SIR INDUSTRIALESIR INDUSTRIALEExpandable PolystyreneExpandable Polystyrene

Who we areWho we are

p The P & R Group includes 15 Companies operating in different chemical sectors ranging over resins, fine chemicals, pharmaceuticals and biocompatible materials.

p P & R has its point of reference in its private italianshareholders. They started in 1984 with a company in northern Italy, and through the years with the take over of SIR Industriale S.p.A. in 1996, of Solchem S.p.A. in 1998, of Laboratories MAG S.p.A. and Fidia Farmaceutici S.p.A. in 1999 and finally of Antibioticos S.p.A. in 2003..

p The Group is active worldwide with a large and diversified range of products, through its own commercial organizations, distributors and agents.

p The Group’s turnover in 2008 has been about 750 million US $. Based on official European

Statistic, this result brings the P & R Group among the top five players in Italy by turnover.

p The P & R Group employs about 2.500 skilled people: 700 working in pharmaceutical industry, 300 in the resins and 1.500 in fine chemicals and APIs.

IntroductionIntroduction

Polystyrene Foam

Polystyrene foam (“sintered expanded polystyrene” or “EPS”) is a lightweight and rigid expanded polymeric synthetic material.

Styrene is polymerized in aqueous suspension, in the presence ofpentane and initiators to form spherical expandable beads of polystyrene. Pentane, a low boiling point natural hydrocarbon, acts as blowing agent.

Already in the early 50es SIR INDUSTRIALE started the production of Polystyrene that became Expandable Polystyrene in the 60es.

Throughout the years the production process has been constantly upgraded with the newest available technologies.

SIRCEL today achieved a very high quality level appreciated by our customers in Italy and in Europe.

IntroductionIntroduction

Upon contact with steam, at temperatures exceeding 90°C, the blowing agent expands, the polystyrene beads increase their volume by a factor of 20-60 maintaining their spherical shape

The expanded beads have a closed cell structure.

Sintering the expanded beads is the next step that is performed inside a closed mold with another application of steam. The pre-expanded beads undergo a further expansion that, due to the constraint of the closed mold, fills the existing voids between the beads and binds them together in a compact shape of polystyrene foam.

EPS is typically expanded to an apparent density of 10-40 kg/m3 and is therefore only 1-4% (by volume) structural polymeric material, the balance being air.

Product RangeProduct Range

SIRCEL ® 330 SR

Suitable for the production of thin walled molded products

SIRCEL ® 400 P

Designed as filler material for lightweight concrete, mortars and bricks

SIRCEL ® 400 SR2

Suitable for the production of thin walled molded products

SIRCEL ® 700 SR2

Suitable for molded articles and 18÷30 kg/m3 blocks

SIRCEL ® 900 N

Suitable for the production of 14÷15 kg/m3 blocks and 9÷12 kg/m3 (with two expansions) with good mechanical properties

SIRCEL ® 900 SR

Suitable for the production of 14÷20 kg/m3 blocks and 11÷13 kg/m3

blocks (with a 2nd pre-foaming)

SIRCEL ® 1200 N

Suitable for the production of 14÷20 kg/m3 blocks and 9÷13 kg/m3

blocks (with a 2nd pre-foaming), also using regenerated material.

Product RangeProduct Range

SIRCEL ® F330 SR

Flame retarded EPS, suitable for production of thin-wall 25÷40 kg/m3

molded articles.

SIRCEL ® F400 SR2

Flame retarded EPS suitable for the production of thin-wall 22÷35 kg/m3 molded articles

SIRCEL ® F700 SR2

Flame retarded EPS suitable for the production of medium or highwall thickness 20÷30 kg/m3 molded articles and 20÷30 kg/m3 blocks

SIRCEL ® F900 SR

Flame retarded EPS suitable for the production of medium (16÷20 kg/m3) and low (12÷15 kg/m3 with a 2nd pre-foaming) density blocks

SIRCEL ® F1200 SR

Flame retarded EPS suitable for the production of medium (14÷16 kg/m3) or low (11÷12 kg/m3) density blocks.

SIRCEL ® 2200 N

Suitable for production of medium density blocks of 11÷15 kg/m3 and low density blocks of 8÷10 kg/m3, also using regenerated material.

