Introduction To Spray Polyurethane Foam (SPF)

Introduction to SprayPolyurethane Foam (SPF) December 11, 2012Pennsylvania Housing Research CenterRick DuncanTechnical DirectorSpray Polyurethane Foam Alliance v2.5 2012 SPFA - Spray Polyurethane Foam Overview

Today’s PresenterRichard S. Duncan, Ph.D., P.E.Technical Director, Spray Polyurethane Foam AllianceRick is currently Technical Director for the SprayPolyurethane Foam Alliance. Prior to joining SPFA, he wasthe Senior Marketing Manager for Honeywell’s Spray FoamInsulation business from 2006 to 2008. From 1997 to 2006,he was the Global Program Director for CertainTeed/SaintGobain Insulation’s New Materials and ApplicationsPortfolio. From 1989 to 1997 he was a Visiting AssistantProfessor of Mechanical Engineering at BucknellUniversity. He holds a Ph.D. in Engineering Science andMechanics from The Pennsylvania State University, MSMEfrom Bucknell and a BSME from the University ofMaryland. Rick is a Registered Professional Engineer inthree states and is a certified BPI Building Analyst. 2012 SPFA - Spray Polyurethane Foam Overview

SPFA History Spray Polyurethane Foam Alliance– Originally founded as the Urethane Foam Contractors Association(UFCA) in 1975– In 1987 it became the Polyurethane Foam Contractors Division of theSociety of the Plastics Industry (SPI) – Since 2003, it has been an independent trade association forcontractors, manufacturers and distributors of polyurethane foam,equipment, protective coatings, inspections, surface preparations andother services.– Maintains strong relationship with the American Chemistry Council(ACC) and their Center for Polyurethanes Industry (CPI) 2012 SPFA - Spray Polyurethane Foam Overview

SPFA Programs and Activities Education and Research––––Accreditation/Certification and Education programsTechnical Literature and Guidelines"Hotline" for Technical questions (1-800-523-6154)Industry Research Programs Promotion and Awareness––––––Regulatory and Legislative ActivitiesPromotional and Marketing ToolsWebsite www.sprayfoam.orgAnnual Spray Foam Conference and ExpositionSpray Foam Professional magazineDirectory and Buyers' Guide 2012 SPFA - Spray Polyurethane Foam Overview

SPFA Website www.sprayfoam.org– Key features of home page– Health and Safety– Technical– Membership 2012 SPFA - Spray Polyurethane Foam Overview

SPFA Publications Spray Foam Professional Magazine– Quarterly magazine through NACE Publishing– SPFA works with SFP editors at Naylor to develop and reviewcontentwww.naylornetwork.com/spfa/ 2012 SPFA - Spray Polyurethane Foam Overview

Poll: Who’s Who? 2012 SPFA - Spray Polyurethane Foam Overview

Content History and products SPF chemistry and delivery methods Safety requirements Environmental impact Performance Applications Building codes 2012 SPFA - Spray Polyurethane Foam Overview

History of SPF in BuildingsSPF in construction for 50 years Late 60’s - Medium Density (agricultural andindustrial) Mid 70’s- Roofing- Medium Density (general const.)- Sealants Mid 90’s- Low Density (residential) 2012 SPFA - Spray Polyurethane Foam Overview

Product CategorySPF: field-applied thermoplastic foam 2007 DEI 2012 SPFA - Spray Polyurethane Foam Overview

Product CategoryFour types of SPF in ConstructionSpray FoamDensity (lb/ft3)Thermal Resistivity (R/in)Air Impermeable MaterialIntegral Air Barrier SystemIntegral Vapor RetarderWater ResistantCavity InsulationContinuous InsulationLow-Slope RoofingStructural ImprovementSealantLDMDRoof0.6 – 1.8NR*0.5 - 1.43.6 - 4.5 1.5 -2.36.2 - 6.8 2.5 - 3.56.2 - 6.8 2012 SPFA - Spray Polyurethane Foam Overview

Basic ChemistryReaction of 1:1 mixing of two liquids A-Side: Blend of monomeric and polymeric MDI(MDI Methylene diphenyl diisocyanate ) B-Side or Polyol–––––polyolsblowing agentsflame retardantssurfactantscatalystsProprietary blend of additives affectcell formation and foam performance 2012 SPFA - Spray Polyurethane Foam Overview

