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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Building Codes and Standards
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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Building Codes and Standards
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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Building Codes and Standards
Mandatory MHQAP Inspections for Insulation Warranty
Mandatory MHQAP Inspections for Air Barrier System
6
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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150 years
Building Codes and Standards
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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150 years
Building Codes and Standards
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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Building Codes and Standards
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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Building Codes and Standards
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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Building Codes and Standards
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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Building Codes and Standards
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
150 years
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
150 years
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
150 years
Health and Safety
First Aid for Isocyanate or Resin Exposure
Ingestion
Do not induce vomiting
If person is alert, they should drink large amounts of water
Get medical attention
Inhalation
Move to fresh air, do not allow person to re-enter work area
Aid in breathing if necessary
Get medical attention
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Health and Safety
First Aid for Isocyanate or Resin Exposure
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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150 years
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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150 years
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
150 years
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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150 years
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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150 years
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
150 years
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
47
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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150 years
Storage and Handling
Isocyanate and Resin Shelf Life
48
Product Shelf LifeWALLTITE v.2 and v.3 6 MonthsENERTITE 1-2-1 6 MonthsELASTOSPRAY 8000A Iso 12 Months
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150 years
Storage and Handling
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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Storage and Handling
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
51
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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Environmental Conditions and Material Selection
52
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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150 years
Environmental Conditions and Material Selection
53
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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150 years
Environmental Conditions and Material Selection
54
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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150 years
Environmental Conditions and Material Selection
55
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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150 years
Environmental Conditions and Material Selection
56
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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Environmental Conditions and Material Selection
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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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150 years
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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150 years
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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Preparation of Substrates
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150 years
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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Preparation of Substrates
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150 years
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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Preparation of Substrates
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150 years
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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Preparation of Substrates
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150 years
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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Preparation of Substrates
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150 years
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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Preparation of Substrates
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Isolation and Ventilation
Requirements
Equipment
Warning Signs
Job Site Set-up
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Isolation and Ventilation
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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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150 years
Isolation and Ventilation
67
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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150 years
Isolation and Ventilation
68
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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150 years
Isolation and Ventilation
69
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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Isolation and Ventilation
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Isolation and Ventilation
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Application of WALLTITE
72
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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150 years
Application of WALLTITE
73
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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150 years
Application of WALLTITE
74
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
The same applies whether spraying vertical or horizontalRev-June 2017
150 years
Application of WALLTITE
75
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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150 years
Application of WALLTITE
76
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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150 years
Application of WALLTITE
77
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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Application of WALLTITE
78
Thickness for WALLTITE
