BASF-Caliber Recertification Training · 150 years Building Codes and Standards The National...

150 years

BASF Canada – WALLTITE® and ENERTITE® 1-2-1MHQAP – Recertification Examination Training

Raising Performance To New Heights®

150 years

Introduction

Standards for spray polyurethane foam insulation are referenced in National Building Code of Canada (NBC) 2010 in Table 5.10.1.1, Sentence 5.3.1.3.(3), 9.25.2.2.1(1)(g) and 9.25.2.5.(1)

These state that the supplier must provide a material that meets CAN/ULC S705.1 and only sell this material to certified installers

Certified installers must follow the CAN/ULC S705.2 application standard which includes following application guidelines, job site testing, proper filing of daily work records (DWR’S), and proper ventilation guidelines

Certification must be verified every 5 years

Complying with the NBC is a legal requirement for all contractors, installers and all suppliers of 2 lb foam and ½ lb foam

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Building Codes and Standards

The National Building Code is a set of rules that specify the minimum acceptable level of safety for constructed objects, such as buildings and non-building structures

The main purpose of building codes are to protect public health, safety and general welfare, as they relate to the construction and occupancy of buildings and structures

The building code becomes law of a particular jurisdiction when formally enacted by the appropriate authority

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It is important to recognize that the National Building Codes will be the minimum requirement and the provincial, municipal, and even county codes, will be higher than the minimum requirement

That being said, it will never be less

When verifying a code, always check closest to the job location

Building inspectors from different regions interpret the code differently

– Verify application with owner and inspector before starting the job

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Canadian Construction Material Centre (CCMC)

Government organization that provides consulting on the building code and a listing service for construction products

Provides approvals to industry standards for spray foam products in Canada

Certification Organization (CO)

Morrison Hershfield Quality Assurance Program (MHQAP)

– Accredited to ISO 17024 to run a certification program for certified installers

– Ensure compliance of BASF SQAP to ULC S718-13 “Standard for Site Quality Assurance Program for Spray Polyurethane Foam”

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Mandatory MHQAP Inspections for Insulation Warranty

Mandatory MHQAP Inspections for Air Barrier System

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Square Feet of Wall Number of Inspections35 000-70 000 170 001-105 000 2105 001-140 000 3140 000 > 4

Square Feet of Wall Number of Inspections0-25 000 125 001-50 000 250 001-75 000 375 001 4

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Exposed Foam

WALLTITE is not to be left exposed to ultra violet rays for more than six months as surface degradation results

ENERTITE 1-2-1 is only approved for interior applications due to possibility of moisture uptake from rain

When used on a building, all polyurethane foam must be covered with a code compliant thermal barrier

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Protection of Foamed Plastics, Approved Thermal Barriers as per NBC

Unless concealed in a floor, ceiling, attic or crawl spaces, all foamed plastics used in residential buildings must be protected by:– 9.29.4 – Plastering

– 9.29.5 – Gypsum Board Finish (Taped Joints)

– 9.29.6 – Plywood Finish

– 9.29.7 – Hardboard Finish

– 9.29.8 – Insulating Fibreboard Finish

– 9.29.9 – Particleboard, OSB or Waferboard Finish

– 3.1.5.12. (2)(e) Thermal barrier that meets class B tested to CAN4-S124-M “Standard Method of Test for the Evaluation of Protective Coverings for Foamed Plastic”

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Crawl space is defined as:

Height is less than 1.8 m (5’11”)

Is not used as a living space

Is not used as a plenum, or

Is not used for the passage of flue pipes

Long Term Thermal Resistance (LTTR)

Only test method approved to determine design R-value for building code purposes

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Responsibilities of the Certified Installer

Applying the material according to the application standard (CAN/ULC-S705.2), the manufacturer’s and the accredited contractor’s instructions

Confirm that the material meets the CAN/ULC-S705.1 by inspection of labels or marking provided by the supplier

Responsible for all health and safety aspects associated with the application of spray foam on the job site

Conduct visual inspections of the installation on an ongoing basis while installing the material and at the end of the project or each day on larger projects

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Responsibilities of the Certified Installer

Responsible for accurately filling out the DWR’s and completing all daily testing requirements, such as density, adhesion, cohesion and environmental measurements

Accurately complete and attach the Job Site Label on a surface that will not be covered by other material

Only supervise two apprentices at a time

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Responsibilities of the Apprentice Installer

When applying the material, the apprentice must be under the direct supervision of the certified installer

– The certified installer is responsible for the application

Must abide by all requirements of the standard, the manufacturer’s instructions and the certification organization

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Installer Ethics

Appearance

Dispose of ripped and worn out coveralls

Reasonably groomed hair and clean shaven

Clean and organized trucks

You never get a second chance to make a first impression

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Installer Ethics

Work habits and attitude:

Be professional

Avoid showing a negative attitude

Avoid complaints about your company, employer, etc.

