Issuu on Google+


info@conceptorro.com

TABLE OF CONTENTS Products Description…......................................................................................................................3 Introduction...................................................................................................................................3 Descriptive…..................................................................................................................................4 Gazbeton Specifications……..........................................................................................................5 Benefits……............................................................................................................................................6 Environmental Impact –at plant…................................................................................................7 Comparison Light-Weight Cellular Concretes…...........................................................................8 Economic Efficiency……….............................................................................................................9 Technologies Overview ....................................................................................................................10 Non-Autoclave Peoner Gazbeton................................................................................................10 Gazbeton Panels…….....................................................................................................................11 Gazbeton Masonry Blocks…........................................................................................................12 Dry Mortars…...............................................................................................................................12 Light-Weight Steel Frame Elements………..................................................................................13 Outside Reinforcing Multi-Lay….................................................................................................16 List of Products..…………………...........................................................................................................17 Sequence of Application of the New System…………………..........................................................18 Construction of Walls…………………………....................................................................................18 Gazbeton filling of Walls….…………………….................................................................................20 Construction of Horizontal Slabs….............................................................................................20 Art and Decoration…….....................................................................................................................22 Peoner Technology Production Line…….....................................................................................23 Housing Crisis Solutions……..........................................................................................................24 Notes……..…………………………………………………………………………………………………………26

Page 2


info@conceptorro.com

PRODUCTS DESCRIPTION INTRODUCTION At the present time light steel frame construction (LSF) is recognized worldwide as an advanced construction system, reducing both building time and material costs. The core element of our system is the creation of a bearing structure (walls, slabs and other building elements) by the use of customized light steel galvanized profile frame (0.8 – 2 mm thickness), which is surrounded by a monolithic lightweight cellular concrete wall (non-autoclave Gazbeton). The LSF constitutes a backbone of the structure, adding to and reinforcing even further the lightweight cellular concrete building wall envelope. This combination and application of non-autoclave aerated Gazbeton as the single monolithic material to the building steel frame provides for a new, affordable, unique and practical construction model. It maintains all the benefits and advantages of LSF construction systems (short construction period, low cost) while adding the benefits of high thermo-insulation properties at low cost, long range durability, high structural strength, intense fire resistance and high acoustic proofing, that come with the use of Gazbeton. Many market surveys found that the main buyer’s reason not to opt for light steel frame housing is what is referred to as the “empty wall” effect, not only for its acoustic flaws, but its perception as a “knock-through” main wall. Our development of light concrete provides property developers with a new low cost opportunity to secure the buyers looking for “strong concrete walls” and to tap into new market segments. The technology and process was developed, implemented and successfully operated since 2007 by PEONER at its production facilities in Belarus. The new system has a direct financial impact since it avoids, in most cases, the use of insulation material or of additional or expensive cement-fibre, calcium-silicate or wooden boards, used for siding. The low cost aerated light concrete panels play both the role of siding panels and structural material. This system regroups all the qualities and benefits that most architectural concepts are aiming at: simple, functional, durable, effective, ecological, antiseismic and economic. The PEONER proprietary technology of non-autoclave aerated Gazbeton has also resulted in the development of different mixes and recipes, providing for the easy and low cost production of products to be sold in the form of pre-mix dry formulas (Dry mix) or as multipurpose light masonry blocks, wall and floor panels and other light precast materials, dry mortars, plasters, grouts and glues, etc. The new system can be used for large construction projects of private, civil and industrial buildings with heights up to four levels (floors), without the use of an additional reinforcing structure. It can Page 3


