IS 12432-3: Application of Spray Applied Insulation - Code of Practice, Part 3: Polyurethane/Polyisocyanurate

11 Pages·2002·1.1 MB·English

by  Bureau of Indian Standards

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IS 12432-3 (2002): Application of Spray Applied Insulation
- Code of Practice, Part 3: Polyurethane/Polyisocyanurate
[CHD 27: Thermal Insulation]
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IS 12432 (Part 3) : 2002
REAFFIRMED
20CI
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Indian Standard
APPLICATION OF SPRAY APPLIED INSULATION
CODE OF PRACTICE
PART 3 POLYURETHANE/POLYISOCYANURATE
res 25.220.20; 83.100
©BIS 2002
BUREAU OF INDIAN STANDARDS
MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002

December2002 Price Group 4
AMENDMENT NO.1 MARCH 2007
TO
IS 12432 (PART 3) : 2002APPLICATION OF SPRAY
APPLIED INSULATION- CODE OF PRACTICE
PART 3 POLYURETHANE/POLYISOCYANURATE
(Page 3,clause6.11)- Substitutethefollowingfortheexistingclause:
6.11 General
6.11.1 In all cases of overdeck insulation where there is a parapet wall or an
upstand around the roof, effectiveness ofjunction between roof and vertical
portionwouldbe ensured by continuingthe treatment to a vertical extension of
0.5 m,Min aroundtheroofperimeter. Suchextraareaaretobemeasured.
6.11.2Fortreatmentsonvertical areasof overdeckinsulation.amultiplication
factor of1.2 shall be applied to the actual area to account for rebound losses!
over thickness.
6.11.3 To account for ex-cess rebound losses in underdeck PURlPIR Spray in
situapplication. measuredareashallbesubjecttoamultiplicationfactorof 1.4.
6.11.4 Spray treatment is applied as a continuous treatment and hence no
deductions shall be made in measurements for cutouts having area of one
squaremetreorless.'
(Page 4,clause6.12)- Deletetheclause.
(Page 4,clause6.12.1)- Deletetheclause.
(Page 4,clause6.12.2)- Deletetheclause.
(CHD 27)
ReprographyUnit, BIS,NewDelhi,India
ThermalInsulationSectional Committee, CHD 27
FOREWORD
This standard (Part 3) was adopted by the Bureau ofIndian Standards, after the draft finalized by the
Thermal Insulation Sectional Committee had been approved by the Chemical Division Council.
Rigid urethane foam is a generic;name given to polyurethane (PUR) or polyisocyanurate (PIR) rigid
foam. These are high efficiencythermal insulationmaterial suitable for use on surfaces operatingwithin
the temperature range of-180 to 110°C for PUR and -180 to 140°C for PIR. When appliedby spray
applicationprocesses,the service temperaturerangeis restrictedto-30to +120°Cfor boththematerials.
Some conspicuous features ofspray polyurethane foam insulationare:
a) the componentraw materials are inliquid form which are relatively stable bythemselves and
afford acceptable shelflife.
b) the process of manufacture docs not involve application of external heating or development
ofhightemperaturesinthe enclosurewhere the materialisgettingformed as in-situ insulation.
c) since it is applied as a liquid, urethane spray applied conforms closelyto any contour.
These features are exploited in in-situ spray application.
This technique is a preferred method adopted for many thermal insulation application, such as for
buildings, storage and otherequipment forthe range ofoperatingtemperatures stipulatedabove. In-situ
spray foaming is particularly suited where:
a) complicated shapes contours arc involved which would not lendthemselves to easy insulation
treatment using preformed rigid materials;
b) ajointfree insulation is desired or where the number ofjoints isto be keptto a minimum: and
c) high disbonding forces are expected to be incident on the insulation system as in cyclone
prone areas.
Though this method of insulation can be extremely efficient and cost-effective, it involves carrying out
a foaming at site, often under difficult site conditions. Hence, there is need for use of appropriate
specialized equipment alongwith specialized skill, adequate inspection during the actual spray foaming
operation,to ensurethatthe same degree ofquality control is obtained comparableto that ofpreformed
insulationmaterials. The purchaseris advised tothoroughly satisfyhimselfthatthe contractoriscapable
of providing these important inputs that is the required specialized equipment and necessary skilled
manpower for the site work. Further, it is necessary to have adequate inspection steps and to have
regular test samples at various stages of project execution on which tests are performed to ensure
compliance with the specification.