Avoid speaking negatively about processing problems you are or have been experiencing

Refrain from political or religious subjects with or around the customer

Avoid telling inappropriate jokes or stories

Avoid swearing, etc.

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Installer Ethics

Site Cleanliness

Clean up

All sources of ignition should be avoided at this time such as;

– Welding torches

– Heaters

– Open flame products

Remove from the site any discarded or broken tools or supports

Remove all isolation barriers or vent blocks, caution tape that is not required, door and window coverings

Discarded rolls of tape

The site should be as good as or better then when you started15Rev-June 2017

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Chemistry

What Is Polyurethane Foam?

A chemical reaction between:

Isocyanate and Resin

No physical by-products

Exothermic reaction

Causes increased internal heat

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Chemistry

Isocyanate

A Side

The most important function of this component is to react with the resin blend

The isocyanate used primarily for spray foams is polymeric MDI

Reacts with moisture to produce carbon dioxide

Only use Elastospray 8000A isocyanate with WALLTITE and ENERTITE 1-2-1

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Chemistry

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Chemistry

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Chemistry

Polyols

Give foam physical properties

Catalyst

Affects speed of reaction and rate of cure

Surfactant

Gives cell structure and surface characteristics

Flame retardant

Affects fire properties of cured foam

Blowing agent

Affects the density and R-value20Rev-June 2017

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Chemistry

Mixing Ratio

Typically 1:1 by volume for spray foam

For every stroke on the proportioner, an equal volume of resin and isocyanate is dispensed to the gun

Spray proportioners are fixed ratio

Off ratio foam affects:

Density, mechanical properties, friability, dimensional stability, flammability, reaction profile

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Health and Safety

Contractors, installers, apprentices, and helpers all must be;

WHMIS trained

Familiar with and understand the Material Safety Data Sheets (MSDS)

Know where the MSDS’s are stored on the truck

Understand the MSDS for every chemical stored on the truck

– Resin

– Iso

– Gun cleaner

– Primer, etc

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Health and Safety

Isocyanate, Resin Routes of Exposure:

Skin or eye contact, inhalation, ingestion

Symptoms of skin or eye contact:

– Redness, irritation, skin sensitization, allergic reaction

Symptoms of inhalation exposure:

– Irritation of eyes, nose, throat, difficulty breathing, tightness in chest, coughing

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Health and Safety

First Aid for Isocyanate or Resin Exposure

Skin Contact

Wash or shower with soap and water

Remove contaminated clothing (decontaminate and launder before reuse)

Get medical attention if irritation develops

Eye Contact

Immediately rinse with running water for 15 minutes

Get medical attention

Contact lenses should not be worn24Rev-June 2017

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Health and Safety


Ingestion

Do not induce vomiting

If person is alert, they should drink large amounts of water


Inhalation

Move to fresh air, do not allow person to re-enter work area

Aid in breathing if necessary


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Health and Safety


Trucks should be equipped with

Eye wash bottles/stations

(Rated for 15 minutes)

Emergency contact numbers

Phone numbers and addresses for local hospitals

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Health and Safety

Isocyanate, Resin and Safety

No person should be within 10 meters (33 feet) of the installer without a fresh air respirator, overalls and gloves

Those with pre-existing lung conditions must avoid all exposure to isocyanates

For skin contact with foam, use hand lotion or mayonnaise to soften and loosen the foam

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Health and Safety

PPE

Within the spray area

Full Face Fresh Air Supplied Respirator

Safety Boots

Protective Overalls

Nitrile Gloves

Working with the raw chemical

Nitrile Gloves

Chemical Resistant Suits

Safety Glasses or Goggles

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Health and Safety

PPE to Prevent Inhalation Exposure

A fresh air breathing apparatus must be used when exposed to isocyanate vapors or mists.

