LIGHT WEIGHT AGGREGATE FOR CONCRETE AND MORTAR
INSULATION SOLUTIONS USING LIGHT WEIGHT AGGREGATE
HyperPore is a lightweight aggregate made by expanding special natural clays at high temperature (1200°C). It is supplied either as granules in a range of sizes or as a crushed version, with a peculiar set of characteristics.
LIGHT WEIGHT AGGREGATE FOR CONCRETE AND MORTAR
ElitesGroup is manufacturing light weight aggregate – insulations HyperPores for the applications in the construction, geology , agriculture and landscaping.
HyperPores brings you the solutions for special structural concrete design, insulation mortars and insulation bricks.
TYPES OF HYPERPORES
All the standard versions of HyperPores normally contain a varying percentage of humidity but on request, can be supplied dry (humidity approx. 1%). HyperPores can also be manufactured as the HyperPores variant, which is dry and hydrophobic (p. 10).
HyperPores – G in granular form optimises the relation-ship between weight, lightness, and insulating ability. The characteristis pherical granules come in a wide range of sizes (denominations 0/2 – 2/3 – 3/8 – 8/20).
HyperPores – C can also be supplied in crushed form, in a range of sizes (denominations 0/2 FRT, 0/4 FRT and 2/4 FRT) suitable for use as a component in some lightweight concrete (e.g. for lightweight blocks and refractory products) and wherever there is a need for a lightweight fne material that has good insulation characteristics.
We use a particular manufacturing process to obtain a special type of HyperPores that has a denser and porous internal nucleus and a thicker, more tenacious ceramic “clinkered” external shell of particularly high compressive strength. Structural HyperPores – S is available in a range of sizes (denominations 0/5 – 5/15 – 5/15) for use as a component of lightweight structural concrete mixes (p. 24-25) and for all applications where particularly good mechanical performance is required.
HYPERPORES’ S CHARACTERISTICS
Lightweight, insulating, strong
Its porous internal structure means it is lightweight (from approx. 320 kg/m3), thermally insulating (from lambda [λ] 0.09 W/mK), and sound-absorbent. The ceramic “clinkered” outer shell surrounding the granules makes them very hard and resistant to compression (up to 12 N/mm).
Extremely stable and durable
iIt will not rot, cannot be attacked by parasites (fungus, rodents, insects, etc.), etc.), is resistant to acids, bases, solvents, and freeze-thaw cycles, is dimensionally stable and non-deformable, and retains its proper- ties unaltered over time; for all practical purposes this material will last forever.
HyperPore is used extensively in construction, both loose on its own or mixed with binders (cement, lime, resins, etc.).
It is widely used as a component of concretes (p. 24-25), in blocks and precast elements (p. 26-27), for agricultural and horticultural applications, and in geotechnical engineering and infrastructure works.
EN 13055-1, EN 14063-1, EN 13055-2
Flat and sloping roofs
When used on a roof HyperPores ensures that the necessary degree of isulation combined with high thermal inertia – the two indispensable requirements for comfortable winter and summer habitation – will be met. Because it is a lightweight material it can be laid to a considerable thickness without excessively loading the structure.
In its loose form, after it has been consolidated on its top surface, or has been bound with cement, it can be used as an insulation layer that can incorporate falls for rainwater run-o, or as ballast on top of a waterproof layer. If it is to take an impermeable membrane, a screed will be required (see p. 7). It can also be applied on roof pitches if is consolidated with cement.
As a base layer for a floor finish.
Because of the low specifc weight of HyperPores it can be laid to considerable thicknesses, and can incorporate services (electrical, water), whilst keeping the structural loading low.
The porous nature of the HyperPores granules gives excellent thermal installation and improves acoustic insulation. For laying the floor fnish, a lightweight insulating top screed is required, either using one of the mixes in the HyperPores range or a traditional sand/cement mix.
Lightweight insulating backfll, including for refractory purposes
New construction often requires a backl material that is stable, durable, lightweight, and non-combustible. It is even more frequently required for structural purposes in the refurbishment of old buildings, for instance as a lightweight l on top of old structural vaults and dierent types of floors and decks, etc. HyperPores is extremely well-suited to these applications. It can also be used as backl in proximity to structural elements that are combustible (such as timber stairs and suspended floors, in relation to which see also HyperPores p.10-11). HyperPores is also extensively used as an insulation material in civil and industrial construction as fre protection, for making safe active or redundant cisterns and storage tanks, for laying underground pipelines, and as insulation at high temperatures, including of refractory type.
Insulation for foundations and earth retaining walls.
The underground parts of buildings must be adequately insulated to reduce heat loss into the ground. HyperPores can be used for this purpose in civil, industrial, and zootechnical buildings, and as a hardcore layer with eective insulating characteristics below most floors, including industrial floors, refrigerated cold stores, or floors that incorporate heating pipework. For these types of application the recommended product is HyperPores (p. 10-11), which is also very effective against rising damp or as insulation and drainage behind vertical earth-retaining structures.
Lightweight structural cast concrete.
HyperPores are special high-strength aggregates that can be used as a component of lightweight structural concretes for the construction of collaborating floors, strengthening existing floors, and for in-situ or precast structures, giving signifcant weight savings as well as a number of other signifcant benefts (p. 24 – 25).
Landscaping and roof gardens
HyperPores is widely used as a lightweight drainage layer in landscaped areas (green roofs, roof gardens, ponds, planters), or as a component of the growing or mulching layer for all types of garden. HyperPores (p. 12-13), the special aggregate with neutral pH, is a suitable product for these applications and for hydroculture.
Blocks and small precast elements, including refractory products.
Geotechnical engineering and road construction
The lightness and strength characteristics (its high angle of internal friction) of HyperPores enable it to be used as a lightweight gravel for constructing embanked roads, reducing the weight of foundations, backling behind gravity retaining walls and reinforced retaining walls, stabilising slopes, backling tunnels and underground cavities, drainage, and in all geotechnical engineering applications (a specifc manual is available for these types of application). HyperPores can also be used as components of bituminous mixes for high-adhesion soundabsorbing asphalts.
PRINCIPAL METHODS OF APPLICATION: GRANULAR PRODUCT
The bearing layer must be solid, stable, free of cracks, discontinuities or loose parts, of high compressive strength, and free of dust or the remains of other materials. Any services previously laid on the bearing layer (electrics, water, drainage, etc.) must be adequately protected and distanced to prevent them from being damaged whilst the HyperPores granules are being laid. If the product is to be spread on the ground, a separating layer (such as a geotextile membrane) must first be laid.
In order to exploit to the full the insulating and lightness characteristics of granular HyperPores, the material should be laid loose and simply levelled to the thickness desired (with slight falls if required). If the top surface is not to be walkable it can be left as it is. If it is to be accessible or walkable or if a surface f nish, such as an impermeable layer or paving, is to be applied, it must be covered with a layer of another material
(various types of panel, a screed, a non-structural or structural floor slab, or plant growth soil), incorporating separation layers if required. N.B. the space to be f lled with HyperPores must be adequately contained at the sides, particularly if the layers are thick and if the material is to serve as backfill.
BINDING WITH CEMENT
Permeable concrete (open-pore structure) HyperPores binds easily with cement to give a lightweight insulating permeable concrete with better mechanical strength as compared to the loose product. These concrete mixes can be prepared using ordinary batchers or mixers.
TYPICAL FORMULATION PER M3:
• 1 m3 (20 bags) of HyperPores in the desired
• 150 kg of type 32.5 cement;
• 80-90 litres of clean water (or less if the material
is already wet).