FLY ASH

Applications for Fly Ash

Fly ash can be used as prime material in many cement-based products, such as poured concrete, concrete block, and brick. One of the most common uses of fly ash is in Portland cement concrete pavement or PCC pavement. Road construction projects using PCC can use a great deal of concrete, and substituting fly ash provides significant economic benefits. Fly ash has also been used as embankment and mine fill, and it has increasingly gained acceptance by the Federal Highway Administration.

The rate of substitution—of fly ash for Portland cement—typically specified is 1 to 1 1/2 pounds of fly ash for 1 pound of cement. Accordingly, the amount of fine aggregate in the concrete mix must be reduced to accommodate the additional volume of the fly ash. The Different Types : There are two common types of fly ash: Class F and Class C. Class F fly ash contain particles covered in a kind of melted glass. This greatly reduces the risk of expansion due to sulfate attack, which may occur in fertilized soils or near coastal areas. Class F is generally low-calcium and has a carbon content less than 5 percent but sometimes as high as 10 percent.

Benefits Fly ash can be a cost-effective substitute for Portland cement in many markets. Fly ash is also recognized as an environmentally friendly material because it is a byproduct and has low embodied energy, the measure of how much energy is consumed in producing and shipping a building material. By contrast, Portland cement has a very high embodied energy because its production requires a great deal of heat. Fly ash requires less water than Portland cement and is easier to use in cold weather. Other benefits include:

FLY ASH
PARAMETERS	PERCENTAGE
MOISTURE	2 % MAX
FINENESS	BLAINE 2000 cm2gm 45 micron residue 35%max
CALCIUM OXIDE	2 % MAX
SILICON DI OXIDE	52 - 60%
ALUMINUM OXIDE	24-30 %
FERRIC OXIDE	6 % MAX
MAGNESIUM OXIDE	1 % MAX
SULPHURIC ANHYDRIDE	1 % MAX
SULPHIDE SULPHER	0.5 % MAX
SODIUM OXIDE	0.5 % MAX
POTASSIUM OXIDE	0.5 % MAX
LOSS OF IGNITION	4 % MAX

LIMESTONE

Limestone has many industrial uses and can be used as mined or processed into a wide variety of products. It is the raw material for a large variety of construction, agricultural, environmental, and industrial materials. Limestone is used in construction almost everywhere. In 2007, crushed limestone was 68% of all crushed rock produced in the United States. Also, limestone is the key ingredient in making Portland cement. Despite our Nation's abundance of limestone, there have been cement shortages in recent years.

Some of the purest of natural limestones are marbles. For centuries, marble has been the decorative stone of choice in government buildings and public statues. Travertine is also used as a dimension stone in tiles and tabletops. Some white limestone is simply crushed and sieved for use in landscaping and roofing. Powdered limestone is used to remove impurities from molten metals like steel. It can also remove toxic compounds from the exhaust of coal-burning power plants. Limestone is used as a filler in a variety of products, including paper, plastic, and paint. The purest limestone is even used in foods and medicines such as breakfast cereals and calcium pills.

Limestone is also the raw material for making lime (CaO) that is used to treat soils, purify water, and smelt copper. Lime has many additional uses in the chemical industries. Dolomites are commonly less suitable than other industrial limestones for most applications. Most dolomite that is mined is simply crushed and sieved for use as aggregate in concrete or asphalt.

PARAMETERS	UNIT	STANDARD SPECIFICATION %
CALCIUM OXIDE	%	50.00 MIN
MAGNESIUM OXIDE	%	2.OO MAX
SILICA	%	3.00 MAX
ALUMINIUM + IRON OXIDE	%	2.00 MAX
LOSS ON LIGNITION	%	41.00 MIN
MAGNESIUM CARBONATE	%	2.00 MAX
PURITY OF CALCIUM CARBONATE	%	90.00 MIN
TOTAL CARBONATE	%	90.00 MIN
MOISTURE	%	0.50 MAX
LIMESTONE PARTICLE SIZE ( 5 - 25 mm )	%	100.00
COLOR		GRAY

MANUFACTURED SAND

Manufactured sand (M-Sand) is a substitute of river sand for concrete construction. Manufactured sand is produced from hard granite stone by crushing. The crushed sand is of cubical shape with grounded edges, washed and graded to as a construction n material. The size of manufactured sand (M-Sand) is less than 4.75mm.