Whenever spraying foam, anyone within 10 m (33 ft) must have a full face fresh air breathing apparatus

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Health and Safety

PPE to Prevent Inhalation Exposure

Requirements for Air-supplied respirators

Supply air equal to atmospheric air:

19.5 % to 23.5% oxygen

Maximum 1000 ppm CO2

Maximum 5 ppm CO

Special fittings for air-line respirators needed to ensure that air-line cannot be plugged into any other gas supply

Ensure masks are fit tested and sealed according to manufacturer’s directions

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Health and Safety

PPE For Hands

Recommend Nitrile gloves (8 hours of protection to isocyanate)

Other suitable gloves

– Butyl rubber

– Neoprene

If using cotton work gloves, nitrile should be worn underneath

Light duty nitrile gloves should not be used when working with solvents.

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Health and Safety

PPE For Hands

Isocyanate and Cleaning Solvents

Solvents can increase amount of isocyanate that penetrates the skin

– Research found that gloves that protect for isocyanate exposure for 8 hours have solvent breakthrough in under 30 minutes

– Replace gloves after exposure to solvent

Never put hands into solvent to retrieve spray parts

– Use pliers or cleaning basket to retrieve parts

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Health and Safety

PPE For Skin

During spray application

Disposable coveralls with attached hood

All skin should be covered

Tape coveralls to gloves and boots as required

Dispose of ripped our worn out coveralls

Be aware of heat exhaustion in warm environments

Disposable coveralls typically provide 15 minutes of protection against liquid isocyanate

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Health and Safety

PPE For Skin

During liquid handling (spill clean-up)

8 hour resistant suit

– Eg. Tyvek/Saranex 22-Film

Chemically resistant gloves and boots

Dispose of overalls after clean-up

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Health and Safety

Fire Protection

Fire Extinguishers:

Properly charged fire extinguishers must be available on all trucks and job-sites

The extinguishers must meet the requirements of CAN/ULC-S508

The net contents of the extinguishers must not be less than 4.5 kg

Extinguishers should be rated for Class A, B, or C fires

Ensure extinguishers are inspected regularly and maintained as required

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Health and Safety

Fire Protection

Because spray foam is combustible;

Don’t smoke on jobsite

Don’t apply too thick

Keep fire extinguisher nearby

Spray foam combustion can produce toxic by-products

Carbon monoxide

Nitrogen oxides

Cyanide compounds

Isocyanates36Rev-June 2017

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Health and Safety

Fire Protection

Smoking

Cigarettes, lighted pipes and cigars must not be allowed in chemical storage or in the application area

Not to be used inside electrical outlets or junction boxes

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Health and Safety

Fire Protection

Heat Emitting Devices

As per NBC, foam plastics may not be closer then 75 mm (3”) to a heat emitting device

Pot lights, exhaust vents, furnace ducts, B-vents

Any substrate over 80°C

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Health and Safety

Fire Protection

Hot Work (welding, soldering, cutting or grinding)

If welding or cutting is required where it may contact the foam, special precautions must be taken

The foam should be stripped away from the area or the insulation should be protected from heat or sparks by a proper thermal barrier

A separate person with a proper fire extinguisher should be present to guard against ignition

Use a fire watch where appropriate

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Spill Response

Spill Kit should contain

Absorbent material

– Clay, kitty litter, sand

Rubber mat to cover catch basins

Absorbent socks

Empty containers to hold absorbent material

Shovels, brooms, squeegees to pick up absorbent material

Decontamination solution

Appropriate PPE

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Spill Response

Decontamination Solution for Isocyanate

Approximately

90% Water

1-5% Ammonia

1-5% Detergent

Have in a container or squirt bottle to decontaminate area after spill cleanup

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Spill Response

Minor Spills (<20 L of chemical and spread over a <50 sq ft area)

From normal procedures such as drum changeovers or gun maintenance

Wipe up with rags

Spray area with decontamination solution for isocyanate

– Spray rags and any waste with decontamination solution

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Spill Response

Major Spills (> 20 L of chemical and spread over a >50 sq ft area)

Could be from drum spills or broken equipment lines

Clear area of unprotected personnel

– Cleanup personnel must wear fresh air breathing apparatus for spills on or near hot surfaces

If water has been contaminated, contact local authorities to police waterways for 36 hours

– Approval must be obtained to continue

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Spill Response

Major Spills

Hard surface or controlled pool

– Protect personnel with fresh air breathing apparatus as required, protective clothing, rubber boots, gloves, etc.

– Cover the spill with absorbent materials such as kitty litter, dry sand, sweeping compounds, diatomaceous earth or cement powder

– Do not use sawdust

– Place the material in open-top drums and place in an isolated area out of doors.

