Advanced Building System: Resistance Thermal Insulation Energy Saving Fast Installation

PANEL SPECIFICATIONS
Advanced building system
 Resistance  Thermal Insulation  Energy Saving  Fast Installation
POLYSTYRENE
INDUSTRIES
LIMITED
1
1. INTRODUCTION CLASSIFICATION OF THE PIL PRODUCTS
Polystyrene Industries Ltd is manufacturing

company which specialises in the fabrication of
building material using Polystyrene technology .
Our factory boasts of state of the art equipment
which can produce both standard and client
tailored products with great efficiency and
precision.
This Technical Manual is to provide guidance and

www.Polyindustries.com.ng
direction for the most suitable method to install
the PIL Building System, in accordance with an Double Panel PSM/PST
Single Panel PSM/PST
acceptable design.
Floor Panel
Staircase Panel
Plot 416, Idu Industrial Layout, Phase 1, Abuja, Nigeria | Tel: +234 9 2916411 | Email: info@polyindustries.com.ng | Website: www.polyindustries.com.ng 1
2. DESCRIPTION OF THE PIL SYSTEM
2.1 FUNDAMENTALS OF THE PIL SYSTEM

The PIL construction system is based on a series of b) Electro-welded steel wire meshes made
polystyrene panels and galvanized steel wire of galvanized drawn steel wires placed
meshes. The shape has been especially designed on both sides of the polystyrene panel
for the introduction of traditional or structural plaster and connected by means of joints of the
during on-site panel installations. same material. The wire gauge steel net
varies according to panel type and mesh
PIL provides a system of industrialized modular direction.
panels allowing for faster assembly than
conventional systems. The PIL system fulfils the
w w w . P o l y i n d u s 2.3
t rPLASTERING
ies.com.ng
required structural and load-bearing functions,
After the panel assembly, structural
offering high thermal and sound resistance and a plaster should be sprayed and/or poured
wide range of shapes and finishes to provide on the panel-depending on panel type.
versatility in the design compaction process.
2.2 COMPOSITION OF THE PIL PANELS

The following are the basic components:
a) A foam polystyrene core which is non-toxic, non-
hazardous, self-extinguishing and chemically inert
with varying density and thickness depending on
panel type.
3. ADVANTAGES OF THE PIL SYSTEM
A. Versatility & diversity of panels to accommodate J. Highly fire-proof material

different architecture and design features. K. Easy and rapid installation of plumbing,
B. Thermal properties and sound resistance heating, electric, telephone system etc.
C. Easy to move, rapid assembly with little or no need L. Panels can be fabricated to customised
for lifting equipment and high durability lengths and thickness.
D. Structural capacity and resistance to earthquakes N. Panel surface and PIL plastering machines are
w w w . P o l y i n d u s t especially
and hurricanes r i e designed
s . c foroa m . nplaster
smooth g
E. No skilled labour is required spraying
F. Less construction time O. PIL panel meshes also include connection
G. Lower foundations costs compared with traditional flanges
systems P. The polystyrene core can avoid the thermal
H. Full utilization within the same building system bridge
I. PIL system easily integrates with traditional Q. PIL panels density does not change following
systems exposure to weather conditions over time.
SINGLE PANEL PSM/PST
4.1. PIL SINGLE PANEL PSM
Galvanized steel wire mesh:
Longitudinal wires: (gauge 12) (2,5 mm.) or gauge 9 (3,5 mm)

every 2.56 in. (65 mm.) Kind of Thickness Thermal transmittance
panel of finished U (W/m2 K)*
Transversal wires: Ø gauge 12 (2,5 mm) every 2.56 in. (65 mm) panel (cm) (in brackets values in BTU/h ft² F)
Cross steel wire: Ø gauge 11 (3 mm) (approx. 6 per ft3 - 68 per
sq.m.) Density 15 kg/m³ Density 25 kg/m³
Steel wire yield: fyk > 87082 PSI (600 N/mm²) (0,94 pound/ft ³ ) (1,56 pound/ft ³ )
Steel wire fracture: ftk > 98692 PSI (680 N/mm²)
Double connector Double connector
Polystyrene slab density: Approx. 1 lb/ft3 (15 Kg/m3) PSM60 13 0,570 (0,101) 0,520 (0,091)
Polystyrene slab thickness: from 1.57 in. PSM80 15 0,440 (0,078) 0,400 (0,070)
Finished masonry thickness: Variable, from 4.33 in.
PSM100 17 0,360 (0,063) 0,330 (0,057)
For the structural use of this panel, the polystyrene core should be at least 2 in. PSM120 19 0,300 (0,054) 0,270 (0,048)
6cm thick and an average quantity of traditional or pre-mixed cement based PSM140 21 0,260 (0,046) 0,240 (0,042)
plaster (lime < 5% on cement weight) of about 1.38 in. (about 1 in. over the
mesh) should be sprayed on each side having structural features of at least
3621 PSI (250 daN/cm2 ) of compressive strength. Sound proofing index: 45 dB **
Fire resistance: REI 120***
This panel is generally used for buildings of no more than 4-6 storeys, also in
seismic areas, for floor slabs and covering slabs with maximum spans of 13 ft.
at.
4.2. PIL SINGLE PANEL PST

