REFERENCE

A11102 5bl2S0

NATL INST OF STANDARDS & TECH R.I.C. 26

NBS

PUBLICATIONS

All 102561 280

iviagnesium Oxychloride

Cement-Based Foam Insulation:

Review of Available Information

and Identification of Research

Needs

Walter J. Rossiter, Jr. Robert G. Mathey

U.S. DEPARTMENT OF COMMERCE

National Bureau of Standards

National Engineering Laboratory

Center for Building Technology

Gaithersburg, MD 20899

Interim Report

June 1986

Prepared for: U.S. Department of Energy

Office of Conservation and

'able Energy — QC lependence Ave., SW

200 ton, DC 20585

- U 5 B

86-3326

1986

NBSIR 86-3326

ts s 0 MAGNESIUM OXYCHLORIDE

CEMENT-BASED FOAM INSULATION: A

REVIEW OF AVAILABLE INFORMATION

AND IDENTIFICATION OF RESEARCH

NEEDS

MBS

RESEARCH

INFORMATION CENTER KJg>^C

Q.LIO0

i c?

z\o,

I 'V b b

Walter J. Rossiter, Jr. Robert G. Mathey

U.S. DEPARTMENT OF COMMERCE

National Bureau of Standards

National Engineering Laboratory

Center for Building Technology

Gaithersburg, MD 20899

Interim Report

June 1986

Prepared for: U.S. Department of Energy

Office of Conservation and

Renewable Energy

1000 Independence Ave., SW

Washington, DC 20585

U.S. DEPARTMENT OF COMMERCE, Malcolm Baldrige, Secretary

NATIONAL BUREAU OF STANDARDS, Ernest Ambler, Director
'
TABLE OF CONTENTS

ABSTRACT . . . ...... . . iv

1. INTRODUCTION ....... 1

1.1 Background 1 1.2 Objectives 4

1.3 Scope of the Study 4

2. MANUFACTURE OF MAGNESIUM OXYCHLORIDE FOAM INSULATION . . 5

3. MAGNESIUM OXYCHLORIDE CEMENT .............. 7

3.1 Chemistry .................... 7 3.2 Uses of Magnesium Oxychloride Cement ....... 9

4. PROPERTIES OF MAGNESIUM OXYCHLORIDE FOAM INSULATION . . 13

5. DISCUSSION 16

5.1 Characterization of the Insulation -- Research

Needs ................ 16

5.2 Standards ............ 22

5.3 Control of Application ............. 22

6. SUMMARY AND RECOMMENDATIONS .............. 24

7. ACKNOWLEDGMENTS .................... 27

8. REFERENCES ....................... 28

i i i
ABSTRACT

This report reviews available information concerning the properties,

performance, and' use of magnesium oxychloride foam insulation.

Laboratory testing was not included in the scope of the study,

and data summarized were not developed based on NBS testing.

These insulations are produced at the job site from formulations

based on the reaction of magnesium oxide and magnesium chloride

to form magnesium oxychloride cement. The low-density foams have

been available in the U„S 0 for insulating walls of buildings for

about three years.

This review indicates that data are not complete regarding the

characterization of this thermal insulation. One density and one

thermal resistance value have been reported, in addition to some

properties that concern the safe use of the insulation. Additional

properties such as composition and structure, durability, effect

on other building materials including corrosiveness, heat of

combustion, shrinkage, strength properties, and water absorption

and moisture transfer, that affect its performance as thermal

insulation in buildings, have not been reported in the archival

literature. It is recommended that more data be developed

through laboratory research and field observations to provide for

the characterization of the insulation.

It is also recommended that caution be exercised when applying

magnesium oxychloride foam insulation in wall cavities that

contain metal objects. The available evidence describing

the corrosiveness of magnesium oxychloride products is not

definitive. As a matter of caution, the foam insulation should

not be installed in wall cavities which have iron, steel, or aluminum objects such as studs, wall ties, or pipes without

evaluation of the potential corrosiveness of the foam on such

metallic components

Key words: cement; foam; energy conservation; magnesium

oxychloride; performance; properties; thermal

insulation; walls.
1. INTRODUCTION

1.1 BACKGROUND

The use of thermal insulation in the exterior walls of residential

as well as commercial and industrial buildings is a key contributor

to efficient energy use. The construction of energy-eff ici ent

buildings not only contributes to the nation's efforts to

conserve energy, but also provides a means for the individual

building owner to reduce heating- and coo 1 i ng -energy consumption

and save fuel costs. For new buildings, insulation is, in most

cases, readily applied during construction before finishing the

walls. For existing buildings, the insulation is often retrofitted

into a cavity that is hard to access and may contain obstructions.

Retrofitting of uninsulated cavities of building walls is

difficult and the finished product can only be inspected using an indirect technique such as infrared thermography. In spite of

the difficulty and costs involved, the retrofitting of residential

building walls has been shown to be cost-effective in many areas

of the United States [1].

