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chemistry creates versatility building with polyurethanes


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INTRODUCTION

Overview


“ We shape our buildings; thereafter they shape us.” W I N S T O N C H U R C H I L L , B R I T I S H S TAT E S M A N

Overview

INTRODUCTION

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INTRODUCTION

Overview


Polyurethanes are all around us... ...in our well insulated and comfortable homes, in our high performing, easy to maintain communal and institutional buildings, in our non-slip, permeable pedestrian areas. It may not be obvious but polyurethane is specified and used within many building components: as insulation in walls, roofs and floors, as foams and sealants around doors and windows, as binders to produce (Oriented Strand Board) OSB and (MediumDensity Fiberboard) MDF sheets, as waterproof protective coatings. Polyurethanes can be supplied in many forms: as raw materials, as products and as building systems. Polyurethane’s versatility will allow the architect or designer to save energy, ensuring buildings stay comfortable in winter and summer, increase durability, speed up construction, protect the environment, enhance safety, lead to innovative building systems and much more. Polyurethanes are all around us. BASF is all around us.

Overview

INTRODUCTION

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RESIDENTIAL

Introduction


Residential external wall constructed using polyurethane spray foam insulation and polyurethane binder in the wood sheathing.

RESIDENTIAL Everyone deserves to live in a comfortable, safe and healthy environment. Through continual research and development, rigorous testing and accreditation, polyurethane helps to achieve this. Polyurethane products make homes more comfortable, functional, affordable and sustainable by providing reliable solutions that boost energy efficiency and performance, reduce carbon dioxide emissions, save construction costs, and prolong the lifespan of the home.

BASF works closely with architects, contractors, developers and manufacturers to create environmentally-sound housing for all types of climates, all over the world and satisfying diverse architectural styles. In the process, we incorporate industry-leading solutions for flooring, roofing, insulation and waterproofing while attending to the smallest of details like joint sealants and tile grouts.

Introduction

RESIDENTIAL

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Polyurethane solutions for residential applications

Thermal insulation

Waterproofing and protection

Windows

Innovative polyurethane spray foams, insulation boards and sandwich panels, through to exterior insulation finishing systems (EIFS). Applicable to walls, roofs, floors and ceilings. Benefits include energy savings, enhanced overall comfort, faster construction and design freedom.

Eco-friendly, high-quality, high-performance surface solutions for interiors and exteriors. Simple to apply, fast curing for reduced construction time, long-lasting and durable, odorless for a healthier environment, easy to clean and low maintenance costs.

Joint sealants and sealing systems to prevent air, water and other environmental elements from entering or exiting a structure while permitting limited movement of the substrates. Glass fiber reinforced polyurethane window profiles provide energy and cost savings.

1 ELASTOPOR or ELASTOPIR for insulation boards

5 ELASTOCOAT on garages and flat roofs

6 LUPRANATE for window sealants 7 ELASTOCOAT for pultruded window profiles

WALLTITE, ENERTITE, COMFORT FOAM or 2 ELASTOSPRAY spray foam insulation 3 EIFS insulation 4 ELASTOPOR for entry and garage doors

Binders

Flooring

Roof underlays and membranes

Lightweight, high-tensile, structural-strengthening systems for masonry and timber elements – help increase the durability of building structures.

Underlays for carpet and adhesives for subflooring. Longer life expectancy with lower maintenance, increased non-slip safety and greater aesthetics.

Innovative roofing felts and membranes, underlays and roofing shingles designed to meet and exceed the requirements of modern architecture and complex roof structures.

8 LUPRANATE for wood binders 9 ELASTOCOAT for non-slip underlays 10 Flooring adhesives

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RESIDENTIAL

Introduction

11 ELASTOLLAN for breathable roof underlays


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Introduction

RESIDENTIAL

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“ A house is a machine for living in.� LE CORBUSIER, SWISS ARCHITECT AND DESIGNER

Polyurethane products make houses more comfortable, functional, affordable and sustainable by providing reliable solutions that boost efficient energy use and performance, reduce carbon dioxide emissions, save construction costs, and prolong their lifespans.

CO2

Increased energy efficiency

Better health and safety

reduces air loss and solar gain, which in turn will lower energy consumption and costs, and decrease carbon dioxide emissions.

including fireproofing, earthquake protection, prevention of moisture ingress, water damage and mold.

Enhanced durability Higher savings on energy bills.

by prolonging the lifespan of the home, lowering the need and costs of maintenance.

Enhanced overall comfort

Increased productivity

with more consistent indoor temperatures and sound-proofed rooms.

by affording faster construction times, easy applications, leading to earlier occupation.

Environmentally-friendly efficient consumption and use of energy and resources, generating low VOC emissions.

