17/104 C · 2020. 12. 2. · Page 2 of 30 • DAU 17/104 • Edition C Control of editions Edition Date Sections where changes have been made regarding the previous edition A 26.04.2017

17/104 C Documento de adecuación al uso

Trade name

Elastospray LWP 1672/10: IsoPMDI 92140

Holder of DAU

BASF Española SL Can Ràbia, 3-5 ES-08017 Barcelona Tel. 934 96 40 00 www.pu.basf.eu/es

Generic type and use

Two-component polyurethane foam system applied in situ for thermal insulation and to contribute to waterproofing the facade.

Manufacturing plant

Compositor Verdi 36-38 ES-08191 Rubí (Barcelona)

Valid edition and date

C 23.11.2020

Validity (conditioned to an anual monitoring [*])

From: 26.04.2017 To: 25.04.2022

Date of initial issuing of the DAU

26.04.2017

[*] The validity of DAU 17/104 is subject to the

Reglament del DAU conditions. The valid

edition of this DAU is found in the ITeC

register maintained by ITeC (available on

itec.es and through the next QR code).

This document contains 30 pages.

Its partial reproduction is forbidden.

ITeC is an authorised organism for awarding the DAU (BOE 94, 19 April 2002) for construction products (building and civil engineering) registered in the General Register of the CTE (Resolution of 3 September 2010 – Spanish Department of Housing).

Page 2 of 30 • DAU 17/104 • Edition C

Control of editions

Edition Date Sections where changes have been made regarding the previous edition

A 26.04.2017 Creation of the document.

B 20.11.2017

Texts have been revised due to the elimination of references to the UNE 92120-1 and UNE 92120-2 standards, and also due the new incorporation of references to the UNE-EN 14315-1 and UNE-EN 14315-2 standards. See sections 2.1.2 (table 2.2), 4.3 (table 4.2) and 6.3.6.

Texts updated. See sections 4 and 6.1.5.1.

C 23.11.2020

Name change of the product, from Elastospray LWP 1672/1:IsoPMDI 92140 to Elastospray LWP 1672/10:IsoPMDI 92140.

Incorporation of the test results of fire reaction for a configuration of Elastospray LWP1672/1:IsoPMDI 92140, of 140 mm thickness, protected with 5 mm of mortar (section 9.2.1).

Incorporation of the test results of initial adhesion and adhesion after agein cicles on concrete and double hollow brick substrates supports (section 9.7.2).

Revision and technical update of the DAU in accordance with the CTE updates of December 2019.

Incorporation of the modifications of edition B.


Contents

1. System description and intended uses 5

1.1. Definition of the construction system 5

1.2. Intended uses 5

1.3. Limitations of use 5

2. System components 6

2.1. Elastospray LWP 1672/10:IsoPMDI 92140 6

2.1.1. Component A (polyol) 6

2.1.2. Component B (isocyanate) 6

2.1.3. Characteristics of the Elastospray LWP 1672/10:IsoPMDI 92140 foam 6

2.2. Protection mortar 7

3. Manufacturing 8

3.1. Raw materials 8

3.2. Manufacturing process 8

3.3. Presentation of the product 9

3.3.1. Packaging of products 9

3.3.2. Labelling 9

4. Production control 9

4.1. Control of raw materials 9

4.2. Control of the manufacturing process 9

4.3. Control of finished product 10

5. Storage, transportation and site reception 10

5.1. Storage 10

5.2. Transportation 11

5.3. Control of site reception 11

6. Project and execution of the system criteria 11

6.1. Project criteria 11

6.1.1. Application thicknesses 11

6.1.2. Design criteria 11

6.1.3. Mechanical resistance and stability 12

6.1.4. Safety in case of fire 12

6.1.5. Health 12

6.1.6. Safety in use 13

6.1.7. Protection against noise 13

6.1.8. Energy economy and heat retention 13

6.1.9. Durability 13

6.2. Construction details 14

6.3. Execution criteria 16

6.3.1. Previous operations 16

6.3.2. Application conditions 16

6.3.3. Preparing the surface 17

6.3.4. Product installation 17

6.3.5. Implementing special points 19

6.3.6. Controls during product installation 19

6.4. Preventing pathologies 19

6.5. Criteria for maintenance and repair 19

6.6. Measures for environmental protection 20

6.6.1. Waste treatment 20

6.6.2. Characteristics of the blowing agent 21

7. Use references 21

8. Site visits 22

9. Assessment of tests and calculations 22

9.1. Mechanical resistance and stability 22

9.2. Safety in case of fire 22

9.2.1. Reaction to fire 22


9.3. Hygiene, health and the environment 23

9.3.1. Watertightness of the facade 23

9.3.2. Watertightness of the insulation 23

9.3.3. Long-term water absorption by immersion and short-term water absorption 23

9.3.4. Degree of impermeability 23

9.3.5. Permeability to water vapour 24

9.3.6. Condensation check calculations 24

9.4. Safety of use 24

9.5. Protection against noise 24

9.6. Energy economy and heat retention 24

9.7. Aspects of durability, service and identification 25

9.7.1. Dimensional stability 25

9.7.2. Adhesion and cohesion 25

9.7.3. Resistance to fatigue 25

9.7.4. Compressive stress at 10% deformation 25

9.7.5. Identification of the components of Elastospray LWP 1672/10:IsoPMDI 92140 foam 25

10. Committee of Experts 26

11. Reference documents 26

12. Assessment of fitness for use 28

13. DAU monitoring 29

14. Use conditions of DAU 29

15. List of changes of the present edition 30


1. System description and intended uses

1.1. Definition of the construction system

Elastospray LWP 1672/10:IsoPMDI 92140 is a two-component polyurethane foam system applied in situ by spraying using the correct machinery. The two components of this system are:

• Component A (polyol): Elastospray LWP 1672/10, consisting of a mixture of polyols, containing catalysts, stabilisers, flame retardants and HFO (hydrofluoro-olefin) as a blowing agent, with a GWP100 equal to 1 (see section 6.6.2). It does not contain HCFC or HFC.

• Component B (isocyanate): IsoPMDI 92140, MDI (Diphenylmethane-diisocyanate).

Once applied, these components form a rigid and continuous foam that adheres to the entire applied surface (see figure 1.1). The final foam has the nominal characteristics given in table 2.3.

The foam expands due to the action of a hydrofluoro-olefin (HFO-1233zd-E) and CO2 (from the chemical reaction of water with the isocyanate). The proportion of these gases within the cell in the foam without ageing is from 25% to 40% of HFO and from 75% to 60% of CO2.

The system is presented in two different reactivities with slight adjustments in the catalysis, depending on the anticipated weather conditions in which it is applied:

• Elastospray LWP 1672/10/V (V=Summer), for warm application conditions (10 ºC to 40 ºC).

• Elastospray LWP 1672/10/I (I=Winter), for cold application conditions (5 ºC to 30 ºC).

Note: The temperatures indicated above are recommendations from the manufacturer to help guide the choice of the most suitable product.

In certain applications, where an improved reaction to fire is required over that offered by the product alone, the foam can be protected with a mortar. The mortar considered in this DAU for this function is Additive 97087, applied with a primer of Additive 97088. A minimum thickness of 5 mm of mortar must be ensured over the entire surface.

1.2. Intended uses

The Elastospray LWP 1672/10:IsoPMDI 92140 system is used for thermal insulation and to contribute to waterproofing the facade, forming a very high resistance barrier to water filtration (performance level B3, according to DB-HS).

In this DAU, six reference construction solutions have been considered that have served as a model for the assessment. These solutions are described in section 6.1.2.

1.3. Limitations of use

No special limitation is considered for the polyurethane foam for the uses and construction solutions considered in this DAU. In all cases, the limitations of each of the construction solutions defined in section 6.1 must be considered.

The most relevant aspects to be taken into account for a possible limitation of the use of the product concern its performance in reaction to fire (internal and external propagation, depending on the case), thermal insulation and limitation of condensation.

A maximum application thickness of the product is not anticipated, but in each specific case an analysis should be made of how insulation thickness can affect the proposed construction solution (for example, the dimensioning of the substructure of the facade cladding considering the length of the anchors, in solutions such as solution 6 of section 6.1.2).

Figure 1.1: Spraying Elastospray LWP 1672/10:IsoPMDI 92140.


2. System components

2.1. Elastospray LWP 1672/10:IsoPMDI 92140

The Elastospray LWP 1672/10:IsoPMDI 92140 polyurethane foam system consists of a polyol (component A) and an isocyanate (component B). This system has CE marking in accordance with UNE-EN 14315-1 standard (declaration of performance number ES19-0017-VV-CPR-18, where VV is the version number).

2.1.1. Component A (polyol)

Component A of the foam is the polyol Elastospray LWP 1672/10, which has the characteristics given in table 2.1 for its two formulas (summer and winter).

Characteristic Method Value

OH index UNE 53985-1 260 ± 20 mg KOH/g

Water content ISO 14897 1.95 ± 0.2% by mass

Density at 25 ºC (*) ----- 1,180 kg/m³

Viscosity at 25 ºC (*) EN ISO 3219 260 mPa·s

Notes:

(*) Typical values (not specifications).

