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Artificial Aggregates

Advanced Materials for a Sustainable World


Artificial
Aggregates

Advanced Materials
for a Sustainable
World
Slag is a co-product of
the iron and steelmaking
process. After
conditioning, screening,
crushing and washing,
the processed material
is an artificial aggregate
possessing many
advantages over natural
aggregates.

It is the first choice for a number of In addition, certain slag types have
construction applications because chemical properties that make them
of its physical and mechanical effective filtering media or fertilising
properties, and also because whole agents.
life costs are minimised owing to its
durability. Lastly, there are significant
environmental advantages in using
Processed slag can be recycled back an artificial material such as slag to
into steelmaking as a metallurgical mitigate the environmental impact of
additive, using a patented method. steelmaking.

Norway
Poland
Canada
UK Czech Republic
Netherlands Romania
Portugal
USA
China

Mexico Saudi Arabia

Indonesia
Brazil

Australia
South Africa
Chile
New Zealand

Harsco sells 10 million tonnes annually of steel aggregates in 18 countries, thereby reducing
The Sustainable Solution landfilling of slag and quarrying of natural aggregates

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Global Knowledge,
Local Solutions

Developing Markets
and Delivering
Solutions
Our approach is to
develop aggregate
solutions entirely adapted
to local market conditions.
This reflects:
 National or State Regulations specifying physical and mechanical properties
of materials to be used
 Additional Product requirements: expected service life, user preferences etc.

Iron and Steel Slag Marketing


Artificial Aggregates
Manufacturer Development

BF Slag Market development team on-site Asphalt Surface Chippings

BOS Slag Liming agent Unbound roads


End user trials
Cement Filter media
EAF Slag
Install production facility Railways Gabion Stones
AOD Slag
Ground Metallurgical
Ladle and Caster Slags Market product
Stabilisation Additives

CASE STUDY SOUTH AFRICA

Asphalt Surfacing prove material properties


and demonstrate
In 1996, South Africa’s advantages of steel slag.
Highways authority was The Consulting Engineer
experiencing quality specified steel slag to
problems with local meet safety and durability
aggregate used in asphalt, requirements.
in terms of premature
deformation and fines The material has been laid
stripping in asphalt. on Van Reenen’s pass,
a steep gradient on the
Harsco developed a steel N3 – the busiest road in
slag surfacing solution. South Africa – connecting
Lab tests and site trials Johannesburg and Durban,
were undertaken in where traffic averages
partnership with a local several thousands of
asphalt manufacturer to vehicles a day.

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Quality
Control

Quality Control
Rigorous quality control
procedures are followed
from raw material to final
product.
 Segregation/Cooling/Conditioning
of source materials
 Testing/Crushing/Screening/
Washing
 Optional Further processing (e.g.
hot mix asphalt).  Computerised mixing and weighing of temperature-controlled slag material for asphalt production

The process includes routine


expansion testing of slag material Quality
during the conditioning phase.
Accreditations
 Conforming to National
Regulations on use of artificial
aggregates as materials
 Testing of products to comply with
specified design characteristics for
material used for specific
applications
 Quality certification of individual
products against specification.  Expansion testing on conditioned slag material

CASE STUDY SteelPhalt UK Asphalt Industry regulations

SteelPhalt operates a crushing plant, the slag


rigorous Quality Assurance is tested for expansion
system complying with potential in accordance
BS EN 13108:21 Factory with EN 1744-1.
Production Control, Sector
The asphalt plant
14. This is achieved by
production process is
continuous inspection,
continuously monitored,
sampling and testing, right
and materials are
along the supply chain.
sampled and tested by
The process starts at the our on-site laboratory – in
steel mill where all slag compliance with Sector 14
is inspected for quality requirements.
before it is dispatched
to SteelPhalt. After
processing through  SteelPhalt Plant certified for asphalt production under UK
our metal recovery and Sector 14 regulations

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Research &
Development

Asphalt
 Sheffield Halam University (UK):
collaboration on research into
skid resistance, deformation, and
thin surfacing materials
 Ministry of Communication
– Roads Research (Riyadh, Saudi
Arabia): Slag aggregate in asphalt
mixes.

