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POLYTECH MODUL SYSTEM

What is Polytech® Module System?

Polytech® Module System is a system of prefabricated wall panels designed for the construction of
internal and external walls in buildings at lightning speed. Polytech® Module System is a response to the expectations of the market for low-energy buildings. The Polytech® MS panels used for external walls are made as permanently fixed two-layer walls. Each such panel consists of a 30-cm thick structural part (or layer) of the Polytech specially modified lightweight thermal insulating mortar material and an additional thermal insulation layer of 17 cm in thickness. There are no air gaps between the two layers!

Why choose prefabricated wall panels?

The Polytech® Module System offers many benefits. These include, in particular, very good thermal
insulation properties. Polytech®MS prefarbicated panels are safe, durable and adequately resistant to mechanical loads. The benefits of the Polytech® Module System can be enjoyed in the production process as well as during the construction of the building and, later, when it is in use.

In the production process and during transport operations

  • The polystyrene foam waste can be reused.
  • The relative low specific weight of the prefabricated panels means that lifting equipment with a lower load capacity can be used to save money. The costs of transporting the panels can also be reduced.
  • Energy consumption in the production of Polytech® Module System panels is low.
  • The dimensional repeatability of the standard panels means that they can be easily modified to suit the particular requirements of your project and to construct a wall of any length ranging from 0.30 m to 3.60 m (with stepless length adjustment) and of up to 3.0 m in height! The standard length of a Polytech® prefabricated panel is 2.40 m.
  • Polytech® MS system includes ready-to-use corner elements for quick and precise installation. These elements are available in a standard size of 90 cm x 90 cm, but they can be produced in non-standard sizes as well.
  • The Polytech® MS production technology means that when a wall with a door or window opening is needed, the wall will be made complete with a lintel in the opening.
  • The overall construction costs can be reduced in a number ways, such as:
    • lower costs of transporting building materials to the site,
    • quick assembly/installation,
    • a small number of workers (2/3) needed.

During the construction process

  • Reduce the amount of construction waste.
  • nstall all the walls on a single storey of your building in a very short time (even one working day is enough if the storey area is not larger than about 200 square metres).
  • Install the walls of your building in virtually any weather conditions, as weather affects the construction process insignificantly.
  • Reduce the number of skilled workers needed at the site.
  • Help save the natural world, as the Polytech® Module System wall panels has no negative impact on the environment.
  • Enjoy the ease of finishing work on the panels.

What are the benefits for building users?

  • The prefabricated walls offer excellent thermal insulation properties.
  • The structural layer of the wall is permanently joined with the thermal insulation layer without the use of mechanical connectors. This has eliminated thermal bridges, which occur when thermal insulation materials are fixed using rawlplugs.
  • The heat transfer coefficient for an external wall with no openings does not exceed 0.15 (U ≤ 0,15 [ W/K∙m2]).
  • The Polytech mortar is a non-flammable, A-2 class material (according to EU 2000/147/EC).
  • Energy management (cooling and heating) is also made easier, which means considerable savings on energy bills.

Production lines

Polytech Module System prefabricated panels are produced on machines supplied by my COISOIMPER. The necessary materials include water, cement, additives and polystyrene granules (these can be recycled material) and moulds. A Kompatto mixer is used to mix the raw materials: polystyrene granules and additives (including the Tech additive). The mixture is then poured into moulds, depending on the requested size of the wall. The panels are left to season and to achieve their initial strength. The moulds are removed and the panels are transported to a storage area by means of overhead cranes, forklift trucks or other lifting equipment.

The production line must be well designed so that the necessary tools and equipment are used
for the intended production volume.

If you are interested in becoming a manufacturer of Polytech Module System prefabricated panels, regardless of the intended production volume, contact us! We will provide you with a set of guidelines for your factory and implementation support.

This is what you need to launch production:

  • a central production unit (machinery),
  • a storage space for raw materials (such as silos),
  • a storage space for finished products,
  • material-handling equipment, such as conveyor belts,
  • lifting equipment/cranes,
  • moulds.
POLYTECH THERM INSIDE

Polytech® Therm InSide

Polytech® Therm InSide are panels for thermal insulation of external walls, designed for use inside
buildings. Polytech® Therm InSide panels are used when traditional thermal insulation methods
(insulation applied on the outer surface of walls) cannot be used because the surface must not be
interfered with (listed buildings are a good example).

