A 1 inch or greater thickness of DuPont™ Thermax™ Light Duty Foam Insulation, DuPont™ Thermax™ Heavy Duty Foam Insulation or DuPont™ Thermax™ Metal Building Board Insulation will span 5 feet and take additional weight as listed below in the supporting tables. Other products may differ.
Additional fasteners/support may be required to prevent the boards from sagging.
Thermax™ White Finish |
Span Distance in Feet |
|||||
Board Thickness | 4' | 5' | 8' | 10' | 12' | allowable additional weight in lbs/sq ft |
1" | 3.5 | 2.1 | 0.2 | NA | NA | |
1.5" | 5.1 | 3.3 | 0.6 | 0.1 | 0 | |
2" | 6.5 | 4.5 | 1.1 | 0.3 | 0.1 | |
2.5" | 7.8 | 5.8 | 1.9 | 0.8 | 0.3 | |
3" | 9 | 6.9 | 2.9 | 1.5 | 0.7 |
Thermax™ Light Duty or Metal Building Board |
Span Distance in Feet |
|||||
Board Thickness | 4' | 5' | 8' | 10' | 12' | allowable additional weight in lbs/sq ft |
1" | 1.5 | 1 | 0.3 | 0.1 | NA | |
1.5" | 4.9 | 3.4 | 0.8 | 0.2 | 0 | |
2" | 7.6 | 5.1 | 1.3 | 0.4 | 0.1 | |
2.5" | 9.5 | 6.6 | 2 | 0.7 | 0.3 | |
3" | 10.8 | 7.9 | 2.8 | 1.3 | 0.6 |
Thermax™ Light Duty or Metal Building Board |
Span Distance in Feet |
|||||
Board Thickness | 4' | 5' | 8' | 10' | 12' | allowable additional weight in lbs/sq ft |
1" | 4.8 | 3 | 0.6 | 0.2 | 0.2 | |
1.5" | 6.5 | 4.4 | 1.2 | 0.5 | 0.4 | |
2" | 8.2 | 5.8 | 1.8 | 0.9 | 0.7 | |
2.5" | 10 | 7.4 | 2.5 | 1.4 | 1 | |
3" | 11.7 | 8.7 | 3.3 | 1.9 | 1.5 |
Paints for use with Thermax™ Brand Insulation products from DuPont.
Painting Thermax™ Facers:
FOIL |
1. Treat surface and prime (optional but recommended). |
2. Clean off rolling oils and dirt/dust by using a mild detergent solution. |
3. Rinse well. |
4. Consult local paint distributor to determine the appropriate industrial-type paint and primer for aluminum metal surface. Use Glidden, Sherwin-Williams or equivalent. |
WHITE FACER |
Use good-quality latex acrylic or latex enamel; NO OIL BASED PAINTS |
Below is a color formula for Sherwin-Williams paint to match Thermax™ white acrylic-embossed insulation boards.
Paint color match can be made at any Sherwin-Williams paint store nationwide. No primer is required, and usually one coat will be sufficient; however, two coats also appear satisfactory. Apply the paint with brush, roller or spray.
Ask for:
DTM Acrylic Coating
B66-W201 Semi-Gloss
1 gallon Color Formula:
B1 - 8+1
P1 - 8_01
L1 - +1
Thermax™ Brand Insulation products can be painted with epoxy-based paints but must first be primed. Discuss industrial-type paint, Glidden, Sherwin-Williams or equivalent for 'pre-paint prep' to coated acrylic metal with a paint representative.
Can any Great Stuff Pro™ Polyurethane Foam Sealant product be used as a fireblock for penetrations?
Great Stuff Pro™ Gaps & Cracks Polyurethane Foam Sealant is a minimal-expanding, single-component polyurethane foam sealant for general purpose building envelope air sealing and retrofit applications. It has been tested and approved as an alternative fireblock material.
Fireblocking is defined by the International Building Code as the use of approved building materials installed in concealed spaces to resist the migration of fire and hot gases.
Visit Great Stuff™ for a list of Great Stuff™ and Great Stuff Pro™ products.
A variety of warranties are available for DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation.
Some products are warranted in certain assemblies or configurations.
The Panel Core products are available in thicknesses up to 4'.
Panel widths available 48' and 50' and lengths from 8' to 18'.
Not all thicknesses are available for different Panel Core products.
Please call your local DuPont sales representative for details.
The ballast options for a PMR are stone, concrete pavers, soil (as in a vegetative, green or garden roof) and lightweight interlocking concrete pavers. A vegetative, green or garden roof is one that is partially or completely covered with plants for aesthetics and energy efficiency.
In all lists of questions, a "new" or "updated" icon will appear next to those questions that have been added or updated recently.
Whenever you select a question, a new window will pop up with the following information:
If you review the knowledge base but do not find the specific information you need, you may ask a question by selecting the "Ask an Expert" option (one of the tabs at the top of the answer window). You do not need to create a personal account or login to use/search "Answer Center," however, you must provide an e-mail address, if you are submitting a question, so that we may respond directly to you in a timely manner.
We're excited that this Answer Center allows customers to learn about DuPont products at their own convenience. We continue to add information to the knowledge base and encourage you to check back if you have additional questions.
Yes.
In both new construction cases and in retrofit applications. Most foam insulation products must be covered with 1/2" thick drywall to comply with building code requirements. Thermax™ Brand Insulation may be left exposed in most applications (in Canada, DuPont™ Thermax™ Brand Insulation, like all plastic foam insulations, cannot be left exposed but must be covered with a thermal barrier).
Use the following steps to install the insulation.
For more information: click here.
ASTM E108 is the “Standard Test Methods for Fire Tests of Roof Coverings”. This standard covers the measurement of the relative fire characteristics of roof coverings under a simulated fire originating outside the building. It is applicable to roof coverings installed on either combustible or noncombustible decks in the assembly intended for use. This test determines whether a roof assembly is a Class A, B or C. This test is equivalent to UL 790 titled “Standard Test Methods for Fire Tests of Roof Coverings”.
Some water vapor might actually make it this far, but the amount will be microscopic at best. The spray foam will seal the back joints, making diffusion the only method by which water could make it to the joint treatment. Diffusion is a slow process and the small size of the Thermax™ Insulation seam will make the rate of water vapor movement to this location insignificant.
Apply when temperature is between 32° - 100°F (0° - 38°C).
Optimum product temperature is 60° - 90°F (15°- 32°C) and humidity <60%.
At relative humidity > 70%, Great Stuff Pro™ Gasket beads will dry with some shrinkage. The gasket function is retained with a final bead height of 1/8” or more. Users may increase bead size from ½' to ¾' to compensate for this greater drying shrinkage.
DuPont™ LiquidArmor™ CM and LiquidArmor™ LT Flashing and Sealant can span gaps up to ¼ inch. For gaps exceeding ¼ inch, fill the gap with a backing material, and then apply LiquidArmor™ over the backing material.
The gap size and location will determine what backing material is most suitable. Popular choices that are compatible with LiquidArmor™ CM include: Great Stuff Pro™ Gaps & Cracks, Great Stuff Pro™ Window & Door, acrylic caulk and foam backer rod. Popular choices that are compatible with LiquidArmor™ LT include: Great Stuff Pro™ Gaps & Cracks, Great Stuff Pro™ Window & Door and foam backer rod. If Great Stuff Pro™ Gaps & Cracks or Great Stuff Pro™ Window & Door is used, be sure it is fully cured before applying LiquidArmor™ LT.
LiquidArmor™ Flashing and Sealant products are designed to span non-moving joints (joints that move <15%). If more movement is needed, consider traditional expansion joint treatments or contact your local DuPont representative for suggestions.
The choice of fastener for Styrofoam™ Extruded Polystyrene Foam Insulation is completely dependent on the application. There are many fastener manufacturers located throughout . Consult your local construction supplier for advice on which fasteners should be used for a particular application. A partial list of fastener manufacturers is shown here:
Simplex Nails, Inc.
Ties and Anchors
Hohmann & Barnard, Inc.
Pos-I-Tie brick veneer anchoring system
Heckmann Building Products, Inc.
TAPCON concrete anchors and other fasteners
ITW Buildex
Insulation anchors for concrete or masonry walls
UCAN Fastening Products
Turn the valve to the "OFF" position. Put a clean, tightly fastened sandwich bag over the open end of the plastic dispensing wand and secure with a rubber band. Leave the wand with the open end pointing down so the DuPont™ Insta Stik™ Quik Set Commercial Adhesive runs into the bag and clogs the end. When you are ready to start up, remove the ball of foam from the bottom of the wand and turn the valve to the "OPEN" position. If the product does not dispense, replace the hose and wand assembly.
Visit DuPont Adhesives to learn more and download literature about DuPont™ Insta Stik™ Quik Set Commercial Adhesive.
No.
The PVC joint clip system for Thermax™ Polyisocyanurate Insulation is not designed to support drywall or gypsum board.
Yes, DuPont™ Weathermate™ Construction Tape is manufactured in the USA.
The Green Globes rating system is developed by Green Building Initiative, one of the leading green program providers. The rating system has a total of 1000 points assigned to the following categories:
Depending on the total points a particular building can obtain points out of the potential 1000 total points, the building is certified to the following levels:
See the attached website link for more information about GBI and Green Globes program.
Ballasted roof assemblies are loose-laid systems that rely on the weight of ballast rock or pavers to keep the roof system in place during wind loads. These types of systems cannot be evaluated in the usual static tests used for mechanically attached and adhered assemblies. Instead, their design is based on wind tunnel testing. The wind design for these types of systems should not be referenced as FM 1-60 or 1-90, or UL Class 60 or Class 90, etc. because those designations are specific to systems tested per static wind design test methods.
Yes. Styrofoam™ Brand Residential Sheathing can be used as interior basement wall insulation. In the United States, all Styrofoam™ Brand insulation, including Styrofoam™ Brand Residential Sheathing are code-approved for exposed interior applications, but thermal barrier, such as interior drywall is still recommended. In Canada, foam plastic insulation exposed to the interior must be covered with an approved thermal barrier or other acceptable covering.
For more information, visit our website.
For detailed chemical resistance listings for rigid foam insulation products from DuPont, call 1-833-338-7668.
Chemical Resistance of Styrofoam™ Insulation (1) | |||
Acid, Inorganic, weak | Excellent | Salts | Excellent |
Acid, Inorganic, strong | Excellent | Insecticides | Not Recommended |
Acid, Organic, weak | Excellent | Kerosene | Poor |
Acid, Organic, strong | Good | Mineral Oil USP | Excellent |
Bases | Excellent | Naphtha (VMP) | Not Recommended |
Alcohols, including isopropyl |
Excellent | Turpentine | Not Recommended |
Methyl Ethyl Ketone | Not Recommended | Beer | Good |
Polyglycols, |
Excellent | Gasoline | Not Recommended |
Hydrocarbons | Not Recommended | Fruit Juices | Good |
Explanation of Ratings:
Excellent = The plastic was unaffected for the duration of the test.
Good = A very slight clouding or discoloration of the plastic.
Poor = Considerable change in plastic during exposure, possible etching, discoloration, dimensional or weight changes.
Not Recommended = Severe attack of the plastic. Became soft and unusable after a few hours of exposure.
NOTE: This table should be used only as a guide. The compatibility of any given chemical will depend not just on the chemical, but also its concentration, temperature, and duration of exposure. It would be impractical to develop a complete listing including all of these variables. For design purposes, specific test data on the intended application may be needed.
There are a couple of ways you can find out:
The differences in insulation requirements for roofs are as follows:
Zone 1 | Zone 2 | Zone 3 | Zone 4 except Marine |
Zone 5 and Marine 4 |
Zone 6 | Zone 7 | Zone 8 | |
ASHRAE 90.1 2004 | ||||||||
Insulation above deck | R15ci | R15ci | R15ci | R15ci | R15ci | R15ci | R15ci | R20ci |
Metal buildings | R19 | R19 | R19 | R19 | R19 | R19 | R19 | R13+R19 |
Attic and other | R30 | R30 | R30 | R30 | R30 | R38 | R38 | R38 |
ASHRAE 90.1 2007 | ||||||||
Insulation above deck | R15ci | R20ci | R20ci | R20ci | R20ci | R20ci | R20ci | R20ci |
Metal buildings | R19 | R19 | R19 | R19 | R19 | R19 | R19 | R13+R19 |
Attic and other | R30 | R38 | R38 | R38 | R38 | R38 | R38 | R49 |
Weathermate™ Housewrap:
United States | Rolls/Unit | Weight/Roll, lbs |
---|---|---|
3' x 100' | 40 | 8 |
4'6' x 150' | 39 | 14 |
9' x 100' | 40 | 19 |
9' x 150' | 39 | 28 |
9' x 195' | 39 | 36 |
10' x 150' | N/A | N/A |
Canada | Rolls/Unit | Weight/Roll, lbs |
---|---|---|
3' x 100' | N/A | N/A |
9' x 100' | N/A | N/A |
9' x 150' | N/A | N/A |
9'6' x 100' | 40 | 20 |
9'6' x 150' | 39 | 29 |
9'6' x 195' | 39 | 37 |
Weathermate™ PLUS Housewrap:
United States | Rolls/Unit | Weight/Roll, lbs |
---|---|---|
3' x 100' | 38 | 8 |
9' x 100' | 38 | 24 |
9' x 150' | 33 | 34 |
10' x 100' | 38 | 27 |
10' x 150' | N/A | N/A |
Canada | Rolls/Unit | Weight/Roll, lbs |
---|---|---|
3' x 100' | 38 | 8 |
9' x 100' | 38 | 24 |
9' x 150' | 33 | 34 |
9'6' x 100' | 38 | 25 |
9'6' x 150' | 33 | 35 |
9'6' x 195' | 22 | 45 |
For more information, please visit:
Fire rated roof assemblies in Canada are tested by method CAN/ULC S107 'Standard Methods of Fire Tests of Roof Coverings'.
Class A, B, and C ratings do NOT refer to fire from within the structure or hourly rated systems but are a relative fire resistance measure from fire sources outside the building. The ratings mean:
Class A: will resist flame spread under severe fire exposure and afford a fairly high degree of fire protection to the roof deck.
Class B: will resist flame spread under moderate fire exposure and afford a moderate degree of fire protection to the roof deck.
Class C: will resist flame spread under light fire exposure and afford some degree of fire protection to the roof deck.
How can I find whether a particular roof assembly has a Class A rating applicable to Canada?
There are a couple of ways you can find out:
Yes. LiquidArmor™ CM, QS and LT are part of several approved NFPA 285 wall assemblies that incorporate DuPont™ Thermax™ Sheathing Insulation and DuPont™ Styrofoam™ Brand Insulation. Please contact your local DuPont sales representative for approved wall details.
Prior to April 1, 2011 the energy efficiency of houses is rated on a scale of 1-100 HERS (Home Energy rating System) pointsand 1-5 stars. A rating of 86 points or 5 stars qualifies a house for the ENERGY STAR designation from the U.S. Environmental Protection Agency (EPA) and the U.S. Department of Energy (DOE) for climate zone 1-5. A rating of 80 or lower is required for climate zone 6-8.
Starting from April 1, 2011, EPA released a new version of ENERGY STAR home (Version 3) requirements. In this new version, there is no longer a fixed HERS rating for an ENERGY STAR home. Depending on the size and climate zone for a particular house, HERS rating of an ENERGY STAR home can be different based on ENERGY STAR Reference Design specifications.
Lower HERS ratings for a home indicate greater energy efficiency. An ENERGY STAR home is independently inspected and certified to be an energy efficient home. For more information about the ENERGY STAR program, please visit EPA and DOE at the links below:
Most designers consider the foundation modulus and the modulus of subgrade reaction to be the same thing. A description of foundation modulus and a table of typical values for various grades of DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation can be found below:
Foundation Modulus in pounds per cubic inch (pci)
Product | 1 inch | 1.5 inch | 2 inch | 2.5 inch | 3 inch |
Styrofoam™ Freezermate™ Insulation | - | - | 700 pci | 655 pci | 610 pci |
Styrofoam™ Highload 40 Insulation | 1,275 pci | 1,100 pci | 980 pci | 850 pci | 750 pci |
Styrofoam™ Highload 60 Insulation | 1,600 pci | 1,400 pci | 1,250 pci | 1,100 pci | 1,000 pci |
Styrofoam™ Highload 100 Insulation | 2,300 pci | 2,050 pci | 1,800 pci | 1,600 pci | 1,400 pci |
DuPont™ Tyvek® Fluid Applied products can be installed on damp surfaces providing that no moisture is transferred to the skin when the exterior gypsum, concrete, or CMU wall substrate is touched. This flexibility reduces substrate preparation and protection requirements.
Oriented Strand Board (OSB) and Plywood sheathings must have a moisture content of less than 15% prior to the application of DuPont™ Tyvek® Fluid Applied products.
9
CAN/ULC-S102.2-M is the 'Standard Method of Test for Surface Burning Characteristics of Flooring, Floor Covering, and Miscellaneous Materials and Assemblies'. The output of this test are flame spread rating and smoke developed classification using a tunnel test with material tested from the floor of the tunnel. Foamed plastics, namely thermoplastics such as extruded polystyrene insulation (EXPS or XPS), expanded polystyrene insulation (EPS) and Spray Polyurtethane Foams (SPF) are tested on the floor.
Under sustained load (dead or stationary loads) or constant live load, visco-elastic materials such as extruded polystyrene foam insulation (e.g., DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation) undergo deformations called compressive creep. As safety factors are needed to assure control; the deflection of these materials over the life of the application due to potential damage from creep.
For sustained dead, stationary and any constant live loads a safety factor of 3:1 is recommended to reduce long-term compressive creep deformation.
Repetitive or cyclical loads applied to extruded polystyrene foam insulation (e.g., Styrofoam™ Brand Extruded Polystyrene Foam Insulation) causes fatiguing of the material and may lead to unacceptably high permanent deflection. Depending on the number of expected cyclical loads different safety factors are recommended:
33% of compressive strength for live loads < 1,000 cycles
20% of compressive strength for live loads 1,000 to 10,000 cycles
12% of compressive strength for live loads 10,000 - 1,000,0000 cycles
10% of compressive strength for live loads > 1,000,000 cycles
For additional information contact the DuPont Contact Center (DCC) at 1-833-338-7668 for information on how to use Styrofoam™ Extruded Polystyrene Foam Insulation in load-bearing applications.
The foundation flashing detail for the DuPont™ Thermax™ Wall System (TWS) shows how this is done. A termination bar is used to secure the top of the flashing back to the steel stud and is then in turn counter flashed to seal the fasteners (see figure). Any non self-adhering rigid flashing can be installed in this manner. If the termination bar needs to be fastened more frequently than the stud spacing, a horizontal piece of steel framing can be installed between the studs to provide the fastening base.
The detail below shows the installation of the base/through wall flashing on the surface of the DuPont™ Thermax™ (ci) Exterior Foam Insulation. It could also be installed behind the Thermax? ci insulation.
You can find this detail and others on the Thermax™ Wall System CAD Details webpage.
Great Stuff Pro™ Gasket is a flexible, water-based, one-component foam designed to form an interior gasket between framing lumber and drywall, which improves air sealing performance. Material is applied and allowed to dry to the face of the top plate, bottom plate and around the perimeter of all rough openings before installing drywall. The unique gasket performance allows product use without any changes to construction sequencing.
Please call your local DuPont sales representative or call 1-833-338-7668.
DuPont™ Thermax™ Sheathing Insulation and DuPont™ Thermax™ White Finish (WF) Foam Insulation may be able to be installed in an air plenum application covered with an appropriate thermal barrier.
Air plenums have a strict definition in the International Mechanical Code. For instance, the area above a drop ceiling that is a dead air space, with no intended air flow, would not be considered an air plenum. This would be considered a 'concealed space' and foam would have to meet a flame spread/smoke developed (FS/SD) requirement ≤25/450. There can be air ducts running through this space and it is still not considered an air plenum. Once the space is designed such that air is intended to move through it, it becomes an air plenum. In some cases the HVAC design uses the space above the drop ceiling to move air, frequently in the return mode. This space would then be an air plenum and have to meet all codes for air plenums such as meeting an FS/SD requirement of ≤25/50. Thermax™ Sheathing and white acrylic-coated Thermax™ Insulation/finish boards do not meet this FS/SD requirement.
Use Froth-Pak™ Foam Insulation if the repair or completion area is less than 2 square feet. If the area is more, contact the DuPont Contact Center (DCC) at (866) 583-2583 for advice.
For small penetrations up to 3 inches that occur after spraying, use Great Stuff™ Gaps & Cracks Insulating Foam Sealant or Great Stuff Pro™ Window & Door Polyurethane Foam Sealant to seal the penetration perimeter.
No. For applications requiring a fireblock foam, we recommend Great Stuff™ Gaps & Cracks Insulating Foam Sealant.
Yes, standard details for the Ultra Air Barrier Wall System are available here:
The details attached show the use of DuPont™ LiquidArmor™ Flashing and Sealant in the Ultra Air Barrier System.
The typical foundation waterproofing materials are:
Sheet Membrane
- Consistent thickness, common, easy to repair (rubberized asphalt with polyethylene film)
- Sticky; difficult to reuse once it is applied
Liquid Membrane
- Quick application, low in-place cost
- Inconsistency in coverage and quality
Cementitious
- Readily available; solid and durable looking
- Not elastic; cannot tolerate joint or crack movement
Bentonite
- Clay material that can expand to 15 times its volume to fill cracks and joints after absorbing water
- Not very common; will not expand until backfill is completed (water must be present)
The Superior Walls System is a method for building a residential foundation incorporating DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation. Superior Walls's foundations feature patented precast insulated panels that are formed in a factory-controlled setting and delivered to the new home job site, where the panels are carefully locked together and permanently sealed. The walls are custom-designed and built to virtually any architectural style, complete with window and door openings.
For more information, click here.
Yes. LEED 2009 for New Construction has a section on energy use that can earn points towards LEED Certification for a commercial building. The Energy and Atmosphere (EA) portion of LEED includes Credit 1: Optimize Energy Performance that can be worth up to 19 points. Using the Ultra Air Barrier Wall System with the appropriate thickness of insulation can contribute significantly towards these points.
The following products are recommended for roof application:
Flat Roof
Protected Membrane Roof
For a specific project, please feel free to contact one of DuPont representatives to further discuss your needs.
R-Value refers to a material's thermal resistance, or how well it is able to retard heat flow The higher the R-Value, the better a material performs as an insulator.
R-Value = thickness/K-value
R-Value = 1/C-value
Imperial units for R-value are expressed in Btu/hr•ft2°F. SI units for R-value are expressed in W/m2K.
DuPont does NOT recommend the use of Weathermate™ Housewrap or Weathermate™ Plus Housewrap in this application. They are to be used in residential or commercial wall applications ONLY.
The following categories and certification requirements are covered in the NAHB Green Guidelines:
Bronze (min) | Silver (min) | Gold (min) | |
Lot Design, Preparation, and Development | 8 | 10 | 12 |
Resource Efficiency | 44 | 60 | 77 |
Energy Efficiency | 37 | 62 | 100 |
Water Efficiency | 6 | 13 | 19 |
Indoor Environmental Quality | 32 | 54 | 72 |
Operation, Maintenance and Home Owner Education | 7 | 7 | 9 |
Global Impact | 3 | 5 | 6 |
Additional 100 points from Sections of Your Choice | 100 | 100 | 100 |
Total Points Required | 237 | 311 | 395 |
Styrofoam™ Extruded Polystyrene (XPS) Foam insulation products have no post-consumer recycle content based on LEED definition.
Styrofoam™ Products contain an average of 20% pre-consumer recycled content.
Virtually 100 percent of the scrap extruded polystyrene generated at DuPont plants is recycled into DuPont products. Styrofoam™ Brand XPS Foam Insulation products can also be reused in many applications.
Gun Applicator Tips:
Shake can vigorously for one minute before dispensing and between uses.
Invert can and screw onto adapter of the foam tool.
Adjust flow control screw on back of foam applicator tool to an open position, and then immediately press trigger to fill the foam applicator tool with foam while dispensing into an appropriate waste receptacle.
Keep can upside down during use.
Use flow control screw on foam applicator tool to adjust bead size.
Clean tool periodically (12 - 24 cans). Rub end of tool on soft wood to free it from foam. Do not use a sharp object to remove foam from the end of the tool.
When not in use, always leave a can of foam attached to the applicator tool, being sure that the flow control screw is completely closed.
When changing cans of foam, use gun cleaner to remove any residual foam from the gun basket (attachment area of the gun).
Reduce the amount of foam in the adapter of the gun when changing cans (glues can to gun). Use Great Stuff™ Foam Cleaner with the red spray nozzle attached to clean the gun adapter area.
Never leave a foam applicator tool without a can of foam attached unless it has been thoroughly cleaned with Great Stuff™ Foam Cleaner.
Never store gun attached to a can of Great Stuff™ Foam Cleaner.
Thermax™ Brand Insulation products can be left exposed to the building interior (i.e., without a thermal barrier such as 1/2 inch gypsum wallboard) in specific non-rated ceiling assemblies or non-rated construction in commercial, industrial and agricultural buildings. Thermax™ Brand Insulation products cannot be left exposed to exterior conditions.
The use of Thermax™ Brand Insulation exposed to the building interior is documented with an ICC Code Report (ESR-1659). See section 2.0 'Uses' of this document. To view the report, click on the link below and type 'Thermax' into the product field.
ICC Evaluation Service Search Reports
NOTE: Thermax™ cannot be used as a duct work or plenum insulation- it does not meet the IBC /IMC for flame spread of 25 or less and smoke developed of 50 or less
No. The product chemistry provides only part of the story. The performance of a fluid applied membrane is dependent on the product’s: material chemistry type, material design, and formulation. Although most people may assume wide variations between membranes of different chemistry, many may not consider the performance variance of products within the same chemistry family, which varies due to the molecular composition and product formulations. For additional information please refer to the white paper titled “Not All Fluid Applied WRBs Are Created Equal”, which is available at www.fluidapplied.tyvek.com.
Yes. The 800-mile-long Trans Alaska Pipeline System (TAPS) is one of the largest pipeline systems in the world. It stretches from Prudhoe Bay on Alaska's North Slope, through rugged and beautiful terrain, to Valdez, the northernmost ice-free port in . Since pipeline startup in 1977, Alyeska Pipeline Service Company, the operator of TAPS, has successfully transported over 14 billion barrels of oil. Styrofoam™ Brand Extruded Polystyrene Foam Insulation was used as highway insulation beneath the Alaskan Pipeline Access Road that parallels the Alaskan Pipeline structure.
The recommended product temperature at time of application should be 70°-90°F (21.1°C). The minimum ambient and surface temperatures should be 50°F (10°C) and rising is recommended. All one component foams are moisture cured. Low humidity (under 40% RH) and cooler temperatures (below 50°F) will extend the cure time. However, final adhesion properties are unaffected.
Under recommended conditions as outlined above, allow a minimum of 4 hours cure time before walking on tiles. If applied outside of recommended conditions allow an additional 8 hours cure time before walking on tiles.
Note: Humidity levels affect Tile Bond™ Roof Tile Adhesive reaction time. In higher humidity conditions, Tile Bond™ Roof Tile Adhesive reacts faster than in lower humidity conditions.
Surface Preparation:
All roof surfaces must be free of any debris, dirt, grease, oil, and standing water before Tile Bond™ Roof Tile Adhesive is applied.
Click here for more information about Tile Bond™ Roof Tile Adhesive.
Styrofoam™ Brand Extruded Foam Polystyrene Insulation products are manufactured to conform to ASTM C578 standards, which require specific minimum densities. Some examples include:
Type X with minimum density of 1.30 pcf
DuPont™ Styrofoam™ Brand Cavitymate™ Extruded Polystyrene (XPS) Foam Insulation
Styrofoam™ Residential Sheathing (RS)
Styrofoam™ Z-MATE™ Insulation
Type IV with minimum density of 1.55 pcf
DuPont™ Styrofoam™ Brand Cavitymate™ Plus Extruded Polystyrene (XPS) Foam Insulation
DuPont™ Styrofoam™ Brand Cavitymate™ Ultra Extruded Polystyrene (XPS) Foam Insulation
DuPont™ Styrofoam™ Brand Deckmate™ Plus Extruded Polystyrene (XPS) Foam Insulation
DuPont™ Styrofoam™ Brand Scoreboard Extruded Polystyrene (XPS) Foam Insulation
DuPont™ Styrofoam™ Brand Square Edge Foam Insulation
DuPont™ Styrofoam™ Brand Tongue and Groove Foam Insulation
Type VI with minimum density of 1.80 pcf
DuPont™ Styrofoam™ Brand Highload 40 Extruded Polystyrene (XPS) Foam Insulation
Styrofoam™ Roofmate™ Insulation
Type VII with minimum density of 2.20 pcf
DuPont™ Styrofoam™ Brand Highload 60 Extruded Polystyrene (XPS) Foam Insulation
DuPont™ Styrofoam™ Brand Plazamate™ Extruded Polystyrene (XPS) Foam Insulation
Type V with minimum density of 3.00 pcf
DuPont™ Styrofoam™ Brand Highload 100 Extruded Polystyrene (XPS) Foam Insulation
Density is sometimes used to select a rigid foam insulation material for a particular application. It should be noted that there are other performance properties listed in ASTM C578 that are often more important to consider when choosing the proper product for an intended application.
In Canada, extruded polystyrene insulation products are covered by the standard ULC S701, which does NOT specify a density requirement.
There have been a few Thermax™ Wall System projects that used panelized construction. There is nothing about the Thermax™ Wall System that would make this unusual or unacceptable.
Joints between panels should be treated in the same manner as the joints in other panelized systems.
In US, the test methods included in ASTM C578, the material standard used for polystyrene insulation are:
- ASTM C518: Standard Test Method for Steady State Thermal Transmission (R-Value)
- ASTM D1621: Standard Test Method for Compressive Properties of Rigid Cellular Plastics (compressive strength)
- ASTM D1622: Standard Test Method for Apparent Density of Rigid Cellular Plastics (density)
- ASTM E96: Standard Test Method for Water Vapor Transmission of Materials (perm)
- ASTM C272: Standard Test Method for Water Absorption of Core Materials for Structural Sandwich Construction (Use for XPS: 24 hour water immersion test)
- ASTM D 2126: Standard Test Method for Response of Rigid Cellular Plastics to Thermal and Humid Aging
- ASTM C203: Standard Test Methods for Breaking Load and Flexural Properties of Block Type Insulation
- ASTM D2863: Standard Test Methods for Measuring the Minimum Oxygen Concentration to Support Candle-like Combustion of Plastics
Extruded polystyrene insulation should also be tested according to ASTM E84 titled “Standard Test Method for Surface Burning Characteristics of Building Materials (flammability)” to show fire resistive requirements based on building codes for a particular jurisdiction.
Vacuum bag molding is a process for molding reinforced plastics in which a sheet of flexible transparent material such as nylon or Mylar plastics is placed over the lay-up on the mold and sealed. A vacuum is applied between the sheet and the lay-up. The entrapped air is removed by the vacuum and the part is placed in an oven or autoclave. The addition of pressure further results in higher fiber concentration and provides better adhesion between layers of sandwich construction. Also known as vacuum bagging.
DuPont does not claim reflective R-values for DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation products.
However, for foil-faced polyisocyanurate insulation products, there is no dispute in claiming reflective R-values when the air space is in conformance with ASHRAE requirements, e.g., plane parallel surfaces with no air movement. So, in these applications, DuPont claims the reflective R-Values as allowed in the ASHRAE Fundamentals Handbook. An example of this type of air space would be a basement wall with a foil-faced insulation product and a layer of drywall furred out with wood studs. In this case, the air space between the drywall and the foil-faced insulation would be a reflective air space.
There is, however, a dispute in claiming any R-Value in applications where the air space does not meet ASHRAE requirements. An example of such an air space is the one created in brick veneer applications. In this application, there is a backup wall consisting of either concrete block or steel studs. Insulation is installed over the backup wall, and a brick veneer is installed over the insulation. There is an air space between the brick veneer and the insulation. This type of air space does not meet ASHRAE requirements because the brick veneer surface is very rough (not a plane surface) and the air space is ventilated (i.e., promotes air movement). These conditions do not meet ASHRAE requirements. In scenarios such as this, DuPont does not support claiming any reflective R-Values.
It is important to pay strict attention to the recommended application temperatures when installing flashing and sealants with potential below freezing conditions, and cold substrates.
DuPont™ LiquidArmor™ LT Flashing and Sealant is the only approved DuPont™ Thermax™ Wall System (TWS) joint treatment for below freezing conditions.
A summary of the flashing options and recommended low temperature application limit is below:
DuPont Wall System Approved Flashing and Sealant |
Low Temperature Application Limit (⁰F) |
LiquidArmor™ CM Flashing and Sealant (sprayable) |
35 |
LiquidArmor™ LT Flashing and Sealant (trowelable) |
-20 |
In a study conducted by McKinsey & Company, and Vattenfall, the value of various Greenhouse Gas (GHG) abatement options were compared. McKinsey & Company studied the costs of implementing various GHG abatement options. ?Insulation improvements? is among the more economical measures at the left of the arrows that provide the fastest payback and should be implemented before doing any of the other measures. And as the graph shows, ?insulation improvements? is by far the best measure in terms of a negative marginal cost. This graph represents only a few of the abatement options researched.
For the graph in its entirety, visit their website.
The Ultra Air Barrier Wall System is a method to install 15 ¾ inches wide DuPont™ Styrofoam™ Brand Cavitymate™ Ultra Extruded Polystyrene (XPS) Foam Insulation boards or 48 inch wide DuPont™ Styrofoam™ Brand Ultra SL Extruded Polystyrene (XPS) Foam Insulation boards in a manner that achieves both water and air barrier properties in addition to thermal insulation. These barrier properties are achieved by sealing the insulation board joints with either Great Stuff Pro™ single component insulating foam sealant or DuPont™ LiquidArmor™ Flashing and Sealant. The result is an inexpensive yet effective system that provides air, thermal, and water barrier properties to rain screen cavity wall systems.
There are two versions of the Ultra Air Barrier Wall System:
1) The standard Ultra Air Barrier Wall System using 15 ¾" DuPont™ Styrofoam™ Brand Cavitymate™ Ultra Extruded Polystyrene (XPS) Foam Insulation with joints sealed with Great Stuff Pro™ single component insulating foam sealant.
2) The 4'x8' DuPont™ Styrofoam™ Brand Ultra SL Extruded Polystyrene (XPS) Foam Insulation solution with joints sealed with DuPont™ LiquidArmor™ Flashing and Sealant.
Click for: Ultra Air Barrier Wall System
Both Thermax™ (ci) Exterior Insulation and DuPont™ Styrofoam™ Brand insulation can be used in some of the same “continuous insulation over steel stud” configurations. Both can satisfy all the code requirements when used behind a brick veneer. However, the rugged facers of Thermax™ (ci) Exterior Insulation makes it far more durable on the job site, allowing it to perform better as an exterior surface prior to the installation of the finish.
In addition, DuPont™ Styrofoam™ Brand insulation has not been tested with other veneer types in the NFPA 285 test and thus is not fully code approved when used with them. Thermax™ (ci) Exterior Insulation has been tested in the NFPA 285 fire test in such a way as to be approved with stucco, metal composite panels, terracotta, metal panels and cement board sidings.
There is no solvent that will remove cured polyurethane foam. If the foam has not cured yet, use Great Stuff Pro™ Gun Cleaner or fingernail polish remover (with acetone) to quickly remove the uncured foam. Test a small area of the substrate first as the chemicals in the nail polish remover and gun cleaner may not be compatible with the substrate being cleaned. For cured foam, remove as much as possible with a dull scraper or a hacksaw blade and then try scrubbing the remaining film with a non-abrasive cleaner. If that does not work, gradually move up to more aggressive means including sanding, sandblasting and repainting.
Visit Great Stuff™ for more information on products for the DIY.
The 'NEC' does not prohibit installing type NM-B cable in SPF. It does however contain requirements for de-rating the conductors when bundled together. These and all other code requirements must be followed.
-297°F is the boiling point of oxygen. DuPont does not recommend using Styrofoam™ Brand Extruded Polystyrene Foam Insulation products in applications below -297°F, because at lower temperatures liquid oxygen could collect in the cells of the foam and present a serious combustibility potential if a spark is present at that time. If you do have an application at this low temperature, please consult a certified engineer who is familiar with this type of application to design your system.
There are three key differences between latex foam and Enerfoam™ polyurethane foam:
ASTM Type | Minimum Density (pcf) | Weight/Board Foot (lbs) |
X | 1.3 | 0.1083 |
IV | 1.45 | 0.120 |
VI | 1.8 | 0.150 |
VII | 2.2 | 0.183 |
V | 3.0 | 0.25 |
Canadian Products:
Estimating weight/ft² for XPS insulation manufactured in Canada is not appropriate since the Canadian product standard for these insulations does not require density requirements.
Canadian XPS foam insulation products must conform to Canadian Standard CAN/ULC S701-01 Standard for Thermal Insulation, Polystyrene, Boards and Pipe Covering.
This standard supersedes the previous standard CAN/CGSB 51.20-M87. Latter CAN/CGSB supersedes the previous standard CGSB 71-GP-14a. All these standards address product types as types 1, 2, 3 or 4. There is no density (min or max) requirement in Canadian standard for polystyrene insulation. Product types are differentiated by compressive, flexural and tensile strengths, water absorption, dimensional stability, water vapour permeability, and thermal resistance. Generally, the higher the type designation of a product, the higher the strength and thermal resistance requirements. Water absorption and water vapour permeance requirements are lower as the type designation number increases.
Yes.
Great Stuff™ products can be used outdoors. However, cured foam will discolor if exposed to ultraviolet (UV) light. If left exposed, the foam will eventually crumble. Paint or coat foam for best results in outdoor applications.
Visit Great Stuff™ for more information on Great Stuff™ products for the DIY.
DuPont™ Styrofoam™ Brand products can typically be produced as 24”x 8’(610mmX2440mm) or 48”x8’(1220mmX2440mm), 48”x48” (1220mmX1220mm) boards at thickness ranging from ½”(12.5mm) to 4”(100mm). Custom dimensions especially length are also available per customer’s request and potential volume. Please call the DuPont office or sales representatives to discuss your needs.
DuPont’s commitment to quality systems and producing high-performance products has always been high. Our commitment to health and environmental safety, as evidenced in our many global programs, is just as important.
We have not formally applied for ISO 9000 or QS 9000 certification for our plant facilities in North America. However, we are able to respond positively to customer requests regarding product quality control and processes relating to these standards.
No. Many contractors have told us that the vertical application method of the 48 inch wide Styrofoam™ Brand Ultra SL Insulation over a block wall is the most efficient for them. But there are some exceptions to this. Either way is acceptable, but we show the most common method used here.
For more information on the Ultra Air Barrier Wall System see:
To create an airtight and moisture-resistant seal we recommend using Great Stuff™ Gaps & Cracks Insulating Foam Sealant (one component product) or for more or larger areas to cover recommend using two component product like Froth-Pak™ Foam Sealant from DuPont, that quickly bond to common building substrates for a flexible, long-lasting seal.
For more information, visit our air sealing website.
The following manufacturers may also recommend an appropriate caulk or sealant for your application. In all cases, check the product container or with the manufacturer to determine if a particular caulk or sealant is compatible with polystyrene-based insulations. This list is not intended to be exhaustive.
DAP 230 Sealant DAP, Inc. |
Dow-Corning 790 or 791 or 795 Dow-Corning Inc. |
Sonolastic NP-1 or NP-2 ChemRex, Inc. |
Yes. DuPont™ Weathermate™ Plus Housewrap has an International Code Council (ICC) National Evaluation Services (NES) report: ICC-ES ESR-3401. An electronic copy of this report can be viewed or downloaded here.
Most state and local building codes comply with the International Residential Code (IRC) or the International Building Code (IBC). Most states still exempt farm buildings from the codes with exception to structural requirements in some states, especially if using metal trusses or metal studs. The best option is to check with your local code agency for specific requirements.
DuPont™ Thermax™ White Finish (WF) Foam Insulation does have an ICC (International Code Council) ESR-1659 building code report. A copy of the report can also be obtained by calling 1-866-583-BLUE (2583).
In addition, Thermax™ meets ASAE Standard 'Guidelines for Use of Thermal Insulation in Agricultural Buildings' compliance with ASAE S-401.2 (American Society of Agricultural Engineers.)
The Volatile Organic Compound (VOC) content and regulatory status of the following Insta Stik™ Quik Set and Tile Bond™ products (size: >16 oz) were determined according to the California Air Resource Board and the South Coast and Ventura Air Quality Management Districts Rule 1168 Adhesives & Sealant (amended Jan 7, 2005) and the Ozone Transport Commission Model Rule for Adhesives and Sealants (effective Jan. 1, 2009).
Insta Stik™ Quik Set Adhesive - 0 wt % (0 g/L) VOC compliant
Tile Bond™ Roof Tile Adhesive (tank or aerosol) - 1.0 wt % (11.7 g/L) VOC compliant
All the above values are calculated values.
Great Stuff™ and Great Stuff Pro™ sealants have no known compatibility issues with PEX (cross linked polyethylene) piping. Stability of the PEX pipe should not be jeopardized providing the Great Stuff™ and Great Stuff Pro™ sealants are applied as per manufacturer's instructions around the pipe.
Adhesion, however, is questionable between any polyurethane spray foam and PEX surfaces. Adhesion can be improved by making sure that the PEX surface is clean and dry by applying a quality bonding primer paint to the PEX pipe.
'Grade II' is the middle level of insulation installation and that the other grades are I and III. 'Grade II' shall be used to describe an installation with moderate to frequent installation defects: gaps around wiring, electrical outlets, plumbing and other intrusions; rounded edges or 'shoulders'; or incomplete fill amounting to 10% or more of the area with less than 70% of the intended thickness (i.e., 30% compressed); or gaps and spaces running clear through the insulation amounting to no more than 2% of the total surface area covered by the insulation. To attain a rating of 'Grade II', wall insulation shall be enclosed on all six sides, and shall be in substantial contact with the sheathing material on at least one side (interior or exterior) of the cavity.
The following illustration represents the boundary conditions between the three RESNET insulation installation grades:
DuPont™ had a historical MEA numbers (152-92 M) for DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation for use in roofing applications, MEA number (124-71) for DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation in built-up roof (BUR) assemblies. DuPont™ Styrofoam™ Brand Square Edge Foam Insulation and DuPont™ Styrofoam™ Brand Cavitymate™ Extruded Polystyrene (XPS) Foam Insulation products could be used on interior walls of CMU or concrete construction via Board of Standards and Appeals (BS&A) 912-52-SM. BS&A was the precursor for MEA.
New York City no longer requires MEA numbers for acceptance of DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation. The current NES Code Report is sufficient documentation for acceptance by New York City.
Call 1-833-338-7668 for more information
Factory Mutual Global (FM) publishes an Approval Guide, which lists approved roofing products and assemblies. In many cases, the listing includes the required fastening pattern to meet 1-60 or 1-90 for that particular assembly.
Factory Mutual Global also publishes Property Loss Prevention Data Sheets, which describe general methods of construction that will reduce the likelihood of damage and property loss for buildings. Chapters 1-28 and 1-29 in Loss Prevention Data for Roofing Contractors outlines a variety of specific fastening patterns to meet the desired wind uplift resistance factors for 1-60, 1-90 and others.
It is important to note that there are no FM roof systems that depend upon the fastening of DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation to achieve a desired wind resistance rating. In all cases, there are other materials or layers in the system that constitute the primary wind resistance layer, which is the basis for the assembly's wind resistance characteristics. So, in this sense, there are no 1-60 or 1-90 fastening patterns for DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation.
Factory Mutual suggests a temporary fastening pattern for placement of insulation prior to the installation of the primary wind resistance layers. This pattern is two fasteners per 2x4 or 4x4 board and four fasteners per 2x8 or 4x8 board. DuPont recommends using five fasteners per 4x8 board to adequately secure the insulation during construction.
Safety Data Sheets (SDS) for all of DuPont's products can be found at the Safety Data Sheets and Product Finder web page on the general DuPont web site.
Select your region and then country from drop down box and then enter the name of the product in the 'Search by Product Name' portion in the next web page. This will bring up a list of products with that name and you can download the desired SDS from the list.
If you can't find the product you are looking for or have problems using the tool, call DuPont to request assistance.
Yes. DuPont offers a variety of American Institute of Architects (AIA) continuing education seminars. To schedule an AIA continuing education seminar, contact your DuPont sales representative or call 1-833-338-7668.
The Dow Chemical Company invented the extruded polystyrene insulation (XPS), also called STYROFOAM™ insulation 60 years ago. Since then, Dow has sold billions of feet of STYROFOAM™ (XPS) insulation into the residential and commercial insulation markets.
BASF invented the expanded polystyrene insulation (EPS) in the 1950s.
Styrofoam™ Brand Extruded Polystyrene Foam Insulation is available with factory applied latex-modified mortar up to 3/8' (9 mm). These coated boards are for use in Protected Membrane Roofing (PMR) applications and exterior foundation insulation applications. Suppliers of these coated products can be reached via the following links:
Click here for more information about Froth-Pak™ sealant products.
Available thicknesses depend on the application. For commercial and residential applications, typical thicknesses include: .5', .75', 1.0', 1.25', 1.5', 1.55', 1.75' and 2.0'.
For agricultural applications, typical thicknesses include: .5', 1.0', 1.55' and 2.0'. Additional sizes may also be available. Contact your DuPont sales representative for details.
For more information, visit our website.
YES.
Froth-Pak™ is commonly used in the entertainment industry to build props. The foam is paintable and can be cut and shaped when hardened. However, the foam is an exothermic reaction so care must be taken to keep the thickness per layer to no more than 2-3 inches. More layers can be added after the foam is cooled and cured (approximately 20 minutes). The bat cave on the set for Batman was constructed using two-component foam.
Click here for more information about Froth-Pak™ sealant products.
Insulation and air sealing products from DuPont can contribute to the following areas in the new ENERGY STAR for Homes V3 program:
For further details about how products from DuPont contribute to ENERGY STAR for Homes Version 3 program, please feel free to call the DuPont Contact Center (DCC) at 1-833-338-7668.
DuPont undertook the independent assessment to allow us to better appreciate where we stand in the overall Cradle-to-Cradle spectrum, where we have made progress and where we need to improve. We also plan to use the results to help us determine our priorities for product improvement and guide our future investments in areas such as ingredient toxicity and material recyclability.
More information about Cradle-to-Cradle certification, visit MBDC website.
LiquidArmor™ CM, QS and LT can be easily painted over with standard latex paint if a different surface color is desired after the product has reached its final cured state. The same latex based paint (with optional primer recommended) can be used on DuPont™ Thermax™ (ci) Exterior Foam Insulation and DuPont™ Styrofoam™ Brand Cavitymate™ Ultra Extruded Polystyrene (XPS) Foam Insulation for rainscreen designs using DuPont™ Thermax™ Wall System (TWS) and DuPont™ Ultra Wall System (UWS).
The drying time for LiquidArmor™ Flashing & Sealant products depends on humidity, temperature, sun exposure and wind direction.
Yes, as long as the brick ties are suitable for use with a foam plastic insulation and a mechanism is included to ensure that the drainage plane surface of the DuPont™ Thermax™ Wall System (TWS) will be maintained after installation. This may include applying DuPont™ LiquidArmor™ Flashing and Sealant to the surface of the DuPont™ Thermax™ (ci) Exterior Foam Insulation prior to installing the veneer tie and/or applying Great Stuff Pro™ Gaps & Cracks Polyurethane Foam Sealant to seal the penetration of the tie into the insulation.
Alternate brick veneer ties can be used without affecting the NFPA 285 approval as long as they are designed to accommodate foam plastic sheathing as the base material. This is a minor component (and more importantly a non-combustible component) in the overall wall assembly. Of course, it is up to the architect to design the tie for appropriate structural considerations.
Dew point analysis models where the condensation is likely to occur in a wall/roof assembly given the components of the wall/roof assembly and the interior and exterior weather conditions. If the temperature of a wall/roof assembly component is colder than the dew point temperature, vapor in this wall component will condense in to liquid water.
The dew point analysis can be done using the Dew Point Analysis modeling program developed by The Dow Chemical Company. The calculations in this modeling program are based on the theory of Water Vapor Migration presented in the ASHRAE 2001 Fundamentals Handbook.
This tool is for evaluation and comparison purposes only. The analysis does not take into account the effects of thermal short/thermal bridging at stud locations. This tool does not predict condensation potential from movement of warm humid air into the wall cavity by infiltration. Actual performance of the wall assembly may be different depending on air infiltration, workmanship and building materials. DuPont assumes no obligation or liability for use of this modeling tool. A qualified architect or design engineer should be consulted to design a particular wall/roof assembly.
If you would like a particular dew point analysis performed, please call 1-833-338-7668.
Great Stuff Pro™ products can be used in a variety of interior and exterior applications, most commonly in air sealing and home retrofit applications.
Visit Great Stuff™ for links to information on Great Stuff™ and Great Stuff Pro™ Insulating Foam Sealant products.
DuPont recommends the following when storing Polyisocyanurate Insulation products:
For more information, visit our website.
The k value, k-factor, or just “k” is a measure of the insulation value of a material, and gives it in terms of how much heat the material will allow to pass through it. The k-value describes how many BTU's will flow in ONE hour through ONE square foot of ONE material ONE inch thick when the temperature difference between the hot side and the cold side is ONE degree F. U.S units expressed in Btu inch/hr.ft2.deg F. SI units (metric) are expressed in W/m.deg C. The smaller the k value, the larger the R-Value per inch of the material. k is the reciprocal of R per inch:
k = 1/R per inch
K is an important measure as it is a standardized method of comparing the insulation value of various products and materials. Since it is always measured at one inch thickness, the comparison of materials is 'apples to apples'.
In all lists of questions, a "new" or "updated" icon will appear next to those questions that have been added or updated recently.
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The through wall flashing detail at the bottom of the wall can be detailed in a variety of ways. Any reasonable flashing detail that provides positive drainage of the drainage plane to the outside can work in the system. DuPont provides a recommendation regarding foundation details. Others are possible as well.
Froth-Pak™ 160 Slow Rise foam can be used inside an open or enclosed mold. However, gel time is fast and product flow is limited. A good general mold release for polyurethane foams is paste wax or Teflon fluoropolymers from DuPont.
Click here for more information about Froth-Pak™ sealant products.
3M_VentureTape (website) produces a foil tape for use with DuPont™ Tuff-R™ (ci) Polyisocyanurate Foam Insulation. This product is typically available through distributors of DuPont™ Tuff-R™ (ci) Polyisocyanurate Foam Insulation or DuPont™ Thermax™ Brand Insulation.
Aluminum Foil Tape 1520 CW NT-
General: Thermax™ Residential Aluminum Tape for use with DuPont™ Thermax™ Sheathing Insulation, DuPont™ Thermax™ Metal Building Board Insulation, DuPont™ Tuff-R™ (ci) Polyisocyanurate Foam Insulation and DuPont™ Tuff-R™ (ci) Polyisocyanurate Foam Insulation products. The Tape has a 1.2 mil (30 micron), aluminum foil coated film with a cold weather (CW) acrylic adhesive system. This pressure-sensitive adhesive combines high quick stick at low, normal and high temperatures with excellent long-term performance at low temperatures and in high humidity environments.
Temperature Range: -40°F to 250°F (-40°C to 121°C)
Minimum Application Temperature: -10°F (-23°C)
Docket 90-A is the “Recommended Fire Safety Practices for Transit Bus and Van Materials Selection” from the Department of Transportation, Federal Transit Administration (FTA). ASTM E-162 (Standard test method for “Surface Flammability of Materials Using a Radiant Heat Energy Source”) and ASTM E-662 (Standard test method for “Specific Optical Density of Smoke Generated by Solid Materials”) are required tests for insulation materials based on Federal Register (Vol. 58, No. 201) to meet the Docket 90 requirements.
Yes, DuPont has various NFPA 285 ratings with DuPont™ Thermax™ (ci) Exterior Foam Insulation. The Thermax™ Wall System (TWS) utilizing Thermax™ continuous insulation and SPF cavity insulation has variety of wall configurations that have been tested and passed NFPA 285 test requirements.
The Class A, B and C rating system is a method to differentiate the flame spread resistance of roof assemblies based on ASTM E108 in the U.S. The method used in Canada is CAN/ULC S 107. In this testing procedure the roof assembly is exposed to a fire source on the exterior side of the assembly. Class A, B, and C do NOT refer to fire from within the structure or hourly rated systems. The ratings mean:
Class A: will resist flame spread under severe fire exposure and afford a fairly high degree of fire protection to the roof deck.
Class B: will resist flame spread under moderate fire exposure and afford a moderate degree of fire protection to the roof deck.
Class C: will resist flame spread under light fire exposure and afford some degree of fire protection to the roof deck.
External Insulation and Finishing system (EIFS) is an important part of energy efficiency method in buildings. For exterior wall, no matter it is external insulation, internal insulation or sandwich insulation, energy consumption can be reduced and indoor climate environment can be improved. However, the external insulation offers some additional advantages for the following reasons:
Being a liquid product, LiquidArmor™ CM, QS and LT conforms very well to complex shapes and contours, sealing these areas by coating all the irregular surfaces and filling small gaps to protect against air and water penetration.
The buoyancy force values of Styrofoam™ Brand Buoyancy Billets vary by size. The values are in the table below. Not all product sizes are available in all regions.
Billet Size, in |
Buoyancy Force, lbs |
7 x 20 x 96 |
425 |
7 x 20 x 108 |
480 |
10 x 20 x 96 |
610 |
10 x 20 x 108 |
690 |
10 x 24 x 96 |
730 |
For more information, visit our website.
There are several distributors across the country that carry Tile Bond™ Roof Tile Adhesive, contact DuPont Contact Center (DCC) at 1-833-338-7668 for more information or to locate a distributor.
The weight listed below is for reference only. There may be variances among boards. All the weights are for boards of 1' thickness (1' x 1' square).
Products | Weight (lb/ft2) |
DuPont™ Thermax™ Light Duty Foam Insulation and DuPont™ Thermax™ (ci) Exterior Foam Insulation | 0.197 |
DuPont™ Thermax™ Heavy Duty Foam Insulation and DuPont™ Thermax™ XARMOR™ (ci) Exterior Foam Insulation | 0.216 |
DuPont™ Thermax™ White Finish (WF) Foam Insulation | 0.187 |
DuPont™ Thermax™ Sheathing Insulation | 0.15 |
DuPont™ Thermax™ Metal Building Board Insulation | 0.195 |
To get weight of 1 inch x 4 feet x 8 feet board multiple the value in table by 32
Example: Thermax™ Light Duty 1 inch x 4ft x 8ft weighs (0.197 x 32) = 6.3 lbs
If electing not to spray apply LiquidArmor™ CM and QS, a paint brush can be used. A 3' Chip Brush has been found to work the best with LiquidArmor™ CM and QS, providing adequate bristle strength to spread the high viscosity material. A typical roller is not recommended for LiquidArmor™ CM and QS Flashing and Sealant because the target 50 wet mil thickness cannot be attained in one pass. The product must become fully cured to apply a second layer for the final target thickness and durable seal.
Yes. Visit our website for simple plans for building a floating dock or swim raft.
DuPont had successfully converted our North American manufacturing facilities that manufacture DuPont™ Styrofoam™ Brand SM Extruded Polystyrene (XPS) Foam Insulation products to its new zero ozone-depleting, no-VOC foaming agent technology. DuPont™ Styrofoam™ Brand SM Extruded Polystyrene (XPS) Foam Insulation is HCFC and CFC free.
The proprietary formulation substitutes the hydrochloro-fluorocarbon (HCFC) 142b, an ozone-depleting compound that U.S. and Canadian regulations under the Montreal Protocol require to be phased out by January 1, 2010 in North America, with a non-ozone depleting compound. It enables DuPont's North American customers to continue receiving Styrofoam™ insulation with the same product performance and cost-leadership position, and reflects DuPont's commitment, as part of its 2015 Sustainability Goals for Addressing Climate Change, to significantly reduce its greenhouse gas emissions.
Yes.
Thermax™ Brand Insulation products can be left exposed in residential basements. A wide variety of fire tests have been performed on Thermax™ Brand Insulation products for several different applications. The results from these tests have been submitted to the major building code organizations. The code reports published by the major building codes indicate that it is acceptable to leave Thermax™ Brand Insulation exposed in residential basements.
The use of Thermax™ Brand Insulation exposed to the building interior is documented with an ICC Code Report (ESR-1659). See section 2.0 'Uses' of this document. To view the report, click on the link below and type 'Thermax' into the product field.
Dow sold the Pipe Insulation product lines to Illinois Tool Works (ITW) several years ago. For Pipe insulation product questions, please visit the ITW website.
Both UL and FM conduct wind uplift tests on adhered roofing systems. In these tests the roof system is subjected to simulated wind loads, in the case of steel roof deck assemblies, or a tensile pull test on other deck types, until failure occurs. The highest force that the roof system was able to withstand before failure is reported as the wind uplift rating for the system. These ratings are reported in lbs/ft2 and are summarized in the respective Guides for FM and UL.
In adhered assemblies there are three methods employed for wind uplift ratings.
Scenario 1: All of the components below the membrane are mechanically attached to the structural roof deck. The roof membrane is then adhered to the top component layer. In this scenario the wind uplift rating is based on the ability of the membrane to remain adhered to the top component layer, and how well the top component layer is attached to the structural deck.
There are no assemblies in which DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation is the top layer in the type of assembly described above. The typical board under the membrane is the cover board, which is either wood fiberboard or Georgia-Pacific DensDeck.
Scenario 2: The first layer of the roof assembly is mechanically attached to the roof deck, and all subsequent layers are then adhered together. An example of this type of assembly would be mechanically attaching a layer of DensDeckto a steel roof deck, and then gluing layers of DuPont™ Styrofoam™ Brand XPS Foam Insulation, cover board and membrane.
There is currently one approved assembly such as this. It applies to a 3-ply organic felt BUR roof membrane and utilizes hot asphalt as the adhesive layer. A layer of 5/8' DensDeck is mechanically attached to a steel roof with fasteners at 1 per 4 ft2. The foam is adhesively attached to the DensDeck with hot roofing asphalt, a cover board is adhesively attached to the top of the foam and the membrane is applied. This system achieves an FM 1-60 rating.
Scenario 3: All layers of the roof assembly are adhered, including adhesion to the structural deck. This is a common procedure used with concrete decks. UL rated system can be achieved by adhering to steel roof decks. FM does not allow adhesion to steel roof decks.
There are currently three approved assemblies such as this.
1) 3-ply organic felt BUR roof membrane and utilizes hot asphalt as the adhesive layer. In this assembly, DuPont™ Styrofoam™ Brand XPS Foam Insulation is adhesively attached to the concrete deck using hot asphalt, a wood fiberboard is attached to the foam and the membrane is applied. This system achieves an FM 1-60 wind uplift rating.
2) DuPont™ Styrofoam™ Brand Deckmate™ Plus FA Extruded Polystyrene (XPS) Foam Insulation is adhesively attached to a concrete deck using either OlyBond 500 from OMG, Inc. installed as 12' OC, 3/4' to 1-1/4' beads or OlyBond Classic full coverage. A DensDeck cover board is adhered to the surface of the DuPont™ Styrofoam™ Brand XPS Foam Insulation using the same adhesive type and coverage as specified above. The membrane is then adhered to the DensDeck. This listing applies to BUR, Mod Bit, and Single-Ply roof membrane systems. The wind uplift rating is limited to the rating of the membrane system.
3) DuPont™ Styrofoam™ Brand Deckmate™ Plus FA Extruded Polystyrene (XPS) Foam Insulation is adhesively attached to a steel roof deck using DuPont™ Insta Stik™ Quik Set Commercial Adhesive installed as 12' OC, 3/4' to 1' beads. A 5/8' DensDeck or gypsum cover board is adhered to the surface of the DuPont™ Styrofoam™ Brand XPS Foa
Styrofoam™ Brand insulation has 2 direct-to-steel deck UL roofing construction listings: UL 440 and UL 260. These are only for DuPont™ Styrofoam™ Brand Deckmate™ Extruded Polystyrene (XPS) Foam Insulation and DuPont™ Styrofoam™ Brand Deckmate™ Plus Extruded Polystyrene (XPS) Foam Insulation. UL 260 construction covers system including either ballasted stone or a fire retardant slip-sheet. UL construction 440 covers systems that contain a cover board, such as Dens-Deck. The table below provides a summary of these constructions:
UL260 |
UL440 |
|
Roof Deck |
Min. 22 gauge unperforated steel (i.e. perforated acoustical decks are not approved) |
Min. 22 gauge unperforated steel (i.e. perforated acoustical decks are not approved) |
Roof Covering |
Single-ply roof covering or metal roof deck |
Single-ply covering or metal roof deck panels |
Overlayment |
Ballast stone, pavers, or slip-sheet, no coverboards |
Dens-Deck, gypsum, wood fiber board or perlite coverboard. |
Maximum foam thickness |
10-inches |
8-inches |
The differences in insulation requirements are as follows: (ci: continuous insulation)
Zone 1 | Zone 2 | Zone 3 | Zone 4 except Marine |
Zone 5 and Marine 4 |
Zone 6 | Zone 7 | Zone 8 | |
ASHRAE 90.1 2004 | ||||||||
Unheated | NR | NR | NR | NR | NR | NR | NR | R10ci |
Heated | R7.5ci | R7.5ci | R7.5ci | R7.5ci | R10ci | R10ci | R10ci | R10ci |
ASHRAE 90.1 2007 | ||||||||
Unheated | NR | NR | NR | NR | NR | R10ci | R15ci | R15ci |
Heated | R7.5ci | R7.5ci | R10ci | R15ci | R15ci | R15ci | R20ci | R20ci |
No. DuPont™ Weathermate™ Plus Housewrap or DuPont™ Weathermate™ Basic Housewrap should not be installed over visibly wet substrates.
Substrates should be visibly dry before installing DuPont™ Weathermate™ Plus Housewrap or DuPont™ Weathermate™ Basic Housewrap. Wood and wood based products within a wall assembly should be dried below 20% moisture content prior to enclosing the assembly on both sides.
The following link helps you identify ENERGY STAR qualified builders and energy efficient mortgages available in your area.
http://www.energystar.gov/index.cfm?fuseaction=new_homes_partners.showHomesSearch
Use the link below to read about the features of ENERGY STAR Qualified New Homes:
http://www.energystar.gov/index.cfm?c=new_homes.nh_features
The "45 degree angle" method is an older method used to determine the pressure on the insulation under a wearing slab of concrete. This level of pressure helped to select the appropriate grade of insulation to use under a concrete wearing slab. This method results in highly conservative designs because it overestimates the pressure on the floor insulation.
In all lists of questions, a "new" or "updated" icon will appear next to those questions that have been added or updated recently.
Whenever you select a question, a new window will pop up with the following information:
If you review the knowledge base but do not find the specific information you need, you may ask a question by selecting the "Ask an Expert" option (one of the tabs at the top of the answer window). You do not need to create a personal account or login to use/search "Answer Center," however, you must provide an e-mail address, if you are submitting a question, so that we may respond directly to you in a timely manner.
We're excited that this Answer Center allows customers to learn about DuPont products at their own convenience. We continue to add information to the knowledge base and encourage you to check back if you have additional questions.
The National Fire Protection Association (NFPA) 285 fire test is a large scale wall assembly test used to determine the potential for flame spread from one story of a building to another through the exterior wall. The NFPA 285 fire test is referenced in the International Building Code (IBC) in section 2603.5.5. As an assembly test, products cannot be accepted as having “passed” the NFPA 285 test by themselves, they can only be considered as having acceptance in an assembly.
Both DuPont™ Styrofoam™ Brand insulation and DuPont™ Thermax™ Brand Insulation have been tested in various assemblies in the NFPA 285 test and engineering reports for each of these product families have been developed which show how they can be used to create acceptable assemblies. Information on these reports can be acquired from your local DuPont Sales Representative or by calling the DuPont Contact Center (DCC) at 1-833-338-7668.
ASTM E84 is the “Standard Test Method for Surface Burning Characteristics of Building Materials”. The purpose of the test is to determine the comparative burning behavior of the material by observing the flame spread along the specimen, smoke density and temperature.
The test is conducted with the specimen in the ceiling position with the surface to be evaluated exposed face down to the ignition source. The material, product, or assembly shall be capable of being mounted in the test position during the test. Thus, the specimen shall either be self-supporting by its own structural quality, held in place by added supports along the test surface, or secured from the back side.
Yes. Customers from anywhere in the United States can obtain the paint color match for Thermax™ white acrylic-embossed insulation boards at any Sherwin-Williams paint store nationwide. No primer is required, and usually one coat will be sufficient; however, two coats also appear satisfactory. Apply the paint with brush, roller or spray.
Ask for:
DTM Acrylic Coating
B66-W201 Semi-Gloss
1 gallon Color Formula:
B1 - 8+1
P1 - 8_01
L1 - +1
FM 4880 - Wall - Ceiling Construction DuPont™ Thermax™ Brand
Metal - Faced - Class 1 Fire Rated to Max
30' Exposure High | 4.25" Thick | 4' Wide |
Thermax™ Board is a rigid board insulation consisting of a glass fiber infused polyisocyanurate foam core laminated between aluminum facers. Panel thicknesses range from 0.5 to 4.25 in (13 to 108 mm). Available board dimensions are 4 x 8 ft and 4 x 12 ft (1219 x 2438 mm and 1219 x 3658 mm). Board joints can be sealed with an optional aluminum tape. Boards are through fastened to supports with 1 fastener with 1 in (25 mm) diameter plate per 1 ft2 (0.09 m2) according to the manufacturer's prescribed placement. Specific trade names are as follows:
Thermax™ (TF610) Insulation Board, Plain Factory Finish (DuPont™ Thermax™ Sheathing Insulation)
Thermax™ (TF600S) Insulation Board, Satin Finish White Finish or Ag-Therm (DuPont™ Thermax™ White Finish (WF) Foam Insulation)
Thermax™ (TF600MB) Metal Building Board (DuPont™ Thermax™ Metal Building Board Insulation)
Thermax™ (TF600) Insulation Board, Embossed Finish or Light Duty (LD) (DuPont™ Thermax™ Light Duty Foam Insulation)
Thermax™ (TF604) Insulation Board, Heavy Duty Embossed Finish or Heavy Duty (HD) (DuPont™ Thermax™ Heavy Duty Foam Insulation)
4 rows of 8 fasteners per row
Penetrate substrate 1 inch longer than Thermax™ insulation board thickness
Insulation products are not given hourly ratings, only wall and roof assemblies. See the UL directory for various hourly ratings for systems using DuPont™ products.
The DuPont™ Thermax™ Wall System (TWS) carries a 1-hour rating. For more information, visit our website.
CAN/ULC S701 is titled “Standard For Thermal Insulation, Polystyrene, Boards and Pipe Covering.” The National Building Code of Canada requires that polystyrene insulation meet or exceed the property requirements of this National Standard of Canada.
The advantages of using DuPont™ Insta Stik™ Quick Set Commercial Adhesive instead of other roofing fastening methods can be:
Visit DuPont™ Insta Stik™ Quik Set Commercial Adhesive to learn more and download literature about DuPont™ Insta Stik™ Quik Set Commercial Adhesive.
If there are holes or cracks in boards of DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation, DuPont recommends they be filled. A continuous layer of insulation is recommended for maximum thermal efficiency. Boards should be butted tightly together. Minimizing gaps helps to avoid thermal shorts and decreases air infiltration. Thermal shorts and air infiltration can compromise the thermal efficiency of a wall assembly.
Depending on the size of the hole or crack, there are several possible materials DuPont recommends for use:
If the DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation is severely damaged, DuPont recommends it be removed and replaced.
Spray foam will add some small amount of racking resistance to a steel stud wall, but this has not been tested by DuPont. Any added resistance should not be considered in design calculations especially since the application of the spray foam takes place at an undetermined time after stud wall construction.
Aluminum foil tapes for DuPont foil-faced insulation products have vapor retarder characteristics and provide improved protection against air infiltration when properly applied. DuPont offers the following aluminum foil tapes:
(Note Thermax™ / Tuff-R™ facer surfaces MUST be clean and free of dirt or dust prior to applying tapes - wipe down with damp cloth and dry, then apply tapes)
IMPORTANT: The physical properties listed above are typical test results obtained from a series of laboratory tests and should not be used for the purpose of writing specifications. Before using this product, user shall determine the suitability of the product for his/her use; user assumes all risks and liability in connection therewith. All test procedures used are in accordance with ASTM and Pressure Sensitive Tape Council (PSTC) methods. DuPont makes no warranties, expressed or implied, as to their characteristics, properties, or performance under any variations from such conditions in actual constructions. DuPont assumes no responsibility for the effects of structural movement.
For additional information, please call 1-833-338-7668.
The International Building Code (IBC) does not specifically address this issue. Small penetrations such as outlets and switches are considered to be too small to affect the overall fire performance of the wall system.
NO.
2-7/8' DuPont™ Weathermate™ Construction Tape is designed and intended for Residential construction, and not part of any of DuPont's commercial building solutions. LiquidArmor™ Flashing and Sealant is the designated flashing component of warranted DuPont commercial wall systems.
The installation temperature of the Ultra Air Barrier Wall System depends on the method used to seal the board joints.
When sealing the board joints with Great Stuff Pro™ Polyurethane Foam Sealant (the 15 ¾ inch version of the Ultra Air Barrier Wall System), the storage and application temperature limitations for Great Stuff Pro™ need to be followed. The internal temperature of cans of Great Stuff Pro™ must be kept at or above 60°F prior to their use. Storing them in a cooler when brought out to the installation location can do this.
The surface temperature of the block and insulation must be above 32°F.
When sealing the DuPont™ Styrofoam™ Brand Ultra SL Insulation (4'x8') joints with DuPont™ LiquidArmor™ Flashing and Sealant (the 48 inch version of the Ultra Air Barrier Wall System), the storage and application temperature limitations for LiquidArmor™ Flashing and Sealant need to be followed. Both the ambient and substrate temperatures must be above 35°F for LiquidArmor™ CM or -20°F for LiquidArmor™ LT.
For more information see Ultra Air Barrier Wall System
For more information see Great Stuff Pro™ Product Information
No.
Polyisocyanurate Foam Insulation (ISO) does not contain any formaldehyde.
Specifically, while we have not analyzed for formaldehyde, it is not an intended raw material, nor is it known to be present in our polyisocyanurate products.
This determination is based on the compositional information provided to DuPont by its suppliers. DuPont relies on its suppliers to provide accurate data.
DuPont does not routinely analyze for additional materials that are not listed in the Safety Data Sheets (SDS) or Sales Specification.
DuPont is not responsible for any misrepresentation resulting from inaccurate information from its suppliers.
Application rates vary depending on tile profile (low/flat, medium, high), roof pitch and uplift resistance required. For complete details, see the attached document Tile Bond™ Roof Tile Adhesive Usage Guide.
Also note the storage parameters:
Store Tile Bond™ adhesive between 40°- 80° F (4.4°- 26.7°C) to ensure adhesive quality, maximum yield and shelf life. Do not exceed 120°F (48.9°C).
Store partially used Tile Bond™ adhesive upright with the hose attached and pressurized. The cylinder valve must be in the off position.
Click here for more information about Tile Bond™ Roof Tile Adhesive.
An approximate yield can be calculated based on the following:
Yield = 825g/can x 1 pad/11g = 75 pads/can
Therefore, at 75 pads/can x 1 tile/2 pads = 37.5 tiles/can
A use of the Canister (23 lb) can
Theoretical yield* the following:
Theoretical Yields*
* Theoretical yields may differ from actual usage, and environmental conditions may vary the actual in-place yields.
For additional information, please contact the DuPont Contact Center (DCC) at 1-833-338-7668.
No. But this depends on the thickness of the Cavitymate™ Ultra Insulation (which is 15 ¾ inches wide). If the insulation is just one inch thick, it would be hard NOT to fill the gap completely with Great Stuff Pro™ Polyurethane Foam Sealant. However, thicker insulation can be well sealed with less than a full width of foam sealant in the insulation board joint gap. You only need enough Great Stuff Pro™ single component foam to bridge the gap.
In this example below, the gap is well sealed, but more foam sealant was used than necessary. Usually filling the gap 50% allows the Great Stuff Pro™ Gaps & Cracks Polyurethane Foam Sealant to expand and fill the rest of the gap without too much flash.
For more information on the Ultra Air Barrier Wall System see:
Yes.
EPD reports are available for DuPont™ Styrofoam™ Brand Insulation, Thermax™ Insulation, and Spray Foam Insulation products that can be used to determine total environmental impacts on all 6 LEED v4 metrics listed in Option 4.
DuPont residential offering has the potential to contribute to the following credits. USGBC or its designated certification agency has the final authority to determine the eligibility of a particular point.
DuPont Products Points Potential |
|
Innovation and Design Process | 4 |
Locations and Linkages | 0 |
Sustainable Sites | 1 |
Water Efficiency | 0 |
Energy and Atmosphere | 10-34 |
Materials and Resources | 10 |
Indoor Environmental Quality | 2 |
Awareness and Education | 0 |
Total Points Potential | 27-51 |
Enerfoam™ sealant does not contain materials that contribute to the depletion of ozone.
Click here for more information about Enerfoam™ Sealant.
In US, climate zone map is used for code compliance such as building code and energy code. You can browse the attached website for a variety of energy code compliance tools and resources. The climate zone map can also be found from this website.
Yes.
In fact, more and more builders/architects are switching from traditional brick veneer with concrete block wall construction to lighter weight, lower cost brick veneer with steel stud backup. In this application, Styrofoam™ Brand Extruded Polystyrene Foam Insulation and Thermax™ Brand Insulation provides a continuous foam sheathing to avoid the thermal shorts in the metal studs and reduce the condensation potential within the wall cavity. In addition, the DuPont™ Thermax™ Wall System (TWS) incorporates continuous insulation, flashing and an air barrier on one system for easy and efficient installation and high performance.
The National Fire Protection Agency (NFPA) 285 test is needed to address Model Building Code concerns for insulation materials in steel stud applications. In the International Building Code (IBC) Section 2603.5: Exterior walls of buildings of Type I, II, III, and IV construction of any height shall comply with Sections 2603.5.1 through 2603.5.7. Section 2603.5.5: requires the wall assembly to be tested in accordance with and comply with the acceptance criteria of NFPA 285 OR UBC Standard 26-4. So passing NFPA 285 is essential for any wall assembly including one incorporating Styrofoam™ Brand XPS Foam Insulation products as part of a brick veneer with steel stud wall assembly.
DuPont has tested and passed NFPA tests for Styrofoam™ Brand XPS Foam Insulation as well as Thermax™ Polyisocyanurate Insulation in steel stud wall constructions. The typical configuration is shown below. From interior to exterior, the wall is constructed as: 5/8'' Type X gypsum board, steel stud, with or without fiberglass batt, optional 5/8' Type X gypsum board or Georgia-Pacific DensGlass, Thermax™ Insulation (2.5' max, 1' min) or Styrofoam™ Brand XPS Foam Insulation (up to 2.5' max), air space and brick veneer. Various tapes, including peel and stick membrane tape can be used outside Thermax™ Insulation or Styrofoam™ Brand XPS Foam Insulation to seal the joints. Peel and stick membrane/tape can also be used outside exterior gypsum board to be sandwiched between exterior gypsum board and foam sheathing to form a more durable design.
One thing to note is that when the Styrofoam™ Brand XPS Foam Insulation assembly is used, 1' mineral wool should be installed along window headers and jambs while the Thermax™ Insulation assembly does not require this detail.
If you have any further questions about NFPA 285 test, Styrofoam™ Brand XPS Foam Insulation or Thermax™ Insulation in steel stud application, please feel free to call DuPont's technical support center at 1-833-338-7668.
Enerfoam™ sealant with the straw applicator can be reused up to a week provided the straw is stored in the folded position immediately after foam application. Bend the straw back onto the plug on top of the trigger assembly. The plug prevents moisture from entering and curing inside the straw or valve. If using Enerfoam™ products with the gun applicator, the valve can be closed allowing you to re-use the can up to 30 days.
Click here for more information about Enerfoam™ Sealant.
CAN/ULC S701 is the applicable Canadian standard for polystyrene insulation. The various types and specified properties are listed in the following table:
Property | Requirements | |||
Type 1 | Type 2 | Type 3 | Type 4 | |
Thermal Resistance, min., (m2 degree C/W) (for 25 mm thickness) |
0.65 | 0.70 | 0.74 | 0.86 |
Water Vapour Permeance, max (ng/Pa.s.m2)* |
300 | 200 | 130 | 90 |
Dimensional Stability, max. (% linear change) |
1.5 | 1.5 | 1.5 | 1.5 |
Flexural, min. (kPa) | 170 | 240 | 300 | 350 |
Water Absorption, max. (% by volume) |
6 | 4 | 2 | 0.7 |
Compressive Strength, min. (kPa) |
70 | 110 | 140 | 210 |
Limiting Oxygen Index, minimum % |
24 | 24 | 24 | 24 |
* Values quoted are maximum values for 25-mm thick-sample with facings intact. Lower values will result for thicker materials.
Since the thickness is variable depending on the size of the freezer, cooler or blast unit; climate conditions, etc., we can express the following general guidelines.
Walls:
Floors:
For Roofs:
For final design, please consult a design specialist who is familiar with this type of design for a particular temperature scenario to verify proper foam insulation thickness requirements.
The vacuum infusion process uses vacuum pressure to drive resin into a laminate. Materials are laid dry into the mold and the vacuum is applied before resin is introduced. Once a complete vacuum is achieved, resin is 'pulled' into the laminate via carefully placed tubing. This results in stronger and lighter reinforced resin parts than those produced by hand layup or vacuum molding.
Styrofoam™ Brand Deckmate™ Plus FA Extruded Polystyrene Foam Insulation is designed for use in fully adhered conventional low-slope roof applications. The board has planed surfaces to provide maximum adhesion. And it features precisely tapered edges for positive slope. It meets ASTM C578 Type IV and CAN/ULC S701 Type 3 with 25psi minimum compressive strength. It also has 15-year thermal warranty (U.S. only).
Styrofoam™ Brand Deckmate™ Plus FA Insulation comes in the following thicknesses (in): 1.5, 2.0, 2.5, 3.0 and 4.0. It is available in 2x8 boards.
Not all these dimensions are available in all the geographies.
For more information about Styrofoam™ Brand Deckmate™ Plus FA, please visit our website.
The following Dow Corning® sealants have been tested and show successful adhesion with DuPont™ LiquidArmor™ LT Flashing and Sealant without primer:
- Dow Corning® 795 Silicone Building Sealant
- Dow Corning® 791 Silicone Weatherseal Sealant
- Dow Corning® 758 Silicone Weather Barrier Sealant
- Dow Corning® 756 SMS Silicone Sealant
This information is based on when the sealant is applied after the DuPont™ LiquidArmor™ LT Flashing and Sealant is allowed to cure for 2 days.
Yes, the exterior skin of the Thermax™ Wall System with the DuPont™ Thermax™ (ci) Exterior Foam Insulation board joints sealed with DuPont™ LiquidArmor™ Flashing and Sealant is a weather resistive barrier as demonstrated by passing the ASTM E331 water penetration test.
The American Society for Testing Materials (ASTM) E331 water penetration test subjects an eight by eight foot wall section containing prescribed penetrations to a two hour exposure of wind driven rain.
A Graco® Silver Plus spray gun or a Heavy Duty texture gun should be used along with Graco® Rac 5 or XHD RAC tips are recommended for spray operations in temperatures above 70°F (21°C).
However, as the temperature drops below 70°F (21°C) and remains above 65°F(18°C), use of the Graco® G-40 air assisted spray gun (with an additional 90 psi at the spray tip) is be recommended, as it aids in more effective atomization of the product.
International Code Compliance – Evaluation Service (ICC-ES) AC12 is the Acceptance Criteria for Foam Plastic Insulation. The purpose of this acceptance criteria is to establish requirements for foam plastic insulation.
ICC-ES AC12
No. This product is water-based and will be degraded permanently by freezing.
Thawing will not restore full performance. Always store above 32°F (0°C).
Only Great Stuff Pro™ Gaps & Cracks Polyurethane Foam Sealant should be used to seal the 15.75" wide DuPont™ Styrofoam™ Brand Cavitymate™ Ultra Extruded Polystyrene (XPS) Foam Insulation board joints in the Ultra Air Barrier Wall system.
Over the years there have been many different sealant materials that have been used to seal insulation board joints. However, only one sealant has been tested with and passed the ASTM E2357 "Standard Test Method for Determining Air Leakage of Air Barrier Assemblies" which measures wall assemblies for their ability to resist air infiltration and is defined in the International Building Code (IBC) as a dependable method of determining the air barrier properties of an assembly.
Great Stuff Pro™ Gaps & Cracks Polyurethane Foam Sealant is a minimal-expanding, single component polyurethane foam sealant for general purpose building envelope air sealing.
For more information on Great Stuff Pro™ Gaps & Cracks Polyurethane Foam Sealant see:
Great Stuff Pro™ Product Information
For more information on the Ultra Air Barrier Wall System see:
Many silicone, polyurethane, and acrylic sealants are also chemically compatible with the DuPont™ Tyvek® Fluid Applied System. For a list of sealants that have been evaluated by DuPont please refer to the bulletin titled, ”Chemical Compatibility of Representative Building Sealants” at www.fluidapplied.tyvek.com. Please contact the sealant manufacturer for additional performance related information for their sealant.
The wind load resistance capabilities of the DuPont™ Thermax™ Wall System (TWS) were investigated using the ASTM E330 Wind Load Test procedure. This testing resulted in the assembly passing wind loading criteria (10-second loading period) of 50 psf when subjected to negative wind loading and 75 psf when subjected to positive wind loading. (Note: 50 psf is approximately 141 mph wind velocity under ideal conditions.)
The recommended DuPont products for standing seam roof applications are:
For detailed information about these products and application, please visit:
https://www.dupont.com/products/styrofoam-brand-deckmate.html
Yes, many! New projects are constantly being completed. Case studies are occasionally listed on the Ultra Air Barrier Wall System web site. Even better, contact your local DuPont representative to get the latest on projects in your area.
On wet surfaces the isocyanate in the reacting foam will react with the water. This will cause improper cross linking, cell collapse and shrink. The result will be 'pull-back' from the substrate and adhesion loss.
In the past the current Dow polyisocyanurate insulation products have been referred to as the following:
THERMAX™ Light Duty = | (TF 600) |
THERMAX™ White Finish = | (TF 600S and THERMAX™ Ag Therm) |
THERMAX™ Heavy Duty = | (TF 604) |
THERMAX™ Heavy Duty Plus HDP = | (TF 665) |
THERMAX™ Sheathing = | (TF 610) |
TUFF-R™ Sheathing = | (TF 420 & 420B) |
Manufactured by Terry Industries, Tru-Dry™ is an elastomeric waterproofing barrier designed to protect residential basements against water leaks. The Tru-Dry™ membrane and DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation are components of the HouseGuard System that waterproofs, insulates, and drains water away from basements. Terry Industries guarantees the HouseGuard System for 20 years.
For more information, visit Terry Industries Inc.
Polyisocyanurate insulation products such as Thermax™ Brand Insulation, Tuff-R™ and Super Tuff-R™ insulation products from DuPont can potentially contribute to the following categories of LEED points based on LEED Green Building Design and Construction Rating System 2009 Edition:
Please feel free to call 1-833-338-7668 when you need additional LEED information for polyisocyanurate Insulation products from DuPont for a particular LEED certified/designed job.
Froth-Pak™ is a two-component polyurethane spray foam that comes in both portable kits and refillable canisters. It is available in multiple densities and is ideal as an insulator or air sealant for either new construction or retrofit applications.
Froth-Pak™ Foam Sealant (12,200,620 kits and refillables) can be used to fill small cavities (max 4" wide x max 2" deep), wall and floor penetrations, cracks and expansion joints, and in cold storage facility and refrigerated trailer applications.