Filter Media
 Phospho Reduc Engineering Inc  New Zealand Steel (BlueScope
(Canada): collaboration on Steel): Research and
research into the use of EAF steel Development into sustainable
slag for phosphorus reduction and applications for melter slag in the
metals reduction in industrial and treatment of storm water drainage
agricultural effluent and waste water.

CASE STUDY AUSTRALIA

Ladle slag as a The UCS results clearly


cementitious binder indicated the slag
would be suitable as
In Australia, a feasibility a cementitious binder
study was undertaken in road stabilisation
by ARRB Research when the slag is ground
laboratories, into to a fine powder and
using ladle slag as a combined with either
cementitious binder in cement or lime depending
road stabilisation. on the application. The
Unconfined compressive slag/cement blends
strength (UCS) testing was were expected to meet
performed for a range of VicRoads standard
binder and host material specification requirements
combinations. for UCS of cement treated  Processed ladle slag can be used as a cementitious binder for
sub-base layers. road stabilisation

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Road
Construction

Basic Oxygen Steel Slag


(BOS) and Electric Arc
Furnace (EAF) Steel slag
have been successfully
utilised as 100% of the
aggregate in asphalt
surfacing materials. The
inherent properties of
steel slag make it an ideal
aggregate for asphalt
manufacture.  Steel Slag has exceptional durability, even on the highest-trafficked roads

Permanent deformation is a major stripping of the bituminous binder this particular factor. Steel slag not
cause of road failure around the due to moisture ingress, causing only has excellent resistance to
world and steel slag asphalt resists the asphalt material to deteriorate. polishing but is able to regenerate its
this failure mechanism by forming In addition to extending the life of surface roughness over time, thereby
strong interlocking aggregate dense asphalts, steel slag is ideal for maintaining its properties throughout
structures within the asphalt. the manufacture of porous asphalts the whole life of the road surfacing.
without the need for expensive anti-
Steel Slag is basic in nature and stripping additives.
has a strong affinity to bitumen,
ensuring strong adhesion to Skid resistance is paramount and
the binder. In contrast, natural highway authorities worldwide are
aggregates may suffer from becoming increasingly focused on

CASE STUDY UK SteelSurf high stress materials

When Nottingham County effective at maintaining


Council (UK) were looking surface stability under the
for a durable surfacing slower-moving scrubbing
material on the busy action of heavy vehicle
A610 route into the city, tyres. Other heavy
SteelSurf was selected as industries such as coal,
the right material for the electricity, ports and sugar
local traffic conditions. manufacturing also use the
product. It is also effective
SteelSurf is a unique
at maintaining surface
product developed for
stability in high-stressed
high stress applications.
locations such as road
It was designed to resist
intersections.
deformation caused by
heavy loading of specialist
vehicles used in steel
ladle transport. It is also  SteelSurf material selected for the A610 in Nottingham, UK

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The Interstate 74 highway (USA), laid with


material using EAF slag aggregate

Chip seal/surface dressing laid in South


Africa using a BOS slag

CASE STUDY CANADA

High-traffic roads The highway authority


specified steel slag for use
Highway 138 is one of on the road. EAF slag was
the oldest highways in selected for its exceptional
Canada, linking Quebec durability and skid
and Montreal. The resistance as an aggregate
Annual Average Daily material.
Traffic (AADT) is 157,000
vehicles, making it the
highest-traffic road in
Montreal.

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Road
Construction

Both iron and steelmaking


slag have been used
for many years as an
aggregate for road
construction in foundation
and sub-base layers.
Iron making slag has been most
commonly used, as it typically has a
lower density than equivalent natural
aggregates. This means that the
contractor requires less material to
construct the roads whilst achieving
the equivalent or in some cases
superior performance.
 0-20mm EAF slag applied as road base in Canada
Steel slag aggregates are also used
as unbound road construction
materials, produced under strictly
controlled conditions to ensure
acceptable levels of expansion for the
application.

Granulated blast furnace slag can be


used as a cementitious binder in slag
bound road construction materials.
The coarse aggregate is normally a
natural aggregate such as limestone,
but mixtures of steel slag and
Granulated Blast Furnace Slag have
also been successfully used.

