“Setting Standards for the Industry”
2010 PRODUCT CATALOG
●
DENVER FOAM
®
OPEN CELL POLYURETHANE BACKER ROD
●
MILE HIGH FOAM
®
CLOSED CELL POLYETHYLENE BACKER ROD
●
ULTRA BLOCK
®
FIRE STOPPING SYSTEMS
Backer Rod Mfg. Inc.
4244 N. Broadway ● Denver, CO 80216
Toll Free 800-595-2950 ● Telephone 303-308-0363 ● Fax 303-308-0393
www.backerrod.com
Backer Rod Mfg. Inc.
Backer Rod Manufacturing – one of the largest manufacturers of
backer rod materials in the world. We are experts in the specialty
caulking field, providing backing for elastomeric and other applied
sealants to the worldwide construction market. No other company
manufactures and supplies backer rod products that are able to
withstand temperature variations from -60°F to over 2000°F.
We serve customers in the construction industry with specific
applications in expansion/construction joints to include:
• highway construction and maintenance
• log homes
• parking decks
• buildings requiring structural fireproofing
fire rated for 1,2,3 and 4 hours construction (ASTME 119)
• seismic movement (ASTME 1399)
Backer Rod offers three distinct products for use in construction
joints: Denver Foam
®, Mile High Foam
®, and Ultra Block
®. The
type of backer rod used is governed by the type of sealant used, plus
environmental, seismic and temperature requirements. Backer Rod
Manufacturing is proud to market our products through authorized
distributors and select OEM customers around the world.
Backer Rod Mfg. Inc.
Reply to: 4244 N. Broadway Denver, CO 80216 2929 Walker Drive P.O. Box 8005 Green Bay, WI 54308-9229 Phone 303-308-0363 Fax 303-308-0393 Phone 920-406-4000 Fax 920-406-4040
GENERAL CERTIFICATE OF COMPLIANCE
DESCRIPTION: BACKER ROD MFG. INC. SEALANT BACKING PRODUCTS
Denver foam
Mile High Foam
Ultra Block
THESE PRODUCTS ARE TESTED TO ONE OR MORE OF THE FOLLOWING
STANDARDS:
DENVER FOAM® MILE HIGH FOAM® ULTRA BLOCK®
• ASTM D 1622 • ASTM D 1622 • UL 2079 • ASTM D 1623 • ASTM C 1016 P. B • ASTM E 814 • ASTM C 1016 • ASTM C 1253 • ASTM E 84 • ASTM D 5249 - 95 • ASTM D 5249 • ASTM E 1399 • ASTM D 3574 • ASTM D 1623 • ASTM E 119 • ASTM C 1330 type O • ASTM C 1330 type C • ASTM C 719
• NFPA 251 • NFPA 255
No asbestos, PCB’s, or lead are used or contained in these products.
Bill Bergel February 10, 2009
___________________________ _________________
Sales and Marketing Manager Date
T
he majority of construction in commercial building today is done by use of large building panels of various types, connected by a high performance elastometric seal-ant material to form a waterproof seal. These panels consist of either precast concrete, prestressed con-crete, or curtain wall which is pre-dominately glass and metal. Any combination of these three types also is commonplace in modern construction.It is vitally important that the connecting link, the sealant, joining all these panels be of top quality, capable of performing satisfactorily for a great many years. without this performance, water tightness soon is lost, resulting in long, costly mod-ifications and repairs.
Many factors must be considered in designing a commercial building which will give many years of trou-ble free service. These include joint design, selection of sealant, surface preparation of joints just prior to caulking and, finally, selection of the proper backer rod (against which sealant is placed). The right decisions in these important areas, plus proper installation of the prod-ucts, ensures desired results.
The backer rod evolves Evolution of the backer rod from the first use of caulking to the present
Hidden, but essential
A technical review
of backer rods
by J.F. GibbAt left,the result of outgassing by a closed cell backer rod. The rod has been removed, and the panels and sealant bead sawed in cross-section to show cavities caused by the bubbles. This is an unsatisfactory seal. Below, the sample at left seen from the side. A cured sealant bead applied above a closed cell backer rod was ruptured when trapped gases escaped from the rod.
John F. Gibb invented and developed the production equipment used to make open cell backer rods, and holds U.S. and foreign patents on this machinery. He is a member of the ASTM C-24 Joint Sealant Committee, and is General Manager/part owner of Backer Rod Mfg. & Supply Co., Denver.
state of the art covers use of many different types of materials. They range from sand in horizontal joints, through wood, fiber board, jute, rope, and twisted paper. About 17 years ago, a product evolved which consisted of an extruded plastic rod.
This new backer rod was a closed cell, flexible foam material. At first, it was made from polyethylene plas-tic. Now it consists of polyethylene and polypropylene, both nearly identical in appearance and per-formance. This new rod is manufac-tured by plastic extrusion: A gas is injected into the material, creating plastic foam. The result might be described best as being somewhat similar to a tube inflated under slight pressure as gas is trapped within its cellular structure. This rod proved to be far superior to what had been used previously in the trade, but was not without its prob-lems.
Problems — and solutions
One of the more serious problems was outgassing. When these closed cells and their outer skin somehow become ruptured, trapped gases slowly escape to the atmosphere. If a high proportion of these cells be-come ruptured or deflated (so to speak), much of the rigidity of the rod is lost. The rod also loses much of its ability to regain its original round shape once it has been de-formed.
The problem of outgassing as-sociated with these new flexible foam backer rods resulted in sealant manufacturers insisting on further research, in the attempt to find a suitable material that would elimi-nate this problem — without
creat-ing even more serious ones.
For many years, in limited appli-cations only, polyurethane foam materials had been used success-fully. This promoted further velopment of this material, to de-termine its suitability for use in backer rods in the caulking busi-ness.
Most early applications em-ployed a backing material cut into short strips (square or rectangular in cross-section). The material exhi-bited a wide range of physical prop-erties, because much of it had been cut from scrap material used by the furniture business. The type of polyurethane used in that industry is required to have a very high de-gree of resilency, and to retain this property through severe usage. This same property is necessary in ex-pansion joint backer rod. Therefore, it proved to be an ideal material for backer rod use.
About six years ago, a round, open cell, flexible polyurethane backer rod was introduced. The product was made from special formulations of these flexible foams, producing a more uniform material. (As noted, uniformity was lacking in previous urethane backer rod produced from scrap.)
Open vs. closed cell
There are some interseting (and im-portant) differences between open and closed cell backer rods.
Both open cell and closed cell are inert to all common and more pre-dominately used sealant materials on the market today. Both have ex-cellent chemical resistance.
Both, too, are classified as
non-staining. This means they contain no materials that would bleed out slowly and seep into the sidewalls (substrate), later to reappear as coloration on the surface (some dis-tance away). This is a particularly important point, if marble or other masonry materials are used.
The open cell rod is more flexible than its counterpart closed cell. The open cell must depend on its chem-ical and physchem-ical make up to attain rigidity, while closed cell rigidity is the result of gases trapped in its interior (as explained earlier).
Rarely in commercial building construction do expansion joint widths conform exactly to design. For instance, a one-half inch joint frequently will vary from as little as one-quarter inch or less to as much as three-quarter inch (or more). It is virtually impossible to manufacture or to erect large building panels economically to such precise di-mensions that joints between such panels stay within close tolerances. A backer rod to be packed between these panels must be flexible enough for easy insertion.
Manufacturers of closed cell backer rods recommend that the product not be compressed more than 25 percent of its diameter. Con-sequently, the applicator must change sizes frequently, using closed cell in commonplace, vary-ing width joints, and open cell rod if he is to exceed the 25 percent max-imum compression limit.
Open cell backer rod must be compressed at least 25 percent; it does not hurt these rods to be com-pressed as much as 75 percent of their diameter. This allows the applicator to use fewer sizes in
ing width joints. Many times, one size will work the full length of the joint (which might not be the case when using closed cell rod).
Three primary purposes
A backer rod has three primary pur-poses. First, it forms a base against which sealant is applied. (It there-fore determines the thickness of the sealant bead.) Also, it forces un-cured sealant out laterally under tooling pressure, resulting in 100 percent contact of sealant to sidewall (substrate). These are the bond lines. Finally, backer rods dictate the cross-sectional config-uration of the sealant bead.
Flexibility of the two backer rod materials plays an important part in tooling the newly applied sealant beads. A backer rod, although im-portant in an expansion joint, is secondary to the primary prod-uct—the sealant. The desired end result is a satisfactory seal that meets or exceeds specifications.
