Water Proofing Solution, Thermal Insulation Construction Material Climate Control - Sinicon PP

  • Intro
  • Benefits
  • Applications
  • Properties
  • Guide
  • Packing
  • Plastering
  • Gallery
  • Contact

Sinicon PP - Intro:

What is Sinicon PP (Pratliperl) ?

It is a unique volcanic glass, a large deposit of which is found at only one location on the earth which is South Africa. Sinicon PP is made out of feed from this mines using patented manufacturing process to convert this volcanic glass into well-sealed tough glass granules which is ideally suited for use with cementitious and other binders.

''Although the climate changes naturally on its own, humans contribute heavily to pollution of the environment. Carbon dioxide emissions, the main greenhouse gas which causes climate change, actually come from the things that we do every day. More and more people are wondering how they can do their part to help reduce the emission of greenhouse gases into the atmosphere.

Sinicon would like to present Sinicon PP (Pratliperl), a product that would contribute to the reduction of green house gas emissions thus help improve our environment and make our world a better place to live, not just for us but for the future generations.''

The Sinicon PP Granule Structure

Under the microscope, each tough granules comprises a froth of glass-walled closed cells each enclosing a near vacuum. Sinicon PP is therefore best described as comprising millions of tiny sealed “thermos flasks”, making it an absolutely unique and unrivalled insulating and fireproofing material.

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Benefits

Highlights:

  • Controlled Climate Makes Living Comfortable.
  • Cool Interior During Summer And Warm Interior During Winter.
  • Saves Electricity Cost.
  • Makes Building Fire Proof And Heat Resistant.
  • No More Spalling Of Plaster And Concrete.
  • Vermin And Termite Resistant.
  • Better Acoustics Hence Good For High Traffic Area.
  • Less Finishing Cost.
  • A Direct Replacement For Sand.

Sinicon PP Plaster Benefits

1. Absolute climate control.

If plastered from inside or outside it protects from harsh weather entering the room. It retains the temperature inside during all weather like a Thermos Flask. No need of extra roofing to cover the building structure.

A 20mm plaster on inside wall would give a reduction in room temperature same as having a double clay bricks wall as shown in the picture.

A 20mm plaster on inside and outside wall would give a reduction in room temperature same as having a two double clay bricks wall as shown in the picture.

2. Large Scale Energy saving

The Thermal Conductivity i.e. ‘K’ value of Sinicon PP plaster 4.5:1, is as low as 0.13 and hence it does not allow heat to pass through it easily. Therefore, less or no air conditioning required thus saving lots of energy cost. 

Rate of Heat Exchange can be derived from:

Q in Joules = K a (Temp1 – Temp2) x t / L

W = Q/t = Ka (Temp1 – Temp2) / L

3. Durability of Structure

Sinicon PP is water resistant and hence does not easily allow water to enter into the structure hence the corrosion to the reinforcement is substantially reduced thus the life of the building is extended many times.

Ideal for plastering in areas where the moisture content is more.

4. Less Maintenance cost

Due to its reduced water permeability factors the painting lasts more than the wall plastered with conventional plastering.

5. Fire Protection

Sinicon PP does not react to the fire and hence the building structure becomes fire resistant and safe. A multi storied building is exposed to the risk of losing total building strength because a fire incident in one small area would affect the strength of the total structure.

(This means that if the steel structure in the World Trade Centre had Sinicon PP applied to it, people in the buildings would have had longer time to evacuate the buildings before collapse).

Less fire insurance premium - Since a fire in one area / apartment does not affect the strength of the building structure you may negotiate the fire premium.

6. No weather effect

No effect on the structure due to frequent changes in the weather i.e. rain/sun switching generally affects the conventional plastering and concrete but has no effect on Sinicon PP in plaster.  Substrate corrosion is substantially reduced and structure life is increased.

7. Amazing resistance to spalling

Under fire conditions and, more severely, under water quench conditions following extreme heat (e.g. from a fire hose of fire brigade) conventional concrete will spall and lose its integrity. Sinicon PP exhibits no such tendency and, following a fire, the material need not be replaced.

The two COMRO (Chamber of Mines Research Organisation) test tunnels for researching on deep mining have Sinicon PP linings which have endured thousands of high temperature test burns.

