SPRAYED FOAM INSULATION FOR COLD STORAGE FACILITIES
NOTE ** Foam Enterprises sprayed polyurethane foam insulation for coolers and freezers.
NOTE **
NOTE ** This section is based on the products of Foam Enterprises, Inc., which is located at:
NOTE ** 13630 Water Tower Circle
NOTE ** Minneapolis, MN 55441
NOTE ** Tel: (800) 888-3342
NOTE ** Fax: (612) 559-0945
NOTE **
NOTE ** This section covers the foam insulation and vapor retarder, plus optional thermal barrier (fire resistive) coating or other material.
NOTE **
NOTE ** This specification is based on the following publication of the Society of the Plastics Industry, Inc., Spray Polyurethane Foam Division:
NOTE **
NOTE ** "Spray Polyurethane Foam Systems for Cold Storage Facilities Operating Between -40degF and +50degF"; copyright 1990.
NOTE **
NOTE ** SECTION 07212 - SPRAYED FOAM INSULATION FOR COLD STORAGE FACILITIES, Copyright 1997, The Architect's Catalog, Inc.
PART 1 GENERAL
1.1 SECTION INCLUDES
NOTE ** Edit items below as required for project.
A. Sprayed polyurethane foam insulation with vapor retarder.
B. Thermal barrier (fire resistive) coating.
1.2 RELATED SECTIONS
NOTE ** Delete any sections below not relevant to this project; add others as required.
A. Section 03300 - Cast-ln-Place Concrete: Cold storage rooms floor slabs over foam insulation.
NOTE ** Roof Decks: This section should not be used to specify foam insulation on the exterior side of a roof -- use a true foam roofing specification for that. Some considerations for foam roofing over cold storage facilities are:
NOTE **
NOTE ** Metal decking or other conductive material should not be continuous between rooms of varying temperature.
NOTE **
NOTE ** When a low perm-rated material is used on the cold side of the insulation in a cold storage facility, such as in panels of metal roof decks, breaks in the exterior vapor retarder will result in the build-up of ice within the insulation. Routine maintenance inspections should be done to repair retarder breaks before this can occur.
NOTE **
NOTE ** A sprayed polyurethane foam roof system or any exterior insulation should not be applied over a lightweight concrete fill.
NOTE **
NOTE ** Roof deck should have a minimum slope of 1/4 inch per foot.
B. Section 07570 - Coated Foamed Roofing: Spray polyurethane foam on exterior side of roof decks.
C. Section 07600 - Flashing and Sheet Metal: Metal trim and flashings associated with insulation.
D. Division 15 - Mechanical: Plumbing and HVAC components penetrating insulation.
E. Division 16 - Electrical: Electrical components penetrating insulation.
1.3 REFERENCES
NOTE ** Add any references to the list below that are included in text you have added to the section.
A. ASTM C 177 - Standard Test Method for Steady-State Heat Flux Measurements and Thermal Transmission Properties by Means of the Guarded-Hot-Plate Apparatus.
B. ASTM C 518 - Standard Test Method for Steady-State Heat Flux Measurements and Thermal Transmission Properties by Means of the Heat Flow Meter Apparatus.
C. ASTM D 1621 - Standard Test Method for Compressive Properties of Rigid Cellular Plastics.
D. ASTM D 1622 - Standard Test Method for Apparent Density of Rigid Cellular Plastics.
E. ASTM D 2856 - Standard Test Method for Open-Cell Content of Rigid Cellular Plastics by the Air Pycnometer.
F. ASTM E 84 - Standard Test Method for Surface Burning Characteristics of Building Materials.
G. ASTM E 96 - Standard Test Methods for Water Vapor Transmission of Materials.
H. SPI bulletin AX-119 - MDI-Based Polyurethane Foam Systems: Guidelines for Safe Handling and Disposal; Society of the Plastics Industry, Inc., Spray Polyurethane Foam Division.