info@conceptorro.com

also be used in high-rise building construction in combination with a dense concrete structure; for low-bearing or non-bearing items like floors, dividing walls, outside walls, and for other similar purposes. The non-autoclave aerated Gazbeton has a wide range of applications and will be in high demand among consultancies and construction companies. DESCRIPTIVE The use of scientific nano-technological innovation and the selection of high-quality raw materials gave an opportunity to achieve an absolutely new non-autoclave, water and moisture resistant Gazbeton. Its specifications surpass all available types of lightweight concretes (including autoclave aerated concrete) and exceeds the requirements of existing British, European and North-America Standards for lightweight cellular concretes (strength, dry density, thermal conductivity, fire resistance). PEONER Gazbeton has also the unique capacity to be produced and delivered as dry mix and mixed with water at the construction sites and pumped to place in heavy liquid form, just like any other semi-liquid concrete, to fill the space in between the wall panels. It penetrates into all small gaps and cracks. The product expands in volume by 2 to 3 times (depending on the mix's target dry density) over 40 to 60 minutes, resulting in the light cellular concrete mass required. PEONER Gazbeton block-panels (ref: Drawing 1) are fixed to the assembled light steel frame with screws from both sides. The block-panels can be made with a width and dry density (from 300 to 600 kg/m³) to fit general building requirements (thermo insulation, acoustic proofing, etc.). Vertical and horizontal lines of block-panels rapidly fill in the gaps with a special adhesive, making the connection hermetic and preventing any potential thermal bridges. The gap between inside and outside block-panels is then filled with the same lightweight cellular concrete, with typical dry density in the 200 – 400 kg/m3 range (higher if required) after expansion and curing. Gazbeton block-panels are produced at a local plant and delivered to the construction sites after cutting them to size. The creation of PEONER Gazbeton monolithic concrete walls around an LSF structure (with the steel frame completely inside the concrete envelope) improves the strength and resistance of the building, extends the LSF durability, in addition to many other benefits already mentioned. The LSF specs and design are adaptable and designed for the project and calculated for bearing all possible loads over the building’s life.

Page 4


info@conceptorro.com

1

4 2 3

1.

Light concrete panel

2.

Self-rising cellular concrete

3.

Light steel profile

4.

Light concrete panel

In order to give harness and resistance to outside walls, the panels are covered with a reinforcing lay, provided also for finishing. Drawing 1: Section view of construction built with LSF and PEONER non-autoclave Gazbeton

GAZBETON SPECIFICATIONS Compressing Strength Grade

2.5 – 3.0 with Dry Density D400, D500

(Possibility to produce with different strength/ 3.5 – 4.0 with Dry Density D600 dry density ratio) Material Discharge rate

500 kg/m³

Watering Ratio

3.51 of water per 10 kg of Dry Mix

Temperature of application

+5 to +30˚ C

Temperature of usage

-70 to +100˚ C

Live period of mixture

20 minutes

Walking on top of the material

After 12 hours

Full curing time (possibility of usage)

28 days for bearing walls and elements

(Depends on temperature and density)

7 days for floor pavements and roofs

Absorbed moisture

4.2%

Adhesion to concrete surface

0.51Mpa

Bending resistance strength

0.5Mpa

Breaking resistance strength

2Mpa or 200N/cm²

Linear temperature extension ratio

8*10 – 6*1/k

Steam penetration ratio

Not less than 0.1mg/m*h*Pa

Efficient activity of natural radio nuclides

108Bk/kg

Color

Grey Page 5


info@conceptorro.com

BENEFITS Constructions using Gazbeton are extremely energy efficient in either very hot or extremely cold climates. Thermal conductivity is 0.11 W/m*K, which is ten times more than dense concrete. This means a significant reduction in energy consumption. There is no need for expensive, inefficient and energy hungry autoclaves for PEONER Gazbeton production and no loss ratio associated with autoclave pressure cracking. Material costs can be further reduced by replacing sand with industrial ashes or slag. The main and inevitable advantage of the Dry Mix is the fast and simple application directly at the construction sites, which can be performed by non-qualified staff. The use of common concrete pumps for delivery of the mixture up to a 30 m height makes the process of application easy and doesn’t require special machines and equipment. The process of drying and acquiring strength is similar to common concrete ready mix. Gazbeton has the ability to let air pass, whilst filtering toxic heavy metals, such as cadmium and chromium. It means that a building, constructed from Gazbeton will behave like wooden building, with the ability to reduce the radioactivity level and to filter hazardous pollution from the air. There is no wastage in the Gazbeton production process; used and crashed Gazbeton can be easily recycled into new production. Gazbeton does not include any active substance or chemical. It is chemically inert and doesn’t react with water or any environmental element. 

Low thermal conductivity (not more than 0.11 w/mK at 400 kg/m³ density)



High sound-proof/acoustic property (40 dB)



High compressive strength (up to 4.0 – 5.0 N/mm² at 600 kg/m³



High fire resistance



Low moisture absorption (3-4%)



Can be easily sawed, nailed, drilled with common tools



Does not include any active material (like lime) and is completely neutral does not react with water or air)



The tested durability is more than 100 years (summer-winter cycles).

