Saturday, November 18, 2017

Table of Contents for Mat-Vantage





Mat-Vantage

Best solutions

Innovative Civil Engineering Solutions Pvt Ltd designs and manufactures next generation building materials that address the growing demand for fast, efficient and sustainable construction methodology. CONSTRUCTION OPPORTUNITIES presents some of them:

ALC is the generic abbreviation for what is known in the industry as Autoclaved Aerated Lightweight Concrete. ALC incorporates features that have long been desired by architects, engineers and builders in the building materials they work with. It helps industry professionals who are on the lookout for materials which provide high overall standards vis a vis better energy efficiency, higher cost savings and better fire safety. ALC is the quintessential green building material. With a lower manufacturing impact on the environment, ALC is recyclable and known to have nil emission of gases during manufacture. It goes on to provide resistance to termites, water, fire and sound. ALC is the preferred choice due to these benefits. ALC comes with a huge variety as a finished product; from wall or roof panels to lintels or blocks, there is a form to suit most needs. It significantly outperforms conventional concrete blocks or poured concrete.

 

MANUFACTURING PROCESS:

ALC panels are normally made of silicon sand, cement, calcium lime, gypsum and small quantities of aluminium. Using steam and high pressure, numerous air holes are produced in the panel which is then reinforced with anti-corrosion steel bars. ALC blocks are also manufactured with the same process without the anti corrosion steel bars. By using computerised software to accurately control the production process which involves mixing the raw material, processing the anti-corrosive steel bars, organising the material into frames, pouring the paste, cutting, steaming, pressing and surface processing, this innovative building material’s impressive performance capabilities is augmented. This is paired with a stringent quality control process to optimise results.

 

Autoclave Treatment

When the forms are removed, the foam like material is stabile but soft enough to be wire cut. This can be done in pre-specified shapes of blocks or panels and then moved into the autoclave chamber for eight to fourteen hours. The final chemical hydro thermal reaction is initiated by the steam pressure process. At 180 Centigrade and a pressure of 12 bars, the quartz sand reacts with the calcium hydroxide to give by-product that gives ALC its high strength properties. Post autoclaving, the material has only to be shrink-wrapped in plastic to be ready for immediate delivery onto the construction site.

 

Post Processing

Based on customer requirements, decorative patterns can be made on the autoclaved panels post treatment.

Quality Inspection

All panels are subjected to strict quality checks prior to delivery to customers

 

BENEFITS:

 

Cost

Rapid installation and less construction manpower lead to lower costs when comparing ALC to traditional masonry technique or materials. An added advantage is a cleaner work environment and a smaller carbon footprint during construction.

 

Space

Compared to a double brick construction method the ALC panels easily generate more internal space with its panel thickness of 100 mm.

 

Weight

With a dry specific gravity of 0.5, ALC panels come in at a fourth of common concrete and third of hollow block. This translates into a substantially lower total weight for a building constructed with ALC panels meaning reduced costs for base and frame as well as reduced ground sill preparation. There is a noticed increase in build quality as well.

 

Acoustic Insulation

ALC panels exhibit good sound barrier ability. ALC wall panels greatly reduce external airborne sound transmission, certified by the Airborne Sound Insulation test. ALC floor panels reduce impact noise transmission and are certified by the Impact Sound Insulation test. These tests are carried out by TUV SUD PSB Pte Ltd based out of Singapore.

 

Fire Resistance

ALC panels possess excellent fire protection properties with a certified result of a four hour fire rating in the Fire Resistance Test. These tests are carried out by TUV SUD PSB Pte Ltd based out of Singapore.

 

BESTA WALL, FLOOR BOARDS AND PANELS:

"Besta board" is the trade name for the factory made Magnesium oxide (MgO) board.

Magnesium oxide, with a melting point of 2800 Centigrade, is often used as a basic refractory material for lining crucibles and furnaces. Its versatility has seen to it being used often in commercial and residential constructions. In addition to general building board uses, magnesium oxide has a higher fire rating, resistance to moulds and mildew and is relatively sound proof. A relatively new inorganic bonded composite, MgO boards are produced using an alkali-resistant fibre-glass mesh as a strengthening material.

