Simprolit three-layer plates (SUP) and Simprolit single-layer plates (SOP)
for facade insulation
BASIC PROPERTIES
Simprolit insulation plate - is a composite product
consisting of styrofoam, cement and special admixtures and it represents
a part of Simprolit system for facade thermo-insulation.
Simprolit plates are easy to work with, they are characterized
by excellent adhesion between composite layers, having also good frost-resistance
(a structure made of Simprolit SUP plates prevents joints from freezing),
as well as exceptional high temperature resistance. All these facts
are very important for the complete durability of a thermally insulated
facade in any climate region (it is a well known fact that the temperature
measured on the facade surface could amount to 80°C, depending on its
color and rate of exposure to the direct sun light).
Simprolit plates are mostly applied for facade thermoinsulation
of already constructed buildings.
Also, Simprolit plates may be applied as an intermediate
layer between concrete and formwork, acting as a thermal protection
of concrete facade walls, beams and columns. After dismounting of the
formwork, concrete elements protected with Simprolit plates may be plastered
immediately, or just skimmed without additional reinforcement or "rabic"
netting.
Application of Simprolit plates in upper floors and
attics construction is also very practical. Namely, these plates can
be used as both thermo-insulation and suspended ceiling plates, which
could be just skimmed with cement paste mixed with fine sand, or with
cement-based glue right after mounting. Upon request, they may also
be plastered using a thin (3-5 mm) layer of cement-lime plaster, or
just primed and painted.
The application of Simprolit plates as a part of Simprolit
system for facade thermo-insulation brings significant work and cost
reduction, no matter if it is a reconstructed or new facade.
Simprolit system for facade thermo-insulation
Simprolit system represents a system for thermo-insulation of
existing and new buildings that satisfies a whole spectrum of engineering
physics' requirements, such as: thermo-insulation, steam permeability,
fire resistance, impact resistance, strength, resistance to extreme
climate conditions and durability (unequaled by other similar materials).
Simprolit system consists of following elements:
-
Simprolit single-layer plates (SOP);
-
Simprolit three-layer plates (SUP);
-
Simprolit fireproof barriers (SPPR);
-
connecting elements (glue, plugs);
-
strengthening elements (angle profiles);
-
reinforcing elements (glass-plastic net);
-
covering elements (skimming or thin plastering);
-
finishing elements (facade coating).
Except the above-mentioned elements, upon special
design request it is also possible to produce other decorative elements
(such as crowns, arches, ornaments, etc.) based on Simprolit polystyrene
concrete.
Each of the above listed elements has a specific
function in the Simprolit system, based on its physical-mechanical
properties. For instance:
- SOP plates are usually used for thermo-insulation of the
plinths, around facade elements (crowns, arches, etc.), for
edge surfaces of facade openings, but also for strengthening
of building's corners, facade decoration and so on.
- SUP plates are mostly applied as economical and good quality
elements for facade thermo-insulation. Besides, they are successfully
used for facade covering of panel structures, as a permanent
solution for tight-sealed facade panel joints.
- Simprolit fireproof barriers (SPPR) are fire-resistant strips
made of Simprolit monolith or Simprolit single-layer plates
coated with cement plaster or glue (5 mm thick). They are usually
installed around facade openings or at places where the facade
thermoinsulation approaches the fire non-resistant roof structure.
If there is a high risk of fire, SPPR plates could be placed
at each slab level around the whole building, in accordance
to the design and fireproofing regulations.
- The basic purpose of connecting elements is to fasten Simprolit
plates to the wall, but also to fulfill other requirements defined
by the Simprolit system, such as: steam permeability, frost
resistance, fire resistance, durability, etc. Connecting elements
include: cement-based glue, plastic plugs with special pegs
made of self-extinguishing ABS plastic, plugs with metal or
stone pegs (if so determined by the design and fireproofing
regulations concerning high fire risk buildings) and bolts.
All these elements must have appropriate quality certificates.
- Strength of Simprolit plates (and especially SOP plates)
has no match between analog products. If the designer decides
it, facade elements can be strengthened at certain places using
Simprolit plates, especially at building's corners that may
be subjected to impact. Strengthening elements also include
"Г" profiles made of perforated aluminium or galvanized sheets.
Lately, there are new materials, such as glass-plastic, applied
for production of these elements.
