Insulation with liquid polyurethane foam. What is liquid foam insulation? PU foam equipment series

Before purchasing any material, each consumer considers the shortcomings. Polyurethane foam is no exception. About this material, which is otherwise called PPU, every builder has heard a lot of information today.

What material to choose

If you have ever thought about warming your home, then you probably paid attention to this option as thermal insulation. Maybe he will be the best solution, because along with the shortcomings, he has many advantages.

Description

Polyurethane foam, the shortcomings of which you should be aware of before starting work on insulation, is a type of plastic. Products from it have a cellular structure. The composition of polyurethane foam includes a gaseous substance, which is contained in a volume of 85 to 90%. The whole structure consists of small cells, which are well isolated from each other by walls, it is these cells that are filled with gas. The remaining percentages of the volume are the solid part, namely the walls themselves.

The disadvantages of polyurethane foam as a heater should be considered. Varieties of polyurethane foam are used quite often today, the material is popular among consumers, since it is very simple to make it, you can do it directly at the construction site. In this case, the two liquid components must be mixed, after which they will enter into a chemical reaction. If the necessary proportions of the ingredients are observed, then a polymer will be synthesized, which is represented by a hardened foam. If you slightly change the technology of preparation, then you can get polyurethane foams, which differ in characteristics from each other. Some of them are suitable for insulating doors and windows, while others are suitable for thermal insulation of buildings made of reinforced concrete or brick. As for the third varieties, they are widely used for pipelines. Thus, depending on the proportions of substances, polyurethanes can be obtained at the output, which consist of many cells. different size. Their walls can have different thicknesses, as well as strength.

The main disadvantage of polyurethane foam

Polyurethane foam, the disadvantages of which will be presented below, can be used in many areas of construction. However, before purchasing, it is important to take a closer look at the cons of the material. The main negative impact sun rays on the surface, which can cause rapid wear of products. In order to exclude the destruction of the heat insulator, it is necessary to provide for its protection. To do this, you can use plaster, ordinary paint and all kinds of panels. These are the methods that experienced builders advise.

The disadvantages of Styrofoam as a wall insulation will let you know if it is worth using it. Protective composition can protect the insulation from ultraviolet exposure, and also make polyurethane foam more attractive. If we consider this minus in more detail, it can be noted that the preservation of the properties of polyurethane foam will require more funds than we carry out work on insulation, which involves materials that do not require appropriate protection. Among other things, not all home craftsmen are able to produce and apply coloring compositions with high quality. As a result, the surface may turn out to be even less attractive than before the refining.

Additional minus

If you decide to choose polyurethane foam, the disadvantages of which for some consumers may be too impressive, then it is worth considering that this material is thermal insulation, which begins to smolder when exposed to fire. This shortcoming is noted by experts. Despite the fact that PPU acts as a slow-burning material, it is not able to cope with fire at 100%. According to the classification, this insulation belongs to the flammability group G-2. This indicates that ignition will not occur when exposed to low temperatures. The flame will go out, the process will stop as soon as the surface of the material can be cooled. If there is a possibility of strong heating or the possibility of ignition of a certain zone of insulation, then in this case polyurethane foam should not be used.

Why you should not choose polyurethane foam for home insulation

Disadvantages of insulation with polyurethane foam, of course, exist. If you decide to produce thermal insulation, then this is important to consider. If the wrong technology is used during the work, this can adversely affect the performance of the building. In order to exclude this, it is necessary to take into account some properties of the described substance. So, PPU has a low vapor permeability - this refers to a rigid variety of material. If the composition is applied to the walls, during processing or other panels, this will certainly lead to dampness on the internal surfaces and in the structure. Dampness and mold can be mentioned as consequences, but if freezing occurs, then the supporting elements will constantly collapse. This point is often noted in their reviews by experienced builders.

The need for fire protection

If you decide to purchase polyurethane foam, the disadvantages of customer reviews should be described in detail to you. After all, it is the negative moments that people notice in the first place. Thus, it is necessary to be prepared for the fact that over time the structure will lose its heat-insulating qualities, at best, they can only decrease. Not only the aging of the material leads to this result, but also temperature changes, as well as exposure to ultraviolet radiation. Quite often, when the spraying method is used, this provides protection from exposure to open flame. If there is no desire to create an additional fire hazard, then appropriate safety measures must be taken. They also become a source of additional expense, which does not always suit consumers.

Minus: the need to take into account the strength of the structure

Polyurethane foam, the shortcomings, reviews of which were analyzed in the article, provides for the need to correctly determine the strength of the structure. This is true in the case when the work involves blowing thermal insulation into the space between the walls. After that, the structure begins to expand, and subsequently the foam can cause destruction. Owners of private houses do not always have the opportunity to make correct calculations.

Why do consumers sometimes refuse to use polyurethane foam

If you decide to use PPU, the shortcomings, reviews of the material should be appreciated by you. So, it is undesirable to use it for insulation inside the building. This can cause a shift to the side of the room. In this case, the wall begins to freeze, the resulting dampness causes the spread of mold, and then the wood begins to rot. In this situation, the walls remain damp even in summer period, which negatively affects the microclimate of the premises. Experts advise, if it is not possible to use analog materials, to use semi-rigid polyurethane foam. In this case, a layer with a thickness of 30 millimeters will be quite enough.

