April 27, 2011


Foam Insulation Equipment Guide:


With rising energy costs and the growing demand to make new buildings more energy-efficient, many contractors are thinking about adding spray foam insulation to their product offering. This guide provides you with the information you will need to make the right choices for your business.


Why should I add spray foam insulation products to my service offering?


Growing demand

Energy costs aren’t going down any time soon. As heating and cooling costs continue to climb, consumers are realizing that spray foam insulation is a smart way to save money on energy bills.


Continued growth is projected

• The spray polyurethane foam (SPF) market has grown 30 to 40 percent every year since 2002 (according to the Spray Polyurethane Foam Alliance)
• The U.S. Department of Energy’s Builders Challenge calls for the U.S. homebuilding industry to build 220,000 high-performance, energy-effi cient homes by 2012
• An NAHB (National Association of Home Builders) study reports that 51 percent of consumers are willing to pay up to $11,000 more for energy effi ciency if energy costs are reduced by $1,000 annually
• Spray foam insulation will be in 40 percent of new homes by 2010 – this growth will be driven by increased energy costs and a more educated consumer base (University of Ohio study)
• Residential insulation spray foam is expected to grow at a rate of 30 to 40 percent annually as consumers embrace the insulation value and resulting energy savings (Center for the Polyurethanes Industry market survey)


Faster installation and less labor

Whether it’s wall cavities, basement or block walls, or roofing applications, spray foam insulation fits in any contour and adheres to a variety of substrates. With its fast, one-step installation, contractors can speed production and save labor costs as well.


Facts about SPF


What is Spray Polyurethane Foam?

SPF is a spray-applied insulating foam plastic that is formed by spraying two components – isocyanate and a resin – to form a rigid, fully adhered, insulating material. Typical spray foam insulation applications use a ratio of 1:1 – one part isocyanate (ISO) and one part resin (polyol).


What’s the difference between open-cell and closed-cell foams?


Open-Cell Foam: Nominal R Value per Square Inch

• Soft and spongy with a light open texture
• The cells of foam are broken and air fi lls the “open” spaces, making the foam softer than closed-cell foam
• Density is 1/2 to 3/4 of a pound per cubic foot (pcf)
• Excellent sound absorption qualities


Closed-Cell Foam:

• Hard and rigid with a dense texture
• The cells of foam are closed and compact, making the foam harder than open-cell foam
• Density is two to three pounds pcf
• Offers added strength to the structure
• Higher R value
• Moisture-resistant


Spray Polyurethane Foam (SPF) offers the highest R-value per inch*


Equipment You Will Need to Get Started

Here is a list of equipment you will need to start spraying foam – plus some information that will help you select the right equipment for your business


Graco Proportioners

At the heart of your foam insulation business is the proportioner. This Reactor machine heats and pressurizes isocyanate (often called “A” material) and resin (“B”) materials at recommended material manufacturer ratios to create a chemical reaction, creating foam. Proportioners come in a variety of pump styles and outputs depending on volumes required for specific applications.


What’s the difference between air-driven, electric and hydraulic proportioners?


Air-Driven Reactors

• Entry level
• Utilize air-driven pumps to create pressure and fl ow to spray polyurethane materials
• Typically used in in-plant and low-output applications


Electric Reactors

• The most popular proportioning systems for residential and commercial foam insulation
• Utilize electric-driven pumps to create pressure and fl ow to spray polyurethane materials
• High value for great performance
• For mid- to high-output applications


Hydraulic Reactors

• Top of the line system for high-production professionals
• Utilize electric motors to power a hydraulic pump to create pressure and fl ow to spray polyurethane materials
• Highest value for the greatest performance
• Provides superior, uninterrupted performance
• Used by contractors who value industry leading accuracy and control from their spray equipment
• For high-output applications


Applicators/Spray Guns

The applicator (also called a spray gun) is used to apply the foam onto the wall or into the wall cavity. The applicator is important, because this is where the isocyanate and resin materials meet and react. Proper mixing is critical to ensure that the material properties are established and maintained over the life of the building. When choosing an applicator, it is important to choose a spray gun that is easy to maintain, easy to spray and applies material according to manufacturer’s recommendations.


What’s the difference between an Air Purge Gun and a Mechanical Purge Gun?


