Available online at ScienceDirect. Procedia Engineering 153 (2016 )

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1 Available online at ScienceDirect Procedia Engineering 153 (2016 ) XXV Polish Russian Slovak Seminar Theoretical Foundation of Civil Engineering Fire resistant thermal insulation material with regulated moulding viscosity and mixed bonding agent Sergey A. Mizuriaev a*, Anna Yu. Zhigulina a, Aleksandr N. Mamonov a, Kseniya V. Ganechkina a a Samara State University of Architecture and Civil Engineering, Molodogvardeyskaya St 194, Samara , Russia Abstract The work contains thermal insulation requirements and fire safety properties of insulation materials. It specifically focuses on insulation materials based on soluble glass. The work also presents research and test results obtained at SSUACE. The aim of the research was to develop new technologies and soluble glass-based formulas for the production of porous insulation materials and other common items. A two-step structuring technology was designed to ensure structural heterogeneity of insulation materials. Porosity and viscosity sufficient for complex shape moulding were achieved due to the use of a modified bonding agent. The test results show that the new insulation materials have proved heat and fire resistant, with excellent thermal insulation properties The Authors. Published by by Elsevier Ltd. Ltd. This is an open access article under the CC BY-NC-ND license ( Peer-review under responsibility of the organizing committee of the XXV Polish Russian Slovak Seminar Theoretical Peer-review Foundation under of Civil responsibility Engineering. of the organizing committee of the XXV Polish Russian Slovak Seminar Theoretical Foundation of Civil Engineering. Keywords: insulation materials; sodium water glass; mixed mineral bonding agent; foaming agent; expansion; moulding; combustibility; fire resistance; fire safety. 1. Introduction The development of efficient, cost-effective, durable and safe thermal insulation materials is a challenge that remains relevant nowadays, as fire safety, particularly fire and thermal resistance, is as important for civil construction today as it ever was [1-3]. Numerous tragic accidents associated with thermal decomposition of * Corresponding author. Tel.: address: mizuriaev@gmail.com The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license ( Peer-review under responsibility of the organizing committee of the XXV Polish Russian Slovak Seminar Theoretical Foundation of Civil Engineering. doi: /j.proeng

2 Sergey A. Mizuriaev et al. / Procedia Engineering 153 ( 2016 ) polymer foam-based insulation make both developers and contractors look for possible alternatives. Mineral fibre insulation has the edge over polymer foam-based insulation, but may still not be the ideal choice. Among its disadvantages are low form stability and high water absorption up to 60-80% of its weight due to the open nature of porosity in mineral fibre items. In terms of minimal open porosity, cellular insulation is by far the most efficient [4-6]. Manufactured from light and ultralight expanded clay aggregate, expanded clay concrete also has a high capacity for thermal insulation [7-10]. However, the extensive clay mining has led to a reduction in expansive clay deposits, thus putting a limit on expanded clay production. The authors believe that the focus now should shift to research and production of sodium water (soluble) glass-based porous materials. These are characterized by intense expansion when heated, with a times increase in volume, while the mineral makeup of soluble glass and soluble glass-based materials is responsible for thermal resistance and fire safety. Similar research studies are carried out by research teams in Saransk [11], Tomsk [12], Saratov [13] and other cities [14]. 2. Research At SSUACE, the research is carried out within the framework of the Programme for Development of Efficient Building Materials and Engineering Structures. The aim of the research is to develop new technologies and sodium water glass-based formulas for the production of porous insulation materials and other common items. Thermal expansion of soluble glass is characterized by non-simultaneous volume expansion, a decrease in soluble glass viscosity and subsequent pore fusion that leads to uneven porosity. This can be mitigated by adding powder and fibre fillers that give structure to soluble glass and help obtain a more homogeneous material. The disadvantage is a greater density of the resulting material due to the use of fillers. Fig. 1. The inner structure of the moulded item. An innovative two-step structuring method was suggested to address the problem of heterogeneity of the structure of insulation materials. Based on this method, the structure of porous material comprises two levels. The structure of the first level is to include highly porous sodium silicate granules 3 to 10 mm in diameter. The structure of the second level is to include water glass and porous fine-dispersed sodium silicate powder with mm particles and a density of about 70 kg/m 3 [15-19]. Both porous granules and porous powder are sodium silicates produced from sodium water glass. This ensures the homogeneous nature of porosity (Fig. 1) and identical properties over the whole volume of end material as evidenced by the results of differential thermal analysis. The properties of the new material are shown in Table 1.

