. . .

The innovation for the concrete industryy

The Presentation
FML – CONCRETEC GmbH

The story

The process

The
Th tests
t t and
d results
lt

Advantages

The system
y

YOUR success
 FML - CONCRETEC GmbH
ƒ FML - CONCRETEC GmbH, located in Herborn (Germany-Hessen), was
founded in March 2008

ƒ Managing Directors: - Frank Michael Loh

- Antonio Catarino

ƒ Sales/Marketing - Antonio Catarino

ƒ Technical Director RD - Thomas Sievers

Technical Director - Holger Reinecke

ƒ Employees: - 10

ƒ Business partners of production: - Bauer Group / MAT

- Loh Group / NEEF
The Story
At the end of the 90ies Thomas Sievers with a team of concrete enthusiasts started
experimenting with physical water treatments to alter its structure and reactivity by changing
the surface tension. In joint projects with the Austrian Universitiy of Innsbruck and the
German Universities of Hamburg-Harburg (TU) and Dresden (TU) he stabilized the process
so that he could produce a „refined water“ quality.

Combining his life time Know how in concrete manufacturing with the process of water
treatment and a patented colloidal mixer a new, revolutionary concrete mixing method was
created and hedged by various international patents.

This new mixing method increased the concrete`s flowability with improvements of up to 70%
with identical ingredients in comparison with conventional mixing procedures.

It reduces time and energy consumption with the production of concrete and at least saves
over 10% whilst at the same time increasing the compressive strength.

FML under the supervision of Thomas Sievers, the technical head of FML Concretec GmbH
f research
for h and
d development,
d l t improves
i existing
i ti recipes
i b changing
by h i the
th water/cement
t / t ratio,
ti
by changing the cement type and by reducing the amount of binding agents, additives and/or
readjusting aggregates.
The Process
The conventional mixing process is divided into 2 steps and 4 procedural phases

Step 1 – Mixing of the suspension

Phase 1
Production of „refined water“ by pulsing frequency-regulated electromagnetic treatment .

Phase 2
Separating the agglomerated binding agents such as cement, fly ash, limestone powder etc.
and additives in a collodial mixer with 1.400 rpm for about 100 sec., distributing it evenly with
the „refined water“ in the suspension/slurry.

Phase 3
Pumping the suspension/slurry in an existing stationary rotary drum mixer or a ready mix
truck.
truck

Step 2 – Mixing of the concrete

Phase 4
Ph
Concrete mixing in a homogenizer, truck mixer or any other existing mixer.
The Process – Water treatment
Phase 1
W t treatment
Water t t t (WTS) by
b pulsing
l i frequency-regulated
f l t d electromagnet
l t t

ƒ Desintegration of clusters, which enlarges the reactive surface of the water

ƒ Free water molecules – each cement particle is optimally brought into reaction
The Process – Water treatment
Water treatment by pulsing frequency-regulated electromagnet
The Process – Suspension mixer
Phase 2
C ll id l suspension/slurry
Colloidal i / l mixer
i with
ith up tto 1400 rpm

Additional process steps

ƒ Desintegration of agglomerates

ƒ Milling of cement particles (wet phase) and due to this increase of the reactive surface of
the cement

ƒ Activation of all cement particles

ƒ Reduction of the water consumption

ƒ Reduction of the water/cement ratio down to 0.30 and lower

ƒ Reduction of the amount of super-liquefiers / plasticizers by up to 25%

The Process – Suspension mixer
Colloidal suspension/slurry mixer – desintegration of agglomerates
The Process – Suspension mixer

Mixing area of the laboratory mixer

1,000 litres containered equipment

The Process – Suspension mixer

2 500 litres
2,500 lit containered
t i d equipment
i t
The Process – Suspension mixer
2,500 litres containered equipment
The Process – Suspension mixer
2,500 litres containered equipment
The Process – Suspension mixer
Colloidal suspension/slurry mixer – desintegration of agglomerates
The Process – Release of the slurry
Phase 3
R l
Release off the
th slurry
l (
(suspension)
i )

