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Like foam concrete, polystyrene concrete has been known for a long time. It is produced as a thick slurry which can hold the required shape. 
The main field of application is making sloping (gradient) layers of roofs, possibly levelling layers of inclined roofs with the slope not exceeding 15° covered with trapezoidal or wave cross section roofing.
Due to low density of the polystyrene concrete, when reconstructing a flat roof, the existing layers usually need not be removed.
 
When making gradient layers of flat roofs, it is recommended to combine polystyrene concrete with polystyrene panels and thus reduce the surface load of a roof slab and increase thermal resistance of the whole roof structure.

It is recommended that polystyrene concrete produced and delivered using SIRCONTEC machines, is applied on site within the temperature range from +5 to 30 °C. At temperature above 25 °C, it is suitable to moisten the surface or treat it with an agent from SIRCONTEC supply.

It can be pumped with SIRCONTEC equipment to the height of more than 60 m.
 
Recycled (crushed) polystyrene with a grain size up to 5 mm can also be used for production of SIRCONTEC polystyrene concrete. Application of EPS pearls is rare with respect to the cost.
Polystyrene concrete PsB produced and delivered by Sircontec equipment can be applied in thickness up to 1000 mm in one layer.
Contraction cracks may appear in PsB layer after having set, which is not a defect with regard to its function in the structure.
 
Utilization of SIRCONTEC PsB polystyrene concrete types according to the temperature of both the atmosphere and the structure in the place of application and the capability of gradient forming:
 
The PsB 40 belongs to often used types of polystyrene concrete mainly for its acceptable price. SIRCONTEC recommends using it especially for making filling layers of various cavities and as a base for gradient layers in the period when the temperature of the surroundings and the sub base reaches above +15°C. As compared with PsB 50 modification, it has slower start-up of setting and therefore the application of the subsequent layers is possible only 72 hours after it has been poured.
 
The PsB 50 is often used type of polystyrene concrete mainly for the favourable ratio price/utility. SIRCONTEC recommends to use it especially for making gradient layers of flat roofs under layers freely laid, anchored by an upper load.
Minimum thickness of PsB 50 on the polystyrene board layer should not be less than 100 mm and it should be reinforced with KARI screen.
In comparison with PsB 40 the setting start-up is faster and the walkable strength is achieved as soon as within 36 hours after having been poured. 
It is not recommended to install mechanical anchoring system of a coat covering into the PsB 50.

The PsB 60 is often used type of polystyrene concrete. SIRCONTEC recommends to use it especially for making gradient layers of flat roofs designed for direct adjustment of the coat covering. It is suitable to combine PsB 40 as a sub base for the upper layer of PsB 60, possibly replace the PsB 40 sub base with polystyrene board. Minimum thickness of PsB 60 on the polystyrene board layer should not be less than 100 mm and it should be reinforced with KARI screen.
In comparison with PsB 50 the setting start-up is faster and thus the surface is walkable with care yet as soon as within 24 hours after having been poured. 
It is not recommended to install mechanical anchoring system of a coat covering into the PsB 60.
Penetration which is to come under asphalt hydro-insulating strips can be applied directly on dry surface of PsB 60 and the hydro-insulating strips are to be subsequently melted on.
SIRCONTEC recommends that, when melting on the basic asphalt strip, a micro ventilation slot is made with connection to the atmosphere, and when the upper strip is melted on, it is exposed to a load.
 
Application table of PsB modifications: 
PsB
40
50
60
Application temperature
°C
above +15
above +8
above +5
Walkability at 20°C
hours
max. 72
max. 36
max. 24
Min. / max. application thickness of PsB material
mm
60/1000
55/1000
50/1000
Ability to form gradient up to
%
2
5
10
Pumping head achieved by SIRCONTEC pumps
m
80
 
Values of compression strength and periods necessary to acquire walkable strength are achieved at the temperature of the base and the atmosphere 20°C.
A lower temperature may cause an extension of the period and a slower acquirement of the final strength.
 
Technical data of the mostly used SIRCONTEC PsB polystyrene concrete types:
PsB
40
50
60
Density after 28 days
kg/m3
380 - 450
450 - 550
550 - 650
Natural moisture content (% by weight)
%
8 – 12
Compression strength after 28 days / 20°C
MPa
0,5
0,8
1,1
Thermal conductivity of the dry substance - λ
W/mK
from 0,10
from 0,12
from 0,14
Inflammability
class
B1 – hardly inflammable
 
The Technical Data apply to PsB produced from CEM II 32,5R class cement.
When applying a coat covering on the PsB layer, requirements of construction physics related to the roof deck must be considered.
 
Illustration photo concerning polystyrene concrete PsB can be seen in Photo Gallery.

Information concerning the lightweight concrete production and delivery machines can be found here.

More detailed technical info on SIRCONTEC PsB polystyrene concrete modifications see in DS No. 125 or in the Download section.
 
General information on Lightweight Concrete find here.

Documents to download:


Tech_Assessment SK_TP-14/0118 EN_v.pdf
Tech_Posúdenie SK_TP-14/0118 PBG&PsB.pdf
2_MixDesign_EPSconcrete_EN.pdf
DS_015_M_1000_Mixing_equipment.pdf
DS_125_PsB_40-60.pdf
DS_413_FP1.pdf
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