Disposable foam installation

Polyurethane foam spraying

The method allows the insulation of structures inside and outside buildings. This method of insulation has a number of advantages that distinguish it from all others:

• PPU tightly sticks to any surface, regardless of the material. The geometry of the surface does not matter.
• No preliminary preparation of the spray object is required. It is enough to remove dirt and dust.
• Not afraid of seasonal temperature fluctuations.
• Unaffected by atmospheric precipitation.
• The lightness of the material means that there is no additional load on the object, which allows spraying polyurethane foam everywhere without restrictions.
• This insulation option further strengthens the structure.
• The absence of seams and joints that can reduce the thermal insulation properties.
• Due to the technical features, it does not require additional transportation costs.
• High environmental safety.

PPU spraying is carried out using special equipment. There are many varieties of such construction equipment for use on an industrial scale and for personal use.

The work of specialists

This is the best way out. Firms that are engaged in PPU spraying use high-power foam generators equipped with a vortex chamber, where pressure up to 140 atm is created. The finely dispersed mixture obtained at the outlet of the chamber forms a rapidly forming layer of insulation.

It is with the help of powerful foam generators that thermal insulation is made from polyurethane foam of increased density of 40, 60 and 80 kg / m³. Today, such material is used in the production and construction of frame houses, where 50 mm of foamed polyurethane replace 110 mm of a brick wall.

As a rule, if thermal insulation is carried out by specialists, the owners can only prepare the surfaces for their arrival. The wall, partition or ceiling requiring insulation must be dry and clean. It is necessary to remove debris and remove scraps of peeling paint. The surface temperature for better adhesion (sticking) of polyurethane foam should not be lower than +10˚.

The polyurethane foam is applied quickly. After 20-30 seconds, the insulation expands to the desired volume and begins to solidify.

The cost of equipment for spraying polyurethane foam with your own hands

The spread of portable installations for independent work with polyurethane foam is explained by the fact that in private houses the area for insulation can be quite small. Brigades of professional workers with expensive equipment simply do not go to such facilities, as it is unprofitable. In other cases, small work will be very expensive due to the lengthy assembly of installations. Disposable kits are designed for safe use by amateurs. On areas less than 20 m 2 they are profitable.

The average cost of a one-time installation is from 16 to 30 thousand rubles. It contains approximately 1 m 3 of polyurethane foam. The same amount of composition, purchased from a specialized company, will cost more than 30 thousand rubles. The benefits of working independently are obvious.

Ready kit for spraying polyurethane Foam Kit

A disposable PPU insulation system, Touch * n Seal Foam Kit, made in the USA, is presented in the following configuration:

1. 2 cylinders, sufficient for private use, filled with PPU.
2. Hose - 4 lm
3. Atomizer - "gun".
4. Nozzles. 8 pieces - 4 each, for flat and round pressure.

Hoses are attached to the cylinders, a suitable nozzle is put on the gun, the gun is mounted to the hose. Several disposable attachments allow you to take breaks in work. The kit is good for use within a month, from the first opening. The layer hardens in 1-2 minutes. Excess will be removed after curing.

Insulation of residential buildings
and buildings for industrial or commercial purposes, experts recommend equipping only the outside. However, installation of insulation on an external wall is not always possible.

reasons
there may be several - from the prohibition of the city authorities to the technical difficulties that arise during the installation process itself.

In such cases, the option internal insulation
subject to the choice of the correct material for insulation.

Among the few cons of polyurethane foam
the most frequently mentioned is the high cost of the material required for the performance of thermal insulation work on equipment and the services of relevant specialists.

but in detailed analysis
each of these disadvantages turns out to be only a small problem that can be solved without much effort. So, the risk of destruction of the coating under the influence of ultraviolet radiation is eliminated by sheathing with lining or drywall.

Acquisition costs
polyurethane foam and spray equipment pays for itself by reducing the amount invested in paying bills and buying drugs, as well as not having to change the insulation two or three years after installation.

