Building with polyurethanes - BASF: leading supplier of

Chemistry creates versatilityBuilding with polyurethanes

INTRODUCTION2 Overview

3INTRODUCTIONOverview

“We shape our buildings;thereafter they shape us.”

WINSTON CHURCHILL, BRIT ISH STATESMAN

INTRODUCTION4 Overview

Polyurethanesare all around us......in our well insulated and comfortablehomes, in our high performing, easyto maintain communal and institutionalbuildings, in our non-slip, permeablepedestrian areas.

It may not be obvious but polyurethaneis specified and used within manybuilding components: as insulation inwalls, roofs and floors, as foams andsealants around doors and windows,as binders to produce OSB (OrientedStrand Board) and MDF (Medium-Density Fiberboard) sheets, aswaterproof protective coatings.

Polyurethanes can be supplied inmany forms: as raw materials, asformulations, as products and asbuilding systems. Polyurethane’sversatility will allow the architect ordesigner to save energy, ensuringbuildings stay comfortable in winterand summer, increase durability,speed up construction, protect theenvironment, enhance safety, leadto innovative building systems andmuch more.

Polyurethanes are all around us.

BASF is all around us.

5INTRODUCTIONOverview

RESIDENTIAL6 Introduction

7RESIDENTIALIntroduction

RESIDENTIALEveryone deserves to live in a comfortable,safe and healthy environment. Through continualresearch and development, rigorous testing andaccreditation, polyurethane helps to achieve this.

Polyurethane products make homes morecomfortable, functional, affordable and sustainableby providing reliable solutions that boost energyefficiency and performance, reduce carbondioxide emissions, save construction costs,and prolong the lifespan of the home.

BASF works closely with architects, contractors,developers and manufacturers to createenvironmentally-sound housing for all types ofclimates all over the world and satisfy diversearchitectural styles. In the process, we incorporateindustry-leading solutions for flooring, roofing,insulation and waterproofing while attending to thesmallest of details like joint sealants and tile grouts.

Residential external wall constructed using polyurethane sprayfoam insulation and polyurethane binder in the wood sheathing.


Thermal insulationInnovative polyurethane spray foams, insulationboards and sandwich panels, through to exteriorinsulation finishing systems (EIFS). Applicable towalls, roofs, floors and ceilings. Benefits includeenergy savings, enhanced overall comfort, fasterconstruction and design freedom.

ELASTOPOR or ELASTOPIR for insulation boards

WALLTITE, ENERTITE, COMFORT FOAM orELASTOSPRAY spray foam insulation

EIFS insulation

ELASTOPOR for entry and garage doors

Waterproofing and protectionEco-friendly, high-quality, high-performancesurface solutions for interiors and exteriors.Simple to apply, fast curing for reducedconstruction time, long-lasting and durable,odorless for a healthier environment, easyto clean and low maintenance costs.

ELASTOCOAT on garages and flat roofs

FlooringUnderlays for carpet and adhesives forsubflooring. Longer life expectancy with lowermaintenance, increased non-slip safety andgreater aesthetics.

ELASTOCOAT for non-slip underlays

Flooring adhesives

BindersLightweight, high-tensile, structural-strengtheningsystems for masonry and timber elements – helpincrease the durability of building structures.

LUPRANATE for wood binders

WindowsJoint sealants and sealing systems to preventair, water and other environmental elements fromentering or exiting a structure while permittinglimited movement of the substrates. Glass fiberreinforced polyurethane window profiles provideenergy and cost savings.

LUPRANATE for window sealants

ELASTOCOAT for pultruded window profiles2

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Polyurethane solutions for residential applications

Roof underlays and membranesInnovative roofing felts and membranes, underlaysand roofing shingles designed to meet and exceedthe requirements of modern architecture andcomplex roof structures.

ELASTOLLAN for breathable roof underlays11

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RESIDENTIAL

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“A house is a machine for living in.”LE CORBUSIER, SWISS ARCHITECT AND DESIGNER

Increased energy efficiencyreduces air loss and solar gain, which

in turn will lower energy consumption

and costs, and decrease carbon

dioxide emissions.

Higher savingson energy bills.

Enhanced overall comfortwith more consistent indoor

temperatures and sound-proofed rooms.

Environmentally-friendlyefficient consumption and use of

energy and resources, generating

low VOC emissions.


Polyurethane products make houses more comfortable,functional, affordable and sustainable by providing reliablesolutions that boost efficient energy use and performance,reduce carbon dioxide emissions, save construction costs,and prolong their lifespans.

Better health and safetyincluding fireproofing, earthquake

protection, prevention of moisture

ingress, water damage and mold.

Enhanced durabilityby prolonging the lifespan of the

home, lowering the need and costs

of maintenance.

Increased productivityby affording faster construction times,

easy applications, leading to earlier

occupation.

CO2

11RESIDENTIALSolutions for roofs

Solutions for roofs

A wide range of materials, formulations and products toinsulate, waterproof, protect and sustain residential roofs.

� ELASTOPOR / ELASTOPIR insulationboards used on green roof, Lohne, GermanyGreen roofs bring biodiversity back into built-up urban areas.

The ability of ELASTOPOR / ELASTOPIR to flow through and

adhere to complex shapes and surfaces provides a freedom

of design as well as complete insulation.

