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SIMPROLIT SYSTEM FOR FACADE THERMO-INSULATION
AND FIRE PROTECTION OF BUILDINGS

Mihailo Muravljov *, Dragica Jevtic *, Dimitrije Zakic *, Milan Devic ** *
Faculty of Civil Engineering, Belgrade University ** SIMPRO, Vojvode Stepe 251, Belgrade

INTRODUCTION

SIMPROLIT polystyrene concrete represents very light, porous composite material which is produced using a protected technological procedure as a mixture of Portland cement, expanded polystyrene grains, water and special admixtures - used in order to achieve the desired lightweight concrete properties. Based on Simprolit polystyrene concrete various products are formed, such as: different types of building blocks for facade and partition walls, semi-prefabricated and monolith slabs and roof plates, as well as three-layered elements (.sandwich. plates). The possible use of these elements is tightly related to the positive properties of Simprolit, among which are:

• low density, i.e. high porosity;
• satisfactory mechanical resistance;
• low water absorption;
• good thermo-insulation properties;
• satisfactory steam permeability;
• high frost resistance;
• chemical and biological durability;
• it is not toxic;
• acceptable price;
• satisfactory fire resistance.

Figure 1. The appearance of a specimen after the burning test (a) in relation to the reference specimen (b)

For the last four years the testing of Simprolit polystyrene concrete, as well as the supervision of its research and application, are done at the Institute for materials and structures (IMK) of the Belgrade Faculty of Civil Engineering, but also parallel at the Institute for Civil Engineering Physics of the Russian Academy of Civil Engineering in Moscow and in several other licensed laboratories in Republic of Serbia and in Russian Federation.

Some of these tests were conducted as a part of the scientific-research project sponsored by the Serbian Ministry of science, technology and development. The tests were related to the individual structural elements, as well as to the whole Simprolit system - from the aspect of its physical-mechanical properties, thermo-technical characteristics, durability and resistance to extreme influences. The testing of fire resistance which was performed at the Institute IMK according to the Yugoslav standard JUS G.S2.659 - Plastics - flammability determination using rod-shaped samples of the material, has shown that Simprolit samples exhibit no signs of combustion, dripping or melting when subjected to the flame from the Bunsen's torch. Therefore, the conclusion can be made that the given material falls into the category of "non-flammable" materials. The appearance of the tested sample, compared to the sample which was not subjected to high temperature, is presented at the Figure 1. This figure shows that the expanded polystyrene grains disappear under high temperature conditions, but also that the structure of the lightweight concrete remains undisturbed. Also, three fire resistance tests were performed in the Russian Federation and each time Simprolit got NG class certificate - which stands for non-flammable material according to the GOST standard.

THE BASIC ELEMENTS OF THE SIMPROLIT SYSTEM FOR FACADE THERMO-INSULATION

Simprolit system for facade walls thermo-insulation is principally based on application of two types of plate: single-layered monolith (SOP) plates and three-layered (SUP) plates.

Single-layered (monolith) SOP plates are produced with thickness variation from 30-120mm (30mm, 50mm, 80mm, 100mm and 120mm), whereas the standard dimensions of these plates are 1000x750mm. These plates have the same basic properties of SIMPROLIT which were described in the introduction paragraph, but especially important are the following characteristics:

• the heat conductivity coefficient λ = 0,055-0,085 W/m°C (the interval of . values is a function of the obtained density of SIMPROLIT, varying between 150 and 300 kg/m³);
• fire resistance - satisfactory (one side of a wooden partition was paneled with 8cm thick and tested according to the regulations of the relevant standards; it "endured" the standard of over 1000°C for more that 120 minutes, after which time the test was stopped resistance was declared to be 2 hours, i.e. class EI 120 according to GOST standard).

Three-layered SUP plates have the same dimensions as the previously described SOP plates. The differences in the total thickness of these plates are achieved by variation of the middle styrofoam layer, while the outer layers made of Simprolit polystyrene concrete usually have the same thickness - 10 mm. In these cases the integral heat conductivity coefficient λ varies from 0,061 W/m°C (for plate thickness 1+2+1=3cm) to 0,041 W/m°C (for plate thickness 1+10+1=12cm).

The laboratory tests of the three-layered SUP panels having total thickness of 12cm, where the two outer Simprolit layers had thickness of 2x4=8cm and the middle styrofoam layer had thickness of 4cm, were conducted at the Fire-testing laboratory of the Russian Ministry of Defense according to the GOST standard; these tests showed the following results: after 90 minutes (according to the standard fire curve with maximal temperature over 1000°C), no loss of integrity nor thermo-insulation ability loss of the tested elements were detected.

