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SIPOREX ( LIGHT-WEIGHT AUTOCLAVED CELLULAR CONCRETE ) THE WONDER BUILDING MATERIAL OF THE WORLD. SIPOREX. Siporex is a light weight autoclaved cellular concrete and is being used all over the world in more than 40 countries since 1930.
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SIPOREX (LIGHT-WEIGHT AUTOCLAVED CELLULAR CONCRETE) THE WONDER BUILDING MATERIAL OF THE WORLD SIPOREX Siporex is a light weight autoclaved cellular concrete and is being used all over the world in more than 40 countries since 1930. In Japan, Siporex is manufactured in about 11 factories amounting to a total production of about 3.3 million cum per year. Partial view of large, well equipped plant showing sophisticated cutting machine Siporex is manufactured by Siporex India Pvt. Ltd., a group company. The plant has a capacity to manufacture 2,70,000 Cum of Siporex products annually Addition of Silicon in wet mass of SIPOREX and applying it on surface makes the productwater repellent Demoulding section Visit for more Learning Resources
SIPOREX Prefabrication: The method in which various components of building structures are casted in factory & then transported to the site where they are assembled. The structures which are constructed by prefabrication & precast are called as prefabricated construction. These are easily transported & dismantled & reused. Methods of prefabrication: a) Plant fabrication b) site fabrication.
SIPOREX Methods of prefabrication: a) Plant fabrication b) site fabrication. Components are manufactured at factory. Components manufactured at site Precise quality control is maintained. Less Q.C. Heavy equipment's are required , no heavy equipment's, High transportation charges. No transport charges. Labs are available at plant. Labs are not available at site Execution & supervision is strict.
SIPOREX Advantages: LIGHTWEIGHT Density 640 Kg/Cum or less, 1/4th the weight of dense cement concrete: Economic design, suitability for made-up or low-bearing soils, seismic zones and for adding storey’s on existing buildings, ease of handling, hoisting and transport. HIGH STRENGTH In its cellular form, the density and strength of Siporex are controlled to meet structural requirements. HIGH FIRE-RESISTANT AND INCOMBUSTIBLE Siporex, which is completely inorganic, is totally incombustible and offers better fire protection than ordinary dense concrete. It is ideal for fire walls and also for fire protection of structural steel. Suitability for use in cotton godowns, and textile mills, plastic, chemical, paper and pulp industries and similar installations subject to fire hazards. Also for fire-resistant casing for steel structures in stores, godowns and steel load frames (columns, girder, beams etc.) of multi-storeyed buildings, for safety and security from fire hazards in banks, treasuries and for use in fire cut-off walls in densely built bazars and markets etc.
SIPOREX HIGHLY INSULATING Cuts the peaks of heat and cold and economy in installation and working of air-conditioning. K value: 0.117 K Cal/m/Hr.oC. Suitablity for boilers, heat exchangers, furnaces, ovens, forges, steel works, galvanizing kettle lining etc. COMFORTABLY WORKED Siporex may be cut, drilled, chiseled or nailed with simple wood-working tools, thus simplifies plumbing, electrical wiring, fixing of joinery and fitting etc. SOUND ABSORPTION Absorbency of airborne sound for 75MM - 100MM walls – 38-40 db, thus absorbency of airborne sound in 200MM thick walls gives increase of 45 db and hence suitable for auditoriums, theatres, cutting off workshop sounds from office area. WATER PENETRATION Siporex structure being of closed cells, there is less capillary action and high surface activity allows fast evaporation of moisture.
SIPOREX – THE WONDER BUILDING MATERIAL OF THE WORLD Siporex was invented and introduced into the Swedish market at the beginning of 1930 and has been in use in Europe and forty other countries of the world for the last 70 years and has stood the test of time in all types of climatic conditions and rainfall areas. “SIPOREX” The wonder building material was brought to India by Mr. B.G. SHIRKE in 1972 and over 2 Lacs housing units have been so far built by Shirke-Siporex Consortium, using new prefabricated industrialized technology. Siporex is Lightweight Autoclaved Cellular concrete. It is an inert structural material. The structure consists of minutes closed cells through out the mass. Chemically, it is Mono-Calcium Silicate Hydrate. Siporex is available in the form of reinforced floor and roof slabs, wall panels and lintels also unrienforced blocks for load bearing and partition walls. Following are the ingredient materials of Siporex.
SIPOREX Dis Advantages Prefabrication: Careful handleing is required. Special attention should be given to joints. Transportation cost may be higher. Heavy lifting equipment like cranes are required Waterproofing at joints is required. No of small units may add to the cost. Components of Prefab: Linear members- beams, lintels, columns & walls Frames- rigid & portal Roofing & flooring materials R.c. doors & windows. Wall panels.
SIPOREX High Silica Sand containing more than 85% of Silica ( for Slabs) Fly Ash ( for blocks) Portland cement Gypsum Lime Aluminium powder Caustic lye other chemicals Through the main raw materials are same as the usual cement concrete process the manufacturing process and steam curing has made it a unique multi-quality structural building material having high strength to weight ratio and very good insulating, fire resistant and incombustible material.