Planting/vegetation layer

Extensive substrate

Water storage panel

ELASTOPOR / ELASTOPIR for insulation boards

Protective layer

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RESIDENTIAL12 Solutions for roofs

Solutions for roofs

� ELASTOSPRAY used on flat roof,Cancun, MexicoMaster Insulation PUR System, used in a pilot apartment

complex for Net Zero Energy consumption in Cancun,

Mexico. ELASTOSPRAY spray foam was used on the roof

in order to reduce the building’s CO2 emissions and energy

consumption by around 23%.

Protective coating

ELASTOSPRAY spray polyurethane foam

Existing concrete roof deck

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13RESIDENTIALSolutions for roofs

� ELASTOSPRAY used on pitched roof,Vantone Casa Villa, Beijing, ChinaThis project is part of a planning concept that focuses on

people first, both culturally and environmentally. Green features,

such as energy-efficiency and underground roadwork allow a

traffic-free living environment.

To meet the stringent LEED standard, ELASTOSPRAY was used

to provide a waterproof and completely seamless roof insulation

reducing additional construction steps and saving time.

Cement tile

Cement mortar

Reinforced gravel concrete

ELASTOSPRAY rigid polyurethane foam

Cement mortar screed

Reinforced concrete slab

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� COMFORT FOAM spray polyurethanefoam insulation, Minnesota, USAAs both an effective insulation and air barrier material,

closed-cell COMFORT FOAM technology substantially

reduces both air leakage and the passage of moisture

through the building envelope with its seamless, self-adhering

and monolithic construction. COMFORT FOAM can help

reduce energy costs compared to other insulation systems.

Exterior cladding

Exterior sheathing

COMFORT FOAM spray foam insulation

Vapour barrier (region specific)

Plasterboard

RESIDENTIAL14 Solutions for walls

Solutions for walls

Meeting and exceeding regulations for interior andexterior walls, both for new-build and refurbishment.

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Installation ofCOMFORT FOAM

15RESIDENTIALSolutions for walls

� WALLTITE spray foam insulation,Hove, United KingdomApplied to the curved penthouse flat roof on

the fifth floor, this fast applied, seamless,

airtight solution virtually eliminates air leakage.

The closed-cell structure helps control the

movement of vapour and moisture throughout

the building, reducing energy loss. WALLTITE

spray foam does not deteriorate with age

and its thermal properties are therefore

maintained over the life of the building.

Curved timber framework

WALLTITE spray foam insulation

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� ELASTOSPRAY used inrefurbishment of exterior walls,Arboga, SwedenA 1950s private dwelling that has been

insulated externally with ELASTOSPRAY.

The surface of the sprayed foam has been

evened out with special equipment and

then covered with a decorative render.

Existing wall and primer

ELASTOSPRAY spray foam insulation

Fiberglass mesh

Decorative render

Solutions for walls

� ELASTOSPRAY in curtain walls,Sant Cugat, Barcelona, SpainExternal insulation behind a curtain wall or

with ventilated cladding can be used both

in new buildings and refurbishment of

existing buildings. The cladding protects

the external components against weathering

and as a decorative facade gives a designer

lots of options.

Masonry

ELASTOSPRAY external insulation

Air gap

Curtain wall with supportconstruction

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Solutions for walls

� Structural Insulated PanelSystem (SIPS), USABASF manufactures emission free wood

binders for engineered wood products

including Oriented Strand Board (OSB),

Medium Density Fiberboard (MDF) and

particle board. SIPS combine superior

insulation with near zero air leakage to

maximize the performance of the building

envelope and allow HVAC systems to

operate more effectively.

LUPRANATE wood binder for OSB

ELASTOPOR for insulating foam core

LUPRANATE wood binder for OSB

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Image: Courtesy of Thermocore

RESIDENTIAL20 Solutions for floors and ceilings

� Polyurethane used in encapsulationof porcelain tiles, USAPolyurethane has many uses. Here it is used to encapsulatea genuine porcelain tile. This encapsulation creates a simpleinstallation method which includes a built-in grout look.Polyurethane allows these tiles to be installed quickly and easily.

Subfloor

ELASTOCAST for tile encapsulation

Porcelain tile

Solutions for floorsand ceilings

Interior and exteriorsolutions from anti-slipflooring to permeable,durable paving.

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21RESIDENTIALSolutions for floors and ceilings

� ELASTOPAVE, Firmacasa House Design,São Paulo, BrazilPolyurethane mixed with an aggregate of glass or stone toconstruct a novel alternative to concrete or tarmac. Largeand small stones are mixed together to create cavities thatallow the finished, porous material to breathe, preventingpuddles and formations of ice.

ELASTOPAVE for binding aggregate

Dynamic course

Base course

Improved subgrade

Subgrade/native soil

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Image: Arthur Calasans

RESIDENTIAL22 Other polyurethane solutions

Other polyurethane solutions for residential applications

Polyurethanes to make solar products more durable,and garage doors quieter and stronger.

� COLO-FAST used in solar panels,Allgau, Kempten, GermanyFast, durable framing of photo-voltaic

panels and solar collectors by a Reaction

Injection Moulding process – COLO-FAST

ensures lasting protection against the

elements. Panels are placed in closed

moulds and then polyurethane is simply

injected. Junction boxes and mounting

fixings can be embedded quickly and

easily in the frame in a one-step-process.

COLO-FAST polyurethane moulding

Photovoltaic module

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Image supplied courtesy Solarzentrum Allgäu GmbH & Co. KG

23RESIDENTIALOther polyurethane solutions

� Garage doors withpolyurethane core, Utah, USAGarage doors insulated with polyurethane

are more than just efficient. Now you can

have an energy efficient, noise reducing

solution which is durable, protects and

enhances the beauty of your home.

