installation - polyurethane foam...

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Installation

Preparation/verification

1. Compatibility – doesn’t stick to substrate 2. Ambient temperature – varies by product and by

conditions 3. Surface conditions

• Wet surface or high moisture content • Too hot or cold • Not fully adhered • Release agent on the surface - waxy beams, vent

chutes form bond break 4. Not the right installation detail for optimal performance

– shape of foam in the framing bay, wrapping doubles

Preparation problems

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Masking was not adequate to protect walls during the roof work

Preparation problem

Preparation problem

Not enough room for specified R-value ~3” for R-38 min.

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Too hot - burnout

Substrate temperature

This spray system is provided in different reactivity profiles to meet varying substrate

temperatures previously noted. At the lower end of the recommended temperature range,

flash passes are to be avoided. FOAM-TECH personnel should be consulted in all cases

where application conditions are marginal.

Climate Conditions

Spray systems should not be applied when the wind velocity is greater than 15 M.P.H to

avoid over spraying of perimeter areas. Higher wind speeds also retard the exothermic

reaction of foam and can lead to poor adhesion and increased density as well as poor

surface texture of the foam itself.

Moisture in the form of rain, dew, frost or other sources can seriously affect the adhesion

of urethane foam to the substrate or to itself. Water reacts with the mixed foam

components, seriously affecting the foam’s physical properties. FOAM-TECH does not

recommend the spraying of this system when the relative humidity exceeds 85F.

Product Data Sheet

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Product Data Sheet

RECOMMENDED SUBSTRATE TEMPERATURES

At time of application RT2045 Winter RT2045 Regular

Minimum 40°F 60°F

Maximum 80°F 120°F

For applications below 40F, FOAM-TECH personnel should be consulted. At the lower

end of the indicated temperature ranges, flash passes should be avoided.

Degrees F 70 60 50 40 30 20 10 0 -10

Thickness Approximate Single-pass Core Densities of Urethanes (Appropriate Seasonal Blend)in Inches At a given substrate temperature on Wood (Metal/Masonry - add .25)

0.50 2.25 2.35 2.50 2.70 2.95 3.50 4.15 4.75 5.50

1.0 2.20 2.25 2.35 2.50 2.70 3.10 3.55 4.15 5.00

1.5 2.15 2.20 2.25 2.35 2.45 2.75 3.25 3.80 4.50

2.0 2.10 2.15 2.20 2.20 2.30 2.60 3.15 3.50 4.00

2.5 2.05 2.05 2.10 2.15 2.15 2.15 2.50 3.10 3.75

3.0 2.00 2.00 2.10 2.10 2.10 2.15 2.35 2.85 3.50

3.5 1.95 1.95 2.00 2.05 2.10 2.10 2.25 2.50 2.75

4.0 1.90 1.95 2.00 2.00 2.05 2.10 2.20 2.35 2.50

4.5 1.85 1.90 1.90 2.00 2.05 2.05 2.15 2.25 2.35

5.0 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.20 2.25

Density varies with temperature and material

thickness (15-year density tracking study)

The Physical Properties of Polyurethane Foam

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Pass thickness

1. Processing to the manufacturer’s specifications (many get more specific for common problems)

2. Requires QA inspections for pass and total insulation thickness

Technical Problems

Hint: Use work report and QA Submittals to assure product quality

Pass thickness test

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Incorrect pass thickness work-arounds

1. Specify processing to the manufacturer’s specifications

(many get more specific for common problems)

2. Require QA inspection reports for tested total insulation

thickness to include average and/or maximum pass

thickness

3. Require a QA inspection record as a submittal

What are the causes of foam problems?

Installation problems

Installation problems

Technique 1. Installing SPF when the relative humidity is 80% or above 2. Passes/lifts are too thick/high 3. Not enough time between passes 4. Improper spray pattern sequencing 5. Improper response to substrate and environmental

conditions 6. Proper work-around protocols not used for extreme

environmental conditions when “the work must go on” 7. More about IPF protocols in the applications section 8. Improper product and performance quality assurance

protocols

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Good technique

Good technique also saves material ($)

Good technique

Better depth control

Self-supporting

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Below-grade application

Good technique

Unvented roof applications

Good technique

Note “fillet” detail along the rafters

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Good technique

Food processing facility

Bad technique

Lack of over-spray protection

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Bad technique

Uneven installation - voids

Bad technique

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Technique – Specialty Approved Foam

Good technique

• The picture framing technique will ensure that insulation seals cracks and crevices without resulting in fold-over along the stud face or air-pockets or voids which will affect the insulation’s performance.

