Composite Materials

Composite Materials Dept. deals with the possibilities of ecological utilization of waste materials in the production of building materials and products. It is not only about the building materials preparation using building materials, but also about the assessment of their technological and ecological suitability for building production and other purposes (backfilling materials, recultivation, landscape-making and others). Wastes from power industry (classical and fluidized ashes and fly-ashes, FGD gypsum, etc.), wastes from heavy industry (waste foundry sands, slags, clinkers, slag-heaps, etc.) and other (polluted soils, various types of sludges, etc.) represent the most frequent resource of waste materials.

We try to develop production technologies with minimal production of waste products, or fully nonwaste technologies for the utilization of industrial waste materials (IWM) in building industry. Verification of designed technological ways and production procedures is realized using laboratory, pilot plant and working tests. An economical analysis of suggested ways of IWM utilization (analisis of final product of production technology) together with the preparation of basis for certification of proposed final product are also very important parts of the design.

In frame of research and custom-made activities Ecological production technologies we carry out, verify and ensure:

Assessment of complex suitability of natural and secondary raw materials for the traditional and non-traditional technologies
Design of optimal production technologies of building materials for processing of industrial waste materials especially in the field of :
- aerated concrete
- foam concrete
- light-weight concrete
- normal concrete
- concrete mixtures for special purposes
- artificial aggregate – cold hardening and hydrothermal hardening
- stabilized materials and others
Design of technological processing ways of re-cultivation mixtures:
- backfilling material
- ground shaping
- road spreadings for winter road maintenance
- sub-bases and others
Assessment of properties of resulting building materials, building products and others

Traditional and nontraditional technologies

Design of new technological processes of building materials production and their simulation in laboratory and pilot plant conditions
Traditional and non-traditional processing technologies:
- pelletizing, granulation
- compacting
- application of economical thermal processes etc.
Fibre concrete production by extrusion
Quality assessment of building works, defects, etc.

Firing processes, ceramics

Modelling tests of firing processes of brick raw materials, sintered aggregate etc.
Assessment of natural and secondary raw materials suitability for heavy ceramics production
Design of optimal technologies

Dry plaster mixtures

Design of production prescriptions of dry plaster mixtures with special properties
Verification of prescriptions

Metakaolin

Metakaolin preparation also from less quality kaolines and clays
Determination of properties and applications of metakaolin
Metakaolin as an additive for cement pastes, concretes and other special applications
Alkali activation of metakaolin

Utilization of secondary raw materials

Fly ash
Slag
Mining waste materials (less suitable clays, kaolins, bentonites, sands, etc.)
Waste materials from processing of natural materials (stone dust, mineral fibres, etc.)

Technical services

Technological regulations of production
Factory standards of products including ecological requirements
Technical assistance for manufacturing corporations
Technological basis for certification including ecological tests
Standards and consultancy activity

Testing laboratories are equipped for testing of:

Technological properties of raw materials for the production of
- concrete
- mortar
- ceramics
- and nontraditional binders (metakaolin – determination of pozzolanic activity – Chapelle test, etc.)
Verification of admixtures and additives and their nontraditional application
- metakaolin, fly ash, slag and others
- plasticizers
- setting stabilizators
- watertight and hydrophobization admixtures, etc.
Physical-mechanical properties of
- composite materials on silicate or polymer basis
- concrete and aerated concrete elements
- ceramics and refractory ceramics
- aggregate (natural and artificial)

Other services

Preparation of laboratory test specimen and pilot plant production of tested products
Durability tests
- Freeze-thaw resistance, durability tests, resistance to defrosting chemicals
- Controlled climate tests under defined temperature and humidity (climate chamber Feutron)
- Accelerated durability test of composite materials (equipment for simulation of weather conditions by changing of water sprinkling and sun radiation, placing in hot water) with relation to results of ecotoxicity tests (see Accredited Test Laboratories)
Special testing methods arranged according to requirements of the customer
Specific tests according to company testing methodologies