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Luca In
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LithoPore®Advanced and Innovative Aerated Concrete Technology
by Luca Industries International GmbH
LithoPore Aerated Concrete (LPAC)
Insulation Construction Materials
© Luca Industries International GmbH 2017, Version 1.02
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© Luca Industries International GmbH 2017, Version 1.02
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LithoPore® Technology - Aerated Concrete
Applications
1 Luca Industries International inside
Technical Properties and Product Keydata
Economical View
6 Investment Options
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History
© Luca Industries International GmbH 2017, Version 1.02
Incorporation of Dr. Lucà & Partner Ingenieurkontor GmbHBiotechnological additives for the textile industry and LithoPore Aerated Concrete
New focus: LithoPore Aerated Concrete (Manufacturing of machines, plant solutions, engineering)
1991
2003
2005
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History
© Luca Industries International GmbH 2017, Version 1.02
Incorporation Dr. Luca Bioengineering and Services Pvt. Ltd. (India)
Cooperation HeidelbergCement (Heidelberger Beton Group)
Cooperation Masa GroupDevelopment of LithoPore©100-150 insulating board (polystyrene substitution)
2009
2010
2011/12
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History
© Luca Industries International GmbH 2017, Version 1.02
Cooperation Knauf Gips KGJoint development of an aerated gypsum board
Cooperation Wienerberger, Schlagmann PorotonDevelopment of an aerated burned clay brick toachieve better insulation results
Cooperation Vicat Group, France
2012/13
2013
2014
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History / Business Model
© Luca Industries International GmbH 2017, Version 1.02
Global Uniform Branding – Establishment of LithoPore
Aerated Concrete Brand - LPAC
Basic business model for plant customers
• Sales Contract for plant machinery
• Longterm Supply Contract for biotechnological additives
• License Contract (granting a license for a certain application,
time period and region, no license fees)
2015
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Company key data
© Luca Industries International GmbH 2017, Version 1.02
Employees: 60 worldwide
Production capacity biochemical additives: 2500 mtons/year
Group turn over 2015: 8 Mio EUR
Customers: 250 in 40 countries
Key markets: Europe, India, South East Asia, Middle East, USA
Certifications: ISO 9001:2008 since 2005 through DQS
Registered brands
LithoPore (end product/aerated concrete )
LithoFoam (biochemical additives)
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© Luca Industries International GmbH 2017, Version 1.02
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LithoPore® Technology - Aerated Concrete
Applications
1 Luca Industries International inside
Technical Properties and Product Keydata
Economical View
6 Investment Options
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© Luca Industries International GmbH 2017, Version 1.02
• Raw materials
– Cement, filler (sand, fly ash, calcium carbonate, stone dust, etc.) waterand a foaming compound
• Production Methodology
– Specialized mixers, foaming equipment, and ordinary moulds.
– Steam cured or water spray-cured under ambient conditions
• Light Weight
– Foam creates millions of tiny voids, hence the name aerated concrete.
• Environment
– Eco-friendly and cost effective
LithoPore© Aerated Concrete - Introduction
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Production of LithoPore® aerated concrete
NetworkformerLithoFoam NWF S
1000 l IBC additive pump
Additive scale
Water
Foaming agent LithoFoam SL 200-L200 l barrel or 1000 l IBC, 20 °C tempered
Foam
Foam generator FG 4 II IND
1000 l IBC with agitator and pump
Stabilizer + water (micro fibre)LithoFoam MRF 2000-S
© Luca Industries International GmbH 2017, Version 1.02
Cement, fillerscale
SlurryMixer
Water scale
Water
Primary Mixer
Ready mixedLitho Pore©
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LithoPore® vs. ordinary aerated concrete
© Luca Industries International GmbH 2017, Version 1.02
201
2011
LithoPore® ordinary aerated
concrete
