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

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Research & Development Targets

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Different Products

Different Application

Different Properties

Properties for Intumescent MaterialsRelevant parameters for passive fire protection products

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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

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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

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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

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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

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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

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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

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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