PRATLIPERL ULTRA LIGHTWEIGHT INSULATING …

1 PRATLIPERL ULTRA LIGHTWEIGHT INSULATING AND FIREPROOFING MIXESSOME TECHNICAL is a unique volcanic glass, a large deposit of which is found at only one location in South Africa and nowhere else on earth. Its properties are similar to classical Perlite but it differs in that the processed (expanded) form is ideally suited for use with cementitious and other binders. It also has truly exceptional fireproofing processing, the volcanic glass ore is crushed to sugar grain size and passed through a specially developed furnace. On heating, the crushed grains of "glass" soften and water trapped within the structure turns to steam which expands or "pops" the grains into a multitude of well-sealed glass beads. During this process, much of the water vapour escapes by diffusion and much of the remaining water is re-absorbed into the glass structure. The loss of water also alters the chemistry of the glass and results in a higher melting the microscope, each tough bead comprises a froth of glass-walled closed cells each enclosing a near vacuum (see photograph).

2 Expanded PRATLIPERL is therefore best described as comprising millions of tiny sealed "thermos flasks", hence its absolutely unique and unrivalled INSULATING and fireproofing properties. Some of the unique properties and the physical reasons for them are listed thermal insulator("k" value in the loose state of + W/m C.)This property is derived from the low density and physical structure of the PRATLIPERL lightweightDensity in the loose state is 100 kg/m and, when mixed with cement, practical concrete densities ranging from 300 kg/m to 1000 kg/m can be achieved. The PRATLIPERL concrete will therefore float on property derives from the ore expansion ratio of 20 times ( 1 m of PRATLIPERL ore expands to 20 m of product). Fire ResistanceNotwithstanding the high melting temperature of 1250 C PRATLIPERL concrete can also maintain its structural integrity at high temperatures due to its thermal INSULATING property. The latter ensures a very high thermal gradient on the outer surface during fire conditions resulting in very low temperatures immediately below the fire exposed surface.

3 Indeed, even if the surface melts, it coalesces into molten glass beads which insulate and protect the with Portland Cement and Other BindersUnlike conventional Perlite, which is often friable and delicate with many fractured cells, PRATLIPERL has a well-sealed tough structure. This prevents severe bead damage during mixing and facilitates low water absorption, hence proper curing of the StrengthUltra LIGHTWEIGHT concretes are generally weak and, in the case of aerated concrete, are extremely vulnerable to total slump shortly after casting, especially if any vibration or disturbance is concrete does not rely on air-entrainment and can be cured under any conditions of vibration. Once cured,the product exhibits surprising strength in comparison to other LIGHTWEIGHT concretes. Strength varies with density but practical strengths in the range of MPa up to 23 MPa are quite (Spray or Plaster)Pratley has developed a chemically "Pre-treated" PRATLIPERL , which, when mixed with cement, can be plastered (without the use of additives) either with a trowel or by spray to most common surfaces with good adhesion.

4 In the case of doubtful surfaces, a recognised cleaning procedure, followed by the application of a bonding agent, "Pratley Plaster Grip Primer", is recommended. In this case, PRATLIPERL plaster will even adhere to smooth Water PermeabilityThe Pre-treated PRATLIPERL , when mixed with cement in the correct ratio, can be deemed to be completely watertight- without the use of any additives (Vide Appendix A - PCI Report). Substrate corrosion is therefore DustNo dust is healthy. PRATLIPERL , due to its amorphous (non-crystalline) structure has however been demonstrated to be a very low health risk Smoke and Zero FumesDue to its inorganic structure " PRATLIPERL " evolves zero smoke and zero fumes under fire resistance to spallingUnder fire conditions and, more severely, under water quench conditions following extreme heat, ( from a fire hose) conventional concrete will spall and lose its integrity. PRATLIPERL exhibits no such tendency and, following a1fire, the material generally need not be replaced.

5 Indeed, the two COMRO test tunnels, formerly at the West Rand Consolidated Mines, have PRATLIPERL linings which have endured several hundred high temperature test Reports: SABS, CSIR and COMRO and PCI2314 SABS, CSIR, COMRO and PCI Test Reports are available. These include mobile hydrocarbon fire tests, plus density, permeability, smoke emission, strength tests and abrasion PRATIPERL TO ORDINARY PERLITENote the good sphericity and high proportion of well-sealed strong cells of PRATLIPERL compared to the large number of fractured cells and poor sphericity of ordinary Perlite. PRATLIPERL bead (Mag 250x) Ordinary Perlite bead (Mag 250x) Well sealed Poorly sealed Good sphericity Poor of Mines Research Organisation - Now CSIR Mining Tech. 2. South African Bureau of for Scientific and Industrial Portland Cement Institute (now the Cement and Concrete Institute).2R1 May 2001 PRODUCTS AND PACKAGING Pre-Treated PRATLIPERL 100 l bag PRATLIPERL 100 l bag (Product Code 99031) (Product Code 99020) PRATLIPERL AND PRE-TREATED PRATLIPERLP ratliperl is supplied in 10 kg (100 l) calendared, polypropylene sacks clearly printed " PRATLIPERL " or "Pre-treated PRATLIPERL ".