 Steel slag applied as a path on a golf course, Canada

 Steel slag used as road base, Montreal Port, Canada

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 Steel slag used as road base, Canada

Steel slag used as road base, Saudi Arabia


 EAF Steel slag used as road base in


Poland for a main road construction
between Warsaw and Krakow

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Cement

Harsco supplies both Cement production


EAF and BOS steel Clinker
Classification
slag into the cement BOS Slag
manufacturing process
in several different
Cement mills
countries.
Slag can be added at different
points of cement manufacturing:
BOS Slag
 Before the rotary kiln (18-22mm)
 Directly into the kiln Rotary kiln

 Into the grinding mill at the


finishing end.

CASE STUDY CHINA

In Zhejiang province, Furnace Slag – preventing


China, Harsco has cracking on large pours.
developed a BOF Slag It also has a corrosion
Superfine cement resistance quality because
substitute product. When of the lack of sand, water
blended with cement in and wearables within the
concrete it produces the product.
same quantities and gives
BOF Superfine Slag
desirable properties such
products are being
as long term strength,
increasingly used in
high elasticity and crack
construction material
resistance.
manufacturing, as
The Superfine product has a cement substitute
a better effect in reducing for concrete based
the heat of hydration than building, marine & large  The facility in China where the BOS slag is milled to Superfine size
Portland Cement or Blast construction projects. – the plant has an annual capacity to process 150k tonnes of slag

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Concrete

The extensive use of slag


over many years has
proved to be a successful
alternative material to
aggregates derived from
natural sources.
Concretes made with slag aggregate
may achieve permeabilities and
strengths that compare favourably
to concrete made with conventional
aggregates.

Addition of slag material in


Concrete
The addition of slag material in
non-structural concrete is made with
BOS slag (aggregate or fine grind).

 Blast Furnace slag used in South Africa


for concrete paving of driveways

CASE STUDY SOUTH AFRICA

AfriSam and civil engineering


applications.
As a leading producer of
cementitious materials for As the cost of landfilling
the construction industry slag becomes prohibitive,
in Southern Africa, materials such as slag
AfriSam South Africa aggregate are increasingly
has successfully used used in the production of
slag aggregates for over concrete.
20 years in all types of
applications.

These include reservoirs,


raft foundations, water
retaining structures,
bridges, drains and
various other building  Concrete being applied in South Africa, made using Air-Cooled
Blast furnace slag

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Railway
Ballast

Steel slag is highly suited


for use as ballast. The
material has been used
throughout the American
continent as railway
ballast for many years.
A rail ballast needs to be cubical
in shape with a high angle of
internal friction and high aggregate
interlocking characteristics. This is
particularly important on track curves,
where the lateral forces on the track
can be very high and the ballast is the
structural element which maintains
the longitudinal alignment.

The material has to be clean and


sound, a nominal 55mm single size,  EAF Slag selected for use as railway ballast in Canada
with a specified maximum ‘Wet
Attrition Value’ of less than 15% in
the USA to comply with national Steel Slag complies with the requirements of:
standards.
 American Railway Engineering Association (AREA)
 Federal Specification SS-S-449
 Brazilian Standard Association (ABNT) – NBR 5564
 Canadian National Railways (CNR) Specification 12-22, Slag Ballast.

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Embankment
Ballast

Embankments need to be
stable and durable.
Its high density, integral aggregate
strength and cubical shape makes
slag a material of choice for the civil
engineer.

Steel slag embankments will resist


both mechanical deterioration and
environmental erosion.

 Steel slag used to support an embankment on a steep gradient in the USA

CASE STUDY PORTUGAL

Seixal Steel Mill


Railway line
Steel slag was used
to support a railway
embankment at Seixal
Rail line was built to connect

steel mill, Portugal.


the mill with a main line in
It was selected as a Seixal, Portugal
durable, strong material
benefitting from low costs
of transportation. The
size fractions used for the
material were 0/40mm
and some additional
40/250mm. Slag was used as a base

layer and then covered with a


natural aggregate mix

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Stone
Columns

Essential properties of
construction materials
used in ground
stabilisation:
 Resistance to abrasion
 Low Water absorption
 Grain hardness
 Chemical stability.

 Site in Saudi Arabia where slag was used for ground stabilisation

The material used for ground Additional benefits of EAF slag are:
stabilisation has to undergo leaching
tests to prevent groundwater
 Aggregate shape
contamination, so the chemical  Angle of internal friction.
stability of slag makes it especially
appropriate for this use.