Table 2.1: Characteristics of component A (polyol).

2.1.2. Component B (isocyanate)

Component B of the foam is the isocyanate IsoPMDI 92140, which has the characteristics given in table 2.2.

Characteristic Method Value

NCO content ASTM D5155 31.5 ± 1.0% by mass

Density at 25 ºC (*) ----- 1,230 kg/m³

Viscosity at 25 ºC (*) EM ISO 3219 220 mPa·s

Notes:

(*) Typical values (not specifications).

Table 2.2: Characteristics of component B (isocyanate).

2.1.3. Characteristics of the Elastospray LWP 1672/10:IsoPMDI 92140 foam

The main characteristics of the Elastospray LWP 1672/10:IsoPMDI 92140 polyurethane foam are given in tables 2.3, 2.4, 2.5 and 2.6.

1 There is an European test method for the determination of a

product's propensity to undergo continuous smouldering (EN 16733:2016) which is not yet included in the harmonized product standard. However, due to the nature of the product, it can

Characteristic Test method Performance

Reaction to fire UNE-EN 13501-1 Class E

Water permeability (*)

UNE-EN 1609 method B

< 0.20 kg/m²

Thermal resistance UNE-EN 12667 See table 2.5

Permeability to water vapour

UNE-EN 12086 method A

Water vapour diffusion resistance

factor, µ = 70

Compressive strength (**)

UNE-EN 826 ≥ 200 kPa

Continuous glowing Standard test method not available1

Durability of performance against ageing / degradation:

Reaction to fire

UNE-EN 14315-1

Reaction to fire does not decrease over time

Thermal resistance See table 2.5

Compressive strength

Compressive strength does not decrease over time

Notes:

(*) Short-term water absorption by partial immersion.

(**) Compressive stress at 10% deformation.

Table 2.3: Characteristics included within the CE marking of the Elastospray LWP 1672/10:IsoPMDI 92140 foam.

Characteristic Test method Performance

Closed cell content UNE-EN ISO 4590 > 90%

Long-term water absorption

UNE-EN 12087 method 1B

< 0.20 kg/m²

Watertightness UNE-EN 1928 Satisfactory (60 kPa)

Dimensional stability (**) at +70 ºC, 90% RH and at -20 ºC

UNE-EN 1604 DS(TH)1

(s/ UNE-EN 14315-1)

Reaction to fire of the protected foam

UNE-EN 13501-1 Class B-s2,d0 (***)

Specific heat (*) ----- 1,400 to 1,500 J/kg·K

Notes:

(*) Typical value, not specification

(**) DS(TH) level determined on specimens without skin (extracted from the core) (see the test performed, section 9.7.1). The values indicated are valid for the range of layer thicknesses considered in this DAU (from 10 mm to 30 mm).

(***) This class is achieved by protecting the product with the mortar indicated in section 2.2 (see the test performed, section 9.2.1).

Table 2.4: Other characteristics contemplated in the DAU.

be considered that this characteristic is not relevant for polyurethane foams.


Thickness (mm)

Declared thermal

conductivity, λD (W/m·K)

Thermal resistance, RD

(m²·K/W)

30 0.028 1.10

35 0.028 1.25

40 0.028 1.45

45 0.028 1.65

50 0.028 1.80

55 0.028 2.00

60 0.028 2.20

65 0.028 2.35

70 0.028 2.55

75 0.028 2.75

80 0.026 3.05

85 0.026 3.25

90 0.026 3.45

95 0.026 3.65

100 0.026 3.80

105 0.026 4.00

110 0.026 4.20

115 0.026 4.40

120 0.025 4.80

125 0.025 5.00

130 0.025 5.20

135 0.025 5.40

140 0.025 5.60

145 0.025 5.80

150 0.025 6.00

155 0.025 6.20

160 0.025 6.40

165 0.025 6.60

170 0.025 6.80

175 0.025 7.00

180 0.025 7.20

185 0.025 7.40

190 0.025 7.60

195 0.025 7.80

200 0.025 8.00

Table 2.5: Thermal performance of the Elastospray LWP 1672/10:IsoPMDI 92140 foam, as indicated on the CE marking.

Characteristic Elastospray LWP 1672/10:IsoPMDI 92140

Formula V Formula I

Mixing ratio (A : B)

100 : 104 ± 2 (by mass)

Cream time (CT)

4 ± 1 s 4 ± 1 s

Gel time (GT) 8 ± 2 s 7 ± 2 s

Tack free time (TFT)

10 ± 3 s 9 ± 3 s

Free rise density

33.0 ± 2.0 kg/m³

Note:

Test methods according to annex E of the UNE-EN 14315-1

standard. Measured at 20 ºC ± 2 ºC and with the specified mixing ratio.

Table 2.6: Control characteristics of foaming of the Elastospray LWP 1672/10:IsoPMDI 92140 foam.

2.2. Protection mortar

For construction solutions which require a more demanding class of reaction to fire than that offered by the Elastospray LWP 1672/10:IsoPMDI 92140 system, the foam must be protected with a mortar which the holder of the DAU sells under the name Additive 97087.

This is a prepared mortar made by mixing selected cements and aggregates with powdered resins, whose characteristics of commissioning and main product characteristics are given in tables 2.7 and 2.8.

Characteristic Value

Kneading water 5 litres / bag (25 kg)

Approximate mixing time 3 minutes (*)

Approximate maturing time 5 minutes (*)

Approximate working time 2 hours

Time after which it is:

• Mechanically loadable

• Loadable with water pressure

3 days 7 days

Application temperature (substrate and material)

From + 5 ºC to + 30 ºC

Note:

(*) Times indicated for manual mixing of the mortar. They do not apply if continuous mixing and spraying systems are used.

Table 2.7: Commissioning properties of the mortar Additive 97087.

When this mortar is applied over polyurethane, a previous layer of the product Additive 97088 should be used as a primer. The total thickness of mortar applied should be at least 5 mm.


Characteristic Test method Value

General appearance and colour

Visual check Grey powder

Density UNE-EN 1097-3 1,310 ± 50 kg/m³

Granulometry of the dry components (% passes the 1 mm sieve)

UNE-EN 12192-1 100%

Consistence EN 1015-3 195 ± 10 mm

Product properties

Mechanical compressive strength

Internal method ≥ 30 MPa (after 28 days)

Mechanical flexural strength

Internal method ≥ 6.5 MPa (after 28 days)

Linear shrinkage UNE-EN 12617-1 < 0.3%

Coefficient of thermal expansion

UNE-EN 1770 αT ≤ 30·10-6 K-1

Permeability to water vapour

EN ISO 7783-1 EN ISO 7783-2

Class I

Capillary absorption and water permeability

UNE-EN 1062-3 ≤ 0.1 kg/m³·h0,5

Resistance to cracking

UNE-EN 1062-7

Class A4 (+ 20 ºC)

Class A3 (- 10 ºC, - 20 ºC)

Thermal

conductivity, λ (*) 0.70 W/m·K

Specific heat, cp (*) 1,000 J/kg·K

Water vapour diffusion resistance

factor, µ (*) 10

Adhesion on initial polyurethane

UNE-EN 1015-12 0.14 MPa

Adhesion on polyurethane after ageing

UNE-EN 1015-12

UNE-EN 1015-21 0.11 MPa

Notes:

(*) Data taken from table 3.5 of the CTE Building Elements Catalogue. They are indicated as a reference for calculations.

Table 2.8: Characteristics of mortar Additive 97087.

3. Manufacturing

Component A (polyol) is manufactured by BASF Española SL at its Rubí plant. Component B (isocyanate) is manufactured by BASF Antwerpen NV in Antwerp (Belgium), and transported to the BASF Española SL plant in Rubí.

3.1. Raw materials

The raw materials used to manufacture the two components of Elastospray LWP 1672/10:IsoPMDI 92140 polyurethane foam are:

Component A (polyol):

• Its raw materials are: polyols of various types, a flame retardant, various reaction catalysts, a blowing agent and other additives.

Component B (isocyanate):

• IsoPMDI 92140.

3.2. Manufacturing process

Component A

The manufacturing process is carried out in discontinuous batch mode. It consists of the following phases:

• Cleaning the reactor.

• Adding raw materials to the mixer. Each raw material is added separately to determine the exact weight, and in the sequence indicated in the manufacturing order.

• Mixing of different raw materials by stirring in the mixer.

• Homogenisation of the mixture, forming a manufacturing batch. Once it is homogeneous, a sample is taken for quality control.

• Packing in drums.

• Labelling.

Throughout the entire process and to ensure traceability, batch numbers are assigned to:

• Each raw material.

• The amount of homogenised mixture during production.

• Each pack.

Component B (isocyanate)

Component B (isocyanate) is manufactured by BASF Antwerpen NV in Antwerp (Belgium) and transported to


the BASF Española SL plant in Rubí where it undergoes the following processes:

• Storage in large capacity tanks.

• Packing in drums.

Throughout the entire process and to ensure traceability, batch numbers are assigned to:

• Each raw material.

• Each pack.