Froth-Pak™ High Density (115 and 400 kits) foam can be used to repair spray-applied polyurethane roofs or damaged insulation boards. It is ideal for filling pitch pockets and low ponding water areas on roof decks, and fabricating on-site cant strips.
Froth-Pak™ Slow Rise (160 kits) foam can be used in various applications that require a slower reaction and gel time such as molds, models, movie sets, art structures, etc.
Froth-Pak™ Class A foam insulation (210,650 kits and refillables) can be used for full coverage insulating of walls, ceilings, rim joists etc. up to maximum of 2 inches thick.
Froth-Pak™ foam bonds to most construction materials including lumber, plywood, particleboard, foam board, masonry, metals, drywall, concrete and foam panels.
Click here for more information about Froth-Pak™ sealant products.
The maximum use temperature for DuPont™ Styrofoam™ Brand products is 74°C (165°F). Applications above the stated maximum temperature are not recommended since deformation, warping and other dimensional change can potentially occur.
A 1" x 3" furring strip fits into the slot between two adjoining DuPont™ Styrofoam™ Brand Wallmate™ Extruded Polystyrene (XPS) Foam Insulation boards.
A 2x3 furring strip can also be used. This will provide ¾” airspace between the foam insulation surface and the drywall interior.
For more information, visit our website.
When you choose Styrofoam™ Brand Extruded Polystyrene Foam Insulation products, you will discover exceptional performance characteristics such as closed-cell structure, ease of installation, specialized facings for durability, excellent R-value, and moisture resistance.
Closed-Cell Foam Structure - Styrofoam™ Brand Extruded Polystyrene Foam Insulation is produced with no holes or voids that allow water to penetrate. It also resists moisture and will maintain its R-value over time.
R-Value - A measurement of resistance to heat flow. The greater the R-value, the greater the thermal efficiency. A small increase in R-value makes a big difference. Cavity insulation, such as batt insulation, only insulates between wood studs, leaving those studs un-insulated. Rigid insulation covers the entire wall, providing a continuous layer of thermal protection and increasing the overall R-value and energy efficiency.
Moisture Resistance - Some insulation absorbs moisture, which reduces the R-value and may lead to mold and mildew problems. Insist on the closed-cell structure of Styrofoam™ Brand Extruded Polystyrene Foam Insulation that will resist moisture absorption and help retain a long-term R-value.
Strength and Durability - Styrofoam™ Brand Extruded Polystyrene Foam Insulation is rigid with excellent compressive strength, so it is durable and maintains its integrity during installation and for years after. Yet, it is easy to cut and work with.
Yes, several CAD details for the use of foam sheathing in residential construction are available here.
DuPont™ Thermax™ Brand Insulation products have a maximum use temperature of 250°F.
DuPont™ Tuff-R™ (ci) Polyisocyanurate Foam Insulation, DuPont™ Super Tuff-R™ Polyisocyanurate Foam Insulation, Tuff-R™ Commercial, Super Tuff-R™ Commercial and DuPont™ Isocast™ R Polyisocyanurate Foam Insulation products have a maximum use temperature of 190°F.
For additional information about these products, please visit Polyisocyanurate Insulation.
Permeability is the water vapor transmission of a homogeneous material under unit vapor pressure difference between two specific surfaces, per unit thickness. An acceptable unit of permeability is perms-inch: grain-in/h.ft2.in.Hg. Permeability is important for specifying insulation materials.
Permeance is the water vapor transmission of a specific sample under unit vapor pressure difference between two specific surfaces. An acceptable unit of permeability is the perm: grain/ h.ft2.in.Hg. Permeance is important for specifying vapor retarders.
It is important to ONLY use permeance when specifying vapor retarders for use over pipe insulation. The industry standard requirements for vapor retarder permeance in mechanical systems are typically 0.02 perms for below 32°F service temperature and 0.05 to 0.10 perms for above 32°F service temperatures. When selecting a vapor retarder, make sure that its permeance meets these requirements. Saran 540 and 560 vapor retarder films easily meet the more stringent of these two requirements (0.02 perms). This makes them suitable for use at service temperatures from ambient down to cryogenic temperatures.
Our supplier has attached the following document outlining our FDA 21 CFR acceptance.
The white facer (1.25 mil embossed white acrylic) on both Thermax™ White Finish and DuPont™ Thermax™ Light Duty Foam Insulation meets the attached.
For more information, please contact the DuPont Contact Center (DCC) by calling 1-833-338-7668.
The Volatile Organic Compound (VOC) content stated below for Froth-Pak™ two-component systems was determined per the California Air Resource Board and the South Coast and Ventura Air Quality Management Districts' Rule 1168 Adhesive and Sealant Applications (amended Jan 7, 2005) and the Ozone Transport Commission Model Rule for Adhesives and Sealants (effective Jan. 1, 2009). The VOC content is stated assuming the two part system, consisting of the isocyanate side and the polyol side, is mixed and reacted together as specified. The CARB and OTC regulations for adhesives and sealants do not apply to the Froth-Pak™ Foam Insulation products.
Froth-Pak™ 1.75 pcf Polyurethane Foam Sealant - <50 g/L Regulatory VOC
Froth-Pak™ 2.75 pcf Polyurethane Foam Sealant - <10 g/L Regulatory VOC
Froth-Pak™ 2.25 SR Polyurethane Foam Sealant - <10 g/L Regulatory VOC
Froth-Pak™ Foam Insulation (Class A) - <50 g/L Regulatory VOC
ENERGY STAR Version 2.5 is designed to help builders to get familiar with the ENERGY STAR Version 3 program requirements which will be formally launched on January 1, 2012. The requirements are:
More information can be found from ENERGY STAR for Homes website:
No.
DuPont™ Thermax™ Brand Insulation or other DuPont polyisocyanurate insulation products do not meet ASTM C591.
ASTM C591 is a specification for block or bunstock foams (foam plastics produced in very
large cross sections, like 18' x 24'), not faced insulation boards.
DuPont™ Thermax™ Sheathing Insulation, DuPont™ Thermax™ Metal Building Board Insulation, DuPont™ Thermax™ White Finish (WF) Foam Insulation, DuPont™ Thermax™ Light Duty Foam Insulation, and DuPont™ Thermax™ Heavy Duty Foam Insulation have a water vapor permeance of 0.03 perms based on ASTM E96. Thermax™ ci exterior has a water vapor permeance of <0.03 perms. Damage of product facer integrity and joint sealing can affect perm rating of the board or the Thermax™ assembly.
For details on particular Thermax™ products: Polyisocyanurate Insulation
Depending on where you live, you can buy Great Stuff™ products from local retail, hardware stores, or dealers near you. Visit the Where to Buy page to find our products near you.
Visit Great Stuff™ for more information on products for the DIY.
The following are recommendations when storing Thermax™ Exterior Foam Insulation:
DuPont™ Great Stuff™ Insulating Foam Sealant is compatible with most building materials and we do not expect adverse effects when using Great Stuff™ with copper plumbing.
The number of DuPont Styrofoam™ Brand Buoyancy Billets that can be shipped per truckload is dependent on the length, width, and height of the billets. The chart below shows the number of billets that can be shipped based on the different sizes available.
Great Stuff™ foam can be used to air seal around and behind electrical boxes and insulated wires, but should never be used inside a box where it may be exposed to bare copper wires.
Visit Great Stuff™ for more information on products for the DIY.
No.
DuPont™ Styrofoam™ Brand spray polyurethane foam does not contain any formaldehyde.
Specifically, while we have not analyzed for formaldehyde, it is not an intended raw material nor is it known to be present in our DuPont™ Styrofoam™ Brand spray polyurethane foam products.
This determination is based on the compositional information provided to DuPont by its suppliers. DuPont relies on its suppliers to provide accurate data.
DuPont does not routinely analyze for additional materials that are not listed in the SDS or Sales Specification. DuPont is not responsible for any misrepresentation resulting from inaccurate information from its suppliers.
Since formaldehyde is typically present and commonly found in the environment, any formaldehyde in the fully cured foam would be consistent with background levels commonly found in the environment.
EPS is the abbreviation for Expanded Polystyrene Insulation.
Froth-Pak™ products can be purchased through your local Building Supply Distributor or from your local Retail Home Improvement Center near you depending on your location. Please contact the DuPont Contact Center (DCC) at 1-833-338-7668 for a list of distributors in your area.
Click here for more information about Froth-Pak™ sealant products.
Click here for more information about Froth-Pak™ insulation products.
Mil gauges are typically available at paint supply stores. If a mil gauge is not readily available, a U.S. dime can be used as a rudimentary measurement for LiquidArmor™ CM and QS. The target application thickness of LiquidArmor™ CM and QS is 50 wet mils (+/- 5) mils, which is roughly the same thickness as a U.S. dime. The target application thickness of LiquidArmor™ LT is 30 wet mils (+/- 5) mils, which is roughly the same thickness as a credit card.
The Upside-Down Roof is also called PMR (Protected Membrane Roof) or IRMA (Inverted Roofing Membrane Assembly). In this type of roofing assembly, the insulation is installed over the waterproofing membrane, protecting the latter from weather-induced cycling, environmental stresses and construction and maintenance traffic. For more information about this type of application, please click here.
Thermax™ White Finish Polyisocyanurate Insulation is available in the following dimensions: 4' x 8', 4' x 9', and 4' x 10'. Additional product sizes are available by custom order.
Contact your DuPont representative about other sizes and lead-time requirements.
For more information, visit our website.
No.
The PVC joint treatments are to be used with Thermax™ white faced products (DuPont™ Thermax™ Heavy Duty Foam Insulation, DuPont™ Thermax™ Light Duty Foam Insulation and DuPont™ Thermax™ White Finish (WF) Foam Insulation).
Only Thermax™ Polyisocyanurate Insulations should be used with the PCV joint clip system.
Cured Froth-Pak™ foam itself is NOT flammable, but it is combustible. The foam will burn if exposed to sparks or flames, and it will present a fire hazard if exposed to temperatures above 240°F (116°C).
Click here for more information about Froth-Pak™ sealant products.
ASTM C1289 (Version 2003) types and properties are as shown below:
Type | I | I | II | II | III | IV | V | VI |
Class | 1 | 2 | 1 | 2 | ||||
Face 1 | Foil | Foil | Felt or glass | Polymer bonded glass | Perlite | Cellulosic fiber | OSB or wafer board | Perlite |
Face 2 | Foil | Foil | Felt or glass | Polymer bonded glass | Felt or glass | Felt or glass | Felt or glass | Perlite |
Thermal Resistance, R value at 75 degrees F 1' 1.5' 2' |
6.5 9.8 13.0 |
6.5 9.8 13.0
|
5.6 8.4 11.2
|
5.3 8.0 10.6 |
7.4 11.4
|
7.3 11.3
|
6.5 10.5
|
7.5 |
Flexural strength, min, psi | 40 | 40 | 40 | 40 | 40 | 40 | 40 | 50 |
Water vapor permeance, max, perm | .3 | .3 | 1.0 | 4.0 | NA | NA | NA | NA |
Compressive strength, min, psi | 16 | 16 |
Grade1:16 Grade 2:20 Grade 3:25
| 16 | 16 | 16 | 16 | 16 |
Water absorption, max, 2hr, % by volume | 1.0 | 1.0 | 1.5 | 1.5 | 1.0 | 2.0 | 1.0 | 1.5 |
Product |
Froth-Pak™ Foam Sealant Theoretical Yield bd ft (m3)** |
Froth-Pak™ Foam Insulation Refillable Cylinders Theoretical Yield bd ft (m3)** |
Froth-Pak™ 17 |
2,060 (4.9) |
2,150 (5.1) |
Froth-Pak™ 27 |
3,240 (7.6) |
3,480 (8.2) |
Froth-Pak™ 60 |
6,860 (16.2) |
7,160 (16.9) |
Froth-Pak™ 120 |
15,430 (36.4) |
16,110 (38.0) |
Froth-Pak™ 350 |
43,890 (103.6) |
45,820 (108.2) |
*Underwriters Laboratories Listed - Foam Sealant
**The theoretical 'yield' has become an industry standard for identifying certain sizes of two-component kits. Theoretical 'yield' calculations are performed in laboratory conditions, without taking into account the loss of blowing agent or the variations in application methods and types.
Use the links below to have a sample sent to you.
Samples
Or call DuPont at 1-833-338-7668 to have a sample sent to you.
No. DuPont™ Insta Stik™ Quik Set Commercial Adhesive is designed, tested and approved for the attachment of various types of insulation boards to various approved substrates. It is not approved for securing vapor barriers or single-ply membranes.
Visit DuPont™ Insta Stik™ Quik Set Commercial Adhesive to learn more and download literature about DuPont™ Insta Stik™ Quik Set Commercial Adhesive.
Cradle-to-Cradle certification analyzes and verifies manufacturers' products for human health, environmental health and recyclability. These criteria are based on the principles of Cradle-to-Cradle design developed by architect William McDonough and chemist Dr. Michael Braungart. Their firm, McDonough Braungart Design Chemistry (MBDC), assesses products for their ingredients and manufacturing processes and serves as an important external reviewer.
DuPont™ Styrofoam™ Brand Extruded Polystyrene (XPS) Foam Insulation products achieved a Silver Certification. DuPont™ Thermax™ ci Exterior Insulation (all Thermax™ products) and Styrofoam™ Brand Spray Polyurethane Foam (SPF) Insulation (RS2030, RS2045 & RS2060) earned a Basic Certification.
More information about cradle-to-cradle certification, visit MBDC website.
The only membranes Styrofoam™ Brand Extruded Polystyrene Foam Insulation will 'interact' with are PVC based single-ply membrane, coal tar pitch membrane and Type I or Type II asphalt membranes. 'Interaction' refers to the potential chemical interaction between the solvents contained in the membranes with Styrofoam™ Brand XPS Foam Insulation. Direct contact may result in cavitation of the insulation due to the dissolving action of the solvents in the membrane. This interaction can be prevented by placing a 6-mil thick (or greater) polyethylene sheet between the foam and the membrane. Use of this slip sheet is a common practice.
The flame spread/smoke developed ratings for DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation products are:
10/200 Max 3/8” thickness, 2.2 pcf density max: LEVEL-R |
0/155** Max 4” thickness, 2.2 pcf density max: Cavitymate™ Ultra |
15/165* Max 4” thickness, 4.0 pcf density max: Styrofoam™ Brand Insulation |
You can also check UL certificate # BRYX R3573 for this information online.
* Flame spread and smoke developed were recorded while the material remained in the original test position. Ignition of molten residue on the furnace floor resulted in flame travel and smoke generation equivalent to a calculated flame spread classification of 125 and a smoke developed classification of over 500.
** Flame spread and smoke developed were recorded while the material remained in the original test position. Ignition of molten residue on the furnace floor resulted in flame travel and smoke generation equivalent to a calculated flame spread classification of 95 and a smoke developed classification of over 500.
Some fluid applied air barrier membranes, including DuPont™ Tyvek® Fluid Applied, will exhibit some “self-gasketing” properties, but DuPont™ does not consider them to be “self-sealing” or “self-healing” when fully cured. Certain fasteners, such as self-tapping screws, can destroy the membrane as they pass through it. DuPont performs extensive water penetration testing on wall assemblies and tests our permeable commercial air and water barrier systems up to the high-performance pressure differential of 15 psf and recommends pre-treating any mechanically attached support fasteners.
DuPont recommends that building components be in contact with LiquidArmor™ Flashing & Sealant products, such as windows, are not installed until the LiquidArmor™ is 'dry-to-touch.'
The Factory Mutual (FM) 4880 test is titled as 'Class 1 (A) Insulated Wall or Wall & Roof/Ceiling Panels (B) Plastic Interior Finish Materials (C) Plastic Exterior Finish Material (D) Wall/Ceiling Coating Systems (E) Interior or Exterior Finish Systems'. It is a large-scale room corner test that has been used to evaluate roof covering assemblies containing thermoplastic foam insulation. FM has used this option because their Calorimeter is not designed to evaluate thermoplastic materials. FM 4880 has no link to UL1256, FM 4450 or the large-scale White House test which is the basis for FM 4450 and UL 1256.
The International Building Code (IBC) does not allow Type I or II buildings to use wood studs in the exterior walls. Type III & IV may have limited amounts as we believe Type IV is heavy duty timber framing. Wood frame construction is typically limited to Type V construction and the restrictions greatly reduced. The requirements in section 2603.5 (exterior walls) exempts Type V construction thus NFPA 285 is not required.
The answer is yes, but it is the designer/contractor’s responsibility to verify if this type of construction falls into, and thereby complies with, the IBC (or appropriate regional building/fire code). Regarding the effective system R-value, the numbers may change significantly since wood does not conduct heat as efficiently as steel. The R-factor reduction of the spray polyurethane foam in the stud cavity with steel studs is approximately 50%. This percentage would be lower when wood framing is used and would depend on stud spacing and the estimated amount of wood framing in the opaque portion of the wall. Typical series/parallel calculations as prescribed in ASHRAE Handbook of Fundamentals can be used to determine this.
No. DuPont™ Styrofoam™ Brand Buoyancy Billets are not treated to deter vermin. Animals or insects may eat the extruded polystyrene foam, but the billets do not contain anything to attract animals nor do they provide any nutritional value. They would not be treated with oil since petroleum products tend to dissolve the foam.
For more information, visit our website.
No. LiquidArmor™ CM and QS is not a hazardous chemical and does not pose a respiratory hazard when used according to instructions. It is recommended that you spray in a well ventilated area to ensure optimal product curing, with safety glasses to protect your eyes. Gloves are recommended, but not required.
The primary function of the roof ballast is to keep the insulation secure during wind and rain storms. The ballast also protects the foam from UV and mechanical (foot traffic) damage. When installed at a minimum rate of 9 lbs/ft2 the ballast provides a Class A fire rating as well.
Yes, DuPont has an Environmental Product Declaration (EPD) and Health Product Declaration (HPD) for DuPont™ Tyvek® Fluid Applied products.
Certified Styrofoam™ Brand SPF Spray Foam applicators can be found by contacting your local DuPont sales representative or calling the DuPont Contact Center (DCC) at 866-583-2583.
Froth-Pak™ foam does not contain organic solvents that will dissolve Styrofoam™ Brand Extruded Polystyrene Foam Insulation or other plastics. Froth-Pak™ foam will bond permanently to all commercially available plastics except for Teflon™ fluoropolymers from Chemours™ and lubricious polyolefins such as polypropylene and polyethylene.
Click here for more information about Froth-Pak™ sealant products.
Yes. DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation (such as DuPont™ Styrofoam™ Brand Deckmate™ Plus Extruded Polystyrene (XPS) Foam Insulation) can be used under an asphalt built-up roof (BUR) waterproofing membrane. A cover board or protection board layer needs to be placed between the BUR membrane and the insulation. This protection layer can be gypsum board products, fiber board or perlite board. DuPont™ Insta Stik™ Quik Set Commercial Adhesive or mechanical fasteners can be used to attach the protection boards and insulation to the deck. Be sure to follow all applicable codes and standards in the design and construction of this type of assembly.
In cases where a roof waterproofing membrane is being replaced and the underlying insulation is in good condition, additional retrofit insulation can be added to the underlying insulation before a new membrane is installed. Another way to retrofit a conventional roof is to install additional insulation above the conventional roof in the form of a protected membrane roof (PMR). This assumes that the existing roof is capable of supporting the new insulation and ballast.
For more information, visit Conventional Roofs.
For more information about PMR systems, visit here.
DuPont has a long history of commitment to the Triple Bottom Line definition of Sustainable Development, namely economic prosperity, environmental stewardship and corporate social responsibility.
The wall ties (or other fastening system) that penetrate the DuPont™ Thermax™ (ci) Exterior Foam Insulation layer do represent a thermal short. However, keep in mind the magnitude of this thermal short. Steel studs represent a continuous penetration of the cavity insulation in a standard wall and thus can contribute mightily to heat loss. But the brick ties are proportionally much smaller in the amount of steel that penetrates the insulation, so the effect is also much smaller. The American Society of Heating, Refrigerating, and Air Conditioning Engineers (ASHRAE) considers the effect of such fasteners through the continuous insulation to be insignificant.
Heat moves easily through steel around the fiberglass insulation.
Yes. The foam should be applied thick enough to cover features such as misaligned plates which occur from warping or knots, bumps or nail heads, metal straps such as hurricane tie downs, etc.
Each unit of DuPont™ Insta Stik™ Quik Set Commercial Adhesive is stamped with an expiration date. This date is 15 months from the date of manufacture.
Visit DuPont™ Insta Stik™ Quik Set Commercial Adhesive to learn more and download literature about DuPont™ Insta Stik™ Quik Set Commercial Adhesive.
Please see the definitions below:
The criteria for B1 fire ratings are:
• Minimum left length after fire > 0 mm
• Average left length after fire >150mm
• Average smoke temperature <200℃
• Flame height < 150mm
• Rate of smoke density (SDR) <75The criteria for B1 fire ratings are:
• Minimum left length after fire > 0 mm
• Average left length after fire >150mm
• Average smoke temperature <200℃
• Flame height < 150mm
• Rate of smoke density (SDR) <75
“Blueboard” is a term sometimes used to describe DuPont™ Styrofoam™ Brand insulation products. Styrofoam™ Brand insulation is usually blue in color. This Answer Center contains a wealth of information on 'blue' Styrofoam™ Brand insulation products.
The following 2 wall assemblies have UL tested hourly ratings:
Styrofoam™ Brand Sill Seal Foam Gasket is a foundation sill sealing material. Styrofoam™ Sill Seal Foam Gasket reduces the air infiltration that occurs between the foundation and the sill plate, around windows and doors, and even between floors. Reducing this air infiltration will help reduce the heating and cooling costs. The dimensions available are:
THICKNESS x WIDTH ** |
ROLL LENGTH |
.25' x 3.5' |
50' |
.25' x 5.5' |
50' |
.25' x 7.5' |
50' |
For more information, please visit:
http://building.dow.com/na/en/products/specialty/wmsillseal.htm
Polyisocyanurate Insulations with aluminum foil facers can be cut with a utility knife. A thicker-mil facer may require a band saw or circular saw. Use safety glasses and construction gloves to avoid cuts.
Elongation and recovery determines the elastomeric behavior. The more elastomeric a membrane is, the more reversible the movement will be. Non-elastomeric behavior is irreversible elongation like the stretching of chewing gun.
DuPont™ Tyvek® Fluid Applied WB+™ exhibits exceptional elastomeric behavior, with 99% recovery after 300% elongation. When stretched, Tyvek® Fluid Applied WB+™ acts like a rubber band and will recover as a building naturally moves.
Yes, DuPont Sill Seal is manufactured in the USA.
The weight listed below is for reference only. There may be variances among boards. All the weights are for boards of 1' thickness (1' x 1' square).
Product Thickness (inches) | Weight (grams) |
---|---|
Tuff-R™ Insulation, 1/2 | 30-40 |
Tuff-R™ Insulation, 1 | 68-75 |
Tuff-R™ Insulation, 2 | 143-153 |
Super Tuff-R™ Insulation, 1/2 | 30-40 |
Super Tuff-R™ Insulation, 1 | 68-75 |
Super Tuff-R™ Insulation, 2 | 143-153 |
Weathermate™ Housewrap should not be left uncovered for more than 60 days. Weathermate™ Plus Housewrap should not be left uncovered for more than 120 days (60 days in Canada).
For more information please visit:
LiquidArmor™ CM, QS and LT can be exposed to sunlight with no exterior cladding up to 12+ months.
The trilaminate facer on Tuff-R™ Commercial Polyisocyanurate Insulation has a water vapor permeability of < 0.03 perms. The product is tested per ASTM E 96 (desiccant method) , perms of < 0.03.
United States Occupational Safety and Health Administration (U.S. OSHA) recently announced a National Emphasis Program (NEP) for Occupational Exposure to Isocyanates. Under this NEP, OSHA will conduct workplace inspections that will include all companies handling isocyanates, even those with less than 10 workers.
ASHRAE Standard 90.1-2010 Parallel Path Method Specified Correction Factors are:
Nominal Framing Depth |
Nominal Insulation Value |
Correction Factor |
Effective R-Value |
4' @ 16' O.C. | R-11 R-13 R-15 |
0.50 0.46 0.43 |
R-5.5 R-6.0 R-6.4 |
4' @ 24' O.C. | R-11 R-13 R-15 |
0.60 0.55 0.52 |
R-6.6 R-7.2 R-7.8 |
6' @ 16' O.C | R-19 R-21 |
0.37 0.35 |
R-7.1 R-7.4 |
6' @ 24' O.C. | R-19 R-21 |
0.45 0.43 |
R-8.6 R-9.0 |
8' @ 16' O.C. | R-25 | 0.31 | R-7.8 |
8' @ 24' O.C. | R-25 | 0.38 | R-9.6 |
Data Source: Adopted from ASHRAE/IES Standard 90.1-2010 Table A 9.2-2.
No. The U.S. Green Building Council (USGBC) certifies buildings not products. DuPont products will contribute to the Leadership in Energy & Environmental Design (LEED) points in different categories. USGBC will certify a particular building after all the potential LEED points are counted for all the products. For more information on LEED, please visit USGBC.
DuPont™ Styrofoam™ Brand Cavitymate™ SC Extruded Polystyrene Foam Insulation and/or Thermax™ Polyisocyanurate Sheathing can be used in these types of applications. Assemblies incorporating both products passed NFPA 285 tests required by the building code for these types of applications. Any other ASTM Type IV and Type X Styrofoam™ Brand XPS Foam Insulation products can also be used in this type of construction if desired.
Of particular interest to commercial builders is the Thermax™ Wall System that incorporates continuous insulation, flashing and an air barrier all in one system. Dow's systematic approach offers simplified design, streamlined construction and optimized energy consumption for a reduced carbon footprint. The Thermax™ Wall System meets all applicable IBC and ASHRAE requirements.
For more information on the Thermax™ Wall System, please visit:
For more information on Styrofoam™ Brand Cavitymate™ SC Insulation, please visit:
Both Froth-Pak™ Class A Foam Insulation and Froth-Pak™ Foam Sealant kits and refills have a water vapor permeance of 6.4 perms at 1' thick and 3.2 perms at 2' thick based on ASTM E96 (dry cup method).
This will classify all Froth-Pak™ kits at both 1' and 2' thick as a Class 3 vapor retarder.
Vapor Retarder Perm Ratings | |
Class 1 |
0.1 perm or less |
Class 2 |
0.1 perm to 1.0 perm |
Class 3 |
1.0 perm to 10 perm |
Tech Solutions 508.3 Ballast Design Guide for PMR Systems outlines various options for securing Protected Membrane Roofs over loose laid and adhered roofing membranes. Download a copy of this document from our website.
You may also request Form No. 43-D100241-enUS-1019 from your DuPont representative or by calling 1-833-338-7668.
For more information on PMR systems, here.
Formerly manufactured by The Dow Chemical Company, LIGHTGUARD, now manufactured by Fin Pan, is a lightweight, insulating roof panel to be used in IRMA/PMR systems. It is made by casting a 3/8" layer of concrete onto a 2' x 4' DuPont™ Styrofoam™ Brand Roofmate™ Extruded Polystyrene (XPS) Foam Insulation board. These panels are installed directly on top of the waterproofing membrane and offer a lightweight PMR solution.
Distributor for Fin Pan is T. Clear Corp at 1-800-544-7398 (www.tclear.com)
For more information on Protected Membrane Roofing (PMR) go here.
In Canada, there is a product called CTI Roof panels made by Tech-Crete Processors Ltd. You can find more information about this product at their web site:
Tech-Crete
Yes.
All foamed plastics must pass the National Fire Protection Association (NFPA) 285 fire test for wall assemblies to be used in Type I through IV commercial construction as referenced in Chapter 26 of the International Building Code (IBC). An actual result of NFPA 285 testing on the Thermax™ Wall System combined with engineering analysis has resulted in several possible configurations that meet this code requirement. This analysis was performed by the Jensen-Hughes Associates.
The following spray intumescent products have been considered and are listed as being acceptable for use with the Thermax™ Wall System and meeting the requirements of passing the NFPA 285 fire test:
Growing environmental and health concerns associated with CCA (Chromium Copper Arsenate) for wood treatment has led to use of alternative and more acceptable wood treatment chemicals. One such group of chemicals is ACQ (Alkaline Copper and Quaternary Ammonium) compounds.
While ACQ wood treatment is designed to provide effective protection against rot, decay and pests, ACQ-treated wood’s compatibility with building materials, including polyisocyanurate foam insulations from Dow has been questioned.
Polyisocyanurate insulations from DuPont are composed of rigid, closed cell polyisocyanurate foam with a facer on each side of the board. Some facers are composed of coated/reinforced Kraft while others are composed of aluminum foil of various thicknesses. Coated or reinforced Kraft are chemically resistant to the ACQ compounds used to treat wood products. Aluminum on the other hand is not compatible with the alkaline nature of the ACQ chemicals. All polyisocyanurate insulations from Dow, except those products with aluminum facers can be installed in direct contact with ACQ treated wood. If aluminum-faced polyisocyanurate insulation from DuPont is to be installed over ACQ-treated wood, a separator sheet of 0.008 inch polyethylene is recommended to prevent potential degradation of the foil facer.
Note: ACQ-treated wood use in normal construction may come in contact with other building materials such as flashings, concrete, fasteners, joist hangers, sheathing products, insulation, etc. DuPont cannot comment on the compatibility of other manufacturers’ products with ACQ-treated wood. Specific products’ compatibility concerns with ACQ-treated wood should be addressed by contacting the specific building material manufacturers.
Yes. Railroad facilities such as track, at grade crossings, switching yards, etc. are at risk of frost damage if the underlying soils are susceptible to frost heave and spring breakup. Engineers have found DuPont™ Styrofoam™ Brand Highload 40, 60 and 100 Extruded Polystyrene (XPS) Foam Insulation, when placed beneath these railroad facilities, reduces the potential for damaging effects of frost heave or spring thaw weakening.
The thickness and width of the DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation used for a particular roadway can be determined based on figures and computer models developed by The Dow Chemical Company. The variables needed are average frost penetration in feet/m, freezing degree days for a particular location, roadway cross section materials and thickness, soil type, etc. If you have a particular situation using DuPont™ Styrofoam™ Brand Highload Insulation, please call 1-833-338-7668 for calculations.
For more information:
Please find below the flashing tape options which have met the design intent of Thermax™ Wall System requirements. Any technical support, warranty, or guarantees of these products are the sole responsibility of the flashing tape manufacturer.
In the United States, DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation can be left exposed in crawl spaces provided the space is separated from the basement, is not used for storage and has no heat producing systems. Details for this approval are outlined in the ESR-2142 ICC Evaluation Service Report in Section 4.3 To view the report, click on the link below and type 'STYROFOAM' into the product field.
In Canada, building codes do not permit the installation of any plastic foam insulation, including DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation, without an interior finish or thermal barrier. Normally 1/2' gypsum board is installed However, other finishes are acceptable depending on type of construction.
ICC Evaluation Service Search Reports
For more information, visit our website.
For Froth-Pak™ Sealant the LTTR value (Long term thermal resistance) measurement at 1 inch thick is 5.3 ft²•h•°F/Btu (R value) per inch. When sprayed to 2 inches thick the LTTR value (Long term thermal resistance) measurement at 2 inch thick is 5.5 ft²•h•°F/Btu (R value) per inch which is R11.0 at 2 inches thick.
For Froth-Pak™ Insulation (Aged 180 days @ 75°F):
Thickness (inches) | R-Value (ASTM C518, F.ft2.h/Btu) |
1.0' | 6.0 (when sprayed at 1 inch thick) |
2.0' | 12.2 (R5.6/inch when sprayed at 2 inches) |
The following performance criteria you should keep in mind when you choose different panel insulation products:
•Insulation efficiency
•Flame/smoke performance
•Moisture resistance
•Mechanical properties
•Chemical resistance
•Machinability
•Adhesion/Bonding
•Environment/health concerns
For details about these criteria, you may browse the link below:
Performance Criteria
Styrofoam™ Brand Extruded Polystyrene Foam Insulation products available in Canada fit into the following types:
Type 2
Styrofoam™ Brand Cladmate™
Styrofoam™ Brand Wallmate™
Styrofoam™ Brand Deckmate™
Styrofoam™ Brand Cavitymate™ SC
Styrofoam™ Brand Panelmate™ (Type 2)
Type 3
Styrofoam™ Brand Cavitymate™
Styrofoam™ Brand Cavitymate™ Ultra
Styrofoam™ Brand Deckmate™ Plus
Styrofoam™ Brand Deckmate™ Plus FA
Styrofoam™ Brand Cladmate™ CM20
Styrofoam™ Brand Panelmate™ (Type 3)
Styrofoam™
Type 4
Styrofoam™ Brand SM
Styrofoam™ Brand Perimate™
Styrofoam™ Brand Roofmate™
Styrofoam™ Brand Highload 40
Styrofoam™ Brand Highload 60
Styrofoam™ Brand Highload 100
Great Stuff™ is the brand name for a line of one-component polyurethane insulating foam sealants that can help make your home more comfortable and energy efficient by sealing the gaps and cracks where air conditioned and heated air escape. Great Stuff™ can be used for both small and large air sealing and retrofit applications by DIY’s or professionals. Great Stuff™ comes in both cans (with straw applicator) and Pro series which are; larger cans and use the dispensing guns to apply. (Straw cans are in 12, 16, and 20 oz sizes - Pro series are in 20, 24 & 30 oz sizes).
Visit Great Stuff™ for a list of Great Stuff™ and Great Stuff Pro™ products.
Great Stuff Pro™ Window & Door Adhesive information can be accessed here.
To meet the appropriate wind uplift criteria, please contact the Standing Seam Roof Manufacturer for proper fastener type and fastening pattern. With Thermax™ insulation boards, a general guideline is to use a minimum of 5-8 fasteners with roof plates (to offset loading) penetrating 3/4' into framing or substrate. If the Thermax™ insulation is exposed to the interior of the building and is FM insured, consult with DuPont Building Knowledge Center (BKC) for latest FM approval.
DuPont™ Tyvek® Fluid Applied WB+™ can be spray applied using industry standard electric or gas hydraulic airless sprayers that provide a minimum of 3,300 psi. Always ensure there is no water or foreign material in the spray system prior to the introduction of Tyvek® Fluid Applied WB+™. Please refer to the spray matrix or the installation guidelines for additional information.
Refer to pump manufacturer’s guidelines regarding the operation and maintenance of the pump system. Operation of pump equipment can be hazardous. All manufacturer limitations, warnings, and safety recommendations should be followed.
You can get-in field technical advice on spray equipment needs, spray setup, and proper configurations in all types of weather conditions by calling ‘CJ Spray’ at 1-888-257-7729. CJ Spray’s trained representatives can diagnose most equipment problems over the phone and provide equipment related solutions to the DuPont representative.No. Great Stuff Pro™ Gasket is water-based, whereas one-component polyurethane reacts with water to cure. Mixing the two would permanently clog the gun.
The Great Stuff Pro™ Gasket Dispensing Gun has a blue handle which matches the blue collars on its can. This is a visual check to only use blue guns with blue collars, and black guns with black collars.
One of the best ways to manage moisture / condensation concerns in steel stud wall assemblies is to use a continuous layer of insulating sheathing, such as DuPont™ Styrofoam™ Brand Cavitymate™ Extruded Polystyrene (XPS) Foam Insulation or DuPont™ Thermax™ (ci) Exterior Foam Insulation, on the exterior side of the steel studs.
For more information, visit the Thermax™ web page.
Penetrations in an Ultra Air Barrier Wall System should be handled in the same way as a regular block or steel stud back-up wall: they should be sealed to the air barrier. This is especially easy to accomplish with the Ultra Air Barrier Wall System because you are already sealing the board joints and the penetrations should be sealed in a similar manner.
First, cut the DuPont™ Styrofoam™ Brand Cavitymate™ Ultra Extruded Polystyrene (XPS) Foam Insulation boards (when using the 15 ¾ inch wide version of the Ultra Air Barrier Wall System) or DuPont™ Styrofoam™ Brand Ultra SL Extruded Polystyrene (XPS) Foam Insulation boards (when using the 48 inch wide version of the Ultra Air Barrier Wall System) to fit around the penetrations (small penetrations may not need this and a simple hole should be made in the insulation board). After the boards are installed on the wall, seal the penetration to the Insulation board as shown below (this example shows the 15 ¾ inch wide version of the system. The 48 inch wide version would be done the same way).
For more information on the Ultra Air Barrier Wall System see:
Certain areas of the protected membrane roof (PMR) insulation require additional ballast to overcome high wind loads and to restrain the foam from floating during heavy rain storms. This ensures that individual stones cannot migrate to below the foam and abrade the membrane. Areas needing such additional ballasting are:
Perimeter Edge of Insulation: which is an 8-foot-wide swath running along the perimeter edge of the roof insulation (and which includes any insulation adjacent to higher walls).
Penetrations Through Insulation: which are four-foot-wide swaths running around any roof insulation penetrations which exceed 4 feet in any direction, such as skylights, expansion joints, equipment pads, etc.
Corners: where arrays of concrete pavers are required in higher wind zones or with low parapet walls.
These requirements are consistent with both the ANSI/SPRI RP-4 Ballast Design Guide (the procedure required by the International Building Code) and Factory Mutual requirements (Factory Mutual Property Loss Prevention Data Sheet 1-29 Page 18).
For more information, download Tech Solutions 508.3: Ballast Design Guide for PMR Systems (43-d100241). Call 1-833-338-7668 for ballast design information in Canada.
It is a Factory Mutual (FM) tested assembly with excellent performance but the use of sprinkler protection is required.
DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation does not perform well either at absorbing sound or at blocking sound transmission as compared to a variety of materials that have been designed and/or are sold for acoustical control/sound absorption purposes. Styrofoam™ Brand Extruded Polystyrene Foam Insulation is an ineffective sound-deadening material.
No.
Exterior Insulation and Finish System (EIFS) manufacturers (such as Dryvit and STO) are responsible for determining which substrates are allowable for their systems. Since DuPont has not worked with these manufacturers regarding the DuPont™ Thermax™ Wall System (TWS), we cannot recommend it as a substrate when it is not DuPont's decision. DuPont is working with an EIFS manufacturer to determine if the DuPont™ Thermax™ (ci) Exterior Foam Insulation can be a substrate for an EIFS system.
There are currently 44 listings on the Miami Dade Website showing Tile Bond™ Roof Tile Adhesive as part of the adhesive system used to attach their tile products.
See the attached spreadsheet.
Both outside and inside corners are best handled by staggering the DuPont™ Styrofoam™ Brand Cavitymate™ Ultra Extruded Polystyrene (XPS) Foam Insulation boards at the corners. This may require some planning to ensure that the alternating rows of insulation boards are of slightly different lengths.
For more information on the Ultra Air Barrier Wall System and installation techniques see:
Ultra Air Barrier Wall System Installation for 15 ¾ inch insulation
Building codes require that Styrofoam™ Brand Extruded Polystyrene Foam Insulation be protected from the interior side of a wall or roof system by a 15-minute thermal barrier such as gypsum board. In certain circumstances, Styrofoam™ Brand XPS Foam Insulations can be left exposed in residential crawl spaces and attics when these spaces meet certain requirements such as being separated from the rest of the residence and being free of any mechanical heat producing appliances such as a furnace or water heater.
For more information, consult ICC-ES Report ESR-2142, and https://www.dupont.com/building/foundations-and-basement.html.
Green building design may add up to 2% to 11% total cost, depending on the situations involved in the specific projects.
For more information, visit USGBC and CAGBC.
Since local regulations vary, it is best to contact your local waste disposal facility to inquire about disposal of pressurized aerosol canisters. In many areas, the Tile Bond™ Roof Tile Adhesive canister (when depressurized and completely emptied of chemical contents) can be discarded in a dumpster. DuPont manufacturing facilities are typically not licensed to receive hazardous waste and therefore cannot take back used cans.
Click here for more information about Tile Bond™ Roof Tile Adhesive.
What alternate thermal and ignition barriers can be used with Froth-Pak™ Foam Insulation (Class A)?
Alternate Thermal Barriers for Froth-Pak™ Foam Insulation
Thermal Barrier - A thermal barrier is a material, applied between foam plastics (including spray polyurethane foam) and interior spaces designed to delay the temperature rise of the foam during a fire situation and to delay or prevent the foam's involvement in a fire.
Alternate Ignition Barrier for Froth-Pak™ Foam Insulation
Ignition Barrier - Model building codes allow an exception to the thermal barrier requirement in attics and crawlspaces where entry is made only for repairs or maintenance (IRC) or for the service of utilities (IBC). In these cases, the foam plastic insulation is protected against ignition using one of the following ignition barrier materials:
No. In general, the use of gypsum drywall on the exterior side of the steel studs is not necessary for a successful application of Styrofoam™ Brand Ultra SL Insulation in the Ultra Air Barrier Wall System.
However, there are some situations where this may not be true, especially where an hourly rated fire wall is required.
For more information on the Ultra Air Barrier Wall System see:
Yes.
Product Transparency reports are available for DuPont™ Styrofoam™ Brand Insulation, Thermax™ Insulation, and Tuff-R™ Insulation products. This product transparency report is intended to summarize the environmental performance and chemistry attributes associated to Styrofoam™ Brand XPS Thermax™ Insulation, and Tuff-R™ Insulation products to use for obtaining LEED v4 credits.
Yes.
Enerfoam™ sealant can be used outdoors. However, cured foam will discolor if exposed to ultraviolet (UV) light. If left exposed, the foam will eventually crumble. Paint or coat foam for best results in outdoor applications.
Click here for more information about Enerfoam™ Sealant.
The polypropylene film backer and acrylic adhesive that make up Weathermate™ Construction Tape are known for their longevity. As used in the construction industry, tapes made of such components have a history of solid performance. Furthermore, DuPont backs its Weathermate™ Construction Tape with a 10-year weatherization warranty.
For more information, click here.
DuPont™ Insta Stik™ Quik Set Commercial Adhesive Complete is supplied in a 31 lb (13.6 kg) unit, 23 lb (10.4 kg) net chemical weight, with a flexible dispensing wand assembly. An on/off ball valve at the end of the dispensing hose allows operational control for singlehand application. DuPont™ Insta Stik™ Quik Set Commercial Adhesive Tank Only is supplied in a 31 lb (13.6 kg) unit, 23 lb (10.4 kg) net chemical weight, with no dispensing equipment.
Visit DuPont Adhesives to learn more and download literature about DuPont™ Insta Stik™ Quik Set Commercial Adhesive.
DuPont manufactures surf board material. Call 1-833-338-7668 for additional information.
Compatibility of DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation and ACQ treated wood is based on:
Growing environmental and health concerns associated with CCA (Chromium Copper Arsenate) for wood treatment has led to use of alternative and more acceptable wood treatment chemicals. One such group of chemicals is ACQ (Alkaline Copper and Quaternary Ammonium) compounds.
While ACQ wood treatment is designed to provide effective protection against rot, decay and pests, ACQ-treated wood’s compatibility with building materials, including DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation has been questioned.
DuPont™ Styrofoam™ Brand XPS Foam Insulation is a rigid closed-cell extruded polystyrene insulation. Some DuPont™ Styrofoam™ Brand XPS Foam Insulation products are available with a plastic film facer while others have the natural polystyrene extruded surface. All DuPont™ Styrofoam™ Brand XPS Insulations exhibit good to excellent chemical resistance to inorganic compounds. Based on chemical resistance testing of solid polystyrene and film facer materials in accordance with ASTM D543-60T, DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation products should not be adversely affected if in long-term contact with ACQ compounds. Continued direct contact of DuPont™ Styrofoam™ Brand XPS Foam Insulation products for a period of months to years with liquid ACQ compounds is expected to cause, at most, very slight foam discoloration. Long-term contact of DuPont™ Styrofoam™ Brand XPS Foam Insulation products with ACQ-treated wood products is expected to show no more, but most likely, even less effect.
Note: ACQ-treated wood use in normal construction may come in contact with other building materials such as flashings, concrete, fasteners, joist hangers, sheathing products, insulation, etc. DuPont cannot comment on the compatibility of other manufacturers’ products with ACQ-treated wood. Specific products’ compatibility concerns with ACQ-treated wood should be addressed by contacting the specific building material manufacturers.
International Code Council (ICC) is a formal consolidation of BOCA, ICBO and SBCCI in 1994 with a single, 50,000-member organization.
The purpose of the ICC is to provide world-class service to members and customers, and remains dedicated to public safety through the development of building safety and fire prevention codes. For more information about ICC, please click the link below:
http://www.iccsafe.org/
LiquidArmor™ CM Flashing and Sealant, when stored in its original air tight container, has a shelf life of 18 months.
LiquidArmor™ QS Flashing and Sealant, when stored in its original air tight container, has a shelf life of 12 months.
LiquidArmor™ LT Flashing and Sealant, when stored in its original air tight container, has a shelf life of 12 months.
Pultrusion is a manufacturing process for producing continuous lengths of FRP structural shapes. Raw materials include a liquid resin mixture (containing resin, fillers and specialized additives) and reinforcing fibers. For more information about pultrusion, please visit the following website:
Pultrusion Industrial Council
The following adhesives are recommended to be used with Styrofoam™ Brand Deckmate™ Plus FA Extruded Polystyrene Foam Insulation:
OlyBond Insulation Adhesive from OMG, Inc. For more information, please visit: http://www.olyfast.com/products.aspx?catID=14
The Thermax™ Wall System is an insulated steel stud wall assembly designed from the ground up to be highly energy efficient, highly resistant to moisture condensation, and highly resistant to air infiltration. It uses DuPont™ Thermax™ XARMOR™ (ci) Exterior Foam Insulation as the continuous insulation, DuPont™ LiquidArmor™ Flashing and Sealant to seal board joints and penetrations to achieve a weather resistant barrier, and Styrofoam™ SPF Spray Foam Insulation to seal the wall system against air infiltration.
History: In late 2007, Building Scientists in DuPont's Building Solutions Business sat down with a blank sheet of paper with the objective of creating a simple, effective, and very energy efficient wall assembly. After months of design and engineering effort, the Thermax™ Wall System was born.
The Thermax™ Wall System is a systematic approach to achieving efficiency at every level: simplified design, streamlined construction, and optimized energy consumption for a reduced carbon footprint.
DuPont's three-in-one system with insulation, air barrier, and flashing meets all applicable International Building Code (IBC) and American Society of Heating, Refrigeration, and Air-conditioning Engineers (ASHRAE) requirements.
The Thermax™ Wall System results in a tight, efficient wall assembly, allowing for downsizing to less expensive Heating, Ventilation, and Air Conditioning (HVAC) equipment, which in turn reduces fuel consumption and greenhouse gas emissions.
For more information see the Thermax™ Wall System website.
Yes, DuPont will warrant, at no additional cost, the adhesion of DuPont™ Insta Stik™ Quik Set Commercial Adhesive for a period of ten (10) years. Fifteen (15) and twenty (20) year warranties may be purchased for an additional fee. Must meet qualifications prior to receiving warranty. Contact your DuPont representative for more information.
Visit DuPont™ Insta Stik™ Quik Set Commercial Adhesive to learn more and download literature about DuPont™ Insta Stik™ Quik Set Commercial Adhesive.
The thermal conductivity properties of some typical building materials are:
To convert m2-W/K to Btu-in/ft2-hr-F multiply by 6.934
DuPont™ Tyvek® Fluid Applied System can be used as a stand-alone offering or as part of an integrated system combined with DuPont™ Tyvek® Commercial Wrap or Tyvek® CommercialWrap® D. The two air and water barrier systems integrate easily using DuPont’s butyl based self-adhered flashing products, primarily DuPont™ StraightFlash™.
On buildings where you have multiple substrates, DuPont offers an integrated air barrier system. For proper installation of DuPont™ Tyvek® Fluid Applied System and Tyvek® Commercial Wraps, the products should be integrated in accordance with the current DuPont Installation Guidelines to ensure proper adhesion, and to maintain the high performance of all materials.
To ensure the best transition between the mechanically fastened wrap and the fluid applied material, first terminate the Tyvek® CommercialWrap® product on the adjoining substrate by using DuPont™ StraightFlash™. Be sure to prime the substrate where the DuPont™ StraightFlash™ will be adhered if the current DuPont Installation Guideline calls for such priming with DuPont™ Adhesive/Primer. Next, apply DuPont™ Tyvek® Fluid Applied WB+™, overlapping it by a minimum of 2 inches onto the StraightFlash™. For detailed installation instructions, please see the DuPont™ Tyvek® Fluid Applied WB+™ Wall and Substrate Guidelines at www.fluidapplied.tyvek.com.
Yes.
COMCheck is a computer program available from the US Department of Energy. Its purpose is to calculate trade-offs between various envelope, HVAC and other elements in a commercial building while determining if that building meets a given energy code. The application of the trade-off method used in various energy codes allows some flexibility in how a designer can meet the code.
COMCheck accounts for steel stud walls as one possible wall assembly in a building and properly calculates the effective R-value of an insulation installed between steel studs.
To enter the DuPont™ Thermax™ Wall System (TWS) into COMCheck, simply add a steel stud wall and use 10.2 as the R-value of the cavity insulation (this is the R-value of 1.5 inch spray foam and the leftover air space). Then enter the R-value of the DuPont™ Thermax™ (ci) Exterior Foam Insulation based on the thickness of the insulation. COMCheck will properly calculate the resulting effective U-value.
In the following example, COMCheck calculates an R-value of 13.3 (1/0.075) for a Thermax™ Wall System with one inch of insulation. This is very close to the value DuPont promotes, which is 13.2.
DuPont™ Styrofoam™ Brand is the brand name for the Extruded Polystyrene Insulation manufactured by the DuPont with manufacturing facilities around the world. It has been used worldwide as insulation for buildings to improve energy efficiency and other specialty applications for more than 60 years.
DuPont has the following hourly rated wall listed with Underwriters Laboratories (UL):
For details about these constructions, please visit Underwriters Laboratories Online certification directory under DuPont for these particular design numbers.
No. The Ultra Air Barrier Wall System meets all of the requirements for an air barrier as specified in the building code. An additional air barrier can be installed as a back-up to the air barrier capabilities of the Ultra Air Barrier Wall System, but it is not necessary.
For more information on the Ultra Air Barrier Wall System see:
Thermax™ Exterior Foam Insulation has a lower compressive strength than other sheathings like exterior gypsum board (that also has facings) or plywood, so the fasteners used to install Thermax™ Exterior Foam Insulation can be over-driven. But the fasteners for these other sheathings can also be over-driven with careless installation. So the quality of the installation process affects all sheathings. There is no reason to believe that Thermax™ Exterior Foam Insulation will be installed at any different level of quality than any other sheathing.
The typical features are:
•Tight construction (reduced air infiltration)
•Tight ducts
•Improved insulation
•High performance windows
•Energy efficient heating and cooling equipment
For more detailed description of each feature, please follow the following link:
http://www.energystar.gov/index.cfm?c=new_homes.nh_features
The 15 ¾ inch wide version of the DuPont™ Styrofoam™ Brand Cavitymate™ Ultra Extruded Polystyrene (XPS) Foam Insulation is used only in brick and block wall systems with eye and pintle brick ties. For this reason, the insulation board width is sized to fit in the 16-inch gap between the wall ties.
This isn't new, 16-inch wide products have been available for this application for decades. However, in the Ultra Air Barrier Wall System there needed to be a ¼ inch gap to hold the Great Stuff Pro™ single component foam that is applied after the boards are mounted to the wall. This foam sealant provides the air and water barrier properties for the assembly. This is why the insulation boards are only 15 ¾ inch wide.
For more information on the Ultra Air Barrier Wall System see:
THERMADRY® was once sold by The Dow Chemical Company but is now manufactured by T. Clear Corp. A foundation insulation and drainage product, THERMADRY® consists of DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation with both multiple, bi-directional grooves and an adhered geotextile fabric on one face. It is installed with grooves facing out on a foundation and then soil is back-filled against it. The grooves provide drainage for water at the foundation and the fabric filters out the dirt so the grooves don?t clog over time.
For more information, visit T. Clear Corp.
DuPont offers DuPont™ Styrofoam™ Brand Perimate™ Extruded Polystyrene (XPS) Foam Insulation, a product very similar to THERMADRY® that has grooves but does not include the filter fabric.
For more information, visit our website.
The details of the new Version of ENERGY STAR Homes 2011 program can be found at http://www.energystar.gov.
The major proposed changes are outlined as below:
Upon examination of the raw materials and compositional details for DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation products, it has been concluded that neither of these fire retardants is used in the production of this foam.
This determination is based on the compositional information provided to DuPont from its suppliers. DuPont relies on the suppliers to provide accurate data. DuPont is not responsible for any misrepresentation resulting from inaccurate information from its suppliers.
Caulking or taping the seams of a sheathing over metal or wood studs has historically been done to reduce air infiltration through these seams (the air that passes through the seam and into the building). Styrofoam™ Brand Extruded Polystyrene Foam Insulation sheathings such as Styrofoam™ Brand RS Insulation, DuPont™ Styrofoam™ Brand Duramate™ Plus Extruded Polystyrene (XPS) Foam Insulation and DuPont™ Styrofoam™ Brand Cavitymate™ SC Extruded Polystyrene (XPS) Foam Insulation act as “gaskets” over the stud members (when properly installed) that will reduce air infiltration without the need for tape or caulks. However, some codes may specify the use of such joint tapes or other methods in certain circumstances. To maximize sealing effectiveness, you can apply Great Stuff Pro™ Gaps & Cracks Polyurethane Foam Sealant to the joints prior to forming the joint. Be sure to check with the local code official to decide whether you need to tape or caulk the seams.
More recently, concerns regarding bulk water intrusion into wall systems have brought about the concept of a “weather barrier.” The International Residential Code (IRC) has developed a standard named Acceptance Criteria 71 (AC-71) for the evaluation of foam plastic sheathings as a weather barrier. Several Styrofoam™ Brand Extruded Polystyrene Foam Insulation and polyisocyanurate insulated sheathing recently passed certified, third-party evaluations to qualify as “weather-resistive barriers” (WRB) for residential construction. If the foam sheathing is used as a WRB, the seams should be taped.
For more information on controlling air infiltration, visit our website.
There are two categories of recycle content qualified for LEED recycle content credit: pre-consumer and post-consumer recycle content:
LEED recycle content credit is calculated as: post-consumer recycle material + ½ Pre-consumer recycle material for all the materials used on a particular project.
Yes. Thermax™ Brand Insulation products have an International Code Council (ICC) ESR 1659.
An electronic copy of this report can be viewed or downloaded here.
Yes. Thermax™ White Finish Polyisocyanurate Insulation has successfully passed the Factory Mutual Standard 4880 (Class 1 Insulated Wall or Wall & Roof/Ceiling Panels; Plastic Interior Finish Materials; Plastic Exterior Building Panels; Wall/Ceiling Coating Systems; Interior or Exterior Finish Systems) Class 1 Fire-Rated to maximum 30' high, 4.25” thick, 4’ width when installed as described in the current edition of FMRC approval guide. It is also considered a Class 1 foam plastic per ASTM E84 with a Flame Spread Index of 25 or less and a Smoke Developed Index of 450 or less.
For more information, visit our website.
The Volatile Organic Compound (VOC) content and status of the following Great Stuff™ consumer products (size: 20oz or less) were determined according to the California Air Resource Board’s (CARB) Regulation for Reducing Volatile Organic Compound Emissions For Consumer Products, the South Coast Air Quality Management District's (SCAQMD) Rule 1168, and the Ozone Transport Commission (OTC) Model Rule for Consumer Products. These regulations exclude insulating foam sealants.
Great Stuff™ Insulating Foam Sealants:
Window & Door | <15 wt % VOC (<160 g/L) | exempt from CARB and OTC; compliant for SCAQMD |
Gaps & Cracks | 15 wt % VOC ( 160 g/L) | exempt from CARB and OTC; compliant for SCAQMD |
Big Gap Filler | <15 wt % VOC (<160 g/L) | exempt from CARB and OTC; compliant for SCAQMD |
Fireblock | <15 wt % VOC (<160 g/L) | exempt from CARB and OTC; compliant for SCAQMD |
Pestblock | <15 wt % VOC (<160 g/L) | exempt from CARB and OTC; compliant for SCAQMD |
Pond & Stone | <15 wt % VOC (<160 g/L) | exempt from CARB and OTC; compliant for SCAQMD |
Multipurpose Black | <15 wt % VOC (<160 g/L) | exempt from CARB and OTC; compliant for SCAQMD |
The ENERGY STAR Version 3 program requirements are required for ENERGY STAR home compliance on January 1, 2012 and beyond. The requirements are:
More information can be found from ENERGY STAR for Homes website:
For information about where DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation can be recycled, please contact your local recycling company or consult your waste management authority to learn more about recycling centers in your area.
For more information, visit Plastics.
AC -71 is an International Code Council (ICC) Acceptance Criteria (AC) titled, “PROPOSED CRITERIA FOR FOAM PLASTIC SHEATHING PANELS USED AS WEATHER-RESISTIVE BARRIERS”. The purpose of these acceptance criteria is to establish requirements for foam plastic sheathing panels to be recognized as an alternative to the prescriptive requirements for weather resistive barrier as specified in Section R703.2 of the International Building Code (IRC).
The recommended installation temperature is 15°F to 120°F. After application, temperature resistance is -40°F to 220°F.
Additional information about Weathermate™ Construction Tape can be found: Weathermate™ Construction Tape
Unfaced DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation products used in commercial and residential construction generally have a water vapor permeance of 0.9 to 1.5 max perms per inch based on ASTM E96 depending on the product. The thicker the product, the lower the permeance.
Faced DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation products, such as Styrofoam™ Brand Residential Sheathing and Styrofoam™ Brand Duramate™ Plus, have a lower perm rating. Styrofoam™ Brand Residential Sheathing has a perm rating of 0.3 and Styrofoam™ Brand Duramate™ Plus has a perm rating of 0.7.
Vapor Retarder Perm Ratings | |
Class 1 |
0.1 perm or less |
Class 2 |
0.1 perm to 1.0 perm |
Class 3 |
1.0 perm to 10 perm |
View this website and select your Styrofoam™ Brand Extruded Polystyrene Foam Insulation and consult its Product Information Sheet.
There are two key differences between Great Stuff™ and Great Stuff Pro™ products:
Visit Great Stuff™ for a list of Great Stuff™ and Great Stuff Pro™ products.
Great Stuff Pro™ Construction Adhesive information can be accessed here.
Visit Great Stuff™ for more information on products for the DIY.
Uncured Fluid Applied material can be cleaned from tools, and equipment by using 100% mineral spirits free of water, naphtha, or citrus-based cleaner. DuPont™ Tyvek® Fluid Applied products are moisture cured, thus avoid cleaning with water as this will advance the curing process. Cured fluid applied material can be removed by soaking an item in naphtha or citrus-based cleaners.
When applying the product using a spray gun or power roller, the pump system should be completely free of water and any old water-based or incompatible material. If the system is not completely clean, products can react and cause the Tyvek® Fluid Applied WB+™ to cure in the system. To ensure optimal performance of the pump, DuPont recommends that the low pressure portions of the pump be taken apart and thoroughly cleaned by hand. Refer to ‘CJ Spray’ or the pump manufacture for the recommended cleaning procedure. Before the next use, flush any remaining solvent out of the system and make sure good product is being pumped out of the spray gun or power roller, before applying the DuPont™ Tyvek® Fluid Applied WB+™ to the wall substrate.Yes, it can. The structure of two-component Froth-Pak™ foam is closed cell, which makes it water resistant. Froth-Pak™ foam will float in water just the same as a paddleboard or buoy. Froth-Pak™ 1.75 density foam is recommended for marine/flotation applications. Froth-Pak™ foam has been tested in-house in accordance with U.S. Coast Guard guidelines for flotation.
Caution: When filling a high volume of foam such as in a drum, we recommend filling smaller amounts at a time and letting the foam cure first. This is due to the fact that the heat generated by the Froth-Pak™ foam while curing can get up to >1000°F and may start a fire. The foam will cure very quickly (in just about 1 minute) so waiting time to add layers is very minimal. Wait for the container to cool down before touching the filled drum.
Click here for more information about Froth-Pak™ sealant products.
Click here for more information about Froth-Pak™ sealant products.
LiquidArmor™ QS can be applied to help flash and/or seal insulation board joints, rough openings, building penetrations as well as counter flash.
Finally, when sealing, flashing, or counter-flashing penetrations, LiquidArmor™ QS should extend a minimum of 2 inches onto the sheathing face and a minimum of 2 inches onto the penetration substrate or primary flashing substrate.
For EIFS (Exterior Insulation and Finish Systems) applications, a strong and long lasting bond is essential to the long term performance of the wall system. A planed XPS (Extruded Polystyrene Insulation) surface normally has better adhesion properties than boards with a skin surface (unplaned). DuPont recommends planed XPS boards in EIFS applications.
The quick cure Froth-Pak™ foam products expand with a lot of force. Since the installer cannot see how much foam is injected, the expanded foam can buckle or bow a wall. Please contact the DuPont Contact Center (DCC) at 1-833-338-7668 for additional recommendations on existing wall applications.
Disclaimer: The Dow Chemical Company has not performed any testing to determine suitability of Froth-Pak™ foam for this application and cannot guarantee results. Use Froth-Pak? foam at your own risk.
Click here for more information about Froth-Pak™ sealant products.
Product |
Theoretical Field* |
Density |
Yield |
Yield |
Froth-Pak™ 12 Sealant |
12 |
1.9 |
0.974 |
0.03 |
Froth-Pak™ 115 High Density Sealant |
90 |
3.4 |
7.258 |
0.20 |
Froth-Pak™ 120 Sealant |
120 |
1.75 |
9.943 |
0.28 |
Froth-Pak™ 160 Slow Rise |
125 |
2.9 |
10.35 |
0.29 |
Froth-Pak™ 200 Sealant |
200 |
1.75 |
16.343 |
0.46 |
Froth-Pak™ 210 Insulation |
210 |
1.75 |
17.171 |
0.48 |
Froth-Pak™ 620 Sealant |
620 |
1.75 |
51.429 |
1.46 |
Froth-Pak™ 650 Insulation |
650 |
1.75 |
53.942 |
1.52 |
*Note: Actual yield will depend on various factors of the application and the environment, including temperature, foam thickness, the number of foam spray passes, the specific nozzle used, etc.
Click here for more information about Froth-Pak™ sealant products.
In the USA, DuPont™ Styrofoam™ Brand Roofmate™ Extruded Polystyrene (XPS) Foam Insulation and Styrofoam™ Brand Highload 40, 60 and 100 Extruded Polystyrene Insulation have a minimum compressive strength of 40 psi.
In Canada, only Styrofoam™ Brand Highload 40 has a compressive strength of 40 psi.
Yes. Regardless of whether or not your project requires a warranty, a Pre-Job Qualification Form must be submitted to DuPont prior to job start-up. For non-warranted jobs, we will issue an approval letter to you stating that the job is not warranted. The purpose of the letter is to specify details such as the perimeter bandwidth and the number of units required for the project. This letter must be signed by the contractor and returned to DuPont for your protection.
Visit DuPont Adhesives to download a Pre-Job Qualification Foam and to learn more about DuPont™ Insta Stik™ Quik Set Commercial Adhesive.
Thermax™ facer tears can be easily repaired with LiquidArmor™ CM, QS or LT Flashing and Sealant. Depending on the extent and location of the damage, the approach may vary. When the facer damage is minimal and the facer is not significantly protruding from the foam board, LiquidArmor™ CM, QS or LT can be directly applied over the damaged facer area (coating the exposed foam area) to create a seal. If the facer has partially pulled away from the board, either cut this portion of the facer away or bend it back flush with the board surface. Then, apply LiquidArmor™ over the exposed foam board surface and any bend back facer material.
UL 1256 is the “Fire Test of Roof Deck Constructions” to decide whether a thermal barrier can be removed from a roof assembly and also measure flame spread potential. This fire test evaluates the performance of metallic and nonmetallic roof deck constructions subjected to internal (under deck) fire exposures for the purpose of determining the contribution of the roof covering material, insulation, and other components of the roofing system to the spread of fire within a building.
Being a very thin material (as compared to insulation boards), DuPont™ Weathermate™ Housewrap and DuPont™ Weathermate™ Plus Housewrap, like all other housewraps, do not contribute to the R-Value of a wall system. DuPont™ Weathermate™ Housewrap and DuPont™ Weathermate™ Plus Housewrap save energy by reducing the amount of air infiltration that occurs through the wall. This energy savings is sometimes compared to the savings generated by an insulation of appropriate R-value. But housewraps in and of themselves have essentially no R-Value.
In general, Class A rated roof assemblies can be achieved by the methods shown in the following table. An “X” in the box indicates a Class A can be achieved. As indicated in Column 1, roof assembly with ballast rock or pavers is considered a Class A. Specific approvals vary based on roof slope and membrane manufacturer. If you have a particular membrane from a particular manufacturer, you may call the membrane manufacturer directly to verify whether a particular assembly has a Class A rating.
Membrane |
Ballast rock |
Base or ply sheet |
Atlas FR10 or VersaShield |
Wood Fiber Board |
Perlite | Gypsum | Dens-Deck |
EPDM | X | X | X | X | |||
TPO | X | X | X | X | |||
PVC | X | X | X | X | X | X | |
EIP | X | X | X | X | |||
Mod Bit | X | X | X | X | X | X | |
BUR | X | X |
The recommended spray equipment for applying LiquidArmor™ CM and QS is summarized in the table below for two different spray equipment manufacturers. When larger openings require greater coverage widths, the RAC X521 is recommended.
Sprayer Model |
Tip Size |
Gun |
Hose |
Titan Speeflo 1200 SF OR Titan Impact 1140 |
519 to 521 TR2 tip 519/213 |
S-5, S-3 and LX-80 |
50’ to 100’ 3/8” hose with ¼” whip |
Graco TexSpray Mark IV OR Graco GMAX II 5900 |
XHD325 or RAC X521 |
Flex Plus Gun or standard contractor gun |
50’ to 100’ ¼” BlueMax II Airless Hose |
The primary differences spray tips as it relates to the application of LiquidArmor™ CM are the orifices’ shape and size. The first digit of the spray tip size provides an indication of the spray width to be anticipated using the tip. For example, the RAC X521 is anticipated to have a spray width almost twice that of the XHD325 at a given application distance. The second and third digits provide information about the orifice size. Accordingly, the orifice size is slightly smaller with the RAC X521 than the XHD 325 spray tip.
While selecting a suitable spray tip size is important to successfully applying LiquidArmor™ CM, other variables such as sprayer pressure, spray nozzle orientation, applicator nozzle movement speed and application distance are also help to control many of the same parameters as the spray tip size.
The White House test is a large-scale test used to determine whether a thermal barrier is needed on a roof deck below insulation material or whether an insulation material can be directly applied on the roof deck without a thermal barrier. The test involves a 20’ wide x 100’ long x 10’ tall building. A fire source simulating a small fire which rapidly accelerates into a large fire is initiated in one end of the building. Fire spread in the roofing assembly is directly evaluated under these very severe conditions. This test is the basis for FM 4450 and UL 1256.
1/7/16-adding a Review On date to replace "No Value" in order to get on monthly reporting (mrs); Yes, there is a UL Listed assembly with a 2 hour fire rating. It is BXUV - V499. It is also load bearing. This is slightly different from what might be considered a pure DuPont™ Thermax™ Wall System (TWS) in that there are additional layers of gypsum drywall added to achieve the higher fire ratings. Ratings range from 45 minutes up to two hours depending on the number of layers of gypsum board included.
The full details can be found at the UL website.
Click on "Certifications Directory" and search for "V499" in the UL File Number field.
We do not recommend the use of DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation products in applications where they will be exposed to temperatures of greater than 165°F (74°C). However, some expansion of the insulation will occur - anywhere from 1 to 5% in volume - as the product is exposed to temperatures beyond 165°F (74°C). They can also warp or distort at these higher temperatures. As the exposure temperature exceeds 200°F (93°C), the expansion of the insulation can become severe, in some cases up to 50% or more of the original volume. This expansion can be accompanied by a great deal of force, as much as 5 psi. Beyond 250°F (120°C), the insulation begins to collapse.
LiquidArmor™ CM and QS is an aqueous, rather than solvent based material. Accordingly, LiquidArmor™ CM’s and QS's Volatile Organic Compound (VOC) content is inherently low, (< 50 g/L), in compliance with California's South Coast Air District.
The typical physical properties of DuPont™ Styrofoam™ Panel Core panels are as shown in the table at the following link:
Styrofoam™ Brand Panel Core 20
The sample orientation is the same for both methods. However, the calculations are different and CAN/ULC S102 requires the Corner Wall Test CAN/ULC S127. If the flame spread ratings are greater from CAN/ULC S127, these values take precedence over the numbers from CAN/ULC S102. CAN/ULC S127 is the “Standard Corner Wall Method of Test for Flammability Characteristics of Non-Melting Building Materials”.
The damage needs to be repaired in such a way as to restore the integrity of the drainage plane. This can be done in many cases with flashing tape but the installer is free to use other methods that accomplish this goal.
Yes. DuPont™ Styrofoam™ Brand Highload products (40, 60 and 100) can be tapered in a manner similar to DuPont™ Styrofoam™ Brand Deckmate™ Plus FA Extruded Polystyrene (XPS) Foam Insulation. The fabricator may need to adjust the cutting (tapering) speed to account for the higher density of these products.
For more information, visit Highload.
FMVSS 302 stands for Federal Motor Vehicle Safety Standard test method FMVSS 302. It is a test for flammability in accordance with Motor Vehicle Safety Test Methods Section 302 of schedule D to the Motor Vehicle Safety Regulations.
DuPont™ Styrofoam™ Brand Spray Polyurethane Foam, like all other foam plastic insulation, is combustible and will need to be protected (with a piece of drywall) or removed prior to any hot work (soldering or welding) performed in close proximity. It is the responsibility of the hot work contractor to ensure that appropriate precautions are taken. After the plumbing has been installed and soldered, any foam that has been removed can be refilled and sealed with Froth-Pak™ Foam Insulation.
Great Stuff Pro™ Gasket is designed to seal best when compressed between two building elements.
The Coefficient of Linear Thermal Expansion (CLTE) is generally defined as the fractional increase in length per unit rise in temperature. The unit for CLTE is in/in.°F
Yes, DuPont™ Styrofoam™ Brand products can be used in cold storage buildings on walls, floors and roofs to provide the insulation needs.
Yes.
DuPont™ Styrofoam™ Brand Perimate™ Extruded Polystyrene Foam Insulation is a foundation insulation drainage board product made by DuPont. For more information, visit our Website.
As confirmed by updated CCMC reports, Styrofoam™ Brand exceeds the minimum thermal performance for each XPS type. Refer to the table below for the summary by product type.
Product | Type | CAN/ULC S701-11 |
Tested & Reported (CCMC Report) Long-term Thermal Resistance (LTTR) |
Deckmate™, Cladmate™, Cladmate™ XL, Panelmate™ Wallmate™ |
2 |
RSI - 1.68 |
RSI - 1.73 |
Cladmate™ CM20, Deckmate™ Plus, Deckmate™ Plus FA, STYROSPAN™, Cavitymate™, Cavitymate Ultra, Panelmate™ Ultra, PanelCore 20, STYROFOAM Ultra SL | 3 |
RSI - 1.68 |
RSI - 1.73 |
Roofmate™, Tech-Crete Blanks, Perimate™, Highload 40, 60, 100, Panelcore 30, 40, 60 | 4 |
RSI - 1.68 |
RSI - 1.8* |
* Higher compressive strength grades can have higher LTTR within the same product family. Product
unit labels will use the RSI of 1.73 for Type 4 to be consistent across all Types.
Plastic cap nails are appropriate fasteners for DuPont™ Weathermate™ Plus Housewrap. There are pneumatic nailers for plastic cap nails that make fastening fast and secure. Plastic cap nails should be spaced about 16 inches in each direction. Staples with minimum 1-inch crown may also be used when spaced about 12 inches in each direction.
Tack hammers with 1/2' crown staples may be acceptable when installing our DuPont™ Weathermate™ Plus Housewrap. However, 1' crown staples is the best practice. When ½' crown staples are used, placing more staples than the recommended 12 inch in each direction is highly recommended.
All fasteners should penetrate at least 1/2 inch into the nail base.
More information can be found here.
DuPont™ Styrofoam™ Brand products are particularly suited for metal deck applications such as DuPont™ Styrofoam™ Brand Deckmate™ Extruded Polystyrene (XPS) Foam Insulation, DuPont™ Styrofoam™ Brand Deckmate™ Plus Extruded Polystyrene (XPS) Foam Insulation and DuPont™ Styrofoam™ Brand Deckmate™ Plus FA Extruded Polystyrene (XPS) Foam Insulation. For specific project, please call your local DuPont representative for assistance.
The facers of Thermax™ insulation and Tuff-R™ Polyisocyanurate Insulation can be painted with an industrial-type latex acrylic paint. The facers must be clean and dry before applying paint. Oil-based paints can also be used.
Painting Thermax™/Tuff-R™ foil Facers:
FOIL: Treat surface and prime (optional but recommended). follow paint mfg directions for preferred surface preparation, or:
The system consists of:
DuPont™ Tyvek® Fluid Applied WB+™ - DuPont™ Tyvek® Fluid Applied weather barrier (WB+) is a vapor permeable, low VOC, single-component product with excellent elasticity and flexibility. It is easily applied in one coat and has very low shrinkage during curing.
DuPont™ Tyvek® Fluid Applied Flashing and Joint Compound+ - Is a vapor permeable elastomeric flashing product that can be applied by trowel or brush. It is used for flashing rough openings of windows and doors, treating substrate seams and voids, sealing around penetrations and as a transition between common building components. DuPont™ Tyvek® Fluid Applied Flashing and Joint Compound+ pass AAMA 714-15.
DuPont™ Sealant for Tyvek® Fluid Applied System – A low vapor permeable sealant specifically designed to work with the DuPont™ Tyvek® Fluid Applied system. DuPont™ Sealant for Tyvek® Fluid Applied System has excellent adhesion to DuPont Tyvek® Fluid Applied System products, DuPont™ StraightFlash™, DuPont™ FlexWrap™ NF, and most common building materials. It is used to seal around windows, doors, and penetrations.
DuPont™ StraightFlash™ - A premium self-adhered membrane for flashing windows and doors. It is also used to treat transitions between materials and for terminations. It is made with DuPont™ Tyvek® and a 100% butyl-based adhesive layer. DuPont™ StraightFlash™ is designed to withstand up to 9 months of UV exposure and to be utilized with DuPont™ Tyvek® Commercial air and water barriers. DuPont™ StraightFlash™ meets AAMA 711.3 material standard at the highest classification levels: Class A and Level 3 Thermal Exposure (80°C / 176°F for 7 days).
DuPont™ FlexWrap™ NF - A premium performance, extendable self-adhered flashing material that efficiently conforms around corners and irregular shapes. It is made with DuPont™ Tyvek® and a 100% butyl-based adhesive layer. DuPont™ FlexWrap™ NF is designed to withstand up to 9 months of UV exposure. DuPont™ FlexWrap™ NF meets AAMA 711.3 material standard at the highest classification levels: Class A and Level 3 Thermal Exposure (80°C / 176°F for 7 days).
Yes, Weathermate™ Straight Flashing and Flexible Flashing are both manufactured in the USA
Green Roofs contribute to a wide variety of LEED credits for New Construction. DuPont™ Styrofoam™ Brand insulation is an ideal insulation product used in green roof applications along with many other products such as filter fabric, drainage layer, water proof membrane, vegetation, growing media, etc. Green roofs with DuPont™ Styrofoam™ Brand insulation potentially contribute to the following credits based on LEED NC V2.2:
SS Credit 5.1 Site Development, protect and restore habitat
SS Credit 5.2 Site Development, maximize open space
SS Credit 6.1 Storm Water Design, quantity control
SS Credit 6.2 Storm Water Design, quality control
SS Credit 7.2 Heat Island Effect, roof
WE Credit 1.1 Water Efficiency Landscaping, reduced by 50%
WE Credit 1.2 Water Efficiency Landscaping, no portable use or no irrigation
EA Prerequisite 2 Minimum Energy Performance, required
EA Credit 1: Optimize Energy Performance (2 points mandatory for projects registered after June 27, 2007)
MR Credit 4.1 Recycle Content, 10% (post consumer + 1/2 pre-consumer).
MR Credit 4.2 Recycle Content, 20% (post consumer + 1/2 pre-consumer)
Styrofoam™ Products contain an average of 20% pre-consumer recycled content.
MR Credit 5.1 Regional Materials, 10% extracted, processed and manufactured regionally
MR Credit 5.2 Regional Materials, 20% extracted, processed and manufactured regionally
EQ Credit 7.1 Thermal Comfort, Design
ID Credit 1.1 100% green roof for exemplary performance of SS Credit 7.2
ID Credit 1.2 Green Roof account for 40% of the project site area for SS Credit 5.1
ID Credit 1.3 Green roof area doubles the requirements of SS Credit 5.2 depending on local zoning of open space requirements.
One recommended wall tie is from Heckmann Building Products Inc.
http://www.heckmannbuildingprods.com/
The POS-I-TIE is a two-piece system for attaching brick veneer to various existing backups. It incorporates a barrel-screw piece that allows easy installation using an ordinary drill with a special chuck adapter. For backups with insulation or gypsum board, the screw penetrates the insulation, screws into the backup, and then seals the hole in the insulation with a neoprene washer. The barrel makes a positive contact with the backup wall, transferring all compression and tension loads to the backup wall and not to the insulation/gypsum board. The screws are a part of the system; therefore, no inferior screws can be substituted. The barrel is manufactured of ZAMAC 2 - a 92% zinc alloy. The screws are heat treated and Stalgard (registered trademark of Acument Intellectual Properties, LLC) coated for maximum corrosion resistance. Wire ties are available in hot dip galvanized after friction or stainless steel.
LiquidArmor™ Flashing & Sealant products have been engineered to conform to complex shapes and adhere to most substrates found in construction. Applying LiquidArmor™ CM, QS or LT completely over a fastener and its washer poses no concerns nor does it necessitate any special application instructions. In fact, it is recommended that the fasteners and washers along the board joints in the Thermax™ Wall System be completely covered with LiquidArmor™ CM, QS or LT.
Styrofoam™ Brand Extruded Polystyrene Foam Insulation has been used successfully with some kinds of fiberglass reinforced plastic (FRP) compounds. However, this depends on the materials used. Check with the FRP compound manufacturer for compatibility with polystyrene-based foams.
Yes, DuPont offers both applicator and instructional training on the proper use of Tile Bond™ Roof Tile Adhesive; in addition we will be offering in the future a video showing hands on training. In certain jurisdictions, actual hands-on training of product is required. For additional information, please contact the DuPont Contact Center (DCC) at 1-833-338-7668.
Note: in the future DuPont will offer on-line training for Tile Bond™ Roof Tile Adhesive
The hourly rated DuPont™ Styrofoam Brand Extruded Polystyrene Foam Insulation roof assemblies are as shown in the table below.
The assembly is denoted as:
• P225 is the assembly number. The details of this or another particular assembly can be found in the UL online database.
• The numbers in the parentheses () are the hourly ratings. P225 (1, 1 ½) means assembly P225 can achieve a 1 hour or 1.5 hours rating depending on construction specifics.
Type of Protection | Construction Number (potential hourly ratings) |
Direct Applied Misc. | None Available |
Concealed Grid System | None Available |
Exposed Grid System | P225 (1, ½) P251 (1, 1 ½, 2) Cellular Concrete System P229 (1, 1 ½) P259 (1, 1 ½) P230 (1, 1 ½) P261 (1) Cellular Concrete System P235 (1) |
Metal Lathe Gypsum Board |
P404 (1 ½) PMR only P505 (1 ½) PMR only P513 (1 ½) cellular concrete system P507 (1 ½) PMR only P510 (1, ½) |
Spray Applied Fire Resistance Materials |
P701 (3/4, 1, 1 ½, 2) P734 (3/4, 1, 1 ½, 2) P741 (1, 1½, 2) P742 (1, 1 ½, 2) P835 (1, 1 ½, 2, 3) P811 (1 ½, 2) PMR only P714 (1, 1 ½, 2) PMR only P738 (1, 1 ½, 2) PMR only P908 (1, 1½, 2) P927 (1, 1½, 2) P942 (1, 1½, 2) P945 (1, 1½, 2) |
Uprotected | P902 (1, 1 ½, 2) cellular concrete P909 (1, 2) P912 (1 ½, 2) PMR only P904 (½, 2) P915 (2) P929 (1, 1 ½, 2) cellular concrete |
Yes. DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation products are easy to cut. Styrofoam™ Brand Extruded Polystyrene Foam Insulation Products can also be painted with water-based paints for building models of various kinds.
For product recommendations for a particular model construction project, call 1-833-338-7668.
The differences in insulation requirements for above grade wall are as follows:
Zone 1 | Zone 2 | Zone 3 | Zone 4 except Marine |
Zone 5 and Marine 4 |
Zone 6 | Zone 7 | Zone 8 | |
ASHRAE 90.1 2004 | ||||||||
Mass | NR | NR | R5.7 ci | R5.7 ci | R7.6 ci | R9.5 ci | R11.4 ci | R13.3 ci |
Metal Building | R13 | R13 | R13 | R13 | R13 | R13 | R13+ R13 |
R13+ R13 |
Metal Frame | R13 | R13 | R13 | R13 | R13+ R3.8 ci |
R13+ R3.8 ci |
R13+ R7.855 ci |
R13+ R7.55 ci |
Wood Frame & Other | R13 | R13 | R13 | R13 | R13 | R13 | R13 | R13+ R7.55 ci |
ASHRAE 90.1 2007 | ||||||||
Mass | NR | R5.7 ci | R7.6 ci | R9.5 ci | R11.4 ci | R13.3 ci | R15.2 ci | R15.2 ci |
Metal Building | R13 | R13 | R13 | R13 | R13 | R13 | R13+ R13 |
R13+ R13 |
Metal Frame | R13 | R13 | R13+ R3.8 ci |
R13+ R7.5 ci |
R13+ R7.5 ci |
R13+ R7.5 ci |
R13+ R7.5 ci |
R13+ R7.5 ci |
Wood Frame & Other | R13 | R13 | R13 | R13 | R13+ R3.8 ci |
R13+ R7.5 ci |
R13+ R7.5 ci |
R13+ R15.6 ci |
These are historically (past 60+ years) code organizations:
ICBO: International Conference of Building Officials
SBCCI: Southern Building Code Congress International
BOCA: Building Officials Code Administrators
Each of these code organizations had its own set of code documents and building requirements (though often very similar). Each tended to cover a different region of the United States. In 1995 these code organizations merged to become one code organization with one set of code documents. The new organization is the International Code Council (ICC) which publishes the International Building Code (IBC) for commercial structures and the International Residential Code (IRC) for residential structures. Most states and municipalities have adopted the new code, but some have yet to make the change.
For more information about ICC, please click the link below:
www.iccsafe.org
DuPont™ LiquidArmor™ LT Flashing and Sealant can be easily wiped off most plastic troweling tools and friction cleans without cleansers from metal tools and other objects. Dow Corning DS 1000 and DS 2025 silicone cleaners can also aid in removing DuPont™ LiquidArmor™ LT Flashing and Sealant. Note that DuPont™ LiquidArmor™ LT Flashing and Sealant will adhere well to clothing, work boots and gloves. Contaminated clothing items should be separated. DuPont™ LiquidArmor™ LT Flashing and Sealant can be a skin sensitizer and care should be taken to avoid direct skin contact.
Yes. LiquidArmor™ Flashing and Sealant products do comply with the 2009, 2012 and 2015 International Building Code (IBC), flashing material requirements under the IBC center around moisture management. In addition, some fire testing is required for flashings used in exterior walls containing foam plastics.
Product | Compressive Modulus |
Styrofoam™ Highload 40 Insulation | 1,400 psi (9,650 kPa) |
Styrofoam™ Highload 60 Insulation | 2,200 psi (15,170 kPa) |
Styrofoam™ Highload 100 Insulation | 3,700 psi (25,510 kPa) |
Yes.
