PENOIZOL EQUIPMENT: PENA 2000
Foam Generating Units
2000 type units do not have conventional foam
generators. Foam is produced inside an expandable ten-meter long
hose. The volume of foam is twice as much as can be produced by
a foam generator from the same amount of material.
Running a foam generator means everyday clogging
problems, since the component flows always begin blocking each other
in case of a slightest pressure drop. In the “no foam generator”
system of a PENA 2000 unit, each component flows strictly in the
determined direction, so even if any of the pumps or air is disconnected
none of the components will flow into wrong cavities. Thus, a PENA
2000 unit’s design completely excludes any overflows, channels blocking
each other, choking, or other similar problems.
The resin flow rate (12 to 35 kg/m3) is preset
before the equipment is started and remains unchanged throughout
the operation. The selected resin flow rate determines the 1m3 casting
time (10 to 6 minutes) and the density of the end-product.
The unit is very easy to operate and has only
two air cocks. When in operation, the 1st cock is always opened
and the 2nd cock is shut; to stop casting, the 1st cock must be
closed and the 2nd cock must be opened, respectively. It does not
matter which of the pumps is started or shut down first, or which
cock position is changed first. When stopping the operation, it
is NOT necessary to shut off the air, NO overflow will happen.
The foam jet is even and smooth from the very
beginning. The casting hose may jerk only if the 2nd cock is in
a wrong position. The unit operator does not have to think, guess
or try to feel the best cock position; it is preset and does not
The unit can be washed through both channels.
The solution pump can be washed separately from the resin pump (which
largely extends its service life, because when the pump is clean
it cannot be harmed by orthophosphoric acid). One can choose to
wash the casting sleeve only or simultaneously the casting sleeve
and one or both channels of the unit.
The components (resin, solution, and air) flow
separately from each other before they are mixed in a standalone
agitator. The agitator is designed is such a way that when the flows
join together, all the components’ speed vectors coincide, which
helps avoid suppression of foam by resin and, therefore, results
in a greater volume of the product.
The hose length is 10 meters between the unit
and the agitator and 6 meters between the agitator and the casting
The required air supply rate is 500 liters per minute, and the air
pressure can be varied within the range from 2 to 4 atmospheres.
The unit is specially designed
in such a manner that no pipes are located directly above the electrical
pumps to avoid even the slightest possibility of contact between
the liquids and the wiring.
The Penoizol manufacturing
process has two options: the liquid jelly-like plastic foam can
be either cast into molds (to manufacture precast sheets) or cast
directly into cavities (in situ).
The Penoizol sheet manufacturing procedure consists
of several process stages.
At the first stage, the
UF foam compound is cast into molds.
The second stage is conditioning
in the molds for 3 or 4 hours, which is necessary for final resin
polymerization and foam setting. At this stage, the material can
shrink by as much as 3% inside the mold. Then the mold walls are
removed and the conditioning continues for another 3 or 4 hours,
during which the moisture is drained and primary drying takes place.
During the next phase,
the blocks are cut to make the drying faster and to increase the
mold and production area turnover. Penoizol can be cut with any
sharp tool, including unheated wire. The dimensions and thickness
of the blocks can be easily controlled. The final drying is done
on racks where air is supplied to all sides of the product, and
the duration of this stage depends on the room temperature, humidity,
ventilation, and the foam block dimensions.
Penoizol can be easily
processed into crumbs and packaged to be later used as fill insulation.
Thus, Penoizol production is waste-free.
Casting Penoizol into
The other Penoizol manufacturing process is in-situ
casting of the jelly-like compound directly into building structures.
In-situ UF foam has a better heat insulating performance than prefabricated
sheets because it helps avoid the heat loss that occurs through
numerous cold joints (cavities, void pockets or air gaps that appear
when the sheets do not adhere firmly to each other or to the load-bearing
The on-site casting of Penoizol provides a means
to save more electric power, fuel, and component and transportation
costs than the sheet prefabrication. It also increases the heat-transfer
resistance of a carrying wall by 10 or 15% on average.
The possibility to cast Penoizol directly on
a building site makes is a really unique material, since no other
thermal insulant is workable enough to fill the entire volume of
any cavity and to ensure a reliable thermal protection of bearing
Penoizol can be conveniently cast into internal
cavities of walls during renovation of old buildings; it becomes
unnecessary to demolish the brickwork or remove the wood casing.
In addition, the low density of UF foam minimizes the incremental
load on the time-worn bearing structures of old buildings.