3.3. Presentation of the product

3.3.1. Packaging of products

Generally, the two components of the system are supplied in the following containers:

• Component A: closed blue 205 l type 1A1 drum.

• Component B: closed red 205 l type 1A1 drum.

Very occasionally and at the customer’s request the product can be supplied in IBC-type containers, 50-litre closed drums or in bulk in a tanker.

Drums can be palletised and strapped at the customer’s request.

3.3.2. Labelling

All containers are labelled. The following information is included on each label:

Component A (polyol)

• Indication of component A with the corresponding formula type (V or I).

• Mixing ratio with component B.

• Expiry date.

• Pack batch number.

• Description of the system.

Component B (isocyanate)

• Description of the product.

• Indication of component B.

• Expiry date.

• Pack batch number.

• Indication of the system.

The classification for the transport of each of the components is found in the shipping documentation.

4. Production control

BASF Española SL manufactures products of the Elastospray LWP 1672/10:IsoPMDI 92140 system at its plant in Rubí, where it has implemented a production control system in the factory for these products.

The production control implemented covers the phases of the receipt of raw materials, manufacturing and the dispatch of the finished product.

The company has a certificate that certifies that its manufacturing complies with UNE-EN ISO 9001 and a certificate conforming to the UNE-EN ISO 14001 standard on environmental management.

4.1. Control of raw materials

Raw materials Controlled parameter Control frequency

Polyols

Colour

Each batch

Viscosity

Water content

OH index

Acidity

Flame retardant

Colour and appearance

Each batch Acidity

Water content

Catalyst

Water content

Each batch Viscosity

Refractive index

Additive Viscosity Each batch

Blowing agent Purity Each batch

IsoPMDI 92140

Colour and appearance

Each batch Viscosity

Free isocyanate content

Table 4.1: Control of raw materials (by type of product).

4.2. Control of the manufacturing process

Processes related to the following are controlled:

• Cleaning the reactor.

• Loading raw materials.

• Stirring.

• Packaging and labelling.

• Storage.

• Dispatch.


4.3. Control of finished product

Table 4.2 lists the controls performed on the components, as well as the product resulting from mixing them both. These controls are carried out in the manufacturer’s own laboratory.

Characteristic Method Frequency

OH index of the polyol (component A)

Internal method (*)

Every 5 batches

Water content of the polyol (component A) Internal method

(*)

Each batch

NCO content of the isocyanate (component B)

Cream time (CT)

Internal method (**)

Gel time (GT)

Tack free time (TFT)

Free density

Initial thermal conductivity

UNE-EN 12667

4 per year

Aged thermal conductivity 1 every 2 years

Reaction to fire UNE-EN 13501-1

4 per year Closed cell content

UNE-EN ISO 4590

Compressive strength at 10%

UNE-EN 826

Note:

(*) Methods of BASF Española SL.

(**) Methods of BASF Española SL, based on the EN 14315-1 standard.

Table 4.2: Control of finished product

5. Storage, transportation and site reception

5.1. Storage

To ensure the correct preservation of the products and their subsequent processing, the following parameters must be respected. This information is also included in the documentation that the manufacturer provides to each of its customers (technical information and safety data sheets).

Temperature

The optimum storage temperature is +10 ºC to +25 ºC.

At higher temperatures, the blowing agent dissolved in component A (polyol) is released, exerting overpressure on the drums. This overpressure causes the drums to swell and can generate uncontrolled boiling when the drum is opened.

The drums should not be exposed to direct sunlight and high temperatures for long periods of time.

The drums should not be exposed to temperatures below -10 °C for long periods of time, as this may result in crystallisations in component B (isocyanate) which will later obstruct the ducts of the spraying machine.

Humidity

Components A and B are sensitive to moisture, so they should always be stored in drums or hermetically sealed tanks. Containers must be protected from water and moisture.

The absorption of water by component A can cause errors during processing. On the other hand, component B reacts with moisture, forming solid adducts of urea and releasing CO2 gas. The presence of CO2 causes overpressure inside the drums.

Validity

Both component A and component B have an optimal time established for their use, indicated on their respective labels together with their manufacture and expiry dates.

Within this period, both components retain their physical properties, the proper reaction time between the two components is maintained and the foam obtained presents all its properties.

After this time, there may be a loss of reactivity of the system, which could cause problems in its application.

BASF Española SL dispatches both components guaranteeing that the end user has a time of use of at least 2 months.

Flammability

None of the components of the Elastospray LWP 1672/10:IsoPMDI 92140 system has a flash point below 100 ºC. Therefore, they are not flammable and no


special handling, storage and transport measures are required.

The blowing agent in component A (polyol) is also not classified as flammable. For more information, see the safety data sheet of the components.

5.2. Transportation

Before each supply, all the containers are checked to see if they are properly labelled and their external condition is inspected to check that they are not dented or swollen.

The conditions of dispatch of the products until their delivery to the customer are established according to:

• The legal conditions of the product and transportation.

• The technical conditions of transport.

The transport of the product drums is carried out by trucks that meet the load and safety standards demanded by BASF Española SL.

5.3. Control of site reception

• Visual check of labelling.

• Document checks of the analysis bulletin of the system components.

• Visual inspection of drums: no major dents or swelling.

6. Project and execution of the system criteria

6.1. Project criteria

6.1.1. Application thicknesses

The foam thicknesses to be applied are defined in the project according to the climate area in which the building will be located and the energy classification aimed for it.

The layers needed to obtain the thickness indicated in the project must be applied. The application thickness of each layer should be between 10 mm and 30 mm. To maintain good foam stability, it is not advisable to apply layers with a greater thickness (see figure 6.1).

Figure 6.1: Example of application by layers.

6.1.2. Design criteria

6.1.2.1. Variants of the system

This DAU considers the following types of construction solutions:

• Solution 1: insulation on the inner face of the exterior layer with exposed brick finishing, with ceramic partitions (see figure 6.2).

• Solution 2: insulation on the inner face of the exterior layer with exposed brick finishing, with laminated gypsum partitions (see figure 6.3).

• Solution 3: insulation on the inner face of the exterior layer of hollow brick or concrete block with cement plaster, with ceramic partitions (see figure 6.4).

• Solution 4: insulation on the outer face of the ceramic interior partition (see figure 6.5).

• Solution 5: insulation on facade with natural stone finishing (see figure 6.6).

• Solution 6: insulation on ventilated facade (see figure 6.7).


The polyurethane foam must be applied from the inside or from the outside, depending on the type of construction solution considered. The specific details of each case are given in section 6.3.5.

6.1.2.2. Relevant aspects to be considered in the design

The following aspects must be considered in the project of the building’s thermal envelope:

1. The minimum foam thickness to be applied.

2. The characteristics and dimensions of the other elements that form the building’s thermal envelope (profiles, claddings, etc.).

3. The tolerance in thickness for the application of the foam.

4. The tolerance in thickness for the application of the mortar protection.

In addition to the minimum thickness needed to meet thermal requirements, it may be necessary to set a maximum thickness of the foam (and of the protective mortar, when applicable) to maintain the dimensions of each layer of the thermal envelope and thus guarantee its function. Especially in facades of the type of solution 6, the minimum anticipated thickness of the air chamber and the correct fixing of the ventilated facade cladding should be ensured. These aspects should also be considered in other types of construction solutions, although they may be less relevant.

The applicators of these products should be informed of the minimum and maximum thicknesses in the project for the application of the foam and of the protective mortar.

6.1.3. Mechanical resistance and stability

This requirement does not apply to the polyurethane foam considered in this DAU.

6.1.4. Safety in case of fire

6.1.4.1. Reaction to fire

The reaction to fire performance of the polyurethane foam exposed to fire without any type of protection is class E. The construction solutions considered in this DAU always have a certain degree of protection and therefore the following considerations must be considered in the planning phase.

Internal propagation

Table 4.1 of the section SI1 of the Basic Document (hereinafter DB) DB-SI of the Spanish Technical Building Code (hereinafter CTE) summarises the reaction to fire conditions that must be met by the building elements to limit the risk of spread of fire inside the building. The requirement also covers those materials which are in layers contained within the walls and which are not protected by at least one EI 30 layer. In this sense:

• Solutions 1, 3, 4, 5 and 6 provide protection of EI 30 or higher to the polyurethane foam, so this requirement is not applicable.

• Although solution 2 does not offer EI 30 fire resistance, according to Royal Decree 110/2008, it is considered that its reaction to fire in its final application of use is:

- B-s1,d0: with laminated gypsum boards with a

thickness of ≥ 9.5 mm, gypsum core with a

density of ≥ 600 kg/m³ and board weight of

> 220 g/m2 and ≤ 320 g/m2.

- A2-s1,d0: with laminated gypsum boards with a

thickness of ≥ 9.5 mm, gypsum core with a

density of ≥ 600 kg/m³ and board weight of

≤ 220 g/m².

At the same time, the conditions indicated in said Royal Decree (relating to the assembly, fixing and sealing of the laminated gypsum boards) must be complied with.

The requirements of section 3 of section SI1 of the DB-SI relating to the passage of installations through spaces concealed in fire compartmentation elements shall also be considered, where applicable.

