Innovative microfiller made from normal electrocorundum that doubles the strength of concrete and asphalt and serves as an excellent filler for paints.
P.G. Drygulyich, Candidate of Geological Sciences, Deputy Director for Strategy at PrJSC“Zaporizhzhia Abrasive”.
The micropowder of normal electrocorundum (-63 μm, 13A) is a highly effective micropowder based on aluminum oxide (Al₂O₃), shown in Fig. 1 (hereinafter also referred to as EN micropowder). The micropowder is the product of the final stage of grinding electrocorundum lumps.
Fig. 1. Micropowder of normal electrocorundum
Compliance with Standards: The fine-dispersed microfiller of normal electrocorundum, in terms of its mineralogical composition, meets the requirements of TU U 26.8-00222226-016:2006. All products of PrJSC “Zaporizhzhia Abrasive” are certified according to the international standard ISO 9001:2015.
Environmental and Strategic Aspects Modernization of aspiration systems at the production facility has improved the air quality in the working area and minimized emissions of pollutants into the atmosphere. This, in turn, has allowed the company to return the captured EN micropowder back into the technological cycle and increase the production volumes of valuable products.
This approach creates a comprehensive effect:
- Ecology and Health: The natural environment and personnel are protected from the negative impact of industrial emissions.
- Business Benefits: Enterprises in various sectors of the economy receive a stable, high-quality, and technological product at the lowest price.
Legal and Commodity Status of the Material This material is a commodity within the meaning of the Law of Ukraine “On Foreign Economic Activity” and is intended for sale or paid distribution.
- Filler for Paints The micropowder of normal electrocorundum (synthetic aluminum oxide) is an ideal functional filler for high-temperature and heat-resistant paints. It provides thermal resistance up to 1800–2000°C, high hardness (9 on the Mohs scale), and resistance to chemical exposure.
Thermal Insulation and Fire Resistance: The filler prevents the destruction and burnout of paint at extreme temperatures, which is critical for furnaces, grills, chimneys, and industrial equipment. Mechanical Strength: The coating becomes resistant to abrasion, scratches, and impacts due to the high strength of corundum particles. Anti-Corrosion Properties: A dense ceramic layer reliably protects metal from oxidation.
What are the technical requirements for the filler? Dispersity: For paints, finely dispersed micropowders of normal electrocorundum with a grain size from 5 to 60 μm are used. The finer the grind, the higher the adhesion and the smoother the paint layer. Our product has a grind size of -63 μm. Proportions: The dosage of the filler is selected individually (usually from 10% to 40% of the total mass), depending on the required dry film thickness and the purpose of the coating (enamel, fire-retardant composition, or anti-stick paint).
- Filler in Construction Results of independent laboratory tests in construction: • +50% to strength: Significantly strengthens finished building structures. • Maximum savings: Significantly reduces the cost of material production. • Durability: Significantly extends the service life of reinforced concrete products (RCP) and roads.
Why is this relevant? In modern construction and road management, the issues of material quality, work speed, and cost reduction are more pressing than ever. The fine-dispersed microfiller produced by PrJSC “Zaporizhzhia Abrasive Plant” is a ready-made solution to these challenges. It dramatically improves the physical and mechanical characteristics of both cement and asphalt concrete mixtures.
Confirmed Results in Concrete (Source: Tests at PJSC “Zaporizhzhia Reinforced Concrete Sleepers Plant”, February 2024, Protocol No. 1)
Independent tests of modified concrete cubes of grade M350 showed impressive results: • Accelerated strength gain (5 days): ◦ Standard sample — 9.31 MPa. ◦ Sample with 20% EN micropowder (sand replacement) — 20.1 MPa (2.1 times increase). ◦ Sample with 10% EN micropowder (by mixing volume) — 20.0 MPa. • Maximum strength (28 days): ◦ Standard M350 formulation — strength corresponding to grade 333. ◦ Sample with 15% EN micropowder (cement replacement) — reached grade 500 (strength increase of nearly 50%).
Additional Benefits for the Concrete Industry: • Hydrophobicity: A pronounced water-repellent effect appears, protecting structures from moisture and frost. • Direct Savings: The additive allows reducing cement consumption by approximately 100 kg per 1 m³ of concrete without loss of strength. • Competitiveness: An effective solution for reinforced concrete product plants, manufacturers of precast reinforced concrete, and monolithic construction. • State Interest: The country’s infrastructure receives significantly more durable roads and capital reinforced concrete structures.
Confirmed Results in Asphalt Concrete (Source: Research by Lviv Polytechnic National University, August 2024, Contract No. 313-2024)
Scientists from the Department of Highways and Bridges conducted a comprehensive study of the micropowder obtained from the smelting and grinding of normal electrocorundum. • Main Conclusion: The EN micropowder fully meets the strict requirements of DSTU 9246-1:2023 for mineral fillers of Grade I in terms of its grain composition. This allows its official use in road construction as a high-quality structuring component of asphalt concrete mixtures.
Technical Advantages and Material Characteristics • Exceptional Hardness: The hardness of corundum (Al₂O₃) is 9 points on the Mohs scale, while the hardness of granite (a traditional filler in construction materials) is only 6–7 points. • Economic Efficiency: The cost of the material is significantly lower compared to traditional limestone mineral powder, providing a high economic effect. • Strength Enhancement: Complete or partial replacement of limestone powder (experimental mixes No. 2–No. 4) significantly improves performance indicators: ◦ Compressive strength of concrete at 20°C increases by up to 21%. ◦ Compressive strength of concrete at 50°C increases by up to 30%. ◦ The water resistance coefficient is significantly improved (according to express test results). • Optimal Formulation: Mix No. 3 (5% EN micropowder + screenings adjustment) is the rational choice. It guarantees excellent coverage of grains with binder, satisfactory water saturation, and the best price/quality ratio.
Conclusion of the scientists: The EN micropowder is the most promising alternative to traditional fillers for concrete due to the combination of exceptional technical efficiency and low cost.
Why Does EN Micropowder Work So Effectively? Thanks to its high Al₂O₃ content (>90%) and ultra-fine dispersity, the material acts as an active microfiller of the structure: • Optimizes Structure: Fills micropores and significantly increases the density of the matrix. • Improves Mixture Properties: Accelerates hydration processes and enhances adhesion. • Increases Durability: Reduces water permeability, increases resistance to abrasion, frost, dynamic loads, and temperature aging. • Effects in Concrete: Allows cement savings and accelerates strength gain. • Effects in Asphalt Concrete: Completely replaces expensive mineral powder and increases the heat and shear resistance of road surfaces.
Scientific Confirmation and Expertise The effectiveness of normal electrocorundum micropowder has been officially confirmed by independent laboratory tests and expert opinions from leading Ukrainian institutions. The results are documented in: • Test protocols from PJSC “Zaporizhzhia Reinforced Concrete Sleepers Plant” (February 2024); • Scientific report from Lviv Polytechnic National University under Contract No. 313-2024 (August 2024).
Ready to implement an innovation that simultaneously improves quality and reduces the cost of your products?
The micropowder of normal electrocorundum (-63 μm, 13A) is not just a mineral additive. It is an advanced technology that makes your concrete and asphalt concrete stronger, more durable, and much more cost-effective to produce.
Contact us to receive: • Free samples of the material for laboratory testing; • Detailed technical recommendations on dosage and component replacement; • Individual calculation of the economic effect tailored to your production specifics; • Technological support during industrial implementation.
We look forward to your inquiries and are ready for mutually beneficial cooperation!
Contact Information: Yulia Arkadiyivna Bykovchenko PrJSC “Zaporizhzhia Abrasive” [email protected]