– Fill drums with water and leave for at least 48 hours

– Wash spill area with decontamination solution44Rev-June 2017

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Spill Response

Major Spills

Porous areas (railway beds or gravel roads)

– Flood the spill with water

– Spray area with decontamination solution

– Keep area isolated for a least 48 hours

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Spill Response

Major Spills

Recommend having emergency response procedure for large spills

Emergency contact information available on MSDS sheets

24 Hour Emergency Response Information

CANUTEC (reverse charges)

– 613-996-6666

– Call this number first with the chemical identity

BASF Hotline

– 1-800-454-COPE (2673)

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Storage and Handling

Isocyanate and Resin Storage Temperatures

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Product Storage TemperatureWALLTITE v.2 and v.3 15-25°C 60-77°FENERTITE 1-2-1 15-25°C 60-77°FELASTOSPRAY 8000A Iso 15-25°C 60-77°F

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Isocyanate and Resin Shelf Life

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Product Shelf LifeWALLTITE v.2 and v.3 6 MonthsENERTITE 1-2-1 6 MonthsELASTOSPRAY 8000A Iso 12 Months

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Drum Decontamination

Iso Drums

Drain remaining iso into a pail at the shop, then pour over residual into drums to be used on the next job

Empty isocyanate drums can not be re-used and can only be disposed of when they are completely decontaminated

During the decontamination process:

– Wear appropriate PPE, gloves

– Gloves, safety glasses and boots

– Ensure adequate ventilation

– Ensure drums are stored such that they will not be contaminated with water

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Drum Decontamination

Decontamination procedure:

Spray or pour 5 to 25 liters of solution into the drum making sure the walls are well rinsed

Use spray head or roll drums

Leave the drum unsealed for 24 hours to allow complete reaction, do not seal the drum as there will be excessive pressure development of carbon dioxide

Drain and filter liquid decontaminate into a storage vessel for re-use or disposal

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Environmental Conditions and Material Selection

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Extreme storage temperatures at or above 25ºC may cause the blowing agent in the resin to boil

This may cause cavitation in the dispensing equipment

Adequate ventilation or air conditioning may be required

Ambient temperatures at or below 15ºC may cause the material in the drums to get too thick to pump

Heat may be required during cold times of the year

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Ambient and Substrate Temperature:

Important to know ambient temperature, substrate temperature and relative humidity to determine if application is close to dew point on the substrate

Substrates in the sun will be warmer then substrates in the shade, equipment adjustment may be necessary when moving to different areas of the building

Spray from top of the building and work down

– Heat generation from spray application can cause condensation issues on cold surfaces

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Ambient and Substrate Temperature:

When there is a difference of more than 17°C between the ambient temperature and the substrate temperature, the chemical manufacturer should be consulted

Heated interior of a metal building in the winter could have moisture issues

If spraying on the exterior, need to be aware of any previous precipitation and any forecasted precipitation

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Wind

WALLTITE should not be sprayed when the wind speed exceeds 15 km/h, unless wind screens are used

Without wind screens the wind increases effect of over spray which results in poor yield

High winds may also contribute to the over spray making contact with other items or materials such as cars, windows, doors, etc.

Exercise extreme caution if using windscreens as they reduce the risk of overspray, they do not eliminate it as a possibility

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Humidity and Moisture

Relative humidity is the percentage of moisture that the air is holding at a given temperature relative to the maximum amount of moisture that the air can hold at that temperature

As air temperature increases the air can hold more moisture

When the relative humidity rises above 80%, there is an increased risk of blistering, weakened adhesion and cohesion

Closer to the dew point and closer to condensation

As ambient temperature drops below freezing, dew point could be within 2 degrees

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Material Selection

Ambient and substrate temperature ranges WALLTITE reactivity grades

Substrate service temperature for WALLTITE

– -60°C to 80°C (-76°F to 176°F)

– Design temperature of the substrate when in operation

– Eg. Hot water holding tanks, boilers, cold vessels, freezers

Reactivity Grade TemperatureRegular 10°C to 40°C 50°F to 104°FF 0°C to 20°C 32°F to 68°FCT -10°C to 10°C 4°F to 50°F

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Material Selection

Ambient and substrate temperature range for ENERTITE 1-2-1

Substrate service temperature for ENERTITE 1-2-1

– -60°C to 80°C (-76°F to 176°F)

Reactivity Grade TemperatureRegular -10°C to 40°C 14°F to 104°F

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Wood, gypsum board and fiberboard: Moisture content should be less than 19% as per NBC Surface treatments on some wood may adversely effect adhesion

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Preparation of Substrates

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Wood, gypsum board and fiberboard: For ENERTITE applications, wood must be less then 19% moisture

content, wall should be studded, and installed in a location such that it does not get wet (interior application)

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Concrete must be dry on the surface. If adhesion is suspect due to moisture content of the concrete, an adhesion test should be performed.