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RESIDENTIAL

Introduction


Solutions for roofs A wide range of materials, formulations and products to insulate, waterproof, protect and sustain residential roofs.  ELASTOPOR / ELASTOPIR insulation boards used on green roof, Lohne, Germany Green roofs bring biodiversity back into built-up urban areas. The ability of ELASTOPOR / ELASTOPIR to flow through and adhere to complex shapes and surfaces provides a freedom of design as well as complete insulation. 1

Planting/vegetation layer

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Extensive substrate

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Water storage panel

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ELASTOPOR / ELASTOPIR for insulation boards

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Protective layer

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Solutions for roofs

RESIDENTIAL

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Solutions for roofs  ELASTOSPRAY used on flat roof, Cancun, Mexico Master Insulation PUR System, used in a pilot apartment complex for Net Zero Energy consumption in Cancun, Mexico. ELASTOSPRAY spray foam was used on the roof in order to reduce the building’s CO2 emissions and energy consumption by around 23%. 1

Protective coating

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ELASTOSPRAY spray polyurethane foam

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Existing concrete roof deck

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RESIDENTIAL

Solutions for roofs


 ELASTOSPRAY used on pitched roof, Vantone Casa Villa, Beijing, China This project is part of a planning concept that focuses on people first, both culturally and environmentally. Green features, such as energy-efficiency and underground roadwork allow a traffic-free living environment. To meet the stringent LEED standard, ELASTOSPRAY was used to provide a waterproof and completely seamless roof insulation reducing additional construction steps and saving time. 1

Cement tile

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Cement mortar

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Reinforced gravel concrete

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ELASTOSPRAY rigid polyurethane foam

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Cement mortar screed

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Reinforced concrete slab

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Solutions for roofs

RESIDENTIAL

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Solutions for walls Meeting and exceeding regulations for interior and exterior walls, both for new-build and refurbishment.  COMFORT FOAM spray polyurethane foam insulation, Minnesota, USA As both an effective insulation and air barrier material, closed-cell COMFORT FOAM technology substantially reduces both air leakage and the passage of moisture through the building envelope with its seamless, self-adhering and monolithic construction. COMFORT FOAM can help reduce energy costs compared to other insulation systems. 1

Exterior cladding

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Exterior sheathing

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COMFORT FOAM spray foam insulation

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Vapour barrier (region specific)

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Plasterboard

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Installation of COMFORT FOAM

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RESIDENTIAL

Solutions for walls


 WALLTITE spray foam insulation, Hove, United Kingdom Applied to the curved penthouse flat roof on the fifth floor, this fast applied, seamless, airtight solution virtually eliminates air leakage, The closed-cell structure helps control the movement of vapour and moisture throughout the building, reducing energy loss. WALLTITE spray foam does not deteriorate with age and its thermal properties are therefore maintained over the life of the building. 1

Curved timber framework

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WALLTITE spray foam insulation

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Solutions for walls

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RESIDENTIAL

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Solutions for walls  ELASTOSPRAY used in refurbishment of exterior walls, Arboga, Sweden A 1950s private dwelling that has been insulated externally with ELASTOSPRAY. The surface of the sprayed foam has been evened out with special equipment and then covered with a decorative render. 1

Existing wall and primer

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ELASTOSPRAY spray foam insulation

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Fiberglass mesh

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Decorative render

 ELASTOSPRAY in curtain walls, Sant Cugat, Barcelona, Spain External insulation behind a curtain wall or with ventilated cladding can be used both in new buildings and refurbishment of existing buildings. The cladding protects the external components against weathering and as a decorative facade gives a designer lots of options. 1

Masonry

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ELASTOSPRAY external insulation

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Air gap

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Curtain wall with support construction

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RESIDENTIAL

Solutions for walls

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Solutions for walls

RESIDENTIAL

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Solutions for walls  Structural Insulated Panel System (SIPS), USA BASF manufactures emission free wood binders for engineered wood products including Oriented Strand Board (OSB), Medium Density Fiberboard (MDF) and particle board. SIPS combine superior insulation with near zero air leakage to maximize the performance of the building envelope and allow HVAC systems to operate more effectively. 1

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LUPRANATE wood binder for OSB

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ELASTOPOR for insulating foam core

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LUPRANATE wood binder for OSB

RESIDENTIAL

Solutions for walls

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Image: Courtesy of Thermocore

Solutions for walls

RESIDENTIAL

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Solutions for floors and ceilings Interior and exterior solutions from anti-slip flooring to permeable, durable paving.  Polyurethane used in encapsulation of porcelain tiles, USA Polyurethane has many uses. Here it is used to encapsulate a genuine porcelain tile. This encapsulation creates a simple installation method which includes a built-in grout look. Polyurethane allows these tiles to be installed quickly and easily. 1

Subfloor

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ELASTOCAST for tile encapsulation

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Porcelain tile

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RESIDENTIAL

Solutions for floors and ceilings


 ELASTOPAVE, Firmacasa House Design, S達o Paulo, Brazil Polyurethane mixed with an aggregate of glass or stone to construct a novel alternative to concrete or tarmac. Large and small stones are mixed together to create cavities that allow the finished, porous material to breathe, preventing puddles and formations of ice. 1

ELASTOPAVE for binding aggregate

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Dynamic course

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Base course

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Improved subgrade

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Subgrade/native soil

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Image: Arthur Calasans

Solutions for floors and ceilings

RESIDENTIAL

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Other polyurethane solutions for residential applications Polyurethanes to make solar products more durable, and garage doors quieter and stronger.  COLO-FAST used in solar panels, Allgau, Kempten, Germany Fast, durable framing of photo-voltaic panels and solar collectors by a Reaction Injection Moulding process – COLO-FAST ensures lasting protection against the elements. Panels are placed in closed moulds and then polyurethane is simply injected. Junction boxes and mounting fixings can be embedded quickly and easily in the frame in a one-step-process. 1

COLO-FAST polyurethane moulding

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Photovoltaic module

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Image supplied courtesy Solarzentrum Allgäu GmbH & Co. KG

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RESIDENTIAL

Other polyurethane solutions


 Garage doors with polyurethane core, Utah, USA Garage doors insulated with polyurethane are more than just efficient. Now you can have an energy efficient, noise reducing solution which is durable, protects and enhances the beauty of your home. 1

ELASTOPOR for door insulation

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Sheet metal

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Surface finish

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Other polyurethane solutions

RESIDENTIAL

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Project case study

“

The spray foam was installed quickly and met all of the criteria that we needed. It has proven to be a great product that has made the roof construction possible.� Simon Moore, Project Architect

The curved nature of the roof in the penthouse flat presented an issue in relation to the original insulation specified as this could not achieve the radius required. Certain traditional mineral fiber solutions are not guaranteed to stay in place down the curve and attain the required U-value of 0.1W/m2K. A spray foam insulant would be the ideal solution.

