Typical installation technique for Polymaster R-501

SPECD

FOAMED-IN-PLACE INSULATION 07 21 19

Polymaster, Inc

Cio Polymaster

oams

1. Product Name Polymaster R-501 Foamed-In-Place Insulation

2. Manufacturer Polymaster, Inc. 10523 Lexington Drive Knoxville, TN 37932-3210

(800) 580-3626 (865) 966-3005

Fax: (865) 675-3300 E-mail: info@polymaster.com www.polymaster.com

3. Product Description

BASIC USE Polymaster R-501e foam insulation is a cost-effective, environmentally friendly thermal and acoustical insulating material designed for use in cavity, concrete dock or frame walls. It can be used in new or retrofit commercial, residential and industrial applications. Polymaster foam can be used to insulate concrete block by using top or side pressure fill techniques. It provides higher R-values than inserts or vermiculite and is easier to install. Polymaster insulation can be installed in 10 - 12 (3 - 4 m) lifts during construction. 6", 8" and 12" (152, 203 and 305 mm) block can be easily filled in both running bond or stacked configurations. Pressure fill applications require holes as small as 5/8" (15.9 mm) and no larger than in (25.4 mm) drilled directly into the masonry. Foam will fill the cavity up to 12 (4 m) in either vertical direction from the hole. Pressure filling gener-ates a complete fill of the core and head joints as the application progresses down the run of the wall.

Polymaster foam completely fills the cavity between double walls, fascia walls or internal/ external cosmetic walls, producing excellent sealing around fittings, conduit, fixtures and pipe chases, while still allowing the wall to weep as constructed. It can provide R-values comparable to, or higher than, rigid board insulation. Polymaster is acceptable for use under many fire codes.

Commercial structures can be easily retrofit with Polymaster foamed-in-place insulation to improve thermal and acoustical properties. It

provides high R-values and enhances the comfort and efficiency of the building. Polymaster can be installed easily, making it a cost-effective choice, especially for buildings that would require extensive renovation with other types of insulation.

Superior R-values can be obtained by pump-ing Polymaster foam into the frame wall stud cavity. It eliminates deficiencies commonly found with some insulation products, such as settling, collapsing and thermal drift.

COMPOSITION & MATERIALS Polymaster R-501 is a 3-part polymer foamed-in-place plastic insulation consisting of a proprietary dry powder resin mixed with a cata-lyst and foamed with nitrogen or compressed air. The foam hardens through a chemical process similar to that of epoxy resin. Complete drying requires 72 hours or more, depending on local environmental conditions. Polymaster is shipped in dry powder form and has a 1 year shelf life.

LIMITATIONS Polymaster foam should not be used in wall cavities that will not permit water vapor trans-mission during the initial 72 hour curing period.

4. Technical Data

APPLICABLE STANDARDS ASTM International • ASTM C518 Standard Test Method for Steady-

State Heat Thermal Transmission Properties by Means of the Heat Flow Apparatus

• ASTM C1363 Standard Test Method for the Thermal Performance of Building Assemblies by Means of a Hot Box Apparatus (replaces ASTM C236)

• ASTM D2842 Standard Test Method for Water Absorption of Rigid Cellular Plastics

• ASTM E84 Standard Test Method for Surface Burning Characteristics of Building Materials

• ASTM E90 Standard Test Method for Laboratory Measurement of Airborne Sound Transmission Loss of Building Partitions and Elements

• ASTM E96 Standard Test Methods for Water Vapor Transmission of Materials

• ASTM E119 Standard Test Methods for Fire Tests of Building Construction and Materials

• ASTM E413 Standard Classification for Rating Sound Insulation

• ASTM D5116 Standard Guide for Small-Scale Environmental Chamber Determinations of Organic Emissions from Indoor Materials/ Products

ENVIRONMENTAL CONSIDERATIONS Polymaster R-501 foam insulation is biodegradable. It is shipped in recydable product containers.