Foam insulations, which can be applied in-situ, may offer an advantage for retrofitting, because of their ability to be used

on irregularly shaped surfaces or in spaces where access is

difficult. Polyurethane and urea-formaldehyde foams [2] have been

used in the past for retrofitting uninsulated cavities of

building walls, but their use has not been without problems.

Efforts to insulate the exterior walls of buildings, particularly

1
by retrofitting techniques, has prompted development of some new

insulation products. For example, Cartmell and Brown [4]

reported on the use of a polyurea cellular plastic for retrofitting.

The motivation for developing new insulation products may stem

from a variety of factors including cost, improvement of performance

properties, and availability of materials having a wide range of

applications. Regarding this last factor, some of the presently

available insulations have limits to their use. Batt type

insulations are commonly used for wood-frame and steel-stud walls

of new constructions, while loose-fill materials are commonly

blown into uninsulated cavities of existing buildings, as well as some other spaces (e.g., attics) in new buildings.

3 During the last three years ago, a new low-density (2 lb/ft or

3

32 kg/m ) inorganic foam insulation has been available in the

U.S. [3]. When the present study began, according to the

manufacturer, the production of the insulation was based on magnesium oxychloride cement technology. At the time the present

report was being finalized, the manufacturer indicated that

changes in foam production have occurred. The manufacturer now

states that the current product is referred to in general terms

as an oxychloride cement foam insulation, but is more properly

described as a calcium magnesium oxychloride silicate composition.

The present report addresses the properties, performance, and

uses of magnesium oxychloride foam insulation.

2
As indicated by the manufacturer, magnesium oxychloride foam

insulation has been available in about one third of the states

from a network of 9 distributors. The insulation has been

marketed for use in a variety of building constructions including new

and existing wood-frame, steel-stud, masonry cavity walls,

and curtain walls, and for filling hollow-cores in masonry walls.

The insulation is foamed-in-pl ace from aqueous solutions at the

building site in a manner similar to some plastic foams. The

unset foam insulation may be pumped under pressure into closed

cavities where access is obstructed and which may be difficult to

fill with loose-fill insulation. After application, the foam

hardens in place to a self-supporting material.

Because of the potential benefits of having available a new

insulation material, the U.S. Department of Energy (DOE) requested

that the U.S. National Bureau of Standards (NBS) review the

properties, performance, and use of magnesium oxychloride

foam insulation. This report presents the results of the review,

which was phase I of a study regarding these insulations and

identification of research needs. It is intended that, in phase

II, field observations and laboratory testing will be conducted

to provide needed data concerning the properties and performance

of magnesium oxychloride insulations.

3
1.2 OBJECTIVES

The objectives of this report are:

(1) to describe the process used in the production of

low-density magnesium oxychloride foam insulation,

(2) to review available information concerning the properties, performance, and use of the insulation, and

(3) to identify areas where data are lacking regarding

the properties and performance, and to recommend needed

research for filling in the gaps in this knowledge.

1.3 SCOPE OF THE STUDY

The present study was limited to a review of existing information.

No laboratory or field tests were conducted.

Since magnesium oxychloride foam insulation has only been

available for a short period of time in the U.S., the information

regarding its properties and performance was limited. The major

sources of information were: (1) the archival chemical and

engineering literature; (2) building research organizations in

Canada and France; and (3) literture from and discussions with a manufacturer of low-density magnesium oxychloride foam insulation. During the study, an NBS staff member had the opportunity

to observe the production of magnesium oxychloride foam insulation at the facility of a distributor.

4
2. MANUFACTURE OF MAGNESIUM OXYCHLORIDE FOAM INSULATION

The information provided here is based primarily on that supplied

by one manufacturer and the observations of an NBS research staff

member during its production. The chemical formulations used in

the preparation of the insulation are proprietary. A description

of the process for manufacture of low-density foam insulation,

based on magnesium oxychloride cement technology, was not found

in the archival literature.

The manufacture of the low-density foam insulation involves three

major ingredients: an aqueous cementitious slurry, a surfactant

(or foaming agent) solution for cell generation, and compressed

air. The cementitious slurry consists mainly of magnesium oxide

dispersed in an aqueous solution of magnesium chloride. The

slurry also contains proprietary additives such as: fillers or extenders, agents to control the rate of chemical reaction

(hardening), agents to alter properties of the finished product

(e.g., moisture absorption), and colorants. The aqueous cementitious

slurry is prepared at the job site, since it has a limited pot

life (a few hours) due to the hardening of the magnesium oxychloride

cement. The foaming agent solution is also proprietary. It may

be prepared in ad vance of its use, since it has an extended pot

life.