The more rigid closed cell backer
rod is able to withstand a heavier pressure. The greater flexibility of the open cell rod requires the caulker to use lighter tooling pressure, to minimize spring back. (It is not a difficult technique to master, for open cell backer rod has been used successfully for 20 years or more.)
Tooling the hour glass
Tooling is done with a variety of in-struments. Most incorporate a semi-flexible blade, like a spatula. It is the tooling operation that gives the cross-sectional shape to the newly applied sealant bead. This shape is referred to as an “hour glass” configuration.
The hour glass shape is impor-tant. It results in a maximum bond-ing surface on the sidewalls, and a thinner section midway between. This means the adhesive bond to the sidewalls will be of sufficient strength to eliminate failure caused by repeated elongations and con-tractions of the sealant material. In simple terms, the strength of the
bond to the sidewalls forces ellastic movement of the sealant. Elasticity of the sealant comes into play by al-lowing stretching and contraction at the thinnest point, avoiding ex-cessive stress at the bonds to the sidewall. Choosing the correct backer rod obviously plays an im-portant part.
If a backer rod is placed incor-rectly (too deeply) or so it doesn’t force an hour glass cross section, cohesive or adhesive failure be-comes a distinct possibility.
Proper cross sections
Figures 1 and 2 show the dif-ferences between the proper cross section of a newly applied sealant bead, and an incorrect one. Figure 2 is incorrect because the ratio of thickness of the sealant bead at the bond line to that at the midway point is too small. Movement of the joint sidewalls will put undue stress on the bond lines. The high cohe-sive strength of the overly thick sealant bead will make it very dif-ficult or impossible for the sealant to elongate. The bonds may fail even-tually because of this; they will not if they have the correct ratio de-picted in Figure 1.
This problem can be com-pounded if an incorrect back-up is used in cases where three-sided adhesion occurs. In these cases, a sealant cures while adhered to both sidewalls, and to the backer rod. When the back-up rod is composed of a rigid, unyielding material, problems can arise.
Closed cell backer rods, being an olefin-type plastic material, are well known for their anti-stick prop-erties. Usually, any inital adhesion to these back-ups break down quickly, and the sealant comes free.
This was thought to be the case with open cell rods as well, since the weak open cell surface structure also shears away from the sealant bead. In cases where it does not, however, the flexibility of the open cell rod allows it to move with the sealant bead (with absolutely no ill effects) for the life of the sealant.
This has been demonstrated both
in laboratory tests of 10,000 cycles (excess of 25 years) and in over 20 years of actual use in the field. Prob-lems do arise when a rigid back-up is used: the sealant bonds to it tenaciously. When the joint moves, the sealant doesn’t—and failure likely will occur.
Closed cell rods tend to take a set when compressed for extended periods of time. This is not the case for open cell rods. It is a basic re-quirement of these open cell foams in the furniture and padding indus-try that they not take a set. On occa-sion, closed cell rods have been known to move back into a joint under gunning pressure, if the rod first was placed in the joint too far. (This permits too thick a sealant bead, risking bond failure.)
Open cell rods have a high coeffi-cient of friction, and do not slide easily over most surfaces. This re-sults in a good grip to sidewalls, and a resistance to movement under gunning presuure. Open cell rod can move, however, if it is not
com-pressed the recommended 25 per-cent in joint packing.
Moisture Absorption
One of the myths that existed for years about open cell backer rod was its alleged moisture absorption. Many felt its open cell structure made it perform as a sponge. Open cell foam will absorb some water, but under most situations it does not retain it for long. Twenty-four hour total submersion tests indicate 50 percent absorption is about average. (This, of course, is not encountered in the field, but whatever water might be absorbed in actual practice still is not retained long.) Closed cell rod, on the other hand, is virtu-ally non-absorbent; therefore, no problem.
This open cell feature has proven to be an important asset, because an escape route for gases always is readily available. Should some moisture become trapped between the sidewalls and the backer rod, the area usually is much slower to dry
out than is that part of the joint not covered by the backer rod—and ex-posed to the air. (See Figure 3 and Figure 4.) The portion to be caulked, however, is dry enough to be sealed.
When this moisture problem oc-curs and the wetness begins to evaporate, vapor pressure is built up between the backer rod and the sidewalls. In the case of the open cell rod, when these vapors take the course of least resistance they go through the backer rod to escape. As for closed cell, being impervious, the only escape route is through the newly applied sealant bead. When this occurs, the sealant bead blis-ters. Channels can develop throughout it; at times, the bond line fails or is seriously weakened.
Another important plus for open cell rod which became obvious in the application of air cured sealants (silicones) was the fact that a cure is initiated from both sides. This speeds up the cure substantially (highly desirable with slow-curing sealants). This faster cure to a large extent eliminates precure adhesive or cohesive failure problems.
Two-sided curing is impossible with closed cell rod material, there-fore air curing sealants remain in an uncured or semi-cured state for a longer period of time. (See Figure 5 and Figure 6.)
Outgassing
Bubbling of newly applied or semi-cured sealant beads is referred to as outgassing. The results are similar to those caused by trapped mois-ture. This is a common problem when using closed cell rod. For many years, it was suspected this bubbling in newly applied sealant beads was caused by the sealant. However, more precise observation showed it to be from closed cell backer rod.
It was explained earlier that closed cell backer rod contains trapped gases within its surface skin and inside its closed cells. Also, it was pointed out that if this skin and/or some of these cells become ruptured, the gas begins to seep out. The impervious nature of the closed cell backer rod prevents escaping
gases from going any place other than through the newly applied sealant beads.
This seepage bubbles in the seal-ant, that, at times, can extend from the vent hole in the backer rod completely through the sealant bead, to its outer surface. This causes a leak in the seal. Most outgassing and bubbling isn’t quite this severe. Usually, these gas bubbles stay within the sealant bead, though
they do detract from appearance, and weaken the sealant bead. (See Figure 7.)
Backer rod rupture
Rupture of closed cell backer rod can occur in several ways. Rough masonry surfaces often (and easily) cut open the surface skin and under-lying cells, allowing enclosed gases to escape. Rupture also can be caused by equipment used to pack
the backer rod into the joints. As mentioned earlier, closed cell rod should not be compressed over 25 percent of its diameter. Variation in joint width is so predominant that over-compression occurs often; this too can cause rupture of the skin and underlying cells.
Over-compression in packing the joint requires heavier pressure in use of the packing tool, which in-troduces more chance of rupture of the skin and underlying cells, at the point of contact of the tool. The more over-compression, the more points of contact, therefore the more chance of rupture. Should the joint be in a rough masonry wall, the problem is compounded. The rough surfaces also will tear open the backer rod when it is subjected to such over-compression.
This problem can be com-pounded further if heat is involved, and rapid expansion of the building panels occurs. The more rapid clo-sure of the joints (and expansion of the gases) due to heat forces gases into the uncured sealant faster, only adding to the troubles.
Another cause of outgassing with closed cell rod is sharp bends. Again, the surface skin and underly-ing cells can be ruptured. It is better to break closed cell backer rod at sharp turns than to bend it. The break provides an avenue of escape for these gases, away from the seal-ant bead.
One proposed partial solution to this outgassing problem was to pack the joint well in advance of (days be-fore) the caulking operation. How-ever, this would increase labor costs substantially. The closed cell rod would take a permanant set, par-tially releasing its grip to the sidewalls. This would risk move-ment during caulking (what’s more, it was found closed cell rod still gassed, even after a year in a joint).
Outgassing is one problem that does not exist with open cell rod. The lack of an outer skin (or closed cells) totally eliminates any possi-bility of this occurring. In fact, pre-vention of outgassing was the pri-mary reason open cell backer rod was developed.
Other consequences of heat
Closed cell backer rod is a thermo-plastic olefin material. This charac-teristic limits its usage if higher temperatures are encountered. (The maximum allowable temperature recommended by manufacturers is 160°F.) Open cell backer rod is a thermosetting plastic material with much higher heat resistance. It has been used successfully for limited periods under hot-applied sealant material (up to 500°F), with no ill ef-fects.
The effects of elevated tempera-tures on successful application of a satisfactory sealant bead are of vital importance. New construction in hot climates reportedly will en-counter temperatures of nearly 300°F for some materials. A backer rod material installed under such conditions must be able to with-stand these temperatures without having a detrimental effect on applied sealants. The possibility of backer rod outgassing or shrinking brought about by contact with hot surfaces should be considered care-fully.
