1. UTILIZATION OF IRON-SILICATE FINES AS REPLACEMENT OF FINE AGGREGATES IN CEMENT CONCRETE PAVEMENTS
eng. Emanuela Manolova, Ph.D
Iron-silicate Business Development Manager
eng. Vanya Stoyanova, Ph.D
R&D Manager
AURUBIS BULGARIA

2. Iron-silicate fines (ISF) - application in concrete pavements
Content
Aurubis as a company
Iron-silicate fines (ISF) - application in concrete pavements
Influence of ISF on fresh concrete mixture
Influence of ISF on hardened concrete
Conclusions 2

3. Aurubis Group Globally
Production plants
Copper production
Copper processing
Commercial
Primary copper
Commercial
Copper products
Avellino, Италия
Buffalo, USA
Dolnẏ Kubin, Slovakia
Emmerich, Germany
Hamburg, Germany
Mortara, Italy
Olen, Belgium
Pori, Finland
Birmingham, UK
Stolberg, Germany
Zutpen, Netherland
Hamburg, Germany
Olen, Belgium
Pirdop, Bulgaria
Röthenbach, Germany
Commercial
Recycling / Presious metals
Fehrbellin, Germany
Hamburg, Germany
Lünen, Germany
Olen, Belgium
International sales and distribution network of Aurubis products – more than 20 countries (Europe, Asia and North America) 3 3

4. Aurubis is the leading company in world recycling market
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Aurubis is the leading company in world recycling market
Global scale recycling materials consumption (in thousand tones)
Aurubis
Copper scrab
Metallo Chimique (Belgien)
Boliden (Schweden)
Brixlegg (Цsterreich)
Electronic scrap
Източник: Интернет страница на конкурент, изчисления на Аурубис 4 4

5. Aurubis is the second international producer of cathodes
100
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Aurubis is the second international producer of cathodes
International producers of cathodes (in thousand tones)
Aurubis 5 5

6. Production for 2016 Processed: Produced:
Metallurgy
Warehouse
Sulphuric Acid Plant
Flotation Plant
Processed:
Copper concentrates t
Copper scrap t
Produced:
Anodes t
Cathodes t
Sulphuric acid t
Iron-silicate fines t

7. Production process
Компанията винаги се е развивала възходящо на базата на сериозни инвестиции от акционерите.
Iron-silicate fines

8. Iron-silicate fines (ISF) - application in concrete pavements
Aurubis as a company
Iron-silicate fines (ISF) - application in concrete pavements
Influence of ISF on fresh concrete mixture
Influence of ISF on hardened concrete
Conclusions 8

9. Iron-silicate fines: definition & characteristics
By-product, generated by a flotation of copper slag (both from furnaces and convertors), during the metallurgic process in the copper plant.
Chemical composition
Mostly ferrous and silicate oxides (Fe2O3 in the form of fayalite (Fe2SiO4) and magnetite (Fe3O4)), together with smaller quantities of aluminium, calcium and magnesium oxides.
Physical characteristics
dark angular particles with rough texture and irregular shape
specific density is 3.8 g/cm³ (EN ) 9 9

10. Iron-silicate fines: definition & characteristics
Grain size
50% of the grains are between 20 μm and 200 μm
50% of the grains are smaller than 20 μm
Pozzolanic activity
Presence of certain activity (EN and ASTM-95) 10 10

11. Iron-silicate fines as a building material
Industrial wastes in concrete production
counteracting the decrease of natural resources;
reducing the cost of construction materials;
solving the problem of disposal of waste materials, generated by different industries;
improving the properties of composite materials – both in fresh and hardened state.
Replacement material
sand
cement
Quarry for aggregates
Disposal of industrial wastes 11 11

12. Iron-silicate fines (ISF) - application in concrete pavements
Aurubis as a company
Iron-silicate fines (ISF) - application in concrete pavements
Influence of ISF on fresh concrete mixture
Influence of ISF on hardened concrete
Conclusions 12

13. Fresh concrete mixture with ISF
Concrete mix design
application: vibro-compression cement pavements in industrial scale;
ISF – 15%, 20%, 25% and 30% sand substitution;
reduces quantities of natural sand 0.4mm.
Material
Reference mix
Mix 1
(15 % ISF)
kg/m³
Mix 2
(20 % ISF)
Mix 3
(25 % ISF)
Mix 4
(30 % ISF)
Cement 52.5 R
355
Coarse aggregate 4/12.5 mm
810
Natural sand 0.4 mm
850
531
488
410
347
Crushed sand 0/4 mm
340
Iron-silicate fines –
300
400
500
600
Water
145
Chemical admixture
2.1 13 13

14. Fresh concrete mixture with ISF
Behaviour of the fresh concrete with ISF
improved workability;
better filling up of the space between the coarser grains;
compacting the voids and pores;
less energy for vibration;
less bleeding;
reduce heat of hydration and water demand;
affect setting characteristics.
Casting and Curing of concrete pavements
in the bottom layer, 30 sec vibration;
humidity chamber (20⁰C, 50%), 28 days
outside storage of ISF as a building material
concrete mix with ISF 14 14

15. Iron-silicate fines (ISF) - application in concrete pavements
Aurubis as a company
Iron-silicate fines (ISF) - application in concrete pavements
Influence of ISF on fresh concrete mixture
Influence of ISF on hardened concrete
Conclusions 15

16. Hardened concrete with ISF
Properties of hardened concrete
Increases mechanical strength;
Smooth polished surface;
Reduces permeability;
Improves durability.
15%
20%
25%
30% №
Percent sand substitution
Flexural strength, MPa
Water absorption, %
Measured value
Limit 1.
15 %
3.7
≥3.6
5.9
≤6.0 2.
20 %
5.8 3.
25 %
4.9
5.7 4.
30 %
4.5 16 16

17. Hardened concrete with ISF
Properties of hardened concrete
25% sand substitution gives the maximum strength;
ISF could reduce the material needed;
ISF reduces the water absorption of pavements, due to compacted structure. The higher is the quantity of ISF, the lower is the absorption.
Reasons:
Proven pozzolanic activity by EN and ASTM-95.
SAI index of testing samples with ISF is 81%, compared so reference samples with cement only (75% in the standard). 17 17

18. Iron-silicate fines (ISF) - application in concrete pavements
Aurubis as a company
Iron-silicate fines (ISF) - application in concrete pavements
Influence of ISF on fresh concrete mixture
Influence of ISF on hardened concrete
Conclusions 18

19. Ongoing investigations
Conclusions
Ongoing investigations
Successful utilization in concrete pavements in industrial scale;
Making sustainable, high strength, durable and eco-friendly concrete products;
25% sand substitution gives equilibrium in properties both in fresh and hardened state;
Further investigations
Application of ISF as a cement replacement;
Production of ready-mix concrete in industrial scale;
Production of ready-mix mortar in industrial scale; 19 19

20. Thank you for your attention!