I. SSPC-SP 6 - Commercial Blast Cleaning (Part of Painting Manual, Volume 2); Steel Structures Painting Council.
1.4 SUBMITTALS
NOTE ** Delete types of submittals not required. Coordinate submittal statements with other provisions in the section.
A. Submit under provisions of Section 01300.
B. Product Data: Manufacturer's data on products to be installed.
1. Application or installation instructions.
2. Listing, classification, and approval certifications.
3. Safety and handling instructions for storage, handling and use of the materials.
C. Certifications: If manufacturer's published data sheets do not indicate compliance with all specification requirements, provide letter of certification that all products comply with the specification requirements; include primers (if required), foam and coatings.
D. Shop Drawings: Show materials and details of fabrication of sheet metal, accessories, or other fabricated items.
E. Qualification Statements:
1. Manufacturer qualifications.
2. Installer qualifications.
3. Independent inspector qualifications.
F. Applicator's Field Quality Control Procedures: Written description of procedures to be utilized to insure proper preparation and installation of foam and coatings, detail work and follow-up inspection.
G. Maintenance Data: Manufacturers' recommended protection, cleaning, and repair procedures, including recommended frequency of inspection.
NOTE ** It is strongly recommended that a maintenance program, including annual inspections, be established with the installer for the system to achieve its full value.
1. Include proposal for annual inspection program.
1.5 QUALITY ASSURANCE
NOTE ** Delete the following if not required, as these provisions add cost to the project.
A. Foam and Coating Manufacturer Qualifications: Firms which can show evidence of ability to manufacture the products specified and sufficient financial resources and manufacturing facilities to furnish materials on this project; evidence required includes references, past project descriptions, specimen warranty, product data, test data, and code approvals.
B. Installer Qualifications: A firm with experience installing insulation systems of the type specified.
NOTE ** Delete the following paragraph if not required.
NOTE **
NOTE ** The Society of the Plastics Industry Spray Polyurethane Foam Division conducts an Accreditation Program for improvement of quality in the application of spray polyurethane foams and coatings.
NOTE **
NOTE ** Individual accreditation attests that required courses and field inspection requirements have been successfully completed.
NOTE **
NOTE ** Contractor level accreditation requires that a company employ at least one individual who has achieved management level accreditation and at least one individual who has achieved foreman level accreditation.
NOTE **
NOTE ** The list of accredited individuals and firms is available from SPFD.
1. Show contractor level accreditation by SPI SPFD Accreditation Program.
NOTE ** Delete the following paragraph if the manufacturer does not have an approved installer program.
2. Approved or certified by the foam manufacturer as qualified to install the specified system.
3. Provide information concerning projects similar in nature to the one proposed including location and person to be contacted.
C. Manufacturer Field Representation: Provide qualified representatives of the foam and coating manufacturers to monitor and inspect the installation of their products.
NOTE ** Independent inspection is highly recommended, especially if single source responsibility is not specified or no warranty is specified.
D. Independent Inspection: Provide inspection of the installation by a qualified SPI SPFD inspector member.
1.6 DELIVERY, STORAGE, AND HANDLING
A. Provide materials packaged in the manufacturer's original, tightly sealed containers or unopened packages, clearly labelled with the manufacturer's name, product identification, safety information, and batch or lot numbers where appropriate. Where materials are covered by a referenced specification, the labels shall bear the specification number, type and class, as applicable.
B. Store materials out of the weather and out of direct sunlight in locations where the temperatures are within the limits specified by the manufacturer.
1.7 PROJECT CONDITIONS
NOTE ** Normally safety procedures are the responsibility of the contractor. For more information about polyurethane foam see SPI Bulletin AX-119, "MDI-Based Polyurethane Foam Systems: Guidelines for Safe Handling and Disposal."