Both closed cell and open cell ma-terials have good cold temperature characteristics under normal caulk-ing environments. However, in ex-tremely cold temperatures the open cell has a definite edge, remaining flexible at minus 60°F.
A minor role?
The backer rod in an expansion joint appears to play somewhat of a minor role. After the sealant has at-tained a full cure, the rod serves no further purpose other than, perhaps, offering some insulating properties in the expansion joints.
Although the role backer rods play may seem minor, it is impor-tant that architects, specification writers, caulking contractors and building owners ensure that seals in expansion joints perform well, and do not become the prematurely weak link in the structure.
It is in making possible that im-portant seal that the backer rod per-forms its hidden, but essential task.
THE CONSTRUCTION SPECIFIER/MARCH ’80 45
From top to bottom: (1) A typical rough masonry joint which will be sealed with a caulking material, after a backer rod has been packed between the panels. (2) An open cell backer rod being packed into an expansion joint prior to caulking. (3) A properly caulked joint in rough masonry, using an open cell backer rod (note the absence of bubbles in the cured sealant bed).
Manufactured under U.S. and foreign Patents and Applications
DENVER FOAM®is a ROUND, LABOR-SAVING, continuous-length, compressible open-cell polyurethane
foam used primarily as a “NON-GASSING” backer rod in caulking and sealant applications, such as expansion joints.
TIME PROVEN APPLICATION: Open-cell polyurethane foam, in various shapes and densities, has been used successfully for many years in the caulking and sealant trade without adverse effect.
1. Note that DENVER FOAM®is dispensed from core - - 2. Note ease of application from scaffold. Small bales will
“binder-twine” type bale enables workman to secure sit flat and can be lashed easily. Bales can be stepped to scaffold without dispensing problems. over easily.
ADVANTAGES:
1. LABOR SAVING: DENVER FOAM® can be installed rapidly with any type tool WITHOUT REGARD FOR SURFACE DAMAGE. Since round, compressible DENVER FOAM® can be installed in continuous form IN JOINT WIDTHS OF LARGE
VARIA-TION without the necessity of changing backer rods sizes excessively, DENVER FOAM®can be installed TWO OR THREE TIMES FASTER than conventional closed-cell polyethylene or rectangular shaped backer rod materials.
2. “NON-GASSING”: DENVER FOAM® is open-cell polyurethane foam, and, being
vir-tually “gas-free”, can be installed rapidly without regard to surface damage, thereby eliminating potential sealant failures and expensive repairs due to “gassing” action ex-perienced by damaged closed-cell polyethylene backer rod materials.
3. “BINDER-TWINE” PACKAGING: DENVER FOAM® is packaged in continuous length bales in preshrunk, transparent polyethylene in such a manner that DENVER FOAM®is dispensed from the center of the bale. Several bales are packed in a master
bag of extra-strength polyethylene, and tied with a removable and reusable plastic tie. Each diameter is designated by a different color label, and premarked at nominal 100 foot intervals. (NOTE: See explanation next page for master-compressed FREIGHT-SAVING shipping bales, and also pre-packed MINI-BAGS for small requirements.)
D7
DENVER FO AM ® 1992 SEALANT BA CKER-R ODADVANTAGES (continued):
4. COMPETITIVE: DENVER FOAM® is competitively priced, throughout the World, with most backer rod materials
5. SEALANT ADHESION TO BOTH OPEN-CELL AND CLOSED-CELL BACKER ROD: Unbiased third party laboratory tests and extensive field experience show that sealant materials usually adhere to both open-cell polyurethane backer rod and closed-cell polyethylene backer rod. Performance of both type backer rod materials was found to be similar in that the behavior of the sealants was essentially the same with each back-up. Sealants subjected to dynamic movement will not be adversely affected by adhesion to DENVER FOAM®due to the low surface strength and shearing capabilities of the backer rod.
6. NON-STAINING: DENVER FOAM®is white to beige in color, odorless, and non-staining.
7. INERT: DENVER FOAM®is physically and chemically compatible with virtually every sealant.
8. COMPRESSIBLE: 25% nominal at 1 to 11⁄2p.s.i. (70 to 100 gms./sq.cm) with an approximate density of 4# to 6# per cubic foot (64Kg to 96 Kg per cubic meter).
9. FLEXIBILITY: DENVER FOAM®has been found to handle much easier than closed-cell
polyethyl-ene due to it’s greater flexibility, resulting in faster application and usage, without size change, in a wider range of joint width.
10. LESS INVENTORY INVESTMENT: Because each size of DENVER FOAM®can be used in such a
wide range of joint widths, the amount of dollar investment to carry a full inventory is greatly reduced. 11. LESS STORAGE SPACE REQUIREMENT: Due to compression packaging of DENVER FOAM®,
considerably less storage space is required to carry an adequate inventory.
12. EASE OF JOB CLEAN-UP: Since DENVER FOAM®is packaged in easily-disposable polyethylene bags, the problem of container disposal is reduced to a minimum.
13. EASE OF SHIPMENT: Since DENVER FOAM®is packaged in compact, compressed, light-weight
master bags, ease of hauling sufficient material to the job in a minimum of space is greatly facilitated. Also, emergency shipments of a substantial amount of backer rod can be made very easily by United Parcel Service or other small package carriers.
14 WIDE TEMPERATURE RANGE: DENVER FOAM®has been used successfully at temperatures of -70°F. (-57°C.) up to intermittent temperatures of 500°F. (260°C.). It has been determined by an in-dependent testing laboratory that DENVER FOAM®subjected to 300°F. (149°C.) for six weeks will
start to deteriorate, but since hot-pour sealants cool quite rapidly, DENVER FOAM®IS AN
ADVANTAGES (continued):
15. NON-WICKING: DENVER FOAM®does not wick water, and is non-hygroscopic. DENVER FOAM®
does not absorb water readily under field conditions. If wetted during a rainstorm, the DENVER FOAM®is usually dry enough to caulk when the sidewalls of the joint are dry enough to apply the sealant. It is recommended that DENVER FOAM®should be reasonably clean, relatively dry, and
free of contamination at the time of caulking application.
16. FREIGHT SAVING ADVANTAGE: Since DENVER FOAM® is a highly resilient open-cell polyure-thane foam, it can be compressed substantially to increase the density (weight per cubic foot or meter) enough to take advantage of the lowest available freight rate, thereby offering MAXIMUM FREIGHT SAVINGS without damaging the product.
The above picture clearly shows the two-stage compression packaging.
The Back Row contains 10 full sized Master Bags approximately 17" x 31" (43 cm x 79 cm) weighing about 16 pounds (7.3 Kg.) each. The middle row contains 10 Master Bags semi-compressed and contained in a reinforced paper sleeve of about one-half the original size. The compressed bale in the foreground contains 10 semi-compressed sleeves further compressed to a size of approximately 18" x 21" x 36" (46 cm x 53 cm x 91 cm) having a total weight of approximately 175 pounds (79 Kg.), and a resultant density of approximately 22 pounds per cubic foot (357 Kg. per cubic meter). Upon releasing the restraining packaging, the DENVER FOAM® rapidly returns to it’s original size without any detrimental effect to the material. EXTREME CAUTION SHOULD BE USED WHEN CUTTING STEEL RETAINING BANDS.
NOTE: The compressed bale in the foreground may contain all the same diameter, or mixed diameters of Master Bags including Master Bags of MINI-BAGS as indicated on back page.
1. PRODUCT NAME DENVER FOAM®
2. MANUFACTURER
Backer Rod Mfg. Inc. 4244 N. Broadway Denver, CO 80216 Phone: (800) 595-2950 (303) 308-0363 Fax: (303) 308-0393 Web: www.backerrod.com 3. PRODUCT DESCRIPTION
Basic Use:DENVER FOAM®is a
backer rod used as a backing for elastomeric and other applied caulk-ing sealants. DENVER FOAM®
con-trols the depth and amount of sealant required.
DENVER FOAM®also forms the
correct hour glass shape of sealant. Specific Uses: For use in expansion/construction joints in concrete and precast concrete walls, floors, partitions, bridge construc-tion, parking decks, curtain walls, glazing, log home construction, highway construction, and pave-ment maintenance.
Both hot and cold installations can be installed with DENVER FOAM®backer rod.
