Note: Descriptions are shown in the official language in which they were submitted.
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Heat-insulating, fire-proof, water-resistant, permeable-to-air, flexible
lightweight concrete
The subject of the invention is a heat-insulating, fire-proof, water-
resistant, permeable-
to-air, flexible lightweight concrete with a volume-density below 500 kg/m3,
made with
polystyrene pearl, which is equally suitable for heat-, and sound-insulation
of walls and
slabs, as well as decreasing their water permeability or water-absorbing
capacity, as
well as increasing their resistance to fire at the same time keeping their
ability to be
permeable to air and humidity, when renovate old buildings or built new
buildings.
In the state of the art there are several heat-insulating materials and
lightweight
concretes. The most common materials among heat-insulating ones are the glass
wool,
rock wool or basalt wool base solutions of boards or plates, solid polystyrene
boards,
and among lightweight concretes there is pearlitic concrete, or plaster,
respectively the
lightweight concrete including polystyrene pearl is known as well, with a
volume-
density generally above 500kg/m3. I could not find a lightweight concrete,
which is
water-resistant and permeable-to-air, made of polystyrene pearl (or from other
insulating material) containing nothing else beside binding materials.
The drawback of the heat-insulating materials used earlier is, that they each
have
deficiencies in certain advantageous properties, such as: the glass wool, rock
wool or
basalt wool base solutions of boards and plates are not water-resistant, this
way
moisture can condensate in them, worsening their heat-insulating ability, they
are not
fire-proof and they can not resist to rodents and insects. The polystyrene
boards are not
permeable-to-air, so moisture can condensate behind them, worsening their heat-
insulating ability and they are not fire-proof. Lightweight concretes,
plasters with
pearlite are not water-resistant and their volume-density is high, resulting
in very low
heat-insulating capacity.
The volume-density of lightweight concretes containing polystyrene pearl as
well is also
higher, as they contain different materials, heavier than polystyrene pearl,
which are
often not water-resistant.
The GB 1333487 patent description makes known a method for the production of
lightweight building elements. The lightweight building elements are obtained
from a
hardened mixture of cement, water and a vinyl latex which mixture is
homogenized
with expanded polystyrene which has been pretreated with an aqueous dispersion
of an
epoxy glue, a hardener and an organic solvent. Specified vinyls are the
acetate which
can be copolymerized with acrylic or methacrylic esters and copolymers of
styrene with
such acrylic esters. Portland and aluminous cements are used, and the expanded
polystyrene has a maximum size of 3 mm. Polyamines are the hardeners, and
surfactants, e.g. sulphonates and Et20 condensates with phenols are optional.
In the
course of the method disclosed in the document the polystyrene particles are
pretreated,
and the volume-density of the produced lightweight building elements is 200-
800
3
kg/m.
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The GB 1291941 patent description makes known an insulating lightweight
cellular
concrete, which comprises an aggregate of multicellular glass nodules in a
cellular
cement matrix. The outer continuous skin of the nodules can be of a different
composition from the core. Air entrainers are lignosulphonates, licorice root,
Vinsol and
Darex (both Trade Marks). A hydroxylated COOH derivative reduces the water
requirements for workability. The lightweight building elements made known
above are
not permeable-to-air and not flexible.
The HU 203 507 patent description filed under No. P 85 02259 makes known a
lightweight concrete for heat insulating layer, which contains the mixture of
water, soda
glass, cement and insulating granular material. The lightweight concrete
disclosed in the
document contains the mixture of 160-240 1 water of drink water quality, 5-20
kg soda
glass of technical quality, 30-180 kg cement, 40-170 kg fly ash, 1 m3 granular
polystyrene foam of 2-20 mm diameter, and its air-dry body density is 200-400
kg/m3.
The lightweight concrete made known in the document is not permeable-to-air.