Polyurethane foam can rightly be called a new generation of insulation. IN last years this technology of thermal insulation of buildings is gaining more and more popularity among the owners of private houses. Do-it-yourself insulation with polyurethane foam is quite possible, but only if available necessary equipment, the master studied the technology of applying this material quite well.

Polyurethane foam is suitable for insulating buildings both from the outside of the walls and from the inside. The material has a lot positive qualities, which is why it has been used more and more in recent years. However, you need to be aware of the negative aspects that may arise when using this type of thermal insulation.

How polyurethane foam is used for insulation

Insulation with polyurethane foam is most often done by spraying a heat-insulating layer on almost any surface. Adhering well to it and gaining volume, the foam composition increases in size several times. Polyurethane foam, expanding, penetrates into all, even the smallest cracks, creates a dense and practically airtight coating, thanks to which the walls and roof are not afraid of cold and wind.

The most common method of using polyurethane foam is spraying it on walls.

Most common the method of its installation is spraying, but it should be noted that the pouring method is sometimes used. Most often, this technology is used at the stage of production of thermal insulation structures. Polyurethane foam is poured into special molds, and the resulting parts are used only after complete solidification.

Another pouring option is to fill with foamed composition certain horizontal areas or voids where spraying is not possible. For example, this method is used when it is necessary to fill a cavity between already installed or erected walls, or the space between installed layers of finishing material.

Polyurethane foam is a mixture of two of its constituent polymers, which are usually in liquid form - a polyol and a polyisocyanate. These components are mixed together without air access during the spraying process, foaming when exposed to carbon dioxide and heated to high temperature.

The finished mixture is fed through hoses to the spray gun and applied to the structure due to the high pressure generated. The foam composition perfectly adheres to the prepared surface and begins to actively expand, forming an insulating layer of the desired thickness.

Video - Modern method of thermal insulationII - polyurethane foam spraying

Polyurethane foam properties

This material is used for insulation of both industrial and residential premises. Polyurethane foam spraying is carried out on the floors of houses, inner surface roofs, various partitions, floors and walls. It is especially popular for warming the walls of frame structures.

Polyurethane foam is universal - it can be used to insulate walls, floors, ceilings, roofs, etc.

During the period of its active use, it has shown its unconditional effectiveness not only as a heater, but also as a waterproofing and soundproofing material. It perfectly protects the premises of the house from freezing, moisture penetration and external noise.

The main advantages of polyurethane foam

So, the remarkable properties of polyurethane foam include:

Excellent adhesion, that is, reliable adhesion to almost any surface, be it concrete, wood, metal or roofing from other materials.
The low thermal conductivity of polyurethane foam allows you to save the accumulated heat in the premises, if the insulation is made from the inside, creates a reliable barrier against the penetration of cold air, if the material is sprayed from the outside of the walls.
Polyurethane foam tightly fills all holes and crevices, which helps to isolate the room from extraneous sounds streets. When sprayed on the inner surface of the roof, the insulation is able to drown out the sounds of raindrops, which is especially important for rooms located in the attic of houses.

This insulation counteracts the appearance of corrosion on metal structural elements and protects the surface from the negative effects of an external aggressive environment.
When spraying polyurethane foam, it covers not only large surfaces, but also neutralizes cold bridges that occur at the locations of the batten guides. No other types of material can close them as reliably, therefore, even if insulation is used in mats or slabs (for example, mineral wool or polystyrene foam), cold bridges are still treated with polyurethane mounting foam.
Spraying can be carried out on the most complex structures in their configuration, on which it is simply impossible to install conventional heaters.
Polyurethane foam refers to slow-burning materials, since polyol substance A is included in one of its components. One of the flame retardants giving the insulation the ability to self-extinguishing, to cessation burning even if the material enters the fire zone. The ignition of polyurethane foam is possible only at temperatures not lower than 450-500 degrees.
The light weight of polyurethane foam allows it to be sprayed on any roofing material from the side of the attic or on the attic floor, without fear of weighing down these building structures. Moreover, the applied layer of insulation after complete solidification will also give them additional rigidity.

Video - The use of polyurethane foam for roof insulation

When sprayed, the material forms a seamless surface, which cannot be done using other heaters without using additional means for their connection (mechanical or adhesive).
Polyurethane foam is applied very quickly, expands and hardens in a short time. Therefore, the whole process of insulation will take a little - only one ÷ two days, depending on the area and complexity of the structures to be insulated.
Due to the moisture resistance of polyurethane foam and the ability to seal surfaces, when using it, there is no need to use a vapor barrier and windproof film.
Polyurethane foam is not subject to decay, mold, damage and insects.
Leading manufacturers establish a guarantee for the life of polyurethane foam in 50 years. However, judging by its components and application technology, the insulation will last much longer without losing its qualities if the PPU spraying and its exterior finish are arranged correctly.
Such high scores does not possess not alone existing insulation material, because not alone of them does not possess such adhesive properties.

Material disadvantages

It is impossible not to say about the shortcomings of polyurethane foam - with self-insulation them and during further operation:

The big disadvantage of this insulation technology is its price, since buying or even renting equipment for applying polyurethane foam is not cheap.
For work on spraying, it is necessary to purchase personal protective equipment - a special suit and a respirator to protect against damage respiratory tract. Be sure to cover all areas of the skin, mucous membranes, eyes.