ELASTOPOR for door insulation

Sheet metal

Surface finish

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RESIDENTIAL24 Project case study

The spray foam was installedquickly and met all of thecriteria that we needed.It has proven to be a greatproduct that has made theroof construction possible.”Simon Moore, Project Architect

“Project case study

The curved nature of the roof in the penthouse flat presented anissue in relation to the original insulation specified as this could notachieve the radius required. Certain traditional mineral fiber solutionsare not guaranteed to stay in place down the curve and attain therequired U-value of 0.1W/m2K. A spray foam insulant would be theideal solution.

Project: A new five-floor mixed use development

comprising ground floor/basement retail and

office accommodation with residential flats above

Location: Hove, UK

Product used: WALLTITE spray foam insulation

Architect: Felce and Guy Partnership

Contractor: Isotech Sprayfoam

25RESIDENTIALProject case study

NON-RESIDENTIAL26 Introduction

27NON-RESIDENTIALIntroduction

NON-RESIDENTIALPolyurethane products improve the performance,functionality and sustainability of manycomponents used in non-residential buildings.

BASF contributes to a full range of intelligentsystems and solutions that meet constructionchallenges head on: from insulations to expansionjoint systems to high-performance waterproofcoatings.

This results in buildings that are more energyefficient, durable, faster to build, with a lowerlifecycle cost and reduced environmental impact.

Polyurethane insulation and floor coating systems usedon a ground floor concrete slab construction in a university.


Solutions for non-residential applications

Thermal insulationInnovative polyurethane spray foams, insulationboards, sandwich panels and SIPS, through toexterior insulation finishing systems (EIFS).Applicable to walls, roofs, floors and ceilings.Benefits include energy savings, sustainableperformance, enhanced overall comfort, fasterconstruction and design freedom.

ELASTOPOR or ELASTOPIR for insulation boardsin flat roof

WALLTITE, ENERTITE, COMFORT FOAM orELASTOSPRAY spray foam insulation

EIFS insulation

Waterproofing and protectionSecure waterproofing for all exposed areas.Spray applied fast curing solutions satisfy themost rigorous waterproofing demands. Eventhe most complex architectural shapes can beseamlessly sealed. Small concrete cracks canbe repaired to extend the building’s life.

ELASTOCOAT for roof waterproofing

Coatings and protectionEco-friendly, high-quality, high-performancesurface solutions for interiors and exteriors.Simple to apply, fast drying for reducedconstruction time, long-lasting and durable,odorless for a healthier environment, easyto clean and low maintenance costs.

ELASTOPAVE for atriums

FlooringSelf-levelling polyurethane solutions providean abrasion-resistant floor coating.

ELASTOCOAT for floors

Cladding and facadesLightweight, high-tensile, structural-strengtheningsystems for masonry and timber elements – helpincrease the durability of building structures.

LUPRANATE binders for OSB

PERMASKIN TPU surface finishing

Sealants and sealing systemsJoint sealants and sealing systems to preventair, water and other environmental elements fromentering or exiting a structure while permittinglimited movement of the substrates.

ELASTURAN or LUPRANATE for window sealants

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29NON-RESIDENTIALIntroduction


“Buildings should be good neighbors.”PAUL THIRY, AMERICAN ARCHITECT

Increased energy efficiencyreduces air loss and solar gain, which

in turn will lower energy consumption

and costs, and decrease carbon

dioxide emissions.

Higher savingson energy bills.

Enhanced overall comfortwith more consistent indoor

temperatures and sound-proofed rooms.

Environmentally-friendlyefficient consumption and use of


low VOC emissions.

Innovative polyurethane solutions that meet constructionchallenges head on, resulting in non-residential buildingsthat are more energy efficient, durable, faster to build, andwith a lower lifecycle cost and reduced environmental impact.

Better health and safetyincluding fireproofing, earthquake

protection, prevention of moisture

ingress, water damage and mold.

Enhanced durabilityby prolonging lifespan of the home,

lowering the need and costs of

maintenance.

Increased productivityby affording faster construction times,

easy applications, leading to earlier

occupation.

CO2

31NON-RESIDENTIALSolutions for roofs

Solutions for roofs

Offering practical,sustainable, flexiblematerials for architectsand designers.

� ELASTOSPRAY used in roof insulation,Norway Pavilion, World Expo, Shanghai, ChinaThis chic, irregular roof design used ELASTOSPRAY on part of

the rear roof. The spray foam allows design freedom and meets

the technical challenges created by the innovative architecture.

Decoration plate

ELASTOSPRAY spray foam

Reinforced concrete slab

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Photography by Patrick Wack

� ELASTOSPRAY spray polyurethane foam roofingsystem used in Scope Arena, Norfolk, Virginia, USABuilt in 1968, the Scope Arena’s roof is a concrete monolithic dome

measuring 440 feet in diameter and encloses an area of 85,000

square feet. The entire roof was coated with ELASTOSPRAY

spray applied polyurethane foam roofing and ELASTOCOAT

protective coating, giving the Scope a modern appearance.

ELASTOCOAT protective coating


Existing concrete roof

NON-RESIDENTIAL32 Solutions for roofs

Solutions for roofs

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33NON-RESIDENTIALSolutions for roofs

� ELASTOSPRAY used on renovated roof,University of Puerto RicoExisting building roof gets a high performance upgrade.