SIPOREX BRIEF MANUFACTURING PROCESS ; Silica sand is ground with lime in a ball mill to a fine paste, having the same specific surface as Portland cement and then mixed in proper proportion with water and other ingredients like cement, gypsum, which are added by weight. While manufacturing of blocks Fly Ash is directly mixed with water and the other ingredients are added by weight. This Siporex slurry mix with chemicals is then discharged into a mobile mixer where aluminum powder is added. Slurry from the mixer is discharged into the steel moulds (with or without reinforcing grid according to the product mix of blocks/slabs) where hydrogen is formed as also the closed cells and the cellular mass rises in the moulds. Hardening takes 5 to 6 hours, after which the mass is cut into blocks or slabs as the case may be accurately to the correct sizes on a sophisticated cutting machine. Then the moulds go into the autoclaves for steam curing under high pressure and temperature of 200 Degree Centigrade. The moulds remain in the autoclaves for about 14 to 16 hours, during this period the crystallization and curing get completed. The moulds getting out of the autoclaves, are opened, blocks going to store sheds and the slabs going to the milling (profiling) machine, where they get the chamfers and the tongue and grooves. A well equipped laboratory is available to carry out all the analysis and tests of raw materials and finished products as per BIS (ISI) standards and also to carry out “in plant” research and development. Siporex combines the flowing unique qualities.
SIPOREX ANTICORROSIVE TREATMENT Reinforcement in conventional R.C.C. structure is not treated normally against corrosion. The treatment to the steel in Siporex slabs provides effective protection to the reinforcement against corrosion. The treatment consist of two coats of A.C.M. Anticorrosive mix (Latex, Casein, Cement) and over this one coat of Intertol 4253 (Inertol 4253 + Cement). These coats are given by dipping and drying. It has been observed from accelerated rigorous laboratory tests as well as actual in buildings for long period, that this anti-corrosive treatment is quite effective in different climatic conditions. Apart from anticorrosive treatment, we are also adding SILICON OIL to the Siporex wet mass during manufacturing process. This makes slabs water repellent. Thus gives additional protection to the reinforcement against corrosion.
SIPOREX EVALUATION BY CENTRAL BUILDING RESEARCH INSTITTUTE (CBRI) ROORKEE: SIPOREX INDIA PVT. LIMITED had also entrusted the work of the evaluation of this anti-corrosive treatment to Central Building Research Institute (CBRI) Roorkee and after rigorous tests for more than eighteen months, site visits to buildings constructed at Bandra/Oshiwara in Mumbai. CBRI findings reveal that “This anticorrosive treatment coating (2 Coats of ACM + one coat of INERTOL 4253) is highly satisfactory for preventing corrosion of M.S. reinforcement in Siporex concrete in coastal and highly polluted areas” The multifarious SAVINGS AND BENEFITS of Siporex and complementary prefabs in building construction are : 1.More carpet area is available in same built-up area due to lesser widths of walling and cladding (i.e. 200 mm, 150 mm, 100 mm in Siporex instead of 350 mm, 230 mm and 115 mm in conventional systems respectively) and land required is also less; 2.Fast accrual of returns from investment due to speedy construction and earlier starting of production in case of factories; 3.Saving in cement, steel construction supervision costs, construction time, water requirements for construction, timber required for conventional system for centering and form work; 4.Uniform quality due to mass production in the factory.
SIPOREX • SPECIAL APPLICATIONS OF THE PRODUCT • Convenient for use in congested and water deficient areas. • Suitable for use in multi-storeyed buildings for external walls and partitions walls; suitable for use in cotton godowns, ginning factories and textile mills, plastic, chemical, paper and pulp industries and similar installations subject to fire hazards. • For construction of air-conditioned enclosures and for safety and security from fire hazards, in banks and treasuries. • For heat insulation in hot climate areas, Siporex roof or insulation on existing roofs helps. • For adding floors on existing buildings, because fo light weight. • For Thermal Stations and laboratories, where risk of firer exists. • 7. For architectural features – such as fins etc.
SIPOREX • 11. SPECIFIC ADVANTAGES OF THERMAL INSULATING : • K value – Thermal Conductivity of Siporex is 0.117 K Cal/Hr.deg.C m. Thermal Conductivity is dependent upon density of the product. The details are as follows: • Density Compressive Strength Thermal • Conductivity • Kg/M3 Kg/Cm2 K Cal/M/HoC • 300 7.0 0.06 • 11.9 0.07 • 500 20.0 0.09 • 600 29.8 0.11 • 800 49.7 0.16 • 59.5 0.21 • Because of this property if the Siporex product is used in building construction building will be more comfortable than the building constructed with brick or other conventional material i.e. Siporex house will be cooler in Summer and Warmer in winter. In view of this we have carried out number of field trials and as well as calculations which clearly shows energy up to 25% is saved in building constructed with Siporex products. For instance during 1987, We carried out observations of inside and outside temperatures at Talegaon for Army accommodations. The difference in the inside and outside temperature was about average 6 to 6.5 degrees. Similarly we also carried out various observations of difference in inside and out side temperatures in our office building during May 1988 at various timings. Here also the difference in outside and inside temperature was varying from 6.5 to 7.5 degrees.
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