During this past decade we have conducted an intense R&D program to manufacture a vastly improved range of building products ie; Sheeting in various densities for both internal and external applications.
Our initial product range was for the Passive Fire Protection Market however we have now extended that range to general construction board to compete with Fibrous cement sheet, Plasterboard and the myriad of other products now becoming available to meet the new 5 star ratings worldwide to combat the rising costs of heating and cooling and so reduce the energy demand.
We are now concentrating exclusively on vermiculite based insulative products in density ranges from 300 to 2,000 kg per M ³which will incorporate structural and non - structural materials.
These products have been developed to compete with those low-density products already established on the world market and enjoying a substantial market share as well as creating new markets in the high-density area of which no vermiculite-based or Passive fire protection materials have ever been successful due to the fact that no one has ever been able to manufacture them.
It must not be assumed that our main market would be the fibrous cement sheeting market; we are only competing in that area because we see a huge advantage for us there. Fibrous cement cannot compete in the passive fire protection area because it just does not qualify at all, in fire resistance or insulative ability.
The conventional binder compositions used in the manufacture of these materials, mainly calcium silicates, potassium silicates, sodium silicates and of course the poorly performing resins and cements have not changed significantly since the 1940's.
Apart from various additives basics have remained the same and conventional production still encounters the same limitations of spring-back, autoclaving, baking, sanding, low early strength, excessive handling and breakage and high energy costs. All of these situations are avoided with our system.
The refractory grade binder uses no water, which will produce high early bond strength and allow higher ratios of vermiculite. This in turn enhances the performance in thermal conductivity and flame resistance. Our plants will have no waste at all as all sawdust and off cuts are recycled to secondary products. Unlike our competitors we have no water- recycling problem because we have no use for it.
Because of our fast setting ability, products require one pressing only. The estimated cycle time per sheet is approximately 8 seconds unlike our competitors who require baking and autoclaving and cycle times of 24hrs to one week.
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