ELASTOCOAT top coat

ELASTOCOAT base coat


Uninsulated metal deck

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NON-RESIDENTIAL34 Solutions for walls

Solutions for walls

Providing answers today for tomorrow’s requirements.

� WALLTITE used as part of a refurbishedwall cavity, Montreal, CanadaWALLTITE spray foam insulation provides both

insulation and air barrier.

Existing brickwork

WALLTITE spray foam insulation

Brick ties

New brickwork

� Metal-faced ELASTOPOR / ELASTOPIRsandwich panel system, hot dip galvanizingplant, Dalian, ChinaMetal-faced polyurethane sandwich panels provide rapid

installation times and can be fitted together accurately.

With their high thermal insulation properties and low product

weight, they are ideal for creating striking facades in large-scale

industrial buildings.

Profiled metal sheet

ELASTOPOR / ELASTOPIR foam core

Profiled metal sheet

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35NON-RESIDENTIALSolutions for walls

Image supplied courtesy ThyssenKrupp Steel Europe AG

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NON-RESIDENTIAL36 Solutions for walls

Solutions for walls

� Polyurethane sandwich panel,Indianapolis, USAArchitectural metal sandwich panels

insulated with a polyurethane foam core

are a perfect choice for various building

types. These building systems allow for

increased construction time savings.

The increased energy efficiency achieved

by these panels contributes to the

sustainability of the projects.

Architectural metal skin

Polyurethane foam core

Architectural metal skin

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37NON-RESIDENTIALSolutions for floors

Solutions for floors

Attaining higher performancethrough innovation and chemistry.

� ELASTOPAVE used in car showroom,Berlin, GermanyAn ideal solution for heavy traffic areas that need to

stay in pristine condition, ELASTOPAVE provides an

easy to maintain, hygienic and aesthetic finish to interior

as well as exterior surfaces.

ELASTOPAVE for binding aggregate

Concrete sublayer

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� ELASTOCORE used in SPS panels, terracing,Ascot race course, United KingdomThis Sandwich Plate System terracing, using a polyurethane

core, was specified as a viable alternative to concrete or

stiffened steel. The installed SPS solution offered a 75%

weight reduction, savings on both substructure and foundation

costs, as well as excellent vibration characteristics.

Metal backing plates

ELASTOCORE polyurethane core

Metal backing plates

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NON-RESIDENTIAL38 Solutions for floors

Solutions for floors

39NON-RESIDENTIALOther polyurethane solutions

Other polyurethane solutionsfor non-residential applications

Providing thermal solutionsto window, door and otherproduct manufacturers.

� ELASTOCAST used in window frames, New York, USAPolyurethanes used for the thermal break/window spacer in the windows used to

retrofit this 44-story building, Confucius Plaza – the tallest building in Chinatown.

The multi-use complex replaced all its original aluminum windows in 762

apartment units. The extra-thick insulated profile and low-E coated insulated

glass will provide decades of comfort to over 2000 tenants.

ELASTOCAST window spacer1

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NON-RESIDENTIAL40 Project case study

We will show how wood can beused to innovate architectureand urban concepts.”

Helen & Hard Architects

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Project case study

The Norwegian Pavilion at the Shanghai Expo in 2010 was “an

exercise in architecture powered by nature” – its design inspired

by the Norway’s nature. Fifteen individual tree-like sections, each

having a trunk, body and limbs that supported a canopy, came

together to create the pavilion as a whole. ELASTOSPRAY was

used to insulate various elements in the structure.

Project:

Location:

Product used:

Architect:

41NON-RESIDENTIALProject case study

Photography by Patrick Wack

INFRASTRUCTURE42 Introduction

Elastopave used as a stable, flexible and poroussurfacing for sidewalks and pedestrian areas.

43INFRASTRUCTUREIntroduction

INFRASTRUCTUREToday’s modern infrastructure projects demandstrength and the ability to endure the wear andtear of daily life. From piazzas, play areas andrailways to underground district piping andmeeting areas – BASF products and solutionsmust be affordable for the end user, easy tobuild with and safe. BASF Polyurethanes’systems and solutions meet these challenges,as well as meeting and exceeding industryregulations and standards.

Polyurethane solutions provide the greatestversatility for infrastructure projects, from makinghard landscaping paved to ensuring a softlanding around playground equipment toprotecting coastal areas and river banks fromerosion and flooding.

Binders for playground surfacesMaterials to provide permeability and anti-slipto pavements, as well as impact absorption forrubber crumb matting used in recreational areas.

ELASTOTITE for play areas


WaterproofingSecure waterproofing for all exposed areas.Spray applied fast cure solutions can cope withthe most rigorous waterproofing demands andprotect the most complex architectural shapes.

ELASTOCOAT for shelters

Polyurethane solutions for infrastructure

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Sandwich Plate Systems (SPS)Steel-elastomer-steel composites are superiorto conventional concrete or steel structures:they offer higher stability, better vibration isolation,weight reduction and lower total costs incomparison with conventional component parts.

ELASTOCORE for footbridges

Pipe insulation and protectionRigid polyurethane foam systems are commonlyused for the protection and insulation of districtheating and cooling and other industrial pipeswhere heat, natural gas, hot or cold liquids andother resources are carried through.

ELASTOPOR for district heating

River bank protectionCoarse aggregates bound together with a two-component polyurethane to produce a strong,porous material. It provides a cost-effective andaesthetically pleasing alternative to rock orconcrete revetments.