PHYSICAL/CHEMICAL PROPERTIES • Thermal properties R-value on 8 inch (203 mm)

CMU at 105 pcf (1682 kg/m 3) (ASTM C1363) -R-value 11.05 ft 2 x h x °F/Btu (1.94 m 2 x K/W)

• Thermal properties K-value and R-value per inch thickness at 25 degrees F (-4 degrees C) (ASTM C518) - K-value 0.216 Btu/(ft 2 x h x °F) (0.37 WArn x K)). R-value 4.63 ft 2 x h x °F/Btu (0.81 rn 22

x K/VV) • Thermal properties K-value and R-value per

inch thickness at 75 degrees F (24 degrees C) (ASTM C518) - K-value 0.244 Btu/(ff 2 x h x °F) (0.42 Wi(rn x K)). R-value 4.09 ff 2 x h x °F/Btu (0.72 rn .2 x K/VV)

• Water vapor transmission (ASTM E96) - 4.655 grains/hr x ft2

• Permeance (ASTM E96) - 6.631 (381 ng/(Pa x s x m2)) perms/inch

• Water vapor absorption (ASTM D2842) -10% by volume at 24 hours, at 25 degrees F (-4 degrees C)• at 100% relative humidity

• Shrinkage - 2% maximum • Sound Transmission Classification (STC) - 52

(Retrofoam) • Corrosivity - Noncorrosive • Asbestos or glass fiber content - None • CFC content - None • Biodegradability - Biodegradable

Test reports are available upon request.

4r

SFIC-DATA° and MANIU-SPEC• the registered trademarks of Peed Bsevier Inc. The ten port SPEC-DATA farnot conforms to the editorial style of The Construction Spedficatials hstttute ands used with their permissions. The manufacturer is reseal -6,01e 'a tectricci accuracy. 0201C Reed Conshucticn Data. All Rights eserved. SmartBu ilding

SPEC 0 3=1

Polymaster foam completely fills CMU cavities.

FIRE PERFORMANCE • Surface burning characteristics (ASTM E84) -

Flamespread 20, smoke developed 50, thick-ness 4" (101.6 mm). Building code surface burning classification: Class I or Class A

• 4 hour fire resistance rated masonry wall design - Standard 8" (203 mm), 105 pcf (1682 kg/m 3) density block with 30.5% grouted cells. See NCMA TEK 7-1A, 1999

SOUND PERFORMANCE When tested according to ASTM E413, 3 1/2" (89 mm) stud frame cavity walls have achieved a rating of STC 44. When tested

Polymaster 12-501 applied in wythe cavity

according to ASTM E90, 3 1/2" (89 mm) stud frame cavity walls have achieved a rating of STC 52 (Retrofoam).

5. Installation

PREPARATORY WORK Handle and store product according to Polymaster recommendations. Ensure cores or spaces are free of mortar or other restrictions to the free flow of foam insulation. Verify that all work within the wall voids is complete prior to installation. Allow masonry mortar to set prior to installing insulation. Select the most aesthetically pleasing locations for foam injection, induding locations to be concealed where possible, such as: masonry joints, wythe side of walls and cov-ered side of walls. For pressure fill installation, drill fill holes into CMU cores. Drill hole size: minimum diameter 5/8" (15.9 mm), maximum diameter 1" (25.4 mm),

METHODS Install foam insulation in CMU cores to a uni-form density using the pressure fill method or the top fill method. Completely fill all spaces, crevices and voids. If pressure fill method is used, fill and point drill holes in masonry units with mortar after installation.

Verify insulation density of each foam batch by random sampling of foam before installation. RH a 1 gal (3.8 L) nonsealing plastic bag with foam. The bag weight shall be between 285 - 325 grams.

Verify complete filling of voids by drilling or removal of block face. Fill and point drill holes in masonry with mortar after inspection. Correct any foam installation found to be noncompliant with manufacturer's require-ments. Complete installation recommenda-tions are available from the manufacturer.

PRECAUTIONS Do not install foam insulation when product temperature is below 50 degrees F (10 degrees C).

BUILDING CODES Comply with the requirements of applicable code jurisdictions.

6. Availability & Cost

AVAILABILITY Polymaster is available through a network of authorized installers. Contact manufacturer for more information.

COST Budget installed cost information may be obtained from the manufacturer.