Manufactured sand is an alternative for river sand. Due to fast growing construction industry, the demand for sand has increased tremendously, causing deficiency of suitable river sand in most part of the word. Due to the depletion of good quality river sand for the use of construction, the use of manufactured sand has been increased. Another reason for use of M-Sand is its availability and transportation cost. Since manufactured sand can be crushed from hard granite rocks, it can be readily available at the nearby place, reducing the cost of transportation from far-off river sand bed.

It is well graded in the required proportion. It does not contain organic and soluble compound that affects the setting time and properties of cement, thus the required strength of concrete can be maintained. It does not have the presence of impurities such as clay, dust and silt coatings, increase water requirement as in the case of river sand which impair bond between cement paste and aggregate. Thus, increased quality and durability of concrete. M-Sand is cubical in shape and is manufactured using technology like High Carbon steel hit rock and then ROCK ON ROCK process which is synonymous to that of natural process undergoing in river sand information.

Higher Strength of concrete The manufactured sand has required gradation of fines, physical properties such as shape, smooth surface textures and consistency which makes it the best sand suitable for construction. These physical properties of sand provides greater strength to the concrete by reducing segregation, bleeding, honeycombing, voids and capillary. Thus required grade of sand for the given purpose helps the concrete fill voids between coarse aggregates and makes concrete more compact and dense, thus increasing the strength of concrete.

Durability of concrete. Since manufactured sand (M-Sand) is processed from selected quality of granite, it has the balanced physical and chemical properties for construction of concrete structures Work-ability of concrete. Size, shape, texture play an important role in work-ability of concrete. With more surface area of sand, the demand for cement and water increases to bond the sand with coarse aggregates. The control over these physical properties of manufacturing sand make the concrete require less amount of water and provide higher workable concrete. The less use of water also helps in increasing the strength of concrete, less effort for mixing and placement of concrete, and thus increases productivity of construction activities at site.

Construction defects during placement and post-concreting such as segregation, bleeding, honeycombing, voids and capillarity in concrete gets reduced by the use of M-Sand as it has optimum initial and final setting time as well as excellent fineness.

NATURAL GYPSUM

Gypsum (CaSO4.2H2O) is a naturally occurring mineral mined from deposits formed by ancient sea beds as a raw material, white when pure, but commonly grey, yellow, red or brown, owing to impurities. The anhydrous form (CaSO4), anhydrite, is common.

Natural Gypsum is one of the most superior qualities and consistent material available for Import and Export. Natural Gypsum has adequate whiteness, high purity as well as it is low in cost which makes it absolutely feasible for white cements as well as Plaster Of Paris manufacturing and for the Cement Industry all together. One more important quality that distinguishes Natural Gypsum from others is its hardness which is less as compared to other sources and allows different industries to easily grind the same for processing into final product which in turn results in to reduced power consumption for manufacturing industries.

TEST	METHOD	UNIT	MIN	RESULT
PURITY	ASTM C471 M	% WT	90	93.23
COMBINE WATER			18 - 20	19.51
Sio2			1-4	0.98
SO3			41.5	43.35
CaO			29 -32	30.36
MgO			0.1 - 1.50	0.88
R2O3 ( IRON & ALUMINUM OXIDE			0.08 - 2.5	0.9
CHLORIDE			0.005 -0.04	0.006
MOISTURE			0.4 -2.1	0.46
SIZE 0 -50 MM			100	100

SLAGS

Blast furnace slag is a nonmetallic coproduct produced in the process. It consists primarily of silicates, aluminosilicates, and calcium-alumina-silicates. The molten slag, which absorbs much of the sulfur from the charge, comprises about 20 percent by mass of iron production. Figure 3-1 presents a general schematic, which depicts the blast furnace feedstocks and the production of blast furnace coproducts (iron and slag).