ELASTOCOAST for river revetments

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Artificial turf underlayGreen turf fibers are underlaid with energy-absorbing BASF Thermoplastic polyurethane(TPU) padding. This increases player comfortand helps prevent sports injuries. The specialstructure makes the artificial turf durable,low-maintenance and weather-resistant.

ELASTOLLAN for football pitches6

45INFRASTRUCTUREIntroduction

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“Life is what happens when you arebusy making other plans.”JOHN LENNON, MUSIC IAN

Enhanced durabilityLonger lifespan, lowering the need and

costs of maintenance.

Better safetyCoatings in various surface textures

help provide slip resistance for

pedestrian areas. Special panels and

sealants help prevent the spread of

fire and smoke.

Polyurethane solutions provide the greatest versatilityfor infrastructure projects from making hard landscapingpaved, to ensuring a soft landing around playgroundequipment to protecting coastal areas and river banksfrom erosion and flooding.

Increased productivityFaster construction speed, easy

applications.

Cost savingsReduced construction costs and

energy bills.

Environmentally-friendlyEfficient consumption and use of


low VOC emissions.

47INFRASTRUCTURESolutions for infrastructure

Solutions for infrastructure

Making our public spaces and walkways,pavements and other high traffic areassafer, longer-lasting and easier to maintain.

� FILTERPAVE, Western Oregon University,Monmouth, USAWestern Oregon University chose FILTERPAVE porous

pavement for its aesthetic quality, design flexibility, recycled

material content and stormwater benefits.

FILTERPAVE

Dynamic layer

Base course

Improved subgrade

Subgrade

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INFRASTRUCTURE48 Solutions for infrastructure

� ELASTOTITE rubber crumb binder,playground, New York, USAELASTOTITE polyurethane system is used as a binder

for rubber crumb material in this playground in New York.

This provides a stable, safe and comfortable surface while

taking advantage of the durability of polyurethane to adhere

the aggregate material.

Recycled crumb rubber with ELASTOTITE binder wearing layer

Base course

Improved subgrade

Subgrade

Solutions forinfrastructure

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� ELASTOCOAT spray coating on deck, car park,Schipol airport, Amsterdam, The NetherlandsELASTOCOAT is spray applied on this park deck to prevent

leakage to structures below the deck as well as a seamless

transition to the existing drainage system.

ELASTOCOAT top coat

Top primer layer with embedded aggregate

Bottom layer of primer

Concrete deck

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� ELASTOCOAST used on shoreline, Hallig Groede, GermanyELASTOCOAST bonds rock or other

substrates together to provide the ultimate

protection against the forces of nature.

These innovative materials can be used for

river and coastal protection or other types

of erosion control.

Cover layer with ELASTOCOAST binder

Compensating layer

Geotextile layer

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� Sandwich panels, D-Runway,Haneda - Tokyo InternationalAirport, JapanPart of the 4th runway, 2500m long, of this

international airport stands on 100m

deep pile foundations in the middle of Tokyo

Bay. It has a unique hybrid structure that

combines landfill with a pier – the latter being

necessary so as not to disrupt water flow in

the estuary of the River Tama.

Sandwich panels, consisting of rigid

polyurethane foam cores sandwiched

between titanium coated plates, cover the

bottom and side surface of the taxi area.

Titanium coated plate

Rigid polyurethane foam core

Titanium coated plate

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Solutions forinfrastructure

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� ELASTOTRACK railway ballast binder,Wyandotte, USAELASTOTRACK, a railway ballast binder, is a two-component

polyurethane system developed for the reinforcement and

stabilization of loose bulk ballast stones on railway tracks.

Top ballast bindedwith ELASTOTRACK

Ballast

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� ELASTOLLAN rail seat padsAn anti-vibration pad made of ELASTOLLAN is placed

between concrete sleeper and the rail. The pad takes

up the loads and dampens the vibrations.

Anti-vibration padmade of ELASTOLLAN(used with concretesleeper)

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� ELASTOCORE used in Sandwich Plate System,Dawson Bridge, Edmonton, CanadaSandwich Plate System used in an award-winning renovation

of this important, historical traffic artery which handles in excess

of 17,000 vehicles each day.

Metal backing plate

ELASTOCORE polyurethane core

Metal backing plate

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� ELASTOCOAT used on an anaerobicdigester tank, Nebraska, USAELASTOSPRAY and ELASTOCOAT were chosen to coat

the exterior of an anaerobic digester tank in Nebraska.

These coatings allow the tank to maintain temperature

and increase the durability and longevity of the tank.

ELASTOCOAT elastomeric coating

ELASTOSPRAY spray

polyurethane foam

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� Insulated pipes for chilled water,Marina Bay Sands Casino resort, SingaporeThe casino resort Marina Bay Sands in Singapore extends

200m up in the sky and is reportedly ‘one of the largest

gravity-defying cantilevers in the world’. Approximately

70,000kg of polyurethane foam was used to make

insulated pipes to the chilled water supply network.

Inner pipe

ELASTOPOR polyurethane foam

Outer pipe

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INFRASTRUCTURE56 Project case study

The elastomer core is called ELASTOCORE. It helps the system to

absorb vibrations and displays high tolerance to jolts and impacts.

Panels weigh up to 70% less than reinforced concrete while being

at least as strong and more durable.

The system was fabricated off-site and then bolted together on

the bridge. The replacing of the bridge deck in just 6 weeks was

due to no need for time-consuming welding. This meant that

long-term closures to the 17,000 vehicles per day which use the

bridge, were avoided.

