POLY PANEL SPECIFICATIONS.

PANEL SPECIFICATIONS
Advanced building system
1
POLYSTYRENE
INDUSTRIES
LIMITED
• Resistance • Thermal Insulation • Energy Saving • Fast Installation

w w w . P o l y i n d u s t r i e s . c o m . n g
1. INTRODUCTION
The purposed of this Technical Manual is to provide
guidance and direction for the most suitable method to
install the PIL Building System, in accordance with an
acceptable design.
These pages will enable the erection of buildings having
standard features using panels and other elements that
are normally employed in the PIL Building System. For
more complex uses, the system must be addressed in a
specific design.
1Plot 416, Idu Industrial Layout, Phase 1, Abuja, Nigeria | Tel: +234 9 2916411 | Email: info@polyindustries.com.ng | Website: www.polyindustries.com.ng
This panel is shaped from a foam polystyrene
block according to the design requirements,
coated with two layers of steel wire mesh and
assembled with electro-welded steel wires.
The stairs panel is suitable to be reinforced
and finished with casting at site. It also
accommodates external finishing such as
traditional plaster, tiles or other material
extremely well.
specific design.

2.1 FUNDAMENTALS OF THE PIL SYSTEM
The PIL construction system is based on a series of
polystyrene panels and galvanized steel wire
meshes. The shape has been especially designed
for the introduction of traditional or structural plaster
during on-site panel installations.
PIL provides a system of industrialized modular
panels allowing for faster assembly than
conventional systems. The PIL system fulfils the
required structural and load-bearing functions,
a) Electro-welded steel wire meshes made
of galvanized drawn steel wires placed
on both sides of the polystyrene panel
and connected by means of joints of the
same material. The wire gauge steel net
varies according to panel type and mesh
direction.
2.3 PLASTERING
After the panel assembly, structural
2. DESCRIPTION OF THE PIL SYSTEM
required structural and load-bearing functions,
offering high thermal and sound resistance and a
wide range of shapes and finishes to provide
versatility in the design compaction process.
2.2 COMPOSITION OF THE PIL PANELS
The following are the basic components:
a) A foam polystyrene core which is non-toxic, non-
hazardous, self-extinguishing and chemically inert
with varying density and thickness depending on
panel type.
After the panel assembly, structural
plaster should be sprayed and/or poured
on the panel-depending on panel type.

A. Versatility & diversity of panels to accommodate
differential architecture and design features.
B. High heat/cold and sound resistance
C. Easy to move, rapid assembly with little or no need
for lifting equipment and high durability
D. Structural capacity and resistance to earthquakes
and hurricanes
E. No skilled labour is required
M. Solid panel connection
N. Panel surface and PIL plastering machines are
especially designed for a smooth plaster
spraying
O. PIL panel meshes also include connection
flanges
P. The polystyrene core can avoid the thermal
bridge
3. ADVANTAGES OF THE PIL SYSTEM
F. Lower cost and erection time
G. Lower foundations costs compared with traditional
systems
H. Full utilization within the same building system
I. PIL system well integrates with traditional systems
J. Highly fire-proof material
K. Easy and rapid installation of the plumbing, heating,
electric, telephone systems, etc.
L. Panels, of customised length and thickness
Q. PIL panel does not change following exposure
to weather conditions
R. Ecological in all its parts

The PIL panels, applications, standard sized and
complementary products are described below.
The panel thickness and the length of the panels
may be customized, according to the different
project requirements and customer’s demands.
Initially, the thickness of a panel is determined
primarily according to its different conditions of
heat insulation and required structural behaviour.
4. CLASSIFICATION OF THE PIL PRODUCTS
Single Panel PSM/PST
Double Panel PSM/PST
Floor Panel
Staircase Panel
A greater moment of inertia may be achieved by
increasing spacing between the two concreted or
plastered surfaces,
The typical insulation of polystyrene is for a
finished panel of 4 in. thickness with 2 in. thick
polystyrene core (density 0.936 (density 0.936
lbs/ft3 or 15 kg/m3) corresponds to the insulation
properties of an ordinary brick wall 25. thick.