The thermal insulation layer obtained thanks to the sprayed polyurethane foam will last at least five decades
, and its properties (high strength, moisture resistance, non-toxicity, environmental friendliness), structure and shape remain the same as immediately after installation.

As additional plus
It is worth mentioning the significant savings in space eaten up when using other types of heaters. As for the costs of specialist services, they can also be eliminated if you do the insulation yourself.

For even more savings
, you should not buy large volume cylinders. Intentional or forced interruption of work, exceeding 1 month, leads to the need to purchase a new spraying installation. The device, which was in operation, becomes unusable.

How polyurethane foam is made basic principle

The production of PPU involves a very complex technological process. The PU foam is formed by the reaction between a polyol and a diisocyanate or polymeric isocyanate in the presence of certain catalysts and other additives. Since the polyurethane foam itself has to be produced immediately before pouring or spraying, the manufacturer supplies two phases of the polyurethane foam mixture in separate containers. The phases are mixed in special installations before the work is done. Here is what happens when two phases are mixed:

Due to the variety of isocyanates and the huge range of polyols, it is possible to obtain polyurethanes with different properties and applications. It can be flexible foam, rigid foam, elastomer, etc. It is impossible to learn everything about the production of polyurethane foam, since the exact formulation of the phases is kept secret by the manufacturers. Even if all the necessary components are available, an experienced chemist will have to select the right proportions for a long time to ensure the required properties of the mixture.

Polyurethane foam spraying technology

Before performing insulation by spraying polyurethane foam, it is necessary to prepare the surface to be treated. To do this, clean it from dirt and dry it well.

It is important to remove all rust from metals and degrease them. Aluminum requires a mandatory coating with a primer with a high degree of adhesion, this will help increase the adhesion of the insulation to the surface.

An important place in the technological process of deposition is occupied by the temperature of the environment and components. To obtain a highly effective layer, it is necessary that the composition be from 10 to 25 ° C

The optimum temperature for the room is above +5 °C. Work in a colder environment can only be carried out with a solution heated to the desired state.

Polyurethane foam spraying, reviews of which are almost always positive, is carried out under pressure above 100 atmospheres.Approximately two seconds after spraying, a foaming reaction occurs, followed by solidification of the composition. The resulting layer provides excellent thermal and waterproofing.

Thermal insulation of the house with polyurethane foam

The technology of home insulation with polyurethane foam is valued for its efficiency and speed, meeting safety standards, and excellent insulating properties.

It is suitable for any external and internal structures, including loaded ones, the only limitation of application is the high price. Feedback from building owners is mostly positive, many are thinking about purchasing equipment.

Among the noted advantages, high adhesion, the absence of cold bridges, the possibility of processing complex and hard-to-reach areas, strength and resistance to moisture and fungus are distinguished.

Features of polyurethane foam

The technology is relevant for any building surfaces, including metal. Moreover, it successfully protects the latter from corrosion by forming a film directly on the area in contact with the pipe or fittings.

The cured foam is completely impervious to external influences and is only afraid of mechanical damage and UV rays. There are two varieties: with an open and closed cell structure, in the cold climate of the Russian Federation, the second, more expensive and dense, is more often used for construction purposes.

Such PPU belongs to the class of slow-burning materials and prevents the spread of flame.

Density is a controlled indicator, on which the cost of spraying polyurethane foam directly depends.

Changing the chemical composition and equipment settings allows you to vary this characteristic from 15 to 80 kg / m3 (it can be higher - up to 300, but according to reviews this is not necessary), which is important when insulating structures with varying degrees of load.

There is a clear relationship between the volume of foam formed and the ambient temperature (with the same insulation thickness, 17% more components are consumed), in the cold season additional heating is required.

