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SIMPROLIT POLYSTYRENE CONCRETE

Simprolit polystyrene concrete:
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Simprolit polystyrene concrete – is a patented mixture made of expanded polystyrene granules, Portland cement, water and special admixtures, with best thermo-physical properties in the class of light-weight concretes:

• excellent ecological (sanitary-epidemiological) properties, which are a whole class higher than values required by the GOST R 51263-99 standard;
• buildings made of Simprolit elements offer to their residents exceptional durability and comfortable living conditions;
• Simprolit structures and elements do not pollute the environment, neither during production nor during the long-lasting exploitation period;
• Simprolit structures and elements can be defined as "dry" (no more than 4% humidity). When exposed to flood or other natural disasters, Simprolit elements dry very quickly, without any loss of strength or other thermo-physical properties;
• possible application in all climate regions of the world, from arctic to tropical zone;
• Simprolit has the most favorable coefficient of relation between strength and thermo-insulation ability, among other similar materials;
• Simprolit has the highest coefficient of relation between humidity resistance and thermo-insulation properties, among other similar materials;
• Simprolit also has the highest coefficient of relation between durability and thermo-insulation properties, among other similar materials;
• Simprolit polystyrene concrete is a unique non-flammable material in the whole class of polystyrene concretes; panels made of this material and styrofoam as the middle layer have passed all tests at the Russian Ministry of Defence Research Center "Opitnoe» - according to the testing results the following conclusion has been derived: "During 90 minutes of fire-resistance testing no integrity loss or thermo-insulation ability loss have occured".

Simprolit polystyrene concrete and Simprolit elements are applied for residential, business, industrial, sports, rural and other special structures, such as:

• Monolith and prefabricated structures, thermo-insulating and soundproofing covering layers;
• Self-supporting walls in all types of buildings;
• Outer soundproofing and thermo-insulation cladding of facade structures and other structural elements;
• Inner self-supporting partition walls;
• Permanent thermo-insulation formwork for monolith structures;
• Thermo-insulating, soundproofing and leveling layers for slabs and roof structures.

Simprolit monolith and its products are certified for application all over the Russian Federation territory and may be applied for all types of structures, considering that they fulfill the requirements of the following norms:

• СНиП II-3-79* "Thermo-technics in Civil engineering"
• СНиП II-12-77 "Noise protection"
• СНиП II-26-76 "Roofs"
• СНиП 3.04.01-87 "Isolating and finishing layers"
• СНиП 23-01 "Civil engineering climatology"
• СНиП standards for specific types of buildings and special structures
• СанПин 2.1.2.729-99 "Polymeric and polymer-composite building materials, products and structures. Ecological (hygienical) safety requirements"
• suitable fire-safety norms (НПБ)
• recommendations of НИИСФ РААСН about Simprolit monolith and Simprolit elements' application in the coldest climate regions of the Russian Federation.

According to the conclusions and the certificate issued by the Fire-safety Testing Center (ИЦ ПБ) "Pozpolitest", ANO, and the "Elektrosert" certification Simprolit falls into the category of non-flammable materials (group NG).

Using special water-repellent admixture as a component material made it possible to apply Simprolit in any type of building - either with dry,normal or humid regime of exploitation.

Simprolit monolith and Simprolit elements are produced and brought to the market according to the license agreement signed with the "SIMPRO HOLDINGS LTD".

Application of Simprolit

The above mentioned characteristics of Simprolit enable this type of polystyrene concrete to be applied not only as a thermo-insulation material but also as a permanent thermical formwork for different structural elements. Small weight of Simprolit polystyrene concrete, its good workability and presence of a cementitious "structural truss" (which serves not only as anticorrosion protection for steel rebars, but also takes part in the redistribution of structural influences within the structural element), makes it possible to apply Simprolit for design of various elements or parts of bearing structures, such as:

1. Roof thermo-insulation, both in monolith and in prefabricated variant.
2. Outer and inner sound- and thermo-insulation of walls, slabs and roof plates.
3. Building construction for various functions and various heights.
4. Adaptation and additional building.
5. Construction of houses and weekend cottages.
6. Production of elements varying their type and purpose:
   • blocks of different types and dimensions for inner and outer walls
   • facade thermo-insulation plates
   • partitions, waterproofing and floor plates
   • prefabricated and semi-prefabricated slabs and roof plates, etc.
7. Thermo-insulation of special buildings and structures:
   • covering plates for underground water reservoirs filled with drinking water or atmospheric water, for reversible water-supply systems, for shelters, breeding places, etc. In any case, Simprolit polystyrene concrete may be reinforced, consequently taking on some of the structural functions
   • collecting pools – accumulations as a part of complex heating plants, steam power plants, hydroelectric power stations and other power resources
   • pipe lines, fittings or other structures with complex form
8. Application in the state of emergency (earthquakes, floods, etc.) with the possibility to quickly start the production of elements at the site, which could drastically reduce the reparation work deadlines and consequently the building costs; also, the erected objects are not just a temporary solution, but permanent buildings suitable for settlement of endangered population.

GENERAL PROPERTIES OF SIMPROLIT POLYSTYRENE CONCRETE

• The requirements which Simprolit polystyrene concrete must fulfill are designed according to:
  ГОСТ Р 5263-99,
  ГОСТ 25192,
  ГОСТ 25820
  СТ СЭВ 1406,
  And also in accordance to Technical conditions ТУ 5741-003-52775561-2003 "Polystyrene concrete Simprolit and its products"
• The strength of Simprolit polystyrene concrete is defined as the compressive strength at the designed age:
  В0,5; В0,75;
  В1; В1,5;
  В2; В2,5.
• The strength of Simprolit polystyrene concrete used for elements which are not subjected to requirements of СТ СЭВ 1406, is defined as the compressive strength:
  М2; М2,5;
  М3,5; М5.
• The relation between concrete classes and grades of Simprolit polystyrene concrete according to the Russian standards, with normative variation coefficient equal to 18%, is given in the Table 1-1.

Table 1-1.

Concrete class (by strength)	Average concrete strengthR, (MPa)	Approximate grade of Simprolit polystyrene concrete (by strength)
В0,5	0,73	М7,5
В0,75	1,09	М10
В1,0	1,45	М15
В1,5	2,16	М20
В2,0	2,90	М25
В2,5	3,60	М35

• Using average density of the dry material as indicator, the following classes of Simprolit polystyrene concrete could be defined:
  D150,
  D200, D250, D300, D350, D400, D450,
  D500, D550, D600.
  D900, D1000 – special soundproofing sand-based Simprolit polystyrene concrete

CLASSES AND GRADES OF SIMPROLIT POLYSTYRENE CONCRETE

For Simprolit polystyrene concrete, which is applied for elements and structures subjected to cyclic freeze-thaw treatment during exploitation, the following frost resistance classes are defined: F25, F35, F50, F75, F100. The choice of necessary frost resistance class of Simprolit polystyrene concrete is made according to design requirements, class of building, exploitation regime and calculated outside air temperatures for the given climate region.

The classes and grades of Simprolit polystyrene concrete used for specific types of elements and structures are defined according to the standards or technical requirements for such elements or structures, taking into account the design normatives and values presented in the Table 1-2.

Table 1-2.

Concrete grade by strength)	Simprolit polystyrene concrete class (by compressive strength)	Density class of Simprolit polystyrene concrete	Frost resistance class of Simprolit polystyrene concrete
М2 М2,5 М3,5	- - -	D150 D200 D250	F25 - F35 F35 - F50 F35 - F75
М5	- В0,5 В0,75 В1,0 В1,5 В2,0 В2,5	D200 D250 D300 D350 D400 D500 D550, D600	F35 - F50 F35 - F50 F35 - F75 F35 - F75 F35 - F75 F50 - F100 F50 - F100

NORMATIVE AND CALCULATED STRENGTHS OF SIMPROLIT POLYSTYRENE CONCRETE

Normative and calculated strengths of Simprolit polystyrene concrete, which are necessary for calculation and design of structures, could be applied using values presented in the Tables 1-3.