Physical Properties: • Density: 1.7 pcf. ASTM D-1622 • Tensile: 25 psi. ASTM D-1623 • Moisture Absorption: .024% by
volume. ASTM C-509 • Out Gassing: None
• Temperature Service Range: -60°F to +500°F. ASTM D-5249-95 • Auto Ignition: 700-800°F • Elongation: 90% ASTM D-3574 • Air Flow: 90%. ASTM D-3574 • Compression Set: less than 5%
(after 80% compression for 30 days). ASTM D-3574
5. INSTALLATION
DENVER FOAM® should be
installed in expansion/construction joints free from all contaminants, loose materials, and dry and free from frost. Install under 25% com-pression to offer a good tooling base. Systems can be installed with-out the fear of with-out-gassing associat-ed with polyethylene.
DA
T
A
TECH
Backer Rod Mfg. Inc.
Backer Rod Mfg. Inc. January 2009
GLAZING EXPANSION JOINTS LOG CONSTRUCTION
GLASS SEALANT SEALANT SEALANT DENVER FOAM® DENVER FOAM® DENVER FOAM®
Open cell DENVER FOAM® has
an advantage allowing air to reach both sides of sealant offering a faster and more uniform cure. This is especially true for one part non-sag sealants. DENVER FOAM® can
also be used in floor joints with self-leveling sealants or in traffic areas where additional support is required.
Limitations: Whatever restric-tion the sealant manufacturer places on their product, the same will apply to DENVER FOAM®.
Composition and Materials: DENVER FOAM® is continuous
lengths of flexible, round, fabricated open cell polyurethane. Yellow in color and available in a wide range of diameters.
Packaging:Both mini bags and master bags are compressed into super bundles for economical ship-ping and storage. Each individual size is color coded for identification.
4. TECHNICAL DATA
DENVER FOAM® is chemically
inert and will resist oil, gasoline and most solvents. Material is odorless and will not stain. The open cell con-struction eliminates the out-gassing and cold flow problem associated with closed cell polyethylene backer rods. Plus sealant has benefits of a two-sided cure.
6. AVAILABILITY AND COST
DENVER FOAM® is marketed
nationally and internationally by our distributors. For name, address, and telephone number of your nearest distributor please contact us at:
Backer Rod Mfg. Inc.
4244 N Broadway Denver, CO 80216 Phone: (800) 595-2950 Phone:(303) 308-0363 Fax: (303) 308-0393 Web: www.backerrod.com
DENVER FOAM®is available in
other sizes, shapes, and colors. Please contact Backer Rod Mfg. Inc. for availability on custom made items.
7. WARRANTY
Unless otherwise agreed to in writing, product is sold without war-ranty. In no case will Backer Rod Mfg. Inc. be liable for incidental or consequential damages on any product.
8. MAINTENANCE
No maintenance is needed.
9. TECHNICAL SERVICES
Contact Backer Rod Mfg. Inc. for technical guidance or special project engineering designs and drawings.
DENVER FOAM®PACKAGING INFORMATION
Backer Rod Mfg. Inc.
4244 N Broadway Denver, CO 80216 Phone: (800) 595-2950 Phone: (303) 308-0363 Fax: (303) 308-0393 Web: www.backerrod.com
Backer Rod Mfg. Inc. January 2009
Color Code Diameter Ft/per Mini Bag Ft/per Master Bag Ft/per Super Bundle Clear Red Orange Green Yellow Blue 3/8" (10mm) 5/8" (16mm) 7/8" (22mm) 11/8" (29mm) 11/2" (38mm) 2" (51mm) 200' (61m) 100' (30m) 100' (30m) 75' (23m) 40' (12m) 25' (7.6m) 3,600' (1097m) 2,000' (608m) 1,050' (319m) 600' (182m) 350' (106m) 200' (61m) 36,000' (10972m) 20,000' (6090m) 10,500' (3,192m) 6,000' (1,824m) 3,500' (1,064m) 2,000' (608m)
Material Safety Data Sheet
May be used to comply withOSHA’s Hazard Communication Standard, 29 CFR 1910.1200. Standard must be consulted for specific requirements.
U.S. Department of Labor
Occupational Safety and Health Administration (Non-Mandatory Form)
Form Approved OMB No. 1218-0072
IDENTITY(As Used on Label and List)
DENVER FOAM
Note: Blank spaces are not permitted. If any item is not applicable, or no information is available, the space must be marked to indicate that.
Section I
Manufacturer’s Name
BACKER ROD MFG., INC.
Address (Number, Street, City, State and ZIP Code)
4244 No. BROADWAY
DENVER, COLORADO
80216
Emergency Phone Number
920-406-4000
Telephone Number for Information
1-800-595-2950
Date Prepared
August 12, 2002
Signature of Preparer (optional)
Section II – Hazard Ingredients/Identity Information
Hazardous Components (Specified Chemical Identity; Common Name(s)
OSHA PEL ACGIH TLV Other Limits Recommended % (optional)
DOES NOT APPLY (DNA)
NO HAZARDOUS INGREDIENTS
THIS IS THE SAME FOAM USED IN BEDDING, FURNITURE, AUTOMOBILE
SEATS, CARPET PADDING & WINTER CLOTHING
Section III – Physical/Chemical Characteristics
Boiling Point
Vapor Pressure (mm Hg.)
Vapor Density (AIR = 1)
Solubility in Water
NO
Specific Gravity (H2O = 1) Melting Point Evaporation Rate (Butyl Acetate = 1)SOLID
DNA
DNA
.038
DNA
DNA
Appearance and Odor
ROUND DIA/IN COILS (LITE YELLOW, OR BLACK) SOLID MATERIAL NO
VAPORS OR ODOR
Section IV – Fire and Explosion Hazard Data
Flash Point (Method Used) 600 – 650 F Flammable Limits N/A LEL UEL
Extinguishing Media
H2O – CO2 OR DRY CHEMICAL EXTINGUISHERS
Special Fire Fighting Procedures
DRENCHING OR SOAKING WITH WATER, FIRE FIGHTING
PERSONNEL SHOULD USE FULL MASK & SELF CONTAINED
BREATHING APPARATUS
Unusual Fire and Explosion Hazards
NONE
Section V – Reactivity Data
Stability Hazardous Polymerization Unstable Stable May Occur Will Not Occur Conditions to AvoidNONE
DO NOT STORE NEAR OPEN FLAMES
Conditions to Avoid
NONE DNA
DIA
X
Incompatibility(Materials to Avoid)
PRODUCT DEGRADED BY STRONG ALKALI OR
ACID & SWOLLEN BY SOLVENTS
Hazardous Decomposition or Byproducts
NONE AT TEMPERATURE PRODUCT IS USED
Section VI – Health Hazard Data
Route(s) of Entry:
Health Hazards (Acute and Chronic)
NONE DNA
Signs and Symptoms of Exposure
DNA
Medical Conditions
Generally Aggravated by Exposure
DNA
Emergency and First Aid Procedures
Inhalation?
DNA
Skin?DNA
Ingestion?DNA
Carcinogenicity: NTP?
NONE
IARC Monographs?NONE
OSHA Regulated?NONE
Section VII – Precautions for Safe Handling and Use
Steps to B Taken in Case Material is Released or Spilled
DNA SOLID PRODUCT
Waste Disposal Method
DNA
Precautions to Be Taken in Handling and Storing
KEEP AWAY FROM OPEN FLAME
Other Precautions
NONE
Section VIII – Control Measures
Respiratory Protection (Specify Type)
SOLID MATERIAL NO VAPORS
Protective Gloves
NONE NEEDED
Other Protective Clothing or Equipment
NONE
Work/Hygienic Practices
NONE
Eye Protection
NONE NEEDED
Ventilation Local Exhaust
NONE NEEDED
Mechanical (General)
NONE
Special
DNA
Other
DNA
DENVER FOAM
®
Engineering & Technical Bulletin
Open Cell Polyurethane Backer Rod
HOT POUR TESTED TO + 500°F
Date: October 25, 2004
Manufacturer -
Backer Rod Mfg. Inc., 4244 N. Broadway, Denver, CO 80216
Trade Name -
DENVER FOAM
®Prescribed Tests -
ASTM D 5249 – 95
U.S. Dept. of Commerce National Institute of Standards
Description -
Denver Foam
®is a backer rod serving as a backing for elastomeric,
hot applied and other applied caulking sealants. Denver Foam
®controls the depth and amount of sealant required.