PPU with a closed structure has a vapor permeability close to zero, which limits its use in internal insulation schemes. In any case, it is not recommended to completely cover both the floor and the walls in non-ventilated rooms. As an option, a composition with a density below 12 kg / m3 with open cells and appropriate vapor and waterproofing is used.

Technology and basic schemes

PPU insulation work begins with the choice of its density, taking into account the bearing capacity of structures and the thickness of the future layer according to the climatic conditions of the region. When doing it yourself, it is recommended to adhere to the following scheme of actions (using the facade as an example):

1. Surface preparation: applied to stable, clean and dry structures, heated if necessary. Evenness does not play a special role, but there should not be peeling pieces of the old coating.
2. Installation of the crate (recommended). Theoretically, no frame is needed, but installing rails helps control the level and facilitates the finishing process. The height of the crate is selected taking into account the future thickness of the insulation.
3. Application of polyurethane foam: a thin layer (not more than 5 mm) in the direction from bottom to top. If necessary, the process is repeated.
4. At the end of the polymerization process, excess foam is cut along the guides and the exterior finish is carried out. Plastering PPU requires the placement of a chain-link mesh (similar to foam plastic, with fixing on a crate or material). The easiest way is to sheathe the facade with siding, clapboard, with an unlimited budget - overlay with bricks.

This guide is also suitable for roofs or floors on joists, experienced operators consume raw materials without residue even without battens.

It is allowed to use polyurethane foam in systems with heating elements (both pipes and cables), it is believed that such insulation reduces the cost of space heating.

When insulating pipelines, tanks or metal walls, the preparatory stage includes the removal of old peeling paint and rust. A mandatory step in any scheme is sealing and hiding from ultraviolet radiation.

Characteristics of polyurethane foam

PPU is popular not only because applying polyurethane foam with your own hands is a fairly simple process. This material has excellent characteristics:

• thermal conductivity coefficient 0.019-0.028 W / m * K;
• vapor permeability tends to zero;
• density 30-60 kg/m. cube;
• does not burn - according to GOST 12.1.044 refers to slow-burning materials;
• does not absorb moisture - the percentage of closed cells is from 85 to 95.

This also applies to the insulation of frame walls with expanded clay. Plus, it's quite heavy.

It has good adhesion (adhesion) with all materials. Due to the almost complete water tightness, PPU protects metals from corrosion. In the characteristics of polyurethane foam, there is also such a thing as start time. This is the number of seconds it takes for foaming to occur. The start time for different types of work is slightly different. For horizontal surfaces the foaming time should be in the order of 5-10 seconds. To insulate the ceiling, this period is reduced to 3 seconds.

Polyurethane foam application equipment

Polyurethane foam sprayers come in high and low pressure. The main elements are a compressor and a spray gun in which the PPU components are mixed. In low-pressure equipment, mixing occurs at 5-10 atmospheres, and in high-pressure equipment, at 100 atmospheres or more.

Different pressure affects the mixing method:

• at low pressure, the components are mixed by swirling;
• at high pressure, mixing is carried out by diffusion of the components.

And the leader in this niche is Rocklight stone wool insulation made from basalt.

Low pressure units are smaller, cheaper, easier to operate. In them, you can set the mixing ratio (1:1 or 1:2) and smoothly adjust the performance directly in the process. High-pressure installations allow you to create a more even layer of thermal insulation, you can work at a distance from tanks with mixed components up to 125 meters. The productivity of such equipment is much greater (up to 500 square meters in 8 hours). These are professional installations, and therefore they are quite expensive.

Let's take a look at some of the most common small objects.

1. The smallest object from 5 to 20 sq.m.

S object - 6 sq. m. Layer thickness - 3 cm.

The cost of work is 4,500 rubles. The cost of components is 1500 rubles. Working time - 10 minutes.

Profit - 3,000 rubles.

2. Small object from 20 to 50 sq.m.

S object - 20 sq.m. Layer thickness - 3 cm.

