Modifoam Construction Panels
Modifoam panel is made of two engineered welded mesh of 2" x 2" slot connected with a Zigzag G.I. wire at every 6". The core is polystyrene foam which acts as a filler shuttering material. Size of the panel is 10' x 4' & core thickness is 1.5" & 4", but it can be of any other thickness also.
These panels are extremely light weight (400 gm/ sq.ft for a 4" core panel). The panel can be cut & shaped as per requirement at site.
Specification
Procedure of Erection
Advantages
Gallery
FIRE RATING
| Ratings are valid for Fire Exposure from EITHER SIDE | |
| Fire rating is derived from the wire mesh gauge in combination with Concrete Thickness. | |
| The Foam Polystyrene Core demonstrates a flame spread index of 25 or less & a smoke developed rating of 450 or less, when tested in accordance with ASTM – E 84. |
(THE FOAM POLYSTYRENE CORE DOES NOT CONTAIN ANY OZONE DAMAGING CFC'S)
| FOAM POLYSTYRENE CORE | 100mm | 100mm | 100mm |
|---|---|---|---|
| PLASTER THICKNESS EACH SIDE | 35mm | 50mm | 80mm |
| FIRE RATING | Min. 1Hr 30 min | Min. 2Hrs | Min. 4Hrs |
(Note:Fire Rating increases with greater quantities of cement applied on each side and FOAM POLYSTYRENE CORE WILL NOT BURN)
ACOUSTIC VALUES
The SOUND TRANSFER COEFFICIENT (S.T.C.) attenuation of walls made out of Modifoam Panels is EXCELLENT.
The double shell configuration of the concrete plus foam Polystyrene plus concrete sandwich minimizes sound transmission.
TYPICAL S.T.C. is as follows:
| a. | 38mm Plaster on each side = [0.1304 x 38] + 43.48[4.9552] + 43.48 = STC of 48.4352 |
| b. | 50mm Plaster on each side = [0.1304 x 50] + 43.48[6.52] + 50.00 = STC of 50.0000 |
IMPACT RESISTANCE
The walls made of Modifoam Panels have a very high WIND LOAD BEARING CAPABILITY. It has been tested at 630 Kg/M2 pressure, which represents over 225 Mph wind pressure. Thereby proving its very high Impact Resistance.
THERMAL RESISTANCE
The R – VALUE (i.e., the material resistance to thermal penetration) of walls made of Modifoam Panels is exceptional as against most of the building materials. The foam Polystyrene core used in MODIFOAM PANELS has an excellent R-Value Rating. At 20 Kg/M3 density, as used in our panels, the R-Value of 5 per inch is available. The finished wall with plaster on both sides along with 100mm foam polystyrene core in between gives the wall an R- Value of 18 (one of the best thermal resistance for comfort conditioning applications)
Panel Erection Procedure
Modifoam Panels (Size: 3M x 1.2M) are erected in following format with ancillaries such as Jointing Mesh and "U" Clamps
| i) | "U" Clamps are fixed on the line on which the wall is to be created on both, floor and ceiling slab at a distance of approximately 24" from each other, by means of concrete nails. |
| ii) | Modifoam Panels are then placed on suchclamps and secured by means of binding wire. The panel to panel joints are secured by overlapping jointing mesh to defeat any possibility of cracks at the joints. |
| iii) | If any corner or curve is to be created in the panels, corner mesh are used to secure the joints. |
Concealed Wiring and Plumbing
Creation of cavities within the panels for Conduits and pipes is very simple.
| i) | After the marking of concealed wiring, switch boxes, plumbing pipe lines, cavity is made by a simple point naked flame which is shown on the core of the panel to create required cavity. During this process, the Foam Polystyrene core disintegrates when it comes in contact with the naked flame and cavity to run the electrical and plumbing services is created. |
| ii) |
After this, the services will be passed through the
cavities created by
your appointed agencies.For Switch Boxes or any other
services, if any wire
needs to be cut out from the mesh of the panels, the
same can be done with
the help of a bolt cutter. Please NOTE: While cutting such wires, the panels does not get sacrificed in any way. |
Fixing Door Frames & Window Sills
The edge of the PANEL, which is to take the door frame or be a window sill, will be reinforced by a "U" mesh which will be tied with the panels. Depending on the structural requirements, bit of the foam polystyrene core on the frame will also be removed to allow more concrete on the areas which will house-in the Window / Door JAMBS (Nails or Screws and Bolts).
Plastering and finishing
Once all the concealed services are in place, wall is ready to be finished with simple 1:4 sand – cement mortar application on both sides.
| i) | The plastering job is carried out in 2 coats to the desired thickness and finish of plaster. |
| ii) |
Once the wall is plastered and finished, the outputs
one gets is
An INSULATED & REINFORCED LIGHT WEIGHT CONCRETE
WALL. Now such wall is ready for its secondary finish and can be used or finished in every way, as done on a conventional Concrete wall. |
Fixing of Mounts
The basic procedure of fixing any kind of mounts over the walls made out of MODIFOAM PANELS is just the same as it would be done on a conventional concrete wall. For example, to mount a Plasma TV or a Mirror Panel or a Cabinet, one needs to bolt in a few screws in these walls as per the structural requirement of such product to be mounted.
Joints between the Panel and Concrete wall
Commonly, the partition walls made of Modifoam Walls will end on the regular RCC Pillar or Shear Wall and any other concrete surface. The cracks in the plaster at these joints are always the point of concern.
