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Manufacturing Process: The bulk raw chemicals (polyol & MDI) are mixed with catalysts and additives before being metered onto a moving conveyor onto a bottom layer of facer. The chemical mix then starts to rise, due to the effects of the blowing agent, to produce the foam. The foam continues to rise until it contacts the top layer of facer material as it enters the double-belt laminator, where it is then cured at high temperature to produce the rigid, thermoset foam board. The board exits the lamination oven and then cut to size, and then sent to a cooling zone to cool down. Final trimming of edges then takes place, and then the board is ready for dispatch to the market. Off-cuts from the cutting and trimming are compressed on-site, and sent to landfill.
The board consist of 77% to 82% MDI and polyol, with 23% to 18% minor constituents, such as flame retardant, silicone, amine and trimer catalysts. these percentages vary depending on the particular intended application of the PIR board. A foil facing is applied to both faces of the PIR board, which also includes Kraft paper.
The PIR 100mm TnG board is used as insulation in cavity walls.