Polytech® Therm InSide panels are easy to finish. They can be used for thermal insulation of both walls, floors and ceilings. The thickness of the thermal insulation layer made of Polytech® Therm InSide panels and the finishing method should depend on an assessment of the technical condition of the building.

Where to use Polytech® Therm InSide panels?

If the outer surface of the wall in your building must not be interfered with because it is a listed building or if thermal insulation work on the outside of a wall is difficult (for example because the wall is situated on a land boundary), the walls may have to be thermally insulated inside rather than outside the building.

Polytech® Therm InSide panels are the perfect choice whenever you need to thermally insulate a listed building inside or areas difficult to access, such as space near doors, windows, concealed window roller blind boxes or recessed spaces for heaters. They can also be used to make thermal insulation work easier inside staircases or cellars. They are a good solution where thermal insulation of the outer surface of walls is impossible. Polytech® Therm InSide are also recommended for use in building where the external walls are finished with natural stone, clinker tiles or timber cladding materials.

What are the benefits of Polytech® Therm InSide?

  • Polytech® Therm InSide panels offer excellent thermal insulation properties.
  • Therm InSide panels are non-flammable.
  • The alkaline nature of the product (pH11) minimises the risk of mould on the walls.
  • The heat transfer coefficient of the panels is very good (λ ≤ 0.06 [ W/K∙m]).
  • The panels are available in a wide range of thicknesses, ranging from 5 cm to 30 cm, depending on what is needed.
  • The panels are suitable as a thermal insulation material for listed buildings and where the external walls are finished with natural stone, clinker tiles or timber claddi
  • Polytech® Therm InSide are an eco-friendly material; they are made of construction waste.
  • Polytech® Therm InSide are easy to finish and install.

The technical properties of Polytech Therm InSide panels were confirmed in empirical
studies described in scientific journals, such as https://www.mdpi.com/1996-073/14/7/1844 and
https://www.sciencedirect.com/science/article/abs/pii/S0950061818324991

If you are interested in becoming a manufacturer of Polytech® Therm InSide panels for thermal
insulation of external walls inside buildings, regardless of the intended production volume, contact us! We will provide you with a set of guidelines for your factory and implementation support.

intonaco isolante POLYTECH® THERM.

POLYTECH® THERM

Ready-mixed thermo insulating plaster

POLYTECH® THERM is an insulating plaster premixed in bags, composed by cement, hydraulic lime, POLYTECH® THERM RESIN (compound of additives designed for plaster) and polystyrene beads treated with TECH additive.
This formulation allows an excellent adhesion to the surface, plasticity of the mortar and waterproof plaster after curing. Moreover, an immediate saving on heating costs.

All you need to do is just add water, since every component of the compound is already into the bag and a normal mixer or plaster machines.

Advantages:
Allows big cost savings compared to traditional insulation methods
Water repellent
It does not cause cracks
Eliminate thermal bridges
Ensures good thermal insulation and good sound absorption
Allows a considerable energy saving

Technical characteristics:
Thermal conductivity: 0,056 W/mk.
Compliant with UNI EN 998-1 (T-CS1-W1).
Resistance to vapor diffusion (EN 1015-19) 4,5.
Fire classification M0 (non-flammable).

Fields of use:
Thermal insulation coatings, thermal insulation of internal walls, thermal insulation on the ceiling, elimination of thermal bridges of buildings and in general, protection of facades from rainwater.

Necessary for the production of POLYTECH® THERM:

  • Bagging machine BMP
  • CD1
  • TECH additive
  • POLYTECH® THERM RESIN
  • Cement
  • Hydraulic lime
  • Polystyrene beads
calcestruzzo alleggerito in polistirolo POLYTECH® MP.

