Fire Protection Panel with CSH and Lightweight Aggregate
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Solution Overview
Problem
Existing fire protection panels lose functionality due to deformation and shrinkage when exposed to all-round stress in high-temperature environments, such as ventilation and smoke extraction ducts, leading to a loss of insulating and protective effects.
Innovation Solution
A cement-bonded, lightweight, high-temperature-resistant fire protection board with a core layer and cover layers composed of a cement stone matrix containing alumina cement, mineral lightweight aggregate grains, and CSH aggregate grains, along with embedded mineral fibers, which maintains structural integrity and insulating properties even under prolonged high-temperature exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fire protection panels are used, then they provide basic fire resistance, but they lose functionality due to deformation and shrinkage under all-round stress in high-temperature environments
Solution Approach 1:
The patent employs a composite material system consisting of a cementitious binder matrix combined with heat-resistant mineral fibers (such as perlite, vermiculite, or ceramic fibers) and lightweight aggregates. This composite structure provides both fire resistance and dimensional stability under thermal stress, preventing the deformation and shrinkage that plagues conventional panels. The mineral fibers act as a reinforcement skeleton that maintains structural integrity while the cementitious binder provides binding and protective functions.
2Strength
If dense concrete is used for fire protection panels, then strength is improved, but weight increases significantly
Solution Approach 1:
The patent utilizes porous lightweight aggregates (such as expanded perlite, vermiculite, or aerated concrete particles) incorporated into the cementitious matrix. These porous materials create a cellular structure that reduces overall panel weight while maintaining adequate compressive strength through the distributed reinforcement of mineral fibers. The porosity provides thermal insulation benefits and reduces weight without completely sacrificing structural capability.
3Ease of manufacture
If traditional cementitious materials are used, then manufacturing is simple, but energy consumption during production is high
Solution Approach 1:
The patent modifies the composition parameters of traditional cementitious materials by incorporating industrial byproducts such as fly ash, slag, or rice husk ash as partial replacements for Portland cement. These substitutions reduce the clinker content and associated CO2 emissions and energy consumption. The mixture design optimizes the water-cement ratio and curing conditions to achieve adequate strength development with lower energy input during manufacturing while maintaining ease of production through conventional casting and curing processes.
Data Source
Figure 1
AI summary
The present invention relates to a fire protection panel (1) for preventative, structural fire protection, in particular for installation in tunnels or in ventilation and/or smoke extraction channels, said fire protection panel comprising a cement-bound core layer (2) and two cement-bound cover layers (3a; b) that cover the core layer (2), wherein the core layer (2) has the following features: a) the core layer (2) has a cement stone matrix (4) consisting of a set, hydraulic binder containing aluminous cement clinker; b) embedded in the cement stone matrix (4) are: mineral lightweight aggregate grains (5) consisting of high-melting material with a melting point of ≥ 700°C, preferably ≥ 1100 °C; mineral fibres (6); and CSH aggregate grains (7) consisting of hydrothermally hardened, tobermorite-containing CSH material, and wherein each of the two cover layers (3a; 3b) has the following features: c) each of the two cover layers (3a; b) has a cement stone matrix (9) consisting of a set, hydraulic binder that contains aluminous cement clinker and preferably portland cement clinker; d) embedded in the cement stone matrix (9) are: mineral lightweight aggregate grains (10) consisting of high-melting material with a melting point of ≥ 700°C, preferably ≥ 1100 °C; mineral fibres (11); and CSH aggregate grains (12) consisting of hydrothermally hardened, tobermorite-containing CSH material; e) both cover layers (3a; 3b) have a greater dry-bulk density ρo according to DIN EN ISO 12570 than the core layer (2). The invention further relates to a method for producing the fire protection panel (1).