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Polyurethane foam insulation for roofs

Ceilings and laminated roof covers that have water and air filtration, breakage and other problems, can be covered by the outside with Polyurethane Foam and extend its useful life for a period similar or greater to the service that provides a new cover, also winning to isolate the heat of the sun , decreasing more than 30% the temperature of your roof , this will provide a pleasant work environment and a saving of up to 40% energy.

The polyurethane foam is known to be an insulating material of very good performance, therefore low thicknesses can be applied obtaining similar performances than other materials in much greater thicknesses. Its application can be done from the bottom or from the top. It also has excellent properties such as acoustic insulation.



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Polyurethane Foam is a synthetic and duroplastic material, highly crosslinked and non-fusible, obtained from the mixture of two components generated by chemical processes from oil and sugar: Isocyanate and Polyol . The mixture under suitable conditions of these two components will give us a foam of variable stiffness, according to the proportion of each of the two products that has been used.

Polyurethane foam, as thermal insulation and roofing.

About 5 cm of polyurethane foam equals 15 cm in polystyrene plates, with the advantage of having no joints. In a short time the investment of the application is paid, with the lowest consumption of energy used by your air conditioner.

The application of polyurethane foam waterproofs, insulates, and seals effectively , preventing the formation of moisture by condensation and eliminates possible thermal bridges.

polyurethane ceilings

Polyurethane foam by the Spray or Injection method, provides excellent insulation.

The layer of this foam can be applied to various surfaces: The application includes Tanks, Pipes, Refrigerating Chambers, Flotation Elements, Civil Construction. It is especially appropriate for Ceilings and Walls.


Polyurethane is presented as the ideal solution for the construction of new construction and rehabilitation of buildings , especially on the roof of these, which is the part where more heat is lost, seals all kinds of irregularities and cracks, levels inequalities, adds little weight to the constructive solution and improves the structural resistance of the whole, reason why the total sanitation of the substrate to be repaired can be avoided.

polyurethane foam application

The thermal insulation capacity of Polyurethane foam is not achieved with any other known insulating material.

This special feature is due to the very low thermal conductivity of the foaming gas occluded inside the closed cells.

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THERMAL INSULATION WITH PROJECTED POLYURETHANE

THE PROJECTED POLYURETHANE

The polyurethane foam, besides acting as an insurmountable thermal insulator, waterproofs. It is not necessary to coat the back of the walls to guarantee the impenetrability before rainwater. It is considered a continuous waterproof system, which meets the new CTE in any circumstance.



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•     In inclined roofs other anchors are not necessary due to the strong cohesion of the foam with the other materials.
•     On flat roofs and on the upper face of slabs , higher density foams capable of withstanding an> 200 kPa compression should be used.
•     In industrial roofs it is successfully applied for the insulation and waterproofing of industrial light covers. A foam with a density of not less than 45 kg / m3 is used and must be protected from solar ultraviolet (UV) rays with a quality coating of sufficient thickness. It is a very effective insulation to avoid heat and cold in industrial buildings. With only a thickness of 30 mm, it reduces the thermal transmission of the roof by 7 times.
•     Being integrated in the same cover sheet, prevents condensation.
•     As it is a continuous coating, it covers the joints and waterproofs the cover.
•     The fire rating of the foam assembly plus its protection, is Broof.
•     It encapsulates the surface avoiding the migration of asbestos fibers in those covered with old fiber cement sheets, which are manufactured with this dangerous material.
•     When applied on the outside of the roof, the work of the industry does not interfere, an advantage that is very much appreciated by the clients.