ƒ Slurry gets released or pumped into the compulsory mixer

or

ƒ Slurry gets released or pumped into a homogenizer /gravity mixer

or

ƒ Slurry
yg gets p
pumped
p over a large
g distance or on g
great heights/great
g g depths
p directly
y to the
installation point

or

ƒ Slurry gets released or pumped into a truck mixer

The Process – Release of the slurry
Optimized recipe
Comparison of the results: CEM 52.5 / CEM 42.5
Customer Prefab plant Germany
Customer recipe 6XXXX Concrete specification
Basic cement type 1 CEM II/A-S 52.5R C 50/60 Humidity class W A
Basic cement type 2 Extra fast cement F 4 Exposure class X D3,S3,A3,M2,M3
Cement type optimized CEM I 42
42.5R
5R GK 16 C
Project number FML XX3

Reference mixture Comparison mixture Alternative mixture 1 Alternative mixture 2 Alternative mixture 3
V126 A1 V126 A2 CcT 20 V126 A3 CcT 20 V126 A4 CcT 20 V126 A5
Cement 200 kg CEM II/A-S 52.5R 410 kg CEM I 42.5R 410 kg CEM I 42.5R 410 kg CEM I 42.5R 410 kg CEM I 42.5R
Extra fast cement 210 kg
Plasticizer 1 55% BASF ACE 48
1.55% 1.55%
1 55% BASF ACE 48 1.55%
1 55% BASF ACE 48 1 55% Grace Advaflow 440
1.55% 1 55% Grace Advaflow 440
1.55%
W/B / W/B in the CcT-mixer 0.439 / - 0.39/0.25 0.39/0.25 0.39/0.25 0.39/0.25
Mixing time gravity mixer 10 min 2.5 min 2.5 min 2.5 min 2.5 min

Additonal remarks WTS4+Squelch+US WTS4+Squelch WTS4+Squelch+US WTS4+Squelch +US Sspäter

diff. to reference diff. to reference diff. to reference diff. to reference
should be diff. T. sb m. m. m. m.
Spread mm mm % mm mm % mm mm % mm mm % mm mm %
after 10 min 490 390 -20,4% 375 -15 -3,8% 345 -45 -11,5% 545 155 39,7% 465 75 19,2%
after 30 min 490 435 -11,2% 410 -25 -5,7% 375 -60 -13,8% 535 100 23,0% 470 35 8,0%

should be Refer. mixt. Comparison mixture Alternative mixture 1 Alternative mixture 2 Alternative mixture 3
fck,cub diff. to reference diff. to reference diff. to reference diff. to reference
,
fck,cube e diff. T. sb fck,cube
, m. fck,cube
, m. fck,cube
, m. fck,cube
, m.
Early strength N/mm² N/mm² % N/mm² N/mm² % N/mm² N/mm² % N/mm² N/mm² % N/mm² N/mm² %

after 6 h 2,35 3,77 1,42 60,4% 4,97 2,62 111,5% 0,0% 0,0%
no tests of early no tests of early
after 7 h 4,49 7,66 3,17 70,6% 9,01 4,52 100,7% 0,0% 0,0%
strength possible strength possible
after 7,5 h 8,50 11,9 3,40 40,0% 14,01 5,51 64,8% 0,0% 0,0%

after 8 h 12,41 15,22 2,81 22,6% 18,98 6,57 52,9% 0,0% 0,0%
after 24 h 41,76 44,15 2,39 5,7% 44,61 2,85 6,8% 40,55 -1,21 -2,9% 41,51 -0,25 -0,6%
Strength
after 3 d 56,51 58,07 1,56 2,8% 57,62 1,11 2,0% 59,29 2,78 4,9% 60,21 3,70 6,5%
after 7 d 63,84 66,31 2,47 3,9% 62,25 -1,59 -2,5% 70,07 6,23 9,8% 68,07 4,23 6,6%
after 28 d

Density [kg/dm³] should be Refer. mixt. Comparison mixture Alternative mixture 1 Alternative mixture 2 Alternative mixture 3
after 6 h 2,436 2,455 0,019 0,8% 2,439 0,003 0,1% 2,47 0,034 1,4% 2,476 0,04 1,6%
after 7 d 2,46 2,47 0,01 0,4% 2,45 -0,01 -0,4% 2,48 0,02 0,8% 2,49 0,03 1,2%

