BJ Steele, a Field Technical Manager at Progressive Materials, has been testing the quality of roofing materials on-site for years using a hand operated machine. Finally frustrated with a broken machine, Mr. Steele required a better solution for testing spray polyurethane roofing foam. TestResources provided him with a more accurate, easy to use, and portable solution.
The million dollar test
Spray Polyurethane Foam, typically called SPF, is an insulating plastic that is sprayed as a liquid and expands into a hard, waterproof material. To help reduce heating and cooling costs, lower noise levels, and keep roofs waterproof in homes and commercial properties, builders use rigid polyurethane spray foam.
Progressive Materials, a manufacturer of sustainable roofing and building products based out of Indiana, produces spray polyurethane foams for roofing materials. Progressive Materials tests their spray foam to ASTM D1621, a standard compression test for expanded plastics and foams. Several SPF samples must pass the compression tests in ASTM D1621 for Progressive Materials to approve.
The million dollar problem
Premature failure on a roof can cost millions of dollars’ worth of damage and repair. Roofing material replacement alone can cost $50,000 for an average size shopping center. And If not caught immediately the problem can get much worse - costing double. It can lead to mold and mold can lead to sick building syndrome, therefore this leads to great incentive to prevent this problem.
Product quality is a top priority for Progressive Materials. They use a simple test to prevent quality problems from the beginning. On-site Mr. Steel uses a sample cutter to retrieve cylindrical core samples of the hard polyurethane foam. He then uses a hand-cranked compression tester to test the foam to ASTM D1621.
The challenge of on-site testing to a specification written for laboratory testing
Progressive Materials has been testing their foam for years on-site using this hand operated tester. This portable foam compression tester works with a single arm crank that is manually rotated by the operator. The operator must attempt to compress the sample at a constant rate of 5 revolutions per minute to relate approximate results of a laboratory tester crosshead speed of 0.5 inches per minute. While convenient, this test presents a challenge for the operator to provide a constant rate of motion from test to test. This is more work for the operator and can provide sloppy results if not done carefully. Mr. Steele needs accurate results testing to ASTM D1621, or problems can arise later down the line for the roofing material.
“If (the foam) is too rigid it breaks under pressure and the roof fails prematurely. If it’s too soft it will be porous and take in water, both costing significant money in repairs,” Mr. Steele stated.
When Progressive Material’s hand-operated compression tester broke down, Mr. Steele sought out a better solution. He found TestResources online and reached out for a portable and accurate solution for testing to ASTM D1621.
An easy solution
TestResources provided Progressive Materials with a compact compression test machine for spray foam coatings. The 100 Family Test Machine is small and accurate with a portable Pelican Case option for transporting to on-site testing. The machine tests in accordance with ASTM D1621, and comes with specialized compression platens.
Additional challenges for on-site testing
Mr. Steele’s test requires use of four square inch core samples of at least one inch thickness. ASTM D1621 recommends using samples that are flat, parallel, and free of flaws, but it is difficult to acquire perfectly formed specimens of foam anywhere let alone on the top of a building out in the elements.
TestResources engineers provided Steele’s 100 Family Test Machine with specialized compression platens and an upper spherical seat. The upper spherical seat allows for the compression platen to slightly pivot and conform to the uneven sample. This provides more accurate testing results.
The machine tests in accordance with ASTM D1621, testing in compression at a constant load rate of 0.5 inches per minute. The machine will end at the yield point and provide accurate results for the properties of the spray polyurethane foam.
Outcome
B.J. Steele travelled to TestResources headquarters in Shakopee, Minnesota, to learn first-hand how to run and test samples on his machine. TestResources engineers worked with Steele to run the machine step by step in the training room.
Steele found it more desirable to gather large quantities of foam core samples on site and bring them back to Progressive Materials for testing with the TestResources 100P Family Test Machine. Mr. Steele is satisfied with his easier testing solutions and more accurate test results. Mr. Steel said after his visit,
“TestResources understands that my company finds it important to have accurate test results certifiable to ASTM D1621. I was surprised to find such a cost effective solution for my test machine, and they took the time to teach me how to use it too.”