ADVANTAGES OF PROJECTED POLYURETHANE

•     Polyurethane foam is the most insulating material that exists. Its coefficient of thermal conductivity is the lowest of all insulating materials (lambda 0.028 for an already aged material). With equal thickness, we obtain greater thermal resistance and therefore more insulation.
•     Polyurethane has great ease and speed of application. A team can apply between 300 and 600 m2 of foam per day.
•     The polyurethane when being pumped from a truck on the outside, does not require lifting to work or occupation of space with bulky materials.
•     Seal possible cracks and air intakes. It waterproofs the wall of external humidities that could penetrate by capillarity of the work.
•     It is not necessary the internal plaster of the back of the wall. (Report 17.257 of 11/10/1999 of the Eduardo Torroja Institute).
•     Polyurethane is considered to be a continuous waterproof coating.
•     The polyurethane foam by itself is sufficiently resistant to water vapor that it does not require a vapor barrier under normal conditions of use.
•     Yes, it will be required in special applications such as in cold rooms. However, it allows the building to breathe.
•     The polyurethane foam, lacking joints to be perfectly adhered to the support on which it projects, does not allow the formation of dampness by condensation between the insulator and the backing in the enclosure wall.
•     The polyurethane foam improves the acoustic insulation of the enclosure with foam thicknesses of 2 to 4 cm. In a reduction in the measured noise step in decibels comparable with other fibrous insulators (Report nº 17,691 of the Eduardo Torroja Institute of 30/07/02001).
•     Polyurethane is preferred by architects and other building professionals, in the most used system for the insulation of walls and roofs. It has become the benchmark for all other insulators.
•     Since January 1, 2004, European polyurethane foams do not use gases that damage the ozone layer.
•     When it is served to work in liquid form, which occupies 50 times less volume than the foam that will obtain these components, it saves a great amount of energy in its transport.
•     It has calculated its "life cycle" for a period of 50 years and is enormously favorable and ecological. (The "life cycle" analyzes and calculates the energy that will be saved in that time compared to the energy consumed in the manufacture and placement of the material).
•     The polyurethane foam can be recycled.
•     The polyurethane foam does not require maintenance or replacement throughout its useful life.
•     The projected polyurethane, in addition, does not contain CFCs or HCFC's, so it does not contribute to the destruction of the Ozone layer, and helps to combat the effects of global warming.
•     A good level of thermal insulation, with a uniform treatment of the singular points guarantees the absence of condensation, and avoids the formation of molds and humidities that can damage the building.

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The physical properties of polyurethane foam

Polyurethane foam is the material we use to make our garage column protectors . It is a very used material due to its special properties. Let's see more carefully what are the physical properties of polyurethane foam .

Physical properties of polyurethane foam

Polyurethane is an extremely versatile elastomer that is used in countless applications throughout the world. There are many properties of polyurethane foam based on its molecular structure.



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High load capacity

The polyurethane foam has a high load capacity both in tension and in compression. The polyurethane can change shape under a heavy load, but will return to its original shape once the load is removed.

Flexibility

Polyurethane foam works very well when used in applications of high bending fatigue. The flexural properties can be isolated allowing a very good capacity of elongation and recovery.

Resistance to abrasion and impact

Due to this property, polyurethane foam is very useful in applications where severe wear occurs, even at low temperatures. A very useful capaxity in garage protection .

Resistance to water, grease and gasoline

The properties of polyurethane foam remain intact (with minimal swelling) if immersed in water / oil or grease. Therefore, polyether compounds last for many years in underwater applications.

Production facilities

Compared to conventional thermoplastic materials, polyurethane has a relatively short manufacturing time, and tool costs are significantly cheaper.

Color range

Different color pigments can be added to the polyurethane during its manufacturing process.

Resistance to mold and mildew

Most polyurethanes based on poly ether are not compatible with the growth of fungi or mold and therefore are very suitable for tropical environments.

Resistance to hostile conditions

Polyurethane is very resistant to extreme temperatures, that is, to harsh environmental conditions. Likewise, many chemicals will not cause material degradation.

Electrical properties

The polyurethane foam has good electrical insulation properties.

These are the most remarkable physical properties of polyurethane foam , which provide some remarkable advantages over conventional materials such as rubber, metal or plastic.

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Benefits of the use of polyurethane in electricity and electronics

•     Polyurethane resin has a series of properties that make it an ideal product for use in electronics and electricity.
•     Encapsulating capacitors and circuits provides protection against corrosion, moisture, chemicals, shock, dissipates heat, etc.
•     With some variations in the formula you can transform a resin, which is an electrical insulator, into a conductor, opening a new range of possibilities.
•     In Formulations we have an R & D department with the necessary resources to manufacture any solution that our clients may need, specific to each requirement in the case of the electrical, electronic, motorization, etc. sector.

Its properties allow multiple applications

The first way in which polyurethane was found useful was as foam. But if the foaming agents are removed, a resin with very surprising properties can be obtained.



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Having no longer a cell structure, which gives it its foam form, loses the property of thermal insulation, but gains other very interesting qualities such as high hardness and resistance to compression, resistance to environmental elements (except for the UV rays), high dielectric strength and heat dissipation capacity. These characteristics make polyurethane resin an ideal product for use in electronics and electricity.
       
Encapsulation of circuits and capacitors

On the motherboards of many computers you can see capacitors and circuits covered with a hard product with a vivid color and a smooth surface. That product is the polyurethane resin that is used to encapsulate them and that protects them from corrosion, humidity, chemicals and shock. It also dissipates heat, prevents discharges and overloads and prevents the circuit layout from being copied, thus preventing its falsification (thus protecting intellectual property).

In addition, with slight variations in the formula you can transform a resin that is an electrical insulator into a conductor, opening a new range of possibilities.

Polyurethane resin is also used to protect the circuitry of lightning rods and prevents them from overloading when lightning strikes.

