Claycrete is a Clay Soil Stabilising Treatment manufactured in Western Australia and exported to several international locations. Claycrete is an Ionic soil stabiliser specifically designed for clay and clay bearing soil. Claycrete is a liquid chemical additive which reacts with only the clay fraction of a material. Long after the product has biodegraded the clay will remain in its stabilised state. The improved properties of the clay make it suitable for use in higher portions in road materials.
Clay has been stabilised in the past by the use of lime but the process is expensive and application and mixing is difficult. CLAYCRETE is unique because the stabilisation does not depend on the presence of a residual product. After the reaction period is completed the stabilised clay is remaining binder. Where a process depends on the introduced product acting as the binding agent there will be progressive loss of benefit due to leaching. Additional loss is caused by the mechanical stresses resulting from expansion and contraction of the untreated clay.
A well bound pavement is what every road builder aims to achieve because a road that is low in void, will be strong and durable. Road builders in Australia most commonly use cement as a binder and this practice has been relatively successful, however it is too expensive to apply this solution to every problem or on a large scale.
Clay materials have compromised many road building projects because of their unstable nature when exposed to moisture. It I s common practice to remove these materials from road projects often at great cost, just as it is common to stop digging when you encounter gravel with too much clay.
Clay can be used in many instances as an affordable binder in place of cement, but it must be stabilised to eliminate the well-known problems with moisture.
In one treatment CLAYCRETE stabilises clay, allowing the use of material that would have been once left behind or removed. The presence of additional clay reduces void and improves the binding of the pavement materials. Traditional specifications of low plasticity material imposes costly limitations on material sources.
The costs associated with sealed and unsealed road networks can be reduced by healthy margins by tackling the age old problem of clay with a new solution. Roadwork’s that have been constructed using a clay gravel stabilised with CLAYCRETE have improved noticeably in key areas.
Clay gravels are often easier to find, many pits can be re-used because they were closed as soon as too much clay was reached.
Clay gravels are usually cheaper to buy because they are often viewed as inferior product.
Stabilised clay materials produce high CBR’s this translates to a reduced pavement thickness for the same strength.
Treated materials are easier to work.
Treated materials requires less water to behave as if optimum moisture content has been achieved. Treated material requires less compacting effort to achieve compaction levels.
Unsealed roads will need less routine maintenance because the treated material is more durable.
Less ravelling takes place because the pavement is better bound.
Seal need less maintenance because the pavement is stronger. Seals will adhere readily to a treated surface. Treated roads can be left longer prior to sealing, allowing better inspection and savings by accumulating areas to be sealed.
Clay is comprised of microscopic platelets which resemble small irregular pieces of paper. The pieces of clay (platelets) carry a minute charge which has a negative value on the edge of the platelet and a positive value on the face. In terms of the platelet’s size the charge is strong and is responsible for the unusual characteristics of clay.
In dry clay the face to edge bond of the clay is strong enough to hold the clay together but the edge charge is more easily satisfied by bonding to water. Water molecules are adsorbed onto the edge of the platelet and the more water that is present the less the platelets bond to each other. If enough water is added the clay floats apart more and more until it has the characteristics of a colloid and ultimately a liquid.
This then is the nature of clay that gives it swell and shrink problems and make it unreliable in any structural application unless it is permanently fixed in dry state.
CLAYCRETE is viscous liquid that is mixed into the water that clay normally absorbs. The special formulation of CLAYCRETE means that the clay platelets have a greater affinity for CLAYCRETE than for water alone.
CLAYCRETE satisfies the charge imbalance in the clay platelets and allows the random bonding of the platelets to be changed to a more orderly arrangement approaching a layered bond. Water molecules which are normally bonded to clay platelets become free water and drain off. The result of the treatment is a stronger bond, increased density, increased mechanical strength and a greatly increased resistance to water.
Claycrete Increases: • Soil strength • Soil densities • CBR • Soil compaction • Pavement life • Water resistance • Wear resistance
Claycrete Decreases: • Plasticity index • Moisture • Abrasion loss • Shrinkage • Swell • Maintenance • Dust
Subgrade stabilisation: • Road building sub grade stabilisation • Runway, aprons, taxiways and helipads • Hard stands, loading areas, road train assembly areas • Land fill areas • Pressure injections for deep stabilisation
Base course and surface stabilisation: • Rural unsealed and sealed roads • Forestry and plantation roads • Mine and quarry haul roads • Subdivision and housing project roads, sealed and unsealed • All forms of sealed surfaces and stabilisation prior to sealing
CLAYCRETE is suitable for roads and runways which will be sealed and whether you seal now or in the future you can be sure of a good finish if your base course is CLAYCRETE treated.
Stablisation of shoulders is a simple and speedy process with CLAYCRETE. Using a Rotary Hoe, a Grader, a Water Tanker and a Roller.
Depending upon the moisture content and the properties of the material, high increases in strength can be achieved during the compaction process. The long term curing can continue for several months and increases in CBR continue throughout the curing process.
Road crews with water binding experience will simply follow their regular procedure with the only additional step being the addition of the CLAYCRETE into the water tanker.