Page 6


info@conceptorro.com

ENVIRONMENTAL IMPACT – at plant A B C D E F

Expected impact on people, buildings and manmade structures Expected impact on plants, animals Expected impact on land Solid non-hazardous waste/hazardous waste Expected impact on water Wastewater, drainage and surface runoff

No Impact No Impact No Impact No Waste No Impact

Source and nature

Water wastage after cleaning of mixing units

Volumes

Not more than 800 L/day

Methods of treatment/control

Collection of used water for re-usage

Final disposal site/method

Two artificial wells for water treatment

Expected impacts on air quality G

Source and nature of air emissions Quantities

Cement and sand dust

Methods of treatment/control

Not substantial Dust control system will consist of an extraction system complete with suction blower, cyclone, dust collector for collecting dust from all probable points in the plant. Capacity approx. 8000 m³/H Air cleaning ratio: 99%

Final discharge

Door of the dust collector should be opened periodically, tray with dust to be taken out, dust will be re-used in manufacturing process and tray is to be put back in position and door closed.

Monitoring/modelling of air emissions

H

I J K

The cleaning of the filters is done with the help of compressed air shacking arrangement. For that purpose an air receiving tank is provided on the topside of the dust collector, which supplies air with pressure to shake the filters

Identity and quantify noise and vibration source (in dBA)

It not substantial

Public environment (outdoors)

Sound: 80-90 dBA; Vibration: ±5 dBA

Working environment (indoors) Toxic and Hazardous Materials Explosives Radioactive materials

No No No

Page 7


info@conceptorro.com

COMPARISON LIGHT-WEIGHT CELLULAR CONCRETES CONCRETES

Aeration Method No Autoclave

Autoclave

No Autoclave

Materials properties Cement

Cement, Lime

Cement

Filler (Sand, Ashes or Slag)

Aluminium Powder

Filler (Sand or Ashes or Slag)

Non-active chemical additive Carbon emission, Reacts with Special Foam substance (2-4%) Eco-friendly, Non- water Eco-friendly, Non-active, active, Zero pollution, Zero emission Zero pollution, Zero emission

Structure Strong Structure, Closed Cells

Strong Structure, Open Cells Absorbs Water and Moisture

Low Strength structure, Closed Cells

Application Universal, In-situ, Simple process, No special equipment, Casting slabs In-situ, Architectural forms

Special, Blocks Only, Insulation required, No Slabs and Panels, Transportation from factory

Special, needs special equipment and skills, Limited length of slabs and panels, Low strength, re-bars need

Durability Increasing Strength with time

Page 8

Maximum 15 years (Usually much less, especially with high humidity)

Average


info@conceptorro.com

ECONOMIC EFFICIENCY: Construction of Buildings (average prices) Brick Building

Concrete Slabs Building

Gazbeton Building

Page 9


info@conceptorro.com

TECHNOLOGIES OVERVIEW NON-AUTOCLAVE PEONER GAZBETON PEONER Gazbeton is a unique lightweight cellular concrete material, which allows for making blockpanels and internal filling, multipurpose light masonry blocks, wall and floor panels and other light precast materials. The initial industrial production of Gazbeton was made by the “O.O.O. PEONER Construction Company” in Belarus. The material and its successive improvements passed through complete government testing and certification procedures and were certified for commercial production under the PEONER (ПИОНЕР) brand. When PEONER Gazbeton is poured, it expands and fills the receiving space (between panels or in moulds) homogeneously and gives uniform dry density, strength and properties throughout; naturally integrating itself at the micro level with the panels having material of the same nature, resulting in a reduced dead weight, monolithic and uniform concrete construction. 1. Light steel profile 2. Self-rising cellular concrete

1

3

3. Light concrete panel

3

2

Photo 1: The cellular concrete self-expand Page 10


info@conceptorro.com

Building structures erected using non-autoclave Gazbeton benefit from the following product properties: Gazbeton Panels Non-autoclave light-weight cellular concrete cubic blocks are cut into panels of the required dimensions for delivery to building sites (Photos 2, 3 and 4 below)

Photo 2: Production of Gazbeton panels

Photo 3: Sawing machine cutting Gazbeton cube into panels Page 11


info@conceptorro.com

Photo 4: ready-made Gazbeton panels at construction site

Gazbeton Masonry Blocks Gazbeton masonry blocks have different sizes and specifications. They meet existing BS and DIN standards and have better specifications than other lightweight concrete blocks available in the market (e.g.: AAC blocks). These masonry blocks don’t have any equivalents worldwide in terms of technical specifications, economic indicators and ecological approach. The masonry blocks are produced by casting Gazbeton in large cubes and then cutting to the desired size with special automatic sawing machine. After that step, blocks are palletized and are ready for delivery to the construction site. Dry Mortars They differ from other products available (e.g.: expensive polymer based products) by their higher strength, plasticity, adhesion, freeze-thaw durability and ease of application. They are also more ecological and some (like glues) have a low discharge rate. The Peoner thermo-insulating plasters have no comparable in the market and we expect these plasters to be in high demand for both the renovation and the new construction market. These mortars, plasters and glues are the end-products offering the highest margins from the producer’s point of view. They are made using the base nanogazbeton with additives (sand, stones, gypsum, polymers, etc.); there are more than 30 different formulas and mix preparations.