External propagation

In order to limit the propagation of fire through the outside of the building, te section SI2 of the DB-SI stipulates that the insulation systems located inside ventilated chambers must have at least, the following classification of reaction to fire according to the total height of the façade:

• D-s3,d0 on facades of height up to 10 m;

• B-s3,d0 on facades of height up to 28 m;

• A2-s3,d0 on facades of height greater than 28 m.

This requirement is applicable to solution 6 (application in ventilated facades). To comply with this class of reaction to fire, it is necessary to protect the polyurethane foam with the mortar indicated in section 2.2 of this DAU. Two reaction to fire tests were carried out with a representative sample of the foam protected with 5 mm of mortar, the result of which is summarised in section 9.2.1 and shows that this solution meets the requirement for the limitation of external propagation, for an average foam thickness of 140 mm or less.

6.1.5. Health

6.1.5.1. Degree of impermeability to rainwater

The Elastospray LWP 1672/10:IsoPMDI 92140 foam applied with a minimum thickness of 30 mm can be considered to offer a very high resistance barrier to filtration, i.e. a type B3 barrier, in addition to being a thermal insulator. In accordance with the DB-HS, a type B3 barrier (rendering) must have the following characteristics:


• Watertightness

• Adhesion to the substrate

• Permeability to water vapour

• Adaptation to the movements of the substrate

• Stability against physical, chemical and biological attacks.

Section 9.3.4 indicates the checks that have been made in this DAU to justify these characteristics with a minimum foam thickness of 30 mm.

With the foam being a type B3 barrier rendering, it can be considered that all the construction solutions considered in this DAU have a degree of impermeability of 5, since the main layers of the facade can be classified as type C1.

In all cases, it must be considered that to ensure the impermeability of the facade, it is important that the external wall is correctly executed, especially considering potential weak points of the wall tightness in mortar joints, window and door jambs, slab edges, etc.

Whenever it is relevant for the proposed solutions, the indications in section 2.3.3.5 of the section HS1 of the DB-HS regarding the evacuation of water that can penetrate the main layer of the facade must be followed.

Solutions at particular points should ensure that the impermeability of the facade is maintained and that, in addition, no thermal bridges are produced. Section 6.3.5 gives indications for some of these points.

6.1.5.2. Limitation of condensation

Characteristics have been established to perform the hygrothermal calculations indicated in the CTE. They are: thermal conductivity, absolute density, specific heat and water vapour diffusion resistance factor, with the aim of calculating the risk of condensation in the planning phase.

The hygrothermal characteristics of Elastospray LWP 1672/10:IsoPMDI 92140 foam are shown in table 2.3.

The calculation should be made using the application thickness defined in the plans, depending on the needs of the building.

6.1.6. Safety in use

Since the product is always hidden from the building user, this requirement does not apply to the polyurethane foam considered in this DAU.

6.1.7. Protection against noise

The contribution to the insulation of airborne noise by construction solutions involving Elastospray LWP 1672/10:IsoPMDI 92140 has not been assessed.

When applicable, the values of insulation of airborne noise given in the CTE Building Elements Catalogue

corresponding to the solutions considered in this DAU can be taken as a reference (see 6.1.2.1).

In all cases, it should be considered that in general the acoustic insulation of the facades largely relies on the insulation of their openings (windows and doors). In addition, the foam can contribute to sealing any fissures in the facade that can compromise its acoustic insulation.

6.1.8. Energy economy and heat retention

6.1.8.1. Thermal insulation

The characteristics needed to perform the hygrothermal calculations in accordance with the CTE of the solutions involving the Elastospray LWP 1672/10:IsoPMDI 92140 foam are indicated in table 2.3 and 2.5 (see table 2.8 for the protective mortar). The designer, depending on the particular conditions of the facade, will consider the need to introduce the correction of the value of the thermal conductivity due to the influence of humidity and temperature, in accordance with that indicated in the UNE-EN ISO 10456 standard.

The tests performed are summarised in section 9.6.1.

The thermal conductivity value given is estimated for an average period of 25 years.

6.1.8.2. Thermal inertia

The relevant data for the calculation of thermal inertia are:

• Specific heat, J/(kg·K).

• Surface mass, kg/m².

• Density, kg/m³.

• Resistance, m2·K/W, or thermal transmittance, W/m²·K.

These data can be obtained from the information in tables 2.3 and 2.4 of this DAU (table 2.8 for the protective mortar). The typical values of thermal inertia of the foam layer are much lower than the thermal inertia of the ceramic or concrete layers of the enclosure.

6.1.9. Durability

The durability of Elastospray LWP 1672/10:IsoPMDI 92140 is ensured with good design measures in the plans (see section 6.1), and proper implementation paying particular attention to the solution of the particular points (see sections 6.2 and 6.3).

Tests carried out with ageing of the test specimens allows to assume that the performance of the polyurethane foam indicated in this DAU is maintained during its working life.

The characteristics tested that are considered relevant for the durability assessment are listed in section 9.7.


6.2. Construction details

1. Perforated brick 1/2 foot, 115 mm. 2. Elastospray LWP 1672/10:IsoPMDI 92140. 3. Non-ventilated air chamber, 20 mm. 4. Hollow brick, 40 mm / 70 mm. 5. Gypsum plastering, 20 mm.

Figure 6.2: Solution 1: Insulation on the inner face of the exterior layer with exposed brick finishing, with ceramic partitions.

1. Perforated brick 1/2 foot, 115 mm. 2. Elastospray LWP 1672/10:IsoPMDI 92140. 3. Uprights and non-ventilated air chamber, 30 mm 4. Laminated gypsum board or panel, 13 mm

Figure 6.3: Solution 2: Insulation on the inner face of the exterior layer, with laminated gypsum partition.

1. Cement rendering, 15 mm. 2. Hollow brick, 115 mm, or concrete block, 140 mm. 3. Elastospray LWP 1672/10:IsoPMDI 92140. 4. Non-ventilated air chamber, 20 mm. 5. Hollow brick, 40 mm / 70 mm. 6. Gypsum plastering, 20 mm.

Figure 6.4: Solution 3: Insulation on the inner face of the exterior layer of hollow brick or concrete block with cement plaster, with ceramic partitions.

1. Perforated brick 1/2 foot, 115 mm. 2. Non-ventilated air chamber, 20 mm. 3. Elastospray LWP 1672/10:IsoPMDI 92140. 4. Hollow brick, 70 mm. 5. Gypsum plastering, 20 mm.

Figure 6.5: Solution 4: Insulation on the outer face of the ceramic interior partition.


1. Natural stone finishing, 120 mm. 2. Mortar. 3. Elastospray LWP 1672/10:IsoPMDI 92140. 4. Hollow brick, 115 mm. 5. Metal or plastic connector. 6. Gypsum plastering, 20 mm.

Figure 6.6: Solution 5: Insulation on facade with natural stone finishing.

1. Exterior finishing, 20 mm. 2. Ventilated air chamber, 40 mm. 3. Elastospray LWP 1672/10:IsoPMDI 92140. 4. Primer Additive 97088. 5. Protection mortar Additive 97087, 5 mm. 6. Concrete block, 140 mm, or perforated brick 115 mm. 7. Gypsum plastering, 15 mm.

Figure 6.7: Solution 6: Insulation in a ventilated facade with exterior cladding.

1. Floor. 2. Full shutter and shutter box. 3. Extruded polystyrene board (Styrodur®). 4. Elastospray LWP 1672/10:IsoPMDI 92140. 5. Prefabricated shutter front lintel

Figure 6.8: Shutter box on the outside.

1. Floor. 2. Full shutter and shutter box. 3. Extruded polystyrene board (Styrodur®). 4. Elastospray LWP 1672/10:IsoPMDI 92140. 5. Exterior layer.

Figure 6.9: Shutter box on the inside.


1. Exterior layer. 2. Non-ventilated air chamber, 20 mm. 3. Interior partition. 4. Elastospray LWP 1672/10:IsoPMDI 92140.

Figure 6.10: Insulation between pillar on facade and exterior layer. Insulation surrounding the contour.

1. Exterior layer. 2. Elastospray LWP 1672/10:IsoPMDI 92140. 3. Non-ventilated air chamber, 20 mm. 4. Interior partition.

Figure 6.11: Insulation between pillar on facade and exterior layer. Formation of half-round shape.

1. Expansion joint. 2. Exterior layer. 3. Elastospray LWP 1672/10:IsoPMDI 92140. 4. Air chamber. 5. Interior partition. 6. Non-stick plastic film.

Figure 6.12: Handling with expansion joints.

6.3. Execution criteria

6.3.1. Previous operations

Prior to the application of Elastospray LWP 1672/10:IsoPMDI 92140 on site, an inspection will be carried out which will include the following actions:

• Identify the type of substrates to be insulated, the consistence of the material that forms it and the conditions in which it is found. It will be verified that the substrates are free of dust or grease.

• Determine the surface area to be insulated.

• Identify the expansion joints and ventilation holes that may exist on the application surface of the polyurethane foam.

