PRATLIPERL

The Modern Solution

For
Energy Efficient
Building

5/2/2014

A PRODUCT OF PRATLEY PERLITE MINING CO (PTY) LTD

P.O. Box 3055 • Kenmare 1745 • Gauteng • South Africa www.pratley.com
Tel: +27 11 955 2190 • Fax: +27 11 955 3918 • [email protected] /PratleySA @PratleySA
1 PRATLIPERL
THE MODERN SOLUTION FOR
ENERGY EFFICIENT BUILDING
Pratliperl, when mixed with cement,
produces an eco-friendly, ultra lightweight,
thermally insulating & fireproof concrete.

BENEFITS:
Exceptional thermal insulation.
Energy saving “green” product.
Ultra lightweight; reduces high rise
structural building costs.
Nailable.
Completely fireproof.
Durable.
Good acoustic properties.
Easy to apply.
May be gunited when applied to Use Pratliperl to render your buildings
large surfaces (e.g. mine tunnels). SANS 204 complient.
SOME EXAMPLES OF PRATLIPERL USAGE:
Thermally insulating and fireproof
wall plaster. Pratliperl
Ultra lightweight concrete, bricks
and boards.
Underfloor insulation and insulated
roof decks.
Lightweight screeds on corrugated Slope for water drainage
iron or concrete roofs. and
Fire proofing structural steel columns. fantastic thermal insulation.
Insulating industrial cryogenic tanks.
Loose fill thermal insulation in wall
cavities.
Pizza oven liners. Pratliperl screed at Loftus Stadium
Lightweight tile adhesive filler.

PROPERTIES:

Excellent Thermal Insulator - As a result of Pratliperl's Resistant to Spalling - Under fire conditions and, more severely, under
low density and physical structure, it keeps your house water quench conditions (e.g. from a fire hose) following extreme heat,
warm in the Winter and cool in the Summer. conventional concrete will spall and lose it's integrity. Pratliperl remains
intact.
SUMMER
Superb Strength -
Once cured, Pratliperl has
superior strength when
compared to ordinary
lightweight concretes.
Thermally insulated fireproof
Compatible with Cement Pratliperl roof
cool and Other Binders -
Pratliperl mixed with cement (and many other binders) can produce ultra
warm lightweight panels, boards, bricks and blocks that can be cut, nailed and
Just 16mm drilled.
of Pratliperl Plaster
doubles the thermal Non-toxic and Completely Environmentally Friendly.
insulation of a
two leaf (220mm) During a Fire, Pratliperl Will Not Spall nor Release Smoke or Toxic Fumes.
external brick wall!
Exceptional Fire and Heat Resistance - Can withstand temperatures up
to 1250°C without losing it's structural integrity.
WINTER

Pratliperl used
to insulate
Cryogenic tanks

warm
Fire Resistant
cool Pratliperl wall
Just 16mm between
of Pratliperl Plaster
doubles the thermal transformers
insulation of a
two leaf (220mm)
external brick wall!

Page 1
Eco-friendly
2 PRATLIPERL INTRODUCTION

Pratliperl and Pre-Treated Pratliperl are unique ultra lightweight and insulating materials of volcanic
origin. A deposit of which is found at only one location in South Africa and nowhere else. The
properties are similar to classical Perlite but differ in one significant respect. The pre-treated form is,
unlike ordinary Perlite, ideally suited for use with cement and other binders. This leads to an absolutely
unique 21st century building material.

During processing, ore is crushed to sugar grain size and passed through a specially developed
furnace. The grains of Pratliperl volcanic glass soften and the water trapped within the structure turns to
steam. The grains expand into a multitude of well-sealed lightweight glass beads. During this process,
much of the water escapes by diffusion. The remainder is re-absorbed into the glass structure. This loss
of water alters the
chemistry of the
glass and
significantly raises 10kg (±100l ) 10kg (±100l )
its melting
temperature. Under
the microscope,
each lightweight
tough bead
comprises a froth of
glass-walled closed
cells, each
enclosing a partial
vacuum. Expanded
Pratliperl is best
described as
comprising millions
of tiny sealed
"vacuum flasks";
hence its absolutely Untreated (For loose fill) Eco-friendly Treated (For use with cement)
unrivalled insulating
and fireproofing
properties.

3 PRATLIPERL PROPERTIES
See
www.pratley.com

3.1. Excellent Thermal Insulator

Pratliperl has a conductivity (k) value in the loose state of 0.05 W/m.K. This is 20 times more insulating
than sand! This property derives from the low density and the “vaccuum flask” like structure of Pratliperl
beads.

Just 16 mm of Pratliperl plaster each side gives the same thermal insulation as a double brick (220 mm
thick) wall. This incredible insulation value makes it easy for architects to comply with strict (SANS 204)
energy saving regulations.
SUMMER WINTER

cool warm

warm cool
Just 16mm
Just 16mm of Pratliperl Plaster
of Pratliperl Plaster doubles the thermal
doubles the thermal insulation of a
insulation of a two leaf (220mm)
two leaf (220mm) external brick wall!
external brick wall!

Pratliperl Insulating Plaster Pratliperl Insulating Plaster

Page 2
3.2. Ultra Lightweight
Loose density is approximately 100 kg/m³ and, when mixed with cement, practical concrete densities
range from 300 kg/m³ to 800 kg/m³ depending upon the mix. CONCRETE THAT FLOATS ON WATER!

3.3. Exceptional Fire Resistance

In addition to the almost refractory melting temperature of 1250°C, Pratliperl concrete also maintains its
high temperature structural integrity via its incredible thermal insulation.
The latter ensures a very high thermal gradient on the heated surface during fire conditions resulting in
low temperatures immediately below the surface. Even if the surface melts, it coalesces into molten
glass beads which continue to insulate and protect the interior.

3.3.1. Zero Smoke and Zero Fumes

Pratliperl is inorganic and therefore releases no smoke or fumes during a fire.

3.3.2. Amazing Resistance to Spalling

Under fire conditions and, more severely, under water quench conditions following a fire, (e.g.
from a fire hose) conventional concrete will spall and lose its integrity.
Pratliperl exhibits no such tendency.