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RESIDENTIAL

Project case study

Project:

A new five-floor mixed use development comprising ground floor/basement retail and office accommodation with residential flats above

Location:

Hove, UK

Product used:

WALLTITE spray foam insulation

Architect:

Felce and Guy Partnership

Contractor:

Isotech Sprayfoam


Project case study

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NON-RESIDENTIAL

Introduction


NON-RESIDENTIAL Polyurethane products improve the performance, functionality and sustainability of many components used in non-residential buildings.

This results in buildings that are more energy efficient, durable, faster to build, with a lower lifecycle cost and reduced environmental impact.

BASF contributes to a full range of intelligent systems and solutions that meet construction challenges head on: from insulations to expansion joint systems to high-performance waterproof coatings.

Polyurethane insulation and floor coating systems used on a ground floor concrete slab construction in a university.

Introduction

NON-RESIDENTIAL

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Solutions for non-residential applications

Thermal insulation

Waterproofing and protection

Coatings and protection

Innovative polyurethane spray foams, insulation boards, sandwich panels and SIPS, through to exterior insulation finishing systems (EIFS). Applicable to walls, roofs, floors and ceilings. Benefits include energy savings, sustainable performance, enhanced overall comfort, faster construction and design freedom.

Secure waterproofing for all exposed areas. Spray applied fast curing solutions satisfy the most rigorous waterproofing demands. Even the most complex architectural shapes can be seamlessly sealed. Small concrete cracks can be repaired to extend the building’s life.

Eco-friendly, high-quality, high-performance surface solutions for interiors and exteriors. Simple to apply, fast drying for reduced construction time, long-lasting and durable, odorless for a healthier environment, easy to clean and low maintenance costs.

4 ELASTOCOAT for roof waterproofing 1

ELASTOPOR or ELASTOPIR for insulation boards in flat roof

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WALLTITE, ENERTITE, COMFORT FOAM or ELASTOSPRAY spray foam insulation

5 ELASTOPAVE for atriums

3 EIFS insulation

Flooring

Cladding and facades

Sealants and sealing systems

Self-levelling polyurethane solutions provide an abrasion-resistant floor coating.

Lightweight, high-tensile, structural-strengthening systems for masonry and timber elements – help increase the durability of building structures.

Joint sealants and sealing systems to prevent air, water and other environmental elements from entering or exiting a structure while permitting limited movement of the substrates.

6 ELASTOCOAT for floors 7 LUPRANATE binders for OSB 8 PERMASKIN TPU surface finishing

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NON-RESIDENTIAL

Introduction

9 ELASTURAN or LUPRANATE for window sealants


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Introduction

NON-RESIDENTIAL

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“ Buildings should be good neighbors.� PA U L T H I R Y, A M E R I C A N A R C H I T E C T

Innovative polyurethane solutions that meet construction challenges head on, resulting in non-residential buildings that are more energy efficient, durable, faster to build, and with a lower lifecycle cost and reduced environmental impact.

CO2

Increased energy efficiency

Better health and safety

reduces air loss and solar gain, which in turn will lower energy consumption and costs, and decrease carbon dioxide emissions.

including fireproofing, earthquake protection, prevention of moisture ingress, water damage and mold.

Enhanced durability Higher savings on energy bills.

by prolonging lifespan of the home, lowering the need and costs of maintenance.

Enhanced overall comfort

Increased productivity

with more consistent indoor temperatures and sound-proofed rooms.

by affording faster construction times, easy applications, leading to earlier occupation.

Environmentally-friendly efficient consumption and use of energy and resources, generating low VOC emissions.

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NON-RESIDENTIAL

Introduction


Solutions for roofs Offering practical, sustainable, flexible materials for architects and designers.

 ELASTOSPRAY used in roof insulation, Norway Pavilion, World Expo, Shanghai, China This chic, irregular roof design used ELASTOSPRAY on part of the rear roof. The spray foam allows design freedom and meets the technical challenges created by the innovative architecture. 1

Decoration plate

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ELASTOSPRAY spray foam

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Reinforced concrete slab

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Photography by Patrick Wack

Solutions for roofs

NON-RESIDENTIAL

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Solutions for roofs

 ELASTOSPRAY spray polyurethane foam roofing system used in Scope Arena, Norfolk, Virginia, USA Built in 1968, the Scope Arena’s roof is a concrete monolithic dome measuring 440 feet in diameter and encloses an area of 85,000 square feet. The entire roof was coated with ELASTOSPRAY spray applied polyurethane foam roofing and ELASTOCOAT protective coating, giving the Scope a modern appearance.

