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 05.04.2017

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

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

Aurubis is the leading company in world recycling market 29.11.2018 14:24 29.11.2018 14:24 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

Aurubis is the second international producer of cathodes 100 29.11.2018 14:24 29.11.2018 14:24 29.11.2018 14:24 Aurubis is the second international producer of cathodes International producers of cathodes (in thousand tones) Aurubis 5 5

Production for 2016 Processed: Produced: Metallurgy Warehouse Sulphuric Acid Plant Flotation Plant Processed: Copper concentrates 1 200 000 t Copper scrap 56 000 t Produced: Anodes 350 000 t Cathodes 230 000 t Sulphuric acid 1 220 000 t Iron-silicate fines 677 000t

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

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

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 1097-6) 9 9

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 450-1 and ASTM-95) 10 10

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

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

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

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

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

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

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 450-1 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

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

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

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