All foamed plastics must pass the National Fire Protection Association (NFPA) 285 fire test for wall assemblies to be used in Type I through IV commercial construction as referenced in Chapter 26 of the International Building Code (IBC). Actual results of NFPA 285 testing on the Thermax™ Wall System combined with engineering analysis has resulted in thousands of possible configurations that meet this code requirement. This analysis was performed by the Hughes Associates.
The following spray fireproofing products have been considered and are listed as being acceptable for use with the Thermax™ Wall System and meeting the requirements of passing the NFPA 285 fire test:
All DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation products and foil faced polyisocyanurate products are ENERGY STAR Qualified. Please look for the ENERGY STAR logo on the product unit label. For more information, please visit: ENERGY STAR.
RSI stands for R-Value Système International. It is the metric equivalent of R-value and is the measure of the insulating 'power' of an insulation product. Higher numbers indicate greater insulating capabilities. To convert R-value to RSI, multiply the R-value by 0.176. To convert RSI to R-value, multiply RSI by 5.68.
RSI is primarily used in Canada. R-value is primarily used in the United States.
Yes. The propellant is flammable, so the cans must be handled as other flammable aerosol products. Only use away from flames, sparks and sources of ignition.
The products formerly known as Styrofoam™ CT and Roofmate™ CT are currently manufactured and marketed by Tech-Crete Processors Ltd. under new trade names. Roofmate™ CT is now marketed as CTI™ Roof Panel (also available with a white concrete topping - trade name SRI™ Roof Panel), and Styrofoam™ CT is now marketed as CFI™ Wall Panel. CTI™ and SRI™ Roof Panels are light weight, self-ballasted insulated panels intended for Protected Membrane Roof assemblies produced with highly efficient Styrofoam™ brand insulation and a durable concrete topped surface. CFI™ Wall Panels are insulated panels intended for use below, and above grade, against masonry, providing STYROFOAM™ brand insulation and a durable concrete facing in a one step installation.
Contact Tech-Crete Processors Ltd 250-832-9705 Tech-Crete
The following link will show you all the literature DuPont provide to support the panel market. It includes product information sheets, Safety Data Sheets, case studies and others.
Panel Literature
Visit DuPont™ Insta Stik™ Quik Set Commercial Adhesive to learn more and download literature about DuPont™ Insta Stik™ Quik Set Commercial Adhesive.
Adhesives from DuPont offer dependable, long-term service for a wide variety of applications and are compatible with most construction materials. Find a selection of DuPont adhesives here.
Manufacturers listed herein should be consulted for their recommendations as to use of their materials in the application of DuPont products.
DuPont cannot be responsible for the performance of products manufactured or marketed by others.
SureBond, Inc. - SureBond's Website
SB-400
OSI Sealants - OSI Sealant's Website
PL 200 Construction Adhesive- panel adhesive
PL 300 Construction Adhesive- foam board adhesive
PL 375 Construction Adhesive- heavy duty adhesive
H.B. Fuller Co., 315 South Hicks Road, Palatine, IL 60067
“Max Bond” Panel and Construction Adhesive
“Tan Mastic” Construction Adhesive
Miracle Adhesives Corp., 250 Pettit Avenue, Bellmore, New York 11710
Miracle MS-120
Miracle DSA-20
Tremco - Tremco's Website
Vulkem 116 (one part urethane sealant)
hSpectrum 1 (one part silicone sealant)
Schnee-Morehead, Inc. - Schnee-Morehead's Website
SM 7108 Permathane Polyurethane sealant / adhesive
Note: this is a suggested list of sealant manufacturers others may perform equally as well and are not mentioned here. Please consult manufacturer for acceptability with DuPont insulations.
No. When tested according to ASTM E84 as three ¾' beads at 5' on center, the Flame Spread and Smoke Development Indices were both 0.
For 15.75 inch wide DuPont™ Styrofoam™ Brand Cavitymate™ Ultra Extruded Polystyrene (XPS) Foam Insulation board:
Nominal Board Thickness (in) |
R-Value |
1.75 |
10.0 |
2.18 |
12.0 |
2.5 |
14.0 |
3.0 |
16.8 |
For 48 inch wide Styrofoam™ Ultra SL insulation board:
Nominal Board Thickness (in) |
R-Value |
1.75 |
10.0 |
2.125 |
12.0 |
2.5 |
14.0 |
3.0 |
16.8 |
For more information on the Ultra Air Barrier Wall System see:
The FM Class 1 rated roof assemblies for Concrete Deck for DuPont™ Styrofoam™ Brand products are:
DuPont offers two different types of insulation for interior basement wall insulation: DuPont™ Styrofoam™ Brand Wallmate™ Extruded Polystyrene (XPS) Foam Insulation and DuPont™ Thermax™ Brand Insulation. Both products provide high thermal resistance, helping create a warm, comfortable basement environment.
In US construction, both Styrofoam™ Brand Insulation, including Wallmate™, and Thermax™ insulation are code-approved for exposed interior applications, but thermal barrier, such as interior drywall is still recommended.
In Canada, construction building codes require a thermal barrier on the interior surface of any exposed plastic foam insulation, including DuPont™ Styrofoam™ Brand insulation and Thermax™ insulation.
For more information, visit Interior Basement Wall.
Window header details for the Ultra Air Barrier Wall System are available here:
Tuff-R™ Sheathing product recycle content depends on product and thickness. See table below.
Please note that the recycle content listed in table below is based on the compositional information provided to DuPont from its suppliers. DuPont relies on the suppliers to provide accurate data. DuPont is not responsible for any misrepresentation resulting from inaccurate information from its suppliers.
The Tuff-R™ product recycle content is shown as follows:
PRODUCT | THICKNESS | GLASS MAT RECYCLE % BY WEIGHT | RECYCLE % BY WEIGHT | TOTAL PRE-CONSUMER RECYCLE CONTENT |
Tuff-R™ | 0.5' | 0 | 19.4 | 19.4 |
1' | 3.28 | 14.22 | 17.5 | |
Tuff-R C™ | 1.5' | 3.28 | 12.02 | 15.3 |
2' | 2.85 | 10.55 | 13.4 |
Now known as DuPont™ Styrofoam™ Brand Ribbed Roofmate™ Extruded Polystyrene (XPS) Foam Insulation, this ribbed paver board is used in paver ballasted protected membrane roof (PMR) systems. For more information, visit our website.
For more information on the PMR concept, visit the PMR Website.
Yes. Several DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation products meet Federal Specification HH-I-524C (ASTM C578).
Federal Specification HH-I-524A was the federal standard covering both molded (expanded) and extruded polystyrene thermal insulation in 1971. It was superseded by HH-I-524B and HH-I-524C, and in 1985 the HH-I-524 series was superseded by ASTM C578: 'Standard Specification for Rigid Cellular Polystyrene Thermal Insulation.'
Canada uses the standard CAN/ULC S701 to classify polystyrene insulations. This standard is significantly different from the ASTM standard, and this results in different classifications.
For more information on which classification is met by a particular DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation product in the USA and in Canada consult our webpage.
No.
Enerfoam™ sealant is designed to fill cracks and gaps. The foam does not cure properly if it is used to fill large voids unless it is put down in layers and allowed to cure before the next layer is applied. Do not use Enerfoam™ sealant to fill enclosed voids such as behind drywall or under tub surrounds.
Click here for more information about Enerfoam™ sealant.
YES.
The International Code Council (ICC) International Building Code (IBC) defines a water-resistive barrier (or weather barrier) as:
'WATER-RESISTIVE BARRIER: A material behind an exterior wall covering that is intended to resist liquid water that has penetrated behind the exterior covering from intruding into the exterior wall assembly.'
The IBC specifies that the test method ASTM E331 'Standard Test Method for Water Penetration of Exterior Windows, Skylights, Doors, and Curtain Walls by Uniform Static Air Pressure Difference' be used to determine if a given wall assembly meets the criteria of a water-resistive barrier.
The Ultra Air Barrier Wall System has been tested using this method and has passed both with DuPont? LiquidArmor? Flashing and Sealant and Great Stuff Pro? single component foam as the sealant method for the insulation board joints.
For more information see Ultra Air Barrier Wall System
This voluntary certification program is available to installing professionals of DuPont Weatherization Systems products to help educate them and/or improve their understanding on the nuances and considerations when using our products, like Tyvek® Fluid Applied Systems products. However the installing professional of DuPont™ Tyvek® Fluid Applied Systems products no longer has to be a certified installer to obtain the 10-Year Product Replacement Limited Warranty.
Great Stuff™ cans featuring the newly launched SMART DISPENSER™ may be reused up to 30 days.
Great Stuff™ foam with the straw tube applicator will seal shut if left to sit for more than 2 hours after its last use. However, if you leave the straw assembly attached to the can and insert a pipe cleaner (soaked in WD-40) into the straw, this may allow the can to be re-used up to 30 days.
Visit Great Stuff™ for more information on Great Stuff™ products for the DIY.
Tile Bond™ Roof Tile Adhesive is a portable, one-component polyurethane foam adhesive for attaching concrete and clay roof tiles to a roof deck. With its easy-to-use, self-contained dispensing equipment, Tile Bond™ Roof Tile Adhesive can be quickly and consistently dispensed, eliminating the need for expensive equipment and problematic ratio and calibration issues typical in two-component systems. Tile Bond™ Roof Tile Adhesive is designed for use with low/flat, medium, high and two-piece barrel profiles of roof tile in new, re-roof and specialty applications when applied to a pre-approved* underlayment.
Tile Bond™ Roof Tile Adhesive is also available in a 28 oz can which is ideal for patch and repair as well for specialty applications like hip and ridge, rake and valley and field and eave installations. For the Yield of the 28 oz can it is approximately:
Yield = 825g/can x 1 pad @ 11g = 75 pads/can
Therefore at 75 pads/can x 1 tile @ 2 pads = 37.5 tiles/can
*Current pre-approved underlayments are available by calling the DuPont Contact Center (DCC) 1-833-338-7668. Please also contact the DCC for available training.
Click here for more information about Tile Bond™ Roof Tile Adhesive.
The national codes available that are related to insulation are:
LiquidArmor™ Flashing and Sealant is used in multiple applications and is listed within multiple Guide Specifications. The link below will take you to our document library for the available Guide Specifications:
Hand lay-up is also called contact molding. It is a production technique suitable for prototypes and low volume production of fiber composite material parts.
The fibers are manually placed into a one-sided gel coated male or female mold. A matrix of thermo-setting resin is rolled onto the fibers using a hand roller. More layers can be added and, after drying, the composite part can be removed from the mold.
This technique is easy to control fibers orientation. Furthermore, the process is very flexible as it can produce from very small, up to very large parts of different kinds of geometry. The cycle time per part is very long, and only small series can be produced.
The fastener pattern for the Thermax™ Brand Insulation used in the Thermax™ Wall System was determined using engineering analysis and verified using the ASTM E330 wind load testing. This testing resulted in the assembly passing wind loading criteria (10-second loading period) of 50 psf when subjected to negative wind loading and 75 psf when subjected to positive wind loading. (Note: 50 psf is approximately 141 mph wind velocity under ideal conditions.)
To represent a wall system with the least strength, testing was conducted with 5/8" thick Thermax™ Brand Insulation only - and without any joint treatment, Styrofoam™ Brand SPF (CM Series) in the stud cavity or any bracing of the studs. Testing was conducted on Thermax™ Brand Insulation alone as this is the first product to go on the wall, and applying the flashing tape over joints and behind penetrations as well as spray foam in the stud cavity may not immediately occur. In the wind load test, 5/8" thick Thermax™ Brand Insulation was attached to 18 gauge steel studs using several different fastening schedules, and also at 16" and 24" o.c. stud spacings.
The goal of this testing was to determine the most robust fastening schedule that could be used to adhere Thermax™ Brand Insulation independent of the product thickness and stud spacing.
Fastening Thermax™ Brand Insulation
As a result of the American Society for Testing Materials (ASTM) E330 testing, DuPont recommends a fastening pattern of 12" o.c. around the perimeter and 16" o.c. in the field. Perimeter fasteners can be detailed to bridge the gap of abutting board joints due to the 1.75" diameter of the washer used to fasten the board to the studs. This detail can be used to bridge a maximum of two board joints, thus two fasteners should be used at the intersection of three or four boards.
Recommended Fasteners
The TRUFAST® Walls (formerly Rodenhouse Inc.) Thermal-Grip® ci Prong Washer with the Grip-Deck® Self-drilling screws are the current recommended fastener to be used.
To learn more about these fasteners, please call (616) 454-3100 or click here.
Styrofoam™ Brand BLUEGUARD™ Insulation is a termite-resistant extruded polystyrene foam insulation, formerly manufactured and sold by DuPont, that was specifically designed for insulating foundations in areas with termite activity.
When the steel stud is abutted against the bottom of the structural I-Beam, the area above the I-Beam becomes inaccessible to the spray foam.
There are three issues to address here.
XPS or XEPS are abbreviations for Extruded Polystyrene Insulation.
The recommended DuPont products for PMR application are:
For details about these products, please visit:
https://www.dupont.com/products/styrofoam-brand-roofmate.html
https://www.dupont.com/products/styrofoam-brand-plazamate.html
The effective system R-Value for the Thermax™ Wall System will depend upon the thickness of DuPont™ Thermax™ (ci) Exterior Foam Insulation, the thickness of the DuPont™ Styrofoam™ Brand SPF (up to 1.5 inches) and, to a much smaller extent, the type of veneer. The table below outlines the effective system R-values for various thickness of Thermax™ Exterior Foam Insulation with a veneer of stucco.
The CM Series spray polyurethane foam insulation R-value is adversely affected by the steel stud thermal shorts in the same manner as the typically installed glass fiber insulation. The DuPont™ Thermax™ Wall System (TWS) calls for the installation of 1.5 inches of spray foam between the steel studs. By itself, the spray foam would have an R-value of 1.5 x 6.4 (2045) = 9.6. There is also an air space left over between the studs, and this contributes about one additional R so the total between the studs is about 10.6. As mentioned earlier, this R-value will be compromised by the steel studs, reducing it by about 50% to an overall effective R-Value of 5.3 at 16' stud spacing.
Thickness of Thermax™ (ci) (in) |
Effective R-Value (hr ft²°F/BTU) |
U Factor (BTU/hr ft²°F) |
0.625 | 10.8 | 0.0924 |
1.0 | 13.2 | 0.0756 |
1.55 | 16.8 | 0.0595 |
2.0 | 19.7 | 0.0507 |
Replacing the stucco veneer with a brick rain screen veneer will increase each R-Value by about 1.7 Rs (assuming an R of 1.0 for the non-reflective air space and 0.7 for the brick veneer minus the stucco). Terra cotta, metal panel and fiber cement siding veneers will probably not appreciably increase the R-Value of the system.
Generally speaking, XPS (Extruded Polystyrene Insulation) has much better moisture and moisture vapor resistance, higher thermal resistance (R-value) and higher strength. EPS insulation is not appropriate to be used in a wet environment such as Upside-Down roof application, geotechnical application and other applications where moisture is a concern. In this type of environment, XPS insulation should be used instead.
ASTM C1289, titled “Standard Specification for Faced Rigid Cellular Polyisocyanurate Thermal Insulation Board” includes the following test methods:
ASTM | C518 | Standard Test Method for Steady State Thermal Transmission (R-Value) |
ASTM | D1621 | Standard Test Method for Compressive Properties of Rigid Cellular Plastics (compressive strength) |
ASTM | D1622 | Standard Test Method for Apparent Density of Rigid Cellular Plastics (density) |
ASTM |
E96 | Standard Test Method for Water Vapor Transmission of Materials (perm) |
ASTM | C209 | Standard Test Method for Water Absorption of Cellulosic Fiber Insulation Board (Use for ISO: 2 hour water immersion test) |
ASTM | D2126 | Standard Test Method for Response of Rigid Cellular Plastics to Thermal and Humid Aging |
ASTM | C203 | Standard Test Methods for Breaking Load and Flexural Properties of Block Type Insulation |
No. The Ultra Air Barrier Wall System consists of 15 ¾ inch wide DuPont™ Styrofoam™ Brand Cavitymate™ Ultra Extruded Polystyrene (XPS) Foam Insulation installed between the wall ties. The wall ties that connect the block and brick walls together have been found to interfere with the proper sealing of the flashing tape over the board joints. We have found it impossible to create an adequate air seal in this configuration. Great Stuff Pro™ single component foam must be used.
For more information see Ultra Air Barrier Wall System
DuPont lends support to Habitat for Humanity in many ways, including funding, donations of DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation, public visibility for Habitat for Humanity programs, and employee volunteer work crews at projects around the world.
DuPont is the official supplier of Styrofoam™ Brand Extruded Polystyrene Foam Insulation for all projects in North America. DuPont's donation of products, such as Styrofoam™ Brand Extruded Polystyrene Foam Insulation and Weathermate™ Housewrap, gives new homeowners the opportunity to reduce their natural gas consumption and provides overall reductions in electricity consumption. Homeowners can enjoy a more comfortable living space and lower utility bills.
For more information, visit our website.
DuPont™ Styrofoam™ Brand products are easy to fabricate/cut with utility knives. Some Styrofoam™ Brand products can also be hot wired, sawed and routed into shapes if needed. Depending on a particular application, please feel free to discuss your needs with one of DuPont's professionals.
Yes. Thermax™ White Finish Polyisocyanurate Insulation can be pressure-washed @ 1000 psi and at a distance from the board of 3', using a 15 degree nozzle.
For more information, visit our website.
Yes. A very careful and talented installer might be able to install the Great Stuff Pro™ single component foam in a three-inch thickness board joint gap in such a way as to be very hard to see from a distance. But in practice this is very hard to do. Proper installation practice calls for the orange Great Stuff Pro™ single component foam to be visible after installation.
For more information on the Ultra Air Barrier Wall System see:
Adhesives from DuPont offer dependable, long-term service for a wide variety of applications and are compatible with most construction materials. For more information, visit our website. The following adhesive manufacturers may also recommend an appropriate adhesive for your application. In all cases, check the adhesive container or with the manufacturer to determine if a particular adhesive is compatible with polystyrene-based insulations. This list is not intended to be exhaustive.
PL 300 or PL Premium Ohio Sealants, Inc. Mentor, OH 800-321-3578 |
DAP Beats The Nail Inviroline DAP, Inc. Baltimore, MD 800-534-3840 |
Sonneborn 200 ChemRex, Inc. Shakopee, MN 800-243-6739 |
QB-300 Ohio Sealants, Inc. Mentor, OH 800-321-3578 |
Enerbond™ Professional |
Great Stuff Pro™ |
DURAPRO AC 0054 |
Loctite PL300 Loctite® Brand - Consumer Products Henkel Corporation 26235 First Street Westlake Ohio 44145 |
Cradle-to-Cradle Certification analyzes and verifies manufacturers' products for human health, environmental health and recyclability. These criteria are based on the principles of Cradle to Cradle design developed by architect William McDonough and chemist Dr. Michael Braungart. Their firm, McDonough Braungart Design Chemistry (MBDC), assesses products for their ingredients and manufacturing processes and serves as an important external reviewer.
Performance Building Solutions has completed a rigorous, external assessment of its building insulation products conducted by MBDC (McDonough Braungart Design Chemistry, LLC), a global sustainability consulting and product certification firm DuPont™ Styrofoam™ Brand Extruded Polystyrene (XPS) Foam Insulation, DuPont™ Thermax™ (ci) Exterior Insulation and DuPont™ Styrofoam™ Brand Spray Polyurethane Foam (SPF) Insulation, have all achieved Cradle to Cradle® Certification , a process that assesses products for their ingredients' human health, environmental health and recyclability profiles.
The two basic differences between Thermax™ insulation products and other DuPont polyisocyanurate insulation products are:
1) The maximum use temperature for Thermax™ insulation products is 250°F. The maximum use temperature for other DuPont polyisocyanurate insulation products is 190°F.
2) The unique materials and manufacturing process for Thermax™ insulation products give them increased fire resistance properties, allowing them to be installed on the interior of a building without a thermal barrier.
3) Thermax™ also has multiple facer configurations - see FAQ #91.
For additional information about these products: Polyisocyanurate Insulation
DuPont offers several board joint treatment options when installing Thermax™ White Finish Polyisocyanurate Insulation, including standard white-coated aluminum foil tape, ship lapped edges (board thickness must be greater than 1.5' to achieve proper lip edges), PVC clip strip, PVC J-channel and PVC interlocking system. In roof systems where the temperature of the roof exceeds 150°F, it is recommended to use two layers of Thermax™. First (closest to roof panel) should be Thermax™ Sheathing. Then (exposed to interior) would be Thermax™ White Finish Insulation. Board joints should be staggered between the layers. Use of white tape or the Clip Strip will provide the ideal look and finish.
The board joints should be cleaned (via wiping and drying) prior to installing white tape, and a stiff bristle brush should be applied to bond tape to embossed surface of Thermax™ White Finish Polyisocyanurate Insulation.
NOTE: if using Thermax™ on concrete wall or Tilt Up wall a good construction practice is to apply 3 beads (3/8 inch bead) of sealant or caulking behind the boards (top - middle - bottom) to prevent moisture migration occurring behind the boards.
For more information, visit our website.
The Volatile Organic Compound (VOC) content and regulatory status of the following Great Stuff Pro™ and Enerfoam™ products (size: 20 oz or greater) were determined according to the California Air Resource Board (CARB), the South Coast Air Quality Management Districts (SCAQMD) Rule 1168, and the Ozone Transport Commission (OTC) Model Rule for Adhesives and Sealants.
Insulating Foam Sealants:
Great Stuff Pro™ Window & Door Polyurethane Foam Sealant 12-14 wt % (~125-150 g/L) VOC - exempt from CARB and OTC; compliant for SCAQMD
Great Stuff Pro™ Gaps & Cracks Polyurethane Foam Sealant 12-14 wt % (~125-150 g/L) VOC - exempt from CARB and OTC; compliant for SCAQMD
Great Stuff Pro™ Pestblock Polyurethane Foam Sealant 12-14 wt % (~125-150 g/L) VOC - exempt from CARB and OTC; compliant for SCAQMD
Enerfoam™ ENER43 RV BL HC Foam Sealant - 15 wt % (160 g/L) VOC - compliant
Enerfoam™ HC Foam Sealant - 15 wt % (160 g/L) VOC - compliant except for the South Coast and Ventura Air District of California (if the ENERFOAM™ label claims adhesive properties which cause it to have to meet adhesive VOC limits)
ADHESIVES:
Enerbond™ ENER45 SF Polyurethane Foam Adhesive - 13 wt% (142 g/L) VOC - compliant except for the South Coast and Ventura Air District of California
Enerbond™ ENER47 MF Polyurethane Foam Adhesive - 13 wt% (142 g/L) VOC - compliant except for the South Coast and Ventura Air District of California
Great Stuff Pro™ Construction Adhesive - 13 wt % (142 g/L) VOC - compliant except for the South Coast and Ventura Air District of California
DuPont™ Insta Stik™ Quik Set Commercial Adhesive - 0 wt % (0 g/l) VOC - compliant
Tile Bond™ Roof Tile Adhesive (tank or aerosol) - 0 wt % (0g/l) VOC - compliant
Great Stuff™ Foam Cleaner - 10 wt % VOC (51 g/L) - compliant (acetone is exempt)
All the above values are calculated values.
Both. DuPont™ engineered the DuPont™ Tyvek® Fluid Applied Flashing and Joint Compound+ to meet the needs of the commercial market by offering dual functionality.
DuPont™ Tyvek® Fluid Applied Flashing and Joint Compound+ offers dual functionality: it is ideal for projects that require both a flashing material (especially for window openings with complex geometries) and a joint compound that performs well on sheathing seams, penetrations, or other discontinuities in the wall.
Yes. Standard DuPont™ Styrofoam™ Brand Square Edge Foam Insulation (U.S.) and DuPont™ Styrofoam™ Brand SM (Canada) Extruded Polystyrene Foam Insulation can be installed with Z-furring strips. In the United States, DuPont™ Styrofoam™ Brand Z-MATE™ Extruded Polystyrene Foam Insulation is also made specifically for use with Z-furring strips.
Although Z-furring strips are effective for fastening DuPont™ Styrofoam™ Brand extruded polystyrene insulation to walls, the metal strips constitute a significant thermal bridge. To reduce this effect surface mounted furring systems like DuPont™ Styrofoam™ Brand Wallmate™ Extruded Polystyrene (XPS) Foam Insulation are recommended.
Caulks are mastic type compounds which are non-elastomeric materials used for filling small joints (1/4” / 6 mm or less) where little or no movement is expected. 'Caulk' refers to material with little flexibility and joint movement capability as opposed to sealants.
DuPont™ Tyvek® Fluid Applied WB+™ must be cured for a minimum of 48 hours prior to the installation of the exterior facade.
Yes. The following table outlines the conditions under which these Thermax™ Brand products can be power washed.
Allowable Spray Pressure, psi (MPa) | Thermax™ White Finish | Thermax™ Light Duty | Thermax™ Heavy Duty | |
1000 (6.9) | Any spray tip greater than 15 degrees, 3 feet minimum distance from the surface | Any spray tip greater than 15 degrees, 3 feet minimum distance from the surface | Any spray tip 15 degrees, 3 feet minimum distance from the surface | |
2000 (13.8) | Not Allowed | Not Allowed | Any spray tip greater than 15 degrees, 3 feet minimum distance from the surface | |
Caution: Prolonged spray at board joints will cause facer to become disbonded from the insulation board. Always point nozzle perpendicular to board surface no closer than the minimum distance. |
Great Stuff™ foam does not contain materials that contribute to the depletion of ozone.
Visit Great Stuff™ for more information on products for the DIY.
The R-Value for most of DuPont's Polyisocyanurate Insulation products, including Thermax™ Brand Insulation and Tuff-R™ (ci) Polyisocyanurate Foam Insulation, is 6.5 at 1 inch.
Thermax™ Products tested at 75F per ASTM C518 (°F· ft2· h/ BTU) |
Tuff-R™ Products tested at 75F per ASTM C518 (°F· ft2· h/ BTU) |
|||
Thickness(in) | Posted R-Value | Thickness(in) | Posted R-Value | |
0.50" |
3.3 |
0.5 |
3.3 |
|
0.75" |
4.9 |
0.75 |
4.9 |
|
1.00" |
6.5 |
1 |
6.5 |
|
0.50" |
3.3 |
1.25 |
8.2 |
|
0.75" |
4.9 |
1.5 |
9.8 |
|
1.00" | 6.5 | 1.55 | 10.1 | |
1.25" | 8.2 | 1.75 | 11.4 | |
1.50" | 9.8 | |||
1.55" | 10.1 | 2 | 13 | |
1.75" | 11.4 | |||
2.00" | 13.0 | |||
2.25" | 13.8 | |||
2.50" | 15.3 | |||
2.75" | 16.9 | |||
3.00" | 18.4 | |||
3.20" | 19.6 | |||
3.50" | 21.5 | |||
3.75" | 23.0 | |||
4.00" | 24.5 | |||
4.25" | 26 |
Call the DuPont Contact Center (DCC) at 1-866-583-2583 for additional information
Polyurethane foams are very sensitive to UV light. Exposure to UV light (even indirect sunlight) will cause the foam to darken to an orange or reddish color in a matter of days or weeks. Constant exposure to direct sunlight will eventually cause the foam to break down and crumble. The foam must be painted or coated with UV-resistant coating if used outdoors.
Froth-Pak™ foam may be used to fill cavities in trees. As with all outside applications, the foam should be coated to protect it from UV and water exposure.
Click here for more information about Froth-Pak™ sealant products.
Moisture permeating from the interior of a building into a roof system poses a potential condensation problem in winter conditions. The best way to manage roof moisture is to design the roof system in a way to be inherently moisture resistant. The Protected Membrane Roof (PMR) system is such a roof system.
Different considerations for condensation control may be required for low-temperature storage application such as freezer and coolers.
For more information about PMR systems, visit our webpage.
Since local regulations vary, it is best to contact your local waste disposal facility to inquire about disposal of pressurized aerosol cans. DuPont manufacturing facilities are typically not licensed to receive hazardous waste and therefore cannot take back used canisters. If you have additional questions, call our DuPont Contact Center (DCC) at 1-833-338-7668.
Click here for more information about Froth-Pak™ sealant products.
No, Froth-Pak™ Brand Polyurethane Spray Foam does not contain any formaldehyde.
Specifically, while we have not analyzed for formaldehyde, it is not an intended raw material nor is it known to be present in our Froth-Pak™ products.
This determination is based on the composition information provided to DuPont by its suppliers. DuPont relies on its suppliers to provide accurate data.
DuPont does not routinely analyze for additional materials that are not listed in the MSDS or Sales Specification.
DuPont is not responsible for any misrepresentation resulting from inaccurate information from its suppliers.
Since formaldehyde is typically present and commonly found in the environment, any formaldehyde in the fully cured foam would be consistent with background levels commonly found in the environment.
Froth-Pak™ is commonly used in this application to fill a void under a pool or spa to stop flexing, provide structural support, insulate and reduce vibration. However, installers should be aware that the foam will expand 3 to 5 times and will exert a lot of pressure on the pool or spa. Use a brace to secure the pool/spa or fill the pool/spa with water to add weight to keep the pool/spa in place when foaming. It is always recommended to check with the local building code official to confirm the use of Froth-Pak? in these applications.
Click here for more information about Froth-Pak™ sealant products.
Although the easiest and fastest application is through spray, LiquidArmor™ CM and QS can be brush applied to achieve the equivalent air and water barrier performance as long as the wet film thickness and application width complies with DuPont’s recommendations.
Can DuPont™ Insta Stik™ Quik Set Commercial Adhesive be used on roof decks greater than 2:12 slope?
For slopes greater than 2:12, please contact the DuPont Contact Center (DCC) at 1-833-338-7668 for application instructions.
Visit DuPont™ Insta Stik™ Quik Set Commercial Adhesive to learn more and download literature about DuPont™ Insta Stik™ Quik Set Commercial Adhesive.
LiquidArmor™ CM, QS and LT are all uniquely formulated to provide specific flashing efficiency options for installers. All three products offer installers the ability to flash and seal complicated geometries with ease. LiquidArmor™ CM and QS are water-based, sprayable acrylic flashings that enables the flashing to be applied at rapid rates and cleaned up quickly with water.
The ASTM E119 test 'Standard Test Methods for Fire Tests of Building Construction and Materials' determines hourly ratings for a building assembly. The test methods are applicable to load-bearing and other walls and partitions, columns, girders, beams, slabs, roofs, and floors. This test measures the time it takes for heat to move through the assembly from the fire-exposed side to the unexposed side. The basis for the rating is the time it takes for the temperature on the non-fire exposed side to increase by 250°F. If it takes an hour for this temperature rise to occur, then a one-hour rating is granted, etc.
Yes. Many vinyl siding manufacturers have given specific approval for the use of DuPont’s foil-faced polyisocyanurate insulation products behind their products. If you are unsure, check with the specific vinyl siding manufacturer.
FM 4450 (Approval Standard for Class 1 Insulated Steel Roof Decks) is a test conducted on roof deck constructions to a standard internal (under-deck) fire exposure. The results depend on the flame spread potential of a roof covering assembly by measuring its heat release potential. Due to the nature of this test, a burn-through of the roof assembly is not allowed. If it is a burn-through, the potential heat release cannot be measured. Thus, the test assembly does not meet the requirements. To meet the requirements of this standard, the insulated steel roof deck must meet the following requirements:
Test | Performance Requirement |
Internal fire resistance | Pass calorimeter test |
Wind resistance | Resist 60 psf wind uplift load (minimum) |
Foot traffic resistance | Pass |
Corrosion of steel fasteners | Pass |
Impact resistance of plastic fasteners/plates | Pass |
Susceptibility to heat damage of cellular plastic insulation | Pass |
LiquidArmor™ Flashing and Sealant products should not be 'cut' or diluted with water. LiquidArmor™ CM, QS and LT have all been formulated to achieve optimal performance. All product testing was conducted using LiquidArmor™ Flashing and Sealant products as they are currently sold. DuPont cannot guarantee the same product performance to what was tested and claimed in literature, if water or other substances are added to LiquidArmor™ Flashing and Sealant products to alter their viscosity.
DuPont™ Styrofoam™ Brand RECOVERMATE CR Extruded Polystyrene Foam Insulation is recommended for conventional roof recovery applications. If the building owner wants to add insulation during roofing recovery, Styrofoam™ Brand Deckmate™ Extruded Polystyrene Foam Insulation products can be used.
For details about these products and roof recover applications, please visit:
http://building.dow.com/na/en/applications/building/rca/recover.htm
Styrofoam™ Brand RECOVERMATE CR
http://building.dow.com/na/en/products/insulation/recovermatecr.htm
Hundreds of distributors across sell DuPont™ Weathermate™ Housewrap.
Call 1-833-338-7668 for information about distributors near you.
No. DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation products are designed for insulation purposes and are not intended to support the high loads imposed by a brick veneer facade.
Depending on veneer facing loads Styrofoam™ Brand LT Load Bearing Blocks could possibly be used. Contact the DuPont Contact Center (DCC) for more information at 1-833-338-7668.
There are many different metal panel manufacturers and even more fabricators that cut panels and provide the attachment method. There are simply too many different attachment methods from these various fabricators for DuPont to be able to provide these details in a meaningful way.
DuPont has partnered with Knight Wall Systems to provide one possible design system to incorporate the continuous insulation of the DuPont™ Thermax™ Wall System (TWS) with the beauty and durability of a metal panel rain screen. A wide variety of finishes in addition to metal panels are available from Knight Wall Systems.
Other metal panel manufacturers and fabricators can provide details regarding the use of their products and attachment systems.
LiquidArmor™ LT Flashing and Sealant is a silicone-based product, and only silicone sealants will adhere to it. When sealing windows after LiquidArmor™ LT, only silicone sealants should be used, and not self-adhered flashing tapes. It is important to use compatible silicone sealants and ensure the LiquidArmor™ LT is fully cured before applying additional sealants around windows. Similarly, LiquidArmor™ LT can affect the cure process of some sealants, such as Dow Corning 790. Proper cure time must be allowed when installing over existing sealants.
A 15-minute thermal barrier is a phrase used to describe a material of a given thickness that can withstand 15 minutes of exposure to a fire source generated by the ASTM E119 fire test specification. A 1/2 inch thickness of gypsum drywall is an accepted 15-minute thermal barrier.
LiquidArmor™ CM and QS can be washed off or wiped off with water very quickly while it is still liquid. If dried on surfaces such as metal or glass, excess product can be scrapped off unintended surfaces. If LiquidArmor™ CM and QS gets on clothing or fabric, wash with water immediately, or it could stain like "paint".
R-Value refers to a material’s thermal resistance, or how well it is able to retard heat flow. The R-Value indicates the ability of a material to 'resist' the flow of heat. The higher the R-Value, the better its performance as an insulator. U.S units expressed in hr sq ft deg F/BTU. SI units expressed in m2 degC/W.
R-Value is the reciprocal or inverse of conductivity or conductance.
1/R = c (conductance)
1/R per inch = k (conductivity)
R-Value is important because it describes the ability at resisting heat flow of a given insulation product. Higher R-Value products will better resist heat flow, saving the building owner or occupants energy and as a result, money. Higher insulation value products save more money and are worth more in the long run.
R-Value works both in the winter to save heating costs and in the summer to save air conditioning costs.
There are no requirements for flame spread rating for residential construction. For commercial construction, the flame spread rating should be less than 500 according to CAN/ULC S102.2 (for thermal plastic materials) or CAN/ULC S102 (for thermoset materials).
2015 IRC R602.10 defines wall bracing with DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation. The prescriptive approach (R602.10 and Table R602.10.1) defines the length and position of braced wall sections based on:
Intermittent Bracing Method Chart
Continuous Bracing Method Chart
For SI: 1 inch = 25.4 mm, 1 foot = 304.8 mm, 1 degree = 0.0175 rad, 1 pound per square foot = 47.8 N/m², 1 mile per hour = 0.447 m/s.
A.) Adhesive attachment of wall sheathing, including Method GB, shall not be permitted in Seismic Design Categories C, D°, D¹ and D².
B.) Applies to panels next to garage door opening when supporting gable end wall or roof load only. Shall only be used on one wall of the garage. In Seismic Design Categories D°, D¹ and D², roof covering dead load shall not exceed 3 psf.
C.) Garage openings adjacent to a Method CS-G panel shall be provided with a header in accordance with Table R602.5(1). A full height clear opening shall not be permitted adjacent to a Method CS-G panel.
D.) Method CS-SFB does not apply in Seismic Design Categories D°, D¹ and D².
E.) Method applies to detached one and two-family dwellings in Seismic Design Categories D° through D² only.
Yes. WUFI is a complex vapor drive / moisture absorption computer modeling program developed by the Oak Ridge National Laboratory (ORNL) and the Fraunhofer Institute for Building Physics (IBS). The DuPont™ Thermax™ Wall System (TWS) was investigated in several climate zones and was found to exhibit the same fundamental condensation resistance that was seen in the simpler dew point analysis.
The can may be left attached to the blue Great Stuff Pro™ Dispensing Gun for up to 90 days. Close the adjustment dial and store up-right where the can will not be punctured. To restart, shake vigorously for 60 seconds, dispense a small amount of foam into a trash can until normal bead expansion is observed. Proceed with normal application
The FM Class 1 rated roof assemblies for Concrete Deck recovering application for STYROFOAM™ Brand Extruded Polystyrene Foam Insulation products are:
FM Class 1 rated roof assemblies for Metal Deck recovering application for STYROFOAM™ Brand Extruded Polystyrene Foam Insulation products are also possible.
For more information on specific wind ratings associated with specific roof assembly components consult Factory Mutual's RoofNav site.
A roofing assembly with Factory Mutual (FM) Class 1 approval has met FM Global’s requirements for durability, wind and fire resistance without the use of sprinkler protection. These requirements are described in FM 4450 'Approval Standard for Class 1 Insulated Steel Roof Decks' and FM 4470 “Approval Standard for Class 1 Roof Covers'.
Yes.
4' limestone veneer installed in a manner similar to 4' brick veneer is acceptable.
No. This product is an air sealant and functions best when compressed as a gasket.
All of the different grades of Styrofoam™ Brand Extruded Polystyrene Foam Insulation have a buoyancy factor very close to 60 pounds/cubic foot. This means that a one cubic foot block of Styrofoam™ Brand XPS Foam Insulation could just barely float a 60 pound load. A one foot by one foot by four inch block, for example, of Styrofoam™ Brand XPS Foam Insulation (one third of a cubic foot) could just barely float a 20 pound load. For buoyancy design projects, DuPont recommends using the 60 pounds/cubic foot buoyancy factor along with a safety factor appropriate to the application.
Yes, DuPont™ Styrofoam™ Brand insulation products can be used in pitched roof applications or steep slope roof applications. In this type of applications, like any other type of insulation products used, Styrofoam™ insulation should be secured on the roof during construction so it does not slide down the roof to cause safety incidents.
Yes.
DuPont™ Styrofoam™ Brand Buoyancy Billets are made to be used in flotation or buoyancy applications.
For more information, visit our website.
Spray polyurethane insulation products from DuPont can potentially contribute to the following categories of LEED v4 points:
Please feel free to call 1-833-338-7668 when you need additional LEED information for Styrofoam™ Extruded Polystyrene Insulation products from DuPont for a particular LEED certified/designed job.
Taping of the seams is a best practice in the installation guidelines, but it is only required to achieve an air barrier. Additionally, an overlap of 6 inches on vertical seams and 2 inches on horizontal seams in a shingle fashion is required.
Factory Mutual (FM) Global is one of the world's largest commercial and industrial property insurance and risk management organizations specializing in property protection. Many DuPont products have been tested at Factory Mutual to establish flame spread and assembly ratings. This information is important for architects/owners who design/own buildings which will be Factory Mutual insured. Often this information is used to show that a particular product complies with specification requirements.
For more information about FM Global, please visit the FM Global Home Page
The total post-industrial recycled content for Thermax™ polyisocyanurate insulation is 10% to 29% depending on which Thermax™ product is being selected.
Yes.
This meets the U.S. EPA minimum recovered materials content of 9%.
There are many possible roof-wall juncture configurations, so it would be impossible to offer details or specific instructions. Instead, here are guidelines to follow in designing the roof wall juncture.
1. Wrap the roof membrane over the parapet and tie it onto the surface or behind the DuPont™ Thermax™ (ci) Exterior Foam Insulation to form a continuous water barrier across the juncture.
2. Wrap the Thermax™ ci Insulation over as much of the parapet as possible to create a continuous thermal layer at the juncture.
3. Consider using a spray foam like Froth-Pak™ Foam Insulation to ensure a continuous air barrier at the juncture. Froth-Pak™ Foam Insulation can be sprayed up to 2 inches thick and 6 inches in height for an unlimited length and can be left exposed as per NFPA 286 testing.
DuPont residential product offering has the potential to contribute to the following NAHB Green guideline credits. NAHB Research Center has the final authority to determine the eligibility of a particular point.
|
DuPont Products Points Potential
|
Lot Design, Preparation and Development
|
0 |
Resource Efficiency |
48 |
Energy Efficiency |
Performance: 37-100 |
Water Efficiency |
0 |
Indor Environmental Quality |
9
|
Operation, Maintenance and Home Owner Education | 0 |
Global Impact | 5 |
Additional 100 points from Sections of Your Choice | vary |
Total Point Potential | 99-162 |
Weathermate™ Housewrap is 6 mils thick and Weathermate™ Plus Housewrap is 18 mils thick.
For more information please visit:
Styrofoam™ Brand Extruded Polystyrene Foam Insulation is typically packaged in 4' x 8' units that are 96' tall. This constitutes 256 cubic feet of insulation. A truck typically carries 12 such units. One truck carries 3,068 cubic feet of foam plastic insulation or 36,816 board feet. This can vary slightly with some products.
In Eastern Canada, there can be either 22 (33,792 bf) or 24 (36,864 bf) 4' x 4' units. In Western Canada, there can be either 11 or 12 4' x 8' units.
For detailed information about a particular product order, call:
1-800-232-2436 (English)
1-800-565-1255 (French)
In North America, Exterior Insulation Finishing Systems (EIFS) are developed and sold by a variety of manufacturers. The manufacturers themselves are responsible for their own systems and for the appropriateness of the materials used. Thus, each manufacturer (not DuPont) must determine if Styrofoam™ Brand Extruded Polystyrene Foam Insulation is appropriate for the systems they sell.
One EIFS Manufacturer has a system which specifically use Styrofoam™ Brand Insulation as the insulation component. You can find more information on this system at the manufacturer's web site:
Beyond this specific system, there are two kinds of EIFS: Hard Coat (PM) and Soft Coat (PB). Styrofoam™ Brand Extruded Polystyrene Foam Insulation tends to be used in Hard Coat (PM) type systems. Some selected EIFS manufacturers include:
In Canada:
Yes.
Froth-Pak™ Foam Sealant is perfect for sealing up drafty barns or poultry houses, ideally you can add 1 inch of Froth-Pak™ Foam Sealant and compared to a non-insulated poultry house can save up to 4 x the amount of propane used (test performed in actual facility in AL and documented by Auburn University).
For larger projects like 3 or 4 poultry houses DuPont suggests using the refill systems - easy to use and when you're done DuPont picks up the tanks. For more information please visit our website for more information.
The ASTM C1289 classifications for DuPont polyisocyanurate products are as shown below:
ASTM C1289 Types | Products |
Type I, Class I | Tuff-R™, Super Tuff-R™ |
Type I, Class 2 | Tuff-R™ Commercial Super Tuff-R™ Commercial |
Type I, Class 2 | Thermax™ |
Type I, Class 2 | Thermax™ ci Exterior Insulation |
Type I, Class 2 | Thermax™ Heavy Duty Insulation Commercial |
Type I, Class 2 | Thermax™ Light Duty Insulation Commercial |
Type I, Class 2 | ThermaxXARMOR™ Insulation |
Type I, Class 2 | Thermax™ Metal Building Board |
Type I, Class 2 | Tuff-R™ ci Insulation |
Type I, Class 2 | Thermax™ White Finish Insulation |
Yes, DuPont™ Styrofoam™ Brand Extruded Polystyrene (XPS) Foam Insulation can be used between the wood studs in a house, but it is not the most efficient way to use Styrofoam™ Brand XPS Foam Insulation for two reasons:
It is recommended that Styrofoam™ Brand XPS Foam Insulation be used over studs to create a continuous insulation sheathing to save energy and provide comfort for the home/building.
Isocast™ R polyisocyanurate insulation product has recycle content on glass matte and aluminum facers. The recycle content depends on product and thickness. See table below.
Please note that the recycle content listed in table below is based on the compositional information provided to DuPont from its suppliers. DuPont relies on the suppliers to provide accurate data. DuPont is not responsible for any misrepresentation resulting from inaccurate information from its suppliers.
The Isocast™ R product recycle content is shown as follows:
Product | Thickness | Total Pre-consumer Recycle Content % (up to) |
Isocast™ R | 1' | 14.6 |
Isocast™ R | 2' | 12.4 |
These are previously three Model Building Codes:
UBC - ICBO’s Uniform Building Code
SBC - SBCCI’s Standard Building Code
BNBC - BOCA’s National Building Code
These codes have been merged into the International Code Council’s (ICC) International Building Code (IBC) and International Residential Code (IRC). For more information about ICC, please click the link below:
http://www.iccsafe.org/
That depends on the substrate:
Note: Additional fasteners will be needed to install the Flex-Tite product.
DuPont™ Weathermate™ Housewrap is not regulated for transportation.
The purpose of the fasteners that attach the DuPont™ Thermax™ (ci) Exterior Foam Insulation to the steel studs is to keep the insulation in place until the veneer is installed. In many cases this can be months. During this time of exposure, the building might be exposed to high winds during a storm. The fasteners will hold the insulation boards in place during this high exposure.
If fewer insulation fasteners are used, the insulation boards will be more vulnerable to high wind exposure and dislodgement or damage. To use the veneer anchors as insulation fasteners, the anchors would have to be installed essentially at the same time as the insulation board fasteners. If, due to sequencing issues, the anchors cannot be installed in a timely manner, the full set of insulation fasteners for the Thermax™ Exterior Foam Insulation must be used.
The Knight Wall System is a method of attaching a variety of veneers to a steel stud back up wall which is sheathed in a continuous insulation layer. It uses the rain screen design concept to provide moisture management.
The Knight Wall System is unique in that is designed to minimize the thermal shorts in the continuous insulation layer. It minimizes these thermal shorts by keeping the amount of metal that penetrates the insulation to an absolute minimum. The result is a beautiful rain screen wall system that is very thermally efficient.
For more information see the Knight Wall System website.
Over 1 million ft2 of DuPont™ Insta Stik™ Quik Set Commercial Adhesive have been applied. As a single-component adhesive, it's easily installed vs. two-component foam adhesives.
For more information, visit DuPont™ Insta Stik™ Quik Set Commercial Adhesive.
The thermal resistance (R-value) of the insulation material will decrease when it gets wet. As a rule of thumb, for every 1 vol % of water absorption, evenly distributed across the insulation's thickness there is a reduction in R-value of about 5%. The original material R-value can be regained if the material dries out and remains undamaged.
As other aerosol products, the product can is under pressure. Store where the temperature will not exceed 100 °F (38°C), and where cans cannot be punctured or crushed.
This depends upon the specific configuration of the juncture. The code does prescribe testing to be done but only under certain design circumstances. Section 713 of the International Building Code (IBC) addresses any requirements for fire testing in joint systems. To require specific fire resistant testing, the wall and floor/roof must first be required to have an hourly fire resistance rating.
If the fire resistance ratings are required, the fire resistance rating of the joint between the wall and the floor/roof only needs to be tested if there is a void between the wall and the floor/roof.
Yes, DuPont™ Insta Stik™ Quick Set Commercial Adhesive has system approvals with some roof membrane manufacturers. Please call the DuPont Contact Center (DCC) at 1-833-338-7668 for details about a particular roof membrane manufacturer that you are interested in.
Visit DuPont™ Insta Stik™ Quik Set Commercial Adhesive to learn more and download literature about DuPont™ Insta Stik™ Quik Set Commercial Adhesive.
U-value is a measure of the insulation capabilities of an assembly such as a wall or roof system. It refers to how many Btu will flow in one hour through one square foot of one or more materials of any thickness when the temperature difference between the hot side and the cold side is one degree Fahrenheit, including the insulation values of the thin films of air that cling to the inside surface and outside surfaces of the building section. So, the U-value tells how many Btu will flow in one hour through one square foot of an entire building section when the temperature difference between the hot side and the cold side is one degree Fahrenheit.
Imperial units for U-value are expressed in Btu/hr•ft2°F. SI units for U-value are expressed in W/m2•K.
Yes. The following table shows the various insulation thicknesses that will meet the proscribed R-Values listed in various energy codes.
LEED is the acronym for the U.S. Green Building Council Leadership in Energy and Environmental Design rating system. The Canada Green Building Council has developed a rating system based on the U.S. model. LEED promotes green building design (e.g., energy efficiency).
Find more information on LEED USGBC and CaGBC.
Only the standard personal protective equipment is needed for the installation of the Ultra Air Barrier Wall System. Safety glasses and Safety Gloves are all that are required.
For more information on the Ultra Air Barrier Wall System see:
Gatorfoam, produced by Alcan Composites, is used in various graphic art applications. It is made of white or black DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam sandwiched between resin-hardened paper. It is sometimes referred to as “artboard.”
Yes, Tile Bond™ Roof Tile Adhesive is referenced by a number of building or country codes including:
Florida product approvals FL717 & FL 22525
Miami Dade NOA # 16-0222.01, expires 8/23/2021
Texas Department of Insurance RC 28, re-evaluation June 2018,
UL ER18231-01 code Report
Click here for more information about Tile Bond™ Roof Tile Adhesive.
If the surface of the 48 inch wide DuPont™ Ultra SL Wall System (UWS-SL) gets dirty the joint treatment will not adhere properly to it. The surface of the insulation can be cleaned with soap and water to remove dirt and oils.
For more information see Ultra Air Barrier Wall System
There is no cost to take the certification. DuPont™ only requires the installer’s time, attention and commitment. The certification is currently issued to the participating company, not an individual once the certification process has been completed.
For indoor applications such as interior wall insulation, Canadian building codes require the use of a 15-minute thermal barrier (such as 1/2 inch drywall) as a covering over the Styrofoam™ Brand Extruded Polystyrene Foam Insulation. In the US a maximum of 2' thickness of Styrofoam™ Brand Extruded Polystyrene Foam Insulation is permitted to be installed without a thermal barrier. In this interior application, painting is not necessary. However, for non-insulative uses, such as in model railroad layouts and decorative items, Styrofoam™ Brand Extruded Polystyrene Foam Insulation can be painted with any commonly available latex paint. Avoid petroleum or oil based paints as they might partially dissolve the insulation.
For exterior applications where the insulation is not covered by a weatherproof finish, DuPont recommends a cementitious or thin stucco coating (such as products sold by Styro Industries), an application of a fiberglass-reinforced plastic sheet or a metallic covering.
Great Stuff™ Gaps & Cracks Insulating Foam Sealant and Great Stuff™ Big Gap Filler Insulating Foam Sealant are both cream color. Great Stuff™ Pestblock Insulating Foam Sealant is pale grey and Great Stuff™ Window & Door Insulating Foam Sealant is yellow. Great Stuff™ Fireblock Insulating Foam Sealant is orange. Great Stuff™ Multipurpose Black Insulating Foam Sealant and Great Stuff™ Pond & Stone Insulating Foam Sealant is black. Great Stuff™ products are given different colors to help identify the specific product for its intended use.
Visit Great Stuff™ for more information on Great Stuff™ products for the DIY.
Sound Transmission Classification (STC) ratings are for systems, not individual products. DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation products are lightweight and rigid, so do not have a significant impact on the STC ratings for wall or roof assemblies.
ENERBOND™ MH is a professional polyurethane foam adhesive specially designed for manufactured housing & modular construction. The polyurethane based adhesive formulation has superior bonding power on dry and damp surfaces. ENERBOND™ MH is the ideal adhesive for drywall, back panel, shear wall and sub-floor applications.
Underwriters Laboratories Inc. (UL) is an independent, not-for-profit product-safety testing and certification organization. Many DuPont products have been tested at UL to establish flame spread/smoke developed ratings and assembly ratings.
For more information about UL, please visit: www.ul.com
No special surface preparation is needed to use LiquidArmor™ CM, QS and LT. For best results, remove excess dirt and debris from the substrate before applying LiquidArmor™ CM, QS and LT. Do not install LiquidArmor™ CM, QS and LT on surfaces with standing water or frost.
The following is a link to the Structural Insulated Panel Association that may be helpful for you in the panel market.
Structural Insulated Panel Association
The United States Green Building Council (USGBC) Leadership in Energy and Environmental Design (LEED) green building rating system in the ENERGY and ATMOSPHERE (EA) section has a credit with the highest number of possible points as compared to any other credit in LEED.
Credit 1 - Optimize Energy Performance, Option 1 has the potential for 19 credit points.
These points can be earned by outperforming the energy efficiency levels set out in the American Society of Heating Refrigeration and Air Conditioning Engineers (ASHRAE) 90.1 2007 on whole building energy simulation as outlined in Appendix G. Points are granted based on the percentage the building exceeds the code as shown below. The first percentage listed is for new buildings; the second percentage is for existing building renovations:
Option 1 requirements:
Because the Thermax? Wall System can reach far greater levels of effective insulation than most wall systems, it is an ideal choice to improve building performance towards meeting these 19 points and reaching even higher levels of LEED certification.
International Code Council – Evaluation Services EG-239 (ICC-ES EG-239) is The Evaluation Guideline For Termite-Resistant Foam Plastics. The purpose of this acceptance criteria is the evaluation is to establish requirements for termite-resistant foam plastics in heavy termite areas.
The Sections included in the National Building Code of Canada are:
nPart 1 - Scope and Definition
nPart 2 - General Requirements
nPart 3 - Fire Protection, Occupant Safety & Accessibility
nPart 4 - Structural Design
nPart 5 - Environmental Separation
nPart 6 - Heating, Ventilating and Air-Conditioning
nPart 7 - Plumbing Services
nPart 8 - Safety Measures at Construction and Demolition Sites
nPart 9 - Housing and Small Buildings
More information about National Building Code of Canada can be found HERE
Asphalt based adhesives and/or mastics are not recommended for use with DuPont™ Tyvek® Fluid Applied products.
When DuPont™ Tyvek® Fluid Applied WB+™ is to be integrated with asphaltic based through wall flashing membrane, the top edge of the through wall should be pretreated with DuPont™ Tyvek® Fluid Applied Flashing and Joint Compound+ or DuPont™ Sealant for Tyvek® Fluid Applied System. Trowel the product a minimum of one inch (1”) onto the exposed wall and top of the through wall flashing or extend to the bottom edge of the termination bar if used. For additional information refer to the DuPont™ Tyvek® Fluid Applied WB+™ Wall and Substrate Guidelines.
Yes, the Thermax™ Wall System can be used. DuPont does NOT have an Hourly Rated Wall Assembly for a load bearing wall assembly which includes all of the Thermax™ Wall System components. However, there are load bearing one hour wall assemblies which include Thermax™ and the continuous insulation design concept. BXUV.V454, BXUV.V460, BXUV.V424, and BXUV.V425 are all bearing walls with one or more hours of fire resistance.
To learn more about these listed wall systems, go to the UL website and search for the respective wall design number.
Click on 'Certifications Directory' and search for 'VXXX' in the UL File Number field.
Styrofoam™ Brand products are thermoplastic materials and can burn at the right conditions. Like any other plastic material, Styrofoam™ Brand products should be protected from fire exposure.
Please conform to applicable building code or consult your local DuPont representative.
The recommended DuPont products for conventional roofing are:
For details about these products, please visit:
https://www.dupont.com/products/styrofoam-brand-deckmate.html
Yes, DuPont has standard CAD details for the Thermax™ Wall System. See the attachments below for various details in PDF format. Details are also available on the Thermax™ Wall System web site.
DuPont™ Styrofoam™ Brand insulation can be used in soil and geotechnical applications to greatly minimize the potential for frost heave by retarding the heat flow from underground/ambient environment to dissipate to ambient environment/underground. If you have a project that Styrofoam™ insulation can be used to minimize frost heave, you are strongly recommended to discuss with one of DuPont representatives or consult your professional engineer.
The FM Class 1 rated roof assemblies for Styrofoam™ Brand Extruded Polystyrene Foam Insulation on Steel Deck are:
Most Styrofoam™ Brand Extruded Polystyrene Foam Insulation products have a stabilized R-value of 5.0 per inch. Unlike other insulation materials, the R-value for Styrofoam™ Extruded Polystyrene Foam Insulation does not appreciably decrease over time.
DuPont™ Styrofoam™ Brand Cavitymate™ Ultra Extruded Polystyrene (XPS) Foam Insulation and DuPont™ Styrofoam™ Brand Panelmate™ Extruded Polystyrene (XPS) Foam Insulation have an R-value of 5.6 per inch.
DuPont™ Styrofoam™ Brand Perimate™ Extruded Polystyrene (XPS) Foam Insulation has an R-value slightly lower than 5.0 per inch to compensate for special drainage grooves in the foam.
For more information, visit our website.
Yes, all the DuPont™ Styrofoam™ Brand rigid insulation, Polyisocyanurate board insulation, Great Stuff™ Insulating Foam Sealant, Great Stuff Pro™ Polyurethane Foam Sealant and Froth-Pak™ Foam Insulation and sealants are manufactured in the USA.
The R-Value of Thermax™ White Finish Polyisocyanurate Insulation is 6.5 per 1".
For additional R-Values, please contact the DuPont Contact Center (DCC) at 1-833-338-7668 or see FAQ #80.
Styrofoam™ Brand Extruded Polystyrene Foam Insulation is typically installed in commercial building roofs by commercial roofing contractors. Thousands of these contractors are located all across . Contact your DuPont representative or call 1-833-338-7668 for assistance in selecting a roofing contractor.
'Grade III' is the lowest or worst level of insulation installation and that the other grades are I and II. 'Grade III' shall be used to describe an installation with substantial gaps and voids, with missing insulation amounting to greater than 2% of the area, but less than 5% of the surface area is intended to occupy. More than 5% missing insulation shall be measured and modeled as separate, uninsulated surfaces. This designation shall include wall insulation that is not in substantial contact with the sheathing on at least one side of the cavity, or wall insulation in a wall that is open (unsheathed) on one side and exposed to the exterior, ambient conditions or a vented attic or crawlspace. The presence of an air-impermeable barrier, such as housewrap, will be considered to enclose the building cavities.
The following illustration represents the boundary conditions between the three RESNET insulation installation grades:
The most important characteristic of a damp-proofing, as far as the installation of DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation is concerned, is the type and amount of solvent in the damp-proofing. There are many different damp-proofing products on the market.
Damp-proofing products with water as the solvent base can easily be used with DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation.
Damp-proofing products that use organic solvents may be used but should be tested for compatibility with the insulation before installation. A simple way to test for compatibility is to adhere two pieces of insulation together with the damp-proofing, wait for a few hours, and then break the two insulation pieces apart and inspect them for degradation.
Time plays an important role when considering the compatibility of insulation with damp-proofing. Most of the organic solvents typically evaporate from the damp-proofing a day or two after installation, forming a hard skin over the underlying damp-proofing. Installation of DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation over this hard skin is acceptable.
Check with the manufacturer of the damp-proofing or waterproofing products regarding whether its products are considered to be compatible with polystyrene foam. At no time should solvent-based damp-proofing be used as an adhesive for DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation.
The ASTM C578 classifications for DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation products are as shown below:
ASTM C578 Types | DuPont Products |
Type X | Styrofoam™ Brand Residential Sheathing |
Type IV | Styrofoam™ Brand Tongue and Groove Insulation |
Type VI | Styrofoam™ Brand Highload100 40 Insulation |
Type VII | Styrofoam™ Brand Highload100 60 Insulation |
Type V | Styrofoam™ Brand Highload100 Insulation |
Possible causes include operating pressures too high, improper gun tip size and improperly sized (or dirty) mix module. Elevated operating temperatures (chemical temperatures above those recommended by DuPont) can also cause frothing and pin-holes.
With a vapor permeance of 22 perms, DuPont™ believes DuPont™ Tyvek® Fluid Applied WB+™ is the ideal solution for use over a wide range of substrate types. For above grade applications, DuPont™ Tyvek® Fluid Applied System provides a pathway to allow the concrete or CMU materials to dry through diffusion to the exterior. Providing a pathway for a high mass wall to dry to the exterior can help prevent mold growth. Additionally, once properly installed, DuPont™ Tyvek® Fluid Applied WB+™ provides an air and water barrier to help protect the concrete and CMU from additional absorption of exterior moisture.
The blue facer of Tuff-R™ polyisocyanurate insulation typically faces out. However, from a technical perspective, it really doesn't matter when used on wood studs of exterior. If, however, Tuff-R™ is used on interior of CMU block and furring is placed over it, creating a reflective air space, then the shiny aluminum side need to be facing the interior of the building. Tuff-R™ also needs to be covered with a 15 minute Thermal barrier like gypsum wallboard.
Yes, in addition to the full 15 year thermal warranty there is also a 6-month exposure warranty for the DuPont™ Thermax™ (ci) Exterior Foam Insulation.
DuPont™ Tyvek® Fluid Applied products may contribute toward LEED® points in the areas of Energy and Atmosphere (EA): Optimizing the Building Envelope and Indoor Environmental Air Quality and (EQ): Materials & Resource (MR): Building Product Disclosure and Optimization – Material Ingredients, Construction IAQ Management Plan and Low Emitting Materials. In addition, the use of a continuous air barrier is a pre-requisite for LEED applications requiring compliance with ASHRAE 90.1-2010. For additional information please refer to the Product Information bulletin titled “DuPont™ Tyvek® Contributes to Green Building Design” at www.Weatherization.Tyvek.com
DuPont™ Tyvek® Fluid Applied complies with California Department of Public Health (CDPH).
No, Great Stuff™ does not contain any formaldehyde.
Specifically, while we have not analyzed for formaldehyde, it is not an intended raw material nor is it known to be present in our Great Stuff™ products.
This determination is based on the compositional information provided to DuPont by its suppliers. DuPont relies on its suppliers to provide accurate data.
DuPont does not routinely analyze for additional materials that are not listed in the Safety Data Sheets (SDS) or Sales Specification.
DuPont is not responsible for any misrepresentation resulting from inaccurate information from its suppliers.
Since formaldehyde is typically present and commonly found in the environment, any formaldehyde in the fully cured foam would be consistent with background levels commonly found in the environment.
Visit Great Stuff™ for more information on products for the DIY.
These products are globally defined as articles, which do not require Safety Data Sheets according to chemical laws in the following:
The products listed do not release or otherwise result in exposure to a hazardous chemical under the intended conditions of use and meet all other listed requirements of an article. Therefore, these products meet the global definitions of articles which do not require SDS creation or distribution.
Click here for more information about Froth-Pak™ sealant products.
The primary difference among Thermax™ products is the type and thickness of their facers, but the core foam remains the same for all Thermax™ products and complies with the most current ASTM C 1289 "Standard Specification for Faced Rigid Cellular Polyisocyanurate Foam Insulation". Thermax™ is classified as a Type 1/Class 2 category and has a Class A Fire approval per ASTM E 84 testing. Contact DuPont for additional Fire Performance testing for Thermax™.
Thermax™ Product |
Information |
Thermax™ Sheathing |
Thermax™ Sheathing is specially designed to have a Class A fire rating and can be used in a range of concealed and exposed applications, above and below grade. Because of the improved fire performance, it is best suited for hourly rated assemblies. It has nominal 1.0 mil, smooth aluminum foil facers on both sides. A rigid foam insulation that effectively reduces condensation for exceptional moisture protection. |
Thermax™ White Finish |
Thermax™ White Finish polyisocyanurate insulation is designed as an insulation and interior finish system for interior masonry or concrete walls, plus walls and ceilings in metal, wood post frame, and concrete or masonry buildings, as governed by building codes. It features a nominal 1.25 mil embossed white acrylic coated aluminum sheet on one side and nominal 1.0 mil aluminum on the other side. The white embossed surface of Thermax™ White Finish is aesthetically pleasing and easy to clean. It can be pressure-washed up to 1,000 psi with a 15-degree or greater spray tip (at minimum 3' distance). |
Thermax™ Metal Building Board |
Thermax™ Metal Building Board is an ideal choice for metal building owners and builders but is also versatile in a wide range of applications such as steel framing or metal buildings or tilt-up concrete wall panels and parking garage ceilings - or wherever thermal performance and a washable interior surface would enhance a structure. The polyisocyanurate foam core features nominal 1.25 mil embossed aluminum foil facer on both sides to dampen noise from the system's movement when outside temperatures change. The easy-to-clean facers provide a finished look while adding to the overall value package of strength, durability and moisture control. |
Thermax™ Light Duty |
Thermax™ Light Duty is designed as an insulation and interior finish system for walls and ceilings in metal, wood post frame, and concrete or masonry buildings, as governed by building codes. The mid-range nominal 1.25 mil white acrylic embossed aluminum surface of Thermax™ Light Duty (Both sides) makes a durable insulation/finish choice for use in light-impact areas. It can be pressure-washed up to 1,000 psi with a 15-degree or greater spray tip (at minimum 3' distance). Maximum length is 30 ft. (9.1 m) and maximum thickness of 3.5 inches (76.2 mm).. |
Thermax™ Heavy Duty |
Thermax™ Heavy Duty is designed as an insulation and interior finish system for walls and ceilings in metal, wood post frame, and concrete or masonry buildings, as governed by building codes. The tough nominal 4 mil white acrylic embossed aluminum surface one side and nominal 1.25 mil embossed aluminum on other side of Thermax™ Heavy Duty makes it the insulation with the most durable finish choice for use in moderate-impact areas, and it can be pressure-washed up to 2,000 psi with a 15-degree or greater spray tip (at 3' minimum distance). Maximum length is 30 ft. (9.1 m) and a maximumthickness of 3 inches (76.2 mm). |
Thermax™ (ci) Exterior Insulation | Our mid-range nominal Thermax™ (ci) has a 1.25 mil embossed BLUE™ thermoset-coated aluminum on one side and 0.9 mil smooth, reflective aluminum on other side, offers mid-range durability for an insulation that continues to outperform offering builders more flexibility to choose the rightfacer option for the project needs. |
Thermax™ XARMOR™ | The toughest insulation for the patented Thermax™ Wall System and the most efficient way to achieve air, water, vapor and thermal control layers. Boasting the strongest embossed exterior acrylic coated foil facer nominal 4.0 mil embossed and nominal 1.25 mil embossed aluminum other side, this solution provides builders with more durability for long-term performance. Thermax XARMOR™ (ci) is also the only Thermax™ insulation with a dark exterior facer optimized to go behind rain screen exteriors. |
Application rates are determined by following Factory Mutual 1-28 and 1-29 guidelines. The DuPont Building Knowledge Center reviews building height, parapet wall height, building configuration and geographical wind zone. For estimation purposes, use the approximate yield of 6 squares per tank and add a 10% waste factor.
Visit DuPont™ Insta Stik™ Quik Set Commercial Adhesive to learn more and download literature about DuPont™ Insta Stik™ Quik Set Commercial Adhesive.
It is recommended to apply LiquidArmor™ CM and QS at 50 (+/-5) mils and LiquidArmor™ LT at 30 (+/-5) wet mills, respectively. LiquidArmor™ CM, QS and LT were designed and tested to perform optimally in this thickness range. A wet film thickness gauge, typically available at paint supply stores, can be used to verify product application thickness during installation.
Styrofoam™ Brand Extruded Polystyrene Foam Insulation must be covered to protect it from sunlight (UV or ultraviolet light). It should be covered within 90 days of its installation. Sunlight will very slowly begin to degrade the insulation, changing the surface from a rigid blue plastic to a yellow powder. This discoloration may be rapid depending on solar exposure conditions. If this powdery surface is removed, degradation of the newly exposed blue surface will continue. This does not change the properties of the insulation below the surface, but it can result in a loss of insulation thickness over very long periods of time (years). Any loss on R-value is limited to the thickness of powdery layer present.
If the adhesive has not cured or hardened, use acetone. If the adhesive has hardened, there is no solvent that will remove it. It will not harm your skin and will wear off in several days. To remove cured DuPont™ Insta Stik™ Quik Set Commercial Adhesive, soak skin in warm, soapy water and use a pumice stone (available at most drugstores). Then apply petroleum jelly.
Visit DuPont Adhesives to learn more and download literature about DuPont™ Insta Stik™ Quik Set Commercial Adhesive.
LiquidArmor™ CM, QS and LT adhere well to most common building materials.
Dow Roofing Systems, LLC is in the process of restructuring its company to better serve the needs of its customers. DRS will continue to honor Limited Warranties and receive claims during the period of reorganization, but determinations of whether claims are warranted may be delayed. Please visit the DRS website at www.DRSclaims.com for more information about the reorganization, including instructions on how to send communications or claims to DRS during the reorganization period.
DuPont™ Insta Stik™ Quik Set Commercial Adhesive cannot be applied when surface and ambient temperatures are below 33°F. Applying DuPont™ Insta Stik™ Quik Set Commercial Adhesive in temperatures below 33°F will result in poor adhesion and will void the adhesion warranty. Substrate temperature range is 33°F to 110°F (1°C to 43°C). DuPont™ Insta Stik™ Quik Set Commercial Adhesive should be stored between 50°F to 75°F (10°C to 24°C).
Visit DuPont™ Insta Stik™ Quik Set Commercial Adhesive to learn more and download literature about DuPont™ Insta Stik™ Quik Set Commercial Adhesive.
LiquidArmor™ CM and QS has been formulated to achieve optimal performance without any additives. Further, all product testing was conducted using LiquidArmor™ CM and QS as it is currently sold. Accordingly, additives should not be added to LiquidArmor™ CM and QS to suppress its freezing temperature. DuPont cannot guarantee the same product performance to what was tested and claimed in literature, if glycol or other chemicals are added to the product.
Both Underwriters Laboratories (UL) and Factory Mutual (FM) conduct wind uplift tests on mechanically attached systems. In these tests the roof system is subjected to simulated wind loads until failure occurs. The highest force that the roof system was able to withstand before failure is reported as the wind uplift rating for the system. These ratings are reported in lbs/ft2 and are summarized in the respective Guides for FM and UL.
In mechanically attached systems the insulation is attached via a preliminary fastening schedule. This fastening schedule is only meant to hold the insulation in place until the mechanically attached roofing assembly is completed. DuPont's recommended fastening pattern is 5 fasteners per board for a 4x8 board (one in each corner and one in the center) and 4 fasteners per board for 2 boards (one in each corner).
If a designer has specified wind uplift resistance requirement, the roof assembly design recommendation must come from the membrane manufacturer.
Froth-Pak™ Foam Insulation (Class A):
FM 4470 (Approval Standard for Class 1 Roof Covers) provides a basis for the evaluation of membrane-type (e.g., built-up, single-ply) roofing systems. Specific criteria evaluated include: internal fire (FM 4450), external fire (ASTM E108), wind-uplift, hail, water-leakage, foot-traffic, and corrosion resistances. Specific criteria are listed as:
Test | Performance Requirements |
External fire resistance | Minimum Class C per ASTM E108 |
Internal fire resistance | Pass calorimeter test |
Wind resistance | Resist 60 psf wind uplift load (minimum) |
Foot traffic resistance | Pass |
Corrosion of steel fasteners | Pass |
Hail resistance | Pass |
Resistance to water leakage | Pass |
Susceptibility to heat damage | Pass |
Puncture Resistance | Pass |
LiquidArmor™ CM and LiquidArmor™ LT can be used to help ensure compliance with the 2009, 2012 and 2015 International Energy Conservation Code (IECC) air leakage requirements under the Commercial sections of this Code.
LiquidArmor™ Flashing & Sealant Product Page
Thermax™ Wall System (TWS) Home Page
The typical hourly rated wall consists of (from the inside out) nominal 5/8' Type X Gypsum, empty steel studs cavity or fiberglass filled cavity, and nominal 5/8' Georgia-Pacific DensGlass or nominal Type X Gypsum. Material can be added to the exterior side of the base assembly. If you are interested in a particular assembly and what type of hourly rating it has, visit Underwriters Laboratories online certification directory.
Look for the Fire Resistive Design U numbers such as U457 or V499 for a particular manufacturer.
There are thousands of distributors across the United States for Thermax™ Brand Insulation, Tuff-R™ Polyisocyanurate Foam or other polyisocyanurate insulation products. We can sell into Canada and Mexico if requested. Check with local sales representative to ensure all codes are met.
Call 1-833-338-7668 for information about distributors near you.
Is there a list of projects that have been completed using the DuPont™ Thermax™ Wall System (TWS)?
For a current list of projects see:
Thermax™ Wall System (TWS) Case Studies
First Thermax™ Wall Project: 735 Forest in Birmingham, Michigan.
“Grayboard” was a gray extruded polystyrene insulation that was manufactured by Dow. It has been replaced with DuPont™ Styrofoam™ Brand UtilityFit™ XPS 15 PSI Extruded Polystyrene Foam Insulation with a blue color. DuPont™ Styrofoam™ Brand UtilityFit™ XPS 15 PSI Extruded Polystyrene Foam Insulation is an ASTM C578 Type X product.
For more information, visit our website.
LiquidArmor™ CM, QS and LT should not be 'tinted' to change their color. The product has been formulated to achieve optimal performance. Adding substances to LiquidArmor™ Flashing & Sealant products could negatively alter their performance. DuPont cannot guarantee the same product performance to what was tested and claimed in literature if the product is tinted from its original color.
DuPont’s Panel Products can be used in a variety of applications from sandwich panels to composite applications. For details of a variety of applications, please visit the link below:
Panel Applications
DuPont™ Thermax™ Polyisocyanurate Sheathing and Tuff-R™ Commercial Sheathing have passed the required tests and meet DOT Docket 90 requirements (includes ASTM E 162 and ASTM E 662.) If you need a report on this, please call 1-833-338-7668.
To meet the appropriate wind uplift criteria, please contact the standing seam roof manufacturer for proper fastener type and fastening pattern. With DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation boards, a general guideline is to use a minimum of 5 fasteners per 4x8 board (one in each corner and one in the center of the board).
For more information, visit Standing Seam Roof.
No single method will ensure air sealing around commercial windows, so the designer and installer must use diligence in applying flashings, one-component sealant foams, caulks, and spray polyurethane foams to ensure complete sealing of the window area for a given window assembly.
The water-based product can be cleaned from the blue handled gun with the cleanout adapter provided in the Great Stuff Pro™ Dispensing Gun packaging. Remove the empty can, screw the adapter into the gun's basket, screw this assembly onto a garden hose or similar source of water.
DuPont™ Styrofoam™ Brand Buoyancy Billets carry a 10-year limited warranty for flotation.
For more information, visit our website.
In August 2000, Dow participated in a testing program through the Extruded Polystyrene Foam Association (XPSA) that obtained an FM Approved Class 2 (sprinkler protection provided) roofing assembly. This assembly allowed for the use of XPS directly on a steel roof deck. In September 2004, FM changed their Approval process and no longer will approve assemblies that use sprinkler protection as part of the assembly. As a result, this assembly was moved from the Approved section of the FM Approval Guide, to the blue pages, known as the specification tested section of the Approval Guide. The specifics of the system are listed below:
The FM Class 1 rated roof assemblies for DuPont™ Styrofoam™ Brand products on Steel Deck are:
The Wind-Lock ci-LOCK washer / fastener combo was used in all of the full scale wall assembly tests and is therefore what Dow recommends for use with the DuPont™ Thermax™ Wall System (TWS). The choice of fastener / washer combo is detailed in the NFPA 285 approval.
Can I continue to use my current drywall installation methods while using Great Stuff Pro™ Gasket?
Yes.
Great Stuff Pro™ Gasket is designed to tolerate standard drywall installation techniques, including when boards are placed against the wall studs and slid up to meet the ceiling drywall. While this motion may deform the round gasket bead profile to a 'shark fin', it will remain in place on the top plate and keep its thickness to seal the gap between the top plate and back side of the drywall.
No.
A dark-colored, such as black, mechanically fastened single ply roof membrane cannot be installed directly on DuPont™ Styrofoam™ Brand Insulation. The dark (e.g., black) color will absorb the sun's heat, allowing the roof membrane to reach temperatures that exceed the maximum use temperature for DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation (165°F). Use of a separation board, such as 1/4' gypsum or 1/2' fiber board or perlite board, between the insulation and the dark membrane is required. This caution applies to all DuPont™ Styrofoam™ Brand XPS Foam Insulation products. For more information consult Tech Solutions 519.0 'Styrofoam™ Brand Extruded Polystyrene (XPS) Foam Insulation and Dark Roofing Membranes and Other Dark Coverings'
For additional information, contact your DuPont representative or call 1-833-338-7668.
DuPont™ Styrofoam™ Brand products can be used for interior wall insulation applications.
You can find more information of the Styrofoam™ application in internal wall insulation here:
For a specific project, please feel free to contact one of DuPont representatives to further discuss your needs.
DuPont™ Styrofoam™ Brand Extruded Polystyrene Insulation products comply with California Department of Public Health (CDPH) indoor air quality, Section 01350 for building products based on Standard Method for Testing and Evaluation of Volatile Organic Chemical Emissions from Indoors Sources using Environmental Chambers Version 1.2.
LEED v4 New Construction Credit
• EQ Credit 2: Low-Emitting Materials (1 Point).
• To reduce concentrations of chemicals contaminations that can damage air quality, human health, productivity, and the environment.
Please feel free to call 1-833-338-7668 when you need additional LEED information for Styrofoam™ Extruded Polystyrene Insulation products from DuPont for a particular LEED certified/designed job.
DuPont takes sustainability and environmental stewardship seriously. DuPont™ Styrofoam™ Brand Extruded Polystyrene (XPS) Foam Insulation was recently converted to a more sustainable and environmental friendly zero-ozone depletion and no-VOC foaming agent technology at the beginning of 2010 to comply with Montreal Protocol and US EPA Guidelines - an industry first among all other extruded polystyrene insulation manufacturers.
As a result of this improved foaming agent formulation, DuPont announced an unprecedented 50 year thermal warranty for all Styrofoam™ Brand Extruded Polystyrene (XPS) Foam Insulation products 1.5' or greater in thickness. This is another industry first among all the foam insulation manufacturers which demonstrates DuPont's confidence in supplying Styrofoam™ Brand Extruded Polystyrene (XPS) Foam Insulation products backed with superior long-term performance.
The details of the warranty can be found at the website at Styrofoam™ Brand Warranty Information
Underwriters Laboratories Inc. (UL) is an independent, not-for-profit product-safety testing and certification organization. Many DuPont products have been tested at UL to establish flame spread/smoke developed ratings and assembly ratings.
For more information about UL, please visit: http://www.ul.com
Styrofoam™ Brand Extruded Polystyrene Foam may be stored indoors or outdoors, in any kind of weather. It should not be stored outside under sunshine for a prolonged period of time (over a month) to avoid excessive exposure to sunlight (UV). Styrofoam™ Cavitymate™ ULTRA, is stored outside for over a month should be covered with a white colored polyethylene film.
Styrofoam™ Brand XPS Foam Insulation is combustible and should be stored away from any open flames or heat sources.
DuPont™ Thermax™ Brand Insulation and Tuff-R™ Polyisocyanurate Insulation do not outgas any toxic material over their lifetimes. Foam insulation, like wood and other organic materials, can release toxic smoke if ignited.
All wall assemblies which incorporate foam plastic must pass the National Fire Protection Association (NFPA) 285 fire test for wall assemblies to be used in Type I through IV commercial construction as referenced in Chapter 26, Section 2603.5.5, of the International Building Code (IBC). DuPont has performed three NFPA 285 fire tests on different configurations of the Thermax™ Wall System.
Hughes Associates, a fire science and engineering consulting company, has analyzed these fire tests and combined this with their knowledge of fire science to create an engineering study which outlines the possible configurations which meet the NFPA 285 fire test criteria. This engineering study serves as the evidence that designers and code officials can use to demonstrate that a given Thermax™ Wall System configuration meets the NFPA 285 portion of the code. Information on these reports can be acquired from your local DuPont Sales Representative or by calling the DuPont Contact Center (DCC) at 1-833-338-7668.
The current leading green programs for commercial building and its respective emphasis are as follows:
1. LEED by US Green Building Council (USGBC)
Visit USGBC website for more details: U.S. Green Building Council Website
2. Green Globes by Green Building Initiative (GBI)
Similar to LEED program, a variety of environmental factors are considered for a particular building. GBI currently has New Construction and Existing Building rating systems.
Visit GBI website for more details: Green Building Initiative and Green Globes
3. Energy Star by EPA and DOE
ENERGY STAR program only focuses on energy efficiency, other environmental factors such as site, water, materials and indoor environmental quality are not considered.
Visit ENERGY STAR website for more details: ENERGY STAR Program
When the above stated products are used as Water-Resistive Barrier, 2-7/8" Weathermate™ Construction Tape must be used to tape all the seams between boards. Tape is not required over fastener penetration in the interior of the panel. Also be sure products and installation instructions meet code requirements for your particular location. The following link shows the installation instructions for these products:
PBS Product and Installation Information
Froth-Pak™ products consist of two main intermediate components - isocyanate (A) and polyol (B) - that are mixed together to form polyurethane foam. Both "A" and "B" tanks are pressurized. The hose assembly (which is attached to the gun applicator) includes two hose lines; one is connected to the "A" tank and one is connected to the "B" tank.
Click here for more information about Froth-Pak™ sealant products.
No.
Although these products can be used exposed in most interior applications, they were not designed to withstand the rigors of exterior exposure.
For more information, visit:
Residential Exterior Basement Walls
“Continuous Path for Moisture Drainage to the Exterior” consists of a designed path for continuous moisture drainage which must allow moisture to drain freely and without interruption along the drainage plane. Examples of obstructions that can interrupt drainage are: eyebrows, band boards, building returns, etc. The intent is to ensure that any moisture that penetrates the exterior cladding and reaches DuPont™ Tyvek® Fluid Applied WB+™ can drain and exit the building envelope. The wall system should be designed to prevent moisture accumulation (trapping moisture) within the assembly. Materials should be installed in shingle fashion to provide positive drainage; with sealed penetrations, kick-out or diverter flashing at windows, doors, and any vertical to horizontal changes of the building plane. Proper shingling and integration with kick-out or diverter flashings and/or through wall membranes is essential to moisture management.
A cementitious brush-on coating is one method that can be used to protect Styrofoam™ Brand Extruded Polystyrene Foam Insulation installed on a residential foundation.
The following company provides brush-on, trowel-on and pre-coated options:
Styro Industries Inc.
Also, vinyl or aluminum coil stock can also be used as a covering. This is typically fastened to the foundation wall. You can find more information at the foundation insulation application page.
The concern is that a heavy veneer hung on the exterior of the wall will result in a force on the exterior portion of the anchors resulting in a cantilever effect on the fasteners and some sort of downward movement in the anchors, insulation, and veneer finish. This concern is greater when the insulation is thicker.
A variety of studies including computer finite element modeling and actual full scale laboratory testing have shown that proper design of fastener spacing and insulation compressive strength will completely prevent this from occurring.
A formal engineering document is available on the Dr. J Certification Web site here:
<http://www.drjcertification.org/system/files/drj/ter/node/767/drr141008attachingexteriorwallcoveringsthroughfs.pdf>
For detailed chemical resistance listings for rigid foam insulation products from DuPont, call 1-833-338-7668.
The chemical resistance table below applies for the following DuPont products: All Thermax™ Polyisocyanurate Insulation products, Tuff-R™, Tuff-R™ Commercial.
