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New Palusol Generation

Palusol® fire-protection panels are classified as non-combustible building material. In case of fire, the silicate panel expands under the action of heat with generation of foaming pressure. The non-combustible, heat-insulating and pressureresistant foam formed prevents fire and smoke from spreading to other rooms for a given period of time by filling joints and gaps.

Presentation held at the Palusol Celebration September 22/ 23, 2016.
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New Palusol Generation

  1. 1. New Palusol® Generation Chemistry of silicate based passive fire protection materials BASF SE | Ludwigshafen | Andreas Bolz | Performance Material
  2. 2. Intumescent Materials The 3 fundamental product types 222.09.2016 Silicate – based products (Palusol®) Sodium-Silicate split off water vapor at >100C and begins to foam, developing of a non-combustible, rigid, heat-insulating and pressure resistant foam. Graphite – based products (Exterdens®) Graphite, the natural foaming raw material, expands at >150/200C its volume, developing of a combustible, flexible, heat-insulating and low pressure resistant foam. Phosphate – based products (Interdens®) Complex reaction of Phosphate with other ingredients at >250 C with the evolution of gases (blowing agent), forms a high volume, soft and compressible, heat-insulating foam.
  3. 3.  At temperatures above 100C split off water vapor which act as a blowing agent  Palusol starts foaming a pressure-resistant non-combustible foam, that seals gaps and joints and prevents fire and smoke from spreading to other rooms  The endothermic energy absorbing reaction develops a cooling effect due to the evaporating water How Palusol works 2 mm 12 mm Characteristics of Palusol®  made from hydrated sodium silicate  since 1966 offered in form of sheets, which are usually converted into strips for edge sealing  since 2005 also available in form of pre-fabricated sandwich panels About the product Sheets SW panelsBrand 322.09.2016
  4. 4. Research & Development Targets 422.09.2016 Different Products Different Application Different Properties
  5. 5. Properties for Intumescent Materials Relevant parameters for passive fire protection products 522.09.2016 Palusol Foaming Factor Intumescent Pressure High Temperature Stability Process Capability Material Brittleness/Flexibility Water & CO2 Resistance
  6. 6. Specified Technical Data of Palusol Properties specified in the new ETA-15/0345 622.09.2016 Typ 100 Typ 104 Panel Thickness [mm] 1,9 ± 0,4 3,6 ± 0,6 Density [kg/m²] 3,0 ± 0,75 5,8 ± 1,5 Residue On Ignition (ROI) [kg/m²] 1,5 - 2,2 kg/m² 3,0 - 4,2 kg/m² Foaming Factor 5,0 - 9,5 5,0 - 9,5 Intumescent Pressure [N/mm²] 0,95 - 1,60 0,95 - 1,60 Water Content [%] 25 - 40 25 - 40 Fire Behavior accord. to EN 13501-1 A2-s1,d0 A2-s1,d0
  7. 7. Approaches for New Silicate based Intumescent Materials 722.09.2016 Manufacturing Method of Water Glass Lithium PotassiumSodium Modules Composites Gelling Agent Other AdditivesBlowing Agent 𝑀𝑜𝑑𝑢𝑙 = 𝑆𝑖𝑂2 𝑀2 𝑂 SiO2= Quartz Sand M=Li, Na, K Alkali Oxide Silicon Dioxide
  8. 8. Silicate Chemistry Basics and challenges 822.09.2016  The silicate structure is very complex  The more substances are used the more complex the crystal lattice a) Silicon b) Quartz Sand c) Alkali Silicate Glass
  9. 9. Silicate Chemistry Gelling process from the water glass solution 922.09.2016  Cross-linking through polycondensation by splitting off water Warning: Reverse reaction possible – hydrolysis / water solubility  After stabilization alkali silicates can be deformed through mechanical load Warning: “Cold Flow”
  10. 10. Silicate Chemistry Degradation reaction of unprotected Palusol® sheets 1022.09.2016  The higher the carbon dioxide content the more silicic acid can be split off, the worse the foaming behavior becomes in the fire resistance applications Warning: The Epoxy resin coating must be applied to protect the material from exposure to moisture and carbon dioxide Na4SiO4 + 2 CO2+ 2 H2O Si(OH)4 + 2 Na2CO3 2 H2O + SiO2 Blooming Effect: Sand & Soda do not foam t, T, CO2
  11. 11. Targets for New Palusol Generation Foaming factor 1122.09.2016  Double of foam height  Optimized foam cell structure  Higher flexibility of the sheets 0 2 4 6 8 10 12 14 16 18 ? +100% ? Palusol NewPalusol 100 5 - 8,5
  12. 12. Targets for New Palusol Generation Reduced intumescent pressure 1222.09.2016  Reduced foaming pressure by approx. 30%  Rigid foam stability as usual 0,0 0,5 1,0 1,5 2,0 -30% ? Palusol New ? Palusol 100 0,95 – 1,45
  13. 13. Target for New Palusol Generation Increased temperature stability 1322.09.2016 40 min; 1000 °C Before After Evaluation Scale:  Reduction ≤ 33%  High temperature stability  Reduction 33% to 66%  Medium temperature stability  Reduction ≥ 66%  Low temperature stability
  14. 14. Many Thanks For Your Attention ! 1422.09.2016

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