The equipment for generation of the foam on site includes a compressed air pump, and a mixing or foaming gun. The foaming

5
agent is first pumped into the gun, where the compressed air

mixes with it in an expansion chamber, and expands it into a foam bubbles. Just before the bubbles exit from the nozzle of

the gun, they are mixed with the magnesium oxychloride cement

slurry, which has been pumped through a separate line into the

gun. The foam is then pumped under pressure from the gun.

Expansion of the foam is complete at this point and no expansion

occurs after installation. Initial hardening of the magnesium

oxychloride foam has proceeded to an extent sufficient for it to

be self-supporting as it exits the gun. Complete hardening of

the cement reportedly occurs a few weeks after application.

Hardening depends, in part, on the formulation of the magnesium

oxychloride cement and the environmental conditions present in

the insulated walls.

When it exits from the nozzle of the foaming gun, the unset lowdensity foam contains about 50 to 60 percent water by mass. This

water has to be released from the wall after application of the

foam. Drying may lead to problems such as damage to wood and

steel members of the wall, blistering of paint on the outer wall

surface, or damage to interior wall surfaces.

6
3. MAGNESIUM OXYCHLORIDE CEMENT

3.1 CHEMISTRY

Archival literature on the chemistry of magnesium oxychloride

cements is limited. The information is important because the

production of magnesium oxychloride foam insulation depends in

part upon the chemistry of the process. The reaction producing

magnesium oxychloride cement from the component materials must be

controlled to proceed rapidly and uniformly to provide an acceptable product [5].

Magnesium oxychloride cements were first described by Sorel [6]

over one hundred years ago and are often referred to as Sorel

cements. They are prepared by the addition of magnesium oxide to

a solution of magnesium chloride. At temperatures between 20 and

100 °C (68 and 212 °F), two major ternary phases are formed

during the reaction [7,8]:

5Mg(0H)

2 .MgCl

2

.8H

2

0

3Mg(0H)

2 .MgCl2

.8H

2

0

These two phases are often called the 5-form and the 3-form,

respectively. The chemistry of the reaction was reviewed and

investigated in 1955 by Demediuk et al. [7], who indicated that

the reaction between magnesium oxide and magnesium chloride was

complex. They proposed that the reaction proceeded through the

formation of a complex (unidentified) ion that subsequently

reacted with magnesium hydroxide, formed by rapid hydration of

7
magnesium oxide, to yield amorphous (noncrystalline) oxychloride

gels which in turn slowly crystallize.

Demediuk et al . C 7 ] also reported on the phase equilibria for the

reaction. In the case they studied, the amount of the magnesium

oxide was low in relation to that of magnesium chloride. They

reported that, for a given quantity of magnesium oxide, the 3-

form predominates at higher concentrations of magnesium chloride,

while the 5-form is predominantly produced at lower concentrations of magnesium chloride. They also indicated that,

at the lowest concentrations of magnesium chloride used, magnesium

hydroxide was the major crystalline phase produced.

In 1976, Sorrell and Armstrong [8] re-examined the phase equilibria

of the process, particularly with regard to the reactivity of the

magnesium oxide. They indicated that the magnesium oxide must be

sufficiently reactive to be rapidly dissolved by the magnesium

chloride solution to form a solution that rapidly gels and then

crystallizes. They described reactive magnesium oxide as having

relatively small crystallite size and narrow size distribution,

and a low state of aggregation. It was found [8] that, when the

magnesium oxide was reactive, the magnesium oxychloride reaction

was uniform and rapid (complete in 4 days). When the magnesium

oxide was not reactive, it was slow to dissolve, the reaction

with magnesium chloride was also slow (incomplete after 2 weeks),

and compositional gradients occurred through the product. For

8
example, they demonstrated that when the reaction was slow, water

evaporated from the free surface of the reaction vessel, resulting

in incomplete formation of magnesium oxychloride at that location.

Also, unreacted magnesium chloride migrated to the free surface

where it precipitated.

3.2 USES OF MAGNESIUM OXYCHLORIDE CEMENT

Magnesium oxychloride cement has been reported to have engineering

properties desirable for certain specific applications [9]. The

density of the cement in applications other than foam insulation

3 3

is considerably greater than 2 Ib/ft (32 kg/m ). The compressive

strength and hardness of the hardened product are usually greater

than those properties of normal (portland) cement pastes [9]. During

production, its rate of strength gain is relatively rapid,

although the rate of reaction may be retarded by the addition of

additives. In addition, magnesium oxychloride cement is compatible

with a wide variety of granular, mineral, vegetable, and polymeric fillers, and does not produce alkaline attack on glass

[9]. Two limitations of using magnesium oxychloride cement are

that it is attacked by water and has a corrosive action on iron

products [10,11]. These two references did not discuss corrosive

action towards other metals.