SINGLE PANEL PSM/PST
Plot 416, Idu Industrial Layout, Phase 1, Abuja, Nigeria | Tel: +234 9 2916411 | Email: info@polyindustries.com.ng | Website: www.polyindustries.com.ng 5

4.1. PIL SINGLE PANEL PSM
Galvanized steel wire mesh:
Longitudinal wires: (gauge 12) (2,5 mm.) or gauge 9 (3,5 mm)
every 2.56 in. (65 mm.)
Transversal wires: Ø gauge 12 (2,5 mm) every 2.56 in. (65 mm)
Cross steel wire: Ø gauge 11 (3 mm) (approx. 6 per ft3 - 68 per
sq.m.)
Kind of
panel
Thickness
of finished
panel (cm)
Thermal transmittance
U (W/m2 K)*
(in brackets values in BTU/h ft² F)
Density 25 kg/m³
Plot 416, Idu Industrial Layout, Phase 1, Abuja, Nigeria | Tel: +234 9 2916411 | Email: info@polyindustries.com.ng | Website: www.polyindustries.com.ng
w w w . P o l y i n d u s t r i e s . c o m . n gsq.m.)
Steel wire yield: fyk > 87082 PSI (600 N/mm²)
Steel wire fracture: ftk > 98692 PSI (680 N/mm²)
Polystyrene slab density: Approx. 1 lb/ft3 (15 Kg/m3)
Polystyrene slab thickness: from 1.57 in.
Finished masonry thickness: Variable, from 4.33 in.
For the structural use of this panel, the polystyrene core should be at least 2 in.
6cm thick and an average quantity of traditional or pre-mixed cement based
plaster (lime < 5% on cement weight) of about 1.38 in. (about 1 in. over the
mesh) should be sprayed on each side having structural features of at least
3621 PSI (250 daN/cm2 ) of compressive strength.
This panel is generally used for buildings of no more than 4-6 storeys, also in
seismic areas, for floor slabs and covering slabs with maximum spans of 13 ft.
at.
Sound proofing index: 45 dB **
Fire resistance: REI 120***
Density 15 kg/m³
(0,94 pound/ft ³ )
Density 25 kg/m³
(1,56 pound/ft ³ )
Double connector Double connector
PSM60 13 0,570 (0,101) 0,520 (0,091)
PSM80 15 0,440 (0,078) 0,400 (0,070)
PSM100 17 0,360 (0,063) 0,330 (0,057)
PSM120 19 0,300 (0,054) 0,270 (0,048)
PSM140 21 0,260 (0,046) 0,240 (0,042)
6

w w w . p o l y i n d u s t r i e s . c o m . n g
4.2. PIL SINGLE PANEL PST
Kind of
panel
Thickness
of fin-
ished
Thermal transmittance
(in brackets values in BTU/hft² F)
U(W/m2K)*
Longitudinal wires: Ø gauge 12 (2,5 mm.) every 2.56 in. (65 mm.)
w w w . p o l y i n d u s t r i e s . c o m . n gished
panel
(cm)
U(W/m K)*
Density 15 Kg/m³
(0,94 pound/ft ³ )
Densità 25 kg/m³
(1,56 pound/ft ³ )
PST40 9 0,814 (0,143) 0,743 (0,130)
PST50 10 0,674 (0,118) 0,613 (0,107)
PST60 11 0,574 (0,101) 0,522 (0,091)
PST80 13 0,444 (0,078) 0,402 (0,070)
PST100 15 0,361 (0,063) 0,327 (0,057)
PST120 17 0,305 (0,054) 0,347 (0,048)
PST140 19 0,264 (0,046) 0,275 (0,042)
PST160 21 0,232 (0,041) 0,209 (0,037)
PST180 23 0,208 (0,036) 0,187 (0,033)
PST200 25 0,188 (0,033) 0,169 (0,030)
Sound proofing index: 41 dB **
Cross steel wire: Ø gauge 11 (3 mm) (approx. 6 per ft3 - 68 per
sq.m.)
Polystyrene slab thickness: from 1.57 in (4 cm) to 12,60 in (32 cm).
Finished masonry thickness: variable, from 3.54 in (9cm) to 14.57
in (37 cm).
The PST panel can be used as internal partitions, external curtain walls,
Insulating walls etc. It’s similar to the PSM panel except for its polystyrene
core outline that is thinner and requires less plaster for its finishing.
7