Foaming agent type
synthetic protein
(artificial) using
Molecular
Engineered Protein
extracted protein or
tensid based
Further additivesNetworkformer,
Stabilizernone
Foaming systemlow pressured
(energy saving)
compressed air
system
Density area 100-1800 kg/cbm 400-1800 kg/cbm
Compressive strength (600 kg/cbm) 3-4 mPa 1-2 mPa
Stability high low
Equipment complete system incomplete system
Local raw material qualitywill be considered
individually
is not respected
sufficiently
LithoPore® = advanced complete technology with innovative applications
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Foaming Agent
• LithoFoam® SL 200-L
Networkformer
• LithoFoam® NWF S
• LithoFoam® NWF NT
Stabilizer
• LithoFoam® MRF 2000-S
Accelerators
• LithoFoam® CC
© Luca Industries International GmbH 2017, Version 1.02
Chemical Additives
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LithoFoam® SL 200-L
MEP – Molecular Engineered Protein
• Worldwide Unique
• Artificial Protein
• Compound not only Foaming Agent
© Luca Industries International GmbH 2017, Version 1.02
Foaming Agent
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LithoFoam® NWF S
• Strength increasing agent
• Chemical reaction between NWF S with cement and foam
• Faster hardening
• LithoPore® density: ≥ 200 kg/m³
LithoFoam® NWF OAS
• Strength increasing agent
• Chemical reaction between NWF OAS with cement
• LithoPore® density: ≥ 75 kg/m³
LithoFoam® NWF NT
• Fills gaps between cement particles
• Shrinkage reducing agent
• Reduces pore structure
• LithoPore® density: ≥ 75 kg/m³
© Luca Industries International GmbH 2017, Version 1.02
Networkformer
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© Luca Industries International GmbH 2017, Version 1.02
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LithoPore® Technology – Aerated Concrete
Applications
1 Luca Industries International inside
Technical Properties and Product Keydata
Economical View
6 Investment Options
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Application – Cast at site / frame work filling
© Luca Industries International GmbH 2017, Version 1.02
Major countries: Africa, South East AsiaDry density target: 1000-1600 kg/cbm
End product trade name: LithoPore®1000-1600
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Application – Roof insulation
© Luca Industries International GmbH 2017, Version 1.02
Major countries: India, Middle EastDry density target: 400-800 kg/cbm
End product trade name: LithoPore®400-800
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Application – Panel production (at site or precast)
© Luca Industries International GmbH 2017, Version 1.02
Major countries: USA, Australia, ItalyDry density target: 800-1400 kg/cbm
End product trade name: LithoPore®800-1400
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Application – Lightweight floor screeds
© Luca Industries International GmbH 2017, Version 1.02
Major countries: East and South Europe, TurkeyDry density target: 400-800 kg/cbm
End product trade name: LithoPore®400-800
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Application – Blocks
© Luca Industries International GmbH 2017, Version 1.02
Major countries: India, South East AsiaDry density target: 400-800 kg/cbm
End product trade name: LithoPore®400-800
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Innovations - Heat insulating compensation layer below floorscreed
© Luca Industries International GmbH 2017, Version 1.02
Major countries: Germany, DenmarkDry density target: 200-300 kg/cbm
End product trade name: LithoPore®200-300
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Innovations - Heat insulating compensation layer below floorscreed
© Luca Industries International GmbH 2017, Version 1.02
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LithoPore® – advantages at a glance
Low density area of 75-100 kg/cbm
Manufacturing of aerated lightweight mortar without any EPS beads (polystyrene)
Constant and safe adjustment of fresh density
Transportation in truck mixers for 2 hours
Ready to use product ex works
Simple logistics
Realisation of smaller consignments
Fire protection class A1 (no organic ingredients) instead of B1
In case of future renovations: only ordinary recycable construction waste
