MPI Materialprüfinstitut Hellberg GmbH

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MPI Materialprüfinstitut Hellberg GmbHLaboratory for slip testing of all kinds of flooringsResearch and development for concrete andgeopolymerPresentation at the Geopolymer CampRheological improvement and water reduction with theMPI - Concrete mixing system.presented byChristo M. CosterusTechnical Director of the MPI Hellberg GmbHMPI Hellberg GmbH – Artlenburger Landstr. 39-41 – 21365, AdendorfTelefon: 49 4131 8843 947 / Telefax: 49 4131 8843 948 / Email: info@mpi-gmbh.deGermany

MPI Materialprüfinstitut Hellberg GmbHNew innovative technologyof the two-step concrete productionusing the MPI Concrete technology:1. Suspension mixing with energeticallyv modified water andv a colloidal mixer2. Mixing of the aggregates and the suspension in ahomogenizerMPI Hellberg GmbH – Artlenburger Landstr. 39-41 – 21365, AdendorfTelefon: 49 4131 8843 947 / Telefax: 49 4131 8843 948 / Email: info@mpi-gmbh.deGermany

MPI Materialprüfinstitut Hellberg GmbHMixing concrete in a way our ancestors already did .The following aspects have been fully disregarded so far:oInfluence of the characteristics of the water usedoDifferent requirements of the components as far as the mixing technology andthe mixing techniques are concerned, not to forget the time and energy whichare needed to fully decompose the componentsThe MPI Technology consists of:oWater treatment by electrodynamics and electrical impactsoSuspension mixing technology (colloidal mixer)MPI Hellberg GmbH – Artlenburger Landstr. 39-41 – 21365, AdendorfTelefon: 49 4131 8843 947 / Telefax: 49 4131 8843 948 / Email: info@mpi-gmbh.deGermany

The Presentation""""""MPI Concrete TechnologyMPI Water TreatmentMPI Colloidal MixingMPI Technical EquipmentEffects and AdvantagesSummaryMPI Hellberg GmbH – Artlenburger Landstr. 39-41 – 21365, AdendorfTelefon: 49 4131 8843 947 / Telefax: 49 4131 8843 948 / Email: info@mpi-gmbh.deGermany4

MPI Water Treatment TechnologyWater treatment by electro-dynamical and electrical impactsThe MPI-water treatment facilities can be optimally adjusted toall types of water (as well recycled water) suitable for theconcrete production.The MPI-water treatment effectuates:oBreakup of a large number of water-molecule-clusters (reduction of thebondage by hydrogen bridges between the molecules)oChanges in the electrical charge of the waterMPI Hellberg GmbH – Artlenburger Landstr. 39-41 – 21365, AdendorfTelefon: 49 4131 8843 947 / Telefax: 49 4131 8843 948 / Email: info@mpi-gmbh.deGermany

MPI Concrete Technology practiceEffectiveness of the MPI water treatmentCement per m³300 kg CEM III/A 42.5N-NAFly ash per m³60 kgPlasticizer based on cement0.35 % SIKA VC1051Spread5 minSlump5 minSpread60 min31.2%Slump60 min 150.0%28d-compr. strengthmm² 3.5%Reference „0“-mix495 mm140 mmMPI WTS-mix580 mm200 mm385 mm505 mm80 mm200 mm27.6 N/mm²MPI Hellberg GmbH – Artlenburger Landstr. 39-41 – 21365, AdendorfTelefon: 49 4131 8843 947 / Telefax: 49 4131 8843 948 / Email: info@mpi-gmbh.deGermany 28.4 N/

MPI Concrete Mixing TechnologySuspension Mixing Technology (colloidal mixer)The MPI-CCT suspension mixing process effectuates:oBreakup of agglomeratesoComplete activation of all cement particles – Possible reduction of the cement contentor substitution of cement by other binding agentsoReduction of the water demand – Reduction of the water/binding agent-ratiooFaster disintegration of plasticizers – Less demand for plasticizersoCrushing of cement particles (wet milling) – Increase of the reactive surfaceMPI Hellberg GmbH – Artlenburger Landstr. 39-41 – 21365, AdendorfTelefon: 49 4131 8843 947 / Telefax: 49 4131 8843 948 / Email: info@mpi-gmbh.deGermany

MPI Mixing TechnologyColloidal suspension/slurry mixerDisintegration of agglomerates - Shearing and cavitations processesMPI Hellberg GmbH – Artlenburger Landstr. 39-41 – 21365, AdendorfTelefon: 49 4131 8843 947 / Telefax: 49 4131 8843 948 / Email: info@mpi-gmbh.deGermany

