How to handle the Spray Foam Insulation Barrel Sets

Two-component spray foam systems, sprayed on the spot and sprayed onto polyurethane foam insulation mixtures, are typically stored in steel 55-gallon barrels and divided by volume weight in a paired set. A Paired Set is two barrels consisting of one “A” side (Activator/Isocyanate) and one “R” side (Resin/Polyol) ranging in a combined liquid weight from 970 lbs. between 1050 and 970 lbs. It is important to note that often the components are identified as “A” or “B” to 1050 lbs, respectively. In general, the spray foam system is manufactured with a minimum of six months of shelf-life in the barrel, which was unopened at the beginning. They are stored between 60 to 75 degrees F (15 to 24C). Do not require any additional additives. However, B sides might require mixing or continuous stirring.

The color of the barrel varies between blenders. The standard procedure for spray foam rigs to identify the components of each side by color is commonly employed, where red is used to identify”the “A” side, while blue is used to identify the “B” “B” part. Due to the extremely reactive nature of the two components, cross-contamination of barrels has to be prevented.

It is essential to focus on maintaining the two components free of moisture. Adding moisture to resins can alter the chemical reaction and the physical properties that are part of the insulation. However, even tiny amounts of water (even the moisture in the air) can trigger reactions that alter the capacity for spray foam equipment to function efficiently and attain the desired density and physical properties of a high-quality insulation product. Isocyanates are well-known for their capacity to absorb moisture. If subjected to water, they can form tiny solid crystals or a tough layer of skin on top of the liquid (like paint in an open bucket). When these solids have formed the liquid, reversal of their formation is expensive. The liquids will require extensive filtration when the sides are affected by small amounts of water absorption.

After the barrels have been placed and stored in your warehouse, preventing water contamination and other circumstances that make the barrels unusable is the SOLE obligation of the owner. The processing equipment and barrels are usually stored in specially-designed rigs like enclosed trailers, boxes, truck trailers, or even in a factory. Sometimes referred to as the “spray foam rig” and the “foam rig,” the enclosed characteristics give the initial level of protection from the environmental elements. Excess material storage at construction sites is typically done using storage containers. Still, it can also be as simple as an outdoor staging space in which the elements open.

Particulates and moisture contamination are reduced or prevented by the following methods:

Don’t permit the storage of open barrels when they are in contact with water or in conditions that could lead to contamination getting into the barrel. Use barrel covers and tarps designed as barrel covers to protect these materials from the elements.

Don’t leave barrel lids and caps unlocked for an extended time without using dry-nitrogen shields or single-way air dryers.

Learn methods of handling remaining materials for reuse and manage inventory flow effectively.

Another important aspect that affects storage in barrels is the temperature. In addition, the “A,” as well as the “B” components on the sides are becoming increasingly dense (i.e., their thickness, (or resistance to flow increases) as temperatures drop. This means that when the temperature in the barrel is not properly controlled, the liquids inside get too thick for them to flow smoothly enough to transfer into the primary spray foam machine (also referred to as a proportioner), even if positive pressure is attained. Lack of flow to the proportioner pump could result in an off-ratio mix.

Two main factors come into the equation when cold liquids are at the proportioner. The first is the highest centipoise (a measurement that determines the viscosity of water, which is the equivalent of 1 centipoise) the machine can handle, and then what is the delta t (max capacity to heat) for the system that is heating. You can request the material temperature curve for mixtures of each component with the material supplier. Also, you should be aware of the maximum amount of centipoise that the spray foam equipment will process, which can be determined from the foam manufacturing process. These details will enable you to manipulate spray foam insulations to achieve their highest efficiency and yield.

But it doesn’t stop there, even with cold temperatures. Most liquids will freeze at around 32 F. However, some isocyanate blends will melt once the temperature falls below the threshold of 40F (4C). Isocyanate that has been frozen looks similar to water contamination and creates tiny crystals. To find out whether you are frozen on the “A” side, rub the crystals with your fingers. If the crystals disintegrate, the product is frozen. Reversing the crystals that have formed because of the freezing temperature back to their original liquid state requires heating materials to temperatures of 90 degrees. Talk to your material compounder to determine the best methods.

Closed-cell resin blends containing highly reactive blowing agents will expand when temperatures are higher than the boiling point (as low as 90 degrees). The loss of blowing agents causes an increase in insulation density but also poor yields. Open resin barrels in high temperatures are the primary source of reduction in blowing capacity.

The following methods can achieve protection against extreme temperatures in the environment:

Mechanical measures to control the air temperatures during storage and use.

Barrel heaters have been proven to be the best and most efficient method to control the temperature of barrels.

Keep drums away from direct sunlight when it is too hot.

If you are dedicated, you can create methods for handling and control to be implemented so that exposure or contamination doesn’t result in a less than satisfactory product or make the equipment ineffective from functioning properly. The prevention is accomplished by shielding the liquids contained in the barrels from extreme conditions of the environment that encourage the contamination of the great product.

Spray Foam Reactor Troubleshooting Tips

A Quick List of Spray Foam Reactor Troubleshooting Tips

Are you often fighting with the rigors of your spray foam device? One of the most frequent culprits in troublesome machines is the spray foam reaction. Spray foam reactors and proportioners are vital elements of the spray foam line-up. What should you do when the equipment struggles against you, flashing an error after error? Find some simple tips for solving the problems with spray foam reactors and mistakes you might encounter.

Reactor Error Codes

Spray foam reactor error codes signal the contractor of the existence of a particular issue with the device. Reactors may encounter various issues working and can be affected by high fluid temperatures to the failure of communication between components within the machine. Since all reactors differ and have different requirements, the best method to fix these error codes is to consult your particular instructions manual for your machine and refer to the error code. Continue reading to discover some of the most frequent errors that can be encountered.

Issues with Temperature

An error code common to several proportioners and reactors can be found in the temperature code. If the temp of the spray foam mixture is higher than the specified range, your reactor might show an error message. Temperature error codes may result from damaged thermocouples, poor control board connectivity, loose wires, or failures in heater elements. To fix this issue, check the temperature reading, clean and reconnect the connections, and verify there are no loose wires. If you still have issues, you should schedule an appointment for a professional inspection.

Connector or electrical error

Your spray foam reactor or proportioner may notify you when disconnecting cables, sensors, or other parts. If these issues occur, then the temperatures of the spray foam mixture may become unstable, and you may be at risk of compromising the safety that you get from your spray foam application and other equipment. To address issues like those, your manual for your reactor might suggest unplugging and reconnecting these wires or sensors. If the problem persists, you should consider scheduling an inspection of your unit or replacing the component.

Don’t let a reactor issue or proportioner malfunction cause you to put your spray foam task on hold. Remember these spray foam reactor troubleshooting suggestions and refer to your instruction manual to get your equipment back in operation. If your machine needs replacement parts to restart work having spare parts in stock can be helpful. Get your hands on the Graco spray machine from ArmorThane to be ready for any situation.