Kind of Thickness Thermal transmittance
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Longitudinal wires:
Transversal wires:
Ø gauge 12 (2,5 mm.) every 2.56 in. (65 mm.)
Ø gauge 12 (2,5 mm) every 2.56 in. (65 mm)
panel of fin-
ished
(in brackets values in BTU/h ft² F)
U(W/m2K)*
Cross steel wire: Ø gauge 11 (3 mm) (approx. 6 per ft3 - 68 per panel Density 15 Kg/m³ Densità 25 kg/m³
sq.m.) (cm) (0,94 pound/ft ³ ) (1,56 pound/ft ³ )
Steel wire yield: fyk > 87082 PSI (600 N/mm²) PST40 9 0,814 (0,143) 0,743 (0,130)
PST50 10 0,674 (0,118) 0,613 (0,107)
PST60 11 0,574 (0,101) 0,522 (0,091)
PST80 13 0,444 (0,078) 0,402 (0,070)
Polystyrene slab density: Approx. 1 lb/ft3 (15 Kg/m3)
PST100 15 0,361 (0,063) 0,327 (0,057)
Polystyrene slab thickness: from 1.57 in (4 cm) to 12,60 in (32 cm).
PST120 17 0,305 (0,054) 0,347 (0,048)
Finished masonry thickness: variable, from 3.54 in (9cm) to 14.57
PST140 19 0,264 (0,046) 0,275 (0,042)
in (37 cm).
PST160 21 0,232 (0,041) 0,209 (0,037)
PST180 23 0,208 (0,036) 0,187 (0,033)
The PST panel can be used as internal partitions, external curtain walls,
PST200 25 0,188 (0,033) 0,169 (0,030)
Insulating walls etc. It’s similar to the PSM panel except for its polystyrene
core outline that is thinner and requires less plaster for its finishing.
Sound proofing index: 41 dB **
DOUBLE PANEL PSM/PST
4.3. PIL DOUBLE PANEL PSM/PST
The double panel PSM consists of

two single panels facing each other
and joined by steel pins keeping
www.Polyindustries.com.ng them at the distance established by
the static requirement to be met.
The space between them is filled
with cast concrete having suitable
longitudinal steel wires:
Transversal steel wires
Ø 3,0 mm
Ø 2,5 mm
resistance strength.
Joint steel wire Ø 3,0 mm
fkt: Ø 606 N/mm² Externally, the panels must be
fkt: Ø 681 N/mm²
sprayed on with plaster as the
single panels.
Polystyrene slab density 20-25 kg/m³
Polystyrene slab thickness: approx. 4.50 cm Although no additional
Finished masonry thickness: variable from 25 to 35 cm reinforcement is necessary for
Heat insulation coefficient: Kt < 0, 40 Kcal/h m² ºC (min)
Soundproofing index 1> 34 dB at 500 Hz (in frequency band)
buildings up to three storey’s, for
taller buildings the panel should be
further reinforced with internal
additional meshwork.
FLOOR PANEL PSM/PST
4.4 FLOOR PANEL PSSG2E AND PSSG3E
This type of panel enables the use of

the PIL system for floors and roofs
by inserting reinforced ribs in the
PSSG2E special spaces and subsequent
concrete casting on site. In fact the
reinforcement of the panel is
integrated during the panel
assembly by the insertion of
additional reinforcement bars-to be
PSSG3E substantiated by calculations –
inside the panel ribs.
longitudinal wires: ∅ 2,5 mm every 65 mm It is an ideal solution for floor slabs
transversal wires: ∅ 2,5 mm every 65 mm
joint wire: ∅ 3,0 mm having spans up to 6.5m. and the
steel wire yield: fyk > 600 N/mm² double rib for spans of up to 10m
steel wire fracture: ftk > 680 N/mm²
overloading up to 400 daN/m2.
Polystyrene slab density: 15 Kg/m3 furthermore, where the assembly
Heat insulation coefficient: Kt < 0,366 W/m2 °C (min.)
Soundproofing index: I > 38 dB at 500 Hz (in frequency band between sequence needs to be maximised,
100 and 3150 Hz) as far as the erection schedule is
concerned, it is possible to use iron
stiffening rib in the pods of the panel.
STAIRCASE / LANDING PANEL PSSC
VARIABLE RISER AND TREAD
METAL FRAMEWORK, H=13cm