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Good technique

Good technique also

saves material ($)

Industry processing & installation troubleshooting guide

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Safety

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Technical problems

Safety

• Personal protection – Leads to inexperienced installers – Dangerous practices can cause injury, damage, and

delays

• Site protection – Air-quality management required

– Re-occupancy

• Fire protection issues – Improper pass thickness can start a fire

– Code requirements

Required by ICC Model Building Codes (I-codes) – Delays combustion and ignition of SPF

– Provides extra time needed for worker and occupant egress

– Requirements for Foam Plastics

• IBC Chapter 26, Section 2603

• IRC Chapter 3, Section R316

©2011 Spray Polyurethane Foam Alliance

Codes Require Ignition & Thermal Barriers

http://www.internationalcodes.net/2009-building-codes-100-3536-09.shtmlhttp://www.internationalcodes.net/2009-international-residential-codes-100-3538-09.shtmlhttp://www.internationalcodes.net/2009-international-energy-conservation-codes-100-6533-09.shtmlhttp://www.iccsafe.org/

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Technical problems

Fire protection issues

1. Thermal and ignition barriers

2. Exposed applications

3. Understanding the code exceptions and rulings

4. Knowledge of the protections available

a. Coatings

b. Other

5. Refer to the HCF foam code matrix

Locations - Attics

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Ignition Barriers

Exceptions to the 15-minute thermal barrier requirement

1. Building location exceptions

2. Prescriptive PFI barriers

3. Other types of protection

4. Protect from ignition coatings or barriers

5. Using approved sheet goods as a work-around

No PFI barrier

Basement rim joists

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Exceptions – Specialty Approved Foam

Attic application

Thermax rigid foam

board

Post installation problems

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Typical post-installation problems

1. Inadequate quality assurance protocols 2. Failure to maintain minimum cure

requirements – thermal shock 3. Lack of protection against damage by related

trades (open flames, air barrier penetrations for mechanical systems, etc.)

Hint: Product Data sheets and ESRs report cure requirements –

specify and verify compliance with the manufacturer’s requirements.

Temporary insulation can extend the installation conditions.

Foam problem!

Thermal shock plus

deep pass thickness

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Foam problem!

Field testing

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Tools of the trade

1. Pull / adhesion test kit 2. Density check kit 3. Compressive strength gauge 4. Temperature meter 5. Relative humidity meter 6. Slit test knife 7. IR camera 8. Blower door 9. Theatrical fog machine

Testing foam properties

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Foam inspections – Project identification

• Identify the materials used

– Manufacturer

– System number

– Lot number

– Seasonal formulation

– Documentation to require

• Product data sheet (Technical data, Product specification)

• MSDS forms (A, B, and finished product)

• ESRs

• Manufacturer’s installation instructions

• Processing reports

Foam inspections – Project identification

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Removing an SPF sample for density testing


Tapered sample extraction

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Repair methods

Flexible foam

plugs

Foam inspections – Installation quality

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Installation quality assurance

Graduated beaker

displacement

density test

Courtesy: Air Barrier Association of America

Adhesion test required?

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Adhesion test

Adhesion test

CMU

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Adhesion test

Glazed TC tile

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Adhesion test


Industry-standard foam testing:

• Compressive Strength (Closed-cell foam only): Compressive strength of spray foam should be measured within 15% of the minimum reported on the manufacturer’s data sheet.*

SPFA

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Cell Geometry

Polyurethane foam

Cell Geometry

• Elongated cells are stronger parallel to the long axis than perpendicular to it (similar to the grain in wood).

• Elongated cells usually mean improper application technique.

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Elongated cells are weaker perpendicular to the grain and thermal shock causes the material to shrink laterally.