3.4. Compatible with Cement and Other Binders

Pre-treated Pratliperl has a well-sealed and tough bead structure. This ameliorates bead damage
during mixing and facilitates low water adsorption and proper curing of the cement. Pre-treatment
renders the Pratliperl beads electrostatically attractive to cement and other binders.

3.5 Superior Strength

Ordinary lightweight concretes are typically weak. Aerated concrete is also susceptible to total slump
shortly after casting, especially if any vibration or disturbance like passing traffic is present. Pratliperl
concrete does not rely on air-entrainment and can be cured under any conditions of vibration. Once
cured, it exhibits surprising strength in comparison to other lightweight concretes. Strength varies with
density, but practical strengths in the range of 1.5 MPa up to 15 MPa are possible. This is nearly double
the strength of aerated concrete of similar density.

TYPICAL STRENGTH
Mix Ratio 6:1 10 : 1
(By volume) 3:1 4.5 : 1
Praliperl : Cement Mix Ratio Mix Ratio Mix Ratio Mix Ratio
Low High Low High Low High Low High
Water Quantity Water Water Water Water Water Water Water Water
Mix Mix Mix Mix Mix Mix Mix Mix
7 -day ISO comprehensive 3.9
14.2 5.0 12.6 5.2 2.3 N/A N/A
strength (Mpa)
28 -day ISO comprehensive 19.8 7.5 16.9 6.3 4.4 2.9 N/A N/A
strength (Mpa)
Dry density (kg/m3) 1100 900 800 650 550 450 360 350

3.6. Plaster Adhesion

"Pre-treated" Pratliperl, mixed with cement, can be plastered (without the use of
additives) either with a trowel or by spray to most common surfaces. In the case of
doubtful smooth surfaces, a recognised cleaning procedure, followed by the
application of a bonding agent, "Pratley Plaster Grip Primer", is recommended. In
this case, Pratliperl plaster will even adhere to smooth steel. Further Pratley Plaster-
Grip Primer data is presented on Pg 17 of this leaflet (see www.pratley.com).
3.7. Low Water Permeability is Possible
The Pre-treated Pratliperl, can be rendered almost watertight without the use of additives by mixing with
cement in the correct (3:1) cement rich ratio. Substrate corrosion can thereby be minimised.
3.8. Non-Toxic Dust
No dust is healthy. However, Pratliperl, due to its amorphous (non-crystalline) structure is classified as a
low health risk dust.

3.9. Ultra Smooth Plaster Finish

An ultra smooth plaster finish can be obtained just by steel trowel floating. No gypsum or finishing
plaster is necessary.
Page 3
4 PRATLIPERL TYPICAL APPLICATIONS

Internal & External thermally

Insulation for under floor
insulating plaster.
Building up lightweight heating elements.
floors in high rise buildings. Lightweight tile Adhesive
Thermally Insulating roof Filler.
decks. Ultra-lightweight concrete,
Fire seals and fire barrier bricks and boards.
walls. Pizza oven liners.
Lightweight Pre-cast Insulating Cryogenic tanks.
mouldings like flower pots. Loose fill thermal insulation.
Thermally insulating &
Paint texturing agent.
fireproofing mines & tunnels.
Refractory cements.
Lightweight thermally
insulating screeds. Insulation on surface of
Insulation below bath tubs. molten metal.
Internal & External thermally
insulating plaster.

Thermally Insulating roof decks.

Pizza oven liners.

Pratliperl concrete can be gunnited

Insulating Cryogenic tanks.
(Special Grade 45 Pratliperl Fire barrier wall between
required) transformers.

Insulation on surface of Pratliperl Concrete is Fireproof

Computer server room plastered molten metal and has a low Termal Conductivity
with Pratliperl to reduce
energy requirements for cooling. Typical K=0.13 W/mK°

Page 4
5 PRATLIPERL HOW TO MIX PRATLIPERL WITH CEMENT

1. Cement Type
For Pratliperl Plaster, use a reputable multipurpose cement. Screed mixes must be produced using
either a 42.5 Mpa or 52.5 Mpa cement with a CEM I or CEM II additive class (see back of cement bag
for class).
2. Mix Ratios
All mixing ratios are volume based!
3. Tip The volume of a Pratliperl bag = ±100 Litres.
The volume of a Cement bag (Pocket of Cement) = ±33 Litres.

1 Bag 1 Pocket

A 3:1 mix may therefore be achieved by mixing

1 bag of Pratliperl with 1 pocket of cement.
1 Bag ± 100 1 Pocket ± 33

3 Bags 2 Pockets
Similarly a 4.5:1 mix
may be achieved by mixing
3 bags of Pratliperl with 2 pockets of
cement. 1 Bag ± 100 1 Pocket ± 33

4. Mixing
Automated mixing is recommended
and a pan mixer is preferred. Drum
mixers can sometimes cause the
formation of balls. This phenomenon
results from Pratliperl's ultra light
weight. Where automated mixing is Pan Mixer
not possible, mixing small quantities
with a shovel is very effective.

4.1 In both automated and manual mixing, it is essential that the Pratliperl and cement are mixed in a
dry state before adding any water. This ensures uniform mixing of the cement powder and
Pratliperl beads. Adequate mixing is indicated by a uniform light grey colour throughout the dry mix.
Only once the dry mix is thoroughly blended, should water be added.

4.2 Once Pratliperl and cement has been thoroughly mixed, the recommended water volumes must be
added (see tables 1 to 4 on the mix ratio chart page 6). When compared to ordinary concrete, the mix
may appear dry. This is completely normal. It is important to monitor the amount of water added
since small variances in water have a significant effect on the overall consistency and slump. Do not
overdo mixing, approximately 30 seconds in a pan mixer is sufficient.

4.3 Yield
Approximately 11 bags of Pratliperl will be required for each cubic meter of screed/plaster. This value
is valid for all Pratliperl mix ratios and accounts for compaction and slight spillage. for more accurate
yields refer to tables 1 to 4 on the mix ratio chart page 6.