Fusion Air Purge Guns

• The most commonly used guns in the residential foam market
• Use a blast of compressed air to keep the mixing chamber clean. (The mixing chamber is the area where the ISO and resin materials meet and mix. The mixing chamber needs to stay as clean as possible to maintain good material properties and a consistent spray pattern.)
• Contain fewer parts than mechanical purge guns
• Easier to spray and maintain than mechanical purge guns


Fusion Mechanical Purge Guns

• Use a steel rod to physically push any residual polyurethane material out of the mix chamber to keep it clean
• Contain more parts than air purge guns
• Require more maintenance than air purge guns
• Offers widest range of flow rates


Feed Systems


How do the A and B materials get from the barrels to my equipment?

The incoming feed system supplies the ISO and resin components from bulk containers to your proportioner. Once the materials are heated and pressurized, the outgoing feed system delivers properly proportioned materials to your spray gun applicator through heated hoses.

Incoming feed system

Typical spray foam applications use stick or diaphragm pumps to supply bulk materials to the proportioner. The type and size of supply pump depends on the type of material you are spraying. Material manufacturers will recommend a type of pump needed to supply their material.

Outgoing feed system

Heated hoses are used during the spray foam process to maintain material temperatures between the proportioner and the spray gun applicator. Heated hose lengths can be up to 400 feet (122 meters) long, therefore, it is necessary to keep the material heated as it travels through the hose temperatures out to the spray gun. Maintaining temperatures helps to ensure proper mix and ratios at the point of application.


Power


Power requirements for your equipment

The spray foam equipment needed for your specific application will dictate your power needs. Electrical power is required to run motors that drive pumps and support the auxiliary equipment needed to spray foam insulation. No matter what your power requirements are, it is very important to make sure that consistent power is supplied to your equipment. Power fluctuations or an under supply of electricity increases wear and could damage spray equipment in the long run.

Pole power

Pole power is power that is supplied through existing electrical panels located at the job site. Pole power is an adequate method to supply power to your mobile spray rig, but requires the presence of a professional electrician to make sure wiring is done correctly and safely, and to ensure there is an adequate supply of power to support your equipment.

Generator

Power from generators is a consistent and proven way to provide power to your spray foam equipment. Diesel generators are commonly used to supply the needed electrical power to equipment and are widely used in the industry today. When specifying generator size, it is important to make sure you consider the overall power requirements of your rig.

Power take-off

Power take off (PTO) generators utilize the truck engine to supply power to your spray equipment. When specifying PTO generator size, it is important to consider the overall power requirements of your rig and to make sure the PTO system does not void any engine warranties offered through the vehicle’s manufacturer.


Air Supply

You will also need a supply of air for the following:
• Material pumps may be air-driven
• Material supply pumps use air motors to move materials from bulk containers into proportioners
• Applicators (spray guns) use a blast of air to keep the mixing chamber free of formed material
Supplied breathing air systems are also used to maintain a safe working environment for the contractor


Air Compressors

Several types of air compressors are available: reciprocating air compressors, which produce compressed air utilizing a piston driven cylinder, and screw compressors, which produce compressed air using two intertwined cylinders. Both types of compressors work well within the spray foam industry. When specifying a source of compressed air, you need to consider requirements for air fl ow (CFM) and pressure (PSI). It is important to choose a compressor that will provide sufficient airflow at the required pressure for your mobile spray rig.


Mobile Spray Rigs


In order to successfully install foam insulation, you need to control the ambient air temperature surrounding the ISO and resin materials. A spray rig is essentially a mobile plant that helps control temperatures surrounding the A and B materials. So in cold weather, it’s easier to get materials up to spray temperatures. In warm weather, air conditioning helps prevent material overheating and expanding drums, and keeps humidity at acceptable levels. In short, by storing materials at temperatures closer to material manufacturers’ recommendations, you have better control of the reaction between A and B materials, which leads to better material yields. The two most common mobile spray rig configurations are trailers and box trucks.


Trailers

Trailers are usually chosen by contractors who have an existing truck capable of towing a trailer or by contractors who have the flexibility to leave their trailer at job sites. Trailers are used by contractors who operate in remote locations or in residential / commercial locations that are more wide open.


Box Trucks

Contractors who operate in urban areas and tend to return to a fixed shop location usually choose box trucks because they are more compact and do not require a separate vehicle to tow spray foam equipment to the job site. Common sizes are 20- and 24-foot box trucks. Both of these sizes are capable of supporting all types of spray foam equipment and the equipment needed to run them.