Technical Problems

Density Profiles Sample 10A Sample 5BPass thicknesses 1.5" - 7" 1.5" - 2"

Percent change 6% 25%

Average density for entire sample ~1.8 ~2.2

Slice #1 2.95 2.56

Slice #2 1.94 2.15

Slice #3 1.69 2.14

Slice #4 1.56 2.35

Slice #5 1.77 2.47

Slice #6 1.78 2.32

Slice #7 1.95 2.15

Slice #8 - 2.13

Technical Problems

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Density Profiles

Sample 10A Sample 5B

Pass thicknesses 1.5" - 7" 1.5" - 2"

Percent change 6% 25%

Average density for entire sample ~1.8 ~2.2

Slice #1 2.95 2.56

Slice #2 1.94 2.15

Slice #3 1.69 2.14

Slice #4 1.56 2.35

Slice #5 1.77 2.47

Slice #6 1.78 2.32

Slice #7 1.95 2.15

Slice #8 - 2.13

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Density Profiles

Density over sample profile

1

1.2

1.4

1.6

1.8

2

2.2

2.4

2.6

2.8

3

1 2 3 4 5 6 7 8

Den

sit

y (

#/c

u. ft

.)

Density over sample profile

1

1.2

1.4

1.6

1.8

2

2.2

2.4

2.6

2.8

3

Slice #1 Slice #2 Slice #3 Slice #4 Slice #5 Slice #6 Slice #7

Den

sit

y (

#/c

u. ft

.)

Correct pass thickness

Blue line: Incorrect pass thickness

Red line indicates minimum density (2.1#/cu. ft.) for good dimensional stability

Pass thickness

1. Processing to the manufacturer’s specifications (many get more specific for common problems)

2. Pass vs. “total” and “daily total” insulation thickness

3. Theoretical variations for acceptable non-compliance


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Pass thickness test


Foam thickness

methods/tools

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Visual Inspections

Foam thickness should be

3” for this project.

Dimensional stability

1. Cold and hot testing

2. Slit testing


Hint: Use work report and QA Submittals to assure product quality

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Freezer test – No dimensional change at -5F for 48 hours

R-value

1. R-value testing cannot typically be done on site

2. Rely on the manufacturer’s information on the Product Data sheet

3. This applies only if the foam was processed properly

• Closed-cell foam - Off ratio and/or poorly mixed foam will not have closed cells and maintain low-conductivity gas in the cells.

• Open-cell foam – Off ratio and/or poorly mixed foam will have very large cells, buy will generally still perform as insulation


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R-value (Calculated)

1. R-value per unit of thickness for the product from the Product Data sheet

2. Average thickness – per the industry thickness standard test method

3. Multiply the R-value times the average thickness to get the average R-value

4. Average R-value vs. Minimum R-value


Hint: Use work report and QA Submittals to help assure product quality

Theatrical fog used for localized air-leakage testing

Foam inspections – Performance quality

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Air-barrier testing

First Instance Testing – window

opening

Foam inspections – Performance quality

Smoke puffers for localized air-leakage testing

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Blower Door Testing

Museum

Type: Closed-cell foam Type of masonry: CIPC Method: IPF Not drained Function: H, A, M Coating/protection: TB NY, NY Project date: 2007 & 2009

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Museum

Museum

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Foam Panel/SIP problems and

repair QA techniques

SIP Problems

SIP problems are almost always

related to sealant issues at the panel

joints. Here you can see the

concentration of damage along and at

the top of the panel joints.

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SIP Problems

SIP problems are almost always related to sealant issues at the panel joints.

In this project, ants at the ridge and along the soffits raised the alarm.

SIP Problems Here the panel joints are being enlarged and

cleaned out to allow full-depth air sealing. The

foam leakage at the interior verifies that the

panel joints were the air leakage path that

caused the moisture damage.

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Building Science on Panel joints

SIP Problems

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Panel joint moisture failure

Stressed-skin panel failure

Diagnostics on the fly

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Finished (chainsaw)

carpentry



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Panel joint failure

Tubes and extensions

1998

http://en.wikipedia.org/wiki/File:Vermont_law_school_oakes_hall_20040808.jpg

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1998

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Theatrical fog used for localized air-leakage diagnostics


Note: A 10’ length of 1-1/2”

PVC schedule 40 would

work nicely here


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Fill the interior volume approach


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Fill the interior volume, then pressurize One classroom filled with fog and the blower window ready

to pressurize the space


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Fog washing

at soffit

Verify air leakage is occurring from the interior up into the roof vent space

Fog

generator

Gravity flow approach for roof ventilation

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3. Terminology

Neutral

Fog washing

at soffit

Fog

generator

Timing roof vents to calculate the flow rate

When you don’t need

them, roof vents work

well!

Testing roof vent chutes for flow rate

installation - polyurethane foam...

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