Equipment penoizol technology mini business. Reviews of construction companies. What has been improved in the new equipment

There are products with a cellular structure on the building materials market, for example, penoizol. With their own hands from scrap materials, it is created not only by professionals, but also by ordinary people who have some experience. This is an inexpensive raw material that requires the use of simple equipment. For this reason, the specified insulation has a low cost.

Features and material description

The material is a modified foam. Its main characteristics are:

resistance to fire;
good thermal insulation characteristics;
installation by spraying.

Penoizol has good resistance to fire

The basis is made up of three components. It is orthophosphoric acid, carbamide resin and a foaming agent. These ingredients are mixed in exact proportions and the device is laid. A jelly-like mixture is formed. It has a white tint. Under the influence of compressed air, it moves outward. She:

fills any space;
provides tightness;
forms a lush foam after hardening.

Several steps are required for hardening. After application, the composition sets slowly. This takes about 15 minutes. After 3 hours, the foam becomes slightly hard. But this is not enough for it to fulfill its functions. The material takes its final form after 3 days.

In the finished form, not solid, but liquid penoizol is formed. Some home craftsmen are trying to make it with their own hands, since it has good technical characteristics and is considered easy to manufacture. The material is elastic, after any mechanical stress it easily restores its shape. It contains up to 90% of the air. Outwardly, it resembles expanded polystyrene, but differs from it in the small structure of cells.

The improved properties of penoizol made it popular in the field of insulation of private houses. It finds application in thermal insulation of complex structures, floors and floors.

Key varieties

Exists different types urea foam. All of them are suitable for thermal insulation of buildings.

Penoizol can be used for thermal insulation of complex structures, floors and floors.

Main types:

Liquid penoizol. Received the greatest distribution. It can be cooked directly on construction sitebecause it is very convenient. The material is used for thermal insulation of various structures, as well as for repairs. Foam is poured into an enclosed space to form additional sound insulation in frame buildings. When it comes to repair work, penoizol in liquid form is used to fill cracks and gaps.
Granular penoizol. It has several names: foam-insulating crumb, thermovata. It comes in the form of elastic granules. During manufacture, the polymer is crushed into fractions up to 15 mm in size. The volume of the finished material after grinding is doubled compared to the original amount. it a good option to save on installation. Granular penoizol is used to fill the cavity between walls for laying on the floor.
Sheet penoizol. Liquid material is poured into a special mold. After cooling, it is cut on special machines or simply by hand until the required thickness is given. After that it is dried and machined. The product is used to insulate buildings under construction. Installation is carried out with dowels from the outside of the walls. On top, sheathing with decorative panels or siding is laid. In addition, the slabs are placed between the joists on the floor.

More about the production of penoizol:

Penoizol can have different density depending on the manufacturer. It varies on average from 6 to 35 kg per cubic meter.

Technical indicators

Penoizol has many advantages over traditional insulation materials. The main characteristics worthy of attention include:

Thermal conductivity. The only low indicator is 0.041 W / m / K. To ensure good performance, it is enough to lay a layer 10 cm thick.
Soundproofing. Sound absorption is at a quite decent level. It is about 65%.
Fire resistance. The flammability group to which penoizol belongs is designated as G-1. Its flammability category is B-2. This indicates that it does not melt when exposed to fire. When high temperatures are reached, the material will begin to evaporate, and toxic substances will not be generated. Under the condition of an open fire, 10 times less smoke is formed compared to foam.
Resistance to chemical components. The insulation does not react to aggressive environments. This primarily concerns organic solvents.
Resistance to moisture. Penoizol has a good moisture absorption property, but it gives it away with equal success. The characteristics of the material are not affected. It is able to absorb up to 1/5 of moisture. In the future, penoizol evaporates it. To prevent the formation of mold on the wall, equip a ventilation gap. The heat insulator absorbs approximately 20% moisture throughout the day.
Water vapor permeability. The insulation in question is hygroscopic, and therefore provides the walls with the ability to breathe. Air circulates freely through the structure.

Penoizol has good vapor permeability, which allows the walls to breathe

Among other characteristics, biostability can be distinguished. This means that penoizol is not afraid of fungi, pathogenic microflora, and domestic rodents. The material is soft, therefore it adheres closely to any uneven surfaces. It fills in any gaps. With a linear deformation of 9%, the compressive strength is 0.5 kg per square centimeter.

Penoizol began to be produced relatively recently, so we can only talk about its durability approximately. It appeared on the market only 50 years ago. But manufacturers claim that it can last up to 30 years. Environmental friendliness is another of its advantages, since toxic compounds are not emitted either during installation or during operation.