6 Product CodeDescription99020 PRATLIPERL 100 l Bag99031 Pre-treated PRATLIPERL 100 l BagWe recommend the use of Pre-treated PRATLIPERL for all cementitious PRATLIPERL is to be plastered onto smooth surfaces, a primer may be used to ensure good adhesion. Pratley Plaster Grip Primer will even permit the plastering of ULTRA smooth surfaces like flat CodeDescription99026 Pratley Plaster Grip Primer 5 l plastic :1)If mix is to be applied to smooth surface, eg PVC or steel, use Pratley Plaster Grip )For spray applications, use special concrete pump or spray machine. (Consult Pratley for details.)3 Mix Ratio (by volume) PRATLIPERL : Cement3 : 11 Bag Pre-treated PRATLIPERL (100l ) + 1 pocketOPC (33l ) : Bags Pre-treatedPratliperl (150l ) +1 pocketOPC (33l )6 : 12 Bags Pre-treatedPratliperl (200l ) +1 pocketOPC (33l )10 : Bags Pre-treatedPratliperl (350l ) +1 pocketOPC (33l )Water (l) per 10 kg (100l )bag of PratliperlLowWater*23 Highwater29 Lowwater* * * (mm)55250452405023030+90+ (mm)Measured air content (%)Drying Shrinkage (%)Wetting expansion (%)7-day ISO flexural strength(Mpa)7-day ISO compressivestrength (Mpa)28-day ISO compressivestrength (Mpa)7-day 100mm cube strength(Mpa)28-day 100mm cube strength (Mpa)Wet density (kg/m )140011501250100090080075070011009008006 50550450360350 Dry density (kg/m )28-day ISO flexural strength(Mpa)*Recommended water content as indicated in boldThe above are expected values using quality OPC, standard mixing times, proper curing practice and correct water ratio.

7 *NB! The water : cement ratio is very important. Numbers shown are per 100 l of Pre-Treated PROPERTIES3 : 11 Bag Pre-treated PRATLIPERL (100l ) + 1 pocketOPC (33l ) : Bags Pre-treatedPratliperl (150l ) +1 pocketOPC (33l )6 : 12 Bags Pre-treatedPratliperl (200l ) +1 pocketOPC (33l )10 : Bags Pre-treatedPratliperl (350l ) +1 pocketOPC (33l )NOTE:- Before selecting a mix, check structural design and For improved fire resistance use 1 x 5kg bag Pratley Fire Mix Additive . 3 = suitable* For smooth substrate surfaces use Pratley Plaster Grip Primer . x = not suitable OPC = Ordinary Portland CementSUITABILITY GUIDEE xternal Plaster * =TYPICAL APPLICATIONSMix Ratio (by volume) PRATLIPERL : Cement33XX333X33XX333X33333333333 XXX33 Internal Plaster * =Built-up floorsInsulating roof DecksFire SealsCastablesSpray Applications *Cast Thermal Insulation4 HOW TO MIX PRE-TREATED PRATLIPERL WITH CEMENTI ntroductionAll the principles of good concrete practice apply to Pre-treated PRATLIPERL mechanical means of mixing is suggested.

8 A pan mixer is preferable as a drum mixer tends to make this equipment is not available, manual mixing with shovels is Pre-treated PRATLIPERL is a non-absorbent volcanic glass, water will not be absorbed into the material. The use of a sealed, leakproof container is, therefore, recommended to prevent leaching of the required amount of Mix Pre-treated PRATLIPERL and cement in the dry state first (a little water may be used to dampen slightly in order to suppress dust). the correct amount of water (refer to the table on Page 4 - and note that the water quantity is given in litresper 100 l of Pre-treated PRATLIPERL !). The product may appear very dry, especially if hand-mixed, but this is is important to monitor the amount of water added since small differences in water content have a large effect on overall consistency and , but do not overdo, mixing time - about 30 seconds in a pan mixer is all that is required (longer mixing entrainstoo much air).Yield!

9 Approximately 11 bags Pre-treated PRATLIPERL will be required for each cubic metre of concrete/plaster to be mixed(cement and water to be added to this quantity of Pre-treated PRATLIPERL ). This applies to all mixes mentioned in the table of Typical Properties (page 4).Gunnite and Loose-fillPre-treated PRATLIPERL concrete may also be gunnited. Because lower air velocities are used than for ordinary gunniting procedures, the rebound is lower. A further advantage is that the rebound can be can also be used as a loose-fill (without cement) to fill cavities for thermal insulation Very Important water content is extremely important. Too much water will yield poor results and lead to shrinkage, weak concrete and cracking. Use only the water per table on page When plastering, use good conventional plastering techniques. Particular attention should be paid to the degree to which the plaster has set prior to levelling with straight edge. As with any plaster, it should be set sufficiently so that it is difficult to cause an indentation by applying thumb pressure.

10 If the straight edge is applied prematurely, it will cause the plaster to de-bond from the wall and slump cracks will form. On smooth surfaces, use Pratley Plaster Grip with any concrete or plaster, proper curing under damp conditions and out of direct sunlight is vital for application will determine the exact water : cement ratio. For example - for casting and plastering applications, the user may decide to use the high water content (refer to the table on Page 4), whereas for screeds a drier consistency and stronger product may be preferred, hence the low water content may be applied, the surface must be kept moist for the first 14 days while curing. If the finished product is to be exposed to direct sunlight or fast cured, contact our office for advice on specialised wish to plaster my company's computer room internally to improve thermal to the suitability guide, a :1 mix is selected since it can be plastered with ease and has sufficient wall area of the room is 80 m and the plaster is to be 30 mm thick.