MPI Concrete Technology practiceApproval of increased early strength and upgrading of cementCement „0“-mix per m³Plasticizer based on cementWTSCCT-mixSpread5 min7.75h-compr. strength390 kg CEM I 52.5R1.1 % BASF ACE 430Reference „0“-mixMPIC 600 mm 600 mm2.5 N/mm²22.6 N/mm² 820.8 %MPI Hellberg GmbH – Artlenburger Landstr. 39-41 – 21365, AdendorfTelefon: 49 4131 8843 947 / Telefax: 49 4131 8843 948 / Email: info@mpi-gmbh.deGermany

MPI Concrete Technology practiceApproval of increased early strength and upgrading of cementCement „0“-mix per m³450 kg CEM I 42.5RPlasticizer based on cement0.4 % BASF ACE 430Should be compressive strength15 N/mm² after 8hReference „0“-mixMPIC WTSCCTmixSpread5 min460 mm435 mm8h-compr. strength5.5 N/mm²16.0 N/mm² 190.6%Material cost reduction*3.15 /m³ CO2reduction*Cement 42.5 R 75.00 /t – Cement 52.5 R 82.00 /tMPI Hellberg GmbH – Artlenburger Landstr. 39-41 – 21365, AdendorfTelefon: 49 4131 8843 947 / Telefax: 49 4131 8843 948 / Email: info@mpi-gmbh.deGermany

Feststoff 3Solid 3WasserwaageWater scaleFeststoff 4Solid 4FeststoffwaageSolid scaleZusatzmittelAdditiveSuspensionsmischerSlurry mixerSuspensionsauslaufSlurry outletMPI Hellberg GmbH – Artlenburger Landstr. 39-41 – 21365, AdendorfTelefon: 49 4131 8843 947 / Telefax: 49 4131 8843 948 / Email: schwasserFresh waterFeststoff 2Solid 2WasseraufbereitungWater TreatmentFeststoff 1Solid 1RecyclingwasserRecycling waterProcedure plan*

Colloidal Mixing System CCTDetached Unit CCT2200MPI Hellberg GmbH – Artlenburger Landstr. 39-41 – 21365, AdendorfTelefon: 49 4131 8843 947 / Telefax: 49 4131 8843 948 / Email: info@mpi-gmbh.deGermany

System drawingMPI “Suspension r tankWater treatmentController (PLC)MixerAdditive dosageMPI Hellberg GmbH – Artlenburger Landstr. 39-41 – 21365, AdendorfTelefon: 49 4131 8843 947 / Telefax: 49 4131 8843 948 / Email: info@mpi-gmbh.deGermany

MPI Concrete TechnologyTesting of the fresh concretecharacteristics„Container-Castle“ at the RMC plant of „HolcimBeton und Zuschlagstoffe GmbH“ in Geesthacht(Hamburg)MPI Hellberg GmbH – Artlenburger Landstr. 39-41 – 21365, AdendorfTelefon: 49 4131 8843 947 / Telefax: 49 4131 8843 948 / Email: info@mpi-gmbh.deGermany

MPI Concrete Mixing TechnologyThe combined MPI contained equipment2.200 (2,500) liter-suspension mixer water treatment systemMPI Hellberg GmbH – Artlenburger Landstr. 39-41 – 21365, AdendorfTelefon: 49 4131 8843 947 / Telefax: 49 4131 8843 948 / Email: info@mpi-gmbh.deGermany

MPI Concrete TechnologyThe MPI Concrete Technologyleads to an increased workabilityand an improvement of quality, e. g. :§ less differences between the mixtures§ higher equality of colours§ higher early strength, higher strength and increased durability§ less pores and reduction of efflorescences§ better workability and compactability§ less segregation and bleeding§ improved pumpabilityMPI Hellberg GmbH – Artlenburger Landstr. 39-41 – 21365, AdendorfTelefon: 49 4131 8843 947 / Telefax: 49 4131 8843 948 / Email: info@mpi-gmbh.deGermany

MPI Concrete TechnologyThe MPI Concrete Technologyleads to a reduction of costs:§ reduction of cement and/or lowering of the w/c-ratio§ exchange of cement against other materials§ upgrading of the cement§ less additives and pigments§ normal concrete can be transformed into a SCC§ less mixing time (higher output)§ less energy consumption and abrasion§ earlier stripping of the mould for prefabricated concrete parts§ reduction of CO2-emissionsMPI Hellberg GmbH – Artlenburger Landstr. 39-41 – 21365, AdendorfTelefon: 49 4131 8843 947 / Telefax: 49 4131 8843 948 / Email: info@mpi-gmbh.deGermany

Effects of the MPI Concrete TechnologyMPI Hellberg GmbH – Artlenburger Landstr. 39-41 – 21365, AdendorfTelefon: 49 4131 8843 947 / Telefax: 49 4131 8843 948 / Email: info@mpi-gmbh.deGermany