Page 5
 PRATLIPERL MIX RATIO CHART
TABLE 1. 3 : 1 MIX RATIO (BY VOLUME)
3 : 1 Volume Mix Ratio
Recommended Uses
Mix Ratio PRATLIPERL Cement Water
May vary with cement type
Approximate Compacted
Volumetric yield
External Plaster. 1 Bag ± 100 1 Pocket ± 33 Litres for Screed = 25-30
Internal Plaster. Pratliperl : Cement
Built Up Floors (Heavy Loads).
Insulating Roof Decks. 1 Bag : 1 Pocket Litres for Plaster = 28-37 ± 0.093m3
Fire Seals.
Castables (High Strength).
DON'T
Spray Applications. USE
Underfloor Heating Insulation. TOO MUCH
Lightweight Screeds (High 3 : 1 Mix Ratio by 1 Bag = 10 Kg's 1 Bag = 50 Kg's WATER
Strength). Volume = ± 100 Litres = ± 33 Litres

TABLE 2. 4.5 : 1 MIX RATIO (BY VOLUME)

4.5 : 1 Volume Mix Ratio
Recommended Uses Mix Ratio PRATLIPERL Cement Water
May vary with cement type
Approximate Compacted
Volumetric yield
External Plaster. 1 Bag ± 100 1 Pocket ± 33 Litres for Screed = 58-72
Internal Plaster. Pratliperl : Cement
Built Up Floors (Light Loads). 3 Bags : 2 Pockets Litres for Plaster = 74-93
± 0.280m3
Insulating Roof Decks (No Heavy
Loads).
Fire Seals. DON'T
Castables (Medium Strength). USE
Spray Applications. TOO MUCH
Lightweight Screeds (Medium 4.5 : 1 Mix Ratio by 3 Bags = 30 Kg's 2 Bags = 100 Kg's WATER
Strength). Volume = ± 300 Litres = ± 66 Litres

TABLE 3. 6 : 1 MIX RATIO (BY VOLUME)

6 : 1 Volume Mix Ratio
Recommended Uses Mix Ratio PRATLIPERL Cement Water
May vary with cement type
Approximate Compacted
Volumetric yield
1 Bag ± 100 1 Pocket ± 33
Pratliperl : Cement Litres for Screed = 39-45
3
Insulating Roof Decks. 2 Bags : 1 Pocket ± 0.186m
Fire Seals.
Castables (Low Strength). DON'T
Spray Applications. USE
TOO MUCH
6 : 1 Mix Ratio by 2 Bags = 20 Kg's 1 Bag = 50 Kg's WATER
Volume = ± 200 Litres = ± 33 Litres

TABLE 4. 10 : 1 MIX RATIO (BY VOLUME)

10 : 1 Volume Mix Ratio
Recommended Uses Mix Ratio PRATLIPERL Cement Water
May vary with cement type
Approximate Compacted
Volumetric yield
(Low Strength) 1 Bag ± 100 1 Pocket ± 33
(Reenterable)
Pratliperl : Cement Litres for Screed = 134-170
7 Bags : 2 Pockets
Fire Seals. ± 0.651m3
Castables
(Low Strength Very Light DON'T
Reenterable) USE
TOO MUCH
Insulation Between WATER
Cavity Wall.

10 : 1 Mix Ratio by 7 Bags = 70 Kg's 2 Bags = 100 Kg's

Volume = ± 700 Litres = ± 66 Litres

6 PRATLIPERL APPLICATION PROCEDURE:

A. PRATLIPERL PLASTERING PROCEDURE
1. Dampen the wall surface prior to plastering. This prevents premature
drying and cracking of the plaster mix.
2. For smooth surfaces, Pratley Plastergrip Primer is recommended. (Mixing
a small amount of Pratley Plastergrip Primer into the Cement/Pratliperl mix
will also enhance the bond). Previously plastered surfaces should be chipped
and then cleaned before applying Pratliperl plaster. This will ensure good
adhesion. A “slush” mix of cement, Pratliperl, Pratley Plastergrip Primer, river
sand and water can also be splashed onto the wall to improve adhesion.
Pratliperl should then only be plastered onto the “slush” after at least 12 hours.
3. Unlike ordinary plaster application methods, where the plaster is typically
“thrown” onto the wall, Pratliperl plaster is forcefully smeared onto the wall
with a float trowel using an upward motion. Pratliperl plaster is very light and
has less inertia than ordinary “sand plaster mixes” if thrown onto the wall.
Smearing the plaster upwards with pressure ensures a good bond and minimizes the possibility of air
being trapped between the wall and the plaster.
4. Allow the plaster to dry for at least an hour before applying a straight edge. A good check is to try
and indent the plaster using your thumb. It should only be possible to apply a small dent to the
Pratliperl plaster. Should a large dent occur, more time must be given before applying a straight edge.
Failure to do this will result in “smiley face” delamination.
5. Once leveled the plaster may be floated using a steel or wooden trowel.
6. Steel floated Pratliperl produces an extremely smooth finish. The application of a gypsum based
finishing plaster is therefore unnecessary.
7. As with ordinary plaster, Pratliperl plaster should be kept moist for at least 3 days after application (7
days recommended). The plaster should not be allowed to dry in direct sunlight or drying winds.
Cement within any plaster that dries too quickly does not have sufficient time to hydrate, resulting in
brittle plaster and cracks.
Page 6
 B. PRATLIPERL SCREEDING PROCEDURE
1. Ensure the surface to be topped is clean and free from any oil,
loose dust or particles.
2. Prior to screeding, smooth surfaces should be painted with
Pratley Plastergrip Primer. This ensures excellent adhesion. Pratliperl
screeds can even be applied to smooth steel/galvanised roofs
with the use of Pratley Plastergrip Primer. The Pratley Plaster-
grip Primer must not dry completely and should still be tacky
when the screed is applied. NOTE:- To prevent “chalking”
surface temperatures above 10ºC (preferably 15ºC) degrees
are essential when using Pratley Plaster Grip Primer.
3. Use a mix ratio and water content per the chart on page 6. NOTE:- The mix should appear very dry.

4. Using your hands, form a ball with the Pratliperl Screed mix. If the mixture binds together, the correct
amount of water and cement has been used. When the mixture is compressed between your hands
no water should flow from the mix. Water flowing from the mix indicates that too much water has
been added and The Pratliperl mix will have significantly reduced strength. Over use of water can be
easily rectified by adding the applicable ratio of dry cement/Pratliperl into the mix. Remember to
always premix the dry cement/Pratliperl mix before exposing it to water.
5. Pack the screed onto the surface and compact by tamping with a wooden trowel. When casting thick
sections, it is recommended that the screed be compacted (tamped) in sections of 100 mm.