7. Warranty Contact manufacturer for complete warranty details.

8. Maintenance No specific maintenance is required.

9. Technical Services Factory trained service personnel offer design assistance and technical support. For techni-cal assistance, contact Polymaster or an authorized Polymaster R-501 installer.

10. Filing Systems • SmartBuilding Index (SBI) • MAN U-SPE-C® • Additional product information is available

from the manufacturer upon request.

FOAMED-IN-PLACE INSULATION 07 21 19

Polymaster, Inc.

SPEC-DATA• and MANU-SPEC• are registered trademarks of Reed Bsevier Inc. 'he ten part SPEC-DATA farnat conforms to the editorial sit* of The Construction Specifications Institute and is used with their permission. The manufacturer is responsible for technical accuracy. 02010 Reed Construction Data. All Rights Reserved. SmartBuilding

:1501 foamed- In Place Insulation AIA Short Form Guide Specification

SECTION 07214 - FOAMED-IN-PLACE MASONRY WALL INSULATION

PART 1 - GENERAL

DESCRIPTION OF WORK:

A. Applications of insulation specified in this section include the following:

Foamed-In-Place masonry insulation for increased thermal and sound values.

QUALITY ASSURANCE:

A. Insulation shall be installed as per manufacture's recommendation and must come from the manufacturer in dry-mix recyclable containers to ensure fresh product and enviromental responsible handling. One year product and installation warranty will be issued by both the manufacturer and installer.

B. Engage an experienced dealer/applicator who has been trained and licensed by the product manufacturer and which has not less than three years direct experience in the installation of the product used.

PART 2 - PRODUCTS

ACCEPTABLE MANUFACTURERS

A. "R501" as manufactured by Polymaster 10523 Lexington Dr. Knoxville, TN 37932 (800) 580-3626 No substitutions allowed.

MINIMUM PRODUCT PERFORMANCE STANDARDS

(1) Thermal Performance: (ASTM C1363) 8" CMU at 105pcf meets R-value of 11.05 (2) Surface Burning Characteristics: (ASTM E84) Maximum flame spread, smoke

developed at 4 inch thickness meets Class 1 or Class A classification. (3) Fire-Resistance Ratings: (ASTM E119) Minimum two (2) hour fire resistance wall rating for 8" and 12" concrete masonry units when used in standard two (2) hour rated CMUs. (4) Thermal Values: "R" Value of 4.63/inch @ 25 degrees F mean; ASTM C-518. (5) Sound Abatement: (ASTM E413, ASTM E90) ''STC" rating of 52 and a minimum

rating of 44 for 3.5" cavity wall assembly

PART 3 - EXECUTION

INSTALLATION GUIDELINES

Fill all open cells and voids in hollow concrete masonry walls where shown on drawings. The foam insulation shall be pressure injected through a series of 5/8" to 1" holes drilled into every vertical column of block cells (every 8" on center) beginning at an approximate height of four (4) feet from finished floor level. Repeat this procedure at an approximate height of twelve (12) feet above the first horizontal row of holes (or as needed) until the void is completely filled. Patch holes with mortar to resemble existing surface.

:026:4G N.V.S. 'COX. SNI,

IS PREFERRED BY AMERICAS LEADERS!

WAL*MART

EiA13 523, -L)63

0-501's R-Values are higher, yielding lower energy costs for building owners. R-501 Foam yields an R-4.63 per inch or an 11-11 in a conventional 8" block wall.

Loose fill is hard to handle and blows away easily in the breeze.

Loose fill drains out of the wall if puncture occurs, with no way to reinstall it.

R-501 totally fills the wall cavity and stays there.

Wall Board, also referred to as rigid board insulation is commonly seen hanging on the exterior of block buildings under construction. This insulation is usually made of polystyrene and is available in thicknesses of one to two inches. Its purpose is to insulate the block wall in the wythe cavity — the space between the blocks and the brick fascia.

*8 INCH BLOCK R-VALUES 11.1

acm. OTHER NO BLOCK FOAMS INSUL. DENSITY

10.1

9.0 2.2 100

5.0 1.9 140

'8' GROUTED cr. 0 4e co COISo 5.14 overall R.-value In G1363 test

12 INCH BLOCK R-VALUES 20.1 N h

3501 OTHER OIRS DBELNIOSCI

kowE's Foamsd-in-Placs Insulation

THE WORLD'S FIRST DRY FOAM. POLYMASTER FOAM PERFECTED "DRY FOAM" TECHNOLOGY.