Temperature [°C] should be Refer. mixt. Comparison mixture Alternative mixture 1 Alternative mixture 2 Alternative mixture 3
Slurry 34,0 30,0 29,0 42,5
Concrete 21,3 22,2 22,0 19,5 22,3
Comparison
Co pa so ofo the
t e results:
esu ts CCEM 5
52.5
5/C
CEM 3
32.5
5
Customer Prefab plant Germany
Customer recipe 5XXXX Concrete specification
Basic cement type 1 CEM II/A-S 52.5R C 45/55 Humidity class A
Basic cement type 2 Extra fast cement F 4 Exposure class X D3,S3,A3,M2,M3
Cement type optimized CEM I 32.5R GS 16 C
Project number FML XX3

Reference mixture Comparison mixture Alternative mixture 1 Alternative mixture 2

V118 A1 V118 A2 CcT 20 V118 A3 CcT 20 V118 A4 CcT 20
Cement 260 kg CEM II/A-S 52.5R 260 kg CEM II/A-S 52.5R 260 kg CEM II/A-S 52.5R 360 kg CEM I 32.5 R
E t ffastt cementt
Extra 100 kg
k 100 kgk 100 kgk
Plasticizer 1.4% BASF ACE 430 1.4% BASF ACE 430 1.4% BASF ACE 430 1.55% Grace Advaflow 440
W/B / W/B in the CcT-mixer 0.44 / - 0.44 / - 0.44 / - 0.39/0.25
Mixing time gravity mixer 5 min 5 min 5 min 2.5 min
Additonal remarks WTS1+Squelch WTS1+Squelch+Turbo WTS4+Squelch+US
diff. to reference diff. to reference diff. to reference
should be diff. T. sb m. m. m.
Spread mm mm % mm mm % mm mm % mm mm %
after 10 min 490 300 -38,8% 535 235 78,3% 310 10 3,3% 605 305 101,7%
after 30 min 490 310 -36,7% 540 230 74,2% 280 -30 -9,7% 475 165 53,2%

should be Refer. mixt. Comparison mixture Alternative mixture 1 Alternative mixture 2

fck,cub
fck cub diff to reference
diff. diff to reference
diff. diff to reference
diff.
fck,cube e diff. T. sb fck,cube m. fck,cube m. fck,cube m.
Early strength N/mm² N/mm² % N/mm² N/mm² % N/mm² N/mm² % N/mm² N/mm² %
after 14 h 25,02
after 16 h 32,13 32,13 31,39 31,39 26,84
after 18 h 31,27 31,27 36,27 36,27 28,87
after 20 h 35,84 36,71 0,87 2,4%
after 23 h 38,90
Strength
after 5 d 54,23 60,13 5,90 10,9% 61,59 7,36 13,6% 54,04 -0,19 -0,4%
after 7 d 56,51 67,98 11,47 20,3% 62,83 6,32 11,2% 56,81 0,30 0,5%
after 28 d

Density[kg/dm³]
i [k /d ] should
h ld bbe Refer.
f mixt.
i Comparison
i mixture
i Alternative
l i mixture
i 1 Alternative
l i mixture
i 2
after 5 d 2,436 2,417 -0,02 -0,8% 2,406 -0,03 -1,2% 2,436 0,00 0,0%
after 7 d 2,428 2,442 0,014 0,6% 2,412 -0,02 -0,7% 2,441 0,013 0,5%
Comparison – slump/spread test
Standard formula/mixture Standard formula/mixture

Standard mode/process CONCRETEC-process

42 cm / 107 inches 59 cm / 150 inches !!! = + 40%

Certificates
Test results
Test-results
Ad
Advantages
t – workability and quality
The FML-CcT-Technology leads to higher quality and advantages with utilization

