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Innovation

Superwalls latest generation building blocks for accelerated construction

In the design and construction of your low-rise buildings today, various firms and construction companies offer to focus on the use of outdated technologies using building blocks of the following sizes: 

Large: intended for mass construction, as a rule, of multi-storey buildings;

Small: oriented for the construction of small construction and utility rooms.

 

Technical and economic calculations today indicate that for the construction of low-rise buildings this choice is not optimal for the reasons listed below.

We offer a more rational option for choosing medium-sized building blocks for the construction, which combine the basic criteria of your right choice, namely:

  • The optimal estimated cost of building your home
  • Highest quality end product;
  • A rational combination of the two above parameters (price + quality);
  • Maximum speed and minimum construction time;
  • Guaranteed high rates of quality, reliability and durability.

Today, our company has implemented many real projects for the construction using Superwalls

In the near future, we plan to build up entire cottage villages, and even small towns with our own infrastructure

When choosing our offer, your building object at the lowest cost and the highest quality in 5 – 6 months will look like this:

technology

Superwalls building blocks

Our building blocks are high-tech modern products of the latest generation, which combine the best qualities of similar world-class products from leading domestic and foreign manufacturers.

The medium-sized building blocks of the latest generation of our company Superwalls through the introduction of innovative technologies allow getting the walls with high technical and economic indicators in accordance with European standards and state standards of the Russian Federation (GOST 27296-87; GOST R 56501-2015; GOST 33929-2016 ; SP 50.13330.2012; SNiP 23-02-2003, etc.).

The most promising and high-tech  building products are polystyrene concrete blocks of our production, which include Portland cement, lightweight filler in the form of granules of expanded polystyrene (polystyrene beads), quartz sand, water and superplasticizer* manufactured by our company Superwalls.

In general, polystyrene concrete is a type of lightweight cellular concrete and is a highly effective structural and heat-insulating material, in terms of energy-saving characteristics, it is 2-3 times more effective than gas, foam, expanded clay, perlite and other types of light concrete. This material allows building reliable, warm and durable buildings .

 

* Superplasticizer manufactured by our company

Superplasticizer of the latest generation is a broad-spectrum additive, manufactured on the basis of modified polycarboxylate, which allows to achieve a very low water-cement ratio and high strength of polystyrene blocks.

Technical characteristics:

Consistency: milky-green liquid

Density at +20°C. (g / cm): 1.055±0.02

Solid dry residue ( % ): 25.00 ±1.2

Chloride content ( % ): <0.1

Alkali content ( % ): <1.5

PH value: 7,5 ± 1

The state of superplasticizer liquid

Restoration of quality after freezing: complete restoration of the properties of the plasticizer after effective mixing.

Packaging: cans from 1 to 50 liters.

Dosage: 0.3-3.0 kg per 100 kg of cement. The optimal dose is 0.8-1.2 % of the cement weight.

Method of application: added to water for mixing.

Hazard identification: does not pose a health or environmental hazard

Flammability: not flammable

Superplasticizer shelf life: 12 months

Polystyrene concrete products are obtained by vibropressing (vibroforming)

The concrete mix is mixed more concentrated (more cement, less water). It is loaded into forms and sent to a vibrating press, where it is held to a semi-dry state. When stripping, blocks with a clear geometry are obtained, which are then sent for final drying.

Polystyrene concrete with different densities is obtained by changing the ratio of components and the type of polystyrene granules (the larger the diameter of the polymer balls, the lower the specific gravity and strength of the material).

Polystyrene concrete blocks are at the same time very durable, and do not need additional insulation. Blocks can be subjected to all the necessary processing – sawing, drilling, ditching channels for hidden wiring in them.

Our products are in high demand among construction organizations, individual developers and trading companies of building materials.

Due to the optimal composition and constantly improving technologies, the polystyrene concrete of our production has significant advantages relative to other types of lightweight concrete according to the indicators listed below:

Moisture resistance

This parameter is very important, since it directly affects almost all characteristics of the material: strength, durability, thermal insulation, microclimate, etc. The worst results for gas and foam blocks by this criterion are explained by the open pore structure. Polystyrene concrete does not absorb moisture, and the presence of wood tar carries a waterproofing function. Moisture does not affect the strength and heat-insulating properties of polystyrene concrete. The moisture ratio under operating conditions in polystyrene concrete is 5 times lower than in foam concrete and aerated concrete block. This explains the absence of microorganisms (mold and bacteria) inside the structure, which extends the life of this building material. Polystyrene concrete walls have the ability to "breathe", i.e. do not interfere with air exchange, and due to high vapor permeability - regulate air humidity. As a result of this, a favorable microclimate is established in the premises, close to the microclimate of wooden houses.