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NON-RESIDENTIAL

Solutions for roofs

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ELASTOCOAT protective coating

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ELASTOSPRAY spray foam

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Existing concrete roof

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 ELASTOSPRAY used on renovated roof, University of Puerto Rico Existing building roof gets a high performance upgrade. 1

ELASTOCOAT top coat

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ELASTOCOAT base coat

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ELASTOSPRAY spray foam

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Uninsulated metal deck

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Before

Solutions for roofs

NON-RESIDENTIAL

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Solutions for walls Providing answers today for tomorrow’s requirements.  WALLTITE used as part of a refurbished wall cavity, Montreal, Canada WALLTITE spray foam insulation provides both insulation and air barrier. 1

Existing brickwork

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WALLTITE spray foam insulation

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Brick ties

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New brickwork

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NON-RESIDENTIAL

Metal-faced polyurethane sandwich panels provide rapid installation times and can be fitted together accurately. With their high thermal insulation properties and low product weight, they are ideal for creating striking facades in large-scale industrial buildings. 1

Profiled metal sheet

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ELASTOPOR / ELASTOPIR foam core

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Profiled metal sheet

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 Metal-faced ELASTOPOR / ELASTOPIR sandwich panel system, hot dip galvanizing plant, Dalian, China

Solutions for walls

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Image supplied courtesy ThyssenKrupp Steel Europe AG

Solutions for walls

NON-RESIDENTIAL

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Solutions for walls

 Polyurethane sandwich panel, Indianapolis, USA Architectural metal sandwich panels insulated with a polyurethane foam core are a perfect choice for various building types. These building systems allow for increased construction time savings. The increased energy efficiency achieved by these panels contributes to the sustainability of the projects. 1

Architectural metal skin

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Polyurethane foam core

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Architectural metal skin

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NON-RESIDENTIAL

2

Solutions for walls


Solutions for floors Attaining higher performance through innovation and chemistry.  ELASTOPAVE used in car showroom, Berlin, Germany An ideal solution for heavy traffic areas that need to stay in pristine condition, ELASTOPAVE provides an easy to maintain, hygienic and aesthetic finish to interior as well as exterior surfaces. 1

ELASTOPAVE for binding aggregate

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Concrete sublayer

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Solutions for floors

NON-RESIDENTIAL

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Solutions for floors  ELASTOCORE used in SPS panels, terracing, Ascot race course, United Kingdom This Sandwich Plate System terracing, using a polyurethane core, was specified as a viable alternative to concrete or stiffened steel. The installed SPS solution offered a 75% weight reduction, savings on both substructure and foundation costs, as well as excellent vibration characteristics. 1

Metal backing plates

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ELASTOCORE polyurethane core

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Metal backing plates

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NON-RESIDENTIAL

Solutions for floors


Other polyurethane solutions for non-residential applications Providing thermal solutions to window, door and other product manufacturers.  ELASTOCAST used in window frames, New York, USA Polyurethanes used for the thermal break/window spacer in the windows used to retrofit this 44-story building, Confucius Plaza – the tallest building in Chinatown. The multi-use complex replaced all its original aluminum windows in 762 apartment units. The extra-thick insulated profile and low-E coated insulated glass will provide decades of comfort to over 2000 tenants. 1

ELASTOCAST window spacer

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Other polyurethane solutions

NON-RESIDENTIAL

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Project case study

The Norwegian Pavilion at the Shanghai Expo in 2010 was “an exercise in architecture powered by nature” – its design inspired by the Norway’s nature. Fifteen individual tree-like sections, each having a trunk, body and limbs that supported a canopy, came together to create the pavilion as a whole. ELASTOSPRAY was used to insulate various elements in the structure.

Project: Location: Product used:

“ Architect:

We will show how wood can be used to innovate architecture and urban concepts.” Helen & Hard Architects

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NON-RESIDENTIAL

Project case study


Photography by Patrick Wack Project case study

NON-RESIDENTIAL

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Elastopave used as a stable, flexible and porous surfacing for sidewalks and pedestrian areas.

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INFRASTRUCTURE

Introduction


INFRASTRUCTURE Today’s modern infrastructure projects demand strength and the ability to endure the wear and tear of daily life. From piazzas, play areas and railways to underground district piping and meeting areas – BASF products and solutions must be affordable for the end user, easy to build with and safe. BASF Polyurethanes’ systems and solutions meet these challenges, as well as meeting and exceeding industry regulations and standards.

Polyurethane solutions provide the greatest versatility for infrastructure projects from making hard landscaping paved, to ensuring a soft landing around playground equipment to protecting coastal areas and river banks from erosion and flooding.

Introduction

INFRASTRUCTURE

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Polyurethane solutions for infrastructure

Waterproofing

Sandwich Plate Systems (SPS)

Binders for playground surfaces

Secure waterproofing for all exposed areas. Spray applied fast cure solutions can cope with the most rigorous waterproofing demands and protect the most complex architectural shapes.

Steel-elastomer-steel composites are superior to conventional concrete or steel structures: they offer higher stability, better vibration isolation, weight reduction and lower total costs in comparison with conventional component parts.

Materials to provide permeability and anti-slip to pavements, as well as impact absorption for rubber crumb matting used in recreational areas. 3 ELASTOTITE for play areas

1 ELASTOCOAT for shelters 2 ELASTOCORE for footbridges

Pipe insulation and protection

River bank protection

Artificial turf underlay

Rigid polyurethane foam systems are commonly used for the protection and insulation of district heating and cooling and other industrial pipes where heat, natural gas, hot or cold liquids and other resources are carried through.

Coarse aggregates bound together with a twocomponent polyurethane to produce a strong, porous material. It provides a cost-effective and aesthetically pleasing alternative to rock or concrete revetments.