The epoxy resin in electronics

Another polymer that is used in electronics is epoxy resin. This has as an advantage, compared to the polyurethane resin, which is transparent and if it has protection against yellowing by UV rays it can be used to cover the LED lights, giving them protection and allowing the light to pass without problems.

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 MC Polyurethane insulation

Description of rigid polyurethane foam

So far we have described rigid polyurethane foam as a very good thermal insulator, enumerating its fundamental properties. We will now see chemically what it is and how it is formed.

Basically, the rigid foam is obtained from three chemical components, whose denomination is the following:

•     1) - Polyisocyanate.
•     2) - Polyhydroxylated resin.
•     3) - HCFC 141b, expansion agent whose boiling point is 32ºC.

By mixing the three indicated components, the polyisocyanate reacts chemically with the polyhydroxylated resin generating heat, which produces the evaporation of the blowing agent. As a result, the mixture begins to expand while hardening, eventually reaching the formation of a foamed plastic, closed cells and virtually sealed. Inside the same the agent of expansion in gaseous state is caught, being the main responsible, by its very low thermal conductivity, of the very good insulating effect of this foam.



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In practice, the application procedure is relatively simple, since it requires only a few steps: The hydroxylated resin is premixed with the blowing agent, there being no chemical reaction in this case. At the time when it is desired to produce the foaming, the previous premix is ​​contacted with the polyisocyanate, thus producing the expansion and hardening process detailed above (Figure 1.)

Figure 1: Expansion and hardening process.

Very low heat transfer, fundamental characteristic of rigid polyurethane foams.

As is known, the efficiency of a material as a thermal insulator is measured through its value of thermal conductivity, which we will call K and one of its expression units, among others is:

Figure 2: Efficiency of a material as a thermal insulator.

This value indicates the amount of heat, in kilocalories per hour, that passes through the two sides of a plate of one (1) centimeter of thickness and one square meter of surface for each degree centigrade of temperature difference existing between said two faces (Figure 2). Therefore, the lower the thermal conductivity mentioned, the less amount of heat is transmitted through the material and then, the latter works better as an insulator.

Table 1 shows densities and coefficients K for some of the products usually offered on the market. In the exposed values ​​it can be seen that the lowest thermal conductivity corresponding to rigid polyurethane foam and, in fact, up to now , is the material with better insulating properties that is known.

A point to note, more important: if we look closely at table 1, with the concept of thermal conductivity in mind, we can realize that as the coefficient K decreases, the thickness of material to obtain a desired degree of insulation also decreases . Let's take an example: imagine the roof of an enclosure that we want to isolate for. For this we use rigid polyurethane foam, which has an average K coefficient of 2.0 and the calculated insulation thickness is, for example, 25mm. If we place agglomerated cork instead, we need approximately 80% more thickness, that is, 45 mm. If we used expanded polystyrene, this thickness would be approximately 36 mm, that is, 44% above the value indicated for the rigid polyurethane foam. All of the above is important when considering the cost of an insulation, since for the material in question the thicknesses used are lower and the application procedure is extremely fast, especially if the blow-off method is used. in detail later.

Typical thermal conductivities of insulating materials

Material
l, Kcal.cm/m2.°C. hour
Density, kg / m3
Rigid polyurethane foam
35-60
1,7- 2,3
Expanded polystyrene
15-35
2,8-3,3
Glass wool
32-87
2.8-3.0
Agglomerated cork
90-160

As an additional comment we will say that using smaller thicknesses of insulation can also make the possibilities more flexible
of design of a certain structure.

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APV S.A. The advantages of a thermal insulation efficient with foam of polyurethane

APV has achieved a satisfactory market penetration in the area of housing more than a year after implementing the business unit dedicated to the application of polyurethane foam. The reasons? A thermal insulation of excellent characteristics, combined with a team of experts in its application and the use of first level technology. We talked with Daniel Henríquez Vallejo, Civil Industrial Engineer of the Catholic University and Head of Development of APV, about the characteristics and strengths of this system.



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What is polyurethane foam?
Polyurethane foam is a thermal insulator with excellent characteristics. It consists of two chemical compounds that, when mixed, expand and adhere to the surface, creating thermal insulation. This mixture is made by a special team of Graco brand, the Reactor E-20, ideal for these applications, since it has been developed for that purpose by a globally consolidated brand, using the highest technology.