Chemical Resistance of Polyisocyanurate Insulation | |||
Acid, inorganic | Not Recommended | Hydrocarbons | Excellent |
Acid, organic | Excellent | Insecticides | Excellent |
Alcohol | Excellent | Kerosene | Excellent |
Asphalt, water-based | Good | Mineral Oil USP | Excellent |
Bases (caustics) | Poor | Naphtha | Excellent |
Brines and other salts | Excellent | Paints, alcohol-based | Excellent |
Cements and mortar | Poor | Paints-water based | Excellent |
Gases, carbon dioxide |
Excellent | Polygolycols, including propylene glycol |
Excellent |
Gasoline | Excellent | Water¹ | Excellent |
Note: This table should be used on as a guide. For design purposes, specific test data on the intended application may be needed.
¹Water may cause discoloration of aluminum facers. This does not impact the R-Value of dry, core insulation.
Yes. When Weathermate™ or Weathermate™ Plus Housewrap products are used, overlap the vertical seams at least 6' and seal with tape. Overlap all horizontal seams at least 2' shingle fashion and seal with tape (the higher piece on the wall should lap over the lower piece). Tape should be contractor grade similar to Weathermate™ Construction Tape. Ensure tape is properly applied to seams to create a weather-tight seam.
For detailed instructions:
Housewrap/Building Wrap
Life Cycle Assessment (LCA) models the complex interaction between a product/system/building and the environment from cradle to grave. It is also known as Life Cycle Analysis or Eco-balance.
National Fire Protection Agency (NFPA) 285 and Uniform Building Code (UBC) 26-9 are technically equivalent. Differences are only in formats, etc.
The UBC 26-4 was the original large two-story building test upon which the UBC 26-9 or NFPA 285 is based. UBC 26-9 and NFPA 285 were developed to provide an equivalent test to UBC 26-4 with smaller, more controlled test procedures. In the 2000 IBC both NFPA 285 and UBC 26-4 were referenced (thus both tests small and large, could be used for approvals). In the 2003 IBC, the UBC 26-4 was eliminated (not a consensus standard) and only the NFPA 285 is referenced. Manufacturers who ran and used the UBC 26-4 to qualify systems are still allowed via ICC-ES Reports.
The current version of NFPA 285 was published in 2012 and contains an annex note that explains the history of NFPA 285 and its relationship to UBC 26-4 and UBC 26-9.
Yes. It has a Class A UL 723 or ASTM E-84 rating, meaning less than 25 flame spread was achieved and less than 450 smoke.
A Rainscreen cavity wall is an assembly in which the exterior veneer is not water proof or water shedding, but instead is designed to absorb the driving force and pressure of impinging rain and allow some of the water (after this driving force has been removed) to drain within a cavity behind the veneer which drains to the exterior. There are two types of rainscreen designs: drained/back ventilated and pressure equalized. They are very similar in design but it is beyond the scope of this answer to discuss the differences.
A rainscreen cavity wall has three basic components:
The cladding serves as the aesthetic veneer and the outer barrier to rain which deflects the majority of the impinging rain.
The drainage cavity provides a path for bulk water to exit the wall as well as being vented which allows excess water to evaporate as well as drain.
The weather resistive barrier is the last line of defense from bulk moisture protecting the inner part of the wall from the moisture that gains entrance to the cavity.
Multi-Bead Applicator (MBA) offers speed of application in roofing applications. It dispenses up to eight beads of DuPont™ Insta Stik™ Quik Set Commercial Adhesive with continuous 3/4' to 1' diameter beads. The MBA is generally used on roof decks with few penetrations and obstructions.
For more information and to download literature about DuPont™ Insta Stik™ Quik Set Commercial Adhesive and the Multi-Bead Applicator, visit DuPont™ Insta Stik™ Quik Set Commercial Adhesive.
Mold or mildew can grow wherever sufficient moisture, spores, optimal temperatures and nutrients are present. The key factor is moisture, which can be controlled by adhering to sound construction practices. In addition, condensation can be a source of moisture and a potential contributor to mildew growth. Condensation may occur when water vapor permeates through the wall, cools and condenses on the first cold surface it encounters.
One of the ways to manage moisture is to add insulation such that the condensing surface is not inside the wall system. Walls constructed with proper construction techniques and using an appropriate thickness of insulating sheathing will:
DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation products and DuPont polyisocyanurate foam insulation products help reduce moisture condensation and infiltration, thereby reducing the potential for mold growth.
DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation products and DuPont polyisocyanurate foam insulation products are not expected to provide a nutrient source for mold; they resist moisture absorption in the insulation itself and thus further reduce the potential for mold and mildew growth.
It is important to note that no building assembly is likely to be completely free from the potential for mold formation, but good building practices unrelated to insulated sheathing will further reduce the potential or mold formation. Ultimately, good construction detailing, compliance with proper installation guidelines for materials, and maintenance of the wall system are key to managing the moisture infiltration into the building envelope.
Great Stuff Pro™ Gasket is a water-based, flexible foam that is water clean-up before the material is cured.
The flexible foam Gasket is designed to be applied to the face of framing lumber and left exposed to air to cure.
The foam setting process will take between 2 to 24 hours to fully cure depending on temperature and humidity.
Unlike rigid one-component foam, after application, it does not expand further, and in fact shrinks slightly.
Once dried, the foam bead is highly compressible, and forms an airtight gasket when drywall is installed over it.
By contrast, the Great Stuff Pro™ Insulating Foam Sealant products are moisture cured, rigid foams.
They become a rigid bead foam which expands significantly after application with more thickness variations.
As such, rigid, rapid expansion foams are not suitable for use between framing lumber and drywall
where smooth, even planes are expected for finished surface quality.
|
Great Stuff Pro™ Gasket |
Great Stuff Pro™ Series |
Composition |
Water-based flexible foam |
Water-cured rigid foam |
Dispense |
Special Great Stuff Pro™ Dispensing Gun, Blue handle for compatibility with water |
Great Stuff Pro™ Dispensing Gun, Black handle |
Foam clean-up |
Before cure, easily removed with water or wet cloth |
Cannot be removed after cure. Before final cure, can be removed with solvent-based cleaner |
Gun clean-out |
Water clean-out: Hose attachment included with gun |
Solvent-based can of Great Stuff Pro™ Gun Cleaner |
Cure method |
Air drying. Fastest at low humidity |
Reacts with moisture in air. Fastest cure at high humidity |
Cure speed |
2-24 hours depending on humidity |
Tack free in less than 30 min, and cures in 60 min depending bead size and conditions |
Shrinkage upon cure |
A 0.5" fresh bead will cure in low humidity without further expansion. At high (>70%) humidity, it may lose up to half its height upon drying but will still be performing as a gasket for overall wall air seal. Gasket foam is designed to seal flat and not create a gap. |
Cures with expansion. It is important not to overfill. Rigid Great Stuff™ foam is designed to fill gaps and take up volume. |
Flexibility/Compressibility |
Final cured gasket foam is still flexible. A 0.5" bead can easily be compressed to <1/16" by the force of screwing on drywall |
Final cured foam is rigid and not compressible |
This product was divested to R.L. Adams Plastics, Inc. Please contact them for further information.
Great Stuff™ sealants use moisture in the air to cure. They are designed to fill small cracks and gaps. The foam does not cure properly if it is used to fill large voids unless it is put down in layers and allowed to cure before the next layer is applied. Do not use Great Stuff™ sealants to fill enclosed voids such as behind drywall or under tub surrounds. Instead of using Great Stuff™, consider using Froth-Pak™ Foam Sealant system in cavity applications. Click the following link for more information on Froth-Pak™.
Visit Great Stuff™ for more information on products for the DIY.
The ANSI/SPRI (American National Standards Institute/Single Ply Roofing Industry) RP-4 Ballast Design Guide provides ballast requirements and is required by the International Building Code. Factory Mutual also provides requirements which are used in Factory Mutual insured buildings.
For more information, download Tech Solutions 508.3: Ballast Design Guide for PMR Systems 43-d100241.
For more details, contact your DuPont representative or call 1-833-338-7668.
For more information about SPRI and Factory Mutual, please visit the links below:
Since Great Stuff Pro™ Gasket is highly compressible, even a large bead size can still be compressed. Due to drying time, we don't recommend a bead size over 1' since drying will be much slower at greater thicknesses.
Yes.
The Ultra Air Barrier Wall System is a fully tested air barrier configuration which has passed the code requirements needed to be called an official air barrier. It was tested using the ASTM E2357 test method and the results of this testing far exceeded the required performance for an air barrier. The test results are the evidence that this system meets the code requirements for an air barrier.
Background:
An Air Barrier is defined in the 2012 International Building Code (IBC) as "Material(s) assembled and joined together to provide a barrier to air leakage through the building envelope. An air barrier may be a single material or a combination of materials."
The code goes further to outline what is required of an air barrier assembly in this section:
C402.4.1.2.2 Assemblies. Assemblies of materials and components with an average air leakage not to exceed 0.04 cfm/ft² (0.2 L/s • m²) under a pressure differential of 0.3 inches of water gauge (w.g.)(75 Pa) when tested in accordance with ASTM E 2357, ASTM E 1677 or ASTM E 283 shall comply with this section.
The test procedure ASTM E2357 "Standard Test Method for Determining Air Leakage of Air Barrier Assemblies" measures wall assemblies for their ability to resist air infiltration. This test not only tests the opaque part of the wall assembly, but also the ability to seal around penetrations in the test wall. Wall assemblies must be tested using this method and the result of this test must be less than 0.04 cfm/ft² (as stated above) if that wall assembly can be claimed to be an air barrier assembly that meets the code definition.
Tests were performed at Exova.
ASTM E2357 Test Equipment
Test Results
Both the 15.75 inch wide DuPont™ Styrofoam™ Brand Cavitymate™ Ultra Extruded Polystyrene (XPS) Foam Insulation board assembly with board joints sealed with Great Stuff Pro™ Gaps & Cracks Polyurethane Foam Sealant and the 48 inch wide DuPont™ Styrofoam™ Brand Ultra SL Extruded Polystyrene (XPS) Foam Insulation board assembly with board joints sealed with DuPont™ LiquidArmor™ Flashing and Sealant have been tested with this method and easily passed the code required air leakage rate of exceed 0.04 cfm/ft² (0.2 L/s • m²) under a pressure differential of 0.3 inches of water gauge (w.g.)(75 Pa). The test results are shown in the graph below.
The results from this testing show that the Ultra Air Barrier Wall System far exceeds the necessary air resistance as compared to the code requirement. The code requires an air infiltration level of no more than 0.04 cfm/ft² under a pressure differential of 0.3 inches of water gauge. The measured results, as can be seen in the chart, are about 0.016 cfm/ft² for the 15 ¾ inch wide DuPont™ Styrofoam™ Brand Cavitymate™ Ultra Extruded Polystyrene (XPS) Foam Insulation board assembly with board joints sealed with Great Stuff Pro™ Gaps & Cracks Polyurethane Foam Sealant and about 0.004 cfm/ft² the 48 inch wide DuPont™ Styrofoam™ Brand Ultra SL Extruded Polystyrene (XPS) Foam Insulation board assembly with board joints sealed with DuPont™ LiquidArmor™ Flashing and Sealant.
For more information see Ultra Air Barrier Wall System
The system R-values for the DuPont™ Thermax™ Wall System (TWS) are calculated using a methodology outlined by the American Society of Heating, Refrigeration, and Air-conditioning Engineers, ASHRAE, an organization with an extensive background and expertise in heat flow. This methodology is based upon the fundamental physics of heat flow and hundreds of full scale measured R-values.
Mice, raccoons and large pests, if determined enough, can chew through many materials, including Enerfoam™ sealant. If a barrier is needed for large pests, it is recommended a wire mesh be installed and Enerfoam™ sealant applied generously on both sides of the mesh. If a barrier is needed for insects, Great Stuff Pro™ Pestblock Polyurethane Foam Sealant provides a long-lasting, moisture resistant foam barrier that blocks out pests by sealing gaps, cracks and holes where they enter a home.
Click here for more information about DuPont™ Enerfoam™ Professional Foam Sealant.
Click here for more information about Great Stuff™ Pestblock Insulating Foam Sealant.
Click here for more information about Great Stuff Pro™ Pestblock Polyurethane Foam Sealant.
The block wall surface can be damp, but there must be no visible drops of water on the surface of the block. Like all adhesives, the presence of liquid water will interfere with the adhesive capabilities of the Great Stuff Pro? single component foam. (this applies to the 15 ¾ inch version of the Ultra Air Barrier Wall System).
For more information on the Ultra Air Barrier Wall System see:
Yes.
The spray foam can be installed in a thickness as low as 0.5 inches. Keep in mind that this will also reduce the thermal insulation contribution provided by the spray insulation toward the effective R-value of the wall. R-values and U-values listed in published tables for the Thermax™ Wall System will no longer be valid.
The 1.5 inch installed thickness will provide better assurance that all the air infiltration blocking properties are fully realized.
In a clean, dry area, store Tile Bond™ Roof Tile Adhesive at 40°F - 80°F (4.4°C - 26°C) to ensure adhesive quality, maximum yield and shelf life. DO NOT STORE AT TEMPERATURES ABOVE 120°F (49°C). Avoid prolonged storage in direct sunlight or near heat sources. Shake can prior to use - see information sheet on Tile Bond™ usage.
Click here for more information about Tile Bond™ Roof Tile Adhesive.
This varies dramatically with the expertise and care of the installer and with the thickness of the 15 ¾ inch wide DuPont™ Styrofoam™ Brand Cavitymate™ Ultra Extruded Polystyrene (XPS) Foam Insulation. About 200-400 linear feet of board joint can be sealed with a single 24 oz. can of Great Stuff Pro™ single component foam installed in a one-inch board thickness ¼ inch gap. An expert installer could probably get this same kind of yield on all thicknesses of insulation, but in general this doesn't happen. The table of approximate yields is shown below.
Board Thickness (in) |
Yield per 24 oz can (Linear Feet) |
1.0 |
200-400 |
2.0 |
150-300 |
3.0 |
100-200 |
For more information on the Ultra Air Barrier Wall System see:
Styrofoam™ Brand Extruded Polystyrene Foam Insulation is very moisture-resistant. Styrofoam™ Brand Extruded Polystyrene Foam Insulation is a good choice for residing because it does not absorb water and helps to keep water out of the wall. When used under new siding the continuous external insulation provided by the Styrofoam™ Brand Extruded Polystyrene Foam Insulation keeps the wall cavity warmer reducing the likelihood of moisture condensation. As for any wall retrofit work it is advised that the pre-retrofit condition of the wall be confirmed prior to work. Any defects that can allow moisture entry in the wall cavity should be eliminated prior to adding external insulation with new siding.
For more information, visit our website.
Enerbond™ Professional Foam Adhesive has the following benefits:
No. Thermax™ White Finish Polyisocyanurate Insulation does not have any additives in it to make it insect-resistant. However, covering the exposed edges of the foam with aluminum foil tape, along with regular pest control around the perimeter of the building, can reduce insect infestation.
For more information, visit our website.
Since local regulations vary, it is best to contact your local waste disposal facility to inquire about disposal of pressurized aerosol cans. DuPont manufacturing facilities are typically not licensed to receive hazardous waste and therefore cannot take back used canisters. If you have additional questions, call our DuPont Contact Center (DCC) at 1-833-338-7668.
When installed appropriately, DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation products can reduce or prevent damaging frost heave in a variety of applications. The correct thickness to prevent frost heave in a given application needs to be calculated based on the winter conditions in your area. Call 1-833-338-7668 for assistance with this calculation.
Yes, the canister can be recycled as long as it is completely depressurized and emptied of all chemical contents. Please check with your local landfill on safe disposal practices per jurisdiction. Please know that DuPont does not take back empty canisters.
Visit DuPont Adhesives to learn more and download literature about DuPont™ Insta Stik™ Quik Set Commercial Adhesive.
The major difference is sample orientation. The sample orientation for ASTM E84 is on the ceiling and the sample orientation for CAN/ULC S102.2 is on the floor. ASTM E84 is mainly used in the United States while CAN/ULC S102.2 is used in Canada.
For the best results, LiquidArmor™ CM and QS should not be installed over wet surfaces. Damp surfaces will delay the cure times for LiquidArmor™ CM and QS. Surfaces with standing water should be avoided.
Product Storage – DuPont™ Thermax™ (ci) Exterior Foam Insulation
The NFPA test is a two-story built wall assembly with a window. The pass/fail criteria is that flame propagation does not occur either vertically beyond an acceptable distance from the area of flame plume impingement on the exterior face of the wall assembly (second floor).
The NFPA test is needed to address model building code concerns. In the International Building Code Section 2603.5: Exterior walls of buildings of Type I, II, III and IV construction of any eight shall comply with Sections 2603.5.1 through 2603.5.7. Section 2603.5.5 requires that the wall assembly be tested in accordance with and comply with the acceptance criteria of NFPA 285 or UBC Standard 26-4.
DuPont has tested and passed NFPA tests for both DuPont™ Thermax™ Brand Insulation and DuPont™ Styrofoam™ Brand Insulation in steel stud wall constructions. The test reports for both DuPont™ Thermax™ Brand Insulation and DuPont™ Styrofoam™ Brand Insulation are available by calling 1-833-338-7668.
Steel is a very good conductor of heat. The R-Value** of steel varies with its precise makeup, but a representative value is about R-0.003 per inch according to the American Society of Heating Refrigeration and Air Conditioning Engineers (ASHRAE) Fundamentals Handbook. Figure 1 shows how the R-value of steel compares with other selected construction materials. (Note that the R-Value of steel is so low that it cannot be seen.)
The very low R-Value of steel means that heat moves through it almost effortlessly. Even small amounts of steel can transport large amounts of heat from one place to another. This property has serious consequences in the real- world performance of steel stud walls. Typical steel stud wall design places batt insulation between the studs, which are then sheathed with other low R-Value materials like gypsum board. This results in an uneven thermal distribution over the wall. The steel studs act as thermal short circuits, where heat moves rapidly around the batt insulation, reducing the system?s thermal performance.
ASHRAE has tabulated in Table A9.2A, in their 2010 ASHRAE 90.1 Standard and in 2013 ASHRAE 90.1 Standard, both measured and calculated effective R-Values for a variety of steel stud configurations which reveals the actual effective thermal performance of batt insulation compared to its claimed R-Value (see Table below).
The presence of the steel studs dramatically reduces the effective R-Value of the fiberglass insulation. This is why continuous insulation placed over the steel studs is so important in achieving higher insulation values.
Yes, Styrofoam™ Brand insulation can be installed directly on studs, without exterior sheathing, as long as all walls are properly braced in accordance building codes. See ESR 2142 for details.
DuPont™ Styrofoam™ Brand extruded polystyrene foam products should be stored on a clean, flat surface in an area free from flammable or volatile materials. When large quantities of the boards are stored indoors, it is recommended that the building be ventilated to allow a minimum of two air changes per hour.
When stored for long periods outside, the boards should be protected from exposure to direct sunlight in order to avoid surface degradation. Light colored plastic sheeting is the recommended protective cover. Avoid dark or transparent materials as they may cause excessively high temperatures to develop underneath the cover.
Solvent attacks may occur if the extruded polystyrene products are used in direct contact with materials containing volatile components.
Care should be taken to protect the boards from flames or other ignition sources during storage, installation and in use.
Buildings are covered in the National Building Code of Canada (NBCC) under:
Part 3 (Fire Protection, Occupant Safety and Accessibility)
Part 5 (Environmental Separation)
Part 9 (Housing and Small Buildings)
Yes, however not all pressure treated lumbers are treated (compositional make-up). In general pressure treated lumbers of the following chemistries are chemically compatible with DuPont™ Tyvek® Fluid Applied products: chromated copper arsenate, alkaline copper quaternary, and copper azole.
Pressure treated lumbers of disodium octaborate tetrahydrate (DOT) are not chemically compatible with DuPont™ Tyvek® Fluid Applied products.
The Sound Transmission Class (STC) of the Thermax™ Wall System was measured at 32 using two inches of DuPont™ Thermax™ (ci) Exterior Foam Insulation and no veneer. A typical brick veneer has an STC of 45-49 all by itself. DuPont estimates that the Thermax™ Wall System with a brick veneer will result in a system with an STC rating of 47-51 (STC ratings are not additive). Other veneers, such as metal panel, will result in a finished Thermax™ Wall System that will be less than that estimated for the brick veneer assembly but will probably result in an STC rating of 39-40.
Yes, DuPont™ Styrofoam™ Brand products can be used as building interior applications. See successful application of Styrofoam™ for building interior by following the links below:
INTERIOR FOUNDATION INSULATION
However, Styrofoam™ Brand products should not be left exposed. A layer of Gypsum board or other fire resistant board should be used to cover the Styrofoam™ Brand products. In some instances, Styrofoam™ Brand insulation can be left exposed. Please consult the building code applicable to your jurisdiction.
Was there a change in facer color regarding the DuPont™ Isocast™ R Polyisocyanurate Foam Insulation?
While the facer color on some DuPont Polyisocyanurate Insulation products did change from black to blue, the DuPont™ Isocast™ R Polyisocyanurate Foam Insulation facer color did not change.
Yes, there are some details for balloon steed stud framing for the Thermax™ Wall System. Details in PDF format are attached below this answer. Details are also available on the Thermax™ Wall System web site.
Contact your local DuPont representative to discuss custom details.
DuPont™ Styrofoam™ Brand products have excellent moisture resistance which allows it to maintain its thermal performance for a very long period of time. Past experience showed that Styrofoam™ Brand products can be used underground for 30 years and still maintain excellent thermal value. In DuPont North America, there are limited 15, 30 and 50- year thermal warranties for Styrofoam™ Brand products, which shows DuPont's confidence in the long-term thermal performance of Styrofoam™ when properly used and installed.
The following ICC-ES evaluation reports are available for DuPont products:
If you need a copy of the above mentioned evaluation reports, please call 1-833-338-7668.
YES.
The foam should not be exposed to sunlight (UV) or submerged in water or it will break down over time. Coating or painting the foam with a waterproof, UV resistant elastomeric coating will protect it from UV degradation and water infiltration. Froth-Pak™ is water resistant but not waterproof. Typically the foam is not harmful to fish or other animals; however, DuPont has not performed specific testing in this area.
Click here for more information about Froth-Pak™ sealant products.
Canadian Standard CAN/ULC S701 covers the physical and thermal properties required for various types of extruded polystyrene insulation. This standard does not specify density requirements for the various types of products. For this reason, DuPont does not report product densities for extruded polystyrene insulations made in Canada.
The U.S. Standard ASTM C578 covers the physical properties required for extruded polystyrene insulations made in the U.S. Search ASTM C578 for information on the properties in this standard. Visit their website for more information.
There are multiple benefits for continuous insulation to be used in homes looking for ENERGY STAR Version 3 compliance. The major benefits are outline as following:
For further details about how continuous insulation products from DuPont Performance Building Solutions contribute to ENERGY STAR for Homes Version 3 program, please feel free to call the DuPont Contact Center (DCC) at 1-833-338-7668.
More information can be found from ENERGY STAR for Homes website:
The approximate weight for Thermax™ White Finish Polyisocyanurate Insulation is:
1/2' board weighs 3.6 lbs 1' board weighs 6.0 lbs 2' board weighs 11.0 lbs
For more information, visit our website.
DuPont™ Insta Stik™ Quik Set Commercial Adhesive is recommended and warranted for use with 4' x 4' polyisocyanurate insulation boards ONLY. All other insulation and recover boards can be applied with 4' x 8' boards. Failure to use 4' x 4' polyisocyanurate boards will void all adhesion warranties.
Visit DuPont™ Insta Stik™ Quik Set Commercial Adhesive to learn more and download literature about DuPont™ Insta Stik™ Quik Set Commercial Adhesive.
Yes, a 'Grade I' insulation installation is required for homes to be certified based on the new ENERGY STAR for Homes Version 3 requirements.
No. Much has been written on the so-called "double vapor barrier myth." This is a misconception that water vapor will become trapped between the vapor barrier on the warm side of the wall and a low permeance sheathing, like DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation, on the cold side. This moisture is thought to cause the studs to rot and the building to decay. DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation products are usually targeted because of their low water vapor permeance. Also, some allege that DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation does not "breathe" as some competitive products claim. Testing experience by The Dow Chemical Company, third parties as well as field testing has demonstrated that the "double vapor barrier" is indeed a myth. New homes with DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation sheathing have proven to perform well and actually have dryer wall cavities than those with conventional non-insulating sheathings.
In retrofit applications, DuPont™ Styrofoam™ Brand extruded polystyrene foam insulation can be used under new siding finishes. Such walls may originally have little or no insulation and a separate interior vapor barrier may be absent. There is a fear that the new exterior insulating sheathing will act as a vapor barrier, trapping moisture in the wall. In fact, if the original wall did not suffer from any moisture accumulation in the cavity prior to adding insulation in a retrofit/residing, then the addition of exterior insulation will only improve the thermal and moisture performance of that wall.
For more information:
Tech Solutions 214.0: Reduce Wall Condensation Potential With Insulated Sheathing describes in detail the concerns and the reality of this phenomenon (923 KB)
The ASTM C578 (2012b) physical property requirements and types for extruded polystyrene insulation products are as shown in the table below:
Properties | Type X | Type IV | Type VI | Type VII | Type V |
Thermal Resistance R-value per inch at 75°F |
5.0 | 5.0 | 5.0 | 5.0 | 5.0 |
Density, min, pcf |
1.30 | 1.45 | 1.80 | 2.20 | 3.0 |
Water Vapor Permeance, max, perms for 1' |
1.5 | 1.5 | 1.1 | 1.1 | 1.1 |
Compressive strength, min, psi |
15 | 25 | 40 | 60 | 100 |
Water absorption, max, % by volume |
.3 | .3 | .3 | .3 | .3 |
Dimensional Stability, max % |
2 | 2 | 2 | 2 | 2 |
Styrofoam™ Brand SPF and Styrofoam™ Brand XPS Insulation work very well together. However, close attention must be given to proper application. Keep the Styrofoam™ Brand SPF first layer thickness to 1.0 - 1.5 inches or less. Make sure that the first layer is cooled and cured before adding extra layers. This reduces the exposure of Styrofoam™ Brand XPS Insulation to excessive heat generated by the exothermic reaction of SPF application. Styrofoam™ Brand XPS Insulation will “curl” or “warp” if it gets too hot. Keep in mind that the maximum use temperature for Styrofoam™ Brand XPS Insulation is 165°F.
ASTM C1289 "Standard Specification for Faced Rigid Cellular Polyisocyanurate Thermal Insulation Board" (Version 2005) types and properties are as shown below:
Polyisocyanurate foam insulation products from DuPont are made to ASTM C1289 standards, which require certain minimum properties; density is not part of this standard. According to ASTM D1622, the typical nominal densities are 2.0 pcf.
Although density is sometimes used to select a rigid foam insulation material for certain applications, it should be noted that there are other performance properties listed in ASTM C1289 that are usually more important to consider when choosing the proper product for the intended application.
Yes, it is a 1-Hour, Non-Load Bearing UL rated assembly # V482. This assembly has passed the standard test ASTM E119 for the determination of hourly rated wall systems. This is only for the DuPont? Thermax? Wall System (TWS) with several possible veneers in addition to standard brick:
The full details can be found at the UL website.
Click on 'Certifications Directory' and search for V482 in the UL File Number field.
Depending on where you live, you can buy Great Stuff Pro™ products from local hardware stores (i.e. Lowes, Home Depot, Menards) near you.
Please contact the DuPont Contact Center at 1-833-338-7668 for a list of distributors in your location.
Great Stuff Pro™ Products
Froth-Pak™ foam does not contain organic solvents that will dissolve Styrofoam™ Brand Extruded Polystyrene Foam Insulation or other plastics. Froth-Pak™ foam will bond permanently to all commercially available plastics except for Teflon™ fluoropolymers from Chemours™ and lubricious polyolefins such as polypropylene and polyethylene.
Click here for more information about Froth-Pak™ sealant products.
As a result of the ASTM E330 testing, DuPont recommends a fastening pattern of 12” o.c. around the perimeter and 16” o.c. in the field. The Rodenhouse Inc. Thermal-Grip Fastener is recommended, but other designs may be acceptable.
Perimeter fasteners can be detailed to bridge the gap of abutting board joints due to the 2” diameter of the washer used to fasten the board to the studs. These self-sealing fasteners and washers do not need additional sealing. Tighten fasteners until washer lies tight and flat against the insulation board, thus creating a seal.
Rodenhouse Thermal-Grip Fasteners
• 2” diameter washer with solid cap design (no keyholes)
• Pre-spotting prongs
• Stiffened center “Bullseye” ring prevents fastener pull-through
• Flexible perimeter compresses on surface and reduces tearing
• Flattens on surface of insulation
• Carbon Black UV Stablilizers
Detailed installation tips:
For fastener type and frequency guidance to installing cladding over thick foam sheathing, refer to the Foam Sheathing Coalition, TechMatters: Guide to Attaching Exterior Wall Covering Through Foam Sheathing to Wood or Steel Wall Framing. Download details from www.bia.org.
If your spray pattern becomes noticeably different (i.e. cone spray changes to stream), this may be caused by dispensing foam with a used nozzle. Always inspect a nozzle prior to dispensing to make sure you have an unused nozzle mounted in the INSTA-FLO™ gun dispenser. Another issue that may cause a clogged nozzle would be storing at too low of temperatures.
If the foam or spray pattern does not react properly, replacing the nozzle will usually correct the problem. If the problem persists, remove the nozzle and carefully activate the dispenser (without a nozzle attached) into a waste container. Two chemical streams of approximately equal volume should flow. If streams are unequal, a blockage has occurred. Shut off the tank valve on the side that is flowing properly and activate the trigger full force for fifteen (15) seconds. Once the blockage is freed, turn off all tank valves. Use a rag to clean any chemical from the face of the INSTA-FLO™ dispenser and reapply petroleum jelly. Insert an unused nozzle, open all valves and dispense a test shot into a waste container. After curing, check the foam quality.
If problems still occur, stop foaming. Turn off canister valves, eject the used nozzle, and release chemical line pressure by activating the dispenser into a waste container. Slowly loosen the hose connections at the valves. Clean chemical from the threads and replace with a new INSTA-FLO™ dispenser/hose assembly. If the replacement of the INSTA-FLO™ dispenser/hose assembly does not solve the problem, please contact the DuPont Contact Center (DCC) at 1-833-338-7668.
To prevent hoses from clogging. If your dispenser has not been used for one week or longer, activate the system for a few seconds by turning on the tank valves and squeezing the trigger fully without a nozzle attached to dispense twin streams into a waste container. This will clear and repressurize the hoses and should be done every week when the system is idle. Re-apply petroleum jelly and reinsert used nozzle for storage.
If dispensed foam is friable or brittle. The foam is ISO rich, and a partial blockage of the polyol side exists. Clear the blockage from the POLYOL side.
If dispensed foam remains soft or mushy, the foam is POLYOL rich and a partial blockage of the ISO side exists. Clear the blockage from the ISO side.
What is the heat combustion content of DuPont™ Thermax™ Brand Insulation polyisocyanurate products?
Southwest Research Institute Report 01.19865.01.002 documents the results of NFPA 259-98, 'Standard Test Method for Potential Heat of Building Materials' on the core foam used in Thermax™ Brand Polyisocyanurate Insulation boards. The results were:
Potential Heat of Combustion = 10,930 BTU/lb.
LiquidArmor™ CM, QS and LT have been designed to seal and flash, including the foam insulation boards, for the intended service. LiquidArmor™ CM, QS and LT have been tested and shown outstanding outcomes in both accelerated laboratory testing.
LiquidArmor™ QS has undergone performance testing per AAMA 714 after conditioning intended to accelerate product aging via QUV and elevated temperature exposure.
Real Time Weathering: LiquidArmor™ CM has been left uncovered, exposed outdoors since 2010 and counting. It has survived hurricane Sandy and Irene, several cold winters and hot summers. No material cracking or color degradation has been observed. Further, weather elements and time have had no visible impact on adhesion. Similarly, LiquidArmor™ LT has been left uncovered, exposed outdoors in Climate Zone 5 for over 2 years with no material cracking, degradation or visible impact on adhesion.
Accelerated Laboratory Testing: In addition to field testing, LiquidArmor™ CM and LT have undergone performance testing per ASTM C794 after conditioning intended to accelerated product aging via QUV and elevated temperature exposure.
Flame spread and smoke developed values are reported by product AND by thickness based on CAN/ULC S102.2. The following table outlines the values for products made in Canada:
Since local regulations vary, it is best to contact your local waste disposal facility to inquire about disposal of pressurized aerosol canisters. In many areas, the DuPont™ Insta Stik™ Quik Set Commercial Adhesive canister (when depressurized and completely emptied of chemical contents) can be discarded in a dumpster. DuPont manufacturing facilities are not licensed to receive hazardous waste and therefore cannot take back used cans.
Visit DuPont Adhesives to learn more and download literature about DuPont™ Insta Stik™ Quik Set Commercial Adhesive.
HH-I-530A was the federal standard covering both faced and unfaced polyurethane and polyisocyanurate thermal insulation in 1971. It was superseded by HH-I-530B (unfaced products) and HH-I-1972 (faced products) in 1981, and more recently by ASTM C1289 'Standard Specification for Faced Rigid Cellular Polyisocyanurate Thermal Insulation.'
Many specs have request for HH-I 1972. Type 1 / Class 2, which is DuPont™ Thermax™ Brand Insulation.
ASTM C1289 types for the polyisocyanurate insulation boards produced by The Dow Chemical Company are:
Tuff-R™, Super Tuff-R™: Type I, Class 1 or 2 depending on thickness
Tuff-R™ Commercial, Super Tuff-R™ Commercial: Type I, Class 2
ISOCAST™ R: Type I, Class 1
Thermax™ family of products: Type I, Class 2
The coverage rates for LiquidArmor™ CM, QS and LT vary with the thickness and width applied as well as the building design. The theoretical yield for a 5 gallon pail, assuming a 50 wet mil application thickness, is:
Table 1: LiquidArmor™ CM Flashing and Sealant Theoretical Yield
Application Width (Inches) |
Theoretical Yield/Pail at 50 wet mil (Linear feet) |
2 |
794 |
3 |
529 |
4 |
397 |
6 |
265 |
8 |
198 |
The coverage rates for LiquidArmor™ LT vary with the thickness and the width applied as well as the building design. The house theoretical yield for a 2 gallon pail and 20 oz sausage, assuming a 30 wet mil application thickness, is:
Table 2: LiquidArmor™ LT Flashing and Sealant Theoretical Yield
Application Width (Inches) |
20 oz Sausage Theoretical Yield at 30 mil wet (Linear Feet) |
2 Gallon Pail Theoretical Yield at 30 mil wet (Linear Feet) |
1 |
105 |
1120 |
2 |
53 |
560 |
3 |
35 |
373 |
4 |
26 |
280 |
6 |
18 |
187 |
8 |
13 |
140 |
DuPont™ Thermax™ Polyisocyanurate Insulation or other polyisocyanurate insulations are NOT recommended for use in radiant floors. Various DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation solutions are recommended for use in this application.
For additional information, visit our website.
Styrofoam™ Brand Extruded Polystyrene Foam Insulation has been tested according to ASTM D1929 (NFPA 259) “Standard Test Method for Potential Heat of Building Materials” with the result of a potential heat of 17,779 BTU/lb.
Thickness (inches) |
Btu/ sq.ft. |
1 |
2,667 |
2 |
5,334 |
3 |
8,001 |
4 |
10,667 |
These results are for the product tested (1.8 lb/ft3 nominal density). Styrofoam™ Brand Extruded Polystyrene Insulations with a density less than the Styrofoam™ Brand Insulation tested would have a lower heat potential. Styrofoam™ Brand Extruded Polystyrene Foam Insulations with a density more than the Styrofoam™ Brand Insulation tested would have a higher heat potential.
Factory Mutual publishes a series of Loss Prevention Data Sheets to provide guidance on how to minimize losses primarily due to wind and/or fire events. One of these data sheets is 'Roof Deck Securement and Above Deck Roofing Components'. Loss Prevention Data Sheet 1-29 provides recommendations for the proper design and installation of above-deck roof components, including roof covers, insulation, and vapor retarders. It includes fastening patterns for insulation boards of 2x4 (2-9 fasteners), 3x4 (3-12 fasteners), 4x4 (4-14 fasteners), and 4x8 (8-24 fasteners). It also contains ballast recommendation for ballasted roof assemblies. If you have further questions on this topic, please call 1-833-338-7668 or visit the FM Global web site:
DuPont recommends the use of DuPont™ Weathermate™ Housewrap or DuPont™ Weathermate™ Plus Housewrap in Portland cement stucco systems, only when the Housewrap is not in direct contact with the stucco. Separation from the stucco can be achieved with appropriate foam, air space, Grade D building paper or No. 15 felt.
For more information on Weathermate™ Housewrap, visit our website.
Yes.
Froth-Pak™ Foam Insulation has been used over the years in a multitude of Transportation applications from foaming refrigerated trailers to boat hulls, the INSTA-FLO™ gun and nozzles make this application ideal for Froth-Pak™. For additional Information please contact DuPont Contact Center (DCC) at 1-833-338-7668.
The 2012 International Building Code (IBC) requires that foam plastic insulation can be separated from the interior of the building by means of a thermal barrier unless specific requirements are met. The exact wording in the code is:
'Except as provided for in Sections 2603.4.1 and 2603.10, foam plastic shall be separated from the interior of a building by an approved thermal barrier of 1/2-inch (12.7 mm) gypsum wallboard or a material that is tested in accordance with and meets the acceptance criteria of both the Temperature Transmission Fire Test and the Integrity Fire Test of NFPA 275. Combustible concealed spaces shall comply with Section 718.”
“Section 2603.4.1.5 Roofing: Foam plastic insulation under a roof assembly or roof covering that is installed in accordance with the code and the manufacturer's instructions shall be separated from the interior of the building by wood structural panel sheathing not less than 0.47 inch (11.9 mm) in thickness bonded with exterior glue, with edges supported by blocking, tongue-and-groove joints or other approved type of edge support, or an equivalent material. A thermal barrier is not required for foam plastic insulation that is a part of a Class A, B or C roof-covering assembly, provided the assembly with the foam plastic insulation satisfactorily passes FM 4450 or UL 1256.”
The basis of DuPont's approval to install DuPont™ Styrofoam™ Brand Deckmate™ Extruded Polystyrene (XPS) Foam Insulation directly on steel roof decks with some roof covering assemblies is that DuPont™ Styrofoam™ Brand Deckmate™ Extruded Polystyrene (XPS) Foam Insulation passed UL 1256 for the roofing assemblies listed in UL 440 and UL 260.
There are several acceptable joint treatments for DuPont™ Thermax™ Brand Insulation products listed above:
Note: PVC cannot support Thermax™ board alone - additional fasteners are required.
Yes. One method to meet with the air barrier requirements of the 2013 version of ASHRAE 90.1 is to comply with Section 5.4.3.1.3, which states that assemblies can be tested per ASTM E2357. If the tested assembly’s air leakage rate does not exceed 0.2 L/s-m2 at a 75 Pa pressure differential it meets the ASHRAE 90.1 requirement.
The attached link offers suggestions from the U.S. Department of Energy to help you build a home that saves energy. Use of insulating sheathing, like DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation products, DuPont™ Thermax™ Brand polyisocyanurate foam sheathing, Froth-Pak™ Foam Sealant and Great Stuff Pro™ Foam Sealant can help homeowners save energy, reduce potential moisture problems and enhance occupant comfort for many years.
Styrofoam™ Brand Extruded Polystyrene Foam Insulation is sold through hundreds of distributors and building material dealers across .
Call 1-833-338-7668 for information about a distributor near you.
Factory Mutual Global (FMG) has very few requirements for commercial wall systems that are different than the standard International Building Code (IBC) requirements. There are no special requirements that the Thermax™ Wall System would need to meet when it comes to FMG.
It is possible, but not certain. The size of the Heating, Ventilating, and Air Conditioning (HVAC) equipment depends on many factors of which the opaque wall area is just a portion. If the effective R-Value of the opaque wall with the DuPont™ Thermax™ Wall System (TWS) is significantly greater than the original assembly and the wall area is a significant portion of the total envelope, then HVAC size reduction becomes far more likely. The engineer sizing the HVAC for the particular project should determine if HVAC size reduction is possible.
ASTM C1289 is a U.S. standard used to classify polyisocyanurate-based foam insulations. It is a Standard Classification as Standard Specification for Faced Rigid Cellular Polyisocyanurate Thermal Insulation Board. The standard classifies these insulations based on their physical properties such as: R-value, compressive strength, water absorption, and facers.
No.
The exterior facer of Thermax™ (ci) Exterior Foam Insulation was also tested for extended contact with a high pH material per ASTM D1308. Testing was conducted with a solution that had a pH of approximately 12.5, which is similar to the pH of uncured mortar/concrete. This solution was placed on the surface of the Thermax™ (ci) Exterior Foam Insulation and allowed to sit for a period of 28 days while maintaining the pH of 12.5. During this 28-day period the samples were checked for any detrimental effects that the solution would have on the surface of the Thermax™ (ci) Exterior Foam Insulation, such as facer deterioration or discoloration. No detrimental effects were noted during this testing, thus qualifying this material for incremental contact with mortar during the build-up of a brick veneer assembly.
C-value, c-factor, or just “c” is a measure of the insulation value of a material. It refers to how many BTU's will flow in ONE hour through ONE square foot of ONE OR MORE MATERIALS of ANY THICKNESS when the temperature difference between the hot side and the cold side is ONE degree F (e.g. a 3.5' thick fiberglass batt with a factory-applied vapor retarder). C-values get smaller numerically as the insulation gets thicker. Since the c-value is identifying the number of Btu's being 'lost' through the insulation, increasing the thickness of insulation has the effect of decreasing the amount of heat passing through the insulation. U.S units expressed in Btu/hr.ft2.deg F.
SI units expressed in W/m2.deg C.
CAN/ULC S102 is titled “Surface Burning Characteristics of Materials” (Steiner Tunnel - Ceiling Mounting), the tunnel test used in Canada for thermoset products or materials that do not melt.
DuPont™ Styrofoam™ Brand SILL SEAL Foam Gasket is a closed-cell polyethylene foam with excellent chemical resistance properties. Based on chemical resistance testing of solid polyethylene in accordance with ASTM D543-60T, Styrofoam™ Brand SILL SEAL Foam Gasket should not be adversely affected if in long-term contact with ACQ compounds. Continued direct contact of STYROFOAM™ Brand SILL SEAL Foam Gasket for a period of months to years with liquid ACQ compounds is expected to cause, at most, very slight foam discoloration. Therefore long-term contact of DuPont™ Styrofoam™ SILL SEAL Foam Gasket with ACQ-treated wood products is expected to show no more, but most likely, even less effect.
Note: ACQ-treated wood use in normal construction may come in contact with other building materials such as flashings, concrete, fasteners, joist hangers, sheathing products, insulation, etc. DuPont cannot comment on the compatibility of other manufacturers’ products with ACQ-treated wood. Specific products’ compatibility concerns with ACQ-treated wood should be addressed by contacting the specific building material manufacturers.
The installation guides for DuPont Weatherization Systems products can be found at: http://www.dupont.com/products-and-services/construction-materials/building-envelope-systems/articles/how-to-install.html
This will depend upon how much fireproofing had been applied to the steel stud and how tenaciously it is attached. The spray foam will adhere very well to almost anything it touches, including the fireproofing. However, if the fireproofing is friable or poorly attached to the stud, it will act as a release agent. The best alternative is to scrape the steel studs as clean as possible before spraying.
The steel stud and DuPont™ Thermax™ (ci) Exterior Foam Insulation substrates must be free of moisture (dew or frost), grease, oil, solvents and other materials that would adversely affect the adhesion of the polyurethane foam. Poor adhesion will result in stud line cracking of Styrofoam™ Brand Spray Polyurethane Foam.
YES.
Thermax™ Brand Insulation and Tuff-R™ (ci) Polyisocyanurate Foam Insulation product lines carry a 15-year limited thermal warranty. Actual thermal resistance is warranted to not vary by more than 10% during the warranty period.
The FM Class 1 rated roof assemblies for Concrete Deck for Styrofoam™ Brand Extruded Polystyrene Foam Insulation products are:
FM Class 1 rated roof assemblies with Styrofoam™ Brand Extruded Polystyrene Foam Insulation are also achievable with Steel Decking.
The requirement for B2 fire rating is flame height < 150mm.
The following insulations can be used with DuPont™ Insta Stik™ Quik Set Commercial Adhesive:
Visit DuPont™ Insta Stik™ Quik Set Commercial Adhesive to learn more and download literature about DuPont™ Insta Stik™ Quik Set Commercial Adhesive.
No. DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation products are not now, nor have they ever been, manufactured with or contain asbestos.
This determination is based on compositional information provided to DuPont by its raw material suppliers. DuPont relies on the suppliers to provide accurate data. DuPont is not responsible for any misrepresentation resulting from inaccurate information from its suppliers.
Approved fasteners for the DuPont™ Thermax™ Wall System (TWS) are listed below and here.
Wind-Lock
Wind-LOCK Fasteners and Washers
www.wind-lock.com/
1-800-872-5625
Heckmann Building Products
POS-I-TIE System or Drill Bolt System
www.heckmannbuildingprods.com
1-800-621-4140
FERO Slotted Stud Tie (Type II)
www.ferocorp.com
1-780-455-5098
Hohmann & Barnard
X-SEAL Anchor
www.h-b.com
1-800-645-0616
Dayton Superior
Dur-O-Wal Veneer Anchors
www.daytonsuperior.com
1-877-632-9560
When installed as a gasket (on an 8' x 8' test wall according to ASTM E283) on the bottom plate, side studs and upper of the double top plates, Great Stuff Pro™ Gasket blocked 98% of air leakage at 50Pa, and 94% at 500 Pa, vs a wall with no drywall gasket.
Yes. DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulations have International Code Council (ICC) National Evaluation Services (NES) reports.
The specific NES evaluation reports can be viewed or downloaded here.
Surprisingly enough, many homeowners believe that insulation saves energy in the winter but not in the summer. But heat is slowed by insulation whether it is moving inside to out or vice versa. In fact, most homes built in northern climates have much lower energy costs than do homes built in southern climates because of this very misconception (homes in the North are better insulated than homes in the South). Additional effort to insulate a home in the South will reap the same monetary saving benefits as homes in the North. The proper use of an insulated sheathing such as DuPont™ Styrofoam™ Brand or Tuff-R™ Brand Insulations and air infiltration sealants such as Great Stuff™, can have a dramatic impact on air conditioning energy costs for homes built in southern climates.
TMThe DuPont Oval Logo and DuPont™ are trademarks or registered trademarks of DuPont de Nemours, Inc. or its affiliates.
No. DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation products have been shown not to have met any hazard category.
DuPont has tested various underlayments. In Addition, our current Underwriters Laboratory ESR report also lists approved underlayments. UL ER18231-01 A copy of the approvals is available through the DuPont Contact Center (DCC). If a specific product is not on the list, please contact the DuPont Contact Center (DCC) at 1-833-338-7668 to discuss testing options.
Click here for more information about Tile Bond™ Roof Tile Adhesive.
Styrofoam™ Brand rigid insulation products can potentially contribute to the following categories of LEED v4 points:
Please feel free to call 1-833-338-7668 when you need additional LEED information for Styrofoam™ Extruded Polystyrene Insulation products from DuPont for a particular LEED certified/designed job.
No. Foam plastic insulation should be covered with a thermal barrier in accordance with the Canadian National Building Code (NBCC).
Please make sure to check with your local code official for final product approval of use.
Prior to ENERGY STAR Home Version 3, Version 2 ENERGY STAR home is a home with energy efficiency 15% or better compared to 2004 International Energy Conservation Code (IECC). Homes built to the current Version 3 ENERGY STAR home program are approximately 20% more efficient than homes built to the 2009 International Energy Conservation Code (IECC).
More information about the ENERGY STAR home requirements, please visit EPA website at:
DuPont™ Thermax™ Brand Insulation polyisocyanurate products have been tested. Their STC is in the very low 10-15 range. The foil facers do not absorb sound and instead they may reverberate it into the room.
When z-furring is used to secure the insulation sheathing, is it still considered to be continuous?
No.
Insulation placed between z-furring does not meet the definition of continuous insulation. This is because the z-furring represents a line of continuous metal penetrating the insulation and short circuiting heat around the insulation. This dramatically reduces the effective R-Value of the insulation.
A continuous insulation layer can only be achieved when the amount of metal that penetrates the insulation can be made very small, such as when only fasteners penetrate the insulation.
When you compare the two illustrations, you can see that fasteners contain only a small fraction of the metal cross section as does the z-furring. Insulation held in place with fasteners is considered continuous, z-furring is not.
The current leading green program for residential market is as follows:
1. NAHB Green Program
National Association of Home Builders launched its Green Model Home Buildings Guidelines in February 2008. It addresses a variety of environmental issues such as site, energy, water, resources, operation and maintenance and home owner education, and global impact. Different points are assigned in each of these categories. Total points obtained and minimum points achieved in each category determine the final rating of the green home.
2. LEED for Homes
LEED for homes is launched at the beginning of 2008 by US Green Building Council. Similar to NAHB Green guidelines, LEED for Homes also has a variety of environmental issues addressed such as Innovation and Design, Location and Linkage, Sustainable Sites, Water Efficiency, Energy and Atmosphere, Materials and Resources, Indoor Environmental Quality, and Awareness and Education. Total points obtained and minimum points achieved in each category determine the final rating of the green home.
3. ENERGY STAR Program
ENERGY STAR program only addresses energy efficiency for a home. Other environmental features such as those included in NAHB Green Guidelines and LEED are Homes are not included in ENERGY STAR program. There are two approaches to certify whether a home is meeting ENERGY STAR requirements:
Ø The Performance path
Ø The Prescriptive path
An ENERGY STAR home requires 15% or more energy efficient compared to 2004 IRC. A certified HERS (Home Energy Rating System) rater is required to certify the HERS index of a home. The HERS index requirements are:
Ø 85 or lower for climate zone 1-5
Ø 80 for climate zone 6-8
In addition to meeting the HERS index listed above, thermal bypath checklist is also required for either of the above stated approaches.
DuPont no longer makes Styrofoam™ Brand Roofmate™ CT Extruded Polystyrene Foam Insulation. However, DuPont continues to offer several other rigid foam insulation products designed for roofing applications:
Styrofoam™ Brand Deckmate™
http://building.dow.com/na/en/products/insulation/deckmate.htm
Styrofoam™ Brand Deckmate™ Plus
http://building.dow.com/na/en/products/insulation/deckmateplus.htm
Styrofoam™ Brand Deckmate™ Plus FA
http://building.dow.com/na/en/products/insulation/deckmateplusfa.htm
Styrofoam™ Brand Highload 40
http://building.dow.com/na/en/products/insulation/highload40.htm
Styrofoam™ Brand Highload 60
http://building.dow.com/na/en/products/insulation/highload60.htm
Styrofoam™ Brand Highload 100
http://building.dow.com/na/en/products/insulation/highload100.htm
Styrofoam™ Brand Plazamate™
http://building.dow.com/na/en/products/insulation/plazamate.htm
Styrofoam™ Brand Roofmate™
http://building.dow.com/na/en/products/insulation/roofmate.htm
Styrofoam™ Brand Roofmate™ Ribbed
http://building.dow.com/na/en/products/insulation/roofmateribbed.htm
Thermax™ Heavy Duty
http://building.dow.com/na/en/products/insulation/thermaxhd.htm
Thermax™ Heavy Duty Plus
http://building.dow.com/na/en/products/insulation/thermaxhdplus.htm
Thermax™ Light Duty
http://building.dow.com/na/en/products/insulation/thermaxld.htm
Thermax™ Metal Building Board
http://building.dow.com/na/en/products/insulation/thermaxmetal.htm
Thermax™ Sheathing
http://building.dow.com/na/en/products/insulation/thermaxsheathing.htm
No. There are no Styrofoam™ Brand Extruded Polystyrene Foam Insulation products that are used in this manner.
Yes. Tapered roof insulation is probably the most common example of hot wire cut Styrofoam™ Brand Extruded Polystyrene Foam Insulation. Care needs to be taken in the use of a hot wire cutter. Wire temperature and speed of cutting are important factors in achieving clean cuts without excessive melt back or fire hazard. Manufacturers of a variety of hot wire cutters include:
Demand Products Inc.
CROMA Foam Cutting Technologies
For detailed chemical resistance listings for rigid foam insulation products from DuPont, call 1-833-338-7668.
One side of Super Tuff-R™ and Super Tuff-R™ Commercial Polyisocyanurate Insulations has an outer polymer layer, thus the chemical resistance is different compared to the foil-faced side.
The dual listing for cements and mortar must be used any time a chemical resistance table is referencing Super Tuff-R™, Super Tuff-R™ Commercial because the outer layer of each side is different.
Chemical Resistance of Polyisocyanurate Insulation | |||
Acid, inorganic | Not Recommended | Hydrocarbons | Excellent |
Acid, organic | Excellent | Insecticides | Excellent |
Alcohol | Excellent | Kerosene | Excellent |
Asphalt, water-based | Good | Mineral Oil USP | Excellent |
Bases (caustics) | Poor | Naphtha | Excellent |
Brines and other salts | Excellent | Paints, alcohol-based | Excellent |
Cements and mortar | Poor (aluminum foil facers)/ Excellent (other facers) |
Paints-water based | Excellent |
Gases, carbon dioxide (CO2) | Excellent | Polyglycols, including propylene glycol |
Excellent |
Gasoline | Excellent | Water¹ | Excellent |
NOTE: This table should be used only as a guide. For design purposes, specific test data on the intended application may be needed.
¹Water may cause discoloration of aluminum facers. This does not impact the R-value of dry, core insulation.
LiquidArmor™ Flashing and Sealant products meet many industry standards and Code requirements. They meet the >100 50 g/L Volatile Organic Content (VOC) limit under California's South Coast Air District's current rules. LiquidArmor™ CM, QS and LT are a liquid flashing material that can help to meet Florida Building Code requirement for flashing exterior windows and door openings as it is one of the product types called out in AAMA200 Installation of Windows with Frontal Flanges for Surface Barrier Masonry Construction for Extreme Wind/Water. In addition, LiquidArmor™ CM, QS and LT are compliant with and can help meet the International Building Code (IBC), International Energy Conservation Code (IECC) and the 2013 ASHRAE 90.1 requirements for air and/or water-resistive barrier systems.
The differences in insulation requirements are as follows:
Zone 1 | Zone 2 | Zone 3 | Zone 4 except Marine |
Zone 5 and Marine 4 |
Zone 6 | Zone 7 | Zone 8 | |
ASHRAE 90.1 2004 | NR | NR | NR | NR | NR | NR | R7.5ci | R7.5ci |
ASHRAE 90.1 2007 | NR | NR | NR | NR | R7.5ci | R7.5ci | R7.5ci | R7.5ci |
NFPA 285 test is a two-story built wall assembly with a window. The pass/fail criteria is that flame propagation does not occur either vertically or laterally beyond an acceptable distance from the area of flame plume impingement on the exterior face of the wall assembly (2nd floor). NFPA is different from hourly related assemblies. Hourly related assemblies are based on ASTM E119 measuring the resistance of wall for heat penetration/temperature rise for a certain period of time.
“Therm” typically refers to a quantity of heat: 100,000 BTUs. Gas utilities typically charge by the Therm, which is usually about 100 cubic feet of natural gas.
Bison ScrewJack pedestals are compatible with DuPont™ Styrofoam™ Brand Highload 40, 60 and 100 Extruded Polystyrene (XPS) Foam Insulation in plaza deck construction applications. The large bearing area of the base of the ScrewJack pedestal is well designed to spread the load of pavers and foot traffic, which reduces the pressure on the insulation and increases design flexibility.
Bison Screwjack Pedistals
As with all pedestal/paver assemblies using the Protected Membrane Roofing (PMR) design concept, care must be taken in selecting the proper grade of Styrofoam™ Brand Highload Insulation for the conditions expected on the traffic surface.
For more information on PMR Plaza Deck assemblies, visit: Plaza Protected Membrane Roofing
Yes. Spray-applied polyurethane foam can be applied directly to DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation and DuPont polyisocyanurate foam insulation. When applied over Styrofoam™ Brand Extruded Polystyrene Foam Insulation the SPF application must be applied in layers no more than 1.0-1.5 inches thick and each layer must be allowed to cool for at least 20 minutes before adding extra layers. However, since there are many different spray-applied polyurethane and polyisocyanurate foam products on the market, always consult the manufacturer for compatibility with Styrofoam™ Brand Extruded Polystyrene Foam Insulation products and DuPont polyisocyanurate insulation products.
OlyBond Adhesive from OMG is a two component polyurethane adhesive with faster set-up times than single-component polyurethane adhesives, for attachment between:
Insulations (e.g. STYROFOAM™ Brand DECKMATE™ Plus FA Extruded Polystyrene Foam Insulation)
Roof Decks (concrete and sheathing)
Cover boards (gypsum and Georgia-Pacific DensDeck)
The coverage for OlyBond Adhesive is:
OlyBond 500: ¾'-1' beads on max. 12' o.c. or
OlyBond: 1.25 gal/100 ft2
The adhesive system should be applied at roof temperatures between 40°F and120°F. For additional information, please see manufacturer's recommendations.
No, Great Stuff Pro™ Gasket is only dispensed with the special gun identifiable by its blue handle.
Yes, the Ultra Air Barrier Wall System as properly installed in a rain screen cavity wall does pass the NFPA 285 fire test under certain veneers and thus can meet that particular requirement in the International Building Code (IBC) Chapter 26:
'2603.5.5 Test standard. The wall assembly shall be tested in accordance with and comply with the acceptance criteria of NFPA 285.'
The NFPA 285 test is referred to in the industry as the Multistory Flammability Test. Extensive testing by The Dow Chemical Company along with Fire Science analysis by Hughes Associates has resulted in an Engineering Judgment and an International Code Council-Evaluation Service (ICC-ER) code report that describes the wall assemblies and veneers that pass the NFPA 285 test and meet this portion of the IBC.
Code Report ESR-2142 for all Styrofoam™ Products (off site)
Window details will be an important part of passing this requirement in the test. See the details on the Ultra Air Barrier Wall System web site for more information.
The contents of Great Stuff™ should be as close to room temperature as possible when dispensed.
Apply when temperatures are between 32° - 100°F (0° - 38°C) optimum temperature 60° - 90°F (15°- 32°C.) When using Great Stuff Pro™ Construction Adhesive, apply when temperatures are between 40° -100°F (4°- 38°C.) When using Great Stuff Pro™ Window & Door, apply when temperatures are between 60° -90°F (4°- 38°C).
Visit Great Stuff™ for more information on products for the DIY.
k-value (or just 'k') is a measure of the insulation value of a material, given in terms of how much heat the material will allow to pass through it. The k-value tells how many Btu will flow in one hour through one square foot of one inch thick material when the temperature difference between the hot side and the cold side is one degree Fahrenheit.
Imperial units for k-value are expressed in Btu•in/hr•ft2°F. SI units for k-value are expressed in W/m•°C. the smaller the k-value, the larger the R-value per inch of material. k is the reciprocal of R per inch.
k = 1/R per inch.
The following factors should be considered when designing a ballasted PMR system:
Yes.
The Air Barrier Association of America (ABAA) in an effort to support the design community has defined a process to evaluate key product and assembly requirements to meet the definition of an air barrier. This evaluation is a comprehensive review of the product/assembly's capability to effectively perform as an air barrier. External (third party) testing is required for this review, including ASTM E2178 and ASTM E2357. Additionally, other key physical property performance metrics are evaluated such as water vapor transmission, compressive strength, and water absorption. The Ultra Wall Air Barrier System has been evaluated against all of these performance metrics and has been approved by ABAA as an approved air barrier material and assembly.
This is listed on the ABBA website:
For more information on the Ultra Air Barrier Wall System see:
Based on FM's test results, roof assemblies receive one of three fire ratings:
For more information about FM Global, please visit:
www.FMglobal.com
Yes. The storage and application temperature limitations for Great Stuff Pro? single component foam need to be followed. The internal temperature of cans of Great Stuff Pro? must be kept at or above 60�F prior to their use. Storing them in a warmed cooler when brought out to the installation location can do this when ambient temperatures are low.
For more information on the Ultra Air Barrier Wall System see:
For more information on the Great Stuff Pro? single component foam see:
DuPont™ Tyvek® Fluid Applied WB+™, DuPont™ Tyvek® Flashing and Joint Compound+, and DuPont™ Sealant for Tyvek® Fluid Applied System carry a 1-Year Product Replacement Limited Warranty, or DuPont also offers a 10-year Product Replacement Limited Warranty for Tyvek® Fluid Applied WB+™ and Tyvek® Flashing and Joint Compound+.
Please review the full warranty located at www.warranty.tyvek.com
As the brick veneer is installed by the mason, the mason’s trowel may come in contact with the Thermax™ Exterior Insulation surface. The concern is that this sharp edged trowel may cut the aluminum skin of the Thermax™ Exterior Insulation, which may compromise the integrity of the system.
DuPont has observed the installation of hundreds of DuPont™ Thermax™ Wall System (TWS) projects and this has not happened. The strength of the thick aluminum skin combined with the expertise of the mason has resulted in the facers being undamaged.
Should damage occur, DuPont™ LiquidArmor™ Flashing and Sealant can be used to restore the integrity of the facer.
Lastly, water absorption testing of the Thermax™ Exterior Insulation suggests that any water intrusion into the foam will be insignificant through such a cut in the facer.
Great Stuff Pro™ Polyurethane Foam Sealant does not have good initial tack so it does not immediately hold the 15 ¾ inch wide Cavitymate™ Ultra Insulation boards to the wall. The friction fit of the board between the wall ties does hold the board against the wall while the Great Stuff Pro™ single component foam cures. The curing of the Great Stuff Pro™ single component foam used as the adhesive for the insulation boards typically takes between 30 minutes and 90 minutes to achieve essentially full strength. This time period is determined by the ambient temperature and relative humidity.
When fully cured the insulation boards are very firmly held in place by the adhesive.
For more information on the Ultra Air Barrier Wall System see:
Thermax™ Brand Insulation and the Thermax™ Wall System is included in the following Steel Framed Hourly Rated Wall Approvals. The table below contains key components that are included in the listed ratings. This table is provided for information purposes only. The exact assembly and component/layer specifics should be examined in the UL Directory prior to specifying the system.
UL Listing # | Rating | 1.5' SPF CM Series |
Veneer | Gypsum Layers Required |
U424 | Load Bearing, up to 2 hour, Interior Face Only. Fire Exposure from both sides allowed when brick veneer is used. | - | Metal Panel siding, Brick, 3 Coat Stucco, Cemintitious Backer Units | Int. & Ext., thickness required is rating dependent. |
U425 | Load Bearing, up to 2 hour, Interior Face Only. Fire Exposure from both sides allowed when brick veneer is used. | - | Metal Panel siding, Brick, 3 Coat Stucco, Cemintitious Backer Units | Int. & Ext., thickness required is rating dependent. |
U454 | Load Bearing, 1 hour. | X | Metal Panel, MCM, Brick, 3-Coat Stucco, Fiber Cement, Stone | Int. & Ext., 5/8' Type CKNX. |
U482 | Non-load Bearing, 1 hour. | X | Brick | Int. only, 5/8' Type CKNX. |
There is an ICC-ESR report 1961 covering Great Stuff™ family products as well as Enerfoam™ sealant. Call 1-833-338-7668 for a copy of the report.
Visit Great Stuff™ for more information on Great Stuff™ products for the DIY.
These products are globally defined as articles, which do not require Safety Data Sheets according to chemical laws in the following:
The products listed do not release or otherwise result in exposure to a hazardous chemical under the intended conditions of use and meet all other listed requirements of an article. Therefore, these products meet the global definitions of articles which do not require SDS creation or distribution.
Enerfoam™ sealant can be used around and behind electrical boxes and insulated wires but should never be used inside a box where it may be exposed to bare copper wires.
Click here for more information about Enerfoam™ Sealant.
Resin transfer molding (RTM), sometimes is referred to as liquid molding. RTM is a fairly simple process: It begins with a two-part, matched, closed mold, made of metal or composite material. Dry reinforcement -- a preform -- is placed into the mold, and the mold is closed. Resin and catalyst are metered and mixed in dispenser equipment, then pumped into the mold under low pressure through injection ports, following predesigned paths through the preform. Extremely low-viscosity resin is used in RTM applications for thick parts, to permeate preforms quickly and evenly before cure. Both mold and resin can be heated, as necessary, for particular applications. RTM produces parts that do not need to be autoclaved. However, once cured and demolded, a part destined for a high-temperature application usually undergoes postcure. Most RTM applications use a two-part epoxy formulation. The two parts are mixed just before they are injected into the preform. Bismaleimide and polyimide resins also are available in RTM formulations.
A frost protected shallow foundation (FPSF) is a building technique whereby insulation is used to reduce heat loss from a foundation. Reducing this heat loss prevents the frost line from penetrating below the insulation and under the foundation and floor slab, allowing for the construction of a much shallower foundation footing, which saves on excavation and material costs. The thickness and location of the insulation are dependent on the severity of the winter in a given location. In many northern locations, builders can save hundreds of dollars in construction costs on a single house. Shallow foundations can be used for heated and unheated buildings.
For more information on this innovative and cost-saving construction technique visit,
Frost Protected Shallow Foundations
For specific questions, call 1-833-338-7668.
The prescription requirement in the code for steel studs would depend upon which code and the year of release for the code as well as the climate zone. The following table shows the prescriptive requirements for the most recent versions of the codes. One code is published by the American Society of Heating, Refrigeration, and Air-conditioning Engineers (ASHRAE) and is usually referred to by its number: 90.1. The other code is the International Energy Conservation Code (IECC) published by the International Code Council (ICC). The following table is for non-residential construction as defined by the Energy Code.
Table 1 - Prescriptive R-Values for non-residential Construction for Various Energy CodesCode | Zone 1 | Zone 2 | Zone 3 | Zone 4 | Zone 5 | Zone 6 | Zone 7 | Zone 8 |
2012 IECC u-Factor |
R13+ 5.0ci 0.077 |
R13+ 5.0ci 0.077 |
R13+ 7.5ci 0.064 |
R13+ 7.5ci 0.064 |
R13+ 7.5ci 0.064 |
R13+ 7.5ci 0.064 |
R13+ 7.5ci 0.064 |
R13+ 7.5ci 0.045 |
ASHRAE 90.1 2010 u-Factor |
R13 0.124 |
R13 0.124 |
R13+ 3.8ci 0.084 |
R13+ 7.5ci 0.064 |
R13+ 7.5ci 0.064 |
R13+ 7.5ci 0.064 |
R13+ 7.5ci 0.064 |
R13+ 7.5ci 0.064 |
2009 IECC u-Factor |
R13 0.124 |
R13 0.124 |
R13+ 3.8ci 0.084 |
R13+ 7.5ci 0.064 |
R13+ 7.5ci 0.064 |
R13+ 7.5ci 0.064 |
R13+ 7.5ci 0.064 |
R13+ 7.5ci 0.064 |
ASHRAE 90.1 2007 u-Factor |
R13 0.124 |
R13 0.124 |
R13+ 3.8ci 0.084 |
R13+ 7.5ci 0.064 |
R13+ 7.5ci 0.064 |
R13+ 7.5ci 0.064 |
R13+ 7.5ci 0.064 |
R13+ 7.5ci 0.064 |
2006 IECC u-Factor |
R13 0.124 |
R13 0.124 |
R13 0.124 |
R13 0.124 |
R13+ 3.8ci 0.084 |
R13+ 3.8ci 0.084 |
R13+ 7.5ci 0.064 |
R13+ 7.5ci 0.064 |
ASHRAE 90.1 2004 u-Factor |
R13 0.124 |
R13 0.124 |
R13 0.124 |
R13 0.124 |
R13+ 3.8ci 0.084 |
R13+ 3.8ci 0.084 |
R13+ 7.5ci 0.064 |
R13+ 7.5ci 0.064 |
R13 refers to the R-Value of the fibrous batt placed between the steel studs. The number before “ci” refers to R-Value of the continuous insulation installed as sheathing over the steel studs. The u-Factor is the effective conductance value of the assembly.
DuPont™ Styrofoam™ Brand products are CFC (chlorofluorocarbons) free. They do not contain fully halogenated chlorofluorocarbons regulated by the United Nations Environmental Program (UNEP) in the Montreal Protocol and other relevant regulations.
For years, CFCs, a type of blowing agent, were commonly used to improve the insulation performance of plastic foam products. However, when evidence first began to appear linking CFCs to ozone depletion in 1978, DuPont began its own program to stop using these blowing agents and convert to an environmentally friendly product. DuPont was the first manufacturer to do so.
Today, all 25 DuPont plants worldwide manufacture DuPont™ Styrofoam™ Brand products with either HCFC blowing agents, which have an ozone depletion potential less than 10 percent of standard CFC blowing agents, or even HCFC-free blowing agents with zero depletion potential.
DuPont has the following hourly rated wall assemblies listed with the Underwriters Laboratories involving Thermax™ Polyisocyanurate Insulation products:
DuPont™ Tuff-R™ (ci) Polyisocyanurate Foam Insulation is also listed in U424, U425, U460, U902, U904, U905, U906, U907, V454, V499
For details about these constructions, please visit Underwriters Laboratories Online certification directory under DuPont for these particular design numbers.
Can DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation be used in ice rink applications?
Yes. DuPont Styrofoam™ Brand Extruded Polystyrene Foam Insulation is ideal for use below ice rinks to reduce energy costs and the damaging effects of frost heave.
There are three key differences between latex foam and Great Stuff™ polyurethane foam:
Visit Great Stuff™ for more information on products for the DIY.
The USGBC Leadership in Energy and Environmental Design (LEED) green building rating system encourages and accelerates global adoption of sustainable green building and development practices. Acquiring LEED points and an eventual LEED rating is slightly different for schools. One difference is that there is a Sound Transmission Class (STC) requirement for exterior walls. This requirement is:
“Design classrooms and other core learning spaces to meet the Sound Transmission Class requirements, excepting windows, which must meet an STC rating of at least 35.”
The Thermax™ Wall System with various veneers will most likely meet this requirement. Brick veneers will allow the Thermax™ Wall System to reach an STC of ~50.
Water based adhesives and some urethane-based adhesives compatible with DuPont™ Styrofoam™ Brand. Normally solvent based adhesives will damage the Styrofoam™ Brand insulation. In this type of application, a small scale test is highly recommended before a large scale construction begins. Always consult the adhesive manufacturer for detailed installation guidelines.
Picture Framing is when applying SPF in a stud wall cavity the applicator outlines the interior of the cavity first. The applicator will spray the joint areas at the stud and wall board first, outlining the two sides and top and bottom first and then filling in the center.
Most roofing membranes are compatible with DuPont™ Styrofoam™ Brand polystyrene insulation. However, when PVC, hot mortar or coal tar are used, a separation layer is required between the membrane and Styrofoam™ Brand to minimize the adverse impact the membranes may have for Styrofoam™ Brand insulation.
ENERGY STAR® is a partnership of the U.S. Department of Energy, U.S. Environmental Protection Agency, product manufacturers such as DuPont, maker of Styrofoam™ Brand Extruded Polystyrene Foam Insulation, along with local utilities and retailers. Partners educate consumers and business owners on the benefits of energy efficient products, how they reduce air pollution, and lower heating and cooling costs. They also help promote efficient products by labeling them with the ENERGY STAR® logo that, in the case of insulation, means products that:
To learn more about the ENERGY STAR Program, the value of insulation, how much is enough, the various types available, and tips on proper installation, visit ENERGY STAR.
The attached letter contains Dow's position on Conflict Minerals along with a listing of products that have been reviewed and determined to be free of Conflict Materials in their raw materials.
The weight of fiberglass or blown-in cellulose that Thermax™ White Finish Polyisocyanurate Insulation can support is:
• Fastened at 4' roof purlins: 3.5 lbs/sq ft @ 1' and 6.5 lbs/sq ft @ 2' thick
• Fastened at 5' roof purlins: 2.1 lbs/sq ft @ 1' and 4.8 lbs/sq ft @ 2' thick
• Fastened at 8' roof purlins: 0.2 lbs/sq ft @ 1' and 1.1 lbs/sq ft @ 2' thick
All boards were tested with 5 fasteners across the width at each purlin spacing, typically using a fastener long enough to penetrate the rafter or truss 3/4' and having a plastic 1.25' diameter washer on the fastener.
All testing was done at Center for Applied Engineering as Uniform Load Testing.
The weight for Thermax™ White Finish Polyisocyanurate Insulation is:
•1/2' board weighs 3.6 lbs
•1' board weighs 6.0 lbs
•2' board weighs 11.0 lbs
For more information, visit our website.
The Dow Chemical Company has completed in-house testing on various vapor barrier/base sheets for compatibility with the use of DuPont™ Insta Stik™ Quik Set Commercial Adhesive. Please follow the link to a list of approvals. However, if you have concerns as to whether or not a specific product has been tested, please contact the DuPont Contact Center (DCC) at 1-833-338-7668.
Visit DuPont™ Insta Stik™ Quik Set Commercial Adhesive to learn more and download literature about DuPont™ Insta Stik™ Quik Set Commercial Adhesive.
In 1941, a DuPont scientist working on flotation materials for the U.S. war effort discovered extruded polystyrene foam. Since then, DuPont has continuously improved the special manufacturing process that gives Styrofoam™ Brand Extruded Polystyrene Foam Insulation its outstanding insulating and water resistance characteristics.
The distinctive BLUE™ rigid Styrofoam™ Brand Extruded Polystyrene Foam Insulation is manufactured through a carefully controlled continuous extrusion process. All components are mixed at high temperature and pressure. The resulting product is one consisting of tiny, closed cells and is void free. Because of this closed-cell structure, Styrofoam™ Brand Extruded Polystyrene Foam Insulation has a superior insulation value, excellent water resistance, and high compressive strength.
Here is a simplified diagram of the manufacturing process:
Substrate priming is not required for the use of DuPont™ Tyvek® Fluid Applied products due to the excellent adhesion level of our unique STPE formulation. The one exception is to stabilize loose gypsum along cut gypsum board edges.
DuPont™ Adhesive/Primer is required when DuPont™ self-adhered flashings are utilized at window and door openings prior to the installation DuPont™ Tyvek® Fluid Applied products. Self-adhered flashing installed over cured DuPont™ Tyvek® Fluid Applied WB+™ doesn’t require additional priming. The installing professional may simply use any of the DuPont™ Tyvek® Fluid Applied products as a primer/wet bed for the self-adhered flashing.
Is there any formaldehyde in DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation products?
No, DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation does not contain any formaldehyde.
Specifically, while we have not analyzed for formaldehyde, it is not an intended raw material nor is it known to be present in our Styrofoam™ products.
This determination is based on the compositional information provided to DuPont by its suppliers. DuPont relies on its suppliers to provide accurate data.
DuPont does not routinely analyze for additional materials that are not listed in the SDS or Sales Specification.
DuPont is not responsible for any misrepresentation resulting from inaccurate information from its suppliers.
DuPont produces many product and application literature pieces in French for our Canadian customers.
If you cannot find the piece you are looking for, call 1-800-363-6210. A French-speaking DuPont representative will help you with your needs. You may also call 1-833-338-7668 to be directed to a French-speaking DuPont sales representative to help with your needs.
The California Air Resource Board (CARB) Volatile Organic Compound (VOC) requirements for professional adhesives and sealants, varies for each air district. There are 35 air districts. District Rule 1168 has the most stringent requirements for the applications applicable to DuPont's adhesives and sealants.
Factory Mutual (FM) Global uses a procedure based on their construction materials calorimeter to evaluate the resistance of roofing systems to an internal fire. In this procedure a 4' x 4' section of the roof assembly is exposed to an internal fire source. The heat released into the test chamber is measured and compared to the performance of a standard system that has been deemed to be acceptable. The standard system was selected based on successful performance in the full-scale White House fire test. In order to be acceptable, the maximum allowable fuel contribution of the roofing assembly is:
Time Interval | Max. fuel Contribution (BTU/ft²/minute) |
3 | 410 |
5 | 390 |
10 | 360 |
Average for 30 minutes | 285 |
This procedure cannot be used to evaluate the performance of thermoplastic foams installed directly on a steel roof deck because these materials melt when exposed to the internal fire source and allow heat to escape out of the test unit. Because of this behavior, the heat release cannot be accurately measured. In order to meet the requirements of this test with a thermoplastic insulation, such as DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation, a minimum 5/8' thick Georgia-Pacific DensDeck or a minimum 1/2' thick Owens Corning StrataGuard must first be installed on the deck. For more information about FM Global, visit FMglobal.
DuPont™ Tyvek® Fluid Applied WB+™ can be used alone to treat sheathing joints less than 1/16” but it was specifically engineered for fast and effective application to the building envelope exterior wall surface by spraying or power rolling. The lower viscosity of the product makes it more difficult to fill gaps and voids and achieve the mil thickness required for optimum performance around the window openings and other penetrations.
DuPont™ Tyvek® Fluid Applied Flashing and Joint Compound+ has been specifically engineered for flashing commercial windows. DuPont™ Tyvek® Fluid Applied Flashing and Joint Compound+ is a higher viscosity product but can be brushed or troweled to easily treat the window opening while offering exceptional gap filling performance.No. None of the polyisocyanurate-based insulation products made by DuPont are recommended for use below grade. DuPont™ Styrofoam™ Brand products below grade are a better option - they do not have foil facers which DuPont Polyisocyanurate do and therefore Styrofoam™ tends to be more water resistant.
Thermax™ is used in the roof and walls of many ice rinks and arenas to help in energy efficiency of the facility.
For more information: Ice Rinks
No.
No type of foam plastic insulation made by any manufacturer can be installed directly to a steel deck to obtain an hourly rating without some form of additional protection on the deck, either gypsum board or spray-on coatings. For polystyrene foams the additional protection can be provided by 5/8' gypsum, or in some cases ½' Georgia-Pacific DensDeck cover board on top of the deck. For polyisocyanurate insulation, the protection can be offered by either a gypsum product or with a spray applied fire resistant coating on the bottom of the steel deck, or a combination of both.
Thermax™ Light Duty and Thermax™ Heavy Duty can be attached to garage ceilings with stick clips adhered to the concrete. Drill and screw type concrete fasteners must be used.
Per ICC ESR 1659 code report section 4.1.1
INTERIOR fastening (NON FM Insured)
Use white or foil tape or PVC for joint treatment
Contact your local DuPont representative for additional information.
If using FM 4880 approval must be installed using latest FM approval guide recommendations.
See answer center Answer ID 19066
For more information, visit:
Thermax™ Brand Insulation
LiquidArmor™ Flashing and Sealant products have been tested for water leakage and air infiltration and passed with a variety of fasteners and brick anchors penetrating through the LiquidArmor™ with additional LiquidArmor™ applied over them.
Any roof includes three major components: deck, insulation and waterproofing membrane. The major difference between a PMR and a conventional roof is the sequence in which the materials are applied. The key to the PMR is that the insulation is placed above the waterproofing membrane resulting in superior long-term performance and durability by protecting the membrane from UV exposure induced degradation, freeze-thaw cycles and harmful exposure and physical abuses during and after construction.
For more information about PMR and conventional roof applications, please visit:
https://www.dupont.com/building/roofing.html
Yes. The DuPont™ Thermax™ Wall System (TWS) has been analyzed in several configurations in all North American climates. As expected, the Thermax™ Wall System performed extremely well in having a very low condensation potential. This is not surprising as the fundamental advantage for the Thermax™ Wall System is the placement of the insulation outside of the cavity which dramatically reduces condensation potential.
No. The load bearing portion of the ASTM E119 Hourly Rated Assembly test is an effort to investigate a wall’s ability to bear loads in a fire. The code or the designer may demand that the assembly be able to carry the load even in a fire situation. Because we have not tested this, we cannot use the DuPont™ Thermax™ Wall System (TWS) assembly as load bearing where the load bearing hourly rating is required.
Great Stuff Pro™ Gasket is designed for compression seal between substrates. We recommend applying a tall enough bead to bridge all possible framing-to-drywall gaps; then compressing it in place to form the snug gasket. There is no risk of the flexible gasket foam preventing drywall from being screwed flat to the framing.
Yes, for additional information, see Code Approvals.
Disclaimer: The use of Froth-Pak™ may be restrictive or prohibited in certain areas by local building codes covering the use of cellular plastics. ALWAYS check local code(s) before using product.
Warning: The foam produced by Froth-Pak™ is organic and combustible and may constitute a fire hazard. Do not expose foam to flame or temperatures above 240°F (116°C).
Always read Froth-Pak™ operating instruction and Safety Data Sheet prior to use.
Click here for more information about Froth-Pak™ sealant products.
DuPont™ LiquidArmor™ CM and LiquidArmor™ LT Flashing and Sealant have been engineered for durability and efficient application. Their formulations and theology were uniquely designed to allow for them to easily flow through a spray hose or sausage gun tip, respectively. Both materials have enough liquid strength to ensure they can span gaps up to ¼ inch.
Visit DuPont Adhesives to learn more and download literature about DuPont™ Insta Stik™ Quik Set Commercial Adhesive.
Based on FM’s test results, roof assemblies receive one of three fire ratings:
For more information about FM Global, please visit:
LiquidArmor™ CM and QS may be successfully applied with spray tips other than the DuPont suggested tips. The DuPont recommended spray tips are intended to be a starting point for first time applicators. With application experience, a specific installer may grow to prefer a different spray tip size to reach desired product thicknesses and widths. Note, if a sprayer other than a Graco model is selected, the spray tip sizes may not correlate with the DuPont recommended spray tips sizes. Generally, though, all spray tip manufacturers utilize the first digit to communicate the relative spray width and the second and third digits to provide information on the spray tips orifice size.
Styrofoam™ Brand FLOORMATE™ Extruded Polystyrene Foam Insulation is a product sold into non-loadbearing floor applications in Europe but NOT .
For more information on Styrofoam™ Brand Extruded Polystyrene Foam Insulation products sold in Europe, visit our website and select the appropriate country from the drop-down menu on the left side.
For U.S. residential building applications with no vehicular traffic, DuPont™ Styrofoam™ Brand Square Edge Foam Insulation, DuPont™ Styrofoam™ Brand Tongue and Groove Foam Insulation or DuPont™ Styrofoam™ Brand Scoreboard Extruded Polystyrene (XPS) Foam Insulation is recommended. Each of these products has a compressive strength of 25 psi and will take a live load of 720 lbs/ft² (1:5 safety factor) and dead load of 1,200 lbs/ft² (1:3 safety factor).
For Canadian residential building applications with no vehicular traffic, DuPont™ Styrofoam™ Brand SM Extruded Polystyrene (XPS) Foam Insulation is recommended.
Super Tuff-R™ and Isocast™ R product recycle content depends on product and thickness. See table below.
Please note that the recycle content listed in table below is based on the compositional information provided to DuPont from its suppliers. DuPont relies on the suppliers to provide accurate data. DuPont is not responsible for any misrepresentation resulting from inaccurate information from its suppliers.
The Super Tuff-R™ and Isocast™ R product recycle content is shown as follows:
PRODUCT | THICKNESS | GLASS MAT RECYCLE % BY WEIGHT | RECYCLE % BY WEIGHT | TOTAL PRE-CONSUMER RECYCLE CONTENT |
Super Tuff-R™ | 0.5' | 0 | 20.1 | 20.1 |
1' | 3.28 | 13.92 | 17.2 | |
Super Tuff-R C™ | 1.5' | 3.28 | 11.92 | 15.2 |
2' | 2.85 | 10.45 | 13.3 | |
ISOCAST-R™ | 1' | 3.28 | 11.32 | 14.6 |
2' | 2.85 | 9.55 | 12.4 |
Periodically plant growth such as grass, weeds, or small trees will occur on protected membrane roofs (PMR) assemblies (also known as inverted roof membrane assemblies, or IRMA) and other low-sloped commercial roofing systems. Good roofing practice will include a maintenance program that includes periodic inspections for this growth.
