Building Research Institute

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1 Building Research Institute W A R S A W F I L T R O W A 1 p h o n e : ( ) , ( ) f a x : ( ) M e m b e r o f t h e E u r o p e a n U n i o n f o r t e c h n i c a l a p p r o v a l i n c o n s t r u c t i o n U E A t c M e m b e r o f t h e E u r o p e a n O r g a n i s a t i o n f o r T e c h n i c a l A s s e s s m e n t E O T A Series: TECHNICAL APPROVALS ITB TECHNICAL APPROVAL In accordance to the Regulation of the Minister of Infrastructure of 8 November 2004 on technical approvals and organisational units authorised to issue them (uniform text: Journal of Laws of 2014, item 1040), as a result of the approval proceedings performed at the Building Research Institute (Instytut Techniki Budowlanej) in Warsaw upon a request submitted by: RAWLPLUG S.A., Kwidzyńska 6, Wrocław, we hereby confirm that the following products are suitable for use in construction: Polyurethane foams RAWLPLUG POLYURETHANE FOAM, RAWLPLUG POLYURETHANE FOAM WINTER VERSION, and RAWLPLUG POLYURETHANE FOAM FOR PVC under the conditions laid down in the Appendix hereto forming an integral part of this ITB Technical Approval. Expiration date: 27 December 2021 /Stamp:/ Building Research Institute /Stamp:/ DIRECTOR of the Building Research Institute Marcin M. Kruk, Ph.D. Eng. (-) Appendix: General and technical requirements Warsaw, 27 December 2016 The document of ITB Technical Approval AT /2016 consists of 13 pages. Contents of this document may only be copied in entirety. No publication or dissemination of any parts of this Technical Approval in any form whatsoever shall be permitted without written arrangement with the Building Research Institute. 1

2 A N N E X GENERAL AND TECHNICAL REQUIREMENTS TABLE OF CONTENTS 1. OBJECT OF THE APPROVAL INTENDED USE, SCOPE AND CONDITIONS OF APPLICATION TECHNICAL PROPERTIES. REQUIREMENTS PACKAGING, STORAGE AND TRANSPORT ASSESSMENT OF CONFORMITY General principles Preliminary type testing Factory production inspection Testing of finished products Testing frequency Testing methods Sampling for testing purposes Assessment of test results FORMAL AND LEGAL PROVISIONS EXPIRATION DATE... 9 ADDITIONAL INFORMATION... 10

3 1. OBJECT OF THE APPROVAL This ITB Technical Approval pertains to polyurethane foams distributed under the following trade names of: RAWLPLUG POLYURETHANE FOAM, RAWLPLUG POLYURETHANE FOAM WINTER VERSION and RAWLPLUG POLYURETHANE FOAM FOR PVC. The foams subject to this Approval are manufactured by RAWLPLUG S.A. based at Kwidzyńska 6, Wrocław. The foams known as RAWLPLUG POLYURETHANE FOAM and RAWLPLUG POLYURETHANE FOAM WINTER VERSION are both one-component polyurethane resin-based foams containing the foaming agent addition, produced in the form of an aerosol. The material intended for application is supplied in pressurised metal containers which can be used for foaming purposes with a foam gun or via an integrated nozzle (straw variant). The RAWLPLUG POLYURETHANE FOAM FOR PVC IS one-component polyurethane resin-based high-yield foam containing the foaming agent addition, produced in the form of aerosol. The material intended for application is supplied in pressurised metal containers which can be used for foaming purposes with a gun (gun variant). Foaming of the products takes place at the application point, and once the application is completed, they harden as an effect of moisture absorption from the environment. The required technical properties of the foams subject to this Approval have been provided in item INTENDED USE, SCOPE AND CONDITIONS OF APPLICATION The foams subject to the Approval are intended for the sealing of voids between door and window reveals and frames made of wood, PVC-U or metal, or for installation of windows and doors (except doors classified for fire resistance) with the reservation that the installation should be performed using mechanical fasteners. The foams subject to the Approval can be used to fill cracks and small stationary gaps in joints between elements of building partitions (except for partitions classified for fire resistance). RAWLPLUG POLYURETHANE FOAM can be applied at temperatures ranging between +5 C and +30 C. RAWLPLUG POLYURETHANE FOAM WINTER VERSION can be applied at temperatures ranging between -10 C and +30 C. RAWLPLUG POLYURETHANE FOAM FOR PVC can be applied at temperatures ranging between +5 C and +30 C, retaining its elasticity over the entire temperature range. Where the polyurethane foams are used for sealing purposes, work should be conducted under conditions of temperature and humidity not exceeding the threshold values declared by the product Manufacturer. The polyurethane foams should be protected against effects of UV radiation by shielding with appropriate mastic or other products resistant to weather conditions. Do not apply the foams in proximity of an open fire. While using the polyurethane foams subject to the Approval at work, observe their application conditions defined in the Manufacturer s instructions as well as conditions of door and window installation, as provided in instructions from respective manufacturers. The foams should be applied in accordance with the relevant technical documentation and requirements of the applicable Polish Standards and building regulations, and particularly with the Regulation of the Minister of Infrastructure of 12 April 2002 on technical conditions for buildings and their location (uniform text: Journal of Laws of 2015, item 1422). 3

