Transforming waiting time into productive time. LEAP (Non-crystalline Alumina Cement) dramatically changes on-site productivity.
Overview of Imerys' LEAP Fit "Farewell, steam curing." -- LEAP changes the common sense of precast. Until now, "steam curing," which consumes a significant amount of energy, was essential for increasing productivity in precast factories. LEAP fundamentally overturns this common understanding. Remarkable early strength without steam curing Thanks to its unique technology (amorphous calcium aluminate), it cures extremely quickly even at room temperature. Molding can be released in just a few hours without heating. It achieves stable strength even in low winter temperatures, allowing for an ideal production schedule year-round. Double reduction in costs and CO2 By eliminating or reducing steam curing, boiler fuel costs are significantly cut. Combined with the low carbonization of cement (up to 30% reduction), the product's CO2 footprint can be minimized to the extreme. Maximize production capacity while minimizing investment With no waiting for curing, it becomes possible to produce more than twice a day with the same formwork, effectively doubling the factory's output. It also prevents maintenance costs for steam equipment and deterioration of formwork due to heat. LEAP simultaneously achieves "decarbonization" and "high profitability" for precast factories without the need for heating or waiting.
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basic information
1. Basic Specifications and Components: This off-white powder mainly consists of super-reactive amorphous calcium aluminate (approximately 50%) and anhydrous gypsum (approximately 50%). It has high storage stability, allowing for long-term storage of over one year. 2. Amazing Curing Properties (when replacing 20% of cement): While ensuring a working time of 30 minutes, the initial setting time is significantly reduced from 260 minutes to 60 minutes. It enables demolding in as little as 4 hours without heating (steam curing). Stable strength development is expected even in low temperatures during winter. 3. Strength Specifications: 24-hour strength: 40-50 MPa 28-day strength: over 60 MPa. It dramatically enhances early strength while maintaining long-term strength equivalent to or greater than that of ordinary Portland cement. 4. Adjustability and Durability: The setting time can be freely adjusted with common retarders, and fluidity can be controlled with PCE-based superplasticizers. Durability indicators such as carbonation, chloride diffusion, and elastic modulus maintain performance equivalent to conventional materials. It simultaneously achieves "ultra-rapid curing" and "CO2 reduction (up to 30%)" while utilizing existing manufacturing facilities.
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Applications/Examples of results
1. Main Applications: It broadly accommodates all types of precast concrete products. High-strength components: Prestressed concrete slabs (C50, etc.) High-flow products: Self-compacting concrete (high-flow concrete) Building materials and panels: Sandwich panels for exterior walls, concrete blocks, brick walls Civil engineering and repair: Road construction, repair mortars, grout materials Next-generation building materials: Mineral foam with excellent thermal insulation and fire resistance (insulation blocks, etc.) 2. Main Achievements and Implementation Effects Dramatic reduction in demolding time: In the case of C50 slabs, demolding time was reduced from 14 hours to 6 hours. Doubling of production capacity: By reducing curing wait times, it is possible to increase the pouring cycle from once a day to twice a day (two-shift system). Reduction of CO2 emissions: In the case of self-compacting concrete, CO2 emissions from binders were reduced by 25%. Performance enhancement of low-carbon cement: Addressed the issue of "low initial strength" associated with low-clinker cements like LC3, achieving practical strength development.
Company information
We are experts in solutions for specialized industries based on mineral resources. We support a wide range of fields, including construction, automotive, and consumer goods, providing highly regarded specialized solutions based on the processing and refining of mineral resources, synthetic minerals, and formulations. We support our customers with advanced technical services, enabling them to easily implement our solutions, achieve their goals, and maximize the use of minerals. Contact Us ：imerys.japan.sales@imerys.com
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