In the absence of experience in the installation of such a heater, the work may drag on for a long time, and its quality will not be guaranteed.
Polyurethane foam is not combustible, but when in contact with fire, it smokes heavily. At the same time, the smoke contains a large amount of substances harmful to humans.

Polyurethane foam should never be left open for a long time to sunlight - ultraviolet quickly "kills" the material

If the insulation is applied from the outside of the building and is not closed finishing materials, then it quickly begins to break down under the influence of ultraviolet radiation, decomposing at the same time into monomers that are dangerous to human health.

How to make insulation with polyurethane foam

Many would like to carry out the process of insulating their own housing with polyurethane foam on their own, however, you need to know that this is quite possible only theoretically, but in practice you will need specific equipment, materials and certain work skills. It should also be noted that the technological equipment requires a certain adjustment before the start of deposition, and it is necessary to be able to do it correctly.

One of the main difficulties is the need for special equipment for spraying polyurethane foam.

If there is an idea of how the whole system works, but there is no equipment, it can be rented, for which, however, as mentioned above, you will also have to pay a lot.

So what can be the conclusion? Probably, it will be easier to invite a master with his own equipment - he will quickly, without delay, complete all the technological steps for warming, freeing the homeowner from a lot of problems.

If, nevertheless, it is decided to test your own strength, then you need to take into account some features of such a process:

Warming with this material can be carried out during the construction of a building or in an already built house. In addition, spraying is carried out on separate areas or on the entire surface. Or, if necessary, fill the cavities with polyurethane foam.

We insulated the house from the outside, and now find out and also consider options on how to choose the right insulation from our new article.

When carrying out work, it is necessary to take into account the region where the building is located, since from climatic conditions will depend on the thickness of the sprayed layer of insulation.

The measures for insulation with polyurethane foam include the following actions:

Insulated surfaces require some preparation. For example, existing old coatings should be removed from walls if they are clearly unstable (such as old crumbling plaster or peeling paint).
Further, on the wall it is necessary to arrange a crate of wooden bars or metal profiles. The thickness of the guides is selected depending on which layer of insulation should be applied to the surface.

In addition, the crate can play a leveling role for the wall. It is mounted on the wall surface in terms of level and plumb, and the openings between its elements are then filled with polyurethane foam, which will fill in the bumps and bring the coating to the proper level.
A foaming insulation is sprayed onto the prepared plane using a special gun.
The intensity of spraying also needs to be adjusted, since if a layer that is not too thick is needed, then it is necessary to set up the apparatus in such a way that the composition is sprayed in very small jets. Lathing, in this case, must be made of bars or profiles having a small thickness, as they will determine the thickness of the insulation layer.
Spraying polyurethane foam always start from the bottom of the wall, and apply it to the surface between the elements of the crate.

Polyurethane foam is applied in a thin layer, which immediately acquires volume. If the thickness of the first layer is not enough, then another layer of insulation is applied on top.

After the polyurethane foam has hardened and the frozen coating has been leveled along the batten guides by cutting off the protruding reliefs of the insulation, it is fashionable to install siding and lining. Nothing prevents you from doing outside and brickwork or plastering the walls of the house.
If it is planned to plaster the wall after insulation, then it must be tightened with a chain-link mesh, fixing it on the rails of the crate. Then apply the technique of throwing on the wall cement mortar. After its setting and initial hardening, it will be possible to apply any leveling composition of the plaster, as it will lie well on this base.

Video: the process of self-applying polyurethane foam to the wall

In conclusion, I would like to note that two factors are very important in any work on insulation - the quality of the material used and the experience of the master. Therefore, it is best to entrust the work to a proven specialist who will save you from unnecessary worries and carry out spraying quickly and efficiently.

Prices for popular models of air compressors

Air compressors

Step-by-step instructions for insulation with polyurethane foam using a disposable kit "PENOGLAS ™ KIT"

The appearance in the assortment of stores of disposable kits for applying polyurethane foam has significantly expanded the horizons for using this effective insulation. It is possible to do without inviting a team of specialists with their equipment. The kit provides everything you need, up to personal protective equipment, without which it is not recommended to work with polyurethane foam.

One of the brightest examples of such equipment is a set of domestic production - "PENOGLAS ™ KIT".

The whole set is placed in three boxes, total weight about 30 kilograms. Everything is very compact, so a normal car trunk is enough to carry the whole set.

The manufacturer declares the following physical and operational characteristics of the created thermal insulation:

The system is two-component, giving foam with a closed cell structure, which minimizes possible water absorption.
The density of polyurethane foam after complete curing is from 35 to 40 kg/m³.
Thermal conductivity coefficient - 0.024 W / m × ºС.
The number of closed cells is not less than 85%.
The full volume expansion of the PENOGLAS™ KIT-400 kit is 1 m³, which will correspond to an area of 20 m² covered with a 50 mm thick thermal insulation layer.
The period of complete solidification of polyurethane foam is 1 hour.

The kit includes:

Two cardboard boxes, each of which contains a cylinder with one of the components. Both the boxes and the cylinders themselves have a clear color and letter marking: component “A” is indicated in red, component “B” in blue. The components are in cylinders under pressure of 8 atmospheres.