The main use of magnesium oxychloride cement has been as a flooring material with inert fillers and pigments to provide

color [10,11]. As a flooring material, the product is hard and

9
strong, but must be protected from water. This is reported to be

accomplished by polishing with wax in turpentine.

A 1965 British Standard Code of Practice for in-situ floor

finishes included reference to magnesium oxychloride cement

flooring [12]. This document indicates that the product is

suitable for industrial, commercial or domestic use, and has good

durability. It also recommended that the flooring not be used

where it may be exposed to high humidity or damp conditions. A

noteworthy guideline in the Code of Practice advises that

metalwork, such as gas, water, and electrical services in contact

with magnesium oxychloride flooring, is liable to corrode. The

Code of Practice thus recommends that the metalwork should be

isolated from the flooring or protected by a coating of asphalt

or coal tar. In this regard, one reference [10] has stated that

iron pipes passing through such flooring are subject to the

corrosive action of the cement. Another reference [13] pointed

out that magnesium oxychloride compositions used in flooring

stimulate corrosion of aluminum under moist conditions.

Another use of magnesium oxychloride cement has been as decorative

interior plasters and exterior stuccos [8,14]. It has been

reported [8] that exterior applications have encountered such

problems as dimensional instability, lack of resistance to

weathering, and release of corrosive solutions. Sorrell and

Armstrong [8] have discussed the weathering ch ar ac ter i s t i c s of

10
magnesium oxychloride cement. They indicated that both the 3

-

form and 5 -form phases are unstable in water and dissociate to

magnesium hydroxide (which is not a strong binder) and magnesium

chloride (which can leach from the cement as a corrosive solution).

However, the stability of the cement for exterior applications is

enhanced by two reactions which occur in service [8]. First, the

cement reacts with atmospheric carbon dioxide (CC^) to produce a magnesium ch 1 or oc ar bon ate , Mg(OH) 2*MgCl 2MgC02* 6H2O. This

chlorocarbonate tends to protect the surface of the cement from

rapid attack by water and slows the leaching of magnesium

chloride. Second, as water slowly leaches magnesium chloride

from the protected surface of the cement, insoluble hydromagnesite

(4MgO.3CO2.4H2O) is formed which stabilizes the stucco.

In a test related to the weathering characteristics of magnesium

oxychloride cement, Demediuk et al . [ 7 ] exposed both the 3 -form

and 5 -form phases to air, a CO2 atmosphere, and a CC^-free

atmosphere at various relative humidities. In air at 65 percent

relative humidity, they reported little change in either form.

In the CO2 atmosphere, magnesium chlorocarbonate was formed at a rate which increased with relative humidity. In CO 2 -free

atmosphere at 95 percent relative humidity, both forms were

unstable and magnesium hydroxide and magnesium chloride were

produced. A minimum level of relative humidity, above which the

magnesium oxychloride phases became unstable, was not reported.

11
Magnesium oxychloride has been described as having excellent fire

resistive properties and has been used for over 25 years as a fireproofing coating material for structural steel in building

constructions [15,16]. When applied as a fireproofing, its

density may fall within the range of 20 to 80 lb/ft 3 (320 to

3 1280 kg/m ) depending on the product [17]. Its fire resistance

is due to water of hydration being released as vapor when the

material is exposed to fire, and heat being absorbed. Depending

on the form of the magnesium oxychloride cement, the water of

hydration accounts for approximately 35 to 40 percent of its

mass. The chemically-bound water is released at temperatures in

the range of 350 to 550 °F (177 to 288 °C) [16].

As with other uses of the cement, a limitation to its use as fireproofing on steel is its corrosiveness [16]. Protective

measures against corrosion of the steel are required. For

example, one manufacturer recommends priming steel before

application of the magnesium oxychloride fireproofing.

Another limitation for use as a fireproofing material has been

the effect of weather conditions during application. Such

factors as humidity, temperature, and wind can influence and

alter the chemistry of the hardening reaction [15]. In particular,

if the water present during application dries too fast (e.g.,

hot, dry weather), the setting reaction may be incomplete and

yield some magnesium hydroxide and unreacted magnesium chloride.

12
4. PROPERTIES OF MAGNESIUM OXYCHLORIDE FOAM INSULATION

One finding of the review on magnesium oxychloride foam insulation

is that little information is presently available regarding its

properties and performance. This was not unexpected, since the

use of magnesium oxychloride cement as thermal insulation is a relatively recent development. No descriptions of the properties

and performance were found in the archival technical literature.

The data that have been summarized here (table 1) were made

available from one manufacturer that sponsored testing at

independent laboratories during the development and marketing of

its product [18-25]. It must be emphasized that none of these

data were developed based on NBS testing.

