ThermoneX pre-cast panels are made using a cellular construction. This involves casting mesh-reinforced X-Concrete around a series of 120-220 mm thick polystyrene blocks, forming a series of interconnected reinforced concrete boxes.
 
These interconnected boxes make up the pre-cast panels. Panel sizes of up to 3.2m x 13.0m can be constructed, with panel thicknesses ranging from 250 mm to 400 mm. The panels are designed for use as load-bearing walls, floors and roofs. The reinforced structural design is carried out in accordance with BS 8110:1985.
 
Mesh sizes B196 and A98 are used in the moulds, with 10-20mm re-bars being used in the structural ribs. All panels are tied together with industry-standard cast-in loops, reinforcing bars, dowels and non-shrink grouts. For an illustration on how ThermoneX panels are fixed together, see typical details on left.
 
ThermoneX X-Concrete panels can be easily transported and lifted into place on site.

Aggregate Composition of X-Concrete
 
Material.....................Fraction

Expanded clay..............4-10mm
Expanded clay...............2-4mm
Polystyrene pellets.......0.5-2mm
Air voids................0.02-0.5mm
Sand
Cement
 

X-Concrete Properties

SALT AND FREEZE/THAW RESISTANCE:
The porous structure and hydrophobic nature of X-Concrete gives it the highest classification according to Swedish Standards.
 
WATER PENETRATION:
A water penetration test gives an indication of the durability of concrete, the slower the penetration the greater the durability. In standard Swedish water tightness tests on normal weight concrete a water penetration of 50mm is acceptable. Similar tests on X-Concrete registered a maximum penetration of between 2 and 10mm.
 
CHEMICAL AND CORROSION PROTECTION:
Resistance against chemical attack, X-Concrete achieves the same standards as a normal weight C45 grade concrete. Protection against corrosion of the reinforcement X-Concrete achieves the same standards as a normal weight C45 grade high quality concrete.
 
THERMAL PROPERTIES:
The porous structure and the lightweight aggregates give X-Concrete good insulating properties, with a thermal conductivity W/mK range, depending on strength grades of 0.27-0.44W/mK. By comparison normal weight concrete has a value of 1.7W/mK.
 
FIRE RESISTANCE:
X-Concrete achieves a far higher resistance than that of conventional concrete, a 120mm thick wall element provides more than 4 hours fire resistance according to Norwegian Fire Tests. The open texture of X-Concrete prevents degradation when heated as the aggregate is more easily compressed. The capacity of the concrete to withstand thermal shock prevents the risk of explosion under fire fighting conditions.