When working with the kit, the cylinders are not removed from the boxes - the very design of the package allows you to carry out all operations without completely removing it.

The third box contains all the fixtures, tools and spare parts necessary for the job. It contains:

- Spray gun, in which the components are mixed. Two flexible transparent hoses are connected to the gun, ending with fittings with union nuts - for connecting to cylinders. Typically, the hoses are also color-coded - so that when reusing the kit, you do not get confused with the “polarity” of connecting to the cylinders. The length of each hose is 3 meters.

- For spraying a mixed composition, special interchangeable heads with a spray nozzle are put on the gun. The set includes ten such heads.

Silicone grease is used to facilitate the attachment of heads to the gun and ensure a reliable seal of this connection - a small package of it is included in the kit.

Attaching the hoses to the cylinders requires tightening the union nuts with a wrench, which is also provided in the accessory kit.

- The manufacturer also thought about the observance of safety measures - the basic kit always includes a set of personal protective equipment - gloves, goggles and a respirator.

Working with the system "PENOGLAS™ KIT-400" is quite simple and does not require any special qualification of the user. The entire assembly and preparation of equipment for use takes a matter of minutes. There is no need to use any power sources - the kit is completely autonomous. More details about this are in the instruction table below:

Illustration	Brief description of the operation to be performed
	The kit is delivered to the place of work. A small box is opened - you need to get it and immediately put on protective equipment.
	Gloves can be rubber or polyethylene. You can, of course, use your own, but the use of protective equipment - required condition, since the PPU components are very toxic, and the resulting foam is very difficult to wash off from the skin. It is not included in the kit, but it is also strongly recommended to use a disposable work suit - it is impossible to wash off the foam that has got on ordinary fabrics.
	Boxes with cylinders are being prepared for work. You can open the top covers of the boxes completely by cutting a strip of adhesive tape with a knife ...
	..and then - unfastening interlock connection covers.
	And you can even just push inside the windows on the lid, perforated around the perimeter. By the way, these windows are also convenient for carrying boxes - immediately below them are the metal handles of the cylinders.
	On the side wall of the box there is another window - a round shape. It is also easy to push it inward - there is a cardboard perforation around the perimeter. Directly behind this window is the fitting of the cylinder with the PPU component.
	The illustration clearly shows the threaded fitting of the cylinder and the valve - to open the supply of the PPU component.
	A spray gun with hoses attached to it is taken out of the box.
	Hoses collected in a bay must be unwound along the entire length.
	The ends of the hoses with connecting fittings (with union nuts) are near the windows of both boxes. Please note that hoses may be color-coded and should be adhered to. Of course, by and large, there is not much difference which hose to which cylinder to connect now - no. But it happens that the work needs to be suspended, rescheduled (it is allowed to use the contents of the cylinders for one month) or move to another facility. The system can then be temporarily disassembled. It is also practiced that during large-scale work, several pairs of cylinders and one set of accessories for them are purchased. Here it will be extremely important to keep the same “polarity” that was during the initial assembly. And color coding will help in this. By the way, there are kits that do not have color markings on the hoses - you should pay attention to this.
	The ends of the hoses are brought into cardboard boxes through round windows.
	Then the union nuts of the hoses are screwed onto the fittings of the cylinders with PPU components. At first, as far as possible, twisting is carried out manually ...
	... and then the connection is tightened with the wrench included in the delivery. In exactly the same way, the operation is repeated on the second cylinder.
	Next, you need to make sure that the pistol trigger is locked. The spray nozzle should not be on it yet. After that, both valves on the cylinders are fully opened. It is necessary to take an empty plastic bag (or any other unnecessary container), and make a trial release of the components into it, for two to three seconds. This ensures that the pressure of the components is even in both hoses and that nothing prevents them from passing freely through the gun.
	Next, you need to put a spray nozzle on the gun. To facilitate this operation, use the special silicone grease included in the kit. They coat the end of the gun with it ...
	... and the cylindrical part of the removable nozzle and the nozzle at the edges.
	Then the spray nozzle is inserted into the gun and pressed firmly, so that the connection is securely fixed by the stopper located at the top of the gun (well shown in the illustration - yellow).
	Cylinders are located in a place convenient for work, taking into account that the length of the hoses is three meters. It is allowed to move the cylinders only by the metal handles located on their bodies. Carrying by the crane is strictly prohibited!
	You can proceed to the application of polyurethane foam. The gun is directed to the area to be insulated. The optimal distance from the spray nozzle to the surface of the building structure is 600 mm. Spraying is carried out sequentially, in a thin layer, gradually moving the polyurethane jet to the untreated areas.
	Often they start from traditionally hard-to-reach or vulnerable places in terms of the formation of “cold bridges”. This illustration shows that the wizard first processed the corners between the floor beams and the rough coating, and then moved on to filling free space between them.
	And this illustration shows the foam filling of the often overlooked area of \u200b\u200bthe connection of the Mauerlat, floor beams and rafter legs. The use of polyurethane foam allows you to cope with this task.
	This technology is also excellent for filling other voids formed at the junctions of building structures. For example, the figure shows the insulation of the junction of an old partition with a newly erected ceiling - filling this gap with polyurethane foam will provide both insulation and the necessary sound insulation.
	Excellent polyurethane foam lays down and on metal constructions, which, due to their very high thermal conductivity, are always the most pronounced "cold bridges".
	Do not try to immediately apply a thick layer of thermal insulation. The foam expands very quickly and without experience with this material it is very easy to make the mistake of wasting material unnecessarily. The optimal solution is to apply a thin layer, and after about 20 minutes, evaluate the degree of expansion of the foam. If necessary, then briefly bring the insulation layer to the thickness required by the calculations. (The calculation of the thickness of the insulation will be discussed below).
	In the process of work, it is necessary to monitor the quality of the applied foam. So, if it does not rise well or has changed in color (it has become darker or a pronounced brown tint has appeared), then the mixing proportions are violated. If the canisters are not empty and the hoses are fine, there is a good chance that one of the channels in the mix/spray head is clogged. There are spare heads in the kit, and, therefore, it is necessary to replace. To do this, the trigger lever is placed on the lock. Then the interchangeable head stopper is lifted.
	The head is gently pushed forward with the force of the fingers.
	Its cylindrical guides come out of the channels of the gun, and then it is completely removed and removed as unnecessary.
	To install a new head, the above-mentioned lubrication of the mating areas with silicone grease is carried out. Then the head is inserted into place ...
	... and sags with the force of the fingers to the end, so that the upper stopper, which fixes the atomizer in the gun, works.
	After that, you can again proceed to the spraying of polyurethane foam - the normal mixing of the components and good spraying of the jet will be restored.

