Introduction To Phenotherm® : Phenolic Foam...
Transcript of Introduction To Phenotherm® : Phenolic Foam...
Introduction To Phenotherm® :
Phenolic Foam Insulation
Who We Are?
Bakelite Hylam Limited is a company set up in 1947 to manufacture thermosetting
Plastics in India. Since then the product range of Bakelite supported by its strong R & D
grew manifold. Bakelite Hylam now manufactures Decorative and Industrial Laminates,
Resins and Varnishes, Textured wall covering material, paints, and Phenotherm®
Phenolic Foam. The manufacturing facilities are spread over three plants employing at
total of 500 employees Bakelite Hylam believes in delivering value to its customers by
consistent adherence to standards and continuous product development and quality
improvement. In 1982 Bakelite Hylam Limited was the first and the only manufacturer
who introduced Phenolic Foam Insulation – Phenotherm® in India, made on a modern
continuous foaming plant imported from Europe. Under insulation material we also
manufacture rigid Polyisocyanurate Foam (PIR), Polyurethane Foam (PUF) in form of
slabs as well as pipe section for cold as well as hot insulation.
Why Building Insulation?
Insulation of building is necessary for various reasons. Some of the
Important functions of thermal insulation are:
• Energy conservation
• Fire protection against accidents
• Control of temperature and heat transfer
• Resource Sustainability
Thermal insulation is used as a barrier between two bodies to reduce the
heat ingress into cooler body. By reducing the quantum of heat transfer and by
reducing the air volume of enclosure (e.g. false ceiling). In addition to economy, the
insulation system also helps in preventing condensation, a normal phenomenon
associated with surfaces at temperatures lower than the dew point
What is Phenotherm®?
Phenotherm® Phenolic foam is a rigid cellular foam insulation
material with following properties:
• Fire Resistant
• Not easily ignitable
• No smoke in case of Fire
• Extremely Low Thermal Conductivity
• Excellent Self extinguishing properties
• Negligible smoke generation, less than 5% obscuration
• Very Low water absorption, keeping humidity under control
• Corrosion & chemical resistant
• Emits zero toxic gases
• Does not disintegrate while burning keeping low local temp
•Does not nourish mould growth
•Immune to vermin and insect attack
• Prefabricated wall panels
• Underdeck Insulation
• False Ceiling
• Partition Cavity
• Overdeck Insulation
• Cavity Flooring
• Duct Insulation
• Chilled/Hot Water Pipes
• Vessel Insulations
• Hull Insulations in Ships
Various Phenotherm®
Application
•Significant CO2 savings can be achieved compared to other insulation materials
•Phenolic foam is available in both CFC and HCFC free forms
The reasons for this excellent performance are:
• Phenolic foam has a low water vapour permeance and is therefore highly resistant to
the passage of water vapour
• Phenolic foam has low water absorption which takes place predominantly in the
cut/broken surface cells of the foam
•Phenolic foam is non-wicking. This means that if water enters the insulation system
due to the vapour barrier becoming punctured, any moisture ingress is limited and
confined to the punctured area. This ensures moisture
does not build up and compromise the
whole system
ENVIRONMENT
Phenolic foams have an excellent strength/density relationship being lightweight
but strong. Higher density phenolic foams are typically used for:
• Pipe supports
• Duct supports
• Steel faced composite panels
(including walk-on ceilings)
Mechanical Properties of Phenotherm are:
• BS 4370 Part 2 (KN/M2)
• Compressive Strength – 170 to 250
• Shear Strength - 100 to 110
• Tensile Strength – 250 to 280
Phenolic foam has been used successfully in structural applications for over 24
years.
STRUCTURAL STRENGTH
Phenolic foams offer a range of thermal conductivity performance. The closed cell type
offers the lowest thermal conductivity available from any insulation material resulting
from:
• Closed cell structure of greater than 82%
• Extremely small cell diameter
• Low thermal conductivity gas permanently encapsulated in cells
Phenolic foam offers the following benefits:
• λ values from 0.016W/m-K depending on national certification requirements
• Excellent low thermal conductivity allows reduction in long term energy costs
• Phenolic foam can be up 50% more thermally efficient than other common insulation
materials
• Higher thermal efficiency allows reduced insulation thicknesses to be used thereby
saving valuable space
THERMAL PERFORMANCE
Using G.I Powder Coated False
Ceiling Grid
1. Fabricate and fix 6mm MS Rods,
suspended at specified intervals
with necessary ‘J’ bolts and nuts
etc. The suspender shall be
treated with a coat of Red Oxide
2. Fabricate and fix Aluminium
framework in specified (2’x2 or
4’x2’) grid at specified height
from the floor. The Aluminium
framework shall consist of:
• Wall Angles : 25x25x1.5mm
• Main Tees : 35x25x1.5mm
• Cross Tees: 25x25x1.5mm
Tees will be jointed with necessary
cleats, etc.