Specific Uses -
For use in expansion/construction joints in concrete and pre-cast
concrete walls, floors, partitions bridge construction, parking decks,
curtain walls, glazing, log home construction, highway construction,
and pavement maintenance.
Recommendation -
WIDE TEMPERATURE RANGE: Denver Foam
®can be used
successfully at temperatures of -70° (-57°C) up to intermittent
temperatures of 500°F (260°C). Denver Foam
®is an excellent hot
pour sealant backer rod. Tested under ASTM 5249-95 at +500°F,
Denver Foam
®showed no signs of deterioration and actually
expanded in the joint. Cross linked (hot type) backer rods shrink and
break down at approximately 180°F.
Denver Foam
®is chemically inert and will resist oil, gasoline, jet fuel
and most solvents. Material is odorless and will not stain. The open
cell construction eliminates the out-gassing problems associated with
closed cell cross linked (hot type) backer rods. Denver Foam
®is
100% non out-gassing.
Easy installation: Denver Foam
®can be compressed as much as 80%
of its original diameter. This allows the applicator to use fewer sizes
in varying and/or twisting joint widths.
“Setting Standards for the Industry”
Backer Rod Mfg. Inc.
4244 N. Broadway • Denver, CO 80216
800 595 2950 • 303 308 0363 • Fax 303 308 0393
1. PRODUCT NAME MILE HIGH FOAM®
2. MANUFACTURER
Backer Rod Mfg. Inc. 4244 N. Broadway Denver, CO 80216 Phone: (800) 595-2950 (303) 308-0363 Fax: (303) 308-0393 Web: www.backerrod.com 3. PRODUCT DESCRIPTION
Basic Use: MILE HIGH FOAM®
is a backer rod used as a backing for elastometric and other applied sealants. MILE HIGH FOAM®
con-trols the depth of sealant required. Specific Uses: MILE HIGH FOAM®is a soft, resilient,
polyethyl-ene backer rod used as a backup material for construction joints and applications that require sealants. MILE HIGH FOAM® performs as a
depth control for most known cold applied sealants. Sealants will not adhere to MILE HIGH FOAM®; no
bond breaker is required.
Composition and Materials: MILE HIGH FOAM® is a round,
black, resilient, extruded closed cell polyethylene backer rod with a water resistant outer skin. It is com-patible with most known cold applied sealants such as urethane, silicone, acrylic, butyl, polysulfides, latex, and chinking sealants.
Specific Uses Include: • Expansion joints • Highway joints • Glazing
• Log home chinking • Parking Decks • Curtain Walls • Coping joints • Isolation joints • Temporary joint seal Limitations: M I L E H I G H F O A M®should be installed with a
roller or blunt, flat-sided tool. Please follow sealant manufacturer specifi-cations for recommended sealant width and depth ratio. For best results, do not puncture, fold or overly stretch the product. MILE HIGH FOAM®is made with a
water-resistant outer skin. Where moisture resistance is important, care should be taken not to puncture this outer surface skin.
Packaging: MILE HIGH FOAM®
is available in a wide variety of diameters in 3 carton sizes:
Mini Carton 18" x 18" x 13" Standard Carton 18" x 18" x 30" Super Carton 131⁄2" x 131⁄2" x 73"
All cartons are UPS-able. For quanti-ty per carton and rod size per joint, see charts on reverse side.
4. TECHNICAL DATA
MILE HIGH FOAM® is
chemi-cally inert and will resist gasoline, oil, and most solvents. Product will not stain or adhere to sealants.
Physical Properties: Density: 1.25-2lbs./cu. ft. Moisture Absorption: Less than 1% by volume
Temperature Range: -40°F to 200°F
5. INSTALLATION
Joint or opening must be free of all contaminants, loose materials, dry and free of frost. Select correct rod size for joint width. With a blunt instrument or roller, seat rod to depth recommended by sealant manufacturer.
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Backer Rod Mfg. Inc. January 2009
GLAZING EXPANSION JOINTS LOG CONSTRUCTION
GLASS
MLE HIGH FOAM® MLE HIGH FOAM®
MLE HIGH FOAM®
SEALANT
SEALANT
6. AVAILABILITY AND COST
MILE HIGH FOAM®is marketed
nationally and internationally by our distributors. For name, address, and telephone number of your nearest distributor please contact us at:
Backer Rod Mfg. Inc.
4244 N Broadway Denver, CO 80216 Phone: (800) 595-2950 Phone:(303) 308-0363 Fax: (303) 308-0393 Web: www.backerrod.com
MILE HIGH FOAM® is available
in other sizes, shapes, and colors. Please contact Backer Rod Mfg. Inc. for availability on custom made items.
7. WARRANTY
Unless otherwise agreed to in writing, product is sold without war-ranty. In no case will Backer Rod Mfg. Inc. be liable for incidental or consequential damages on any product.
8. MAINTENANCE
No maintenance is needed.
9. TECHNICAL SERVICES
Contact Backer Rod Mfg. Inc. for technical guidance or special project engineering designs and drawings.
MILE HIGH FOAM®– PACKAGING
MILE HIGH FOAM®– JOINT WIDTH TO ROD SIZE
Rod Size Mini Carton 18" x 18" x 13" Standard Carton 18" x 18" x 30" Super Carton 131⁄2" x 131⁄2" x 73" 1⁄ 4" 3⁄8" 1/2" 5/8" 3/4" 7/8" 1" 1-1/4" 1-1⁄ 2" 2" 2-1/2" 3" 4" 3⁄ 16" 1⁄ 4" 3⁄8" 1/2" 5/8" 3/4" 1⁄ 4" 3⁄ 8" 1⁄2" 5/8" 3/4" 1" 1" 1-1/8" 1-5/8" 2" 2-1/2" 3 1/2" 1-1⁄ 4" 1-1/2" 2" 2-1/2" 3" 4" 2500 LF/Ctn 1400 800 550 400 6400 LF/Ctn 3600 2500 1550 1100 850 550 400 MFG’D in 6' lengths 420 LF 70 pcs 252 LF 42 pcs 156 LF 26 pcs 102 LF 17 pcs 54 LF 9 pcs
Joint Width Rod Diameter Joint Width Rod Diameter
Backer Rod Mfg. Inc.
4244 N Broadway Denver, CO 80216 Phone: (800) 595-2950 Phone: (303) 308-0363 Fax: (303) 308-0393 Web: www.backerrod.com
Material Safety Data Sheet
May be used to comply with
OSHA’s Hazard Communication Standard, 29 CFR 1910.1200. Standard must be consulted for specific requirements.
U.S. Department of Labor
Occupational Safety and Health Administration (Non-Mandatory Form)
Form Approved OMB No. 1218-0072
IDENTITY(As Used on Label and List)
MILE HIGH FOAM
Note: Blank spaces are not permitted. If any item is not applicable, or no information is available, the space must be marked to indicate that.
Section I
Manufacturer’s Name
BACKER ROD MFG., INC.
Address (Number, Street, City, State and ZIP Code)
4244 No. BROADWAY
DENVER, COLORADO
80216
Emergency Phone Number
920-406-4000
Telephone Number for Information
1-800-595-2950
Date Prepared
August 12, 2002
Signature of Preparer (optional)
Section II – Hazard Ingredients/Identity Information
Hazardous Components (Specified ChemicalIdentity; Common Name(s)
OSHA PEL ACGIH TLV Other Limits Recommended % (optional)
DOES NOT APPLY (DNA) NO HAZARDOUS INGREDIENTS
“POLYURETHANE FOAM” (FLEXIBLE)
NOT HAZARDOUS AS DEFINED IN 29 CFR 1910.1200 (OCCUPATIONAL SAFETY
AND HEALTH STANDARDS FOR GENERAL INDUTRY 29 CODE OF FEDERAL
REGULATIONS, SECTION 1910, PART 1200)
Section III – Physical/Chemical Characteristics
Boiling PointDNA
Vapor Pressure (mm Hg.)