The following two standards are relevant in this field:
IS No. Title
13205 : 1991 Code ofpracticefortheapplicationofpolyurethaneinsulationbyin-situpouringmethod.
14164 : 1994 Industrial application and finishing of thermal insulating materials at temperatures
from -80 "Cand up to 750°C - Code ofpractice.
There is no ISO Standard on the subject. This standard has been prepared based on indigenous datal
practices prevalent in the field in India.
The composition ofthe Committee responsible for formulation of this standard is given inAnnex A.
IS 12432 (Part 3) :2002
d) Lot orbatch number; method that he shall select. However, the completed
applicationoffoamshallberenderedmonolithicwith
e) Recommended storagetemperature range;
adjacent areas where normal spray application is
f) A caution label giving safety instructions for applied.Allfoamoverroofsofbuildings ortanksshall
handling and storage temperaturerange; beappliedinsuchamannerastoprovideeasydrainage
ofwater and prevent ponding.
g) Mixinginstructions; and
6.4 Extremecautionshallbetakentopreventspraying
h) Listing agency label, if applicable, plus
in the presence of water/moisture (rain, fog,
certificateofconformance.Thecontractorshall
condensation) as well as when wind velocities are
keep a record of this information throughout
greater than 25km/h. Shielded scaffoldsmaybeused
the guarantee period.
toallowsprayinginhigh windvelocities with client's
5.2.3 Containersshallbestoredunder coverandshall approval.
not be opened until ready for immediate use, undue
6.5 The equipment shall be operated with the
agitation of containers shall be avoided.
temperature settings within the range specified bythe
5.2.4 In the case ofbulk shipments, the sprayfoam foam manufacturer.
contractor may transfer each of the urethane
6.6 Compressedairsourcesshallhavemoisturetraps.
components into appropriately sized clean dry
Before spray application begins, all hoses and guns
containersorcontainersthathavepreviouslycontained
shall be solvent-flushed and inspected to ensurethat
the same material. Care shall be taken to exclude
no moisture ispresent.
moisture pick-up during transfer operations. An
openedcontainershallbeblanketedwithaninert, dry 6.7 Allflames, sparks, welding andsmoking shall be
atmosphere, if needed. prohibitedin the applicationarea.
6 APPLICATION OF SPRAY FOAM 6.8 Allaffecteditems, inthe surrounding area, shall
beprotectedfromoverspray.Spraygunsmustbeheld
6.1 Manufacturer's application instructions should
near perpendiculartothesurfacebeing insulated and
be followed at all times. Only qualified applicators
pressures adjusted sothat overspray is minimized.
with prior experience ofspraying the specifiedfoam
system should be deployed. Prior to application of 6.9 The applicator shall keep with him on the
the spray foam, the contractor shall applya test area scaffolding or on the roof, or in both locations,
on the surface to be insulated. This areashall be sufficientbuckets, plastic film, etc, to enable him to
checked for: discharge any test foam without causing unwanted
deposition on the application area.
a) Local surfaceroughness;
6.10 Careisrequired when spraying onroofsurfaces
b) General foamsurface appearance;
through which chimneys/ducts/pipespenetrate when
c) Specifiedfoam thickness; their temperature exceeds the maximum service
temperature limit of foam. An appropriate hot face
d) Foamquality,suchasstriations,voids,uniform
insulatingmaterial25to50mminthickness shall be
cells; and
installed prior to foam application in the area
e) Foam adhesion. .approximately 600 mm x 600 mm on the surface
6.2 The panel with theaccepted/approvedfoamshall surrounding allsuchhotchimneyinlet oroutletlines,
or anyarea where hot spotsare likely.
be treated as the standard for the subsequent
implementation ofthe foaming work. 6.11 General - Ovcrdeck Insulation
6.3 The foam shall be applied to roofsubstrate at a 6.11.1 Inall caseswhere there isaparapetwall or an
surfacetemperatures in the range of l5°C·to 50°Cin upstand around the roof, effectiveness ofjunction
12mm thick (minimum) passes to reach the desired between roof and vertical portion would be ensured
over all thickness with -3 to+10nun tolerance. The bycontinuing the treatmenttoavertical extensionof
substrate temperatures stated above may vary 0.5m(Alin)aroundtheroofperimeter.Suchextraarea
depending upon the foam system selected. In areas areto bemeasured and paid for.