Video on how to make a foam generator:

Cons of the product

The main disadvantage of penoizol is that it gives a sediment in the range of 0.1-5%. These indicators are better for the material that is between the walls under some pressure. Other disadvantages include:

Low tensile strength. It is quite easy to break it.
Increased moisture absorption. In some situations, this is a significant drawback. This feature does not allow the use of this type of foam in the underground part of the foundation and when arranging the screed. We have to lay additional waterproofing.
The need to use special equipment. This is true for liquid foam forms.
Installation temperature requirements. It should be above + 5 ° C. High-quality foam will be obtained only if this requirement is met. In addition, liquid urea foam can release phenol formaldehyde during installation. This is possible if it contains a low-quality resin.

Selection criteria and equipment purchase

In most cases, liquid penoizol is chosen when it comes to domestic use. It is applied using special equipment. It can be rented to save money.

To apply penoizol, a special installation is required, it can be rented in order to save money

To produce penoizol with your own hands at home, you will need to equip the installation. You can equip it from scrap materials. You will also need a compressor, molds for finished products, and optional equipment for lighting and ventilation. Budget installation options involve a combination of:

gas-liquid equipment;
a supply hose;
set of cranes;
plastic barrels;
compressor.

Urea resins and catalyst are mixed in the unit. They are placed there with a pump. Compressed air is available here. The main attention should be paid to the purchase of a pump, since it plays the role of a key element in production. Dosing errors are especially important. A vortex or plunger pump is the most profitable and efficient option. But in any case, foreign particles should not be allowed to get inside, as this will ruin the whole process.

More about liquid foam:

List of materials and manufacturing technology

Penoizol is made from foamed carbamide resin. Its production is characterized by efficiency, affordable price and speed of work. To make it you will need:

polymer resin;
foaming agent;
hardener;
specially prepared water.

Several methods of making penoizol are envisaged, according to which sheets and mats are produced. Raw materials are poured right at the place where the insulation work is carried out. If the casting radius of the equipment is large, the material making process becomes efficient.

You can take gas-liquid installations, which are easy to use and low cost. For the production of insulation, installations of the Standard and Foam 2000 type are suitable. The first is characterized by an original dosage system. There is also a second generation system with an extended range.

For the production of penoizol, you will need a special gas-liquid installation

Comparison with polyurethane foam

The two materials are often compared in terms of financial benefit and performance. Safety of use is in the first place in importance. The manufacturers declare that Penoizol is neutral and safe for humans and animals. But at the same time, in a number of states of Canada and America there is a law according to which it is prohibited to use carbamide foam for construction. It is considered a source of potential health hazard.

This situation is also observed in some European states. This is explained by the release of formaldehyde during the polymerization of liquid foam. You can reduce the likelihood of adverse effects by using a vapor barrier on the inside of the wall.

As for polyurethane foam, there are no prohibitions in relation to it in any country in the world. He has all the necessary certificates of quality and safety.

In terms of water absorption, polyurethane foam has minimal indicators, since its structure is porous, closed. It retains heat well and is equipped with protection against corrosion, mold and mildew. Condensation is excluded here. Despite the positive properties of penoizol, excess moisture can lead to its destruction. You can avoid this if you equip moisture insulation.

High humidity can lead to the destruction of penoizol

Penoizol is also slightly inferior in strength and physical and mechanical properties. It is resistant to mechanical stress, but according to this indicator, it is still ahead of polyurethane foam. At a price, urea foam is an order of magnitude cheaper than polyurethane foam.

Winter use

Work in winter period difficult, since problems are created due to low air temperatures. This factor adversely affects the structural composition of penoizol. About 50% of the resin is water. For this reason, the viscosity of the material increases. Despite all these unfavorable moments, it is possible to fill in penoizol under certain conditions. Its components must be stored in a warm room at a temperature of at least + 15 ° C, for example, in a garage.

The unit must also be located in a warm place. You can set up the cheapest tourist tent for this. The materials must be compactly rolled up, covered with a layer of plastic wrap, and then a fan heater must be installed. Before starting work, it is necessary to warm the solution to + 40 ° С, and the resin - to + 20 ° С. For this, a conventional boiler is used.

More about do-it-yourself foam:

If all these rules are followed, you can get penoizol, which is no different from the material mounted under normal conditions. It is unacceptable to keep it at temperatures below + 15 ° C, as it dries poorly. The moisture contained in it will freeze. It will perform its role as a heat insulator only with the onset of spring. Moisture not frozen in spring will evaporate by itself. The dry foam will remain unchanged.

