PAGE 1/2 AIB 005 Quality Aggregates and Manufactured Sand for Concrete Aggregate content is a factor which has direct and far-reaching effects on both the quality and cost of concrete. Unlike water and cement, which do not alter in any particular characteristic except in the quantity in which they are used, the aggregate component is infinitely variable in terms of shape and grading. With coarse aggregates graded in fractions between 5mm and 40mm, differences in particle shape and surface texture affect the bulk void content and frictional properties of concrete. Optimum Shape The optimum shape is cubical. Similarly, an even gradation of the total coarse aggregate fraction is desirable so that the smaller particles can fit between the larger particles, thereby minimizing the voids. Well shaped aggregates also minimize the incidence and degree of segregation. It has been proven that more than 20kg of cement can be saved for every cubic metre of concrete that is made by replacing a poorly shaped aggregate with a cubical aggregate. In addition, both compressive strength and flexural strength are improved by using cubical aggregates, which also increases workability and reduces bleeding and shrinkage. The impact of the physical characteristics of the sand used in the concrete mix is even greater than that of the coarse aggregate fractions, both in the concrete's plastic and hardened states. Void Content The principles of total internal friction and void content apply equally to the fine fraction, but because of the vastly smaller particle size and therefore the greatly increased surface-area-to-volume ratio, any detrimental or undesirable shape or texture properties will be greatly amplified. Similarly, manufactured sand presents an opportunity to control the mineral content in the particles. Natural sand often contains undesirable minerals and clays, and the effect of these materials on both the fresh and the hardened states of concrete can be extremely harmful. For example, the effect of clay particles in fresh concrete is not obvious, as the particles absorb disproportionate volumes of water and hence swell to many times their original size. This swelling occupies a volume in the cement paste in its fresh state. When it hardens, however, the clay particles contract and leave minute voids which in turn increase the shrinkage and permeability and hence reduce the concrete's chemical resistance and compressive strength. Other undesirable materials, ranging from basic chlorides to harmful chemicals, can exist in this fine material fraction. The use of manufactured sand, however, reduces the risk of impurities. Shortage The growing shortage of natural sand is another question the construction industry must consider. While this may not appear to be a priority topic, pressure from environmentalists and conservationists worldwide will continue to encourage both legislators and construction engineers to look for viable alternatives to natural sand. Cubical sand manufactured from crushed rock is the most desirable fine material for concrete production. It is generally accepted that particle shape depends on the rock type, breakage energy and the type of crusher used. It is also generally accepted that the crushers most successful at producing non-flaky aggregates are autogenous (rock on rock) and vertical-shaft impactors, such as the Barmac B-Series VSI crusher. Flexibility Accepting feed material up to 50mm in size, and thus acting as a finishing crusher, the B-Series VSI offers considerable flexibility. With the Hydracascade feature, a single crusher can, in one pass, produce the same quality and fraction of aggregate achieved in up to three stages by other plants. The ‘rock-on-rock’ principle also maximizes sand production without compromising either the shape or the texture, thus ensuring that tight specifications can be met. The reason for this lies in the crusher technology which allows the material to crush itself by the action of centrifugal force and attrition, rather than by relying on breaker bars, hammers or cones. This results in lower energy consumption and wear costs than other types of crushers, providing further economies in the overall production cost. Also, fracture takes place along the rock's natural grain, producing the characteristic cubical shape and surface texture. AIB05 PAGE 2/2 Abrasive The feed materials predominately used can be particularly abrasive. Whether flint gravel or granite, the effect on conventional crushers can be unacceptable in terms of the overall economics. The B-Series rock-on-rock principle, however, ensures that throughput can be maintained without incurring high wear costs and prolonged downtime. Furthermore, as wear does inevitably occur, the product grading will remain unaltered, ensuring continuity of quality. Barmac B-Series VSI crushers are in use throughout the world, producing good-quality aggregates and 0-5mm concrete sands. These machines are also well established in the industrial minerals sector crushing such diverse materials as Chinese bauxite, sintered magnesite, fused aluminas and recycled glass, where shaped and fine sizes are desirable characteristics of the finished material specification New Model Recently Metso Minerals launched the new B1100 Series VSI which has been designed to offer higher capacity for a given motor size, plus easier servicing and reduced operating costs. These benefits have been achieved through an improved hopper design and the development of new rotor design technology. The new model gives capacity increases of up to 25%, as well as an improved capability to handle coarse feed fractions. Specific energy consumption can be reduced by up to 20% and average wear costs are reduced in many cases by 15%. Typical Barmac B-Series VSI Aggregate and Sand Circuit New Feed –40 +20mm Feed: New 140 TPH Recirculating: 60 TPH B7100 VSI 185kW [250 hp] Tip Speed: 47 m/s 10% Cascade 3-Deck Screen Cut 1 = 20mm Cut 2 = 10mm Cut 3 = 5mm 0–5mm 5–10mm 10–20mm For more information regarding this circuit see AIB001. Barmac VSI crushers are also used in the industrial minerals, mining, recycling and general quarrying industries. A wide range of materials are processed through Barmac VSI crushers worldwide. For more information on this or any other application, please contact your nearest Barmac representative. Metso Minerals (Matamata) Limited Mangawhero Road, Private Bag 4071, Matamata, New Zealand Tel. +64 7 881 9060, fax +64 7 888 5244 [email protected] AIB005 – 1 – 7/01
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