CASE STUDY SAUDI ARABIA

Ground Stabilisation Abuhaydriah Riyadh Road


Property/Test Steel Slag
In the Eastern Province Steel slag exhibited Limestone Limestone
of Saudi Arabia the properties far superior to
Specific Gravity (Bulk)
natural surface conditions local natural aggregates in 3.75 2.56 2.59
ASTM C 127
cannot support building Saudi Arabia.
construction without civil Water Absorption (%) 0.4 1.5 1.61
engineering to ensure
L.A. Abrasion (% Loss)
ground stabilisation. ASTM C 131
16 35 25

An on-site assessment Magnesium Sulphate


was undertaken for Harsco Soundness Loss 0.9 12 12
by a German consultant, ASTM C 88
who used German
Angle of Internal
standards specifically 40-50 20-35 20-35
Friction
for the environmental
controls. Hardness (Mohs Scale) 6-7 3-4 3-4

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How do Stone Columns
work?
Certain ground conditions cannot
support standard foundations for
construction of buildings. The
ground requires stabilisation in
order to support the foundations.

Stone columns work by forming


deep vertical shafts in the ground,
using large vibrating pokers and
high pressure water jets. The hole
is filled with graded aggregate,
and compacted using the same
poker. The poker also provides
densification to the surrounding
soil.

 Vibro-flotation method allows slag to seep into constructed hole as digging proceeds

Harsco has supplied EAF


steel slag from the Hadeed
steel mill into stone
column piling since 1995,
for over 21 construction
projects.

This has consumed over


970,000 Tonnes of steel
slag aggregate. Size
fractions used are 19/37
for dry applications and
25/75 for wet.

 Site where ground stabilisation has enabled building construction to proceed in Hadeed, Saudi Arabia

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Insulation

Steel Slag is used to make


Rockwool® insulation
– so called ‘stone wool’
materials. Rockwool® is
a global manufacturer
of thermal insulation
products that are both
energy-saving and
environmentally friendly.

 EAF Steel Slag is valued for its high density (noise insulation) and fire-resistance properties,
which are both vital characteristics of Rockwool® products

Rockwool® building insulation key


properties:

 Thermal insulation
 Noise suppression
 Fire resistant.

Rockwool® has an open fibrous


structure making it ideal for
absorbing and regulating noise.
It maintains the indoor climate of
buildings leading to reduction in
energy use for heating and cooling.  Production of RockWool® stone wool

 RockWool® products are used for all


insulation applications, from industrial
to domestic

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Wall
Construction

Wall construction requires Iron and Steelmaking Slag is an


effective substitute for stone in wall
the use of a hard material construction due to its interlocking
which has sufficient mass cubical shape and high specific
density.
to support sideways
forces. Commonly used
materials are limestone,
sandstone, concrete
debris, granite, brick or
basalt.  Iron melter Slag used for wall
construction in New Zealand

Gabion walls – wire mesh cages


filled with stone – are an economical
alternative to concrete walls and
have additional benefits in terms
of versatility (flexible shape) &
permeability (natural drainage).

Main applications are:

 Containment of edges in rivers


and channels
 Protection against collision on
earth embankments and bridges
 Barrages or flood control.
 A Gabion retaining wall made using
steel slag

CASE STUDY BRAZIL

RipRap retaining reinforced block that


walls resists the load created by
soil erosion.
RipRap and Gabion walls
are approved in Brazil for This construction system
use as a roadside retaining is extremely economic,
structure, under DNER-ES because it uses the earth
343-97. embankment as part of
the containing structure.
Steel slag has been used
Steel slag was also used
as a material for a road
in this same project for
building project in Brazil.
constructing the concrete
RipRap retention walls
curbs and the asphalt
to reduce soil erosion
surfacing.
are made using soil
mixed with steel slag.  This project in Brazil used steel slag as a construction material for
The material forms a the road surface, concrete curbs and retaining wall

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Metallurgical
Additives

Harsco Minerals
High Performance
Slag Solutions
Harsco Minerals’ range of Our patented engineered materials
technology utilises various slag
Performix ladle refining building additives to meet specific
products are engineered steel refining requirements. The
generation of a liquid ladle slag with
for clean steelmaking high CaO and low FeO contents
practices in high increases the absorption capacity of
both oxide inclusions and sulfur.
productivity steel shops.
These custom-designed This is necessary to achieve the
steel product specifications required
additives quickly generate for today’s applications.
a fluid ladle slag to
improve shop productivity
Benefits of synthetic slag
and final product quality. usage
Harsco Minerals is part of 1. More cost-effective than
Harsco Corporation. buying calcium aluminate
2. Acts as an absorbent liquid
sponge (sulphur and oxide
inclusions)
3. Insulates steel from
temperature loss
5. Protects refractory from
electric arcs
6. Protects refined steel from
re-oxidation.