© Luca Industries International GmbH 2017, Version 1.02
worldwide unique
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Innovations – pre cast insulating board
© Luca Industries International GmbH 2017, Version 1.02
Masa-LithoPore®-TechnologyLithoPore75-150
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Innovations – pre cast insulating board Applications
© Luca Industries International GmbH 2017, Version 1.02
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Innovations – pre cast insulating boardTechnical properties
© Luca Industries International GmbH 2017, Version 1.02
• Non-inflammable
• Totally inorganic construction material based on cement
• Similar insulating properties as mineral/rock wool
• excellent steam diffusion
• fully recycable
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Standard product typeLithoPore75 LithoPore150
Dry density DIN EN 1602 [2] ρ105 °C 75-85 kg/m3 140-155 kg/m3
Moisture absorption DIN EN ISO 12571 [3] Δm, 23/80 ≤ 19 M.-% ≤ 19 M.-%
Thermal conductivity DIN EN 12667 [13] λ10, tr ≤ 0,0398 W/m*K ≤ 0,0518 W/m*K
Thermal conductivity DIN EN 12667 [13] λ 0,046 W/m*K 0,060 W/m*K
Compressive Strength DIN EN 826 [4] σ10% ≥ 40 kPa ≥ 220 kPa
Tensile strength perpendicular to faces DIN EN 1607 [5] σmt ≥ 10 kPa ≥ 20 kPa
Bending strength DIN EN 12089 Methode B [6] σb ≥ 10 kPa ≥ 60 kPa
Behaviour under point load at 1mm NPD ≥ 1400 N
DIN EN 12430 [8] εFp
Water absorption DIN EN 1609 [9]Wp, 24h ≤ 3,5 kg/m2 ≤ 4,5 kg/m2
Fire behaviour DIN EN 13501 Class A1 Class A1
Steam diffusion DIN EN ISO 12572 [10] μ ≤ 3,0 ≤ 4,0
Dimensions stability DIN EN 1604 [11] ≤ 0,1 % ≤ 0,1 %
Hydrophobic product typeLithoPore75H LithoPore150H
All values as for standard product, however:
Water absoprtion DIN EN 1609 [9]Wp, 10s ≤ 0,7 kg/m2 ≤ 0,7 kg/m2
Wp, 24h ≤ 0,9 kg/m2 ≤ 0,9 kg/m2
© Luca Industries International GmbH 2017, Version 1.02
Innovations – pre cast insulating boardTechnical properties
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© Luca Industries International GmbH 2017, Version 1.02
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LithoPore® Technology - Aerated Concrete
Applications
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Technical Properties and Product Keydata
Economical View
6 Investment Options
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• Can be produced in a range of densities (75 – 1600 Kg/m3)– The lower density range of 75-600 kg/m3 is most suitable for use as insulation
over roofs, prefabricated insulation panels or as filling in sunken areas of floors– The mid-range density of 600-1000 kg/m3 is excellent for making non-load-
bearing cladding panels or pre-cast blocks for non-structural filler wallmasonry
– The higher density range of 1,200-1,600 kg/m3 is used in structural elements,either as reinforced components or in the form of block-work for load bearingmasonry wall.
• Closed cellular structure– The intrinsic structure of the aerated concrete consists of very small sized
unconnected individual air bubbles, uniformly spaced over the body of thematerial
– Due to absence of coarse aggregate (gravel), aerated concrete flows by itselfinto the moulds, shuttering and any cavities, thereby avoiding the necessity ofcompaction or vibration.
© Luca Industries International GmbH 2017, Version 1.02
Characteristics of LithoPore© aerated concrete I
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• Ease of production– Aerated concrete may be cast into pre-cast blocks or pre-cast reinforced
panels for walling, roofing etc. or poured in-situ, into appropriately reinforced dwelling units or specific structural elements in a building
– It can also be easily produced in hilly areas or in deserts since it has limited requirements for the materials
• Lower water absorption– As a consequence of the closed cellular structure of the material, the water
absorption of aerated concrete is in the range of 5% to 25%, depending on density thus, lower than that of Aerated Autoclaved Concrete (AAC) blocks which is in the range of 45%.
– As a result, aerated concrete provides excellent protection of the reinforcing steel and does not require to pre-coat steel bars in reinforced elements. When using AAC, because of its high absorption, it is mandatory to pre-coat the reinforcing steel.
