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Low water requirement binder (LWRB)
Low water requirement binder is a heavy-duty hydraulic binder produced by intergrinding of portland cement clinker, gypsum rock, and high range water reducer (S-3). As a result of mechanochemical interaction between cement clinker minerals and superplasticizer during fine grinding, the material attains unique and specific properties distinguishing it from ordinary portland cement.
As compared to ordinary portland cement, LWRB is characterized by higher dispersability (specific surface area 4000 to 5000 cm2/g), low water requirement (standard cement paste consistency is 18.0 to 20.0% on average as compared to the standard consistency of M400 and M500 portland cement of 26.5% and 26.0%), activity in terms of strength index is up to 100 MPa. In terms of its material composition, LWRB is divided into purely clinker binders (LWRB-100) and multi-component binders with different mineral additives: optimized combination of active and inert additives.
Blast-furnace slags and pulverized fuel ashes are used as active mineral additives; inert additives: mortar sand, tailings of mining, and concentrating mills; non-metallic carbonate materials can be used as well (limestone, dolomite, marble, etc.).
A characteristic feature of LWRB-based cement systems is a significant deceleration of the structure formation during the first 4 to 8 hours after mixing with subsequent intensive crystallization and curing.
Tube-ball mills are used to produce low water requirement binders. However, as revealed by research, ball mills with a separator are preferable. They ensure specified particle size.
Duration of the induction period is reduced, as the clinker component in its composition increases. LWRB is characterized by long-term preservation of activity and intensive cement stone and concrete strength gain at various, including early, curing times.
LWRB is applied when it comes to production of high-strength concrete and reinforced concrete; production of wood concrete with enhanced physical and mechanical properties; and as a polymer-cement coatings and industrial buildings floorings component, and for the purposes of heat-free concreting in wintertime.
Low water requirement binder (LWRB). History of creation.
It all began in 1989. Back then, the Soviet Union produced 145 million tons of cement per year. However, these figures were insufficient. Production capacities had to be increased. The country's government decided to buy cement plants in Japan. A group of Soviet specialists has been instructed to go abroad and study Japanese cement plants.
Followings research, an alternative has been offered to the country's government. This alternative was to increase cement output by means of the new technology which implied modifying portland cement into nano cement rather than building new plants..
More details about the proposed technology. According to the new technology, ball mills are used for production of cement. Each cement grain is activated by means of triboactivation and is coated with a super-thin nano-layer of other substance ranging from 20 to 50 nm. Performance of the produced material is twice as high as that of ordinary portland cement.
By the order of the USSR government, a group of specialists brought these cements to the USA for the purposes of testing. Americans managed to obtain fantastic results: nano cement-based concrete showed the world record — grade 600 within 24 hours of curing in normal conditions, while it takes 28 days for traditional portland cement to come to a full cure resulting in grade 400 to 500. Thus, our specialists have proved that they had managed to produce best cement and concrete in the world!
Production of new cements (which have been called "low water requirement binders") began within the scope of the USSR cement industry's production plans for 1990 through 1991. It is confirmed by the RECOMMENDED PRACTICE FOR APPLYING LWRB IN CAST-IN-SITU PAVEMENT CONCRETE document, developed by SOYUZDORNII in 1990. However, further development of this trend was suspended due to commonly known reasons.
The main advantages of low water requirement binder (LWRB) as compared to its portland-cement-based equivalents.
Low water requirement binder offers some significant advantages over its portland-cement-based equivalents.
As compared to ordinary portland cement, LWRB is characterized by higher dispersability (specific surface area 4000 to 5000 cm2/g), low water requirement (standard cement paste consistency is 18.0 to 20.0% on average as compared to the standard consistency of M400 and M500 portland cement of 26.5% and 26.0%), activity in terms of strength index is up to 100 MPa.
• reduced water requirement of mortar and concrete mixes by 25 to 30% at equal fluidity;
• long-term preservation of activity and intensive cement stone and cement stone-based concrete strength gain at various, including early, curing times;
• high LWRB-based concrete strength gain intensity makes steam treatment unnecessary and allows obtaining the strength necessary for release of shuttering within 18 to 24 hours;
• freeze-thaw durability is 2 to 3 times as high as that of portland-cement-based concretes due to the fine-pored concrete structure;
• ensuring B60 to B100 concrete strength grade;
• high sulfate resistance (sulfate resistance coefficient is no less than that of sulfate resistant cement);
• decreased heat release during curing.
Storage at room temperature (up to 180 days) of such a binder containing from 30 to 100 (LWRB-30 and LWRB-100) clinker component in paper bags did not result in any change of dispersability, water requirement, and strength performance in standard mortars (both designed and early, from 1 to 3 days old).