POLYTECH® MP

Ready-mixed thermo insulating base

POLYTECH® MP  is an insulating concrete premixed in bags composed by cement and polystyrene beads treated with TECH additive. It is suitable for the production of insulating lihtweight concrete, with a particularly low specific weight and low thermal conductivity.
All you need to do is just add water, since every component of the compound is already into the bag.
The product can be used for light screeds, slopes and wherever low weight, together with good compressive strength, is required, providing thermal and acoustical insulation.

POLYTECH® MP can be mixed with normal mixers, it not require specific machines.

Advantages:
Fire classification M0 (non-flammable).
Buona resistenza a compressione.
Breathability to water vapor.
High thermal insulation
Excellent workability.
Not require specific machinery.

Necessary for the production of POLYTECH® MP:

  • Bagging machine BMP
  • CD1
  • TECH additive
  • Cement
  • Polystyrene beads



polistirolo additivato POLYTECH® bag.

POLYTECH® bag

Treated polystyrene bag with TECH additive.

POLYTECH® bag is a bag with polystyrene beads homogeneously treated with TECH additive.
It is packaged in the factory using CD1 system which nebulizes the polystyrene beads with TECH additive and fill the bags. (normally bags of 250 lt and 500 lt).
POLYTECH® bag with the adding of water and cement, is used for the production of POLYTECH® and it is mixed by specific machines as Mp1 or KOMPATTO Series or with normal mixers.

TECH additive is a liquid solution of anionic surface-active agents with neutral PH and it is omogenously mixed with polystyrene beads, ensuring an accurate mixing of the concrete with the polystyrene (EPS) avoiding the separation and sedimentation.
Moreover, it also increases the mixture volume, avoid the problems of shrinking and related consequences as: cracks and deformations, without modifying curing times of concrete mixture.

Advantages:
Fire classification M0 (non-flammable).
Buona resistenza a compressione.
Breathability to water vapor.
High thermal insulation
Excellent workability.
Not require specific machinery.

Necessary for the production of POLYTECH® bag:

  • CD1
  • TECH additive
  • Polystyrene beads

CLC BLOCKS

FOAM CONCRETE blocks.
Lightweight and strength at the same time.

These make it possible to maintain a comfortable indoor temperature, without thermal energy loss, guaranteeing considerable cost savings in the use of environmental air conditioning systems.
These increase the breathability of the walls preventing the formation of mould and considerably lightening the structure of the building.

How to use CLC blocks.
Applications.

CLC blocks (or FOAM CONCRETE) are used as filling for outdoor walls and to build partition walls, as their breathability, lightweight and fire resistance make them ideal.  Also used for the construction of load-bearing walls in non-earthquake areas, with a thickness of no less than 25 cm and a minimum density of 800 – 1,000 Kg/m³ with smooth blocks or with holes for the installation of steel bars and concrete casting.
Lastly cellular concrete blocks are very commonly used for the fencing of containment walls or the perimeter of dwellings.

How to make CLC blocks.
Material and machinery for the production of CLC blocks.

In the production of CLC blocks, the raw materials (water, cement and sand) are mixed in a mixer, the foam produced by the TECHCELL HT foaming agent and by a foam generator is then added.
For a maximum daily production of 15 m³, the material is pumped into moulds in series and after at least 8 hours the produced panels can be cut into blocks of the required sizes.

For larger production, the material is poured into 1 m³ moulds and cut into blocks after at least 8 hours.
The drying stage is carried out without the addition of specific machinery such as furnaces or autoclaves.
The FOAM CONCRETE (CLC) is left in the moulds until the cutting phase.

Thanks to the type of blade of our Block cutter, the material can be cut wet or dry therefore it is not necessary to cut within a certain amount of time.

To increase the technical characteristics of CLC blocks, the auxiliary additives for CLC, DSP XL, FBR, HDR can be added to the mixture.

Advantages to the use and the production of CLC blocks.

Thermal insulation, lightweight, reduced cost of production, easy workability and versatility (ideal of construction and restructuring). With Coisoimper machines, the independent production of cellular concrete blocks required for the construction of civil and industrial buildings is even more advantageous.
COISOIMPER machines are used to entirely customise the block production process based on space, costs, quantity, size and density Plus, the advantages of CLC blocks production with Coisoimper machines are found at every stage.

