INSTALLATION INSTRUCTIONS

Transcription

1 QuadFoam 500 NatureSeal QuadFoam 500 NatureSeal is a 2 component, spray applied, low density, open cell polyurethane foam insulation, air barrier and vapor retarder material. QuadFoam 500 NatureSeal is applied at a nominal density of 0.5 lb. /cu. ft. NatureSeal is Class 1 rated and meets AC 377 Appendix X requirements without an Ignition Barrier Coating in Attics and Crawl Spaces. QuadFoam 500 NatureSeal approved for use in residential and commercial construction, for interior applications both above and below grade. QuadFoam 500 NatureSeal can be applied in wall cavities, on flat walls, floor assemblies, ceiling assemblies, attics and crawlspaces. 1. Appearance: QuadFoam 500 NatureSeal Part A is a brown liquid; QuadFoam Part B is a tan liquid and when mixed/sprayed and cured, the resulting foam is a homogenous cream colored solid. 2. Storage: QuadFoam 500 NatureSeal Part A & Part B should be stored between 60 to 85 F. QuadFoam 500 NatureSeal has a 6 month shelf life when properly stored. 1 P a g e

2 3. Mixing: QuadFoam 500 NatureSeal must be mixed well prior to application. Continue agitation throughout application process. Drum mixer needs to have aggressive agitation, minimum required is Graco Expanding Blade Bung-Mounted Agitator shown below (part # 24C729). If the drum temperature is less than 85 F, place a heat blanket on the drum and heat the material to 85 F - 95 F with agitation. QuadFoam 500 NatureSeal Part B side material must be thoroughly mixed 20 to 30 minutes prior to application. Quadrant recommends the use of a Graco Air-Driven Expanding Blade Bung-Mounted Agitator (Part Number: 24C729). To properly drive the mixer, 22 scfm of air is required. Using less air volume may require extended mixing times. A thorough high-speed mix is an essential step in high-quality foam production. QuadFoam 500 NatureSeal must be continually agitated throughout the entire spraying process in order to avoid any separation of the Part B side material. 2 P a g e

3 To speed up the initial mixing process, open the drum and use a handheld drill with two fold out four inch blades (shown below). NOTE: After initial mix, agitation must be maintained throughout the spray process with a mixer such as the Graco Expanding Blade Bung-Mounted Agitator (part # 24C729). To ensure that QuadFoam 500 NatureSeal is mixed well, prior to application open the drum to verify that the material has a uniform and opaque appearance as shown below. If there is a clear layer on top, or any swirling appearance to the material, then the mixing should continue until it has a uniform opaque appearance. Initial Appearance After Thorough Mixing Unmixed (Note Clear top layer) Uniform mix (Note opaque appearance) 3 P a g e

4 Thorough mixing is effected by several factors such as; blade configuration, and ambient temperature. NOTE: QuadFoam 500 NatureSeal has a unique chemistry and any contamination from other Part B drums will have a permanent adverse effect on its performance. 4. Changeover When QuadFoam 500 NatureSeal has been uniformly mixed, begin the changeover process. Before spraying QuadFoam, you should purge any previous material from your system by slowly pumping it in to the correct A-side and Part B drum. It is important not to mix different Part A and or Part B products, whether from Quadrant or other manufacturers. Turn off and disconnect air to all transfer pumps. Remove the drum pumps from the Part A and Part B drums and wipe pump/dip tube clean. Also make sure the drum pump housing is emptied of any Part B. Place the drum pumps/dip tubes in to the QuadFoam 500 NatureSeal drums. Re-connect or turn on the air to the drum pumps. Use the drum pumps to purge the hoses of the Part A and Part B materials back to their corresponding drums or in to containers for re-use. Watch for a color change or other indications; approximately 1-2 gallons of materials are purged, depending on length of hose. Remember to also remove the old material from the circulation hoses before spraying as pressure relief later may cause contamination. Always check and clean the strainer screens prior to spraying. NOTE: If the initial foam sprayed shows curling, shrinkage, color streaks or other issues, then re-purge the hose prior to continued spraying. You are now able to spray QuadFoam 500 NatureSeal. 4 P a g e