6. Once compacted, level with a straight edge and smooth using a wooden or steel trowel.

7. If the Pratliperl surface is to be tiled, a wooden float or broom finish is recommended.

8. Following application, the Pratliperl screed should be kept wet for at least 3 days (7 days recommended).
Direct sunlight and drying winds must be avoided during curing. Drying under plastic is by far the most
preferred.

9. The screed must be dry and fully cured before applying ceramic tiles, paint, Bitumen and the like.

C. PRATLIPERL GUNITING PROCEDURE

Lower air velocities are used than those used when applying ordinary concrete. Lower velocities
minimize rebound and reduces waste. Pratliperl rebound can however be put back into the gunite
machine and re-used. A more cohesive mix is obtained by using a fly ash rich cement. This is recom-
mended.

D. PRATLIPERL AS A LOOSE FILL

Wall cavities can be filled with Pratliperl to enhance the thermal insulation. When using Pratliperl as a
loose fill, standard Pratliperl (product code 99020) must be ordered. For other applications requiring
cement, Pre-treated Pratliperl “For Plaster, Screed & Concrete” (product code 99031) must be used.
Pratliperl For “Plaster, Screed & Concrete” has been treated with a chemical which makes it com-
patible with cement. Standard Pratliperl contains no additives and is therefore used as a loose fill.

7 PRATLIPERL PRATLIPERL ENERGY SAVINGS

PRATLIPERL, REDUCES ENERGY COSTS AND SAVES YOU MONEY.

Thermal Properties:
A material that insulates well has a low "K" value (conductivity value). Pratliperl plaster insulates extremely
well and therefore has a very low "K" value. "K" has the units : W/mºK
Where: W = Watts
ºK = Kelvin or Degree Celsius
m = Meter
A wall material with a “k” value of say 0.8W/mºK would conduct 0.8 Joules of heat
energy per second through every square meter of a wall which is 1m thick and
where the temperature difference across the wall is 1ºC. The typical K values for
common brick, ordinary plaster and Pratliperl plaster are given below.

Wall Type K Value

Common brick 0.84 W/mK
Ordinary Plaster 0.80 W/mK
Pratliperl Plaster 0.12 W/mK
Page 7
Example of Energy Saving
16 220 16
Consider a 4m x 4m room with 220mm
double leaf brick walls. For comfort the
inside temperature is kept at 23ºC using COLD WARM
3°C 23°C
heating. Assume the outside air tempera-
ture is a wintery 3ºC.
For ease of calculation the convective HEAT
heat transfer on the wall surface has LOSS HEAT
LOSS
been neglected, similarly windows and
doors have been neglected.*
BRICK THICKNESS
RB = BRICK 0.220
The thermal resistance of the Brickwork is CONDUCTIVITY = 0.84 = 0.262

RP = PLASTER CONDUCTIVITY = 0.016 = 0.020

PLASTER THICKNESS
The thermal resistance of the Plaster is
0.80
PLASTER THICKNESS 0.016
The thermal resistance of the Pratliperl Plaster is RPP= PRATLIPERL PLASTER CONDUCTIVITY = = 0.133
0.12

The electrical analogue for the plastered wall is:

RP RB RP

Calculating the Heat transfer we get:

Unplastered Brick Wall

Q= t Note: The electrical analogue
RB

= 20
0.262
( ohm’s( ) law
I (Current) = V (Voltage)
R (Resistance)
(
Q = 76.4 W/m²
RB

Ordinary Plastered Q= t
Brick Wall RTOTAL
20
ORDINARY
= .020 + .262 + .020
PLASTER
Q = 66.2 W/m² RP RB RP

Pratliperl Plastered Q= t
RTOTAL HALVES TH
E
Brick Wall HEAT LOSS
!
20 76
PRATLIPERL = .133 + .262 + .133 38 VS
PLASTER
Q = 37.9 W/m²
RPP RB RPP

The Pratliperl Plaster DOUBLES the thermal insulation of the wall and HALVES the heat loss!
For our 4m x 4m room (with 40m² of walls) this is a saving of 1.54 Kw.
Assuming electricity costs R1.085 / Kw hr this is a saving of R40.10 / DAY!
If the floor screed was Pratliperl and the roof was insulated further savings would be achieved.
(*: If the convective heat transfer coefficient were accounted for the % of saving would be less but still very significant.

SUMMER WINTER

cool warm

warm cool
Just 16mm
Just 16mm of Pratliperl Plaster
of Pratliperl Plaster doubles the thermal
doubles the thermal insulation of a
insulation of a two leaf (220mm)
two leaf (220mm) external brick wall!
external brick wall!

Page 8
8 PRATLIPERL APPENDIX A - PRATLIPERL TEST REPORTS
The pages of this Appendix comprise summaries of official test reports issued by:
• 1. CSIR (Council for Scientific and Industrial Research)
• 2. SABS (South African Bureau of Standards)
• 3. PCI (Portland Cement Institute - now the Cement and Concrete Institute)
• 4. *COMRO (Chamber of Mines Research Organisation) - Now CSIR Mining Tech.
Reports:
CSI The Fire Properties of Pratliperl Panels
SABS Hydrocarbon Fire Tests (and Fire Resistance on Cable Penetration).
SABS Fire exposure Tests on Protected Steel Columns (2500mm x 200mm x 150mm).
SABS Termal Conductivity Tests.
SABS Surface Fire Index on Pratliperl.
SABS Non-Combustibility Test on Pratliperl.
PCI Evaluation of “Pre-treated Pratliperl”.
*COMRO Heat Gain Measurements on Pratliperl Insulation Systems.

1. CSIR TEST REPORTS

CSIR - THE FIRE PROPERTIES OF PRATLIPERL PANELS
A summary of a report undertaken by The Division of Building Technology, CSIR follows (the complete
report is available for inspection upon request).

Procedure: Three large panels (3 m x 1 m x 75 mm, masses 102 kg, 142 kg, and 182 kg, respectively)
consisting of Pratliperl aggregate with portland cement binder applied over “Space-frame” reinforcing
cage were tested for non-combustibility (SABS 0177: Part 5), for suitability as transformer fire shield and
for fire resistance, using the standard time-temperature mode.