Page 12


info@conceptorro.com

Lightweight steel frame elements Lightweight steel material, well known and widely used in the construction industry worldwide, is used for setting-up the shape and structural base of the building, under the proposed construction method. The dimensions and thickness of galvanised steel profiles are calculated in accordance with each project’s specifications.

The LSF are made from extruded profiles and given the desired construction design. The size and specs of metal frames will vary and are made to order – resulting into a wide choice of profiles. Reliability of the profiles is also dependent on the extruder used – we are recommending Howick equipment. It is up to the engineers involved with your building project to design the type of profile that suits the proposed design and meets the required specifications. With Howick profiles, industry standards are largely met if not exceeded. For example, the 65 mm section in 1.2 mm material has the advantage of being capable of load-bearing and can be part of the buildings structure. There are several buildings of 11 floors using it. Amount of framing per tonne (Illustration) Section Size (m)

Material thickness (mm)

Meters per Tonne

63.5

0.55

1485

63.5

0.75

1090

63.5

0.95

860

75

0.55

1385

75

0.75

1015

75

0.95

800

89

0.55

1285

89

0.75

940

89

0.95

740

Page 13


info@conceptorro.com

Traditional steel framed drywall systems are built with light gauge stud and track profiles, which are supplied in lengths and cut to size on site. The assembler has to measure and place each piece accurately to ensure the wall is straight and the window and door openings are plumb and square. In the production process, Howick framing machines remove the waste and inaccuracies from building steel frame walls. The machine which produces wall panel steel, provides framing components in a fully finished state ready to assemble, including inkjet marking and recessed screw holes. The benefits are: 

Swaged to fit studs with location dimples and recessed screw holes giving flush walls with no steps of protruding screw heads.



omponents finished ready to assemble.



No cutting or waste on site



Lipped top and bottom track add rigidity to the frame.



Door and window openings are accurately sized.



Panels can be made on a Just in Time basis.



Reduced on-Site labour and skill requirements.



Holes can be pre punched in position for services removing the need to manually create the holes.

Page 14


info@conceptorro.com

Lightweight steel profiles frame, as assembled and shown in Photos below, before and after fixing the Gazbeton panels.

Photo 5: The light-weight steel frame.

Photo 6: The light-weight steel frame with Gazbeton panels Galvanized profile manufacturers claim an open air material life span of 100 years for their products. Our building system, providing the steel structure to become embedded inside the lightweight concrete, without exposure to outside air and moisture, the lifetime of the steel frame can only substantially extend. Page 15


info@conceptorro.com

Outside Reinforcing Multi-lay Typically, with our system, the external finishing will be in the form of an adhesive-based reinforcing compound applied on a fibreglass mesh as support. A decorative plaster will cover the compound. Such external finishing provides protection from mechanical impacts and an elegant finish. The photo below shows a magnified view of such external finishing and illustrates the reinforcing adhesive, the fibreglass mesh, and decorative plaster. The finishing lay can be replaced with any cladding, siding or any other finishing variant which will protect the Gazbeton from direct mechanical impacts. 1. Plaster finishing 2. Reinforcing adhesive 1

3. Fiberglass mesh 4. Reinforcing adhesive

2 3 4

Photo: Sample of multi-layer external finishing.

Page 16


info@conceptorro.com

LIST OF PRODUCTS Dry Mix Masonry Blocks Dry Mortars Glues

For PEONER nano-gazbeton production

Nano-modified construction mortars KP-1E For Ceramic Tiles - Indoor KP-1 For Ceramic Tiles - Indoor & Outdoor KP-2 /(KP-2B) For tiles - Excessive fixation ability, hydrophobic. Indoor & Outdoor - Application in high humidity KP-3 / (KP-3B) For Tiles - High Plasticity. Frost Resistant. Indoor & Outdoor - Application in high humidity KP-7X For Tiles - Chemical Resistance KP-9 For tiling of rugged base with floor ceramic tiles. Indoor & Outdoor KU-4 (KU-4M-Anti Frost) Universal. For fixing of thermo-insulation and creation of reinforced lay. Indoor & Outdoor KU-5 For fixing of building thermo-insulation. Indoor & Outdoor KU-6 (KU-6M-Anti Frost) For fixing of bricks, Gazbeton and ceramic masonry blocks. Indoor & Outdoor KG-8 For GRP fixing. Indoor F-1 (F-1B) Elastic, hydrophobic, anti-fungal. Indoor & Outdoor Fx-3 Chemical Resistant