A. Comply with the manufacturer's instructions and recommendations as to handling and safety procedures.
PART 2 PRODUCTS
2.1 MANUFACTURERS
A. Provide products manufactured by Foam Enterprises, Inc., 13630 Water Tower Circle, Minneapolis, MN 55441. ASD. Tel: (800) 888-3342. Fax: (612) 559-0945.
B. Substitutions are not acceptable.
NOTE ** Delete paragraph above or below. Edit Section Number as required for project.
C. Submit requests for substitutions in accordance with provisions of Section 01600.
2.2 MATERIALS
NOTE ** Most published data is run on laboratory produced samples, not in-place material. The thickness of polyurethane foam sprayed, number of passes, temperature of substrate, ambient temperatures, etc. have a pronounced effect on all properties. Verify the following values for Foam Industries' product in-place.
A. Foam: Sprayed-in-place two-component closed-cell polyurethane made by combining an isocyanate (A) component with a polyol (B) component, with the following physical characteristics:
1. Density in place, when tested in accordance with ASTM D 1622: ___ lb/cu ft (___ kg/cu m).
2. Compressive Strength, when tested in accordance with ASTM D 1621: ___ psi (___ Pa), minimum.
3. Closed Cell Content, when tested in accordance with ASTM D 2856: ___ percent, minimum.
4. Thermal Conductivity ("K"), when measured in accordance with ASTM C 177 or C 518: _____.
NOTE ** From a fire safety standpoint, polyurethane foams can be used safely. It is important, however, that all persons associated with the design, fabrication, storage and installation understand the materials and environments involved.
NOTE **
NOTE ** Polyurethane foam insulation is combustible and should be treated as such. Flame spread ratings provided for polyurethane products using small scale tests are not intended to reflect the hazards presented by this or any other materials under actual fire conditions. Care must be taken to ensure that the foam is not exposed to heat or flame.
5. Flame Spread Index, when tested in accordance with ASTM E 84: Less than 75.
6. Smoke Developed Index, when tested in accordance with ASTM E 84: Less than 450.
B. Primers: As recommended by the manufacturer of the spray foam materials specified.
NOTE ** Enter a description of the vapor retarder below. A vapor retarder is always required for cold-storage facilities, due to the increased vapor pressure between outside and inside and the damage that condensation can do to the insulation.
NOTE **
NOTE ** The following items must be considered when choosing a vapor retarder:
NOTE ** 1. Perm rating required.
NOTE ** 2. Surface preparation required.
NOTE ** 3. Adhesion of all systems components.
NOTE ** 4. Foam manufacturer's recommendations.
NOTE ** 5. Environment in which it is to be used.
C. Vapor Retarder: Fluid-applied coating, _____________.
1. Moisture Vapor Transmission: 0.01 perm or less, when tested in accordance with ASTM E 96, Method D.
NOTE ** Consult the applicable building code to determine whether a thermal barrier (fire resistive) is required over polyurethane foam exposed on the interior of the building. In some cases, a thermal barrier is not required in cold storage facilities. Typically, the minimum thermal barrier is a material that constitutes 15 minutes of fire protection for the foam. Materials that have been used include sprayed cementitious or fiber material (such as fireproofing) and gypsum board.
NOTE **
NOTE ** Consider the following items in the selection of a thermal barrier:
NOTE ** 1. USDA (food contact) and building code requirements.
NOTE ** 2. Adhesion to the spray polyurethane foam.
NOTE ** 3. Environment in which it is to be used.
NOTE ** 4. Aesthetic qualities.
NOTE ** 5. Ease of maintenance.
D. Thermal Barrier: Sprayed or fluid-applied coating, _____________.
1. Fire Resistance: 15 minute rating.
E. Insulation Boards: Type, size, and thickness as required; stagger joints of multiple layers.
F. Flashings and Waterproof Coverings for Expansion Joints: Compatible with the foam and coating systems and as recommended by manufacturer.
G. Other Materials Used in System: Selected for compatibility with insulation materials and as recommended by the manufacturer; including, but not limited to, adhesives, sealing and caulking compounds, metal flashings, vents and drains.