Project:

Location:

Product used:

Contractor:

To have successfully completed this project in thecity where SPS was initially developed makes it aspecial achievement.”

Michael Kennedy, CEO, Intelligent Engineering

“After a structural survey found the original century-old decking of

this important landmark in Edmonton had to be replaced, it became

clear that the best approach was to limit the bridge’s dead load

with a new lightweight deck (a traditional concrete deck would have

been too costly and too heavy for the aging existing steel structure).

The design team recommended an entirely new lightweight SPS

solution – a sandwich plate system – from Intelligent Engineering Ltd.

This represented the best combination of weight saving, a thin

profile and a simple and rapid installation time.

At over 770 feet long and 26 feet wide, the Dawson Bridge is the

first major bridge to make use of SPS technology.

SPS consists of two steel face plates sandwiching a core of

polyurethane. The finished product is a composite panel of high

rigidity and strength.

Project case study

57INFRASTRUCTUREProject case study

PRODUCT RANGE58 Introduction

59PRODUCT RANGEIntroduction

PRODUCT RANGESUMMARYBASF's polyurethane solutions are the buildingblocks of many successful construction projects.Their use has been proven in many structuralcomponents for more than 50 years. They helpsave energy, make materials stronger, speed upconstruction times, protect the environment,enhance safety and much more.

Every construction project poses different andunique challenges to our customers. The expertsfrom BASF Polyurethanes work closely witharchitects, engineers, designers, contractors,builders, owners and manufacturers to deliverinnovative and customized solutions based onthe understanding of industry trends.

Our primary product families are outlined over thefollowing pages, including information on ourrigorous testing procedures. To reach a BASFPolyurethanes expert for more information on anyof our product families or systems, please refer tothe list of contacts found on page 67.

PRODUCT RANGE60 Summary

Rigid foambuilding insulation

Spray foambuilding insulation

ELASTOPOR (polyurethane) andELASTOPIR (polyisocyanurate)Characterized by a very low thermal conductivityand durability. Produced by insulation materialmanufacturers as insulation boards or sandwichpanels, they offer ideal solutions for the thermalinsulation of almost all types of construction.

WALLTITEA closed-cell spray polyurethane foam thathas the ability to last the life of the building.Sprayed on the substrate, it adapts to anygeometry, creating a seamless insulation layer.By virtually eliminating uncontrolled air leakage,the WALLTITE insulating air barrier systemhelps control vapour movement, reducing therisk of condensation, mold, moisture, icedamming, spalling and premature deteriorationof building materials.

ENERTITEA low-density open-cell spray appliedpolyurethane foam insulation. Applied as a liquid,this water-blown foam quickly expands to manytimes its original size completely filling wallcavities. ENERTITE easily flows in and arounddifficult-to-reach areas such as pipes and wiring,creating a seamless seal.

ELASTOSPRAYClosed-cell spray polyurethane foam insulationapplied directly on the substrate to be insulatedusing a spraying process. The material forms acontinuous, even insulating layer with no jointsor gaps, providing an ideal solution for buildinginsulation. The range of applications is extensive,from external insulation of roofs, to internal andexternal insulation of external walls, basementceilings and soffit insulation.

COMFORT FOAMAn excellent insulation system for both new(walls, foundations, attics) and retrofit (attics,exposed wall stud cavities during renovations)applications within residential markets inthe USA.

LUPRANATELUPRANATE MDI is used to bind woodenflakes and fibers which are pressed intoengineered wood products such as OrientedStrand Board (OSB), Medium DensityFiberboard (MDF) or particle board.

Wood binders

61PRODUCT RANGESummary

ELASTOCASTThe polyurethane-based ELASTOCAST thermalbarrier offers efficient insulation for windowsystem manufacturers. Using the ‘pour anddebridges’ method, it can eliminate heat lossby breaking the thermal bridge in the aluminumwindow frame. It also helps combat water,moisture and air infiltration thereby improvingthe structural integrity of the building.

Waterproofing andcorrosion protection

ELASTOCOATELASTOCOAT coatings provide industry-leadingprotection for roofing, specialty storage andinfrastructure applications. With a fastapplication time, higher tensile strength andimproved low-temperature elongation, thesecoatings can stand up to almost anything whileremaining cost-effective.

ELASTOCOAT can be applied on steel orwood and protects substrates from damageby impact, abrasion, chemicals or corrosion.

Windows Sealants andsealing systems

LUPRANATEJoint sealants prevent air, water and otherenvironmental elements from entering or exitinga structure while permitting limited movementof substrates. BASF has a comprehensiverange of joint sealants and sealing systemsthat allows sealing of joints from facades tofloors to wide, high-movement joints.LUPRANATE is also used in sealing foamsfor around windows and doors.

ELASTOCASTTwo-component, custom-formulated cold cureelastomer systems used to encapsulate andprotect other materials such as porcelain.ELASTOCAST allows floor tiles to be installedquickly and easily.

ELASTOCOATWhen compared to aluminium window frameswith their high thermal conductivity, glass fiberreinforced ELASTOCOAT window profiles showa 400-times lower value providing energy andcost savings. These profiles are produced in apultrusion process – which ensures a rigidcomposite structure and offers considerabledesign freedom.

PRODUCT RANGE62 Summary

Pipingsystems

ELASTOCOATELASTOCOAT bonds well with a varietyof surfaces and cures quickly (even in highhumidity). It is ideal for industrial storageapplications including exterior storage tankand vessel applications and interior liningsfor potable water systems.

