32,5 N) 3,096 0,421

Sample determination of

density and specific

surface (Blaine);

comparison with

standard cement.

chemical analysis and

comparison of recycled

concrete and mechanically

activated concrete

microfiller.

Original crushed

cocrete

Grinded material

(KR)

Grinded material

(DR)

(%) (%) (%)

SiO2 66.01 66.02 66.88

TiO2 0.13 0.13 0.13

Al2O3 3.72 3.74 3.12

Fe2O3 1.24 1.25 0.31

FeO 0.32 0.35 3.17

MnO 0.03 0.03 0.06

MgO 1.11 1.12 1.4

CaO 15.48 15.52 13.75

Na2O 0.45 0.46 0.44

K2O 0.99 0.99 0.94

P2O5 0.03 0.03 0.03

H2O- 1.67 1.54 0.94

H2O+ 3.79 3.77 4.76

CO2 4.59 4.6 4.4

Stot 0.3 0.3 0.25

Compound

Application in Cold Pavement Recycling

Mix

3.5E

+

5PC

3.5E

+

3PC

3.5E

+

5ML

3.5E

+

3ML

4.5F+

1.5C+

1.5PC

4.5F

+

5PC

4.5F

+

3PC

4.5F

+

5ML

4.5F

+

3ML

2.5F

+

9.6PC

2.8F+

10.6L

0/2

2,5F

+

3PC

RAP 0/22 0/11 0/22

Bit. emulsion 3.5 3.5 3.5 3.5 -

Foamed bitumen - 4.5 4.5 4.5 4.5 4.5 2.5 2.8 2.5

PC 5.0 3.0 - 1.5 5.0 3.0 - 9.6 - 3.0

ML - 5.0 3.0 - 5.0 3.0 -

Limestone 0/2 - 10.6 -

Cement - 1.5 -

Pulverized concrete from railroad ties

Application in Cold Pavement Recycling

cold mix variations with

bitumen emulsion and

cement;

substitution of cement

by milled limestone or

pulverized concrete;

results of indirect tensile

strength.

cold mix variations with

foamed bitumen and

cement;

substitution of cement

by milled limestone or

pulverized concrete;

results of indirect tensile

strength

Cold Pavement Recycling with Activated Fly-Ash

Mix design REC REF

REC P01

REC P02

REC P03

REC P04

REC P05

REC P06

REC P07

REC P08

Water 4.5% 4.5% 5.0 % 5.5% 5.5% 5.0% 5.0% 5.0% 5.5%

Cement CEM II/B - S32,5R 3.0% - - 1.0% - - - 1.0% 1.0%

Bituminous emulsion C60B7 3.5% 3.5% 3.5 % 2.5% 3.5% 3.5% 3.5% 2.5% 2.5%

Fly-ash (Ledvice) - 3.0% 7.5 % 10.0% - - - - -

Bottom-ash (Počerady) - - - - - - - 10.0% 15.0%

Mechanically activated fly-ash - - - - 3.0% 7.5% 10.0% - -

Reclaimed asphalt material 0/11 89.0% 89.0% 84.0 % 81.0% 88.0% 84.0% 81.5% 81.5% 76.5%

Mix

Indirect tensile strength (MPa) ITSR* Decrease of ITS Frost susceptibility

7 air 14 air 7 air + 7 water 28 air

REC REF 0.45 0.84 0.56 0.91 0.68 1.24 0.91

REC P01 0.71 1.05 0.78 0.82 0.74 1.10 -

REC P02 0.51 0.58 0.43 0.82 0.74 0.84 0.88

REC P03 0.4 0.55 0.41 0.63 0.74 1.02 0.60

REC P04 0.66 0.63 0.54 0.65 0.86 0.82 -

REC P05 1.14 1.18 1.37 1.42 1.16 1.20 0.88

REC P06 1.23 1.19 0.97 1.63 0.82 0.79 0.81

REC P07 0.49 0.51 0.42 0.66 0.82 0.86 -

REC P08 0.41 0.49 0.40 0.55 0.82 0.98 -

Micromilled Limestone for Asphalt

18

use of various limestone waste dust or sludge products;

high pulverization coefficient reached by applying a continuous milling

without any additional surfactant additive (example: Czech limestone

from Krty location – one milling cycle with 0-4 mm grading);

material on the edge between micro- and nano-particles with broad

range of applications (by far not only limited to building industry).

Micromilled Limestone for Asphalt

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Reference mix (no additive)

Mech. activated dolomite

Filter fly-ash Bottom-ash AdHere (type A) Limestone filler + dolomite

19

Use of pulverized limestone as an active filler for improving

asphalt mixture durability – example of dolomitic limestone

Application in Road Infrastructure

Mechanical chemical activation is believed to transform some waste

materials into a raw material suitable for cold recycled mixes or soil

stabilizations.

Properties improved in time.

In the case of pulverized recyclable concrete additions of this material

modified by high-speed milling resulted in a slight reduction of

stiffness and indirect tensile stress; however, the reduction is far from

essential and mixes containing pulverized concrete had no problems

meeting the requirements .

The optimal content of added pulverized concrete around 5-7 %.

Pulverized limestone effective in asphalt mixtures.

Potential also for other by-products like e.g. fly-ash (another

alternative binder).