Hose stream application after one minute. Condition of panels after Slight inwards dashing of
application of hose steam. the panels after 3 hours.
Results:
Non-combustibility -
1000 FIGURE 1 - Temperatures recorded in furnace
Temperatures recorded are
presented in Figure 1. (PRE-TREATED PRATLIPERL PANELS)

Tr a n s f o r m e r F i r e S h i e l d Te s t 800
The maximum deflection, in the form of
Temperature (°C)

slight inwards (into the furnace) dishing

600
was 15 mm in the centre of the panels.
This slight dishing after 3 hours exposure Average surf. temp. (102 kg panel)
can be seen in the enclosed photographs. Average surf. temp. (142 kg panel)
400
The condition of the fire-exposed face of Average surf. temp. (182 kg panel)
the panels immediately after the test and Average exposed face temp.
after shock quenching can also be seen in
200
the enclosed photographs. The fire-
exposed surfaces of the panels showed
only surface cracking, with none of the
0
cracks extending through the thickness
0
20
40
60
80
100
120
140
160
180
200
220
240

of the panels. There were no signs of

spalling and the panels were strong Time (minutes)
enough to be removed from the furnace
frame without the panels disintegrating.
Page 9
CSIR - THE FIRE PROPERTIES OF PRATLIPERL PANELS
Results (See page 9):
Fire Resistance
Average temperature on cold face of panel after 2 hours fire-exposure = 70°C.
Furnace temperature = 1 055°C.
Calculations indicate that a 75mm thick panel made of Pratliperl with a density of 1 000 kg/m³ will have a
fire-resistance of at least 4 hours, as a non-loadbearing element.

Conclusions:
• Pratliperl in non-combustible and liberates no smoke or toxic gas on exposure to fire.
• Unlike normal concrete panels, Pratliperl panels with “Spaceframe” reinforcing do not spall and deflect
only slightly on exposure to fire. Heat-flow through these panels is substantially less than through
normal concrete of equivalent thickness.
• The panels also did not disintergrate or spall explosively when subjected to a hose stream when hot,
like ordinary concrete panels do.

Fire shields constructed of Pratliperl panels will effectively protect adjacent equipment such as transformers
from radiation and conducted heat from a transformer oil fire for periods of at least 4 hours. When used as
a non-loadbearing element in buildings or for other applications, a fire-resistance rating of at least 4 hours
can be allocated to 75mm thick panels with a density of 1000 kg/m³.

2. SABS TEST REPORTS

SABS - HYDROCARBON FIRE TESTS
A summary of reports undertaken by SABS, 20 June 1991 [Ref. 19/03/21/07; Report Nos
653/82280/H3723/A, B, C, D, E] follows (the complete reports are available for inspection upon request).
A series of tests was conducted to evaluate samples for cable protection in high risk fire areas.

Test Procedure:

A cable tray was installed in the removeable wall of a vertical

furnace, extending approximately 800mm horizontally into the
furnace. A cable length was installed in the tray in such a
manner to form a loop. The cable tray was filled with a 3:1
Pratliperl plaster mix. Thermocouples were attached to the
cable, one to the top of the cable, one underneath the cable
and one to the side of the cable. The compositions described
were exposed in the vertical furnace, in accordance with the
procedures described in SABS 0177II. During the test, a 220V
electrical current was passed through two conductors of the
cable. The current was used to glow an electric light bulb. The
time at which the bulb failed to glow was recorded. The
temperature/time curve recorded was the hydrocarbon fire curve, also known as the “Mobile Fire Curve”.

Sample Minimum Cover Thickness (mm) Time Taken by Light Bulb to Stop (min)
3:1 Pratliperl fire-mix : OPC 35 103

Table 1: results of
Hydrocarbon Fire tests
Remarks:
The exposure of materials to a
simulated hydrocarbon fire
(Mobile Fire Curve) is a
method to study the behaviour
of materials under defined fire
conditions. The designer of a
specific construction can use
the information obtained to
decide on the parameters to
be specified for specific
applications.
Page 10
SABS - FIRE EXPOSURE TESTS ON PROTECTED STEEL COLUMNS
A summary of reports undertaken by the SABS, 15 July 1991 [Nos 653/82280/h3724 and H3725] follows
(the complete reports are available for inspection upon request).

Sample:

Standard H Section Steel Columns, 2 500 mm x 150 mm, with an average flange thickness of 15mm and
a weft thickness of 10 mm were protected as follows:
• The steel surface was treated with Pratley Plaster Grip Primer.
• A layer of plaster material, 30 mm thick, was applied to the column.
5:1 Pratliperl : OPC
3:1 Pratliperl : OPC

Nature of Tests:

The tests were conducted in a vertical furnace in accordance with procedures described in code of
practice SABS 0177-II

Observations and Remarks:

A 5:1 Pratliperl : OPC: At the end of the 120 min test procedure, the average steel temperature
was temperature of 314°C (furnace temperature 1046°C)
B 3:1 Pratliperl : OPC: At the end of the 120 min test procedure, the average steel temperature
was 364°C and a single highest point reached a temperature of 384°C
(furnace temperature 1050°C

SABS - THERMAL CONDUCTIVITY TESTS

A summary of reports undertaken by SABS, 5 August 1996 [Nos 722/82402/4249] follows (the complete
reports are available for inspection upon request).

Method of Testing:
Samples A-D were tested on a Heat Flow Meter Apparatus in accordance with ASTM C518.

Table 1: Results of Thermal Conductivity Tests

MEAN TEMP. MIX RATIO NORMAL THERMAL

SAMPLE (Pre-treated DENSITY CONDUCTIVITY
(°C) Pratliperl:Cement) (kg/m³) (W/m.K)

A 25.5 3:1 770 0.15

B 25.3 4.5:1 670 0.13
C 25.3 6:1 480 0.12
D 25.3 10:1 360 0.09

SABS - SURFACE FIRE INDEX TEST ON PRATLIPERL.

A summary of a report undertaken by the SABS, 16 October 1987 [Nos 653/81590/D2462] follows (the
complete report is available for inspection upon request).