3 606 Sergey A. Mizuriaev et al. / Procedia Engineering 153 ( 2016 ) Table 1. Properties of thermal insulation material obtained by thermal expansion. Properties Results Average density, kg/m Average compressive strength, MPA Average bending strength, MPA Thermal conductivity, W/(m*K) 0,088-0,0-94 Organic compounds, % absent Fire resistance threshold limit for a 20 mm thick steel construction, in minutes >30 Heat resistance, in thermal cycles >100 Maximum temperature, 730 The results indicate the efficiency of the new material in terms of insulation, non-combustibility, fire resistance and fire safety. The suggested technology is waste-free, as possible waste products with a low density can be used as fine-grained fillers. The uniformity of the parameters allows for the use of automatic control systems with specifically designed algorithms [20, 21]. The use of this technology is limited though to exclude thermal insulation of equipment with a complex configuration as the final solidification occurs at no less than 150 degrees Celsius [22, 23, 24]. A new technology of production of insulation materials at lower temperatures (20-40 degrees Celsius) [25] was designed to overcome this limitation. It uses dehydrated hydrogen peroxide as a foaming agent and a water glass and Portland cement-based solidifier. Expanded glass granulate is added to reduce the weight of the final product and to increase its porosity. The material obtained after solidification and expansion (Fig. 2) has the following properties: density g/cm 3 ; compressive strength kgf/ cm; even distribution of small closed pores; ease of moulding A distinctive feature of this material is its expansion at degrees Celsius and its ability to preserve porosity and structural viscosity. The expanded material can be moulded into any shape without the deterioration of its insulating properties. Fig. 2 shows the structure of a solidified 40 mm thick porous tile. Fig. 2. The Structure of a solidified 40 mm thick porous tile. Figures 3-5 illustrate the application of insulation plates to the pipe, the exterior and the inner structure of insulation after solidification.

4 Sergey A. Mizuriaev et al. / Procedia Engineering 153 ( 2016 ) Fig. 3. The application of insulation plates to a 35 mm pipe. Fig. 4. The exterior after application and solidification. Fig. 5. The inner structure of insulation after application and solidification. 3. Conclusion It can be concluded that the technology presented in this article is economically viable as it does not require a costly heat treatment. Standard dispensers and faucets can be used for the application. The resulting insulation has a low density and sufficient strength, making it attractive for developers and contractors likewise. The mineral makeup and the absence of organic fillers mean that the new insulation material is characterized by noncombustibility, fire resistance and fire safety. Depending on the components, the fire resistance threshold limit is degrees Celsius. References [1] A. Zhigulina, Building Envelopes: An Objective Measure of Comfort in Residential Buildings, Urban Planning, 1, 2012, pp [2] T. Arbuzova, S. Korenkova, N. Chumachenko, Materials Engineering: New Challenges, Building Materials, 12, [3] S. Korenkova, Filled Foam Concretes in Building Envelope Construction, Building Materials, 8, 2000, pp [4] L. Pavlova, Modern Energy-Efficient Building Envelope: Walls, Samara State University of Architecture and Civil Engineering, Samara, 2011, p. 64 [5] A. Dmitriev, Experimental Engineering: Energy-Efficient Buildings, Industrial and Civil Engineering, 2002, pp [6] Y. Vytchikov, I. Belyakov, Building Envelope: the Method of Dimensionless Properties in Humidity Conditions Investigation, Proceedings of Higher Education Institutions: Construction Engineering, Novosibirsk, 8 (476), [7] V. Gorin, S. Tokareva, M. Kabanova, A. Krivopalov, A. Vytchikov, The Use of Expanded Clay Aggregate in Modern Residential Construction, Building Materials, 12, 2004, pp [8] Y. Vytchikov, Better Energy Efficiency in Buildings and Structures. Interuniversity Collection of Articles, Samara State University of Architecture and Civil Engineering, Samara, 2012, Vol.7. [9] B. Komissarenko, A. Chiknovoryan, V. Gorin, S. Tokareva, The Prospects of Expanded Clay Aggregate Production and Expansive Clay- Based Structures Manufacturing, Building Materials, 11, 2006, pp [10] A. Chiknovoryan, Porous Lightweight Clay Aggregate in Construction, Tradition and Innovation in Construction and Architecture, Proceedings of the 70 th All-Russia Scientific and Technical Conference (2012), Samara State University of Architecture and Civil Engineering, Samara, 2013, Vol.2, pp [11] S. Korotaev, V. Yerofeyev, Lightweight Concrete Production Based on a Porous Glass Bonding Agent, Proceedings of Mordovia State University, 4, 2008, pp [12] A. Kudyakov, T. Radina, M. Ivanov, Silica Fume-Based Granular Thermal Insulation Material, Building Materials, 2004, 11, pp [13] Y. Ivaschenko, A. Surnin, N. Zobkova, I. Pavlova, The Formula for the Production of Spherical Granules for Insulation, Patent no