ƒ less differences between the mixtures

ƒ higher equality of colours

ƒ higher strength

ƒ higher early strenth and durability

ƒ fewer and smaller capillary pores

ƒ less pores on the surfaces

ƒ reduction of effloressences

ƒ better workability and compactability

ƒ l
less sedimentation
di t ti and
d bleeding
bl di

ƒ increased pumpability
Advantages - economically
The FML-CcT-Technology leads to a reduction of costs by

ƒ reduction of cement (lower w/c ratio)

ƒ use of fly ash instead of cement or greater amount of fly ash (or slag …)

ƒ upgrading
pg g of the cement ((CEM 32,5 will be upgraded
pg to a 42,5 or 52,5))

ƒ increase of the content of sand, at the same time reduction of gravel

ƒ less additives

ƒ less pigments

ƒ normal concrete can be made into a SCC

ƒ less mixing time (less energy, higher output, less abrasion)

ƒ earlier stripping of the mould for prefabricated concrete parts

Advantages – reductions and increases
Reduce
ƒ costs for concrete production due to reduction of cement and additives or
the change in the aggregates
ƒ (ECC/SCC concrete could be produced for the price of regular concrete)
ƒ water consumption
ƒ water/binding agents ratio
ƒ p q
super-liquifiers /pplasticizer
ƒ mixing time
ƒ energy consumption for dry mixing
ƒ CO2 output
ƒ actual
t l wear costst

Increase
ƒ compressive strength (early strength and 28-day strength)
ƒ concrete flowability
ƒ output of a ready-mix concrete plant
ƒ surface quality – almost nonporous – no excessing water
ƒ fluidity - better processing ability – better pumpability
ƒ dispersion of coulour pigments / no formation of shades
View of and into a system
Procedure plan

F eststoff 1 F eststoff 2 F eststoff 3

S olid 1 S olid 2 S olid 3

W asser
W ater

W assera ufb ere itu n g

W a ter T re atm en t

S uspensionsm ischer
S lurry m ixer

Z usatzm ittel
A dditive
S u sp e nsion s-
a u sla uf
S lu rry ou tlet
System drawing
Container-system
• j Container

• k Water treatment

• l Water tank

• m Additive dosage
g

• n Mixer

• o Outlet
O tl t pump

• p Control
Résumé
ƒ Using FML-CONCRETEC systems in paver, block or flag producing plants,
plants for p
p prefabricated concrete p
parts,, ready-mixed
y concrete pplants or directly
y
at the construction sites, guarantees a cost-effective production of concrete,
an increase of quality and a possible doubling of the output/production
capacity.

ƒ Both, the time required to produce a mixture of concrete and the time to fill a
truck mixer can be halved which means that less truck mixers are needed.

ƒ The usually high energy consumption for the dry mixing can be reduced to
less than a third. The wear costs of the existing mixing systems decrease to a
minimum.

ƒ The period of redemption (ROI- return on investment) of an FML-

CONCRETEC system is about 5-10 months, depending on the production
quantity and the site of operation.
FML-CcT for YOUR success!
Equations for YOUR success:

CcT-Suspension Mixer
+ FML-Technology
FML Technology
+ FML-Experience
+ Homogenizer
H i (e. g. truck mixer)

= Quality concrete of a new dimension

YOUR success= +Workability+Quality-Costs

How to cooperate with FML Concretec
1. FML Concretec and customer sign a mutual non disclosure agreement.
2. Customer sends recipes/formulation and details (density, moisture, price) of
presently used agents,
agents aggregates,
aggregates additives and water as well as details of
the concrete and the production (e. g. expected early strength after ? hours and probably
other objections, max daily output, yearly output).

3
3. Customer
C t sends
d samples l off presently
tl used d agents,
t aggregates
t and
d
additives (alternativly the tests can start with 8.).
4. FML Concretec identifies and tests the formula on basis of own mixtures.
5. FML Concretec optimizes the formula and calculates saving potentials.
6. Customer receives the optimized FML Concretec formula including test
certificates.
7. Customer could come over to the FML Concretec technical support center
for own tests,
tests or
8. FML Concretec carries out tests with customer`s approval at customer`s
plant/site or at his laboratory. FML charges the costs thereby incurred.