Ftk>4500 Kg/cm2
POLYSTYRENE PANEL
Density 15kg
ELECTROWELDED MESH
Ftk>6000 Kg/cm2
4.5 PIL STAIRCASE PANEL PSSC & LANDING PANEL PNR
The panel consists of an expanded

polystyrene block shaped according to
designing requirements and reinforced by a
Variable tread and riser
steel mesh. The block is joined by steel wire
connectors welded in electro-fusion across
the polystyrene core.
Electrowelded mesh
ftk≥ 680 N/sq.mm.
Suitable reinforced and finished with casting
w w w . P o l y i n d u s t r i e s . c o m . n g
on site in the suitable spaces, it is used for
the construction of flight of stairs up to a
Foam polystyrene
maximum spans of 20 ft having a live load
density 15 Kg/cu.m.
of 82 lb/ft2 (400 Kgm2)
Additional reinforcement
(lattice of ribbed bars) The reinforcement steel bars have to be
Fyk≥ 430 N/sq.mm.
placed inside the holes.
Longitudinal wires: Ø gauge 12 (2,5 mm.)
Transversal wires: Ø gauge 12 (2,5 mm) Landing Panel Typical Section
Cross steel wire: Ø gauge 11 (3 mm)
Steel wire yield: fyk > 87082 PSI (600 N/mm²)
Polystyrene slab density: Approx. 1 lb/ft3 (15 Kg/m3)

Fire resistance REI 120*:
4.6 TECHNICAL SPECIFICATIONS AND USE OF STAIRCASE PANEL
This panel is used for the construction of

flight of stairs of up to 6m long (floor at
approx. 3-m intervals) having an accidental
overload of 400 kg/m².
During construction and prior to panel
assembly, the stair panel, lower channels
are filled with concrete (the panel being
placed upside down). This pre-cast operation
confers greater stiffness to the panel during
its assembly enabling at the same time a
drastic reduction of the number of props
used.
www.Polyindustries.com.ng Once the stair panel is assembled and the

lattice is placed inside the panel internal
channels, the latter are completed with
gravel concrete (whose particles size is < 12
mm and its minimum strength is Rck > 250
dN/cm²
The concrete may be cast in the panel ribs
Landing
Panel contemporaneously with casting of the upper
coating. In case this already exists, the
concrete may be applied to both the ribs and
upper joist.
Successively, the plaster layers (2.5cm thick)
are applied upon the flight of the stairs, first
the lower side and then the upper one, in
order to form the basis on which the flooring
(marble, ceramic tiles, etc) is to be laid.
5. BRACING MESHWORKS
Designed with 1inch galvanized steel wire, the

meshwork is used to reinforce all the openings and
corner-joint between panels so as to obtain a
continuity of the structural mesh.
Joints or crams are used to attach the mesh to the
panels.
ANGULAR MESHWORK RG1:

* Reinforces angle-connections.
Estimated efficiency:
4 units per angle (2 internal and
2 external) on average
FLAT MESHWORK RG2:

* Reinforces (at 45°) openings angles
* Restores meshwork that had been
previously cut
* for any joints between panels
Estimated efficiency:
2 units per door.
4 units per window.
“U” SHAPED MESHWORK RU:

* Restores the continuity of the panels
Along the perimeter of doors and windows
6. PIL PLASTER SPRAYERS FOR WALL User’s Instructions
AND CEILINGS
• The air pressure should be kept constant within a
The use of the devices easily enables time saving by 70-120 pound _500-800kPa range.
50% and with no need for skilled labour. With PIL
• No special plastering-machines are needed and the
sprayers, the plaster may be applied with a degree of
panel to be plastered required no previous
adherence that could not be achieved manually, in one
hour, one worker using a plaster sprayer with a preparation.
continuous flow of material placed nearby can apply a • For the plaster to be applied to the wall, the container
plaster layer of about 1cm over an area of up to 646 ft2 should be placed at a distance of 10-20cm.
(60 m2). PIL plaster sprayers are available in two • For the plaster to be applied to the ceiling, the upper
versions. edge of the container should almost touch the panel
W for walls and C for ceilings. Both models feature four at a maximum distance of 2-3cm.
holes for different types of plaster and come with all the
necessary tools to clean the machine after use.
Plaster sprayers maintenance
w w w . P o l y i n d u •s t r i e s . c o m . n g
Engine Power (HP)
From 3 to 4
Air Production (l/min)
350-400
No. Machines
1
During the usual interval between the application of
From 5 to 6 600-700 From 2 to 3
two layers of plaster, we recommend you place the
From 8 to 10 900-1000 From 3 to 4 empty container in a bucket filled with water and
make it work two or three times.
Note 1: • Remove lateral bolts and wash the inside of the
We recommend the use
the use of high pressure
machine at least once a week.
½” hoses note exceeding
30 linear meters. Compressors:
Either electrical or internal-combustion engine
compressors may be used keeping in mind the
following data.
Note 2:
When only one plastering-
machine is used, the ideal
cubic capacity of the
compressor container is
220 litres (not lower than
130 litres, but with pressure
regulator).
PIL Standard One
Bedroom 49sqm
ONE BEDROOM POLY-HOUSE FR