The recommended maintenance procedure for controlling plant growth is as follows: to perform routine inspections, to pull out the growth, and treat the area with a weed killer such as Roundup, manufactured by Monsanto and marketed under the Scotts Roundup brand.
Roots from plant growth can sometimes damage the roofing membrane. With a protected membrane system there is less chance of this happening since the membrane is protected by the foam, fabric and rock (ballast). However, left untreated even roots on a protected membrane system can ultimately work their way down to the membrane.
For more information on PMR or IRMA systems, please visit our website.
LiquidArmor™ CM is rain resistant once it has a good quality skin developed, which is before final product curing. For LiquidArmor™ CM, this will typically occur within 24 hours after the product is applied; however, the time does vary based on humidity, product application thickness, temperature, air flow and sun exposure.
The design wind speed changed because the American Society of Civil Engineers (ASCE) changed their standard ASCE-7. The wind speed map in ASCE-7 changed from a fastest mile wind speed to a 3-second gust wind speed. All building code wind pressure calculations are based on this standard. Areas that previously had a 70mph fastest mile wind speed, now have a 90mph 3-second gust wind speed.
Which DuPont Performance Building Solutions products can be used in lightweight fill applications?
DuPont™ Styrofoam™ Brand Square Edge Foam Insulation, DuPont™ Styrofoam™ Brand Highload 40, 60 and 100 Extruded Polystyrene (XPS) Foam Insulations are recommended for use in lightweight applications. Care must be taken to select the appropriate insulation from this list. For more information, visit our website.
The DuPont™ Tyvek® Fluid Applied System was designed through extensive research and testing to meet the high-performance demands of commercial construction. Tyvek® Fluid Applied System is composed of several products that were designed to work together as best in class to protect the building envelope by keeping out air and water while allowing internal moisture vapor to escape.
The table below shows the 2014 UL Thermax™ Polyisocyanurate Insulation listings in roofing applications. Using the following table, TF600 is equivalent to DuPont™ Thermax™ Light Duty Foam Insulation. TF604 is equivalent to DuPont™ Thermax™ Heavy Duty Foam Insulation due to 4 mil facer. TF610 is equivalent to Thermax™ Sheathing due to 1 mil aluminum facer.
For detailed assembly information, visit Underwriters Laboratories online certification directory at the UL Website.
Look for DuPont listing numbers such as shown (TGKX).
Roof Deck Construction # (TGKX) |
Uplift | Roof Deck Gauge |
Thermax™ Only | Uplift | Roof Fire Tested |
26 | I-60 or I-30 |
26 | Yes | ||
83A | I-90, I-60 or I-30 |
26 | Yes | ||
93 | I-90 | 24 | |||
99 | 22 | Yes | |||
112 | I-90 | 26 | Yes | ||
113 | I-90 | 24 | Yes | ||
113A | I-90 | 24 | Yes | ||
115 | I-90 or I-60 |
24 | Yes TF Series |
I-30 | |
119 | I-90 | 26 | Yes | ||
120 | 22 | Yes | |||
123 | 22 | Yes | |||
130 | I-90 | 26 | Yes | ||
139 | I-90 | 24 | Yes | ||
165 | I-90 | 24 | Yes | ||
178 | I-90 | 24 | I-30 | ||
185 | I-90 | 24 | Yes | I-30 | |
185A | I-90 | 24 | Yes | I-30 | |
227 | I-90 | 26 | Yes | ||
245 | I-90 | 24 | Yes | ||
246 | I-90 | 24 | Yes |
Visit Underwriters Laboratories, Inc. (UL) online to find out whether the particular roof assembly has an hourly rating. Use the following steps:
1. Go to UL Website.
2. Enter the manufacturer name of any component of the roof assembly or UL file name if you know it. If you look for a roof assembly involving products from The Dow Chemical Company, you may enter “The Dow Chemical Company,” “Dow” or “Dow Chemical” to search by manufacturer name.
3. A series of listed roof assemblies for that company will appear on your screen. Generally look for P assemblies listings, which will give you hourly ratings for roof assemblies.
Please note that these hourly rated roof assemblies are very specific and must be followed exactly as UL describes. No substitutions are allowed.
Yes, DuPont makes DuPont™ Styrofoam™ Brand XPS (white and green) foam for floral and craft applications. Fabricators/distributors located throughout the United States use saws, routers and hot wires to cut the foam into assorted shapes that they package and sell to floral and craft wholesalers and national chain stores. These shapes can be balls, eggs, wreathes, cones and sheets you find in retail, craft and discount stores.
For more information on purchasing Styrofoam™ Brand floral and craft products, please visit:
You can also contact one of the following Dow fabricators to find the stores near you:
SDS's are available through your local DuPont representative.
Where can I get a sample of a DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation product?
Call 1-833-338-7668 to receive a sample of one of the DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation products.
All foamed plastics must pass the National Fire Protection Association (NFPA) 285 fire test for wall assemblies to be used in Type I through IV commercial construction as referenced in Chapter 26 of the International Building Code (IBC). Actual results of NFPA 285 testing on the Thermax™ Wall System combined with engineering analysis has resulted in several possible configurations that meet this code requirement. This analysis was performed by the Hughes Associates.
The veneers that can be used over the Thermax™ Wall System depend upon the thickness of DuPont™ Thermax™ (ci) Exterior Foam Insulation over the steel studs. These veneers can be used under the following circumstances.
Walls with a Maximum of 3 inch thick Thermax™ insulation:
Masonry veneer 7 - Knight Wall Systems to include:
Can DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation be used in roadway applications?
Yes. Whenever roadway underlying soils are susceptible to frost, roadways will suffer frost heaving and spring breakup. The damaging effects of this frost action play havoc with traffic on major arteries as well as posing a monumental expense for repair year in and year out.
DuPont™ Styrofoam™ Brand Highload 40, 60 and 100 Extruded Polystyrene (XPS) Foam Insulation has been successfully used to reduce frost and thaw damage on countless roadways in Canada, the United States, Japan and throughout Europe. When properly installed between the subsoil and gravel base. Styrofoam™ Brand Highload Insulation products reduce heat loss from the frost susceptible sub-grade so that frost heaving and spring breakup are held at bay.
The thickness and width of the Styrofoam™ Brand XPS Insulation used for a particular roadway can be determined based on figures and computer models developed by The Dow Chemical Company. The variables needed are average frost penetration in feet/m, freezing degree days for a particular location, roadway cross section materials and thickness, soil type, etc. If you have a particular situation using Styrofoam™ Brand Highload Insulation, please call 1-833-338-7668 for calculations.
Not all wall/roof junctures are designed the same way. When the steel studs are designed to reach beyond the structural steel I-beam (see figure), the space between the studs will be wide enough to allow the contractor to spray up into the area at an angle.
This will allow the BASF SPRAYTITE® 81206 Spray Polyurethane Foam to continue to seal the stud cavity to the top of the steel stud. Be aware, however that maintaining BASF SPRAYTITE® 81206 Spray Polyurethane Foam depth may be difficult on an angle.
Depending on the thickness sprayed, it can reach 210°F.
The concern is that a heavy veneer hung on the exterior of the wall will result in a force on the exterior portion of the anchors resulting in a cantilever effect (transverse loading) on the fasteners and some sort of downward movement in the anchors, insulation, and veneer finish.
A variety of studies including computer finite element modeling and actual full scale laboratory testing have shown that proper design of fastener spacing and insulation compressive strength will completely prevent this from occurring.
A formal engineering document is available on the Dr. J Certification Web site here:
<http://www.drjcertification.org/system/files/drj/ter/node/767/drr141008attachingexteriorwallcoveringsthroughfs.pdf>
U-value is a measure of the insulation capabilities of an assembly such as a skinned panel or wall system. It refers to how many BTU's will flow in ONE hour through ONE square foot of ONE OR MORE MATERIALS of ANY THICKNESS when the temperature difference between the hot side and the cold side is ONE degree F, including the insulation values of the thin films of air which cling to the inside surface and outside surfaces of the building section. So, the U-value tells how many Btu's will flow in ONE hour through ONE square foot of an entire building section when the temperature difference between the hot side and the cold side is ONE degree F. U.S units expressed in Btu/hr.ft2.deg F. SI units expressed in W/m2.deg C.
Should the vapor barrier in a radiant heat floor assembly be installed over or under the insulation?
The vapor barrier or retarder should be installed below the insulation.
For more information, visit our website.
Installing the Ultra Air Barrier Wall System is very similar to installing insulation in a standard brick and block cavity wall or continuous insulation in a steel stud wall system. An installation brochure is available on the Ultra Air Barrier Wall System web site:
For more information on the Ultra Air Barrier Wall System see:
The FM Class 1 rated roof recover assemblies for Styrofoam™ Brand Extruded Polystyrene Foam Insulation products for Steel Deck are:
Which roof decks/substrates are compatible with DuPont™ Insta Stik™ Quick Set Commercial Adhesive?
The following roof decks/substrates can be used with DuPont™ Insta Stik™ Quick Set Commercial Adhesive:
Visit DuPont™ Insta Stik™ Quik Set Commercial Adhesive to learn more and download literature about DuPont™ Insta Stik™ Quik Set Commercial Adhesive.
What are the new product requirements for XPS in the 2015 National Building Code of Canada (NBC)?
CAN/ULC S701-11 is the updated product standard for both extruded and expanded polystyrene insulation in the 2015 NBC.
a. CAN/S701-11 lists two methods for thermal resistance:
i. R-value (ASTM C 518 or ASTM C177) - with CAN/ULC S701-11 conditioning requirements
ii. Long-term thermal resistance (LTTR) per CAN/ULC-S770 - a new requirement
b. The Long Term Thermal Resistance (LTTR) values represent the 15 year time weighted average
R-value, equivalent to 5 year storage at standard laboratory conditions.
c. CAN/ULC S701-11 specifies a minimum LTTR value of 1.68 RSI. DuPont™ Styrofoam™ Brand
products exceed this value, with a 1.73 RSI (measured at 50 mm thickness), equivalent to R-5/inch
for Types 2 and 3; and a 1.80 RSI (measured at 50 mm) for Type 4.
Weathermate? Sill Seal foam gasket reduces the air infiltration that occurs between the foundation and the sill plate. Reducing this air infiltration will help to reduce the heating and cooling costs for your home.
For more information:
Weathermate? Sill Seal foam gasket
DuPont™ Styrofoam™ Brand products are particularly suited and have a long history of successful use in EIFs applications. For specific project, please call your local DuPont representative for assistance.
Rub-R-Wall from Rubber Polymer Corporation is a trade name for a line of elastic coating materials used for damp-proofing or waterproofing. The manufacturer claims Rub-R-Wall CG is compatible with DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation in foundation applications.
For more information, visit Rub-R-Wall.
If the adhesive has not cured or hardened, use acetone. If the adhesive has hardened, there is no solvent that will remove it. It will not harm your skin and will wear off in several days. To remove cured Tile Bond™ Roof Tile Adhesive, soak skin in warm, soapy water and use a pumice stone (available at most drugstores). Then apply petroleum jelly.
Click here for more information about Tile Bond™ Roof Tile Adhesive.
Polyisocyanurate insulation products such as Thermax™ insulation, DuPont™ Tuff-R™ (ci) Polyisocyanurate Foam Insulation and DuPont™ Super Tuff-R™ Polyisocyanurate Foam Insulation products can potentially contribute to the following categories of LEED v4 points:
Please feel free to call 1-833-338-7668 when you need additional LEED information for DuPont™ Styrofoam™ Brand products from DuPont for a particular LEED certified/designed job.
An ENERGY STAR commercial building has a rating of 75 or higher based on ENERGY STAR online portfolio manager. A score of 50 indicates that the building is performing at the industry average and therefore does not qualify for ENERGY STAR. The rating is determined by the energy usage of the rated building compared with national commercial property energy use intensity survey results. The types of building currently ENERGY STAR program rated are:
More information about the online portfolio manager and how to use the tool to rate a building can be found on the ENERGY STAR website as follows:
A Dealer is the same as a Lumber Yard or Building Supplier Dealer (BSD). Lowe's is an example of a Dealer. Dealers sell directly to customers such as building contractors or DIY homeowners.
A Distributor purchases insulation directly from DuPont and distributes (sells) the material to the Dealers. This is an example of a two-step distribution channel. Georgia Pacific and Weyerhaeuser are examples of Distributors.
You can purchase Enerfoam™ products from any of DuPont's distributors. Call 1-833-338-7668 for a list of distributors.
Click here for more information about Enerfoam™ Sealant.
No. High elongation-at-break does not guarantee good performance, but elongation within a relevant elongation range followed by high elastic recovery is a key property when comparing fluid applied membranes.
Several competitors may have a much higher elongation at break than DuPont™ Tyvek® Fluid Applied WB+™ but they exhibit very little recovery. To maintain continuity, the fully-bonded air and water barrier membrane must be able to accommodate expansions and contractions experienced by the substrate without loss of properties, e.g. achieve full elastomeric recovery. Many competitive products simply deform when stretched and do not recover to their original shape. DuPont™ Tyvek® Fluid Applied WB+™ offers 99% recovery at 300% elongation.The fastening schedule used to support the lath for a 3 coat stucco system over the Thermax™ Wall System should be the same as is usually used with 3 coat stucco systems.
Please check with stucco manufacturer for additional requirements.
The termination bar at the base of the wall can be installed either over or underneath the DuPont™ Styrofoam™ Brand Cavitymate™ Ultra Extruded Polystyrene (XPS) Foam Insulation. Both ways have been used successfully. The installation guides for the Ultra Air Barrier Wall System go into greater detail.
Ultra Air Barrier Wall System Installation for 15 ¾ inch insulation
Ultra Air Barrier Wall System Installation for 48 inch over Steel Stud and Block
The gust speed is the highest sustained gust over a 3-second period of time.
The fastest mile speed is the highest sustained speed over a longer period.
Gust is typically 20%-25% higher than fastest mile. Model building codes have converted to 3-second peak gust wind speeds because that means of measurement is now commonly used at wind speed reporting stations across the U.S.
The conversion between the 3-second gust wind speed and fastest mile wind speed can be found in the International Residential Code Chapter 3 Table R301.2.1.3.
In the roofing industry, IRMA stands for either Insulated Roof Membrane Assembly or Inverted Roof Membrane Assembly. This is another way of referring to a Protected Membrane Roof (PMR) Assembly. In a protected membrane roof assembly, the insulation is placed on top of the membrane, improving the performance and longevity of the roof system. The insulation in a PMR assembly must be able to withstand wet environments (without sacrificing insulation performance) and foot traffic. That's why durable, moisture resistant DuPont™ Styrofoam™ Brand Extruded Polystyrene Foam Insulation is an excellent choice for PMR.
A PMR roof assembly also helps building owners meet the goal of sustainable construction ? including contributing to the achievement of USGBC Leadership in Energy & Environmental Design (LEED) points.
For more information on IRMA or PMR roofing assembly, please visit our website.
DuPont makes several Styrofoam™ Brand Extruded Polystyrene Foam Insulation products designed for use in panels: DuPont™ Styrofoam™ Brand Panelmate™ Extruded Polystyrene (XPS) Foam Insulation, DuPont™ Styrofoam™ Brand Panelmate™ Ultra Extruded Polystyrene (XPS) Foam Insulation, DuPont™ Styrofoam™ Brand Panel Core 20 Freezer Extruded Polystyrene (XPS) Foam Insulation, DuPont™ Styrofoam™ Brand Panel Core 30 Freezer Extruded Polystyrene (XPS) Foam Insulation and DuPont™ Styrofoam™ Brand Panel Core 40 Freezer Extruded Polystyrene (XPS) Foam Insulation products. The following documents go into greater detail regarding these products.
Styrofoam™ Brand Panelmate™ and Panelmate™ Ultra Insulation
Styrofoam™ Panelcore 20, 30, 40
There are several types of composite panels:
A. Structural Insulated Panels (SIPs) - typically OSB faced sandwich panels used for walls, roofs and floors of residential and small commercial buildings. There are many fabricators of such panels located across , including:
B. Metal faced "architectural panels" - typically steel or aluminum faced sandwich panels used for cladding commercial buildings (e.g., airports, small office buildings, etc.). These need to be special ordered because they are rarely produced using Styrofoam™ Brand Extruded Polystyrene Foam Insulation. Typically beadboard or polyisocyanurate insulation is used for the core. Architectural panel manufacturers include:
Kingspan Benchmark Architectural Systems, (there is a security risk when you try to open Kingspan site)
www.kingspanpanels.us
Alply Inc.
www.alply.com.
C. Integral deck/insulation/finish panels for roofs - Typically Tectum board on one side and OSB on the other. Used in cathedral ceilings and some low slope roofs.
Tectum Inc., www.tectum.com
D. Miscellaneous panels - A wide variety of materials (sheet metal, OSB, Tectum, plastic, gyspum board, etc.) can be laminated to Styrofoam™ Brand Extruded Polystyrene Foam Insulation to produce custom panels for various applications. All of the companies mentioned above can perform this lamination to one degree or another.
E. Concrete sandwich panels - Styrofoam™ Brand Extruded Polystyrene Foam Insulation can be used in standard concrete sandwich panel applications. See:
Yes, the Thermax™ Wall System is an air barrier as evidenced by its passing the American Society for Testing Materials (ASTM) E2357 for air penetration of an assembly, the standard test for determining this quality in a wall system according to Section C.402.4 'Air Leakage' in the International Energy Conservation Code (IECC). The Thermax™ Wall System is also listed with the Air Barrier Association of America (ABAA) as an approved air barrier assembly (http://www.airbarrier.org).
DuPont offers three fluid applied flashing solutions: LiquidArmor™ CM, LiquidArmor™ QS and LiquidArmor™ LT. All three products offer installers the ability to flash and seal complicated geometries with ease.
The mission of the Green Building Initiative is to accelerate the adoption of building practices that result in energy-efficient, healthier and environmentally sustainable buildings by promoting creditable and practicable green building approaches for residential and commercial construction.
GBI is similar to US Green Building Council promoting green building practice. GBI's rating system is called Green Globes. More information about GBI and its rating system can be found from GBI website as follows:
DuPont™ Insta Stik™ Quik Set Commercial Adhesive is a single component polyurethane adhesive for attachment between:
Insulation (e.g., DuPont™ Styrofoam™ Brand Deckmate™ Plus FA)
Roof Decks (Concrete, 22 ga metal or sheathing)
Cover Boards (gypsum, Georgia-Pacific DensDeck, fiberboard)
The coverage for DuPont™ Insta Stik™ Quik Set Commercial Adhesive is ¾'-1' beads on max. 12'o.c. It can be applied at roof temperatures between 33°F -111°F (DuPont™ Insta Stik™ Quik Set Commercial Adhesive 70-80°F) and the material should be attached within 5 minutes of application. After attachment, one should walk on boards every 5-7 minutes for 45 minutes until bonded.
DuPont™ Insta Stik™ Quik Set Commercial Adhesive is a portable/pressurized 23 lb. tank and requires no external power source to apply.
For more information, visit DuPont™ Insta Stik™ Quik Set Commercial Adhesive.
Wood skewers pushed through the boards at a 30-45 degree angle should be used to secure the boards together. Two to three skewers per 2' x 8' board should be adequate. No adhesive is necessary. Skewers should be 1/4 to 5/16 inch in diameter and be long enough to penetrate two insulation boards. Alternately, small diameter reinforcing bars (¼" diameter) can be driven through boards or bundles to secure the insulation to itself and the underlying fill. For information, visit our website.
Open joint rain screen veneers have space between the veneer elements that can allow bystanders looking at the wall see the material behind the veneer. If the surface of the material behind the rain screen is light in color, this could potentially conflict with the desired appearance of the veneer. The light blue color of the DuPont™ Thermax™ (ci) Exterior Foam Insulation facer could potentially create this problem.
This aesthetic problem can be avoided by either:
Saran is a better performing product at a lower installed cost. The lower installed cost savings are due to the potential savings on elbow and fitting installation labor. Saran film and tape is a more durable product, longer lasting, less call backs for potential failures.
There are hourly rated wall configurations in which the Ultra Air Barrier Wall System (all versions) can be placed to achieve an hourly rated wall:
These can be viewed in detail at the UL web site:
For more information on the Ultra Air Barrier Wall System see:
No, not at this time.
DuPont is working with the Florida Building Code and Miami Dade to obtain system acceptance for the DuPont™ Thermax™ Wall System (TWS) in these localities.
If the foam has not cured or hardened, use fingernail polish remover (with acetone); a polyglycol-based skin cleanser or corn oil may be effective. Then wash with soap and plenty of water. If the foam has hardened, there is no solvent that will remove it. It will not harm your skin and will wear off over time. To remove cured foam from skin, use a pumice stone (available at most drug stores) and warm, soapy water. Then apply petroleum jelly.
Visit Great Stuff™ for more information on products for the DIY.
C-value (or just 'c'), which is shorthand for thermal conductance, is a measure of the insulation value of a material. It refers to how many British thermal unit (Btu) will flow in one hour through one square foot of one or more materials of any thickness when the temperature difference between the hot side and the cold side is one degree Fahrenheit (e.g., a 3.5' thick fiberglass batt with a factory-applied vapor retarder). The C-value, unlike K-value, is dependent on the thickness of the material. C-values get smaller numerically as the insulation gets thicker. Since the c-value identifies the number of Btu being 'lost' through the insulation, increasing insulation thickness has the effect of decreasing the amount of heat passing through the insulation.
C-value = K-value/thickness
Imperial units for c-value are expressed in Btu/hr•ft2°F. SI units for c-value are expressed in W/m2•°C.
Cohesion is a material property. Cohesive failure can occur within the adhesive or material itself.
Any location where drywall will be installed tight against framing lumber is particularly suitable for
Great Stuff Pro™ Gasket. In particular, the face of top plates, bottom plates and the framing
around rough window and door openings, as well as inside and outside framing corners.
The DuPont™ Styrofoam™ Brand Cavitymate™ Ultra Extruded Polystyrene (XPS) Foam Insulation boards are adhered to the block wall with Great Stuff Pro™ Gaps & Cracks Insulating Foam Sealant to ensure that the assembly performs in the long term.
Insulation boards that are allowed to be loose in the cavity can be moved around by varying air pressure from wind gusts. Over time this movement might compromise the foam sealant between the boards resulting in a loss of the air barrier performance of the system. Adhering the insulation boards to the block wall prevents this from happening.
For more information on the Ultra Air Barrier Wall System see:
ASTM E1677 (Standard Specification for an Air Retarder Material or System for Low-Rise Framed Building Walls) describes the tests used to evaluation an air barrier. The results for Weathermate™ and Weathermate™ Plus Housewraps are:
For more information:
The contents of Enerfoam™ should be as close to room temperature as possible when dispensed. Apply when temperatures are between 32° - 100°F (0° - 38°C) optimum temperature 60° - 90°F (15° - 32°C.) The shelf life is 1 year if stored at 75°F.
Click here for more information about Enerfoam™ Sealant.
DuPont recommends Styrofoam™ Brand products be disposed based on your local government regulations. Depending on your particular region, Styrofoam™ Brand products can be disposed to land fill, recycle, garbage bin, etc.
No. Extensive hygroscopic analyses have been performed on a variety of Ultra Air Barrier Wall Systems in various locations. This includes both simple Dewpoint Analysis and the much more complex WUFI Analysis. The results indicated that the Ultra Air Barrier Wall System is one of the most robust wall configurations possible.
In Northern climates the insulation layer warms the interior of the wall assembly, which dramatically reduces the condensation potential and increases the drying potential.
In Southern climates the insulation layer reduces the movement of air and water vapor into the interior of the wall assembly, which also dramatically reduces the condensation potential and increases the drying potential.
For more information on the Ultra Air Barrier Wall System see:
Rough Concrete/Styrofoam™ Brand Extruded Polystyrene Foam Insulation | 0.9 kinetic typical |
Smooth Concrete/Styrofoam™ Brand Extruded Polystyrene Foam Insulation | 0.65 kinetic typical |
Latex Modified Concrete/Water Film/Styrofoam™ Brand Extruded Polystyrene Foam Insulation | 0.58 kinetic typical |
DuPont™ Styrofoam™ Brand Highload 40, 60 and 100 Extruded Polystyrene (XPS) Foam Insulation | static 0.6 |
DuPont™ Styrofoam™ Brand SM Extruded Polystyrene (XPS) Foam Insulation | static 0.61 |
The continuous insulation shouldn’t be adhered to Tyvek® Fluid Applied WB+™ with sealant, mastic, primer/adhesive, or spray foam. In addition, installations featuring continuous insulation of any type that is not mechanically fastened to the structural member of the wall assembly will void the eligibility for DuPont™ Tyvek® Fluid Applied 10-Year Product Replacement Limited Warranty.
DuPont™ requires the exterior insulation to be mechanically attached over DuPont™ Tyvek® Fluid Applied WB+™ after a minimum of 48 hours of curing. However, the 1-Year Product Replacement warranty would remain in effect for installation not in complete alignment with our published fluid applied installation guides. Please see the DuPont™ Tyvek® Fluid Applied WB+™ Products Limited Warranty document for terms and conditions.
Polyisocyanurate foam insulations from DuPont are produced with hydrocarbon blowing agents that have no ozone depletion potential.
No. Many contractors have told us that the horizontal application method for Styrofoam™ Ultra SL Insulation is most efficient for them over steel studs. But there are some exceptions to this. Either way is acceptable, but we show the most common method used here.
For more information on the Ultra Air Barrier Wall System see:
Yes. Styrofoam™ Brand Extruded Polystyrene Foam Insulation can be used in radiant floor heating. Indeed, the moist environment typically found in radiant floor environments make Styrofoam™ Brand Insulation ideal for this application.
The maximum use temperature for Styrofoam™ Brand Extruded Polystyrene Foam Insulation is 165ºF (74ºC), which is normally well within the range of temperatures seen in radiant floor heating. For more information, visit our website.
Yes. DuPont has standard CAD details for an insulated brick and block masonry cavity wall. See the link below for various details in PDF format.
Yes. DuPont™ Weathermate™ Basic Housewrap has an International Code Council (ICC) National Evaluation Services (NES) report: ICC-ES ESR-3003. An electronic copy of this report can be viewed or downloaded here.
There are many CAD details that have been created to use as a reference point for applications of LiquidArmor™ CM, QS and LT. These details are meant only as a reference and not as a 'one size fits all' model.
'Grade I' shall be used to describe insulation that is generally installed according to manufacturers' instructions and/or industry standards. Grade I is the highest or best level of insulation installation. The other grades are II and III. A 'Grade I' installation requires that the insulation material uniformly fills each cavity side-to-side and top to-bottom, without substantial gaps or voids around obstructions (such as blocking or bridging), and is split, installed, and/or fitted tightly around wiring and other services in the cavity. To inspect, probe in, around, or through the insulation and/or vapor retarder in several places to see whether these requirements are met. Replace or repair the vapor retarder and insulation as necessary. During inspection (typically before drywall is installed), if the exterior sheathing is visible from the building interior through gaps in the cavity insulation material, it is not considered a 'Grade I' installation.
To attain a rating of 'Grade I', wall insulation shall be enclosed on all six sides, and shall be in substantial contact with the sheathing material on at least one side (interior or exterior) of the cavity.
Compression or incomplete fill amounting to 2% or less, if the empty spaces are less than 30% of the intended fill thickness, are acceptable for 'Grade I'.
Based on the above criteria, it is very difficult for fiberglass cavity insulation to achieve Grade I installation.
The following illustration represents the boundary conditions between the three RESNET insulation installation grades:
The DuPont™ Tyvek® Fluid Applied WB+™ offers 2 to 3 times the coverage of competitive products with less than 90% solids. We offer a theoretical coverage rate of 50-65 sq. ft /gal in one coat due in part to Tyvek® Fluid Applied WB+™ being 99% solids. This is a huge advantage over competitive products that are less than 90% solids, many of which must be applied at coverage rate of 60-90 wet mils with 30-45 dry mils.
Enerbond™ Professional Foam Adhesive is polyurethane foam adhesive for wall and floor construction.
Click here for more information about Enerbond™ Professional Foam Adhesive.
Factory Mutual (FM) Global is one of the world's largest commercial and industrial property insurance and risk management organizations specializing in property protection. Many DuPont products have been tested at Factory Mutual to establish flame spread and assembly ratings. This information is important for architects/owners who design/own buildings which will be Factory Mutual insured. Often this information is used to show that a particular product complies with specification requirements.
For more information about FM Global, please visit: www.FMglobal.com
Vacuum-assisted resin transfer molding (VARTM) refers to a variety of related processes, which represent the fastest growing new molding technology. VARTM-type processes and standard RTM differ in that VARTM draws resin into a preform through use of a vacuum, rather than positive pressure. VARTM does not require high heat or pressure. For that reason, VARTM operates with low-cost tooling, making it possible to inexpensively produce large, complex parts in one shot.
In the VARTM process, fiber reinforcements are placed in a one-sided mold, and a cover (rigid or flexible) is placed over the top to form a vacuum-tight seal. The resin typically enters the structure through strategically placed ports. It is drawn by vacuum through the reinforcements by means of a series of designed-in channels that facilitate wetout of the fibers. Fiber content in the finished part can run as high as 70 percent. Current applications include marine, ground transportation and infrastructure parts.
The excellent performance features of Styrofoam™ products include:
An ENERGY STAR home has the following benefits:
Radius of curvature (ROC) is a description of the amount of curvature in a given surface. It is measured and reported in linear units, usually feet or meters. The ROC refers to a circle with that given radius being of the same curvature as the surface in question. The ROC for a given insulation product is a description of how much it can be curved or bent to conform to a building surface to which it is being applied WITHOUT breaking. The ROC depends upon the type of core insulation, any facers on the insulation the thickness of the insulation.
The following table lists the radius of curvature for various DuPont insulation products.
Thickness, in. |
Product |
ROC, ft. |
1 |
Unfaced Styrofoam™ Brand XPS Foam Insulation* |
2-3 |
2 |
Unfaced Styrofoam™ Brand XPS Foam Insulation* |
10-12 |
3 |
Unfaced Styrofoam™ Brand XPS Foam Insulation* |
30 |
1 |
Thermax™ Sheathing |
75 |
2 |
Thermax™ Sheathing |
125 |
Rodents and small animals, if determined enough, can chew through many materials, including Great Stuff™ foam. We have specifically designed a variation of our Great Stuff™ foam to solve this issue, Great Stuff™ Pestblock Insulating Foam Sealant. Great Stuff™ Pestblock, BLOCK insects and pests from entering the home by sealing gaps, cracks and holes where they commonly enter. Great Stuff™ Pestblock expands to fill, seal and insulate gaps up to 1" (25 mm), forming a long-lasting, airtight and water-resistant barrier. For more information on Great Stuff™ Pestblock, click the following link.
Visit Great Stuff™ for more information on Great Stuff™ products for the DIY.
DuPont™ scientists and engineers have optimized the thickness of the fluid applied material by taking advantage of the superior elongation and recovery properties to provide a durable, robust membrane. At 25 mils, the DuPont™ Tyvek® Fluid Applied WB+™ provides the ideal combination of air and water hold out while providing optimal vapor permeability of 22 perms. In addition, Tyvek® Fluid Applied WB+™ offers 99% recovery at 300% elongation.
The prices for different DuPont™ Styrofoam™ Brand products are different. Please contact your local sales representative or DuPont offices for details if you have a project that Styrofoam™ Brand products can be specified.
Styrofoam™ Brand Extruded Polystyrene Foam Insulation product in Canada do not have thermal warranties.
Store the Froth-Pak™ polyurethane foam system at 75°F (24°C) in a clean, dry area. DO NOT STORE AT TEMPERATURES ABOVE 120°F (49°C). Avoid prolonged storage in direct sunlight or near heat sources. Store a partially used kit with the safety ON (do not tie trigger down) and valves CLOSED. Remove used nozzle, reapply petroleum jelly to face of INSTA-FLO™ dispenser, and reinsert the used nozzle prior to storing. Do not bleed pressure off hoses during storage. Be sure to shake the container and install a new nozzle prior to use.
Click here for more information about Froth-Pak™ sealant products.
Each unit of Froth-Pak™ is stamped with an expiration date. This date is 15 months from the date of manufacture.
Tile, paint or any kind of texture can be used as the surface of an EIFS application. It depends on the individual preference of the facility/building owner/architect. When paint is used, low permeability and excellent water resistance of the paint are required.
Similar to previous ENERGY STAR for Homes programs, there are two compliance paths available -Prescriptive and Performance. When the home size of a particular home is less than the benchmark home size required by the ENERGY STAR for Homes program, this home can use either the prescriptive path or performance path for compliance. However, if the home size of a particular home is larger than the benchmark home size, the performance path is the only path for compliance. More information can be found from ENERGY STAR for Homes website:
If the recommended fasteners are used (Rodenhouse Thermal-Grip or Plasti-Grip III), then no additional method of flashing or sealing of the fasteners is necessary to achieve a Weather Resistant Barrier (WRB). Board joint seams will have to be sealed and some types of veneer anchors also need sealing. All of these fasteners have been tested for water penetration and have been found to meet the requirements for water resistance for the Thermax™ Wall System (as specified in the building code and measured by ASTM E331).
From simple everyday efforts, to major investments in new technology, working toward a cleaner, greener planet is one of DuPont's top priorities.
Heating and cooling savings. Insulating and air-sealing products from DuPont can save up to 20 percent on a building owner’s heating and cooling costs.
U.S. savings. Installed in over 20 million buildings worldwide, Styrofoam™ Brand Extruded Polystyrene Foam Insulation insulates over 20 billion ft², saving the U.S. over $10 billion in energy costs annually.
CO² reduction. The total 20-year n production capacity of DuPont insulation products (Styrofoam™ Brand, DuPont™ Thermax™ Brand Insulation, Great Stuff™) when properly installed in buildings, could save over 10 trillion pounds of a carbon dioxide (CO²) equivalent during their useful lifetime. This represents a CO² impact equal to planting 5 billion trees or removing 850 million cars from the road for one year.
Oil reduction. For every million buildings insulated with Styrofoam™ Brand Extruded Polystyrene Foam Insulation, energy consumption is reduced by over one billion barrels of oil during the average life of the structures.
Recycling and reuse. Virtually 100 percent of the scrap extruded polystyrene generated at DuPont plants is recycled into DuPont products. In addition, Styrofoam™ Brand Extruded Polystyrene Foam Insulation can be reused over and over again. Styrofoam™ Brand products contain an average of 20% pre-consumer recycled content.
Windmill production. DuPont is enabling the generation of 2,400 megawatts of renewable energy through the use of Styrofoam™ Brand Extruded Polystyrene Foam Insulation in windmill blades. DuPont epoxy is also a critical component in most wind turbines operating today.
Waste reduction. DuPont’s commitment to the planet extends to its employees. For example, in 1986, the company launched the Waste Reduction Always Pays (WRAP) Award Program, which continues today. Through reduction, reuse and recycling efforts, employees have reduced more than 230,000 tons of waste, 13 million tons of wastewater, and 8 trillion Btu of energy.
Water reuse. Since February 2007, municipal household wastewater in Terneuzen, the Netherlands, has been flowing via a special pipeline to DuPont’s production facility there, where it is reused. DuPont accepts 2.6 million gallons of water every 24 hours and purifies more than 70 percent of it to generate steam and feed its manufacturing plants.
No. While DuPont™ LiquidArmor™ Flashing and Sealant products provide excellent water resistance around fenestration, smaller wall penetrations and foam boards joints, they were not specifically formulated or tested for use in roof applications. Accordingly, LiquidArmor™ Flashing and Sealant products should not be used in roofing applications at this time.
For uplift ratings there are many, especially in FM and also in UL. The following are just a few. Call DuPont Contact Center (DCC) at 1-833-338-7668 for more ratings and additional information.
Listing Agency | Rating | Deck Type | Adhesive Type | Cover Board | Membrane Type |
UL | 165 psf | Steel min. 22 msg. | Insta Stik™ Quik Set Commercial Roofing Adhesive | 5/8' Gypsum or DensDeck from Georgia-Pacific | Carlisle Sure-Weld, FleeceBack 1000 (TPO) |
FM | Maximum membrane uplift rating | Concrete | OlyBond 500 or OlyBond Classic from OMG, Inc. | DensDeck | BUR, Mod. Bit., Single-ply |
District Rule 1168 for Adhesives and Sealants requires architectural sealants' VOC's to be less than 250 g/L. Subfloor, VCT (vinyl composition tile made from thermoplastic resins, fillers and pigments) and asphalt tile, dry wall and panel adhesives must be below 50 g/L. Ceramic tile adhesives must be below 65 g/L and multipurpose construction adhesives below 70 g/L.
Pressure vessels are available with different diameters, lengths, and pressure ratings. When selecting a pressure vessel, the chosen pressure rating must be high enough to allow for a pressure increase to compensate for irreversible fouling (typically 10% more than needed in a 3-year design).
When dynamic permeate backpressure is employed during plant operation, the limiting component for some pressure vessels is the permeate port. Please see the following link for additional details.
Pressure Vessels (38KBPDF)
It is recommended to choose the appropriate technology for the final use application. Please see the application overview page for recommendations for specific uses.
It is also necessary to consider the characteristics of the feedwater as well as the quality of final water needed.
This pre-treatment applies to anion and cation exchange resins used for chromatographic separation applications. Ion exchange resins for other applications require a different procedure Ion Exchange Resins - Food Processing and Contact
Good practice in the food processing field requires careful preparation of processing equipment prior to use. To assist the food processor in preparing chromatographic separation resins for such use, the following conditioning procedures are outlined.
Experience has shown that these simple steps, done under normal processing conditions and supplementing the normal manufacturing pretreatments, should assure that the level of organic extractives in the resin-in-use complies with the U.S. Food, Drug, and Cosmetic Act as amended under Food Additive Regulation 21 CFR #173.25.
To a bed of resin in the normal backwashed, settled and drained condition:
Flush the resin bed with at least three bed volumes of treated water1 for a contact period of at least two hours at a temperature at least 2°C (4°F) above the expected operating temperature. Continue flushing until the effluent is clear. If the resin is backwashed with hot treated water, the backwash volume can be counted toward the three bed volumes.
1 For most chromatographic resins, properly treated water must be hot, degassed, and deionized. For the AmberLite™ CR99 K Chromatographic Separation Resin family of resins (potassium form resins), the properly prepared rinse water can be hot (80°C (180°F) minimum), degassed, softened water.
CCRO systems can be used for any application where traditional reverse osmosis is used — and some places it cannot (e.g. sites with varying feedwater or high silica concentrations).
This makes them ideal for a wide range of applications across industries, including but not limited to Food and Beverage, Consumer Goods, Chemicals and Refineries, Power Generation, and Metals and Plastics, among others. Some of the applications include:
Because of their extremely high-water recovery rates and unique operational flexibility, CCRO systems are especially well-suited for reducing water use and working with varying-quality water sources.
Dry elements have not been exposed to water testing. There are no individual Certificates of Analysis for dry delivered membranes. DuPont, however, guarantees that all dry delivered membranes meet or exceed the specification as per the datasheet of the elements. A rigorous statistical quality control process is in place to ensure that membrane elements meet or exceed specifications. Certificate of Compliance (CoC) can be provided upon request.
Additional Information:
FilmTec RO Element 3-year Prorated Limited Warranty (25KB PDF)
General operating guidelines for cation and anion resins are given in the tables at the following links,
Suggested Operating Temperatures for Ion Exchange Resins
Recommmendation for Free Chlorine Limits for Cation Exchange Resins
For detailed design on ion exchange systems, please consider the WAVE Software, along with the generally recommended Steps to Design an Ion Exchange Resin System. Specific recommended operating conditions for individual ion exchange resins can be found in the product datasheets in the Product Information Section.
For 8" elements the package materials are:
Additional Information:
Handling and Preservation for FilmTec Elements (22KB PDF)
FilmTec Membranes - Packaging & Shipping
In most cases, when stored under proper conditions and in their original packaging, unused ion exchange resins may be stored for longer than their recommended shelf life without experiencing a decline in their physical properties. Standard demineralizing and softening resins are expected to experience minimal change in chemical properties over the course of a five-year period. For more sensitive applications, alternate maximum storage time periods may be recommended and exceptions are indicated in the specific product data sheets. The following table gives the general guidelines:
Application |
Typical recommended storage time (max) |
---|---|
Industrial water |
5 years |
Power |
3 years |
Ultra Pure Water (semi-conductor) |
3 years |
Drinking water (Point of Use) |
3 years (1 year) |
Catalysis & chemical processing |
3 years |
Nutrition |
3 years (OH form anion : 2 years) |
Bioprocessing |
3 years |
Inert resins |
8 years |
The manufacturing and re-test date are reported in the Certificates of Analysis and written on most of the packing labels. It is recommended to check the resin after the recommended shelf life for standard characteristics.
Resins should be stored in their original unopened packaging in a cool dry area. An indoor storage facility with climate control between 2–40°C (36–105° F) should be used for the best results.
Storage temperatures above 40°C (105°F) can cause premature loss of capacity for anion resins, particularly those stored in the OH-form. While cation resins can withstand higher temperatures (up to 80°C/175°F), it is best to store all resins under similar conditions. Storage temperatures below 0°C (32°F) can cause resin freezing. Tests of DuPont resins under repeated freeze-thaw cycles show that bead damage can occur. Frozen resin should be thawed out completely under room temperature conditions before loading and use.
As with new resins, used resins should be stored under climate controlled conditions, where feasible, to maximize the life of the resins.
Additionally, care should be taken that resins are not exposed to air because they will dry out and shrink. When rehydrated, these resins are susceptible to bead breakage due to rapid re-swelling of the resin beads. If resin beads are allowed to become dry, they should be hydrated with a saturated NaCl solution. The high osmotic pressure will minimize the rapid re-swelling. The salt can then be removed by successive dilutions to prevent rapid change in osmotic pressures and resulting bead breakage.
Biological growth problems can be caused by inactivity of the resin during extended storage. In order to minimize the potential for biofouling, inactive systems should be stored in a biostatic solution such as concentrated NaCl. In addition to minimizing biogrowth, the concentrated brine solution will prevent freezing.
The recommended procedure for resins used for water demineralization is as follows:
To significantly reduce the rate of membrane fouling, RO systems employ cross-flow filtration, which allows water to pass through the membrane while the separate flow of concentrate sweeps rejected salts away from the membrane surface.
Cross flow feed velocity can be calculated by taking the feed flow rate divided by the cross sectional area of feed channel spacer.
For instance, if the feed channel spacer is 30 mils thick and 40 inches wide, then the cross sectional area is 0.030 x 40 = 1.2 sq. inches which is 0.008333 sq.ft.
If the feed flow rate is 1 gpm, then feed velocity is (1 gal/min)x(1min/60 sec)x(0.13368 ft3/gal)/(0.008333 ft2) = 0.27 ft/sec.
Additional Information:
Flow Rate Guidelines for FilmTec Elements
Membrane compaction is when membrane is crushed or compacted under a combination of high pressure and temperature. As a result permeate flow and the output of the system decreases. Compaction results in irreversible damage to the membrane element. Generally, thin film composite membranes are noted to be more resistant to membrane compaction than the cellulose acetate membranes.
A brackish water (BW) or seawater (SW) element can be used depending on the specific permeate water quality requirements and economics. Seawater elements will give a better permeate water quality (i.e. lower permeate TDS) than brackish water elements since SW membranes have higher solute rejection than the BW membranes. However, brackish water elements operate at lower pressure than seawater elements, and therefore, the cost of operation is lower.
Please see Select Membrane and Element Type for details on selecting an element for your design.
Thje WAVE software program allows you to design membrane systems using FilmTec elements and predict system performance.
It is recommended that you run a projection using BW30 elements to see if the permeate quality meets your requirements. If the permeate TDS is not low enough for you, then you can try our seawater elements.
Additional information regarding FilmTec™ products is available as follows:
As with most conventional filtration methods, sand filters and media filtration require consistent raw water quality to deliver quality effluent, which is not always possible. They also don't provide an absolute barrier. Traditional media filters typically remove particles to down to about 5 microns.
Ultrafiltration (UF), however, does not suffer from those limitations. This technology uses an ultrafiltration membrane barrier to exclude particles 0.02 to 0.05 microns, including bacteria, viruses, and colloids, meeting increasingly stringent water-quality standards around the world, and providing a stable, reliable, and consistent water quality.
UF offers:
When used as a pretreatment for reverse osmosis (RO) , UF also helps reduce fouling of the RO membranes, which can lead to:
Potassium hydroxide (caustic potash, KOH) can be used to regenerate anion exchange resins. It is not frequently used because KOH typically costs more on a per weight basis than NaOH. In addition, the equivalent weight of KOH is 56 g/eq versus 40 g/eq for NaOH. That means you have to use 40% more KOH to get the same equivalent concentration of hydroxide ions. So, if the regenerant dosage using sodium hydroxide was 100 g/l-R (6.2 lbs/ft3), then 140 g/l-R (8.7 lbs/ft3) of potassium hydroxide would be required to obtain the same degree of regeneration.
Additional Information:
Ion Exchange Resins - Recommended Operating Conditions
Properties, Impurities, and Concentrations of Regenerent Chemicals (124KB PDF)
Resin Type | pH Range |
Strong Acid Cation Resins | 0-14 |
Weak Acid Cation Resins | 5-14 |
Strong Base Anion Resins | 0-14 |
Weak Base Anion Resins | 0-7 |
DuPont's Ultrafiltration modules are made from high strength, hollow fiber membranes that offer the following features:
The hollow fiber membranes are 1.3 mm outside diameter and 0.7 mm inside diameter and are made from PVDF polymer. The fibers are strong because of a combination of the PVDF polymer, asymmetric dense spongy layer, and skins formed on each side of the fiber. The PVDF membranes offer high chemical resistance and are tolerant to temperatures of 40ºC. The hydrophilicity of the PVDF fibers is increased by using a proprietary treatment during manufacturing.
The 0.03μm nominal pore size combines high filtration performance and high flux. The smaller pore size provides stabile long term filtration performance compared to microfiltation.
Salinity and pressure are constantly cycling inside the CCRO system as the blended feedwater gradually becomes more concentrated before being flushed. This deprives microorganisms of the environmental stability they would need to survive.
Since anion exchange resins tend to have a shorter lifetime than cation exchange resins in mixed beds due to kinetic impairment and a higher rate of physical degradation, they are sometimes replaced singly. This can sometimes lead to poor performance of the mixed bed due to kinetic impairment of the old cation exchange resin. Before making a single resin replacement the performance of the remaining resin should be checked. DuPont offers a full range of resin analysis services through our System Optimization Services program.
Additional Information:
Resin Sampling Procedure (PDF)
Heat Distortion
The increase in heat distortion temperature of styrene/divinylbenzene copolymers is linear with increasing divinylbenzene content, and is approximately equivalent to 3.3° C for each 1% increase in divinylbenzene.
Impact Strength
Like tensile strength, impact strength increases with the first few % of divinylbenzene, and then falls off rapidly. Copolymers with high divinylbenzene content are very brittle.
Tensile Strength
The tensile strength increases with the first 5% divinylbenzene, and then drops off rapidly to a very low value.
Hardness
Hardness increases steadily with increasing divinylbenzene concentration.
Aluminum will have an adverse effect on the membrane over time, especially if there is any silica (SiO2) present. The maximum allowable limit for aluminum in the feed is 0.05 ppm. For a home or small commercial application the best way to remove the Al is with a water softener.
AmberSep™ IRC748 UPS is an iminodiacetic acid chelating cation exchange resin with high selectivity for calcium, magnesium, and strontium in chloralkali brines. It also exhibits high selectivity for heavy metal cations over alkali metal ions found in various process and waste streames. Selectivity is achieved by the iminodiacetic acid functionality chemically bound to a resin matrix. Because of the high preference of AmberLite 748i for metals and excellent kinetic performance, this resin can remove metals from solutions even in the presence of high concentrations of sodium or calcium salts, with very low metal leakage.
The apparent selectivity of any ion exchange resin for a given metal depends upon concentration, the presence of other species, and pH. This makes absolute selectivities very difficult to determine. Because of this, laboratory testing is essential when a resin is required to remove one or more types of metal ions selectively. In general, the selectivity follows the order:
Example: AmberLite IRC748
Selectivity: Fe3+ > Hg2+ > Cu2+ > Pb2+ > Ni2+ > Zn2+ > Cd2+ > Co2+ > Fe2+ > Mn2+ > Ca2+ >> Na+
The affinity for H+ at pH 4 is situated between Pb2+ and Cu2+. Consequently, for the metals with selectivities less than Cu2+, the resin should be in the salt form (e.g., the Na+ form) to minimize metal leakage. At a pH of 2, the resin will be extensively in the H+ form and will only efficiently remove Fe3+, Hg2+ , Cu2+. Selectivity at various pH conditions are given in the product data sheet.
Each element uses FilmTec FT30 membrane which is known for its robust, long lasting performance over a wide range of pH operating (pH 2-11) and cleaning (pH 1-13) conditions. The membrane leaves that make up a FilmTec element are shorter than conventional elements that allows for improved efficiency by reducing permeate backpressure and providing a uniform flux along the membrane leaf which improves the fouling resistance of the element. FilmTec elements have precise and uniform glue lines made possible by automatic glue application improving the physical integrity of the membrane element. Precision fabrication allows the accurate insertion of a greater number of membrane leaves providing a high active area and ensuring that each and every element has consistent membrane area. The precise spacing of the membrane leaves around the product water tube allows FilmTec to use thicker spacers than conventional elements without reducing the active area of the elment.
Using these resins results in a chemical savings of 5 to 25% compared to reverse flow regeneration systems using standard sized resins. UPS and specially graded resins also allow higher flow rates than standard resins, due to their higher mechanical strength and fewer small resin beads.
Using other resins may lead to average or erratic results due to many possible reasons, such as:
Additional Information:
Recommended AmberLite™ ion exchange resins for packed bed systems in industrial water treatment
The FTNORM spreadsheet only allows a single pass system calculation. If you wish to use FTNORM on a double pass system, you can use a separate FTNORM spreadsheet for each pass.
Additional Information:
When RO or NF membrane is used in the RO/NF process, the feed must be dechlorinated to prevent oxidation of the membrane. FilmTecTM membranes have some chlorine tolerance before noticeable loss of salt rejection is observed. The first sign of chlorine attack on RO/NF membrane is loss of membrane flux followed by an increase in membrane flux and salt passage. Eventual degradation may occur after approximately 200-1,000 hours of exposure to 1 mg/L of free chlorine (200-1,000 ppm-h tolerance). The rate of chlorine attack depends on various feed water characteristics. Under alkaline pH conditions, chlorine attack is faster than at neutral or acidic pH. An acidic pH is preferred for better biocidal effect during chlorination. Chlorine attack is also faster at higher temperatures and higher concentrations of heavy metals (e.g., iron), that can catalyze membrane degradation. Since oxidation damage is not covered under warranty, FilmTec recommends removing residual free chlorine by pretreatment prior to exposure of the feed water to the membrane. Other oxidizing agents such as chlorine dioxide, hydrogen peroxide, ozone, and permanganate are capable of damaging RO/NF membranes also if not used properly.
Residual free chlorine can be reduced to harmless chlorides by activated carbon or chemical reducing agents. An activated carbon bed is very effective in the dechlorination of RO feed water according to following reaction:
C + 2Cl2 + 2H2O → 4HCl + CO2
Sodium metabisulfite (SMBS) is commonly used for removal of free chlorine and as a biostatic. Other chemical reducing agents exist (e.g., sulfur dioxide), but they are not as cost-effective as SMBS.
When dissolved in water, sodium bisulfite (SBS) is formed from SMBS:
Na2S2O5 + H2O → 2 NaHSO3
SBS then reduces hypochlorous acid according to:
2NaHSO3 + 2HOCl → H2SO4 + 2HCl + Na2SO4
In theory, 1.34 mg of sodium metabisulfite will remove 1.0 mg of free chlorine. In practice, however, 3.0 mg of sodium metabisulfite is normally used to remove 1.0 mg of chlorine.
The SMBS should be of food-grade quality and free of impurities. SMBS should not be cobalt-activated. Solid sodium metabisulfite has a typical shelf life of 4–6 months under cool, dry storage conditions. In aqueous solutions, however, sodium bisulfite can oxidize readily when exposed to air. A typical solution life can vary with concentration as follows:
Concentration (wt %) |
Solution Life |
10 |
1 week |
20 |
1 month |
30 |
6 months |
Although the dechlorination itself is rapid, good mixing is required to ensure completion. Static mixers are recommended. The recommended injection point is downstream of the cartridge filters in order to protect the filters by chlorine. In this case, the SMBS solution should be filtered through a separate cartridge before being injected into the RO feed. Dechlorinated water must not be stored in tanks.
When RO/NF membranes are fouled with heavy metals such as Co and Cu, residual SBS (u
The following table gives the approximate shelf life of DVB under maximum ambient storage temperatures, assuming TBC and dissolved oxygen concentrations are maintained above the minimum levels. Refrigerated storage will significantly extend the shelf life of DVB.
The shelf life of stored DVB can also be extended with timely aeration. A 5–10 minute air sparge is recommended on a monthly basis for drums and pails stored at temperatures between 70–80°F (21-27°C). DVB containers stored at temperatures from 40–70°F (5-21°C) need to be aerated according to the following table. With aeration and maintenance of p-tert butylcatechol (TBC) level above 400–600 ppm the clock is effectively resent to the recommended storage times.
Recommended Shelf Life of DVB (All Grades)
Storage Temperature |
Storage Time |
Aerate Within |
|
<40°F |
<5°C |
12 months |
6 months |
40–50°F |
5-10°C |
8 months |
6 months |
50–60°F |
10-16°C |
4 months |
4 months |
60–70°F |
16-21°C |
2 months |
2 months |
70–80°F |
21-27°C |
1 month |
1 month |
Guidelines for minimum concentrate flow rate and maximum feed flow rate are depended upon the membrane element size and type.
Large diameter elements with more membrane area require more feed and concentrate flow rate than the smaller diameter elements with less membrane area.
Full-fit elements have a higher maximum feed flow rate than the standard tape-wrapped and/or fiberglassed elements because they have a controlled bypass flow around the element. Operating within the guidelines of minimum concentrate flow and maximum feed flow is important since it has a direct impact on the performance and life of the membtrane.
Detailed guidelines can be seen in the Membrane System Design Guidelines for 8-inch and Midsize (2.5- 4 inch) FilmTecTM Elements below.
Additional Information:
Membrane System Design Guidelines for 8-inch FilmTec Elements (126KB PDF)
Commercial Design Guidelines for Midsize FilmTecTM Elements (126KB PDF)
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Representatives from DuPont Water Solutions can guide you in the process of choosing the right product for any application. The figure, below, can be used as a guide to target the proper product. For further help, please submit your question by selecting Ask-An-Expert.
Additional Information
The vessels should be made from typical, well-known materials of construction such as rubber-lined carbon steel or fiberglass. The vessel should have distribution / collector systems that give a good distribution of fluids during all phases of the operation. For this reason, a maximum vessel diameter of 3.5m (11.5 feet) is recommended. It is advisable to install sight-glasses in order to check resin levels and separation in the case of layered beds and mixed beds.
The design of the vessels should give a maximum resin bed depth, while limiting the pressure drop across the resin bed to ~1 bar. The optimum column diameter must be a balance between the resin bed height, the ratio of resin height to diameter (H/D) and the linear velocity. H/D should be in the range 2/3 to 3/2.
Vessel sizing should be adjusted to allow for resin expansion if backwashing is performed (80-100% of the settled resin bed height), resin swelling during service, the minimum bed height requirements and the guidelines given for service and regenerant flow rates in the Design Guidelines table below. These values are for orientation and should not be regarded as exclusive. Some applications may function outside of the guidelines. Typical resin bed depth is 1.2 m (4 ft) for co-current and block regeneration systems and 2 m (6.5 ft) for counter-current packed bed systems.
Design Guidelines for Operating AmberLite™ Resins
Additional Information
Steps to Design an Ion Exchange Resin System
Gel ion exchange resins are translucent and are composed of a polymer matrix which results in the formation of a homogeneous continuous phase throughout the bead. There are no permanent pore structures in a gel resin. The only porosity in a gel resin is the space between the polymer chains. This microporosity is typically less than 30 Ångstroms.
The Symptoms of Trouble, Causes and Corrective Measures - Troubleshooting Grid describes the symptoms and causes of typical problems that may arise and offer solutions or suggestions to improve the system operation. There are links to additional information such as cleaning procedures, etc., where appropriate.
To diagnose, you will need to answer the following questions:
In general:
What is the nature of your problem:
Loss of salt rejection and loss of permeate flow are the most common problems encountered in reverse osmosis. If the salt rejection and/or the permeate flow decreases slowly, this may indicate a normal fouling / scaling which can be handled by proper and regular cleaning. A rather fast or an immediate performance decline indicates a defect or misoperation of the plant. In any case, it is essential that the proper corrective measure is taken as early as possible, because any delay decreases the chance of restoring the plant performance.
Keeping Data Records
A prerequisite for early detection of potential problems is proper record keeping and plant performance normalization. This includes proper calibration of all instruments. Without accurate readings it might be too late before a problem can be detected and corrected. Another key to successful troubleshooting is understanding the effects of changing system parameters on system performance. Some apparent plant problems are simply the normal reaction of the plant to changing feed or other operating parameters.
Please contact-us and submit a request, specifying the error you have received.
Temperature affects many aspects of ion exchange resin performance including the following:
Additional Information:
Proper Storage Conditions for Ion Exchange Resins (12KB PDF)
Ion Exchange Resins - Recommended Operating Conditions
Chloramines are formed by the addition of chlorine to ammonia according to the following equilibrium equations:
Cl2 + H2O « HOCl + H+ + Cl-
HOCl + NH3 « NH2Cl + H2O
HOCl + NH2Cl « NHCl2 + H2O
HOCl + NHCl2 « NCl3 + H2O
Since these reactions are in equilibrium, it is possible that free chlorine will be present under certain conditions of pH, temperature and the ratio of chlorine to nitrogen. Free chlorine will degrade an ion exchange resin. This occurs primarily via decrosslinking in a cation resin and defunctionalization in an anion resin. In addition to the free chlorine that is formed when the equilibrium is shifted on these equations, the chloramines, while less oxidative than chlorine, will oxidize the anion resin functional group. Chloramines and free chlorine should be removed prior to ion exchange resin beds. Degradation products of these reactions include ammonia, hydrochloric acid, nitrogen, and in the case of anion resin oxidation - trimethylamine. The ionic species will likely be removed from the water by the downstream ion exchange resin and seldom have an impact on product water quality.
Recommendations for Maximum Free Cl2 Limits for Cation Exchange Resins (91KB PDF)
The Removal of Oxygen and Chlorine from Water, Tech Fact (13 KB PDF)
The length of a service cycle for a mixed bed should be based on a conductivity or silica end point, depending on treated water specifications. When the effluent water quality reaches the conductivity or silica break, the mixed bed is regenerated. The regeneration frequency of a mixed bed will depend on several parameters such as feed water chemistry, resin volume, and regenerant levels. A mixed bed after a demineralization train may be regenerated after a few days, while a mixed bed after RO may last for several months. At no time should the silica load be allowed to exceed 8 g/l anion resin or the organic load to exceed 1 g TOC/liter of anion resin before the mixed bed is regenerated.
Additional Information:
Ion Exchange Resins - Recommended Operating Conditions
Symptom | Possible Causes | Remedies |
Long rinse times | Leaking valves |
Repair or replace as appropriate |
Damaged laterals |
Repair or replace as appropriate | |
Weak and Strong Acid |
Calcium sulfate precipitation |
Clean (9KB PDF) and check acid injection concentrations or implement step-wise regeneration (19KB PDF) |
Weak and Strong Base Anion Resin Units | Organic fouling. | Measure rinse volume for each resin. If water quality is not achieved, take resin sample (602KB PDF) for resin analysis of possible fouling |
Cation resin in anion. |
Investigate cause (e.g. broken strainers or traps). Replace anion | |
Poor flow, plugging or dead zones in vessel. | Check unit for possible caustic hideout | |
Resin degradation. | Take sample and confirm with resin analysis, clean or replace resin as appropriate. |
|
Increased Rinse Volume in the Boiler or Steam Generator | High sodium in the polisher effluent. | |
High chloride in the polisher effluent. | ||
High sulfate in the polisher effluent. | ||
Cation resin fines and fragments carrying forward from the condensate polishers. | Check resin traps to confirm the presence of cation resin pieces. Replace screens if necessary. Determine if resin choice is appropriate for the particular system design and operation. | |
Cation resin with poor oxidative stability resulting in a high release of organic sulfonates which decompose under high temperatures to form inorganic sulfate. | Take sample and confirm with resin analysis. If necessary, select a resin product with better oxidative stability. |
Analysis of elements that have been used in service is available from DuPont under the System Optimization Services (SOS) program.
Membrane Element Evaluation - Troubleshooting (KB PDF)
Membrane Element Evaluation - Sample Selection (24 KB PDF)
Membrane Element Evaluation - Visual Inspection and Weighing (23 KB PDF)
Membrane Element Evaluation - Vacuum Decay Tests (KB PDF)
Membrane Element Evaluation - Performance Test (38 KB PDF)
Membrane Element Evaluation - Cleaning Evaluation (KB PDF) - 8.4.6
Membrane Element Evaluation - Autopsy (24 KB PDF) - 8.4.7
Membrane Element Evaluation - Membrane Analysis (27 KB PDF) - 8.4.8
AmberLite™ IRN Ion Exchange Resins are designed specifically for use in nuclear loops where highest resin purity and stability are required, and where the "as supplied" resin must have a minimum of ionic and non-ionic contamination. These attributes combine to achieve reliable and safe production whilst reducing the need for equipment maintenance where minimizing the impact of unscheduled outages is important.
Key features:
High salt passage may occur along with a high or a normal permeate flow. The following are possible causes for each situation.
High Solute Passage and Normal Permeate Flow
High Solute Passage and High Permeate Flow
Please see the following brochure for descriptions and pictures of the various causes, tests that may be run to determine the causes, and corrective measures.
Symptoms of Trouble, Causes and Corrective Measures - High Salt Passage (117KB PDF)
A polishing mixed-bed will be required if the product water specification is below that achievable from the demineralization plant alone or if a higher degree of safety is required to ensure water quality. The mixed bed outlet water should be about 0.10 µS/cm at 25°C and 0.010 to 0.020 mg/l as SiO2 (10 to 20 ppb).
Below are some general guidelines for designing a working mixed bed downstream of a demineralization plant:
Additional Information
Most standard residential FilmTec™ elements are certified to NSF/ANSI Standard 58.
In addition, systems using FilmTec elements have the option of qualifying for eleven distinct NSF 58 contaminant removal claims, including - lead, chromium, fluoride, and arsenic V. This can save significant time and costs in obtaining these performance claims individually.
Performance Guide for FilmTec Home Drinking Water RO Elements certified to NSF/ANSI Standard 58:
Component |
NSF / ANSI Standard 58 Performance Test |
Component |
Also Reduces / Rejects |
Arsenic |
Pass |
Magnesium |
X |
Barium |
Pass |
Calcium |
X |
Chromium (+3) |
Pass |
Sodium |
X |
Chromium (+6) |
Pass |
Nickel |
X |
Cadmium |
Pass |
Mercury |
X |
Copper |
Pass |
Zinc |
X |
Cysts |
Pass |
Iron |
X |
Fluoride |
Pass |
Ammonium |
X |
Lead |
Pass |
Bicarbonate |
X |
Radium (226/228) |
Pass |
Sulfate |
X |
Selenium |
Pass |
Tannin |
X |
Turbidity |
Pass |
Chloride |
X |
Please follow the instructions below to reset your new keycode:
If you have any questions, please see the attachment to see how to enter the key code.
Additional Information
CADIX 6.2
Nickel is present as a cation, but all the acid prevents its removal with a simple cation exchange resin. In the presence of acid, AmberSep M4195 resin does a very good job of Ni removal. This is the resin that is used for Ni mining from acid mine solutions.
Additional Information:
Mining and Hydrometallurgy
The following link describes the dog-bone interconnectors used in our 8-inch elements and the iLECTM interlocking endcaps used in the iLEC elements. It also provides both the part number of the interconnector and the part number and equivalence for the o-rings should they need replacement during system maintenance.
Interconnector Technology (104KBPDF)
Corrosion Control: Corrosion is a common concern in modern industrial facilities. Whether it is a brand new plant or an aging facility, making equipment last is a top priority. Computers and electronic systems are very sensitive to corrosive acid vapors. The cost and expense of corrosion can be the result of lost production, unnecessary repairs and maintenance and premature replacement of equipment.
Many facilities deal with corrosion by neutralization with base. However, precision neutralization is not always easy and the resultant neutralized salts stay in the process stream, contributing to sludge and other disposal costs.
An alternative method is to use a weak anion exchange resin, which acts as an acid absorber. This is because it contains immobilized bases that remove acid from solution and neutralize, but releases nothing back into the solution that will make a sludge or change the process stream.
These resins are versatile acid absorbers, removing both mineral and organic acids, such as HCl, HBr, HF, HI, H2SO4, H3 PO4, acetic, formic, propionic, and benzoic acid.
A higher capacity acid absorber that is well suited to remove phosphoric acid from phosphate ester lubricants. The higher capacity means longer service life for the media.
Acids can be removed from organic process streams with a weak base anion resin, such as AmberLyst A21 (PDF).
Acids can also be removed from air. These resins have a porous surface and the beads can be incorporated into a filter, placed between two screens or held in an open tray.
If chloramines are present in the water, we recommend dechlorination prior to RO.
While there is a certain amount of tolerance for monochloramine and other chloramines, these agents cannot be treated as a fully compatible material for RO membranes, but rather should be treated as a potential mild oxidizing agent.
The primary reason is that chloramines are in an equilibrium reaction with hypochlorous acid (free chlorine) that can be impacted by variables such as pH, certain analyte concentrations, and temperature.
Cl2 + H2O ↔ HOCl + H+ + Cl-
HOCl + NH3 ↔ NH2Cl + H2O
HOCl + NH2Cl ↔ NHCl2 + H2O
HOCl + NHCl2 ↔ NCl3 + H2O
In addition, the presence of iron, aluminum, and possible other transition metals can act as catalysts to significantly accelerate polyamide oxidation reactions in the presence of monochloramine and other oxidizing agents. These kinds of variables make it difficult to control an operation to where no free chlorine is available and presents a real risk of RO membrane chlorination/oxidation.
For these reasons, it is not recommended to consider use of monochloramines without dechlorination treatment prior to the RO process. Other RO compatible biocides such as DBNPA or CMIT/MIT may be preferred for non-potable water process applications. Also, offline peroxide in peracetic acid can act as a sanitization treatment under controlled conditions.
Additional Information:
Combined Chlorine (23KBPDF)
Chlorination - Dechlorination (53KB PDF)
DuPont's EDI modules must be stored indoors, protected from the environment, and not exposed to direct sunlight or freezing temperatures. Modules must always remain wet, or damage to the ion exchange resin and membranes will occur. If long term storage is required, drain residual water out of the each module. All inlet and outlet valves must be securely closed. Additionally, all the hydraulic connections should be firmly capped and modules should be stored in vertical position. EDI modules can be stored for six months at ex/work state.
If the system is shutdown for less than 12 hours, no special precautions need to be taken to protect the ion exchange resin. Turn off the rectifier, concentrate recirculation pump, and stop the dilute flow. This will prevent exhaustion of the ion exchange resin that would otherwise necessitate regeneration during restart. To prevent damage to resin and membranes do not allow modules to drain.
Keep modules wet when the system is off-line for more than 3 days, electro-regeneration for 8-16 hours may be necessary to achieve the desired product water quality at restart. EDI modules do not allow the growth of microbes during regular operation due to biostatic condition created by pH polarization.
No, 100% separation is not possible with thin film composite membranes. Also, 100% recovery is not possible with thin film composite membranes. With thin film composite membranes, there are always three streams (feed, concentrate, and permeate). As the permeate water is being produced, the feed water is being concentrated, but it can not be separated 100%. Also, since there is always a concentrate stream, 100% recovery is not possible. Percent recovery is defined by permeate flow rate divided by feed flow rate x 100%.
Additional Information:
Quick Reference Card - Reverse Osmosis (31KB PDF)
FilmTec Membranes - System Recovery
Estimated Percent Rejection of Various Solutes by FilmTec Membranes (135 KB PDF)
Additional Information:
Start Up Sequence (85KB PDF)
Additional information for internal viewing and use:
A sudden increase in feed pressure should be avoided. It is best to ramp up the feed pressure over the course of 1 to 2 minutes.
Terry Marsh did some bisulfite rinse-out studies on a Cuno/Shaklee Home Tap unit back in August, 1989. Data was collected on a 3.8 ft2 FilmTecTM TW30-1811 element at a permeate flow of ~30 mls/min ( 3.0 gfd = 5.1 lmh). The initial (equivalent) sulfite concentration was 4100 ppm as SO3. This figure is lower than the nominal 8400 ppm SO3 (based on 1% SMBS = Na2S2O5) due to residual air oxidation in storage. Aim was to verify the minimum required permeate volume to get the sulfite residual in the permeate below 10 ppm, which, at that time, was the FDA proposed 'no effect' level for sulfites in foods. For interest, this figure is probably valid for the vast majority of the population, except perhaps the small minority of people with acute sulfite sensitivity. The data shows that the 10 ppm level at the 3.0 gfd permeate rate was achieved after about 18 minutes. If the starting concentration had been 8400, the required flush time would have been slightly longer, ~ 24 minutes. The last sulfite measurement was made after 40 minutes and indicated a 2000 X concentration reduction from the initial, or about 2 ppm. At higher flux rates and for an 8040 element, one may expect these residuals to be lower by roughly the inverse of the flux starting ratio. Using this assumption, and assuming an initial stating concentration of 8420 ppm SO3, my flush out data suggests a minimum time of about 14 minutes. Hence nominal recommendations of one hour rinse out are quite conservative with respect to bisulfite. If this must be cut back, one may drop it to no lower than 20 minutes.
Please search the product name of interest at SDS Finder.
Alkalinity titrations are carried out using an acid solution of 0.1 N and a 100 mL water sample, or using a 1 N solution and a 1 L water sample. The volume of acid, expressed in mL of acid added to cause color change of the indicator is reported as alkalinity; therefore:
1 mL acid = 1 meq/L alkalinity
If phenolphthalein is used as indicator, P-alkalinity is measured. If methylorange is used, M-alkalinity is measured.
Although alkalinity numbers as such are interesting, it is also necessary to know the concentrations of the species making up this alkalinity; the main contributors are hydroxyl (OH–), bicarbonate (HCO3–) and carbonate (CO3– – ) ions. Their concentrations can be calculated from P- and M-alkalinity assuming:
The table below can be used to calculate the concentrations of the different species for different cases of P- and M-alkalinity. Results are obtained in meq/L.
Example: If P-alkalinity is 0.5 mL and M-alkalinity is 3 mL, then P < 1/2 M applies
carbonate = 1.0 meq/L
bicarbonate = 2.0 meq/L
Table 11. Calculating concentrations for P- and M-alkalinity
P- and M-Alkalinity |
Hydroxyl (OH) |
Carbonate (CO3) |
Bicarbonate (HCO3 ) |
P = O |
0 |
0 |
M |
P < ½ M |
0 |
2P |
M – 2P |
P = ½ M |
0 |
M |
0 |
P > ½ M |
2P – M |
2(M – P) |
0 |
P = M |
M |
0 |
0 |
Although ozone can be used as a pretreatment for RO feed waters, extreme care must be taken to remove the residual O3 before it reaches the membrane. Removal of ozone by UV radiation has been successfully used. However, activated carbon treatment or bisulfite addition would be preferable. For sanitizing applications for non-potable water applications, one should consider DBNPA instead of ozone.
Additional Information:
Reverse Osmosis - Pretreatment
Sanitization of FilmTec Elements with DBNPA (39KB PDF)
Other Sanitization Agents, Biofiltration, MF-UF, UV Irradaition, Use of FR Membranes (40KBPDF)
Some effects of a change in salinity are:
Type of change | Effect |
---|---|
Higher salt content | Shorter runs, lower throughput, sometimes lower quality of the treated water |
Lower salt content | Longer runs, higher throughput |
Change in ionic balance (e.g. less bicarbonate, more chloride) |
Change in treated water quality. The resin volumes become unbalanced, the degasifier has less or more carbon dioxide to handle |
Higher ratio of silica to total anions | This may increase silica leakage and require a change in regeneration conditions. See also breakthrough |
If the water analysis varies according to season, plant performance should be re-assessed, and perhaps operating conditions re-adjusted, to reflect the seasonal variations. If you don't analyse the water yourself, give a sample to a reputable laboratory for testing. If your feed water is city water, you should be able to obtain an accurate analysis from your municipality.
When re-assessing the performance of a plant, or optimising it, it is recommended to use the most probable analysis for the basic calculation, then to re-run the calculation with seasonal analyses to estimate plant throughput under various conditions. All the water analyses should be real, not maxima, averages or minima.
We strongly recommend that you should update the expected performance of the plant based on actual operating conditions.
Additional Information
Seawater with TDS of 35,000 mg/L is considered standard seawater constituting, by far, the largest amount of water worldwide. The composition is nearly the same all over the world. The actual TDS content may, however, vary within wide limits from the Baltic Sea with 7,000 mg/L to the Red Sea and Arabian Gulf with up to 45,000 mg/L. The actual compositions can be proportionally estimated from the standard seawater composition (Table 2.1). The water from seashore wells, however, depending on the soil, influx from inland, etc., can often have salinity and composition quite different from water taken from the sea itself.
The following is the composition of a typical seawater:
Ion | Concentration (mg/L) |
Calcium | 410 |
Magnesium | 1,310 |
Sodium | 10,900 |
Potassium | 390 |
Barium | 0.05 |
Strontium | 13 |
Iron | < 0.02 |
Manganese | < 0.01 |
Silica | 0.04 - 8 |
Chloride | 19,700 |
Sulfate | 2,740 |
Fluoride | 1.4 ppm |
Bromide | 65 |
Nitrate | < 0.7 |
Bicarbonate | 152 |
Boron | 2-5 |
Other | |
TDS | 35,000 |
pH | 8.1 |
Additional information:
Feedwater Type and Analysis (133KB PDF)
Ion exchange resins, when placed in a solution, reach an equilibrium state between ions in the solution and ions on the resin. From this equilibrium state, selectivity coefficients (equilibrium constants) can be defined based on the ratios of ions in the solution vs. ions on the resin.
These selectivity coefficients are a measurement of a resins preference for an ion. The greater the selectivity coefficient, the greater the preference for the ion.
This document presents the relative affinity values of resins for different ions, the affinity of the cation resins for the H+ ion and the affinity of the anion resins for the OH– ion being defined arbitrarily as 1.0.
For example, a styrenic strong acid cation resin with 8% DVB cross–linking has a relative affinity for sodium vs. hydrogen of 1.56, while the selectivity for calcium vs. hydrogen is 4.06. As a result, calcium is selectively removed by the ion exchange resin over sodium.
In column operation, undesirable ions can be selectively removed by regenerating the resin with any ion of lower selectivity. For example, calcium can be removed from a solution by a strong acid cation resin when the resin is regenerated using salt (Na-cycle operation) or acid (H-cycle operation).
Selectivity coefficients can also be used to determine the order of elution in column operation. In a demineralizer (H-cycle operation), sodium with a relative affinity of 1.56 will elute before ammonium with an affinity of 2.01, which is followed by potassium, with an affinity of 2.28.
Ionic leakage from demineralizers can also be predicted by the use of selectivity coefficients. With a knowledge of the degree of regeneration, solution pH and the relative affinity value, an estimate of the ionic leakage can be calculated.
For a complete treatment of the subject, numerous textbooks can be consulted. One excellent reference is Ion Exchange, by Friedrich Helfferich, published by Dover Press under ISBN #61-15453.
Relative affinities of various cations (compared with the hydrogen ion) on sulfonated polystyrene cation exchange resins with different degrees of cross-linking.
Percentage of cross-linking of the copolymer |
||||
Cation |
4% DVB |
8% DVB |
10% DVB |
16% DVB |
Li+ |
0.76 |
0.79 |
0.77 |
0.68 |
H+ |
1.00 |
1.00 |
1.00 |
1.00 |
Na+ |
1.20 |
1.56 |
1.61 |
1.62 |
NH4+ |
1.44 |
2.01 |
2.15 |
2.27 |
K+ |
1.72 |
2.28 |
2.54 |
3.06 |
Rb+ |
1.86 |
2.49 |
2.69 |
3.14 |
Cs+ |
2.02 |
2.56 |
2.77 |
3.17 |
Ag+ |
3.58 |
6.70 |
8.15 |
15.6 |
Tl+ |
5.08 |
9.76 |
12.6 |
19.4 |
UO22+ |
1.79 |
1.93 |
2.00 |
2.27 |
Mg2+ |
2.23 |
2.59 |
2.62 |
2.39 |
Zn2+ |
2.37 |
2.73 |
2.77 |
2.57 |
Co2+ |
2.45 |
2.94 |
2.92 |
2.59 |
Cu2+ |
2.49 |
3.03 |
3.15 |
3.03 |
Cd2+ |
2.55 |
3.06 |
3.23 |
3.37 |
Ni2+ |
2.61 |
3.09 |
3.08 |
2.76 |
Ca2+ |
3.14 |
4.06 |
4.42 |
4.95 |
Sr2+ |
3.56 |
5.13 |
5.85 |
6.87 |
Pb2+ |
4.97 |
7.80 |
8.92 |
12.2 |
Ba2+ |
5.66 |
9.06 |
9.42 |
14.2 |
Relative affinities of various anions (compared with the hydroxide ion) on polystyrenic strongly basic anion exchange resins, both Type 1 and Type 2.SBA resins selectivity coefficients
Ion |
Type 1 |
Type 2 |
OH– |
1.0 |
1.0 |
Benzene sulfonate |
500 |
75 |
Salicylate |
450 |
65 |
Citrate |
220 |
23 |
I– |
175 |
17 |
Phenate |
110 |
27 |
HSO4– |
85 |
15 |
ClO3– |
74 |
12 |
NO3– |
65 |
8 |
Br– |
50 |
6 |
CN– |
28 |
3 |
HSO3– |
27 |
3 |
BrO3– |
27 |
3 |
NO2– |
24 |
3 |
Cl– |
22 |
2.3 |
HCO3– |
6.0 |
1.2 |
IO3– |
5.5 |
0.5 |
Formate |
4.6 |
0.5 |
Acetate |
3.2 |
0.5 |
Propionate |
2.6 |
0.3 |
F– |
1.6 |
0.3 |
HSiO3– |
< 1.0 |
< 1.0 |
H2PO4– |
5.0 |
0.5 |
The reason for mentioning benzene sulfonate in the preceding list is that it is an example of synthetic surfactants frequently found in water. The very strong affinity of the resins for this compound results in a high risk of resin fouling.
The selectivity data is less significant for weak acid cation exchange resins, which operate (in the H+ form) only with feed water containing alkalinity. In addition, selectivity values are less well documented for these resins. However, approximate data is available as follows, with calcium as the reference ion:
Cation |
|
Mg2+ |
0.3 |
Sr2+ |
< 1 |
Ba2+ |
< 1 |
Ca2+ |
1.0 |
Cd2+ |
1.0 |
Ni2+ |
1.4 |
Zn2+ |
1.5 |
Co2+ |
1.9 |
Cu2+ |
2.0 |
Pb2+ |
> 1 |
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FilmTec™ elements featuring iLEC™ interlocking endcaps have the same 8-inch diameter and 40-inch net length of standard elements.
However, the upstream (feed end) iLEC interlocking endcap includes a 0.5-inch extension for collaring the downstream (concentrate end) endcap of the adjacent element. Therefore, while the elements measure 40.5 inches in length, the net length of the connected elements is 40 inches. These elements have been designed to fit into standard pressure vessels and are interchangeable with standard elements.
Please see for information about mixing standard and iLEC elements inside a single vessel.
Standard ion exchange resins have mean particle sizes of 500 - 800 microns. UPS (Uniform Particle Size) ion exchange resins have a narrow particle size distribution while standard Gaussian resins range from 300 - 1200 microns. The bead size varies with the product. Each product information sheet provides either a mean bead size or a bead size distribution. DuPont also carries a line of fine mesh resins, available in the 200 - 400, 100 - 200, and 50 - 100 mesh size.
Mesh size is the number of openings in a square inch of a screen or sieve, or the square of the number of strands of wire per lineal inch. Standard U.S. mesh screen No. 16, for example, equates to a 1.19 mm (millimeter) particle diameter and mesh size No. 100 is 0.15 mm particle diameter.
Many of the Ion Exchange Resin technical data sheets provide the mean particle size and/or range. Ion Exchange Products
Additional Information:
Particle Size Distribution Cross Reference Chart (40KB PDF)
Safety Data Sheets (SDSs) are available for wet FilmTec™ reverse osmosis (RO) and nanofiltration (NF) element. Please see SDS Finder. e.g. by looking up the trade product code:
Note: New customers or existing customers who buy a wet element the first time will automatically receive an SDS. The SDSs are only for the solutions used in the wet modules/elements that are necessary during storage and shipment; Pursuant to 29 CFR 1910.1200 (OSHA Hazard Communication Standard) modules, elements and as-sold components themselves are not hazardous chemicals. Based on the evaluation made by our company, these products have been classified as 'articles' and are not subject to the requirements for a material safety data sheet.
We provides health, safety and environmental information for covered hazardous chemicals through SDSs as well as product labels. These documents are required by law in many countries in which we do business. The SDS summarizes the physical and chemical properties of the hazardous chemical. It also contains useful information such as flash point, toxicity, procedures for spills and leaks, and storage guidelines to help you understand the potential health and physical hazards of a chemical and how to respond effectively to exposure situations. The information provided in the SDS also helps to determine the safe transport conditions of chemicals and the measures to take to protect the environment.
We provide this information in good faith and as may be required by law and assumes no obligation or liability for use of or updating this information and makes no warranty, express or implied. The customer is solely responsible for evaluation of the information, determining the suitability and use of the products, and taking any other action as needed to ensure compliance with applicable laws and other government enactments.
* Under OSHA
'Article' means a manufactured item other than a fluid or particle: (i) which is formed to a specific shape or design during manufacture; (ii) which has end use function(s) dependent in whole or in part upon its shape or design during end use; and (iii) which under normal conditions of use does not release more than very small quantities, e.g., minute or trace amounts of a hazardous chemical (as determined under paragraph (d) of this section), and does not pose a physical hazard or health risk to employees.
The equation for pressure drop is expressed below. Theoretically, the pressure drop is inversely proportional to the square of particle diameter of the ion exchange resin. The diameter of the resin depends on the type and ionic form of the resin. If the mean particle diameter decreases, for example, from 360 mm to 330 mm, the pressure drop increases from 17 to 20%.
DP 173 x m x V0 x Af
--- = -------------------------------
L Dp2
Where DP: Pressure drop [kPa/m-resin bed]
m: Viscosity of water [Pa*s]
L: Bed depth [m]
V0: Flow velocity [m/s]
Af: Coefficient (~1.00)
Dp: Diameter of resin bead [m]
The pressure drop also depends on void fraction in the resin bed. As the void fraction increases, the pressure drop decreases. The pressure drop also depends on the viscosity of water, which decreases with increasing temperature.
There is really no maximum TDS that Ion Exchange can handle. IX resins are used to remove high levels of ions in high value applications such as chemical purification, bioprocessing and the like. For demineralization of water or waste water treatment, when the TDS is in the thousands of ppm, IX resins quickly exhaust and the cost of the regenerants make the process less economical. In these cases, a membrane process is often more economical to remove the bulk of the TDS then an IX system can polish out the remaining, low level ions.
You can estimate the costs of an ion exchange system using our WAVE program (Water Application Value Engine) downloadable from WAVE Download Page. WAVE is an integrated, multi-technology water modeling design software engineering tool for system design and evaluation of plant performance.