The cost of work is 12,000 rubles.

The cost of components is 5000 rubles. Working time - 30 minutes.

Profit - 7000 rubles.

3. Small medium facility from 50 to 200 sq.m.

S object - 50 sq. m. Layer thickness - 3 cm.

The cost of work is 30,000 rubles. The cost of components is 12,000 rubles. Working time - 2 hours.

Profit - 18,000 rubles.

4. Medium object from 200 to 500 sq.m.

S object - 200 sq.m. Working time - 2 days

Profit - not less than 50,000 rubles.

5. Medium large object from 500 to 1000 sq.m.

S object - 500 sq.m. Working time - 3-4 days.

Profit - not less than 120,000 rubles.

6. Large object from 1000 sq.m.

Profit from 200,000 rubles.

—————–

From my own practical experience: every year, each of our full-time PPU spraying specialists earns up to 700,000 rubles.

At the same time, operators spend at the facilities no more than four months in total, and use the rest of the time at their discretion.

If you apply light foam with a density of 15 kg / m3, then the amount of profit will increase. However, lightweight PPU is not used everywhere, there are limitations.

Of course, sometimes there will be large objects with an area of ​​​​more than 1000 sq.m. In this case, an assistant of the lowest qualification will be required to perform work of the “give and bring” type.

Recently, the filling of polyurethane foam in the ventilation gap of the brickwork of houses has become in demand.

Attention! Not to be confused with penoizol! Penoizol contains a large amount of water, which remains in the material for a very long time, nullifying the thermal insulation properties of penoizol. In addition, when dried, penoizol shrinks and cracks.

It is possible to use penoizol as a heater only in the form of pre-dried, i.e.

e. DRY (!) Blocks wrapped in plastic film. For a long time, this was done, until it occurred to someone to make money on the gullibility and illiteracy of people.

It is unacceptable to pour Penoizol into the inter-laying space in the fall on the eve of cold weather. The water will not have time to evaporate, the wet “insulation” will not heat up, and will collapse from frost.

Installations of the Progress series can also perform waterproofing with polyurea.

This newest material is just gaining its positions in the Russian Federation, but it has brilliant prospects. The experience of using polyurea in Europe clearly shows this. There is a growing demand for it every year.

The cost of materials per 1 sq. m. depends on the thickness of the application, 1.5 mm or 3 mm.

With a polyurea layer thickness of 1.5 mm, the cost of the coating is 500-600 rubles, with 3 mm - 1000-1500 rubles. The cost of work starts from 1800 rubles / sq. m.

Price list for installations and components

Compact and powerful equipment of the “Progress” series is used for spraying polyurethane foam on any objects without limitation. Comprehensive heating of components and supply hoses is provided for operation in the cold season.

The minimum batch of components is 100 kg of a rigid PPU system, the cost is 28,000 rubles.

This amount is enough for about 60 square meters. m. with a PPU layer thickness of 3 cm.

Do-it-yourself polyurethane foam spraying

All work must be carried out in good weather. High humidity outdoors and indoors at this time can slightly spoil the polyurethane foam. Do-it-yourself spraying should be done in several layers. This is one of the main principles of work.

Insulation with polyurethane foam by spraying begins with complex surfaces: chimneys, ventilation hatches and pipelines. At the same stage, you need to close all the joints that go outside. The first layer is preferably applied with a thickness of approximately 14 mm. After it hardens, you can proceed to further work.

The second and third layers are applied to each other with a short time interval. It is optimal to carry out all the work in one day. If this is not possible, then, starting each next layer, you need to carefully prepare the surface. With proper planning of working hours, the insulation of a medium-sized private house can be carried out in 2-3 days.

The most effective sound and heat insulation is considered to be a structure consisting of three layers.

FOAM-mini B2 Russia vs PPU Foam Keith USA cylinders

We planned that our PPU household device, like the American one, would work on the “Touch and Seal” principle, i.e. "Touch and isolate." But copying the Yankees 1 to 1 did not work.