R501 is specially engineered for newly constructed concrete block walls. Only Polymaster has the experience and staff to stand behind its dealers and their customers to ensure consistently reliable and superior insulation products.

Not all aminoplast foams are the same. There are distinct and important differences that should be noted by architects, engineers, and general contractors. These are detailed below:

• R-501 is "dry powder foam." R-501's resins are kiln-dried and are delivered to our field partners as a dry powder. Our factory trained installers then are able to produce the foam from fresh components at the time of installation. Pre-mixed resins are unstable, have a short shelf life, and can yield an inferior product when installed.

• R-501 comes in recyclable containers and is installed by trained installers worldwide and is non-toxic, odor-free, CFC-free, and has no ozone depleting off-gassing making installation safe and proficient without disrupting other site work.

• R-501 for commercial applications is a cost-effective, environmentally green thermal and acoustical foam for filling the cores of concrete block (cmu) and wall cavities. R-501 yields higher R-values than industry standards.

R-501 moves thru the blocks webbing to fill all voids.

R501 FOAM VS. LOOSE FILL

Dry fill refers to any type of insulating material that is poured in to the cells of the CMU's from the top as the wall is erected. Materials most commonly used are vermiculite and polystyrene balls. These products yield similar R-Values to R-501 but possess distinct disadvantages.

First, is inefficiency. Every four courses or so, masons must stop laying block, manhandle sacks of material up the wall, then try to pour the material through the open cells. Often wind will blow away the insulation as it is poured causing waste and frustration. Secondly, should any puncture of the block occur by accident or by necessity, the dry fill insulation will drain out through the hole, with no way to replace it. Thirdly, dry fill does not insulate the spaces between the blocks known as the webbing.

R-501 is installed after the masons have finished their job. As the foam is injected, it flows from cell to cell, through the webbing of the blocks, providing a total fill of the wall. Once the foam is in place, it stays there for the life of the building with no fear of loss due to an accidental or intentional hole in the wall.

BENEFITS OF :1501. OVER OTHER TYPES OF CMU INSULATION.

R501 FOAM VS.WALL BOARD

POLYMASTER IS THE R-VALUE LEADER

InsulThane polyurethane spray foams are available in a variety of densities. InsulBloc, a two-pound spray foam for the face of cmu is a self adhesion insulation product that also acts the damp-proofing membrane in wythe cavity applications. It yields an R-6.8 per inch and provides a seamless coating to walls and joints. Polymaster is the only foam company that offers both aminoplast foams and polyurethane spray foams. When used in conjunction, R-501 and InsulThane foams can increase thermal resistance by 120%!

OSHA

INSULTHANE FOAM PROGRAM

R-501 is a less expensive alternative to rigid board, yielding a higher R-Value in the final analysis. Wythe cavities are usually 2" wide. Since many architects wish to leave this cavity open, only 1" of rigid board can be used. One inch of rigid board has an R-Value of 5. An R-501 filled wall, on the other hand, yields an R-11.05 in a conventional 8" block wall.

R-501 is not a damp-proofer, nor is rigid board. The fact is, the only reliable way to control moisture in a block wall is to apply a damp-proof material to the wall before rigid board or any other type of insulation is used with the exception of 2 lb. or higher density spray InsulThane foam).

Material Safety Data Sheet

U.S. Department of Labor Complies with OSHA Hazard Communication

Occupational Safety and Health Administration Standard, 29CFR 1910.120

(Non-Mandatory Form)

IDENTITY (As used on Labeling): PolyMaster R-501 Foam Insulation

Section I - General Information

Manufacturer: (See Note below) Emergency Telephone PolyMaster, Inc. Number: 1-(800) 580-FOAM

10523 Lexington Drive Knoxville, TN 37932 Telephone Number

for Information: (865) 966-3005

NOTE: PolyMaster is a distributor and is not the manufacturer of the product

described under this MSDS. This MSDS is based on information supplied to

PolyMaster from the manufacturer, therefore PolyMaster cannot warrant the Date prepared/revised: 01/21/2011 accuracy of information contained in this MSDS.