Also, according to the test performed in the Russian Federation, a wall made of 12cm thick Simprolit partition blocks "endured" the standard temperature (over 1000°C) for more than 180 minutes, after which time the test was stopped and the fire resistance was declared to be 3 hours, i.e. class EI 180 (according to GOST standard). This is particularly important if the building is thermo-insulated by covering the facade walls with Simprolit partition blocks.

SIMPROLIT SYSTEM FOR FACADE THERMO-INSULATION

The thermo-insulation system based on the application of SOP and SUP plates involves the installation of these plates over brick, concrete and other types of walls. This procedure is done using cement based glue and mechanical means - plastic plugs with "hats" and plastic wedges, or in some cases plastic plugs with "hats" and metallic wedges. The details of the described thermo-insulation system are presented in Figure 2. It has to be underlined that the single-layered SOP plates are usually applied at the beginning and at the end of sections - as the first elements over the plinth (Fig. 3a), or the last (upper) elements on the facade, as corner elements (placed either on one or both walls joining at the corner - Fig. 3b), or as "paneling" elements for window openings, etc.

Figure 2. SIMPROLIT system for facade thermo-insulation - scheme of layers

LEGEND:

1. Basic material – wall made of bricks, concrete, etc.
2. Simprolit «SOP» plates
3. Simprolit «SUP» plates installed with «overlaps» in the next row
4. Prefabricated plastic plugs with «hats» and plastic «wedges»
5. Prefabricated plastic plugs with a «hat» and a plastic «wedge»
6. Overlapping of Simprolit «SOP» and «SUP» plates at the outside corners
7. Prefabricated mesh «5x5» mm, made of plastic or glass-fibers
8. Cement based glue or polymer-cement plaster, with embedded plastic or glass-fiber mesh
9. Decorative-protective layer (a thin plaster layer with finishing facade color).

The thermo-insulation of facade walls also implies the fulfilling of fire resistance requirements for the insulated surfaces, as well as for the entire building. In relation to that, the following basic principles have to be considered:

• it is necessary to prevent spreading of fire from the affected area (apartment, floor) over the facade insulated with combustible materials to the adjacent sections of the building;
• it is necessary to prevent spreading of fire from the burning roof, which is made of combustible materials, over the facade insulated with combustible materials to the adjacent sections of the building;

In addition to the above stated facts, the facade surfaces which are insulated with Simprolit three-layered (SUP) plates are also equipped with special Simprolit fireproof joints, especially if the building is subjected to the higher risk of fire. These joints are in fact particular stripes made of Simprolit monolith (single-layered elements), which are from both sides coated with cement plaster or with 5mm thick glue layer. These elements are usually being installed around the facade openings (windows, doors), but also at the upper wall ends - at joints between the thermo-insulation system and the roof with the insufficient fire resistance. If the thermo-insulated building has a higher risk of fire, the fireproof joints are also placed around the entire perimeter - at all slab levels. The schemes of all the described solutions are presented in the Figure 4.

Figure 3. The detail of the system above the plinth (a) and the detail of the outer corner (b)

LEGEND:

1. Wall made of bricks, concrete, etc.;
2. Cement-based glue apllied for installation of the plates;
3. Simprolit three-layered plate «SUP»;
4. Simprolit single-layered plate «SOP»;
5. Perforated pipe made of aluminium, zinc-coated sheet or hard plastics, with «hermetic» at the contact between upper and lower layer («SOP» and plinth);
6. Prefabricated mesh, made of plastic or glass-fibers, embedded into cement based glue or polymer-cement plaster;
7. Decorative-protective layer (a thin plaster layer with finishing facade color);
8. Plinth.

Figure 4. Scheme of possible arrangement of SIMPROLIT fireproof joints (SPPR)

LEGEND:

1. Plinth;
2. Simprolit single-layered plates «SOP»;
3. Simprolit three-layered thermo-insulation plates (SUP);
4. Simprolit fireproof joints «SPPR»;
5. Roof or Fireproof slab joints «SPPR»;
6. Roof

Figures 5a and 5b represent the details of installation of SIMPROLIT fireproof joints around the window openings (detail at the lower end "a" and at the upper end "b"). Figure 6. shows a detail of the ending of the thermo-insulation with the SIMPROLIT joint between the system and the roof made of flammable materials, which do not satisfy the fire resistance requirements.

Figure 5. Details of solutions at the lower (a) and the upper (b) end of the window

LEGEND:

1. Wall made of bricks, concrete, etc.;
2. Cement-based glue applied for installation of the plates;
3. Simprolit three-layered «SUP» plate;
4. Simprolit single-layered «SOP» plate;
5. Simprolit fireproof joint «SPPR»;
6. Window frame;
7. Prefabricated mesh, made of plastic or glass-fibers, embedded into cement based glue or polymer-cement plaster;
8. Decorative-protective layer (a thin plaster layer with finishing facade color);
9. Zinc-coated windowsill (solbank);
10. Hermetic material.