DNA
Vapor Density (AIR = 1)
DNA (SOLID MATERIAL)
Solubility in Water
Specific Gravity (H2O = 1)
ASTM D 792
Melting Point
ASTM D 1525
VICAT SOFTENING POINT
Evaporation Rate
(Butyl Acetate = 1)
DNA
DNA
DNA
DNA
2
LBS/CU
FT
196°F
DNA
NOT WATER SOLUBLE
Appearance and Odor
ROUND DIA./IN COILS OR SIX FOOT PIECES, BLACK IN COLOR,
SOLID MATERIAL, NO VAPORS
Section IV – Fire and Explosion Hazard Data
Flash Point (Method Used)341 F ASTM D 1929
Flammable LimitsAUTO IGNITION
343°F
LELDNA
UELDNA
Extinguishing MediaWATER SPRAY, DRY CHEMICAL, FOAM OF CARBON
DIOXIDE
Special Fire Fighting Procedures
WATER SPRAY FROM FOGGING NOZZLE IS RECOMMENDED
Unusual Fire and Explosion Hazards
Section V – Reactivity Data
Stability Hazardous Polymerization Unstable StableYES
May Occur Will Not Occur Conditions to AvoidSOFTENED BY HYDROCARBONS AND
CHLORINATED HYDROCARBONS
AVOID OPEN FLAMES
Conditions to Avoid
ATTACKED BY OXIDIZING AGENTS SUCH AS
NITRIC OR
PERCHLORIC ACID AND FREE HALOGENS
X
XX
Incompatibility(Materials to Avoid)
ZYLENE
Hazardous Decomposition or Byproducts
CARBON, CARBON MONOXIDE, CARBON DIOXIDE VAPORS MAY BE
PRODUCED BY THERMAL DECOMPOSITION
Section VI – Health Hazard Data
Route(s) of Entry:Health Hazards (Acute and Chronic)
Signs and Symptoms of Exposure
NO APPLICABLE INFORMATION FOUND
Inhalation?
DNA
Skin?DNA
Ingestion?DNA
Carcinogenicity:
NONE
NTP?NO
IARC Monographs?NO
OSHA Regulated?NO
MAY BURN AT OR ABOVE FLASH POINT, AIRBORNE DUST MAY
EXPLODE IF IGNITED. SEE NATIONAL FIRE PROTECTION BULLETIN 654
Section VII – Precautions for Safe Handling and Use
Steps to Be Taken in Case Material is Released or SpilledPRACTICE GOOD HOUSEKEEPING. RECOIL PRODUCT ON SPOOLS.
Waste Disposal Method
THIS MATERIAL IS NOT A RCA HAZARDOUS WASTE. DISPOSE OF IN
ACCORDANCE WITH STATE AND LOCAL REGULATIONS (RCA: RESOURCE
CONSERVATION ACT 1976)
Precautions to Be Taken in Handling and Storing
AVOID OPEN FLAME OR IGNITION CONDITIONS
Other Precautions
NO APPLICABLE INFORMATION FOUND
Section VIII – Control Measures
Respiratory Protection (Specify Type)DNA
Protective Gloves
DNA
Other Protective Clothing or Equipment
NONE REQUIRED
Work/Hygienic Practices
NO APPLICABLE INFORMATION FOUND
Eye Protection
DNA
Ventilation Local ExhaustXX
Mechanical (General)
NONE
Special
DNA
OtherDNA
Page 2 * U.S.G.P.O.: 1986 - 491 - 529/45775 Medical Conditions
Generally Aggravated by Exposure
NO APPLICABLE INFORMATION FOUND
Backer Rod Mfg. Inc.
Reply to: ❑ 4244 N. Broadway • Denver, CO 80216 Phone 303-308-0363 • Fax 303-308-0393
HIDDEN DANGER
There exists today many high occupancy buildings which claim to meet fire codes
that actually may have some very serious “Hidden Dangers.” These hidden dangers are in
the expansion/construction joints. The fire stopping material used in these joints are almost
always covered over with some type of sealant.
The expansion/construction joints do exactly as the name infers, they open and
close as a result of temperature changes. These changes occur generally once a day.
Warmer temperatures close the joint and cooler temperatures open them. To have an
effective joint packing material it must be capable of moving within the joint, and remain
in place.
There are three well-known fire blocking backup materials used in expansion
/construction joints. Ceramic fibers, mineral wool and Ultra Block
®. All three are capable
of blocking fires in fire rated joints when they are installed with standard construction
sealants. However, only when they are initially installed.
To be an effective fire blocking joint packing material the product must remain in
and completely seal the entire joint for a great number of years.
The structural or movement testing of Ultra Block
®was done by Hauser
Laboratories in Boulder, Colorado. The results were impressive. The test was run on a
±50% joint movement. The tests were run on all three products: ceramic fiber, mineral
wool and Ultra Block
®. Both the ceramic fiber and the mineral wool failed in less than 600
cycles or 1.6 years. Ultra Block
®tested for 28,000 cycles without failure, which represents
76 years of service. There was no physical change in the Ultra Block
®at the end of the
test. When mineral wool and ceramic fibers are subjected to cycling at a ±50%, they fail.
When the joint closes the joint packing compresses, when the joint opens mineral wool and
ceramic fibers do not recover. The ceramic fiber and the mineral wool actually fell out of
the test apparatus. The Ultra Block
®retained its resiliency and looked exactly the same as
it did before it was tested.
Unfortunately, in the past, on a number of occasions, the packing materials used in
perimeter joints, had already fallen out of the joint when there happened to be a fire. In
many instances human lives were lost. The “HIDDEN DANGER” was exposed.
Ultra Block
®would not have let this happen, as it would have still had the joint
sealed from fire. Do not let this “HIDDEN DANGER” cost more lives.
1. PRODUCT NAME ULTRA BLOCK®
Mechanical Expansion and Construction Joint fire stop ping System: 2-Hour, 3-Hour, 4-Hour Fire Rated
2. MANUFACTURER
Backer Rod Mfg. Inc. 4244 N. Broadway Denver, CO 80216 Phone: (800) 595-2950 (303) 308-0363 Fax: (303) 308-0393 Web: www.backerrod.com 3. PRODUCT DESCRIPTION
ULTRA BLOCK® is a
pre-engi-neered, patented, flexible textile fiberglass roll material with a fiber-glass matt facing, containing approximately 30% by weight unex-panded vermiculite.
Specific Uses:ULTRA BLOCK®,
when used together with an approved sealant, provides a 2-Hour, 3-2-Hour, or 4-Hour fire rated joint system as designated by design configuration, which is capa-ble of withstanding ± 50% expan-sion and contraction. Most sealant manufacturers in the United States have tested one or more of their sealants in a UL® classified ULTRA
BLOCK®system ranging in joint size
from 1⁄2" up to 7". Approved sealant
manufacturers include: • Dow Corning • General Electric • Tremco Vulkem • C R Lawrence • Lymtal • Pecora • Quaker • Sika • Sonneborn
• Specified Technologies Inc • Nelson
4. Benefits
Resiliency: To be an effective fire blocking joint packing system, a product must remain highly resilient and must completely fill the moving joint for a great number of years. In most packed and caulked joints, examination of the resiliency of the forming material is difficult to check, as the material is covered up with sealant. Many joint packing materi-als, such as mineral wood and ceramic fiber, are not designed to handle joint movement and may fall out or slump in the joint when sub-jected to continuous joint expansion and contraction. Under fire situa-tions, the fire blocking material must be in the same condition as when it was installed, meaning that the material must completely fill the void in order to block a fire. ULTRA BLOCK® has a unique patented,
hinged design and composition that remains highly resilient under the most extreme conditions.
Structurally Rested:The struc-tural testing of ULTRA BLOCK®was
performed by Hauser Laboratories. The test was run on a ± 50% joint movement. Mineral wool and ceramic fiber joint packing materials were also tested. The joints were packed in the fully open position and were under the 25% joint side compression. The test ran continu-ously until either failure occurred or the test was terminated. Failure of both the mineral wool and ceramic fiber materials occurred in under 600 cycles, or 1.6 years. The ULTRA BLOCK® successfully performed for
over 28,000 cycles without failure or loss of resiliency, representing 76 years of service at one cycle per day!
Fire Stopping:ULTRA BLOCK®
has been proven to withstand the test of time in joint expansion and contraction. The ULTRA BLOCK®
system also has a very unique fea-ture not present in either mineral wool or ceramic fiber material. ULTRA BLOCK® contains
vermicu-lite, which expands when exposed to heat. As the vermiculite expands it produces thousands of reflective shields that reflect heat back away from the expansion joint. When exposed to fire on the caulked and uncaulked side there is no passage of destructive heat to the sealant bead on the opposite side.
ULTRA BLOCK®is a fire
block-ing material in the fire rated joints that will be in place if and when needed. It is the only fire rated joint system today, which gives this pro-tection using standard construction sealants! In addition, it does not require metal cover plates as some systems do.
