Insulation in decks and bulkheads –PYROLIQ® sealing compound system

 

 

 

 

 

 

 

PYROLIQ® casting compound

In industry, ship construction and offshore areas, very high require-ments are placed on cable and pipe penetrations through decks andbulkheads. Besides water- and gas-tightness, the fire resistance of thecomponents must be taken into account in the safety concepts of thesystems. Cable and pipe penetrations must be insulated to prevent thespread of fire and fire gases. The PYROLIQ® casting compound systemis used here: Frames for the penetration are created using existing ma-terials and, after the installation of cables and pipes, are cast using thecomponents of the PYROLIQ® system with just a few actions. The insu-lation is waterproof up to a pressure of 2.5 bar and gas-tight up to 30mbar.

 

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Highest level of safety in case of fire

According to the valid maritime regulations, fireresistances of up to 60 minutes are required fordecks and bulkheads. Besides the constructiveinsulation made of mineral fibre mats, thePYROLIQ® casting compound system ensuresthe fire resistance of the penetrated installations.

Comprehensive tests were performed accordingto the IMO resolution  A.754(18), in order toprove fire resistance. Fire tests were performedvery successfully on deck and bulkhead penetra-tions of various dimensions and with differentlevels of filling, such as cables, metal and plasticpipes, as were tightness tests. Certificates ofGermanischer Lloyd confirm the excellent proper-ties of the casting compound system PYROLIQ®

and its fire resistance class A60.

 

 

Resistant to seawater

 

Simple, flexible mounting

 

Fireproof

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PYROLIQ®: Simple. Safe. Economic.

Easy processing, few error possib-ilities and safe mounting make thePYROLIQ® casting compound sys-tem a highlight amongst insula-tions. In comparison with modularinsulation, the use of PYROLIQ®

does not require any planningwork nor any extreme storage.Just a few components ensure ex-cellent clarity.

 

Simple use, minimal sources of error

 

Requires no planning work

 

Gas-tight and watertight as well as fire-resistant

 

Few components, simple storage

 

Approved for all types of ships' cables, as well as vari-ous plastic and metal pipes

 

For bulkheads and decks made of steel and aluminiumcomponents

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Simple handling – professional result

 

 

1. Insert expanding modules

The expanding modules are inserted into the twofront sides of the constructed frame as lost lining.They are used to single out the cables and pipesand prevent the outflow of the casting compound.Cable intersections within the penetration are noproblem.

 

2. Saturate with impregnation fluid

After insertion, the expanding modules are satur-ated with impregnation fluid. As a result, they in-crease their volume and seal off the cavitiesbetween the cables and pipes. After the expandingmodules have been impregnated, they are hardlyflammable.

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3. Fill with casting compound

The casting compound is mixed together from drymortar and drinking water and is filled into the pen-etration through the filling nozzle on the steel frame.The casting compound enters all the cavities andseals the penetrating installations hermetically. Theexpanding modules can be still moist on filling,meaning that rapid mounting is possible.

   

6 mm

60 mm

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Deck insulation

Penetrations in decks are made in the same wayas for wall mounting: However, expanding mod-ules are only required on the underside. Withinthe ship or system, no additional measures arerequired after casting.

Insulation which can come into contact with salt-water, oils and chemicals must have its surfaceclosed with the sealing compound for outdoorareas. If the frames are already full of water, thewater-repelling sealing compound is used.

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Wall insulation

The PYROLIQ® casting compound system is approved for the pen-etration of various plastic pipes. Materials such as PVC, ABS, PEand PP with outer diameters up to DN200 are no problem for theinsulation.

For the insulation to remain safe despite the use of combustibleplastic pipes, a two-layer insulation strip is placed around the ap-propriate pipes before the casting compound is added, and fixed inthe centre of the steel frame. If there is a fire, the insulation stripfoams up around the burning plastic pipes, sealing them off.

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EMC requirements

Special areas require electrically shielded cables according to theEMC directive, in order to keep the signal quality at the highestlevel. For this, the cables must be connected to the steel body ofthe ship or system using a conductive substance. The conductivesealing compound of the PYROLIQ® system is used here.

 

Creating a conductive connection

After filling of the main frame, an additional frame isflanged to the insulation. The appropriate cable isstripped and the conductive sealing compound castinto the second frame. The exposed cable shieldingallows the creation of a conductive connection tothe steel body.

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Approvals and certificates

The certificates of Germanischer Lloyd (GL) comprise all the type approvals of modules B+D according to theSOLAS 74 regulation and IMO resolution. The technical data is summarised in the table.

 

30mbar

 

2,5bar

 

 

 

Casting compound, gas-tight and watertight as well as fire-resistant

Class A60  

Watertightness 2.5 bar  

Gas-tightness 30 mbar  

  Cables Pipes

CertificatesType approval DNV GLEC Certificates (Module B+D)95 500-14 HH, 11 103-14 HH, 11 105-14 HH

Type approval DNV GLEC Certificates (Module B+D)11 101-14 HH, 11 102-14 HH, 11 104-14 HH

Testing standards

SOLAS 74 regulation II-2.9IMO resolution A.754(18)IMO resolution MSC. 61(67)IMO resolution MSC. 307(88), clause 8

SOLAS 74 regulation II-2/18.1.1, II-2/9.3.1IMO resolution A.754(18)IMO resolution MSC. 308(88)MSC/Circ 916, MSC/Circ 1004, MSC/Circ 1276