Penoizol - official trademarkregistered russian company NST. There are several brands of equipment for the production of penoizol. These are: Foam-200, Foam-2000DMU, Foam-2000 / 10UM and Foam-2000R. Each modification of equipment for the production of penoizol differs in the method of production and some technological characteristics of operation.

There are several methods for producing penoizol - classic and double strench. Let's consider them in more detail.

The classical method of penoizol production involves the introduction of a special resin into an aqueous or acidic solution, and the "double strench" method is characterized by imparting increased strength to penoizol especially for the manufacture of boards and shells from penoizol.

Foam capacity ranges from 6.0 to 10 cubic meters per hour, while actual production is actually up to 54 cubic meters per shift, with resin consumption ranging from 27 to 18 liters per cubic meter, assuming the temperature is environment is at least 22 degrees Celsius. The performance and setting of the flow rate of components in the production of penoizol is usually controlled mechanically, although there are modifications of equipment with built-in electronic units that regulate the setting of the flow rate using throttles.

In the production of penoizol using the classical method, a centrifugal pump is required, and for the production of penoizol by the double strench method, gear, plunger or vortex pumps are already needed.

Consumption and maximum allowable pressure of compressed air in the production of penoizol ranges from 0.2 cubic meters per minute to 7 atmospheres.

Penoizol lifting height is possible up to almost 28 meters. Also, in the production of penoizol, a compressor is required, which is needed to obtain the compressed air necessary for the operation of the entire installation. A regular one, operating from a 220 Volt network and a power of 0.97 to 1.5 kW, is suitable.

In general, the mass of a complete set of equipment required for the production of penoizol is from 40 to 80 kg.

Cost on site Russian Federation reaches up to 200 thousand rubles. It should be borne in mind that the cost of the compressor is not included in the standard delivery of equipment for the production of penoizol, and you will have to purchase it separately.

Penoizol production. Method "Classic"

Penoizol is produced using the "Classic" technology, when you need to fill the voids in the walls directly at the construction site, that is, directly at the customer's site.

Main hallmark This method of production of penoizol is that water, into which a special acid has been introduced, is passed under pressure through a special channel called a foaming agent. In the foaming agent, the resulting mixture is exposed to an air flow under pressure, as a result of which the initial mixture foams with the formation of a fine-porous, closed-cell and homogeneous foam. Subsequently, a special resin is mixed with this foam, which envelops the formed water bubbles. Within 10-15 minutes, when the resin comes into contact with an acid, a process scientifically called resin polymerization occurs, since the resin hardens only in an acidic environment.

Thus, we have obtained the volumetric structure of thermal foam. At the next stage, we need to remove moisture from the resulting material, which can reach almost 40 liters for each cubic meter of the resulting material. Due to the water-repellent properties of penoizol, complete removal of moisture, that is, in fact, drying of penoizol, occurs within 1-2 days, depending on the humidity of the ambient air and temperature regime, climate in the region, seasonality and other factors.

Penoizol according to the "Double Strench" technology

Penoizol is produced using the Double Strench technology only in working conditions, in an industrial workshop. In this way, foam insulation boards and foam insulation shells are produced.

For work on this technology, units Pena2000DMu and Pena2000 / 10 can be used

Pena-2000DMU is the most budgetary variant of equipment for the production of penoizol, characterized by ease of use and operation. This model has earned itself the fame of the people's apparatus, as it is the most common model on russian market equipment for the production of penoizol. In addition, this device has a low cost and excellent technical characteristics, since it has a very comfortable overall length of the sleeves from the device itself to the filling point.

Foam2000 / DMU has a high performance, the ability to conveniently control the air leaving the compressor both in foaming and mixing modes. Foam-2000 / DMU has a low weight and overall design convenience for transportation and transportation of equipment.

The device provides a flushing function for all channels, and flushing can be carried out both separately for each channel, and all together, it is also possible to flush only the filling sleeve.In general, the Pena-2000DMU device is an excellent and unpretentious equipment for the production of penoizol.

Today, a huge number of manufacturers offer a large number of types of installations for the production of penoizol.

It is often difficult for an uninitiated buyer to understand this variety, therefore, as a rule, a choice is made in favor of cost.

Buyers are guided by simple proven wisdom - if they do buy equipment for penoizol "Blindly", then at least make it cheaper.