• Check the machinery regulations.

For applications of polyurethane foam from the outside and in windy conditions, it is totally advisable to cover the whole facade to be sprayed with a protective canvas to avoid staining the adjoining areas.

It is not necessary to add additives to the components of the polyurethane foam or to shake them before use.

Staff applying the product must have sufficient experience in the application of this type of products (see section 6.3.6).

6.3.2. Application conditions

To achieve optimum performance of Elastospray LWP 1672/10:IsoPMDI 92140, the application conditions given in the following sections must be respected. The applicator should check that these conditions are met before applying the foam.

Regarding the mortar Additive 97087, the holder of the DAU has available an Application Guide and a Protection System Sheet, which contain the most relevant recommendations and conditions for its correct application.

6.3.2.1. Environmental conditions

Weather conditions influence the declared quality and properties of the foam in works where it is sprayed and can modify the performance of the product.

It is therefore important to control:

Ambient temperature and substrate temperature

During spraying, the ambient temperature and that of the substrate must not be lower than those indicated below, depending on the formula of component A used:

• 10 ºC for Elastospray LWP 1672/10/V:IsoPMDI 92140.

• 5 ºC for Elastospray LWP 1672/10/I:IsoPMDI 92140.

Lower temperatures can hinder the adhesion of the foam to the substrate and cause reduced performance.

Likewise, at high temperatures the foaming reaction takes place very violently on the surface, which can


cause damage to the substrate and give a foam density that is lower than desired.

Ambient humidity and substrate humidity

The application surface must be clean and dry. On the surfaces of porous materials (ceramic or concrete), the humidity of the substrate should not exceed 20%. On non-porous surfaces, it will be verified that there is no surface condensation.

The relative humidity of the air in the workplace must be less than 85% to minimise the risk of surface condensation.

The presence of surface humidity leads to the formation of a highly porous foam with deficient mechanical properties and low adhesion on the substrate.

Sporadic water droplets can cause clearly visible blisters on the foam.

When spraying, it is important to ensure that the compressed air of the machine is completely dry.

Wind speed

As a general criterion, applying the foam from the outside must be avoided whenever the wind speed exceeds 30 km/h.

Higher wind speeds can lead to:

• High consumption of the material due to losses caused by the wind

• Problems of dirt in locations near the spraying area.

• Highly irregular surface of the applied foam.

In each case, the applicator must assess whether the wind or air currents can prevent the proper spraying of the foam if sprayed from the interior.

6.3.2.2. Conditions of the spraying machine

The spraying machine must be specially designed to mix and spray the product. These machines are usually high pressure with a self-cleaning gun.

The following parameters can be set in the machine:

Mixing ratio

The product will be applied with the following mixing ratio:

A / B = 1 / 1 by volume or 100 / 104 by mass.

The ratio will be controlled prior to each application by measuring the flow rates of the two components before they pass through the mixer in the spraying machine. The value must not differ from 5% by mass to the indicated value.

Temperature and pressure of components

The machine must have a temperature controller in the preheaters and in the hoses. The working temperature must be set between 30 ºC and 50 ºC depending on the ambient conditions.

The pressure of the products must be set between 50 bar and 80 bar (high pressure machines).

The correct temperature and pressure settings of the machine will be needed depending on the type of gun and mixing chamber to guarantee the mixing quality of the product and obtain a suitable spraying aperture for the correct application of the foam.

6.3.3. Preparing the surface

In favourable weather conditions, the adhesion of Elastospray LWP 1672/10:IsoPMDI 92140 to most materials used as a substrate (concrete, brick, wood, steel...) is good, as long as they are clean (free of dust and grease) and dry.

In all cases and before proceeding to the application by spraying, a small test of adhesion to the substrate should be made to guarantee good bonding.

6.3.4. Product installation

6.3.4.1. Product installation overview

The foam will be sprayed in sections. The spraying will start at the top of the section. Each section is sprayed in a horizontal direction, from right to left and from left to right, continuously.

The application thickness of each layer should be between 10 mm and 30 mm. The applicator must check the total thickness applied by means of a depth gauge with measuring pin to ensure the thickness defined in the plans (see figure 6.13).

Figure 6.13: Example of a depth gauge with measuring pin.

It is recommended that the distance of application between the gun and the application surface is about 80 cm, although variations can be permitted.

The first layer of foam will be applied as a primer (a very thin layer using a quick pass) to give good anchorage to the surface (see figure 6.14). Once this layer is cured (dry to the touch), the successive layers will be applied until the final thickness is reached. In the case of the application of thick layers, the waiting time between layers will be at least 10 minutes to guarantee that the remaining heat in the newly applied material has dissipated.


The applicator must be aware of the aspects indicated in section 6.1.2.2 related to the dimensional tolerances to be respected in ventilated facade solutions.

During application, avoid contact with open flames and the presence of ignition sources, and ensure proper ventilation in the work area.

The Safety Data Sheets of each of the products and the Safety and Precaution Measures when Handling Polyurethane Systems from BASF Española SL should be considered whilst preparing and handling the system.

Thanks to the short reaction times, the spraying can be performed on vertical walls without resulting in sagging. The foam hardens quickly and can withstand mechanical stresses after a few minutes, although the foam will not be completely cured until approximately 24 hours have passed.

Figure 6.14: Application of the primer layer.

6.3.4.2. Applying the foam from the exterior

Applying the foam from the exterior is done with the aid of scaffolding or an elevator or crane. Once the structure has been made and the inner layer has been raised (cladded), the polyurethane layer is applied to the outer face of this layer following the recommendations indicated in the previous sections.

The entire wall should be sprayed, if necessary, including slab faces.

When the outer layer is produced, an air chamber is left between the sprayed foam and said layer, as shown in figures 6.5, 6.6 and 6.7.

Special considerations for solution 6

If during the installation of the ventilated facade it is necessary to weld the metal elements that fix it in place, this must be done before applying the polyurethane foam. Any other damage that may occur to the foam during the installation of the substructure of the facade cladding must be repaired before installing the cladding (see an example of this application in figure 6.15).

Figure 6.15: Installation of the system on the exterior in the case of a ventilated facade.

Where it is considered necessary in the plans, a layer of mortar should be applied to protect the foam against the propagation of fire from the exterior (see section 2.2). No more than 2 months should pass between applying the foam and the mortar.

6.3.4.3. Applying the foam from the interior

Once the outer layer has been raised, the polyurethane foam is applied to the inner face of the outer layer, following the recommendations given in the previous sections.

When fitting the cladding, a chamber should be left between the sprayed foam and the inner air layer, as shown in figures 6.2, 6.3 and 6.4.

Special considerations for solution 2

In the case of internal laminated gypsum partitions with metal profiles, it is possible to proceed in two ways:

• With the metal profiles installed, the polyurethane foam is sprayed between the uprights. In this case, applying wax or oil to the uprights is recommended to make them easier to clean after spraying.


• The upper and lower guides of the profiles are installed and the polyurethane foam is sprayed onto the inner surface of the outer layer. Subsequently, the profiles are installed before the sprayed polyurethane. Waiting until the foam has completely cured is recommended.

6.3.5. Implementing special points

As a general criterion, the usual solutions for sealing the main layer of the facade must be followed at the height of the profiles of the slab edges and other especially sensitive points like shutter boxes or expansion joints to prevent water from penetrating by these points.

Solutions specific to the system that is the object of the DAU are described below:

Column connection

If the inner layer of the enclosure meets the column, the latter can be insulated by applying the polyurethane foam around its entire contour (see figure 6.10).

If the column meets the inside layer of the enclosure and it is not possible to apply the foam around the entire contour, a half-round shape should be made on each side of the connection with the column so that the entire visible area of the column is covered with the foam (see figure 6.11).

Upper and lower slab connection

In interior applications, it is recommended to make a half-round shape in the connections with the lower and upper slabs (see figure 6.2, 6.3 or 6.4).

Shutter gaps

Both the shutter boxes installed from the interior and those installed from the exterior will be sprayed with the foam around their perimeter.

Expansion joints

Directly applying the foam to the expansion joints should be avoided.

At these points, an elastic separating membrane about 30 cm wide centred on the joint must be installed beforehand. This sheet should be made of a non-stick material, such as synthetic rubber.

Once the sheet is installed, the foam will be applied over it in the usual way.

6.3.6. Controls during product installation

Personnel applying the product must have sufficient experience in the application of this type of products and carry out the verifications and reports provided for in the UNE-EN 14315-2 standard.

For correct processing, the basic starting conditions are as follows:

• During application, the spray aperture must be regular, circular in section, constant and without interruptions.

• The sprayed material should emerge from the gun tip in liquid form and foam quickly after meeting the surface.

Possible problems that may arise in relation to spraying, as well as the solution proposed by the manufacturer, are presented in tables 6.1 and 6.2.

To control the applied product, section 5 of the standard UNE-EN 14315-2 must be followed (self-verification checks to be carried out by the applicator concerning thickness, density and other controls indicated by the manufacturer). In addition to ensure the minimum thickness specified by the client (based on the mínimum thickness specified by the manufacturer), it can be considered also necessary to ensure the maximum application thickness (see section 6.1.2.2).