4 3. TECHNICAL PROPERTIES. REQUIREMENTS The required technical and operating properties of the foams subject to this Approval have been provided in tables 1 3. Table 1. Requirements Item Properties RAWLPLUG POLYURETHANE FOAM Testing methods gun variant straw variant Apparent (total) density, kg/m 3 19 ± 15% 24 ± 15% item Foam height increase (expansion) when applied in a crack, % 68 ± 10% 150 ± 10% item Cutting time, minutes 25 ± 10% 36 ± 10% item Water absorption on 24-hour partial immersion in water, kg/m 2 1 PN-EN 1609:2013 method A 5 Dimensional stability after 48 h at +40 C and RH 95%, in: - length and width ± 5 PN-EN 1604: thickness (foam growth direction) ± 9 6 Compressive stress on 10% strain, kpa 15 PN-EN 826: Tensile strength perpendicular to faces, kpa 50 PN-EN 1607: Shear strength, kpa 35 PN-EN 12090: Foam adherence to wooden, PVC-U or metal substrate at temperatures ranging between +5 C and +30 C based on tensile strength, kpa 50 PN-EN 1607:2013 Table 2 Requirements RAWLPLUG Item Properties POLYURETHANE FOAM Testing methods WINTER VERSION gun variant straw variant Apparent (total) density, kg/m 3 22 ± 15% 35 ± 15% item Foam height increase (expansion) when applied in a crack, % 122 ± 10% 136 ± 10% item Cutting time, minutes 25 ± 10% 45 ± 10% item Water absorption on 24-hour partial immersion in water, PN-EN 1609: kg/m 2 method A Dimensional stability after 48 h at +40 C and RH 95%, in: 5 - length and width ± 5 PN-EN 1604: thickness (foam growth direction) ± 9 6 Compressive stress on 10% strain, kpa 15 PN-EN 826: Tensile strength perpendicular to faces, kpa 50 PN-EN 1607: Shear strength, kpa 35 PN-EN 12090:2013 Foam adherence to wooden, PVC-U or metal substrate at 9 temperatures ranging between -10 C and +30 C based on 50 PN-EN 1607:2013 tensile strength, kpa

