Perlite lightweight insulating aggregate for sustainable...
Transcript of Perlite lightweight insulating aggregate for sustainable...
Perlite lightweight insulating aggregate for sustainable BUILDING APPLICATIONS
Member of
GULF PERLITE CONSTRUCT® for lightweight concrete / floor and roof fills / blocks / pre-cast panels
NATURAL INSULATION FOR YOUR BUILDING
GULF PERLITE PLASTER® for fireproofing and thermal insulation plasters
GULF PERLITE® for masonry loose fill insulation & gypsum-boards
100% natural mineral. Neutral pH. Asbestos-free
Ultra lightweight aggregate
Superior thermal and acoustic insulation
Fire resistance up to 4 hours. Non-combustible
Substantial savings in energy consumption and
construction costs
Excellent workability
PERLITE APPLICATIONS:During the last 70 years Expanded Perlite has been utilized in countless commercial applications in Europe, in the USA and worldwide, such as:
In the Construction Industry, as a lightweight thermal and sound insulation aggregate for roof and floor fills and walls, blocks, panels, plasters, mortars, gypsum boards, etc.
In Agriculture, as a medium for hydroponics, soil preparation for flowers or crops, landscaping and gardening.
In Industrial Applications, for cryogenic insulation, for storage/transportation of liquefied industrial gases, for absorption of industrial/hazardous liquids in contaminated areas, for filtering drinks, in metallurgy, etc.
2 - 5mm 0.5 - 3mm 0 - 1mm
GRANULOMETRIES OF EXPANDED PERLITE
Perlite is a 100% natural volcanic glass mineral formed by the sudden cooling and solidification of volcanic ash, which traps crystalline water into its mass. Perlite’s most important natural property is the ability to expand when rapidly heated in temperatures of 800°C – 950°C.
The abrupt, controlled rise of temperature when we heat perlite, causes the formation of white minuscule glass bubbles. Perlite melts and expands in an extremely porous surface and increasing its volume (between 4 and 20 times), which in turn results in superior thermal insulation and sound proofing properties, as well as an extreme lightness (weights 32-240 kg/m3). As a volcanic glass Perlite is non–flammable. These characteristics, make perlite an ECO-CLEAN product.
What is Perlite?
Expanded Perlite with grain sizes 0,5-3mm, mixed with cement, sand and water along with lubrication additives, is the best value–for-money LIGHTWEIGT INSULATING CONCRETE for high resistance substrates, like filling floors and roofs.
ULTRA LIGHTWEIGHT
Density from 320 Kgs/m3, the lightest of all lightweight concretes.
Common cement 10cm screed of 100sq.m weighs 19-22 tons. Perlite concretein contrast weighs just 3.2-14.4 tons. Perlite reduces by 50% the dead load of buildings, thus saving substantially on concrete and steel when structurally designing a building.
8 MPa for floor fills, i.e. up to 5 times higher than foam concrete (1.62 MPa) and up to 21.5MPa using special additives.
Perlite forms a firm, monolithic surface, free from flaking and cracks, ready to apply in four days the final floor marble/ceramic tiles or waterproofing.
SUPERIOR THERMAL INSULATION
Thermal conductivity value from λ10=0.07 W/mK. Perlite gives 20 times more insulation power than ordinary concrete, reducing thermal losses from/to upper/lower floors and the costs of cooling/heating.Replaces polystyrene insulation on roofs, saving money and construction time.
NON-FLAMABLE / NON-COMBUSTIBLE
Up to 4-hours fire resistance rating.
REDUCES AIRBORNE AND IMPACT SOUND
Perlite provides cavities within the screed system giving better sound insulation properties at any given levels of mass/unit area values.
Sound reduction coeff. Rw = 65dB.
EASY WORKABILITY
Easy to handle because of its low weight. Reduces labor costs.One instant construction phase for up to 15cm thickness.Job-mixed or transit mixed, and then poured or easily pumped into place, reducing cost of placement. Productivity at more than 300 m2/day.Perlite Concrete can be nailed, sawed and worked with carpentry tools.Mixes with 36% to 43% less water than other aggregates.Perlite Screed dries within 4 days and is ready to glue marble / ceramic tiles.
ROBUST & DURABLE NATURAL MINERAL
Neutral pH, chemically inert odorless.Asbestos - free, free of weeds and bacteria.Environmentally friendly natural mineral that lasts for a lifetime.