A major observation from table 1 is that, at a dry density of

3 3 2.1 lb/ft (33 kg/m ), the reported value of thermal conductivity

2

for a foam specimen was 0.257 Btu.in./h.ft ,°F (0.0371 W/m.K)

[19]. The mean temperature of the specimen during the test was

not reported. The value of thermal conductivity (table 1) is

comparable to those of other insulations commonly used for walls

of buildings. For example, Weidt et al . [26] have reported that

the thermal conductivities of a number of loose-fill mi n er a 1 -f i ber

and cellulosic insulations removed from the walls of retrofitted

residences averaged about 0.26 and 0.28 Btu . i n . /h . f

2

. ° F (0.038

and 0.040 W/m.K), respectively. It would be desirable to have

thermal conductivity values for a range of densities over which

the foam may be applied and also for various mean temper atures

13
The other properties of the foam for which tests have been

conducted concern behavior on heating, flammability, release of

formaldehyde, presence of metallic elements in the foam, and

constituents of smoke (table Do These tests in general relate

to the safe use of the foam. For example, four of the test

reports cited [18, 21-23] in table 1 concern the release (offgassing)

of formaldehyde. These tests may have been conducted because of

current concerns regarding the release of formaldehyde from

building materials and its resulting effect on indoor air

quality. The results of the tests cited indicated that formaldehyde

was not detected. As is also evident from table 1, values of

flame spread, smoke density, and fuel contribution measured

according to the ASTM E 84 tunnel test procedure were found to be

zero [20].

The results of the ash content test (table 1) appear to contradict

evidence given in the literature concerning the loss of water of

hydration from magnesium oxychloride cement during heating. The

test report [18] indicated that the ash content of a foam

specimen on heating for 24 hours at 700 °F (371 °C) was 98

percent. The temperature at which the ash test was conducted was

at the limit of thermal decomposition of the product. It has

been reported [15] that magnesium oxychloride begins to decompose

significantly between 770 and 1000 °F (371 and 538 °C). However,

the temperature of this ash test was considerably greater than

the temperature range of 350 to 550 °F (177 to 288 °C) over which

14
the water of hydration is reportedly released from magnesium

oxychloride cement used as fireproofing for steel [16]. In

addition. Cole and Demediuk [27] have indicated that all forms of

magnesium oxychloride dehydrate upon heat treatment to form

anhydrous phases. They presented thermogr av i metr i c analysis

results over the temperature range of 68 to 932 °F (20 to 500

°C). Mass loss began about 212 °F (100 °C). The 3-form and 5-

form cements lost approximately 25 and 35 percent of their

mass, respectively, when heated to about 572 °F (300 °C). Mass

loss continued when the temperature surpassed 572 °F (300 °C).

Thus, on the basis of this literature data, the ash test (table

1) of the magnesium oxychloride cement insulation would have been

expected to yield a much lower ash content. Reasons for this

apparent contradiction have not been investigated.

15
5. DISCUSSION

5.1 CHARACTERIZATION OF THE INSULATION -- RESEARCH NEEDS

As with most new building materials, magnesium oxychloride

foam insulation has been introduced into the market with little

service life history. The characterization of a thermal insulation

should consider a number of properties in addition to those given

in table 1. To assist in the review of available information, a preliminary list of performance characteristics for in-situ foam

insulations was prepared. The list of performance characteristics

is given in table 2 along with a comparison of the information

available on the properties and performance of magnesium oxychloride

foam insulations. The comparison of available information with

the preliminary list of performance characteristics is based on

the information provided in table 1. As is evident from table 2,

little data have been published regarding many of the performance

characteristics of these insulations.

Research is needed to provide data concerning these performance

characteristics. This section of the report focuses on the

following properties (which are discussed below): composition

and structure, durability, effect on other building materials

including corrosiveness and fungal growth, heat of combustion,

shrinkage, strength properties, and water absorption and moisture

tr an sf er .

16
o Composition and Structure. During the present study,

reports were not found in the archival literature characterizing

the chemical composition of the foam insulation. In

addition, the cellular structure (e.g., cell size and

nature) of the foam insulation has not been described.

o Durabi 1 i ty

This is the capability of the material to

maintain its serviceability over a specified time [28]. For

magnesium oxychloride foam insulation, little data are

available regarding durability. Observations of older

foams in service have not been made. Characterization of

foams removed from walls of buildings should be made to

assist in assessing their durability.

With regard to durability, the temperature and humidity

conditions, as well as moisture exposure conditions, in

service are considered important. Some literature citations

[8,10,11] have indicated that magnesium oxychloride cements

may have poor resistance to water, and another reference [7]

suggested that they may undergo decomposition when exposed

to high relative humidity (95%). Although in normal

conditions encountered in wood-frame and steel-stud building

use, wall insulation is not expected to be in contact with

liquid water, high humidities or moisture vapor driven

through walls may be experienced depending on factors such

as the season, geographic location of the building, location

17
of vapor retarders, and occupancy. The moisture drive may

result in accumulation of moisture in the foam insulation.