Sample:
Boards made of 5:1 Pratliperl : Cement

Nature of Test:
Tests to establish the surface fire index were carried out in a tunnel furnace
according to SABS 0177: Part III.

Results:
Spread of flame index 0
Heat contribution index 0
Smoke emission index < 0.1
Surface fire index 0
Class 1
Page 11
SABS - NON-COMBUSTIBILITY TEST ON PRATLIPERL
A summary of a report undertaken by the SABS, 16 October 1987 [Nos 653/81590/D2463] follows (the
complete report is available for inspection upon request).

Sample:
Blocks made of 1:5 cement: Pratliperl.

Nature of Test:
Tests to determine the non-combustibility of the material were carried out in a furnace according to SABS
0177: Part V.

Results: The sample was found to be non-combustible.

3. PORTLAND CEMENT INSTITUTE REPORTS

PORTLAND CEMENT INSTITUTE - EVALUATION OF “PRE-TREATED PRATLIPERL”

A summary of a report produced by the PCI, 30 March 1992 [Ref. 984/94NPD/jaf] follows (the complete
report is available for inspection upon request)

A series of tests was conducted to evalute Pre-treated Pratliperl. These included strength tests and limited
shrinkage tests on nominal 3:1, 4.5:1, 6:1 and 10:1 (volume) mixes covering a range of consistence
between 40 mm slump and 120 mm slump. In the list of tests which follow, the test procedure adopted is
shown in parenthesis.

• 7-day and 28-day compressive strength on water- and air-cured specimens (SABS Method 863)
• Permeability tests at 28 days (DIN 1048)
• Wet density (100 mm cube specimens, weiging immediately after demoulding).
• Dry density and rate of moisture loss (weighing, to constant mass, 100 mm cube specimens air-dried
and in a drying oven between 100°C and 110°C.
• Initial drying shrinkage (SABS Method 836).
• Wetting expansion (SABS Method 836).
• Slump (PCI TM 6.2)
• Flow (SABS Method 862-2)
• Air content (SABS Method 1252)
• Water retentivity (BS 4551)
• Consistence retentivity (BS 4551)
• ISO flexural and compressive strength (EN 196)
• Modulus of elasticity (PCI TM 7.6)
• Assessment of “plasterability” of each mix.

COMMENTS

General
• The water : cement (W:C) ratio is very important. It was considered better to measure properties
over a range of water contents rather than a range of slumps, since consistence achieved was
dependent on mixing time.
• The water requirement is fairly consistent over a wide range of aggregate : cement ratios. Water
should be added slowly during mixing over a period of time to activate the admixture in case the
required slump is exceeded.

Compressive Strength
• For richer mixes, water content had a large influence on the resultant consistence, compressive
strength and flexural strength. Its influence diminished as the aggregate : cement ratio increased.
The compressive strengths achieved were well above average for a lightweight mortar using OPC.
• Relationship between 7-day and 28-day strengths are normal for standard-cured specimens.
• Specimens dry-cured dor 28 days yielded strengths approximately 70% of standard-cured specimens.
At 7 days there was vitually no difference.
• Results of ISO tests follow a similar pattern.
Page 12
PORTLAND CEMENT INSTITUTE - EVALUATION OF “PRE-TREATED PRATLIPERL”
COMMENTS (Also see page 12)

Density
• Wet densities varied from approximately 700 kg/m³ to 1 100 kg/m³. Dry densities varied from
approximately 300 kg/m³ to 800 kg/m³.
• Graphs showing the rate of moisture loss are shown in Figure 1.
• Specimens were virtually dry in 24 hours at 100°C (oven drying). Specimens took longer than two
weeks to dry (Figure 1) when air-dried under favourable drying conditions (22,5°C, RH<50%). No
micro-cracking was observed for both methods.

Permeability
• According to DIN 6.5.72 a concrete with thickness of 100-400mm will be waterproof if maximum
penetration is not >50mm. Further, the W:C ratio should not be >0.6.
• The 3:1 mix was deemed watertight. This may be partially due to the mix having a W:C ratio of 0.57
and partially due to the high air content (18.5%).
• The 4.5:1 mix was not tested.
• The 6:1 mix was not watertight. Very little water passed through at 1 bar pressure but this
increased significantly when pressure was increased to 3 bars.
• The 10:1 mix was not watertight.

Initial Drying Shrinkage and Moisture Movement

• The shrinkage values are relatively low for lightweight mortar.
• The shrinkage values are only slightly affected by change in consistence but significantly affected
by change in cement content.
• Wetting expansion values are abive average for conventional aggregate but are quite normal for
lightweight aggregate.

Slump Testing
• If slump tests are not done quickly, water bleeds from the base of the slump cone, leaving a mortar
with poor flow properties. This leads to anomalous slump readings, especially for the 10:1 mixes.
In these situations the flow test is considered a better test.

Air Content
• The measured air content increased with increasing consistence and with decreasing cement
content.
• Mostly, air contents were in the order of 20%. Notable exceptiond were the rich 3:1 mixes,
particularly at the drier consistence.

Water and Consistence Retentivity

• BS 4551 recommends that, when masonry cement is used , water retentivity should be between
70% and 95%. The European standard for masonry cement (EN 413-1) specifies that water
retentivity should fall between 80 and 95%. PCI believes that for good workability the value should
fall between 85 and 95%.
• Water retentivity, for 3:1 and 4.5:1 mixes, was considered satisfactory. It was considered borderline
for the 6:1 mix and poor for the 10:1 mix.

Plasterability
• The ability to successfully plaster with the various nominal mixes is in line with the measured and
observed water retentivities.
• The 3:1 and 4.5:1 mixes could be used for plaster without difficulty. The 6.1 mix could be used for
plaster but the mix lacked adequate cohesion. The 10:1 mix was unsuitable for plastering.