- Basic function of plaster reinforcement is to avoid crack
appearance. The cracks may occur at different parts of the thermo-insulation
layer: at the plate joints, around facade openings, at the junctions
between thermoinsulation and facade ornaments, at different
materials' intersection, or as a result of too quick drying
of the plaster layer. Normally, a glass-plastic net is used
as the reinforcement, but additional metal "rabic" net may also
be applied as a special protection against vandalism.
- Basic function of the plaster layer is to protect the surface
of Simprolit plates from mechanical influences by strengthening
the outer layer of a plate. Simprolit system does not require
a thick plaster layer; on the contrary, instead of applying
a 3-5 mm cement-lime plaster layer, Simprolit plates could be
skimmed using just cement paste mixed with fine sand or standard
ceramic-tile glue. If the thermo-insulation layer has no openings
for steam conduction, the final plaster layer must be steam-permeable
(for this purpose, standard cement-lime plaster may be applied,
as well as ordinary steam-permeable cement based glue).
- Basic function of the finishing layer – facade coating -
is to protect the thermally insulated facade from the atmospheric
influences, especially from the rain. The choice of the material
to be applied as the finishing coat depends only on its steam
permeability and moisture resistance.
Comparison with other thermo-insulation systems
When compared to other widely spread thermo-insulation
systems using so called "effective" plates (three-layered panels
made of styrofoam, mineral wool, etc.), insulation with Simprolit
system has many advantages, such as:
- cost-effectiveness: production complexity and production costs,
together with installation costs of Simprolit system elements
are between 25 – 50% smaller then the costs of other similar
materials. Simprolit plates are produced in dimensions and weights
that are very convenient for installation. The fact that Simprolit
system does not require smooth wall surfaces for installation
(which is the basic condition in other systems, especially for
thermo-insulation with mineral wool which requires a hard and
flat wall surface) also represents a particular advantage. This
becomes even more obvious if we add that very often a contractor
spends up to 3 times more glue or plaster then necessary (according
to the producer's instructions) in order to level the walls
of an old building prior to installation of the new thermo-insulation.
- steam permeability: is an exceptionally important advantage
of the Simprolit system. Namely, a wall insulated by Simprolit
system can "breathe", which significantly improves the ecological
conditions during the exploitation of the building. This is
achieved on account of balanced conditions of moisture distribution
through the layers of the thermally insulated facade and the
final result are more comfortable living conditions. On the
other hand, thermo-insulation systems using mineral wool or
styrofoam are based on application of polymer-cement, which
is a material with a high coefficient of steam-permeability
resistance. As a result, a large amount of steam remains inside
the thermo-insulation layer (and it is a known fact that mineral
wool, with just 1% humidity increment, loses almost 20% of its
thermo-insulation ability; also, mineral wool has particular
ability to absorb water which in time dissolves mineral salts
forming extremely aggressive solutions -consequently causing
corrosion of metal connecting elements);
- exploitation stability: the fact that the temperature at a
facade wall surface could reach even 80°C (depending on its
position and facade color) is often forgotten by thermoinsulation
system designers. This has a negative influence on any heterogeneous
facade thermo-insulation system, significantly reducing its
durability. For instance, when subjected to the temperature
higher then 70°C styrofoam starts to dry out and evaporate.
At the same temperature, there is usually crack appearance between
the styrofoam plates, i.e. in the area of mineral wool fireproofing
joints;
- durability: good steam permeability, no condensation effect,
homogeny of the system and moisture resistance have direct influence
on durability of the applied thermoinsulation system. Lately,
there is an increased number of scientific papers and studies
on this subject. According to these papers, the durability of
standard mineral wool is limited to 30 years, whereas the pure
styrofoam (depending on the place and method of its installation)
may last for no more then 20 years. On the other hand, Simprolit
system showed satisfactory results after 50-years durability
test, and currently there is a 100-and-more-years test running;
- ecological cleanliness: problem of mineral wool's aging is
a well known fact - due to increased moisture content and oxidation
processes in time mineral wool becomes needle-like dust which
is extremely health hazardous. On the other hand, when subjected
to the same conditions high-class styrofoam may also produce
harmful substances, especially when a low-quality production
material or inadequate technological process is applied. Sanitary-epidemiological
testing of Simprolit plates showed the presence of only 3 harmful
substances (among 20 possible), and these 3 were found in minor
quantities which were up to ten or more times smaller then allowed.
- strength: strength and mechanical impact resistance of Simprolit
thermo-insulation system elements are much better then the same
properties of analogue materials.