whereobstaclesdonotpermitnormalspraytechniques
6.11.2Fortreatmentsonverticalareas,amultiplication
andtheapplicationtolerancesspecifiedabovecannot
factor of 1.2 shall be applied to the actual area to
be met, the contractor may apply the specified
account forrebound losses/overthickness.
minimum thickness of foam required by a suita ble
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IS 12432 (Part3) : 2002
6.12 General- Underdcck Insulation e) History of similar applications or laboratory
data relating tothe applicationin question;
6.12.1 Toaccount for excessrebound lossesinunder
deckPURIPIRsprayin-situ application,measuredarea 1) Combustibility characteristics;
shallbe subjecttoa multiplicationfactor of 1.4.
g) Watervapourpermeance (where relevant),
6.12.2 Spray treatment is applied as a continuous
h) Application conditions (temperature relative
treatment and hence no deductions shall be made in
humidity,etc); and
measurementsfor cutoutshaving areaof1nr' orless.
j) Requirements for conformance to building
7 COATINGS
codes,ifany.
7.1 General
7.3 Application
Whenfoamisexposedtotheweather/ultra-violetrays,
7.3.1 The coatingshallbeapplied inaccordancewith
or usedin areas where water willaccumulate, orin a
manufacturer'sinstructionsandshallbeappliedwithin
corrosiveatmosphere,aprotectivecoatingisnecessary.
24 h after the foam insulation is installed (except in
Sincecoatingperformance ishighlydependentonthe
case of unusual circumstances), and with foam
applied film thickness, appropriate minimum film
applicator's approval. In anycase the coatingshould
coatings should be ensured.
not be applied until the foam has reached its full
7.2 Selection rigidity.
7.2.1 Coatings shall be polyurethane based for best 7.3.2 The foamshall be dry,clean, free of dust, and
compatibility with the sprayed foam and shall be
foamoverspraybeforecoating application.
applied within 24 h of completion of spraying
7.3.3 The proper average thickness ofthe approved
application. Brush applied high solidbuild coatings
coating forthe intendedapplication shallbe applied.
of0.5 rum to 1mm, DFT (Typical)preferably single
The coating maybe installed in one or more passes.
componentmoisturecuretypearebestsuitedtoprovide
Ifmorethan onecoatisspecified,contrastingcolours
protectiontothesprayedfoam.Mostofthese coatings
may be used with the final coat being the finished
canbesprayappliedbytheuseofairlessgunsaswell.
colour. It is also good practice to install additional
Two component polyurethane coatings are also
thickness around heavilyworked areas, such asman
available but care is needed at construction sites to
ways,vents, etc.
maintain correct ratio and to ensure that each mix is
Mechanicalprotectionintheformofawearingcoarse
usedwithinthe pot-life ofthe mix.
isalsorequired iffrequent-foottraffic isexpected.
Other types of coatings which are suitable include
chlorosulphonatedpolyethylenebasedsolventbearing 7.3.4 The first coat shall be stopped approximately
products and high solid acrylic latex coatings. When 150 to 300 mm from the edge of the applied foam.
non-urethane based coatings are used, there may be The final coating can beextended to the edges ofthe
need for a primer. In each case, it must be ensured foamandbeyond,ontothebuilding structures.Around
that: eachprotrusiononthe roofareaandinthe areawhere
the stairs adjoin the insulated wall (size of the area
a) Coating iselastorneric; and
selectedbyclient), the coating shall be reinforced in
b) Dry film thickness ofcoating is not less than oneofthe following manners. Prior toapplication of
0.75 mm. thefinalcoatinupstandandpenetrationareas embed
an open-weave reinforcing fabric extending to
7.2.2 Forselectionofcoatingmaterials, thefollowing
approximately ISOmmfromthecorner, either wayin
parameters should beconsidered:
tothe wetfirstcoat.Cautionshouldbetaken toembed
a) Environmenttowhichthe insulation systemis
thereinforcing fabric totally within the coating.
exposed(hightraffic,hail,rain, chemical,etc);
7.3.5 Apply an extra (0.50 mm) minimum of the
b) Resistance tospilled vesselcontents;
selectedcoating in oneor more passes.
c) Life expectancy;
7.3.6 After the coating application is complete, the
d) Ease ofmaintenance; followingmarking shouldbe prominentlydisplayed:
4
IS 12432 (Part3) : 2002
'FOAM INSULATION. DO NOT WELD, BURN 8.1.1 It is recommended that personnel involved in
ORDAMAGE' the applicationoffoamwear forced air supply masks.