Page 13
PORTLAND CEMENT INSTITUTE - EVALUATION OF “PRE-TREATED PRATLIPERL”

FIGURE 1 - PRE-TREATED PRATLIPERL FIGURE 2 - PRE-TREATED PRATLIPERL

Rate of Loss of Moulding Moisture Strengths - Range of Consistence
400
Moisture Loss (g)
30

Compressive
Strength
300 20

(MPa)
200 10
100 0
0 0 5 10
0 2 4 6 8 10 12 14 16 1820 22 24 26 2830
Aggregate/Cement Ratio (Volume)
Time (Days)

3:1 6:1 10:1 low slump high slump

FIGURE 3 - PRE-TREATED PRATLIPERL FIGURE 4 - PRE-TREATED PRATLIPERL

ISO Strengths - Range of Consistence
Approximate Slump vs Compressive Strength
0.20
ISO Compressive

25

Compressive
Strength (MPa)

0.15

Strength
28 day

(MPa)
15
0.10
5
0.05 -5
0 100 200 300
0.00
Approximate Slump(mm)
0 5 10
Aggregate/Cement Ratio (Volume)
3:1 4.5:1 6:1 10:1
low slump high slump

FIGURE 6 - PRE-TREATED PRATLIPERL

Density vs Air/Cement (vol) Ratio
FIGURE 5- PRE-TREATED PRATLIPERL
1600
Water Content vs Slump
Density (kg/cu m)

300 1100
Water Content
(l/cu m)

250 600
200
100
150
0 100 200 300 -400
0 5 10
Approximate Slump(mm) Air/Cement Ratio (vol)
3:1 4.5:1 6:1 10:1 wet density - low slump
wet density - high slump
dry density - low slump
dry density - high slump

FIGURE 7- PRE-TREATED PRATLIPERL

FIGURE 8- PRE-TREATED PRATLIPERL
Air/Cement Ratio (vol) vs Compressive Strength
Cement Content vs Air/Cement Ratio (vol)
25
Strength (MPa)

600
Approximate
Compressive

(kg/cu m)
Cement
Content

15 400
28 day

200
5
0
-5 0 5 10 0 5 10
Air/Cement Ratio (vol) Air/Cement Ratio (vol)
low slump high slump

Page 14
 4. CHAMBER OF MINES REPORTS

CHAMBER OF MINES - HEAT GAIN MEASUREMENTS ON PRATLIPERL

INSULATION SYSTEMS
A summary of reports undertaken by the COMRO (Chamber of Mines Research Organisation - Now CSIR
Mining Tech.), in April 1989, follows (complete reports are available for inspection upon request).

The following insulation systems were tested:

1. Loose Pratliperl (thickness approximately 50 mm).
2. Evacuated Pratliperl (thickness approximately 36 mm; vacuum measured to be 200 µm of mercury
[approximately 27 Pa absolute]).
3. Half sections of Pratliperl with a phenolic foam binding agent (thickness approximately 52 mm).

Procedure: AIR
HEAT FLUX
Figure 1 shows the apparatus used PAD
to measure heat flow through the PRATLIPERL
insulation system. STEEL PIPE

CHILLED
WATER

SURFACE FOR
RADIANT
HEAT
TRANSFER

Figure 1: Cross Section Through Insulated Pipe and Heat Flux Pad in situ.
Results:
Table I lists the test conditions and the measured heat gain under these conditions, compared to the
corresponding heat gain under the conditiions listed in the Anglo American specification for thermal insulation
of chilled water reticulation piping.
Table I: Test Conditions and Results

ACTUAL TEST CONDITIONS ANGLO AMERICAN SPECIFICATION

SAMPLE 1 SAMPLE 2 SAMPLE 3 SAMPLE 1 SAMPLE 2 SAMPLE 3

PARAMETER Phenolic Phenolic
Loose Evacuated Loose Evacuated
Pratliperl Pratliperl Binder + Pratliperl Pratliperl Binder +
Pratliperl Pratliperl
Water Velocity (m/s) 0.9 0.9 0.9 1.0 1.0 1.0
Water Temperature (°C) 6.4 6.3 5.8 5.0 5.0 5.0
Air Velocity (m/s) 6.5 6.5 6.5 5.0 5.0 5.0
Air Temperature (°C) db 33.2 34.2 34.0 32.0 32.0 32.0

Heat Gain (W/m) 14.5 7.8 10.9 15.2 8.0 10.5

The heat gain value measured under the above test conditions was used to calculate the equivalent
thermal conductivity of the insulation system:-

Sample No. 1:-

Heat gain: 14.5 W/m (corresponds to an effective thermal conductivity of
0.049 W/mK ±10%).
Anglo American specification: 15.2 W/m (Max.)

Sample No. 2:-

Heat gain: 7.8 W/m (corresponds to an effective thermal conductivity of
0.018 W/mk±10%)
Anglo American specification: 8.0 W/m (Max.)

Sample No, 3:-

Heat gain: 10.9 W/m (corresponds to an effective thermal conductivity of
0.033 W/mK±10%).
Anglo American specification: 10.5 W/m (Max.)
Page 15
9 ON-SITE PRACTICAL TRAINING & COUNTRYWIDE DELIVERY

ISO 9001

CE N
RTIF
ICATIO TM
MANAGEMENT

Intertek
SYSTEMS
014

A Student

Feb 2014

Page 16
10 OTHER PRODUCTS IN THE PRATLEY CONSTRUCTION RANGE

PLASTER-GRIP
PRIMER
ADHESIVE: Pratley Plaster-Grip Primer renders almost any
surface plasterable, even smooth surfaces like
Cat. no. 98031
10l Bucket
steel or glass!
SEALANT: It also saves paint by bonding and sealing
porous surfaces prior to painting.
When plastering
It is useful on poor or porous substrates or on smooth
surfaces like steel. For example, Pratliperl fireproof
plaster can be applied to steel structures primed with
Plaster-GripPrimer.
When painting
It saves paint by sealing porous surfaces. It also
facilitates painting directly onto old lime (white wash)
surfaces and the painting of galvanized iron.

DIRECTIONS-
Stir before use.
Paint or spray Pratley Plaster-Grip Primer
onto the surface.
Plaster-Grip Primer will become
Use only one coat of transparent in about 20 minutes.
Plaster-Grip Primer remains tacky for
paint instead approximately 30 minutes after becoming
of three! colourless.
Plaster or patch work must commence as
soon as the product becomes transparent,
Cat. no. 98030 Cat. no. 98032 viz. it must still be tacky!
5l Bucket 1l Bucket Plaster-Grip Primer will lose its efficacy if
plastering is attempted after it dries
completely (tack-free).
Allow to dry completely (tack-free) before
COVERAGE 4 m2/ on porous surfaces.
painting.
6-8 m2/ on non porous surfaces.
WARNING:- To prevent "whitening" do not
use in ambient temperature below 10°C.