5 Table 3 Requirements Item Properties RAWLPLUG POLYURETHANE Testing methods FOAM FOR PVC gun variant Apparent (total) density, kg/m 3 25 ± 15% item Foam height increase (expansion) when applied in a 84 ± 10% item crack, % 3 Cutting time, minutes 22 ± 10% item Water absorption on 24-hour partial immersion in water, kg/m 2 1 PN-EN 1609:2013 method A 5 Dimensional stability of foam in a crack, measured along thickness (foam growth direction), %: after 14 days at +23 C and RH 50% ± 5 item after 14 days at +23 C and RH 50% and after 24 h at +40 C and RH 95% ± 6 6 Properties on tension: - tensile strength perpendicular to faces, kpa - relative elongation on shear failure, % 7 Properties on shear: - shear strength, kpa - relative elongation on shear failure, % 8 Foam adherence to PVC-U, wooden or metal substrate at temperatures ranging between +5 C and +30 C based on tensile strength, kpa 9 Plastic strain [%] on compression to 30% of thickness (foam growth direction) maintained for 22 hours at +23 C and RH 50%, determined after 24 hours of decompression PN-EN 1607:2013 PN-EN 12090:2013 PN-EN 1607:2013 PN-EN ISO 1856: PACKAGING, STORAGE AND TRANSPORT The polyurethane foams subject to the Approval should be packed, stored and transported in a manner which ensures that they are secured against destruction or mechanical damage to the containers. Packing conditions may be arranged between the Manufacturer and the recipient. Each item of packaging should be accompanied with a tag containing the following data: - manufacturer's name and address, - product trade name, - net volume or net volume and net weight, - expiration date, - number of ITB Technical Approval, - number and date of issue of a domestic declaration of conformity, - construction product marking. The way the construction product marking should be affixed shall conform with the Regulation of the Minister of Infrastructure of 11 August 2004 on the methods for declaring conformity of construction products and marking them as construction products (Journal of Laws no. 198/2004, item 2041). 5

6 Furthermore, where separate regulations impose an obligation of marking the given product in accordance with the Regulation of the Minister of Health of 20 April 2012 on labelling of packaging containing hazardous substances and hazardous mixtures and some specific mixtures (uniform text: Journal of Laws of 2015, item 450) and Regulation no. 1272/2008 of the European Parliament and of the Council on classification, labelling and packaging of substances and mixtures, amending and repealing Directives 67/548/EEC and 1999/45/EC, and amending Regulation (EC) no. 1907/2006 (CLP), and on providing information on hazards to health and life resulting from safety data sheets based on Regulation (EC) no. 1907/2006 (as amended) of the European Parliament and of the Council concerning the Registration, Evaluation, Authorisation and Restriction of Chemicals (REACH), the product should be accompanied by documentation of adequate form containing all the marking and information required under the applicable regulations. 5. ASSESSMENT OF CONFORMITY 5.1. General principles. Pursuant to article 4, article 5, section 1, item 3 and article 8, section 1 of the act of 16 April 2004 on construction products (Journal of Laws no. 92/2004, item 881, as amended), products covered by this Technical Approval can be traded and used in construction works in a scope corresponding to their operating properties and intended use provided that the Manufacturer has performed the conformity assessment procedure, issued a domestic declaration of conformity with ITB Technical Approval and labelled the products with construction product marking in accordance with the applicable regulations in force. Pursuant to the Regulation of the Minister of Infrastructure of 11 August 2004 on the methods for declaring conformity of construction products and marking them as construction products (Journal of Laws no. 198/2004, item 2041, as amended), the assessment of conformity between the products in question and ITB Technical Approval AT /2016 is to be performed by the Manufacturer by application of system 3. Where system 3 is used for the conformity assessment purposes, the Manufacturer shall be entitled to issue a domestic declaration of conformity with ITB Technical Approval based on the following grounds: a) preliminary type testing conducted by an accredited laboratory, b) factory production inspection Preliminary type testing. Preliminary type testing is a procedure intended to confirm the required technical and operating properties, conducted before products are released to trade. Preliminary type testing comprises the following: a) for the RAWLPLUG POLYURETHANE FOAM and the RAWLPLUG POLYURETHANE FOAM WINTER VERSION: - water absorption on partial immersion, - dimensional stability, - compressive stress on 10% relative strain, - tensile strength, - shear strength, - adherence to substrate, b) for the RAWLPLUG POLYURETHANE FOAM FOR PVC: - water absorption on partial immersion, - dimensional stability, - properties on tension, - properties on shear, - adherence to substrate,

