Spray foam

Spray foam is a chemical product used in construction and engineering primarily as insulation and as a filler material. It is produced as a liquid but quickly expands and hardens into a stiff, lightweight structure. It is created by a chemical reaction of two component parts, commonly referred to as side A and side B. Side A contains very reactive chemicals known as isocyanate. Side B contains a polyol, which reacts with isocyanates to make polyurethane, and a mixture of other chemicals, including catalysts, flame retardant, blowing agents and surfactants. These react when mixed with each other and expand up to 30-60 times its liquid volume after it is sprayed in place. This expansion makes it useful as a specialty packing material which forms to the shape of the product being packaged and produces a high thermal insulating value with virtually no air infiltration.

History

is credited with the invention of polyurethane in 1937. He succeeded in synthesizing polyurethane foam by exploring his basic idea that mixing small volumes of chemical substances could create dry foam materials.
Polyurethane was further developed for different applications, ranging from shoe soles and cushions to industrial uses. In the 1940s rigid foam was applied to airplanes, and in 1979 polyurethane began being used as building insulation.

Properties

Thermal resistance

is the term given to thermal resistance to heat flow. The higher the R-value of an insulation product, the more effective the insulation properties. Spray polyurethane foam comes in a range of densities and cell structure. Low density foams are referred to as open cell SPF while higher density foams are referred to as closed cell foam. 1.8-2 pound polyurethane foam has the highest R-value of readily available spray foam insulation used in homes and buildings.
Polyurethane is a closed-cell foam insulation material that initially contains a low-conductivity gas in its cells. As a result of the high thermal resistance of the gas, spray polyurethane insulation typically has an initial R-value around R-3.4 to R-6.7 per inch. In comparison, glass wool typically has an R-Value of only R-3 to R-4 per inch.
Foam insulation blocks all three forms of heat transfer:
;Conductive heat transfer:The flow of thermal energy through a substance from a higher to a lower temperature region. Foam thermoset plastics reduce conductive heat transfer due in part to having very loose molecular bonds; In addition the cells of the installed spray foam are either filled with air in the case of open cell foam or HFCs or HFOs, 1233zd) in closed cell foam.
;Radiant heat transfer: The process by which heat energy in the form of light is emitted more strongly by warm surfaces and absorbed by other materials especially those of low IR reflectivity. Radiant heat transfer does not require a medium. Foam insulation materials, such as spray foam insulation, are opaque to thermal radiation, like most solid materials.
;Convective heat transfer: Heat which is created elsewhere that is transported by means of a fluid, such as water or in our case air. Spray foam insulation's most important attribute is the ability to air seal creating a custom airtight envelope within the building structure. The added benefit to air sealing is the ability to block convective heat transfer from interior to exterior during heating months and vice versa during cooling months, as the heat cannot escape through gaps in the buildings envelope without the aid of air movement from infiltration as a means of transport.

Applications

Packaging applications

Spray foam is a very specialized packing material, often required for use in shipping valuable fragile items. Engineered packaging principles are designed to protect sculptures, vases, large fossils, lamp bases, busts, computers, furniture, chandeliers and other objects of unusual shape. By virtue of the liquid foam expanding by up to 30-60 times the volume of its liquid state, it efficiently protects almost any size, form and weight.
The custom fit of the molds, top and bottom, securely and uniformly cushions the object. There are many types of alternative materials that can be used to handle more specific needs.

Building applications

Spray foam insulation or spray polyurethane foam is an alternative to traditional building insulation such as fiberglass. A two-component mixture composed of isocyanate and polyol resin comes together at the tip of a gun, and forms an expanding foam that is sprayed onto roof tiles, concrete slabs, into wall cavities, or through holes drilled into a cavity of a finished wall.
Closed-cell polyurethane foam is widely regarded as a versatile material and is employed in a range of applications beyond conventional wall and roof insulation. It is commonly used to insulate roofs, floors, windows, and walls, as well as containers, boats, crawl spaces, and basements. In addition to providing thermal resistance, it can help to prevent condensation on windows and walls, reduce noise transmission by filling hollow spaces, and minimise thermal bridging. Owing to its dense structure, closed-cell PU foam is also frequently applied to seal cracks and construction joints, contributing both to air tightness and structural integrity.
"Spray foam" is also an informal term used to refer to various plastic foam materials that are used in building construction to provide thermal insulation and minimize air infiltration. Polyurethane and polyisocyanurate are two types of foam used in this application.