The HU 174 868 patent description makes known a method for the production of
lightweight concrete with additive. With the help of the disclosed method,
homogenous
lightweight concrete with apparent density of 200-800 kp/m3, from additives of
granular
polystyrene foam and/or glass foam with cement binding material and with
aluminium-
hydrosilicate can be produced. The lightweight concrete produced with the said
method
is applicable for heat insulating purpose in a prefabricated or monolithic
way. The
advantage of the method is that the granular polystyrene foam and/or glass
foam can be
mixed in the cement binding material without surface-activation and pressure
application. The basis of the production of the lightweight concrete disclosed
in the
document is the production of the thixotrope binding material paste.
The HU 162 516 patent description makes known a method for the production of
gravel
consisting of medium layer and cement, and for the production of lightweight
concrete
binding lyophobic and also lyopylic materials, from porous granular
thermoplastic -
preferably from expanded polystyrene pearl. In the course of the method the
porous
granular thermoplastic is mixed with 5-20 volume%, preferably 10 volume% water
dispersion counting on its volume, which contains maximum 5% surface-active
material
and 0.5-5% polyacrylate or ethylene-vinyl-acetate copolymer. In the course of
the
production of gravel the granular plastic is coating with the water dispersion
of the
medium material, and the resulting granular material is homogenized with
cement. The
gravel can be used for the production of lightweight concretes, in 6-30 kg/m3
quantity.
The lightweight concretes produced with the above type of gravel have an
excellent
flexibility and stability. In the course of the method disclosed in the
document the
polystyrene pearl is pretreated, and the volume density of the resulting
lightweight
concrete is 200-700 kg/m3.
The KR100788746 patent description makes known a mortar composition for
preventing inter-floor noises, which is provided to need no step of adding a
separate
noise-protecting layer on a concrete slab, and to realize excellent
compression strength
and impact noise-protecting effect. A mortar composition for preventing inter-
floor
noises comprises: 100 parts by weight of Portland cement; 10-30 parts by
weight of
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styrene-butadiene synthetic rubber latex containing a mixed surfactant
containing an
anionic surfactant and a non-ionic surfactant in a weight ratio of 1:9-0:1; 20-
400 parts
by weight of waste tire powder; and 50-100 parts by weigh of sand, wherein 5-
40 wt%
of the mixed surfactant is used based on 100 wt% of the solid content of the
styrene-
butadiene synthetic rubber latex.
The KRI00521694 patent description makes known a composition for preventing
heat
isolation, sound absorption and shock sound using polystyrene waste materials
comprising crushed particles, synthetic zeolite, inorganic flame retardant,
synthetic
filament waste materias, soluble binder, cellulose fattening adhesive and
inorganic
pigment.
The US5482550 patent description makes known a structural building unit formed
from
a set solid mixture consisting essentially of about 30% to about 75% by weight
portland
cement, about 1% to about 25% by weight percent ground expanded cellular
polystyrene, about 1% to about 35% by weight ground cellulosic fiber, about 2%
to
about 15% by weight fly ash, about 1% to about 10% by weight silica fume,
about 1%
to about 15% by weight bentonite, about 25% to about 50% by weight water,
about 0%
to about 3% by weight air entrainer, about 0% to about 10% by weight paraffin
wax
emulsion and about 0% to about 15% by weight rubber emulsion.
The US3869295 patent description makes known uniform lightweight concrete and
plaster. They are prepared by a novel method which assures that the aggregate
is
uniformly admixed with the cementitious material and other relatively heavy
ingredients
of the concrete and plaster mixes. This is accomplished by wetting the
surfaces of the
lightweight aggregate particles with an aqueous medium, admixing the wet
aggregate
particles with dry finely divided cementitious material to form a coating
thereon, and
thereafter adding additional aqueous medium in an amount to produce a coherent
formable uncured concrete or plaster matrix. The uncured concrete or plaster
matrix
may be formed into a desired configuration, and then is allowed to set in the
usual
manner. The addition of hydrated lime improves the cohesive properties of an
uncured
concrete matrix. Increased strength in cured lightweight concrete may be
obtained by
admixing pozzolan, hydrated lime and/or finely divided inert inorganic fillers
such as
sand with the uncured concrete matrix. A lightweight aggregate including
expanded
polystyrene beads is preferred, and further increased strength may be obtained
by using
polystyrene beads expanded in hot water.