Harsco Minerals Service

 Removal of ladle slag from the


steelmaking site
 Processing in dedicated plant
 Supply of specially-blended
secondary steelmaking products
 Technical support and analytical
lab services.

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Desulfurizers the ladle. A more effective slag Slag products. They are chemically
deoxidation process results which engineered to rapidly form a highly
Harsco Minerals offers custom-
improves alloy recoveries, increases basic and fluid slag that will absorb
designed lime-based Desulfurizers
desulfurisation efficiency and impurities such as sulfur as well as
for efficient steel refining in
provides protection to the ladle the products of steel deoxidation.
the ladle. Our products are
slaglines. This ladle refining treatment
engineered to provide cost effective
helps create a steel product with
desulfurisation during and after These custom-designed products low inclusion levels and within
furnace tapping. This is achieved are available with specific levels specification to maximise castability,
by the immediate production of of metallic aluminum or silicon productivity and product quality.
a molten slag with an increased reductants to lower the oxidation
desulfurisation potential. The potential of the ladle slag. This
rapid fluidisation of the entire ladle decreases alloy fade and thereby
slag increases the absorption of minimises caster clogging and
sulfur and non-metallic inclusions quality downgrades. The result is
throughout each stage of ladle a cost effective and efficient ladle
refining. refining process.
These custom-designed products
are available with specified levels Calcium Aluminates
of metallic aluminum or silicon Our calcium aluminates are
to improve the efficiency of the engineered to be a cost effective
desulfurising process. This allows approach to fluorspar-free ladle slag
the specified sulfur levels to be fluxing. As many aluminum killed
reached within the time required. steel shops are restricted in the
Premelted MgO is also provided use of fluorspar, calcium aluminate
to generate rapid and ongoing consumption has increased as a
refractory protection. means of fluidising CaO in a quick
and effective manner.
Ladle Slag Deoxidizers
Our extensive line of calcium
Our aluminate products offers a wide
aluminum or range of chemistries to balance ladle
silicon-based slag chemistries while providing
Ladle Slag the basicity and fluidity required for
Deoxidizers effective steel refining in the ladle.
are designed
to quickly
Synthetic Slags
assimilate into the entire ladle slag
volume. This facilitates a complete We deliver effective ladle metallurgy
reaction with the carryover furnace treatment through our line of calcium
slag to effectively reduce the FeO aluminate, calcium silicate and
and MnO contents of the slag in calcium fluoride-based Synthetic

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Filter
Media

The ability of slag


aggregates to remove or
reduce Phosphorous (P)
and Heavy Metals from
degraded water is not
new.
The cubical and vesicular nature
of steel slag makes it an effective
medium for trickling filters in
 The alkalinity of steel slags offsets acidic mine water, in this case of an Acid mine water run
sewage treatment works, surface off, USA
water run offs, farming effluent, or
industrial effluent.

Filtered degraded water can be


reused in secondary applications
such as irrigation of sports fields,
crops or a myriad of other
applications that do not require
drinking water standards.

 Run off water treatment in New Zealand using steel slag

Slag’s vesicular nature provides a microbes that help consume the


greater surface area contact for the bacteria.
elements in solution and for the

CASE STUDY NEW ZEALAND

Filtering storm of their storm water


water runoff.
As a result of a joint The results from these
venture with New Zealand filters have been very
Steel, Harsco developed satisfactory, particularly
a solution for treating the in the reduction of Zinc
mill’s surface water run- which is present at the
off. NZ Steel, based on site, but also for the
the findings of the early reduction of solids.
studies of melter slag in Additional filters were
the 1990’s and to support subsequently installed to
Harsco’s water treatment polish water run off from a
marketing initiatives, contractor’s compound.
began installing melter
slag filters in 2005 to  Steel slag filter beds are used to treat industrial effluent (surface
improve the water quality water run off) at the NZ Steel Glenbrook mill, New Zealand