Green turf fibers are underlaid with energyabsorbing BASF Thermoplastic polyurethane (TPU) padding. This increases player comfort and helps prevent sports injuries. The special structure makes the artificial turf durable, low-maintenance and weather-resistant.

4 ELASTOPOR for district heating

5 ELASTOCOAST for river revetments 6 ELASTOLLAN for football pitches

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INFRASTRUCTURE

Introduction


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Introduction

INFRASTRUCTURE

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“ Life is what happens when you are busy making other plans.� JOHN LENNON, MUSICIAN

Polyurethane solutions provide the greatest versatility for infrastructure projects from making hard landscaping paved, to ensuring a soft landing around playground equipment to protecting coastal areas and river banks from erosion and flooding.

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INFRASTRUCTURE

Introduction

Enhanced durability

Increased productivity

Longer lifespan, lowering the need and costs of maintenance.

Faster construction speed, easy applications.

Better safety

Cost savings

Coatings in various surface textures help provide slip resistance for pedestrian areas. Special panels and sealants help prevent the spread of fire and smoke.

Reduced construction costs and energy bills.

Environmentally-friendly Efficient consumption and use of energy and resources, generating low VOC emissions.


Solutions for infrastructure Making our public spaces and walkways, pavements and other high traffic areas safer, longer-lasting and easier to maintain.  FILTERPAVE, Western Oregon University, Monmouth, USA Western Oregon University chose FILTERPAVE porous pavement for its aesthetic quality, design flexibility, recycled material content and stormwater benefits. 1

FILTERPAVE

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Dynamic layer

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Base course

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Improved subgrade

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Subgrade 1

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Solutions for infrastructure

INFRASTRUCTURE

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Solutions for infrastructure  ELASTOTITE rubber crumb binder, playground, New York, USA ELASTOTITE polyurethane system is used as a binder for rubber crumb material in this playground in New York. This provides a stable, safe and comfortable surface while taking advantage of the durability of polyurethane to adhere the aggregate material. 1

Recycled crumb rubber with ELASTOTITE binder wearing layer

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Base course

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Improved subgrade

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Subgrade

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INFRASTRUCTURE

Solutions for infrastructure


 ELASTOCOAT spray coating on deck, car park, Schipol airport, Amsterdam, The Netherlands ELASTOCOAT is spray applied on this park deck to prevent leakage to structures below the deck as well as a seamless transition to the existing drainage system. 1

ELASTOCOAT top coat

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Top primer layer with embedded aggregate

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Bottom layer of primer

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Concrete deck

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Solutions for infrastructure

INFRASTRUCTURE

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Solutions for infrastructure  ELASTOCOAST used on shore line, Hallig Groede, Germany ELASTOCOAST bonds rock or other substrates together to provide the ultimate protection against the forces of nature. These innovative materials can be used for river and coastal protection or other types of erosion control. 1

Cover layer with ELASTOCOAST binder

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Compensating layer

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Geotextile layer 3 2 1

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INFRASTRUCTURE

Solutions for infrastructure


 Sandwich panels, D-Runway, Haneda-Tokyo airport, Japan Part of the 4th runway, 2500m long, of this international airport stands on 100m deep pile foundations in the middle of Tokyo Bay. It has a unique hybrid structure that combines landfill with a pier – the latter being necessary so as not to disrupt water flow in the estuary of the River Tama. Sandwich panels, consisting of rigid polyurethane foam cores sandwiched between titanium coated plates, cover the bottom and side surface of the taxi area. 1

Titanium coated plate

2

Rigid polyurethane foam core

3

Titanium coated plate

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Solutions for infrastructure

INFRASTRUCTURE

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Solutions for infrastructure  ELASTOTRACK railway ballast binder, Wyandotte, USA ELASTOTRACK, a railway ballast binder, is a two-component polyurethane system developed for the reinforcement and stabilization of loose bulk ballast stones on railway tracks. 1

Top ballast binded with ELASTOTRACK

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Ballast

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 ELASTOLLAN rail seat pads An anti-vibration pad made of ELASTOLLAN is placed between concrete sleeper and the rail. The pad takes up the loads and dampens the vibrations. 3

Anti-vibration pad made of ELASTOLLAN (used with concrete sleeper)

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INFRASTRUCTURE

Solutions for infrastructure


 ELASTOCORE used in Sandwich Plate System, Dawson Bridge, Edmonton, Canada Sandwich Plate System used in an award-winning renovation of this important, historical traffic artery which handles in excess of 17,000 vehicles each day.

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2 1

Metal backing plate

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ELASTOCORE polyurethane core

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Metal backing plate

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Solutions for infrastructure

INFRASTRUCTURE

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Solutions for infrastructure

 ELASTOCOAT used on an anaerobic digester tank, Nebraska, USA ELASTOSPRAY and ELASTOCOAT were chosen to coat the exterior of an anaerobic digester tank in Nebraska. These coatings allow the tank to maintain temperature and increase the durability and longevity of the tank. 1

ELASTOCOAT elastomeric coating

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ELASTOSPRAY spray polyurethane foam 1 2

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INFRASTRUCTURE

Solutions for infrastructure


 Insulated pipes for chilled water, Marina Bay Sands Casino resort, Singapore The casino resort Marina Bay Sands in Singapore extends 200m up in the sky and is reportedly ‘one of the largest gravity-defying cantilevers in the world’. Approximately 70,000kg of polyurethane foam was used to make insulated pipes to the chilled water supply network. 1

Inner pipe

2

ELASTOPOR polyurethane foam

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Outer pipe

3 2 1

Solutions for infrastructure

INFRASTRUCTURE

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Project case study

To have successfully completed this project in the city where SPS was initially developed makes it a special achievement.” Michael Kennedy, CEO, Intelligent Engineering

After a structural survey found the original century-old decking of this important landmark in Edmonton had to be replaced, it became clear that the best approach was to limit the bridge’s dead load with a new lightweight deck (a traditional concrete deck would have been too costly and too heavy for the aging existing steel structure). The design team recommended an entirely new lightweight SPS solution – a sandwich plate system – from Intelligent Engineering Ltd. This represented the best combination of weight saving, a thin profile and a simple and rapid installation time.