These checks must be performed at least once at the beginning of each working day and each new building project.

Once the foam has been installed, the applicator must declare that it has been carried out in accordance with the requirements of the standard by issuing a certificate or report.

The following should be checked when applying mortar Additive 97087:

• External appearance (texture/consistence of the mortar, adhesion and detachment)

• Thickness once applied

In some cases, the application by spraying of this mortar can leave some parts completely uncovered, for example, around the vertical profiles of the ventilated facade. In such cases, all exposed areas should be touched up by hand, at the very least in the locations indicated as being most relevant to the external propagation of fire (see section 6.1.4.1).

The person in charge of the site must check that the specifications of the product prescribed in the plans and of the final product applied match.

6.4. Preventing pathologies

Once the product is applied, certain pathologies can occur if it has not been sprayed under the right conditions. Table 6.3 identifies these potential problems, as well as explaining how to prevent them. All the defects mentioned are irreversible and can appear some time after applying the polyurethane foam.

6.5. Criteria for maintenance and repair

Once applied, the system does not require maintenance.

Damaged or poorly applied material should be completely removed and re-applied.


Problem Possible cause Solution

The product reaches the surface well but takes time to react

Low temperature of the application surface

Increase the temperature of the hoses Incorrect adjustment of the temperature of the components

The gun is frequently clogged

Excess temperatures of the components Slightly decrease the temperature of the hoses

Table 6.1: Possible problems when applying the product and their solutions.


Irregular-shaped aperture Spray gun needle poorly adjusted Adjust the position

Presence of dirt in the mixing chamber Clean the chamber

Aperture with coloured streaks

Excess temperature of the components Slightly decrease the temperature of the hoses

High difference in viscosity between components Adjust the temperature of the components. Increase the temperature of the component that looks most viscous

Very tight aperture High viscosity of components Increase the temperature of the components and the mixing pressure

Very open aperture, formation of a lot of fogging

Too much air at the tip of the spray gun Reduce the passage of air

Excessive temperature Reduce temperature slightly

Excessive mixing pressure Reduce pressure slightly

Table 6.2: Possible problems with the spraying aperture and their solutions.


Foam lifts off

Very cold surface Avoid applying to substrates below 5 ºC

Non-stick or dusty surface Perform an adhesion test

Presence of moisture Check that the substrate is dry

Non-consistent surface Do not apply to surfaces that are not firm (*)

Failure of the 1st layer to cure (primer) Wait until it is dry to the touch

Excessive shrinkage or deformation of the foam

Application of very thick layers Do not apply layers with a thickness greater than 30 mm

Components have absorbed moisture Keep drums closed

Addition of blowing agents or other substances Do not add the product, other than when indicated by the manufacturer

Very rough finish (informative, not relevant)

Insufficient pressure of components

Poorly regulated temperature

Adjust the machine correctly to give the correct reaction and aperture opening conditions

Application with wind Avoid application when the wind is strong or use protection screens

Notes:

(*) Polyurethane foam applied to surfaces that are not firm can lift or move, due to the normal shrinkage of the polyurethane, being able to take with it the surface to which it has been applied.

Table 6.3: Possible problems with the sprayed foam and proposed means of prevention.

6.6. Measures for environmental protection

The consumption of material should be optimised to avoid leftover product and minimise waste.

6.6.1. Waste treatment

Following the entry into force of Decision 2000/532/EC and its amendments, which establishes the European List of Waste (ELW), it is mandatory that the products are assigned an ELW code that allows the user to know

the type of waste management which corresponds to it. The ELW codes declared for the different components are shown in table 6.4.

The waste generated during the installation must be managed according to the legislation in force by a manager authorised for this purpose (see Royal Decree 105/2008 regulating the production and management of construction and demolition waste).


Components ELW code TR

Polyol (*) 070207 Special

Isocyanate (*) 080501 Special

Polyurethane foam 200301 Inert

Other materials/packaging

Drum (plastic or metal) 150110 Special

Wood pallet 150103 Not special

Retractable plastic 200139 Not special

Notes:

(*) In a normal application, no residues of the component usually remain.

Table 6.4: Declared ELW codes.

6.6.2. Characteristics of the blowing agent

The Elastospray LWP 1672/10:IsoPMDI 92140 system uses a hydrofluoro-olefin (HFO) known under the technical name HFO-1233zd-E as a blowing agent.

Note: LWP is the acronym for Low Warming Potential.

The GWP100 (Global Warming Potential over 100 years) of this blowing agent is 1, i.e. equal to the CO2, reference value, as indicated in table 8.A.1 of Climate Change 2013: The Physical Science Basis from the Intergovernmental Panel on Climate Change (IPCC).

The use of the blowing agent HFO complies with the requirements laid down in (EU) Regulation No. 517/2014 on fluorinated greenhouse gases, repealing (EC) Regulation No. 842/2006.

7. Use references

The Elastospray LWP 1672/10:IsoPMDI 92140 system has been used since 2016.

The following list of works has been provided as references of usage:

• Apartment building in Barcelona (Sants district).

• Detached home in Middlenton, Manchester (United Kingdom).

• Detached home in Castelldefels (Barcelona).

• Detached home (renovation) in Odón (Teruel).

Other references of works with an insulation system with polyurethane foam (whose only difference to Elastospray LWP 1672/10:IsoPMDI 92140 is that of the blowing agent) manufactured by BASF Española SL in the same facilities as the product the subject of the DAU, are those listed below:

• Detached home in Bellpuig (Lleida)

• Apartment building in Lleida

• Apartment building with 36 homes in Mungia (Vizcaya)

• 12-floor apartment building in Barcelona

• Public building in San Sebastián

• IQS university centre in Barcelona

• Residence for the elderly in Avilés (Asturias)

• State school in Fontcoberta (Girona)

• Cultural centre in Santa Margarida de Montbui (Barcelona)

• FC Barcelona stadium box office

• Municipal library of Badalona (Barcelona)

• Apartment building with 62 homes in Barcelona


8. Site visits

Two works in the process of being built have been visited at the time of application of the Elastospray LWP 1672/10:IsoPMDI 92140 system.

The selected works were inspected by qualified technicians, giving rise to the Site visit report which appears in the Dossier Técnico del DAU 17/104 2.

The purpose of the visits has been, on the one hand, to check the applicability of the installation instructions with the human and material resources defined by BASF Española SL and, on the other hand, to identify the aspects that allow any pathologies that may affect the system to be avoided.

The relevant aspects highlighted whilst carrying out site visits have been incorporated into the project and execution criteria indicated in chapter 6.

2 Technical Dossier of DAU 17/104.

9. Assessment of tests and calculations

The fitness for use of the Elastospray LWP 1672/10:IsoPMDI 92140 system has been assessed in relation to compliance with the Procedimiento Particular de Evaluación del DAU 17/104 3.

This procedure has been devised by the ITeC considering the Spanish construction regulations applicable in each case:

• in building, the basic requirements established by the CTE for each of the basic requirements are considered,

• in other areas of construction, the specific regulations to be applied are considered,

as well as other additional requirements related to the durability and service conditions of the system.

The tests that are part of this assessment have been carried out in Tecnalia and Applus+ LGAI laboratories on samples taken at the BASF Española SL production plant in Rubí (Barcelona) by ITeC staff. The initial type tests carried out by BASF Española SL for the CE marking of the product in its own laboratories, as well as at CEIS, Applus+ LGAI and FIW-München, have also been considered.

All test and calculation reports, as well as the sampling report, are included in the Dossier Técnico del DAU 17/104 2.

9.1. Mechanical resistance and stability

This requirement does not apply because the Elastospray LWP 1672/10:IsoPMDI 92140 system does not contribute to the strength and stability of the building structure.

9.2. Safety in case of fire

9.2.1. Reaction to fire

According to a test provided by the manufacturer and a test carried out at Applus+ (report 17/13682-412), the reaction to fire class property of polyurethane foam exposed to fire without any protection is class E.

The classes of reaction to fire of the construction solutions considered in this DAU are specified in section 6.1.4.1.

3 Particular Assessment Procedure of DAU 17/104.


Two reaction to fire tests were carried out on two representatives samples of the system, protected with the mortar indicated in section 2.2.

The test specimens of the report 10/102136 2724M1 of Applus+ LGAI were made up of 70-mm-thick polyurethane foam applied on a standard substrate and protected with 5 mm of the mortar indicated in section 2.2. The result of the test allows this solution to be classified with the B-s2,d0 reaction to fire class.

The test specimens of the report 3637T18-2 of AFITI LICOF, were made up of 70-mm-thick polyurethane foam applied on a standard substrate and protected with 5 mm of the mortar indicated in section 2.2. The result of the test allows this solution to be classified with the B-s2,d0 reaction to fire class.

The reaction to fire classification is valid for solutions with a foam thickness equal or less than that tested.

Adhesion tests of the protective mortar on the polyurethane foam have been carried out, both at the start and after ageing. The results, summarised in table 2.8, meet the requirements of EAD 040083-00-0404 (section 2.2.11) for plasters in external thermal insulation systems (> 0.08 MPa).

