Construction Methods using Spray Foam

Josef Goetz

Peter Wintermann

Josep Maria Bringué

06/07/2006 2

Table of Content

Wall Insulation MethodsInsulating from the inside / outsideDifferent finishing

Roof InsulationFlat roofs / sloped roofsIndustrial roofs / residential roofs

Floor Insulation Various insulation applications

06/07/2006 3

1. Wall Insulation1.1. Interior Insulation

Insulation with plasterboard mounted on studs

Mounting of the studs

Application of PUR

Installation of plasterboard

06/07/2006 4

1. Wall Insulation1.1. Interior Insulation

Advantages:

Easy installation, no need for scaffolding

No problems of exterior emissions

Cost-effective method

Faster Heating (Wall has less thermal inertia)

Insulation with plasterboard mounted on studs

Inconveniences:

Having to clean the studs if the rails are installed first

Loss of space, if the studs are installed after

Low thermal inertia

06/07/2006 5

1. Wall Insulation1.1. Interior Insulation

Japanese methode

Installation of studs not neededAround 20 million square meters installed every year in Japan

06/07/2006 6

Wall Insulation

Interior Finish with Ceramic Bricks

1. Wall Insulation1.2. Intermediary Insulatio

06/07/2006 7

Advantages:

Easy installation, no need for scaffolding

No problems of exterior emissions

Cost-effective method

Faster Heating (Wall has less thermal inertia)

Inconveniences:

Difficult treatment of thermal bridges, like wall-floor intersection

Medium Thermal Inertia

Standard solution in Spain, with approximately 25 million square meters every year.

1. Wall Insulation1.2. Intermediary Insulation

Interior Finish with Ceramic Bricks

06/07/2006 8

1. Wall Insulation1.3. Exterior Insulation

06/07/2006 9

Advantages:

Excellent treatment of thermal bridges

Possibility of installing ventilated façades

Multiple options for exterior finish

Low possibility of interstitial condensations

Inconveniences:

Difficult application, need for scaffolding or cranes

More product loss and emissions into the environment

Parked cars may be stained my small dropplets

High dependence on weather conditions

1. Wall Insulation1.3. Exterior Insulation

06/07/2006 10

Many possibilities for external finish:

•Ceramic Brick

•Concrete Blocks

•Marble or Petro Plates

•Ceramic Plates

•Metallic Plates

•Stone finish

•etc

1. Wall Insulation1.3. Exterior Insulation

06/07/2006 11

Ceramic Brick

1. Wall Insulation1.3. Exterior Insulation

06/07/2006 12

Marble or Petreo Plates

1. Wall Insulation1.3. Exterior Insulation

06/07/2006 13

Marble or Petreo Plates

Gugenheim Museum in Bilbao

1. Wall Insulation1.3. Exterior Insulation

06/07/2006 14

Marble or Petreo Plates

1. Wall Insulation1.3. Exterior Insulation

06/07/2006 15

Ceramic Plates

Example on:http://www.keraben.com/Portales/ADMIN/PDF/Catalogo_Keraben_Systems.pdfSee Appendix

1. Wall Insulation1.3. Exterior Insulation

06/07/2006 16

Metallic Plates

1. Wall Insulation1.3. Exterior Insulation

06/07/2006 17

Stone finish

1. Wall Insulation1.3. Exterior Insulation

Metallic conecting rods to mount the stones

06/07/2006 18

Canadian Solution

http://www.basf.com/basf-canada/kun_walltite_e.shtm

1. Wall Insulation1.3. Exterior Insulation

06/07/2006 19

2. Roof Insulation2.1. Inclined Roofs

Inclined roof with ceramic roof tiles:

06/07/2006 20

2. Roof Insulation2.1. Inclined Roofs

The roof tiles are mounted on wooden studs

06/07/2006 21

2. Roof Insulation2.1. Inclined Roofs

Sheet metal roofs

06/07/2006 22

2. Roof Insulation2.2. Flat Roofs (Renovation of Roofs)

Roof in need of reconstruction Sprayfoam application

Sprayed roof Application of UV-protection

06/07/2006 23

2. Roof insulation2.2. Flat Roofs (Renovation of Roofs)

Advantages: - Sealing and insulation in one step- Buildings can be used „as usuall“ during the reconstruction- cost effective

Finished roof

06/07/2006 24

2. Roof Insulation2.3. Inclined Roofs (Renovation of Roofs)

•Foam is applied over existing roof•Foam needs to be covered by a UV protective cover

06/07/2006 25

•Application of foam from the inside•The foam insulates, seals and holds the tiles in place

2. Roof Insulation2.3. Inclined Roofs (Renovation of Roofs)

06/07/2006 26

•Removal of old tiles•Application of foam•Installation of new tiles

2. Roof Insulation2.3. Inclined Roofs (Renovation of Roofs)

06/07/2006 27

2. Roof Insulation2.4. Hanging Roofs (Insulation from Inside)

06/07/2006 28

3. Floor Insulation3.1. Typical application in Belgium

06/07/2006 29

ConcreteConcrete

Installations (Pipes, Cables)

Floating floor screed

Floating floor screed

Elastopor H Sprayfoam

Insulation

Decking

Decking

Levelling course (concrete or porous concrete)

Space advantage

Conventional technique

Sprayfoamtechnique

Advantages in costs, construction time and space!

3. Floor Insulation3.1. Typical application in Belgium

06/07/2006 30

3. Floor Insulation3.2. Insulation of Crawl Space (Netherlands)

06/07/2006 31

Minimum Compression of 200 kPa (40 kg/m3 density or more)

3. Floor Insulation3.3. Terrace Insulation

06/07/2006 32

4. Various Insulation Applications4.1. Walls in Contact with the Ground

High Compression required (50 kg/m3 density or more)

06/07/2006 33

Subsequent insulation of agricultural buildings e.g.

- Stables- Warehouses for grain, potatoas etc.

4. Various Insulation Applications4.2. Agricultural Buildings

06/07/2006 34

5. New Applications5.1. Spray Foam Covered by plaster

•Insulating Spray Foam from the outside•Installation of a special plaster for the final finish (experimental process Turkey)