PIR Foam Stability

PIR Foam Stability

Materials failure analysis is our business and insulation foams form a core part of our laboratories work. Rigid insulation foams are polymer based materials which resist the transfer of heat via conduction, convection or radiation. These foams are very commonly used to insulate the floors, walls and roofs of all types of buildings and are most typically pre formed boards made on a continuous process or liquid compositions injected into cavities. The most commonly used foam being polyisocyanurate (PIR).

On a very regular basis, our laboratories are asked to assess both the physical and chemical properties of both rigid and cavity injected insulation foams. The request for these examinations typically arise in cases where latent defects, hidden problems which cannot be discovered during reasonable or customary inspections, come to light.

Rigid foams tend to be less problematic as they are manufactured on continuous line. The most common question we are asked to answer is that of the dimensional stability of the foam. This request arises when it is suspected that the foam under the floor did undergo a level or shrinkage outside that of the foam manufacturers Declaration of Performance.

When properly installed, cavity injected foams do provide long-lasting insulation however the installation of these systems is a job for the trained and certified. The most common problems with cavity injected foam is generally not related to the product, but rather the process of application. The most common issue being incorrect ratio of polyol to isocyanate, incorrect component temperature, incorrect injection pressure or over-filling of the cavity. In particular, poorly installed cavity injected foam will shrink, expand, crack and release odours.

Over the years we’ve been asked to investigate many installation sites where the improper installation of cavity injected foam has had a negative effect both on the fabric of the building and the occupants. These can be difficult cases to investigate as the foam his hidden and can be only accessed by core drilling,

In the investigation of matters concerning either rigid or injected insulation foam, the process has two stages:

  1. A visual assessment of the in situ foam. This assists in determining if the foam is correctly installed, the surface profile and if any signs of delamination, expansion or shrinkage. The examination of insitu spray foams allows us to determine if the foam has fully adhered to the surface, has not delaminated or cracked etc.
  2. Material Assessment. This involves measuring both the physical and chemical properties of the foam. The physical properties include Dimensional Stability (EN 1604) and Density (EN 1602). In addition, using digital microscopy, we have the ability to examine individual foam cells for the percentage of closed cells, foam cell circularity and cell long diameter.

In addition, to physically testing the insulation foam, we are commonly asked to identify the foam type. It is not possible to visually distinguish between PIR or PUR foams and this is where we use our Bruker Lumos 2 Fourier Transform Infrared Spectroscopy (FTIR) microscope. FT-IR microscopy allows us to chemically fingerprint a foam, an important aspect given the somewhat better fire performance of PIR.

Our laboratories have a comprehensive suite of analytical instruments to identify, characterise identify flaws in the composition and installation of insulation foams. Contact us today!

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