Production Experience and Use of Manufactured Sand in Norway

Production experience and
use of manufactured sand in

Norway
Dr. ing. Svein Willy Danielsen
Content
1. Background and relevance

2. Aggregate technology
3. Developments in production and use of
manufactured aggregates
1. Development in aggregate production
2. Development in concrete mix design
4. What lies in the future?
15/12/2003 Dr. ing. S. W. Danielsen 2
1
Background and relevance
Environmental The non-renewable
challenges character of resources
The environmental
impact from production
Norwegian - on neighbourhood
relevance and society
Land use conflicts
Lack of sustainability in
Technical

production
challenges
Environmental / health
impact of materials

Traditional abundance of
sand/gravel aggregates
Environmental Increasing market share for
challenges crushed aggregates
Uneven geographic
distribution of sand/gravel
resources call for alternatives
Norwegian On-coming shortage due to
rapid depletion of key
relevance resources
Use of hard rock offers
options by selecting rock
properties
Technical Producers need to have a
total utilization of crushed
challenges products
2
Norwegian relevance
Large total resources (sand/gravel)

Theoretically 12”’m3 Æ 450 years
Much less available resources (50 Æ 15%)
Land use conflicts
Geological issues / technical quality
Location, practical availability
Size, production economy
About 50% of total resources too far from realistic
markets
Shortage near most populated areas within 10 – 30 years
Norwegian relevance
Production value in mio. NOK Mio. m3

2002
Year 1982 1991 1997 2000 2002
Sand/ 1000 900 900 760 590 15

gravel
Crushed 800 1350 1859 1825 1950 35
aggregate
Total 1800 1920 2759 2585 2540 50
% sand/ 56 47 33 29 23
gravel
3
Environmental Miss balance of particle
sizes, especially more
challenges crushed sand (e.g.0-4 mm)
than can normally be placed
on the market
High fines content in the
crushed sand
Norwegian Sharp angular / flaky
relevance particle shape, especially in
the intermediate size
fractions
Deposition costs
Technical Mix design challenges in
concrete – water
challenges requirement
Aggregate technology
1. Knowledge of Suitability of a manufacturing
process will depend on the
geology rock type and the intended end
The basis for aggregate use of the product.
sources Concrete proportioning will
have to be adapted to the
aggregate characteristics,
given by
2. Production the geological parameters
technology parameters derived from
The processing of processing
aggregates Requirements to the end
product may decide the choice
of
3. Materials technology raw material
the production process to be
The use of aggregates designed
4
Aggregate technology
Materials technology
•The use of aggregates
The basic
interdependency in
aggregate technology
Production technology Knowledge of geology

•The processing of •The basis for aggregates
aggregates sources
Developments in production and use of

manufactured aggregates in Norway
A holistic approach to enable local supply and
production
Utilise local resources of sand and hard rock
Minimize long transport of remote materials
Obtain a no-waste production
Plan for an optimum mass balance in production and
market
Minimize the need for depositing surplus products
Two directions for technology development
Improved aggregate production from hard rock
A tolerant concrete mix design that plays with the
aggregates
5
Two principal directions for R&D
Aggregate production Concrete mix design
To develop an aggregate To develop a concrete mix

production that can design system that can
deliver more cubical deliver economically and
materials in all critical technically feasible
sizes, and still keep a recipes with the more
control with the total sharp angular and fines
mass balance and avoid containing crushed
excess volumes of fines. aggregates.
Development in aggregate production
1. The ”traditional” set-up Originally designed for size

reduction, not for quality
products
2. Vertical shaft impactor 2 – 4 steps, starting with a
jaw, ending with cones
3. Impact crusher Secondary crushers often
produce flaky materials
Deliver satisfactory
4. The new Rhodax products > 8 mm
concept Critical size range 2 – 8
mm
< 20% below 4 mm
5. Sorting / sieving
Work well for road materials
6
Modern lay-out for a ”traditional” quarry
A modern, ”traditional” lay-out

(Lierskogen):
•Takes 0-20, 0-60, 20-120 as quarry run,
before C1
•Uses a large cone as C2, takes out ballast
and other materials of ”moderate quality
requirements” before C3 Acrobat Document
•Two parallel cones in C3, feeding 4-45 mm
•Produces good quality aggregates (asphalt
and concrete) down to approx. 8 mm
1. The ”traditional” set-up Rotopactors/duopactors