Flooringsystems

ELASTOCOATELASTOCOAT’s self leveling flooring systemseals and protects the concrete foundation ofindustrial buildings. The elastomeric nature ofthis product helps bridge cracks caused bystress of the substrate structure.

ELASTOCOAT provides a reliable solutionwhich is easy to care for, durable, abrasionproof, resistant to chemicals and mechanicalimpact.

ELASTOPORELASOPOR pipe insulation is designed for oiland gas transportation, offering resistence tohigh temperatures, durability, good insulatingproperties and simple processing methods.Special flame-proof ELASTOPOR grades areused in the production of insulated pipes foruse in the chemical industry.

ELASTOSHOREOffshore pipeline are installed by compactELASTOSHORE heavy duty parts. These partsprotect the pipeline from damage by currents,over bending and impacts caused during pipelaying or rough sea beds.

ELASTOPAVEELASTOPAVE is a completely new conceptfor the construction of durable surfaces onpaths and plazas. Strong, safe andenvironmentally friendly. ELASTOPAVEcombines aggregate such as granite, stone,or recycled glass with a polyurethane binderto create a water permeable surface. Rainwater can simply seep away and helpreplenish the groundwater supply.

ELASTOTITE / ELASTANELASTOTITE and ELASTAN are used as abinder for rubber crumb material and providesa stable, safe and comfortable surface.

Permeablepavements

63PRODUCT RANGESummary

Railways

ELASTOTRACKELASTOTRACK is a railway ballast bindersystem developed for the reinforcement andstabilization of loose bulk ballast stones onrailway tracks.

ELASTURANRailway sleepers are insulated from the railwaytrack by foamed ELASTURAN damping mats.This technology reduces train vibrations toprotect the track bed and chassis from impactand damage.

ELASTOCOASTELASTOCOAST provides reliable coastalprotection and also preserves the ecologicalbalance. Tests conducted at the FraunhoferInstitute have established that, unlike concrete,ELASTOCOAST is PH-neutral even duringinstallation and is thus totally harmless forfauna and flora.

In addition, bank reinforcements and streamscan be safeguarded quickly and easily withthis technology. Nature benefits from manynew habitats thanks to the open structure ofthe ELASTOCOAST-pebble mix.

River and canalbank protection

ELASTOLLANELASTOLLAN thermoplastic polyurethaneelastomers (TPU) have the impressive tear andcut resistance, excellent abrasion resistanceand low-temperature flexibility necessary towithstand the harsh conditions of theconstruction industry. Several grades ofELASTOLLAN are also certified by NSFInternational for use in potable water mains.

ELASTOLLAN is also used in construction ofartificial sports pitches, breathable roofunderlays and vibration pads.

PERMASKINPERMASKIN is a durable surface finish usedas an alternative to wet coatings – and suitablefor many exterior and interior applicationsincluding doors, garage doors, windowshutters, wall panelling, facades or strips.

TPU (thermoplasticpolyurethanes)

COLO-FASTCOLO-FAST allows a quick, reliable andhigh-quality framing of photovoltaic (PV)modules. The UV-stable and weather-resistantpolyurethane system replaces the conventionalaluminum frames for both, roof-top and roofintergrated PV modules. COLO-FAST offersthe customer a variety of colors and a highdegree of design freedom. With COLO-FAST,mounting features like clamping elements orscrews and electrical components can beembedded in the frame in just one processingstep. PV modules framed with COLO-FASTcan be integrated perfectly into the roof andare highly aesthetic.

Renewableenergy

PRODUCT RANGE64 Testing and accreditation

Accurate scientific measurement both inthe laboratory and in the field is the way toprove the true impact of constructionproducts over the entire lifecycle. Frommanufacture through to disposal, productsshould have a minimal impact on theenvironment.

To address rising energy costs, buildings mustachieve higher levels of energy efficiency. Theymust also achieve other practical benefits suchas durability and robustness to withstand theeffects of ever-changing weather patterns,affordability and speed of construction, to realizea quicker ROI and ease of maintenance.

BASF understands that our customers cannotappreciate what we do not measure. That’s whywe develop award-winning tools that helpbenchmark the impact of our products andsystems on the triple ‘pillars’ of ecology,economy and society.

The third-party validated BASF Eco-EfficiencyAnalysis has been developed to assess andbalance ecologic and economic performance.It enables scientifically sound comparisons ofsimilar products or processes for dedicatedapplications.

It assesses costs of a product or manufacturingprocess over the whole lifecycle as well asenvironmental impacts in six categories:

� resource utilization

� energy consumption

� emissions to air, water and soil

� toxicity potential

� misuse and risk potential

� land use.

Elsewhere our polyurethanes are continually testedfor suitability of use in construction projects all overthe world. Typical accreditation bodies throughwhich our products have been officially tested orcontribute towards attaining a building’s certificationinclude LEED, BREEAM, BBA and DGNB.

Testing and accreditation

LEED standardsDeveloped by the U.S. Green BuildingCouncil, LEED standards provide a frameworkfor assessing building performance andmeeting sustainability goals. The LEEDprogram emphasizes state-of-the-artstrategies for sustainable site development,water savings, energy efficiency, materialsselection and indoor environmental quality.For more information visit www.usgbc.org

65PRODUCT RANGEPolyurethanes and sustainability

Polyurethanes and sustainability

BASF believes that for a business to besuccessful in the long term, it must actresponsibly toward the environment andsociety. Contributions to ‘sustainableconstruction’ (through our products) is anintegral part of our strategy and thinking.This means innovating, creating andcontinually developing products andsystems that meet and exceed regulationsand standards as well as industry challengesand requirements.