Whereas the strength of grade-500-portland-cement-based mortar has decreased by 17 to 20 % already after 30-day storage in similar conditions. Moreover, after 6-month storage, the strength is amounted to only 35 - 37% of its initial value. In this case, cement specific surface area has decreased from 3200 to 2600 cm²/g. It serves as the evidence that clinker particles have agglomerated.
Low water requirement binder production lines (LWRB) (equipment). Areas of application and basic parameters
Continuous operation low water requirement binder (LWRB) production line (equipment) with a capacity of 30 to 40 thousand tons per year is designed for producing high-efficient binder in compliance with Specs 21-26-20-92
Capacity (t/h) is within 6 to 7
Weight (without heat insulation and lining) line equipment set, tons, no more than 220
Installed power, kW, no more than 625
Specific compressed air consumption, m3/min. no more than 18
Overall line dimensions, m (length, width, height) 45x20x14
Specific surface area (dispersability of the finished LWRB product), cm2/g 3500 to 4000
Supply electric mains 3-phase, AC, 380 V, 50 Hz frequency
At customer's request, the line can be supplied complete with a separator ensuring the consistent particle size of the output product.
Strommashina Corp. was founded in 1942 as an engineering and industrial equipment manufacturer.
Today our offering includes variety of products, complete systems, projects and solutions in all of the following areas: Mining & Minerals, Thermal Processing (Pyro Processing), Oil & Gas, Power Generation, Environment & Recycling, Agglomeration, Materials handling, etc.
Due to our deep process know-how, combined with technology and strong service capabilities Strommashina Corp. is recognized as an industry leader in Russian Federation and become a well-known manufacturer and supplier in European countries. All of our systems and industrial equipment are developed with longevity and rentability in mind, and can be configured to a variety of specifications.
We provide our customers with the verify products and related services built on technological excellence, experience and the highest safety standards.
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Whether you know exactly, what you need, or you are not sure, where to start, we can help.
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Tel.: +7 (846) 3-741-741 ext. 322
Samara Plant Strommashina is a large machine-building plant that produces processing equipment for different industries such as metallurgy, mining and concentrating, oil refining, construction materials manufacturing and others.
In recent years, customers' requirements are focused on packaged supplies. Supply packages often include infrastructure facilities for industrial plants, which are produced from METAL STRUCTURES, such as:
Many years of production experience, availability of proper expert team and powerful manufacturing base allow us to insure high quality and strict production and delivery terms for our customers. At our plant we implement a continuous program for the improvement of production efficiency, as well as adopt and introduce the state-of-the-art technologies.
At the present time Samara Plant Strommashina can produce more than 300 tons of metal structures of all types and complexity per month. Development program insures production capacity growth up to 1,000 tons per month.
For manufacturing of metal structures only, the following equipment was installed:
- Band sawing machines
- Crop shears up to 20 mm
- Plasma cutting machine with CNC up to 60 mm
- Bending machine with 3 rolls for metal sheets forge-rolling up to 20 mm
- Metal sheets banding machine up to 160 tons
- Complex of turn-milling machines
- Semi-automatic welding machines Taurus
- Sand blasting and shot-blasting equipment
- Turning, milling and drilling machines
- Lifting equipment up to 20 tons
We manufacture customized products in full compliance with the technical requirements of the customer and quality control procedures for finished products.
Quality management system according to ISO 9001 has been adopted at out plant.
The staff of the plant include highly skilled specialist, and all personnel undergo mandatory certification for competency in due time.
The modern market of metal structures is characterized by a very high competition, but according to our customers opinion, Samara Plant Strommashina has a number of advantages over similar producers:
- Long-term experience of plant operation (more than 70 years in the market)
- The geographical position.
- Permanent professional personnel.
- span financial position of the plant (availability of payment delays)
- Continuous renewing of the complex of processing equipment
- Direct contact with producers of raw materials (metal).
- Availability of quality assurance.
- Flexible pricing and discounts, various payment options.
- Availability of railway sidings (for shipment by trains)
- Possibility to design steel structures details.
Cooperation with Samara Plant Strommashina reduces the risk for our customers in the implementation of a variety of their projects.
Reliable business relations with us have been highly appreciated by such companies as LUKOIL, ROSNEFT, Uralgidromed, Uralelectromed, Central Urals Copper Melting Plant, Severstal, Kazkhrom, Kazakhmys Corporation, Karabashmed, EVRAZ, Norilsk Nickel, RUSAL, Polyus Gold and others.
We will be glad to see you among our customers!
For all possible questions about metal structures manufacturing, please, contact us:
Tel.: +7 (846) 3-741-741 ext. 322
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