Surface must be dry and free of debris

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For metal, surfaces must be free of any oils, solvents or other foreignmaterials that may effect adhesion

Remove any loose scale or rust Metal must be primed

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Modified Bitumen Membranes must be adhered to the substrate Confirm with membrane manufacturer that the product has been installed

properly, primer used, free of wrinkles and voids, and properly rolled

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Suggested technique when spraying WALLTITE onto modified bitumen membranes Spray 0.5” to 1” onto the membrane Spray remainder of wall with a 1-2’ gap from the membrane Fill in the gap after the foam has cured

– Limits strain placed on membrane during curing of the foam If installation of modified bitumen membranes are in doubt, mechanically

fasten as per membrane manufacturer’s requirements WALLTITE and modified bitumen membranes are both air barrier

materials and can be used together to form part of a buildings air barrier system, care must be taken to ensure both components are installed properly

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Examples of unacceptable substrates Building wrap Tar paper 6 mil polyethylene Dimpled drainage board Any loosely adhered substrate that can cause the foam to lift the

substrate during curing Ensure substrates are installed/fastened as per manufacturer’s

requirements or have been passed by the building inspector When in doubt, contact BASF field representative to verify application prior

to foaming

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Isolation and Ventilation

Requirements

Equipment

Warning Signs

Job Site Set-up

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Requirements

Isolation Requirements

When spraying in an inhabited building, isolation of the application area is required

This may require the use of polyethylene sheet, or equivalent, to drape over openings and separate the application area from the occupied space

Intakes to mechanical systems, which circulate air to other parts of the building, must also be protected

No one may be allowed into the isolated area without proper personal protection

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Requirements

Isolation Requirements

Open sources of flame in the area, such as pilot lights, furnaces, or hot water tanks, must be shut off

– To avoid airborne overspray from being burned, producing unwanted by products from combustion

Isolation and ventilation is not required for new construction or uninhabited buildings

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Requirements

Ventilation during spraying

When applying any spray foam in an inhabited building, mechanical ventilation is required

The rate of ventilation must be equal to, or greater than, 0.3 air changes per hour

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Requirements

Post Installation Ventilation

Ventilation at a rate of 0.3 air changes per hour must continue for 24 hours after the application is completed

Required for WALLTITE and ENERTITE 1-2-1 applications

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Application of WALLTITE

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Technique

Hose heat and primary heaters between 32°C-49°C (90°F-120°F)

115°F suggested starting temperature

Dispense pressure of 850-1200 psi

Suggested 1000 psi dispense pressure

Verify mix quality and pattern by spraying onto a disposable substrate

Verify that substrate is properly prepared as outlined in Substrate Preparation section

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Technique

Distance of gun to substrate

Approximately 12 to 24 inches from the substrate

Too close will cause;

– The foam to be blown away by excessive pressure

– An extremely rough and uneven surface

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Technique

Speed of the arm or wrist dictates the thickness of the pass

At the left and right edge, move the gun faster to apply less product

This is called feathering

Continue back over your first pass but at a ¾ overlap

Continue down the wall at the same speed

As the foam is sprayed with a ¾ overlap, the sprayer will notice a wave effect

Continue feeding the wave until the substrate is covered

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Technique

Too far from substrate;

Increases pattern diameter and amount of overspray

Pebbled surface

Decrease in yield

The delivery of foam to the substrate is affected by the increased effect of wind and temperature on the spray pattern

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Technique

Perpendicular to substrate

The gun must be held perpendicular to the substrate

Extreme angles can cause elongation of the cell structure and increase chance of overspray

This negatively effects the physical and thermal properties of the foam and create a rough and uneven surface

When spraying flat walls, should maintain pass length to shoulder width (2’-3’) to avoid angles on the spray pattern and higher density foam, cross hatching second pass (perpendicular to first pass) can help produce a smoother foam finish

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Thickness for WALLTITE

The minimum thickness to apply is 15 mm (0.5 inch)

Less than this could;

Negatively effect the rise of the foam

Increased density and a reduction in yield

Compromise the adhesion to the substrate

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The maximum thickness per pass is 50 mm (2 inches)

More than this could cause;

Elongated cells which effects the physical and thermal properties of the foam

Thermal cracking, stress cracking, or shrinkage

You need to allow time for cooling when several passes are required

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Maximum thickness is 50 mm (2 inches) per pass