8. Light Weight

Being a light weight material the dead weight of a building can be considerably reduced and proportionately the structure size could also be reduced resulting reduction in overall project cost.

9. Less Finishing Cost

Sinicon PP gives the wall surface a very smooth finish thus the cost on applying putty can be substantially saved if not completely avoided.

10. Improved Acoustic Properties

Sinicon PP improve the acoustic properties of  the building reducing the unwanted noise from outside however, improving the interior sound conductivity. You can better enjoy music if plastered from inside.

Ideal for high traffic and noisy area construction.

11. Durable – Vermin and Termite Resistant

Being an inorganic material it is vermin and termite resistant hence cannot be rot, ensuring increased life of the structure and also the wooden fittings attached to it.

Applications

What are the applications of Sinicon PP ?

  • External and internal plastering.
  • Heat proofing/insulating roof decks.
  • Light weight concrete screed for metal roof.
  • Building up of floors.
  • Fire proofing of structures and Fire Seals.
  • Pre-Cast Items.
  • Cast Thermal Insulations.
  • Architectural applications.

Sinicon PP can also be used for other applications such as –

Building up of Floors

Sinicon PP could be used as a light weight material for the purpose of building floors. Example, Loftus Versfeld Stadium is having floors (9m x 7m) span built using GI sheet, Sinicon PP (Pratliperl) + Cement resting on 'I' Sections.

Fire Rated Walls

Sinicon PP + Cement Plaster mix has excellent fire rating properties and can be used in applications like Fire Rated Walls for Transformers, Passenger terminals at airports, chemical stores etc.

Note :  75mm thick panel with a density of 1000kg/CuM will have a fire resistance of atleast 4 hours, as a non load bearing element

Roof Screed

Sinicon PP is a very effective screed material to control heat as well as strengthen the roof structure.

Floor Screed

Sinicon PP can be used as a floor screed where the filling of floor or leveling of floor or heat resistance of floor is to be done.

Tiles

Sinicon PP + Cement mix Tiles are effective heat proofing solution for buildings when laid on top of roof as well as on walls.

In case of clay tiled roof designs, the clay tiles can be fitted over the Sinicon PP tiles to meet architectural requirement.

Architectural Purpose

Sinicon PP is a light weight material however, the granules are tough and strong hence it outsmarts the conventional light weight concrete. Thus, architects can better work with Sinicon PP to achieve their special requirements.

Properties

Overview

What are the major characteristics of Sinicon PP ?

  • A zero fire product.
  • It cannot be burned.
  • A zero fume product.
  • It does not release fume when fire applied.
  • A zero smoke product. Since it can not be burned it does not emanate smoke.
  • A light weight product.
  • A sand like product.

Fire Resistance Test Video

This video shows Sinicon PP's fire resistance capability. The test material is a tile made out of Sinicon PP and Cement.

What are the physical properties of Sinicon PP ?

  • Not flamable. It is safe to handle like sand.
  • Not explosive. It is safe to handle like sand.
  • Not hazardous to skin. Could be cleaned with water.
  • Not hazardous to eyes except abrasion. Washable with water.
  • Not hazardous to Ingestion however avoid ingestion. If consumed, drink 2 x 250 ml of water to dilute.
  • Not Toxic.
  • A Substitute for sand in plastering and other applications.

What are the material characteristics of Sinicon PP ?

1. Exceptional Fire Resistance

Melting temperature is 1250 Deg. C

Sinicon PP concrete can maintain its structural integrity at high temperatures due to its thermal insulating property. Thus it ensures a very high thermal gradient on the outer surface during fire conditions resulting in very low temperatures immediately below the  fire exposed surface. 

1.1a Fire/Heat Resistance Test

Large panels of 3m x 1m x 75mm, masses 102kg,  142kg and 182kg consisting of Sinicon PP aggregate with portland cement binder applied over “Spaceframe” reinforcing cage were tested for noncombustibility (SABS 0177 : Part 5), for suitability as transformer fire shield and for fire resistance, using standard time temperature mode.