Different forms of slag product are produced depending on the method used to cool the molten slag. These products include air-cooled blast furnace slag (ACBFS), expanded or foamed slag, pelletized slag, and granulated blast furnace slag.

Air-Cooled Blast Furnace Slag If the liquid slag is poured into beds and slowly cooled under ambient conditions, a crystalline structure is formed, and a hard, lump slag is produced, which can subsequently be crushed and screened.

Expanded or Foamed Blast Furnace Slag If the molten slag is cooled and solidified by adding controlled quantities of water, air, or steam, the process of cooling and solidification can be accelerated, increasing the cellular nature of the slag and producing a lightweight expanded or foamed product. Foamed slag is distinguishable from air-cooled blast furnace slag by its relatively high porosity and low bulk density.

Pelletized Blast Furnace Slag If the molten slag is cooled and solidified with water and air quenched in a spinning drum, pellets, rather than a solid mass, can be produced. By controlling the process, the pellets can be made more crystalline, which is beneficial for aggregate use, or more vitrified (glassy), which is more desirable in cementitious applications. More rapid quenching results in greater vitrification and less crystallization.

Granulated Blast Furnace Slag If the molten slag is cooled and solidified by rapid water quenching to a glassy state, little or no crystallization occurs. This process results in the formation of sand size (or frit-like) fragments, usually with some friable clinker like material. The physical structure and gradation of granulated slag depend on the chemical composition of the slag, its temperature at the time of water quenching, and the method of production. When crushed or milled to very fine cement-sized particles, ground granulated blast furnace slag (GGBFS) has cementitious properties, which make a suitable partial replacement for or additive to Portland cement.

ACBFS has been used as an aggregate in Portland cement concrete, asphalt concrete, concrete, asphalt and road bases. Pelletized blast furnace slag has been used as lightweight aggregate and for cement manufacture. Foamed slag has been used as a lightweight aggregate for Portland cement concrete. Granulated blast furnace slag has been used as a raw material for cement production and as an aggregate and insulating material. and granulated slag have also been used as sand blasting shot materials. Ground granulated blast furnace slag is used commercially as a supplementary cementitious material in Portland cement concrete (as a mineral admixture or component of blended cement).

ACBFS - Aggregate Substitute  Many specifying agencies consider ACBFS to be a conventional aggregate. It is extensively used in granular base, hot mix asphalt, Portland cement concrete, and embankments or fill applications. The material can be crushed and screened to meet specified graduation requirements using conventional aggregate processing equipment. Special quality control procedures may be required to address the lack of consistency in some properties such as gradation, specific gravity, and absorption.

GGBFS and Vitrified Pelletized BFS — Supplementary Cementitious Materials GGBFS is used as a mineral admixture for Portland cement concrete. Granulated blast furnace slag and vitrified pelletized blast furnace slag are also used in the manufacture of blended hydraulic cements (AASHTO M240).⁽³⁾ When used in blended cements, granulated blast furnace slag or vitrified pelletized slag are milled to a fine particle size in accordance with AASHTO M302 requirements.⁽⁴⁾ The ground slag can be introduced and milled with the cement feedstock or blended separately after the cement is ground to its required fineness.

The U.S. Environmental Protection Agency (EPA) has recommended that effective May 1, 1995, procuring agencies specifically include provision in all construction contracts for the use of GGBFS in Portland cement concrete contracts. ⁽⁵⁾

 Air-Cooled Blast Furnace Slag Crushed ACBFS is angular, roughly cubical, and has textures ranging from rough, vesicular (porous) surfaces to glassy (smooth) surfaces with conchoidal fractures. There can, however, be considerable variability in the physical properties of blast furnace slag, depending on the iron production process. For example, some recently produced ACBFS was reported to have a compacted unit weight as high as 1940 kg/m³ (120 lb/ft³).⁽⁸⁾ Higher unit weights that are reported are generally due to increased metals and iron content in the slag and tend to occur in slags that are generated from blast furnaces with higher scrap metal additions.

