Spray insulation

Spray insulation

PUR foam spray thermal insulation

Spray insulation systems made with polyurethane foam (PUR) are currently one of the leading choices for thermal insulation. Above-average ingress protection, speed of application and the possibility of thermally insulating any element of the building’s structure are just some of the reasons why so many investors decide to use spray foam thermal insulation as an alternative to traditional thermal insulation materials.

The PCC Group offers a wide range of high-end spray insulation products and systems available under the Crossin® brand. The knowledge and many years of experience of our experts allow us to develop the most efficient, environmentally friendly, reliable spray insulation and thermal insulation systems for demanding customers.

Spray foam – material properties

The fact that polyurethane spray works perfectly as a material for thermal insulation has been known for a long time. The popularity of this type of solutions results directly from the physical and chemical properties of PUR foam. One of the most desirable is to create an structure with extreme ingress protection, high density and volume, allowing for effective insulation of residential interiors against moisture and extreme temperatures. From a biological point of view, it is a material fully resistant to the development of moulds and fungi. Rodents also cannot settle in PUR foam. At the same time, PUR foams used in spray insulation systems are completely free of harmful chemicals, which makes them materials friendly for people, animals and the environment.


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Where is spray insulation used?

Given the above parameters and the wide range of advantages of this material, it is not surprising that spray insulation foam is so widely used. With its help, it is possible to perform both comprehensive insulation of the building and its thermal insulation or thermal modernisation. PUR foam spray thermal insulation is suitable for, among others, thermal insulation of slantsics, flat roofs, foundations, external structural walls, as well as ceilings in residential, commercial, utility and industrial buildings.

Key benefits of PUR foam spray thermal insulation

The decision to make the spray insulation from polyurethane foam will bring a number of measurable benefits to investors – both in terms of finances and increased living comfort. The most important advantages of PUR spray foam nclude:

  • excellent thermal insulation properties,
  • ensuring the breathability of partitions thanks to the vapour-permeable properties of PUR foam,
  • quick and easy installation of the insulation, precise application in the most inaccessible gaps,
  • ensuring uniform density and ingress protection of the material at any point,
  • effective elimination of the risk of thermal bridges by getting the foam into every gap,
  • seamless nature of spray insulation,
  • fully environmentally and domestically safe spray insulation.
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PUR shower insulation and traditional thermal insulation systems

The advantage of spray polyurethane over alternative thermal insulation systems is best seen by combining the properties of PUR spray foam with traditional insulation materials such as polystyrene or mineral wool. The seamless structure allows for a significant reduction of heat loss, generating considerable savings in heating costs. Spray foam insulation virtually eliminates any leaks that have to be taken into account when choosing traditional thermal insulation systems. The key differences between PUR foam and mineral wool and other products are shown in the table below.

PUR foam spray insulation Insulation made of traditional materials
Maximum fit for any surface and shape Difficulties with laying in places with difficult access
Resistance to moisture, water and biological corrosion Tend to absorb water from the air
No seams, homogeneous, stable structure Incorrectly installed wool or polystyrene panels can slide and create leaks
Universal application – for all structural elements of the building Due to its shape, it is recommended to thermally insulate straight surfaces (walls, attics)
Very good thermal insulation and soundproofing properties Good quality of thermal and acoustic insulation


Ingress protection of polyurethane foam insulation

Although the above comparison shows significantly better or similar insulation parameters in all key aspects, tightness is the most important reason why spray insulation is so widely appreciated by investors. The main advantage of spraying PUR foam is, of course, the possibility of its precise application on any surface – even in the most inaccessible corners. Investors who decide to use thermal insulation systems made of traditional panelled materials often have problems with the exact fit of wool or polystyrene in the most difficult to reach places, which significantly reduces the effectiveness of the thermal insulation system. There are no such problems with spray polyurethane, which additionally has the advantage of being a homogeneous and holistic structure, so there are no gaps or joints on the whole insulation. Even a few times the volume of PUR foam during spraying, combined with fast curing, guarantee excellent ingress protection of the entire system and its long-term stability.

How is polyurethane foam insulated?

The process of spraying polyurethane foam is carried out using modern aggregates and machines for precise, even application of the preparation. Due to the necessity to use special equipment, it is not possible to perform this operation alone, as is the case with thermal insulation with polystyrene or mineral wool. The PUR foam application itself is very fast and after just a few seconds the foam reaches the desired volume and hardness, filling all gaps and recesses evenly. As a result, an area of approx. 100 m2 can be completely thermally insulated with PUR spray foam in no more than a few hours.