- fire resistance: according to the testing results of the Russian
Ministry of Defense Research Center, after 90 minutes of fire-resistance
testing of 110 mm thick 3-layer Simprolit panel (the middle
layer was made of 30 mm thick styrofoam), at maximum temperature
of 1000°C, limit state of integrity loss and thermo-insulation
ability loss did not occur .
- working with standard materials: existing thermoinsulation
systems usually need a special polymer plaster to be applied
over styrofoam or mineral wool plates, as well as special finishing
materials, special technological procedures and consequently
special work crews. On the other hand, Simprolit plates can
be plastered using standard procedures, applying standard cement-lime
plaster with just 3-5 mm thickness. Also, they can be just skimmed
with cement paste containing fine sand or with steam permeable
cement-based glue.
- possibility of previous preparation: Simprolit plates can
be previously prepared and adopted so that the finishing may
follow right after their mounting to the facade (some of the
operations such as grounding and skimming may be partially done
before mounting of the plates).
Dimensions and types of Simprolit plates
Simprolit plates are produced in standard dimensions
length 1000 mm, width 750 mm and various thicknesses: 30 mm, 50
mm, 80 mm, 100 mm, 120 mm and 150 mm. Upon request, plates with
other dimensions may also be produced.
Dimensions of standard Simprolit plates are defined
in accordance to the following criteria: optimum weight of the elements
during mounting process, structural relation between width and length
of elements being 3:4 - which reduces the deformation of plates,
simple manipulation, proximity to standard spans with minimum dispersion
(for example, for thermo-insulation of attics the plates could be
built in between the roof beams almost with no waste of the material).
Principally, 2 types of Simprolit plates are produced:
- Simprolit "SOP" single-layer plates and
- Simprolit "SUP" three-layer plates.
SOP - Simprolit single-layer plates are completely
produced using Simprolit monolith of class D 350. In comparison
with three-layer Simprolit plates, the single-layer plates have
lesser thermo-insulation ability, but on the other hand larger strength,
steam permeability, fire resistance and impact resistance. In accordance
to that, Simprolit single-layer plates are used for thermo-insulation
of plinths, staircases, buildings' corners, around window and door
facade openings, as well as at other appropriate places. Because
of all the above stated facts, Simprolit SOP plates represent an
important part of the Simprolit facade thermo-insulation system.
Simprolit single-layer SOP plates are produced
without folds, in one of six standard types: "SOP3"; "SOP5"; "SOP8";
"SOP10"; "SOP12" and "SOP15", were SOP stands for Simprolit single-layer
plate, and numbers (3,5,...15) represent the plate thickness in
cm (for instance: SOP5 stands for 5 cm thick Simprolit single-layer
plate).
SUP - Simprolit three-layer thermo-insulation plates
Comparing thermical properties - heat transfer
coefficient (K) and heat transfer resistance coefficient (R) of
Simprolit SUP plates with thermically equivalent full and hollow
bricks, the conclusion can be derived that 31 cm thick full-brick
wall can be replaced with 3 cm Simprolit plate (SUP3), and 218 cm
thick full-brick wall can be replaced with 15 cm Simprolit plate
(SUP15).
The middle layer of three-layer Simprolit SUP
plates consists of styrofoam with 12-15 kg/m3 density, and outer
layers are made of 10 mm thick Simprolit polystyrene concrete -class
D300.
Simprolit thermo-insulation plates are produced
in two kinds (with or without folds) and in many various types (thicknesses).
Simprolit facade thermo-insulation plates with
folds (SUP) are produced in following standard types:
- "SUP5" - 5 cm thick Simprolit thermo-insulation plates with
folds;
- "SUP8" - 8 cm thick Simprolit thermo-insulation plates with
folds;
- "SUP10" - 10 cm thick Simprolit thermo-insulation plates with
folds;
- "SUP12" - 12 cm thick Simprolit thermo-insulation plates with
folds;
- "SUP15" - 15 cm thick Simprolit thermo-insulation plates with
folds.
Simprolit facade thermo-insulation plates without
folds (SUP_r) are produced in following standard types:
- "SUP3r" - 3 cm thick Simprolit thermo-insulation plates without
folds;
- "SUP5r" - 5 cm thick Simprolit thermo-insulation plates without
folds;
- "SUP8r" - 8 cm thick Simprolit thermo-insulation plates without
folds;
- "SUP10r" - 10 cm thick Simprolit thermo-insulation plates
without folds;
- "SUP12r" - 12 cm thick Simprolit thermo-insulation plates
without folds;
- "SUP 15r" - 15 cm thick Simprolit thermo-insulation plates
without folds.