Urethane Foam Knowledge

Easy to use effective economical do it yourself

Filling Door FrameHAMIL SELENA

Proposed improvement on filling work applying one component type polyurethane foam

Summary

Construction industry accomplishes surprising growth and development in these days and number of new materials as well as new technologies and construction method are developed so technical capability also has reached to quite high level. However, there still are lots of problem with technical issues and development of excellent materials, which are subject we confront but the reality is that many of us in the industry still stay in the past experience and hold habitual routine of the past. To cope with the problem, Hamil Selena Co. recently has developed one component type polyurethane foam using new material and construction method. By applying the product to insulation work, fittings, filling chassis and door frames and filling work for various buildings, we expect to save manpower and labor cost based on simplified work, improve quality based on the excellence of materials, shorten work period, remove cause of defect and get other efficient results.

Review the reality of existing construction method

Construction industry accomplishes surprising growth and development in these days and number of new materials as well as new technologies and construction method are developed so technical capability also has reached to quite high level. However, there still are lots of problem with technical issues and development of excellent materials, which are subject we confront but the reality is that many of us in the industry still stay in the past experience and hold habitual routine of the past. To cope with the problem, Hamil Selena Co. recently has developed one component type polyurethane foam using new material and construction method. By applying the product to insulation work, fittings, filling chassis and door frames and filling work for various buildings, we expect to save manpower and labor cost based on simplified work, improve quality based on the excellence of materials, shorten work period, remove cause of defect and get other efficient results.

The types of existing gap filling and general filling method.

Mortar injecting: Filling space with mixture of cement and sand.

Rock wool filling: Fill space using rock wool which is cut in proper size.

Styrofoam filling: Filling space by cutting out expanded polystyrene foam.

Back-up material filling: Filling space using expanded polyethylene foam which is cut in proper size.

Insulation mortar: Mix cement, sand and lightweight landfill concrete to make foam in proper size and then fill space.

Filling using other materials: Filling simple space using glass fiber or news printing paper.

Much labor cost for workability.

Most materials used for existing construction method have high heat conductivity or low density so insulation effect is minor and energy loss is significant.

In case of mortar filling method which is frequently used and one of the methods of existing construction method, if worker fills mortar a little bit exceedingly, each door frame rises and rework should be done after detach the material, which wastes much expense.

ach gap between door frames is not filled enough and cracks or condensation take place after finishing, which causes major defect. Poor watertightness (Mortar treatment on bumpy cross section of the chassis is not possible).

Takes long work time as workability is late. It is inconvenient as lots of preparation are required before start working. Many workers should be inputted at once and work control is not strict, which may lead to incomplete work.

Name of improved construction method

WORLD FOAM, TYTAN 65, WORLD PLUS, WORLD PLUS 65, WORLD 360°FOAM, WORLD SPRAY FOAM On site expanded foaming

Properties and characteristics

World foam, Tytan65, World plus, World plus 65, World360° foam, World spray foam (hereinafter “PU Foam”) are high performance foam which is high molecular compound generated when two kind of material (A: isocyanate, B: polyol) of petrochemistry system reacts to each other to take place complicated reaction repeatedly in a short time.

In PU Foam, MDI (methyl diisocyanate: hardener), PPG (poly propylene glycol: foaming agent), foaming catalyst, surfactant and other additives are mixed properly. It is used for insulation of general constructions and material for filling or specially applied to insulation of freeze warehouse, freeze vehicle and vessel.

One of the features for work is that it makes averaged filling work effect freely regardless the shape of the object as it has no joint and can work in the thickness as required specific gravity.

90% of the PU Foam consists of independent micro foam so its structure is stable and not deformed. Except for a few solvents such as concentrated nitric acid and sulfuric acid, its waterproofing and chemical resistance are excellent. Also, its vapor-proofing, sound proof, anti vibration and heat conductivity are very acceptable and it has strong weather resistance, physical strength and excellent adhesiveness to concrete, panel and metal.