Respiratory protective equipment shall be inspected
8 SAFETY
regularlyand maintainedin good conditions.
8.1 It is important that all persons associated with
Protective clothing and gloves shall be worn. Skin
design, storage, installation, and repair of such
areas notcoveredbyclothingshouldbeprotectedbya
insulated areas understand the fire hazards involved,
suitable cream.
and safety precautions in handling and spraying of
PUR/PIR systems. During application there are 8.1.2 Duringapplicationofthe sprayfoam, smoking,
numerous storage and application safety precautions open flames, high temperatures, welding or electric
thatshouldbeobservedandtheownersandapplicators sparks shall be strictlyprohibited.
are encouraged to familiarize themselves with such
data.

5
IS 12432 (Part3) :2002
ANNEXA
(Foreword)
COMMITTEE COMPOSITION
Thermal Insulation Sectional Committee, CHD 27
Organization Representative(s)
In personal capacity (8-138 Sarita Vihar, New Delhi) PROFB.C. RAYCHAUDHURI(Chairman)
BASF India Limited, Mumbai SHRID. R. THUSE
SHRI S.N. PAL (Alternate)
Bakelite Hylam Limited, Mumbai SHRIP.Roy
SHRIP.P.KAvERIAPPA (Alternate I)
SHRI T.R. GHOSH (Alternate II)
Beardsell Limited, Chennai SHRIC.V.VENKATAKRISHNAN
SHRIK. R. S. NAIR (Alternate)
BHEL, Hyderabad SHRIR. SANKARAN
SHRIRAVINDRA PRAKASH(Alternate I)
SHRI S. S. PHOGAT (Alternate II)
Central Building Research Institute, Roorkee DRV.V.VERMA
SHRI B. M. SUMAN (Alternate)
Department ofCoal (Ministry ofIndustries), New Delhi DIRECTOR
Department ofIndustrial Development, New Delhi SHRIN. C. TIWARI
SHRI S. K. JAIN (Alternate)
Engineers India Limited, New Delhi SHRIB. K.ROUT
SHRI R. NANDA (Alternate)
Hyderabad Industries Limited, Ballabgarh SHRIA. K. GUPTA
SHRIA. KATOCH (Alternate)
Indian Oil Corporation Limited (R&P Division), New Delhi SHRIM. P.CHITRE
SHRI SOVNATH (Alternate)
Lloyd Insulation (India) Limited, New Delhi SHRIN. SRINIVAS
SHRI C. P.KHANNA (Alternate)
Metallurgical and Engineering Consultants (India) Limited, Ranchi SHRIM. K.CHOURASIA
Ministry of Power, New Delhi SHRIJ. P.KARDUM
SHRI D. K. GILHOTRA (Alternate)
Minwool Rock Fibres, Mumbai SHRIR. K.BADRUKA
SHRIANURAG SHARMA (Alternate)
National Physical Laboratory, New Delhi DRR. G.SHARMA
SHRI N. K.KOHLI (Alternate)
National Thermal Power Commission, New Delhi SHRIR.K. SINGHAL
SHRI JADAV DATTA (Alternate)
Newkem Products Corporation, Mumbai SHRI NIMISH V.SURA
SHRI V.A. SURA (Alternate)
Nuclear Power Corporation, Mumbai SHRI S.K.RASTOGI
SHRI S.A. DOBRA(Alternate)
Petroleum Conservation and Research Association, Dchra Dun SHRITAPAN DUTTA
SHRI K. K.BHATNAGAR (Alternate)
PIBCO Limited, Ncw Delhi SHRIT.UDAYAKUMAR
SHRI A. K. SEN (Alternate)
Projects & Development (India) Limited, Sindri SHRI K.KARKUM
DRS. P.S.KHALSA (Alternate)
Punj Sons Pvt Limited, New Delhi SHRIR. P.PUN!
SHRI GAURAV PUN) (Alternate)
Research, Design & Standards Organization, Lucknow SBRID. R. GUPTA
SHRIA.K. CHAUDHURY (Altemate)
6 (Continued onpage7)