Insulation in decks and bulkheads PYROLIQ sealing compound system
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1 Insulation in decks and bulkheads PYROLIQ sealing compound system
2 PYROLIQ casting compound In industry, ship construction and offshore areas, very high requirements are placed on cable and pipe penetrations through decks and bulkheads. Besides water- and gas-tightness, the fire resistance of the components must be taken into account in the safety concepts of the systems. Cable and pipe penetrations must be insulated to prevent the spread of fire and fire gases. The PYROLIQ casting compound system is used here: Frames for the penetration are created using existing materials and, after the installation of cables and pipes, are cast using the components of the PYROLIQ system with just a few actions. The insulation is waterproof up to a pressure of 2.5 bar and gas-tight up to 30 mbar. 2
3 Highest level of safety in case of fire According to the valid maritime regulations, fire resistances of up to 60 minutes are required for decks and bulkheads. Besides the constructive insulation made of mineral fibre mats, the PYROLIQ casting compound system ensures the fire resistance of the penetrated installations. Comprehensive tests were performed according to the IMO resolution A.754(8), in order to prove fire resistance. Fire tests were performed very successfully on deck and bulkhead penetrations of various dimensions and with different levels of filling, such as cables, metal and plastic pipes, as were tightness tests. Certificates of Germanischer Lloyd confirm the excellent properties of the casting compound system PYROLIQ and its fire resistance class A60. Resistant to seawater Simple, flexible mounting Fireproof 3
4 4
5 PYROLIQ : Simple. Safe. Economic. Easy processing, few error possibilities and safe mounting make the PYROLIQ casting compound system a highlight amongst insulations. In comparison with modular insulation, the use of PYROLIQ does not require any planning work nor any extreme storage. Just a few components ensure excellent clarity. Simple use, minimal sources of error Requires no planning work Gas-tight and watertight as well as fire-resistant Few components, simple storage Approved for all types of ships' cables, as well as various plastic and metal pipes For bulkheads and decks made of steel and aluminium components 5
6 Simple handling professional result. Insert expanding modules The expanding modules are inserted into the two front sides of the constructed frame as lost lining. They are used to single out the cables and pipes and prevent the outflow of the casting compound. Cable intersections within the penetration are no problem. 2. Saturate with impregnation fluid After insertion, the expanding modules are saturated with impregnation fluid. As a result, they increase their volume and seal off the cavities between the cables and pipes. After the expanding modules have been impregnated, they are hardly flammable. 6
7 3. Fill with casting compound The casting compound is mixed together from dry mortar and drinking water and is filled into the penetration through the filling nozzle on the steel frame. The casting compound enters all the cavities and seals the penetrating installations hermetically. The expanding modules can be still moist on filling, meaning that rapid mounting is possible. 6 mm 60 mm 7
8 Deck insulation Penetrations in decks are made in the same way as for wall mounting: However, expanding modules are only required on the underside. Within the ship or system, no additional measures are required after casting. Insulation which can come into contact with saltwater, oils and chemicals must have its surface closed with the sealing compound for outdoor areas. If the frames are already full of water, the water-repelling sealing compound is used. 8
9 Wall insulation The PYROLIQ casting compound system is approved for the penetration of various plastic pipes. Materials such as PVC, ABS, PE and PP with outer diameters up to DN200 are no problem for the insulation. For the insulation to remain safe despite the use of combustible plastic pipes, a two-layer insulation strip is placed around the appropriate pipes before the casting compound is added, and fixed in the centre of the steel frame. If there is a fire, the insulation strip foams up around the burning plastic pipes, sealing them off. 9
10 EMC requirements Special areas require electrically shielded cables according to the EMC directive, in order to keep the signal quality at the highest level. For this, the cables must be connected to the steel body of the ship or system using a conductive substance. The conductive sealing compound of the PYROLIQ system is used here. Creating a conductive connection After filling of the main frame, an additional frame is flanged to the insulation. The appropriate cable is stripped and the conductive sealing compound cast into the second frame. The exposed cable shielding allows the creation of a conductive connection to the steel body. 0
11 Approvals and certificates The certificates of Germanischer Lloyd (GL) comprise all the type approvals of modules B+D according to the SOLAS 74 regulation and IMO resolution. The technical data is summarised in the table. Casting compound, gas-tight and watertight as well as fire-resistant 30 mbar 2,5 bar Class A60 Watertightness 2.5 bar Gas-tightness 30 mbar Cables Type approval DNV GL Certificates EC Certificates (Module B+D) HH, 03-4 HH, 05-4 HH SOLAS 74 regulation II-2.9 IMO resolution A.754(8) Testing standards IMO resolution MSC. 6(67) IMO resolution MSC. 307(88), clause 8 Approved media Insulation dimensions in cm Shipping and maritime cables of all types Pipes Type approval DNV GL EC Certificates (Module B+D) 0-4 HH, 02-4 HH, 04-4 HH SOLAS 74 regulation II-2/8.., II-2/9.3. IMO resolution A.754(8) IMO resolution MSC. 308(88) MSC/Circ 96, MSC/Circ 004, MSC/Circ 276 Steel and CuNiFe pipes to DN 200 Copper pipes to DN 00 Plastic pipes ABS, PVC,PE, PP to DN 200 Multi-layer composite pipes to DN 32 Bundle pipes, stainless steel, to 23 mm GRP pipes to 34 mm Dimensions Insulation (wall) Deck (ceiling) Round, rectangular, oval min./max. 9 x 9 / 50 x 25 9 x 9 / 50 x 25 Min. insulation thickness / casting length 23/8 20.5/8 Min. sealing --- Material Steel Aluminium Component strength / frame strength min Maximum approved assignment of the opening area with installations: 40%. The data in the named certificates apply. Fire resistance class A60 only in connection with approved insulation mounted during construction.