The elastomer core is called ELASTOCORE. It helps the system to absorb vibrations and displays high tolerance to jolts and impacts. Panels weigh up to 70% less than reinforced concrete while being at least as strong and more durable. The system was fabricated off-site and then bolted together on the bridge. The replacing of the bridge deck in just 6 weeks was due to no need for time-consuming welding. This meant that long-term closures to the 17,000 vehicles per day which use the bridge, were avoided.

At over 770 feet long and 26 feet wide, the Dawson Bridge is the first major bridge to make use of SPS technology. SPS consists of two steel face plates sandwiching a core of polyurethane. The finished product is a composite panel of high rigidity and strength.

Project: Location: Product used: Contractor:

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INFRASTRUCTURE

Project case study


Project case study

INFRASTRUCTURE

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PRODUCT RANGE

Introduction


PRODUCT RANGE SUMMARY BASF's polyurethane solutions are the building blocks of many successful construction projects. Their use has been proven in many structural components for more than 50 years. They help save energy, make materials stronger, speed up construction times, protect the environment, enhance safety and much more.

Our primary product families are outlined over the following pages, including information on our rigorous testing procedures. To reach a BASF Polyurethanes expert for more information on any of our product families or systems, please refer to the list of contacts found on page 67.

Every construction project poses different and unique challenges to our customers. The experts from BASF Polyurethanes work closely with architects, engineers, designers, contractors, builders, owners and manufacturers to deliver innovative and customized solutions based on the understanding of industry trends. Introduction

PRODUCT RANGE

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Rigid foam building insulation

Spray foam building insulation

ELASTOPOR (polyurethane) and ELASTOPIR (polyisocyanurate)

WALLTITE

ELASTOSPRAY

LUPRANATE

A closed-cell spray polyurethane foam that has the ability to last the life of the building. Sprayed on the substrate, it adapts to any geometry, creating a seamless insulation layer. By virtually eliminating uncontrolled air leakage, the WALLTITE insulating air barrier system helps control vapour movement, reducing the risk of condensation, mold, moisture, ice damming, spalling and premature deterioration of building materials.

Closed-cell spray polyurethane foam insulation applied directly on the substrate to be insulated using a spraying process. The material forms a continuous, even insulating layer with no joints or gaps, providing an ideal solution for building insulation. The range of applications is extensive, from external insulation of roofs, to internal and external insulation of external walls, basement ceilings and soffit insulation.

LUPRANATE MDI is used to bind wooden flakes and fibers which are pressed into engineered wood products such as Oriented Strand Board (OSB), Medium Density Fiberboard (MDF) or particle board.

Characterized by a very low thermal conductivity and durability. Produced by insulation material manufacturers as insulation boards or sandwich panels, they offer ideal solutions for the thermal insulation of almost all types of construction.

Wood binders

COMFORT FOAM ENERTITE A low-density open-cell spray applied polyurethane foam insulation. Applied as a liquid, this water-blown foam quickly expands to many times its original size completely filling wall cavities. ENERTITE easily flows in and around difficult-to-reach areas such as pipes and wiring, creating a seamless seal.

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PRODUCT RANGE

Summary

An excellent insulation system for both new (walls, foundations, attics) and retrofit (attics, exposed wall stud cavities during renovations) applications within residential markets in the USA.


Windows

Waterproofing and corrosion protection

Sealants and sealing systems

ELASTOCAST

ELASTOCOAT

ELASTOCOAT

LUPRANATE

The polyurethane-based ELASTOCAST thermal barrier offers efficient insulation for window system manufacturers. Using the ‘pour and debridges’ method, it can eliminate heat loss by breaking the thermal bridge in the aluminum window frame. It also helps combat water, moisture and air infiltration thereby improving the structural integrity of the building.

When compared to aluminium window frames with their high thermal conductivity, glass fiber reinforced ELASTOCOAT window profiles show a 400-times lower value providing energy and cost savings. These profiles are produced in a pultrusion process – which ensures a rigid composite structure and offers considerable design freedom.

ELASTOCOAT coatings provide industry-leading protection for roofing, specialty storage and infrastructure applications. With a fast application time, higher tensile strength and improved low-temperature elongation, these coatings can stand up to almost anything while remaining cost-effective.

Joint sealants prevent air, water and other environmental elements from entering or exiting a structure while permitting limited movement of substrates. BASF has a comprehensive range of joint sealants and sealing systems that allows sealing of joints from facades to floors to wide, high-movement joints. LUPRANATE is also used in sealing foams for around windows and doors.

ELASTOCOAT can be applied on steel or wood and protects substrates from damage by impact, abrasion, chemicals or corrosion.

ELASTOCAST Two-component, custom-formulated cold cure elastomer systems used to encapsulate and protect other materials such as porcelain. ELASTOCAST allows floor tiles to be installed quickly and easily.