Expanded Blast Furnace Slag Crushed expanded slag is angular, roughly cubical in shape, and has a texture that is rougher than that of air-cooled slag. The porosity of expanded blast furnace slag aggregates is higher than ACBFS aggregates. The bulk relative density of expanded slag is difficult to determine accurately, but it is approximately 70 percent of that of air-cooled slag. Typical compacted unit weights for expanded blast furnace slag aggregates range from 800 kg/m³ (50 lb/ft³) to 1040 kg/m³ (65 lb/ft³).⁽⁶⁾

Pelletized Blast Furnace Slag Unlike air-cooled and expanded blast furnace slag, pelletized blast furnace slag has a smooth texture and rounded shape. Consequently, the porosity and water absorption are much lower than those of ACBFS or expanded blast furnace slag. Pellet sizes range from 13 mm (1/2 in) to 0.1 mm (No. 140 sieve size), with the bulk of the product in the minus 9.5 mm (3/8 in) to plus 1.0 mm (No. 18 sieve size) range. Pelletized blast furnace slag has a unit weight of about 840 kg/m³ (52 lb/ft³).⁽⁷⁾

Granulated Blast Furnace Slag Granulated blast furnace slag is a glassy granular material that varies, depending on the chemical composition and method of production, from a co arse, popcornlike friable structure greater than 4.75 mm (No. 4 sieve) in diameter to dense, sand-size grains passing a 4.75 mm (No. 4) sieve. Grinding reduces the particle size to cement fineness, allowing its use as a supplementary cementitious material in Portland cement concrete.

PROPERTIES	UOM	VALUE RANGE
Sio2	%	34-40
Cao	%	34-40
Al2o3	%	`7-11
Mgo	%	`6-9
Mno	%	0.5-2.5
Feo	%	0.3-1.3
Tio2	%	1.5-4.5
V205	%	0.05-0.35
Na2o	%	0.25-0.75
K2o	%	0.3-1.3
Sio2	%	0.9-1.5
Cao/Sio2	%	0.80-1.11
H2o	%	`1-7
	%
Granulation
SIZE	UOM	VALUE
0.63 mm	%	15
0.63-1.0 mm	%	25
1.0-1.6 mm	%	25
1.6-2.5 mm	%	20
2.5-3.75 mm	%	6.5
3.75-4.75 mm	%	5
plus 4.75 mm	%	3.5

AGGREGATES, GABRO, BOULDERS, ROCK SANDS

The word aggregate refers to mineral based materials. Examples of aggregates are typical things you would find in a landscape center such as sand, rocks, boulders, gravel, etc. These materials bind together with other ingredients to create asphalt and concrete, which are also considered aggregates .

The word aggregate refers to mineral based materials. Examples of aggregates are typical things you would find in a landscape center such as sand, rocks, boulders, gravel, etc. These materials bind together with other ingredients to create asphalt and concrete, which are also considered aggregates.

Aggregates that are derived from natural sources typically come from three different rock types: igneous, sedimentary and metamorphic. The mineral properties of the aggregate determine the appearance of the rock and also help determine its capabilities, including if and how it can be used for paving. Manufactured rock comes from specialty rock and industrial byproducts. Chemical properties are important if the aggregate is being used as a paving material. Aggregates contain different chemical properties that help determine what each specific aggregate will be used for.

Aggregates are typically produced by rock quarry blasting. Rocks are then filtered using screens and crushers and sometimes washed. Natural gravel and sand are usually dug out of quarries, or lakes and rivers.

Aggregates influence almost every aspect of concrete, which contains 60-75 percent total volume of aggregates. The type of aggregate used in the concrete mix will affect the concrete in almost every way- from color to durability, strength and so on. The concrete used for industrial floors, for instance, uses aggregates such as quartz and granite because these aggregates have a higher abrasion resistance and can handle heavy industrial traffic.

We can Supply any size of stones and we have agreement with mining owners to cater the needs of the customers. We can supply from INDIA, UAE, OMAN origin of stones and boulders at any quantity.