Basic ChemistryTwo Competing Chemical ReactionsBLOW: Expansion of liquid into a cellular structurea.b.MDI chemical blowing agent (H2O) CO2 gasExothermic heating of polymerization transforms liquidphysical blowing agent (HFC) into vaporSET: Polymerization of liquid into solid polyurethanea.MDI polyols polyurethaneOther additives are important: Catalysts control polymerization reaction time and temperature (speed) Surfactants control cell formation and structure Flame retardants embedded in PU provide built-in fire resistance 2012 SPFA - Spray Polyurethane Foam Overview

Basic ChemistryB-Side Formulation:FlameRetardants,10%Catalysts, 3%Surfactants,2% These are the five basiccategories of B-side chemicals. Percentages will vary based onfoam type (oc vs cc) andmanufacturer.BlowingAgents, 20%Polyols, 65% Some foam formulationscontain small amounts ofadditional additives forappearance and addedfunction, such as colorantsand anti-microbial chemicals. 2012 SPFA - Spray Polyurethane Foam Overview

Basic ChemistryB-Side Formulation: PolyolsFlameRetardants,10%Catalysts, 3%BlowingAgents, 20%Surfactants,2% Provide the hydroxyls (OH) thatcombine with MDI (NCO) to formpolyurethane Petroleum polyols are polyesterand/or polyether blendsPolyols, 65%Polyols plus MDI are basic buildingblocks needed to make polyurethane Some natural oil polyols, likesoybean oils or sucrose-basedpolyols can be blended withpetroleum polyols (20 45) Some products add brominateddiols (polyols) to improve flameretardancy 2012 SPFA - Spray Polyurethane Foam Overview

Basic ChemistryB-Side Formulation: Blowing AgentsFlameRetardants,10%Catalysts, 3%Surfactants,2% Create the gas needed to expandthe liquid polyurethane mixture Physical blowing agents convertfrom liquid to a gas from the heatof the reaction (HFC-245fa)BlowingAgents, 20%Polyols, 65% Chemical blowing agents aregases created from chemicalreactions. Water MDI CO2 Some SPF uses blend of water andHFC-245faWithout blowing agents to expandfoam, solid polyurethane wouldresult Non-flammable when used in SPF,No VOC 2012 SPFA - Spray Polyurethane Foam Overview

Basic ChemistryB-Side Formulation: Flame RetardantsFlameRetardants,10%Catalysts, 3%Surfactants,2% Polyurethane foam is an organicmaterial and is combustible. Without fire retardants, foamplastics would not meet buildingcode flame spread requirements.BlowingAgents, 20%Polyols, 65%Flame retardants necessary forbuilding fire safety No brominated FRs – (PBDE) Some use Br-diols in polyolblend Uses halogen-phosphorous FRssuch as TCPP – most common TDCP – phasing out TEP – increased interest 2012 SPFA - Spray Polyurethane Foam Overview

Basic ChemistryB-Side Formulation: CatalystsFlameRetardants,10%Catalysts, 3%BlowingAgents, 20%Surfactants,2% Amine catalysts are used tocontrol the polyurethanereaction. Reactive Non-Reactive (odor-prone) Metal catalysts may also be used.Polyols, 65% To achieve proper desired foamproperties, competing balancebetween BA expansion andpolyurethane curing – stabilizingthe foam.Catalysts control rise andcure of SPF 2012 SPFA - Spray Polyurethane Foam Overview

Basic ChemistryB-Side Formulation: SurfactantsFlameRetardants,10%Catalysts, 3%BlowingAgents, 20%Surfactants,2% Surfactants control cell formationrheology (flow properties) anddegree of opening of panes insideeach cellPolyols, 65%Surfactants control cell structure 2012 SPFA - Spray Polyurethane Foam Overview

Basic ChemistryTypical (generic) B-Side FormulationsB-SIDERAW MATERIALPolyolsBlowing AgentsFlame ral Oil (Soy)CompatibilizerPolyetherReactive (H2O)Physical (HFC)TCPPTDCPAmineMetalSiliconeB-Side WGT % (Generic)0.5 pcf 2.0 pcf 3.0 pcf45.0% 35.0%30.0% .0%0.5%1.0%1.6%7.0%8.0%2.0%0.4%1.0%Generic formulations used for SPFA’s Life-Cycle Assessment (LCA) 2012 SPFA - Spray Polyurethane Foam Overview