Magnesium oxide derives its strength from the oxide bond. It is often used as a new age substitute for the traditional gypsum drywall, ceiling cover material or as sheathing. Magnesium oxide also finds use in construction applications like fascias, soffits, shaft-liner & area separation wall sheathing, and as tile backing (backer board) or substrates for coatings and insulated systems.

Available in various sizes and thickness, magnesium oxide boards are classified as a non paper covered material. Magnesium oxide boards are widely used in Asia as the primary construction material. It was designated as the 'official' construction specified material of the 2008 Summer Olympic Games. It was used extensively on the inside and outside of all the walls, fireproofing beams, and as the sub-floor sheathing in what was once the world's tallest building the Taipei 101.

 

Besta materials and manufacture

Besta boards are made as individual pieces that are cut to length as they are poured onto a casting tray. The initial set occurs horizontally.

However the final cure occurs vertically or with spacers between the sheets in the steam cure chamber. The Besta is cast in a liquid slurry-like form (a mixture of MgO2 powder, Magnesium ¬Chloride and other additives).

The cast boards are then cured at curing ¬chamber temperature. Besta Board is manufactured by combining the various minerals together with high strength fibrous reinforcements. Since Besta is manufactured from mineral components, it does not contain any organic solvent, asbestos, oil or toxic component, nor any heavy metal salts. No energy is consumed in the manufacturing process since the entire process is completed at room temperature. All manufacturing excess may be reground and reused for subsequent production.

Dust and sawdust may be safely buried in landfills; it is non-toxic and will not cause contamination to the surrounding areas or environmental damage. Besta fireproof boards have primarily been used as finishing materials to walls and ceilings in offices, shopping centre, private apartments, condominiums, airports, hotels, theatres, restaurants, private institutions, universities, schools, hospitals, sports complexes, stadiums, etc. Some patterned products have been selected and used as decorative boards.

Magnesium Oxide boards are primarily used as wall-board alternative to conventional gypsum-based drywall. The boards can be scored and snapped, sawed, drilled, and fastened to wood or steel framing. It can be used for interior or exterior applications. Magnesium oxide boards are a good example of the advances made in construction materials to meet changes in building codes for safety and durability.

 

Besta Application and history

Magnesium oxide boards can be used in the same ways as gypsum and portland cement sheathings in many applications. The substitution while not totally identical is very similar. Difference in terms of sheet thicknesses, fastening methods and joint treatments do exists at times. This makes Magnesium oxide boards an easy product to use. Some of it many uses are listed below :

Interior Wall and Ceiling Board

Exterior Sheathing

Trim Materials

Fascias

Soffits

Shaft-liner and area separation wall board

Tile backing (backer board) and underlayment

Substrates for coatings and insulated systems such as: Direct-Applied Finish Systems, EIFS, SIPS, Portland type Stucco and Synthetic Stuccos.

 

The modern use of Magnesium oxide to make sheathing panels goes back several decades. Magnesium oxide boards have been used in Asia and the Middle East on many large, world-class projects, particularly for partitions and fire walls. While the use of sheathing of this type is relatively new in the Indian market, it has a a long, successful track record elsewhere around the globe.Magnesium oxide boards come in various forms. The thinnest boards are about a quarter inch thick, while the thickest are about an inch. Sheet sizes are similar to those of drywall.Various surface finishes are available for these boards. Some are super smooth and can be painted as-is, while others are rougher and better suited for non-aesthetic purposes, such as structural sheathing or a tile backer board, or for the application of thick coatings. Magnesium oxide board is a "low-tech" and "energy-friendly" product. Carbon dioxide, attributed to causing global warming, is high on the list of "greenhouse" gases. Magnesium oxide production is simple, energy efficient, and produces few "greenhouse" gases. This aspect, from the standpoint of being a green or eco-friendly product, would indicate that Magnesium oxide based products have a promising future.