© Luca Industries International GmbH 2017, Version 1.02
Characteristics of LithoPore© aerated concrete II
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© Luca Industries International GmbH 2017, Version 1.02
Characteristics of LithoPore© aerated concrete IIIWater absorption
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© Luca Industries International GmbH 2017, Version 1.02
Characteristics of LithoPore© aerated concrete IVCompressive Strength (average values)
1,9
3,7
5,8
8
10,5
13,5
0,7
2
3,7
5,5
7,4
9,5
0
2
4
6
8
10
12
14
16
400 600 800 1000 1200 1400
Ave
rage
Co
mp
ress
ive
Stre
ngt
h in
MP
a
Dry desity of LithoPore® Aereted Concrete in kg/m3
Cement + Fine Sized Filler (Fly Ash, Calciumcarbonate, 50-200 micron Sand, etc) + Additives Cement + 0-2mm Sand + Additives
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© Luca Industries International GmbH 2017, Version 1.02
Characteristics of LithoPore© aerated concrete VFire Resistance
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© Luca Industries International GmbH 2017, Version 1.02
Durability
• Sound insulation
• Thermal insulation
• Fire resistant
Workability
• Drilling
• Cutting and installing
• Nailing
• Sawing
Characteristics of LithoPore© aerated concrete VI
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Overall technical data at a glance
© Luca Industries International GmbH 2017, Version 1.02
LithoPore® 200 LithoPore® 400 LithoPore® 600 LithoPore® 1000 LithoPore® 1400
Dry Density in kg/cbm and
(lb/cu.ft)200 (12.5) 400 (25.0) 600 (37.5) 1000 (62.5) 1400 (87.5)
Compressive strength in
mPa and (PSI)
0.25-0.45
(37-66)
1.5-2.5
(220-368)
2.5-4.0
(368-588)
5.0-7.0
(735-1029)
8.0-11.0
(1176-1617)
Thermal conductivity
W/(m*K)0.06-0.065 0.10-0.11 0.17-0.19 0.30-0.33 0.44-0.47
U-Value W/(m2*K)
100 mm / 4´´ thick material 0.60-0.65 1.00-1.10 1.70-1.90 3.00-3.30 4.40-4.70
R-Value per inch 2.22-2.40 1.31-1.44 0.76-0.85 0.44-0.48 0.31-0.33
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© Luca Industries International GmbH 2017, Version 1.02
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LithoPore® Technology - Aerated Concrete
Applications
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Technical Properties and Product Keydata
Economical View
6 Investment Options
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Technology overview by application
© Luca Industries International GmbH 2017, Version 1.02
Market entrance
Technology Masa-LithoPore®-Technology
LithoPore®-Technology
Product (density) LithoPore®75-150 LithoPore®200-300 LithoPore®400-600
LithoPore®600-1600
Block production X
Pre cast panel production X
Filling of hollow blocks (burned clay and concrete) x
Pre cast insulating board x
Heat insulation layer below floor screed X
Cast in place wall filling X
Lightweight floor screed X
Lightweight concrete X
Flat roof insulation X X
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Technology overview by capacity
© Luca Industries International GmbH 2017, Version 1.02
Market entrance
Technology Masa-LithoPore®-Technology
LithoPore®-Technology
Product (density) LithoPore®75-150 LithoPore®200-300 LithoPore®400-600
LithoPore®600-1600
less than 100 cubic meters daily production x x x
100 up to 400 cubic meters daily production(semi automatic)
x x
above 400 cubic meters daily production(fully automatic)
x x
Summary: with the Masa-LithoPore-Technology fly ash blocks and cementitious insulating boards can be manufactured with the same fully automated plant
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Economical Details
© Luca Industries International GmbH 2017, Version 1.02
For further economical details (involved costs into machinery or average costs per cubic meter of LithoPore® aerated concrete) please contact us. We will assist you with a detailedcost break down.
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© Luca Industries International GmbH 2017, Version 1.02
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LithoPore® Technology - Cellular Lightweight Concrete
Applications
1 Luca Industries International inside
Technical Properties and Product Keydata
Economical View
6 Investment options
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Mobile Systems
• LithoPore® Foam Generator FG4 II IND
• LithoPore® Station
• LithoPore® Pump 800/1200
Semi-Automatic Plants
• LithoPore® Station (Plant version)
• LithoPore® Silos and Sand Bunkers
• LithoPore® Cuttingmachine SM25/SM50/SM100
• Steam Curing Chamber
• Accessories (Moulds, Rails, Turntables etc.)
Fully-Automated Plants
• Machinery made by MASA
© Luca Industries International GmbH 2017, Version 1.02
Equipment
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LithoPore® Foam Generator FG4 II IND
• Stand-Alone Machine e.g. for RMC Concrete Plants
• High output
• Remote controlled
© Luca Industries International GmbH 2017, Version 1.02
Mobile Systems
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LithoPore® Station
• All-in-One Machine
• Including LithoPore® Foam Generator FG4 II IND
• Unique mixing arm design to mix slurry and Foam
• Suitable for start-up projects, small plants (SM25)
• Precise weighing scale included
© Luca Industries International GmbH 2017, Version 1.02
Mobile Systems
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LithoPore® Pump 800/1200
• Special designed Pump for Pumping LithoPore®
© Luca Industries International GmbH 2017, Version 1.02
Mobile Systems
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Fully Automatic Mixing Tower and Cutting Machine.