In the last step to ”repair”
the particle shape
2. Vertical shaft impactor Cubical aggregates in all
size fractions
3. Impact crusher >> 30% below 4 mm
High fines content in sand
fraction
4. The new Rhodax Surface coating on coarse
concept particles
Downside of cubicity:
5. Sorting / sieving inferior mass balance
a need for washing
7
F5635E.mox
Assumed Feed to Plant
Kurva 62 Kurva 63
Feed rate approx.: 350 MTPH
Bulk density: 1,6 t/m3
Type of material:
Feed curve:
(see diagram)
Impact Work Index: 24
Abrasion Index: 0,55
Matare
HGF 1652 Moisture content: 1 % (by weight)
Knuse Contamination: Free from clay
Warning! Sep = 120 mm
JM 1511
-Feed Spalt = 160 mm
Load: 38 %
Sikt Knuse
FF 1220 S Warning! H6800-EC
Sep = 120 mm +Topsize! Spalt = 32 mm
Sep = 60 mm Slag = 28 mm
Warning!
Sep = 20 mm ASR
+Topsize
Load: 51 %
Load: 21 % H-6800
Load: 94 %
Sikt
CS144 lll
Sep = 40 (63) mm
0-20/60 mm 20-120 mm 0-250 mm Sep = 16 mm 62 MTPH
Warning!
Sep = 4 mm
Flow in: 60 MTPH Flow in: 0 MTPH Flow out: 324 MTPH +BLoad
Load: 90 %
34 MTPH 25-63 mm
Flow in: 0 MTPH

339 MTPH
Knuse
H4800-F Knuse
Flow left: 131 MTPH H4800-F
Spalt = 12 mm Flow right: 162 MTPH
Slag = 32 mm Spalt = 16 mm
4-16 mm Slag = 36 mm
ASR
ASR
Flow in: 0 MTPH
H-4800
H-4801
Load: 100 % Load: 100 %
293 MTPH
Sikt Products
CS173 ll
Sep = 22 mm
244 MTPH
Sep = 16 mm
Sikt
CS173 ll
129 MTPH Sep = 11 mm Load: 80 %
Sep = 8 mm
Load: 72 %
Load: 44 %
0-2 mm 2-4 mm 4-8 mm 8-11 mm 11-16 mm 16-22 mm + 22 mm
In silo: 44 MTPH In silo: 27 MTPH In silo: 58 MTPH In silo: 46 MTPH In silo: 69 MTPH In silo: 0 MTPH In silo: 0 MTPH
Flow out: 0 MTPH Flow out: 0 MTPH Flow out: 0 MTPH Flow out: 0 MTPH Flow out: 0 MTPH Flow out: 42 MTPH Flow out: 6 MTPH
PlantDesigner®
Sandvik Rock Processing Flow Sheet Calculations
Lic. No.: 47131728253 Last calc.: 2003-01 13:23:41
Date: 021220 Customer: Franzefoss
Drawn by: UCa Project: Lierskogen. Ny krossanläggning
Approved by: Två nya H 4800 i tredje trinn
Project No: P12573 Flowsheet No: 459.5635E
Please note that Plantdesigner® gives typical indicative values, based on typical operating conditions. Since
operating conditions can vary very widely, no warranty of these recommendations either expressed or implied
is given by Plantdesigner® , its owners or suppliers.
F5635E.mox - 1
F5635E.mox
H-6800 H-4801 H-4800 Products
Cap: 386 MTPH Cap: 131 MTPH Cap: 162 MTPH Cap: 293 MTPH
Sieve Passing Sieve Passing Sieve Passing Sieve Passing
(mm) through (mm) through (mm) through (mm) through
0,075 0% 0,075 3% 0,075 2% 0,075 2%
0,25 1% 0,25 5% 0,25 4% 0,25 5%
1 4% 1 11 % 1 9% 1 10 %
2 6% 2 17 % 2 13 % 2 15 %
4 9% 4 28 % 4 21 % 4 24 %
8 15 % 8 51 % 8 38 % 8 44 %
11,2 20 % 11,2 70 % 11,2 53 % 11,2 61 %
16 29 % 16 93 % 16 76 % 16 83 %
20 38 % 20 100 % 20 90 % 20 95 %
22 42 % 22 100 % 22 96 % 22 98 %
25 50 % 25 100 % 25 100 % 25 100 %
32 67 % 32 100 % 32 100 % 28 100 %
45 92 % 45 100 % 45 100 % 32 100 %
63 100 % 63 100 % 63 100 % 40 100 %
90 100 % 90 100 % 90 100 % 90 100 %
125 100 % 125 100 % 125 100 % 125 100 %
200 100 % 200 100 % 200 100 % 200 100 %
300 100 % 300 100 % 300 100 % 300 100 %
500 100 % 500 100 % 500 100 % 500 100 %
1000 100 % 1000 100 % 1000 100 % 1000 100 %
Topsize: 53 mm Topsize: 19 mm Topsize: 24 mm Topsize: 24 mm
F5635E.mox - 2
Vertical shaft impactor
Manufactured gravel 0-4mm
•Improves particle shape 0