Summary

PRODUCT RANGE

61


Flooring systems

Permeable pavements

ELASTOCOAT

ELASTOPAVE

ELASTOCOAT’s self leveling flooring system seals and protects the concrete foundation of industrial buildings. The elastomeric nature of thisproduct helps bridge cracks caused by stress of the substrate structure.

ELASTOPAVE is a completely new concept for the construction of durable surfaces on paths and plazas. Strong, safe and environmentally friendly. ELASTOPAVE combines aggregate such as granite, stone, or recycled glass with a polyurethane binder to create a water permeable surface. Rain water can simply seep away and help replenish the groundwater supply.

ELASTOCOAT provides a reliable solution which is easy to care for, durable, abrasion proof, resistant to chemicals and mechanical impact.

ELASTOTITE / ELASTAN ELASTOTITE and ELASTAN are used as a binder for rubber crumb material and provides a stable, safe and comfortable surface.

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PRODUCT RANGE

Summary

Piping systems

ELASTOPOR

ELASTOCOAT

ELASOPOR pipe insulation is designed for oil and gas transportation, offering resistence to high temperatures, durability, good insulating properties and simple processing methods. Special flame-proof ELASTOPOR grades are used in the production of insulated pipes for use in the chemical industry.

ELASTOCOAT bonds well with a variety of surfaces and cures quickly (even in high humidity). It is ideal for industrial storage applications including exterior storage tank and vessel applications and interior linings for potable water systems.

ELASTOSHORE Offshore pipeline are installed by compact ELASTOSHORE heavy duty parts. These parts protect the pipeline from damage by currents, over bending and impacts caused during pipe laying or rough sea beds.


TPU (thermoplastic polyurethanes)

Railways

River and canal bank protection

Renewable energy

ELASTOLLAN

ELASTOTRACK

ELASTOCOAST

COLO-FAST

ELASTOLLAN thermoplastic polyurethane elastomers (TPU) have the impressive tear and cut resistance, excellent abrasion resistance and low-temperature flexibility necessary to withstand the harsh conditions of the construction industry. Several grades of ELASTOLLAN are also certified by NSF International for use in potable water mains.

ELASTOTRACK is a railway ballast binder system developed for the reinforcement and stabilization of loose bulk ballast stones on railway tracks.

ELASTOCOAST provides reliable coastal protection and also preserves the ecological balance. Tests conducted at the Fraunhofer Institute have established that, unlike concrete, ELASTOCOAST is PH-neutral even during installation and is thus totally harmless for fauna and flora.

COLO-FAST allows a quick, reliable and high-quality framing of photovoltaic (PV) modules. The UV-stable and weather-resistant polyurethane system replaces the conventional aluminum frames for both, roof-top and roof intergrated PV modules. COLO-FAST offers the customer a variety of colors and a high degree of design freedom. With COLO-FAST mounting features like clamping elements or screws and electrical components can be embedded in the frame in just one processing step. PV modules framed with COLO-FAST can be integrated perfectly into the roof and are highly aesthetic.

ELASTOLLAN is also used in construction of artificial sports pitches, breathable roof underlays and vibration pads.

PERMASKIN

ELASTURAN Railway sleepers are insulated from the railway track by foamed ELASTURAN damping mats. This technology reduces train vibrations to protect the track bed and chassis from impact and damage.

In addition, bank reinforcements and streams can be safeguarded quickly and easily with this technology. Nature benefits from many new habitats thanks to the open structure of the ELASTOCOAST-pebble mix.

PERMASKIN is a durable surface finish used as an alternative to wet coatings – and suitable for many exterior and interior applications including doors, garage doors, window shutters, wall panelling, facades or strips.

Summary

PRODUCT RANGE

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Testing and accreditation Accurate scientific measurement both in the laboratory and in the field is the only way to prove the true impact of construction products over the entire lifecycle. From manufacture through to disposal, products must have a minimal impact on the environment. To address rising energy costs, buildings must achieve higher levels of energy efficiency. They must also achieve other practical benefits such as durability and robustness to withstand the effects of ever-changing weather patterns, affordability, speed of construction to realize a quicker ROI and ease of maintenance. BASF understands that our customers cannot appreciate what we do not measure. That’s why we develop award-winning tools that help benchmark the impact of our products and systems on the triple ‘pillars’ of ecology, economy and society.

The third-party validated BASF Eco-Efficiency Analysis has been developed to assess and balance ecologic and economic performance. It enables scientifically sound comparisons of similar products or processes for dedicated applications. It assesses costs of a product or manufacturing process over the whole lifecycle as well as environmental impacts in six categories:  resource utilization

 energy consumption

 emissions to air, water and soil  toxicity potential

 misuse and risk potential  land use.

Elsewhere our polyurethanes are continually tested for suitability of use in construction projects all over the world. Typical accreditation bodies through which our products have been officially tested or contribute towards attaining a building’s certification include LEED, BREEAM, BBA and DGNB.

LEED standards Developed by the U.S. Green Building Council, LEED standards provide a framework for assessing building performance and meeting sustainability goals. Based on wellfounded scientific standards, the LEED program emphasizes state-of-the-art strategies for sustainable site development, water savings, energy efficiency, materials selection and indoor environmental quality. For more information visit www.usgbc.org

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Testing and accreditation


Polyurethanes and sustainability

3 Sustainable construction needs to be proven We can measure and evaluate with lifecycle, multi-criteria, application-oriented and databased evaluation. With our long-standing competencies and know-how in Eco-Efficiency Analysis, green building ratings, Environmental Product Declaration (EPD) tools, show houses, and our data-sets and case studies, we can provide sound, scientific information on sustainability.