When working, it is necessary to monitor the constant observance of safety precautions. If the components or the finished foam get on unprotected areas of the body or, even worse, on the mucous membranes, it is necessary to immediately rinse out with plenty of clean water. When washing off the skin, you can use ordinary soap. Foam that has frozen on your hands will not give in to soap - you can wipe it off with a rag soaked in a nitro-based organic solvent (acetone or 646).

What should be the thickness of the insulation sprayed with polyurethane foam?

In order to determine this parameter, you can independently carry out a thermal calculation. Its meaning lies in the fact that any building structure (wall, ceiling or roofing) after insulation must have a total resistance to heat transfer not lower than the normalized value established for a given area, taking into account its climatic features.

The initial data will be:

Parameters of the insulated structure. This refers to its thickness and the coefficient of thermal conductivity of the material of manufacture. In addition, the structure may have a multilayer structure. For example, a wall (ceiling, inner side of a roof slope) has a continuous finish (sheathing) made of a material that also contributes to the overall thermal insulation. Those layers that are separated from the outside of the building from the main structure by a ventilated gap (ventilated facade or roof) are not taken into account.
Normalized value of resistance to heat transfer. It can be determined by the proposed map-scheme - for your region.

Map-scheme for determining the normalized value of thermal resistance for building structures

Please note that for each area, three values \u200b\u200bare indicated - separately for walls (purple numbers), floors (blue) and coverings (red). They differ significantly, and it is necessary not to confuse the values when calculating the thickness of the insulation of a particular structure.

Knowing the listed values, it is possible to carry out the calculation using a special formula. The formula, however, will not be given, because below is a convenient calculator for quick and accurate calculations. All the necessary dependencies and table values are already included in it.

PPU - polymer No. 1 in the world!

The material belongs to the class of gas-filled plastics or, as they are also called, foams. Among the latter there are also resole, urea, polystyrene and other varieties.

Polyurethane foam was first synthesized in 1937 in Germany. Since then, it has found wide application in various fields of activity. One of the main directions is as a thermal insulator having a closed porous structure. PPU has the lowest coefficient of thermal conductivity in comparison with analogues and minimal moisture absorption.

The popularity of polyurethane foam is due to the fact that it can be obtained directly at the place of insulation by mixing liquid components. As a result of a chemical reaction, foaming of the mixture occurs.

The foamed material is 85-90% composed of an inert gas phase. The initial components for its production are polyol and polyisocyanate, which are processed on specialized equipment for polyurethane foam.

PPU equipment of the FOAM series

Applications for polyurethane foam

Polyurethane foam is obtained by two main methods:

spraying with the help of special PPU equipment on the surface directly on the object;
pouring on equipment for the production of polyurethane foam in the production of molded products in the workshop.

Polyurethane products have a wide range of applications: automotive, furniture and design industry, building renovation, hydro and thermal insulation of enclosing structures, insulation of refrigeration equipment, isothermal vans and much more.

Read more about polyurethane foam production methods:

Areas of application for polyurethane foam:

Construction of prefabricated industrial and civil facilities (sandwich structures);
Construction and overhaul residential buildings, individual houses, cottages (insulation of external walls, foundations, internal insulation of the roof, window openings, doors, etc.);
Industrial and civil construction (external heat and waterproofing of roofs with rigid sprayed polyurethane foam);
Pipeline transport (thermal insulation of fuel oil and oil pipelines, high-performance insulation of low-temperature pipelines at chemical facilities under a pre-assembled casing);
Heating networks of settlements (thermal insulation with filling PPU of hot water supply pipelines during a new laying or during a major overhaul);
Refrigeration equipment (thermal and cold insulation of domestic and commercial refrigerators and freezers, warehouses for food and agricultural products);
Transport refrigeration equipment (thermal insulation of refrigerated trucks, railway refrigerated cars of the "thermos" type);
Radio and electrical engineering (giving vibration resistance to various electrical devices, hydroprotection of contact joints);
Automotive industry (molded parts of the interior of a car based on elastic, semi-rigid, integral, thermoformed polyurethane foams);
Furniture industry (manufacturing upholstered furniture(foam rubber), body and decorative elements made of rigid polyurethane, varnishes, glue, coatings, etc.);
Light industry (manufacture of synthetic leather and products, duplicated fabrics, etc.);
Car building and aircraft building (molded elastic products with increased fire resistance, noise and heat insulation based on special grades of raw materials);
Mechanical engineering (products made of thermoplastic polyurethanes, as well as special grades of PU and polyurethane foam).

