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2/23/2014
1
Installation
Preparation/verification
1. Compatibility – doesn’t stick to substrate 2. Ambient temperature – varies by product and by
conditions 3. Surface conditions
• Wet surface or high moisture content • Too hot or cold • Not fully adhered • Release agent on the surface - waxy beams, vent
chutes form bond break 4. Not the right installation detail for optimal performance
– shape of foam in the framing bay, wrapping doubles
Preparation problems
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Masking was not adequate to protect walls during the roof work
Preparation problem
Preparation problem
Not enough room for specified R-value ~3” for R-38 min.
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Too hot - burnout
Substrate temperature
This spray system is provided in different reactivity profiles to meet varying substrate
temperatures previously noted. At the lower end of the recommended temperature range,
flash passes are to be avoided. FOAM-TECH personnel should be consulted in all cases
where application conditions are marginal.
Climate Conditions
Spray systems should not be applied when the wind velocity is greater than 15 M.P.H to
avoid over spraying of perimeter areas. Higher wind speeds also retard the exothermic
reaction of foam and can lead to poor adhesion and increased density as well as poor
surface texture of the foam itself.
Moisture in the form of rain, dew, frost or other sources can seriously affect the adhesion
of urethane foam to the substrate or to itself. Water reacts with the mixed foam
components, seriously affecting the foam’s physical properties. FOAM-TECH does not
recommend the spraying of this system when the relative humidity exceeds 85F.
Product Data Sheet
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Product Data Sheet
RECOMMENDED SUBSTRATE TEMPERATURES
At time of application RT2045 Winter RT2045 Regular
Minimum 40°F 60°F
Maximum 80°F 120°F
For applications below 40F, FOAM-TECH personnel should be consulted. At the lower
end of the indicated temperature ranges, flash passes should be avoided.
Degrees F 70 60 50 40 30 20 10 0 -10
Thickness Approximate Single-pass Core Densities of Urethanes (Appropriate Seasonal Blend)in Inches At a given substrate temperature on Wood (Metal/Masonry - add .25)
0.50 2.25 2.35 2.50 2.70 2.95 3.50 4.15 4.75 5.50
1.0 2.20 2.25 2.35 2.50 2.70 3.10 3.55 4.15 5.00
1.5 2.15 2.20 2.25 2.35 2.45 2.75 3.25 3.80 4.50
2.0 2.10 2.15 2.20 2.20 2.30 2.60 3.15 3.50 4.00
2.5 2.05 2.05 2.10 2.15 2.15 2.15 2.50 3.10 3.75
3.0 2.00 2.00 2.10 2.10 2.10 2.15 2.35 2.85 3.50
3.5 1.95 1.95 2.00 2.05 2.10 2.10 2.25 2.50 2.75
4.0 1.90 1.95 2.00 2.00 2.05 2.10 2.20 2.35 2.50
4.5 1.85 1.90 1.90 2.00 2.05 2.05 2.15 2.25 2.35
5.0 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.20 2.25
Density varies with temperature and material
thickness (15-year density tracking study)
The Physical Properties of Polyurethane Foam
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Pass thickness
1. Processing to the manufacturer’s specifications (many get more specific for common problems)
2. Requires QA inspections for pass and total insulation thickness
Technical Problems
Hint: Use work report and QA Submittals to assure product quality
Pass thickness test
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Incorrect pass thickness work-arounds
1. Specify processing to the manufacturer’s specifications
(many get more specific for common problems)
2. Require QA inspection reports for tested total insulation
thickness to include average and/or maximum pass
thickness
3. Require a QA inspection record as a submittal
What are the causes of foam problems?
Installation problems
Installation problems
Technique 1. Installing SPF when the relative humidity is 80% or above 2. Passes/lifts are too thick/high 3. Not enough time between passes 4. Improper spray pattern sequencing 5. Improper response to substrate and environmental
conditions 6. Proper work-around protocols not used for extreme
environmental conditions when “the work must go on” 7. More about IPF protocols in the applications section 8. Improper product and performance quality assurance
protocols
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Good technique
Good technique also saves material ($)
Good technique
Better depth control
Self-supporting
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Below-grade application
Good technique
Unvented roof applications
Good technique
Note “fillet” detail along the rafters
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Good technique
Food processing facility
Bad technique
Lack of over-spray protection
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Bad technique
Uneven installation - voids
Bad technique
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Technique – Specialty Approved Foam
Good technique
• The picture framing technique will ensure that insulation seals cracks and crevices without resulting in fold-over along the stud face or air-pockets or voids which will affect the insulation’s performance.