Section II - Identity Information / Hazardous Ingredients

POLYMASTER PLASTIC FOAM INSULATION — R-501

Hazardous Ingredients (Specific Chemical Identity/ CAS Number OSHA PEL ACGIH TLV Other Limits

None.

DOT NAME: Not regulated, Solid N.O.S.,

PERSONAL PROTECTION: None required

NFPA: Health = 0; Fire = 1; Reactivity = 0; Special Hazards = 0

IARC: None. (0 = none; 1 = Slight 2 = Low; 3 = Moderate; 4 = Extreme)

Section III - Physical /Chemical Properties

Boiling Point: Not Applicable (solid) Bulk Density: 0.75 lbs/cu ft

Vapor Pressure: Not Applicable Melting Point: N/A

Vapor Density: Not Applicable pH: N/A

Solubility in Water: Insoluble Decomposition: High temperature

Appearance and Odor: Rigid White foam.

Section IV - Fire and Explosion Hazard Data

Flash Point: None Flammable Levels (LELJUEL): Not Flammable, Meets Class I

Extinguishing Media: As required by fire Unusual Fire/Explosion Hazards: Will decompose at high temperature producing oxides of nitrogen.

01 MSDS Foam 01/11cpe

Material Safety Data Sheet

U.S. Department of Labor Complies with OSHA Hazard Communication

Occupational Safety and Health Administration

Standard, 29CFR 1910.120

(Non-Mandatory Form)

Section V - Reactivity Data

Stability: Unstable ( ) Conditions to avoid: Contact with freshly prepared foam may Stable (X) cause eye, skin, or respiratory irritation - wash liberally with

water.

Incompatibility (materials to avoid): Strong caustic or acid.

Hazardous Decomposition or Byproducts: Conditions to Avoid: Ammonia, oxides of carbon and Hazardous Polymerization: nitrogen, formaldehyde, and hydrogen cyanide may be - will occur ( ) - will not occur (X) liberated during high temperature decomposition.

Section VI - Health Hazard Data

Routes of Entry: Inhalation: Yes (dust, vapor) Skin: Yes (dust) Ingestion: Induce vomiting if swallowed.

Health Hazards (Acute and Chronic): None.

Toxicity: None

Carcinogenicity: IARC: No IARC Monographs: None OSHA/EPA: No

Signs and Symptoms of Exposure: Irritation (i.e. dusts)

Medical Conditions Generally Aggravated by Exposure: None known.

Emergency and First Aid Procedures: None. Use normal safety precautions.

Section VII - Precautions for Safe Handling and Use

Steps to be taken if material is released or spilled: Use a dust mask and gloves when sweeping up residuals of foam.

Waste Disposal Method: Dispose of foam as solid waste in accordance with local regulations. Material is not regulated under DOT or Federal regulations.

Precautions to be Taken in Handling and Storage: Dusts may be irritating. Avoid breathing dusts.

Other Precautions: None

Nuissance Dust: Exposure limits, OSHA / ACGIH 10 mg/m 3

01 MSDS Foam 01/11cpe

Material Safety Data Sheet

U.S. Department of Labor Complies with OSHA Hazard Communication

Occupational Safety and Health Administration

Standard, 29CFR 1910.120

(Non-Mandatory Form)

Section VIII - Control Measures

Respiratory Protection: Dust mask, (dusts)

Ventilation Type Required: None

Protective Gloves: Gloves (dusts)

Eye Protection: Safety glasses. (dusts)

Other Protective Clothing or Equipment (specify Type): None. Coveralls recommended.

Work/Hygienic Practices: As a general precaution, do not eat, smoke or drink when handling materials.

Section IX — Regulatory Statements

DOT Shipping Name: Not regulated.

Regulation under TSCA: None of the ingredients are regulated under TSCA.

Regulation under SARA Title Ill: Not regulated.

Regulation under OSHA: None.