7 - plastic strain after compression. The tests which provided grounds for establishing the technical and operating properties of the products in question under the approval procedure function as the preliminary type tests under the conformity assessment Factory production inspection. The factory production inspection system comprises the following: 1) specification and verification of raw materials and components, 2) in-production and finished product inspection and testing (item 5.4) conducted by the Manufacturer in accordance with a pre-arranged testing plan and as per the rules and procedures set forth in the factory production inspection documentation, adapted to the production technology and aimed at obtaining products of required properties. The production inspection should prove that the given product conforms with ITB Technical Approval. Results of the inspection should be recorded on a systematic basis. The relevant records should confirm that the product in question complies with criteria of the conformity assessment. Individual products or product batches and the related manufacturing details must be fully traceable Testing of finished products Testing schedule. The testing schedule comprises the following: - in-progress testing, - periodical testing In-progress testing. In-progress testing comprises verification of the following details: - apparent density, - cutting time Periodical testing. Periodical testing comprises verification of the following: a) for the RAWLPLUG POLYURETHANE FOAM and the RAWLPLUG POLYURETHANE FOAM WINTER VERSION: - expansion, - water absorption on partial immersion, - dimensional stability, - compressive stress on 10% relative strain, - tensile strength, - shear strength, b) for the RAWLPLUG POLYURETHANE FOAM FOR PVC: - expansion, - water absorption on partial immersion, - dimensional stability, - properties on tension, - properties on shear, - plastic strain after compression Testing frequency. In-progress tests should be conducted in accordance with the testing schedule, but not less frequently than as defined for testing of each product batch. The product batch size should be defined in the factory production inspection documentation. Periodical tests should be conducted at least every 3 years. 7

8 5.6. Testing methods Tests should be conducted by application of the methods defined in Table 1 and according to the following specifications Conditions for preparation of test samples. Foamed using a foam gun or a nozzle: a) directly on the substrate for samples tested for apparent (total) density and cutting time, b) in moulds made of plywood lined with foil (from the top) on a substrate defined in table 1 (from the bottom), simulating a crack for samples tested for adherence to substrate, c) in moulds made of plywood lined with paper, simulating a crack for samples used in other tests. The foam is applied inside an environmental chamber at the temperature of +23 C and the relative humidity (RH) of 50% for tests of apparent (total) density, cutting time and expansion, in upper and lower limits of application temperature at RH of 50% for substrate adherence testing, and in upper limits of application temperature at RH of 30% for other tests. Moulds containing foam for testing as per b) and c) (except for expansion testing) should be left for 24 hours under foam formation conditions, then the test material should be removed from moulds and conditioned under laboratory conditions for 14 days, and then test samples can be prepared Testing of apparent (total) density. Tests are to be conducted using samples of free foamed product in unit sections of the bead of ca. 15 cm in length and at least 30 mm in diameter. Sections of the bead should be developed on a flat foil-covered surface. Samples should be left under foam formation condition (see item 5.6.1) for 24 hours or 14 days. After 24 hours or 14 days from foam formation, each of the six samples (including the skin) is weighed with the accuracy of up to 0.01 g to establish its mass m. Samples are one by one immersed in water-filled measuring cylinder graduated to 10 cm 3 (initial water volume v0), and the volume increase is read (v1). Apparent density ρ is measured in kg/m 3 according to the following formula: ρ = [m: (v1 - v0)] 1000.The test result is a mean of six measurements Testing of foam height gain in a crack (expansion). The foam height gain is tested by forming the foam inside a special mould, being a one metre long crack of 30 x 30mm in width and height. Two moulds (cracks) should be prepared for the test. Immediately after foam injection into one mould, another mould is placed on its surface, and after 24 hours from foam formation, the foam height is measured at a half of the mould length and in a distance of 10cm from the crack ends using a slide caliper of accuracy not inferior to 0.01mm. The foam height increase measurement result is compared with the original crack filling and stated in per cent. Before testing, both the foam container and the moulds are to be conditioned for 24 hours under laboratory conditions. The test result is the mean value obtained from at least three measurements Testing of cutting time. Tests of cutting time are conducted under laboratory conditions. On a sheet of paper, several individual beads of foam are developed (bead sections of at least 30mm in diameter) spaced at 2 up to 3cm from one another. Using a template of 60mm in width and 30mm in height, a foam bead section with the height of 30 mm is found and cut by means of a knife in 3-minute intervals, and every minute at the end of the test. If foam remains on the surface of the knife blade after cutting or if the cutting destroys the foam structure (cells), the process is repeated on successive sections of the foam bead. The test result is the time after which no foam remains on the knife surface and no foam structure is destroyed by cutting Dimensional stability testing for the RAWLPLUG POLYURETHANE FOAM FOR PVC. Dimensional stability is verified by application of the FEICA TM 1004:2013 method. The test consists in determination of the thickness change in foam samples kept for 14 days under laboratory conditions and kept for 24 hours at +40 C and RH 95%. The test is conducted on three samples, and the mean value is calculated in per cent.