All in all the task to be solved was the working out of such a heat-insulating
material,
which is very light, but fire-proof, water-resistant, permeable-to-air and
flexible in one.
Theoretically the ideal way of it is, if only the gaps between the polystyrene
pearls are
filled with fire-proof, water-resistant, permeable-to-air and flexible binding
material.
this way by kind of sticking them together, and so the material resulting from
it is fire-
proof, water-resistant, permeable-to-air and flexible, and remains light at
the same time.
However it is not possible to mix polystyrene pearls only with cement and
water, as it
gets assorted due to the very big difference of volume-density.
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This problem was solved, when we realized, that homo-, co-, and terpolymers -
which
are water-soluble and/or can be dispersed in water, and do not include and do
not emit
volatile organic hydrocarbons hazardous to the environment - should be used as
organic
binding material.
The invention is a heat-insulating, fire-proof, water-resistant, permeable-to-
air, flexible
lightweight concrete with a volume-density below 500 kg/m3, which is equally
suitable
for heat-, and sound-insulation of walls and slabs, as well as decreasing
their water
permeability or water-absorbing capacity, as well as increasing their
resistance to fire at
the same time keeping their ability to be permeable to air and humidity, for
renovation
old buildings or building new buildings, which is characterized by that it can
be easily
mixed and its composition is: polystyrene pearl, or recycled polystyrene of 1-
10mm
diameter particle size, water, cement and organic binding material mixed with
cement:
such homo-, co-, and terpolymers, which are water-soluble and/or can be
dispersed in
water, such as vinyl-chloride, vinyl esters of saturated,- unsaturated and
aromatic
organic acids, vinyl-butirate, ethylene, acrilic acid esters, styrene, alkyl-
izocianates,
silanes, siloxalates.
In one preferred realization of the solution according to the invention, for
the sake of
making processing easier, additional organic additives are added, such as
polyvinyl-
alcohols, cellulose ethers and other protecting colloids, sedimentation
blockers,
plasticizers.
In an other preferred realization of the solution according to the invention,
the cement is
mixed, or replaced by gypsum.
In a further preferred realization of the solution according to the invention,
polystyrene
pearl is mixed or replaced by a material, which is of small volume-density,
(max. 400
kg/m3), consists of granules and is water-repellent.
In a further preferred realization of the solution according to the invention,
materials
used as additives are the following:
as organic binding material any homo-, co-, and terpolymer can be used, which
is water
soluble and/or can be dispersed in water, in given case the are produced with
using
vinyl-chloride, vinyl esters of saturated,- unsaturated and aromatic organic
acids, vinyl-
butirate, ethylene, acrilic acid esters, styrene, alkyl-izocianates, silanes,
siloxalates.
and/or
additional organic additives can be polyvinyl-alcohols, cellulose ethers and
other
protecting colloids, sedimentation blockers, plasticizers,
and/or
as mineral additives.rock grist, in given case limestone, dolomite, pigments,
in given
case iron-oxide, titaiume-dioxide etc., pearlite, mica schist, etc. can be
used.
In a further preferred realization of the solution according to the invention,
materials
used as filling material are the following:
- polystyrene pearl: its density is between 20-30 kg/m3, its size is 0-20 mm,
and/or
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- plastics: recycled ground plastic, ground rubber, in given case tyre,
and/or
- plant fibres, organic materials, in given case wood-waste, ground wood,
dried plant-
waste, stalk, bast, pine needle, paper,
and/or
- metals, ground metal-waste, in given case household metal-wastes comminuted,
ground to an appropriate size,
and/or
- building waste, in given case glass, ground concrete, ground asphalt, etc.
In a further preferred realization of the solution according to the invention,
the size of
the filling material is between 0-20 mm, and the filling materials falling in
different
size-range are preferably used in a fractional in such a way, that the
materials fall in the
same size-range, or in given case they are used in a non-fractional way.
In a further preferred realization of the solution according to the invention,
at the
production of the heat-insulating material the components are mixed with a
traditional
technology, in given case with mixing machine, in the following order, first
we feed the
water, than cement is added to it, following it the additive is fed, from
these three
components we mix a material of a dilute sour cream consistence, in the end we
add the
filling material to the compound at continuous mixing, we mix the total
material
composition into a homogenous state, and we use the compound produced this way
appropriate to the application.