Spraying more than 50 mm (2 inches) in one pass may cause severe charring which could lead to combustion

Systems based on the new generation of blowing agents are hotter than the previous 141b systems, extra care must be exercised

Allow time for cooling when several passes are required

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Wait time between passes for WALLTITE

Reactivity Grade Wait Time BeforeSecond Pass (4”Application)

Wait Time Before Additional Passes

Maximum Thickness per 12 Hour Period

Regular 10 Minutes 1 Hour 200 mm (8”)F 10 Minutes 2 Hours 150 mm (6”)CT Cool to Ambient

Temperature (1 hour)

12 Hours 100 mm (4”)

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Winter application technique

When application temperatures are at -10°C (14°F) and overnight temperatures are lower during the curing time of the foam

If the final application calls for more than 2 inches (50 mm) allow the foam surface to cool to room temperature prior to additional applications

If possible, provide dry heat in application area, hoard if necessary

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When spraying on open walls during cold periods, the following procedures are recommended if heating and hording are not provided Start in the corners or where the ceiling or walls intersect Spray out approximately 2-3 feet in each direction Leave a space of 1-2 feet and spray another strip of the same width Continue this method until the end of the wall or ceiling is reached Allow the foam surface to cool to room temperature and then fill in the

spaces Warm foam and cold adjacent substrates could result in condensation

formation

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If condensation formation occurs, stop until the condition returns to normal

Constantly check for proper adhesion

If thermal cracking should happen, spraying in this manner will limit the area effected and not the entire wall

The foam will not detach itself, and can be filled in later

RH above 80% may cause concerns for the application such as;

Blistering at the interface of the foam and substrate

Blistering at the interface of the first and second, or subsequent passes of the foam

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Indicator Dye

A typical 50mm (2 inch) pass will contain a 25mm (1 inch) light purple / light turquoise core, and purple skins

Indicates optimized machine settings for physical properties and density

Cutting a core density, from a standard 2” pass, provide a good visual indication for the installer, verifying optimal temperature and pressure settings on the machine

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Time Between Passes Density of Top Pass (pcf)*

% increase in material use vs. 1.81 pcf

1 min 2.00 – 2.10 16%2 min 1.95 – 2.10 12%5 min 1.90 – 2.05 9%10+ min 1.81 – 1.95


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Indicator Dye

Optimal physical properties, and maximum mileage, is obtained when waiting the required interval between the 1st and 2nd pass

You should achieve the lowest core density of both passes (1.80-1.90 pcf) and the highest mileage

You can have better cohesion between passes

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Indicator Dye

Waiting 1 to 2 minutes between passes

Waiting 2 to 5 minutes between passes

Waiting 10+ minutes between passes

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Application of ENERTITE 1-2-1

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Machine Requirements

Mixing

Application

On Site Testing

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Machine Requirements

1:1 by volume

Capable of 850-1200 psi dispense pressure

Minimum of 10 kW primary heating capacity

Corkscrew style mixer, such as Graco Twistork Mixer

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Mixing Resin

Use a corkscrew style drum mixer with an air motor

Electric paddle mixers don’t provide enough shear to mix the resin properly

Air supply should be a minimum 10 cfm at 100 psi with appropriate sized airline

Mix on high speed (800 rpm) for a minimum of 30 minutes prior to flushing out old material

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Mixing

During start up

Mix drum on high for 15 minutes

Recirculate fresh material into the hoses

Turn on hose heat after recirculating and continue mixing for another 15 minutes before spray foam application begins

Constant mixing required on low speed (400 rpm) during spray application

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Properly mixed material

Banana cream colour throughout

Insufficient Mix

Brown surface

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Properly mixed material

Banana cream colour throughout

Can be verified by lifting drum pump straight up from bung hole

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Application

Hose heat and primary heaters between 54°C-65°C (130°F-150°F)

130°F suggested starting temperature

Dispense pressure of 850-1200 psi

Suggested 1000 psi dispense pressure

Verify mix quality and pattern by spraying onto a disposable substrate

Verify that substrate is properly prepared as outlined in Substrate Preparation section

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Thickness for ENERTITE 1-2-1

Because it is a low density open cell foam, not as much heat is developed and the heat is dissipated sooner then closed cell foam

Maximum 305 mm (12”) per pass

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Application

Hold spray gun perpendicular to the substrate between 23-30 cm away (9-12 inches)

Overlap a minimum of 75% between passes, adjust arm speed to control thickness

Fill stud cavity width completely with spray pattern

Keep passes to less then 2’ wide to reduce voids

Spray wet onto wet, just in front of the foam wave

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On Site Testing for Quality Control