Gas-liquid plant (GZhU)

In terms of the number of proposals, the palm is the first generation plants - GZhU. The simplicity and low cost of such equipment make it easy to copy this product and put it into production.

Principle of operation

A special solution is poured into a separate container, let's call it "acid": water, phosphoric acid and a foaming agent. All components are thoroughly mixed. Urea-formaldehyde resin is poured into another container, let's call it "resin".

There are taps on the containers. They are opened and filled with GZhU pumps. Centrifugal pumps, flooded, do not tolerate airing. Therefore, the containers must be located above the pumps. In this case, the solution and resin enter the GZhU by gravity. Then the pumps are switched on and the required consumption of the foam insulation components is adjusted using the control valves.

Includes compressed air - requires a separate air compressor with a minimum capacity of 400 l / min. and pressure from 2 to 6 kgf / cm2. Pressure control - according to pressure gauges installed on the GZhU.

An intermediate container - a foam generator - serves for mixing the components. This is where foaming takes place, from where the foam enters the mixer. In the mixer, a jet of resin is injected into the foam stream and the resulting cocktail "enters the mixing hose, in which the final mixing of resin and acid takes place. During the movement along the hose, the polymerization reaction is triggered, and at the exit from the hose, penoizol ready for pouring is obtained.

The length of the mixing arm varies from manufacturer to manufacturer and generally ranges from 5 to 10 meters. For dosing solutions, jets and a system of valves and taps are used.

Advantages of GZHU

Due to the fact that this is the most "ancient" equipment, it is possible to consult on the nuances of its work with colleagues.

Low cost.
disadvantages
Small range of 5 to 7 meters.
The steam generator is often clogged and needs to be cleaned regularly.
A high-performance air compressor is required, which is connected to a 380 volt power grid, which is not available in all buildings and structures.
The control system does not provide an accurate flow rate of the components.
The installation uses centrifugal pumps, capricious to "airing".
Requires the presence of special containers "acid" and "resin" equipped with taps and valves.
Thorough filtration of working solutions is required.
Taps and valves on containers bring a lot of inconvenience and constantly break off during transportation.

Equipment for the production of penoizol of the third generation - STANDARD unit

It has an original dosing system - a gear-type pump with electronic system shaft speed adjustment. This design solves one of the main disadvantages of all installations for the production of penoizol - accurate resin dosage.
There is no need to filter components as the gear pump is capable of handling solids up to 8 mm in size.
There are no jets, taps and valves in the installation. That is, there is simply nothing to clog up here.
The design of the unit allows the suction of the working solution through the top of the containers. There is no need for special containers.
Longer range. In the standard version, the unit can supply penoizol at distances up to 40 meters, and if necessary, this figure can be easily increased by connecting a more powerful air compressor.
The installation used innovation system foam generation, eliminating the risk of breakage and not clogging in principle.
Supply of working components with just two hoses, original design and convenient layout.

№	Specifications	FOAM 3000 / 10UM	FOAM 2000DMU
1	Penoizol productivity, [m3 / hour]
2	Pump type: resin / solution	Gear Screw	Centrifugal Centrifugal
3	Air consumption, [l / min]
4	Power consumption (without compressor), [kW]
5	Supply voltage, [V]
6	Working air pressure, [atm]
7	Mixing ratio, resin / solution
8	Penoizol density adjustment	Air pressure	Selection of nozzles
9	Density of penoizol in dry condition, [kg / m3]
10	Working pressure of components (up to the mixing chamber), [atm]
11	Hose length, [m] to mixer
12	Overall dimensions, mm]
13	Weight, [kg]
14	Warranty	1 year

Installation of PENA-3000 / 10UM

PENA-3000 / 10UM is a "Business +" class equipment for penoizol. Ideal solution for small businesses and construction organization... It can be used both for pouring thermal foam on site and for sheet production. Penoizol productivity - up to 29 cubic meters / hour. The installation is made at 220 V (possibly at 380 V).

FOAM-3000 / 10UM allows to obtain material of excellent structure, elastic, non-flowing, odorless, fine and closed-cell, with low water absorption.