What are its advantages?
Compared to glass wool or expanded polystyrene, polyurethane foam is able to insulate with thicknesses 40% less. According to the thermal regulation, in the roofs of Santiago a thickness of 8.19 cm of glass wool would be required, while with polyurethane foam only 5 cm would be needed. Glass wool is a good insulator, but over time it deteriorates and loses its insulating capacity. To maintain optimal levels of thermal insulation this product should be replaced in five to ten year terms. Polyurethane foam does not lose its properties over time. Another advantage of this is that it adheres to any surface, which greatly benefits the application in walls and ceilings. In addition, by not having unions, thermal bridges are eliminated, which is where energy is generally lost. It also has good properties as a waterproofing, since it does not allow the passage of moisture and, being completely sealed, it solves problems such as leaks or others. Thus, its advantages can be summarized in duration, adhesion, structural resistance, energy saving and waterproofing.

What is its impact in terms of energy savings?
In practical terms, we have estimated that our product can reduce energy expenditure between 30% and 40% in a house, achieving a rapid return on investment through this energy saving. With the serious energy deficit that our country has, added to the high cost of fuel and electricity, it is necessary to make a contribution and we believe that this product should contribute with its grain of sand. With respect to the ecological requirements, it complies with the regulations and requirements to protect the Ozone layer.

Another feature is that this material has a fire retardant retardant that makes it hardly combustible. The future development of this product goes hand in hand with new constructions. It is necessary to encourage real estate companies to use superior methods of thermal insulation and thus support energy saving policies. It is proven that the so-called "ecological" constructions will gain more and more importance and people are willing to pay more for them.

How do you apply this product?
APV has an expert team in the application of this product and use of the equipment, and sees in this business a great development opportunity in the future. Polyurethane foam is a thermal insulator with excellent characteristics that we believe will be very important for future real estate developments and for anyone who wants to improve thermal insulation in their home and save energy in the process. For any question, you can contact us by sending an email to aplicaciones@apv.cl and we will gladly answer your requirements.

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Projected polyurethane insulation. Price square meter (m2)

Projected polyurethane insulation has excellent properties: it is an economical, popular, versatile material widely used in homes (houses and flats), industrial buildings and sectors such as construction for the benefits it provides.

Therefore, it is not necessary to think only about the cost or price of the installation, you also have to evaluate its benefits and the money that you indirectly save in energy efficiency throughout its useful life.

Important fact is that, under normal conditions, when it is used as a thermal or acoustic insulation product (construction sector) it has an average longevity of 50 years (depending on the use that is given, of course).



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How much does the projected polyurethane cost? Price m2

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These are some examples of projected polyurethane m2 prices, only the product, without counting labor, machinery and other costs.

•     Foam projected "in situ", density 35 kg / m³, average thickness 30 mm, Euroclass E reaction to fire: € 2.98
•     Density 40 kg / m³, average thickness 50 mm, Euroclass E: € 5.10
•     Density 40 kg / m³, average thickness 80 mm, Euroclass E: € 6.52

We will mention the aspects that you have to take into account to calculate the projected polyurethane foam price, all of them increase the final cost per square meter (m2).

•     Thickness : influences the thermal insulation and is regulated by the CTE according to the climatic zone. In provinces where it is colder they require greater thickness as we can see in the image.
•     Density : in spite of the fact that polyurethane is a solution that generates a waterproof foam membrane in the thermal bridge, it allows transpiration to water vapor.

    The density of the material facilitates that the permeability to the steam is greater or smaller, so according to the risk of condensation of the building you will apply more or less. The higher the density, the higher the cost.

•     Behavior before fire : taking into account the use of the construction and its final application (plastered cement, plastering plaster, metal cover, etc.) you have to project polyurethane of one kind or another, classified in Euroclasses.
•     Surface condition : the thermal insulation of polyurethane requires that the receiving surface is prepared, clean and without moisture, otherwise it will have to be treated and the price will increase.
•     Indirect costs : here comes everything that has nothing to do with the material itself, ie, labor, difficulty of execution and necessary means (scaffolding, lifting cranes, etc).

We recommend you read more about POLYURETHANE

•     Polyurethane foam
•     Polyurethane paint

Steps for the projected polyurethane

If you do not know how to project polyurethane by yourself, the first thing you should know is that this job requires in most cases a qualified professional and company with an applicator stamp, we do not recommend applying the insulation yourself.


    The first thing is to have an individual protection equipment for access to work: helmet, diver and very important, mask for organic gases.

•     A polyurethane projecting machine in which you control the power, the flow, the pressure, and that you can plug into an external power outlet.
•     Review the manufacturer's product quality sheet.
•     Protect all elements susceptible to being stained by the insulation product.
•     Check that the surface on which it is going to be applied is in good condition: consistent, dry, clean and free of obstacles.
•     Otherwise, it should be reviewed for possible breakage, cracks, holes, lack of mortar between pieces, etc.
•     To control the conditions of temperature of the substrate (superior to 5 ºC) and humidity of the atmosphere (inferior to 80%) for an optimum application.
•     The projected polyurethane is carried out with a previous primer on which it will be applied in successive layers of about two centimeters of maximum thickness until achieving the desired thickness.