1.1b Fire/Heat Resistance Test - Temperature Measurements

Measurement After 2 Hours

Furnace temperature  = 1050 Dec.C

Average temperature on cold face of panel after 2 hours fire exposure = 70 Deg.C.!

93% heat has been blocked.

Note: 75mm thick panel with a density of 1000kg / CuM will have a fire resistance of atleast 4 hours, as a non load bearing element.

1.2a Fire Exposure Test on Protected Steel Column

1.2b Fire Exposure Test on Protected Steel Column (After 2 Hours)

2. Compatibility with Portland Cement:

Sinicon PP has a well sealed tough structure. This prevents severe granule damage during mixing and facilitates low water absorption, hence proper curing of the cement. 

Note : The conventional Perlite based light concrete products are often friable and delicate with many fractured cells and looses whatever properties it has while mixing.

3. Superior Strength

Ultra lightweight concretes are generally weak and, in the case of aerated concrete, are extremely vulnerable to total slump shortly after casting, especially if any vibration or disturbance is present.

Sinicon PP concrete does not rely on air-entrainment and can be cured under any conditions of vibration. Once cured, the product exhibits surprising strength in comparison to other lightweight concretes.

Strength varies with density but practical strengths up to 23MPa can be easily achieved.

4. Excellent Thermal Insulator:

Very low thermal conductivity factor.

Loose

Sinicon PP : Cement  

4.5 : 1

Sinicon PP : Cement 

3 : 1

‘k’  Value (W/m Deg.C) 0.05 0.13 0.15
Note : ‘k’ value of conventional plaster : 0.72 W/m Deg.C

5. Light Weight

Loose Density = ≈100 kg/m³

Density when Mixed with Cement : (Sinicon PP : Cement)

Ratio 3 : 1    770 kg/m³
Ratio 4.5 : 1 670 kg/m³
Ratio 6 : 1 480 kg/m³
Ratio 10 : 1 360 kg/m³

Note : Sand + Cement (4:1) Mortar will have approx. 2000 kg/m³

6. Low Water Permeability

Sinicon PP when mixed with cement in the correct proportion, can be deemed to be completely watertight – without the use of any additives. Substrate corrosion is therefore substantially reduced.

7. Good Adhesion (in Plaster)

Sinicon PP when mixed with cement can be plastered (without the use of additives) to most common surfaces with good adhesion.

8. Zero Smoke and Zero Fumes

Due to inorganic structure “Sinicon PP” evolves zero smoke and zero fumes under fire conditions.

9. Vermin and Termite Resistant

Due to inorganic nature it is vermin and termite resistant and it cannot be rot.

10. Non-Toxic Dust

Dust is not healthy however, Sinicon PP, due to its amorphous (non-crystalline) structure has however been demonstrated to be a very low health risk dust.

Guide

Overview

SUITABILITY GUIDE OF SINICON PP
Note: Before selecting a mix, check structural design and properties.
Mix Ratio (by volume) Sinicon PP : Cement 3:1 4.5:1 6:1 10:1
TYPICAL PROPERTIES 1 Bag Sinicon PP (100L) + 1 Bag OPC (33L) 1.5 Bag Sinicon PP (150L) + 1 Bag   OPC (33L) 2 Bag Sinicon PP (200L) + 1 Bag   OPC (33L) 3.5 Bag Sinicon PP (350L) + 1 Bag    OPC (33L)
External Plaster * † x x
Internal Plaster * † x
Built-up Floors x x
Insulating roof decks x
Fire Seals
Castables
Spray Applications * x
Cast Thermal Insulation x x
† For improved fire resistance use 1 x 5kg bag "Pratliperl Fire Mix Additive"
 * For smooth substrate surfaces use "Pratley Plaster Grip Primer"
√ = Suitable
X = Not suitable
"OPC" = Ordinary Portland Cement

Packing

Product Packing

Regular Bag is 33 Ltrs. Regular Bag is 100 Ltrs. Information
Note : Equal to the volume of 1 No. of cement bag of 50 kg. Note : Equal to the volume of 3 Nos. of cement bags of 50 kg. This is the economy packing size. Note : Mix information is printed on the bag.

Plastering

Overview

Plastering Methods

Check Suitability Guide for suitable mix ratio.