PART 3 EXECUTION
3.1 GENERAL
A. Comply with the instructions and recommendations of the foam and coatings manufacturers.
B. Familiarize all installers with correct and safe application and handling procedures:
1. See SPI Bulletin AX- 119, "MDI-Based Polyurethane Foam Systems: Guidelines for Safe Handling and Disposal."
2. Refer to appropriate Materials Safety Data Sheets (MSDS) for additional safety information.
3.2 DESCRIPTION OF INSULATION AND SEQUENCE OF CONSTRUCTION
NOTE ** The following is an example of the sequence of installation of foam insulation in a new construction application. Edit as required for project.
NOTE **
NOTE ** Specify the foam thickness below. The thickness should be sufficient to provide the thermal resistance required and to prevent condensation. Factors such as exterior temperature, facility temperature, and humidity should be considered to determine the final thickness of the insulation.
A. Due to the need for coordination with installation of other building components, the installation of insulation cannot be accomplished in a single operation. Sequence installation as follows:
NOTE ** Cooler floors (above freezing) may not need to be insulated.
B. Freezer Floors: Insulation thickness of ____ inch (____ mm).
NOTE ** The ultimate load capacity of the spray polyurethane foam insulated floor is dependent on the thickness and compressive strength of the insulation and strength of the concrete wearing slab. The concrete wearing slab is placed directly on the sprayed polyurethane foam and slip sheet. The concrete wearing slab over spray polyurethane foam insulation must have a strength of at least two (2) times the long-term load factor estimated for the facility, allowing for point loading of racks.
NOTE **
NOTE ** Reinforce all wearing floors subject to truck traffic and/or heavy loadings. Where contraction joints are provided in such floors. incorporate slip rods, tongue-and-groove or equivalent reinforcing at the joint to compensate for any vertical movement between the slabs.
NOTE ** All freezer floors should be vented and/or heated. A heat source must be provided under the insulation in all areas that are designed to operate below 32EF. This may be in the form of ducts to circulate warm air, pipes for warm fluid, or electric heating cables. The capacity of the heat supply must be sufficient to replace the heat that is lost to the cold room. A thermocouple should be installed to allow monitoring of under-floor temperature during operation of the facility. The design of the subgrade heating system should be based on local soil conditions and the thermal conductivity of the sprayed polyurethane foam insulation system (BTU/hr sq ft F).
1. Apply vapor retarder and sprayed foam insulation to base of columns.
2. Install heated mechanical equipment and vent pipes.
3. Pour base slab (recess to allow for thickness of insulation).
4. Allow new concrete to cure a minimum of 28 days before applying vapor retarder.
5. Apply vapor retarder and sprayed foam insulation.
6. Secure slip sheet and pour concrete wearing slab.
NOTE ** Hollow walls between two freezers are not recommended.
NOTE **
NOTE ** Walls which separate a low-temperature space from a heated space require more insulation than would be used on walls that separate cold spaces from each other.
C. Walls: Insulation thickness of ____ inch (____ mm).
1. Complete all penetrations through walls before vapor retarder and sprayed foam are applied.
NOTE ** Suspended ceilings should have sufficient working space above and should be vented.
NOTE **
NOTE ** Hanger rods should be insulated and spaced to provide safe support for anticipated loads.
NOTE **
NOTE ** Where the ceiling finish in front of the refrigeration blowers is subject to wet-drying and freeze-thawing, it is recommended that a deflector the width of the coil be attached to the surface in this area.
D. Ceilings: Insulation thickness of ____ inch (____ mm).
1. Insulate hanger rods for distance of 4 times the ceiling insulation thickness measured from the outside face of the insulation.
E. Doors: Insulation thickness of ____ inch (____ mm).
F. Complete all insulation and thermal barrier work prior to activation of refrigeration equipment.
3.3 PREPARATION
A. Ferrous Metal: Sandblast iron and steel surfaces which are not primed, shop painted, or otherwise protected in accordance with SSPC SP-6. Remove loose rust and unsound primer from shop primed iron and steel surfaces by scraping or wire brushing.