The curing characteristics of CLAYCRETE have been carefully designed to be controllable on site. The moisture levels and the workability of the material can be adjusted to lengthen or shorten the workable time of the mixed material. “Step up” times can be as short as hours or as long as days. Mixed material has been left in windrow storage for as long as four months before final laying and compaction, without loss of performance.
Highway Construction - Stabilisation of sub-standard sub grade materials - Use of sub-standard materials by modification - Reduction of base thickness by increasing CBR of material - Stabilisation of embankments and fill - Shoulder stabilisation – reduces maintenance and stops water getting under sealed surfaces.
Airport Construction - Stabilising sub grades
Mine and Quarry - Haul roads and stockpiling floor areas
Long Haul - Stabilising base course of taxi ways and aprons
Roads - Reducing maintenance and increasing wet weather access
Plantation Roads - Safer access on slopes, and less water damage in run off areas
Dams & Embankments - Stabilising fill materials and decreasing permeability
Land Fill Areas - Stabilising land fill in layers to resist land slide
MINING - Mines have a critical need for low-cost roads in remote areas. Mines are often not located close to significant infrastructure network, yet they need to move large quantities of material to a port. In addition, the initial investment required when starting a mine is very onerous – especially prior to the start of revenue generation.
CLAYCRETE roads are a cost – effective and timely solution compared to asphalt roads and rail lines and CLAYCRETE helps mine sites meet their Health, Safety and Environment goals.
GOVERNMENTS - CLAYCRETE is a good road building solution for developed countries, whether it is used to replace unsurfaced roads or improve the base of existing roads. Even in developed countries, there are considerable lane-miles of unsurfaced (gravel) roads.
Using CLAYCRETE on these roads will reduce maintenance andprovide an improved all-weather surface. CLAYCRETE improves surfaced roads by creating an improved solid base that is impervious to water damage.
AGRICULTURE AND FORESTRY - Roads in plantations and logging operations often become impassable during rainy periods, making harvesting impossible. CLAYCRETE can turn these roads into permanent all-weather roads that require little maintenance.
CLAYCRETE products have no negative effect on the soil and do not leach into adjacent areas. Roads can easily be removed by simple ripping, and then the area may be replanted.
OIL AND GAS - CLAYCRETE is a good solution for oil and gas field well-pad construction and service roads. Initially it is necessary to bring expensive, heavy drill rigs to the site. Later, during drilling operations, a pad must be available to the support of the rig. In addition, access roads must be maintained to allow 24/7 service in case of failures or injuries.
Currently, roads in this industry are expensive due to required bearing capacities, the need for extensive maintenance, and their quick deterioration.
CLAYCRETE is transported in concentrations to avoid the unnecessary cost of moving diluted material. It is added to water at the site by pumping it directly into water in a full water tanker.
Reasonable precautions must be taken at the time of transfer. Precautions include the wearing of rubber gloves and safety glasses. Full “on site” support is provided until operators are familiar with the handling procedures.
CLAYCRETE is a corrosive liquid in its concentrated form but no more hazardous than many commonly used household cleaners. Once it is diluted in the application process it presents very little hazard to users.
The active ingredients in CLAYCRETE are exhausted during the treatment of the soil. The passive ingredients are comprised of biodegradable materials which are digested by enzymes in the soil.
Your shifting sands problems can now be solved with minimum fuss and minimum cost. ZEROSION means zero erosion from the moment it hits the sand or other loose material.
ZEROSION is an environmentally friendly sand stabiliser that is easily applied by water cannon or spray. Once ZEROSION hits the sand that is the end of sand storms and migrating dunes. The treatment dries to leathery jacket which incorporates the sand and looks totally natural.
During rain ZEROSION absorbs moisture and when the rain stops the ZEROSION dries and hardens agains. One simple application will last for months. Heavier applications will last far more than a year.
Areas which are damaged by accident or trespass are easily repaired. Beach stabilisation can be achieved and dune erosion can easily be prevented or arrested by this product. Stockpile management becomes a breeze even in heavy weather. Dust storms from tailings dams are no longer a necessary part of the mining environment.
This amazing product is made from naturally occurring materials which are friendly to the environment and the most user friendly stabiliser that is possible.
ZEROSION is a viscous brown liquid product that is delivered in 25, 200 and 1000 litre delivery units. Tanker delivery and application is also available. ZEROSION is safe in our environment and safe to handle.
ZEROSION consists of a complex blend of naturally occurring cellulose polymer products and waterproofing agents that are environmentally sensitive. Small amounts of preservatives are added to extend product shelf life. ZEROSION weather resistant characteristics improve with age.
ZEROSION binds loose soil particles to form a bound stiff surface with limited flexibility. This surface is extremely resistant to wind abrasion and dust lift. With many surfaces dust lift is aggravated by the abrasive properties of wind which is already carrying sand. The material will become soft and pliable when wet but as it dries it becomes harder each time.
Durability of the treatment will depend on many factors but periods of up to eighteen months of stability from a 100mls per square meter treatment are predicted.