Thermal insulation

One of the best qualities of a polystyrene concrete block is high thermal insulation with low thermal conductivity. When using these blocks for building a house, we get a cozy and warm house. Insulate the walls from the outside is not necessary. During the summer hot season, inside the house there is a pleasant coolness, and in the cold winter heat is retained. The practice of erecting such houses shows that owners have the opportunity to significantly save on the heating season, up to 5 times in monetary terms. The level of thermal conductivity of polystyrene concrete blocks is 2–2.5 times higher compared to traditional foam concrete and expanded clay concrete. It is proved that in such a house is much warmer than in a house made of solid wood. In the winter season, if the heating is turned off in such a house, then it will cool down gradually, about one degree per day.

Soundproofing

Polystyrene concrete provides the best indicator of noise absorption, with a block thickness of 18-20 cm, it is absorbed from 70 decibels of sound. Warm concrete has small air pores in its composition, due to this, short sound waves are absorbed, and due to the presence of large pores, long waves are absorbed. Therefore, in such a house of polystyrene concrete creates a special comfort: Noises from the street and inside from the neighboring rooms and bathrooms do not bother.

Environmental friendliness

The international building code classifies polystyrene as one of the most energy-efficient and environmentally friendly materials. Compliance with the technology for the preparation of polystyrene concrete and the use of high-quality certified materials at the stage of preparation of the mixture gives a guarantee of the ecological purity of the material for use in construction.

Light weight

Polystyrene concrete is one of the only types of concrete for which low weight is characteristic. This allows reducing the cost of transporting blocks to the construction site due to the larger capacity. For example: the polystyrene block of the D-400 grade has parameters of 600x300x200 mm and weighs only 15.2 kg. Due to the lightness of the source material, the erected structure itself also has a reduced weight. Due to this advantage, the pressure on the foundation is much lower (about 7 times less) compared to if the house was built using brickwork.

Frost resistance

The ability to tolerate multiple alternate freezing and thawing in the most water-saturated state without loss of strength. Therefore, high water absorption and porous capillary structure determines low characteristics of frost resistance of foam and gas blocks. In contrast, polystyrene concrete has very high frost resistance, precisely because the material does not absorb moisture and does not cause damage to material when it freezes/thaws. Tests for frost resistance and amplitude of temperature fluctuations from + 750С to -400С were carried out at densities D300, D350, D400 for 150 cycles, D450, D500 for 200 cycles without loss of integrity and heat-insulating ability.

Seismic resistance, tensile strength in bending

The seismic resistance of polystyrene concrete from 9 to 12 points, having high elasticity, the unit withstands large vibration loads. Foam concrete and aerated concrete are fragile materials, they do not have a very important quality - bending and tensile strength, which means that earthquake resistance will be at a very low level - in case of an earthquake, the block is very likely to become covered with cracks and faults, which can cause the collapse of the whole design even with weak magnitude. Therefore, even a slight deformation of the foundation can lead to large cracks in the entire structure, and not along the seams, but along the blocks themselves.

Fire resistance

Polystyrene concrete does not burn, is able to withstand high temperatures caused by a fire, and due to its unique coefficient of thermal conductivity, it does not allow heat to penetrate deeper into the wall. Fire resistance EI180, Flammability group - NG non-combustible from density D300 and more. Fire hazard class K0. In the production of polystyrene concrete, polystyrene is used, which includes special fire-fighting additives - flame retardants due to which it does not support combustion and dampens.

Durability

Erected from polystyrene concrete blocks houses have a life of more than 200 years. This is due to the fact that the strength of cement every year only increases. Moreover, polystyrene granules found in the cement "cocoon" do not age. This is achieved due to the fact that the granules are not exposed to ultraviolet rays. Raw materials do not rot, as they cannot act as habitats for various microorganisms and fungi.

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