Other Statements: The information in this data sheet have been assembled by the manufacturer based on its own studies and on the work of others and are believed to be truthful and accurate. The manufacturer makes no warranties, express or implied, as to the accuracy, completeness or adequacy of the information herein. Neither the manufacturer or PolyMaster shall be liable (regardless of fault) to the consumer, the consumer's employees, or others, for any direct, indirect, special, or consequential damages arising out of, or in connection with the accuracy, completeness, adequacy or furnishing of such information.

01 MSDS Foam 01/11cpe

PolymastEr® 10523 Lexington Drive

Knoxville, TN 37932 USA 1.800.580.3626

Dear: To whom it may concern

In reference to MRc5 LEED credit (Regional Materials):

The regional material (local water) that is extracted to make the liquid raw material components for our R501 product is 54% on the resin side and 96.3% on the foaming agent side. The total percentage of "local raw material" (water) extracted to make the liquid components is 78.9% of the total mix. The dry powdered resin and foaming concentrate only count for 21.9% of the total raw liquid concentrate used to manufacture the foam on site.

POLYMASTER

:1501 Foamed-in-Place Insulation

Product Information for LEED credit

Project:

Installer:

MRc5 Credit (Regional Materials): The R501

components which are the prime liquid resin and

liquid foaming agent are produced/mixed by the

installer and the R501 foam is manufactured on

site. The prime liquid components are

produced/mixed miles from the project.

Meeting the 500 mile radius standard for this credit.

**Note the recyclable nature of the component

containers.

:1501 Foamed-in-Place Insulation

Polymaster, Inc. Limited Warranty

Polymaster, Inc. warrants that R501 and Plastic Foamed-In-Place Insulation components shall be free of defects when received by our certified applicator. The resulting application, when done by a Polymaster Certified Applicator/Contractor in accordance with approved procedures will result in a finished product that will meet the published designed values.

Limited Warranty: Polymaster does not control or supervise the installation of these products; therefore Polymaster limits its warranty to the performance of the materials themselves, and does not include installation and/or performance of the applicator.

Polymaster stands behind its product in the finished state in place provided that the installation meets the above criteria and the instructions for application have been followed accurately by a certified applicator/contractor. Customer satisfaction in the finished product is our goal.

This warranty replaces and voids any other and serves to support Polymaster, Inc., its distributors, applicators, specifies customers, and end-users.

IECC Code:

C402.1.1 Insulation and fenestration criteria. The building thermal envelope shall meet the requirements of Tables C402.2 and C402.3 based on the

climate zone specified in Chapter 3. Buildings with a vertical fenestration area or skylight area that

exceeds that allowed in Table C402.3 shall comply with the building envelope provisions of

ANSI/ASHRAE/IESNA 90.1.

C402.2 Specific insulation requirements (Prescriptive) — Will Not Meet Code Requirements for Mass Walls (Masonry) in table due to the call for continuous insulation, except in climate zones 1 and 2 (Refer to "c." under table 402.2) c. R-5.7ci is allowed to be substituted with concrete block walls complying with ASTM C 90, ungrouted or partially grouted at 32 inches or less on center vertically and 48 inches or less on center horizontally, with ungrouted cores filled with materials having a maximum thermal conductivity of 0.44 Btu-in/h-f 2 °F.

C402.1.2 U-factor alternative. An assembly with a U-factor, C-factor, or F-factor equal or less than that specified in Table C402.1.2 shall be permitted as an alternative to the R-value in Table C402.2.

To comply with 2012 energy code requirements for Mass/ masonry walls in all other climate zones (3-7), an insulation product has to have the required assembly test (ASTM C236 or C1363) to validate the assembly U-factor. Refer to Polymaster R501's compliant test results at www.polymastencom.

ASTM C-236 (1363) Overall wall assembly R-value of 8" cmu at 98pcf with R501 is 11.05: U-Factor of

.090

• Extrapolated R-value of 10.5 in 8" cmu & 19.1 in 12" cmu at 140pcf: U-Factor of .095 and .051

• Extrapolated R-value of 20.1 in 12" cmu at 120pcf: U-Factor of .0497

Certificate of Completion This is to Certib that

Southern Foam Insulation Ifas Successfully Completed - the

Technical- Training For

PolymastEr €rs m

as of 9\rovember 3 f t , 1998

Charlie Leno. Vice (President of Sales

Stephen Sayers President

4

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