Composition and Materials:All ULTRA BLOCK® systems are
manu-factured in accordance with project requirements. ULTRA BLOCK® is
manufactured in various widths and thicknesses, depending on the joint width, and sold in rolls.
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5. EASY INSTALLATION
ULTRA BLOCK® requires no
cutting, fitting, or fabrication. Simply open the bag, unwind the roll, fold in half with the matt side facing outward, compress and slide it in the joint to required depth. Apply sealant per manufacturers instructions.
When joining ends of rolls, cut each end at a 45° angle, alternating cuts so that the folded over ULTRA BLOCK® forms an interlocking v-shape. (See drawing below.)
SPLICING
6. TECHNICAL INFORMATION
All ULTRA BLOCK® systems
are covered with a nominal sealant (see list of manufacturers). System designs can range from 1-Hour, 2-Hour, 3-Hour or 4-Hour fire ratings and joint widths from 1⁄2" up to 7"
wide.
ULTRA BLOCK® systems allow the mechanical expansion/construc-tion joint to funcexpansion/construc-tion and fulfill the purpose it was designed for, MOVE-MENT.
Testing of ULTRA BLOCK® for
use in expansion/construction joints was conducted at Underwriters Laboratories®, Northbrook, Illinois.
Tests were performed to the full-scale, 180 sf surface area, and each joint tested was 12 ft. long. Our test-ing also included the hose stream portion. The full scale testing earned us classifications by UL®for use in
horizontal and vertical joints plus compliance with all major codes in the United States.
Seismic testing of ULTRA BLOCK®systems was performed by
the University of California-San Diego. The seismic ”earthquake“ simulation test was a joint project between the US and Japan. ULTRA BLOCK® performed perfectly under
the most severe conditions.
Specific Compliance: ULTRA BLOCK® Systems comply with
and/or have been tested under the following standards and building codes:
• UBC – Uniform Building Code • BOCA – Building Officials and
Code Administrators Interna-tional
• SBCCI – Southern Building Code Congress International • City of Los Angeles Building
Code
• UL 2079 – UL Standard for Safety Tests for Fire Resistance of Building Joint Systems • UL 263-92 – UL Standard for
Safety Fire Tests of Building Construction and Materials • UL 1479 – UL Standard for
Safety Fire Test of Through Penetration Firestops
• UL 723 – UL Standard for Safety Test for Surface Burning Characteristics of Building Materials
• ASTM E119 – Method for Fire Tests of Building Construction and Materials
• ASTM E814 – Methods of Fire Tests of Through Penetration Fire Stops
• ASTM E84 – Test Method for Surface Burning Character-istics of Building Materials • ASTM E136 – Test Method for
Behavior of Materials in a Vertical Tube Furnace at 750°C • ASTM E90 – Test Method for
Laboratory Measurement of Airborne Sound Transmission Loss of Building Partitions • ASTM E1399 – Test Method of
Cyclic Movement and Measur-ing the Minimum and Maxi-mum Joint Widths of Architec-tural Joint System
• ASTM C719 – Test Method for Adhesion and Cohesion of Elastometric Joint Sealants Under Cyclic Movement • ASTM C920 – Specification for
Elastometric Joint Sealants • NFPA 251 – Fire Test of Building
Construction Materials
• NFPA 255 – Burning Character of Building Materials
7. WARRANTY
Unless otherwise agreed to in writing, product is sold without war-ranty. SIZING CHART PACKAGING INFORMATION JOINT WIDTH* ULTRA BLOCK® THICKNESS ULTRA BLOCK® WIDTH 2-HOUR FIRE RATING CONFIGURATION ULTRA BLOCK® WIDTH 3-HOUR FIRE RATING CONFIGURATION ULTRA BLOCK® WIDTH 4-HOUR FIRE RATING CONFIGURATION 1⁄ 2" 3⁄4" 1" 1-1⁄ 2" 3⁄ 8" 1⁄ 2" 3⁄4" 1" 3⁄ 8" 1⁄ 2" 3⁄4" 1" 70 LF 60 LF 40 LF 30 LF 1260 1080 700 600 400 300 630 540 360 270 420 360 240 180 280 240 160 120 210 180 120 90 NO. 1 6" 6" 6" 6" NO. 1 8" 8" 8" 8" NO. 1 12" 12" 12" 12" NO. 2* 2" 2" 3-1⁄2" 3-1⁄2" NO. 2* 4" 4" 4" 4" NO. 2* 6" 6" 6" 6"
*Configuration NO. 2 requires ULTRA BLOCK® on both sides of joint opening. The above table represents the requirement for only one side of the joint opening. Please call us for information regarding joint widths of 2" or greater. ULTRA BLOCK® THICKNESS* 2" WIDE LF PER BAG 3-1⁄2" WIDE LF PER BAG 4" WIDE LF PER BAG 6" WIDE LF PER BAG 8" WIDE LF PER BAG 12" WIDE LF PER BAG ROLL LENGTH
Knauf Fiber Glass GmbH
MATERIAL SAFETY DATA SHEET
Health Hazard 1 Fire Hazard 0 Physical Hazard 0 Personal Protection B
HMIS RATING NFPA RATING
0 0 1
←
SECTION I - CHEMICAL PRODUCT AND COMPANY IDENTIFICATION
SECTION II - COMPOSITION/INFORMATION ON INGREDIENTS
SECTION III - HAZARDS IDENTIFICATION
Product: Ultrablock Fire Proof Insulation MSDA Number: 1011
Trade Designations: Backer rod insulation material
Manufacturer: Knauf Fiber Glass GmbH Date Issued: August 1, 2003
Address: One Knauf Drive Product Stewardship Support Line: 317-398-4434, X8102
Shelbyville, IN 46176-1496 24 hr Emergency (Chemtrec) Phone: 800-424-9300
Chemical Name CAS Number % TLV PEL
Fibrous Glass (Textile) 65997-17-3 60-70 10 mg/m3(PNOC) 15 mg/m3(PNOR)
Phenol formaldehyde resin (cured) 68585-23-9 16-20 None None Vermiculite Ore 01318-00-9 25-30 10 mg/m3(PNOC) 15 mg/m3(PNOR)
Black Mat Facing NA 1-2 None None
Key: TLV = ACGIH, 8 hr. time weighted average (TWA); PEL = OSHA permissible exposure limit. PNOC = Particulates Not Otherwise Classified (ACGIH - Inhalable)
PNOR = Particulates Not Otherwise Regulated (OSHA - Total dust)
Emergency Overview: Airborne particulate which may be created during cutting is considered nuisance dust which
should be minimized through the use of good work practices and adequate ventilation. Acrid smoke may be generated in a fire. Exposure to high temperatures may release airborne concentrations of thermal decomposition products such as carbon monoxide, especially in enclosed or poorly ventilated areas.
HMIS Rating: Health: 1 Fire: 0 Reactivity: 0 Protection: B
Primary Routes of Entry: Via particulate to the lungs and respiratory system and airborne fibers to the skin and eyes. Primary Target Organs: Lungs, respiratory system, skin and eyes.
Potential Health Effects:
Inhalation: Irritating to the mucous membranes and respiratory tract. Skin Contact: Irritation and redness due to excessive exposure.
Eye Contact: A mechanical irritant which can cause moderate to severe eye irritation.
Ingestion: Non-hazardous when ingested. Potentially a mild irritant to the GI tract if excessive quantity is
ingested.
Medical Conditions Aggravated by Exposure: Pre-existing chronic upper respiratory and lung diseases such as,
but not limited to, bronchitis, emphysema, and asthma. Skin disease such as dermatitis.
Carcinogenicity: This product is manufactured using textile grade glass filaments which are classified by IARC as
group 3 (Unclassifiable as to carcinogenicity to humans). It is not classified by NTP or OSHA.
2Trade Name: Knauf Ultrablock Fire Proof Insulation MSDS Number: 1011
SECTION IV - FIRST AID MEASURES
Inhalation: Remove to fresh air. Drink water to clear throat and blow nose to evacuate dust. If coughing and irritation
develop, call a physician.
Eye Contact: Flush with large amounts of water until irritation subsides, as least 15 minutes. See a physician if
irritation persists.
Skin Contact: Normal good personal hygiene practices. Wash with mild soap and warm water after each exposure. Ingestion: Emergency procedures not normally required. May be a temporary irritant to the GI system.