In a further preferred realization of the solution according to the invention,
the heat-
insulating material is used in bottoming, borders, road concrete elements,
building basic
units, building elements, and/or in monolithic concrete structures prepared in
the place,
lattice blind elements, in given case as heat-insulating plaster, heat-
insulating panel,
permanent lattice blind, wall element, brick, prefabricated building elements,
insulation
of heat,- gas,- oil,- water lines.
In a further preferred realization of the solution according to the invention,
in the case
the volume-density of the filling material is bigger than 100 - 200 kg/m3, it
is used as
building material instead of concrete, or we produce elements, bricks from it.
In the case of the most general realization of the solution according to the
invention, the
invention is a heat-insulating, fire-proof, water-resistant, permeable-to-air,
flexible
lightweight concrete with a volume-density below 500 kg/m3, which.is equally
suitable
for heat-, and sound insulation of walls and slabs, as well as decreasing
their water
permeability or water-absorbing capacity, as well as increasing their
resistance to fire at
the same time keeping their ability to be permeable to air and humidity, when
renovate
old buildings or built new buildings. Its components are materials known in
themselves:
polystyrene pearl of 1-10mm diameter, hydraulic inorganic binding material,
organic
(polymer) binding material, mineral and organic additives, water. We can
achieve the
optimal properties by choosing their type and proportion.
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The refuse of disintegrated used packaging material in suitable size can be
preferably
used as polysterene pearl, the recycling of the refuse. result in solving a
considerable
environmental protection problem as well.
As hydraulic binding material any type of cement, gypsum and anhydrite type is
appropriate, the principle of choice is strength, binding time etc.
As organic binding material any homo-, co-, and terpolymer can be used, which
is water
soluble and/or can be dispersed in water, does not include and does not emit
volatile
organic hydrocarbons hazardous to the environment. Such materials are widely
known:
they are made with the use of vinyl-chloride, vinyl esters of saturated,-
unsaturated and
aromatic organic acids, vinyl-butirate, ethylene, acrilic acid esters,
styrene, alkyl-
izocianates, silanes, siloxalates. Their common characteristic is, that even
in small
quantity they allow the mixture of polystyrene and hydraulic binding materal
making
the product of excellent strength, adherence and water-proof.
Additional organic additives can be polyvinyl-alcohols, cellulose-ethers and
other
protecting colloids, sedimentation blockers, plasticizers, making the
production process
easier. As mineral additives rock grist, (limestone, dolomite) pigments (iron-
oxide,
titane-dioxide etc.) perlite, mica schist, etc. can be used. The water should
be free of
contamination, preferably drink water, tap water.
The heat-insulating material produced this way is very light after setting,
depending on
the quantity of organic binding material and cement, it can be 100 kg/m3, so
it is of
excellent heat-insulating capacity.
The invention is set forth by the following examples:
Example 1
The invention can be realized by the simple mixing of the following materials:
I in3
polystyrene pearl of 1-10 mm particle size or recycled polystyrene of 1-10 mm
particle
size, 100 1 water, 80 kg cement and 10 kg organic (polymer) binding material,
which is
mixed to the cement. The material prepared such a way, will be of 100 - 120
kg/m3
volume density, after drying. The quantity of the added cement determines the
actual
volume density of the ready material, because the mass of other materials
altogether are
only 20 kg/m3.
Example 2
components
water 100 1
cement 80 kg
additive 10 kg
filling material: polystyrene pearl I m3
(its density is between 20-30kg/m3)
The material prepared such a way, will be of appr. 100 kg/m3 volume density,
after
drying.
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Example 3
components
water 1001
cement 80 kg
additive 10 kj
filling material: ground plastic 1 m
(its density is max. 30kg/m3)
The material prepared such a way, will be of appr. 100 kg/m3 volume density,
after
drying.
Example 4
components
water 901
cement 180 kg
additive 8 kg
filling material: polystyrene pearl 1 m3
(its density is between 20-30kg/m3)
The material prepared such a way, will be of appr. 200 kg/m3 volume density,
after
drying.