5 5. Drum Temperature: During processing, both the QuadFoam 500 NatureSeal Part A and Part B drum temperatures need to be in the range of 85 to 95 F. 6. Proportioner Temperatures: The primary Part A & Part B heaters as well as the hose heat for all QuadFoam 500 NatureSeal should be set between 115ºF to140ºf for best results. The temperature settings are a guideline, and substrate temperatures may require temperature settings outside of these parameters. If the ambient temperature is high: then reduce the Part A & Part B side heater and hose temperatures gradually. If the ambient temperature is low: increase all temperatures gradually. 7. Humidity: Care should be taken whenever the relative humidity rises above 80%. High relative humidity can cause blistering and weaken foam adhesion. 8. Application: Experienced sprayers should find that QuadFoam 500 NatureSeal sprays the same or better than other products they are used to. First time users of QuadFoam 500 NatureSeal should contact Quadrant Technical Services or an authorized distributor for guidance. QuadFoam 500 NatureSeal may be sprayed in practical lifts/passes, 4-12 inches are typical. A minimum foam thickness of 2 inches is required or adhesion to the substrate may be disaffected. 5 P a g e

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7 General Applications Guidelines: 9. The following areas are suitable for the installation of QuadFoam : All wall, ceiling and floor spaces for the purpose of thermal insulation and air leakage control. It may be applied directly to wood, metal, masonry and concrete substrates. It may be applied in single and multi-family residential buildings, commercial, industrial, agricultural buildings of any type. It may be applied above or below grade; interior or exterior. Air sealing and insulating of attic and crawl spaces. 10. The following areas are not recommended for QuadFoam : For roofing applications where the material is applied above the roof decking. Exterior applications where the material is exposed to ambient weather or UV exposure. Whenever a proposed application is beyond the scope of this Guide, then contact Quadrant Urethane Technologies or an authorized distributor for additional guidance. 7 P a g e

8 11. Troubleshooting: The most common reasons for substandard material are mix or technique related: Mix related problems are a result of any one or both of the following: Temperature: uneven temperatures of components Part A and Part B during application or insufficient heat in the drums. Pressures: too low pressure, uneven pressures of components Part A and Part B or uneven temperatures of the components which lead to one component developing a higher pressure than the other and poor mixing. Spray technique related problems are a result of any one of the following: Distance: holding the gun too close to the substrate when spraying tends to blow material and air into the rising foam as you overlap to build thickness, and causes dripping when spraying overhead, holding the spray gun too far away from the surface allows the outer edges of the spray pattern to fall on part of the foam that is done expanding, making it a higher density material with a rough, popcorn like finish and lower yield, which also makes it difficult to cover when applying a coating over it. Gun speed: moving the spray gun too slow causes the foam to ripple making a rough foam surface, affecting the density, cell structure and yield, and may also lead to dripping when spraying overhead. 12. Material Trouble Shooting: 8 P a g e

9 13. Good Material Classification: Color: cream, uniform and no streaks Cell structure: uniform, small and tight. Skin: smooth, orange peel like and dense Density: Nominal per product type These characteristics should be observed whenever spraying QuadFoam. 9 P a g e

10 14. Poor material classification: Part A Rich: the resulting foam will be a brown color or have color streaks friable and may have a musty smell and may exhibit signs of shrinkage, be Part B Rich: the resulting foam will be a darker color or have color streaks and may exhibit signs of shrinkage, flexible or soft to the touch and may be tacky/sticky. Part B Not Mixed: the resulting foam will be a dark colored hard and friable. Poor material can be corrected or avoided by following some basic troubleshooting techniques. These are mainly preventive measures that ensure good quality material: Follow recommended storage conditions. Temperature control storage and trailers, Heat blankets (use band heaters with caution due to possible over heating concerns) on the drums may be necessary to aid the pre-heating and to maintain the drum temperature during processing. When using heaters, be careful not to exceed the recommended drum temperatures. Do not open the Part A drums until needed. Avoid airborne moisture from getting into the Part A drum which will lead to crystallization. Crystallization can clog filter screens and may damage equipment and spray guns. The hose thermocouple unit should be within the same environment as the spray gun, ensuring a more accurate and even delivery of the heated material components. 10 P a g e