Plaster Mix Ratio 3 : 1 - 

Jumbo Bag

1 X 100Ltr Sinicon PP Jumbo Bag

33Ltr (50Kg) Cement

Note : Sand is not required in the Sinicon PP Plaster.

Plaster Mix Ratio 4.5 : 1 - 

Jumbo Bag

1.5 X 100Ltr Sinicon PP Jumbo Bag

33Ltr (50Kg) Cement

Note : Sand is not required in the Sinicon PP Plaster.

How to Mix Sinicon PP Sinicon PP with Cement

All the principles of good concrete practice apply to Sinicon PP mixes.

1. Equipment

A mechanical means of mixing is suggested. A pan mixer is preferable as a drum mixer tends to make balls. If this equipment is not available, manual mixing with shovels is acceptable.

As Sinicon PP is a non-absorbent volcanic glass, water will not be absorbed into the material. The use of a sealed, leakproof container is therefore recommended to prevent leaching of the required amount of water.

2. Mixing Instructions

Mix Sinicon PP and cement in a dry state first (a little water may be used to dampen slightly in order to suppress dust).

Add the correct amount of water (refer to ‘Mix design and suitability guide’ – and note that the water is given in litres per 100 litres of Sinicon PP!). The product may appear very dry, especially if hand-mixed, but this is correct. It is important to monitor the amount of water added since small differences in water content have a large effect on overall consistency and slump.

Mix, but do not overdo mixing time – about 30 seconds in a pan mixer is all that is required (longer mixing entrains too much air).

3. Yield

Approximately 11 bags of Sinicon PP will be required for each cubic metre of concrete/plaster to be mixed (cement and water will be added to this quantity of Sinicon PP.) This applies to all mixes mentioned in the mix design and suitability guide.

4. Gunnite and Loose-fill

Sinicon PP concrete may also be gunnited. Because air velocities are used than for ordinary gunniting procedures, the rebound is lower. A further advantage is that the rebound can be re-used.

Sinicon PP can also be used as a loose-fill (without cement) to fill cavities for thermal insulation purposes.

Surface Preparation for Plastering

Splash water on the surface to be plastered and make it wet and cool.

If surface is very smooth apply Plaster Grip Primer. (After applying the plaster grip primer, plastering can be done on any kind of smooth surface. (You can plaster on Glass!).

For plastering on roof top of the existing / old buildings. Surface preparation is very important. Remove fungus and dirt by way of scraping the surface by wire brush to ensure good adhesion for the new Sinicon PP cement plaster. You may also apply plaster grip primer if surface is very smooth.

Plastering

Push apply the plaster on the wall or roof. It need not be thrown on the surface like conventional plastering.

Leave rough applied plaster to dry and mature for some time; say 5-10 minutes. The Plaster must be set prior to leveling with straight edge. However depending upon the cement variation in some cases it can be done instantly.

Check whether plaster is set by applying thump pressure and it should be difficult to cause an indentation on the plaster surface.

If plaster is set Level the plaster with the straight edge. Note that if the straight edge is applied prematurely, it will cause the plaster to de-bond from the wall like conventional plaster.

Float finish the surface with Wood Float with little water splashed on with a brush, and then by using the steel trowel to give the surface a very smooth finish.

Ensure surface is well done with the Steel Trowel so that there is no porous holes on the plaster surface in order that  putty application may be avoided.

Curing Methods

Standard method being adopted for conventional cement plaster is sufficient.

The surface must be kept moist for the first 14 days while curing.

Sufficient wetting of the plastered surface is required so as to allow for the setting of cement over a period of time to achieve the required strength.

Gallery

Contact

M/S. Konkraft Enterprises™

Admin - +91 72002 28883
Email: info@konkraft.in
Regd. Address:
No.133, MIG NH1,       
Vallal Nalliyakodan Street,
Maraimalai Nagar,
Kancheepuram Dst,
Chennai – 603209.

M/S. Konkraft Enterprises™

Services - +91 81483 99165
Email: enquiry@konkraft.in
Our Address:
W-54, IIIrd Main Road,
Anna Nagar,
Chennai – 600 040,

(Opp. to Anna Tower Main Entrance).



 
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