Much of the above can be achieved with state-of-the-art PU foam equipment from NST: PU foam sprayers and PU foam casting equipment.

We are ready to transfer technology to you, install and adjust equipment for the production of polyurethane foam, help you select the necessary raw materials: components for pouring and components for spraying polyurethane foam, equip you with knowledge and skills, in a word, do everything so that you can set up your own production.

Physical and mechanical properties of rigid polyurethane foams:

PPU products and chemical compounds:

Advantages of polyurethane foam as a heater

Polyurethane foam is considered one of the most the best heaters thanks to a set of high installation and operational qualities. The structure of polyurethane foam is cellular, filled up to 90% with gas. It provides the insulation with low weight, eliminating excessive load on the thermally insulated object.

The cured polymer has a thermal conductivity of 0.020-0.035 W/(m K), which is better than mineral wool and gas glass. Unlike expanded polystyrene, such products are resistant to all chemical environments, moisture, external factors. Polymerization prevents the corrosion process, so the pipeline system insulated with polyurethane foam does not rust. At the same time, its moisture absorption is extremely low.

From point of view fire safety this polymer has no equal. The material is non-flammable, self-extinguishing, does not spread smoke. According to environmental standards, it is completely harmless. Serves as a heater for at least 30 years.

Due to the high adhesive strength, it is not necessary to use fasteners or adhesives - the polyurethane foam sprayed with the help of special equipment is securely held on the surface. At the same time, it is possible to insulate a surface of any geometric shape, slope and size.

Polyurethane foams also provide high acoustic insulation, so they can also be used as sound protection.

The customer can independently choose a system of liquid components, on which the density of the finished PPU thermal insulation layer depends.

Foamed polyurethane is used for insulation of industrial and civil facilities made of concrete goods, bricks, foam and gas blocks, wood, metal and other materials. Due to the seamless application of the composition, there are no so-called cold bridges through which heat escapes from the room.

Thermal insulation with polyurethane foam

If the ingredients (isocyanate and polyol) are mixed with air, then a fine aerosol is formed, which is applied to the surface. This process is called polyurethane foam spraying. To do this, you must use a spray gun (shown in the photo below in operation and large).

The work is very similar to painting with a spray gun: the operator moves along the surface that needs to be protected with thermal insulation (whether it be a wall, floor, ceiling or even a pipe).

polyurethane foam insulation technology

PPU spraying technology is currently one of the most popular ways to quickly insulate surfaces. With the help of PPU equipment and a spray gun, liquid components are positionally supplied in the form of an aerosol, which passes through the stage of expansion and solidification in a few seconds.

Insulation with the use of polyurethane foam significantly saves money on the transportation of materials, since the production of polyurethane foam can be carried out on the required scale right on the construction site.

Unlike other methods of insulation, polyurethane foam spraying has undeniable advantages:

dew points are excluded, where standard moisture is collected, due to the ideal filling of all cracks, even in hard-to-reach places;
adhesion comparable to professional building adhesives;
the sprayed layer does not leave seams, joints;
cooling of the material is weak, due to the diffusion process of cold air penetration (gradual cooling of the gas in the cells).

Such polyurethane foam insulation creates the effect of a thermos. In addition, high sound insulation is provided. The only thing - you need to provide protection from UV rays.


Facade for cladding

Hangar, inside view	attic floor

heating main

roofs

Polyurethane foam is a highly efficient, technologically advanced, high-quality, affordable and unique in its characteristics heat-insulating material.

Pouring polyurethane foam

If the ingredients are mixed without access to air, then a monolithic, even jet is formed, which can be injected into a limited cavity. This process is called pouring polyurethane foam. To do this, you must use the filling head (shown in the photo below in operation and large).

A distinctive feature of this technology is efficiency. It is enough to cover the bottom of the mold with a mixture of ingredients, and after 20-25 seconds the composition increases in volume, filling the entire space. Other distinguishing feature- the ability to receive products of any relief.

Thanks to this, the polyurethane foam filling technology allows the production of a wide range of different products:

heat-insulating shells;
plates, sandwich panels, panels with cladding, thermal panels;
thermolars, elements of refrigerators;
graters, baguettes, stucco;
furniture elements;
bee hives;
elements of air ducts and ventilation systems ...

And much more!


Shells and furniture decor in molds

Construction graters	Thermal insulation boards

shells	half cylinders

Slab with cladding (roof element)	Window leaf (element of the ventilation system)

Panel with clinker tiles

Another promising direction is the production of insulated polyurethane beams, which has long been known abroad. Polyurethane foam is poured between two boards, which, foaming, “seams the boards together”. Subsequent processing on the machine gives an imitation of logs. Advantage: such a 150 mm thick log corresponds to a real 800 mm thick log in terms of thermal conductivity! But a house built from such a bar is lighter, cheaper and warmer!