10-30%
10
•Increases the fines 20
content up to 50% 30
Mass passing sieve (%)

(0-0,125mm) 40
Without Rotopactor
Speed 42m/s
50 Speed 49m/s
•How does different speed 60
Speed 55m/s
influence: 70
- a test in full scale,
80
reducing speed from 55
90
to 42 r/s shows:
100
0,075 0,125 0,25 0,5 1 2 4 8
Sieve size (mm)
Vertical shaft impactor
Taking out the rotopactor and

replacing it (and 2 cones)
with a Rhodax:
Less total crushing
Reduced energy
consumption
Reduced dust generating,
better working environment
More simple flow-chart, and
fewer transporters
Better mass balance
A cleaner product (and no
need for washing)
8
1. The ”traditional” set-up Mostly used in step 3

Successful with soft rocks and
in recycling (then even as step
2. Vertical shaft impactor 2 or sole crusher)
Upside:
3. Impact crusher Efficiency (except for
recirculating loads) and good
products
4. The new Rhodax Downside:
Dependency on operator skill
concept
Mechanical wear, maintenance

in hard rock
5. Sorting / sieving Improved particle shape
Moderate increase in fines
content
1. The ”traditional” set-up Originally developed for

industry purpose (slag,
minerals)
2. Vertical shaft impactor Recently redeveloped for
aggregate quarries
3. Impact crusher A different operating
principle causing extremely
inter-particular crushing and
4. The new Rhodax high degree of reduction
concept Combines
Cubical shape even in
critical intermediate sizes
5. Sorting / sieving Modest content < 4 mm
Replaces 2 – 3 crushers
Still in pioneering stage
2 units operating (Fr, No)
9
Rhodax crusher
Can feed up to 150 mm

and still obtain cubical
aggregate products
Capacity approx 180 t/h
of 0-25 mm from 16-65
mm (throughput 200-230
t/h)
Feeding is important
Regulation by gap,
rotational speed, load
defacing, torque
Very promising, bur still
pioneering
Rhodax crusher
Conventional Crusher Rhodax® Mill

Mono-granular Comminution Bed Compression
10
1. The ”traditional” set-up The Norwegian approach

has not included fines
removal by
2. Vertical shaft impactor wet processing, or
advanced sieving / air
processing
3. Impact crusher Reasons
winter climate
4. The new Rhodax economy
concept removed fines must be
deposited
”Flip-flow” sieves in small
5. Sorting / sieving / fractions effective
handling Moisture control important
in manufactured sand
approx. 1,5%
Development in concrete mix design
A statement:
1. The materials technology and the mix design
philosophy in different countries are based on the
properties of the local aggregates.
2. National materials standards have been based on
each country’s technology, thus depending on the
aggregate resources.
3. This is a challenge when it comes to cross boarder
technology transfer, and harmonising of standards.
4. It also calls for new thinking when sand/gravel is to
be replaced by a different product.
11
R&D challenge:
Mostly connected with the sand aggregates. The
use of crushed, coarse aggregate has been state-of-
the-art technology since Roman time.
The Norwegian approach:

To play with the aggregates – tailor the concrete
recipes to aggregate properties more than tailoring
the aggregates to the recipes.
Development in use of manufactured

aggregates from Franzefoss’ plants
Use of chruse d gra ve l in concre te de live re d from 3 of our qua rrie s
60000
50000
40000
V interbro
30000 V as s f jell
Steins kogen
20000
10000
0
1990 1992 1994 1996 1998 1999
12
Manufactured sand characteristics
•More sharp angular Crushed and natural gravel
•Denser grading
0
•More fines
20
% mass passing sieve