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Good technique
Good technique also
saves material ($)
Industry processing & installation troubleshooting guide
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Safety
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Technical problems
Safety
• Personal protection – Leads to inexperienced installers – Dangerous practices can cause injury, damage, and
delays
• Site protection – Air-quality management required
– Re-occupancy
• Fire protection issues – Improper pass thickness can start a fire
– Code requirements
Required by ICC Model Building Codes (I-codes) – Delays combustion and ignition of SPF
– Provides extra time needed for worker and occupant egress
– Requirements for Foam Plastics
• IBC Chapter 26, Section 2603
• IRC Chapter 3, Section R316
©2011 Spray Polyurethane Foam Alliance
Codes Require Ignition & Thermal Barriers
http://www.internationalcodes.net/2009-building-codes-100-3536-09.shtmlhttp://www.internationalcodes.net/2009-international-residential-codes-100-3538-09.shtmlhttp://www.internationalcodes.net/2009-international-energy-conservation-codes-100-6533-09.shtmlhttp://www.iccsafe.org/
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Technical problems
Fire protection issues
1. Thermal and ignition barriers
2. Exposed applications
3. Understanding the code exceptions and rulings
4. Knowledge of the protections available
a. Coatings
b. Other
5. Refer to the HCF foam code matrix
Locations - Attics
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Ignition Barriers
Exceptions to the 15-minute thermal barrier requirement
1. Building location exceptions
2. Prescriptive PFI barriers
3. Other types of protection
4. Protect from ignition coatings or barriers
5. Using approved sheet goods as a work-around
No PFI barrier
Basement rim joists
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Exceptions – Specialty Approved Foam
Attic application
Thermax rigid foam
board
Post installation problems
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Typical post-installation problems
1. Inadequate quality assurance protocols 2. Failure to maintain minimum cure
requirements – thermal shock 3. Lack of protection against damage by related
trades (open flames, air barrier penetrations for mechanical systems, etc.)
Hint: Product Data sheets and ESRs report cure requirements –
specify and verify compliance with the manufacturer’s requirements.
Temporary insulation can extend the installation conditions.
Foam problem!
Thermal shock plus
deep pass thickness
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Foam problem!
Field testing
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Tools of the trade
1. Pull / adhesion test kit 2. Density check kit 3. Compressive strength gauge 4. Temperature meter 5. Relative humidity meter 6. Slit test knife 7. IR camera 8. Blower door 9. Theatrical fog machine
Testing foam properties
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Foam inspections – Project identification
• Identify the materials used
– Manufacturer
– System number
– Lot number
– Seasonal formulation
– Documentation to require
• Product data sheet (Technical data, Product specification)
• MSDS forms (A, B, and finished product)
• ESRs
• Manufacturer’s installation instructions
• Processing reports
Foam inspections – Project identification
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Removing an SPF sample for density testing
Removing an SPF sample for density testing
Tapered sample extraction
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Removing an SPF sample for density testing
Repair methods
Flexible foam
plugs
Foam inspections – Installation quality
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Installation quality assurance
Graduated beaker
displacement
density test
Courtesy: Air Barrier Association of America
Adhesion test required?
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Adhesion test
Adhesion test
CMU
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Adhesion test
Glazed TC tile
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Adhesion test
Foam inspections – Installation quality
Industry-standard foam testing:
• Compressive Strength (Closed-cell foam only): Compressive strength of spray foam should be measured within 15% of the minimum reported on the manufacturer’s data sheet.*
SPFA
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Cell Geometry
Polyurethane foam
Cell Geometry
• Elongated cells are stronger parallel to the long axis than perpendicular to it (similar to the grain in wood).
• Elongated cells usually mean improper application technique.
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Elongated cells are weaker perpendicular to the grain and thermal shock causes the material to shrink laterally.
Technical Problems
Density Profiles Sample 10A Sample 5BPass thicknesses 1.5" - 7" 1.5" - 2"
Percent change 6% 25%
Average density for entire sample ~1.8 ~2.2
Slice #1 2.95 2.56
Slice #2 1.94 2.15
Slice #3 1.69 2.14
Slice #4 1.56 2.35
Slice #5 1.77 2.47
Slice #6 1.78 2.32
Slice #7 1.95 2.15
Slice #8 - 2.13
Technical Problems
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Density Profiles
Sample 10A Sample 5B
Pass thicknesses 1.5" - 7" 1.5" - 2"
Percent change 6% 25%
Average density for entire sample ~1.8 ~2.2
Slice #1 2.95 2.56
Slice #2 1.94 2.15
Slice #3 1.69 2.14
Slice #4 1.56 2.35
Slice #5 1.77 2.47
Slice #6 1.78 2.32
Slice #7 1.95 2.15
Slice #8 - 2.13
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Density Profiles
Density over sample profile
1
1.2
1.4
1.6
1.8
2
2.2
2.4
2.6
2.8
3
1 2 3 4 5 6 7 8
Den
sit
y (
#/c
u. ft
.)