More information can be found at www.basf.com/sustainability

Typical case study: annual savings and return on investment of polyurethane insulation A pitched roof was renovated and insulated with 140mm of PU in Germany* Heat losses through the roof before renovation:

17,250 kWh/a

Heat losses through the roof after renovation:

1,970 kWh/a

Heating oil prices 2009 (incl. auxiliary energy):

0.063 €/kWh

Annual heating oil savings:

1,520 l/a 962 €/a

Cost savings for energy:

As the roof had to be renovated anyway, the additional cost for insulation was limited to 7,100 €. This will lead to the following returns on investment for different oil price increases: Increase in oil price p.a. Investment 2010 (€) ROI p.a.

0%

4%

8%

7,100

7,100

7,100

10.31%

14.17%

18.02%

* Data showing economical impact: Source – ‘Sustainability and polyurethane insulation – Today's solution for tomorrow's needs’ by PU Europe (www.pu-europe.eu)

Insulation thickness at same R-value

Necessary thickness d (mm) for R=7.5m2 K/W U-value 0.13 W/(m2K) d= R x λ Higher thickness mm for same insulation level 450 300 150

Cellular foam glass

2 Sustainable construction needs tailor-made solutions BASF offers one of the broadest and versatile portfolios of chemical raw materials, formulations, end-use products and systems to the construction industry worldwide. These can be specified and used to contribute to a variety of sustainability improvements, for instance in energy efficiency, indoor-air emissions and affordable housing.

Mineral wool

1 Sustainable construction means performance It is not about self-proclaimed ‘green’ issues. It’s about high performance, quality and safety and the integration of fact-based, appropriate techniques into holistic solutions for everyday life.

5 Sustainable construction demands improved regulations and better solutions Regulations are being determined not only by governments, but increasingly from the marketplace, demanding and enforcing higher levels of sustainability performance. As a member of several green building councils and standardization bodies, BASF embraces and welcomes this strategy wholeheartedly. However, regulations will fail to reach their goals if they are simply based on single criteria or non-scientific requirements. To achieve better solutions, it is vitally important to improve regulations by introducing scientific, data-based evaluations.

XPS / EPS

BASF’s approach to sustainable construction is summarized in 5 key messages:

4 Sustainable construction defines our product development For BASF, sustainable construction means continually striving for more advanced products and proving their commercial, ecological and social benefits via measurable contributions. Working alongside our customers, we aim to be at the forefront of technological development.

Polyurethane

BASF believes that for a business to be successful in the long term, it must act responsibly toward the environment and society. Therefore contributions to ‘sustainable construction’ (through our products) is an integral part of our strategy and thinking. This means innovating, creating and continually developing products and systems that meet and exceed regulations and standards as well as industry challenges and requirements.

Polyurethane insulation with lowest thickness

20 30 40 50 Design λ value (mW/(m2K))

Data showing environmental impact: Source – Insulation for Sustainability: A Guide, XCO2 Conisbee, 2002

Polyurethanes and sustainability

PRODUCT RANGE

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BASF System House, Srem, Poland

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CORPORATE

About BASF Polyurethanes


About BASF Polyurethanes

Contact us For further information on BASF Polyurethanes products and materials, or if you would like to know more about any of the projects featured in this brochure please contact us at the relevant web address below:  For European enquiries: www.pu.basf.eu

 For Asian enquiries: www.polyurethanes.asiapacific.basf.com

BASF Polyurethanes, part of BASF Group, is the leading global supplier of polyurethane solutions for systems, specialties and PU products. With a worldwide network of polyurethane System Houses and its comprehensive product and service portfolio, BASF is the preferred partner for many industries, including building and construction.

Through its System House network, BASF Polyurethanes provides fast local support, from technical service and sales to production and marketing during the development of customized solutions.

 For North American enquiries: www.polyurethanes.basf.us

 For South American enquiries: www.basf.com.br

With its world-scale plants, BASF Polyurethanes secures its leading market position in the production of polyurethane basic products in all regions of the world.

Space for business card Space for printer’s FSC logo Disclaimer Any product information or other information published in this brochure is given to the best of BASF's knowledge. All this information shall not, however, as far as legally permissible, create any guarantee or representation of any kind or any liability of BASF and shall not relieve the User from undertaking its own investigations and tests. Except as otherwise specifically provided in writing, BASF's General Conditions of Sale shall not be altered by this brochure's content, materials and information. BASF Polyurethanes operates a policy of continuous development and innovation. Therefore product information may change without notice. All product data and usage should be confirmed using technical data sheets (available on request). It is the customer’s responsibility to consult local codes and building officials to ensure products meet usage requirements. Registered trademarks The following product names are trademarked: COLO-FAST, COMFORT FOAM, ELASTAN, ELASTOCAST, ELASTOCOAST, ELASTOCOAT, ELASTOCORE, ELASTOLLAN, ELASTOPAVE, ELASTOPIR, ELASTOPOR, ELASTOSHORE, ELASTOSPRAY, ELASTOTITE, ELASTOTRACK, ELASTURAN, ENERTITE, FILTERPAVE, LUPRANATE, PERMASKIN, WALLTITE.

About BASF Polyurethanes

CORPORATE

67


BASF – The Chemical Company


BASF Polyurethanes in Construction  

BASF Polyurethanes in Construction

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