Only mould handling is by hand.
• Up to 400m³ per day/shift
• All inclusive – from raw-material storage to package
• Upgradeable 100-200-400m³
© Luca Industries International GmbH 2017, Version 1.02
Semi-Automatic Plants
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© Luca Industries International GmbH 2017, Version 1.02
Semi-Automatic PlantsBlock Plant 50 Block Plant 100 Block Plant 200 Block Plant 400
Capacity [m³/day] 50 100 200 400
Water [m³/day] 15 30 60 120
Voltage [V] 400/230 400/230 400/230 400/230
Total Current [A] 52,5 205 225 312,5
Total Current with Sand Bunker [A] 135 287,5 307,5 395
Total Power [kW] 21 82 90 125
Total Power with Sand Bunker [kW] 54 115 123 158
Molds [pce.] 30 60 120 240
Mold Basements [pce.] 30 60 120 240
Space requirements [m²] 1375 1450 1750 3024
Assemblage / Commissioning time [days, min] 7/7 21/10 21/14 28/14
Recommended days of production supervision 7 14 21 28
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Masa-LithoPore®-Technology (fully automatic plant line)for block production with fly ash and for insulating boards
© Luca Industries International GmbH 2017, Version 1.02
Hardening of cut material Waiting area before cutting
Mixing area with cement storage
Cutting machine
Foaming systemPackage area
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Masa-LithoPore®-Technology (fully automatic plant line)for block production with fly ash and for insulating boards
© Luca Industries International GmbH 2017, Version 1.02
Overall Data
Capacity per hour: 24-72 cbm
Batch size mixer: 6000 liters
Moulds size: approx. 6 cubic meter
Power: 500 kW, 400 V, 50/60 Hz
Staff: 6-12
Characteristics
Fully automatic dosage and mixing
Fully automatic cutting
Fully automatic handling
Fully automatic package
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Contact
© Luca Industries International GmbH 2017, Version 1.02
Company address GERMANY: Luca Industries International GmbH Potsdamerstrasse 12-13 14163 Berlin Germany
Telefon: +49-(0)30-457989-680 Telefax: +49-(0)30-457989-689
Email: info@luca-industries.comInternet: www.luca-industries.com
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Contact – Luca Industries worldwide
© Luca Industries International GmbH 2017, Version 1.02
Country Person Contact details Status
Balkan Mr. Marijan Rados Dr. Lucà & Partner Ingenieurkontor GmbH Potsdamerstrasse 12-13 14163 Berlin Germany Telephone: +49 - 234 3387745Mobile: +49 - 176 57288773Telefax: +49-30-457989-689 marijan.rados@luca-industries.com
Country Manager
India Mr. Sivaram Kumar Dr. Luca Bioengineering and Services Pvt. Ltd. Plot No. 127, Perungudi Industrial Estate, Old Mahabalipuram Road / IT Expressway, Perungudi, Chennai - 600 096 India Telefon: +91-44-42154667, +91 - 97909 27126 Telefax: +91-44-42154668 sivaram.kumar@luca-industries.com
Subsidiary
Middle East Eng. Mohamed SallamMadkour
No.17, Ismael RaafatSafeer squareCairo 11361Egypt
Telephone: +49-30-457989-680Mobile: +20-1119111559Telefax: +49-30-457989-689mohamed.sallam@luca-industries.com
Country Manager(Convertion into Franchisee)
Philippines Mr. Lothar Ulmer Tel: +63 917-5724960lothar.ulmer@dr-luca.de
Country Manager
Turkey Mr. Berkay Denge Tel: +90 507-3032643berkay.denge@luca-industries.com
Country Manager(Convertion into Franchisee)
USA Mr. Michael Baron LithoPore USA LLC,PO Box 24334Santa Fe, New Mexico,87502 USA
Telephone: +1-505-983-2160Mobile: +1-719-588-1772Telefax: +49-30-457989-689michael.baron@luca-industries.com
Country Manager(Convertion into Franchisee)
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Thank you for your attention...
© Luca Industries International GmbH 2017, Version 1.02
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