    On old supports, it is advisable to carry out adhesion tests.

•     The application performance of polyurethane foam is about 100 square meters per hour.
•     The applicator will collect thickness measurements of the entire surface with a graduated punch no more than 2 millimeters thick.
•     The work carried out according to the current regulations will be measured.
•     In case the projected polyurethane is exposed to the weather (6 months - 1 year), it should be protected from direct solar radiation to prevent its degradation.

Applications of projected polyurethane insulation

Let's see at a quick glance the most common constructive solutions where polyurethane sprayed insulation is applied.

•         Insulate interior facade: when you do not want to touch the exterior facade because it is made of stone or brick, you can do the rehabilitation from within.
•         Isolate the facade exterior (SATE system or ventilated façade): this is the best method since you effectively protect all the sites where the cold of the street comes in (fissures, cracks) and waterproof the façade.
•         In old buildings whose facade is formed by two brick partitions with an air chamber in the middle, empty, this can be filled with projected polyurethane.

projected polyurethane facades

•     Terrace floors: just apply the polyurethane insulation layer and protect it with the desired finish. The cheapest is to paint, but you can put on tile or other materials.
•     Before the projection of the polyurethane check that the surface (tape, asphalt cloth, etc) is in good condition, otherwise remove it to avoid problems.
•     Waterproofing flat and inclined roofs: the roofs can be insulated, as well as the facades, both inside and outside under roof tiles.

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Expanded Polyurethane, its advantages guarantee it.

Its use allows thermal insulation and waterproofing in a single operation.

• - A method of external insulation without interfering with the use of the premises.
• - Lightness
• - Great adhesion on the materials normally used in construction and industry.
• - Low absorption of moisture.
• - Easy application.

Among the main characteristics of expanded polyurethane we can highlight:

•     Lightweight
•     Rigid
•     Stable
•     Resistant to chemical products
•     Optimal for temperature insulation between - 200º c and 110ºc
•     Easy to cut and mold
•     It does not constitute food for worms and insects
•     Offers resistance to fungi
•     Non-aggressive to other materials
•     Stable Volume

The production of polyurethane foam takes place "in-situ", in the same place of installation. To do this, mobile machines are used, which dose and mix the components. There are two types of processes: projection and casting.



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- Projection process: It consists in spraying, by means of the aforementioned machine, the mixture of the 2 highly reactive components on the surface to be isolated. Here it expands and hardens quickly. The application is made in successive layers, until reaching the final desired insulation thickness.

- Casting process: in this case, the liquid mixture of the 2 components is filtered in the cavity to be isolated, with a reactivity adjusted to the process. In a short time, the mixture expands (filling the cavity) and hardens.

TECHNICAL INFORMATION

Cell structure: The rigid polyurethane foam has a predominantly closed cell structure. The percentage of closed cells is normally above 90%.

Density: The density of rigid polyurethane foam for thermal insulation is, depending on the application, between 30 and 100 kg / m3, and higher densities can be made for special cases.

Thermal conductivity: The high thermal insulation capacity of rigid polyurethane foam is not achieved with any other known insulating material. This special feature is due to the very low thermal conductivity of the foaming gas occluded inside the cells.

Water absorption : The absorption of water by the rigid polyurethane foam occurs as a function of environmental conditions and can take place by wetting or diffusion and condensation of the steam. It is influenced fundamentally by density and dimensions. In any case, the humidity content, in practice, does not exceed 5% in volume.

Resistance to the transmission of water vapor: In applications with high vapor / temperature gradients (for example, refrigeration applications, ...) it will be necessary to place a vapor barrier on the hot side of the insulation to avoid condensation. It would also be necessary to install a vapor barrier in some cases of insulation and waterproofing of roofs, depending on the climatic zone, or if the finishing or protection of the foam is made with a product that is resistant to the passage of water vapor.

Stability / Resistance: The rigid polyurethane foam is resistant to the materials commonly used in construction. In addition, the rigid polyurethane foam is: Resistant, to a large extent, to the solvents normally used in adhesives, paints, bituminous pastes, preservatives for wood and sealants. Resistant to aging, against the action of roots and inert biochemically, for example, against molds. Stable against fuels, mineral oil and diluted acids and alkalis. Resistant against the action of the exhaust gases or the more agressive industrial atmosphere. Imputrescible, stable to the detritus, odorless and physiologically does not present disadvantages. It is chemically neutral.

Fire behavior: Rigid polyurethane foam, like all plastics, is a combustible material. However, there are polyurethane foams classified from M1 to M4, according to UNE 23727, which must be applied according to the risk to which they will be exposed.