In addition, masonry cavity walls normally provide for

drainage of water which penetrates the outer layer. Water

penetration of the outer layer would be expected to place

the foam insulation in contact with water. Also, the

presence of the insulation in the cavity wall may hinder the

drainage of water from the cavity. The results of the study

did not uncover reports describing the performance of the

insulation under conditions of use in walls.

As previously described, other applications of magnesium

oxychloride cement including flooring, stucco, and fireproofing

have been available for a long time. Although these

applications have generally had success, they have not

been trouble-free [7,8,10,11,15,16]. Such experiences

indicate the importance of understanding the factors that

affect the durability of the insulation.

o Effect on Other Building Materials. The addition of thermal

insulation to walls of buildings should not make the

wall components more susceptible to deterioration over time

than they would normally be in the absence of the insulation.

Factors that need to be characterized include: corrosiveness,

effect on fungus growth, and effect of moisture on other

materials, e.g., wood.

18
Special mention should be made of the findings of the

present study with regard to the corrosiveness of the foam

insulation. The study results regarding the corrosiveness

issue are not definitive. Corrosiveness tests of foam

conducted by independent laboratories on iron, steel, and

aluminum, as well as other metals, were not found. It is

important to assess corrosiveness. One piece of manufacturer's

literature on the insulation states that the product "when

cured, has a neutral pH, minimizing the potential of

corrosion." Conversely, some literature citations

[8,10,11,13,16] have reported that magnesium oxychloride

cements are corrosive to iron and steel, and that the cement

flooring stimulates corrosion of aluminum. As previously

mentioned, the British Code of Practice on in-situ floor

finishes indicates that magnesium oxychloride cement

flooring states that metalwork should be isolated from the

flooring or protected by a coating of asphalt or coal tar.

Also, when magnesium oxychloride cement is used as a fireproofing on steel, protective measures against corrosion

such as priming the steel before application of the fireproofing are required. Because of the inconclusive evidence

on the corrosion issue, caution should be exercised in

applying the foam insulation in wall cavities that contain

metal objects. The corrosiveness of the foam towards metal

objects present in the walls to be insulated should be

evaluated before application of the foam insulation.

19
The presence of water in the f r es h 1 y -ap p 1 i ed foam raises the

issues concerning fungal growth. Although the inorganic

foam may not provide a food for fungus, characterization is

needed to assure that proprietary additives in foam, along

with the water, would not initiate fungal growth in the

i nsu lated wall.

o Heat of Combu s t i on

An advantageous factor affecting the

performance of magnesium oxychloride foam for many insulation applications is its inorganic nature and related

combustibility properties. Measurement of heat of combustion may be used to demonstrate low combustibility.

o Shrinkage. Shrinkage of a foam insulation after application

leads to gaps that provide unwanted heat flow paths. Magnesium oxychloride foam insulation undergoes some shrinkage

after application, as observed (by one of the authors of

this report) in unclosed, simulated wall cavities.

Manufacturer's literature states that shrinkage is less than

1 percent. The extent of shrinkage that occurs in walls in

service was not found in the archival literature. Both

laboratory and field tests on shrinkage are needed. Factors

that may influence shrinkage such as time, foam density,

foam composition, and environmental conditions (temperature

and humidity) have not been investigated.

20
o Strength Properties. Magnesium oxychloride foam insulation

should have sufficient compressive strength to support

itself in the wall. During this study, some evidence was

found that the foam can support itself without collapse.

Two samples, applied in 8 ft (2.4 m) high simulated wall

cavities and reportedly about 1 year in age, were observed

to be intact at the facility of a distributor. Further

data, particularly from field observations, would be

useful .

The foam insulation should also have sufficient strength to

prevent deterioration by vibration and other movement during

service. The observation of some samples demonstrated that

the foam insulation is friable, as indicated by the relative

ease with which it could be damaged by handling or rubbing.

Although the foam is used in closed cavities in service (and

thus protected from mechanical damage), the effect of

building vibration and similar actions on the integrity of

the installed foam should be ascertained.

o Water Absorption and Moisture Transfer. Water absorption of

an insulation under various conditions of use influences its

thermal conductivity and may also affect its durability

including freeze-thaw resistance. Magnesium oxychloride

foam insulations have not been characterized with regard to

water absorption over the range of moisture conditions that

21
may be encountered in service. Data are also not available

describing the effect of absorbed moisture on the thermal

conductivity of the insulation. Reports on the permeability

of the insulation were not found during the study.

5.2 STANDARDS

A consensus standard specification for magnesium oxychloride foam

insulation is not available. Standard specifications for thermal

insulations include requirements concerning thermal resistance,

fire and other safety factors, and quality [29], If magnesium

oxychloride foam insulation is to be used commonly for insulating

the walls of buildings, then the industry including users may

consider that a consensus standard specification should be

developed. The development of any standard should consider the

performance characteri sties listed in Table 2.