•Denser particle packing
40
•More internal friction Crushed
60 Natural
•Better internal stability
80
•Increased viscosity in
concrete with high 100
cement/silica content
120
•Positive on surface 0,063 0,125 0,25 0,5 1 2 4 8
finishing
Sieve size (mm)
Manufactured sand characteristics
Manufactured Natural
Grading Packed/dense Open/straight
Filler content (< 125µm) 10-25% 4-8%
Surface area 2-300.000 m2/m3 50-70.000 m2/m3
Part of cubical particles 30-50% 40-95%
13
Three stages of mix design development:
1. Using limited amounts of manufactured sand

to improve the total sand grading
2. Applying the particle / matrix approach (like
SCC) to obtain a matrix rich concrete
3. Taking advantage of the latest crusher
development to compensate sand curves in
the medium range
Development in concrete mix design (1)
Using limited amounts Where the natural sand

of manufactured sand is low in fines, or has a
particularly ”open”
to improve the total grading
sand grading Low fines sand with low
cement concrete
To counteract
segregation and bleeding
in high-slump mixes
Unchanged design
philosophy
Often less workable
mixes
14
Some general properties of manufactured sand
in concrete
Concrete functionality Benefits Disadvantages
General properties Less prone to bleeding and Higher cohesion may also entail
segregation more need for vibration and
Better pump ability cause a higher water
requirement
Concrete for walls Surfaces without visible voids /
smoother surfaces
Concrete floors High fines content provides good Incorrect vibration may cause a
results by steel finishing concentration of fines in the
Good workability for low top layer
consistency concrete,
Low consistency concrete Workability in spite of low slump
in general values, and cement content
Shotcrete Less waste from sprayed Higher wear on equipment due to
surfaces abrasion
Reduced need for accelerator
Foamed concrete Gets a higher fines content
Smaller Dmax can be used
Less prone to segregation
Applying the particle / Counteract internal friction

from sharp angular particles
matrix approach (like
Finest particles will be kept
SCC) to obtain a matrix floculent in the viscous fluid
rich concrete Fines to counteract
bleeding and segregation
Chemical admixtures to
reduce viscosity
Manufactured sand can
exceed 50%
On-going development on
chemical admixtures,
especially polymer based
15
Taking advantage of Compensating sand

the latest crusher curves by adding cubical,
medium sized
development to aggregates, e.g. 4-8 mm
compensate sand Cases with a fine grained
curves in the medium natural sand (low in sizes
range > 2 mm)
When high fines content
in crushed sand; the
SCC approach should be
taken
Trial mix excample Trondheim – Vassfjell;

gabbro/greenstone
Cement 355 Æ 306 kg Slump +15 mm,
Silica 10 Æ 0 kg Flow +60 mm
Crushed sand 368 Æ 412 Air voids 1,6 Æ 2,4%
kg Strength unchanged (higher
Crushed 4-8 mm 0 Æ 165 early strength)
kg Shrinkage reduced
Changed admixture (2,45 0,30 Æ 0,19 (7 days)
kg Sika Viscocrete 140) 0,65 Æ 0,50 (49 days)
Water reduced by 35 liters Cost reduction for mix
Matrix reduced by 67 kg approx 10%
16
Adapting mix design principles to local,
geological conditions (case)
Trondheim area Eastern Norway
Fine grained natural sand, Sand low in fines, competent
shistous rock, lack of rocks, contains intermediate
intermediate sizes sizes
Will need to use ”principle Compensate grading with
3” – addition of intermediate crushed sand (e.g. 0-2 mm)
sizes from crushing Avoid sharp angular 2-4 mm
Try to avoid excess fines Can use ”principle 1”,
content in crushed sand improve by ”principle 2”
Use ”principle 2” for
proportioning (depend on
admixtures)
What lies in the future?
The real challenge will be to