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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Application of WALLTITE
79
Thickness for WALLTITE
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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Application of WALLTITE
80
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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Application of WALLTITE
81
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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150 years
Application of WALLTITE
82
Winter application technique
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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150 years
Application of WALLTITE
83
Winter application technique
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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Application of WALLTITE
84
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
Rev-June 2017
150 years
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
Application of WALLTITE
85
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
* Results achieved in ideal laboratory conditions and may vary with each applicationRev-June 2017
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Application of WALLTITE
86
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
Rev-June 2017
150 years
Application of ENERTITE 1-2-1
88
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
Rev-June 2017
150 years
Application of ENERTITE 1-2-1
89
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
Rev-June 2017
150 years
Application of ENERTITE 1-2-1
90
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
Rev-June 2017
150 years
Application of ENERTITE 1-2-1
Properly mixed material
Banana cream colour throughout
Insufficient Mix
Brown surface
91Rev-June 2017
150 years
Application of ENERTITE 1-2-1
92
Properly mixed material
Banana cream colour throughout
Can be verified by lifting drum pump straight up from bung hole
Rev-June 2017
150 years
Application of ENERTITE 1-2-1
93
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
Rev-June 2017
150 years
Application of ENERTITE 1-2-1
94
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
Rev-June 2017
150 years
Application of ENERTITE 1-2-1
95
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
Rev-June 2017
150 years
On Site Testing for Quality Control
96
Visual Appearance
Reaction
On Site Testing
WALLTITE
ENERTITE1-2-1
DWR and Job Site Label
Rev-June 2017
150 years
On Site Testing for Quality Control of WALLTITE
97
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
Rev-June 2017
150 years
On Site Testing for Quality Control of WALLTITE
98Rev-June 2017
150 years
On Site Testing for Quality Control of WALLTITE
99
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
Rev-June 2017
150 years
On Site Testing for Quality Control of WALLTITE
100
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
Rev-June 2017
150 years
On Site Testing for Quality Control of WALLTITE
101
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
Rev-June 2017
150 years
On Site Testing for Quality Control of WALLTITE
102
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
Rev-June 2017
150 years
On Site Testing for Quality Control of WALLTITE
103
Reaction
Fast Reacting Foam
Improper chemical system selection
Primary heater and hose settings too high
Substrate temperature too hot
Density may be affected
Rev-June 2017
150 years
On Site Testing for Quality Control of WALLTITE
104
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
Rev-June 2017
150 years
On Site Testing for Quality Control of WALLTITE
105
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
150 years
On Site Testing for Quality Control of WALLTITE
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
106Rev-June 2017
150 years
On Site Testing for Quality Control of WALLTITE
On Site Testing
Density Calculation
g ÷ mL x 1000 = kg/m3
÷ 16 to obtain pcf
Record on DWR
Minimum density is 1.80 pcf
107
Density Calculation, alternative
g ÷ mL x 62.4 = pcf
Rev-June 2017
150 years
On Site Testing for Quality Control of WALLTITE
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
Rev-June 2017
150 years
On Site Testing for Quality Control of WALLTITE
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
109Rev-June 2017
150 years
On Site Testing for Quality Control of ENERTITE 1-2-1
110
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
Rev-June 2017
150 years
On Site Testing for Quality Control of ENERTITE 1-2-1
111
Daily Testing, Density
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
Rev-June 2017
150 years
On Site Testing for Quality Control of ENERTITE 1-2-1
112
Daily Testing, Density
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
150 years
On Site Testing for Quality Control of ENERTITE 1-2-1
113
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
Rev-June 2017
150 years
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
114Rev-June 2017
150 years
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
115Rev-June 2017
150 years
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
116Rev-June 2017
150 years
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
117Rev-June 2017
150 years
Job Site Label
118Rev-June 2017
150 years
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
119
Repair
Fix equipment
– Likely a supply issue
Remove area with off ratio foam and re-spray
Rev-June 2017
150 years
Spray Foam Trouble Shooting
Blisters
Areas of foam that have no adhesion to the substrate
Causes
– Cold foam application
– Moisture
– Wind
– Foreign material (oils, grease, etc.) contaminating substrate
120Rev-June 2017
150 years
Spray Foam Trouble Shooting
Blisters
121Rev-June 2017
150 years
Spray Foam Trouble Shooting
Blisters
122
Repair
Remove blisters to area of positive adhesion
Ensure no contamination exits on substrate before re-spraying
Rev-June 2017
150 years
Spray Foam Trouble Shooting
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
123Rev-June 2017
150 years
Spray Foam Trouble Shooting
Thermal Cracking/Shrinkage
124
Repairs
Cut foam down to properly installed product, complete removal may be required
Re-spray following winter application technique
Rev-June 2017
150 years
Spray Foam Trouble Shooting
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
125Rev-June 2017
150 years
Spray Foam Trouble Shooting
Scorching
126
Repairs
Foam must be removed down to purple residual foam on the substrate and re-spray
Rev-June 2017
150 years
Spray Foam Trouble Shooting
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
Rev-June 2017
150 years
Spray Foam Trouble Shooting
Glossy Cell Structure
Shiny off colour cells
Causes– Cold substrate temperature
– Improper choice of foam system
– 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
150 years
Spray Foam Trouble Shooting
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
Rev-June 2017
150 years
Spray Foam Trouble Shooting
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
Rev-June 2017
150 years
Spray Foam Trouble Shooting
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
131Rev-June 2017
150 years
Spray Foam Trouble Shooting
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
– Improper choice of foam system
– Machine temperatures too low
– Resin rich
Corrective Action Warm up substrate or switch to a
colder temperature version132Rev-June 2017
150 years
133
Raising Performance To New Heights®
Rev-June 2017