Plasters

Sh.T-1 (Sh.T-1M – Anti frost) For levelling of surfaces Indoor & Outdoor Sh.T-2 (Sh.T-2B) Polymer-mineral, with “coat” decorative structure. Stone diameter is 1mm. Indoor & Outdoor Sh.T-3 (Sh.T-3B) Polymer-mineral, with “bark beetle” decorative structure. Stone diameter is 2mm. Indoor & Outdoor Sh.T-4 (Sh.T-4B) Polymer-mineral, with “stony” decorative structure. Stone diameter is 2mm. Indoor & Outdoor Sh.T-5 (Sh.T-5B) Polymer-mineral, with variable decorative surface. Indoor & Outdoor ShT-6 Insulation plaster - Indoor & Outdoor Sh.TG-7 Gypsum based for hand application. Indoor.

Floor Screeds Hydroinsulating Repair mortars

Sh.TG-8 Gypsum based for machine application. Indoor. Sh.T-9 Polymeric with “coat” decorative structure. Stone diameter is 1mm. Indoor & Outdoor. Sh.T-10 Polymeric with “bark beetle” decorative structure. Stone diameter is 2 or 3mm. Indoor & Outdoor. Sh.T-11 Polymeric, mosaic. Indoor & Outdoor. CN-1 Thin-lay, Polymer-Cement, 2-10mm. Inside application incl. floor with heating. CG-3 Thick-lay, gypsum, 10-50mm. Indoor including floor with heating. HI-1 Coating, for units without water pressuring. For Indoor & Outdoor HI-2 Plastering, with high elasticity, for units under dynamic loads and water pressure. For Indoor & Outdoor application. Sh.S-1 For primary surfaces levelling. For Indoor & Outdoor application. Sh.F-2 (Sh.F-2B) Finishing. Grey. Indoor. Sh.G-3 Gypsum. White. Indoor. Page 17


info@conceptorro.com

SEQUENCES OF APPLICATION OF THE NEW SYSTEM CONSTRUCTION OF WALLS

1. Cleaning the surface of the foundation concrete.

2. Preparation of tools and equipment.

3. Assembling of the frame with light gauge steel profiles in accordance with description manual

4. Fixing of Gazbeton panels to steel profiles with fixing screws.

Page 18


info@conceptorro.com

5. Filling gaps and closing connections hermetically with adhesive.

6. In addition to being fixed to steel profiles with screws, panels are joined together with adhesive, providing hermetic connection.

7. Panels should be carefully levelled after fixing.

8. Any part of the panel can be easily cut and adjusted on-site with ordinary saw.

Page 19


info@conceptorro.com

4.1 GAZBETON FILLING OF WALLS

The Gazbeton is confined with water in a mixer and pumped into the space in between of inside and outside panels. After expansion and drying of Gazbeton, further portions of Gazbeton are poured on top until the Gazbeton fills the inside wall volume completely.

4.2 CONSTRUCTION OF HORIZONTAL SLABS

On the left, fixing of block-panels to horizontal elements of steel frame with screws. All gaps and connections again should be filled with adhesives.

On the right, fixed panels shoring temporarily Page 20


info@conceptorro.com

3. Reinforcing steel mesh is put on top of horizontal panels

4. 10-15cm Gazbeton lay is casted on top block panels and steel mesh

5. Gazbeton is pumped on top and is leveled to the top steel edge after. Page 21


info@conceptorro.com

ART AND DECORATION

The Peoner Dry Mix is ideal for making special indoor & outdoor art and decoration. It can be applied for facades as well, providing for a light and strong material, easy to install.

Page 22


info@conceptorro.com

PEONER TECHNOLOGY PRODUCTION LINE

Page 23


info@conceptorro.com

PEONER Gazbeton is the solution to the world housing crisis

Having a safe shelter is a basic human need denied to 1 out of 5 people of the global population. A report to the United Nations in 2005 stated that there were an estimated 100 million homeless people in the world, and an additional 1.6 billion living without adequate housing. Today, that number has not declined.

Page 24


info@conceptorro.com

NOTES

Page 25


info@conceptorro.com

NOTES

Page 26


info@conceptorro.com

NOTES

Page 27



GAZBETON BROCHURE