BASF’s approach to sustainable construction issummarized in 5 key messages:

1 Sustainable construction means performanceIt is not about self-proclaimed ‘green’ issues.It’s about high performance, quality and safetyand the integration of fact-based, appropriatetechniques into holistic solutions for everyday life.

2 Sustainable construction needstailor-made solutionsBASF offers one of the broadest and versatileportfolios of chemical raw materials, formulations,end-use products and systems to theconstruction industry worldwide. These canbe specified and used to contribute to a varietyof sustainability improvements, for instance inenergy efficiency, indoor-air emissions andaffordable housing.

3 Sustainable construction needs to be provenWe can measure and evaluate with lifecycle,multi-criteria, application-oriented and data-based evaluation. With our long-standingcompetencies and know-how in Eco-EfficiencyAnalysis, green building ratings, EnvironmentalProduct Declaration (EPD) tools, show houses,and our data-sets and case studies, we canprovide sound, scientific information onsustainability.

4 Sustainable construction defines ourproduct developmentFor BASF, sustainable construction meanscontinually striving for more advanced productsand proving their commercial, ecological andsocial benefits via measurable contributions.Working alongside our customers, we aim tobe at the forefront of technological development.

5 Sustainable construction demandsimproved regulations and better solutionsRegulations are being determined not onlyby governments, but increasingly from themarketplace, demanding and enforcing higherlevels of sustainability performance. As amember of green building councils andstandardization bodies, BASF embraces andwelcomes this strategy wholeheartedly.However, regulations will fail to reach their goalsif they are simply based on single criteria ornon-scientific requirements. To achieve bettersolutions, it is vitally important to improveregulations by introducing scientific, data-basedevaluations.

More information can be found atwww.basf.com/sustainability

Typical case study: annual savings and returnon investment of polyurethane insulation

A pitched roof was renovated and insulatedwith 140mm of PU in Germany*

Heat losses through the roofbefore renovation: 17,250 kWh/a

Heat losses through the roofafter renovation: 1,970 kWh/a

Heating oil prices 2009(incl. auxiliary energy): 0.063 €/kWh

Annual heating oil savings: 1,520 l/a

Cost savings for energy: 962 €/a

As the roof had to be renovated anyway,the additional cost for insulation was limitedto 7,100 €.

This will lead to the following returns oninvestment for different oil price increases:

Increase in oil price p.a. 0% 4% 8%

Investment 2010 (€) 7,100 7,100 7,100

ROI p.a. 10.31% 14.17% 18.02%

* Data showing economical impact: Source – ‘Sustainabilityand polyurethane insulation – Today's solution for tomorrow'sneeds’ by PU Europe (www.pu-europe.eu)

Data showing environmental impact: Source – Insulationfor Sustainability: A Guide, XCO2 Conisbee, 2002

Insulation thickness at same R-valueNecessary thickness d (mm) for R=7.5m2 K/WU-value 0.13 W/(m2K)d= R x λ

20 30 40 50Design λ value (mW/(m2K))

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450

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150

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CORPORATE66 About BASF Polyurethanes

BASF System House, Srem, Poland

Disclaimer Any product information or other information published in this brochure is given to the best of BASF's knowledge. All this information shall not,however, as far as legally permissible, create any guarantee or representation of any kind or any liability of BASF and shall not relieve the User from undertakingits own investigations and tests.

Except as otherwise specifically provided in writing, BASF's General Conditions of Sale shall not be altered by this brochure's content, materials and information.

BASF Polyurethanes operates a policy of continuous development and innovation. Therefore product information may change without notice. All product dataand usage should be confirmed using technical data sheets (available on request).

It is the customer’s responsibility to consult local codes and building officials to ensure products meet usage requirements.

Registered trademarks The following product names are trademarked: COLO-FAST, COMFORT FOAM, ELASTAN, ELASTOCAST, ELASTOCOAST,ELASTOCOAT, ELASTOCORE, ELASTOLLAN, ELASTOPAVE, ELASTOPIR, ELASTOPOR, ELASTOSHORE, ELASTOSPRAY, ELASTOTITE, ELASTOTRACK,ELASTURAN, ENERTITE, FILTERPAVE, LUPRANATE, PERMASKIN, WALLTITE.

67CORPORATEAbout BASF Polyurethanes

About BASF Polyurethanes Contact us

BASF Polyurethanes, part of BASF Group, isthe leading global supplier of polyurethanesolutions for systems, specialties and PUproducts. With a worldwide network ofpolyurethane System Houses and itscomprehensive product and service portfolio,BASF is the preferred partner for many industries,including building and construction.

For further information on BASF Polyurethanes productsand materials, or if you would like to know more aboutany of the projects featured in this brochure pleasecontact us at the relevant web address below:

� For European enquiries:www.pu.basf.eu

� For Asian enquiries:www.polyurethanes.asiapacific.basf.com

� For North American enquiries:www.polyurethanes.basf.us

� For South American enquiries:www.basf.com.br

Through its System House network, BASFPolyurethanes provides fast local support, fromtechnical service and sales to production andmarketing during the development of customizedsolutions.

With its world-scale plants, BASF Polyurethanessecures its leading market position in theproduction of polyurethane basic products inall regions of the world.

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