11 15. Environmental and Substrate Issues: Ambient conditions: QuadFoam 500 NatureSeal may be sprayed at ambient/substrate temperatures between 45 F and 120 F. Wind: Overspray will stick to almost any substrate, so care must be taken to seal up the spray area when applying material in locations that are subject to wind or air movement, especially when greater than 10mph. Wet Surfaces: Wet or saturated substrates will cause bubbling in the foam, reduced foam properties and poor adhesion. Surfaces should be clean and dry. Metals: All metals must be clean, dust, rust, loose scale and oil free prior to foam application. Galvanized steel should be cleaned with degreaser, dried and a suitable primer applied. Aluminum should be not be cleaned with caustic solutions and be primed prior to the application to prevent corrosion. Stainless steel surfaces should be cleaned with mineral spirits or xylene and then primed. In some cases, it may be necessary to sandblast. In some cases, regardless of metal type, it may be necessary to sandblast and prime prior to foam application. Concrete: Concrete must be dry on the surface before applying spray polyurethane foam. An adhesion test should be performed prior to commencing application. 11 P a g e

12 16. Wood, Gypsum Board and Fiberboard: The moisture content of wood, gypsum or fiberboard should be less than 19%. Special care should be taken in case of composite/laminates. Most have wax like surface treatments and adhesion of the insulation to the substrate may be disaffected. Sanding, cleaning with mineral spirits and or priming may be required. Pre-painted Substrates An adhesion test should be performed prior to commencing application. When the adhesion is uncertain or poor, the paint should be sanded and or primed prior to commencing foam application. Glass Except for cleaning, no special preparation is required for glass. Polyvinyl Chloride (PVC) Polyvinyl Chloride products contain plasticizer, which imparts flexibility and impact resistance. However, excess or high levels of plasticizer, typical to flexible and sheet products, may cause adhesion issue. Rigid PVC products like pipe have low levels of plasticizer. An adhesion test should be performed prior to application to PVC products especially to flexible polyvinyl chloride such as sheathing. When the adhesion is uncertain or poor, the PVC should be cleaned with mineral spirits and or primed prior to commencing foam application Acrylonitrile Butadiene Styrene (ABS) Acrylonitrile Butadiene Styrene (ABS) ABS surface should be cleaned with mineral spirit and primed. 12 P a g e

13 Polypropylene and Polyethylene Adhesion of spray polyurethane foam to these two plastics is extremely poor. The only practical way to apply the insulation is to provide some sort of mechanical attachment to the substrate, such as wire, brackets, nails, brick strapping etc. Primed Surfaces Many primers are solvent or water-borne and adequate time for the complete evaporation of the solvent or water should be allowed prior to application of the foam. Spray Polyurethane Foam Areas that show ultraviolet degradation, chalking and or yellowing, should be sanded or wire brushed prior to the application of more insulation. Spray application of QuadFoam 500 NatureSeal. Keep other trades away from applicator: All other personnel must be kept at least 50 ft. away from the applicator while spraying. It is the responsibility of the helper to ensure that all other trades and spectators are kept away from the applicator while spraying. The sprayer and helper shall wear a full-face supplied air respirator (SAR) or hood, as well as full skin protection when working within 50 ft. of the installer while spraying. Installer s shall post warning signs that include warnings against entry, smoking, eating or welding in the work area and post signs requiring respiratory and visual protections are required. Masking: This is very important, as overspray will stick to most surfaces. Ensure that any surface and finish is carefully covered to avoid damage from overspray. 13 P a g e

14 17. Spray Technique: Smoothness & Yields: A smoother foam surface will improve yield. Good application technique will produce a level stucco like surface. Heavy grain, popcorn or brain like surfaces indicate poor technique or that a particular area of application is difficult to apply. This does not indicate bad foam. Coating: A smoother foam surface requires less coating or protective material to properly cover than a rough- uneven surface. When applying ignition or thermal barrier coatings, do not leave exposed foam. As with all Quadrant products, if you have any questions? Please do not hesitate to call Quadrant Urethane Technologies at Ask to speak to a Technical Services Representative. 14 P a g e