Total: Floor Area 49sqm
No. of Wall Panels: 40
PIL Standard Two
Bedroom 60sqm
TWO BEDROOM POLY-HOUSE FR

PIL Standard Three
Bedroom 80sqm
TWO BEDROOM POLY-HOUSE FR

CONSTRUCTION TECHNIQUE
1. FOUNDATION
Typical foundation incorporating DPCs should be

used. Starter bars either from foundation or ground
floor slab.
2. ASSEMBLY OF WALL PANELS
PIL Panels are anchored to the foundation or floor slab
at ground level with starter bars. In order to guarantee
the continuity among the elements, the PIL panels are
equipped on both sides with mesh overlap from panel
to panel and binding wire is used to secure the mesh
panels.
3. BRACING AND MESHWORK INSTALLATION
All Internal walls are reinforced with angular mesh which

gives the structural mesh greater continuity. By reinforcing
corners where two walls join. This mesh is applied to the
inside and outside of the wall and every intersection.
Door & Window Openings are braced using flat mesh at 45°
above (this acts as the lintel therefore no lintel is needed)
and below corners of the opening. “U” shaped mesh
reinforces the top of every panel, door frames and window
sills to provide extra-strong threshold to anchor frames.
4. SERVICES
The layering of pipes for plumbing, electrical

installation...etc takes place after the polystyrene panels
have been erected and before the spraying of concrete
take place.
The polystyrene is melted using a hot air gun or similar
tool. The electrical flexible pipes are placed under the
meshwork.
The area surrounding the cut should be restored by the
addition of extra mesh connected to the meshwork of
the panel.
5. SPRAYED CONCRETE
An approved concrete mix of 25Mpa is sprayed

on the panels using a plaster sprayer/spray gun.
Prospective Mass Housing
HEAD OFFICE/FACTORY:
ABUJA OFFICE:
PLOT 416 IDU INDUSTRIAL AREA
PHASE 1, ABUJA F.C.T. NIGERIA.
TEL; +234 09- 2916411, 09-2916412
07010612764, 07010612765, 08034040090
E-MAIL: inquiries@polyindustries.com.ng
WEBSITE: www.polyindustries.com.ng
LAGOS CONTACT:
Call:+234 08033076518

Advanced Building System: Resistance Thermal Insulation Energy Saving Fast Installation

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PANEL SPECIFICATIONS

Advanced building system

 Resistance  Thermal Insulation  Energy Saving  Fast Installation

Polystyrene Industries Ltd is manufacturing

This Technical Manual is to provide guidance and

2.1 FUNDAMENTALS OF THE PIL SYSTEM

2.2 COMPOSITION OF THE PIL PANELS

A. Versatility & diversity of panels to accommodate J. Highly fire-proof material

Galvanized steel wire mesh:

Longitudinal wires: (gauge 12) (2,5 mm.) or gauge 9 (3,5 mm)

Galvanized steel wire mesh:

The double panel PSM consists of

This type of panel enables the use of

VARIABLE RISER AND TREAD

METAL FRAMEWORK, H=13cm

The panel consists of an expanded

Polystyrene slab density: Approx. 1 lb/ft3 (15 Kg/m3)

This panel is used for the construction of

www.Polyindustries.com.ng Once the stair panel is assembled and the

Designed with 1inch galvanized steel wire, the

ANGULAR MESHWORK RG1:

FLAT MESHWORK RG2:

“U” SHAPED MESHWORK RU:

ONE BEDROOM POLY-HOUSE FR

TWO BEDROOM POLY-HOUSE FR

TWO BEDROOM POLY-HOUSE FR

Typical foundation incorporating DPCs should be

2. ASSEMBLY OF WALL PANELS

PIL Panels are anchored to the foundation or floor slab

3. BRACING AND MESHWORK INSTALLATION

All Internal walls are reinforced with angular mesh which

The layering of pipes for plumbing, electrical

An approved concrete mix of 25Mpa is sprayed

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