Example 5
components
water 90 1
cement 150 kg
additive 8 kg
filling material: ground plastic 1 m3
(its density is between 50-60kg/m3)
The material prepared such a way, will be of appr. 200 kg/m3 volume density,
after
drying.
Example 6
components
water 80 1
cement 280 kg
additive 7 k~
filling material: polystyrene pearl 1 m
(its density is between 20-30kg/m3)
The material prepared such a way, will be of appr. 300 kg/m3 volume density,
after
drying.
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Example 7
components
water 80 1
cement 220 kg
additive 7 kg
filling material: ground plastic 1 m3
(its density is between 80-100kg/m3)
The material prepared such a way, will be of appr. 300.kg/m3 volume density,
after
drying.
Example 8
components
water 90 1
cement 100 kg
additive 10 kg
filling material: ground plastic I m
(its density is between 180-200kg/m3)
The material prepared such a way, will be of appr. 300 kg/m3 volume density,
after
drying.
Example 9
components
water 1001
cement 380 kg
additive 6 k~
filling material: polystyrene pearl 1 m
(its density is between 20-30kg/m3)
The material prepared such a way, will be of appr. 400 kg/m3 volume density,
after
drying.
Example 10
components
water 90 1
cement 200 kg
additive 6 kg3
filling material: ground plastic 1 m
(its density is between 160-180kg/m3)
The material prepared such a way, will be of appr. 400 kg/m3 volume density,
after
drying.
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Example 11
components
water 90 1
cement 100 kg
additive 10 kg
filling material: ground plastic 1 m3
(its density is between 280-300kg/m3)
The material prepared such a way, will be of appr. 400 kg/m3 volume density,
after
drying.
Example 12
components
water 1301
cement 480 kg
additive 5 k~
filling material: polystyrene pearl 1 m
(its density is between 20-30kg/m3)
The material prepared such a way, will be of appr. 500 kg/m3 volume density,
after
drying.
Example 13
components
water 1101
cernent 250 kg
additive 5 kg
filling material: ground plastic 1 m3
(its density is between 220-250kg/m3)
The material prepared such a way, will be of appr. 500 kg/m3 volume density,
after
drying.
Example 14
components
water 110 1
cement 100 kg
additive 10 k~
filling material: ground plastic 1 m
(its density is between 380-400kg/m3)
The material prepared such a way, will be of appr. 500 kg/m3 volume density,
after
drying.
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In the course of the preparation of the lightweight concrete according to the
invention,
in case more cement is used, then the ready-made material will be heavier, so
it will
have worse heat-insulating capacity and larger compression strength, but the
proportion
of the organic binding material can be changed opposite the proportion of
cement, that
is it can be decreased if the proportion of the cement is increased. With the
changing of
the proportions different heat-insulating materials meeting different demands
can be
made. The ready-made material can be greased, pumped, cast; board, brick or
filling
walls can be made of it, and above 300 kg/m3 volume density it can be
plastered as well.
The invention can be preferably realized by mixing cement with gypsum or using
gypsum instead of cement.
The invention can be preferably realized as well by mixing or replacing
polystyrene
pearl by a material, which consists of granules and is water-repellent and is
of small
volume-density (max. 400 kg/m3).
The heat-insulating, fire-proof, water-resistant, permeable-to-air, flexible
lightweight
concrete with a volume-density below 500 kg/m3, made with polystyrene pearl
according to the invention is equally suitable for heat-, and sound-insulation
of walls
and slabs, as well as decreasing their water permeability or water-absorbing
capacity, as
well as increasing their resistance to fire at the same time keeping their
ability to be
permeable-to-air and humidity, for renovation old buildings or building new
buildings.
Its composition is: polystyrene pearl, or recycled polystyrene of 1-10 mm
diameter,
water, cement and organic (polymer) binding material mixed with cement: such
homo-,
co-, and terpolymers - which are water-soluble and/or can be dispersed in
water.
Resulting from the use of organic (polymer) binding material, the polystyrene
pearls can
be easily mixed with the inorganic binding material and water.