In the case of exterior spray insulation, it is necessary to protect the foam with an additional layer of paint or varnish in order to protect the insulation layer from the adverse effects of UV radiation and to ensure its effective appearance for many years.

Passage of time against the thermal insulation parameters of PUR foam

One of the most interesting issues for those considering PUR foam spray is how such insulation works after several years of operation. Modern products used in spraying systems (especially open-cell foams) guarantee preservation of their thermal insulation parameters for many years. Due to the fact that spray insulation foam hardly ages, its application will not cause the loss of thermal properties, regardless of how many seasons elapse from the moment of thermal insulation.

Impact of spray insulation on health and the environment

In addition to longevity, another argument for choosing PUR foam thermal insulation system is its environmentally safe character. High quality materials such as Crossin® spray foam meet strict environmental and sanitary standards. As a result, they can be used without any fear of introducing chemicals harmful to humans and animals into a dwelling. PUR foam is an allergen-free, dust-free and crush-resistant material, making it fully safe for allergy sufferers and people with respiratory diseases.

CROSSIN® – polyurethane insulation line for demanding customers

The combination of all the above mentioned advantages of polyurethane foam is an idea that has been guiding the experts of the Crossin® brand, belonging to the PCC Group, which is the market leader of high quality polyurethane foams for spray insulation systems. These products do not contain gases or blowing agents that are harmful to the ozone layer. At the same time, spraying Crossin® foam increases the energy efficiency of insulation, which translates into reducing the amount of gases emitted and harmful combustion products in heating systems.

The innovative character of Crossin® products is the result of the resilient work of the manufacturer’s own research and development facilities. Thanks to this, state-of-the-art solutions are introduced to the brand’s portfolio long before competition.

How much does it cost to make spray insulation?

For systems such as spray insulation, the price of the service can vary greatly, depending on many factors. The most important include: the type of PUR foam chosen, the surface and the type of insulation. As far as spray thermal insulation is concerned, the price also depends on labour costs, which, like the prices of materials, may vary considerably between regions of the country.

Given the fact that spray foam is to be used in the building for many years, it is worth asking yourself whether the cost of the service should be the only or the most important criterion when choosing a contractor and a specific system? It is much more important whether the foam spray foam thermal insulation will meet the expectations of the household members and ensure the right standard of use. By choosing products from the Crossin® line, you gain a guarantee of the best parameters and precise application of the thermal insulation system. However, this does not mean that the price cannot be attractive when it comes to the spray thermal insulation we offer. The combination of affordable financial conditions and the best thermal insulation parameters in the case of the PCC Group’s offer always go hand in hand.

PUR spray foam insulation – open-cell or closed-cell foam?

It is no coincidence that spray foam insulation enjoys such enormous popularity, considering the numerous advantages of PUR spray foam, such as efficiency, speed of application and complete elimination of thermal bridges. In order to achieve optimum thermal insulation parameters of a building, it is essential to choose the right type of PUR spray foam insulation. You can choose between open-cell and closed cell foam.

Open-cell foam has a porous structure, consisting mostly of open cells and thus allowing diffusion. Once applied by spraying, the open-cell foam looks like a sponge. Its low deadweight is its unquestionable advantage, which makes open-cell foam an excellent insulator for attics and ceilings. Open-cell spray foam insulation is a material characterised by high “breathability” that is used for thermal insulation of, i.a.:

  • single-family houses,
  • developer investments,
  • warehouse and industrial facilities.

The advantages of open-cell spray foam also include its high resistance to mould, fungi and moisture, low absorbency, protection against overheating of rooms, as well as excellent adhesion to surfaces.

The second type of polyurethane foam available for purchase is closed-cell spray foam insulation. As the name suggests, this type of product has a closed structure, which results in lower air permeability, among others. Spray foam insulation made using closed-cell spray foam is heavier, much stiffer and also less susceptible to crushing than open-cell PUR spray foam insulation.

Due to their properties, closed-cell spray foams are commonly used for insulation purposes of:

  • warehouses,
  • manufacturing halls,
  • farm buildings,
  • water reservoirs,
  • sheet-metal roofs

and various types of industrial facilities.

Open-cell spray foams are light and allow greater breathability, which is why they are recommended for residential buildings – especially for insulation of interiors. In turn, the above-average strength of closed-cell spray foam, its rigidity and the fact that its parameters don’t change over time, make it a suitable insulator for industrial construction.

Read also: Where to buy components for polyurethane foam?