12 Sealing compound Type VMS-TE VMS-TE 2 Contents kg kg/00. Item No , Special mortar Dry compound in plastic container to mix with tap water. Makes a gas-tight and watertight seal of fire resistance class A60 to IMO resolution A.754(8). Including measuring cup. The mixing ratio of water to powder is :2. The mixed compound is pumpable for approx. 45 minutes. The mixture is chemically hardened after 72 hours. Stored in a dry and frost-free environment, the dry compound will keep for 3 years. Expanding module, small Type VMS-QMK Dimension mm 20x25x6 20 kg/00. Item No Foam Expanding foam modules to replace a casing in the sealing compound system if part of the casing has been lost. The modules expand by the factor 0 when sprinkled with the impregnating fluid, closing gaps and joints between the cables installed. After the cables have been impregnated they are hardly flammable, fire-retardant and self-extinguishing. Stored in a dry environment, the expanding modules have an unlimited lifespan. Expanding module, large Type VMS-QMG Dimension mm 800x25x6 5 kg/00. Item No Foam Expanding foam modules to replace a casing in the sealing compound system if part of the casing has been lost. The modules expand by the factor 0 when sprinkled with the impregnating fluid, closing gaps and joints between the cables installed. After the cables have been impregnated they are hardly flammable, fire-retardant and self-extinguishing. Stored in a dry environment, the expanding modules have an unlimited lifespan. Impregnation fluid Type VMS-IF Contents ml 000 Fluid to sprinkle the expanding module. When 5 long expanding modules are used, approx. l impregnation fluid is required. Stored in a frost-free environment it has a lifespan of 2 years. kg/00. Item No Sealing compound for external use Contents Type kg VMS-VA Special mortar kg/00. Item No Flame-retardant sealing compound for insulations in sealing compound systems. Watertight and resistant against common technical oils as well as weak/diluted acids. Halogen-free and coldhardening. 2 components (hardener and resin) in tin with lid to push through. Lifespan of 2 months in original and closed packaging at temperature between +0 and +40 C.
13 Contents Type kg VMS-VW Special mortar Sealing compound, water-repellent kg/00. Item No Flame-retardant sealing compound for insulations in sealing compound systems for the application in water-filled openings. Watertight and resistant against common technical oils as well as weak/diluted acids. Halogenfree and cold-hardening. 2 components (hardener and resin) in tin with lid to push through. Lifespan of 6 months in original and closed packaging at temperature between +0 and +40 C. Contents Type kg VMS-VL Special mortar Sealing compound, conductive kg/00. Item No Electrically conductive sealing compound for insulations in sealing compound systems and for the integration of the woven cable shield in EMV-compliant installations. 2 components (hardener and resin) in tin with lid to push through. Lifespan of 6 months when stored in frost-free storage. Dimension Type mm VMS-RS 000 x 00 x 3 Intumescent material 3 kg/00. Item No Insulation forming strip for the application in sealing compound system when feeding through flammable pipes. Please protect against sunlight. When stored in a dry environment it has an unlimited lifespan. Pipe insulating strip Type VMS-KS DE VMS-KS EN Language German English kg/00. Item No PVC Polyvinylchloride Identification plate for self-labelling of the insulation of the sealing compound system to the IMO A.754(8) with a waterproof and lightproof felt tip pen. Including 2 cable ties for fastening onto the cable or onto the cable tray system in the area of the insulation. Identification plate
14 OBO BETTERMANN Order no. XXXXXXX 03/207 EN OBO Bettermann GmbH & Co. KG PO Box Menden, Germany Customer Service Germany Tel. +49 (0) Fax +49 (0) Building Connections
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