Polyurethane for pouring molds

When pouring polyurethane foam, in contrast to the spraying technique, it is required not only pumping station for mixing components in the filling head, but also for molds in which the process of giving the desired look to finished products takes place. With the help of molds, shells for pipes, facing sandwich panels, decor and furniture details, skirting boards, etc. are made.

The technology for the production of insulation involves pouring a thin layer of polymeric raw materials, after which the mold is tightly closed. It takes up to 20 seconds to increase in volume and harden, after which it is possible to start the process of PPU insulation - the installation of molded products.

So, by pouring polyurethane foam, it is possible to obtain any product. The main thing is to choose the right components and mix the composition with high quality. This will provide the NST equipment. Our company also supplies the necessary molds.

Polyurethane foam (PPU) is a liquid heat insulator that is applied directly to the surface using special equipment. Thanks to the spraying technology, an integral uniform layer is created, the energy efficiency of which is much higher than when using classic heaters (mineral, basalt wool, polystyrene foam, glass wool, extruded polystyrene foam). Reviews of PPU insulation confirm the effectiveness, for example, a 2-centimeter layer of polyurethane foam is comparable in efficiency to a 20-centimeter mineral wool.

What are the opinions?

“According to reviews, thermal insulation by means of PPU spraying is an economical and durable method. From personal experience I can say that it allows you to reduce the cost of heating industrial facilities by 30%. For my hangar, I used the method of internal application, since it is resistant to biological decomposition, inert to chemical environments and high strength, which makes it indispensable for thermal insulation of such buildings.”

Alexander Boyko, Moscow.

“Reviews about polyurethane foam are rather ambiguous: the material is strong and durable, but expensive to install. I want to say that it is better to spend money on insulation once than to constantly lose money on paying for energy resources. I have my own service station, with a similar building, it should be remembered that not every insulation is able to maintain its characteristics when in contact with gasoline vapors and engine oil. I opted for PPU, because it is resistant to chemically aggressive environments.”

Vasily Arkadyevich, Samara.

“Polyurethane foam is a universal insulation that is suitable for various structural elements buildings. Used a liquid thermal insulator for insulation wooden house with an attic, since it does not exert additional load on the structure and allows you to create a uniform layer for structures that have a complex configuration (attic walls and ceiling).

Igor Vlasov, Ufa.

“Reviews and opinions about PPU indicate high protective properties. I decided to buy a material for insulating a metal garage, since the thermal insulator is applied thinly, which saves usable floor space and protects the metal from corrosion.”

Sergey, Leningrad region.

“I want to say, as a person who has been working with a liquid heat insulator for a long time, that it is impossible to spray polyurethane foam with your own hands, since you need special spraying equipment. It is best to entrust this to professionals: a team of 2-3 people is quite capable of insulating a hangar with an area of 1,000 m 2 in 2-3 days.

Kirill Korshun, Smolensk.

An overview of PPU insulation indicates the possibility of using for buildings built from various materials. Polyurethane foam has high adhesion, which provides reliable adhesion to the insulated surface, therefore, there is no need for additional fasteners. In addition, the insulation has sufficient vapor permeability and hydrophobicity, which makes it impractical to install hydro and vapor barriers.

Advantages and disadvantages of polyurethane foam

The advantages of the material include:

high vapor permeability;
low coefficient of thermal conductivity;
fire safety;
environmental friendliness;
durability;
biological and chemical inertness;
hydrophobicity;
adhesion, which makes it possible to mount it directly on the surface without a frame device and the use of fasteners;
light weight;
small thickness of the layer with its energy efficiency;
application for external and internal insulation;
uniformity and integrity avoids the occurrence of cold bridges.

PPU is easily applied to various surfaces, suitable for structures with a complex configuration.

The main disadvantages are the high price and the impossibility of performing thermal insulation work by spraying polyurethane foam without special equipment. As for the cost, it varies depending on the material of the insulated plane, as well as the configuration of the building.

What are polyurethane foams and where are they used? Advantages of rigid polyurethane foam for thermal insulation of buildings and communications. What you need to know about sprayed thermal insulation? We will also consider the preparation of polyurethane foam from industrial components and calculate the cost of 1 m2 of thermal insulation.

Definition

polyurethane foam- a promising synthetic insulation, consisting of a hardened polymer foam, which surpasses most modern analogues in quality.

Polyurethane foam is a synthetic substance with a cellular structure from the group of gas-filled plastics, widely used in construction. It is characterized by minimal thermal conductivity, environmentally friendly, durable and easy to use.

Composition, brands and GOSTs

Expanded polyurethane foam (PPU) is obtained by mixing two liquid polymers: polyol and polyisocyanate. The frozen foam contains up to 90% of gas in its cells, which ensures high thermal insulation qualities of polyurethane foam. Depending on their proportion and the presence of flame retardant additives, the final product differs in structure, technical characteristics and scope.

Soft and elastic foam rubber is used as a filler for furniture and household products. Foam rubber grades have different density (from 5 to 40 kg / m 3) and rigidity:

With the exception of the last brand, foam rubber refers to highly flammable substances according to GOST 30244, according to GOST 30402 - to flammable, according to GOST 12.1.044 - to smoke-forming and toxic during combustion. For these reasons, foam rubber is not used in construction.