For the stabilisation of coal or sand stockpiles Zerosion can be applied by water cannon or by fire hose. Cost is a major factor in dust suppression because most dust suppressants require frequent re-application.
Zerosion is a low cost product that can give lasting results from a little as 10 cents per square meter (Based on an application rate of 100mls per m2)
Zerosion is safe to handle and safe for the environment. Zersion is a natural product that has been kept as free from preservatives as possible, it has a shelf life of only one month and high temperatures should be avoided.
For dust suppression and stabilisation of large areas bulk delivery by tanker ensures that the delivery and application process can be as efficient as possible. Large areas can be handled most effectively by application direct from the delivery tanker, this service ensures rapid application and correct application rates.
Tailing Dams, Stockpiles, Runway and Airstrips Clearways, Helipads and many other surfaces that are dust sources can all be corrected with ZEROSION.
Obligation free quotations are available.
ZEROSION is designed to prevent or minimise the dust, drift and erosion of sands and other loose grained materials that are stockpiled or exposed by earthworks. ZEROSION enhances germination and regrowth and is an excellent preparation for rehabilitation.
ZEROSION can be used for: • Beach stabilisation above high water mark • Sand mining – Rehabilitation stabilisation • Sand mining – Stockpile protection • Civil works – Protection of uncovered areas from erosion by wind. • Airfields and Runways – Protection of runways from drift of sand or other loose materials • Farming – Preservation of loose ground from wind erosion • Highway construction – protection of exposed banks and slopes • Golf Courses – Stabilisation of earthworks during construction • Brick Paving – Stabilisation of sand beds • Agriculture – protection of finely tilted soil from erosion by wind.
After dilution the product can be easily applied by water cannon or any appropriate spray bar or dribble bar. Tank mixes of Zerosion need constant agitation until applied; flex drive pumps can be supplied for use in your tanker.
ZEROSION can be applied at rates from 75 mls to 175 mls per square meter depending on durability required. Repeat applications give accumulative strength.
ZEROSION is nature’s way of binding loose soils. This product is environmentally safe it will not harm flora or fauna in application. The product has a shelf life of 1-3 months and is normally delivered in bulk tankers and used immediately. The strength of the binding process can partly be attributed to the characteristics that lead to a short shelf life. Once applied as directed the benefits my last eighteen months or more.
SHORT TERM STABILISATION UP TO 3 MONTHS - Apply 50 cc of ZEROSION diluted in 500 cc of water for each square meter of surface area. Allow to dry. This surface will be stable but will not stand traffic. Cost of treatment 7.5 cents per square meter.
SHORT TO MEDIUM TERM STABILISATION UP TO 12 MONTHS - Apply 100 – 125 cc in 500 cc of water to each square meter. Durable but will not stand traffic.
LONG TERM STABILISATION UP TO 18 - 24 MONTHS - Apply 175 – 200 cc in 1 litre of water to each square meter. The important relationship is the proportion of product to the square meter of sand.
KALFOSS is a stabiliser for lime soils, crushed limestone, calcrete and sand/limestone mixes. It improves the strength and finish of lime materials and facilitates reduced pavement thickness.
Applied in a diluted form KALFOSS is blended with the pavement material and the mix is compacted while moist. Application can be made through dribble or spray bar or by fan spray. Repeat applications during mixing procedures should be applied at a rate that does not result in “run-off”.
Material is ready for compaction when the material forms a cohesive lump when grasped but should not be so wet that it sticks to the hand. If the treated material sticks to the roller the roller should be withdrawn to allow the reaction to complete. As soon as the material no longer sticks to the roller it should be thoroughly compacted. Once compaction with the steel drum is completed the road may be sprayed again and rolled with a multi tyred roller.
KALFOSS creates a tightly bound surface with high abrasion resistance and high weather resistance. Pavement CBR will be increased depending on depth of stabilisation. The prepared surface is idea for sealing.
KALFOSS is an aquamarine-coloured liquid that disperses immediately in water. It can be pumped using metal or plastic pumps and will not harm cast iron or steel.
KALFOSS does not leach out or lose effect with age. The benefit gained from application will last throughout the pavement life.
KALFOSS is available in 200 litre drums.
Eyes: Mild Irritant.
Skin: Corrosive alkalinity after prolonged exposure.
Ingestion: Causes mild intestinal irritation.
Eyes: Hold eyelids open and irrigate with copious quantities of water for about 15 minutes.
Skin: Wash with plenty of water.
Ingestion: Wash mouth with water. Give milk or water to drink.
Precautions for use
Exposure Limits: Not available.
Ventilation: No speciation requirements.
Personal Protection: Wear rubber gloves or wash hands after contact. Wear glasses to protect against eye contact. Wash clothing at once if spilled on clothes. Wash skin as above if skin contact occurs.
Flammability: Not Flammable.
Storage: Store under agitation. Refrigerate or keep as cool as possible. Keep out of sunlight until use.
Spills and Disposal: Absorb with earth or sand. Place in labelled drums for disposal. Safe for disposal in earth fill in small quantities.
Fire/Explosion Hazard: None.