Besta boards are normally white in colour. Standard production material is very smooth on one side and sand textured on the other. Besta boards complement all paint types and may be wall-papered or tiled with ease. Standard edges are either squared or tapered. Special edges and sizes can be specified prior to the start of the manufacturing process. Besta Board may be cut, trimmed or shaped using basic power or hand tools.

 

BESTA SANDWICH PANEL

BestaTMSandwich Panel is a kind of new and superior non-combustible construction material with numerous application in commercial and residential projects of all kinds. It is a kind of revolutionary product which changes the way of traditional dry wall construction. It can save two third construction time, reduce 50 per cent of the total weight, and save 30 -40 per cent of the total construction cost. It provides a hard, long lasting surface that look and feel like hard cement plastering but is fireproof and resistant to damage from water, humidity, freezing, organisms, chlorine, salt and more. It is an excellent material for fireproof and sound proofing applications and the ideal wall panel for pool buildings, garages, kitchen and wet areas or any of the more demanding locations in buildings.

 

BESTA SANDWICH PANEL

BestaTMSandwich Panel is a kind of new and superior non-combustible construction material with numerous application in commercial and residential projects of all kinds.

It is a kind of revolutionary product which changes the way of traditional dry wall construction. It can save two third construction time, reduce 50 per cent of the total weight, and save 30 -40 per cent of the total construction cost. It provides a hard, long lasting surface that look and feel like hard cement plastering but is fireproof and resistant to damage from water, humidity, freezing, organisms, chlorine, salt and more. It is an excellent material for fireproof and sound proofing applications and the ideal wall panel for pool buildings, garages, kitchen and wet areas or any of the more demanding locations in buildings.

 

PERFORMANCE & PROPERTIES COMPARISION WITH DIFFERENT BOARDS

Parameters

BESTA Board

Calcium Silicate Board

Cement Board

BESTA Board Advantages

Basic Compounds Used

Natural Silicates, (MgO), (CaCo3), Wood Fiber or Glass Fiber

Wood chips, refined sand, cement, cellulose, Additives

Portland/Cement aggregate, water, additives, chemicals

Lightweight, non- flammable, natural minerals, inert & non-contaminating

Density

1100 kg/m3

1300 kg/m3

2700 kg/m3

Lighter weight for comparable strength, stronger & more rigid

Surface & Color

Uniform Smooth & consistent, Chalk white, sandy peach, slate grey

Off-whitish

Grayish

Selection of colors, smoother surface for receiving paint or left natural.

Thermal Conductivity

0.216 W/mK

0.35 W/mK

0.22 W/mK

More energy efficient

Bending Strength

15 N/mm2

Dry 29 N/mm2
Wet 17N/mm2

12N/mm2

Stronger & more flexible

Modulus of Elasticity

6045 N/mm2

6000 N/mm2

5500N/mm2

More rigid

Stability of thickness, swelling after 24hours in water

0.2% (Maximum even after 7 days)

0.78%

1.8% Cement Board – Malaysia
0.7% VirocBrad – Portugal

Moisture resistant, lower swelling rate, won't degrade in water over time.

Dry Shrinkage (heating & cooling when dry)

<0.08%

<0.09%

0.17%

Greater dimensional stability, resistance to cracking

Surface Alkalinity

PH between 10-12

PH 13

Ph 11-13

Relatively lower alkalinity

Moisture Content

10%

10%

12%

Relatively lower moisture content

Fire Resistance & Combustibility

Rated Class 1 through fire resistance Test (Non-Combustible)

Not Available
Not Rated

Not Available
Not Rated

Non- combustible, highly fire resistant, tested for fire rating to 1 hour with 12mm boards

Sound Attenuation

42 dB reduction with 10mm board both sides & 80mm mineral Rock infill, Total thickness is 100mm

Varies with brand, equal or lower depending on thickness

Significant Lower Performance

dB reduction increases using thicker wool & board

 




Leave a Comment

Name  
Email Address
(will not be published)    
Website
Comment