5.3 CONTROL OF APPLICATION

Magnesium oxychloride foam insulation is generated on site at the

building to be insulated. Thus, factory-conducted quality

control techniques are insufficient for this material. Moreover,

the environmental conditions at the job site are not controlled,

but vary depending upon the locale and season of the year. The

satisfactory performance of magnesium oxychloride foam as an insulation depends not only on the properties of the material but

also on its proper application. For a material that is produced

on site, improper application may result in installation defects

22
such as incomplete cavity fill or damage to walls, and can

produce an insulation having less-than-acceptable material

properties. It is noted that the manufacturer of the insulation

has available an application manual for foam installation [3].

Guidelines for assuring proper application should consider both

the quality control of the foam installation and the quality

control of the component materials used in foam production. The

literature review of magnesium oxychloride cements indicated that

proper control of their production is a necessity if the material

is to perform satisfactorily. Attention should be paid to the

preparation of the reactant solutions, as well as the reactivity

of the magnesium oxide [5,7,8].

Environmental conditions during application of magnesium oxychloride

cement can also affect the quality of the finished product

[8,15]. As was mentioned, experience with magnesium oxychloride

fireproofings for steel indicated that their application under

conditions favoring rapid drying resulted in unsatisfactory

products. For the magnesium oxychloride foam insulation, the

effect of environmental conditions during application on the

quality of the finished foam was not found in the archival

literature. The manufacturer indicates in a product brochure

that the foam application "is an all weather process provided

that the temperature of the component products is between 40 and

70 °F (4 and 21 °C) at the time they are delivered to the

application gun."

23
6. SUMMARY AND RECOMMENDATIONS

This report reviews the very limited amount of available information

concerning the properties, performance, and use of magnesium

oxychloride foam insulation. The information reviewed is not

based on data developed by NBS. The foam is produced on site

from formulations which are based on the reaction of magnesium

oxide and magnesium chloride to form magnesium oxychloride

cement. The foam has been available in the U.S. for insulating

walls of buildings for approximately three years. It is being

offered for both new and existing constructions including woodframe, steel-stud, and masonry walls.

This review indicates that data regarding the characterization of

the foam as thermal insulation are not complete. Data are

lacking regarding many of the performance properties of the foam,

and research is needed to provide such data. In this regard,

some data have been reported from independent testing laboratories

that address one value of density and thermal resistance, and

safety -related parameters such as behavior on heating, flame

spread classification, release of formaldehyde, heavy metals in

foam, and smoke characteristics. Other properties that affect

the performance of the foam as thermal insulation have not been

well documented. Such properties include composition and

structure, durability, effect on other building materials

including corrosiveness, freeze-thaw resistance, fungus resistance,

heat of combustion, shrinkage, strength properties, temperature

24
and humidity resistance, water absorption and resistance to water

penetration.

Since the insulation has only been available for a relatively

short period of time, a standard specification and standard

practice for application have not been prepared. Some documents

from one manufacturer are available [3]. The manufacturer's

documents could provide the starting point for consensus standards

development, particularly with regard to application. However,

data on foam characterization would need to be developed through

research to provide the technical basis for standards.

Based on the results of this study, the following recommendations

are made:

1) Additional information regarding the performance of the

insulation should be developed through field observations

and laboratory research. Data are needed on the long-term

performance and durability of the low-density magnesium

oxychloride foam insulation. Data are also needed on

cell structure and composition, shrinkage, effect of

environmental conditions (e.g., temperature and humidity,

water penetration), effect of the foam on other wall

components including corrosiveness, and resistance of the

foam to vibration and other movements.

25
If foams of this type are to be used commonly for insulating

walls of buildings, the industry including users may

consider that a voluntary consensus standard specification

should be developed. A standard could set minimum acceptable

requirements for both performance and safety. The research

conducted to provide the needed data on the properties of

the foam would help develop the technical basis for the

preparation of a performance or other type of standard.

2 ) Caution should be exercised when applying magnesium oxychloride foam insulation in wall cavities that contain metal

objects. The results of the present study have indicated

that the available evidence describing the corrosiveness of

the foam is not definitive. As a matter of caution, the

foam insulation should not be installed in wall cavities

which have iron, steel, or aluminum objects such as studs,

wall ties, or pipes without evaluation of the potential

corrosiveness of the foam on such metallic components. This

recommendation is based on citations in the literature that

magnesium oxychloride cements are corrosive to iron and

steel, and may stimulate corrosion of aluminum. Studies

regarding the corrosiveness of the magnesium oxychloride

foam insulations in the presence of iron, steel, and

aluminum, as well as other metals, were not found in the

1 i ter ature .