Approved media Shipping and maritime cables of all types

Steel and CuNiFe pipes to DN 200Copper pipes to DN 100Plastic pipes ABS, PVC,PE, PP to DN 200Multi-layer composite pipes to DN 32Bundle pipes, stainless steel, to 23 mmGRP pipes to 34 mm

 

Insulation dimensions in cm

Dimensions Insulation (wall) Deck (ceiling)

Round, rectangular, oval min./max. 9 x 9 / 50 x 25 9 x 9 / 50 x 25

Min. insulation thickness / casting length 23/18 20.5/18

Min. sealing  --- 1

Material Steel Aluminium

Component strength / frame strength min. 0.45 +0.05 0.6 +0.05 

Maximum approved assignment of the opening area with installations: 40%. The data in the named certificates apply.Fire resistance class A60 only in connection with approved insulation mounted during construction.

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Sealing compound

2.512.5

TypeVMS-TE 1VMS-TE 2

Contentskg

Pack.pcs11

Weightkg/100 pcs.250.0001,250.000

Item No.72038407203843

Dry compound in plastic container to mix with tap water. Makes a gas-tight and watertight seal offire resistance class A60 to IMO resolution A.754(18). Including measuring cup.The mixing ratio of water to powder is 1:2. The mixed compound is pumpable for approx. 45minutes. The mixture is chemically hardened after 72 hours.Stored in a dry and frost-free environment, the dry compound will keep for 3 years.

Special mortar

 

Expanding module, small

120x25x6TypeVMS-QMK 1

Dimensionmm

Pack.pcs20

Weightkg/100 pcs.0.600

Item No.7203846

Expanding foam modules to replace a casing in the sealing compound system if part of the casinghas been lost. The modules expand by the factor 10 when sprinkled with the impregnating fluid,closing gaps and joints between the cables installed.After the cables have been impregnated they are hardly flammable, fire-retardant and self-extin-guishing.Stored in a dry environment, the expanding modules have an unlimited lifespan.

Foam

 

Expanding module, large

800x25x6TypeVMS-QMG 1

Dimensionmm

Pack.pcs15

Weightkg/100 pcs.5.200

Item No.7203849

Expanding foam modules to replace a casing in the sealing compound system if part of the casinghas been lost. The modules expand by the factor 10 when sprinkled with the impregnating fluid,closing gaps and joints between the cables installed.After the cables have been impregnated they are hardly flammable, fire-retardant and self-extin-guishing.Stored in a dry environment, the expanding modules have an unlimited lifespan.

Foam

 

Impregnation fluid

1000TypeVMS-IF 1

Contentsml

Pack.pcs1

Weightkg/100 pcs.104.500

Item No.7203852

Fluid to sprinkle the expanding module.When 5 long expanding modules are used, approx. 1 l impregnation fluid is required.Stored in a frost-free environment it has a lifespan of 2 years.

Sealing compound for external use

1TypeVMS-VA 1

Contentskg

Pack.pcs1

Weightkg/100 pcs.100.000

Item No.7203858

Flame-retardant sealing compound for insulations in sealing compound systems. Watertight andresistant against common technical oils as well as weak/diluted acids. Halogen-free and cold-hardening.2 components (hardener and resin) in tin with lid to push through. Lifespan of 12 months in originaland closed packaging at temperature between +10 and +40 °C.

Special mortar

 

Sealing compound, water-repellent

1TypeVMS-VW 1

Contentskg

Pack.pcs1

Weightkg/100 pcs.100.000

Item No.7203864

Flame-retardant sealing compound for insulations in sealing compound systems for the applica-tion in water-filled openings.Watertight and resistant against common technical oils as well as weak/diluted acids. Halogen-free and cold-hardening.2 components (hardener and resin) in tin with lid to push through. Lifespan of 6 months in originaland closed packaging at temperature between +10 and +40 °C.

Special mortar

 

Sealing compound, conductive

1TypeVMS-VL 1

Contentskg

Pack.pcs1

Weightkg/100 pcs.100.000

Item No.7203867

Electrically conductive sealing compound for insulations in sealing compound systems and for theintegration of the woven cable shield in EMV-compliant installations. 2 components (hardener andresin) in tin with lid to push through. Lifespan of 6 months when stored in frost-free storage.

Special mortar

 

Pipe insulating strip

1000 x 100 x 3TypeVMS-RS

Dimensionmm

Pack.pcs3

Weightkg/100 pcs.47.000

Item No.7203870

Insulation forming strip for the application in sealing compound system when feeding through flam-mable pipes.Please protect against sunlight. When stored in a dry environment it has an unlimited lifespan.

Intumescent material

Identification plate

GermanEnglish

TypeVMS-KS DEVMS-KS EN

Language Pack.pcs11

Weightkg/100 pcs.2.4002.400

Item No.72038747203878

Identification plate for self-labelling of the insulation of the sealing compound system to theIMO A.754(18) with a waterproof and lightproof felt tip pen.Including 2 cable ties for fastening onto the cable or onto the cable tray system in the area of theinsulation.

PVC Polyvinylchloride

OBO Bettermann GmbH & Co. KG

PO Box 112058694 Menden, Germany

Customer Service GermanyTel. +49 (0)2373 89-1700Fax +49 (0)2373 89-1238E-mail: export@obo.de

www.obo-bettermann.com

Building Connections

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