9.3. Hygiene, health and the environment

9.3.1. Watertightness of the facade

The watertightness of the proposed construction solutions has been assessed by means of the test of resistance to rainwater of external walls under pulsating variable air pressure according to the UNE-EN 12865 standard, procedure A (report 24010 by Tecnalia). The most unfavourable case, considering the solutions proposed in this DAU, is that of an exposed brick facade with its inner face covered by a 30-mm-thick layer of polyurethane foam.

The results of the rainwater resistance test were:

Sample tested Test result

Polyurethane sprayed on inside of exposed brick wall (foam thickness measured: 34 mm)

The watertightness limit is at least

1.800A Pa (*)

Notes:

(*) The test was stopped at 1.800 Pa of pressure without any penetration of water. As defined in standard UNE-EN 12865, the watertightness limit is the maximum pulsed atmospheric pressure difference, in Pa, for which no water penetration occurs during the test.

Table 9.1: Result of the rainwater resistance test.

The result shows that the resistance to water penetration is satisfactory under unfavourable test conditions.

9.3.2. Watertightness of the insulation

The watertightness has been assessed by performing the watertightness test indicated in the document EOTA TR003, identical to method A of UNE-EN 1928, but increasing the pressure to 60 kPa (report 064738 by Tecnalia).

This test method is the one commonly used to assess the watertightness of impermeable membranes applied in liquid form for roofs. The test consisted in subjecting the foam to a water pressure of 0.6 bar (6 m water column) for 24 hours. The result shows that the foam is watertight.

The watertightness has also been assessed using method B of the UNE-EN 1928 standard under the same conditions of pressure and exposure time (report 17/13911-370 by Applus+). Elastospray LWP 1672/10:IsoPMDI 92140 foam has passed the test (it is watertight).

Based on the results of the tests, Elastospray LWP 1672/10:IsoPMDI 92140 can be considered to act as a barrier against water penetration.

9.3.3. Long-term water absorption by immersion and short-term water absorption

Evidence of long-term water absorption by immersion, according to the UNE-EN 12087 test standard, method 1B and method 2B (report 24166 by Tecnalia), are shown in table 9.2.

Test according to method 1B Water absorption, Wlp

Partial immersion of the foam core 0.15 kg/m²

Partial immersion of the outer skin 0.08 kg/m²

Test according to method 2B Water absorption, Wlt

Total immersion of the specimens 1.6%

Table 9.2: Long-term water absorption by immersion.

Short-term water absorption has been tested according to standard UNE-EN 1609 method B (report CAT-0090/16-1 by CEIS). The test result meets the manufacturer’s specifications (< 0.20 kg/m³, see table 2.4).

9.3.4. Degree of impermeability

The foam applied with a minimum thickness of 30 mm, can be considered as a very high resistance barrier to water filtration, i.e. B3, as indicated in section 6.1.5.1, according to the following tests carried out according to the DB-HS of the CTE:

• Watertightness: tests of impermeability and water absorption (see 9.3.1, 9.3.2 and 9.3.3) allow sufficient watertightness to be ensured to prevent its infiltration into the building.


• Adhesion to the substrate: the results obtained (see 9.7.2) show an initial adhesion and an adhesion after ageing cycles on substrates that is considered sufficient to ensure the stability of the foam layer.

• Permeability to vapour: the results of the water vapour diffusion resistance factor (see 9.3.5) are typical of this type of product. These values are not considered to favour the accumulation of vapour between the foam and the main layer.

• Adaptation to the movements of the substrate: the results of dimensional stability, adhesion and cohesion and resistance to fatigue (see sections 9.7.1, 9.7.2 and 9.7.3 respectively), show good behaviour of the foam against thermal stresses and the cracking of the substrate. The proposed solutions for the treatment of expansion joints are considered adequate to avoid cracking of the foam at these points.

• Stability against physical, chemical and biological attacks: the nature of the polyurethane foam and its protected installation in the construction solutions considered (see 6.1.2.1) does not suggest that it can suffer other attacks, in addition to those indicated in the points above. If necessary, the manufacturer can provide additional information regarding the behaviour of the foam against different chemical and biological attacks.

9.3.5. Permeability to water vapour

Tests have been carried out to determine the coefficient

of water vapour diffusion, µ, according to the UNE-EN 12086 standard (report CAT-0090/16-1 by CEIS). The result obtained is shown in table 9.3 and meets the manufacturer’s specification (see table 2.3).

Thickness (mm)

Water vapour diffusion resistance factor,

µ

48.1 78.7

48.7 66.2

48.4 74.3

49.2 77.1

Mean value 74.1

Table 9.3: Permeability to water vapour.

9.3.6. Condensation check calculations

The relevant characteristics for the calculation of condensations are summarised in table 2.3.

The calculation method to be used to calculate the condensations is that indicated in the Support Document to the DB-HE, DA DB-HE/2 of the CTE.

4 λ90/90: value of the thermal conductivity representing the 90% of the

production, determined with a confidence level of 90% obtained from the measured values for specimens without ageing.

9.4. Safety of use

This requirement is not applicable to the polyurethane foam considered in this DAU, since it is not accessible to the building user.

9.5. Protection against noise

The contribution of Elastospray LWP 1672/10:IsoPMDI 92140 polyurethane foam to the acoustic insulation of the facade has not been determined.

9.6. Energy economy and heat retention

The declared thermal conductivity value (λD) has been

determined from λ90/904, defined in Annex A of the

UNE-EN 14315-1 standard and taking the aged values of thermal conductivity obtained following the methodology of section C.5 of the UNE-EN 14315-1 standard.

For the determination of λ90/90, the initial value of thermal conductivity has been measured on a set of more than 10 specimens and the fixed increments corresponding to the foam thickness have been applied, which are defined in the Position Paper NB-CPR/SG19-17/167r2 “Thermal performance of in situ PU polyurethane products used as thermal insulation for buildings with a new blowing agent”. To be able to apply the fixed increments defined in this Position Paper, the permanent character of the blowing agent was established by means of initial study (measured values and procedure described in report L1-16-007B by FIW München).

System Thermal

conductivity (W/m·K)

λ average without ageing 0.0204

λ average aged (ageing: 175 days at 70 ºC)

0.0251

λ90/90 3 0.0212

λD (declared

value of λ)

thickness < 80 mm 0.028

80 mm ≤ thickness < 120 mm 0.026

thickness ≥ 120 mm 0.025

Table 9.4: Thermal conductivity of the Elastospray LWP 1672/10:IsoPMDI 92140 system.


9.7. Aspects of durability, service and identification

Tests have been carried out to analyse compatibility with the substrates and the durability of the system.

The tests done and results obtained are described below.

9.7.1. Dimensional stability

The dimensional stability of the system has been tested under specific conditions of temperature and humidity according to the UNE-EN 1604 standard (report 17/13911-370 by Applus+ LGAI).

Two types of specimens extracted from the core have been tested (without skin):

• 15 mm thickness per layer

• 30 mm thickness per layer

The total thickness of the samples is 30 mm.

The results obtained, shown in table 9.5, meet the manufacturer’s specification (see table 2.4).

Thickness of layer (mm)

Test conditions

Dimensional variation

∆εl (%)

∆εb (%)

∆εd (%)

2 layers of 15 mm

48 h at 70 ºC and 90% RH 1.5 1.5 0.6

48 h at -20 ºC -0.4 -0.4 -0.1

1 layer of 30 mm

48 h at 70 ºC and 90% RH 0.6 0.6 0,.3

48 h at -20 ºC -0.3 -0.3 -0.1

Table 9.5: Dimensional stability of specimens without outer skin under specific conditions of temperature and humidity.

9.7.2. Adhesion and cohesion

The adhesion to the substrate and the cohesion of the product has been tested, as indicated in the UNE-EN 14315-1 standard, subjecting the specimens to a traction perpendicular to the faces following the methodology of UNE-EN 1607. The substrate used was a fibre cement sheet (see annex F of UNE-EN 14315-1). The results obtained are shown in table 9.6.

Test specimens

σA (kPa) E (kPa) Type of

breakage

Minimum value

100 9070 Cohesive in

the foam

Average value

133 9665 Cohesive in

the foam

Table 9.6: Tensile strength perpendicular to faces.

The adhesion on concrete and double hollow brick substrates supports has been tested, as indicated in UNE-EN 14315-1 standard (report 077543 of Tecnalia). The initial adheration and the adheration after agein cycles were determined.

The results of the mentionated tests are shown in table 9.7.

Support σA

(kPa) Break type

Concrete

- Initial adh.: 247 100% cohesive foam

- Agein adh.: 244 100% cohesive foam

Double hollow brick

substrates

- Initial adh.: 282 100% cohesive foam

- Agein adh.: 256 100% cohesive foam

Table 9.7: Adheration on different supports.

Likewise, the available evidence of representative samples of the product in relation to its adhesion on concrete and double hollow brick substrates confirms that the product is also suitable to be placed on this type of vertical facing.

9.7.3. Resistance to fatigue

Fatigue resistance was analysed in tests following EOTA TR008 (report 24169 by Tecnalia).

