Polyurethane Spray Products and Application Analysis

Spray Polyurethane Foam Analysis

Spray polyurethane foam (SPF) is the most preferred product for thermal and acoustic insulation due to its continuous insulation layer, low thermal conductivity, ease of application and numerous other properties compared to other applications. SPF is used today to insulate a wide variety of residential and industrial buildings. Polyurethane offers sustainable energy savings along with a healthy living environment. It provides advanced thermal insulation to buildings without adding extra load. Osa Kimya spray products consist of 90-96% closed-cell structure. High closed-cell content is the reason for low thermal conductivity coefficient and good insulation. Initial thermal transmission coefficient was measured at 0.022, with aged product thermal conductivity coefficient measured at 0.029. Fire safety in residential and industrial buildings with flame non-propagating systems at B1 and B2 levels is a top priority. Flame resistance of polyurethane materials can be achieved through H-PUR and PIR systems. The significant side reactions of halogen compounds and their environmental damage have led to wider use of PIR-synthesized products. Osa polyurethane spray products are PIR-synthesized, with flame resistance classes varying depending on application area but falling in B1 and B2 classes. B2 class products are recommended for building curtain areas, while B1 class products are recommended for roof terraces and external insulation. Polyurethane materials provide ease of application. Low viscosity materials fill cracks and voids more effectively. Osa spray products have the best viscosity among synthesized products. Our viscosity ensures excellent dispersion of components while maintaining all necessary properties within a homogeneous mixture. The application range of polyurethane spray foams is not limited only to external roof insulation. Application properties also make spray polyurethane suitable for application to the underside of roofs. Additionally, it is used in industry for pipe insulation and material tanks such as storage tanks. Correct application of the polyurethane spraying system requires a professional applicator as much as product quality. Proper analysis of the application area by professional personnel regarding which product to use ensures correct use of the product.

Application Analysis

Two-component spray polyurethane insulation materials are applied using high-pressure equipment at a 1V/1V ratio. Mixing systems are guns operating at 6-10 bar pressure. The mixing gun is connected to portable machines via heated hoses. The system managed from the gun can be stopped and resumed at any time. This portable integrated system allows spray polyurethane materials to be applied anywhere desired and to any area of buildings. Polyurethane spray products offer two different product types with gel times of 5-7 seconds and 12-14 seconds according to their reaction profiles. For products with slump in one direction, short gel time products are preferred, while for areas with slump in the opposite direction, longer-setting products are preferred. Whether the application area is an open or closed system is also a factor in this choice. Additionally, it varies depending on the surface to which it will be applied, climate, working time and desired efficiency in the application area. In applications using both product types, the mixture adheres rapidly to the surface in the application area and forms a continuous insulation layer. The foaming process of polyurethane spray materials develops in direct proportion to temperature. Spraying should be performed taking into account the temperature of the surface to be applied and the raw material. The initial layer formed on the sprayed surface cools rapidly due to its thinness. This can unfortunately cause waviness on the surface, brittleness formation and deterioration in the pore structure of the polyurethane material. In such cases caused by climate conditions, products with low gel time are recommended. Furthermore, attention to raw material temperatures and hose temperatures is important. Raw materials reaching standard temperatures absorb this adverse condition. It is recommended that the surface to be applied be above 15 degrees Celsius. If the application area is in the slump direction, a short gel time product should be selected in the system and the surface must be ensured to be free of dust to avoid adhesion problems. If the application area is open and windy, this can cause changes in the product structure. The applicator can protect himself by using a wind panel or tent to avoid exposure to PMDI vapor. Polyurethane spray products can be applied in densities between 35 and 70 kg/m³, in layers of 1.5-10 cm forming total thicknesses up to 10-20 cm. The first layer has higher density due to contact with concrete. In upper layers, density decreases depending on temperature. Other than the first layer, to ensure homogeneous distribution, the product must reach its heat capacity and the first layer should be applied as a thin serviceable layer. This ensures correct use of this material. Applying the first layer thick on concrete surfaces is not recommended. This causes irregularities through the thickness of the sprayed material and density variations. Work should be carried out with moisture eliminated from the application area. The presence of water on the surface or working at high humidity will cause changes in the pore system of the polyurethane material. Surface moisture causes irregularities in the first layer and creates voids between other layers. Areas with high humidity can cause surface irregularities in the material. This also causes valley formation in the material. Other causes of valley formation are application of varying amounts of material to the sprayed area and material temperature. Valleys are responsible for both pore structure deterioration and density irregularities in materials. In the application system, high activation energy is followed by horizontal or vertical lens formation in the material. In such a case, using a product with high gel time or slight reduction in material temperature is effective in eliminating the problem. Single layer thickness must always be limited to 10 cm. This can hinder the foam's hardness and stability. Waiting time between each layer varies between 5 to 15 minutes. Long waits prevent layers from adhering to each other. As standard, layer thickness of 3 cm and 10 minutes between layers renews the material's stability and pore adhesion most efficiently. Orkun Ataman General Manager / OSA Kimya