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New Palusol® GenerationChemistry of silicate based passive fire protection materials
BASF SE | Ludwigshafen | Andreas Bolz | Performance Material
Intumescent MaterialsThe 3 fundamental product types
222.09.2016
Silicate – based products (Palusol®)Sodium-Silicate split off water vapor at >100C and begins to foam,
developing of a non-combustible, rigid, heat-insulating and pressure resistant
foam.
Graphite – based products (Exterdens®)Graphite, the natural foaming raw material, expands at >150/200C its volume,
developing of a combustible, flexible, heat-insulating and low pressure resistant
foam.
Phosphate – based products (Interdens®)Complex reaction of Phosphate with other ingredients at >250 C with the
evolution of gases (blowing agent), forms a high volume, soft and compressible,
heat-insulating foam.
At temperatures above 100C split off water vapor which act
as a blowing agent
Palusol starts foaming a pressure-resistant non-combustible
foam, that seals gaps and joints and prevents fire and smoke
from spreading to other rooms
The endothermic energy absorbing reaction develops a
cooling effect due to the evaporating water
How Palusol works
2 mm
12 mm
Characteristics of Palusol®
made from hydrated sodium silicate
since 1966 offered in form of sheets, which are
usually converted into strips for edge sealing
since 2005 also available in form of pre-fabricated
sandwich panels
About the product
Sheets SW panelsBrand
322.09.2016
Research & Development Targets
422.09.2016
Different Products
Different Application
Different Properties
Properties for Intumescent MaterialsRelevant parameters for passive fire protection products
522.09.2016
Palusol
Foaming Factor
Intumescent
Pressure
High Temperature
StabilityProcess Capability
Material
Brittleness/Flexibility
Water & CO2
Resistance
Specified Technical Data of PalusolProperties specified in the new ETA-15/0345
622.09.2016
Typ 100 Typ 104
Panel Thickness [mm] 1,9 ± 0,4 3,6 ± 0,6
Density [kg/m²] 3,0 ± 0,75 5,8 ± 1,5
Residue On Ignition (ROI) [kg/m²] 1,5 - 2,2 kg/m² 3,0 - 4,2 kg/m²
Foaming Factor 5,0 - 9,5 5,0 - 9,5
Intumescent Pressure [N/mm²] 0,95 - 1,60 0,95 - 1,60
Water Content [%] 25 - 40 25 - 40
Fire Behavior accord. to EN 13501-1 A2-s1,d0 A2-s1,d0
Approaches for New Silicate based
Intumescent Materials
722.09.2016
Manufacturing Method of Water Glass
Lithium PotassiumSodium
Modules
Composites
Gelling Agent Other AdditivesBlowing Agent
𝑀𝑜𝑑𝑢𝑙 =𝑆𝑖𝑂2𝑀2𝑂
SiO2= Quartz Sand
M=Li, Na, K Alkali Oxide
Silicon Dioxide
Silicate ChemistryBasics and challenges
822.09.2016
The silicate structure is very complex
The more substances are used the more complex the crystal lattice
a) Silicon b) Quartz Sand c) Alkali Silicate Glass
Silicate ChemistryGelling process from the water glass solution
922.09.2016
Cross-linking through polycondensation by splitting off water
Warning: Reverse reaction possible – hydrolysis / water solubility
After stabilization alkali silicates can be deformed through mechanical load
Warning: “Cold Flow”
Silicate ChemistryDegradation reaction of unprotected Palusol® sheets
1022.09.2016
The higher the carbon dioxide content the more silicic acid can be split off, the
worse the foaming behavior becomes in the fire resistance applications
Warning: The Epoxy resin coating must be applied to protect the material from
exposure to moisture and carbon dioxide
Na4SiO4 + 2 CO2+ 2 H2O
Si(OH)4 + 2 Na2CO3
2 H2O + SiO2
Blooming Effect: Sand & Soda do not foam
t, T, CO2
Targets for New Palusol GenerationFoaming factor
1122.09.2016
Double of foam height
Optimized foam cell structure
Higher flexibility of the sheets
0
2
4
6
8
10
12
14
16
18
?
+100% ?
Palusol NewPalusol 100
5 - 8,5
Targets for New Palusol GenerationReduced intumescent pressure
1222.09.2016
Reduced foaming pressure by approx. 30%
Rigid foam stability as usual
0,0
0,5
1,0
1,5
2,0
-30% ?
Palusol New
?
Palusol 100
0,95 – 1,45
Target for New Palusol GenerationIncreased temperature stability
1322.09.2016
40 min; 1000 °C
Before After
Evaluation Scale:
Reduction ≤ 33% High temperature stability
Reduction 33% to 66% Medium temperature stability
Reduction ≥ 66% Low temperature stability
Many Thanks For Your Attention !
1422.09.2016