ApplicationsApplicationsConstructionConstruction

ApplicationsApplications The main application of EPS in the construction and building industry is for thermal insulation, thus exploiting its very low thermal conductivity. This property is due to the closed cell structure, to the small dimensions of the cells that prevent convective phenomena, and to the extremely low volume fraction of solid polymer that accounts for negligible conductive phenomena.

ApplicationsApplicationsPackagingPackaging

ApplicationsApplications Polystyrene foam, being expanded to very low densities, is one of the most lightweight packaging materials available, nonetheless EPS packaging is mechanically very resilient. Additionally EPS is resistant to water and moisture, saline and acidic environments and to most oils.

ApplicationsApplicationsAgricultureAgriculture

ApplicationsApplications Polystyrene Sintered expanded polystyrene finds extensive application in agriculture for the manufacture of seed-trays and for frost protection of fruit tree grafts.

Applications Applications Sporting GoodsSporting Goods

ApplicationsApplications Low weight and excellent impact resistance make polystyrene foam the material of choice for the fabrication of protective helmets for various sports and leisure activities (motor sports, cycling, skiing, etc.).

Technical Characteristics Technical Characteristics

Thermal conductivity

In many applications the most interesting characteristic of EPS is its thermal insulation property. Polystyrene foam is made of bonded expanded beads with a fine closed cell structure. Typically only 2-3% (by volume) of the foam is solid polymer, the balance being air. It is this air, constrained in the fine closed cells that is responsible for the excellent insulation properties of EPS.

Thermal conductivity λ of EPS, as for all other materials, is defined as the amount of heat transferred in one hour through a surface of 1 m2 and a thickness of 1 m , when the difference in temperature between the hot and cold surfaces is 1°C. Thermal conductivity of EPS is a function of temperature and of the density of the polystyrene foam.

Expanded SIRCEL® has a relatively high λ for densities <10 g/l which rapidly decreases with growing density, reaching a minimum at approximately 30 g/l, after which it slowly increases again.

Thermal conductivity of expanded and sintered SIRCEL® at 10 and 20°C, as a function of density (UNI 7891)

Technical Characteristics Technical Characteristics

Mechanical properties

Of great interest for most applications of EPS is its compressive strength, measured as the compressive stress that generates a 10% strain in the material. Other important mechanical properties are flexural strength, tensile strength and shear strength. All these properties are linearly dependant on foam density.

The following graphs indicate the correlation with density of these four properties, as measured on expanded and sintered SIRCEL.

Tensile strength as a function of density in expanded SIRCEL

(ASTM C297)

Flexural strength as a function of density in expanded SIRCEL®(EN 12089-B)

Compressive strength (at 10% deformation) as a function of density in expanded SIRCEL® (EN 826)

Shear strength as a function of density in expanded SIRCEL®(ISO 1922)

Technical Characteristics Technical Characteristics

Density

Typical densities of expanded SIRCEL® artifacts ranges between 10 and 40 kg/m3 and depends on the particular SIRCEL® grade used and on the processing (pre-expansion and molding) conditions.

Water absorption

The closed cell structure of EPS accounts for the imperviousness of EPS to water that cannot penetrate the cells. The amount of water absorbed by EPS is typically very low if the material is correctly processed. Water, in fact, penetrates the continuous porosity of the interstices between the individual beads. This porosity in correctly processed material (well bonded) is very limited. Typically EPS will absorb 3-4% (by volume) of water after a 7 day immersion at 25°C.

Diffusion of water vapor

Water vapor can diffuse through the closed cell structure of EPS and eventually condense. Thermal gradients can favor this process which is therefore significant for thermal insulation applications.

Resistance to diffusion of water vapor is measured by the coefficient µ defined as compared to the diffusion in an air gap of equal thickness. For polystyrene foam µ is approximately 50 for densities of 20-25 kg/m3 and grows to over 100 for the higher densities.

Technical Characteristics Technical Characteristics

Dimensional stability

The linear thermal expansion coefficient for SIRCEL polystyrene foam is approximately 0,05mm/m°C and is therefore negligible for most practical applications. In case of extreme thermal excursions (e.g. refrigerators) the mechanical stress on bonds due to thermal expansion is anyway limited because of the low elastic modulus of polystyrene foam.

Post-molding shrinkage is another phenomenon. It is observed in a time span of several hours after molding and is due mainly to cooling of the material. The amount of shrinkage depends on the processing conditions and on the final density.

