General

Polyphen® can be produced in a wide range of densities, from less than 30kg/m3 to 300kg/m3 (2-20lbs/cu ft) or more, depending on the intended application. The density range of greatest commercial interest  is 30-60kg/m3 (2-4lbs/cu ft), which covers most applications for thermal insulation foams. 

One of the most remarkable, and commercially useful features of Polyphen® is its ability to withstand  significant compression without destruction of foam cohesion.  In this respect,  it resembles polystyrene foam rather than polyisocyanurate or phenolic foam, which tend to crumble when compressed. Importantly, this feature enables  Polyphen® to be processed  into steel clad panels on continuous lines, using steel coils and roll-formers to create a variety of inter-locking panel designs for factory and cool store walls. An additional highly attractive feature of Polyphen® is its neutral pH value i.e. it is non-acidic. In contrast, current commercial phenolic foams are generally highly acidic, a negative feature with the potential to induce metal corrosion.

(A) Physical properties

The physical properties of Polyphen® vary with the density of the foam. The following test results were obtained for a nominal 50kg/m3 (3lbs/cu ft) foam:

(B) Acoustics

Polyphen® can be manufactured to have good sound absorbing properties, competing with polyurethane and acoustic foams at lower cost while providing higher fire resistance. By way of example, a 32 kg/m³ density Polyphen® foam was found to have a Noise Reduction Coefficient NRC=0.45 (250-2000 Hz, 30mm thickness).
This means it can be used for acoustic applications e.g. ceiling tiles, wall linings and office partitions, to reduce disturbing echoes. Areas of potential use include restaurants, factories, call centres etc.

(C) Fire resistance

The following test results were obtained:

1) Fire  rating  to AS1530.4 (ASTM E 119, ISO834, BS476pt20-24)

A 2 hour Fire Rating has been achieved by Polyphen® sandwich panels, with 0.6mm steel both sides (tested by Warrington Fire Research).

2) ISO 9705 Room Corner Test

In accordance with the standard ISO 9705 test, a 3.6x2.4x2.4m room was lined with Polyphen® sandwich panels, size 2400x1200x100mm, with 0.6mm steel facings both sides (3 walls and ceiling). One corner of the room was exposed to a flame of 100kW intensity for 10 minutes, then 300kW for a further 10 minutes. The result of the test was remarkably good in that not only did flash-over not occur but the fuel contribution of the Polyphen® panels was extremely low (<50kW ie <20% of the value allowed before flashover is deemed to occur). On dismantling after the test, the foam was partially charred but retained its original shape and size. The result of the test was so good as to award Polyphen® a Class 1 rating under the new Building Code of Australia, effective July 1, 2003. This is the highest possible classification for a building material.

3) Factory Mutual UBC 26-3 Test (Room Test)
FM Global Class 1 Accreditation

This test was performed with 250mm (10 inch) thick steel clad panels with very good results, meeting all requirements for an FM Class 1 fire rating (the highest classification for fire resistance). The panel design was standard tongue-and-groove, with 0.6mm steel skins.

FIRE TEST SUMMARY

In all the above fire tests Polyphen® showed itself capable of retaining most of its original volume when exposed to high heat for a period of time, as a result of its ability to form a fire resistant char. The high fire resistance of Polyphen® is being well received by insurance companies, with facilities rewarded with lower premiums, as Polyphen® greatly reduces the risk of a localised fire in a factory or cool store spreading and resulting in a total loss of the facility.  World-wide insurance claims for factories and cool stores lost to fires in which high fire-risk foam core panels are implicated amount to many hundreds of million of dollars annually.


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