PPU with flame retardant additives is called rigid polyurethane foam. It has a high density (30-86 kg / cm 3), in its finished form it loses elasticity, but it has a lot of other advantages. It is used in construction for heat and noise insulation, and super-dense types (from 70 kg / cm 3) are used for waterproofing in building foundations and on other surfaces.

Construction polyurethane foam is prepared from two components: polyol (component A) and isocyanate (component B). Isocyanate serves as a base chemical process and its composition does not change, and different polyols are used, which affects the foaming rate, density and flammability. According to GOST 307302-2006, PPU belongs to the G3 flammability class (self-extinguishing, flame-retardant, flame-retardant) and is recommended for thermal insulation of buildings and pipelines.

As a thermal insulation material, PPU is easy to manufacture and can be mixed on site, and components for polyurethane foam are often cheaper to buy and deliver to a construction site than to transport a finished product.

With a professional foam generator high pressure and compliance with the proportions of the components, such PPU is in no way inferior to the factory one. Foam can be sprayed onto various surfaces or made into sandwich panels.

PPU release forms

The chemical industry produces the following types of PPU:

Foam rubber - in rolls and mats;
Rigid polyurethane foam - in sheets, panels and cast shells;
Liquid polyurethane foam - in the form of a sprayed coating.

Thermal insulation panels made of polyurethane foam different thickness and with various protective coatings. For sheet polyurethane foam, the price for 1 m 2 is as follows:

Specifications of polyurethane foam

For standard PU foam insulation panel medium density have the following characteristics:

Characteristic, unit of measurement	Meaning	A comment
Compressive strength with deformation up to 10%, MPa		An excellent indicator, for comparison, for foam concrete, the coefficient is 0.4-1.2, for expanded polystyrene (EPS) 0.06, for mineral wool 0.002 MPa.
Bulk weight (density), kg/m3		Ultralight material, for mineral wool the density is 150-250, for foam concrete 250-400 kg / m3.
Shrinkage, mm/m		No shrinkage of the cured foam was detected.
Thermal conductivity, W/m*K		The minimum, lower than that of analogues: PPS - 0.035-0.042, mineral wool - 0.035-0.6, foam concrete - 0.08-0.13 W / m * K.
Frost resistance, cycles		A very high rate.
Water absorption, %		Excellent value among analogues: foam concrete 15-20%, PPS 0.5-1.5%.
Vapor permeability, mg/mhPa		Almost absolute vapor barrier. For PPS, the indicator is 0.002-0.005, for mineral wool 0.29, for foam concrete 0.23.
fire resistance		Hardly flammable self-extinguishing substance.
Cost rub./m2		The price of polyurethane foam panels depends on the thickness and protective layers (paper, foil, galvanized steel, etc.)
Soundproofing		Similar to PPS, superior to foam concrete and mineral wool.
Toxicity (environmental friendliness)	Non-toxic	Does not emit harmful compounds, dust, has no smell. Used in food refrigerators.
Service life, years		One of the most durable types of thermal insulation.

Unique qualities

High adhesion (adhesion) to most surfaces. PPU is sprayed onto concrete, metal, wood, brick, glass;
Installation without fasteners;
The absence of "cold bridges" with seamless thermal insulation;
Corrosion protection of pipes and metal structures;
The possibility of manufacturing heat-insulating "shells" of a given shape by pressing liquid polyurethane foam;
Work in the temperature range from -200 to +200 о С;
Inert to most acids, alkalis and soil salts.

Liquid polyurethane foam allows you to fill cracks and interstitial spaces where it is impossible to lay other insulation. Due to its light weight and adhesive factor, it does not weigh down structures and strengthens them.

Minuses

Destroyed by ultraviolet radiation and needs to be isolated from sunlight. This is a completely solvable issue, the modern range of sandwich panels provides for any coatings for sheet polyurethane foam.
Foam applied only on a dry and warm surface, which limits its use on open construction sites in winter period.
PPU does not burn, but it can smolder from high temperatures, which affects the strength of thermal insulation. For boiler rooms, baths and saunas is not recommended.

Is polyurethane foam harmful to health? The finished product is safe for humans. In the process of mixing and spraying insulation, it is necessary to observe safety precautions, work in a protective suit and only with tested equipment and certified reagents.

Application area

Foamed polyurethane foam is widely used in construction. For clarity, it can be noted that 10 cm of PPU are equivalent to 2 meters of brickwork. In the refrigeration and instrumentation industries, such efficient and compact thermal insulation is indispensable. It is used in the space and rocket industry, automotive industry and furniture production.

Mounting methods

Spraying a heat-insulating coating from PPU is a quick and high-quality installation method. For successful spraying of thermal insulation, you need:

Dry clean work surface;
Lack of precipitation (rain, snow, fog);
Wind not stronger than 5 m/s;
Working surface temperature from +10 o С;
Mixture temperature +18-25 o C;
The thickness of the sprayed layer is 3-5 cm.

Work is carried out in a protective suit and mask, in a ventilated room, starting from hard-to-reach areas (pipes, ventilation hatches, etc.). The sprayed layer in one pass is about 15 mm; for reliable insulation, the surface is treated several times.

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