DOUBLE PANEL PSM/PST
8

4.3. PIL DOUBLE PANEL PSM/PST
longitudinal steel wires: Ø 3,0 mm
Transversal steel wires Ø 2,5 mm
The double panel PSM consists of
two single panels facing each other
and joined by steel pins keeping
them at the distance established by
the static requirement to be met.
The space between them is filled
with cast concrete having suitable
resistance strength.w w w . p o l y i n d u s t r i e s . c o m . n g
Transversal steel wires Ø 2,5 mm
Joint steel wire Ø 3,0 mm
fkt: Ø 606 N/mm²
fkt: Ø 681 N/mm²
Polystyrene slab density 20-25 kg/m³
Polystyrene slab thickness: approx. 4.50 cm
Finished masonry thickness: variable from 25 to 35 cm
Heat insulation coefficient: Kt < 0, 40 Kcal/h m² ºC (min)
Soundproofing index 1> 34 dB at 500 Hz (in frequency band)
resistance strength.
Externally, the panels must be
sprayed on with plaster as the
single panels.
Although no additional
reinforcement is necessary for
buildings up to three storey’s, for
taller buildings the panel should be
further reinforced with internal
additional meshwork.
9

FLOOR PANEL PSM/PST
10

4.4 FLOOR PANEL PSSG2E AND PSSG3E
This type of panel enables the use of
the PIL system for floors and roofs
by inserting reinforced ribs in the
special spaces and subsequent
concrete casting on site. In fact the
reinforcement of the panel is
integrated during the panel
assembly by the insertion of
additional reinforcement bars-to be
substantiated by calculations –
inside the panel ribs.
PSSG2E
PSSG3E
longitudinal wires: ∅ 2,5 mm every 65 mm
transversal wires: ∅ 2,5 mm every 65 mm
joint wire: ∅ 3,0 mm
steel wire yield: fyk > 600 N/mm²
steel wire fracture: ftk > 680 N/mm²
Polystyrene slab density: 15 Kg/m3
Heat insulation coefficient: Kt < 0,366 W/m2 °C (min.)
Soundproofing index: I > 38 dB at 500 Hz (in frequency band between
100 and 3150 Hz)
inside the panel ribs.
It is an ideal solution for floor slabs
having spans up to 6.5m. and the
double rib for spans of up to 10m
overloading up to 400 daN/m2.
furthermore, where the assembly
sequence needs to be maximised,
as far as the erection schedule is
concerned, it is possible to use iron
stiffening rib in the pods of the panel.
11

VARIABLE RISER AND TREAD
METAL FRAMEWORK, H=13cm
Ftk>4500 Kg/cm2
ELECTROWELDED MESH
Ftk>6000 Kg/cm2
POLYSTYRENE PANEL
Density 15kg
STAIRCASE / LANDING PANEL PSSC
12

Variable tread and riser
Electrowelded mesh
ftk≥ 680 N/sq.mm.
4.5 PIL STAIRCASE PANEL PSSC & LANDING PANEL PNR
The panel consists of an expanded
polystyrene block shaped according to
designing requirements and reinforced by a
steel mesh. The block is joined by steel wire
connectors welded in electro-fusion across
the polystyrene core.
Suitable reinforced and finished with casting
on site in the suitable spaces, it is used for
the construction of flight of stairs up to a
Foam polystyrene
density 15 Kg/cu.m.
Additional reinforcement
(lattice of ribbed bars)
Fyk≥ 430 N/sq.mm.
g
Longitudinal wires: Ø gauge 12 (2,5 mm.)
Transversal wires: Ø gauge 12 (2,5 mm)
Cross steel wire: Ø gauge 11 (3 mm)
Fire resistance REI 120*:
the construction of flight of stairs up to a
maximum spans of 20 ft having a live lo9ad
of 82 lb/ft2 (400 Kgm2
The reinforcement steel bars have to be
placed inside the holes.
13
Landing Panel Typical Section