Its insulation performance is excellent (heat conductivity: 0.015) so you can get maximized insulation effect with thinner foaming than other insulation materials and use more space area accordingly, which attracts great attention as a big advantage.

PU Foam has strong magnetic adhesiveness so it adhesives to any material semi-permanently once obstacles (dust, oil, foreign substances) are removed from the materials.

Surface treatment is possible. Fire resistance and weather resistance can be improved by applying paintings and protective coatings after foaming PU foam.

Filling by part

【 Surroundings of fitting chassis 】

Fill PU foam for purpose of insulation, condensation, leak prevention and sound proof around chassis.

As PU Foam’s foaming flexibility is fine, leak from bent and cracked part can be prevented by filling concrete-mortar connected part, corners and complicated bumpy parts on the cross section of chassis completely.

Though internal stability of the work can be achieved by foaming after block one side of inner area using gypsum board or bricks according to process finishing method, if work site condition does not allow such filling work, work can be performed by adjusting working angle while openings of both sides are open.

Fix chassis to inner door frame using anchor and stand the frame and then fill PU foam in the gap with proper working sense. Mend projected parts using knife or similar tool so that plastering or coating process can handle them.

Especially, in case of kitchen window of outside wall, PU Foam must be applied to prevent condensation and leakage and defects which tale place most frequently.

【 Surroundings of ALC brick 】

Apply on site foaming World foam to any openings (door frame, window frame) installed around ALC wall, equipment passing through wall and grouting materials surrounding electric pipes.

Keep 10mm of gap in connection part between upper part of ALC outside wall and slab when fill PU Foam and perform 10mm x 10mm caulking on outside.

Work in the same manner on the part where ALC outside wall contacts side wall or core wall.

PU Foam filling should be done after ALC blocks are cured completely.

Cut and mend projected parts after applying PU Foam so that nest process will not be disturbed.

【 Around the inner doorframe filling 】

Fill PU Foam in the gaps in retaining wall and bricks after install inner door frames by house. Fix each door frame using steel anchor so that there will be no problem when use the door later. In case the gap is wide enough, narrow the gap to about 20mm ~ 40mm using brick or styrofoam before fill PU Foam.

【 Filling PC joint 】

In the past, put back-up materials in the connection part and processed caulking after stood PC concrete plate on each joint and by part of the building but the problem with condensation was not resolved completely.

However, the problem with condensation has been resolved perfectly by developing PU Foam foaming method.

Superiority of the material performance

Outstandingly low heat conductivity: PU Foam provides superior insulation effect to other general insulation materials.

※Excellent effect on preventing condensation

HAMIL SELENA Co., Ltd.

Item	PU FOAM	Styrofoam	Glass fiber	Rock wool	Mortar
Heat conductivity	0.02	0.03	0.03	0.04	0.5

Powerful magnetic adhesiveness: Unlikely general insulation materials, PU Foam adhesives to concrete, wood and metal firmly without using strong magnetic adhesives.

HAMIL SELENA Co., Ltd.

Adhesive surface	Mortar	Steel plate	A L C
Adhesive strength(㎏/㎠)	3.2	2.9	3.0

Excellent compress strength: PU Foam is excellent in flexibility and compress strength and its compress strength to vertical direction is 1.4㎏/㎠. While it is weak against point load, it is strong against surface load.

Workability

When fill using PU Foam, high performance foam is made by being expanded and hardened in just 10 minutes after the foam has been sprayed so you can finish the work area and move to next process.

As PU Foam filling can be done by one person only, you can skip lots of preparation work for main work.

Work which can be done a day by one person in case fill surroundings of fitting chassis outside of a house only (based on 2M (H) - 1M (W) 6 door frames): at least 8 houses.

When filling using PU Fom, work site can be organized and controlled cleanly unlikely to other works.

Economic effect(30mm × 100mm × 1m)

HAMIL SELENA Co., Ltd.

Item	Mortar filling	PU Foam filling
Comparison	- Additional work site organizing cost - Site is dirty - Water tightness is unstable - Repairing cost should be considered	- Easy work site organizing - No work site organizing cost - Preventing potential defects - No repairing is required