If you decide that the operational cost is not prohibitive, we would recommend doing a lab study with a mixed bed resin. (you can purchase a small quanitity from the following web site, Request a Sample. The following brochures describe the 2 levels of studies to evaluate resins in a given application
Storage and Shipping of New FilmTec Elements (37KB PDF)
Preservation and Storage of Used FilmTec Elements (33KB PDF)
Re-wetting of Dried Out Elements (32KB PDF)
Shipping Used FilmTec Elements (32KB PDF)
Disposal of Used FilmTec Elements (31KB PDF)
Preservation of RO and NF Systems in Case of Shut Down (25KB PDF)
Once a membrane system has been started up, ideally it should be kept running at constant conditions. In reality, membrane plants have to be shut down and restarted frequently. Start/stop cycles result in pressure and flow changes, causing mechanical stress to the membrane elements. Therefore, the start/stop frequency should be minimized, and the regular operation start-up sequence should be as smooth as possible. In principle, the same sequence is recommended as for the initial start-up. Most important is a slow feed pressure increase, especially for seawater plants.
The normal start-up sequence is typically automated through the use of programmable controllers and remotely operated valves. The calibration of instruments, the function of alarms and safety devices, corrosion prevention and leak-free operation have to be checked and maintained on a regular basis.
Product selection assistance for ion exchange resins is available through the IX Resins - System Design
Alternatively, you can select products with the following search tools:
By Type of Resin (e.g. strong acid resins)
If you cannot determine wihch product you need, please contact us [LINK TO WS CONTACT US FORM] along with answers to the following questions:
Unfortunately, methanol is so much like water that it is nearly impossible to remove methanol from water. A common practice is to feed this water to a biodigestor so that the methanol can be removed for water discharge.
As you can see from the Estimated Percent Rejection of Various Solutes by FilmTec Membranes,
methanol, with its low molecular weight, has a rejection around 25%, making its removal difficult.
Polymeric Adsorbent Brochure gives adsorption isotherms for various organic molecules. Methanol shows low adsorption capacity.
Without having the actual horsepower (HP) from the motor used to drive the pump, you can estimate the energy usage for a reverse osmosis system by using the following equations.
HP = (Feed Pressure in PSI)(Feed Flow in GPM)/ [(1714) (Pump & motor efficiency)]
kWh = (Feed Pressure in bar)(Feed Flow in m3/h) / [(35.9) (Pump & motor efficiency)]
Kilowatts = HP / 1.34
Cost per day ($) = (Kilowatts required) (24 hours/day) (Cost of electricity in $/kilowatt-hour)
We do not recommend the use of nitric acid for regenerating ion exchange resins because oxidizing agents such as nitric acid attack organic ion exchange resins under certain circumstances. This could lead to anything from slight resin degradation to a violent exothermic reaction (explosion). Before using strong oxidizing agents, consult sources knowledgeable in handling such materials.
Additional Information:
Ion Exchange Resins - Recommended Operating Conditions
Properties, Impurities, and Concentrations of Regenerent Chemicals (124KB PDF)
We recommend to use low pressure water at a low flow rate to flush the air out of the elements and pressure vessels. Flush at a gauge pressure of 0.2 – 0.4 MPa (30 to 60 psi). All permeate and concentrate flows should be directed to an appropriate waste collection drain during flushing. Air remaining in the elements and/or in the pressure vessels may lead to excessive forces on the element in flow direction or in radial direction and causing fiberglass shell cracking, if the feed pressure is ramped up too quickly.
Additional Information:
Pre-Start-Up Check and Commissioning Audit
Metals and organic materials may be removed from acids by use of DuPont ion exchange and adsorbent resins. Ion exchange resins have high capacities for many metals and mineral salts, such as chromium, cadmium, nickel, copper, lead and zinc metal, that can accumulate in acids during use. Ion exchange technology is particularly suitable for the treatment of process rinse waters and of the waste effluent in the metal plating industry. Adsorbent resins also can be effective in removing undesirable color components from a variety of mineral acids.
Purification of concentrated HCl is commonly carried out on a commercial scale. Interestingly, the resin is eluted with plain water. In the absence of excess halide ion the equilibrium shifts back to the left and the neutral salt 'falls off of the resin'.
In any reverse osmosis system, crossflow is one of the most important factors in performance. Water flowing along (i.e. parallel to) a membrane’s surface sweeps away salts and other contaminants. High crossflow reduces scaling and fouling, but in a traditional reverse osmosis system it hampers recovery because high crossflow means potentially recoverable water is being swept past the membranes before it can pass through. In a CCRO system, crossflow can be set independently of recovery by increasing/decreasing the circulation pump flow rate. Increased cross flow decreases concentration polarization (beta), lowering the concentration at the membrane surface — and therefore the scaling potential.
CCRO systems can even push some salts into supersaturation without scaling. Different salts take different amounts of time to crystallize out of solution, even at concentrations over 100%. CCRO systems can push some salts into supersaturation as long as they flush the supersaturated waste out of the system before the dissolved salts have a chance to crystallize.
The operating limits depend on the type of resin that is used. For specific details refer to the Product Data Sheets for each product.
Additional Information:
Suggested Operating Temperatures for DuPont Ion Exchange Resins (12KB PDF)
Dissolved (reactive) silica
Silica (SiO2) exists in water in equilibrium with the bisilicate (HSiO3-) ion as a very weak acid. In the ionic weak acid form, silica can be removed by strong base anion exchange resins operated in the hydroxide cycle, such as AmberLite™ HPR4200 OH, AmberLite™ HPR4700 OH, AmberLite™ HPR4800 OH or AmberLite™ or HPR4811 Cl. Since the two forms of silica exist in equilibrium, silica can be almost completely removed from solution, reaching part-per-billion levels in many applications. When present as a single unit of silica, in equilibrium with bisilicate, the compound is termed reactive silica.
Colloidal silica
Silica can also exist as a polymer, often referred to as colloidal silica. These long chains of individual silica units exhibit virtually no charged ionic character, and cannot be removed by the ionic process of ion exchange. Membrane treatment such as FilmTecTM reverse osmosis membranes and Ultrafiltration Modules can remove colloidal silica. Reverse osmosis offers the additional advantage of significant reduction (98%+) of reactive silica as well.
Additional Information:
A full-fit element is a spiral-wound membrane element designed to minimize or eliminate stagnant areas. Like all membrane elements it has either an outerwrap or hard shell rather than tape or fiberglass, and a rigid polypropylene material gives the element structural support. Full-fit elements also differ from other designs because they do not have a brine seal. While brine seals are used to prevent flow bypass around the outside of an element, they also create stagnant areas. Full-fit elements are designed to have a some bypass flow around the element to minimize stagnant areas where biological activity may occur.
Additional Information:
Food and Dairy Separations
Chloramine, which is used as a disinfectant or biocide to reduce the number of bacteria in feed, is a small molecule and it will permeate through the RO and NF membranes.
POE/POU devices that remove chloramine are filtration systems with granular activated carbon or charcoal.
Additional Information:
CHLORAMINE FACT SHEET - Water Quality Association
Most commercial strong acid cation exchange resins will oxidize slightly upon storage. Although the mechanism of oxidation can vary; oxygen, light, heat and moisture can effect the TOC levels found in a resin over time. For most applications a slight increase of TOC upon storage is not significant enough to affect the performance level of the resin in a given process. For highly TOC sensitive applications, the resin should be pre-conditioned before use either by conditioning the resin with an acid wash followed by a water rinse or by cross regeneration of the resin.
Strong base anion resins are classed as type 1 and type 2.
Strong base anion type 1 resins contain a quaternized amine functional group, which is the more strongly basic functional group and has the
Strong base anion resin type 2 functionality is obtained by the reaction of the styrene-DVB copolymer with dimethylethanolamine. This quaternary amine has lower basicity than that of the Type 1 resin, yet it is high enough to remove the weak acid anions for most applications.
Additional Information:
Fundamentals of Ion Exchange (480KB PDF)
We do not have limits for TOC. In fact, ion exchange processes work just as well in non-aqueous organic streams as they do in water based systems.
However, natually occuring in water can interfere with ion exchange. Organics occuring in natural waters are usually humic substances in concentrations between 0.5 and 20 ppm of TOC. Generally, these TOC levels are expressed as a % of total anions. 1 to 2% is normal, 3 to 5% is above average and >5% is high. These levels impact the anion resin and frequency of brine squeezes and ultimately operating capacity.
Recommendations when the TOC is naturally occuring organic matter, such as humic and fulvic acids:
Low fouling (TOC <2% total anions) | AmberLite™ HPR4800 OH or AmberLite™ HPR4800 Cl Resin |
Moderate fouling (TOC = 2 - 5% total anions) | AmberLite™ HPR4811 Cl Resin AmberLite™ IRA458 Cl |
High Fouling (TOC >5% total anions) | AmberLite™ HPR9200 Cl Resin |
Layered beds with resins such as AmberLite™ HPR9500 or AmberLite™ HPR4580 Cl are also effective at handling natural organics. Weak base anion resins should be used to protect the SBA resin from fouling in the layered bed. Other options for removing natural organics include pretreatment such as UF, coagulation filtration, or Organic Traps. AmberLite™ SCAV3 Cl, AmberLite™ SCAV4 Cl, and AmberLite™ HPR4811 Cl resins, regenerated with NaCl, can be used as organic traps ahead of the other resin beds which increases the efficiency of the demineralization system.
For the recommended operating conditions, please see the product data sheet for the product of interest.
There are two different dosing types: slug dose and continuous feed. With slug dosing, dosification depends on the severity of the biological fouling. With a water less prone to biological fouling, using 50-170 ppm of the 20% active ingredients product for 30 minutes to 3 hours, every 5 days should be enough. If the feed water contains >102 CFU/ml or you knowingly have biofilm within the RO system 170 ppm for 3 hours would be recommended. Once the system is void of significant biofilm, a continuous feed maintenance program can be instituted. 10 to 15 ppm of product would be the recommended dosage. You may wish to go higher or lower depending on normal fluctuations in bacteria levels. At this point, the primary function of DBNPA would be maintaining a negligible level of bacteria.
Additional Information:
DuPont Biocides
Sanitization of FilmTec Elements with DBNPA (23KB PDF)
DVB is similar in many respects to styrene and can be stored in bulk for relatively long periods if carefully prescribed storage conditions are met. In addition to the usual precautions taken with combustible liquids, conditions conducive to polymerization and oxidation must be prevented. This can be accomplished by designing a bulk storage system that prevents excessive temperatures and contamination of the monomer. The system must also conform to insurance underwriters’ codes and to local fire and building regulations. The following figure shows a typical monomer storage layout suitable for DVB.
Copper-containing alloys should never be used in storage and handling equipment for DVB. Oxidation products from copper alloys can interfere with normal polymerization. Rubber parts should also be avoided because the monomers are solvents for natural rubber and most synthetic rubbers.
Special Problems in the Storage of DVB
Air presents a complex problem in the bulk storage of DVB. While TBC is not an effective inhibitor in the complete absence of dissolved oxygen, excessive amounts of oxygen in the storage tank can also lead to problems.
The major problem is that monomer vapors above the liquid level in the tank are uninhibited. When these vapors condense, the droplets are readily oxidized by oxygen and polymerize quite rapidly. The polymer adheres to porous surfaces of unlined tank roofs and sidewalls, forming a coating of stalactites (polymer “icicles”) above the liquid level. The same condition, although less severe, will also occur in lined tanks.
The polymer deposited under these conditions will be discolored, cross-linked, and high in peroxides, aldehydes, and other oxidation products. Deposits of contaminated polymer will eventually produce serious color and polymer problems in monomer stored under air in unlined steel tanks. Internal reflux (the vaporization and condensation due to normal temperature differentials) will dissolve small amounts of this polymer and carry it back into the tank, increasing the polymer content of the stored monomer. Minimizing mechanical structures at the top part of the storage tank will help reduce this problem.
While too much oxygen causes problems, the complete elimination of oxygen from the vapor area will lead to depletion of dissolved oxygen in the liquid monomer. If this dissolved oxygen is not replaced and is allowed to drop below 15 ppm, the inhibitor becomes ineffective and rapid polymerization may result. If an inert blanket such as nitrogen is used, aerate the monomer with dry air once a week for approximately 30 minutes.
DVB stored in drums should be air sparged for 5 to 10 minutes once every three months. The air hose should be clean and dry. Avoid water contamination, since water will react with TBC and iron to form a black sediment, contaminating the monomer.
Monomer Storage Installation
Reducing Oxidation and Side Reactions
To reduce oxidation and hold side reactions to a minimum, stored DVB must be kept cool. Depending on the storage location, various methods can be used including refrigeration, reflective painting, and shading.
Large above-ground tanks with a low throughput or turnover rate should be insulated and cooled by external refrigeration with circulation of the contents. Painting exterior storage tanks with white or other light-reflecting paint also minimizes the absorption of sunlight, reducing heat gain. Slatted shade in open areas where ventilation is assured has proven satisfactory for the protection of small above-ground tanks, pumps, filters, and other handling equipment.
Hydrophobic solvents are not compatible with FilmTecTM membranes.
However, hydrophilic solvents, such as ethanol, may be. While a hydrophilic solvent may not damage the membrane, it will cause it to swell which will change its rejection and flow characteristics. In addition, the high concentration of solvent will extract leachables from the glue and it will most likely lead to long term degradation and failure of the glue. We cannot estimate how long the element will last. We would recommend that you run a compatibility test with a flat sheet membrane sample. If results look promising, you may want to try testing with pilot elements
Yes. As with standard endcaps, the brine seal should be lubricated with an approved lubricant, such as Molykote® 111 Compound, for easier loading and unloading.
Additional Information:
Loading Procedures for FilmTec™ Elements (56KB PDF)
Please click on the Contact Us, and submit a request attaching the ROSA.log file (found in your C:Program Files (x86)Dow ChemicalROSA9 folder) That log file will help us to troubleshoot your issue.
Organics in RO and NF feed water can adsorb onto the membrane surface and cause a flux loss. Organics occuring in natural waters are usually humic substances in concentrations between 0.5 and 20 ppm of TOC. Pretreatment should be considered when the TOC exceeds 3 ppm. Humic substances can be removed by a coagulation process with hydroxide flocs, by ultrafiltration, or adsorption on granulated activated carbon (GAC).
Additional Information:
FilmTec Membranes - Pretreatment Summary
Cleaning Organic Fouling from FilmTec FT30 Elements (15 KB PDF)
Prevention of Organic Fouling by Organics (10 KB PDF)
Colloidal Fouling Prevention (32 KB PDF)
Feed the concentrate to a second system, after specific pretreatment.
Special Design Possibilities (34KBPDF)
Nanofiltration is a membrane liquid separation technology that is positioned between reverse osmosis and ultrafiltration. While RO can remove the smallest of solute molecules, in the range of 0.0001 micron in diameter and smaller, nanofiltration (NF) removes molecules in the 0.001 micron range.
NF is a poly piperazine amide membrane and is essentially a lower-pressure version of reverse osmosis where the purity of product water is not as critical as pharmaceutical grade water, for example, or the level of dissolved solids to be removed is less than what is typically encountered in brackish water or seawater. As such, nanofiltration is especially suited to treatment of well water or water from many surface supplies.
Nanofiltration is used where the high salt rejection of reverse osmosis is not necessary, and yet NF is still capable of removing hardness elements such as calcium or magnesium. Sometimes referred to as 'membrane softening', nanofiltration is an attractive alternative to lime softening or sodium chloride zeolite softening technologies. And since NF operates on lower pressure than does RO, energy costs are lower than for a comparable RO treatment system.
Additional Information:
FilmTec Membrane Chemistry Description (56 KB PDF)
Here are a number of options, depending on the type of system that you have:
Single Stage Design
Problem in front elements:
Problem in rear elements:
Multistage Systems
Problem in front elements (front stage(s)):
Problem in rear elements:
Ion exchange capacity may be expressed in a number of ways. Total capacity, (i.e., the total number of sites available for exchange), is normally determined after converting the resin by chemical regeneration techniques to a given ionic form. The ion is then chemically removed from a measured quantity of the resin and quantitatively determined in solution by conventional analytical methods. Total capacity is expressed on a dry weight, wet weight or wet volume basis. The water uptake of a resin and, therefore, its wet weight and wet volume capacities are dependent on the nature of the polymer backbone as well as the environment in which the sample is placed.
The factor which defines the ability of an ion exchange resin to remove ions from solution is the capacity. The Total Exchanqe Capacity (TEC) is defined as the theoretical number of exchangeable ions per unit volume or weight of resin. The TEC can only be attained by a total and complete regeneration that is not employed in practice due to the prohibitive regenerant costs that would be required.
Operating capacity is a measure of the useful performance obtained with the ion exchange material when it is operating in a column under a prescribed set of conditions. It is dependent on a number of factors including the inherent (total) capacity of the resin, the level of regeneration, the composition of solution treated, the flow rates through the column, temperature, particle size and distribution.
The Operating Capacity is the true measure of a resin's ability to remove a given number of ions from solution. It is defined as the number of exchangeable ions available under a given set of conditions. These conditions are variable from one case to the next, and consist of such parameters as influent composition, effluent requirements, flow rate, regenerant dosage (i.e., degree of regeneration), temperature, exhaustion and rinse end points, resin selectivity, and particle size.
Capacity is commonly expressed in terms of the number of equivalents of ionic species found in a liter or kilogram of resin or, alternatively, the number of kilograins in a cubic foot (1 eq/l = 21.85 kgr/ft3 ). The ionic concentrations are normally expressed in calcium carbonate (CaCO3) equivalents since the Molecular Weight of calcium carbonate is 100. In all solutions, the number of cations (expressed in terms of calcium carbonate) must equal the number of anions (also expressed as calcium carbonate), such that the solution concentration in ppm (as CaCO3) = ppm (as ion) x 50/E.W. where 50 = Equivalent Weight of CaCO3.
Additional Information:
Fundamentals of Ion Exchange (2683KB PDF)
Please contact-us and submit a request, specifying the error you have received.
Possible Causes | Remedies |
Valve(s) partially closed |
Check and adjust all valves. |
Internal distributor blocked |
Repair/clean distributor. |
Flow rate above normal | Reduce flow or change to larger bead resin. |
Low feed water temperature | Reduce flow or change to larger bead resin. |
Increased amount of |
Increase backwash time and frequency. For Packed Bed Systems systems, see guidelines. |
Fouling, precipitation, or biogrowth in resin bed |
Take sample and confirm with resin analysis , clean or replace resin as appropriate. See Ion Exchange - Cleaning Procedures |
Compacted bed | Extended backwash or air brush during backwash. For Packed Bed Systems systems, see guidelines. |
Resin fines | Increase backwash rate to expand bed to a point 6–12 inches (15–30 cm) below the outlet header. Remove or change backwash outlet screens. |
Resin oxidative damage | Take sample and confirm with resin analysis and replace resin as appropriate. |
Inappropriate resin choice | Replace with correct resin type. |
Broken under drain or resin sub-fill system |
Inspect and repair. |
Excessive resin volume in vessel |
Re-adjust volume according to guidelines. |
WAVE is compatible with the Microsoft Windows operating system.
Software Requirements
Hardware Requirements
Minimum Disk Space required:
Operating System Requirements
One of the following OS required:
Users might require administrative privileges while installing the application.
Analysis of ion exchange resins that have been used in service is available from Water Solutions. Analysis of reverse osmosis and ultrafiltration modules that have been in use is also available.
We offer more than just test results. Our technical experts interpret the data and provide you a complete report with a description of the tests performed, the implications of our findings on your operation, and suggestions for how to enhance your system performance. Please contact your Sales or Technical Representative for more information or refer to our web site at System Optimization Services (SOS). At this link you will find more information on the following:
High differential pressure, also called pressure drop or Δp from feed to concentrate, is a problem in system operation because the flux profile of the system is disturbed in such a way that the lead elements have to operate at excessively high flux while the tail elements operate at a very low flux. The feed pressure goes up which means increased energy consumption. A high differential pressure causes a high force in flow direction on the feed side of the element. This force has to be taken by the permeate tubes and, in the case of 8' elements, by the membrane scrolls and the fiberglass shells of adjacent elements in the same vessel. The stress on the last element in the vessel is the highest: it has to bear the sum of the forces created by the pressure drops of upstream elements.
The upper limit of the differential pressure per multi-element vessel is 50 psi (3.5 bar), per single fiberglassed element 15 psi (1 bar). When these limits are exceeded, even for a very short time, the FilmTec elements might become telescoped and mechanically damaged.
Eight-inch elements will break circumferentially at any location of the fiberglass shell, or the endcap will be pushed out, or the spokes of the endcap will break, or the feedspacer will be pushed out from the concentrate channels. Although such damage is easily visible, it does not normally affect the membrane performance directly. However, they indicate that the differential pressure has been too high. Cracks around the endcap cause bypass of feedwater and may lead to fouling and scaling.
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The table, below, summarizes the limits of quality parameters of the feed water. It is recommended to respect these limits to ensure successful operation of the membrane system. Otherwise, more frequent cleaning and/or sanitization may become necessary. The concentrations correspond to the entry to the membrane for a continuous feed stream, including any influences to the feed water from dosing chemicals or piping materials in the pretreatment line.
Guidelines for feedwater quality
Component | Unit | Max. level | Comments & conditions |
SDI |
1 | 5 |
Membrane System Design Guidelines for 8-inch FilmTec Elements (126KB PDF) |
MFI0.45 | 1 | 4 | Target: <1 |
Oil and grease | mg/L | 0.1 | See Prevention of Fouling by Organics (Section 2.7) |
TOC | mg/L | 3 | Synthetic organic compounds (SOC) have generally more adverse effects on RO/NF membranes compared with natural organic matters (NOM). - See Prevention of Fouling by Organics (Section 2.7) |
COD | mg/L | 10 | |
AOC | μg/l Ac-C | 10 | Target: <5 |
BFR | pg/cm2 ATP | 5 | Target: <1 |
Free chlorine | mg/L | 0.1 | Under certain conditions, the presence of chlorine and other oxidizing agents will cause premature membrane failure. Since oxidation is not covered under warranty, FilmTec recommends removing residual free chlorine by pretreatment prior to membrane exposure. - See Chlorination / Dechlorination (Section 2.6.3) |
Ferrous iron | mg/L | 4 | pH <6, oxygen <0.5 ppm |
Ferric iron | mg/L | 0.05 | |
Manganese | mg/L | 0.05 | |
Aluminum | mg/L | 0.05 |
Feasibility testing can be divided into 3 categories: screening test, application test and pilot test. In most cases, the WAVE computer program can predict a system performance when feed water source and composition are well defined. However, in some cases, testing is recommended to support the proper system design and these include:
Testing is typically carried out at different subsequent levels:
A) Screening Test:
The goal of a screening test is to select the appropriate membrane for the desired separation and to obtain a rough idea about the flux (gfd or L/m2-h) and rejection properties of the membrane. A small piece of flat sheet membrane is mounted in a 'cell' and exposed to the test solution using the cross-flow mechanism. The method is fast, inexpensive, and requires only small quantities of test solution. However, a screening test cannot provide engineering scale-up data and long-term effects of the test solution on the membrane, nor does it provide data on fouling effects of the test solution.
B) Application Test:
The application test provides scale-up data such as permeate flux and permeate quality as a function of feed pressure and system recovery. The test typically involves the evaluation of a 15-60 gal (50-200 L) sample solution, using a 2540 (2.5-inch x 40-inch) or 4040 (4.0-inch x 40-inch) sized element. The element is mounted in a test system with engineering features that allow adjustments to the feed flow, feed pressure, and feed temperature in the ranges of the element operating limits.
Determining Operating Pressure
The optimum operating pressure is determined by adjusting the feed pressure until the desired permeate quality and permeate flux rate are obtained (typically between 6-20 gfd (10-34 L/m2-h)). Sufficient feed flow should be maintained to ensure a low recovery rate (<5%) as the membrane flux rate is increased. Permeate and concentrate streams are recycled back to the feed tank during this first test. The feed pressure at which the optimum permeate flux and permeate quality is obtained is the feed pressure used for the second test, determining the recovery rate.
Determining Concentration Factor / Recovery Rate
To aid in the determination of the maximum single element recovery rate (permeate flow / feed flow) the second test is run in batch mode. This is done by directing the permeate stream into a second container while returning the concentrate stream to the feed tank. Both the permeate flow and permeate quality are monitored during the test. The test is stopped when the permeate flow rate has declined to an uneconomically low value or permeate quality has declined below acceptable limits. The concentration factor (CF) is then calculated by dividing the original feed volume by the remaining feed volume. The recovery rate is calculated by subtracting the remaining feed volume from the original feed volume and then dividing by the original feed volume.Repeating the batch test will give an indication of membrane stability and fouling effects. However, long-term performance, including the assessment of cleaning procedures, can only be obtained by pilot tests.
C) Pilot Test:
A pilot test is typically run in the field on the intended feed stream in a continuous operation mode. The pilot plant should have at least one e
Determine which of these scenarios most accurately describes your feedwater.
RO Permeate SDI < 1 | Very low salinity, high-purity waters (HPW) coming from the first RO systems (double-pass RO system) or the polishing stage in ultrapure water (UPW) systems with TDS up to 50 mg/L. |
Well Water SDI < 3 | Water from a ground source that has been accessed via well. Usually has low fouling potential. |
Surface Water with DuPont Ultrafiltration SDI < 2.5 | Water from rivers, river estuaries and lakes. In most cases it has high TSS, NOM, BOD, and colloids. Frequently, surface water quality varies seasonally. This category is divided into 3 types of pretreatment. |
Surface Supply SDI < 3 | |
Surface Supply SDI < 5 | |
Wastewater with DuPont Ultrafiltration SDI < 2.5 | Industrial and Municipal wastewaters have a wide variety of organic and inorganic constituents. These categories refer to filtered municipal effluent or industrial effluent. |
Wastewater with Generic Membrane Filtration (MBR/MF/UF) 1 SDI < 3 | |
Wastewater with Conventional Pretreatment SDI < 5 | |
Seawater (Well or Open Intake) with DuPont Ultrafiltration SDI < 2.5 | Seawater may come from a beach well with any type of pretreatment or be open intake seawater |
Seawater (Open Intake with generic membrane filtration 1 or advanced conventional pretreatment 2) SDI < 3 | |
Seawater (Open Intake with generic conventional pretreatment) SDI < 5 |
1Generic membrane filtration is considered to be: Generic Ultrafiltration / Microfiltration (UF/MF) continuous filtration process using a membrane with pore sizre of <0.2 micron. SDI after UF/MF is typically <3.
2Advanced conventional pretreatment refers to dual stage membrane filtration at low to medium viscosity (<9 m/h) with well controlled chemistry and kinetics of coagulation, typically giving as SDI <3.
Additional information:
Membrane System Design Guidelines for 8-inch FilmTec Elements (126KB PDF)
Membrane System Design Guidelines - Commercial and Light Industrial Elements (126KB PDF)
FilmTec Membranes - Steps to Design a Reverse Osmosis System
FilmTec Membranes - Design of RO System
The following link provides guidelines for loading and unloading FilmTec reverse osmosis (RO) and nanofiltration (NF) elements. For additional loading instructions, contact the individual pressure vessel manufacturer.
Preparation and Element Loading (41KB PDF)
Water Requirements
Reverse osmosis permeate or deionized water should be used for the preparation of cleaning chemicals.
Provisions to Clean Each Stage Individually
One design suggestion to consider is that by providing sufficient piping and valving to clean each stage of a system individually will invariably make the cleanings more effective. Cleaning multiple stages together means that dirt, debris, bio-mass and scale must be pushed from the first stage and through subsequent stages before being removed from the system.
Effective flow rates
CIP systems should also provide adequate flow rates for effective cleanings.
Temperature Controlled Heating Device
CIP skids should also be equipped with a temperature controlled heating device. Heating the cleaning solution is very important in case of organic fouling and biofouling. Alkaline cleanings are more effective at temperatures > 95°F (35°C). Alkaline cleanings at lower temperatures are less effective resulting in increased cleaning frequency and higher operational costs due to frequent cleaning and membrane replacement.
Prefiltration
Cartridge filters on the CIP skid are necessary to remove particulates, including cleaning chemical powders, avoid membrane abrasion and precipitation on the membrane surface area. If the CIP skid is not equipped with cartridge filters, the cartridge filters from the RO system can sometimes be used.
NOTE: If the cartridge filters of the RO system are used to filter the cleaning solution, remember to install new cartridge filters prior to cleaning, otherwise the cleaning solution may dissolve/remove foulant from cartridge filters and deposit it on the membrane surface. System operators have been known to forget to replace the cartridge filters prior to a cleaning, resulting in an inefficient cleaning cycle.
The cleaning solution should always pass through cartridge filters prior to entering the RO/NF system. FilmTec strongly recommends equipping the CIP skid with cartridge filters (absolute pore size < 10 micron).
Avoid the use of the high pressure pump for cleaning of RO systems
During cleaning, it is necessary to create and maintain a sweeping and turbulent effect across the membrane surface to aid in the removal of foulants on the membrane. Cleaning at low pressure is necessary to limit the production of permeate, so only concentrate is produced which maximizes the sweeping effect.
In cases where the high pressure pump is used during cleaning, the cleaning procedure is less effective. Not only is there less cross-flow if too much permeate is produced (resulting in less turbulence), cleaning at high pressure pushes the foulant deeper into the membrane surface and may also cause mechanical damage (telescoping, membrane intrusion). When that happens, RO system performance after cleaning either remains the same or declines further. It is critical for the CIP skid to have a correctly sized low pressure cleaning pump (CIP pump).
Additionally, the permeate valve must be open during cleaning, to avoid possible permeate back pressure damage. Also, when the RO system is put back into operation, the permeate valve must be open to avoid significant damage to the elements and pressure vessel piping.
System Design Suggestions for Troubleshooting Success (31KB PDF)
Additional Information
The placement of shims on the adapter within the vessel to minimizes movement of the individual membrane elements. This reduces wear-out and mechanical abrasion and subsequent o-ring leakage.
Please see the following link for instructions.
Shimming Elements (37KB PDF)
Additional Information:
Membrane stability will depend on many factors such as temperature, pressure, concentration, organic trace contaminants like mineral oils, presence of bacteria, presence of oxidizing compounds, presence of heavy metals, etc. The indication of reliable limits is therefore, not possible. Best practice is to identify potentially harmful factors prior to start-up and prevent them from occurring.
Additional Information:
FilmTec Membranes - Feed Water Quality Guidelines
Testing Chemical Compatibilities with FilmTecTM Membranes (29KB PDF)
Possible Causes | Remedies |
Faulty or inaccurate measurement system (flow meter,conductivity meter,etc.) | Check accuracy of product flow meter against volume delivered. Repair or replace meter. |
Inappropriate rinse water quality |
Use Softened water for cation resins, Decationized water for anion resin, Demineralized water for mixed-bed resin |
Check measurement system. |
Repair or replace if necessary. |
Long rinse down | See “Resin degradation/fouling” below. |
Change in water composition/ increase in influent TDS |
Obtain a current water analysis to confirm (the computer design program WAVE has this functionality), then increase regeneration level or evaluate potential for upgrading system to packed bod. |
Early breakthrough due to decreased water |
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Low flow rate due topressure drop increase | Ion Exchange Resins - Increased Pressure Drop |
Resin loss | Measure resin bed depth, in the same form that the resin was supplied. Add more resin as required. If a sudden high loss of resin occurs, check vessel and distribution system for leaks. |
Inadequate regeneration | Check for correct resin contact time, flow rates, and concentration. |
Leaking/by-pass of regenerant valves | Check and adjust all valves. |
Resin degradation/fouling | Take sample and confirm with resin analysis , clean or replace resin as appropriate. |
Ion exchange resins are normally shipped in the fully hydrated form and should be stored in a sheltered area and in a manner such that moisture within the beads is retained. Resin beads that have dried out become free flowing and some shrinking of the beads may be observed. Macroporous resins sometimes lose their opaque appearance when they dry out. Dry beads will re-swell very rapidly when placed in water or other polar solutions, which may lead to bead breakage. To minimize the amount of bead breakage the dried resins can be re-hydrated with a saturated sodium chloride solution. The salt is removed by successive dilutions, then decantation of the brine, using deionized water. The resin may need to be regenerated prior to use. It should be emphasized that this re-hydration method will not completely eliminate all bead breakage, therefore, it is important that the resin is not allowed to become dry for most applications.
Application Information:
Proper Storage Conditions for Ion Exchange Resins (12KB PDF)
Backing up your project database is considered best practice to prior to updating to a new version of WAVE. You may do this by following the instructions, below:
Additional Information
For large systems, 6-element vessels are standard, but vessels with up to 8 elements are available. The main advantage of 7 or 8 elements per pressure vessel would be cost (since fewer pressure vessels needed), but a disadvantage would be a greater chance of scaling.
The different configurations may be estimated for a particular system by running some projections on our WAVE (Water Application Value Engine) program, downloadable from our resource center here. This can help determine which configuration is better for a particular system.
Please also see our Membrane System Design Guidelines for 8-inch FilmTec Elements (126KB PDF), Commercial Design Guidelines for Midsize FilmTecTM Elements (126KB PDF)
It is normal for operating conditions of reverse osmosis and nanofiltration systems to fluctuate causing permeate flow and salt passage to change. In order to distinguish between such normal phenomena and performance changes due to fouling or problems, the measured permeate flow and salt passage have to be normalized. Normalization is a comparison of the actual performance to a given reference performance while the influences of operating parameters are taken into account.
Analyzing the data will determine if the membrane system's performance has changed over time. This process is called normalization.
You will need to instrument the stages of your unit so that performance data can be gathered and normalized, showing day to day variation in the system performance against a reference condition such as startup. Adequate instrumentation means having conductivity or TDS measurements, pressure measurements, temperature measurements, and flow measurements on the feed, concentrate and permeate of each stage. Given this data, performance of the stage can be monitored and early signs of trouble can be easily detected from the normalized data. Even though a mass balance around the system can be used to eliminate some of the instrumentation, having all the instrumentation means that the mass balance can be used to test the internal consistency of the data and thus monitor the performance of the instruments.
FTNORM is a Microsoft® Excel® spreadsheet that allows you to enter raw operating data and keep track of the plant performance at a normalized test conditions. It is a very useful tool to monitor how well your membrane system is performing. Charts are created showing standardized permeate flow, standardized salt passage / salt rejection and differential pressure.
Additional Information:
Plant Performance Normalization (117KB PDF)
In cases where biological growth has occurred in softening and demineralization resins, an extended air scour followed by a double regeneration may be able to restore the resins to a usable condition. If this procedure is not successful, there are two disinfection procedures that can be used: Peracetic Acid / Hydrogen Peroxide Disinfection (discussed here) and Chlorine disinfection . Oxidative damage can occur from each type of treatment, so these procedures should be considered as a last resort.
Peracetic acid has a wide-band action for removing micro-organisms and is an effective treatment for the disinfection of both cation and anion exchange resins. To ensure good disinfection without damage to the resins, it is important to control the concentration, temperature and contact time of the chemical. The recommended procedure is as follows:
Loss of salt rejection and loss of permeate flow are the most common problems encountered in reverse osmosis. If the salt rejection and/or the permeate flow decreases slowly, this may indicate a normal fouling / scaling which can be handled by proper and regular cleaning .Determination of Foulants A rather fast or an immediate performance decline indicates a defect or misoperation of the plant. In any case, it is essential that the proper corrective measure is taken as early as possible, because any delay decreases the chance of restoring the plant performance.
An immediate decline in performance indicates a defect or misoperation of the plant. In any case, it is essential that the proper corrective measure is taken as early as possible because any delay decreases the chance of restoring the plant performance – apart from other problems that might be created by an excessively low permeate flow and/or too high permeate TDS.
A prerequisite for early detection of potential problems is proper record keeping and FTNORM This includes proper calibration of all instruments. Without accurate readings it might be too late before a problem is detected and corrected. Another key to successful troubleshooting is understanding the effects of changing system parameters on system performance. Some apparent plant problems are simply the normal reaction of the plant to changing feed or other operating parameters.
Once a performance decline has been identified, the first step in solving the problem is to localize the problem and to identify the cause(s) of the problem. The first step is to evaluate the performance and the operation of the system. This can be done using the data of the record keeping logsheet or of some additional on-line measurements. . If these data are not sufficient to determine the cause(s) and to recommend corrective action, one or more membrane elements must be taken from the plant and analyzed. System Optimization Services program offers an extensive array of membrane and element analytical tests which will help not only determine the cause(s) of a problem, but can help with detailed solutions as well.
FilmTec™ System Optimization Services (SOS)
System Optimization Service Brochure (194KB PDF)
Troubleshooting |
Introduction (27KB PDF) |
Evaluation of System Performance and Operation (46KB PDF) |
Most organic molecules are rejected by RO. However these organics, depending on their nature, size, etc. can foul, or in some cases, chemically affect the membrane or may even promote bacterial growth, hence leading to fouling. The COD & BOD values, as the name suggests, only indicate the oxygen demand, but do not indicate any details about the nature of the organics themselves.
For this reason, it is very difficult to generalize what level of COD/BOD would or would not be detrimental to the membrane/system performance. In most cases designers use their experience/judgement in different applications but the aim is always to remove the organics in pretreatment.
Additional Information:
FilmTec Membranes - Pretreatment Summary
Cleaning Organic Fouling from FilmTec FT30 Elements (15 KB PDF)
Prevention of Organic Fouling by Organics (10 KB PDF)
Colloidal Fouling Prevention (32 KB PDF)
In a legacy reverse osmosis system, several sequential membrane stages are all fed water using a single, steady-state pump. The pump must be set at very high pressure to ensure that downstream membranes get the flow they need. As a result, lead arrays end up operating at higher flux than tail arrays, making them especially prone to fouling. While the tail membranes have a low flux and limited/reduced cross flow.
In contrast, CCRO systems use a single membrane stage and increase the high-pressure pump frequency with each cycle (PID loop between VFD and feed flow rate) to ensure that the membranes only get the flux they need for optimal operation. This gives you much better control and reduced energy costs.
A packed bed ion exchange system has minimal freeboard and is designed to run in a reverse-flow mode. For over 30 years, packed bed systems have been recognized as the leading process for employing ion exchange resins at maximum efficiency for demineralization, enabling lowest chemical costs and waste volumes and highest product quality. DuPont has led the way in packed bed innovation through its AMBERPACK™ and UPCORE™ design systems.
Some of the advantages of an AMBERPACK and UPCORE packed bed system are:
Recommended AmberLite ion exchange resins for packed bed systems in industrial water treatment
Please see for NSF information. For information regarding other drinking water statuses, please submit your request to Ask-an-Expert, above, with the name of the regulation of interest and the name of the resin.
Anion resins should be analyzed every six months to monitor system performance. Cation resins should be analyzed annually. Annual to bi-annual analysis of chromatographic resin is sufficient. Contact your DuPont representative for information.
Resin Sampling Procedure (KB PDF)
Permeate water can be taken off from both or either end of the pressure vessel.
You can plug the permeate port on the downstream end and take the permeate from the front end (i.e. the same side as the feed) if you wish. There is no disadvantage to this design. Some actually take the permeate out from both ends. This adds to the piping cost but is a bit more efficient because there is less permeate backpressure.
They both deliver outstanding permeate quality water at high flux for applications requiring sanitary grade membrane elements. The full-fit configuration minimizes stagnant areas and is optimal for applications requiring a sanitary design.
Both types have the same dimension, and use the same interconnectors and adaptors. The main difference is that HSRO can be used to heat-sanitize the membrane system including the membrane element while the RO-FF elements cannot. So, if you do not wish to sanitize the system with chemicals, then HSRO is the right choice. Otherwise, both types give excellent performance.
Additional Information:
FilmTec HSRO-4040-FF Element
Since sulfuric acid is usually less expensive, many ion exchange plant users prefer it over hydrochloric acid. However, certain process advantages can be realized with hydrochloric acid. For example, the operating capacity of a cation exchange resin regenerated with sulfuric acid is usually 30% to even 40% lower versus the same amount of hydrochloric acid. This can be compensated for by using greater quantities of sulfuric acid. However, this will increase the time needed for regeneration when using the same concentration and flow rate. Using hydrochloric acid is especially advantageous when the calcium level in the feed water to be treated is high, since care has to be taken not to use a sulfuric acid concentration that is too high, or it will cause calcium sulfate to precipitate in the resin bed. One of the advantages of sulfuric acid is that it is easier to store in steel containers, whereas hydrochloric acid needs to be stored in non-metallic containers.
Additional Information:
Ion Exchange Resins - Recommended Operating Conditions
Regenerating Strong Acid Cation Resins with Sulfuric Acid (19KB PDF)
Properties, Impurities, and Concentrations of Regenerent Chemicals (124KB PDF)
The freeboard is a key parameter which directly impacts plant performance because it will influence the essential parameters for regeneration. In general it is true that with a larger freeboard the self-cleaning effect improves due to the classification in the settling step. On the other hand when the freeboard is kept small the water quality is better but the self-cleaning effect is somewhat less.
The correct freeboard is always the minimal space considering the most expanded form of the resin.
UPCORE™ resin data sheets provide expected figures for swelling of current resins.
WAVE (Water Application Value Engine) can approximate the necessary resin bed depth and thus the required freeboard.
Additional information:
In co-current operation, the product water quality requirements will define the minimum levels of acid and caustic regenerant to be used. The regenerant levels and the feed water composition will then define the resin operating capacity. Although high regenerant levels result in increased capacity and lower ionic leakages, the chemical efficiency of the system becomes worse.
More precise determinations of resin operating capacities and ionic leakages can be calculated using WAVE Software..
Guidelines for Typical Regeneration Level and Corresponding Resin Operating Capacity:
Regeneration System
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Regenerant Level
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Typical Operating Capacity
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(g/l)
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(lbs/ft3)
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(eq/l)
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(kgr/ft3)
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Co-Current Regeneration: | ||||
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80 - 120
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5 - 7.5
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0.8 - 1.2
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17.5 - 26
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150 - 200
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9.5 - 12.5
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0.5 - 0.8
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11 - 17.5
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80 - 120
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5 - 7.5
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0.4 - 0.6
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8.5 - 13
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Counter-Current Regeneration: | ||||
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40 - 55
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2.5 - 3.5
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0.8 - 1.2
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The presence of free chlorine or other oxidizing agents in the feed water can lead to resin degradation over time. Anion exchange resins are very sensitive as oxidants attack the functional amine group resulting in loss of resin capacity and impaired performance. Continuous exposure of anion resins to >0.05 ppm free chlorine should therefore be avoided.
In the case of a cation resin, oxidation occurs by de-crosslinking the copolymer matrix, leading to an increase in water retention capacity and resin swelling. This results in weakening of the mechanical integrity of the resin and wet volume capacity loss. Temperature and chlorine concentration both impact the rate of de-crosslinking. While it is not possible to accurately predict resin life when other factors are considered, the following guidelines for feedwater chlorine levels will maximize the life of cation resins.
Recommendations for Maximum Free Cl2 Limits (91KB PDF)
Like chlorine; chloramines, chlorine dioxide and ozone also have oxidizing potential. To protect synthetic resins, activated carbon is generally used to remove chlorine and catalytic activated carbon to remove chloramine. In doing this, there may be by-products of ammonia, chloride, or nitrogen gas.
Additional Information:
Ion exchange resin life and performance will be influenced by feed water quality.
Design checklist
Additional Information
Reverse osmosis elements should never be backwashed since it will destroy the integrity of the spiral wound membrane element.
Additional Information:
Cleaning Procedures for FilmTecTM FT30 Elements (146KB PDF)
FilmTec Membranes - Troubleshooting
Symptoms of Trouble, Causes and Corrective Measures - Troubleshooting Grid
Scale Control | |
2.3.1 | Scale Control Introduction (PDF) |
2.3.2 - 2.3.3 | Scale Control by Acid Addition and Scale Inhibitor Addition (PDF) |
2.3.4 - 2.3.5 | Softening with a Strong Acid Cation Exchange Resin and Dealkalization with a Weak Acid Cation Exchange Resin (PDF) |
2.3.6 | Lime Softening (PDF) |
2.3.7 - 2.3.8 |
Preventive Cleaning and Adjustment of Operating Variables (PDF) |
2.4.1 | Scaling Calculations (PDF) |
Scale Prevention | |
2.4.2 | Calcium Carbonate Scale Prevention (PDF) |
2.4.3 | Calcium Sulfate Scale Prevention (PDF) |
2.4.4 | Barium Sulfate Scale Prevention (PDF) |
2.4.5 | Strontium Sulfate Scale Prevention (PDF) |
2.4.6 | Calcium Fluoride Scale Prevention (PDF) |
2.4.7 | Silica Scale Prevention (PDF) |
2.4.8 | Calcium Phosphate Scale Prevention (PDF) |
Yes, if you have a 32 bit computer. If you have a 64 bit computer, please contact us via Ask-An-Expert, and we will respond to you separately.
For Windows 7 and above (32 bit) , you will need to:
Uninstalling IXCalc before an update:
The procedure is the same as that for previous versions of Windows, using the "Control Panel" item to unistall Programs. To uninstall IXCalc, you thus open the control panel, select the "Programs and Features" icon, select IXCalc from the list and click "Uninstall/Change" in the menu bar.
Additional Information
A general rule is the system can be operated at 50%, 75%, and 80-85% recoveries for a single stage, two stage, and three stage systems respectively. % recovery is defined as the ratio of permeate flow to feed flow rate. Parameters such as operating temperature, source of feed, composition of feed, feed concentration, and pH can have an effect on the overall % system recovery and % recovery of individual element. In all cases though, % system recovery is often set to maximize permeate flow while preventing precipitation of super-saturated salts within the membrane system. For more information, please see Scaling Control (10KB PDF).
The following brochures gives recommendations based on element type and feed source.
Membrane System Design Guidelines for 8-inch FilmTec Elements (126KB PDF)
Commercial Design Guidelines for Midsize FilmTecTM Elements (126KB PDF)
WAVE is downloadable from our web site. It is a comprehensive engineering tool for system design that can take into account your specific feed and system parameters and your permeate water requirements.
Additional Information:
FilmTec Membranes - Selecting Feedwater Type for WAVE Projection
DuPont Water Solutions offers a module analysis service called System Optimization Services (SOS), including a variety of inspection, diagnostic and testing procedures. For more information, visit the SOS webpage or To request SOS, please contact your Account Manager or Technical Service Representative. If you are do not have a direct contact, please provide the information in the email form and send to sos@dupont.com. Upon receipt of your request, we will connect you to the appropriate account manager and/or technical service representative to discuss your request.
If the system suffers from loss of normalized permeate flow performance and the problem can be localized, the general rule is:
A low flow performance may be combined with a high, a normal, or a low solute passage. The following are possible causes for each situation.
Low Flow and High Solute Passage
Low flow associated with high solute passage is the most commonly occurring condition for plant failure. Possible causes are:
Low Flow and Normal Solute Passage
Low permeate flow associated with normal solute passage can have the following causes:
Low Flow and Low Solute Passage
Low flow associated with low solute passage can have the following causes:
Please see the following brochure for descriptions and pictures of the various causes, tests that may be run to determine the causes, and corrective measures.
Symptoms of Trouble, Causes and Corrective Measures - Low Flow (339KB PDF)
Molecular weight cut-off (MWCO) is a term used to describe a pore size of a membrane. The smaller the MWCO, the tighter the membrane pore size.
A membrane with MWCO of 100 means it can reject molecules with the molecular weight of 100 well (i.e. >90%).
Additional Information:
Estimated Percent Rejection of Various Solutes by FilmTec Membranes (135 KB PDF)Major Desalination and Filtration Processes (124KB PDF)
Generally, it is recommended to clean an RO plant when a 10% decrease in normalized flux can be observed. For orientation, cleaning frequency can be in the range of 4/year with an SDI of less than 3. With an SDI of 5, the cleaning frequency could double. However, cleaning frequency will depend on the specific situation.
To determine what type of cleaning you need, please see FilmTec Membranes - Appropriate Cleaning for Membrane System
Regenerant capacities equivalents can be calculated with WAVE Software program.
For the purpose of illustration, the example used will be going from 4 lb/ft3 HCl to H2SO4. Resin = Using WAVE (Download WAVE ), run a projection with 4 lbs. of HCl/ft3 to calculate the cation operating capacity under your specific set of operating conditions. Then re-run the projection with different dosages of H2SO4 until you get the same operating capacity.
Additional information:
Properties, Impurities, and Concentrations of Regenerent Chemicals (124KB PDF)
DuPont does not recommend specific commercial products. A Summary of Pretreatment Options is available on our web site, as well as information on how to ensure membrane compatibility of commercial formulations.
Additional Information:
Water Chemistry and Pretreatment Introduction
Testing Chemical Compatibilities with FilmTecTM Membranes (29KB PDF)
DuPont restricted - for internal use only
For requests about scale inhibitors and membrane cleaners from third party suppliers, send the request to the appropriate tech service person.Please note that choice of a regenerant and the allowable impurity levels will be dependent on the application and the necessary quality of the treated effluent.
Chemical |
Formula |
Equivalent Mass |
Remarks |
---|---|---|---|
Ammonia | NH3 | 17 |
WBA. Use 150-180% ratio |
Calcium hydroxide | Ca(OH)2 | 37 |
WBA |
Caustic soda | NaOH | 40 |
Demineralisation anions |
Potassium hydroxide | KOH | 56 |
Demin anions. Use NaOH g/L × 1.40 |
Sodium bicarbonate | NaHCO3 | 72 |
WBA. Use 180% ratio (not very efficient) |
Sodium carbonate | Na2CO3 | 53 |
WBA. Use 150-180% ratio |
Ammonia gas or fumes from concentrated solutions can cause serious irritation to eyes and the respiratory tract. Avoid inhalation and provide adequate ventilation when handling ammonia solutions. Ammonia is mostly offered as a solution in water, containing 20 to 30 weight percent NH3. Impurities are normally minimal and cause no potential problem in ion exchange regeneration. Ammonia is mostly used in concentrations between 3 and 5 percent for regeneration of weakly to medium basic anion exchange resins.
Sodium carbonate does not require special handling precautions. It is supplied as a white, anhydrous powder with over 98 percent purity. Impurity levels are thus minimal and cause no potential problem in ion exchange regeneration. Moreover, higher levels of NaCl or Na2SO4 will not adversely affect the regeneration efficiency, although they will of course not contribute as regeneration chemicals. Sodium carbonate is mostly diluted to between 5 and 8 percent for the regeneration of weakly to medium basic ion exchange resins.
Sodium chloride does not require special handling precautions. It is offered as a white powdered, granulated or pelleted solid of 98 to 99 percent. Sodium chloride is used for regeneration in different processes. Concentrations will differ depending upon the process, as is illustrated in the following table.
Process | Resin Concentration |
Dealkalization | 5 - 10% NaCl |
Organic screen | 10% NaCl + 1% NaOH |
Recommended max. impurity levels for NaCl:
SO4-- 1%
Mg++Ca++ 0.5%Additional information:
A variety of industry-wide test methods exist for ion exchange resins. The most widely used standard is from ASTM:
ASTM D2187-94 Standard Test Methods for Physical and Chemical Properties of Particulate Ion-Exchange Resins.
A copy of this standard can be purchased from the ASTM web site at: www.astm.org
Additional ASTM test methods for ion exchange resins include:
ASTM D2187 Std Test Methods for Physical and Chemical Properties of Particulate Ion-Exchange Resins
ASTM D1782 Standard Test Methods for Operating Performance of Particulate Cation-Exchange Materials
ASTM D5217 Standard Guide for Detection of Fouling and Degradation of Particulate Ion Exchange Materials
ASTM D6302 Standard Practice for Evaluating the Kinetic Behavior of Ion Exchange Resins
ASTM D3375 Std Test Method for Column Capacity of Particulate Mixed Bed Ion Exchange Materials
ASTM D7513 Standard Test Method for Capacity of Mixed Bed Ion Exchange Cartridges
ASTM D3087 Std Test Method for Operating Perf of Anion-Exchange Materials for Strong Acid Removal
ASTM D5627 Standard Test Method for Water Extractable Residue from Particulate Ion-Exchange Resins
ASTM D5042 Std Test Method for Estimating the Organic Fouling of Particulate Anion Exchange Resins
If properly installed, both seals will be leak-free when new. Unfortunately, the sliding seal is prone to damage due to o-ring pinching and rolling during installation, and suffers from wear and tear over time of operation due to the sliding action of start-up and shutdown.
DVB - Typical Chemical Analysis and Structural Formulae1
Structural Formula |
DVB-55 |
DVB-63 |
DVB-HP |
Total Divinylbenzene2 | 56% | 63.5% | 80% |
Meta:Para Divinylbenzene isomer ratio | 2.3 | 2.3 | 2.3 |
Total Ethylvinylbenzene3 | 43.0% | 35.5% | 19% |
Meta:Para Ethylvinylbenzene isomer ratio | 2.3 | 2.3 | 2.3 |
Diethylbenzene | <0.5% | <0.5% | <0.1% |
Naphthalene | <0.04% | <0.04% | <0.04% |
Benzene content | N.D. | N.D. | N.D. |
t-butyl catechol inhibitor | 900-1100 ppm | 900-1100 ppm | 900-1100 ppm |
Color (Gardner) | <4 | <4 | <4 |
Polymer | <5 ppm | <5 ppm | <5 ppm |
1These typical analyses are intended to serve as a guide only and not as specification limits.
2Divinylbenzene CAS #001321-74-0
3Ethylvinylbenzene CAS #028106-30-1
N.D. – Not detectable with current instruments (<50 parts per billion)
Structural Formula:
Water hammer is a term used to describe a hydraulic shock to an element that happens when the high pressure pump is started before all air has been flushed from the system. This could be the case at initial startup or at operational startups when the system has been allowed to drain. It can cause longitudinal and circumferential cracks on fiberglassed elements.
It can also result in membrane compaction which is typically associated with low permeate flow and improved salt rejection. It can also cause o-rings to leak due to mechanical stress caused by element movement. To prevent this from recurring, the elements in the pressure vessel should be shimmed. Shimming the elements at the time they are initially loaded will minimize the shifting that occurs during startups and shutdowns.
Additional Information:
Symptoms of Trouble, Causes and Corrective Measures - Low Flow (339KB PDF) (see pages 5-6)
Is it necessary to purge air from a reverse osmosis system prior to start-up?
Often weak base anion (WBA) and strong base anion (SBA) exchange resins are used in combination in a single vessel. In a layered bed, the WBA resin should be on the top layer to pick up free mineral acids (chlorides, nitrates, sulfates) and the SBA resin on the bottom layer to pick up bicarbonate and silica.
The layered bed concept is made possible by the density and particle size differences between the resins used. Upon exhaustion, the backwashing operation separates the resin layers that may have become partially mixed during service. In order for the full advantages of a layered bed to be realized, good resin separation is important.
The primary of a layered anion resin bed are:
Additional Information:
Recommended AmberLite™ ion exchange resins for layered bed systems in industrial water treatment (
Preventing Silica Fouling of Weak Base Anion Resins (19KB PDF)
Loading Procedure for Layered Bed Anion Resins (19KB PDF)
Cation exchange resins, such as AmberLite™ HPR1200 H, can be dyed with 1.2 g of 4-phenylazodiphenylamine in 1 liter of ethanol per 28 l of resin.
Anion exchange resins, such as AmberLite™ HPR4800 Cl, are dyed with 0.4 g thymolphathalien in 1 liter of 1:1 ethanol:water, per 28 l of resin.
The resin is agitated while adding diluted dye solutions in small amounts. Continue agitation for 30 minutes and rinse until all of the excess dye is removed. These resins will, after dyeing, change color when converted from the regenerated to the exhausted form.
Testing or evaluation of resins for your application should be done in two steps. The first step is to determine if the chemistry of the separation is plausible. This is conveniently done with an equilibrium isotherm or bottle shake test. A copy of the method can be obtained in our website. This method can be used to compare different media under different removal and regeneration conditions.
When the best separation media is identified, column studies are used to identify the proper engineering conditions such as flow rates, contact times, and operational conditions. We recommend that you work with an equipment manufacturer at this point so that the right data is obtained for scale-up and an accurate price quote on a complete system.
Additional Information:
Ion Exchange Resins Equilibrium Isotherm Testing For Liquid Phase Applications (23KB PDF)
Are special tools required for installation of FilmTec™ elements with iLEC™ interlocking endcaps?
No, special tools are not required. For added convenience during installation and removal, DuPont has made available a ratcheting band clamp (P/N 245831) and element pulling tool. The band clamp is helpful for keeping one element from turning while the next is attached. The pulling tool provides a membrane-friendly method of extrating an element from a pressure vessel.
Handling Recommendations for Elements with iLEC™ (813KB PDF)
Please contact us along with the the following information
We also recommend that you check your design using WAVE before replacing elements.
DuPont offers a variety of mixed bed ion exchange resins for industries such as nuclear power generation, semiconductor manufacturing, laboratory and pharmaceutical. As a pre-mixed resin, it also allows for faster initial rinse-up prior to service, which minimizes rinse waste water volume.
Pre-Mixed Resins
AmberLite™ IRN150 H/OH Ion Exchange Resin | A stoichiometric equivalent mixture of uniform particle size gel polystyrene cation and anion exchange resins. It is supplied in the fully regenerated H+/OH- form. The resin combines the properties of high capacity and excellent physical strength. |
A stoichiometric equivalent mixture of uniform particle size gel polystyrenic cation and anion exchange resins, supplied in the fully regenerated H+/OH-forms. Designed to minimize separation of anion and cation during installation and transfer due the combination of high capacity with excellent resistance to bead fracture from attrition and osmotic shock. The less separating properties of this resin make it easily transferable from one location to another, helping to eliminate the formation of a cation layer at the bottom of the service vessel. | |
AmberLite™ IRN170 H/OH Ion Exchange Resin | A fully regenerated nuclear grade mixed bed resin designed for the ultimate performance in non-regenerable nuclear applications. The cation component of this mixed bed product is Amberlite IRN99 resin, which delivers the highest total capacity and the best oxidative stability of any available cation exchange resin. This revolutionary highly cross-linked gel cation resin is combined in a 1 to 1 equivalent ratio with the proven anion exchange resin, Amberlite IRN78 resin, to make Amberlite IRN170 resin. This new mixed bed is now the resin of choice for nuclear applications which demand the highest effluent purity, highest operating capacity, and longest resin life.
|
Regeneration of a mixed-bed consists of the following steps :
Additional Information:
Ion Exchange Resins - Recommended Operating Conditions
Loading an Internally Regenerated Mixed Bed (22 KB PDF)
Regenerating Strong Acid Cation Resins with Sulfuric Acid (19 KB PDF)
Regenerating Concentration Tables (24 KB PDF)
Our Ultrafiltration Modules designs are based on qualified feed water conditions as shown in the table below. The UF modules can tolerate period excursions in feed water quality as shown as the maximum recommended. If the feed water quality is outside of the design basis range shown below, a pilot study should be operated to confirm performance or pretreatment must be considered. If the system is designed and installed to the qualified conditions below but the feed water quality is not maintained DuPont Water Solutions should be consulted.
Parameter |
Unit |
Desirable |
Maximum Recommended |
Turbidity |
NTU |
<50 |
300 |
TSS |
mg/l |
<20 |
100 |
TOC |
mg/l |
<10 |
40 |
COD Mn |
mg/l |
<20 |
60 |
Oil & Grease |
mg/l |
0 |
< 2 |
Particle Size |
micron |
<150 |
300 |
pH continuous |
6-9 |
2-11 |
|
pH cleaning |
|
2-11.5 |
1-12 |
Temperature |
°C |
<35 |
40 |
Feed Pressure |
bar |
<3 |
6 |
TMP |
bar |
<1 |
2.1 |
Cl2 continuous |
mg/l |
0.5 |
200 |
Cl2 cleaning |
mg/l |
2000 |
5000 |
Additional Information:
It is advisable as a general rule to have a resin analysis check-up once every 12 to 24 months. However, the check-up frequency is resin and application dependent. Cation exchange resins tend to last much longer than anion exchange resins and need less frequent analysis. Anion exchange resins used in condensate polishing should be given an annual check-up since these resins may lose kinetic performance that would only be found during a condenser leak or with a laboratory kinetic test. DuPont offers a full range of resin analysis services through our System Optimization Services program.
Additional Information:
Resin Sampling Procedure, Tech Fact (602 KB PDF)
Ion exchange resins, when placed in a solution, reach an equilibrium state between ions in solution and ions on the resin. From this equilibrium state, selectivity coefficients (equilibrium constants) can be defined based on the ratios of ions in solution vs. ions on the resin.
Effectively, these selectivity coefficients are a measurement of a resins preference for an ion. The greater the selectivity coefficient, the greater the preference for the ion.
Please refer to our brochure entitled 'Using Ion Exchange Resin Selectivity Coefficients' (44KB PDF).
Selectivity coefficients of various anions is given in Table 1 (p. 2) and selectivity coefficients of various cations is given in Table 2 (p. 3).
For a complete treatment of the subject, numerous textbooks can be consulted. One excellent reference is Ion Exchange by Friedrich Helferich.
We do not sell pressure vessels. Adapters and end plates are part of pressure vessel and also available from pressure vessel suppliers.
One the other hand, interconnectors are considered an integral part of the membrane element and are provided in each shipping box of the FilmTecTM 8' membrane element. For the 2.5' and 4' elements, it is necessary to order them separately. Extra interconnectors and/or o-rings are available from Online Parts Order System. In order to ensure prompt and accurate delivery, be sure to have the element model number, a list of what you need (part description and needed quantities).
Additional Information:
Interconnector Technology (104KB PDF)
Additional information for internal viewing and use:
If they are looking to retrofit female style elements (flush on both ends) with our elements, which are male, where part of the 40 inch length is includes the product water tube that sticks out over an inch on each side, they need an adaptor to lengthen the male elements. We don't know of vessel manufacturers that provide such adaptors.For anion exchange resins, thermal degradation that results in the loss of functional groups and loss of salt splitting capacity are the most important decomposition mechanisms. For strong base anion exchange resins a Hofmann degradation mechanism has been proposed to account for the loss of resin capacity due to deamination (Equations 1 and 3, where P = styrene/divinylbenzene copolymer backbone) and the formation of weak base groups with the resin (Equations 2, 4, 5).
(1) Type I Resin: P-CH2-N+(CH3)3 + OH- <--> P-CH2OH + N(CH3)3
(2) Type I Resin: P-CH2-N+(CH3)3 + OH- <--> P-CH2-N(CH3)2 + CH3OH
(3) Type II Resin: P-CH2-N+(CH3)2(CH2)2OH + OH- <--> P-CH2OH + (CH3)2N(CH2)2OH
(4) Type II Resin: P-CH2-N+(CH3)2(CH2)2OH + OH- <-->P-CH2 N(CH3)(CH2)2OH + CH3OH
(5) Type II Resin: P-CH2-N+(CH3)2(CH2)2OH + OH- <--> P-CH2 N(CH3)2 + CH3CHO + H2O
It has also been proposed that the loss of quaternary amine groups occurs by a Hofmann-Martius rearrangement reaction in Type I strong base resins and an intramolecular rearrangement reaction in Type II strong base resins.
DuPont restricted - for internal use only
I have equations that show these latter 2 reactions, but they are incomplete - I can no longer find the original source.
(6) P-CH2-N+(CH3)3 + OH- à P --O--N(CH3)2--CH3 GRAPHIC TO BE INSERTED
(7) P-CH2-N+(CH3)2(CH2)2OH + OH- à P-CH2-O(CH2)2N(CH3)2 + H2O
Additional details can be found in: Hall, G.R., et. al., 'Thermal Stability of Ion Exchange Resins', Soc. Chem. Ind., p. 62-70 (1970).
Degradation of cation exchange resins by oxidation usually determines the lifetime of a s
Like all thin film composite polyamide membranes, chlorine will oxidize the surface of the membrane causing it to lose its ability to repel or reject salts. FilmTec FT30 membranes can tolerate up to 1000 ppm-hours of chlorine. Traces of metals will accelerate oxidation. Therefore chlorine should be removed from the RO feed water.
Additional Information:
Chlorination - Dechlorination (53KB PDF)
Testing Chemical Compatibilities with FilmTec Membranes (29KB PDF)
At this time, FTNORM is only capable of normalizing two-stage systems.
Capability to normalize a three-stage system may be available in the future FTNORM version. In the meantime, if you require a FTNORM with three-stage system, please contact us.
In order to have a three-stage system using FTNORM, you must be able to access the following information on two of the three stages in addition to the overall system information: permeate flow rate, feed flow rate, feed pressure, feed concentration, permeate concentration.
Additional Information:
In cases where biological growth has occurred in softening and demineralization resins, an extended air scour followed by a double regeneration may be able to restore the resins to a usable condition. If this procedure is not
successful, there are two disinfection procedures that can be used: Chlorine disinfection (discussed here) and Peracetic Acid / Hydrogen Peroxide Disinfection . Oxidative damage can occur from each type of treatment, so these procedures should be considered as a last resort.
Sodium hypochlorite or bleach cleaning is a very intense treatment for sterilizing and removing organic contaminants on cation exchange resins. As a result, this treatment should be carefully controlled in order to prevent possible resin damage (de-crosslinkage/defunctionalization). Note that chlorine can be explosive under certain conditions.
The recommended procedure for cation resins is as follows:
The recommended procedure for anion resins is as follows:
Additional Information
Preventing Biological Growth on Ion Exchange Resins (55KB PDF)
The choice of whether or not to use buffer beads depends on your system. Some mixed beds use a layer of buffer beads to dilute the crossover region (reducing the risk of crossregeneration). However, the excellent separability of the uniform particle size resins, such as AmberLite ™ HPR resins will reduce the requirement for an intermediate layer, thus increasing the operating capacity of the mixed bed. However, if you require buffer beads, the AmberLite™ 600i inert resin would be the one to choose.
Because the residential RO systems are designed to operate without a pump, the membrane performance is really dependent upon the incoming water pressure. Residential RO systems are designed to operate at 40 to 60 psi water pressure for optimum performance. However, it can be operated at lower than 40 psi, but it will just take longer to fill the product water tank.
Your system manufacturer is best equipped to help you understand the recommended operating ranges of their systems.
The software that controls our systems uses up to three different user-defined set-points to automate adjustments to the filtration process — volumetric recovery (percentage water turned into permeate), brine conductivity (salt content of waste), or maximum feed pressure.
Here’s an example. Imagine a pharmaceutical plant uses a municipal water source that switches seasonally between well water and lower-quality surface water. The plant must meet a consistent permeate quality target, despite varying-quality feedwater.
Depending on the source, the conductivity of the feedwater will change. The plant manager can enter software set-points so that the system automatically detects the conductivity change and adjusts; accordingly, the filtration time and recovery rate will change, but the permeate quality will remain consistent.
This level of flexibility is unprecedented in traditional reverse osmosis systems, which are calibrated when built and cannot be adjusted on the fly.
During closed-circuit (CC) mode, 100% of the brine is recirculated. Like a sand filter, which is backwashed to remove suspended solids, the CCRO system is flushed to remove dissolved solids. The CCRO process concentrates the blended feedwater over time rather than space. The multiple stages of a traditional reverse osmosis design are replaced by multiple cycles in CC mode. Once the desired recovery is achieved after several cycles, the concentrate is flushed. This single-stage loop is what sets CCRO systems apart from traditional reverse osmosis designs.
If the service flow rate is too fast the capacity utilization of the resin will be reduced and higher ionic leakage levels through the resin bed may occur.
If the service flow rate is too slow, poor distribution can lead to channeling and reduced system throughput.
Appropriate service flow rates are given in the Product Datasheet for the Specific Resin. Additionally, general recommendations are given in the .design guidelines
Additional Information:
The key factor in handling a permeate that is pressurized is that the permeate pressure cannot, under any circumstance, exceed the pressure on the feed side of the membrane. Such a situation would cause reverse flow and, rather than the feed pressure compressing the glue lines of the membrane envelope, would pull these glue lines apart. Secondly, the active layer of the membrane could be lifted off the support structure. In either case, the membrane is destroyed.
A tolerance of 5 psi is listed. However, one should aim to have no reverse pressure differential. However, we often deal with pressurized permeate. This is done by equipment / control provisions. For example, one can have a dump valve on the permeate side of the membrane that is connected to a pressure indicator on the feed side of the membrane. If feed pressure is lost, the dump valve automatically opens and releases the pressure on the permeate side of the membrane so that no reverse flow occurs. In designing such provisions, it is important to keep in mind such things as hydrostatic pressure (how high is the dump valve versus the membranes or rest of the equipment, etc.), backups, etc. Check valves often are used in combination with other assurances to prevent reverse flow.
Yes. However, it should be avoided if practically possible. If elements have been frozen, it is recommended that they are thawed thoroughly prior to use.
Additional Information:
Handling and Preservation of FilmTec Elements (22KB PDF)
Depending on how a user's computer is configured, they may not have necessary administrative privileges while installing the and/or using the application. To get around this error, please right click on the icon or file in question and select Properties, then select the tab, Compatibility, and make sure 'Run as Administrator' is checked.
If you do not have this option or it is grayed out, you may have to request access to run as an administrator from your IT Security Group.
Determining when to replace elements is dependent on the type of problem, whether they are fouled, scaled, or damaged.
or Elements
FilmTec™ membrane elements can be very effectively cleaned due to their tolerance for wide range of pH and temperature. However, if cleaning is delayed, it becomes increasingly difficult to remove foulants or scales from the membrane surface. Cleaning will be more effective if it is tailored to the specific fouling problem.
Knowing when to replace them is dependent upon what you can tolerate. If your system cannot meet the water quality and/or permeate flow specifications even though you change operating conditions or cleanings do not restore the performance, then it is probably a time to replace the membranes.
Some foulants/scales are nearly impossible to clean off: e.g. aluminum, oil, grease, calcium, barium, or strontium sulfate scale, calcium phosphate. So if an element is fouled or scaled with these, it will need to be replaced.
Oxidized or Mechanically Damaged Elements (PDF)
Such elements cannot be restored as the membrane has been irreversibly damaged. The elements need to be replaced. Elements with moderate telescoping may be still usable. The Symptoms of Trouble, Causes and Corrective Measures - Troubleshooting Grid (PDF) can help you diagnose symptoms and solve problems.
Analysis of FilmTec membrane elements that have been used in service is available from us under the System Optimization Services (SOS) program. From this analysis, we can advise how to clean your elements and if they need to be replaced.
Additional Information:
How Do I Find Out Which Elements Need to be Replaced?
No, it is generally not necessary. The CCRO process is accurately modelled by WAVE software, and these models have been validated in the field. Furthermore, the CCRO design is inherently flexible — the mechanical design is the same whether it is being run at 75% or 98% recovery. This flexibility, coupled with an inbuilt resistance to scaling and fouling, means that setting up a CCRO system without a pilot is presents a lower risk than setting up a traditional system without a pilot.
Information regarding the Properties, Impurities and Concentrations of the following Regenerant Chemicals can be found by clicking on the link below.
Ammonia: NH3
Hydrochloric Acid (HCl (muriatic acid)
Sodium Carbonate: Na2CO3 (soda ash)
Sodium Chloride: NaCl (salt)
Sodium Hydroxide: NaOH (caustic soda)
Sulfuric Acid: H2SO4
Properties, Impurities, and Concentrations of Regenerent Chemicals (124KB PDF)
The purity specifications of regenerant chemicals are designed to assure trouble-free operation of the ion exchange resin after regeneration. The chemicals, therefore, have to be free of suspended materials, or other materials that may be precipitated on, or absorbed by the resin. They should also be free of ionic species other than the active regeneration agents, as this will decrease the regeneration efficiency and/or increase the leakage of this species during the operational cycle
An RO system is designed to be operated continuously. However, in reality RO systems will start-up and shutdown on some frequency. When the RO membrane system is shut down, the system must be flushed with either permeate water or high quality feedwater, to remove the high salt concentration from the modules. Care must be taken that the elements do not dry out; dry elements will irreversibly lose flux. The RO train can be stopped for 24 hours without preservation and precautions for microbiological fouling. For longer periods, the system must be adequately protected against micro-biological growth, or regular flushing is carried out.
Additional Information:
RO Systems Shutdown and Lay-up Consideration (37KB PDF)
Initial Start Up - Prestart Up Check and Commissioning Audit
A draw-back tank is a small tank in the permeate line that provides enough volume for natural osmosis back-flow when the system shuts down. It is typically employed in seawater systems, but not in brackish water systems. An empty draw-back tank can cause air to be sucked back into the FilmTec elements. This may create the following problems:
• Contamination of the permeate side of the membrane by airborne microbes and fungi.
• Hydraulic shocks and slugs of air that upset meters and set point controllers when the air is expelled from the system on the next start-up.
• Drying of the membrane (flux loss).
• If the feed water is in a reduced status and contains H2S, Fe2+, Mn2+, etc., the air intrusion may cause fouling of the membrane by oxidized and precipitated colloidal matter (see Treatment of Feedwater Containing Hydrogen Sulfide )
If the product water from an RO system is chlorinated, care must be exercised to ensure that the chlorine does not migrate back to the membrane. Air breaks should be employed appropriately.
If a draw-back tank is used, its water level should be higher than the highest pressure vessel, but not exceeding 9.8 ft (3 m) from the lowest vessel. To prevent contamination, the flow is in at the bottom and out at the top, and the tank must be covered. Post-chlorination if performed must be done downstream of this tank.
The volume of a draw-back tank can be sized as follows:
VDBT = (25TE) – VPP
where:
VDBT = Volume of draw-back tank (in liters)
TE = Number of installed elements
VPP = Volume of permeate piping between pressure vessels and draw-back tank (in liters)
We do not have a list of rejection rates for these heavy metals, but we can give you some general guidelines. However, we recommend that you run the experiments under your unique set of conditions and ions/counterions.
Rejection of lead by FilmTec membranes has been reported to be quite high, >99%.
We do not have rejection data on thallium, but would expect it to be high, > 99%. However, we would caution about trying to generalize, based on molecular weight because some salts of heavy metals can give surprisingly high passages because they do not dissociate readily. A prime example is mercury chloride (HgCl2) which reported rejection rates of only 50 to 60%.
These substances may also be removed with ion exchange and chelating resins. Please see Separation of Heavy Metals from Water, Wastewater, and Acids
AmberSep™ M4195 chelating resin is unique in the chemical processing world. It can selectively capture transition metal ions from solutions with pH less than 2, or in the presence of homogeneous chelating agents such as EDTA. The chemistry of AmberSep™ M4195 is based upon a special chelating amine ligand which is partially quaternized by sulfuric acid as received. When in this conjugate sulfuric acid salt form, the resin is fully swollen and hydrated and ready for scavenging metals from acidic media.
It works better than standard iminodiacetic acid or aminophosphonic type chelating resins under the following conditions:
Additional Information
The % recovery is generally defined as permeate flow rate / feed flow rate x 100%. Element recovery (%) = permeate flow rate of element / feed flow rate x 100% Stage recovery (%) = permeate flow rate of stage / feed flow rate x 100% Pass recovery (%) = permeate flow rate of pass / feed flow rate x 100% System recovery (%) = permeate flow rate of system / feed flow rate x 100%
The following table indicates the weight of new dry elements and drained wet tested reverse osmosis elements:
Product Family (Planned Product) | ELEMENT TYPE | Fiberglassed OR Fullfit? | DRY/WET | Memb sq ft | NET WEIGHT (LB) | GROSS WEIGHT (LB) | NET WEIGHT (KG) | GROSS WEIGHT (KG) | |
All 8' | 8040 | FG & FF | WET | 235 - 310 | 28.0 | 35.0 | 12.7 | 15.9 | |
8040 | FG & FF | WET | 320 - 370 | 33.0 | 40.0 |
There are a number of different ion exchange regeneration technologies that can be used, from the basic co-current regenerated systems to counter-flow block systems and through to packed bed technology.
Selection of regeneration system:
Counter-Current Regeneration Systems (Blocked Systems or Packed Bed Systems)
Co-Current Regeneration Systems
Counter-Current Regeneration Systems: in these systems, the regenerant is applied in the opposite direction to the service flow, resulting in reduced chemical consumption, improved water quality and less waste volumes compared to traditional co-current regenerated systems. Counter-current regeneration systems should provide a water quality of better than 2 µS/cm (0.5 MW.cm) and residual silica of 0.020 to 0.050 mg/l as SiO2. Depending upon water composition and regeneration conditions, the specific conductivity could be as low as 0.2 µS/cm (5 MW.cm). The normal counter-current endpoint is 4 µS/cm conductivity. A maximum endpoint value of 0.3 mg/l SiO2 above the average leakage should not be exceeded in order to avoid a high contamination of the polishing resin layer and unacceptably high silica leakage during subsequent cycles. Silica leakage can be minimized by operating the plant at silica break rather than conductivity end point. This secures the lowest silica leakage, but at the expense of a 5 -10 % throughput reduction.
There are two main types of counter-current systems:
Co-Current Regeneration Systems: these are the simplest systems, where the resin is regenerated in the same direction as the service flow (downwards). The vessel has a large freeboard to allow expansion of the resin bed when backwashing is carried out to remove suspended solids and resin fines. Co-current regeneration single bed systems will generally produce water of much lower quality than counter-current systems, with typical leakage values ~10 times higher. Such quality will also be even more affected by the water composition, the type of regenerant chemical and dosage being used.
Additional Information
The recommended cleaning sequence for FilmTec™ reverse osmosis (RO) membranes is alkaline cleaning followed by acid cleaning. RO permeate or deionized water should be used for the preparation of the cleaning solution and for flushing out the cleaning solution after each cleaning step.
Element fouling typically consists of a combination of foulants and scalants, for example a mixture of organic fouling, colloidal fouling, biofouling, inorganic and metal scaling. Very often, the cleaning sequence “acid cleaning followed by an alkaline cleaning” is applied. This cleaning sequence has many limitations because the acid cleaner reacts with silica, organics (such as humic acid) and biofilm present on the membrane surface, causing a further decline of the membrane element performance.
Sometimes, an alkaline cleaning may restore the decline caused by the acid cleaning but often an extreme cleaning will be necessary. An extreme cleaning is carried out at pH and temperature conditions that are outside the membrane manufacturer’s guidelines, or by using cleaning chemicals that are not compatible with the membrane elements. An extreme cleaning is carried out only as a last resort as it can cause irreversible membrane damage.
The acid cleaning is performed only when the alkaline cleaning has effectively removed the organic fouling, colloidal fouling and biofouling. The acid cleaning is effective in removing calcium carbonate scale from the membrane surface. Typically, calcium carbonate scale is located in the last stage of the system. The acid cleaning is then only applied on the last stage
Cleaning Tips (29KB PDF)
Additional Information:
Cleaning Procedures for FilmTecTM FT30 Membranes (146KB PDF)
The fine mesh acid resins can be regenerated with a mineral acid hydrochloric acid (HCl) or sulfuric acid (H2SO4). An excess of acid is needed to regenerate the resin, around 4 to 10 bed volumes of 10% H2SO4 or 5% HCl that is run through the column at a slow flow rate of at least 30-45 minutes. The resin should then be rinsed with multiple bed volumes of water, 10-20, or until the pH of the eluent is acceptable for the next steps of processing.
The fine mesh base resins are regenerated using an excess of base. First load the resin into a column and convert the resin to the OH- form by washing it with 5 to 10 bed volumes of 1 to 2 M NaOH. Be sure to wash the resin with base slowly so that a minimum of 1 hour contact time is achieved. Next wash the resin with DI water until the pH is near neutral or at an acceptable level.
Additional Information:
Equilibrium Isotherm Testing (23KB PDF)
Microorganisms entering a RO/NF system find a large membrane surface where dissolved nutrients from the water are enriched due to concentration polarization, thus creating an ideal environment for the formation of a biofilm. Biological fouling of the membranes may seriously affect the performance of the RO system. The symptoms are an increase in the differential pressure from feed to concentrate, finally leading to telescoping and mechanical damage of the membrane elements, and a decline in membrane flux. Sometimes, biofouling develops even on the permeate side, thus contaminating the product water.
A biofilm is difficult to remove because it protects its microorganisms against the action of shear forces and biocidal chemicals. In addition, if not completely removed, remaining parts of a biofilm lead to a rapid regrowth. Biological fouling prevention is therefore a major objective of the pretreatment process.
Please see the following links for additional details.
Polymerization is generally the greatest concern during shipment and storage of DVB. Under certain conditions (i.e., increased heat, low inhibitor concentration, and low oxygen content), rapid, runaway polymerization may occur with potentially serious consequences such as excessive heat and pressure buildup.
TBC (4-tert-butylcatechol) is added to DVB to inhibit polymer formation and oxidative degradation. When sufficient oxygen is present, TBC prevents polymerization by reacting with oxidation products (monomer peroxy-free radicals) in the monomer. In the absence of oxygen, however, polymerization will proceed as if no inhibitor were present.
Maintaining the shelf life of DVB involves 4 major precautions:
1. Maintaining the inhibitor level above a minimum concentration.
2. Maintaining the oxygen content of the monomer.
3. Storage at proper temperatures.
4. Using recommended materials of construction for storage and handling equipment.
Maintaining Inhibitor Level
During storage, the inhibitor level of DVB must be checked at regular intervals (following table) and inhibitor added as required to maintain the TBC concentration above minimum levels. The minimum TBC concentrations or “danger levels” are given in the following table.
Minimum Inhibitor Levels of DVB
TBC Concentration as Shipped | Minimum TBC Concentration |
900 –1,100 ppm | 400 – 600 ppm |
Suggested Storage Maintenance Schedule
Check Point | DVB |
Inhibitor Analysis | Monthly (Weekly above 80°F, 27°C) |
Polymer Analysis | Monthly (Weekly above 80°F, 27°C) |
Color | Monthly |
Monomer Temperature | Daily |
Inspection Points:
|
At least quarterly |
Date of Last Filling | Running log |
Volume Before Filling | Running log |
Volume After Filling | Running log |
TBC Loss in Stored Monomer
The time required for TBC concentration to fall to a dangerously low level varies greatly for different storage conditions. The following figure shows typical depletion rates in styrenic monomers at room temperature under laboratory conditions. Actual depletion rates may be much faster or slower depending on environmental conditions.
Adding TBC to Stored Monomer
The relatively small quantities of TBC required to raise the inhibitor level in stored monomer can be easily added by using a five or ten percent stock solution of TBC in the monomer. The storage tank (or drum) should always be recirculated (or mixed) after inhibitor is added. The tank or drum should also be aerated as necessary.
A concentrated stock solution of TBC in DVB can be prepared by dissolving 704 grams of pure TBC in 1 gal. of the monomer (186 grams/liter). At this concentration, 1 cc of the concentrate will raise the level of inhibitor 1 ppm in a drum of DVB with a net weight of 410 lbs (186 kg).
Adding TBC to Polymerizing Monomer
If the inhibitor has been depleted and polymerization has already begun, TBC should be added immediately and The Dow Chemical Company or its representative notified as soon as possible (Call Dow’s Distribution Emergency Response System phone number listed on the back cover of this manual). If unstable monomer is not treated promptly, it may become unsalvageable and may also cause excessive heat and pressure build-up. Do not add solid TBC to polymerizing monomer. Use a five or ten percent stock solution of TBC in the monomer or other compatible hydrocarbons, such as ethylbenzene or toluene. Anyone storing or handling quantities of these monomers should keep stock TBC solutions on hand for emergencies. Refer to the TBC MSDS for handling precautions.
Maintaining Oxygen Content
TBC is an effective inhibitor only when dissolved oxygen levels in the monomer are adequate. If the oxygen level is allowed to drop below the minimum shown in the following table, rapid polymerization can occur with potentially hazardous results. An effective test to determine whether polymer is forming in the monomer is ASTM Method D-2121. This test, used in conjunction with the test for TBC level, provides a quick means of monitoring monomer condition on site.
Minimum Oxygen Content in Stored Monomer
Monomer | Oxygen Content as Shipped | Minimum Oxygen Content |
DVB | 28 – 30 ppm (saturated) | 10 –15 ppm |
The Importance of Storage Temperature
Other factors that affect the depletion of TBC are heat, caustic soda, and exposure to alumina and ion exchange beads. Temperature in the monomer storage area should not be allowed to exceed 80°F (27°C) for DVB. In hot climates or during hot seasons where temperatures exceed these limits, the monomer bulk storage installation (or stored drums) should be refrigerated.
