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General comment AESTUVER fire-protection boards are cement-bound, fibreglass-reinforced lightweight concrete boards manufactured in thicknesses of 10 to 60 mm. Boards with thickness <12 mm are formed monolithically, i.e. they exclusively comprise surface layer material. Boards with thickness >12 mm have a sandwich structure, i.e. they comprise surface layer and core material components whose mass ratio varies with thickness. Encompassing the top and bottom of the board core, both surface layers are around 3 mm thick. The surface and core layer material is manufactured from the same raw materials.
Placing on the market / Application rules
The placing on the market of the product in the EU / EFTA (with the exception of Switzerland) is governed by Regulation (EU) No 305/2011 /CPR/. The product requires a declaration of performance taking into account the /European Technical Assessment No. /ETA-11/ 0458/ and the CE marking. The declaration of performance has been prepared: AESTUVER fire-protection board FC-0003.
For use, the respective national regulations apply.
Delivery status
The boards are manufactured in a range of thicknesses from 10 mm to 60 mm. The boards can be up to 3000 mm in length and up to 1250 mm wide.
Manufacture
The production of the AESTUVER fire-protection boards takes place in a fully-automated production process on a production line in layers "fresh in fresh" in steel moulds. In a first step, the lower cover layer is sprayed into the mould together with glassfibre segments cut from a continuous strand. Immediately afterwards, the core layer is applied onto the fresh lower cover layer from a distributor station. In a final step, the upper, covering cover layer is sprayed onto a carrier film, deposited on the core layer and rolled on.
The finished rough strand is then cut according to the mould size; the filled moulds are stacked separately before lingering for several hours in a setting channel. In the demoulding station, the hardened boards are removed from the moulds, placed on stacking grids and dried in the drier until they achieve delivery moisture. After the drying time, the boards are trimmed at the edges, calibrated in thickness, palletised and packaged. The boards remain in stock until a maturation period has elapsed.
The manufacturing plant has been certified to a quality management system according to /DIN EN ISO 9001:2015/ by TÜV Nord since 2010 and operates a system of factory production control oriented to the requirements of the European Technical Assessment and Product Safety Regulations. In addition to incoming goods inspection and permanent production monitoring, this also includes final inspection of the finished products.
Environment and health during manufacture
During production of AESTUVER fire-protection boards, exclusively low-chromate (< 2ppm) cement is used in accordance with /RL 2003/53/EC/ and the /REACH/ Directive (EC), Annex XVII, No. /1907/2006/. Excess process water or cleaning water is mechanically filtered in the process water circuit in order to separate cleaning residue. The cleaned water is added to the manufacturing process as service water.
Noise:
Sound protection analyses have established that all values communicated inside and outside the production facility are far below the requisite technical standards thanks to the sound protection measures taken.
Waste:
All types of waste such as scrap metal, waste oil, foils and plastic chips (packaging), wood (pallets) and paper are separated, stored and directed back into the recycling system.
Product processing / Installation
AESTUVER fire-protection board cuttings are achieved using conventional rail-guided hand-held circular saws with suction, preferably as plunge-cut sawing. For precisely fitting and sharp-edged cuts, the use of carbide-tipped saw blades with alternating teeth is recommended. The dust content is reduced by the use of saw blades with a small number of teeth and at low speeds. Attachment is by means of drywall screws or commercial staples.
Packaging
AESTUVER fire-protection boards are packed lying on wooden pallets and supplied with cardboard edge protection and covered with foil. These packaging materials are separated and returned to the recycling circuit. Wooden pallets can be returned to the respective dealers.
Condition of use
Due to the stable crystalline calcium-silicate hydrate phase binding and achieved after curing solid structure, emissions are normal for the designated product use, are extremely low and are considered to be harmless to health. No risks are associated with water, air and soil if the products are used as intended. The natural ionising radiation of AESTUVER fire-protection boards is extremely low and harmless to health.
Environment and health during use
The Institut für Baubiologie in Rosenheim has tested AESTUVER fire-protection boards and their manufacturing process with regard to healthy living and environmental protection (GA 4012-101). Due to the outstanding test results, the "Tested and recommended by IBR" test seal was awarded. The "Low-emission product" certificate awarded by the eco-Institut in Cologne confirms that AESTUVER fire-protection boards comply with stringent health and ecological requirements (PB 52206-009).
Extraordinary effects
Fire:
In accordance with the /96/603/EC/ and /2000/605/EC/ rulings by the European Commission, uncoated AESTUVER fire-protection boards are classified as Class A1, non-combustible building materials according to /DIN EN 13501-1/. In addition, they are also Class A1 non-combustible building materials according to /DIN 4102/.
Water:
AESTUVER fire-protection boards display neutral reaction when exposed to water (e.g. flooding). No substances are washed out which could be hazardous to water.
Mechanical destruction: Not relevant
2.15 Re-use phase
Cement-bound lightweight concrete boards can be easily deconstructed. They can be treated as normal waste when demolished or deconstructed. With regard to an efficient recycling process, care should be exercised in ensuring dismantling, whereby waste is sorted into as many different categories as possible.
Reuse and further use
Cement-bound lightweight concrete boards usually outlast the service life of the buildings in which they are used. After deconstructing such buildings, the materials can therefore be prepared, classified, assessed (environmental compatibility, building material characteristic values, consistency) and reused. The waste incurred by these boards and any components manufactured from them can be recovered in building material recycling plants before being used as an aggregate for various applications. Unmixed residual materials can be taken back by the manufacturers and reused or recycled. This material can be used as aggregates in production. Building rubble and production rejects should be prepared mixed to ensure the consistent features of lightweight concrete products made from recycled material. The recycled material should comply with the natural requirements of the material standards for the raw material to be replaced. Furthermore, recycled material made from lightweight concrete can also be used for building roads and paths in construction class V.
Disposal
If in exceptional cases, materials can not be directed to a building material recycling plant, AESTUVER fire-protection boards can be disposed of at any building rubble landfill in accordance with the /waste key number 170101/ (concrete).
Further information
Further information on the products is available in the Download area on www.fermacell.de. Safety data sheets can be requested by calling 0800 5235665. |