HIGH COMPRESSIVE STRENGTH
GULF PERLITE CONSTRUCT© for FLOOR and ROOF FILLS
Step 1: Clean from dust and spray with water the floor’s or roof’s surface.Step 2: Apply a 5mm (floors) or a 20–25mm (roofs) expansion joint in the perimeter using bulk expanded Perlite.Step 3: Mark level using laser levels and install aluminum straight edges, as when applying the Cement Mortar.Step 4: First mix Cement with water and admixtures until a slurry is formed. Add the Perlite and mix manually or using a mixer for 3-4min. Add as water as necessary to produce a mix with required density. Use a pump to deliver daily a substrate of 300-400m².Step 5: Apply Perlite Screed in a continuous operation until a section is completed, exactly as when applying the cement screed. Construct the screed on site in temperatures between 4oC to 40oC, like the common concrete. If fill’s width is up to 15 cm, apply the Perlite Concrete in one phase. For higher thickness, apply in two phases (after 2–3 hours within the same day).Step 6: Level the Perlite Concrete when screeding it using an aluminum straight edge.Step 7: Separate large surfaces using construction joints in distances up to 3.5 meters on both directions, to avoid expansion cracks.Step 8: The next day scratch on both directions the Perlite Concrete’s surface with an aluminum line scratcher to clean it and level it. Use a small scratcher for the corners. Spray with water.Step 9: After 3-4 days, when it dries, spray Perlite Concrete’s surface with water and an admixture (optionally) and glue directly on it marble or ceramic tiles or apply water insulation, like bitumen.
PERLITE LIGHTWEIGHT CONCRETE FOR ROOF FILLS
Perlite lightweight concrete Mix Designs, Technical Properties and Consumptions
Perlite lightweight concrete floor fills and roof fills construction:
Air entraining agent; Neutralized vinsol resin or other entrainment agent. Follow manufacturer's recommendations.
"Roof fills tests: Impartial laboratory test data of Robert W. Hunt Co. Engrs under sponsorship of the Perlite institute. Strength data based on ASTM Type I Portland Cement.Floor fills tests: Al Hotty Laboratories, UAE. Admixtures (BASF, K_screed, etc) are used to increase compressive strength."
First mix well Cement with water, sand, admixtures, bentonite and air entraining agent, until a slurry is formed. Add the Perlite and mix manually or using a mixer for 3-4 minutes. Add as water as necessary to produce a mix with the required density. Measure concrete's density to check if mixing is correct.
Consumption of Perlite may be increased due to overmixing (up to +30%), power pumping (up to +20%) or compacting on site. If concrete's density is higher than the required, adjust mixing and pumping parameters.
Cement to Aggregate
Ratio (by vol.)
Cement (Kgs)
Perlite (m3)
Water (m3)
Air Entraining Agent (l)
Wet Density Range
(Kg/m3)
Dry Density Range
(Kg/m3)
Compressive Strength
Range (MPa)
Thermal Conductivity
(W/mK)
Mix designs Technical propertiesMax. Consumption of
Perlite for 1 m2 of Perlite fill (m3) width (mm)
1/4
1/5
1/6
1/8
375
300
250
190
1
1
1
1
0.30
0.29
0.27
0.27
808 +/- 48
728 +/- 48
648 +/- 48
584 +/- 48
544-640
448-544
384-448
320-384
2.413-3.447
1.585-2.344
0.965-1.378
0.552-0.861
0.10-0.12
0.09-.010
0.08-0.09
0.07-0.08
2
2
2
2
40 50 60 80 100 150
0.048 0.060 0.072 0.096 0.120 0.180
PERLITE LIGHTWEIGHT CONCRETE FOR FLOOR FILLS
Cement to Aggregate
Ratio (by vol.)
Cement (Kgs)
Perlite (m3)
0-5mm SAND (m3)
Water (m3)
Bentonite (Kgs)
Air Entraining Agent (l)
Wet Density Range (Kg/m3)
Dry Density Range
(Kg/m3)
Compressive Strength Range
(MPa)
Thermal Conductivity
(W/mK)
Mix designs Technical propertiesMax. Consumption of
Perlite for 1 m2 of Perlite screed (m3) width (mm)
1/4.5
1/5
1/6
1/4.5
1/5
1/6
330
300
250
330
300
250
0.5
0.5
0.5
0.75
0.75
0.75
0.5
0.5
0.5
0.25
0.25
0.25
0.30
0.30
0.30
0.30
0.30
0.30
1,800+/-100
1,700+/-100
1,600+/-100
1,300+/-100
1,200+/-100
1,100+/-100
1,750+/-100
1,650+/-100
1,550+/-100
1,250+/-100
1,150+/-100
1,050+/-100
13.00-14.00
11.00-13.00
8.50-10.00
7.50-10.00
7.00-9.00
5.00-8.00
0.60
0.55
0.50
0.35
0.28
0.20
40
0.022
0.033
50
0.028
0.041
60
0.033
0.050
80
0.044
0.066
100
0.055
0.083
150
0.083
0.124
4
4
4
4
4
4
2
2
2
2
2
2
Perlite Concrete application
GULF PERLITE construct LOOSE - FILL insulationPerlite is used to loose-fill double block walls as a thermal and sound insulating, water and fire–proofing and last-for-a-lifetime natural mineral. Perlite flows and fills completely the double wall, covers all the gaps and offers full protection, avoiding ‘thermal bridges’ that appear when polystyrene is used.