In the case of preferable specific realization of the lightweight concrete
according to the
invention the applicable materials are the following:
Material compound:
The lightweight concrete according to the invention consists of four main
components,
which are the following: water, cement, additive, filling material.
Materials used as additive are the following:
.All homo-, co-, and terpolymers - which are water-soluble and/or can be
dispersed in
water, and do not include and do not emit volatile organic hydrocarbons
hazardous to
the environment - should be used as organic binding material. Such materials
are
widely known: they are prepared with the use of vinyl-chloride, vinyl esters
of
saturated,- unsaturated and aromatic organic acids, vinyl-butirate, ethylene,
acrilic acid
esters, styrene, alkyl-izocianates, silanes, siloxalates. Their common feature
is that even
in small quantity, they make possible the mixing of polystyrene and the
hydraulic
binding material, the excellent adhesion, strength and water-tightness of the
product.
Further organic additives can be the following: polyvinyl alcohols, cellulose-
ethers and
other protective colloids, sedimentation-inhibitors, plasticizers, which
facilitate the
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processing. As mineral additives ground stones (limestone, dolomite), pigments
(iron-
oxide, titanium-dioxide, etc.), pearlite, mica schist, etc. can be used, if
required. The
water is contamination-free, preferably drink water, tap water.
As filling material in the concrete instead of gravel, all materials can be
put in, which
are preferably the following:
- Polystyrene pearl: its density is between 20-30 kg/m3, its size is 0-20 mm.
- Plastics: recycled ground plastic (independent on its material, it can be
the plastic
frame of anything), plastic objects (polished bumper, car pieces: plastic as
dangerous
waste is separated when car is pulled to pieces), the plastic objects
ordinarily qualified
as dangerous waste, ground or in themselves are not dangerous wastes. They can
be
recycled in such a form, for example: tyre and practically all solid plastic
in ground
form.
- Plant fibres, organic materials: wood-waste, ground wood, dried plant-waste,
stalk,
bast, pine needle, paper.
- Metals, ground metal-waste: all household metal-wastes can be put in, after
comminution, grind to an appropriate size.
- Further filling materials: building waste, glass, ground concrete, ground
asphalt, etc.
In the case the volume density of the filling material is greater than 100 -
200 kg/m3, it
is not appropriate for heat-insulation, but it is excellent building material,
it can be used
instead of concrete, or elements (bricks) can be produced from it.
Sizes, rates
The size of the filling material is between 0-20 mm (it is difficult to mix
the powder
with gravel, so powder can be utilized only in certain circumstances).
Preferably the raw materials are used in a fractional way: they must be fallen
in the
same size-range. They can be used also in a non-fractional way.
Conditions of production, technology:
We mix with traditional technology. Order of adding of materials is the
following: 1.:
water, 2.: cement, 3.: additive (among the materials made known above), we mix
a
material of a dilute sour cream consistence from these three components, and
4.: filling
material.
We mix the total into a homogenous state, than we use it appropriate to the
application.
It is an essential idea of the invention, that the additive makes possible to
mix the filling
material into the water+cement compound in a homogenous way.
Applications, utilizations, end-product: heat-insulating plaster, heat-
insulating panel,
permanent lattice blind, wall element, brick, prefabricated building elements,
insulation
of heat,- gas,- oil,- water lines, bottoming, borders, road concrete elements,
building
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basic units, building elements, monolithic concrete structures prepared in the
place,
lattice blind elements.
The loadbearing capacity of the product depends on the strength (compression
strength)
of the cement and on the compression strength of the filling material. The
compression
strength of the cement and the filling material determine together the
compression
strength, statics, heat-transfer coefficient and the possibilities of
application of the end-
product.
The heat-insulating material produced this way can be even 100 kg/m3,
depending on
the quantity of the binding materials. The ready-made material can be greased,
pumped,
cast; board, brick or filling walls can be made of it, and above 300 kg/m3
volume
density it can be plastered as well. The cement can be mixed or replaced by
gypsum.
The polystyrene pearl can be mixed, or replaced by a material, which consists
of
granules and is water-repellent and is of small volume-density (max. 400
kg/m3).