B. Non-Ferrous Metal: Clean galvanized metal, aluminum, and stainless steel surfaces as recommended by the manufacturer of materials to be applied.
C. If metal surface is free of loose scale, rust, weathered or chalking paint, clean using compressed air jet, vacuum equipment, and hand or power broom to remove loose dirt. Remove grease, oil and other contaminants using proper cleaning solutions.
D. New Concrete: Allow to cure for twenty-eight (28) days prior to the application of primer or foam.
E. Previously Painted Surfaces: Remove all paint.
F. Remove loose dirt, dust and debris by using compressed air, vacuum equipment or brooming. Remove oil, grease, form release agents, laitance, and other contaminants using proper cleaning solutions. Do not wash wood or porous materials with water.
G. Grout, tape, or calk all joint openings that exceed 1/4 inch (6 mm) in width.
H. Prime all metal as recommended by manufacturer.
I. Prime all concrete surfaces.
NOTE ** Plywood should be exterior grade not less than 1/2 inch thick, nailed firmly in place.
NOTE **
NOTE ** Priming is required to minimize moisture absorption and eliminate potential adhesion problems.
J. Prime all untreated and unpainted wood surfaces with an exterior grade primer.
3.4 VAPOR RETARDER INSTALLATION
A. Apply vapor retarder in accordance with the manufacturer's specifications and instructions.
B. Apply vapor retarder to all surfaces to be insulated in a continuous film across corners and junctions.
1. Extend 6 inches beyond where the insulation will end.
2. Metal surfaces do not require vapor retarders, but seams and penetrations must be sealed.
C. Allow vapor retarder to cure before the sprayed foam insulation is applied.
D. Repair damage and defects to the vapor retarder prior to the application of foam insulation.
E. Keep vapor retarder free of moisture, frost, debris, and contaminants that might impair the adhesion of the foam insulation.
3.5 FOAM APPLICATION
A. Do not begin application of foam until all preparation requirements have been completed.
B. Do not apply foam when the temperature is below or the humidity is above that specified by the manufacturer for ambient air and substrate.
C. Apply foam in accordance with the manufacturer's specifications and instructions.
D. Apply foam with minimum pass thickness of 1/2 inch (13 mm) and maximum pass thickness of 1 inch (25 mm), unless greater pass thickness is acceptable to foam manufacturer.
E. Apply foam uniformly over the entire surface with a tolerance of plus 1/4 inch per inch (6 mm per 25 mm) of thickness minus 0 inch (0 mm), except where variations are required to conform to building structure or to insulate around projections, door jambs, and corners.
F. Penetrations Through Insulation:
1. Insulate conduits, pipes less than 2 inches in diameter, and hanger rods that project through the insulation with spray foam for a distance of four times the regular wall insulation thickness.
2. Insulate columns and pipes larger than 2 inches in diameter with spray foam for a distance of 4 feet from the wall, ceiling or floor.
3. For insulated metal ducts add spray foam insulation of one half the thickness of the wall or ceiling insulation.
G. Complete the full thickness of foam in any area prior to the end of each day. If the full thickness is not completed in one day, prepare the surface in accordance with the recommendations of the manufacturer.
NOTE ** Delete the following paragraph if the thermal barrier is not a coating to be adhered to the foam.
H. Finish the final sprayed foam surface to a finish suitable for application of the thermal barrier. Remove unsuitable surfaces and reapply to an acceptable surface.
I. Allow the foam surface to cure sufficiently.
J. Repair damage and defects to the surface prior to the thermal barrier application.
3.6 THERMAL BARRIER APPLICATION
A. Apply thermal barrier over entire surface of foam.
B. Allow thermal barrier to cure. Inspect for defects and repair defects prior to subsequent coats.