Weathering

Prolonged exposure to UV radiation can discolor and embrittle the surface of polystyrene foam. Coupled with the action of rain and wind, this embrittlement can give way to erosive phenomena. Various surface protections may be employed (painting, coupling with films, etc) to prevent this degradation of EPS material in outdoor applications.

Chemical resistance

SIRCEL is stable in contact with most construction materials but may be degraded by solvent-based paints and adhesives, bitumen and mineral oils.

In food packaging applications, SIRCEL is not degraded by water, salt, acidic or oily fluids, and is resistant to biological and enzymatic attack.

Fire Reaction

EPS produced with fire-retardant SIRCEL grades (SIRCEL F series) comply with the requirements of the most severe European regulations including the German DIN 4102-B1 and the Italian DM.26.6.84.

Products Products –– Properties and Applications Properties and Applications

X

X

X

Low

Density

X

X

X

X

X

X

Contour

Molding

X

X

X

Thin Wall

Moldings

X

X

X

X

X

X

X

X

X

Fast

Molding

X

X

X

X

X

X

X

X

Blocks

and

Boards

X

X

X

X

X

Flame

Retard.

Low

Thermal

Conduc.

11 – 16

12 – 20

20 – 30

22 – 35

25 – 40

8 – 15

9 – 14

11 – 20

9 – 15

18 – 30

20 – 30

15

23 – 40

Typical

Density

(Kg/m3)

X0,85-1,60F900 SRF900 SR

X0,40-0,70400 P400 P

X0,70-1,00F700 SR2F700 SR2

X1,20-2,20F1200 SRF1200 SR

0,25-0,60F330 SRF330 SR

0,40-0,70F400 SR2F400 SR2

0,85-1,60900 SR900 SR

X0,85-1,60900 N900 N

1,40-2,602200 N2200 N

1,20-2,201200 N1200 N

X0,70-1,00700 SR2700 SR2

0,25-0,60330 SR330 SR

X0,40-0,70400 SR2400 SR2

Lightweight

Mortars and

Bricks

Flooring

Elements

Bead

Size

(mm)Sircel

RecommendationRecommendation

SIRCEL® must be stored in its original containers in a well ventilated cool (<20°C) place and protected against rain and moisture. It is recommended to process SIRCEL® within one month from delivery.

SIRCEL® contains a flammable blowing agent that may form an explosive mixture with air during storage and processing. Avoid the presence of flames or sparks. Use explosion proof devices.

SIRCEL® is supplied in prismatic octagonal cardboard containers (Octabins) lined with PE/PA barrier film to prevent loss of blowing agent. Each Octabin contains 1100 kg net.

SIRCEL® is completely recyclable. Once expanded and sintered it can be reground and mixed with virgin pre-expanded beads for the production of new molded articles. It can also be transformed inGPPS granules and used for injection-molded plastic artifacts.

SIRCEL® does not affect the ozone layer because the only blowing agent used is pentane: no CFCs are used (nor have ever been used) for the manufacture of SIRCEL®.

Used for thermal insulation, SIRCEL® reduces consumption of heating fuels thus reducing carbon dioxide emissions that contribute to the “Greenhouse Effect”.

Safety and StorageSafety and Storage

Environment and RecyclingEnvironment and Recycling

RecommendationRecommendation

SIR INDUSTRIALE SpA manufactures and markets expandable polystyrene under the trademark SIRCEL®.

The SIRCEL® range includes three main grades: “standard EPS”, “flame retardant EPS” and “improved thermal conductivity EPS”.

SIRCEL® is supplied in prismatic octagonal cardboard containers (Octabins) lined with PE/PA barrier film to prevent loss of blowing agent. Each Octabin contains 1100 kg net.

SIR Industriale

Via Bellini 35

20050 - Macherio (MB)

Tel. +39 039 2072.1

Fax +39 039 2072307

e-mail: sir@sirindustriale.com

ContactContact

All statement, information and data presented in this guide is based on laboratory tests and working field experience. SIR INDUSTRIALE SpA does not accept any responsibility for the performance or the results obtained, nor any reclamation regarding leaking or damages incurred while using SIRCEL®

products. The final user is responsible for a correct and safe utilization of the products.

DeliveryDelivery