Fortunately, this problem is simply defeated in Modifoam Walls as such joints are always reinforced with jointing mesh (either flat mesh or corner mesh). Half of the mesh is overlapped on the panel and the other half on the concrete surface by means of u-nails. Thereafter the same gets hidden in the coat of plaster, done on both the surfaces. This way, both the surfaces get homogenized and the plaster coat treats it as one.
With the above procedures, one can get a VERY LIGHT WEIGHT REINFORCED CONCRETE WALL, which is resistant to both, sound and thermal transmission and has a very high Impact Load capability.
Advantages
| MODIFOAM FILL is a GREEN BUILDING PRODUCT, approved by Green Biulding Council. | |
| MODIFOAM FILL is extremely light weight (less than 1% on Soil Weight), making it easy to handle and install at on all floors, reduces weight on the structure, especially for high rise buildings and floors with large plate area. | |
| MODIFOAM FILL has a very high load bearing capacity. It can take a compressive load of 9-20 Tons/sq.mtr. Its Load bearing capacity does not change with thickness since this is a composite foam. | |
| MODIFOAM FILL does not absorb water (less than 1% on 24 Hrs. Immersion). There is No reduction in strength, both in DRY & WET condition. | |
| MODIFOAM FILL is a tailor made product to suit any Site Filling portion. | |
| MODIFOAM FILL can be applied in steps, slopes or any other shape that maybe required suiting the site conditions. | |
| MODIFOAM FILL is a ready to use material at a site, the wastage is virtually NIL and application is very very easy and very fast. | |
| MODIFOAM FILL can accommodate any Cladding, piping or any other utilities that maybe required by simply recessing the foam to any desired dimensions at the time of installation. | |
| MODIFOAM FILL is an excellent Thermal Insulation Material, having an "R" Value of 5 per Inch. This also acts as an excellent Sound Barrier and does not allow vibrations to pass through. |
Construction Panels
Procedure of Erection
Panel Erection Procedure
Modifoam Panels (Size: 3M x 1.2M) are erected in following format with ancillaries such as Jointing Mesh and "U" Clamps
| i) | "U" Clamps are fixed on the line on which the wall is to be created on both, floor and ceiling slab at a distance of approximately 24" from each other, by means of concrete nails. |
| ii) | Modifoam Panels are then placed on suchclamps and secured by means of binding wire. The panel to panel joints are secured by overlapping jointing mesh to defeat any possibility of cracks at the joints. |
| iii) | If any corner or curve is to be created in the panels, corner mesh are used to secure the joints. |
Concealed Wiring and Plumbing
Creation of cavities within the panels for Conduits and pipes is very simple.
| i) | After the marking of concealed wiring, switch boxes, plumbing pipe lines, cavity is made by a simple point naked flame which is shown on the core of the panel to create required cavity. During this process, the Foam Polystyrene core disintegrates when it comes in contact with the naked flame and cavity to run the electrical and plumbing services is created. |
| ii) |
After this, the services will be passed through the cavities created by
your appointed agencies.For Switch Boxes or any other services, if any wire
needs to be cut out from the mesh of the panels, the same can be done with
the help of a bolt cutter. Please NOTE: While cutting such wires, the panels does not get sacrificed in any way. |
Fixing Door Frames & Window Sills
The edge of the PANEL, which is to take the door frame or be a window sill, will be reinforced by a "U" mesh which will be tied with the panels. Depending on the structural requirements, bit of the foam polystyrene core on the frame will also be removed to allow more concrete on the areas which will house-in the Window / Door JAMBS (Nails or Screws and Bolts).
Plastering and finishing
Once all the concealed services are in place, wall is ready to be finished with simple 1:4 sand – cement mortar application on both sides.
| i) | The plastering job is carried out in 2 coats to the desired thickness and finish of plaster. |
| ii) |
Once the wall is plastered and finished, the outputs one gets is
An INSULATED & REINFORCED LIGHT WEIGHT CONCRETE WALL. Now such wall is ready for its secondary finish and can be used or finished in every way, as done on a conventional Concrete wall. |
Fixing of Mounts
The basic procedure of fixing any kind of mounts over the walls made out of MODIFOAM PANELS is just the same as it would be done on a conventional concrete wall. For example, to mount a Plasma TV or a Mirror Panel or a Cabinet, one needs to bolt in a few screws in these walls as per the structural requirement of such product to be mounted.
Joints between the Panel and Concrete wall
Commonly, the partition walls made of Modifoam Walls will end on the regular RCC Pillar or Shear Wall and any other concrete surface. The cracks in the plaster at these joints are always the point of concern.
Fortunately, this problem is simply defeated in Modifoam Walls as such joints are always reinforced with jointing mesh (either flat mesh or corner mesh). Half of the mesh is overlapped on the panel and the other half on the concrete surface by means of u-nails. Thereafter the same gets hidden in the coat of plaster, done on both the surfaces. This way, both the surfaces get homogenized and the plaster coat treats it as one.
Joints between the Panel and Concrete wall
Commonly, the partition walls made of Modifoam Walls will end on the regular RCC Pillar or Shear Wall and any other concrete surface. The cracks in the plaster at these joints are always the point of concern.
Fortunately, this problem is simply defeated in Modifoam Walls as such joints are always reinforced with jointing mesh (either flat mesh or corner mesh). Half of the mesh is overlapped on the panel and the other half on the concrete surface by means of u-nails. Thereafter the same gets hidden in the coat of plaster, done on both the surfaces. This way, both the surfaces get homogenized and the plaster coat treats it as one.
With the above procedures, one can get a VERY LIGHT WEIGHT REINFORCED CONCRETE WALL, which is resistant to both, sound and thermal transmission and has a very high Impact Load capability.
Gallery