Figure 6. Thermo-insulation at the joint between the system and the roof made of flammable materials

LEGEND:

1. Wall made of bricks, concrete, etc.;
2. Cement-based glue applied for installation of the plates;
3. Simprolit three-layered «SUP» plate;
4. Simprolit fireproof joint «SPPR»;
5. Roof made of flammable materials;
6. Prefabricated mesh, made of plastic or glass-fibers, embedded into cement based glue or polymer-cement plaster;
7. Decorative-protective layer (a thin plaster layer with finishing facade color);
8. Hermetic material placed over the sealing tape

In case of the higher risk of fire, the plugs with "hats" and metallic wedges must be applied; these bond elements are placed in the middle of the SUP plates, but they are also used for fastening of Simprolit fireproof joints. Beside that, in such cases the procedure for strengthening of corners around the facade openings is usually applied, as shown in Figure 7.

Figure 7. Installation of SIMPROLIT fireproof joints and the procedure of strengthening the facade openings

LEGENDA:

1. Simprolit three-layered «SUP» plate;
2. Prefabricated plastic plugs with «hats» and plastic «wedges»;
3. Prefabricated plastic plugs with «hats» and plastic «wedges» for buildings with higher risk of fire;
4. Simprolit single-layered «SOP» plates placed around the facade openings;
5. Simprolit fireproof joints «SPPR» placed around the facade openings;
6. Diagonal strengthenings made of plastics or glass fiber mesh at the points of stress concentration – corners of facade openings;
7. Prefabricated mesh (5x5 mm) made of plastic or glass-fibers, embedded into the cement based glue or polymer-cement plaster.

CONCLUSIONS

Based on the above presented text, it is obvious that the patented Simprolit polystyrene concrete - made of styrofoam grains, cement, water and special admixtures - fulfills the high-level requirements set for contemporary civil engineering thermo-insulation materials. This composite material is characterized by its low density and excellent thermo-insulation properties, it is stable and ecologically suitable, which means that it can be applied for all types of

The application of Simprolit products leads to heat energy savings, which is the imperative of this century. In addition to that, walls insulated with Simprolit plates keep their air and steam permeability, which is an extremely important factor for healthy and comfortable living conditions.

Since Simprolit represents a positive material from the ecological point of view, and it also completely satisfies the severe fire resistance conditions - which is confirmed by the experimental testing results, the authors think that it is a product which should have a significant place in our civil engineering, as well as very good perspective for further development. Also, the fact should be pointed out that according to the tests made in the Russian Federation, Simprolit has higher durability in comparison to other concurrent materials (mineral wool, expanded and extruded polystyrene, foam concrete, gas concrete). It means that application of Simprolit also brings satisfactory effects regarding the long-term economical aspect.

LITERATURE:

1. Muravljov M, Jevtic D, Zakic D., Devic M.: Testing of different types of .Simprolit. plates - an example, 10^th International Symposium of MASE, Ohrid, Macedonia, September 25-27. 2003., pp. 393-400.
2. Devic M., Jevtic D., Zakic D.: Simprolit building elements - a complex approach to the thermo-insulation of buildings, Conference .Contemporary Civil Engineering Practice 2003., FTN i DGiTNS, Proceedings - p. 199-215, Novi Sad, 27.-28. March 2003.
3. Jevtic D., Devic M., Zakic D.: Properties and application of SIMPROLIT, patented polystyrene concrete, XXII Congress of JUDIMK, Niska Banja 17-18. October 2002., p. 73-79.
4. Muravljov M., Jevtic D., Zakic D.: Expert opinion on fire resistance, inflammability and behavior under fire of the elements of "SIMPROLIT" thermo-insulation system, a result of the scientific-research project .Research, implementation and application of contemporary materials and products in Civil engineering. financed by the Serbian Ministry of science, technology and development, Belgrade, 2004.
5. Muravljov M., Jevtic D.: Report on flammability testing of "SIMPROLIT", a result of the scientific-research project .Research, implementation and application of contemporary materials and products in Civil engineering. financed by the Serbian Ministry of science, technology and development, Belgrade, 2003.
6. Muravljov M., Jevtic D.: Report on quality testing of "SIMPROLIT" thermo-insulation panels, Belgrade, 2001.
7. Muravljov M., Jevtic D.: «Building materials 2», Faculty of Civil Engineering, Belgrade, 1999.
8. SIMPRO Products' Catalogues.
9. The protocols from fire resistance testing and certificates issued in the Russian Federation and in the Republic of Serbia.
10. Internet address of the Producer in the Republic of Serbia: www.simprolit.com
11. Internet address of the Producer in the Russian Federation: www.simprolit.ru

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