This test method is commonly used to assess impermeable membranes applied in liquid form for roofs. The specimens consist of the foam applied on a concrete substrate with a 1-mm-thick gap. The method consists of subjecting these specimens to 500 cycles of fatigue, in which the gap in the substrate opens and closes +1/-1 mm. It is observed whether there is breakage or loss of adhesion of the foam.

The test result is shown in table 9.7.

Substrate Cycles Thickness

(mm) Result

Concrete 500 cycles (+1/-1 mm)

31 No damage

Table 9.7: Fatigue resistance.

9.7.4. Compressive stress at 10% deformation

The compressive stress has been tested at 10% deformation according to the UNE-EN 826 test standard. The average value obtained (265 kPa) complies with the minimum value declared in the product’s performance declaration (≥ 200 kPa).

9.7.5. Identification of the components of Elastospray LWP 1672/10:IsoPMDI 92140 foam

Identification tests of the components of the polyurethane foam have been carried out.

The results of these tests confirm the characteristics of the polyurethane foam, indicated in chapter 2 of this document.


10. Committee of Experts

This DAU has been submitted for the opinion of an Experts Commission, as indicated in the Reglament del DAU (DAU Regulation) and in the Work Instruction for the elaboration of DAU.

The Experts Commission was constituted by representatives of different organizations and institutions, which have been closen for their knowledge, independence and impartiality to give a technical opinion regarding the scope of this DAU.

The general list of the experts that have made up the experts commissions of DAU is available on ITeC’s website itec.es.

Comments and observations raised by the DAU Commission members have been included in the text of the present DAU.

11. Reference documents

• Technical Building Code. Basic Documents of the CTE: DB-SE, DB-SI, DB-HS, DB-SUA, DB-HR and DB-HE

• CTE catalogue of construction elements.

• Commission Decision 2003/43 / EC of 17 January 2003 establishing the classes of reaction-to-fire performance for certain construction products.

• Commission Decision 2000/532 / EC of 3 May 2000 establishing a list of wastes.

• Royal Decree 110/2008, of 1 February, amending Royal Decree 312/2005, of 18 March, approving the classification of construction products and construction elements based on their properties of reaction and resistance to fire.

• Regulation (EU) No 517/2014 of the European Parliament and of the Council of 16 April 2014 on fluorinated greenhouse gases, repealing Regulation (EC) No 842/2006.

• EAD 040083-00-0404 External thermal insulation

composite systems (ETICS) with renderings

• EOTA TR003: Determination of the

watertightness.

• EOTA TR008: Determination of the resistance to

fatigue movement.

• ASTM D5155. Standard Test Methods for

Polyurethane Raw Materials Determination of the

Isocyanate Content of Aromatic Isocyanates.

• EN ISO 3219. Plastics. Polymers/resins in the

liquid state or as emulsion or dispersion.

Determination of viscosity using a rotational

viscometer with defined shear rate.

• ISO 14897. Plastics - Polyols for use in the

production of polyurethane - Determination of

water content.

• UNE-EN 826. Thermal insulating products for

building applications. Determination of

compression behaviour.


building applications. Determination of

dimensional stability under specified temperature

and humidity conditions.


building applications. Determination of tensile

strength perpendicular to faces.


building applications. Determination of short-term

water absorption by partial immersion.


• UNE-EN 1928. Flexible sheets for waterproofing.

Bitumen, plastic and rubber sheets for roof

waterproofing. Determination of watertightness.


building applications. Determination of water

vapour transmission properties.


building applications. Determination of long-term

water absorption by immersion.

• UNE-EN 12667. Thermal performance of building

materials and products. Determination of thermal

resistance by means of guarded hot plate and

heat flow meter methods. Products of high and

medium thermal resistance.

• UNE-EN 12865. Hygrothermal performance of

building components and building elements.

Determination of the resistance of external wall

systems to driving rain under pulsating air

pressure.

• UNE-EN 13501-1. Fire classification of

construction products and building elements. Part

1: Classification using data from reaction to fire

tests.

• UNE-EN 14315-1. Thermal insulating products for buildings. In-situ formed sprayed rigid polyurethane (PUR) and polyisocyanurate (PIR) foam products. Part 1: Specification for the rigid foam spray system before installation.

• UNE-EN 14315-2. Thermal insulating products for buildings. In-situ formed sprayed rigid polyurethane (PUR) and polyisocyanurate (PIR) foam products. Part 2: Specification for the installed insulation products.

• UNE-EN ISO 4590. Rigid cellular plastics. Determination of the volume percentage of open cells and of closed cells.

• UNE-EN ISO 9001. Quality management systems. Requirements.

• UNE-EN ISO 14001. Environmental management systems. Requirements with guidance for use.

• UNE 53985-1. Plastics. Test methods for polyurethane raw materials. Polyols. Part 1: Determination of hydroxyl numbers.

• Climate Change 2013: The Physical Science Basis. Intergovernmental Panel on Climate Change (IPCC).

• NB-CPR/SG19-17/167r2. Thermal Insulation Products. Sector Group of the Group of Notified Bodies for the Construction Products Regulation (EU) Nº 305/2011 (CPR). Position paper. Thermal performance of in situ PU polyurethane products used as thermal Insulation for buildings with a new blowing agent.


12. Assessment of fitness for use

Based on the following experimental technical evidence obtained during the preparation of the DAU 17/104 according to the criteria defined in the Procedimiento Particular de Evaluación del DAU 17/104, prepared by the ITeC:

• tests and calculations results,

• information from the site visits,

• factory production control,

• instructions for system installation and execution,

• project and execution criteria,

and taking into account the methodology prescribed by the Reglament del DAU, the authorization and the ITeC register for awaring the DAU* and the indications specified in section 5.2 of article 5 of the CTE-Technical Building Code, regarding the assessment of innovative construction products and systems, it is considered that the ITeC has evidence to declare that the constructive

system, based on the Elastospray LWP 1672/10:IsoPMDI 92140 polyurethane foam manufactured in the production plant in Rubí (Barcelona), according to the instructions given in this DAU, is appropriate for its use in:

• Thermal insulation of buildings

• Waterproofing of facades

since it fulfils the relevant regulatory requirements regarding safety in case of fire, thermal insulation, safety of use, health and hygiene, as well as durability and service requirements.

As a result, and once this document has been submitted to the Experts Commission and their comments have been included in it, ITeC awards the DAU to the product manufactured by BASF Española SL.

The DAU validity is subject to the actions and monitoring conditions specified in chapter 13 and to the use conditions given in chapter 14.

______________

(*) ITeC is an authorized organism for awarding the DAU (BOE 94, 19 April 2002) for construction products (building and civil engineering) registered in the General Register of the CTE: www.codigotecnico.org/index.php/menu-04-registro-general-organismos/menu-organismos-autorizados.


13. DAU monitoring

The present DAU is subjected to the surveillance actions that ITeC carries out periodically, in accordance with the Reglament del DAU. The purpose of this monitoring is to check that the characteristics of the product and the constructive system, as well as the execution and manufacturing conditions, are still valid for the envisaged intended uses.

If relevant changes affecting the DAU validity occur, these will result in a new DAU edition that will supersede the previous one (this new edition will take the same DAU code as the superseded one and a new letter edition).

When changes are of minor importance and they do not affect the DAU validity, these will be specified in a list of changes that will be incorporated as chapter 15 of the DAU; furthermore, these changes will be included as well in the DAU text.

The DAU user must always look up the DAU electronic version available in pdf format on ITeC website itec.es, in order to make certain of its possible revisions that may occur during its validity. This document is also available through the QR code included in the DAU stamp.

14. Use conditions of DAU

In granting the DAU, the ITeC is not responsible for:

• The presence or absence of any patent, intellectual property or similar existing rights subsisting in the product or any other product, nor rights that affect third parts or the fulfilment of obligations to any of this third parts.

• The right of the DAU holder to manufacture, supply, install or maintain the product.

• The actual works or individual batches in which the product is installed, used and maintained; including the nature, design, methods and workmanship of or related to the installation.

In addition, the DAU cannot be ever interpreted as a guarantee, commitment or responsibility of the ITeC relating to the commercial viability, patentability, registrability or innovation of the results derived from the preparation of the DAU. This is, then, the holder’s responsibility to check the viability, patentability and registrability of the product.

The assessment of the DAU does not purport in any way to restate the regulatory requirements of the Health & Safety at Work or occupational risk prevention, relating to the manufacture, supply, installation, use and maintenance of this product. Therefore, the ITeC does not accept responsibility to any person or body for any loss or damage, including personal injury, which may occur in the event of breach of the relevant requirements within the mentioned legislative framework.


15. List of changes of the present edition

The electronic version of the DAU includes, if any, the updating, changes and corrections of the present edition C of the DAU 17/104, indicating the date of incorporation, according to the format of the following table. The changes shown in the table will also be integrated in the text of the DAU, which is available on the Institute’s website, itec.es.

The DAU user must always consult the DAU electronic version in order to make certain of its possible revisions, which may occur during its validity.

Number Page and chapter Where it was said... It says…