9 5.7. Sampling for testing purposes The samples for tests are collected at random, as per PN-N Assessment of test results Finished products are considered compliant with the requirements of this ITB Technical Approval if results of all tests are positive. 6. FORMAL AND LEGAL PROVISIONS 6.1. ITB Technical Approval is a document which certifies that the polyurethane foams in question, i.e. RAWLPLUG POLYURETHANE FOAM, RAWLPLUG POLYURETHANE FOAM WINTER VERSION and RAWLPLUG POLYURETHANE FOAM FOR PVC, are suitable for use in the construction industry within the scope of application matching the provisions hereof. Pursuant to article 4, article 5, section 1, item 3 and article 8, section 1 of the act of 16 April 2004 on construction products (Journal of Laws no. 92/2004, item 881, as amended), products covered by this Technical Approval can be traded and used in construction works in a scope corresponding to their operating properties and intended use provided that the Manufacturer has performed the conformity assessment procedure, issued a domestic declaration of conformity with ITB Technical Approval and labelled the products with construction product marking in accordance with the applicable regulations in force The ITB Technical Approval does not infringe any rights arising from regulations on industrial property protection, and particularly of the Industrial Property Law of 30 June 2000 (uniform text: Journal of Laws of 2013, item 1410, as amended). Ensuring that the said rights are not infringed shall be the liability of the party using this ITB Technical Approval By issuing the Technical Approval, ITB assumes no responsibility for any potential infringement of exclusive and acquired rights The ITB Technical Approval shall not release the Manufacturer from any responsibility for sufficient quality of products or any building contractors from any responsibility for the proper use of these products Brochures and publications as well as any other documents related to the trade of the RAWLPLUG POLYURETHANE FOAM, the RAWLPLUG POLYURETHANE FOAM WINTER VERSION and the RAWLPLUG POLYURETHANE FOAM FOR PVC, and the application thereof in the construction industry shall contain information about the products in question being covered by ITB Technical Approval. 7. EXPIRATION DATE ITB Technical Approval shall expire on xx December The validity of the ITB Technical Approval may be extended if the Applicant or a legal successor thereof has submitted a suitable request to the Building Research Institute (ITB) along with the relevant application form not later than 3 months prior to the expiration date hereof. 9

10 T H E E N D ADDITIONAL INFORMATION Related standards and recommendations PN-EN 826:1998 PN-EN 1604:2013 PN-EN 1607:2013 PN-EN 1609:2013 PN-EN 12090:2013 PN-83/N FEICA TM 1004:2013 Thermal insulation products for building applications. Determination of compression behaviour Thermal insulation products for building applications. Determination of dimensional stability under specified temperature and humidity conditions Thermal insulation products for building applications. Determination of tensile strength perpendicular to faces Thermal insulation products for building applications. Determination of short term water absorption by partial immersion Thermal insulation products for building applications. Determination of shear behaviour Statistical quality control. Random sampling Determination of the Dimensional Stability of an OCF canis ter foam General reports, test reports, assessments and classifications 1. LZM /16/Z00NZM. Test Report. Department of Building Materials Engineering of the Building Research Institute, Warsaw, LZM /16/Z00NZM. Test Report. Department of Building Materials Engineering of the Building Research Institute, Warsaw, LZM /16/Z00NZM. Test Report. Department of Building Materials Engineering of the Building Research Institute, Warsaw, 2016.