merge the environmental
issues with the industrial ones;
to create industrial plants,
which are at the same time
environmentally friendly and
economically profitable.
In the future, only those
companies and branches will
survive who can earn their
public acceptance from an
active use of environmental
parameters in their planning
and execution of own
activities.
17
What lies in the future?
Resources and politics Technological development
On-comming shortage of sand/ Production technology to
gravel resources near populated improve materials properties,
areas especially crushed aggregates
Taxation reduce environmental impact of
production, reduce energy
Environmental regulations on consumption
land use and preservation
Application technology to
quarrying, neighborhood
allow for a reduced content of
transport natural sand in concrete (0%?)
use of materials, health effects make more robust recipes
use of substitutes /recycling will do take advantage of different rock
about 10-15% properties and local conditions
An understanding of the need for Integrated, permanent plants
materials (?) quarrying, industrial end-use,
Requirements to ”go mining” (sub- recycling, waste deposits
surface) in urban areas? More advanced mobile plants
18

Production Experience and Use of Manufactured Sand in Norway

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Production Experience and Use of Manufactured Sand in Norway

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Production experience and

use of manufactured sand in

Dr. ing. Svein Willy Danielsen

1. Background and relevance

15/12/2003 Dr. ing. S. W. Danielsen 2

15/12/2003 Dr. ing. S. W. Danielsen 3

Background and relevance

15/12/2003 Dr. ing. S. W. Danielsen 4

 Large total resources (sand/gravel)

15/12/2003 Dr. ing. S. W. Danielsen 5

Production value in mio. NOK Mio. m3

Sand/ 1000 900 900 760 590 15

15/12/2003 Dr. ing. S. W. Danielsen 6

15/12/2003 Dr. ing. S. W. Danielsen 7

15/12/2003 Dr. ing. S. W. Danielsen 8

Production technology Knowledge of geology

15/12/2003 Dr. ing. S. W. Danielsen 9

Developments in production and use of

15/12/2003 Dr. ing. S. W. Danielsen 10

Aggregate production Concrete mix design

To develop an aggregate To develop a concrete mix

15/12/2003 Dr. ing. S. W. Danielsen 11

Development in aggregate production

1. The ”traditional” set-up  Originally designed for size

15/12/2003 Dr. ing. S. W. Danielsen 12

A modern, ”traditional” lay-out

15/12/2003 Dr. ing. S. W. Danielsen 13

Development in aggregate production

1. The ”traditional” set-up  Rotopactors/duopactors

15/12/2003 Dr. ing. S. W. Danielsen 14

Flow in: 0 MTPH

0-2 mm 2-4 mm 4-8 mm 8-11 mm 11-16 mm 16-22 mm + 22 mm

H-6800 H-4801 H-4800 Products

•Improves particle shape 0

•Increases the fines 20

Mass passing sieve (%)

15/12/2003 Dr. ing. S. W. Danielsen 15

Vertical shaft impactor

Taking out the rotopactor and

15/12/2003 Dr. ing. S. W. Danielsen 16

1. The ”traditional” set-up  Mostly used in step 3

 Mechanical wear, maintenance

15/12/2003 Dr. ing. S. W. Danielsen 17

Development in aggregate production

1. The ”traditional” set-up  Originally developed for

15/12/2003 Dr. ing. S. W. Danielsen 18

 Can feed up to 150 mm

15/12/2003 Dr. ing. S. W. Danielsen 19

Conventional Crusher Rhodax® Mill

15/12/2003 Dr. ing. S. W. Danielsen 20

1. The ”traditional” set-up  The Norwegian approach

15/12/2003 Dr. ing. S. W. Danielsen 21

Development in concrete mix design

15/12/2003 Dr. ing. S. W. Danielsen 22

The Norwegian approach:

15/12/2003 Dr. ing. S. W. Danielsen 23

Development in use of manufactured

15/12/2003 Dr. ing. S. W. Danielsen 24

% mass passing sieve

15/12/2003 Dr. ing. S. W. Danielsen 25

Manufactured sand characteristics

Grading Packed/dense Open/straight

Filler content (< 125µm) 10-25% 4-8%

Large total resources (sand/gravel)

1. The ”traditional” set-up Originally designed for size

1. The ”traditional” set-up Rotopactors/duopactors

1. The ”traditional” set-up Mostly used in step 3

Mechanical wear, maintenance

1. The ”traditional” set-up Originally developed for

Can feed up to 150 mm

1. The ”traditional” set-up The Norwegian approach

Using limited amounts Where the natural sand

Applying the particle / Counteract internal friction

Taking advantage of Compensating sand