Density over sample profile
1
1.2
1.4
1.6
1.8
2
2.2
2.4
2.6
2.8
3
Slice #1 Slice #2 Slice #3 Slice #4 Slice #5 Slice #6 Slice #7
Den
sit
y (
#/c
u. ft
.)
Correct pass thickness
Blue line: Incorrect pass thickness
Red line indicates minimum density (2.1#/cu. ft.) for good dimensional stability
Pass thickness
1. Processing to the manufacturer’s specifications (many get more specific for common problems)
2. Pass vs. “total” and “daily total” insulation thickness
3. Theoretical variations for acceptable non-compliance
Foam inspections – Installation quality
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Pass thickness test
Foam inspections – Installation quality
Foam thickness
methods/tools
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Visual Inspections
Foam thickness should be
3” for this project.
Dimensional stability
1. Cold and hot testing
2. Slit testing
Foam inspections – Installation quality
Hint: Use work report and QA Submittals to assure product quality
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Foam inspections – Installation quality
Freezer test – No dimensional change at -5F for 48 hours
R-value
1. R-value testing cannot typically be done on site
2. Rely on the manufacturer’s information on the Product Data sheet
3. This applies only if the foam was processed properly
• Closed-cell foam - Off ratio and/or poorly mixed foam will not have closed cells and maintain low-conductivity gas in the cells.
• Open-cell foam – Off ratio and/or poorly mixed foam will have very large cells, buy will generally still perform as insulation
Foam inspections – Installation quality
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R-value (Calculated)
1. R-value per unit of thickness for the product from the Product Data sheet
2. Average thickness – per the industry thickness standard test method
3. Multiply the R-value times the average thickness to get the average R-value
4. Average R-value vs. Minimum R-value
Foam inspections – Installation quality
Hint: Use work report and QA Submittals to help assure product quality
Theatrical fog used for localized air-leakage testing
Foam inspections – Performance quality
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Air-barrier testing
First Instance Testing – window
opening
Foam inspections – Performance quality
Smoke puffers for localized air-leakage testing
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Blower Door Testing
Museum
Type: Closed-cell foam Type of masonry: CIPC Method: IPF Not drained Function: H, A, M Coating/protection: TB NY, NY Project date: 2007 & 2009
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Museum
Museum
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Foam Panel/SIP problems and
repair QA techniques
SIP Problems
SIP problems are almost always
related to sealant issues at the panel
joints. Here you can see the
concentration of damage along and at
the top of the panel joints.
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SIP Problems
SIP problems are almost always related to sealant issues at the panel joints.
In this project, ants at the ridge and along the soffits raised the alarm.
SIP Problems Here the panel joints are being enlarged and
cleaned out to allow full-depth air sealing. The
foam leakage at the interior verifies that the
panel joints were the air leakage path that
caused the moisture damage.
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Building Science on Panel joints
SIP Problems
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Panel joint moisture failure
Stressed-skin panel failure
Diagnostics on the fly
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Diagnostics on the fly
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Finished (chainsaw)
carpentry
Diagnostics on the fly
Diagnostics on the fly
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Diagnostics on the fly
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Panel joint failure
Tubes and extensions
1998
http://en.wikipedia.org/wiki/File:Vermont_law_school_oakes_hall_20040808.jpg
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Tubes and extensions
1998
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Theatrical fog used for localized air-leakage diagnostics
Tubes and extensions
Note: A 10’ length of 1-1/2”
PVC schedule 40 would
work nicely here
Tubes and extensions
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Fill the interior volume approach
Fill the interior volume approach
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Fill the interior volume, then pressurize One classroom filled with fog and the blower window ready
to pressurize the space
Fill the interior volume approach
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Fill the interior volume approach
Fog washing
at soffit
Verify air leakage is occurring from the interior up into the roof vent space
Fog
generator
Gravity flow approach for roof ventilation
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3. Terminology
Neutral
Fog washing
at soffit
Fog
generator
Timing roof vents to calculate the flow rate
When you don’t need
them, roof vents work
well!
Testing roof vent chutes for flow rate