SOME SUGGESTED APPLICATIONS

Plaster Paint Bond
- Prime smooth steel before - Prime Galvanized iron. Then paint - Prime chipped corners and steps
plastering. directly. before patching.
- Prime smooth concrete before - Prime newly plastered absorbent
plastering. walls (saveup to two coats of paint). - Prime concrete before applying
- Prime poor and absorbent old - Prime old lime washed walls then floor topping screed.
walls before plastering. paint directly with PVA. - Even use as a wood glue.
- Prime steel then apply - Prime onto PVA before applying oil
Pratliperlfireproof Plaster. based paint.
POLICY
STATEMENT
"The performance
of our products must
exceed all others on
the World Market"

CEO

PAINT over Plaster-Grip PLASTER over Plaster-Grip TILE over Plaster-Grip

Primer. Primer. Primer Leaflet no. 201 - 12/4/2013

Page 17
 POLICY

Flexiseal
STATEMENT
"The performance
of our products must
exceed all others on
the World Market"

CEO

PRATLEY FLEXISEAL is a superior quality, permanently flexible acrylic sealant and filler. It also has
exceptional adhesive properties and can be painted over.

Unlike silicone, FLEXISEAL needs no primer to adhere to concrete and brickwork and it is exceptionally
ultra-violet resistant.

Excess product may easily be washed off with water

before it is cured.

When cured it is waterproof and resistant to most

common chemicals.

Contains fungicides (not harmful to humans) so it is

milldew resistant.

SOME SUGGESTED USES:

Ideal for filling wall cracks, then paint over.

Stick Polystyrene insulation sheets under IBR.

Seal window frame and door frame surrounds.

Seal between wall and bath or basin.

Ceramic wall tile adhesive.

Seal corrugated iron roof sheets and roof bolt heads.

Seal around toilet bowl inlet pipe.

Seal and join leaking gutters.

Note:
1) Not recommended for use on
Perspex or Plastic tiles.
Catl. no. 93002 2) Prolonged immersion in water
125g Tube will soften FLEXISEAL.

Cat. no. 93009 Catl. no. 93007

400g Cartridge 500ml Bucket

OUTSTANDING FEATURES: Can be smoothed with a wet

Can be painted. finger/spatula.
Contains fungicide - (Sanitary). Long shelf life.
Exceptionally UV resistant (UV stabilized). No primer required
Exceptional adhesive properties. Permanently waterproof once cured.
Very easy to apply. Retains exceptional flexibility/elongation.
Excess is simply washed off with water. Backed by Pratley technology and service.

PHYSICAL PROPERTIES:
DENSITY Wet Density - 1,42g/m DUMBBELL 100% Modulus - 0,18 - 0,2 Mpa
nominal MODULUS 200% Modulus - 0,25 Mpa

pH 7,3-7,9 (nearly neutral)

SKIN AND Tack-free time: ±20min at 25%C
CURE TIME 100% cure time - (6mØ bead)
400% ± 7 days
ELONGATION TO BREAK

PEEL AND ADHESIVE Excellent on glass, aluminium,

TENSILE STRENGTH 0,26MPa (37,5 Psi) STRENGTH ceramic, wood, some plastics
and most rubbers

Pratley (Pty) Ltd. P O Box 3055 • KENMARE 1745 • Gauteng South Africa • Tel.:+27 11 955-2190/8 • Fax: +27 11 955-3918
www.pratley.com 083
12/4/2013

Page 18
PRATLEY PRATLEYMIX Cat. no. 89247
A very high strength epoxy based industrial adhesive and repair
medium. Formulated to set hard yet be tough enough to take
impact loads. A standard (slow) setting product with wide
industrial applications.
SOME SUGGESTED USES:
1. Seal cracked pipes and floors.
2. Fix loose screws and tiles.
3. Grouting window frames etc. into brickwork.
4. Repair boat hulls, cars and caravans.
5. Repair cracks in toilets, basins and baths.
6. Repair floortiles and flooring. PACKAGING:
7. Fill cracks and chips in stairs. Each pack contains 2
8. Seal gutters, gutter pipes and roofs. x 250ml Jars.

MIXING INSTRUCTIONS
MIXING: 1 NB! Mix equal proportions of each jar
1. Measure equal proportions from each jar using separate
spatulas. Replace lids on the correct jars, according to
colour sticker (see Fig below).
2. Mix throughly until colour is quite uniform.
2
APPLICATION:
Using a suitable tool (putty knife, trowel, etc.) spread Replace lids
Jar with colour on the correct Jar without
and work onto surface. Remove excess and clean sticker on the sticker.
surrounding surface with a damp cloth. Smooth by lid and the jar.
jars.
stroking lightly with tool or wet finger when partially set.
GENERAL INSTRUCTIONS 250 ml 250 ml
1. Remove dirt, grease, rust and paint from the applica-
tion surfaces by wire brushing, scraping or sanding.
Oil or grease should be removed using any non-oily
solvent. The rougher the cleaned surfaces the better 5. This product will set hard in 3 to 6 hours depending on ambient
2. In cold weather slight warming of the jars will make temperature, and cure to maximum strength in 24 hours.
mixing and application easier. Hardening and curing can be accelerated by heating to not
more than 150° C. Warming is recommended in cold weather
3. The two components must be mixed in equal propor- to avoid an unduly long curing period.
tions. Do not mix more than can be used in 15 to 20
minutes. IN THE EVENT OF THE CONTENTS BEING TOO STIFF TO WORK
4. Use separate spatulas for each jar. Do not mix the EASILY, WARM THE JARS IN HOT WATER AND STIR CONTENTS
GENTLY
lids of the jars. Reseal jars properly after use.

PRATLEY SILICONE SEALANT (Clear) Cat. no. 93509

This exceptionally high quality

(acetoxy curing) silicone sealant is
specifically formulated as a multi-
purpose D.I.Y. and industrial
silicone. Unlike other silicones on
the market it has no diluents. It
cures by reacting with atmospheric
moisture and has exceptional
elongation and toughness.

PACKAGING:
Dispensers of 12 x
300ml cartridges plus
nozzles

Page 19