Drums of monomer should not be kept in the sun. As soon as monomer is received, it should be placed in a cool, shaded area. In very hot weather, drums can be temporarily cooled with water spray. It is advisable to keep monomer inventories to a minimum during hot weather, and to use drums in the order they are received so that monomer is not stored any longer than necessary.
Recommended Shelf Life
The following table gives the approximate shelf life of DVB under maximum ambient storage temperatures, assuming TBC and dissolved oxygen concentrations are maintained above the minimum levels. Refrigerated storage will significantly extend the shelf life of DVB.
The shelf life of stored DVB can also be extended with timely aeration. A 5–10 minute air sparge is recommended on a monthly basis for drums and pails stored at temperatures between 70–80°F (21-27°C). DVB containers stored at temperatures from 40–70°F (4-21°C) need to be aerated according to the following table. With aeration and maintenance of p-tert butylcatechol (TBC) level above 400–600 ppm the clock is effectively resent to the recommended storage times.
Recommended Shelf Life of DVB (All Grades)
Storage Temperature | Storage Time | Aerate Within | |
<40°F | <4°C | 12 months | 6 months |
40–50°F | 4°-10°C | 8 months | 6 months |
50–60°F | 10-16°C | 4 months | 4 months |
60–70°F | 16-21°C | 2 months | 2 months |
70–80°F | 21-27°C | 1 month | 1 month |
The typical reason for low (<7.0) pH product water after demineralization plant is that organic molecules containing weak acid groups are not retained by the ion exchange resins. For example, weak organic acids pass through the demineralizing line and appear in the product water with the result that they slightly reduce the pH of the product water.
Another fairly common reason is that the pH measurement is done offline and a certain amount of time goes by until the water sample is measured. Since demineralized water readily absorbs carbon dioxide from the air, after a few minutes the pH usually drops below 6 and then quickly below 5 and eventually reaches the pH (4.2) of the saturated carbon dioxide (carbonic acid) solution in water.
Additional Information:
Troubleshooting Ion Exchange Resins
Initially, we recommend that you consult your original equipment manufacturer (OEM) and discuss your performance problem since they are most familiar with your system. However, the following can help you troubleshoot and solve your problem.
Ion Exchange Troubleshooting Guide
Common problems encountered by a water treatment plant user include:
Any one or a combination of the following may be the cause:
From our experience, the majority of troubleshooting cases are related to mechanical, equipment, or operational failures. It is therefore recommended to take a wide view of the whole plant operation (including the pretreatment) when troubleshooting.
If you do not know the cause of your problem, you may want to have us run an analysis to help identify the cause and direct your efforts to optimize system performance. Analysis of ion exchange resins that have been used in service is available from DuPont under the System Optimization Services (SOS) program for a nominal fee.
Additional Information:
It is recommended that there is:
Recommendations for regeneration:
Additional Information:
Preventing Silica Fouling of Weak Base Anion Resins (19KB PDF)
Understanding Silica Removal by Ion Exchange (20KB PDF)
FilmTec™ Hypershell™ Reverse Osmosis elements can be shipped wet in a storage solution containing 1% by weight sodium bisulfate.
Hypershell™ nanofiltration elements can be maintained in a buffered storage solution.
Hypershell™ elements can be shipped dry. Dry elements have no bisulfate solution.
Additional Information:
As the feed water pressure increases, the permeate flow will increase and salt rejection also increases, although the relationship is less direct than for permeate flow rate.
Improved salt rejection occurs at higher pressures because RO membranes, as imperfect barriers to dissolved salts, will always have some salt passage through the membrane. As feedwater pressure is increased, this salt passage is increasingly overcome as water is pushed through the membrane at a faster rate than salt can be transported.
However, there is an upper limit to the amount of salt that can be excluded via increasing feedwater pressure. A plateau in salt rejection will occur above a certain pressure level, where some salt flow remains coupled with water flowing through the membrane.
Additional Information:
Factors Affecting RO Membrane Performance (65KB PDF)
Step 1: Consider feed source, feed quality, feed/product flow, and required product quality
The membrane system design depends on the available feed water and the application. Please see the attachment, below, which lists the necessary information to collect regarding system design and the feed water analysis.
Step 2: Select the flow configuration and number of passes
The standard flow configuration for water desalination is plug flow, where the feed volume is passed once through the system. Concentrate recirculation is common to smaller systems used in commercial applications, as well as in larger systems when the number of elements is too small to achieve a sufficiently high system recovery with plug flow. Concentrate recirculation systems can also be found in special applications like process liquids and wastewaters. (see Plug Flow vs Concentrate Recirculation)
An RO system is usually designed for continuous operation and the operating conditions of every membrane element in the plant are constant with time. In certain applications, however, a batch operation mode is used, e.g., in treating wastewater or industrial process solutions, when relatively small volumes (batches) of feed water are discharged non-continuously. The feed water is collected in a tank and then periodically treated. A modification of the batch mode is the semi-batch mode, where the feed tank is refilled with feed water during operation. (See also Batch vs. Continuous Process)
A Permeate Staged (double pass) system is the combination of two conventional RO systems where permeate of the first system (first pass) becomes the feed for the second system (second pass). Both RO systems may be of the single-stage or multi-stage type, either with plug flow or with concentrate recirculation. The production of water for pharmaceutical and medical use are typical applications of permeate staged systems. As an alternative to a second pass, ion exchange may also be considered.
Step 3: Select membrane element type
Elements are selected according to feed water salinity, feed water fouling tendency, required rejection and energy requirements. The standard element size for systems greater than 10 gpm (2.3 m3/hr) is 8-inch in diameter and 40-inch long. Smaller elements are available for smaller systems.
The characteristics of FilmTec™ elements and their use in specific applications are described in Element Characteristics. Please also see the elements recommended for a range of applications.
For high quality water applications where very low product salinity is required, ion exchange resins are frequently used to polish RO permeate.
Yes, however there are some extra steps to deal with the additional security requirements. If you get the error message "Run Cancelled, See Log File" or you receive an error about not being able to save into the target folder, this is most likely the case. Please follow these instructions, choosing the option that best meets your needs:
Note: Alternatively, you can choose to install ROSA in C:/Users/Public and pin ROSA.exe to the start menu and/or task bar.
Our dry acid catalysts include
AmberLyst™ 15 DRY Catalyst
AmberLyst™ 35 DRY Catalyst
AmberLyst™ 36 DRY Catalyst
They are sold dry (<3% moisture) and are ready-to-use for many customers. They are very hygroscopic so it is always a good idea to test to verify that they are still dry. This can be done with a simple moisture balance or Karl Fischer titration.
If your reaction is very sensitive to moisture the catalysts may be further dried before use by washing it with a dry water miscible solvent (alcohol or ketone) or by purge with hot nitrogen gas at temperatures up to 120°C.
These catalysts can be used in both batch and packed bed reactions. It is often a good idea to first solvate or swell the catalyst with the solvent or reactant that best swells the catalyst. This is usually the component with the most protic or polar nature and is determined by simply measuring the volume change of the catalyst in the different solvents.
Additional Information:
Your choice will depend on a number of factors.
Ion exchange resins are durable products. When operated according to manufacturer's recommendations, they can last for many years, without seeing much volume loss.
Sometimes resin is lost due to improper backwash flow rates or leaks in vessel or distribution system. In this instance, it is probably fine to top off the bed, after fixing the problem.
If, however, the resins had been exposed to oxidative or high temperature conditions or severe mechanical or osmotic stresses, their capacity may be decreased to an extent where you may be better off replacing the whole bed.
In general, there are different policies regarding whether to top-up or do a complete re-bed. The following or a combination of the following are common scenarios.
After installation click the Start button. Once the WAVE Home page appears, the user can:
Define a system design from scratch
Open and edit an existing design
This will open up the splash screen, which will be followed by the home page.
Generally, all oxidizing agents can harm the membrane and must be removed by methods described in Chlorination / Dechlorination (PDF).
Please see the following link for additional details.
Prevention of Membrane Degradation (23KBPDF)
Ion exchange resins should be buried in a licensed landfill or burned in an approved incinerator according to local, state, and country regulations.
For resin contaminated with hazardous material, dispose of the mixture as hazardous material according to all local, state and country regulations. Refer to the Material Safety Data Sheets for additional information. SDS Finder
DuPont will not take used resin back for disposal.
Additional Information
Safety Data Sheets (SDSs) are available for ultrafiltration (UF) modules at SDS Finder. e.g. by looking up the product name:
New customers or existing customers who buy a module the first time will automatically receive an SDS. The SDSs are only for the solutions used in the wet modules that are necessary during storage and shipment; Pursuant to 29 CFR 1910.1200 (OSHA Hazard Communication Standard) modules and as-sold components themselves are not hazardous chemicals. Based on the evaluation made by our company, these products have been classified as "articles" and are not subject to the requirements for a material safety data sheet.
We provide health, safety and environmental information for covered hazardous chemicals through SDSs as well as product labels. These documents are required by law in many countries in which we does business. The SDS summarizes the physical and chemical properties of the hazardous chemical. It also contains useful information such as flash point, toxicity, procedures for spills and leaks, and storage guidelines to help you understand the potential health and physical hazards of a chemical and how to respond effectively to exposure situations. The information provided in the SDS also helps to determine the safe transport conditions of chemicals and the measures to take to protect the environment.
We are providing this information in good faith and as may be required by law. We assumes no obligation or liability for use of or updating this information and makes no warranty, express or implied. The customer is solely responsible for evaluation of the information, determining the suitability and use of the products, and taking any other action as needed to ensure compliance with applicable laws and other government enactments.
* Under OSHA
"Article" means a manufactured item other than a fluid or particle: (i) which is formed to a specific shape or design during manufacture; (ii) which has end use function(s) dependent in whole or in part upon its shape or design during end use; and (iii) which under normal conditions of use does not release more than very small quantities, e.g., minute or trace amounts of a hazardous chemical (as determined under paragraph (d) of this section), and does not pose a physical hazard or health risk to employees.
Anion exchange resins, especially strong base anion exchange resins in the hydroxide form, may emit odors such as a dead fish smell. The main cause is release of very low levels of amines from the resin (trimethylamine for type I strong base resins). The amines are released due to slight de-amination of the resin by the Hofmann's reaction. This is the primary degradation mechanism for anion exchange resins. Higher temperature will accelerate the rate of resin de-amination, as will allowing the resin to dehydrate (become dry). Amines, such as trimethylamine, have a very low odor threshold (5 ppb) and will be smelled at levels well below the hazardous limits established by regulatory agencies. Trimethylamine is also released by decomposing fish, hence the association of the resin odor with a dead fish.
During regeneration of the anion resin with sodium hydroxide an amine smell may be noticed. To avoid nuisance by the smell, it may therefore be necessary to operate in a well ventilated room. Upon insufficient ventilation (for 8-Hour time weighted average of more > 4.9 mg/m3 trimethylamine) it is recommended to use respiratory protection.
If desired, the amines can be quickly rinsed from the resin using deionized water before placing the resin into service. The total exchange capacity and salt splitting capacity of the anion exchange resin should not be measurably changed by the slight levels of de-amination that occur under normal storage conditions.
Proper installation of membranes is important. Useful information regarding installation is provided below:
Loading of Pressure Vessels
Preparation and Element Loading (41KB PDF)
Shimming Elements (37KB PDF)
Element Removal (25KB PDF)
Interconnector Technology for 8-inch Diameter FilmTec Membranes (104KB PDF)
Installing an Element Spacer (33KB PDF)
Effective cleaning and regular, routine maintenance of ion exchange resins can mean the difference between costly shut-downs and delays and an efficient resin system. Our ion exchange experts have compiled the following materials as a guide to cleaning and maintaining your system.
It is recommended to clean the resin when the amount of water produced is reduced by about 20% (based on the same feed water TDS and quality) or if the product water silica leakage or conductivity doubled. If rinse water volume is higher than 1.5 times the value for new resins, fouling or cross contamination can be the reason and a cleaning should be initiated to avoid irreversible blocking and heavy fouling of the resin. Ion Exchange Resins - Troubleshooting will help you determine what types of foulants you have.
Resin clean-up procedures for fouled resins:
Additional Information:
Procedure for Removing Iron from Anion Resins (10KB PDF)
Procedure for Removing Iron from Cation Resins (25KB PDF)
Procedure for Brine Cleaning of Anion Resins (26KB PDF)
Procedure for Calcium Contamination of a Cation Resin (9KB PDF)
Procedure for Calcium Contamination of an Anion Resin (10KB PDF)
Procedure for Treating Polyelectrolyte Contamination of a Cation Resin by Caustic Cleaning (10KB PDF)
Treating Oil Contaminated Ion Exchange Resins with an Industrial Acid Surfactant (39KB PDF)
Click here if you have further questions: Submit a question.
The process operating parameters for the cleaning steps are provided in the table below.
Backwash Frequency | Once every 20 to 60 minutes (water source or pilot test results) |
|
Backwash Duration | 40 to 120 seconds | |
Backwash Flux | 100 to 150 l/m2∙h (60 - 90 gfd) | |
Air Scour | Maximum Inlet Pressure | 2.5 bar (36 psi) |
Air Flow per Module | 5 to 12 Nm3/h (3 - 7 scfm) | |
DurationAir-Water Mix Entrance Pressure | 20 to 60 seconds per cycle | |
≤ 1.0 bar (14 psi) | ||
Air Quality | Non-oil compressed air | |
Chemically Enhanced Backwash |
Frequency | As needed |
Duration | Backwash Time plus soak 5 to 20 minutes | |
Cleaning Solutions | 0.1 % HCl, 2% Citric, 2% Oxalic 0.1% NaOCl, 0.05% NaOH |
|
Clean In Place | Frequency | When TMP exceeds 1.0 bar above starting TMP (at same temperature) |
Duration | 120 minutes (recycle and soak) or longer | |
Cleaning Solutions | 0.2% HCl, 0.2% H2SO4, 2% Citric, 2% Oxalic 0.1%NaOH +0.2% NaOCl |
|
Cleaning Flux per Module | 1.0 – 1.5 m3/h (6.6 - 8.8 gpm) | |
Temperature Range | 10 to 40 °C (34 - 104 º) |
Fouling
There are four types of fouling common to UF operations including particulate, biological, inorganic, and organic.
Particulate fouling is caused by suspended solids, colloids, and turbidity that can be reduced by coagulation, sedimentation, clarification, and media filtration. The common cleaning method for particulate fouling is air scour and backwash.
Biological fouling is caused by the growth of microorganisms that can be reduced by using in-line chemical feed of chlorine or biocide or by elimination of nutrients by using PAC, GAC, or coagulation. The common cleaning method for removal of biological fouling is Chemically Enhanced Backwash (CEB) with oxidizers or biocides (Cl2, H2O2, SBS).
Inorganic fouling is caused by the precipitation of inorganics on the membrane that can be reduced by using oxidation/precipitation and filtration as pretreatment to the UF or in some cases using low hardness water for the alkali chemically enhanced backwash. The common cleaning method for removal of inorganic fouling is chemically enhanced backwash with acid at pH 2 (HCl, H2SO4, Citric, Oxalic Acid).
Organic fouling is caused by organics adsorbing on the membrane (silt, organic acids, humus) that can be reduced by using PAC, GAC, or coagulation. The common cleaning method for removal of organic fouling is CEB with alkali at pH 12 (NaOH).
The apparent or packaging or bulk density of an ion exchange resin is measured using the ASTM test procedure D2187-94, "Standard Test Methods for Physical and Chemical Properties of Particulate Ion Exchange Resins, Method C", American Society for Testing and Materials, West Conshohocken, PA.
This method is sometimes referred to as the backwash, settle and drain method for measuring the density of ion exchange resins. The true density can be measured using the following procedure:
True Resin Density (g/ml) = (W(f) - W(i)) / (100.0 - V(i))
A more accurate value can be obtained using a picnometer.
Additional Information
Ion Exchange Resin Void Volume (the space that exists between resin beads; calculated using the following equation:
Void Volume (%) = 100 * (1 - (Apparent Density / True Density))
Because our UF is an Outside-In configuration, its fibers are strong enough to withstand air scouring. In fact, our UF modules incorporate air scouring as part of the unique cleaning regime. The air scouring, with minimum pressure as low as 0.35 bar (5.15 psi) for a low power consumption, provides vibration and scrubbing mechanisms to allow a better clean of the hollow fibers. Our UF air scouring feature is advantageous in turbid and challenging water applications.
Though recommended, it is not mandatory to put on the air scouring step in cleaning. In clean water (RO permeate or clean polishing) application, UF would not need air scouring, thus lowering the overall power consumption and enhance recovery. Nonetheless, the power consumption for the 20-40 seconds of air scouring is low, and the use of existing compressors or blowers on site can minimize any CAPEX addition.
Air scouring is an effective addition to the UF cleaning process. It reduces the amount of water and chemicals needed to recover the membranes, and it is a process unique to Outside-In flow membrane only.
Additional Information
The propensity for scale formation will depend on the a variety of factors, including the solubility product of each salt (Ksp) the ion product (IP) of each salt ionic strength of the solution (or total dissolved solids) the temperature of the solution the pH of the solution. The Ksp expression describes the concentration of a combination of ions in a saturated solution at a specific temperature, especially salts with low solubilities, such as CaSO4.
The solubility of CaSO4 at 25ºC is described by the following reaction and equilibrium
CaSO4(s) <--> Ca2+(aq) + SO42- (aq)
Ksp = [Ca2+][SO42- ] = 4.93 × 10-5
where [Ca2+] and [SO42-] represent the concentrations of calcium and hydroxide ions at saturation.
This equilibrium expression states that the product of the calcium and sulfate ion concentrations, [Ca2+]* [SO42-], must always be less than or equal to the Ksp (4.93 × 10-5) in any aqueous solution. If additional Ca2+ or SO42- is added to a saturated CaSO4 solution, the equilibrium will shift to the left to form solid CaSO4, and the value of the product of the Ca ion concentration and the SO4 ion concentration would be restored to 4.93∙10-5.
This is important in ion exchange because precipitation onto ion exchange resin can occur when the exhausted cation resin, that is loaded with magnesium, calcium, and barium, and strontium ions, comes into contact with an initial concentration of sulfuric acid that is high enough in concentration to form sparingly soluble salts such as MgSO4, CaSO4, and BaSO4, and SrSO4.
To minimize the probability of precipitation when using sulfuric acid as a regenerant it is important to utilize a step-wise regeneration procedure particularly in locations with high hardness water.
Regenerating Strong Acid Cation Resins with Sulfuric Acid (19KB PDF)
In reverse osmosis scaling can occur when sparingly soluble salts are concentrated within the element beyond their solubility limit. FilmTec Membranes: Water Chemistry and Pretreatment: Scale Control
Solubility products of sparingly soluble inorganic compounds are listed in the table below.
Table of solubility products of sparingly soluble inorganic compounds
Substance | Formula | Temp °C | Solubility product | Negative log Ksp |
|
Aluminum hydroxide | Al(OH)3 | 25 | 3 × 10-34 | 33.5 | |
Aluminum phosphate | AlPO4 | 25 | 9.84 × 10-21 | 20 | |
Barium carbonate | BaCO3 | 25 | 2.58 × 10-9 | 8.6 | |
Barium sulfate | BaSO4 | 25 | 1.1 × 10-10 | 10 | |
Calcium carbonate | CaCO3 | 25 | Calcite: 3.36 × 10-9 |
8.5 |
|
Calcium fluoride | CaF2 | 25 | 3.45 × 10-11 | 10.5 | |
Calcium phosphate | Ca3(PO4)2 | 25 | 2.07 × 10-33 | 32.7 | |
Calcium sulfate | CaSO4 | 25 | 4.93 × 10-5 | 4.3 | |
Iron(II) hydroxide | Fe(OH)2 | 25 | 4.87 × 10-17 | 16.3 | |
Iron(II) sulfide | FeS | 25 | 8 × 10-19 | 18.1 | |
Iron(III) hydroxide | Fe(OH)3 | 25 | 2.79 × 10-39 | 38.6 | |
Iron(III) phosphate dihydrate | FePO4•2H2O | 25 | 9.91 × 10-16 | 15 | |
Lead carbonate | PbCO3 | 25 | 7.4 × 10-14 | 13.1 | |
Lead fluoride | PbF2 | 25 | 3.3 × 10-8 | 7.5 | |
Lead sulfate | PbSO4 | 25 | 2.53 × 10-8 | 7.6 | |
Magnesium ammonium phosphate | MgNH4PO4 | 25 | 2.5 × 10-13 | 12.6 | |
Magnesium carbonate | MgCO3 | 12 |
2.6 × 10-5 |
4.58 |
|
Magnesium fluoride | MgF2 | 18 |
7.1 × 10-9 5.16 × 10-11 |
8.15 10.3 |
|
Magnesium hydroxide | Mg(OH)2 | 18 25 |
1.2 × 10-11 5.61 × 10-12 |
10.9 11.25 |
|
Magnesium phosphate | Mg3(PO4)2 | 25 | 1.04 × 10-24 | 24 | |
Manganese hydroxide | Mn(OH)2 | 18 25 |
4.0 × 10-14 2 × 10-13 |
13.4 12.7 |
|
Strontium carbonate | SrCO3 | 25 | 5.6 × 10-10 | 9.25 | |
Strontium sulfate | SrSO4 | 17.4 | 3.8 × 10-7 | 6.42 | |
Zinc carbonate | ZnCO3 | 25 | 1.46 × 10-10 | 9.84 |
There is a variety of commercially available anti-scalants with proven long-term performance and chemical compatibility. Most anti-scalants are based on polyelectrolytes. Sodium Hexametaphosphate is still used in some locations. For your specific needs please contact your anti-scalant supplier.
Additional Information:
Testing Chemical Compatibilities with FilmTecTM Membranes (29KB PDF)
FilmTec Membranes - Scale Control by Use of Scale Inhibitors
Ion exchange resins are crosslinked ionic polymers that normally contain 40% to 70% water within the resin beads due to hydration of the exchange sites. The 'wet' state of ion exchange resins means that the resin contains enough water inside the resin beads to reach the fully hydrated state of the resin, without having excess water between the resin beads. It is not necessary to immerse the resin in excess water during storage. Storage conditions should be chosen to minimize the loss of the moisture from the resin during storage.
Additional Information:
Proper Storage Conditions for Ion Exchange Resins (12KB PDF)
Used FilmTec elements can be disposed of as municipal waste, provided:
Disposal of Used FilmTec Elements (31KBPDF)
Adsorbents used for liquid applications can be rinsed and cleaned by a wide range of chemicals and chemistries. You will need to consider:
Do you have any selective solubility data on the adsorbed impurities?
If no data is available, one simple test is to take some of the impurity to dryness and see what solvents can re-disolve the component back into solution. These resins can handle most salts, acids, bases and organics as long as you stay away from oxidizing agents.
Some compounds are readily removed with steam. A typical usage rate would be 3 to 5 lbs of steam per lbs of adsorbed component introduced in a down flow manor.
Vapor phase operations typically use heat and/or vacuum to regenerate adsorbent resins. The heat can be introduced as hot air or nitrogen gas, or conductively via a heat exchanger or microwave energy, assisted with a vacuum. Maximum temperatures of 120 to 130°C are effective for regeneration. Polymeric adsorbents are plastic polymers so a discussion with knowledgeable experts is recommended.
Many FilmTecTM reverse osmosis membranes are available either wet or dry. Dry elements have lower shipping weight, longer shelf life, and easier inventory procedures with no preservative solution to monitor. Wet elements typically achieve stabilized performance up to 48 hours after start-up where dry elements may take up to 72 hours to fully stabilize. In all cases the time for the membranes to stabilize is a function of the operating conditions.
In cases where accelerated stabilization of dry elements is desired, a pretreatment technique can be used to ensure stabilized performance is achieved quickly. This technique is not a requirement but can accelerate start-up performance when time and circumstances permit. Once the elements are loaded into the pressure vessels, the three-step accelerated stabilization technique involves pre-flushing, soaking the elements in sodium metabisulfite solution for 10-14 days, and post-flushing.
A complete procedure can be found in the link, Membrane Start-Up Performance and Stabilization.
The following strong base anion resins are recommended for treating water that contains naturally occurring organic matter, such as humic and fulvic acids, according to the following guidelines:
Low fouling (TOC <2% total anions) | AmberLite™ HPR4800 Cl or AmberLite™ HPR4800 OH Resin |
Moderate fouling (TOC = 2-5% total anions) | AmberLite™ HPR4811 Cl Resin AmberLite™ HPR4580 Cl Resin |
High Fouling (TOC >5% total anions) | Layered Bed (WBA/SBA) |
Layered beds are also effective at handling natural organics. Weak base anion resins, such as AmberLite™ HPR9500 or AmberLite™ HPR4580 Cl, should be used to protect the SBA resin from fouling in the layered bed. Other options for removing natural organics include pretreatment such as UF, coagulation filtration, or organic traps.
AmberLite™ SCAV3 Cl, AmberLite™ SCAV4 Cl, and AmberLite™ HPR4811 Cl Resin regenerated with NaCl, can be used as organic traps ahead of the other resin beds which increases the efficiency of the demineralization system.
The recommended operating conditions are given in the product data sheets.
These resins, regenerated with NaCl, can also be used as organic traps ahead of the other resin beds. Resin selection depends on organic concentration, type, and molecular weight.
Using a degasser to remove CO2 reduces the ionic load on the strong base anion resin, and the consumption of caustic soda is thus lower.
Note that the solubility of CO2 in pure water is high: about 1.5 g/L or more than 30 meq/L at 25°C and atmospheric pressure (see graph). .
The residual CO2 after an atmospheric degasifier is 0.12 to 0.25 mg/L (typically 10 mg/L as CO2). Therefore such degassers are used when the bicarbonate concentration plus free carbon dioxide in the feed water to separate column demineralisation systems is at least 0.6 to 0.8 meq/L (30 to 40 mg/L as CaCO3).
Generally the economical balance is not in favor of a degassifier for small plants (up to about 10 m3/h or 45 gpm).
For larger plants, if the total CO2 is greater than 50-100 mg/l (ppm), the pay-back time for a degassifier should be short.
Atmospheric degassifiers usually reduce residual CO2 down to 5 mg/l. In order to have a safety margin for design, a residual value of 10 mg/l CO2 is recommended.
For systems requiring very low levels of residual CO2, a vacuum degassifier is used. This reduces the CO2 to below 1 mg/L.
Additional Information
A loss in salt rejection may be uniform throughout the system or it could be limited to the front or to the tail end of the system. It could be a general plant failure or it could be limited to one or few individual vessels. Therefore, all individual vessel TDS values have to be checked.
Additional Information:
Troubleshooting Reverse Osmosis Systems
Probing Reverse Osmosis Systems (76KB PDF)
FilmTecTM Membranes Flow and Conductivity Accuracy (46KB PDF)
Our systems are built from standard components, so our life cycles are comparable to traditional systems.
Resin bed depths are usually in the range of 1.8-2.5 meters.
The minimum resin bed depth is dictated by water quality and operating capacity. A shallow bed (1m) will definitively have a lower operating capacity and probably a worse water quality than the more typically usual ones of 2 meters or more. Therefore bed depths of under 1.2 meters are not recommended and seldom found in industrial scale UPCORE™ plants. The correction factor for operating capacity versus resin bed depth is provided in the UPCORE System Engineering Handbook.
The maximum resin bed depth is directly linked to the pressure drop which the equipment can tolerate. The resin will typically not be the limiting factor to optimize the bed depth due to the high physical stability of UPCORE Mono grade resins used.
The largest bed depth in practice used in an UPCORE water treatment plant is, to date, 4 meters.
Packed Bed Ion Exchange Demineralization
We do not recommend the use of phosphoric acid for regenerating ion exchange resins.
Hydrochloric and sulfuric acids are much better choices.
Please also see Properties, Impurities, and Concentrations of Regenerent Chemicals (104KB PDF).
EDI Advantages:
No Leakage: Our EDI modules are reliably sealed with high pressure top and bottom end caps, eliminating leakage problems commonly associated with plate and frame EDI designs.
Quality Control: Each EDI module is performance and pressure tested prior to leaving our factory to ensure trouble free start-up and operation.
Low Maintenance: Unlike plate and frame EDI systems, our EDI modules do not require tightening of nuts and bolts at installation or the retorquing of bolts on an ongoing basis to prevent leaks.
Light Weight Modules, Modular, Easy Access Designs: Our EDI modules result in very modular systems that allow easy access and the light weight modules are easy to work with, no special lifting devices are required. Each module comes with complete with an individual permeate sample port.
Cost Effective: The spiral wound EDI modules allow system integrators to build systems that have both lower capital and operating costs when compared to plate and frame EDI devices.
Electrodeionization (EDI)
EDI-310 Electrodeionization Modules (PDF)
Closed circuit reverse osmosis (CCRO) is Desalitech’s improvement on the traditional reverse osmosis process. Compared to traditional systems, CCRO achieves much higher water recovery rates than traditional systems. Generally, our systems operate in the 90-95% range, but under certain circumstances have operated up to 98% recovery. Furthermore, CCRO is much more energy-efficient, resists scaling, fouling, and biological growth, and has unmatched flexibility.
Precipitation of BaSO4, SrSO4, and CaSO4 into a cation resin bed is a potential problem with H2SO4 regeneration. Removal of the calcium with HCl is only partially effective because the solubility of CaSO4 in this media is also relatively low.
A more effective treatment is to use a complexing agent for calcium removal:
For information on solubility products of common sparingly soluble inorganic compounds, please see: Scale Control Introduction (57KB PDF)
ISO 9000 certification does not apply to projection programs such as WAVE.
Additional Information:
DuPont Products - ISO Certification
WAVE Information
Chromatographic separation is a manufacturing process which uses ion exchange resins as a selective medium to separate one dissolved chemical from another. Industrial chromatographic separation is practiced at commodity scale in the petrochemical industry, the corn wet milling industry, the beet sugar (sucrose) industry, and in production of amino acids. Chromatographic separation is also practiced commercially at smaller scale in the production of therapeutic proteins and active pharmaceutical ingredients. Chromatographic separation with ion exchange resin as the packing is used primarily in the sugar industry and with compounds related to the sugar industry. The chromatographic separation is performed by the resin, which serves as the chromatographic 'packing' or 'stationary phase'. Some example compounds purified by chromatography are sucrose, glucose, fructose, oligosaccharides, raffinose, maltose, xylose, sugar alcohols, betaine, xylitol, sorbitol, and mannitol. In addition, this process has been used in purifying amino acids and various organic acids as well as to purify glycerine by separating salt from glycerine (also known as glycerol) .
The chromatographic separation can occur through various interaction mechanisms, including ligand-exchange chromatography (LEC), size exclusion chromatography (SEC), ion exclusion chromatography (IEC), and reverse phase adsorption chromatography (ADS). Irrespective of the particular mechanism, the engineering basics of the process are the same.
Most industrial chromatography today uses Simulated Moving Bed (SMB) technology. [An older term for SMB is Pseudo-Moving Bed Chromatography.] By utilizing SMB, solvent use and separation media are minimized, leading to a greatly reduced cost of operation when compared to traditional batch chromatography.
Chromatographic Separation of Fructose and Glucose Using Chromatographic Separation Resin (82KB PDF)
Preserved elements should be visually inspected for biological growth 12 months after shipment and thereafter every three months. If the preservation solution appears to be not clear the element should be removed from the bag, soaked in a fresh preservation solution and repacked. Refer to Used FilmTec Elements: Preservation and Storage for guidelines. In case no equipment for re-preservation (fresh solution, clean environment, bag sealing device) is available, the elements can be left in their original packaging for up to 18 months. When the elements are then loaded into the pressure vessels, they should be cleaned with an alkaline cleaner before the plant is started up.
Dry elements do not have an expiration date. For further details, refer to Storage and Shipping of New FilmTec Elements, Tech Fact Form No. 45-D01633 and FilmTec Elements - Warranty
Additional Information:
Storage and Shipping of New FilmTec™ Elements (22KB PDF)
Advanced AmberPack™ Municipal
Rohm and Haas Company designed the Advanced AmberPack system, a revolutionary pre-engineered system, designed specifically for those who require water of the highest quality both quickly and easily.
Advanced AmberPack combines the wealth of Rohm and Haas Company’s ion exchange knowledge and experience, the full capability of our specialty resins, and Amalgamated Research Inc.’s innovative fractal distribution technology, to produce a unique and powerful modular ion exchange system.
Advanced AmberPack Municipal marries the quality and strength of ion exchange with a superior distribution system in a fully automated, skid-mounted system that is easy to install and operate. The system design is such that it is the most water efficient process available today. This can save MILLIONS of gallons of water per year versus other systems. This combination of features saves time, water, and money.
At the end of the AmberPack system service cycle, the resin bed is allowed to settled. Resin regeneration and rinse is then carried out in a downflow direction, providing excellent conditions for optimal regeneration.
Advanced AmberPack™ Municipal is:
The AmberPack system is an upflow service, downflow counter-current regenerated packed bed ion exchange resin system with several hundred plants in over 35 countries around the world. The AmberPack system has a number of benefits:
The AmberPack countercurrent regeneration system uses upflow for the service cycle. At the end of the AmberPack system service cycle, the resin bed is allowed to settled. Resin regeneration and rinse is then carried out in a downflow direction, providing excellent conditions for optimal regeneration.
Additional Information:
We recommend the following:
Soluble iron (Fe2+): maximum allowable concentration = 4 ppm (at pH <6, oxygen <0.5 ppm) Low pH is favorable to retard Fe2+ oxidation.
Insoluble iron (Fe3+): maximum allowable concentration = 0.05 ppm
Pretreatment will be necessary to remove iron above these levels.
Additional Information:
Colloidal Fouling Prevention (32KB PDF)
Low flow in a system that has been in operation is most likely due to fouling or scaling.
Fouling with biogrowth can be verified by removing the element from its housing and smelling the ends. Biogrowth most often has an unpleasant odor.
To solve: Replace element and install or replace cartridge carbon filter.
Scaling can be easily detected in a home drinking water element by removing the element from its housing and squeezing it. If it makes a noise like it is full of sand, it is very likely scaled.
To solve: Replace element and have unit serviced to check the brine bleed setting.
If it's a newly started system, you might want to check your valves. Is the flow restrictor set at the correct point? Is the flow restrictor sized correctly? Is the net pressure (= feed pressure - osmotic pressure - tank pressure) greater than zero? Is a booster pump used (if needed)? Are there any valves that are erroneously turned off?
Additional Information:
Minimum Water Pressure to be used with Residential RO Systems
The pH has a minimal impact on the membrane itself, when operated under the FilmTec guidelines found on each product data sheet (typically 2 to 11). However, changes in pH can affect the ionic character of many dissolved species. For example, weak acids such as citric acid are present in a predominantly non-ionic state at low pH while present in ionic form at high pH. Since charged species are rejected to a greater extent than non-charged species of the same size, the pH can have a dramatic impact on the rejection of certain species.
Additional Information:
Factors Affecting RO Membrane Performance (65KB PDF)
CCRO systems use significantly less power than traditional reverse osmosis systems. In a traditional multi-stage reverse osmosis system, a single pump operates at a constant, predetermined pressure. It needs to provide enough pressure for the downstream stages, even though earlier stages need much less pressure to drive effective reverse osmosis. This wastes energy.
In a CCRO system, the variable-pressure pump only provides as much pressure as is needed for optimal recovery in a given cycle. Furthermore, because our single stages use fewer RO elements, in shorter pressure vessels than typical traditional reverse osmosis, our starting pressure is much lower.
Although DBNPA is non oxidizing, at a concentration of 0.5 ppm to 3 ppm, it does give an ORP response in the < 400mV range. For comparison, chlorine and bromine at concentrations of about 1 ppm will give a response in the > 700 mV range. The response will increase with increasing concentration of chlorine or bromine.
Additional Information:
DuPont Microbial Control
Sanitization of FilmTecTM Elements with DBNPA (23KB PDF) (for non-potable applications only)
Several references in the public domain suggest that the rejection of uranium by nanaofiltration will be better than 90%. We would suggest that a pilot study should be conducted to confirm the removal efficiency.
CCRO systems are constructed using standard off-the-shelf components along with industry leading FilmTec™ membranes. The CCRO design features a variable-speed pump, which recirculates 100% of the brine during closed-circuit (CC) mode. Generally, however, what sets CCRO systems apart is the innovative design, not the components.
Two ways are generally used to remove ion exchange resins from a vessel when the resins are replaced.
The preferred choice depends on the configuration of the equipment. Check with your vessel designer for a recommended resin removal procedure. In ALL cases, the vessel should be thoroughly rinsed with water and checked to make sure all the old resin is removed before adding new resin.
Additional Information:
Loading Procedure for Single Bed Ion Exchange Vessels, Tech Fact (PDF)
Loading Layered Bed Anion Resins PDF
Recommendations for Loading an Internally Regenerated Mixed Bed
Preparation of Chromatographic Separation Resin-Food Processing and Food Contact
DuPont adds TBC (4-tert-butylcatechol) to DVB to inhibit polymer formation and oxidative degradation during shipment and subsequent storage. If sufficient oxygen is present, TBC prevents polymerization by reacting with oxidation products (monomer peroxy-free radicals) in the monomer. However, in the absence of oxygen, polymerization will proceed at essentially the same rate as if no inhibitor were present.
TBC is highly recommended as a storage inhibitor for DVB. It imparts no color, but does require a minimum of 15 ppm oxygen in the monomer to make its inhibitory capability effective. DVB is shipped with a TBC level of 900–1,100 ppm. This level of inhibitor is normally effective in preventing incipient polymerization for 30 days at a maximum temperature of 80°F (27°C), assuming the critical O2 saturation of 28–30 ppm is maintained. If longer storage times are required, special precautions will be necessary.
To prevent runaway polymerization of stored monomer, the inhibitor level, the temperature of the storage facility, and the oxygen content of the monomer should be carefully monitored. Oxygen content is the critical factor in most situations.
The minimum recommended concentration for TBC in divinylbenzene is between 400–600 ppm. This level should be checked at regular intervals (see the following table for a suggested maintenance schedule). Additional inhibitor should be added as required to ensure maximum safety and storage stability.
Suggested Storage Maintenance Schedule for DVB
Checkpoint | Interval |
Inhibitor analysis | Monthly – Weekly if stored above 80°F (27°C) |
Polymer analysis | Monthly – Weekly if stored above 80°F (27°C) |
Color | Monthly |
Monomer temperature | Daily |
Storage Tank Polymer Inspection points for polymer:
|
|
Date of last filling | Running log |
Volume before filling | Running log |
Volume after filling | Running log |
Standard inhibition levels in DVB
The time required for TBC concentrations to fall to a dangerously low level varies greatly for different storage and handling conditions. Most importantly, if the inhibitor has been depleted and polymerization has already begun, TBC should be added immediately, and DuPont or its representative should be notified as soon as possible (call 1-989-636-4400). If unstable monomer is not treated promptly, it may become unsalvageable and may also cause serious consequences
Special cases where inhibitor removal is desired
In special cases, you may want to remove the inhibitor. This can be accomplished by running the DVB through a bed of alumina. Contact DuPont for further information and suggested cautions regarding this subject for your particular application.
Other factors affecting inhibitor level
Other factors that affect the depletion of TBC are heat, caustic, and exposure to alumina or ion exchange resin beads. In hot climates or where temperatures greater than 80°F (27°C) are normally encountered, the monomer bulk storage installation should be refrigerated.
In addition, drums of monomer should not be kept in the sun. As soon as monomer is received, drums should be placed in a cool, shaded area. In very hot weather, drums can be temporarily cooled by water spray. It is advisable to keep monomer inventories to a minimum during hot weather, and to use drums in the order they are received so that monomer is not stored any longer than necessary.
When the conductivity of a feed water is indicated, it needs to be converted to a TDS concentration in order to input it as PPM. For most waters, the ratio of conductivity (µS/cm) to salt content (TDS in ppm) is between roughly 1.2 and 1.7. For projecting with WAVE, the factors of 1.4 (seawater) and 1.3 (brackish water) usually give a good approximation.
Additional information
Conductivity of Solutions (95KB PDF)
Record Keeping (78KB PDF)
Factors for estimating TDS from conductivity (TDS = K x EC25)
Water |
EC251 (mS/m) |
K |
Permeate |
0.1 - 1 |
0.50 |
Seawater |
4,500 - 6,000 |
0.70 |
Concentrate |
6,500 - 8,500 |
0.75 |
The smooth side of the flat sheet should face the feedwater.
There is a wide variety of regenerants available that will work for anion regeneration. Sodium hydroxide, soda ash and ammonia are all well known in the industry and acceptable regenerants. Each of these regenerants has its own strengths and weaknesses. Sodium hydroxide tends to be the most expensive, provides longer rinse times as a resin age, but also provides a higher pH environment and therefore cleans the resin better prolonging resin life. Ammonia requires its own special handling requirements which makes it more complex in engineering and design. It provides low rinse times and low cost but does not provide as low of a pH as sodium hydroxide. Sodium carbonate or soda ash provides a combination of the benefits of the other two regenerants. While its costs are lower than sodium hydroxide it does not provide as much cleaning power to prevent fouling of anion resins.
Additional Information:
Ion Exchange Resins - Base Anion Resins - Regenerants
FilmTec offers a three-year prorated limited warranty.
Additional Information
FilmTecTM FT30 Reverse Osmosis Element Three-Year Prorated Limited Warranty (25KB PDF)
Many of our food grade and potable water grade resins are compliant and/or certified to Kosher requirements. Please click the link, Contact Us, to request additional information. Please also list the name of the product and the compliance or certification that is required.
The cation polisher is sized hydraulically and the regeneration frequency is based on calculated load to avoid overloading the bed with sodium. Counter-current regeneration is always preferred.
Other possible causes of a high pH:
Additional Information:
In ultrapure resin systems, it is not desirable to exhaust the resin or to introduce ionic species, such as peracetate, Na or hypochlorite. Three different methods that can be applied are:
Hydrogen peroxide is an effective treatment for sterilizing both cation and anion exchange resins. To ensure good disinfection without damage to the resins, it is important to control the concentration, temperature and contact time of the chemical. The recommended procedure is as follows:
Additional Information
Preventing Biological Growth on Ion Exchange Resins (55KB PDF)
Ultrapure water (UPW) is generally considered to be >18.2 MΩ-cm resistivity at 25ºC, low ppt in metals, less than 50 ppt in inorganic anions and ammonia, less than 0.2 ppb in organic anions, and below 1 ppb total organic carbon (TOC) and silica (dissolved and colloidal). Particle levels are reduced using the best available ultrafiltration technology. Bacteria are present, on surfaces and to a lesser degree in the bulk fluid, and controlled to very low levels, typically
A single water treatment process cannot effectively deliver the high-purity water required for ultrapure water applications - optimum water treatment solutions utilize reverse osmosis, ion exchange and other technologies. DuPont offers a complete line of brackish water and semiconductor-grade reverse osmosis elements and ion exchange resins to meet stringent water purity standards required in semiconductor devices.
Additional Information:
SEMICONDUCTOR: Semiconductor plants and microelectronics manufacturers rely on pure water, such as that made possible by DuPont Water Solutions technologies, to efficiently and cost-effectively produce the technological gadgets society has come to rely upon. | |
TFT-LCD: DuPont Water Solutions offers specially-designed ion exchange resins providing a long service time and high capacity for polishing high purity water for specialty electronics applications, such as the manufacturing of display devices, lower density integrated circuit (IC) chips and back-end chip dicing and mounting operations. |
Case histories
LED Manufacturer Combines UPCORE™ Packed Bed System and FilmTec RO Systems for Reliable Ultrapure Water Production (179 KB PDF)
UPCORE System Reduces Boron to Undetectable Levels in Ultrapure Water (154 KB PDF)
A retainer sample of the resin when it was new should be kept in a cool, dark and dry environment. Compare the properties of the retainer sample and resin stored in the warehouse. For general demineralization and softening applications, a small sample (50-100 ml) of the resin can be put in a beaker filled with water to see if the resin floats or sinks. Floating indicates the resin has dried out and needs to be re-hydrated. A microscopic look at the resin can reveal any mechanical damage and contamination by foreign particles. Anion exchange resins that were originally white or ivory in color and show brown or grayish-brown color may be contaminated with organic matter. Soaking the resin in an alkaline brine solution will result in a brownish colored liquid coming from the resin if the resin was heavily contaminated with organic material. In food and pharma, nuclear and ultrapure water applications it is advisable to thoroughly test the properties of resin that has been stored for more than three years. A detailed analysis of the resin properties is available through DuPont's System Optimization Services.
Additional Information:
System Optimization Services
Ion Exchange Resins - Troubleshooting
Resin Sampling Procedure, Tech Fact (602 KB PDF)
Please submit your question through 'Contact Us' for additional information. Please list the name of the product and the specific compliance or certification that is required.
WAVE calculates boron rejection on certain membrane element types, specifically for most of FilmTecTM brackish water and seawater elements except for XLE membranes. Boron rejection calculation is not possible with NF membranes.
WAVE can be downloaded from our web site.
The function of a feed spacer is to provide a channel for the feed water to be transported from the feed to the concentrate end of the element. It should also provide turbulent flow against the membrane surface. This prevents concentration polarization and fouling. In general, a wider feed spacer will promote resistance to fouling and improved cleaning.
The factor which has the greatest influence on the membrane system design is the fouling tendency of the feed water. A membrane system should be designed such that each element of the system operates within a frame of recommended operating conditions to minimize the fouling rate and to exclude mechanical damage.
These guidelines apply to:
These guideline values are aligned with specific feed water types; thus a choice of feed water type is effectively a choice of which guideline to use. The higher the fouling tendency of the feed water the stricter are the limits of these parameters. The proposed limits in the following links are recommended guidelines based on many years of experience with FilmTec membranes.
Membrane System Design Guidelines for 8-inch FilmTec Elements (126KB PDF)
Commercial Design Guidelines for Midsize FilmTec Elements (126KB PDF)
Most membrane sanitization procedures are set by the industry that requires the system to be sanitary.
DuPont does not determine how to heat sanitize. We do recommend a pre-conditioning step before use, but this is not to 'sanitize'. Your OEM (Original Equipment Manufacturer) should be able to assist you with sanitization and cleaning procedures. During pre-conditioning step, feed flow rate should be kept as low as possible to minimize pressure drop and feed pressure, but high enough to ensure sufficient mixing and equal distribution.
The procedure for regular sanitization may be the same as for pre-conditioning, but ultimately is the responsibility of the end-user. Certain industries have required sanitizing procedures that may be different from our procedures.
Cleaning is highly dependent upon the type of foulants on the membrane surface. If you are looking to clean your membranes, please see Membrane Troubleshooting Guide below.
Additional Information:
Heat Sanitizable RO Elements (65KB PDF)
Symptoms of Trouble, Causes and Corrective Measures - Troubleshooting Grid (PDF)
Operation of a UF module includes the following modes:
Filtration:
Ultrafiltration systems are most of the time in Filtration mode while in operation. The feed water is pumped through the membrane and is converted to filtrate. Typically all feed is converted to filtrate, in what is referred as dead-end filtration (as opposed to cross-flow filtration where a fraction of the feed leaves the system as reject). Filtration cycles typically range from 20 - 90 minutes, depending on the feed water source and quality. Figure 2 shows a diagram of the Filtration step in Ultrafiltration Modules.
Ultrafiltration systems are typically designed to operate at constant flowrate. As the solids build on the membrane surface, the transmembrane pressure (TMP) increases and eventually the foulants must be removed through a Backwash sequence. The Backwash sequence is generally initiated based on time. Alternatively, it can be initiated based on volume of filtrate or TMP set point (the latter is more appropriate for highly variable feed water quality). The Backwash sequence includes Air Scour, Gravity Drain, Backwash through the module top outlet, Backwash through the module bottom outlet and a final Forward Flush or rinse.
Figure 2. Filtration Step
Air Scour:
The Air Scour step is used to loosen particulates deposited on the outside of the membrane surface. Oil-Free air is introduced through the bottom of the module creating a stream of ascending bubbles which help to scour material off the membrane. Displaced water volume is allowed to discharge through the top port of the module for disposal, as shown in Figure 3. After a minimum of 20 - 30 seconds of continuous Air Scour, the module is drained by gravity.
Figure 3. Air Scour Step
Gravity Drain:
Once the Air Scour step is finished, the module must be drained by gravity in order to flush out of the system the material dislodged from the membrane surface by the preceding air scour step, as shown in Figure 4. The duration of this step will depend on the system volume and piping layout, but it is typically set to 30 - 60 seconds. If gravity drain is not possible due to the system configuration, or it takes too long, it can be substituted by a forced flush through the bottom outlet of the module using the Backwash pump, however this will consume more water and energy.
Figure 4. Gravity Drain Step
Backwash Top:
After the gravity drain step, the Backwash step is initiated. Filtrate water is pumped backwards, i.e., from the inside to the outside of the fibers, in order to push the accumulated material off the membrane. Then it is flushed out to waste through the top module outlet (see Figure 5). The Backwash flux ranges from 100 - 120 LMH, and the duration of the step is 30 - 45 seconds. Sometimes, depending on the application, chlorine might be added to the Backwash stream to help remove foulants or inhibit microbiological activity. Air scour can be combined with the Backwash Top step to increase cleaning effectiveness.
Figure 5. Backwash Top Step
Backwash Bottom:
After the Backwash Top step, the filtrate continues to flow from the inside of the fiber to the outside but now it is flushed out through the bottom outlet of the module (see Figure 6), ensuring the entire length of fibers have been cleaned. The Backwash pump is not stopped in the transition between Backwash Top and Backwash Bottom. The valves must be sequenced to prevent damaging the membranes. Similarly to the Backwash Top step, the duration of the Backwash Bottom is typically 30-45 seconds and optionally chlorine might be added to help remove foulants or inhibit microbiological activity. The Backwash steps can be repeated numerous times depending on the degree of fouling. Monitoring the backwash wastewater quality can be useful to optimize the durations of these steps.
Figure 6. Backwash Bottom Step
Forward Flush:
The Backwash sequence finalizes with a Forward Flush. In this step, feed water is used to rinse the system to remove remaining solids and the air that might have got trapped in the system during the precedent steps. Water flows on the outside of the fibers (feed side) with the filtrate valve closed, and exits through the module top outlet, as shown in Figure 7. This step typically lasts 30 - 60 seconds or long enough to refill the modules and purge air and water from the outlet. After this, the systems returns to Filtration mode and the cycle starts again.
Figure 7. Forward Flush Step
Forward Flush is also performed at initial start-up with the aim to remove any residual chemicals or trapped air from the module. The flush occurs on the outside of the fibers and does not filter the feed water to make filtrate.
Chemically Enhanced Backwash - CEB
CEB operation refers to a Chemically Enhanced Backwash, where chemicals (e.g., chlorine, acid or base) are added in the Backwash stream in order to increase the cleaning effectiveness. The type of chemical used depends on the foulant (refer to Table 9 above), which might be a combination of different ones or change seasonally. The frequency of a CEB is dependent on the feed water quality, but typically is once per day to once per week. For high quality feed waters it may not be required.
The CEB process is typically programmed to occur automatically at a preset frequency but this can be field adjusted after gaining site specific operating experience. Alternatively it can be initiated based on a TMP set point. The CEB is performed using UF filtrate.
The CEB is performed following the same steps of a normal Backwash sequence except a soak step is added after the addition of the chemicals, for 5 - 20 minutes, to allow time for the chemicals to react with contaminants that have attached to the membrane surface or penetrated the fiber wall. It is recommended however to invert the order of the Backwash steps, i.e., Backwash bottom first and then Backwash top as the second step, to make sure that the system remains filled with the chemical solution during the soaking time. Intermittent air scour (e.g., 5 - 10 seconds every 5 minutes) can be applied as well during the soak step to increase effectiveness.
After the soak a routine Backwash including air scour, gravity drain, top and bottom Backwash, and Forward Flush is performed to remove any remaining particulates and purge residual chemicals. After a CEB and at the start of the operating step, the initial filtrate produced might need to be sent to waste to remove residual chemicals. This step is dependent on the system piping and valve design and the downstream requirements for the filtrate. In addition, the CEB can be performed at reduced flux than that used for standard Backwash (e.g., 80 LMH).
2.4 Clean-In-Place - CIP
A clean in place (CIP) operation includes Backwash and chemical recycle to clean the fibers. The CIP is an on-demand operation. The frequency of a CIP is dependent on the feed water quality but can range from once every month to once every 3 months. Prior to a CIP the routine Backwash steps including air scour, draining, Backwash through the top drain, and Backwash through the bottom drain are performed. The Backwash steps are repeated 3 to 8 times to remove contaminants or foulants not requiring chemical removal. After completing the Backwash steps, the module is drained by gravity to remove excess water and prevent dilution of the CIP chemicals. CIP chemicals are recycled on the outside of the module for 30 minutes through the chemical cleaning tank. A small chemical filtrate stream will also be collected and recycled to the chemical cleaning tank. Note that the CIP solution can be heated up to 40ºC to improve its effectiveness at removing contaminants from the membrane. A soak follows the initial recycle step for 60 minutes or longer depending on the degree of fouling that has occurred. After the soak step, CIP chemicals are again recycled on the outside of the module for 30 minutes. When the recycle is completed an air scour is performed and then the module is drained to remove concentrated chemicals. The 2 steps of Backwash and a Forward Flush are performed to remove any remaining contaminants on the outside of the fibers.
The CIP steps described above are for a single alkali or acid chemical solution. If an acid and alkali cleaning are required, the CIP steps would be repeated for each chemical solution.
Ultrafiltration modules are designed to operate for a given range of feed water conditions (TSS, NTU, particle size, TOC, Oil & Grease, temperature etc.). If the feed water quality is outside of the design basis range, then pretreatment must be considered. This can include pre-filtration with bag, cartridge, or disc filters. Depending on the type of water or range of feed water parameters other pretreatment technologies such as oxidation, coagulation, sedimentation and media filtration may also be used.
It's a natural phenomenon when a wet membrane dries out, an irreversible low flow occurs to the dried membrane.
Sometimes, you can rewet elements by permeate pressurization or soaking in methanol or iso-propyl alcohol, but you will not be able to fully recover the flow most of the time. So, you want to avoid wet membranes from drying out.
On the other hand, unused, dry membranes do not show this phenomenon. All FilmTec™ membrane elements undergo many quality tests and inspections prior to being shipped. Dry membrane elements are never wetted during the testing designed to assure the quality standards are met for these elements which is why they can be stored dry without loss of flow.
Please note that seawater elements are all shipped wet.
You can select products with the following search tools:
If you cannot determine which product you need, please contact-us, along with answers to the following questions:
One aspect for selecting a certain arrangement of vessels is the feed flow rate for vessel of the first stage and the concentrate flow rate per vessel of the last stage. Both feed and concentrate flow rate for the system are given (from permeate flow rate and recovery). The number of vessels in the first stage should then be selected to provide a feed flow rate in the range of 35 - 55 gpm (8 - 12 m3h) per 8-inch vessel. Likewise, the number of vessels in the last stage should be selected such that the resultant concentrate flow rate is greater than the minimum of 16 gpm (3.6 m3/h). Flow rate guidelines for different elements are given in the Membrane System Design Guidelines for 8-inch FilmTec Elements (126KB PDF), Commercial Design Guidelines for Midsize FilmTecTM Elements (126KB PDF).
For a system with four vessels in the first stage and two vessels in the second stage the staging ratio is 2:1. A three-stage system with four, three, and two vessels in the first, second, and third stage respectively has a staging ratio of 4:3:2.
In brackish water systems, staging ratios between two subsequent stages are usually close to 2:1 for 6-element vessels and less than that for shorter vessels.
In two-stage seawater systems with 6-element vessels, the typical staging ratio is 3:2.
In 2nd pass RO Systems, typical is 3:1
Color differences are sometimes observed between different batches of ion exchange resins. These cosmetic color differences do not affect the performance of the resins. Sometimes cation exchange resins will develop an orange color due to the formation of low levels of degradation products after long storage times. This color can be removed by rinsing the resin with water or regenerating the resin before use.
Additional Information:
Color Release from Cation Resins (10KB PDF)
The start-up performance of an RO/NF membrane system and the time required to reach the stabilized performance depends on the prior storage conditions of the membrane. Both dry and wet elements, if properly stored, reach the same stabilized performance after some hours or a few days of operation. The flow performance of wet membranes is typically stable right from the start, while dry membranes tend to start at a slightly higher flow and can take as long as 72 hours of operation to reach steady state depending on the operating conditions (feed pressure, osmotic pressure, etc.) The salt rejection of FilmTecTM membranes in general improves during the first few hours or days of operation and remains stable thereafter. Wet membranes stabilize faster than dry membranes.
Element recovery: This refers to a single membrane element recovery rate. Element recovery = Permeate flow rate of single element / feed flow rate to the single element x 100%.
System recovery: This refers to a cumulative recovery rate. System recovery = cumulative permeate flow rate of membrane elements in a system / feed flow rate to the system x 100%
For example: Suppose there are two parallel pressure vessels and each pressure vessel contains 6 membrane elements. Feed flow to the system is 100 gpm. Since there are two pressure vessels in parallel, feed flow to each vessel is 50 gpm. The first element in each vessel would see 50 gpm of feed. Suppose the first element produces 5 gpm of permeate water and the whole system produces 50 gpm of permeate water. Then, the first element recovery = 5 gpm / 50 gpm x 100% = 10% while the system recovery = 50 gpm / 100 gpm x 100% = 50%
Additional Information:
Styrene-DVB copolymer beads are plastic spheres that are converted into ion exchangers and adsorbents. These tough, plastic beads act like plastic ball bearings and function as a lubricant in well drilling applications and are useful as grinding media for deburring and deflashing or grinding kaolin clay. Some grades produced with a very low ash content, can be ground and used as fillers for investment casting. Because they are highly cross-linked, styrene-DVB copolymer beads are insoluble in organic solvents and do not melt at elevated temperatures.
DuPont's styrene-DVB copolymer beads have been used successfully in the following applications:
Rejection of weak acids is dependent upon the pH value and the dissociation constant pK. Generally, the degree of dissociation increases with pH and rejection increases. Hence, a rough guess can be performed on base of the dissociation constant and the pH.
Additional Information
Boron Removal in Sea Water Desalination (91KB PDF)
Boron Removal (with Ion Exchange Resins)
Sanitization with agents containing combined chlorine is generally not recommended. This includes such compounds as chloramine, chloramine-T, and N-chloroisocyanurate. FilmTecTM RO and NF membranes are resistant to low concentrations of mild chlorinating agents. Their effectiveness as disinfectants at low concentrations, however, is limited. These compounds can also slowly damage the membrane because they are in equilibrium with small amounts of free chlorine.
Please see the following link for additional details.
Combined Chlorine (23KBPDF)
For over 30 years, packed bed systems have been recognized as the leading process for employing ion exchange resins at maximum efficiency for demineralization, enabling lowest chemical costs and waste volumes and highest product quality. We have led the way in packed bed innovation through its AMBERPACK™ and UPCORE™ design systems.
Previously only a licensed OEMs were able to design and supply water treatment plants using the licensed packed bed systems. Recently we have moved from a traditional licensing model to an 'open-source on-line model' so that obtaining or renewing an AMBERPACK™ and UPCORE™ license is no longer necessary.
In addition to making it easier to design packed bed systems DuPont has introduced a new WAVE (Water Value Application Engine) Design Software, which includes open modules for AMBERPACK™ and UPCORE™ packed bed system designs, including a series of AmberLite™ HPR products, which can enable all commonly used packed systems to operate at maximum efficiency.
Additional Information:
Recommended AmberLite™ ion exchange resins for packed bed systems in industrial water treatment
Retrofit of Demineralizer with UPCORE System Cuts Chemical Costs by 50% (90 KB PDF)
Concentration polarization is a phenomenon at the membrane surface where actual salt concentration becomes greater than the bulk stream and depends upon feed velocity/turbulence and efficacy of turbulence. So, as the feed velocity/turbulence changes, so does the concentration polarization. Therefore, there is no fixed concentration polarization number for a particular element. In typical RO systems, concentration polarization ranges from 13 to 20% (i.e. 13 to 20% higher concentration at the membrane surface than the bulk stream concentration).
However, when you do a design projection with WAVE, it takes the concentration polarization into account. Our WAVE (Water Application Value Engine) program, a comprehensive engineering tool for system design, is downloadable from our web site.
Additional information which may be helpful:
FilmTec Membranes - Steps to Design a Reverse Osmosis System
Membrane System Design Guidelines for 8-inch FilmTec Elements (126KB PDF)
System Design Guidelines for Commercial Elements (126KB PDF)
Design Equations and Parameters (144KB PDF)
It is impossible to give a quantitative answer since the lifetime depends on a number of factors including the quality of the treated water/product required, the type of ion exchange process being used, the frequency of regeneration, the hydraulic load on the resin and the resin type. The presence of certain organic substances, oxidants and metals (such as Fe, Mn, Cr, and others) may also dramatically decrease the lifetime of some resins as may high temperature and extreme hydraulic conditions. Some general comments can be made about resin lifetime.
Approximation of Useful Life of In-Use Cation Exchange Resins
(based on water retention capacity)
Approximation of Useful Life of In-Use Anion Exchange Resins
(based on remaining salt splitting capacity)
Additional Information:
Ion Exchange Resins - Recommended Operating Conditions
The viscosity of MOLYKOTE ® 111 Compound Valve Lubricant & Sealant is sufficiently high that it cannot be transported to the membrane surface.
You will need run the software in compatibility mode. Please try the following and check to see if the issue is resolved.
If you forget your DuPont Water Solutions Resource Center Premium account password, you can take the following steps:
If strong acid cation resin is stored for several years the organics leachables from the resin are usually higher, which shows in a brown color from the first bed volumes of rinse water passed through the resin. This will be more noticeable if the resin was exposed to changing humidity, light and temperatures; for example if it was stored outside and not properly covered. Weak acid cation resins are less affected but will also show higher organic leachables from their acrylic chemical base polymer structure.
Even if cation resins are stored for 10 years or more, there is usually little noticeable change with regard to their capacity and water content. When the resin is not regularly kept moist it will dry out. When the resin dries out or also when the resin is allowed to freeze several times, some resin beads will crack. Even after years of repeated drying/wetting and/or freezing/thawing the resin, there is rarely an increase of more than 5% of broken and cracked beads.
Anion resin is usually affected in the same way as cation resins with regards to drying out and freezing/thawing and also have higher organic leachables. However, the leachables from weak and strong base resins are usually amine compounds.
Hydrogen form cation resins can get loaded with ammonia and thus be partially converted into the ammonia form and anion resins in hydroxide form are known to be gradually converted to carbonate form by picking up carbon dioxide from the air.
Laboratories that analyze ion exchange resins would normally be able to check if the resin has been affected by unsuitable storage conditions.
DuPont also offers such testing, System Optimization Services.
Additional Information:
Proper Storage Conditions for Ion Exchange Resins (12KB PDF)
The best available technology for determining the colloidal fouling potential of reverse osmosis feed water is the measurement of Silt Density Index (SDI). This is an important measurement to be carried out prior to designing an RO pretreatment system and on a regular basis during RO operation (2-3 times a day is recommended for surface waters). The Standard Test Method has been described in ASTM test D 4189-82. The guideline is to maintain SDI at less than or equal to 5. A number of pretreatment technologies have proven effective in SDI reduction including media filtration, ultrafiltration, and cross flow microfiltration. Polyelectrolyte addition ahead of filtration sometimes improves SDI reduction.
Additional Information:
Silt Density Index (24KB PDF)
Phenolic compounds cause flux losses and are not recommended for use as biocidal agents.
Pressure drop is the loss of pressure from the feed end to the concentrate end of a module or a pressure vessel. Under normal operation condition, the pressure drop for a FilmTecTM element is about 4 to 5 psi (0.3 bar) per element. (Typical pressure drop through a new home drinking water element is 1 psi at 50 psi feed pressure.)
Pressure drop increases with the extent of fouling. A high pressure drop is problematic because it may lead to telescoping and inefficient operation, and thus a decline in system performance.
The maximum recommended pressure drop across a single element is 15 psid (1bar) or 50 psid (3.5 bar) across multiple elements in a pressure vessel, whichever value is more limiting. We recommend designing at maximum of 80% (12 psid) for any element in a system.
Interstage pressure indicators are critical for the assessment of RO plant performance, especially in case of surface waters and city waters since these water sources tend to contribute to high rates of fouling. Interstage pressure indicators enable the pressure drop of each stage to be calculated (feed pressure minus concentrate pressure) so the location (i.e. stage) of the performance problem can be more accurately identified.
Measuring only the total pressure drop of a system can conceal a problem. While the total pressure drop value may be acceptable, it is possible that the pressure drop mainly occurs in one stage. In that case, the membrane elements in that stage may already be damaged.
Example:
A two stage RO system has a total pressure drop of 40 psi. Pressure drop has increased to 50 psi. This amounts to a 25% total pressure drop increase. However, when reviewing individual stage details: the first stage pressure drop increased from 15 psi to 25 psi (60% increase!) while the second stage remained at 25 psi.
Because interstage pressure indicators allow a system operator to pinpoint the areas of high pressure drop, they are strongly recommended.
High Pressure Drop (162KB PDF)
System Design Suggestions for Troubleshooting Success (31KB PDF)
Membrane System Design Guidelines for 8-inch FilmTec Elements (126KB PDF)
Commercial Design Guidelines for Midsize FilmTec Elements (126KB PDF)
You can run a projection even though your particular element is not included. It is best to work from the element already listed (with the same diameter) and then you use the ratio of active membrane areas between the two elements.
An example would be calculating permeate flow with FilmTecTM XLE-2521 element (which is not listed) based on FilmTec XLE-2540 in WAVE (which is listed).
FilmTec XLE-2521= 13 sq. ft. active membrane area FilmTec XLE-2540= 28 sq. ft. active membrane area Area ratio: FilmTec XLE-2521 / FilmTec XLE-2540 = 13ft2 /28ft2 = 0.464
Therefore, the permeate flow and feed flow will be approximately 46% as high.
So, using the same feed composition, you can design a layout using XLE-2540 which will be about 1/0.46 = 2.2X bigger than the system you wish to build with a smaller XLE-2521. For design using XLE-2521, we would recommend the following steps:
This will give an approximation of the permeate flow at the predicted pressure (as calculated by WAVE). All other pertinent data such as operating pressure, rejection, recovery can be used from the projection.
One thing to note: system design warnings are built on 40"-long elements. Please see Commercial Membrane System Design Guidelines for information specific to shorter elements.
Additional information for internal viewing and use:
6 inch elements:
You can design a system using 8" products available in WAVE as a proxy for a 6" product. If you do that, then to make a fair comparison you want to keep the average flux rate the same.
e.g., If you are using 380-sq. ft. 8" products in place of 140-sq. ft. 6" products, then the WAVE design should use feed and permeate flow rates that are higher by the same ratio of 380/140. This will give the same average flux and the same recovery for the two sizes of systems, and that should be a good approximation.
Additional Information:
Steps to Design a Reverse Osmosis System
The piping provides extra volume so that the total system volume can be adjusted. System volume is directly related to sequence time. The normal closed-circuit sequence time is 5 minutes. If you need to increase or decrease this value, you can increase vessel length or decrease elements per vessel. We recommend, however, that you leave the default setting.
Module life is a function of feed water source, pretreatment, frequency of cleaning, system design, and operating conditions. For economic analysis, a 3-5 year life is normally used.
The system is designed to fail closed: if something goes wrong, permeate stops being produced and water stops flowing into your process. Before the system fails, however, our ReFlex Smart monitoring software will alert you and Desalitech of a problem so it can be troubleshot onsite by your staff, our service technicians, or remotely through our ReFlex Smart software.
In a mixed bed of highly regenerated (i.e., new) ion exchange resins, the anion and cation exchange resin components occasionally cannot be separated adequately during the backwash cycle prior to regeneration. This phenomenon is known as clumping or agglomeration, and is due to the attraction of the oppositely charged exchange sites on the surface of the anion and cation exchange resins. The hydrogen form of cation exchange resins and hydroxide form of anion exchange resins have the greatest clumping tendencies. Some possible ways to minimize resin clumping include:
Additional Information:
Recommendations for Loading an Internally Regenerated Mixed Bed (22KB PDF)
Please see the physical properties, operating ranges, module properties and typical process conditions at UF Product Manual, Form 45-D00874-en
Fiber Physical Properties | |
Configuration (fluid flow) | Hollow Fiber (Outside-In) |
Base Polymer | H-PVDF |
Nominal Pore Diameter | 0.03 μm |
Hollow Fiber ID | 0.70 mm (0.028') |
Hollow Fiber OD |
1.3 mm (0.051') |
Typical pretreatment consists of:
Ultrafiltration is also an excellent choice to exclude particles as small as 0.01 microns, including bacteria, viruses and colloids prior to reverse osmosis. Please see our ultrafiltration portfolio
Additional pretreatment considerations:
For more details on pretreatment for a variety of issues, please see:FilmTec Membranes - Pretreatment Summary
Additional Information:
Silt Density Index (24KB PDF)
Cleaning Procedures for FilmTecTM FT30 Elements (137KB PDF)
Colloidal Fouling Prevention (32KB PDF)
Chlorination - Dechlorination (53KB PDF)
Generally, our systems operate in the 90-95% range, but under certain circumstances have operated up to 98% recovery. In contrast, traditional reverse osmosis systems typically max out at around 75% — higher rates are possible, but at the cost of reliability and energy efficiency. Each individual system’s maximum recovery is based on the chemistry of its feedwater, and the only real limiting factor is the feedwater’s scaling potential. Our water specialists are happy to work with you to help you determine the maximum recovery a CCRO system could achieve with your water.
Please visit the WAVE download page and select when you click the download button, you will be prompted to either login or register for an account to the Resource Center Premium. If you register for a new account, follow the prompts to receive an email which will allow you to create a password and view our premium content including download the latest version of our WAVE design software.
The resin bed is mixed using nitrogen or clean air. The air used for mixing resins or scrubbing them, particularly in condensate polishing or UPW applications, should be totally oil-free (traces of oil can originate from the air compressor). In CPP, instrument air is typically used. General recommendations:
There is no limit to the number of repetitive brine squeezes that can be applied to an anion resin to remove organics. In fact, it's probably better to repeat this procedure instead of regenerating between brine squeezes to minimize the osmotic shock that would be experienced by the beads every time the resin is converted from the chloride form to the hydroxide form.
Additional Information:
Ion Exchange Resins - Cleaning Organics Anion Resins
Procedure for Brine Cleaning of Anion Resins (26KB PDF)
This pre-treatment applies to anion and cation exchange resins used for ion exchange applications. Chromatographic separation resins such as AmberLite™ CR99 Chromatographic Separation Resins require a different procedure Ion Exchange Resins - Preparation of Chromatographic Separation Resins
Good practice in the food processing field requires careful preparation of processing equipment prior to use. To assist the food processor in preparing AmberLite™ ion exchange resins for such use, the following conditioning procedures are outlined.
Experience has shown that these simple steps, done under normal processing conditions and supplementing the normal manufacturing operations, should assure that the level of organic extractives in the resin-in-use complies with the U.S. Food, Drug, and Cosmetic Act as amended under Food Additive Regulation 21 CFR #173.25.
General Conditioning Steps
To a bed of resin in the normal backwashed, settled, and drained condition:
Recovery or Removal of Metals from Organic Media:
Ion exchange processes work just as well in non-aqueous organic streams as they do in water based systems. Many DuPont customers use ion exchange resins for removal of acids and metal salts from organic solvents in applications such as color control (shelf life improvement) and precious metal catalyst recovery. Nevertheless, a few simple adjustments are required.
Most ion exchangers are normally delivered as a water wet product. Since water and organic solvents do not mix, an interface will exist at the water-solvent boundary that will inhibit ion mobility into an out of the resin beads. Drying the ion exchange resin will allow solvents to fully permeate the media so the chemistry is fully utilized.
DuPont offers several dried cation exchange resins that are ready to use in organic solvent applications. These products are designated with the word "Dry" in their name, e.g. AmberLyst™ 15Dry.
If you are starting with a non-dried resin (e.g. a fine mesh resin), it can be dried either in an oven at 95°C to 100°C (200°F to 212°F) (please note the maximum recommended temperature for that resin) or via chromatographic displacement using a dry, polar solvent (methanol, ethanol, isoproponol, acetone, etc.). For critical applications, where water must be completely excluded, it is wise to verify that the resin is dry using a Karl-Fisher titration.
When water is removed from ion exchange resins, they typically shrink in size. Care should be taken if they are re-hydrated as they will swell creating high pressures that can damage the resin beads and equipment.
Dehydrated beads are "tighter" or more kinetically inhibited. Ion exchange processes are therefore slower and longer contact times or slower flow rates may be required. Slower reaction kinetics can also be offset by using Fine Mesh Resins. (183KB PDF)
Dry macroporous resins will contain air that will prevent contact between the resin and the solvent. The beads can be degassed by pulling a slight vacuum on the resin solvent mixture.
When we say that a resin has a capacity of 1.8 equivalent/L, we mean that one liter of resin contains 1.8 equivalents of exchange sites. Hence, one liter of H+ form cation exchange resin having a capacity of 1.8 mol/L would load 1.8 mol of Na+. You will also need to consider the number of charges on your target ion (e.g., for Ca++ you need to consider that it has 2 charges) Multivalent ions do not necessarily occupy multiple ion exchange sites as it has more to do with the proximity (cross-link) of the those sites for interaction. We also suggest that a customer assumes only a 65-90% operating efficiency when initially sizing a resin bed. Ion exchange is an equilibrium process and is never 100% efficient. Any resin evaluation is best done with a couple of simple tests such as an equilibrium isotherm test (23KB PDF) and Laboratory Guide for Column Separations (219KB PDF).
When designing an ion exchange installation, the Permanganate value (PV) of a water is used to determine the organic loading on the anion resin. However, this value is often not given and only BOD, COD or DOC values may be available. The following information is intended to help in converting BOD, COD and DOC values into PV values.
PV (Permanganate value) and COD (Chemical Oxygen Demand)
PV and COD are a measure of the amount of reduced compounds in a sample, which have been oxidized by a strong oxidizing agent. Although inorganic substances such as Fe2+, S2- may also be subject to oxidation, for most natural and industrial waters, the matter to be oxidized is organic in nature. Therefore these values can be used to characterize the organic load of a water.
For converting the COD value into a PV value, the following should be taken into account:
Therefore the following ratios have to be taken into account:
Equation 1: PV(ppm KMnO4) = PV(ppm O2) * 4
Equation 2: PV(ppm O2) = COD(ppm O2) * 0.4
To express PV as ppm KMnO4, the value obtained as ppm O2 has to be multiplied by 4 (Equation 1). Equation 2 assumes that in the permanganate test (expresses as ppm O2 ) only 40% of the oxidizable matter are converted whereas the COD conversion amounts to 100%. This means that the COD as ppm O2 has to be multiplied by 0.4 to yield the PV as ppm O2. Equations 1 and 2 can be combined in the following equation (Equation 3):
Equation 3: PV(ppm KMnO4) = COD(ppm O2) * 1.6
Biological Oxygen Demand (BOD)
The BOD characterizes the biological biodegradability and is closely related to the PV, as it describes this part of the COD that is more readily oxidized. Depending on the type of water, the BOD5 (biodegradability in 5 days, expressed as ppm O2) from 0.5 up to 3 times the PV (as ppm O2), and for most waters a value of 1.5 can be applied. This results in the following equations:
Equation 4: PV(ppm O2) = BOD5(ppm O2) * 1.5
Equation 5: PV(ppm KMnO4) = BOD5(ppm O2) * 6
Dissolved and Total Organic Carbon (DOC and TOC)
DOC and TOC are a measure of the amount of dissolved organic carbon and total organic carbon present respectively. Except for municipal wastewaters, sludge-type fluids and other types of contaminated waters, the TOC value which is measured after filtration through a 0.45 m pore size filters corresponds approximately to the DOC.
Equation 6: DOC(ppm C) = TOC
No. The upstream (feed) endcap holds the brine seal and the o-ring for seling the permeate tubes of adjacent elements. The downstream endcap has features that impart a firm 'snap' when the two elements are connected.
Membranes in general are prone to fouling due to several causes, one of which is biofouling caused by bacteria. Biofouling can form a foundation to collect other debris and lead to further problems. Symptoms of a fouled membrane include decreased permeate flow at a constant feed rate, increased pressure necessary to maintain constant permeate flow, decreased salt rejection. When any of these symptoms occur and biological fouling is suspected, users will attempt to "regenerate" the membrane, which typically involves use of a biocide.
The following are the requirements for a biocide:
Some methods used to prevent biofouling include:
Additional Information:
AQUCAR™ Water Treatment Microbiocides
Sanitization of FilmTec Elements with DBNPA (23KB PDF)
System Design Considerations to Control Microbiological Activity (40KB PDF)
Additional Information
UF Product Manual (Form No. 45-D00874-en)
Both types of resins have significant advantages if properly applied. Gel-based resins are typically the resins of choice for standard water treatment applications because of their inherently greater capacity and better regeneration efficiency.
Macroporous (aka macroreticular) resins are generally preferred in more aggressive applications where their highly cross-linked structure is an advantage. (Examples: applications subjected to large osmonic shock, feedwater with elevated chlorine content, higher temperature applications)
Based on the flow rate and throughput required, the number of lines operating at the same time needs to be defined.
The simplest layout with 2 lines (1 in operation, 1 in standby) can be used in most cases.
With large plants (> 400 m3/hr or 1800 gpm), however, it may be more appropriate to have 3 lines (2 x 50% in parallel, 1 in standby) in order to reduce system redundancy, optimize flow conditions and reduce vessel sizing.
In making a design, it is important to ensure that there is enough time for the standby lines to complete regeneration before they are required to go back on line. The optimum number of lines with minimum redundancy can be calculated using the following formula:
If the equation predicts a non-integer result, the number should be rounded down to obtain the optimum number of lines. For example, a 10 hour run length with a 3 hour regeneration time gives a ratio of 4.3, so the number of lines with minimum redundancy would be 4.
Additional Information
Water Treatment Applications: New ion exchange resins do not need to be regenerated as long as they are in their regenerated forms. For instance, water softening resin that is purchased in the Na+ form can be used as is after an initial backwash and rinse.
It is desirable to soak ion exchange resins in demineralized water overnight before being placed in the service vessel. This is required for weak base anion exchange resins to make sure they are fully hydrated and for inert resin to reduce their hydrophobicity. This will minimize the floating and potential loss of these resins if they are backwashed before the first service cycle.
Demineralization: cation resin in the H+ form and anion resin that is in the OH- form can be used as is after an initial backwash and rinse. If they are in the exhausted form (e.g. Na+ form for cation and Cl- form for anion resins), however, then they need to be double regenerated with acid and caustic soda, respectively.
Ultrapure Water (UPW) and Condensate Polishing: Since resins should be purchased in their regenerated forms, they can be thoroughly backwashed rinsed until the desired TOC concentration, resistivity/conductivity is achieved.
It is important that ion exchange resins are loaded properly. Loading procedures for single bed, mixed bed, and layered bed can be found below.
Additional Information:
Loading Procedure for Single Bed Ion Exchange Vessels (12KB PDF)
Loading Procedure for Layered Bed Anion Resins (19KB PDF)
Recommendations for Loading an Internally Regenerated Mixed Bed (22KB PDF)
For resins used in Food Processing and Contact, please see Ion Exchange Resins - Pre-use Preparation - Food Processing and Contact
Temperature (°C) |
Maximum Pressure (bar) |
<20.0 |
6.3 |
<25.0 |
6.0 |
<30.0 |
5.8 |
<35.0 |
5.3 |
<40.0 |
4.8 |
Air presents a very complex problem in the storage of DVB. TBC is not an effective inhibitor for DVB in the complete absence of dissolved oxygen. However, excessive amounts of oxygen in the storage tank may lead to other serious storage and handling problems.
Monomer vapors above the liquid level in the tank are uninhibited. These uninhibited vapors and condensed monomer droplets are readily oxidized by oxygen from the air. These droplets, containing oxidation products, will polymerize quite rapidly and will adhere to the rusted, porous surfaces of unlined steel tanks. They appear in the form of coatings and stalactites, or “polymer icicles,” on the roof and sidewalls above the liquid monomer. The same condition, though less severe, will also occur in lined tanks.
The polymer deposited under these conditions will be discolored, cross-linked, and high in peroxides, aldehydes, and other oxidation products. Deposits of contaminated polymer will eventually produce serious color and polymer problems in monomer stored under air in unlined steel tanks. Therefore, do not allow mechanical structures in the top part of the storage tank as they will collect these impurities.
Polymer deposits in tanks also cause difficult removal and cleaning problems. If stalactites are allowed to grow, their weight may even damage the roof or roof-supporting structure of large vertical storage tanks.
However, the complete elimination of oxygen from the vapor area will lead to depletion of dissolved oxygen from the liquid monomer. If this dissolved oxygen is not replaced and is allowed to drop below 15 ppm, the TBC inhibitor will become ineffective and rapid polymerization—runaway polymerization—may take place
Polymer analysis and dissolved oxygen
If an inert gas blanket such as nitrogen is used, aerate the monomer with dry air once a week for approximately 30 minutes. The oxygen level should always be kept at 15 ppm or greater.
Polymer formation can result from insufficient TBC or insufficient dissolved oxygen. An effective test to determine whether polymer is forming in the monomer is ASTM Method D-2121. This test, used in conjunction with the TBC test for inhibitor level, provides a quick means of monitoring monomer condition on site.
To control bacterial growth and prevent damage caused by drying out, ultrafiltration modules are wetted and stored in pH buffered 1% sodium metabisulfite solution. This solution is automatically injected into the modules, then all inlet and outlet ports are sealed using plastic discs, Victaulic flanges, and plugs. If the modules are exposed to low temperatures, glycerin can be added to the solution to prevent freezing. The modules are sealed in plastic prior to boxing. Depending on the total number of modules and method of shipping, the modules are either shipped on pallets or in crates.
Uninstalled Modules
The modules should be stored horizontally with the connections/ports facing up. To prevent collapse of the packaged modules, stacking should be limited to four layers for the 2660 and 2860 modules and to three layers for the 2880 modules. Storage in a cool, dry, normally ventilated area protected from direct sunlight with an ambient temperature of 20 to 35ºC is recommended. Sealed modules can be stored up to 1 year at the recommended conditions in the original packing. For a 2660 module 2 liters of the storage solution is added. For a 2860 module 4 liters of storage solution it added. For a 2880 module 6 liters of storage solution is added. The UF module shelf life is one year from the manufacture date without taking additional measures for preservation as long as the storage condition instructions are followed.
Storage of Modules Installed on a Skid
Modules installed during assembly of a skid should not be allowed to dry out. Dry membrane fibers will irreversibly lose flux. Blank or “dummy” modules are available through the manufacturer to accurately build and assemble a skid. Consult the manufacturer regarding modules installed on a skid and not planned for operations within 7 days.
If the modules are installed to wet test the system before shipping and it is desired to ship the modules installed on the skid the following steps should be taken: add sodium bisulfite solution, drain the system to remove excess solution and weight, and reseal the system by closing all valves. Once the system arrives on site the modules should be refilled with bisulfite solution prior to start up.
Additional Information
ROSA
(Reverse Osmosis System Analysis) helps you design a reverse osmosis plant to meet your required water treatment specifications.
Download 9.1 English | Download 9.1 Chinese | Microsoft .NET Framework 3.5 Redistributable |
CADIX(Computer Assisted Design for Ion eXchange) helps you design ion exchange systems using legacy ion exchange resins.
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It has been found that oxidative conditions may exist after the SMBS addition. Metals such as Fe, Cu, etc. may reinforce this tendency and it appears to happen more frequently with seawaters. Also the coexistence of NaCl, NaHCO3 and copper seems to promote the oxidative capacity. In critical cases, it is helpful to monitor the Oxidation Reduction Potential (ORP).