Leveling, screeding and final surface of Perlite concrete in a villa project in Abu Dhabi
Heat transmission coefficience λ10 = 0.038kcal/m2hoC, Perlite is 22% more effective than EPS inserts, 12% than EPS beads, 7% than foam and 6% than vermiculite.
Sound reduction coefficience Rw = 57dB.
4-hours fire resistance rating.
Asbestos-free, pH neutral, non-smelling, eco-friendly.
Perlite cost is one third that of polystyrene
GULF PERLITE PLASTER©Perlite plasters consist of a blend of GULF PERLITE PLASTER expanded Perlite aggregate and neat gypsum or Portland cement mixed with water. Apply by gun or trowel to wall or ceiling surfaces or to metal wire or gypsum lath, for structural steel membrane fireproofing of up to 5 hours. (Excellent results based on more than 50 lab tests). Weight 60% less than ordinary sand plaster, saving
1 ton over 60m2 of plaster.
4 times more heat transmission resistant than sand plaster (λ=0.0833Kcal/mh°C), saving on heating and air–conditioning costs.
Up to four–hour of fire resistance.
Reduces sound transmission between partitions.
Absorbs big quantity of water vapor (up to 1Kg/m2 for 1cm width), ideal to apply in indoor swimming pools, gyms, bathrooms, laundries, etc.
GULF PERLITE PLASTER with grain sizes 0-15mm is produced under special specifications to be used by manufacturers of ready mortar and plaster-mortar. To make Portland cement Perlite plaster, mix the required amount of water and air entraining agent in the mixer followed by the cement, and mix until slurry is formed. Add proper amount of Gulf Perlite Plaster to the slurry and mix until required wet density is reached.
Perlite constitutes an excellent component for producing thermal insulating GYPSUM BOARDS, PERLITE BLOCKS, PERLITE PRECAST PANELS, insulating aggregate for under-floor heating/cooling systems, and chimney liners.
UV and water-proof BAGS (100 liter) and JUMBO BAGS (1,000 liter) of GULF PERLITE CONSTRUCT®, GULF PERLITE PLASTER® and GULF PERLITE® for special applications are available.
Constructional Perlite Packaging
Choose Constructional Perlite
Choose Natural…
Modern Bioclimatic Architecture seeks natural and neutral products to improve buildings’ functions and to reduce their environmental footprint. Expanded Perlite as a natural mineral meets the highest of engineering standards and delivers exceptional thermal and sound insulation on floors, roofs and walls. Perlite adds value to construction, it reduces maintenance costs and offers an insulated, quiet and user-friendly living environment.
and enhance cost efficiency and construction quality
By prescribing Perlite in a building's specifications, engineers and consultants can deliver extensive savings in concrete, steel and air-conditioning. Perlite screed offers a robust, natural, environmentally friendly and economical solution.
Our Factory
Gulf Perlite LLC delivers superior quality perlite from its brand new, state-of-the-art perlite expansion factory in Technopark, Jebel Ali. We only process pure European perlite ore under continuous laboratory monitoring for cryogenic, constructional and hydroponics applications.
Member of Perlite Institute Inc.
The Big 5 DubaiDubai – UAE
Eco ConstructAbu Dhabi - UAE
The Big 5 Saudi Jeddah – KSA
The Big Show Muscat - Oman
RECENT PERLITE PROJECTS
Lightweight Perlite filling, Abu Dhabi Financial Centre, Sowwah square Abu Dhabi. Applicator: Abu Dhabi Ready Mix.
Perlite Concrete sound insulating floor fills, Sofitel Hotel in Dubai. Contractor: ALEC.
Perlite Concrete thermal and sound insulating floor fills, Palazzo Versace in Dubai. Contractor: Macair.
Roof fill with thermal insulating lightweight Perlite concrete in Abu Dhabi Airport, Abu Dhabi, UAE. Contractor: ALEC.
Olympic Village in Athens, Greece.
New Athens Airport ‘Eleftherios Venizelos’, Greece Contractor: Hochtief.
Perlite lightweight concrete floor fills in New Dubai Police Head Quarters.
Contractor: City Engineering & Contracting.
Perlite lightweight Concrete roof and floor fills, Villas complex in Abu Dhabi. Contractor: Aremtraco
Exit 13
Exit 13
DIP Roundabout
DE
WA
P
ower
Sta
tion
Abu Dhabi
Emirates RoadTr
uck
Roa
dA
bu D
habi
Sheik Zayed Rd
Sun C
ool
Baker &
Hughes
Chabros
Danube
FurnitureP
an Em
irates
Gulf Perlite LLC factory’s location map
Dubai Sheik Zayed Rd
JAFZA, Gate 7 & 8
Free zone South
Mattex
Mega Carpet
Al B
adda
d ho
ldin
gs
P.O.Box: 263275
Techno Park, Freezone SOUTH, Jebel AliExit 13, Sheikh Zayed Road,Dubai U.A.E Ph: +971 56 123 5248 +971 52 979 5006Email: [email protected]: www.uaeperlite.com www.gulfperlite.ae