SECTION V - FIREFIGHTING MEASURES
NFPA Rating: Health: 1 Fire: 0 Reactivity: 0 Other: 0 Extinguishing Method: Use water, foam, dry chemical or carbon dioxide.
Special Firefighting Procedures: Wear self-contained breathing apparatus and protective clothing. Dense smoke may
limit visibility in enclosed areas.
Fire or Explosion Hazards: Product is not highly flammable however, in a major fire product will be consumed
causing dense acrid smoke.
SECTION VI - ACCIDENTAL RELEASE MEASURES
Clean-up Procedures: Pick up or shovel material into waste container taking care to minimize dust and fiber
generation. Vacuum clean-up is preferred. If sweeping is required use a dust suppressant.
Personal Precautions: If dusty conditions exist, wear a face mask approved for use with dusts such as 3M 8210, N95
or equivalent.
Environmental Precautions: This product is not regulated under RCRA Hazardous Waste Regulations. May be
disposed in landfill. Comply with federal, state and local regulations.
SECTION VII - HANDLING AND STORAGE
Storage Requirements: Store in dry area. Keep area clean. Vacuum clean dust. Use a dust suppressant if sweeping is
necessary.
Special Sensitivity or Incompatibility: Hydrofluoric acid will react with and dissolve glass. Handling Precautions: Assure proper respiratory protection if dust potential exceeds PEL/TLV.
SECTION VIII - EXPOSURE CONTROLS/PERSONAL PROTECTION
Engineering Controls: Maintain sufficient mechanical or natural ventilation to assure fiber concentrations remain
below PEL/TLV. Use local exhaust if necessary. Power equipment should be equipped with properly designed dust collection devices.
Respiratory Protection: When over PEL/TLV wear an approved face mask such as 3M 8210, N95 or equivalent, to
prevent against inhalable glass wool fibers. Concentrations of fibers that exceed the recommendations of the mask manufacturer will need a higher level of respiratory protection, such as a half mask respirator with appropriate dust filters.
3Trade Name: Knauf Ultrablock Fire Proof Insulation MSDS Number: 1011
Eye Protection: Wear safety glasses with side shields, goggles or face shield when handling, installing or fabricating
to protect eyes against dust and fibers.
Skin Protection (clothing): Long-sleeved, loose fitting clothes and head covering are recommended. Wash work
clothes separately from other clothing, towels and linens to prevent fiber migration. Rinse washer thoroughly.
SECTION IX - PHYSICAL AND CHEMICAL PROPERTIES
Physical Form: Yellow fibrous product, slight phenol formaldehyde odor.
Melting Point: >1300°F Specific Gravity: Variable
Solubility in Water: Insoluble Pure/Mixture: Mixture
SECTION X - REACTIVITY
Stability: This is a stable, non-reactive product.
Hazardous Decomposition Products: Thermal decomposition of the resin may include carbon dioxide, carbon
monoxide, formaldehyde, carbon particulate and traces of hydrogen cyanide.
SECTION XII - DISPOSAL CONSIDERATIONS
Waste Disposal Method: This product is not regulated under RCRA Hazardous Waste Regulations. May be disposed
in landfill. If unsure, contact the local office of the USEPA, your local public health department or the local landfill regulators.
SECTION XIII - TRANSPORTATION INFORMATION
US DOT Shipping Name: Not regulated DOT Label: None UN/NA Number: None
SECTION XI - TOXICOLOGICAL/ECOLOGICAL INFORMATION
LD50: N/Av LC50: N/Av
Toxicological Hazards: This product is manufactured with textile grade glass filaments which are classified by IARC
as group 3 (Unclassifiable as to carcinogenicity to humans). It is not classified by NTP or OSHA.
Ecological Hazards: No data exists for this product.
Teratogenicity, Multagenicity, other Reproductive Effects: None known
SECTION XIV - REGULATORY INFORMATION
OSHA Status: This product is considered hazardous under OSHA criteria.
TSCA/CEPA Status: All components of this product are included in the TSCA and CEPA Chemical Inventories. CERCLA Reportable Quantity: N/Ap
SARA Title III:
Section 302 Extremely Hazardous: This product contains no extremely hazardous substances as defined and
listed in section #302.
Section 311/312 Hazard Categories: Irritation and redness due to excessive exposure.
Section 313 Toxic Chemicals: This product does not contain substances which are reportable under Section 313. California Safe Drinking Water and Toxic Enforcement Act (Prop. 65): Not regulated.
Canada (WHMIS): This product is not controlled under Canadian WHMIS regulations.
4Trade Name: Knauf Ultrablock Fire Proof Insulation MSDS Number: 1011
SECTION XV - APPROVALS
Reason for Issue: New MSDS Revision: New Approval Date: August 1, 2003
Prepared by: CCG, Inc. Supersedes Date: None
SECTION XVI - DISCLAIMER
As of the date of this document, the foregoing information is believed to be accurate and is provided in good faith to comply with applicable federal and state laws. However, no warranty or representation of law or fact, with respect to such information, is intended or given.
ULTRA BLOCK
®
SYSTEMS
Engineering & Technical Bulletin
File No. Ultra Block Configuration Designs
“Setting Standards For The Industry”
Backer Rod Mfg. Inc.
ALL WE NEED ARE THE ABC’S OF YOUR PROJECT
AND WE WILL FURNISH YOU OUR DRAWING
ASTM E119 Fire Tested by Under writers Laboratories - All Horizontal & Ver tical Joints.
ASTM E1399 Movement Tested by Hauser Research - 50% movement - 28,000
openings and closing.
Seismic Tested-Drift Tested by University of California San Diego for U.S. Government
on a National Science Foundation project.
Configuration # 1
“A” = Joint Width
“B” = Concrete Thichness “C” = Hourly Fire Rating
of Structure
Configuration # 2
Configuration # 3
4244 N. Broadway • Denver, CO 80216 1-800-595-2950 • 303-308-0363 • Fax 303-308-0393
Backer Rod Mfg. Inc.
4244 N. Broadway • Denver, CO 80216 • Toll Free 1-800-595-2950 • Phone 303-308-0363 • Fax 303-308-0393
Page I
CODE COMPLIANCE U.S.A.
“ULTRA BLOCK
®”, THANKS TO YOU, HAS FULFILLED OUR CONSTRUCTION
INDUSTRY’S NEEDS FOR A
2 HOUR _______ 3 HOUR _______ 4 HOUR _______
FIRE RATED, MOVEMENT CERTIFIED MECHANICAL, EXPANSION, CONSTRUCTION
JOINT SYSTEM
.
“A” FIRE TESTED
UNDERWRITERS LABORATORIES, NORTH BROOK, ILLINOIS, FILE #R-13729,
FULL SCALE FIRE TEST 14' X 17', 180 SQ. FT. FIRE SLAB. JOINT LENGTHS
WERE 12 LF. ALL TESTING INCLUDED THE HOSE STREAM TEST. THANKS TO
UNDERWRITERS LABORATORIES’ GUIDANCE, THE FULL SCALE TESTING
GAVE US TOTAL COMPLIANCE WITH ASTM E 119, NFPA 251, UL-263 FOR ALL
EXPANSION JOINT DESIGNS.
“B” STRUCTURAL TESTED
HAUSER RESEARCH, BOULDER, COLORADO, LISTED IN THE BUILDING
STANDARDS DIRECTORY (ICBO EVALUATION SERVICE INC.) NUMBER
TL-140 AS A STRUCTURAL TEST AGENCY, NONE OF THE FIRE TEST AGENCIES
HAD ESTABLISHED THEMSELVES IN THE STRUCTURAL-MOVEMENT
FIELD. HAUSER TESTED OUR ULTRA BLOCK
®SYSTEMS AT A MOVEMENT
OF ±50% FOR A MINIMUM OF 10,000 OPENINGS AND CLOSINGS. HAUSER
RAN OUR LAST TEST TO 28,775 CYCLES.
THIS IS NOW ASTM 1399.
ULTRA BLOCK
®WAS THE FIRST, AND CONTINUES TO BE THE ONLY,
PRODUCT WITH ENGINEERED MOVEMENT CAPABILITIES DESIGNED IN
PRODUCT.
THE FIRE TESTING PER ASTM E 119 AND STRUCTURAL TESTING TO ASTM E
1399 VERIFIES OUR:
CODE COMPLIANCE U.S.A.
BOCA _____