Advantages of the PENA-3000 / 10UM unit for pouring penoizol:

Both pumps pump by "volume", guaranteed exact dosage and ratio of components from the beginning to the end of filling, regardless of the viscosity and temperature of the components, regardless of the height of the components rise along the hoses;
The fill radius is increased horizontally to 50 m, and vertically to 30 m;
The resin pump is self-priming. Therefore, it is enough to throw the suction pipe with a filter removable at the end into the container barrel from above and start working. In other words, there is no need for a separate resin working vessel;
A compressor with a capacity of 200 l / min is sufficient for operation, i.e. the supply voltage for both the installation and the compressor is 220 V, i.e. PENA-3000 / 10UM can be widely used in the private sector;
The pump along the "foam" line has 3 working channels, of which only one is used, and the other two are reserved. In other words, the life of the pump is practically unlimited;
There is no need to configure the foam insulation system. Regardless of the density, viscosity, temperature of the components, the pump flow has already been adjusted by us in the best ratio and will remain so under any conditions;
Installation control is maximally simplified. The "human factor" is almost completely excluded;
Equipment for penoizol Pena-3000 is equipped with a modified foaming system that allows you to get more and better foam from the same amount of foaming agent solution. It is possible to adjust the density of the foam mass and the performance of the foam insulation directly from the control panel of the installation during operation.

The advantages listed above are interesting, first of all, for those who do not want to experiment. In this case, PENA-3000 / 10UM is very convenient. It is initially built on a 1: 1 resin: solution ratio, which allows for good material. However, in some cases, the conditions for using penoizol require changing the proportion, increasing either the resin or solution consumption. PENA-3000 / 10UM has such an opportunity. The pump capacity for the solution is set rigidly and unchanged. But the pump performance in terms of resin can "smoothly" change due to the fact that the motor of this pump is controlled through a frequency electronic regulator. This is very important and convenient when it is necessary to obtain a ratio of "resin": "solution", for example, 1 to 0.8 or, conversely, 1 to 1.2, etc.

The change in pump performance is carried out directly from the control panel, by rotating the handle of the frequency converter. Clockwise - resin consumption increases, counterclockwise - decreases.

Installation of PENA-2000DMU

PENA-2000DMU is the simplest equipment for the production of Penoizol of the "Business" class, it is distinguished by its simplicity in control and operation. This is the most widespread model, which is facilitated by affordable price and good tactical and technical characteristics: the length of the sleeves from the installation to the pouring point; plant productivity; the ability to control air for foaming and mixing; light weight and ease of construction. The unit can be flushed through both channels (separately or together); it is also possible to flush only the filling hose. Requires 3 working containers for resin; under a solution of a foaming agent and acid; under clean water (for flushing).

The actual price of equipment for the production of penoizol is indicated in the PRICE LIST. You can buy the installation and see it in operation at the training at the NST plant.

If you have opted for the PENA-2000DMU unit, we suggest that you consider purchasing any unit of the RX-27 type and the PIZ-ZhR / 09 hinged unit.

PIZ-ZhR / 09 is a hinged unit that can be mounted on any installation for applying liquid rubber RX-27 (more about equipment for spraying liquid rubber). After that, the equipment for seamless waterproofing is transformed into a unit for pouring penoizol. Thus, there is a possibility of double use of the equipment - for liquid rubber and for penoizol. The foaming and control system is borrowed from the PENA-2000DMU model, but the resin pump (the one used for pumping bitumen mastic) is the same as on the PENA-2000/10. Thus, purchasing the PIZ-ZhR / 09 unit, you get a hybrid of the PENA-DMU and PENA-2000 / 10UM models.

Yes, it will be more expensive than the PENA-2000DMU installation, but at the same time, firstly, you will receive more advanced equipment for penoizol (due to improved modification of the pump for resin), and secondly, you will be able to perform work on applying seamless polymer-bitumen membrane based on liquid rubber.
Having two types of equipment instead of one is better!

You will have the opportunity to expand your business, increase profits, and enter new markets. If you are building your own house, then you can independently perform not only thermal insulation, but also waterproofing, so there is no need to pay third-party contractors. There is the possibility of significant savings, moreover, you can be sure of the quality of work.

This is how a mobile, mobile plant for pouring urea foam penoizol looks like (in the photo - a division of LLC “MPK“ Progress ”, Tyumen - a partner of NST, provides services for pouring penoizol).




Pouring penoizol at a construction site in the Tyumen region

To operate the unit, select the right compressor, because not any compressor for 220 V is suitable. At least 200 liters of air at the outlet is required, with the ability to maintain a constant pressure of up to 8 atm. For example, the Abac Pole Position 310 can be used as a compressed air source.

Other compressors with similar parameters can be used. It should be borne in mind that the performance "at the input" is often indicated. And the real, "at the exit" is 60 ... 70%.

Whenever possible, choose a compressor with a large receiver. Those. if you find a compressor that also delivers 300 l / min at the outlet, but its receiver is 50 l, then this particular model should be preferred.