In the production phase:
– Using raw materials that are available in the world and are not subject to special processes
– Product stability during the production phase
– Easy change of density and dimension
– Contained investments and start-up costs
– Low energy consumption in production
– Reuse of production waste


In the transport phase:
– Reduced costs
– It can be produced directly on site


In the construction site:
– Excellent quality/price ratio
– Easy and quick installation
– 100% recyclable
– No negative effect on the environment
– Easy to process (cutting and shaping with hand saw, grooving, drilling)


At the end of construction:
– Excellent thermal and acoustic insulation
– Fire resistance
– Energy savings
– Considerable mechanical strength
– Tearing strength for unit mounting
– Impact resistance
– Savings of up to 30% for domestic heating and cooling
– No need for insulating plaster

CLC PANELS

Panels in FOAM CONCRETE.
Insulation, lightweight and stability for construction and restructuring.

With COISOIMPER machines it is possible to easily build prefabricated CLC panels for indoor and outdoor walls and buildings.

FOAM CONCRETE combines easy construction of traditional concrete with thermal insulating properties and can be used for a broad range of applications requiring light loads or insulation. CLC panels are easy to process and are ideal for the construction of homes and buildings, in addition to having the advantage of low production costs.
COISOIMPER offers complete and customisable machinery and systems for the production of CLC prefabricated panels of various sizes and densities.

To make CLC panels all you need are water, cement, sand and TECHCELL HT foaming agent.
To increase the technical characteristics of CLC panels, the auxiliary additives for CLCDSP XL, FBR, HDR can be added to the mixture.
Our machines are easy to use, they do not require great maintenance and are fully customisable according to the necessary daily production capacity, automations and equipment, dimensions of the panels and available space.

How to use CLC prefabricated panels.

CLC (or FOAM CONCRETE) panels are used as filling for outdoor walls and indoor partitions
They are also ideal for building prefabricated houses in non-earthquake areas, for fencing and containment walls.

How to make CLC panels.

How to make Cellular Concrete CLC prefabricated panels.

To make CLC panels with COISOIMPER machines all you need are water, cement, sand and TECHCELL HT foaming agent. The production process is carried out by mixing the raw materials in a mixer, the foam produced by the TECHCELL HT foaming agent and by a foam generator is then added.
Is suggested to use also the auxiliary additives for CLC to increase the technical characteristics.

The material is poured into specific forms that determine the panel size.
Based on the forms, the panels can have smooth sides, male/female coupling or holes to pass cables through or to lighten the weight.
The dry density of the prefabricated panels depends on the end use, it can vary from 600 Kg/m3 to 1,000 Kg/m3.
Based on size and weight, the panels can be moved manually or with due systems. 

Advantages to the use and the production of CLC panels.

There are multiple advantages to using CLC panels, the most important being insulation and lightweight.
They are also rigid and stable and are ideal for construction and restructuring, in addition to having a reduced production cost.
Independent production with COISOIMPER machines and local raw materials is therefore even more advantageous.
Our machines are easy to use and do not require great maintenance, they also allow full customisation of the panel production process, based on space, cost, quantity, size and density.
Further advantages of CLC panel production with COISOIMPER machines are found at every stage.

In the production phase:
– Using raw materials that are available in the world and are not subject to special processes
– Product stability during the production phase
– Easy change of density and dimension
– Contained investments and start-up costs
– Low energy consumption in production
– Reuse of production waste


In the transport phase:
– Reduced costs
– They can be produced directly on site


In the construction site:
– Excellent quality/price ratio
– Easy and quick installation
– 100% recyclable
– No negative effect on the environment
– Easy to process (cutting and shaping with hand saw, grooving, drilling)


At the end of construction:
– Excellent thermal and acoustic insulation
– Fire resistance.
– Energy savings
– Considerable mechanical strength
– Tearing strength for unit mounting
– Impact resistance
– Savings of up to 30% for domestic heating and cooling

muri in clcl - coisoimper

CLC WALLS

What are CLC walls?
FOAM CONCRETE casted on site into formworks.

A quick, low cost, single-storey home construction system (Social House) without the need for a factory with production line as the walls are cast directly on site, with FOAM CONCRETE.
Casting is carried out directly on site in formwork where steel reinforcement is already installed, if necessary, and the electrical and hydraulic systems.