3. Place Phenotherm® board of
610mm x 610mm or 1220mm x
610mm size within the
Aluminium grid work and put
pressure clips/nails on top of
Phenotherm® boards to keep the
board in position
Recommended Installation Procedure
with Phenotherm® for False Ceiling
PHENOTHERM® DENSITY &
CONDUCTIVITY COMPARISON
PHENOTHERM® In Textile
Industries
1. Hanil Era Textiles – Patalganga
2. Oswal – Baramati
3. Welspun - Vapi, Anjar, Silvassa
4. Alok Industries – Vapi, Silvassa
5. Grable Alok Impex – Mumbai, Silvassa
6. Prakash Industries – Silvassa
7. GHCL – Silvassa
8. Datta Shetkari Sahakari Soot Girani, Kolhapur
9. Ganesh Cooperative Spinning Mills – Kolhapur
10. Amit Spinning Mills – Kolhapur
11. Tessitura Monti – Kolhapur
12. Amit Cotsyn – Kolhapur
13. Shoktas – Kolhapur
14. Oswal – Kolhapur
15. Nagreeka Exports – Kolhapur
16. Marathe Textiles – Miraj
17. Sharda Spinning Mills – Sholapur
18. Sangola Soot Girani – Sholapur
19. Forbes Gokak – Gokak
20. Abhishek Industries – Barnala
21. Trident Group – Barnala, Budhni
22. Nahar Exports Ltd – Patiala
23. Poddar Projects Ltd – Hyderabad
24. Kumar’s Cotex Ltd – Guntur
25. PSM Spinning Ltd – Sadashivpet
26. RSWM – Banswara
27. Sai Lakshmi Industries Ltd – Mysore, Bangalore
28. Birla Ericsson Optical Lim – Rewa
29. New Era Industries – Gurgaon
30. Woolworth (India) Ltd – Butibori
31. Navnitlal Private Ltd – Dhamni
32. Grasim Industries Ltd – Nagda
33. S.Kumar’s Synfabs Ltd – Dewas
34. Asarwa Overseas – Ahmedabad
35. Kamadgiri Synthetic Ltd – Umbergaon
36. Garden Silk Mills Ltd – Jolwa
37. Century Textiles & Industries – Mumbai
38. Indoworth India Ltd – Nagpur
39. Surbhi Textile Mills Pvt Ltd – Surat
40. Oswal F.M Hammerle Textiles Ltd - Kohlapur
PHENOTHERM® VS GLASSWOOL
Parameters
GLASSWOOL - 24KG WITH AL
FOIL
PHENOTHERM® - 30MM KRAFT
PAPER FACING
THICKNESS
50mm - Tends to squeeze/sag over a
period of time 30mm Rigid board no sagging/squeezing
DENSITY 24 Kg/cuMt 35 Kg/cuMt
Moisture/Water
Absoprtion
Absorbs moisture, squeezes, thickness
reduction & disintegrate & loses
insulation property over a period of time
Having 95% closed cells, does not absorb
much water - little water absorbed will be
breathed out - no damage to structure
RIGIDITY Loose fibres Rigid Foam
FIRE
RESISTANCE Burns & emits dense smoke Does not Burn
BS - 476
CONFORMATION Does Not conform to BS 476
Conforms to BS-476 Obtained Class - I,
Class - O & Class - P Ratings
APPLICATION Wire mesh with wire netting
Adhesive plus screw - easy and fast
application
Note: Phenotherm® is superior to Glasswool in terms of Fire & Thermal properties,
life & applications
PHENOTHERM® VS EPS
Parameters EXPANDED POLYSTYRENE (EPS) PHENOTHERM
THERMAL
CONDUCTIVITY
0.030 0.020
DENSITY 20-40 35 - 70
SERVICE
TEMPERATURE -130 TO 80 -196 TO + 130
BS 476 PT.7
SURFACE SPREAD CLASS – IV (LOWEST RATING)
CLASS – I (HIGHEST RATING)
SMOKE
GENERATION (BS
5111) 25% < 5%
COMPATABILITY
WITH SOLVENTS
REACTS WITH ALL SOLVENTS –
LEAKAGE WOULD EAT AWAY THE
MATERIAL
RESISTANT TO MOST OF SOLVENTS,
WEAK ACIDS & ALKALIES
BIOLOGICAL
SUSPECT OF BEING ATTACKED BY
RODENTS, FUNGUS FORMATION IN WET
CONDITIONS
MILDLY ANTISEPTIC, IMMUNE TO
VERMIN, INSECTS, DOES NOT CORRODE
METAL
PHENOTHERM® VS PUF
Parameters PHENOTHERM® POLYURETHANE (PUF)
THERMAL
CONDUCTIVITY
0.020 0.024
TOXICITY NON-TOXIC HIGHLY TOXIC
COMPRESSIVE
STRENGTH 3.0 KG/sqCm 2.8 KG/sqCm
FIRE RESISTANT FIRE RESISTANT
`HIGHLY FLAMMABLE
APPROVED BY
DEFENCE, NAVY, CPWD, RITES, AIRPORT
AUTHORITY AND MANY MORE NOT RECOMMENDED DUE TO TOXICITY
STANDARDS
CONFORMS TO
IS 13204, BS- 476 (PART 5,6, & 7), BS 5111,
BS 3927 DOES NOT CONFORM
PHENOTHERM® APPLICATIONS
TEXTILE INDUSTRY
False Ceiling
Underdeck Insulation
DEFENCE SHELTERS
Floor Application
Side Walls & Roof Tops of
Bunkers & Shelters
PROCESS INDUSTRY
Equipment Insulation
BUILDING SEGMENT
Under-deck/Over-Deck
Insulation
Duct Insulation
Chilled Water Piping
Hot Water Piping
DIFFERENT FORMS OF PHENOTHERM
PHENOTHERM APPLICATION
THANK YOU!