Thermal behavior: The thermal expansion of rigid polyurethane foam due to temperature is a function of density and substrate fixation. Each material has a certain variation in its dimensions when the temperature varies. In addition, in the case of rigid polyurethane foam, there is a gas occluded in its cells that causes a pressure drop, with cold, and an overpressure, with heat. Therefore, by shrinkage a contraction occurs and by heating a dilation of the cellular structure.

Electrical properties: The rigid polyurethane foam has very low dielectric and reflection losses, as well as a very low dielectric constant. For this reason, rigid polyurethane foam is suitable for applications such as antenna coatings and radar domes.

Physical Characteristics: a Applied density (ISO R-845): from 35 to 60 kg / m3 depending on whether it is impassable or not. b) Closed cap contents (ASTM D 2856): min. 95%. c) Thermal conductivity (ASTM C 177): 0.018 to 0.020 watt / m * C. d) Resistance to compression in the direction of foam growth (ISO R-844): 2.5 to 5.5 kg / cm2. e) Absorption of water (ISO 2896): max: 2% (VOL.%). f) dimensional stability (UNI CT 242/74): max. one%. g) Behavior in the presence of fire (ASTM 1692): meets standard.

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Polyurethane, the best solution for thermal insulation

• What types of polyurethane are there?
• What is the use of polyurethane?
• How does polyurethane act as a thermal insulator?

Polyurethanes are highly versatile polymers that can be used in the manufacture of foams and paints. They are the result of the reaction of a polyol with an isocyanate using catalysts and special additives.



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Thus, we find them in different categories.
Polyurethane categories

Rigid:

• * Low densities: Density range 5 - 50 kg / m³.
• * Half densities: density range 55 - 90 kg / m³.
• * High densities: density range of 100 kg / m³ and up.

Semi- rigid: Rigid materials with a certain degree of flexibility, their densities are 600 kg / m³ and up.

Microcellular : Flexible foams with densities of 250 kg / m³ and up.

Molded flexible foams : High resilience foams molded at room temperature with densities of 30 to 80 Kg / m³.

Full-skin foams: Flexible and semi-flexible foams with excellent skin formation when copying the surface of the mold.

Adhesives : Bicomponent systems free of solvent with curing at room temperature.

Elastomers : Liquid two-component polyurethane rubber cured at room temperature.

Demoulding : These are materials that are used as false substrates, for the molding of different types of polyurethane.

Energy saving worldwide is an important issue, more and more countries including Mexico are concerned and interested in taking concrete actions that help to make this savings more efficient. Eco-technologies in green housing are one of those actions that are being implemented and within them is thermal insulation.
Applications of polyurethane as a thermal insulator

As a thermal insulator, polyurethane has different applications:

•     Floor insulation
•     Internal and external insulation of facades
•     Roof insulation
•     Coating of tanks and pipes

In thermal insulation, applied materials are used in ceilings or slabs and walls, one of the most widely used is the closed cell polyurethane foam (EAPcc).
Polyurethane suppliers for thermal insulation

Next we present to Eiffel Products, polyurethane supplier:

Productos Eiffel is a 100% Mexican company that is a pioneer in the development of polyurethane systems. Within its wide range of products we find the Closed Cell Polyurethane Spray Foam (EAPcc).

Closed-cell Polyurethane Spray Foam (EAPcc)

The closed cell Polyurethane Spray Foam (EAPcc) has an excellent Thermal Resistance (Factor R = 1.20 m² ° C / W) which is higher against insulating materials (Table of Factor R to 1 inch (0.02536 m) of thickness of Insulating materials).

The EAPcc provides comfort inside the house, keeping the cold outdoors during the winter and leaving the heat outside in the summer, also reduces the capacity of the air conditioning thus achieving energy savings.

Thermal Efficiency Table
Thickness vs. Insulating materials

• Material    K factor (*)
• Polyurethane    0.021
• Polystyrene Ext.    0.031
• Polystyrene Exp.    0.036
• Fiberglass    0.036
• Mineral wool    0.041
• Glass foam    0.054
• Expanded perlite    0.054

K Factor: Thermal Conductivity W / m ° C


The lower the value, the better insulator

Example of calculation of R for 1 "(0.02536 mts.) Of polyurethane:

Metric system 1 "x 0.02536 = 0.02536 m

Factor to convert in to m.

R = 0.02536 m / 0.021 = 1.20 m² ° C / W

Table of Factor R to 1 inch (0.02536 m) thickness of insulating materials

• Material    Factor K    Factor R
• Polyurethane    0.021    1.20 m² ° C / W
• Polystyrene Ext.    0.031    0.82 m² ° C / W
• Polystyrene Exp.    0.036    0.70 m² ° C / W
• Fiberglass    0.036    0.70 m² ° C / W
• Mineral wool    0.041    0.62 m² ° C / W
• Glass foam    0.054    0.47 m² ° C / W
• Expanded perlite    0.054    0.47 m² ° C / W

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What are the thermal properties of polyurethane foam?