Where to use the technique CLC walls cast on site?

The on-site casting technique for walls and partitions can be used for the complete construction of low cost, single-storey homes (Social House) or for filling non load bearing walls where the load bearing structure (pillars and beams) are made with concrete or steel. In this application the thickness of the outer walls must not be less than 20 cm with minimum density of 1.000-1.200 kg/m³. While the partition walls can have a minimum thickness of 10 cm.
The on-site wall casting system is also suited for building fences and containment walls.
Walls made with FOAM CONCRETE maintain a comfortable indoor climate, without thermal energy loss, also allowing considerable savings on the costs of use in environmental conditioning systems.
It also increases the transpirability of the walls preventing the formation of mould and considerably lightening the structure of the building.

How to cast CLC walls on site?

It is particularly easy to cast walls on site using the COISOIMPER system.
After installing the formwork, the FOAM CONCRETE is mixed and pumped by a complete machine, KOMPATTO R16, directly into the formwork.
From the next day the formwork can be removed, and it can be of any type as long as it is resistant to hydrostatic pressure and watertight.
To make CLC walls all you need are water, cement, sand and foaming agent TECHCELL HT.

To increase the technical characteristics of CLC walls, the auxiliary additives for CLCDSP XL, FBR, HDR can be added to the mixture.

Advantages of the CLC walls cast directly on site.

There are multiple advantages to using the cast on site technique.
In the production phase:
– It is not needed a factory with production line
– Using raw materials that are available in the world and are not subject to special processes
– Product stability during the production phase
– Easy change of density and dimension
– Contained investments and start-up costs
– Low energy consumption in production

In the transport:
– It is produced directly on site

In the construction site:
– Excellent quality/price ratio
– Easy and quick installation
– 100% recyclable
– No negative effect on the environment

At the end of construction:
– Excellent thermal and acoustic insulation
– Fire resistance
– Energy savings
– Considerable mechanical strength
– Tearing strength for unit mounting
– Impact resistance
– Savings of up to 30% for domestic heating and cooling
– No need for insulating plaster

Machinery and additives for the production of CLC walls.

Equipments required for CLC walls.
COMPLETE PLANTS:
KOMPATTO series
K250 series

Additives required for CLC walls.
FOAMING AGENTS FOR CLC:
TECHCELL HT

Optional equipments for CLC walls.
ACCESSORIES:
– Screw conveyor for cement CTC
– Conveyor belt for sand CBS
– Electronic weighing system EWS
– Cart

Optional additives for CLC walls.
AUXILIARY ADDITIVES FOR CLC:
DSP XL
FBR
HDR

CLC SCREED & FILLING

CLC SCREED

Characteristics of lightweight screed in FOAM CONCRETE.

FOAM CONCRETE is used to make lightweight screed to cover electrical and hydraulic systems installed in the floor and as support to traditional or self-levelling subgrade.The most commonly used density is 350 – 400 Kg/m³ with a minimum thickness of 5 cm.
CLC screed reduces production times and structural load, improving thermal and acoustic walk-on insulation between floors.

Advantages of CLC screed.

Advantages of lightweight screed.
– Quick application
– Much more lightweight and economic than traditional systems
– Thermal insulation
– Acoustic insulation
– Fire resistance
– Fluidity
– High breathability and permeability

Necessary equipment and additives to make CLC screed.

Necessary equipment to make CLC screed.
COMPLETE PLANTS:
– KOMPATTO Series
– K250 Series
– Foam Generators for plaster machines
– PK TM

Additives required for CLC screed.
FOAMING AGENTS FOR CLC:

– TECHCELL

Optional equipment for CLC screed.
ACCESSORIES:

– Screw conveyor for cement CTC
– Electronic Weighing System EWS
– Cart
– Level translator
– Level guides
– Rakes

“CLC HD” the Self Leveling Screed in FOAM CONCRETE

Self leveling and fluid screed with high density, for the direct glue of the tiles. 

The self leveling screed CLC HD is a mixture of water, cement, fine sand, foam and auxiliary additives DSP XM or DSP XML to make a fluid and self leveling product.