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Visual Appearance

Reaction

On Site Testing

WALLTITE

ENERTITE1-2-1

DWR and Job Site Label

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On Site Testing for Quality Control of WALLTITE

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Visual Appearance

Foam should be smooth and uniform

The thickness should be relatively smooth throughout the application

Off colour foam during application can be an indication of off ratio conditions

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Visual Appearance

Cell structure

The cells should be very fine

Course cells greater than 0.5 mm may be a sign of poor mix, or contamination of the chemical by foreign materials such as water or oil

Friability (Chalky)

The foam is friable if, after 48 hours, there is a powdery residue on the surface

Chemical system that is not suitable for low temperature applications

Substrate acting as a heat sink

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Reaction

Hardness/softness

Brittle foam may be a sign of a poor mix, possibly iso rich

Soft or spongy foam may be a sign of a poor mix, possibly resin rich

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Reaction

Surface tack

Poor mix

Applying a pass too thin (heat sink)

Primary heaters set too low

Improper system (too slow)

Chemical system past it’s shelf life

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Reaction

Slow Reacting Foam

Improper chemical system selection

Substrate acting as heat sink

Primary heater and hose settings too low

Poor mix

Chemical system exceeded its shelf life

Density may be affected

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Reaction

Fast Reacting Foam

Improper chemical system selection

Primary heater and hose settings too high

Substrate temperature too hot

Density may be affected

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On Site Testing

Density

– Equipment Required

– A scale accurate to 0.01 g

– A knife with a minimum 180 mm blade or a coring tool capable of cutting a sample

– A graduated cylinder of minimum 1000 ml size with 10 ml maximum graduation

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On Site Testing

Density

– Sampling

– Choose an area shortly after spray foam application starts (approximately 30 minutes) and which represents the average application so far

– Obtain samples from the area where the WALLTITE was sprayed, not off card board or poly

– Cut samples should measure about 1.5” wide, 6” long and full installed thickness of foam

– Sample should weigh a minimum of 5.5 gRev-June 2017

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On Site Testing

Density Method

– Remove top and bottom skins by cutting ¼” of foam off each side

– Removing less or having skins in the test sample will increase the density

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On Site Testing

Density Calculation

g ÷ mL x 1000 = kg/m3

÷ 16 to obtain pcf

Record on DWR

Minimum density is 1.80 pcf

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Density Calculation, alternative

g ÷ mL x 62.4 = pcf

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On Site Testing

Adhesion/Cohesion Testing

Adhesion is how well the foam sticks to the substrate

108

Cohesion is how well different passes of foam stick together

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On Site Testing

Adhesion/Cohesion Testing

– Attach scale and pull past 1 kg

– Record pass on DWR

– No need to test to failure, this will result in damage to pull test equipment

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On Site Testing for Quality Control of ENERTITE 1-2-1

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Daily Testing, Density

Cut and remove test specimens (approximately 5 cm by 5 cm by 10 cm) through the full thickness of the ENERTITE 1-2-1 from the selected test areas

Be careful not to damage or compress the specimen

Remove any loose or compacted material from the specimens

Cut outer skins off and make sample as square as possible

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Equipment required;

– A scale accurate to 0.01 g

– A knife with a minimum 200 mm blade

– A graduated steel ruler or measuring tape capable of measuring in cm

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Weigh the sample in grams (g) then measure it’s L x W x H in cm

– Sample weighs 4.13 g

9.4 cm x 7.9 cm x 6.5 cm = 483 cm3

(1 cm3 = 1 cc = 1 mL)

– g divided by cm3 times 1000 to get density in kg/m3

4.13 ÷ 483 x 1000 = 8.55 kg/m3

– Divide by 16 to get density in lbs/ft3 (pcf)

8.55 kg/m3 ÷ 16 = 0.53 pcf

Record value on DWR along with # of passes in sampleRev-June 2017

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Daily Testing, Adhesion

Open cell foams have very little adhesive and cohesive strength, therefore visual inspection is the only method that can determine adhesion

The test specimen shall not show delamination to the substrate or itself

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On Site Testing for Quality Control

On Site Testing

Thickness

– The thickness is required to be checked continually with a proper depth gauge

– The minimum thickness required by the contract/work order mustbe applied

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Daily Work Record

Must be filled out for every job

At the beginning of the day

Every address change

Every lot# of resin or iso change

Every DWR must be sent to MH by the end of the following month the job was completed