Types

Spray polyurethane foam insulation can be categorized into two different types: light-density open-cell spray foam insulation and medium-density closed-cell spray foam insulation. Both types of SPF are thermoset cellular plastics comprising millions of small cells.
Open cell insulation can be crushed by hand and has a lower insulation value. Closed cell is rigid to the touch and each air cell is completely sealed. While closed cell foam has a higher R-value, it is more costly to buy.
Medium-density closed-cell spray foam
Medium-density closed-cell foam insulation is often referred to as two pound foam. It is a rigid insulating material with a Long Term Thermal Resistance R-value that ranges between 5.1 and 6 per inch When the required minimum thickness of 50 mm is installed, ccSPF is both a vapour barrier and an air barrier.
In Canada, the National Building Code references two standards that apply to the manufacturing and installation of ccSPF: the CAN/ULC S705.1 Material Standard and the CAN/ULC S705.2 National Application Standard. The installation standard requires that all installers of ccSPF in Canada be licensed and carry a photo ID card.
Typically the foam's natural colour is yellow, however in Canada all ccSPF that have CCMC listings are required to have a unique colour for field identification.
Light-density open-cell spray foam
Light-density open-cell SPF is commonly known as half-pound foam. It is a semi-rigid material with a sponge-like appearance that expands during installation and creates small, open cells that are filled with carbon dioxide. Due to its ability to expand during the application process, it fills cracks, crevices and voids and adheres to irregular surfaces or substrates to form an air sealing insulation.
While the R value will vary, most ocSPF products have an R value of around 3.8 per inch. Unlike medium-density closed-cell SPF, thinner layers of ocSPF are not particularly effective as vapour barrier because the air infiltrates through the open cell structure. However, when installed at 5.5 inches or more, ocSPF does act as an air barrier. It is often used for interior walls because it provides sound reduction by blocking and absorbing air leakage. It is usually only recommended for indoor applications.

Application methods

Asia

A type of use quite familiar in South East Asian countries is applying the foam by spraying it against the bottom of roof tiles under high pressure with a spray gun. A hard but flexible layer of rigid foam is then created and seals all the tiles to each other and to the steel structure.
This spraying method, especially very popular in Thailand, is used not only against heavy leaks but helps also as insulation against the enormous heat the roofs constantly face.
This tropical heat causes the steel substructure that supports many roofs in that part of the world, to continuously expand and contract, changing slightly the position of the tiles resting on top of them. This displacement eventually creates small openings between the tiles and the substructure, through which rainwater can seep, creating leaks that can damage the plastered ceilings, electric wiring, and other components of the building supporting the roof.

Europe

Since 24 August 2023, regulations in Europe, including the United Kingdom, have required that all users of polyurethane products receive training and certification in the safe handling of materials containing diisocyanates. Only individuals who have completed this training may continue to use such products.
Some 150,000 properties have been treated with polyurethane foam insulation in the UK. There are systems which have British Board of Agreement approval for use in existing and new build applications and can show compliance to Building Regulations. However, if applied incorrectly or in damp spaces, spray foam insulation can trap moisture and destroy the roof. As a result, very few mortgage lenders in the UK will offer a loan to buy or to refinance any home that has any spray foam insulation, especially the closed-cell type.
Closed-cell spray foam is also commonly employed in specialist applications such as insulating boats, van conversions, cabins, and outbuildings. Its ability to provide both thermal resistance and moisture protection makes it suitable for environments exposed to fluctuating temperatures and humidity.