Additional Information:
Chlorination - Dechlorination (53KB PDF)
Module life is a function of feed water source, pretreatment, frequency of cleaning, system design, and operating conditions. For economic analysis, a 5 year life is normally used.
Dissolved gases like ammonia (NH3) will not be rejected by an RO membrane; however, NH3 is in equilibrium with the ammonium cation (NH4+), as defined by the following equation:
NH3 + H+ <---> NH4+
Decreasing the pH and/or temperature will convert NH3 to NH4+, which is rejected by the FilmTec RO membrane.
For example, as long as the temperature and pH are less than 40°C (104°F) and 7 respectively, more than 95% will be present as NH4+ and the rejection should be better than 98%. However, if both parameters are allowed to increase, the amount of ammonia will also increase, accompanied by a corresponding decrease in rejection by the RO membrane.
Nitrate (NO3) ion rejection is dependent on a combination of factors: pH, flux, ionic strength, counterion mix, membrane type, etc. Typically, its rejection ranges from 85 to 98%.
The terms axial and radial refer to the direction of o-ring squeeze.
Axial or face seals are common in high-pressure industrial applications were the assembled parts remain stationary.
Radial seals are used primarily when relative motion is required. The sliding radial seal is typically designed with less o-ring compression and relies upon careful lubrication to prolong seal life.
Under recommended design and operating conditions, you should be able to expect a turbidity < 0.1 NTU 95% of time and SDI < 2.5 , 90% of time.
Accurate system design is critical to getting the most from your water treatment system. Since dozens of factors can impact the productivity of your system, we recommend use of WAVE Software to offer precise design recommendations to optimize your system performance.
The goal of the designer of an ion exchange system is to ensure that the correct water quality and quantity is delivered with optimized regenerant consumption and capital cost. The optimum design depends on the relative importance of these parameters. Each are described in the following sections.
How to Design an Ion Exchange Resin System:
For detailed design on ion exchange systems, WAVE Software and/or is available. Specific recommended operating conditions for individual ion exchange resins can be found in the product datasheets in the Product Information Section. The attached documents show the information necessary to collect in order to design or retrofit an ion exchange system.
For further questions, please fill out the attached form and submit it through the following link: Submit question .
Free mineral acidity is due to the presence of acids such as sulfuric, nitric, and hydrochloric. The FMA of the feedwater influences the choice of resin.
Ion Exchange Resins - Selection of resin type
To store resins inside the vessel it is important to prevent the resins from drying out (since they will shrink and may break on re-hydration) by maintaining a layer of liquid 30-50 cm (12-20 inches) above the resin bed.
An additional objective for ion exchange resin storage is limiting the potential for biological growth, which can cause elevated pressure drop, channeling through the bed, degraded exchange kinetics, reduced throughput, and increased rinse time when the vessel is returned to service.
Demineralization Resins:
Generally, resins are best left in the regenerated form. Mixed bed resins should be separated, then regenerated prior to storage. Depending on the length of storage, different recommendations may apply.
Short Term Lay-up (less than a week):
Resin is normally regenerated, left submerged in liquid full vessel (water at 2-35°C or 36°F-95°F), and rinsed to quality prior to restart.
Mid Term Lay-up (one week to a month):
Resin is normally regenerated and left submerged in liquid full vessel (water at 2-35°C or 36°F-95°F). It is recommended to run water through the bed for a few hours at the typical service rate (typical fast rinse water) once a week for the duration. Resin is rinsed to quality prior to restart and the initial cycle may have lower than typical throughput due to rinse loading.
Ion exchange systems downstream of RO may consider utilizing the mid-term recommendations for a longer period of time.
Long Term Lay-up (greater than one month):
One option that is practiced includes regenerating the resin, draining the vessel of all water, sealing the vessel as airtight as possible (as soon as possible after draining) while leaving the resin moist. When refilling the vessel, a slow fill (over the course of 6 to 8 hours) would be recommended along with an overnight soak to rehydrate. Regeneration would be recommended prior to start up.
Storage in lined containers under similar conditions as recommended for long term storage in the vessel is an alternative.
Another option if storage is anticipated for several months or longer is that all resins can be stored in the exhausted forms and in a 15-25% brine solution to minimize biological growth and prevent freezing as outlined in the linked tech fact document (Proper Storage Conditions for Ion Exchange Resins).
For long term storage of type II strong base anion exchange resins, it is best if the resin is left in the exhausted form due to functional group stability.
Ultrapure Water (UPW), Mixed Bed Condensate Polishing Resins, and Nuclear Grade Resins::
UPW, mixed bed condensate polishing, and nuclear grade resins should not be contacted with brine, and UPW resins should be stored in water free of dissolved oxygen.
Additional Information:
Proper Storage Conditions for Ion Exchange Resins (12KB PDF)
Additional information for internal viewing and use:
Keeping the resins in their original packing
Recommendations for resin storage . Potential problems
There are a number of different ion exchange regeneration technologies that can be used, from the basic co-current regenerated systems to counter-flow block systems and through to packed bed technology.
Selection of regeneration system:
Counter-Current Regeneration Systems (Blocked Systems or Packed Bed Systems)
Co-Current Regeneration Systems
Counter-Current Regeneration Systems: in these systems, the regenerant is applied in the opposite direction to the service flow, resulting in reduced chemical consumption, improved water quality and less waste volumes compared to traditional co-current regenerated systems. Counter-current regeneration systems should provide a water quality of better than 2 µS/cm (0.5 MW.cm) and residual silica of 0.020 to 0.050 mg/l as SiO2. Depending upon water composition and regeneration conditions, the specific conductivity could be as low as 0.2 µS/cm (5 MW.cm). The normal counter-current endpoint is 4 µS/cm conductivity. A maximum endpoint value of 0.3 mg/l SiO2 above the average leakage should not be exceeded in order to avoid a high contamination of the polishing resin layer and unacceptably high silica leakage during subsequent cycles. Silica leakage can be minimized by operating the plant at silica break rather than conductivity end point. This secures the lowest silica leakage, but at the expense of a 5 -10 % throughput reduction.
There are two main types of counter-current systems:
Co-Current Regeneration Systems: these are the simplest systems, where the resin is regenerated in the same direction as the service flow (downwards). The vessel has a large freeboard to allow expansion of the resin bed when backwashing is carried out to remove suspended solids and resin fines. Co-current regeneration single bed systems will generally produce water of much lower quality than counter-current systems, with typical leakage values ~10 times higher. Such quality will also be even more affected by the water composition, the type of regenerant chemical and dosage being used.
Additional Information
Silica is present in two forms: reactive silica (single unit), and colloidal silica (multiple units).
Additional Information:
Colloidal Fouling Prevention (32KB PDF)
Weak acid cation exchange resins (WAC), such as AmberLite™ HPR8300 cation exchange resin have a high affinity for the divalent cations (which constitute hardness), provided the counter-ions are alkaline.
WACs remove cations and associated alkalinity from water by converting alkaline salts of calcium and magnesium to the corresponding weak acid (dissolved CO2) and subsequently removing the CO2 by degasification. [RCOOH represents the weak acid cation resin.]
2 RCOOH + Ca(HCO3)2 → (RCOO–)2Ca++ + 2 H2CO3
H2CO3→ H2O + CO2
Best results are obtained with hard, alkaline, low-sodium waters.
If the hardness to alkalinity ratio in the feed water is greater than 1.0, use of a weak acid cation (WAC) exchange resin, such as AmberLite™ HPR8300 cation exchange resin, can remove alkalinity both cost effectively and efficiently.
In this process, Ca2+, Mg2+, Ba2+, and Sr2+ associated with bicarbonate alkalinity (temporary hardness) are removed and replaced by H+, thus lowering the effluent pH to 4-5. Because the acidic groups of the resin are carboxylic groups, the ion exchange process stops when the pH reaches 4.2, where the carboxylic groups are no longer dissociated. Therefore, only partial softening occurs. Adding a strong acid cation exchanger in the sodium form to remove residual hardness not associated with bicarbonate alkalinity can be justified when the hardness to alkalinity ratio is >0.8.
The bicarbonate is converted into carbon dioxide:
HCO3- + H+ → H2O + CO2
This unit is usually followed by a degasifier unless the subsequent use of the product water does not require CO2 removal (e.g., a cooling tower).
The advantages of dealkalizing with a weak acid cation exchange resin are:
The disadvantages are:
We recommend use of the WAVE Software to evaluate the various design options.
Copper sulfate is sometimes used to control the growth of algae. Generally the use of copper sulfate is not recommended due to the following:
Perchlorate will be rejected at >90% by FilmTec™ RO membranes. Please note that disposal of reject stream may be difficult if system operates at too high a recovery since the perchlorate will be concentrated.
Perchlorate is an oxidizer under acidic conditions.FilmTec Membranes - Factors Affecting Membrane Stability
Please note that the most cost effective and simplest method is disposable ion exchange. AmberLite™ PSR-2 is a perchlorate selection anion resin and is the global standard for perchlorate removal. Because of its high selectivity for perchlorate over typical ions in ground water including chloride and sulfate, AmberLite™ PSR-2 can operate successfully for long periods of time, often approaching a year in service before replacement is required. It is used in simple down-flow vessels in a lead-lag configuration (see diagram below). When the lead vessel is exhausted, it is replaced with fresh resin and the lag bad is moved into the lead position. In this manner, excellent resin utilization can be achieved. Disposal usually is done via incineration of the perchlorate loaded resin.
For more information, please see Municipal SubMarkets .
DuPont's EDI modules can be disposed of in a sanitary landfill according to local regulations as long as they did not process or come into contact with any hazardous materials.
At high temperature, the applied pressure will be much lower. Despite the lower feed pressure, the first element of the high temperature system will have a higher flow rate than the system operating at lower temperature. However, due to the much lower operating pressure but same osmotic pressure the high temperature's system tail elements flow rates will be lower than for the lower temperature system. Therefore, comparing to the system operating at lower temperature, the high temperature system will have a more unequal flux distribution with higher fluxes in the feed elements and lower fluxes in the tail end of the system.
Factors Affecting RO Membrane Performance (65KB PDF)
FilmTec elements are shipped as either dry or wet. All elements are bagged and sealed in polyethylene bags and then boxed for shipping. For wet elements, they are bagged and sealed in a durable, oxygen-barrier composite plastic bag to retain the integrity of the shipping solution (1.0 % sodium bisulfite). It is recommended that the shipping solution is checked after 6 months to ensure its efficacy.
8-inch elements (8-inches in diameter and 40-inches long) are individually boxed and shipped on 44" x 45" pallets:
5 to a pallet = 44" x 45" x 13"
10 to a pallet = 44" x 45" x 22.5"
15 to a pallet = 44" x 45" x 32"
20 to a pallet = 44" x 45" x 41"
4-inch (4-inches in diameter and 40-inches long) are also individually boxed and shipped on 44" x 45" pallets.
2.5-inch (2.5-inches in diameter and 40-inches long) elements are shipped in boxes or crates. These elements are not individually boxed.
A crate measuring 44" x 45" x 20" will hold 144 2.5-inch elements.
A crate measuring 44" x 45" x 29" will hold 192 2.5-inch elements.
8-inch elements and home drinking water elements (less than 2-inches in diameter) can be double-stacked.
2.5 elements in crates cannot be double-stacked.
Basic truck sizes are 24', 48' and 53' long, and they fit 24 pallets double-stacked, 48 pallets double-stacked and 52 pallets double-stacked respectively. The pallets weigh 40 lbs.
Additional Information:
FilmTec Membranes - Element Weight
When is it more economical to replace an old resin rather than running it at higher operating cost?
Most ion exchange users would consider a capacity loss of 10-20% sufficiently high to justify resin replacement, but since all plants are different and the water quality, quantity, and plant availability needed is different for each and every plant, a universally true statement cannot be made. To assess the situation for a particular plant, the regenerant chemical consumption of the plant when it was new and an average water analysis compared to the present situation needs to be studied. The price of regenerant chemicals plays a very important role since the cost per cubic meter of product water produced increases when more chemicals are needed to regenerate the resin.
Another aspect could be the limitations with regard to the wastewater neutralization system that may be limited in size and thus the volume of wastewater it can treat so it may not tolerate ion exchange resins which need extremely long and water-consuming rinsing steps and frequent regeneration. Caustic soda especially is a relatively expensive regenerant chemical and new, clean anion resins need significantly less excess of caustic for regeneration. Therefore, it is usually cheaper to replace the anion resins and operate the new resins at lower operating cost. This should justify the capital expense for resin replacement.
Additional Information:
Ion Exchange Resins - Cleaning recommendations
Ion Exchange Resins - Recommended Operating Conditions
Resin Wear-Out Guidelines (10 KB PDF)
If you do not show the correct SQL Server Compact 3.5 SP2 entries as shown above, then one of the required programs for WAVE didn't install correctly. To fix this, follow these steps to install SQL Server Compact 3.5.
Ion exchange processes work just as well in non-aqueous organic streams as they do in water based systems. One can use ion exchange resins for removal of acids and metal salts from organic solvents in applications such as color control (shelf life improvement) and precious metal catalyst recovery. Nevertheless, a few simple adjustments are required.
Most ion exchangers are normally delivered as a water wet product. Since water and organic solvents do not mix, an interface will exist at the water-solvent boundary that will inhibit ion mobility into an out of the resin beads. We recommend the use AmberLyst dry catalysts, which have been dried to an optimal degree in order to ensure a high conversion rate and excellent selectivity.
FilmTec reverse osmosis & nanofiltration elements should be stored in the temperature range of 25°F to 95°F (-4°C to 35°C).
Additional Information:
Handling and Preservation (22KB PDF)
Elements are not designed to support the temperature higher than 45°C (113°F). It does not mean that the elements cannot exceed the maximum temperature limit of 45°C. However, a greater potential for element damage exists as the temperature increases above 45°C, and the warranty is void. In order to operate or clean at high temperatures, high-temperature or heat-sanitizable elements with different materials of construction are recommended. FilmTec currently offers heat-sanitizable elements that can be heat-sanitized up to 85°C (185°F).
Please see section 5 of the DuPont Ultrafiltration Manual (Form Number) (pages 18-23), which discusses:
Start Up
Integrity Testing procedures
Shut Down
Operating and Cleaning Logs
In normal operation, the membrane surface in RO elements can become fouled by mineral scale, biological matter, colloidal particles and insoluble organic constituents. Deposits build up on the membrane surfaces during operation until they cause loss in normalized permeate flow and/or loss of normalized salt rejection.
If cleaning is delayed, system performance recovery may be less effective.
Differential pressure (P) should be measured and recorded across each stage of the array of pressure vessels. If the feed spacer within the element becomes plugged, the P will increase. It should be noted that the permeate flux will drop if feed water temperature decreases. This is normal and does not indicate membrane fouling.
A malfunction in the pretreatment, a malfunction of the pressure control or an increase in recovery can result in reduced product water output or increased salt passage. If a problem is observed, these causes should be considered first. The element(s) may not require cleaning. A computer program called FTNORM is available from FilmTec for normalizing performance data of FilmTec RO membranes. This program can be used to assist in determining when to clean and can be downloaded here at no cost from our web site
Also, please note that elements with a 34-mil feed spacer and iLEC™ technology require less frequent cleaning than equivalent elements using a 28-mil feed spacer.
Cleaning Requirements (64KBPDF)
Quinones and their analogues can be removed with anion exchange resins and adsorbents. The conjugated ring of the stabilizer associates with the styrenic ring of the anion exchange resin and the ionic groups pair up to effectively remove the stabilizer from solution. For stabilizer removal, we offers base resins such as AmberLyst™ A26 OH (PDF) . This can treat about 50 bed volumes of monomer containing 100 ppm stabilizer at a flow rate of 2 to 6 bed volumes per hour.
To remove stabilizers from non-aqueous, organic systems , a dry ion exchange resin is needed to facilitate intimate interaction of the solvent with the exchange site. AmberLite™ HPR550 OH and AmberLyst™ A26 OH are sold water wet. They can be dried in a vented oven at 60°C overnight or by washing them with a dry, polar solvent (methanol, ethanol, isopropanol, acetone, etc.).
HSRO membranes have high water permeability before they have been pre-conditioned. After pre-conditioning, they attain their specified flow and salt rejection performance during operation at normal temperature.
New HSRO heat sanitizable spiral elements are to be pre-conditioned prior to initial use by exposure to hot water. Suitable quality water must be used during all pre-conditioning steps.
An appropriate conditioning procedure consists of the following:
Heat Sanitization (37KB PDF)
We have not assigned MWCO values or ranges to each membrane. As a whole, they're considered to be MWCO 200-400, with NF270 as the loosest (higher MWCO) and NF90 being the tightest (lower MWCO).
So the comparison between NF90 and NF270 is: partial (significant) demineralization vs. none or very little demineralization. NF90 membrane is typically used in water softening. NF90 has sodium chloride rejection of between 90-96% while NF270 membrane has approximately 50% rejection. Both NF membranes have high magnesium sulfate rejections (98+%).
Rejection |
NF90 |
NF270 |
NaCl |
90-96% |
50% |
MgSO4 |
98+% |
98+% |
FilmTec NF90 Elements: Removal of TOC, nitrates, pesticides, herbicides, hardness, iron, salts.
FilmTec NF270 Elements: Removal of color, TOC, medium to low calcium passage, high salt passage.
You might want to consider feasibility testing. Page 2 of the brochure, Testing Chemical Compatibilities with FilmTec Membranes, gives a description of how to make a flat cell test unit.
Additional Information:
Major Desalination and Filtration Processes (124KB PDF)
In order to permeate water through RO or NF membranes, the applied pressure must always be greater than the osmotic pressure of the feed solution. As a feed is concentrated, the osmotic pressure increases and the applied pressure must also increase in order to maintain the permeate flow rate. For instance, if you have a seawater with feed concentration of 3.2%, it has osmotic pressure of roughly 350 psi. If you plan to operate the membrane system at 50% recovery, then you are doubling the feed concentration and the osmotic pressure will increase by a factor of two (i.e. 700 psi). So, the applied pressure must be greater than the osmotic pressure of 700 psi in this case and probably 900 to 1000 psi realistically. Also, RO and NF membrane elements have their own pressure limitations.
The maximum operating pressures on our various membranes are given below:
(The rule of thumb is 1 psi osmotic pressure per 100 mg/l of feed TDS.)
Do the membrane design guidelines for Desalitech systems differ from legacy reverse osmosis systems?
CCRO systems follow specific membrane design guidelines that are built into the Wave software. The inherent flexibility of the CCRO process makes it easier to keep RO and NF systems operating within the recommended ranges.
WAVE software coupled with CCRO greatly simplifies system design. For example, if design warnings that concentrate flow rate per pressure vessel is below the recommended value, by decreasing the ‘CC recovery’ parameter, which will directly increase the circulation pump flow rate. In contrast, a traditional system faced with the same problem would require permeate throttling, trying to balance the number of pressure vessels per stage, and/or adding concentrate recirculation.
For transferring the resin to the ion exchange vessel, we recommend use of an ejector (sometimes also called eductor) pump, if possible. The ejector is a very simple and inexpensive device but will not work where resin has to be transferred long distances. In this case, a pump will be needed but extreme care must be taken with pump selection if resin attrition is to be avoided. A low shear pump must be used, such as a diaphragm pump.
When possible, the use of an ejector is a safer and cheaper solution. The ejector pressure must be calculated so that it produces 1 bar (100 kPa or 15 psi) more pressure than the receiving vessel, otherwise its operation will be limited by the back pressure from the ion exchange vessel.
The resin is transferred as a slurry with water. The ratio of water to resin is about 50:50, in practice it varies between 1:1 and 2:1.
We would recommend that you contact your OEM to help you select conveying equipment.
Additional Information:
Loading Single Bed Ion Exchange Vessels PDF
Loading Layered Bed Anion Resins PDF
Recommendations for Loading an Internally Regenerated Mixed Bed, Tech Fact
Ion Exchange Resins - Preparation of Chromatographic Separation Resins
In order to minimize the potential for biofouling, inactive systems should be stored in a biostatic solution such as concentrated NaCl. In addition to minimizing biogrowth, the concentrated brine solution will prevent freezing. There are two recommended procedures depending on if the resins are used for standard water demineralization or mixed bed resins in condensate polishing and other ultrapure water applications
Standard Water Demineralization
Mixed Bed Resins in Condensate Polishing and other Ultrapure Water Applications
The resins should be left in a regenerated condition as follows:
Additional Information
Proper Storage Conditions for Exchange Resins (20KB PDF)
Traditional reverse osmosis systems typically achieve 75% recovery using a two-stage system design, or 87% incorporating a more complicated three-stage design. Each stage recovers 50% of its feedwater, with subsequent stages purifying the “leftovers” from the previous stage. Each additional stage produces diminishing returns and exacerbates problems with balancing water pressure across multiple stages.
Closed Circuit Reverse Osmosis eliminates these problems by using only a single stage. The CCRO process concentrates feed water in time versus space, not allowing enough time for sparingly soluble salts to precipitate. The multiple stages of a traditional system are replaced with cycles in closed circuit mode. After several cycles, the concentrate is flushed to drain. Without the constraints inherent in a multi-stage design, CCRO can achieve extremely high recovery rates. Generally, our systems operate in the 90-95% range, but under certain circumstances have operated up to 98% recovery.
One cycle represents the total volume of the system recirculated through the single membrane array. The time for one cycle is that volume divided by the circulation pump’s flow rate.
Cation Exchange Resins.
Weak acid cation exchange resins are based primarily on acrylic or methacrylic acid that has been crosslinked with a di-functional monomer (usually divinylbenzene [DVB]). The manufacturing process may start with the ester of the acid in suspension polymerization followed by hydrolysis of the resulting product to produce the functional acid group. Weak acid resins have a high affinity for the hydrogen ion and are therefore easily regenerated with strong acids.
The acid-regenerated resin exhibits a high capacity for the alkaline earth metals associated with alkalinity and a more limited capacity for the alkali metals with alkalinity. What this means is that it needs an alkaline anion in solution to get dissociated: for instance, an OH- ion (and also other strong conjugate bases such as CO32- or HCO3-). An alkaline ion will 'tear off' the H+ ion from the carboxylic group, neutralizing the alkaline anion and making the carboxylic group fully dissociated. At this stage, the stripped-off H+ ion will be replaced by a metal cation in solution. This is practically a neutralisation reaction: with OH- originally in solution, giving the product, HOH, i.e. water. With carbonate or bicarbonate, the product is H2CO3, which decomposes to CO2 + H2O.
No significant salt splitting occurs with neutral salts. However, when the resin is not protonated (e.g., if it has been neutralized with sodium hydroxide), softening and/or removal of higher valent cations can be performed, even in the presence of a high salt background.
Examples:
Strong acid resins are sulfonated copolymers of styrene and DVB. These materials are characterized by their ability to exchange cations or split neutral salts and are useful across the entire pH range. Please see Using Ion Exchange Resin Selectivity Coefficients' (44KB PDF) for information regarding selectivities for various cations.
Additonal Information:
Fundamentals of Ion Exchange, Paper (2.7MB PDF)
Yes. Desalitech’s closed-circuit reverse desalination process is protected by 140 patents in 60 countries worldwide.
Yes, cation exchange resins used for softening also remove iron from the water. The removal efficiency depends on the Fe species present. Soluble Fe2+ and Fe3+ are very well taken up by the strong acid cation resin. Particulate iron-oxides are partially removed through filtration. However, if the concentration of iron is greater than 0.05 ppm, it has the tendency to foul the resin and catalyze its degradation. Colloidal or organo-Fe-complexes are usually not removed at all and will pass through into the product water.
Additional Information:
Ion Exchange Resins - Cleaning and Maintenance
Procedure for Removing Iron from Anion Resins (10KB PDF)
Procedure for Removing Iron from Cation Resins (25KB PDF)
There are two types of adjusted feeds, 'initial' and 'after recycles'.
If your feed was adjusted for pH with chemical dosing, then this would be called 'initial adjusted feed'. If your feed includes a recycle stream, then this would be called 'after recycles adjusted feed'. The 'after recycles adjusted feed' can either be a pH adjusted or no pH adjusted feed though.
The element fabrication process involves two steps: First, FilmTecTM FT30 membrane coating is made on membrane sheet, and the membane sheet is rolled into a spiral wound module. Precision automated fabrication allows FilmTec elements to be the most consistent, reliable and long-lasting product with the widest pH cleaning range in the market.
Element Construction (116KB PDF)
Although we have no specific information regarding the chlorine tolerance of weak acid cation (WAC) resins, there is no reason to suspect that these resins are less tolerant than strong acid cation (SAC) resins since chlorine oxidation results in decrosslinking and not defunctionalization. Because both types of resins are crosslinked with divinylbenzene, WAC resins can probably withstand chlorine concentrations up to 0.1 ppm as long as the operating temperature does not exceed 20°C. Note that any amount of chlorine, however, will result in some degree of decrosslinking, although it may be immeasurable.
Additional Information:
What effect does chlorine have on cation exchange resins?
Recommendations for Maximum Free Cl2 Limits for Cation Exchange Resins (91KB PDF)
In general, the highest quality water available to the plant should be used for regenerant dilution and rinse. Water with any ionic content could result in some of the sites being converted to the exhausted form instead of the active form during regeneration. This could result in an increase in leakage during the next exhaustion cycle that might exceed the maximum leakage or conductivity limitation. For this reason, we would not recommend using non-purified water for regenerant dilution and rinse.
Similarly, softened water and other waters with ionic load will pre-exhaust a portion of the resins capacity if used for rinse.
Conversely, most water supplies can be used for backwash, since regeneration is the next step. Keep in mind that any hard ion load (Ca++, Fe++, Mg++) will be picked up by the resin and increase the load to be regenerated.
Co-Current/Co-Flow Regeneration: In general, water treated by the previous column is used for dilution and slow rinse (displacement).
Step | Cation | Anion |
Backwashing | Feed water | Decationized |
Dilution | Feed water | Decationized or demineralized |
Displacement | Feed water | Decationized or demineralized |
Final rinse | Feed water | Decationized |
Counter-current or Reverse-Flow: In general, water treated by the column itself is used for dilution and slow rinse (displacement).
Step | Cation | Anion |
Backwashing | Feed water | Decationized |
Compaction | Decationized or demineralized | Demineralized |
Dilution | Decationized or demineralized | Demineralized |
Displacement | Decationized or demineralized | Demineralized |
Final rinse | Feed water | Decationized |
The reasons are:
Samples of our FilmTec™ Flat Sheet can be purchased online through Octochem’s secure website. Please click on the link to be directed to their website. For questions regarding shipments, please contact Octochem at 1-800-423-0886.
For assistance in selecting the right membrane type for your needs, please see the FilmTec Membrane Product List.
Ozone is an even stronger oxidizing agent than chlorine. However, it decomposes readily. A certain ozone level must be maintained to kill all microorganisms. The resistance of the materials of construction against ozone has to be considered. Usually, stainless steel is employed.
Removal of ozone must be performed carefully to protect the membranes. Ultraviolet irradiation has been used successfully for this purpose.
Additional information
As the feed water temperature increases, the permeate flow will increase, but at the same time the salt passage will also increase.
Typically when flow is increased by increased feed pressure the permeate quality will improve due to a better salt to water passage ratio. This is because salt passage is not changed by feed pressure. But in the case of temperature, the salt passage is increased at a rate of approximately double the increase of permeate flow. This means that the permeate quality will get worse even though the permeate rate is increasing. This may be acceptable if the permeate quality stays within the defined limits. The only other issue to worry about is scale.
Many sparingly soluble salts will come out of solution sooner at elevated temperatures, which in turn could lead to scaling on the membrane surface, which would then lead to lower flow and poorer rejection. In majority of cases, the benefits of raising the temperature will outweigh the negatives. But in some cases raising the temperature will lead to unacceptable permeate quality or shorter membrane life.
Additional Information:
Factors Affecting RO Membrane Performance (65KB PDF)
Mixed beds are primarily used for polishing demineralized water. The mixed bed produces very high purity water from a single unit that contains cation and anion resin in an intimate mixture. This intimate mixture of resin minimizes sodium leakage because the dilute acid formed in cation exchange process is immediately neutralizd by the anion resin. As a pre-mixed resin, it also allows for faster initial rinse-up prior to service, which minimizes rinse waste water volume
Primary Advantages Are:
DuPont offers a variety of mixed bed ion exchange resins for industries such as nuclerar power generation, semiconductor manufacturing, laboratory and pharmaceutical:
Many of the FilmTec elements have ANSI/NSF Standard Certification, standards 58 or 61. The element listings can be found on the linked NSF website below.
NSF/ANSI STANDARD 58: 'It applies to point-of-use and point-of-entry devices designed to reduce specific contaminants from public or private drinking water. These contaminants may include chemical, particulate, and microbiological parameters that may constitute potential health hazards and/or affect aesthetic quality characteristics. In addition, the Standards include requirements for materials and structural integrity.'
NSF/ANSI STANDARD 61: 'Drinking Water System Components – Health Effects is the nationally recognized health effects standard for all devices, components and materials, which contact drinking water.'
Additional Information:
FilmTec Membrane Regulatory Information
For raw waters containing high concentrations of suspended matter resulting in a high SDI, the classic coagulation-flocculation process is preferred. The hydroxide flocs are allowed to grow and settle in specifically designed reaction chambers. The hydroxide sludge is removed, and the supernatant water is further treated by media filtration.
For the coagulation-flocculation process, either a solids-contact type clarifier (see also Lime Softening, Section 2.3.6) or a compact coagulation-flocculation reactor may be used. For details, please refer to the general water treatment textbooks, such as Water Quality and Treatment, 5th Edition, Prepared by the American Water Works Association, McGraw-Hill, Inc., New York, 1999 and Water Treatment Handbook, Degremont Company, 6th Ed 1991.
Please see the following link for additional details.
When shipped from the factory, brine seals are located on the feed end of the element, with the flared side facing the direction of the incoming feedwater. Brine seals can be placed on either end of standard FilmTec™ elements as long as they seal in the feed stream direction with the flared side facing the incoming feedwater.
Note: FilmTec™ iLEC™ elements only have the brine seal on the feed end of the element due to the unique configuration of the end caps.
When loading or installing new elements, here are a few tips:
Possible Causes | Remedies |
Faulty instrumentation |
Check the accuracy of analytical instrumentation used to determine water quality and recalibrate or replace as required. |
Unacceptable resin separation |
Remix or replace resins in non-regenerable beds. |
Improper mixing after loading | Ensure the proper loading conditions are applied. |
Improperly regenerated resins | See Mixed Bed Troubleshooting Guidelines . |
Increase in influent total dissolved solids (TDS) |
Recalculate the throughput according to the new feed water TDS. |
UF systems are designed to run continuously and membrane systems perform better when operated continuously. However, in reality UF systems will start up and shut down on some frequency. When the UF system is shut down, the system must be cleaned using air scour and backwashed with permeate water to prevent bacterial growth in the UF system.
The water used for backwash before shutdown should not contain chemicals. Any feed water and backwash chemical dosing used should be stopped before the last cleaning and shutdown. After cleaning, all valves on the UF system should be closed to seal the system.
To avoid leakage in the module housing end caps and clamps, the backpressure in the modules should be controlled when the UF system shuts down, especially in case of non-scheduled shutdowns, e.g. power failure or emergency shutdowns.
When the system is down for greater than 48 hours, note the following:
• The module should not dry out. Dry membrane fibers will irreversibly lose flux at any time.
• The system should be adequately protected against micro-biological growth, flushed 30 to 60 minutes per
day, or operated every 24 hours.
• The system should be protected against temperature extremes. The UF system can be shut down for 48
hours without adding storage solution and taking precautions for microbiological fouling.
When the system is down for greater than 48 hours, note the following:
• Addition of storage solution is necessary for system down time greater than 48 hours.
Skid Shutdown Summary:
Storage Duration | Recommended Steps |
0 to 48 hours | Air scour and backwash, close all valves |
>2 days to 7 days | Air scour and backwash, close all valves, perform 30 to 60 minutes of operations daily or air scour, backwash, add storage solution then close all valves |
>7 days to 90 days | Add storage solution, renewing the solution every three months |
>90 days | Consult the manufacturer |
Storage of Modules Off Skid:
If the UF system will be out of service for a long time, the modules can be removed from the skid and stored to avoid routine operations as defined above. Air scour and backwash should be applied before decommissioning the equipment. Add 2, 4, and 6 liters of 1% sodium bisulfite solution into the permeate port of a 2660, 2860 and 2880 module respectively. Once the storage solution is added into the module, all inlet and outlet ports should be sealed using the plastic discs, Victaulic flanges, and plugs as shipped from the factory. Modules should be placed in a plastic bag to protect the module. Each module should be placed horizontal with the feed ports facing up into an individual or separate shipping box or crate. If the modules are exposed to freezing conditions, glycerin should be added to the storage solution to achieve a 20% concentration. A table below is provided for reference. Modules prepared as described can be stored for 90 days. Consult the manufacturer for storage durations greater than 90 days.
Glycerin vs. Freezing Point Depression
Glycerin, Wt % |
Viscosity, cP |
Freezing Point Depression, °C |
0.5 |
1.011 |
0.07 |
3.0 |
1.074 |
0.63 |
5.0 |
1.127 |
1.08 |
9.0 |
1.256 |
2.06 |
12.0 |
1.365 |
2.88 |
14.0 |
1.445 |
3.47 |
16.0 |
1.533 |
4.09 |
20.0 |
1.737 |
5.46 |
24.0 |
1.988 |
7.01 |
28.0 |
2.279 |
8.77 |
32.0 |
2.637 |
10.74 |
36.0 |
3.088 |
12.96 |
40.0 |
3.653 |
15.50 |
44.0 |
4.443 |
17.73 |
48.0 |
5.413 |
20.39 |
52.0 |
6.666 |
23.22 |
56.0 |
8.349 |
26.23 |
60.0 |
10.681 |
29.41 |
DuPont UF - Storage and Handling
Cation exchange resin can contaminate the anion exchange resin bed leading to longer rinses, poorer water quality and sometimes necessitating resin replacement. There are two possible ways for the cation exchange resin to contaminate the anion exchange resin:
With upflow service / down flow regeneration (non-UPCORE) small cation exchange resin beads and pieces may accumulate at the top of the cation vessel, which is the closest point to where the water exits the vessel (and closest to the anion resin bed) due to the upflow service. Thus it is more likely for the cation exchange resin fines to get into the anion exchange resin vessel (and possibly a degasifier placed between the resin beds). These systems generally need resin traps and periodic backwashing in a separate backwash vessel to prevent cross contamination.
Additional Information:
UPCORE Packed Bed System
Particulate or colloidal fouling of reverse osmosis (RO) elements can seriously impair performance by lowering productivity and sometimes salt rejection. An early sign of colloidal fouling is often an increased pressure differential across the system.
The source of particulate or colloids in reverse osmosis feedwaters is varied and often includes bacteria, clay, colloidal silica, and iron corrosion products. Pretreatment chemicals used in clarification such as alum, ferric chloride, or cationic polyelectrolytes can also cause fouling if not removed in the clarifier or through proper media filtration. In addition, cationic polymers may coprecipitate with negatively charged antiscalants and foul the membrane.
Several methods or indices have been proposed to predict a colloidal fouling potential of feed waters, including turbidity, Silt Density Index (SDI) and Modified Fouling Index (MFI). The SDI is the most commonly used fouling index.
The turbidity of feed water to RO/NF should be less than 1 NTU as one of the minimum requirements of feedwater. Pretreatment with Ultrafiltration facilitates stable RO membrane performance, resulting in UF filtrate water with average turbidity of < 0.1 NTU, 95% of time, and silt density index (SDI) < 2.5 , 90% of time.
Please see the following links for details about additional methods.
Fouling Prevention |
Assessment of the Colloidal Fouling Potential (62KB PDF) |
Media Filtration (27KB PDF) |
Oxidation - Filtration (27KB PDF) |
In-line Filtration and Coagulation-Flocculation (28KB PDF) |
Microfiltration / Ultrafiltration (23KB PDF) |
Cartridge Microfiltration (26KB PDF) |
Other Methods - Design and Operational Considerations (24KB PDF) |
Design and Operational Considerations (24KB PDF) |
Fouling Prevention |
Prevention of Fouling |
DuPont does not recommend specific commercial products. General Anti-scalant Recommendations (PDF) are available on our web site, as well as information on how to ensure membrane compatibility of commercial formulations.
Additional Information:
FilmTec Membranes - Pretreatment Summary
Testing Chemical Compatibilities with FilmTec Membranes (29 KB PDF)
FilmTec Membranes - Scale Control by Use of Scale Inhibitors
Compatibility with vessels from major manufacturers has been confirmed at installations around the world.
It is recommended to check with vessel manufacturers regarding thrust rings and end adaptors if there are any questions regarding a specific vessel models and iLEC elements.
The level of feed water contaminants depends on the efficiency of the pretreatment, and specific raw water quality requirements will define the necessity of a pretreatment. Suspended solids, oils, organic matter, and certain inorganic substances (e.g. Fe, Mn) in the raw water must be limited to ensure troublefree plant performance.
Heavy metals: Iron, manganese, copper and chrome
Additional Information:
Ion Exchange Resins - Recommended Operating Conditions
Water Conditioning Manual (3.4MB PDF)
From a corrosion point of view, a very harsh environment prevails in an RO water desalination plant. Hence the materials of construction must possess a certain degree of corrosion resistance. This is true for both the exterior parts exposed to spillage and a humid and saline atmosphere as well as for the interior of the system exposed to the wide variety of waters treated.
Although not to be underestimated, the control of exterior corrosion can usually be overcome by using a surface coating (painting, galvanizing, etc.) on materials likely to corrode (mild steel, cast iron, etc.) and by establishing a maintenance program involving periodical flush down and cleaning, repair of leaks, etc.
Selecting materials of construction for the interior wetted system is a far more complicated task. Apart from being compatible with the pressures, vibrations, temperatures, etc., existing in an RO system, the materials must also be able to withstand potential corrosion attacks caused by the high chloride content of the feed water and concentrate stream, the aggressive product water and the chemicals used for applications such as membrane cleaning.
Application of nonmetallic materials such as plastics, fiberglass, etc., are widely used for preventing corrosion and chemical attacks as well in the low-pressure (< 145 psi/10 bar) part of the RO system as in the RO elements and pressure vessels. However, it is usually necessary to use metals for the high-pressure (145–1,000 psi/10–70 bar) parts such as pumps, piping and valves. Carbon and low alloy steels do not have sufficient corrosion resistance, and their corrosion products can foul the membranes.
Lined piping is usually not a realistic alternative because of the often compact piping design and relatively great amount of connections and fittings needed. Al-bronze can be an alternative for pumps etc., but the risk of erosion corrosion and chemical attacks must be taken into account. The most relevant material to be used for the high-pressure parts is stainless steel.
The basic advantage with stainless steel is that it is very resistant to general corrosion and erosion corrosion. Stainless steel is rarely attacked by galvanic corrosion, but it will influence the attack on the other metal in a two-metal couple (e.g. copper, brass, etc.). Stress corrosion cracking of stainless steels in media containing chloride rarely occurs below 158°F (70°C) so it does not need to be considered in an RO desalination plant.
Unfortunately, some stainless steels are prone to pitting and crevice corrosion in the waters occurring in an RO plant. Pitting means localized attacks that result in holes in the metal. Pitting occurs where the passive film formed by chromium oxides breaks and chlorides can attack the bare metal. Crevice corrosion is pitting associated with small volumes of stagnant water caused by holes, gasket surfaces, deposits, and crevices under bolts, etc. In order to avoid pitting and crevice corrosion in the RO water desalination plant the following recommendations can be given:
RO Plants with Concentrate Stream TDS below 7,000 ppm
Stainless steel type AISI 316 L with <0.03% C is the minimum demand for the pipe system because lower grade stainless steels with higher carbon content will suffer from pitting in the welding zones (intergranular corrosion). For non-welded parts, stainless steel type AISI 316 is usually acceptable.
RO Plants with Concentrate Stream TDS higher than 7,000 ppm
Stainless steel type 904 L is recommended for pipes and bends for welding and for similar parts without crevices. Where crevices occur, such as at flange connections, in valves, in pumps, etc., stainless steel type 254 SMO or similar with ≥ 6% Mo is recommended. These two higher alloy stainless steels can be welded together without risking galvanic corrosion. Sen
For o-rings and brine seal, a pure silicone grease lubricant for membrane use, should be used.
Purchase of lubricant in a pail versus a tube or cartridge is that, with one hand, the installer can stick his or her finger into the pail to get just enough of the lubricant for each o-ring. The use of a tube or cartridge requires two hands - one to squeeze and one to collect on his or her finger.
Glycerin can also be used but the shortfalls are that it is soluble and that it is washed away leaving no lubrication on the o-rings.
Application Information:
FilmTec Elements - Installation
Preparation and Element Loading (41KB PDF)
The fouling of membrane surfaces manifests itself in performance decline, lower permeate flow rate and/or higher solute passage. Increased pressure drop between the feed and concentrate side can be a side effect of fouling.
Cleaning is done in order to clean the membrane surface of foulants. Cleaning will be more effective the better it is tailored to the specific fouling problem. Sometimes a wrong choice of cleaning chemicals can make a situation worse. Therefore, the type of foulants on the membrane surface should be determined prior to cleaning.
Fouling of the membrane surfaces may be caused by:
• Inadequate pretreatment system
• Pretreatment upset conditions
• Improper materials selection (pumps, piping, etc.)
• Failure of chemical dosing systems
• Inadequate flushing following shutdown
• Improper operational control
• Slow build-up of precipitates over extended periods (barium, silica)
• Change in feed water composition
• Biological contamination of feed water
Cleaning can be accomplished very effectively because of the combination of pH stability and temperature resistance of the membrane and the element components. However, if cleaning is delayed too long, it could be difficult to remove the foulants completely from the membrane surface.
There are different ways to determine the type of foulants on the membrane surface.
• Analyze plant performance data. Details are given in Evaluation of System Performance and Operation (75KB PDF)
• Analyze feed water. A potential fouling problem may already be visible there.
• Check results of previous cleanings.
• Analyze foulants collected with a membrane filter pad used for SDI value determination (70KB PDF)
• Analyze the deposits on the cartridge filter.
• Inspect the inner surface of the feed line tubing and the feed end scroll of the FilmTecTM element. If it is reddish-brown, fouling by iron materials may be present. Biological fouling or organic material is often slimy or gelatinous.
Can FilmTec help me analyze my elements?
Which cleaning chemicals should I use?
Cleaning and Sanitization Introduction (38KB PDF)
The void volume is the space that exists between resin beads. The void volume can be calculated using the following equation:
Void Volume (%) = 100 * (1 - (Apparent Density / True Density))
Additional information:
Strong acid cation resin
Strong base anion resin
Weak acid cation resin
Weak base anion resin
This can happen if some libraries are missing from your system. Please get copies of the OCX files from the Microsoft web site Download MSCOMCT2.OCX and place in the C:WindowsSysWOW64 folder.
Then click on <All Programs> -> <Accessories> and right click on <Command prompt>, Select 'Run as administrator' Say yes to the Warning pop-up
Symptom | Possible Causes | Remedies |
High conductivity/ |
Faulty or inaccurate |
Check measurement system. Repair or replace if necessary. |
Valve leakage |
Check and adjust all valves. | |
Inadequate regeneration | Check for correct resin contact time, flow rates, and concentration |
|
Internal distributor blocked | Repair/clean distributor. | |
Flow rate above normal |
Reduce flow or change to larger bead resin. | |
Channeling | See high pressure drop causes | |
Low service water flow rate | Increase service water flow rate to minimum operating guidelines to prevent channeling |
|
Resin degradation/fouling | Take sample and confirm with resin analysis , clean or replace resin as appropriate. See Cleaning Procedures. |
|
Poor regenerant quality | See guidelines for regenerant quality. | |
Hardness leakage from cation resins |
CaSO4 precipitation | Clean and check acid injection concentrations or implement step-wise regeneration . |
CO2 leakage from weak anion resins |
Faulty degassifier for systems | Measure pH from weak base anion unit. If pH <4 and CO2 is present in effluent, check/repair degasifier function. |
Silica leakage from weak base anion |
Silica precipitation | In high silica waters, regenerant from strong base anion resin must be initially dumped before applying to weak base anion. |
CO2 leakage from strong anion resins |
Faulty degasifier | Measure pH from weak base anion unit. If pH <9 and CO2 is present in effluent, check and repair degasifier function. |
Silica leakage from strong base anion resins |
Presence of colloidal silica | Review pretreatment and modify as appropriate . |
Silica leakage from strong base anion resins |
High feed water temperature | Adjust regenerant conditions or operating conditions to compensate. |
Low regeneration temperature or lack of bed preheating |
Adjust regenerant conditions or operating conditions to compensate. | |
Low pH, high conductivity, silica leakage from anion resins |
Organic fouling, loss of strong base capacity |
Take sample and confirm with resin analysis , clean or replace resin as appropriate. |
Sodium leakage, high pH, silica leakage from anion resins |
Premature sodium break from cation |
Check cation for calcium sulfate precipitation and regeneration sequence. |
Sodium leakage, high pH from anion resins |
Strong acid cation resin incursion (cross contamination) |
Investigate cause (e.g. broken strainers or traps). Replace anion. |
The basic operating conditions for DuPont's Ultrafiltration Modules are shown in the Table below.
Operating Conditions |
SI | US |
Maximum Inlet Pressure |
6.25 bar @20°C | 90.65 psi @ 68°F |
Operating TMP (Maximum) | 2.1 bar | 30.50 psi |
Backwash TMP (Maximum) | 2.5 bar | 36.25 psi |
Operating Air Scour Flow (Recommended) | 12 Nm3/h/module |
7 scfm/module (4 scfm/h/module for SFP/D‐2660) |
Air Scour Pressure | 0.35 – 2.5 bar | 5.0 – 36.25 psi |
Filtrate Flux @25°C | 40 – 110 LMH | 24 – 65 gfd |
Temperature | 1 – 40°C | 34 – 104°F |
Operating pH Range | 2 - 11 |
|
NaOCl, Cleaning Maximum | 2,000 ppm |
Additional Information
The UPCORE™ system uses a simple countercurrent design, resulting in lower capital costs.
The UPCORE™ countercurrent regeneration system uses downflow for the service cycle. A downflow service cycle has many advantages and is used by most of the ion exchange resin plants in the world (this includes all types of plants including co-flow regeneration systems and counterflow regeneration systems that use an air or water hold down process). At the end of the UPCORE™ system service cycle the resin bed is compacted with water in an upflow direction against a layer of floating inert resin at the top of the vessel. The resin regeneration and rinse is then carried out in an upflow direction, which is the most common practice among countercurrent regeneration processes.
Additional Information:
Recommended AmberLite™ ion exchange resins for packed bed systems in industrial water treatment
Retrofit of Demineralizer with UPCORE System Cuts Chemical Costs by 50% (90 KB PDF)
System Optimization Services (SOS) is the comprehensive service offering made available to customers using our DuPont Water Solutions products. These services are designed to provide sound recommendations and the ongoing guidance you require ensuring optimal system performance and includes the following:
Additional Information:
System Optimization Services (SOS)
Membrane life is a function of feed water source, pretreatment, frequency of cleaning, system design, and operating conditions. For economic analysis, a 5 year life is normally used.
Additional Information
ROSA 9.1
Release date: 21 September 2013
Enhancements:
- Further refinement of model with respect to wider feed pH and feed water concentrations
- Improved modeling for brackish water elements, adding feed TDS dependency
- Includes new ECO products
ROSA 8.0.3
Release date: 12 March 2012
Enhancements:
- Addition of Ultrafiltration Water Types
- Improved pH models for BW elements, reflecting more accurate pH dependence
- Improved compatibility with Windows 7®, both 32 and 64-bit platforms
- Improved EVA calculations Upgraded product specifications for existing elements
- Fixed split stream design warnings
ROSA 7.2.1
Release date: 28 September 2010
Enhancements:
- Upgraded product specifications for existing elements
- Improved prediction of NH4 / NO3 rejections as function of pH
- Batch processor - enabling multiple simulations with increments in temperature
- Use of flow factor (FF) to better represent effect of operating conditions
ROSA 7.0.1
Release date: 2 July 2009
Build date: 1 July 2009Enhancements:
- More accurate projections for low-temperature seawater plants.
- User interface and report bug fixes.
- A contemporary appearance and the choice of two color schemes.
- A Flow Calculator that provides more streamlined definition of system flow rates and recoveries (especially convenient for 2-pass designs).
Systems with more than one stage are used for higher system recoveries without exceeding the single element recovery limits. Usually two stages will suffice for recovery up to 75%, and three must be used for higher recovery. These numbers are based on the assumption that standard pressure vessels with six elements are used. For shorter vessels housing only three elements, for example, the number of stages has to be doubled for the same system recovery. Generally speaking, the higher the system recovery, the higher the number of membrane elements that have to be connected in series. To compensate for the permeate that is removed and to maintain a uniform feed flow to each stage, the number of pressure vessels per stage decreases in the direction of feed flow. A typical two-stage system using a staging ratio of 2:1 is shown in Figure 3.5. The staging ratio is defined as the ratio of pressure vessels in two adjacent stages, upstream vessels: downstream vessels.
Figure 3.5 Two-stage system
Please see the tables and graph in the Suggested Operating Temperatures Brochure (12KB PDF). We would recommend that you operate below the recommended maximum temperatures. That is not to say you cannot have higher temperatures, but it will reduce the lifetime of your resin.
How does the average permeate flux rate in a CCRO system compare to legacy reverse osmosis systems?
The average rate of permeate production is comparable to traditional reverse osmosis, but there may be brief fluctuations in permeate production when concentrated brine is flushed from the system with raw feedwater. Plants with polishers downstream of a CCRO system may experience issues with this flow inconsistency. This can be addressed using a break tank and distribution pump immediately following the CCRO system. Another solution is to hold the permeate flow rate constant by increasing the recovery and feed flow rate during the flush (PF mode).
Our standard product line is designed to handle 50 - 1050 gallons per minute (gpm). Custom units and train configurations are available for projects up to 1400 gpm. We also supply systems smaller than 50 gpm through a partnership.
Styrene-DVB based resins
Strong base anion resins are classed as Type 1 and Type 2.
Type 1 is a quaternized amine product made by the reaction of trimethylamine with the copolymer after chloromethylation. The Type 1 functional group is the most strongly basic functional group available and has the greatest affinity for the weak acids such as silicic acid and carbonic acid, that are commonly present during a water demineralization process. However, the efficiency of regeneration of the resin to the hydroxide form is somewhat lower, particularly when the resin is exhausted with monovalent anions, such as chloride and nitrate. The regeneration efficiency of a Type 2 resin is considerably greater than that of Type 1.
Type 2 functionality is obtained by the reaction of the styrene-DVB copolymer with dimethylethanolamine. This quaternary amine has lower basicity than that of the Type 1 resin, yet it is high enough to remove the weak acid anions for most applications. The chemical stability of the Type 2 resins is not as good as that of the Type 1 resins, the Type 1 resins being favored for high temperature applications.
Weak base resins do not contain exchangeable ionic sites and function as acid adsorbers. This is why the active form is referred to as the free base form. These resins are capable of sorbing strong acids with a high capacity and are readily regenerated with caustic. They are therefore particularly effective when used in combination with a strong base anion by providing an overall high operating capacity and regeneration efficiency.
The WBA resin needs a strong acid in solution, something that will readily supply a H which will "protonate" the amine group, converting it to a quaternary ammonium ion. Once this is done, the active group is fully dissociated and can exchange anions. This is again a kind of neutralisation of the amine by an acid, and the product of the reaction is nothing: the resin has taken up both the H ion and the corresponding anion from solution. Example:
RN(CH3)2 + HCl RN(CH3)2H+ Cl– (quaternary amine salt)
This reaction is also very effective, and not an equilibrium, thus irreversible. To be reversed (regeneration), the active group needs a strong alkali that will supply OH ions to neutralise the quaternary ammonium group, ripping-off the H from it.
Acrylic Based Weak Base Resins
These anion exchange resins are an exception, as their alkalinity is strong enough to remove carbonic acid from water. If you consider carbonic acid as hydrated carbon dioxide:
CO2 + H2O <----> H2CO3
The carbonic acid then reacts with the acrylic resin:
RN(CH3)2 + H2CO3 <----> RN+H(CH3)2 + HCO3–
This last reaction is reversible. The uptake of CO2 is not complete. But, this applies only to acrylic WBA resins. Styrenic and phenolic resins do not remove carbon dioxide at all.
Our ion exchange resins are packaged based on the backwashed and settled density of the resin as determined by ASTM D-2187.
Volume of resin = weight of resin / backwashed and settled density of resin
For example:
The backwashed and settled density of AmberLite™ HPR650 H resin is 49 lbs/ft3
The backwashed and settled density of AmberLite™ HPR4811 Cl resin is 0.670 kg/L.
Dry elements are loaded following the same procedures as are used to load wet elements. The procedures for loading elements are described in the following brochure.
Loading of Pressure Vessels: Preparation & Element Loading (59KB PDF)
Additional information
There are 2 different sets of instructions depending on if you have 64 bit machine or a 32 bit machine.
If you have a 64 bit computer:
If it's a 32 bit computer:
If WAVE installs successfully, but you are unable to open the application after clicking on desktop icon (WAVE splash screen with product information might appear but any error pop up does not appear)
This issue arises if you had previously installed WAVE a long time ago and it was not cleanly uninstalled.
The following link recommends materials of construction for cleaning equipment. It also provides a guideline for sizing a cleaning tank by using the approximate volume of the empty pressure vessels and the volume of the feed and return hoses or pipes. See the link for the detailed calculation and example.
Cleaning Equipment (76KBPDF)
Polymeric adsorbent resins can be used for the concentration of chlorinated and organic solvents from air streams.
AmberSep™ OPTIPORE™ V493 is a polymeric adsorbent resin used for the concentration of chlorinated and organic solvents from air streams, particularly in fluid bed systems.
AmberSep™ OPTIPORE™ V503 is a polymeric adsorbent resin used for the removal of chlorinated and organic solvents from humid air streams, particularly in fixed bed systems.
Additional Information
Formaldehyde Air Emissions Control, Technical Information (32 KB PDF)
Styrene Emissions Control, Technical Information (21 KB PDF)
Fluidized Bed Applications with Polymeric Adsorbents, Technical Information (70 KB PDF)
Offering a Broad Range of Options for Organics Removal (357 KB PDF)
The feed channel spacer thicknesses vary depending upon the element model number, but they typically range from 28-34 mils. Additional information may be found in the product data sheets.
The Unique Design of FilmTec Elements
Membrane systems are sanitized in order to keep the number of living microorganisms at an acceptably low level. There are two main reasons why sanitization is required:
Smooth operation - Microorganisms may grow into a biofilm at the membrane and feed spacer surface and cause biofouling. Biofouling is a major threat to system operation, and regular sanitization is part of a strategy to control biofouling. Regular sanitization helps to keep the level of biological growth low enough to avoid operational problems. In RO systems operating with biologically active feed water, a biofilm can appear within 3–5 days after inoculation with viable organisms. Consequently, the most common frequency of sanitization is every 3–5 days during peak biological activity (summer) and about every 7 days during low biological activity (winter). The optimal frequency for sanitization will be site-specific and must be determined by the operating characteristics of the RO system.
Permeate water quality - Some applications, for example in food and pharmaceutical industries, require a high product water quality with respect to microbiological parameters. Although RO and NF membranes are theoretically rejecting 100% of microorganisms, any minute leakage in the membrane system may allow the permeate water to get contaminated. The risk of contamination is much higher with a biofilm present on the feed side; therefore the membrane has to be kept in a sanitary state. Regular sanitizations in these applications are required to ensure the microbiological quality of the permeate water, even if no operational problems are encountered.
Hydrogen Peroxide and Peracetic Acid
Sanitizing RO and NF Membrane Systems - Introduction (26KBPDF)
The plant configuration will depend on the feed water composition, the water quality required and the economics of operation. The following general guidelines are given to help in configuration and resin selection. Due to their improved performance, the uniform particle size resins are recommended over standard (polydispersed) resins.
Strong Acid Cation Resin
Strong Acid Cation Resin is used for water softening in the Na cycle and for demineralization when the temporary hardness in the feed is < 40%. For small plants and with HCl as regenerant, a strong acid cation also offers a simple effective solution on waters with > 40% temporary hardness.
Weak Acid Cation Resin
Weak Acid Cation Resin is used as a single resin for dealkalization in the H cycle and for brackish water softening in Na cycle. In demineralization, the use of a weak acid cation in front of a strong cation is preferred with feed waters containing a high proportion of temporary hardness (>40%) and low FMA. This configuration has advantages in terms of regeneration efficiency and operating capacity.
With sulfuric acid regeneration, two separate cation columns should be used in order to allow acid dilution at the weak acid resin inlet. For counter-flow regeneration, a double compartment layered bed cation including a facility for acid dilution at the weak acid cation inlet can be used, but is more complex to operate.
Strong Base Anion Resin Type I
Strong Base Anion Resin Type I as a single resin is particularly recommended for treating low FMA (Free Mineral Acid) water with high silica and where low silica leakage is required (~20 ppb in counter-current operation). The resin can be regenerated up to 50°C (122°F) for more effective silica removal.
Strong Base Anion Resin Type II
Strong Base Anion Resin Type II is well suited for small plants, owing to its excellent regeneration efficiencies for water compositions where CO2 and SiO2 are < 30% of the total feed anions. Type II anions have a much better operating capacity and regeneration efficiency compared to Type I, but are limited to lower temperature operation (<35°C/95°F caustic treatment) and have a higher SiO2 leakage (~50 ppb in counter-current operation).
Weak Base Anion Resin
Weak Base Anion Resin is used as a single resin to obtain partially deionized water without removal of CO2 and SiO2. For complete demineralization, the combination of weak base and strong base anion is an excellent choice for larger plants, as it provides optimum operation costs. The weak base has very high regeneration efficiency and provides additional capacity to the system. The weak and strong anion combination is well suited to treat waters with low alalkalinity or degassed feed, when the FMA (Cl + NO3 + SO4) is typically > 60% of the total anions.
Weak base anions are particularly effective in handling natural organics, which are usually high molecular weight weakly acidic compounds that affect both weak base and strong base anion resins. In a weak base - strong base anion configuration, some of the organics will pass through the weak to the strong base. The design should therefore account for SBA organic loading at the end of the cycle, as the resin will require additional NaOH to desorb the organics. There are important differences in loading capacity or reversibility to organics between different anion types.
For treating resins contaminated with silica or organics, see silica removal (20KB PDF) and brine cleaning of anion resins for organic contamination (26KB PDF).
The weak and strong anion resins can either be designed in two separate vessels or for counter-flow regeneration in one vessel with or without a separation nozzle plate.
Additional Information
Analysis of ion exchange resins that have been used in service is available from DuPont
System Optimization Services (SOS)
This page provide information on:
Additional information:
Resin Sampling Procedure, Tech Fact (602 KB PDF)
Ion Exchange Resins System Optimization Service SM (SOS) Request Form (PDF)
If a particular bank or vessel in a reverse osmosis system has an abnormally high salt content (conductivity) in the product water, this is a clear indication that an o-ring is leaking or that an element has failed. The key in locating the problem is to have a system designed to detect and pinpoint any malfunctioning membrane or associated component. This is accomplished by having a series of FilmTec Membranes - Recommended Sampling Points for each vessel and unit subsection, which allows one to trace a problem from the output product water to the problem vessel. Each vessel should have the capability to insert a sampling tube into the product water tubes whereby the conductivity can be measured and the problem located.
O-ring leakage problems are a common source of poor quality product water. However, if a membrane element has been identified as the culprit, it may be advisable to have an autopsy of the element to ascertain the cause of the problem. DuPont offers a wide variety of membrane analysis services.
Please see the following link System Tests - Visual Inspection, Most Effective Cleaning, Profiling and Probing (76KB PDF) for instructions on:
Additional Information:
High Salt Passage (117KB PDF)
FilmTec™ System Optimization Services (SOS)
Strong base anion (SBA) dealkalization, the simplest of the dealkalizing processes, is usually done with a Type II strong base anion exchange resin, in the chloride form, such as AmberLite™ HPR4100 Cl anion exchange resin.
This resin reduces the bicarbonate alkalinity of a water supply by exchanging bicarbonate, carbonate, sulfate, and nitrate anions for chloride anions. While alkalinity is removed, however, the total dissolved solids (TDS) content of the water is not changed. If the hardness to alkalinity ratio in the feed water is greater than 1.0, use of a weak acid cation (WAC) exchange resin may be a better choice.
R+Cl− + NaHCO3 ↔ R+HCO3− + NaCl
2R+Cl−+ Na2SO4 ↔ R2+SO42− + 2NaCl
where R = this resin
Sodium chloride, NaCl, is used to regenerate this resin. Some caustic soda, NaOH, may be added (usually 1 part NaOH to 9 parts NaCl) to improve capacity and reduce leakage of alkalinity and carbon dioxide by converting bicarbonate to carbonate. Calcium carbonate (CaCO3) and magnesium hydroxide (Mg(OH)2) precipitated from NaCl by NaOH can cause hardness leakage from the dealkalizer. This regenerant should be filtered for best results.
SBA dealkalization is especially good for smaller installations and other places where it is desirable to avoid the handling of acid. While it is initially a larger investment than the hydrogen cycle weak acid cation resin process, it is more easily handled by inexperienced operators. The procedure lends itself to automated operation with very simple controls.
Ion Exchange Resins Water Conditioning Manual (4.1 MB PDF)
Yes — the quality of permeate is comparable to that of a traditional reverse osmosis system.
The loading procedure for ion exchange resins varies with the vessel configuration. Complete details can be found through the hyperlinks below. In general, the most common configurations are single bed, layered bed (stratified bed) and mixed bed.
Single bed ion exchange vessels are loaded with only one type of ion exchange resin. These vessels are very common for water softening and demineralization.Loading Procedure for Single Bed Ion Exchange Vessels (12KB PDF)
Layered bed anion exchange vessels are loaded with strong base and weak base anion exchange resins. The weak base resin lies on top of the strong base resin. These vessels are used for water demineralization.Loading Procedure for Layered Bed Anion Resins (24KB PDF)
Mixed bed ion exchange vessels are loaded with a mixture of a strong base anion exchange resin and a strong acid cation exchange resin. Special care must be taken during the loading procedure to keep the resins thoroughly mixed. If the resins become separated, optimum water quality may not be obtained from the mixed bed. These vessels are used for producing high purity water. Recommendations for Loading an Internally Regenerated Mixed Bed (24KB PDF)
The Langelier Saturation Index (LSI) and Stiff & Davis Stability Index (S&DSI) are a measure for the saturation of CaCO3 in water. The LSI should be used for low TDS ranges (<10,000 ppm) and the S&DSI is used for high TDS ranges (>10,000 ppm). In general, the Langelier Saturation Index (LSI) is used for brackish waters and the Stiff & Davis Stability Index (S&DSI) for seawater. At the pH of saturation (pHS), the water is in equilibrium with CaCO3.
The definitions of LSI and S&DSI are:
LSI = pH - pHs (TDS <10,000 mg/l)
S&DSI = pH - pHs (TDS >10,000 mg/l)
To control calcium carbonate scaling by acid addition alone, the LSI or S&DSI in the concentrate stream must be negative. If a high quality scale inhibitor is used, the LSI in the concentrate stream can be < 1.5. This will reduce or eliminate the acid consumption. Many inhibitors allow operation up to an LSI of < 1.8 in the concentrate. Please refer to the inhibitor manufacturer’s own literature for reference points.
Additional Information:
Scale Control (10KB PDF)
There are a number of different ion exchange regeneration technologies that can be used, from the basic co-current regenerated systems to counter-flow block systems and through to packed bed technology.
Selection of regeneration system:
Counter-Current Regeneration Systems (Blocked Systems or Packed Bed Systems)
Co-Current Regeneration Systems
Counter-Current Regeneration Systems: in these systems, the regenerant is applied in the opposite direction to the service flow, resulting in reduced chemical consumption, improved water quality and less waste volumes compared to traditional co-current regenerated systems. Counter-current regeneration systems should provide a water quality of better than 2 µS/cm (0.5 MW.cm) and residual silica of 0.020 to 0.050 mg/l as SiO2. Depending upon water composition and regeneration conditions, the specific conductivity could be as low as 0.2 µS/cm (5 MW.cm). The normal counter-current endpoint is 4 µS/cm conductivity. A maximum endpoint value of 0.3 mg/l SiO2 above the average leakage should not be exceeded in order to avoid a high contamination of the polishing resin layer and unacceptably high silica leakage during subsequent cycles. Silica leakage can be minimized by operating the plant at silica break rather than conductivity end point. This secures the lowest silica leakage, but at the expense of a 5 -10 % throughput reduction.
There are two main types of counter-current systems:
Co-Current Regeneration Systems: these are the simplest systems, where the resin is regenerated in the same direction as the service flow (downwards). The vessel has a large freeboard to allow expansion of the resin bed when backwashing is carried out to remove suspended solids and resin fines. Co-current regeneration single bed systems will generally produce water of much lower quality than counter-current systems, with typical leakage values ~10 times higher. Such quality will also be even more affected by the water composition, the type of regenerant chemical and dosage being used.
Additional Information
Reverse osmosis (RO) is the finest level of filtration available.
Nanofiltration (NF) rejects particles in the approximate size range of 1 nanometer (10 Angstroms),
Ultrafiltration (UF) provides macro-molecular separation for particles in the 20 to 1,000 Angstrom range (up to 0.1 micron).
Microfiltration (MF) removes particles in the range of approximately 0.1 to 1 micron.
Rejection in NF and RO membranes is influenced by the following factors:
Additional Information
The size and type of flow restrictors is selected by the Point-Of-Use system designer/manufacturer. Typically, flow restrictors are set to produce at 20 to 33% recovery for typical point of use systems, (i.e. 1:2, 1:3 or 1:4 ratio between product flow and feed flow rate).
You need to consider the following operating parameters when you change membrane types (but not the element sizes) in your system: operating pressure, membrane system flux, % system recovery and feed/concentrate flow rate.
Operating Pressure: Operating pressure will be affected by the membrane types you choose. For instance, there is a low energy membrane type such as LE and XLE; these operate at low operating pressures compared to the standard BW30 membrane types, but BW30 membrane type gives a better permeate water quality than the XLE and LE membranes.
Membrane System Flux: Membrane system flux does not have to change with the change in membrane types because the feed water qualtiy/type determines the maximum membrane flux. For instance, if feed water quality has a SDI (Silt Density Index) <1, then you can operate your system at higher membrane flux than the feed water quality with SDI of 3 - 5 regardless of membrane type.
% System Recovery:% system recovery does not have to change with the change in membrane types. Sparingly soluble salt scaling potential and the desired permeate water quality would trigger a change in % system recovery. For instance, if you have high alkalinity or silica in your feed, then operating at high % system recovery would create a potential scaling of calcium carbonate or silica. So, your % system recovery must be decreased to prevent scaling. If you must operate at higher % system recovery, then you will have to either adjust the feed pH or use antiscalants to control the scaling. Also, if you wish to get a better permeate water quality, then you can achieve this result by lowering the % system recovery.
Feed/Concentrate Flow Rate: Feed and concentrate flow rates should not change with the change in membrane types unless you decide to change the membrane flux or % system recovery.
Please see the operating parameters for:
Membrane System Design Guidelines for 8-inch FilmTec Elements (126KB PDF)
Commercial Design Guidelines for Midsize FilmTecTM Elements (126KB PDF)
WAVE is free to download and allows you to design systems with different membrane types.
Additional Information:
FilmTec Membranes - Steps to Design a Reverse Osmosis System
Sodium hydrosulfite has shown to be the most effective solution for iron fouling.
Additional Information:
FilmTec Membranes - FilmTec's Technical Manual
Prevention of Iron and Manganese Fouling (40KB PDF)
Cleaning Iron Fouling from FilmTecTM FT30 Elements (15KB PDF)
Macroporous ion exchange resins are easy to identify as they are opaque in appearance, compared to the translucent appearance of a gel ion exchange resin. Macroporous resins are produced from a copolymer to which has been added a non-polymerizable diluent that volatilizes leaving discrete macro pores throughout the bead. These pores are considerably larger (up to several hundred Angstroms) than those found in gel resins and, as such, allow the accessibility of large molecules. Macroporous resins contain as much as 20% DVB in the polymer matrix. They are not simply gel resins with additional crosslinking since the interior of a gel with 20% DVB would inaccessible.
The term thoroughfare regeneration is used when used regenerant from one vessel is introduced into a second vessel. The purpose of thoroughfare regeneration is to increase regeneration efficiency by re-using regenerant that would otherwise be wasted.
Thoroughfare regeneration can be used if the demineralization system is made up of a combination of weak/strong acid cation resins or weak/strong base anion resins. Since weak resins regenerate very efficiently, even waste acid and caustic can fully regenerate these resins. .
The primary concern with thoroughfare regeneration is for demineralization plants that use weak base anion (WBA) exchange resins with strong base anion (SBA) exchange resins. It is necessary to ensure that the silica released by the strong base resin into the caustic is dumped to the drain before the waste caustic is fed to the weak base resin. Generally, the first third of the regenerant from the strong base resin is dumped to the drain. If significant amounts of silica are present in the waste caustic when it is fed to the exhausted weak base resin, the silica will polymerize upon contacting the acid form of the weak base resin. Correcting the situation is usually accomplished by dumping additional caustic to the drain before the thoroughfare begins and cleaning the weak base resin by hot caustic soaks.
When using sulfuric acid to regenerate the cation resins, the waste acid from the strong acid cation must be further diluted to less than 0.7% prior to feeding it to the weak acid cation. There is a high potential for calcium sulfate precipitation if weak acid cations are regenerated with a sulfuric acid concentration greater than 0.7%.
Additional Information:
Ion Exchange Resins - Recommended Operating Conditions
Preventing Silica Fouling of Weak Base Anion Resins (19KB PDF)
Understanding Silica Removal by Ion Exchange (20KB PDF)
Regenerating Strong Acid Cation Resins with Sulfuric Acid (20KB PDF)
Basics of Reverse Osmosis and Nanofiltration | |
1.1 | Historical Background of FilmTec Corporation (PDF) |
1.2 | Major Desalination and Filtration Processes (PDF) |
1.3 | Principle of Reverse Osmosis and Nanofiltration (PDF) |
1.4 | FilmTec Membrane Chemistry Description (PDF) |
1.5 | FilmTec Membrane Performance (PDF) |
1.6 | FilmTec Membrane Safe for Use in Food Processing (PDF) |
1.7 | Element Construction (PDF) |
1.8 | Element Characteristics (PDF) |
If the performance of the membrane system is not satisfactory, the first step is to evaluate the performance and the operation of the entire system. This is done on the basis of normalized plant data, (see FTNORM ). When the actual normalized plant performance is compared against the performance at start-up, any significant performance deterioration can be identified.
In case that the initial system performance at start-up is not satisfactory, a comparison of the actual system performance with the WAVE projected system performance under actual conditions is helpful. Download WAVE
If the normalized actual performance has deteriorated too much compared to the initial performance, or the measured actual performance does not match close enough with the projected performance, check the following (please see the details in the attachment, below):
If all this has been considered and the observed system performance is still outside of expectations, perform the system tests as described in System Tests.
Additional Information
Evaluation of System Performance and Operation (46KB PDF)
Plant Performance Normalization (117KB PDF)
The acetate form of fine mesh resins are available off the shelf from Bio-Rad. Alternatively, you can convert the 1x2, 1x4, and 1x8 gel anion resins to the acetate form yourself. There are a couple of ways to do this. Since the resin is sold in the chloride form, you can first convert it to the OH- form. Load the resin into a column and convert the resin to the OH- form by washing it with 5 to10 bed volumes of 1 to 2 M NaOH. Be sure to wash the resin with base slowly so that a minimum of 1 hour contact time is achieved. Next wash the resin with DI water until the pH is near neutral. Next elute the resin with acetic acid or sodium acetate. The resin will be converted to the acetate form. Rinse off the excess acetic acid / sodium acetate with DI water. The counter ions would be H2O if acetic acid were used or NaOH if sodium acetate were used.
Alternatively, you can convert the Cl form directly with acetic acid or sodium acetate (the counterion coming off will give rise to HCl or NaCl, respectively), but you will end up using more acetate (since Cl- is held with a factor of 22 and Acetate 3.2).
Additional Information:
Using Ion Exchange Resin Selectivity Coefficients (82KB PDF)
Regeneration of strongly basic anion exchangers is influenced by the quality of caustic available. Chloride, chlorate and ferrate ions are potential contaminants in caustic that may affect resin regeneration efficiency and stability. Sodium chlorate itself has very little oxidative properties in neutral or alkaline solutions, but in acid conditions (i.e. during resin exhaustion) chloric acid is generated, which is a powerful oxidizing agent. Chlorates have a strong affinity for the resin and will tend to be exchanged on the resin. It is suspected that the chlorate will be eluted from the column with other anions during exhaustion and when low pH solution contacts the bed, oxidation will result. The recommended caustic quality for strongly basic ion exchangers is as follows:
Component |
Recommended Maximum |
NaOH |
49 - 51% |
NaCl |
1.0% |
NaClO3 |
1,000 mg/l |
Na2CO3 |
0.2% |
Fe |
5 mg/l |
Heavy metals (total) |
5 mg/l |
SiO2 |
50 mg/l |
Na2SO4 |
250 mg/l |
Mercury cell or purified diaphragm cell (rayon) quality sodium hydroxide will normally meet such specifications. Regular diaphragm cell quality caustic soda can contain over 2% NaCl and over 0.1% (1000 mg/I) NaClO3.
Typical analyses for different caustic qualities are given in the following table:
Compound |
Mercury1 Grade |
Rayon1 Grade |
Regular Diaphragm Grade |
Regular Technical |
NaOH |
51% |
50.1% |
50.4% |
98% |
Na2CO3 |
0.02% |
0.2% |
0.2% |
0.5 - 1% |
NaClO3 |
1 mg/l |
The iLEC™ interlocking endcap feature is available on select 8-inch FilmTec™ products. These are designated by the 'i ' at the end of the FilmTec product name.
Additional Information:
|
These programs are no longer being updated and maintained. If you wish to run the Ion Exchange, Reverse Osmosis, and Ultrafiltration plant designs, please use WAVE design software, as it offers an up to date list of products.
Register and download WAVE from our resource center.
Water Application Value Engine (WAVE) — a modeling software program to design and simulate the operation of water treatment systems, integrates three of the leading technologies (ultrafiltration, reverse osmosis, ion exchange resins) into one comprehensive platform.
The arrow indicates the element stac k will be properly supported at the downstream end by the vessel thrust ring. Reversing the elements will cause the elements to be improperly supported and subject to telescoping. It will also increase the effective length of the element stack by 0.5 inch (1.25 cm) and may permit feed bypass around the backward-facing brine seals.
Additional Information:
Handling Recommendations for Elements with iLEC™ (813KB PDF)
Due to differences in the regenerability of strong and weak functionalized resins, the configurations described in "Selection of layout and resin types (configuration)" will have different chemical efficiencies. The chemical efficiency of regeneration (also known as stoichiometry) for an IX resin is defined as:
As the resin usage of the regenerant chemical is non-ideal, the chemical efficiency is always >100%. The efficiency therefore becomes worse as the value increases. The following table gives typical regeneration efficiencies for different resin types and combinations in co-current and counter-current regeneration systems.
Resin type/configuration | Regeneration system | Typical Regeneration Efficiency (%) |
Strong Acid Cation | Co-current HCl | 200-250 |
Counter-current HCl | 120-150 | |
Co-current H2SO4 | 250-300 | |
Counter-current H2SO4 | 150-200 | |
Weak Acid Cation | 105-115 | |
Weak Acid + Strong Acid Cation | 105-115 | |
Strong Base Anion Type I | Co-current | 250-300 |
Counter-current | 140-220 | |
Strong Base Anion Type II | Co-current | 150-200 |
Counter-current | 125-140 | |
Weak Base Anion | 120-150 | |
Layered Bed Anion | 120-130 |
Additional Information
Long rinse times could be due to mechanical problems or resin fouling. Possible mechanical problems include a leaking valve or trapped regenerants in the equipment. Trapped regenerants may be caused by a combination of mechanical distribution problems like leaking valves, dead zones filled with regenerant solution or resin fouling/resin clustering can also be the source. Quantities as low as a fraction of one liter of caustic trapped can lead to long rinse times after regeneration. If the water quality gets better at higher flow rates it indicates that pockets of trapped regenerants may be the cause for the long rinsedown. The higher flow rate dilutes the concentration of the trapped regenerant. Sodium leakages from trapped NaOH may also dissolve silica from anion exchange resins resulting in higher silica levels in the product water. Dead zones in manholes, parts of the piping system and under the lower nozzle plate need to be avoided and if possible filled with a suitable inert material.
If the product water quality gets worse at higher operational flow rates (but is better at low flow rates) and also if rinse times after regeneration get longer, this indicates resin fouling may have occurred. This happens more frequently with strong base anion exchange resins.
Additional Information:
Silica solubility is depenent upon temperature, pH as well as antiscalant types. The solubility of silica increases at low and at high pH. It also increases with the increase in temperature. At pH below 9, silica exists mostly in silicic acid form (H4SiO4). At 25C and pH 7, the solubility constant of silica is 96 ppm. But, it is slow to crystallize, and so the maximum concentration of silica in the brine stream (concentrate stream) can typically be greater than the solubility constant. At a pH greater than 8, the presence of heavy metals (such as iron, aluminum) will react with silicates and cause precipitation. There are antiscalants that can tolerate up to 240 ppm silica. Please consult antiscalant manufacturers for more information.
Additional Information:
Scale Control (30KB PDF)
Colloidal Fouling Prevention (32KB PDF)
FilmTec Membranes are not licensable under the Export Administration Regulations (EAR), US Department of Commerce (DOC), and Bureau of Industry and Security (BIS). Therefore ECCN: EAR 99 / License Exception: NLR is appropriate.
DuPont offers a wide range of fine mesh resins for use in fine chemical and pharmaceutical column separations. Anion and cation resins with mesh sizes including 50-100, 100-200, and 200-400 are available. Cross-linkages (as measured by percent divinylbenzene content) include 2, 4, and 8.
Cross Reference Chart
U.S. Standard Mesh |
Microns |
50 |
297 |
100 |
150 |
200 |
74 |
400 |
38 |
Fine Mesh IX Manual (PDF) (331KB)
The UF module shelf life is one year from the manufacture date without taking additional measures as long as the storage condition instructions are followed.
Additional information:
Ultrafiltration Module Three-Year Prorated Limited Warranty (44KB PDF)
During processing, ion exchange resins can experience mildly different thermal histories. This may cause some resin beads to have a darker or lighter color than the majority of the resin. In mixed resins, many times a cation exchange resin with a dark color is mixed with an anion exchange resin with a light color. This color difference helps the operator differentiate the anion and cation exchange resins during backwashing and determine when the resins are adequately separated during the backwash operation. After resin separation, the presence of substantial dark cation exchange resin beads in the light anion exchange resin, and vice versa, serves as an indicator of non-optimized resin separation.
Sanitization with agents containing combined chlorine is generally not recommended. Polyamide membranes have shown some compatibility with pure chlorine dioxide. Chlorine dioxide that is generated on-site from chlorine and sodium chlorate, however, is always contaminated with free chlorine that attacks the membrane. One should consider DBNPA as a safer and more effective sanitizing agent for non-potable applications.
Additional Information:
Chlorination - Dechlorination (53KB PDF)
Sanitization of FilmTec Elements with DBNPA (39 KB PDF)
There should be enough "distance" between the average leakage of a unit and the endpoint used to terminate the run and trigger regeneration.
Silica vs. Conductivity
Plants generally designed with a more comfortable safety margin on the anion side, so that conductivity breaks through first.
Additional Information
If this is the first time you’ve tried to run WAVE on a new computer, the most likely issue is that one of the required auxiliary programs didn’t install correctly.
Small orders of our ion exchange resins, polymeric adsorbents, and chelating resins, can be requested through Octochem .
Additional information:
Selecting a product (Where you can choose by application or by product name)
Trihalomethanes may be contained in specific types of wastewaters, contaminated ground waters and surface waters that have been exposed to chlorination. Potential formation of suspected cancer-causing compounds, trihalomethanes (chloroform and bromoform) and carbon tetrachloride (CTC), has been a growing concern. Naturally occurring organics, which has significant tirhalomethane formation potential, react with chlorine or bromine to form trihalomethanes. These trihalomethane precursors are medium molecular weight organics; they are highly rejected by FilmTec RO membranes and well rejected by FilmTec NF membranes.
Please note that THM content and the THM formation potential should be differentiated. THM formation potential describes the capacity of a water to form THM compounds when exposed to chlorine or bromine while THM refers to the compounds themselves. THM is not as well rejected by RO membranes and generally not rejected by NF membranes.
Depending on the feed water characteristics pretreatment might be needed in combination with the UF process. Dissolved substances are not removed by UF membranes, so they must be transformed into particulate form if they are the target of the UF process.
Otherwise, very little pretreatment is required if microorganisms and particles are the target contaminants. Prefilters (100 - 300 µm) need to be installed upstream the UF process to protect the UF system from large particles, sand, etc. See Table 3 for strainer selection guidelines. A variety of technologies can be used such as self-cleaning screens and bag, cartridge, or disc filters.
Table Strainer selection guidelines
Source Water | Strainer Size 1 |
Bore Well / Ground | ≤ 300 µm |
City / Tap Water | ≤ 300 µm |
Surface (Pretreated) | ≤ 300 µm |
Surface (Untreated) | ≤ 300 µm |
Seawater | 100 to 300 µm 2 |
Wastewater (Secondary, Tertiary Effluent) | ≤ 300 µm |
1 Recommended for initial specification, and to be reviewed against site-specific raw water quality and project drivers.
2 Strainer size of 100 - 150 µm is recommended to control the growth of barnacles and mussel larvae in process pipework and tanks upstream of the UF.
Depending on the type of water or range of feed water parameters other pretreatment technologies such as coagulation/flocculation, clarification/sedimentation, flotation or granular media filtration may also be recommended.
Additional Information
Sodium metabisulfite (SMBS) is commonly used for removal of free chlorine and as a biostatic. Other chemical reducing agents exist (e.g., sulfur dioxide), but they are not as cost-effective as SMBS. When dissolved in water, sodium bisulfite (SBS) is formed from SMBS:
Na2S2O5 + H2O --> 2 NaHSO3
then reduces hypochlorous acid according to:
2NaHSO3 + 2HOCl --> H2SO4 + 2HCl + Na2SO4
In theory, 1.34 mg of sodium metabisulfite will remove 1.0 mg of free chlorine. In practice, however, 3.0 mg of sodium metabisulfite is normally used to remove 1.0 mg of chlorine. The SMBS should be of food-grade quality and free of impurities. SMBS should not be cobalt-activated. Solid sodium metabisulfite has a typical shelf life of 4 to 6 months under cool, dry storage conditions. In aqueous solutions, however, sodium bisulfite can oxidize readily when exposed to air. A typical solution life can vary with concentration as follows:
Concentration (wt %) Solution life
10 1 week
20 1 month
30 6 months
This question can be best answered when you understand the equilibrium relationship between CO2, HCO3, and CO3. In a closed system, the relative amount of each of these CO2, HCO3, and CO3 vary with pH. At lower pH levels, CO2 is the predominant species. HCO3 is the predominant species at mid pH levels, and CO3 is present at higher pH levels.
Since RO membranes will reject dissolved ions and not reject dissolved gases, the RO permeate and RO feed will contain roughly the same amount of CO2. The HCO3 and CO3, however, are often reduced by 1-2 orders of magnitude. This upsets the CO2, HCO3, CO3 equilibrium that was established in the feed. In a series of equilibrium reactions, CO2 will combine with H2O driving reactions similar to that shown below, until a new equilibrium is established.
CO2 + H2O à HCO3 + H+
The new equilibrium will always result in a lowering of permeate pH if there is CO2 present in the feedwater.
There is typically a 1-2 unit pH drop in the permeate for most RO systems. Usually, the pH drop is largest for waters with high amounts of alkalinity or HCO3.