THERMAX Wall System – STYROFOAM™ Brand SPF (CM Series)

General Application Guidelines
Overspray Notes
Cold Weather Application
Safety and Conditions of Use
Equipment Guidelines
Ambient and Substrate Conditions
Surface Preparation
Recommended Processing Parameters –  CM 2030, CM 2045 and CM 2060
Product Storage
Troubleshooting

General Application Guidelines
Due to the exothermic reaction of the isocyanate and polyol blend, STYROFOAM™ Brand SPF (CM Series) should be applied in layers 1/2" to 1-1/2" thick – with 3/4" the ideal layer thickness for maximum yield and a maximum overall thickness of 1-1/2". Allow foam to cool completely before applying successive layers. Excessive thicknesses can lead to void formation and even internal char, reducing the thermal and mechanical quality of the foam.

To minimize void formation where the sheathing is attached to the steel studs, apply foam in the cavity where the steel stud and sheathing meet (picture framing technique) prior to filling the cavity. Allow the foam to fully cool and then spray to the desired thickness by filling in the area between the previously applied foam using a side-to-side motion within each cavity.

STYROFOAMâ„¢ Brand SPF (CM Series) should be covered as soon as feasible during the construction process. There is no need to wait for any off-gassing of the foam as this happens immediately during application.

Overspray Notes
Overspray can lead to several problems on the job site if not controlled properly. Overspray will coat all surfaces in a room and if windows and doorways are left open, the overspray can reach other rooms and vehicles outside the building.

Cover objects near the application area that might be coated with overspray. Excessive overspray can accumulate on areas that are intended for spray foam application. Overspray can be brittle and may affect the adhesion of the spray foam on oversprayed substrates. When spray foam is applied to an area coated with excessive overspray, delamination can result.

To minimize overspray, do not apply STYROFOAMâ„¢ Brand SPF (CM Series) if there is air movement in the room due to wind or fans. Point the gun perpendicular to the surface being sprayed and as close as possible without causing spattering or a popcorn pattern.

Cold Weather Application
Applying STYROFOAM™ Brand SPF CM 2030 to the interior stud cavity side of THERMAX™ (ci) Exterior Insulation when outside temperatures are below 30°F can be accomplished with the following precautions:

• Heat the area to be sprayed to =30°F for both the ambient and substrate. This is best done with window and doorway areas closed to improve even heating.
• Check the substrates (sheathing and studs) and ensure no moisture condensation is present. After applying the spray foam, maintain the temperature at =30°F for 48 hours.

Safety and Conditions of Use

 

• Read the instructions and Material Safety Data Sheets carefully before use. Visit www.spraypolyurethane.com for further details and supporting information covering a wide range of topics including an overview of SPF health and safety guidelines, suggested personal protective equipment (PPE), typical first-aid treatment, and regulations and information about "green" marketing.
• STYROFOAMâ„¢ Brand Spray Polyurethane Foam contains isocyanate, hydrofluorocarbon blowing agent and polyol. Do not breathe vapor or spray. Use only with a NIOSH-approved supplied air respirator (SAR) in accordance with your company's respiratory protection program. Supplied air respirator or an approved air-purifying respirator equipped with an organic vapor sorbent and a particle filter (P100) is required to maintain exposure levels below ACGIH, OSHA, WEEL or other applicable limits. For situations where the atmospheric levels may exceed the level for which an air-purifying respirator is effective, use a positive-pressure, air-supplying respirator (air line or self-contained breathing apparatus).
• Isocyanate is irritating to the eyes, skin and respiratory system, and may cause sensitization by inhalation or skin contact. Sensitization, or the development of asthma, can lead to permanent respiratory problems.
• STYROFOAMâ„¢ Brand SPF will adhere to most surfaces and skin. Do not get foam on skin. When spraying polyurethane foam, wear MDI-resistant chemical gloves (e.g., nitrile) or fabric gloves coated in nitrile, neoprene, butyl or PVC. Spray applicators should wear chemically resistant coveralls or full body suits with hoods and MDI-resistant fitted boots or booties. Professional judgment is necessary to determine the appropriate PPE necessary for secondary activities such as cleaning and trimming of the cured foam. Cured foam must be mechanically removed or allowed to wear off in time.
• The contents are under pressure.
• STYROFOAMâ„¢ Brand SPF should be installed by a trained SPF applicator.

Equipment Guidelines

• The drum contents are under pressure. Keep the drums out of sunlight and never use heating devices to warm drums. If the drums should cool below 60°F, allow drums to warm naturally to 60°F-90°F prior to application.
• Position drums to be used in a ventilated area out of rain or sunlight. The use of a sealable drum transfer pump is recommended. A transfer pump long enough for totes will rest on the bottom of the drum. If the extra-long drum transfer pump cavitates as the drum empties, the pump can bounce against the bottom of the drum leading to damage and subsequent leakage of the contents.
• Open the bung with the proper tool to minimize damage to the bung cap. Open slowly until gas pressure (warm weather) or vacuum (cool weather) is released and then remove the bung cap completely.
• Never leave drums open for longer than 10 minutes. To prevent cavitation of the drum transfer pump, install a desiccated air dryer on the vent cap to keep the drums at atmospheric pressure.
• Empty isocyanate drums should be left uncapped prior to cleaning and disposal per local regulations. Ambient air contains moisture, which can combine with the residual isocyanate generating pressure in the drum.
• Keep the drums out of direct sunlight and out of the weather while applying the foam.
• Spray equipment must be capable of delivering the proper ratio (1:1 by volume) of polymeric isocyanate and polyol blend at the recommended temperatures and spray pressures. See Recommended Processing Parameters – CM 2030, CM 2045 and CM 2060. To minimize the potential for off-ratio product the use of common drive on the positive displacement pumps of the proportioner is recommended.
• Follow the spray equipment manufacturer's guidelines for all spray operations. Spray units and guns come in a variety of capacities and styles and will require adjustments to achieve the desired spray pattern.

Ambient and Substrate Conditions
Substrate must be at least 5 degrees above dew point, with best processing results when the relative humidity is below 80 percent (<18 percent substrate moisture content if wood or concrete is the substrate). To minimize potential for moisture interference with adhesion of STYROFOAM™ Brand SPF (CM Series) to the substrate, spray only when the relative humidity is below 70 percent (<12 percent substrate moisture content if wood or concrete is the substrate).

Surface Preparation

• The steel stud and THERMAXâ„¢(ci) Exterior Insulation substrates must be free of moisture (dew or frost), grease, oil, solvents and other materials that would adversely affect the adhesion of the polyurethane foam. Poor adhesion will result in stud line cracking of the SPF.
• THERMAXâ„¢ (ci) Exterior Insulation and the steel studs do not need to be primed unless the studs are weathered or previously painted. If priming is desired, clean the surface per primer manufacturer's recommendations and use a primer known to be compatible with spray polyurethane foam.
• Most untreated and unpainted wood does not need to be primed.
• Substrate temperatures should not exceed 120°F for STYROFOAMâ„¢ Brand SPF CM 2060, 100°F for STYROFOAMâ„¢ Brand SPF CM 2045 and 60°F for STYROFOAMâ„¢ Brand SPF CM 2030. Excessive temperatures will lead to fast gel times and low yield.

Ready to make your mark? We'll do our level best to answer your questions.