Basic ChemistryFundamental Cell Model Closed-Cell Foam: Essentiallyall panes are intact ( 90% cc) Open-Cell Foam: One ormore panes open (mostly oc) Reticulated Foam: All panesopen, thick strutsCell structure and size affects density, flexibility, recovery as well asall other physical properties 2012 SPFA - Spray Polyurethane Foam Overview

3. Basic ChemistryOPEN CELL 100x expansion0.5 to 0.8 pcfR-3.6 to R-4.5 per inch (air)CLOSED CELL 30x expansion1.7-3.5 pcfR-5.8 to R-6.8 per inch(trapped low-k gas) 2012 SPFA - Spray Polyurethane Foam Overview

Delivery MethodsOne-Component Low-Pressure Sealants 6-15 BF/min froth A and B pre-mixed;cured by contact withambient moisture Low/high expansion Air-sealing of smallcracks, gaps and holes Non-insulatingRetail DIY productfor air sealing only 2012 SPFA - Spray Polyurethane Foam Overview

Delivery MethodsTwo-Component Low-Pressure Foam 30-40 BF/minute froth A and B in separatepressurized cylinders Mechanical mixing Insulation and airsealing - small jobsProfessionally applied product used byweatherization contractors and by SPFcontractors for small jobs or repair work 2012 SPFA - Spray Polyurethane Foam Overview

Delivery MethodsTwo-Component High-Pressure SPFProfessionally applied insulation androofing SPF installed by trainedcontractors large jobs 100-500 BF/minute spray A and B in unpressurizeddrums or totes Chemicals heated andpressurized by proportioner Larger insulation jobs and allroofing applications Special training and capitalinvestment 2012 SPFA - Spray Polyurethane Foam Overview

Chemical Safety During Application Hazardous chemicals are used for SPF A-side (Isocyanate) is reactive and can cause respiratoryor dermal sensitization B-side components (catalysts) can cause irritation Delivery methods affect exposure Low-pressure: gloves, eyes, APR High-pressure: full-skin, eyes, APR or SAR 2012 SPFA - Spray Polyurethane Foam Overview 2012 SPFA - Spray Polyurethane Foam Overview

Chemical Safety During Application Chemical Safety Measures PPE required during and just afterinstallation Isolate, contain and vent work zone SPF contractor safety plan www.spraypolyurethane.com 2012 SPFA - Spray Polyurethane Foam Overview

Chemical Safety After Application No known chemical hazards for occupants Safe MDI levels in 1-6 hours 24 hour re-occupancy typical Installed SPF is low-VOC (SPF is solvent-free)- GreenGuard Environmental Institute- CAN/ULC-S774 Saskatchewan Research Council 2012 SPFA - Spray Polyurethane Foam Overview

Environmental ImpactRaw Materials Petroleum vs. natural oil polyols0.18-0.27 cfm1.71-2.10 cfm 2012 SPFA - Spray Polyurethane Foam Overview

Environmental ImpactRaw Materials Fluorocarbon blowing agent evolutionYearsGeneration SPF Blowing AgentODPGWP0.18-0.27 cfm1960s -19931CFC-111.047501993 - 20032HCFC-141b0.121.71-2.10 cfm2003 - pres3HFC-245fa010202012?4HFO/HFE06 - 15760 2012 SPFA - Spray Polyurethane Foam Overview

Environmental ImpactRaw Materials Phosphate flame retardants (no brominated) No brominated FRs used TEP, TCPP, TDCP are typical Evaluated as potential carcinogen, mutagen, 0.18-0.27 cfmreproductive system, bio-toxicity, bio-accumulative1.71-2.10 cfm Low risk per EU EEC No. 793/93 Risk AssessmentEU EEC No. 793/93 Risk Assessment 2012 SPFA - Spray Polyurethane Foam Overview

Environmental ImpactDisposal and Recycling Landfill safe Mechanical grinding for fillers and packaging Chemical recycling0.18-0.27 cfm1.71-2.10 cfm 2012 SPFA - Spray Polyurethane Foam Overview

Environmental ImpactLife-Cycle Assessment Industry-wide LCA recentlycompleted by SPFA ISO-compliant to ISO14040/14044 Third-party analysis and review Transparent, credible review Cradle-to-End-of-Life SPF insulation and roofingproducts, by application andclimate zone0.18-0.27 cfm 2012 SPFA - Spray Polyurethane Foam Overview