How A Spray Foam Rig Works
Learning how a spray foam rig works will aid you in understanding the major components needed within a spray foam rig, box truck or portable spray foam units.
Spray Foam Rigs contains the following:
- A generator is used to provide 220 volt power (single phase or 3 phase) pending the system requirements.
- The generator provides a 220V power supply to the spray foam machine and electric compressor.
- A 110V power supply is used to accommodate lighting, heaters, power tools, and additional outlets.
- A compressor is used to supply air to the transfer pumps, drum mixer and spray gun.
- Some drive systems used to operate the spray foam machine may require air.
Example: Spray foam machines that use air type drive systems require larger air compressors to operate than hydraulic spray foam machines.
Air dryers are used to filter out moisture contaminates from the compressor to the spray foam equipment, such as transfer pumps, spray gun, air mixers, or if using a air driven type spray foam machine.
The rigs include a safety supply station and spray mechanic’s work area which can be used to perform any maintenance. The mechanic’s station provides space for tools, PPE, supplies, and manuals for all of the spray foam equipment, and keeps (MSDS) material safety data sheets organized.
A drum rack station is used to secure the 55 gallon drums safely during transport. The rack should be color-coded red on the driver’s side for the (A) component and blue on the passenger side of the spray rig to avoid accidental cross contamination of the product’s feed to the spray foam machine.
Drum heaters are used to keep products warm in cold environments. They are also used to pre-warm chemicals to the manufacturer’s recommendations.
Example: With some open-cell spray foams, chemical manufacturers recommend that the drum temperatures be between 70 to 90 + degrees before the product is pumped to the spray foam machine. Typically, closed-cell spray foam drums are maintained between 70 to 80 degrees.
Transfer pumps consist of an air-motor which moves a shaft fixed to pump packings that work with check-valves by displacing the materials to the spray foam machine. Transfer pump tube holders are used for transit, storage and changing out the drum in the spray trailer.
The spray foam machine is where the manufacturing of spray foam begins. The materials are pumped from the (A) and (B) 55 gallon drums by the transfer pumps to the Y filters (screens) on the machine to pre-filter any contaminates from the drums. From the Y- Filters, the materials are pressurized by two pumps at 1,000 to 1,500 PSI. One pump for the (A) component and one pump for the (B) component, attached to a single-drive system. (PMC hydraulic spray foam machine shown in photo). Once the chemicals are pressurized, they enter the pre-heaters. The pre-heaters are designed to pre-warm the products to the manufacturer’s processing recommendations ranging from 120 degrees to 140 degrees. The materials exits the pre-heaters, passing through two pressure gauges, allowing a user to monitor the materials being processed at a 1:1 ratio. The gauges are also used to trouble-shoot the spray foam machine. From the gauges, the materials enter into the heated spray hoses.
Heated spray hoses are designed to maintain the manufacturer’s pre-heated recommendations from the machine to the spray gun. Heated spray hoses are typically sold in 50ft sections. The end of the hoses has a 10ft heated whip hose used for flexibility for the spay applicator. Pending the spray foam machine chosen, depends on how many feet of heated hose is available to run from the machine to the spray gun. Spray foam machines vary in heated hose lengths with capabilities ranging from 210ft to 410ft.
The spray gun is the final destination as to how a spray foam rig works and the spray foam manufacturing process.
The two (A) and (B) chemicals are blended inside of the spray gun through the internal mixing chamber. Mixing chambers are designed for optional output flows, allowing the user to choose the flow of material as well as the production needed for the spray foam project.