4.6 TECHNICAL SPECIFICATIONS AND USE OF STAIRCASE PANEL
This panel is used for the construction of
flight of stair of up to 6m long (floor at
approx. 3-m intervals) having an accidental
overload of 400 kg/m².
During construction and prior to panel
assembly, the stair panel, lower channels
are filled with concrete (the panel being
placed upside down). This pre-cast operation
confers greater stiffness to the panel during
its assembly enabling at the same time a
drastic reduction of the number of props
used.
Once the stair panel is assembled and thew w w . P o l y i n d u s t r i e s . c o m . n g
Plot 416, Idu Industrial Layout, Phase 1, Abuja, Nigeria | Tel: +234 9 2916411 | Email: info@polyindustries.com.ng | Website: www.polyindustries.com.ng 14
Once the stair panel is assembled and the
lattice is placed inside the panel internal
channels, the latter are completed with
gravel concrete (whose particles size is < 12
mm and its minimum strength is Rck > 250
dN/cm²
The concrete may be cast in the panel ribs
contemporaneously with casting of the upper
coating. In case this already exists, the
concrete may be applied to both the ribs and
upper joist.
Successively, the plaster layers (2.5cm thick)
are applied upon the flight of the stairs, first
the lower side and then the upper one, in
order to form the basis on which the flooring
(marble, ceramic tiles, etc) is to be laid.
Landing
Panel

ANGULAR MESHWORK RG1:
* Reinforces angle-connections.
Estimated efficiency:
4 units per angle (2 internal and
2 external) on average
Designed with 1in galvanized steel wire, the
meshwork is used to reinforce all the openings and
corner-joint between panels so as to obtain a
continuity to the structural mesh.
Joints or crams are used to attach the mesh to the
panels.
5. BRACING MESHWORKS
2 external) on average
FLAT MESHWORK RG2:
* Reinforces (at 45°) openings angles
* Restores meshwork that had been
previously cut
* for any joints between panels
Estimated efficiency:
2 units per door.
4 units per window.
“U” SHAPED MESHWORK RU:
* Restores the continuity of the panels
Along the perimeter of doors and windows
15

w w w . P o l y i n d u s t r i e s . c o m . n gEngine Power (HP) Air Production (l/min) No. Machines
From 3 to 4 350-400 1
User’s Instructions
• The air pressure should be kept constant within a
70-120 pound _500-800kPa) range.
• No special plastering-machines are needed and the
panel to be plastered required no previous
preparation.
• For the plaster to be applied to the wall, the container
should be placed at a distance of 10-20cm.
• For the plaster to be applied to the ceiling, the upper
edge of the container should almost touch the panel
at a maximum distance of 2-3cm.
Plaster sprayers maintenance
• During the usual interval between the application of
6. PIL PLASTER SPRAYERS FOR WALL
AND CEILINGS
The use of the devices easily enables a time saving by
50% and with no need for skilled labour. Thanks to PIL
sprayers, the plaster may be applied with a degree of
adherence that could not be achieved manually, in one
hour, one worker using a plaster sprayer with a
continuous flow of material placed nearby can apply a
plaster layer of about 1cm over an area of up to 646 ft2
(60 m2). PIL plaster sprayers are available in two
versions.
W for walls and C for ceilings. Both models feature four
holes for different types of plaster and come with all the
necessary tools to clean the machine after use.
w w w . P o l y i n d u s t r i e s . c o m . n gFrom 3 to 4
From 5 to 6
From 8 to 10
350-400
600-700
900-1000
1
From 2 to 3
From 3 to 4
two layers of plaster, we recommend o place the
empty container in a bucket filled with water and
make it work two or three times.
• Remove lateral bolts and wash the inside of the
machine at least once a week.
Compressors:
Either electrical or internal-combustion engine
compressors may be used keeping in mind the
following data.
Note 2:
When only one plastering-
machine is used, the ideal
cubic capacity of the
compressor container is
220 litres (not lower than
130 litres, but with pressure
regulator).
Note 1:
We recommend the use
the use of high pressure
½” hoses note exceeding
30 linear meters.
16

HEAD OFFICE/FACTORY:
ABUJA OFFICE:
PLOT 416 IDU INDUSTRIAL AREA
PHASE 1, ABUJA F.C.T. NIGERIA.
TEL; +234 09- 2916411, 09-2916412
07010612764, 07010612765, 08034040090
E-MAIL: inquiries@polyindustries.com.ng
WEBSITE: www.polyindustries.com.ng
LAGOS CONTACT:
Call:+234 08033076518

POLY PANEL SPECIFICATIONS.

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