In fact, there are three differences. One is negative and two are positive. Read on and decide for yourself what is better to buy polyurethane foam for thermal insulation with your own hands: American or Russian cylinders.

FOAM-mini B2 is inferior to the American Foam Kit in that imported cylinders do not require a source of compressed air. Containers with components A and B are already under pressure. Therefore, to get started, it is enough to connect the sprayer, open the valves on the cylinders and spray. The principle of "Touch and Seal" in the truest sense of the word.

Our device requires compressed air, i.e. small household compressor. It is needed to create excess pressure in the cylinders. The Americans pump the gas into cylinders of polyol and isocyanate and seal them somewhere in Florida or California. And to a Russian in Samara or Barnaul, who decided to insulate the PPU with his own hands on a balcony, garage, etc. compressor is not needed. This is a plus.

If, suddenly, there are not enough components in the cylinders, then you need to go to a gas station. The nearest ones from Samara are located in Florida, Georgia and South Carolina. From Barnaul it will be more convenient to California or Arizona. Or without leaving Russia, you can always buy another new set of Foam Kit.

FOAM mini B2 is superior to imported Foam Kit in that our unit is REUSABLE. PENA-mini B2 cylinders are filled with PPU raw materials immediately before work, on the balcony of a house in Samara or a garage in Barnaul.

From one canister we pour component A into the first cylinder, from the second - component B into the second. And now, in order to get started, you need to create excess pressure in the cylinders. This function is performed by the compressor.

Yes, a domestic product requires a source of compressed air, but the components in the cylinders can be topped up and reused. American bottles are disposable.

FOAM-mini is even better because it is cheaper. Domestic cylinders and components for filling them are cheaper than imported Foam Kits.

American cylinders are expensive and can only be used once, i.e.: sprayed and thrown. Therefore, the motto Touch and Seal in relation to Russia can be clarified: Touch, Seal and Threw.

The NST company offers a reusable device FOAM-mini B2 for do-it-yourself PU foam insulation and raw materials for self-refueling.

Types of PPU and scope

1. Open-cell (elastic), with a density of 10-20 kg / m³;
2. Closed-cell (rigid), with a density of 20-30 kg/m³ and above, up to 80 kg/m³.

Polyurethane foam will perfectly protect the room from heat loss, and will also cope with its waterproofing.

In elastic foam, up to 90% of the cells are open. The low density provides it with a certain ability to stretch. In rigid PPU, up to 98% of the cells are closed. This and its high density make it an unusually strong insulating material.

Different types are used in different areas. If we are talking about spraying on a material that can change its size - for example, metal structures that shrink and expand with temperature changes - then flexible polyurethane foam is used. It is indispensable for waterproofing, for protecting the connection between walls and roofs, for spraying on wooden and metal surfaces that come into contact with cold air outside the building.

Closed-cell (rigid) polyurethane foam is used for internal insulation and outdoor work. It is usually sprayed on concrete, cement and brick surfaces. Closed-cell polyurethane foam is also used when they want to give the structure frame additional rigidity. Its high strength allows you to significantly strengthen unstable elements. Both types of PPU have a lot of pluses, and there are very few minuses.

What is polyurethane foam

Few people know, but the polyurethane foam (PPU) that is in demand today was made back in the last century. It was first used as thermal insulation in 1957. Since then, it not only has not lost its relevance, but has also been used in other areas far from construction. It is polyurethane foam that is one of the fillers in upholstered furniture, children's toys, etc. What is polyurethane foam?