Table 1-3.1

Type of load	Normative strength of Simprolit polystyrene concrete and calculated strength of Simprolit polystyrene concrete(in MPa), for the second group of limit states – classified by concrete classes
	М5	В0,5	В0,75	В1,0	В1,5	В2,0	В2,5
Axial compression (strength of prism) Rbn and Rb.ser	0,35	0,5	0,75	1,0	1,5	1,8	2,1
Axial tension Rbtn and Rbt,ser	0,12	0,15	0,21	0,26	0,3	0,32	0,35
Tension at flexure Rbtfn and Rbtf.ser	0,23	0,27	0,38	0,47	0,55	0,58	0,64

Table 1-3.2

Type of load	Calculated strength of Simprolit polystyrene concrete (in MPa), for the first group of limit states – classified by concrete classes
	М5	В0,5	В0,75	В1,0	В1,5	В2,0	В2,5
Axial compression (strength of prism) Rb	0,25	0,35	0,55	0,75	1,05	1,4	1,75
Axial tension Rbt	0,07	0,09	0,12	0,15	0,18	0,20	0,23
Tension at flexure Rbtfn and Rbtfn.ser	0,14	0,16	0,22	0,28	0,32	0,35	0,40

INITIAL ELASTICITY MODULUS OF SIMPROLIT POLYSTYRENE CONCRETE

Table 1-3.3

Simprolit polystyrene concrete class based on average density	Initial elasticity modulus of Simprolit polystyrene concrete at pressure and tension Ео x 10-3 МПа
	М5	В0,5	В0,75	В1,0	В1,5	В2,0	В2,5
D250	0,35	0,45	-	-	-	-	-
D300	0,40	0,50	0,60	-	-	-	-
D350	0,50	0,60	0,70	1,1	-	-	-
D400	-	0,70	0,80	1,2	1,3	-	-
D450	-	-	-	1,3	1,4	1,6	-
D500	-	-	-	-	1,45	1,7	1,9
D600	-	-	-	-	1,6	1,8	2,1

Factual average density of Simprolit polystyrene concrete should not be larger then the value required by the ГОСТ 27005 standard.

STRENGTH OF SIMPROLIT POLYSTYRENE CONCRETE SUBJECTED TO FLEXURAL TENSION

The flexural-tensile strength, depending on the class (grade) of Simprolit polystyrene concrete, should not be smaller then the values presented in the Table 1-4.

Table 1-4

Simprolit polystyrene concrete class or grade (defined by compressive strength)	Limit strength values of Simprolit polystyrene concrete subjected to flexural tension (MPa)
М2	0,08
М2,5	0,10
М3,5	0,15
В0,35	0,25
В0,5	0,35
В0,75	0,50
В1,0	0,60
В1,5	0,65
В2,0	0,70
В2,5	0,73

Depending on its function and exploitation conditions, Simprolit polystyrene concrete in structural elements and structures can possess compact, porous or large-porous (cavernous) structure, according to ГОСТ 25192 standard.

Simprolit polystyrene concrete with compact or porous structure and with cement quantity larger then 200 kg/m², guarantees steel reinforcement protection against corrosion in standard exploitation conditions.

THERMO--TECHNICAL PROPERTIES OF SIMPROLIT POLYSTYRENE CONCRETE

Thermo-technical properties of Simprolit polystyrene concrete, necessary for calculation of structural elements, could be taken from the Table 1-5.

Table 1-5

Simprolit class based on average density	Heat inertia, KJ/(kg °С)	Heat conductivity coefficient λ in dry condition, W/(m °С)	Calculated mass relation of humidity inside the material, (in %), for exploitation conditions		Calculated coefficients for exploitation conditions
					Heat conductivity, W/(m °С)		Steam permeability мg/(g·h·Pa) (А, B) )
			А	B	А	B
150	1,06	0,055	4	8	0,057	0,060	0,135
200	1,06	0,065	4	8	0,070	0,075	0,120
250	1,06	0,075	4	8	0,085	0,090	0,110
300	1,06	0,085	4	8	0,095	0,105	0,100
350	1,06	0,095	4	8	0,110	0,120	0,090
400	1,06	0,105	4	8	0,120	0,130	0,085
450	1,06	0,115	4	8	0,130	0,140	0,080
500	1,06	0,125	4	8	0,140	0,155	0,075
550	1,06	0,135	4	8	0,155	0,175	0,070
600	1,06	0,145	4	8	0,175	0,200	0,068

Settlement of Simprolit polystyrene concrete, applied for monolith outer walls construction, should not exceed 1,0 mm/m.

Heat conductivity coefficient of Simprolit polystyrene concrete in dry condition, at 25°С temperature, should not exceed the limits presented in the Table 1-6 for more then 10 % .

Table 1-6

Simprolit class based on average density	Heat conductivity coefficient in dry condition λ (W/m °С)
D150 D200 D250 D300 D350 D400 D450 D500 D550 D600	0,055 0,065 0,075 0,085 0,095 0,10 0,115 0,125 0,135 0,145

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