MPI Concrete Technology practiceConcrete mix C 80/95 F5 GS16Mixes: 305Dates: 20.01.10Location: TCAMixer / mixing process"0" Reference mix 305 C8Compulsory CMC laboratorymixerMix305 C12WTS laboratory CCT-CmixerMix designWater [l/m³]157145Type of cementCEM I 52,5 RCement [kg/m³]400360Filler (fly ash) [kg/m³]96127Plasticizer (PCE) [kg/m³]each 0,5625% Duriment V565 V566Sand 0/2 [kg/m³] (trocken)870875Grit 2/8 [kg/m³] (trocken)317320Grit 8/16 [kg/m³] (trocken)653657W/B-ratio (Slurry / Concrete)- / 0,3670,291/ 0,354Tests with fresh concreteDensity, fresh (Slurry / Concrete) [kg/dm³]2,4272,438Luftporengehalt [%]NNNNConcrete temperature [ C]25,026,2Spread after 5 min [mm]680600Slump after 5 min [mm]380440Tests with hardened concreteCompressive strenght after 12h [N/mm²]7,524,5Difference in compr. strength [%]Compressive strenth after 24h [N/mm²]Difference in compr. strength [%]Compressive strenth after 24h [N/mm²]Difference in compr. strength [%]Compressive strenth after 7d [N/mm²]Difference in compr. strength [%]Compressive strenth after 28d [N/mm²]Difference in compr. strength [%]20 cm polystyrol cubes5,710 cm cubes57,085,0100,7MPI Hellberg GmbH – Artlenburger Landstr. 39-41 – 21365, AdendorfTelefon: 49 4131 8843 947 / Telefax: 49 4131 8843 948 / Email: ,6%101,60,9%

MPI Concrete Technology practiceConcrete mix C 80/95 F5 GS16Mixes: 310Dates: 28.01.10Location: TCA"0"Referencemixes 310C1Mix310 C6"0"Referencemixes 310C5Mix310 C7Mixer / mixing processCompulsorylaboratorymixerWTS CCT-L compulsorylaboratory CMEmixerCompulsorylaboratorymixerWTS CCT-L compulsorylaboratory CMEmixerMix designWater [l/m³]157,0Type of cementCEM I 52,5 RCement [kg/m³]400Filler (fly ash) / slag [kg/m³]96 fly ashPlasticizer (PCE) [kg/m³]96 slag0,375% Duriment 565 / 0,875% Duriment 566Sand 0/2 [kg/m³] (trocken)870Grit 2/8 [kg/m³] (trocken)317Grit 8/16 [kg/m³] (trocken)W/B-ratio (Slurry / Concrete)653- / 0,3650,240 / 0,373- / 0,3650,240 / 0,3732,4512,432Tests with fresh concreteDensity, fresh (Slurry / Concrete) [kg/dm³]2,4592,430Luftporengehalt [%]NNNNConcrete temperature [ C]22,029,0 / 22,022,029,0 / 22,0NNSpread after 5 min [mm]700690670620Spread after 60 min [mm]660680595660Slump after 5 min [mm]320320350200Slump after 60 min [mm]300250350270Tests with hardened concreteCompressive strenght after 7.5h [N/mm²]2,3Difference in compr. strength [%]Compressive strenth after 7d [N/mm²]Difference in compr. strength [%]Compressive strenth after 28d [N/mm²]89,7Difference in compr. strength 2-0,7%92,25,0%MPI Hellberg GmbH – Artlenburger Landstr. 39-41 – 21365, AdendorfTelefon: 49 4131 8843 947 / Telefax: 49 4131 8843 948 / Email: info@mpi-gmbh.deGermany97,15,3%

MPI Concrete TechnologyYour Chance to ChangeUsing MPI Concrete combined systems in plants for prefabricated concrete parts,ready-mixed concrete plants or directly on the construction sites, guarantees acost-effective production of concrete, an increase of quality and of the output/production capacity.Both, the time required to produce a mixture of concrete and the time to fill atruck mixer can be notably reduced which means that, in a lot of cases, less truckmixers are needed.The usually high energy consumption for the dry mixing can be reduced to lessthan a third. The wear costs of the existing mixing systems decrease to aminimum.The period of redemption (ROI- return of investment) of an MPI Concretesystem will normally be less than 18 months, depending on the productionquantity and the site of operation.The MPI Concrete technologies also play an important role inthe range of activities to reduce the CO2-emissions.MPI Hellberg GmbH – Artlenburger Landstr. 39-41 – 21365, AdendorfTelefon: 49 4131 8843 947 / Telefax: 49 4131 8843 948 / Email: info@mpi-gmbh.deGermany

Concretemix C 80/95 F5 GS16 Mixes: 310 Dates: 28.01.10 Location: TCA "0" Reference mixes 310 C1 Mix 310 C6 "0" Reference mixes 310 C5 Mix 310 C7 Mixer / mixing process Compulsory laboratory mixer WTS CCT-L compulsory laboratory CME mixer Compulsory laboratory mixer WTS CCT-L comp

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