At its core, PPU is one of the varieties of plastics. The uniqueness of the material lies in the fact that the main percentage of the substance is accounted for by gas bubbles. According to studies that have been repeatedly conducted with the finished product, modified plastic in the finished product is only 10-15%. The rest of the space is occupied by gas bubbles. As a result, the material becomes special thermal insulation and performance characteristics
. Namely:

• 3 cm layer of polyurethane foam is identical in thermal conductivity to 7 cm, 16 cm mineral wool, 38 cm foam block and 1 m 70 cm brick wall.
• The material can be prepared directly at the construction site or purchased in cylinders as a ready-made mixture.
• Tests have shown that polyurethane foam retains its performance characteristics in the range - 150° to + 220°.
• Has high adhesion to any surface
  . With the help of PPU, even a metal structure can be insulated.
• After drying, the surface can be plastered or used as a base for laying ceramic tiles.

You need to know that there are several ways to insulate with PPU. You can purchase sheet material, prepare a two-component composition yourself, or use a ready-made mixture sold in cylinders that resemble polyurethane foam.

Spray equipment

Polyurethane foam spraying machines accurately dose and mix the components that make up the finished mixture. From the supply containers, they enter the spray chamber through a hose. There is a connection there. Compressed air acts as a mixing agent. Then the resulting mixture is sprayed onto the prepared surface. The increased pressure with which the foam is supplied allows spraying on any places, including hard-to-reach ones.

Polyurethane foam spraying plants

The Russian manufacturer GK Rosteploizolyatsiya offers: PGM-3S, PGM-8S, PGM-5BN, PGM-5AT, PGM-9BN and PGM-9AT. The listed installations are reliable and not heavy. They are easy to install and move. Productivity - from 3.5 kg / min and up to 3080 cubic meters. cm/min These are portable complexes for isolation of premises. Energy consumption for machines of these brands is 0.7 kW, and with heating - 2.7 kW. The main distinguishing feature of the units is their mobility, the ability to work at the customer's site.

Filling mechanisms

With liquid polyurethane foam, equipment of the following brands is used: PGM-30AT, PGM-45AT, PGM-75AT. The machines are equipped with large tanks. This makes it possible to produce heat-insulating blanks on an industrial scale (they give out up to 36 kg / min). The method of pouring molded products is perfectly realized with the help of installations of this type. The power consumption is between 3.75 and 5 kW.

Universal machines

These include: PGM-10BN, PGM-10AT, PGM-18S, PGM-36S, PGM-36M. These are simple and productive machines. Specifications: up to 30 kg/min of material and up to 34,560 sq. cm/min The use of this equipment is possible for work at the facility and the manufacture of blanks. PGM-10BN, PGM-10AT are highly versatile, so their purchase can solve several problems for thermal insulation in construction at once.

Why is polyurethane good for insulation?

Strengthens load-bearing structures.
Very light, does not overload the walls.
Moisture resistant, therefore, no need for a vapor barrier layer.
It is acceptable to work with polyurethane foam at negative temperatures (up to -10 ° C)
It is possible to insulate almost any wall or facade, PPU is easily compatible with different types of surfaces.
Prevents the development of corrosive and other destructive chemical processes.
Has soundproofing properties.
Non-combustible, which is especially important in the construction of buildings.
Makes rooms much warmer. Residents can save on heating .. Reviews of thermal insulation with polyurethane foam

Reviews of thermal insulation with polyurethane foam

“There was a need to insulate the loggia. We chose polyurethane foam. Insulation at the highest level, moisture does not settle anywhere. The owners of the apartment say they are satisfied with the work done. The adhesive properties of the foam played a significant role.”

Ivan Petrov, Novosibirsk.

“During the construction of the house, sprayed foam was chosen as a heater. It turned out a continuous coating without joints. This made it possible to finish the walls with good clapboard, without fear that the surface would look uneven.

Sergey Krasnov, Krasnodar.

“In the summer, we decided to insulate the facade with polyurethane foam spraying. It was hoped that this would help save on space heating. Indeed, the batteries were turned on only when it was already -5 ºС outside.Now the heating system works only at a third of its capacity.”

Vladimir Cheryomushkin, Moscow.