Applications of polyurethane foam

Polyurethane foam has multiple uses in today's world, some of them are:

•     In mattresses as a main padding or as part of the padding;
•     In furniture, in sofas and chairs seats, stuffed with cushions, etc.
•     In construction, as a thermal insulator or as a filler;
•     In the automotive industry as the main element of defenses, seats, etc.
•     In many items such as toys, clothing, sponges, shoes, pillows, cushions, packaging and in general all types of padding or fillers.
•     In general, flexible polyurethane has applications such as cushioning in furniture, mattresses, under carpets and car interiors. It also offers good performance as a shock absorber with packaging and automotive applications.

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Rigid polyurethane foam

The rigid spray polyurethane foam is the most effective way to simultaneously isolate and seal virtually any type of substrate, since it produces a monolithic layer without joints or thermal bridges, adhering by itself in a hermetic way. It is applied on any type of surface that is clean and dry.

The rigid foam has several applications such as:

•     Insulation and waterproofing of ceilings, slabs, dividing and acoustic walls.
•     Refrigerators and cellars
•     Structural reinforcement, panels
•     Insulation of hot water pipes, heating ducts.
•     Bodywork of trucks and minibuses
•     Bases of roofing surfaces as anti-noise and waterproofing
•     The polyurethane foam has excellent resistance to water, salt water, oils, very diluted acids and alkaline solutions. It is not affected by fungi, bacteria and odors and eliminates excessive noise.

The thermal properties of polyurethane foam

Polyurethane foam is a resource increasingly used, not only for sealing doors, windows and sanitation or repair of walls to insulate from the cold, heat and noise pollution homes, but also as a decorative element.

Some of the characteristics of polyurethane foams that have made it an excellent insulating material are its good thermal properties, since it offers a great resistance to extreme temperatures, maintaining all its technical properties in a spectrum that goes from 50ºC below zero or at 110ºC.

The plates or panels that are made are easily adjustable to any need, since they can be cut, perforated, painted, polished and glued with precision. Other advantages of polyurethane foams are their reduced weight and their absence of dripping in case of fire.

When using it, we must know that these foams can increase from two to five times their volume since they are applied until they are completely hardened. When applying the foam, it adheres to everything that comes in contact with it, so it is advisable to protect those areas that are close with special adhesive bands.

In the market you can find sprays of polyurethane foam of two types, which are constituted exclusively by polyurethane or compounds that have another element (besides the polyurethane) with which they make the reaction.

The main difference is that single-component foams harden as a result of contact with air humidity, while composite foams react when the two components are mixed and harden more quickly than the first.

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Insulations with polyurethane foam in Huelva

Polyurethane foam
At Termyson we know our trade very well. That is why we carry out our insulation works with polyurethane foam , since it is the best thermal insulator and offers a number of advantages and facilities in its application and durability.



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Advantages of polyurethane

•     Solves leak problems
•     It is not flammable.
•     It can be painted.
•     Seal any area safely.
•     Product of very long duration.
•     It does not allow condensation to occur.
•     Extends the useful life of the treated surfaces.
•     Controls dilatations in concrete structures.
•     It acts as a vibration damper.
•     Energy saving used in cooling or heating.

Forms of application of polyurethane

•     In situ by projection or projected polyurethane : it is obtained by simultaneous pulverization of the two components on a surface, partitions, naves, roofs, terraces, farms, etc.
•     In situ by casting, or injected polyurethane : in which the two components are mixed and introduced through a hole previously made in the partition, for expansion. Isolating in this way all the space between the two partitions of the house. It is the method used in houses already built that do not have insulation.

Properties of polyurethane foam
The rigid polyurethane foam is a duroplastic synthetic material, highly spatially crosslinked and non-fusible. In the usual densities, for thermal insulation, the foam contains only a small part of the volume of solid matter (with a density of 35 kg / m³ , only about 3% of the volume is solid matter).

Next, we detail the properties of polyurethane foam.


Cell structure

The rigid polyurethane foam obtained by projection has a predominantly closed cell structure. The percentage of closed cells is above 97%.

Density

The density of the rigid polyurethane foam by projection for thermal insulation is included and standardized in Standards UNE 92120-1 and 92120-2 according to the application, between 30 and 55 kg / m ³ . Although, for special applications, higher densities (100, 200, etc.) or lower densities (acoustic foams: 10, 12, 15, etc.) can be used.