5 608 Sergey A. Mizuriaev et al. / Procedia Engineering 153 ( 2016 ) Russian Federation RU, published on [14] A. Khlystov, Increased Efficiency and Improved Quality of Heat-Resistant Concrete Lining Structures, Refractories and Technical Ceramics, Moscow, 3, 2004, pp [15] S. Mizuriaev, Structuring of Thermal Insulation Materials Based on Water Glass, Achievements and Challenges in Materials Engineering and Modernization of the Construction Industry. Proceedings of the XV Academic readings of Russian Academy of Architecture and Construction Sciences, International scientific and technical conference, Kazan, 2010, pp [16] S. Mizuriaev, Optimization of the Structure of Porous Materials, Tradition and Innovation in Construction and Architecture, Proceedings of the 67 th All-Russia Scientific and Technical Conference (2009), Samara State University of Architecture and Civil Engineering, Samara, 2010, p [17] A. Mamonov, Design and Development of New Products, Tradition and Innovation in Construction and Architecture, Proceedings of the 68 th All-Russia Scientific and Technical Conference (2010), Samara State University of Architecture and Civil Engineering, Samara, 2011, p [18] S. Mizuriaev, Structured Sodium Silicate Porous Material with Improved Heat and Thermal Resistance, Building Materials, 7, 2011, pp [19] S. Mizuriaev, N. Ivanova, A. Zhigulina, A. Mamonov, A Method of Water Resistant Porous Filler Production, Patent no Russian Federation RU, published on [20] K. Galitskov, S. Galitskov, S. Shlomov, The Algorithm and the System of Automatic Correction of Cellular-Concrete Mix Design, Proceedings of Samara State Technical University (Engineering), 4 (32), 2011, pp [21] S. Galitskov, M. Nazarov, K. Galitskov, A. Maslyanitsyn, Ceramic Stones Moulding Management in a Screw Press Using Elements of Associative Memory, Scientific Review, 12, 2013, pp [22] S. Mizuriaev, Thermal Resistance in Construction, The journal of All-Russia Science and Research Institute of Technical Progress and Information in Construction, 3, 2006, pp [23] S. Mizuriaev, The Use of Thermal Insulation for Industrial Piping, Current Problems in Civil Engineering and Architecture. Education. Science. Practice. Proceedings of the 63rd All-Russia Scientific and Technical Conference (2005), Samara State University of Architecture and Civil Engineering, 2006, p [24] S. Mizuriaev, A. Zhigulina, A. Mamonov, A. Tsareva, The Development of Efficient Fire Resistant Cellular Insulation, Industrial and Civil Engineering, 2015, 6, pp [25] S. Mizuriaev, A. Tsareva, The Use of Dehydrated Hydrogen Peroxide as a Foaming Agent in Water Glass, Tradition and Innovation in Construction and Architecture, Proceedings of the 71 st All-Russia Scientific and Technical Conference (2013), Samara State University of Architecture and Civil Engineering, Samara, 2012, pp