Thanks to the high compressive strength, is possible to glue directly the tiles.
The screed CLC HD can be produced by the series KOMPATTO R16 or K250.

Necessary Equipment for SCREED CLC HD.
COMPLETE PLANTS:
– KOMPATTO R16 series
– K250 series

Additives required for SCREED CLC HD.
FOAMING AGENTS FOR CLC:
– TECHCELL

AUXILIARY ADDITIVES FOR CLC:
– DSP XM or DSP XML

Optional equipment for SCREED CLC HD screed.
ACCESSORIES:

– Screw conveyor for cement CTC
– Conveyor belt CBS
– Electronic Weighing System EWS
– Cart
– Level translator
– Level guides
– Rakes

CLC FILLING

How to use FOAM CONCRETE for light and insulated filling.

FOAM COCNRETE is also used to cover pitched roofs and terraces.

The dry density is 350 – 400 Kg/m³ with a minimum thickness of 5 cm and to build pitched roofs specific additives are used to reduce the fluidity of the material.
The bituminous sheath (or waterproof sheath) can be applied directly to the FOAM CONCRETE thereby making the roof insulating and waterproof.

Advantages and equipment for CLC filling.

Advantages for CLC filling.
– Much more lightweight and economic than traditional systems.
– Thermal insulation
– High breathability and permeability
– Quick application

Equipment required for CLC filling:

COMPLETE PLANTS:
– KOMPATTO series
– K250 series
– Foam Generators for Plaster machines
– PK TM

Additives required for CLC filling.
FOAMING AGENTS FOR CLC:

– TECHCELL

Optional equipment for CLC filling
ACCESSORIES:

– Screw conveyor for cement CTC
– Conveyor belt CBS
– Electronic Weighing System EWS
– Cart
– Level translator
– Level guides
– Rakes

Optional additives for CLC filling
AUXILIARY ADDITIVES FOR CLC:

– DSP AG

geotecnica - coisoimper

GeoTech

Geotech, the geotechnical filling system in FOAM CONCRETE.

Filling and stabilization of the subsoil with FOAM CONCRETE.

Filling and stabilization of the subsoil with FOAM CONCRETE.

Geotechnical filling with FOAM CONCRETE (CLC) is an alternative to digging and therefore to replacing unsuitable and unstable land (clay or marshy) with compacting land or other traditional materials suited to modifying the subsoil.

FOAM CONCRETE on top of unstable soil reduces the vertical dead load and increases the amortization capacity and stability with the addition of minimum weight.

Applications of FOAM CONCRETE in the geotechnical filling system.

FOAM CONCRETE is ideal in situations where it is necessary to make areas of clay soil or with stagnant water, stable.
Its fluid characteristic means it can fill any cavity that is irregular or hard to reach with heavy-duty machinery (such as lorries, wheel tractor-scrapers…).
It can also be used to fill derelict cavities (tunnels, cisterns, mines), to fill road ramps, to fill arches in historical centres and to insulate gas lines.

Advantages of FOAM CONCRETE in geotechnical filling.

The Geotech filling system has many advantages, the first being that of facilitating changes to the subsoil, making the land stable using less resources and energy than with traditional methods, without having negative effects on the environment and maintaining a high level of soil permeability.

FOAM CONCRETE also has a high logistic advantage as great amounts of material are not transported, nor is compacting roller machinery, used, rather it is self-produced directly on site with small machines.

Plus, the raw materials are simply water, concrete and TECHCELL foaming additive. Its fluidity allows fast application and is self-compacting and therefore does not need any special processing for levelling.

Necessary Equipment and additives for GeoTech.

Necessary Equipment for GeoTech.
COMPLETE PLANTS:

– KOMPATTO series
– KOMPATTO series with MiV System
– K250 series
– K250 series with MiV System
– PK TM

Additives required for GeoTech.
FOAMING AGENTS FOR CLC:

– TECHCELL or TECHCELL S

Optional equipment for GeoTech.
ACCESSORIES:

– MiV System
– Screw conveyor for cement CTC
– Electronic Weighing System EWS
– Cart



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