For a job sprayed in March, DWR must be submitted to MH by end of April

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Daily Work Record

Must be filled out for ENERTITE and WALLTITE

Only check the CCMC# if there is a building permit issued

Ensure all information is filled out accurately

Complete density, adhesion/cohesion, and substrate verification shortly after spray foam application starts (approximately 30 minutes) as part of the site quality control

On-line DWR is available at

https://secure.basf.com/basf-canada/dwr/dwr.html

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Job Site Label

Must be filled out for ENERTITE and WALLTITE

Only write the CCMC# if there is a building permit issued

Ensure all information is filled out accurately

Place in an area that won’t be covered by drywall

Electrical box

Attic hatch

Duct work by furnace

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Job Site Label

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Spray Foam Trouble Shooting

Off Ratio Foam

Resin rich

– Soft spongy foam

– Typical causes are equipment

Isocyanate rich

– Brittle and glassy in appearance

– Typical causes are equipment

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Repair

Fix equipment

– Likely a supply issue

Remove area with off ratio foam and re-spray

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Blisters

Areas of foam that have no adhesion to the substrate

Causes

– Cold foam application

– Moisture

– Wind

– Foreign material (oils, grease, etc.) contaminating substrate

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Blisters

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Blisters

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Repair

Remove blisters to area of positive adhesion

Ensure no contamination exits on substrate before re-spraying

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Thermal Cracking/Shrinkage

Excessive stress in the foam that forms a crack when the stress is released– If stress is greater than adhesion,

cracks along the stud

– If stress is greater than polyurethane bonds, crack within the surface of the foam

Causes– Most prevalent in winter applications

– Exceeding recommended thickness of 2 inches (or 50 mm) in a single pass

– Failure to allow previous pass to cool before application of next pass

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Thermal Cracking/Shrinkage

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Repairs

Cut foam down to properly installed product, complete removal may be required

Re-spray following winter application technique

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Scorching

Extreme buildup of heat inside overly thick applications of foam

Causes

– Applying foam in passes over 50 mm (2”)

– Spray gun pattern adjustment buns

May increase to the point of burning, emitting flames

All extremely thick pieces must be broken open to release heat

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Scorching

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Repairs

Foam must be removed down to purple residual foam on the substrate and re-spray

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Friability

Chalky appearance at edge of pass on substrate

Causes

– Cold substrate temperature

– Improper choice of foam system

– Off ratio (Iso rich)

127

Repairs

Warm up substrate or switch to colder temperature system

Fix off ratio conditions on equipment

Remove friable section and re-spray

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Glossy Cell Structure

Shiny off colour cells

Causes– Cold substrate temperature


– Off ratio (resin rich)

– Multiple thin passes

Repairs– Warm up substrate or switch to colder

temperature system

– Fix off ratio conditions on equipment

– Apply passes between 15 mm and 50 mm (0.5” and 2”)

– Remove section and re-spray 128Rev-June 2017

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Creeping

Excessive lateral movement of the foam along the substrate that can result in poor adhesion

Causes

– Cold substrate

– Improper foam system

– High wind

– Off ratio

129

Repairs

Warm up substrate or switch to colder temperature system

Hoard in the area and supply heat

If adhesion is adequate, no repairs are required

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Low Density Substrate too hot for foam system

chosen

Machine heat/pressure settings too high

Thick passes

Corrective Action Adjust machine settings and

application technique on disposable substrate until proper density is obtained

Switch to lower output chamber

Remove low density foam from wall and re-spray

130

High Density Substrate too cold for foam system

chosen

Machine heat/pressure settings too low

Thin passes

Cold drum chemical temperatures

Lack of hose insulation

Corrective Action Adjust machine settings and

application technique on disposable substrate until proper density is obtained

Ensure each pass being tested for density is 50 mm (2”) thick with no pass lines present

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Discolored

Result of being exposed to ultra violet light

If exposed longer than 6 months foam must be inspected for degradation of surface

Corrective Action

Surface may need to be scarffedand re-sprayed

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Reversion Not enough heat to allow the

blowing agent to make the foam rise, resulting in the formation of a brittle, non-cellular coating on the substrate

Causes– Cold substrate


– Machine temperatures too low

– Resin rich

Corrective Action Warm up substrate or switch to a

colder temperature version132Rev-June 2017

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Raising Performance To New Heights®

Rev-June 2017

BASF-Caliber Recertification Training · 150 years Building Codes and Standards The National...

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Transcript of BASF-Caliber Recertification Training · 150 years Building Codes and Standards The National...