POLY PANEL SPECIFICATIONS

PANEL SPECIFICATIONSAdvanced building system

1

POLYSTYRENEINDUSTRIES

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.w w w . P o l y i n d u s t r i e s . c o m . n g

1Plot 416, Idu Industrial Layout, Phase 1, Abuja, Nigeria | Tel: +234 9 2916411 | Email: [email protected] | 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/PSTDouble Panel PSM/PST

Floor PanelStaircase Panel


w w w . P o l y i n d u s t r i e s . c o m . n gA 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: [email protected] | 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: [email protected] | Website: www.polyindustries.com.ng


sq.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/h ft² 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 gishedpanel

(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

PSSG3Ew w w . P o l y i n d u s t r i e s . c o m . n g



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 meshftk≥ 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 polystyrenedensity 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: [email protected] | 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 AREAPHASE 1, ABUJA F.C.T. NIGERIA.

TEL; +234 09- 2916411, 09-291641207010612764, 07010612765, 08034040090E-MAIL: [email protected]: www.polyindustries.com.ng

LAGOS CONTACT:

Call:+234 08033076518

Documents

POLY PANEL SPECIFICATIONS