Thermal conductivity

The high insulating capacity of rigid polyurethane foam by projection is not achieved in the construction with any other known insulating material. This special feature is due to the very low thermal conductivity of the foaming gas occluded inside the closed cells.
In this way, the rigid polyurethane foam produced "in situ" can reach a thermal conductivity value of 0.022 W / m • K. Because the cells do not completely prevent the diffusion of gases through their walls, this conductivity value increases slightly with time until it finally stabilizes. In practice, the thermal conductivity value of the foam is considered to be that obtained after 9 months of aging (UNE 92120-1), 0.028 W / m • K.
By applying coatings that prevent the diffusion of gases (vapor barrier) it is possible to achieve that the thermal conductivity of the foam does not show appreciable alterations with time, maintaining values ​​of 0.023 W / m • K.

Water absorption

The absorption of water by the rigid polyurethane foam by projection occurs as a function of environmental conditions and may take place by wetting or diffusion and condensation of the steam. It is influenced mainly by density.
The absorption of water by short-term partial immersion of the rigid polyurethane foam according to the test is less than 0.13 kg / m². It must be borne in mind that the greater amount of water considered is due to the one remaining in the cells that are broken when making the cut to make the test piece.
By vapor diffusion and subsequent condensation, the isolations can absorb water depending on their situation and the temperature and humidity to which they are subjected. In practice, it is necessary to avoid reaching unwanted limits of humidity by diffusion of water vapor modifying the constructive solution. It can be done by increasing the density of the foam or in very extreme cases by placing a vapor barrier on the surface adjacent to the interior of the room (hot side of the insulation).

Resistance to the transmission of water vapor

The values ​​that characterize the resistance to water vapor are the dimensionless mu, or, the resistivity to the diffusion of water vapor.
For rigid polyurethane foam by projection for thermal insulation, in densities 30-60 kg / m ³ , the resistance to the transmission of water vapor ranges between 330-825 MN • s / g • m, being the dimensionless factor, of resistance to the transmission of water vapor from 60 to 150. These values ​​guarantee - in the majority of thermal insulation solutions by rigid polyurethane foam and depending on the density that we adopt - the absence of interstitial condensation, allowing its time the perspiration of the enclosures. Understanding that the transpiration of the enclosures in the building is the most beneficial effect both to avoid pathologies of all kinds, hygiene, health, comfort, etc.
In applications with high levels of steam and / or temperature (for example, cold rooms) it will be necessary to place a vapor barrier on the hot side of the insulation to avoid condensation. In residential buildings the most critical values ​​are usually manifested in flat roofs because waterproofing prevents transpiration.

Stability / Resistance

The rigid polyurethane foam obtained by projection is resistant to the materials commonly used in construction.

In addition, rigid polyurethane foam by projection is:

• - Resistant, to a great extent, to the solvents normally used in adhesives, paints, bituminous pastes, preservatives for wood and sealants.
• - Resistant to aging, against the action of roots and inert. Biochemically, for example, against molds.
• - Stable against fuels, mineral oil and diluted acids and alkalis.
• - Resistant against the action of the exhaust gases or the more aggressive industrial atmosphere.
• - Imputrescible, stable before detritus. Inodora and physiologically does not present disadvantages.
• - It's chemically neutral. Fire behavior: the rigid polyurethane foam has an M3 fire classification. Thermal expansion: the thermal expansion of rigid polyurethane foam by projection due to temperature is a function of density and substrate fixation.

Closed cells and open cells
Each material has a certain variation in its dimensions when the temperature varies. In addition, in the case of rigid polyurethane foam, there is a gas enclosed in its cells that causes a drop in pressure, with cold, and an overpressure, with heat. Therefore, by shrinkage a contraction occurs and by heating a dilation of the cellular structure.

With the usual density, 35 kg / m³, the coefficients of contraction, or expansion of the rigid polyurethane foam, are between 5 and 8 x 10-5 K-1.

The open cell foams, by not using gases of low thermal conductivity, have a cost of raw material approximately 20% lower. In addition, as the applied density of the product is lower, the required amount of material per m² is reduced between 15% and 30%. However, the implementation in order to obtain the minimum benefits required by the project and the current legislation implies additional costs. The application of an open cell polyurethane system, in direct replacement of a closed cell one, without the necessary corrections (greater thickness, mortar plastering, vapor barrier, etc.) can cause multiple problems:

•     Breach of project and / or legislation.
•     Poor insulation and higher energy consumption.
•     Absorption of water in the insulation and deterioration of the insulating properties.
•     Appearance of humidity and mold (unhygienic).
•     Water filtrations. Both the manufacturer and the installer have the obligation to adequately inform their client of the type of product and its suitability for the different constructive solutions.