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Abrasive Blasting
Material

Using a rapid cooling


method – Slag Atomizing
Technology, patented
by Ecomaister – liquid
steel slag can be turned
into a material called
Precious Slag Ball™,
in an environmentally
controlled process.
Product properties:
 Stable spinel structure
 The alkalinity of steel slags offsets acidic mine water, in this case of an Acid mine water run
 Spherical, glassy surface off, USA
 High hardness and resistance to
wear.
How does Slag Atomization Technology work?
Ecomaister process The hot slag is poured directly
Harsco uses the Ecomaister onto the surface of the pelletiser,
process at two sites to blown air causing the material
manufacture Precious Slag Ball™: to disperse into a collection area
for cooling.
1. ArcelorMittal Vanderbjilpark,
South Africa Only the pot top is granulated so
that the metal can be recovered
2. Krakatau Steel, Indonesia separately.
(JV with PBH)

The pelletised ball is suitable for use


in a number of applications:
 Shot blasting, grit, sandpaper
 Roofing granules
 Non-slip surfaces
 Filter media.

The material is screened and bagged


at the production plant according to
size fractions required for end user
specifications.

 The operation in Indonesia which produces slag balls using the Ecomaister process

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Soil
Conditioner

Steel furnace ladle slag In addition to steel slag’s value as Today steel slag is being used as a
a liming agent – reducing harmful liming agent not just in farming, but
has been used as a acidic conditions by replacing much also parks, golf courses, nurseries,
liming agent for nearly needed calcium and magnesium – it greenhouses and even land
is recognized for as many as fifteen reclamation projects.
a century. It is very other trace minerals, including iron,
effective in adjusting the manganese, zinc and molybdenum.
pH balance in soil. The amount of allowable trace
minerals depends on the CCE
(Calcium Carbonate Equivalent).

The ladle slag is ground very finely


to aid slag decomposition through
exposure to air and moisture in the
soil.

 EAF Steel Slag used as a soil conditioner


in Canada

CASE STUDY SOUTH AFRICA

Stainless Steel slag Calmasil supplies in


excess of 80% of the
Harsco collects and
agricultural dolomitic
processes slag obtained
lime requirement
from the Acerinox Plant at
(mainly for maize and
Middelburg, South Africa.
soya cultivation) in the
The slag is de-metalized
Mpumalanga province.
by crushing and milling
Furthermore, it is sought
to < 1 mm, dewatered to
after in the sugar industry
< 20% moisture and then
because of its high silicon
sent by overland conveyor
content. Calmasil’s lime
to Calmasil, a third party.
generally has a CCE lime/
Calmasil dries, screens magnesium value of 97%
and markets the slag and a calcium/magnesium
for agricultural (soil proportion of 1:4, similar
ameliorant/conditioner) to that found in most  Dewatered stainless steel slag can be recycled as feed for soil
and industrial purposes. agricultural soils. conditioner

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Doing Business
with Harsco

Artificial Aggregate Applications:


Reference Country List

Road Surface Treatment Asphalt mixes Unbound Construction


 New Zealand  Brazil Applications
 USA  Canada  Australia  Portugal
 New Zealand  Brazil  Saudi Arabia
 Saudi Arabia  Canada  South Africa
 South Africa  New Zealand  USA
 UK  Norway
 USA  Poland

Filter Media Soil Conditioning Stone Columns


 Canada  Brazil  Saudi Arabia
 New Zealand  Canada
 USA  South Africa
 USA

Rail Ballast Cement/Concrete Insulation


 Brazil  Brazil  RockWool®, Norway
 Canada  China  RockWool®, Poland
 USA  Saudi Arabia
 Spain
 USA

Shot Blasting Metallurgical Additives


 Indonesia  USA
 South Africa
 USA

We will supply on request:


 Further information relating to specific applications and products
 Technical/commercial proposals based on full laboratory
evaluation of slag samples.
For further information, please contact: aggregates@harsco.com

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MultiServ Group Limited
A part of Harsco Corporation

Harsco House, Regent Park


299 Kingston Road, Leatherhead
Surrey KT22 7SG

Tel: +44 (0) 1372 381400


Fax: +44 (0) 1372 381420
Email: aggregates@harsco.com
www.harscometals.com

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