26
7. ACKNOWLEDGMENTS

This study was sponsored by the U.S. Department of Energy, Office

of Conservation and Renewable Energy. The authors appreciated

the support of W. Gerken, DOE, D. McElroy, ORNL, and J. Heldenbrand,

NBS, who provided technical liaison between their respective

organizations during this study.

Special thanks and appreciation are expressed to C.A. Sorrell

(U.S. Bureau of Mines) for assistance in sharing his experiences

regarding the performance of magnesium oxychloride cements, and

in providing valuable comments on the present report. The many

noteworthy comments provided by J.G. Gross (NBS Center for

Building Technology) are appreciated. The assistance of D. Gross

(NBS Center for Fire Technology) in discussing fire testing of

thermal insulations and in reviewing the present report is

acknowledged. Thanks are also extended to Mr. Keene Christopher

(Air Krete, Weedsport, NY) and Mr. & Mrs. Douglas Palmer (Palmer

Industries, Frederick, MD) who provided product information and

test results from independent laboratories and for the demonstration of the generation of the foam.

27
8.

REFERENCES

1. Petersen, Stephen R., "Retrofitting Existing Housing for

Energy Conservation: An Economic Analysis," National

Bureau of Standards (U.S.), Building Science Series 64

(December 1974), 76 pages.

2. Rossiter, Walter J. , Jr. and Mathey, Robert G., "UreaFormaldehyde Foam Insulations: A Review of Their Properties

and Performance," National Bureau of Standards (U.S.),

Technical Note 1210 (March 1985), 70 pages.

3. "Air Krete Technical Manual," Air Krete, Weedsport, NY.

4. Cartmell, M.J. and Brown, R.K., "Polyurea Foam for Retrofit

Insulation - An Update With Case Studies," Journal of

Thermal Insulation, Vol . 6 (April 1983), pp . 250-262 .

5. Sorrell, Charles A., "Oxychlorides, Oxysulfates, and Other

Non-Portland Cements," Paper presented at 10th Annual

Symposium on Refractories, St. Louis, MO (April 5, 1974).

6. Sorel, S., "On a New Magnesium Cement," Comptes Rendus,

Vol . 65 (1867), pp. 102-104.

7. Demediuk, T., Cole, W.F., and Hueber, H.V., "Studies on Magnesium and Calcium Oxychlorides," Australian Journal

of Chemistry, Vol. 8, No. 2 (1955), pp. 215-233.

8. Sorrell, Charles A. and Armstrong, Charles R., "Reactions

and Equilibria in Magnesium Oxychloride Cements," Journal of

the American Ceramic Society, Vol. 59, No. 1-2 (1976),

pp . 51 -54 .

9. Roux, G., Balme, A., and Rivero, J. , "Research and Development of New Materials," in "1984 Activities of the Technical

Groups," Centre Scientifique et Technique du Batiment,

Vol. 261 (July-August 1985), pp. 294-295.

10. Lea, F.M., "The Chemistry of Cement and Concrete," Chemical

Publishing Co., New York (1971), p. 17.

11. Taylor, H.F.W., The Chemistry of Cements," Academic Press

Inc., New York (1964), p. 10.

12. "Magnesium Oxychloride Floor Finishes," in Section 7,

British Code of Practice, "In-Situ Floor Finishes,"

CP 204, British Standards Institution (1965).

13. Bailey, J.C., Porter, F.C., and Pearson, A.W., "Aluminum and

Aluminum Alloys," in Corrosion, Shreir, L.L., Editor,

Vol . 1, 2nd Ed. ( 1976), p. 4:30.

28
14. Seaton, M..Y., "The Inside Facts About Magnesite Stucco,"

Building Supply News (June 6, 1922), p. 850.

15. Herrera, Manuel A., "A Comparison of Critical Properties of

Magnesium Oxysulfate and Magnesium Oxychloride Cements as Used in Sprayed Fire Resistive Coatings," in " Fire Resistive

Coatings: The Need for Standards," ASTM Special Technical

Publication 826, Lieff, M. and Stump f, F., Eds., American

Society for Testing and Materials (1983), pp. 94-101.

16. Kawaller, S.I., "Chemically Reactive Coatings for the

Protection of Structural Steel," Fire Surveyor (August

1980), pp. 36-38.

17. Rains, W.A., "A New Era for Fire Protective Coatings for

Steel," Civil Engineering, Vol . 46. No. 9 (September 1976),

pp . 80-83

18. "Report of Laboratory Examination," Specimen No. 15599,

State of Connecticut, Department of Health Services,

Hartford, CT (July 29, 1983).

19. "The Apparent Thermal Conductivity and Thermal Resistance

of a Specimen of a Cementitious Foam Insulation Material,"

Report No. CLR-3, Dynatech, Cambridge, MA (January, 1983).

20. "Report on Surface Burning Characteristics Determined by

ASTM E - 84 Twenty-Five Foot Tunnel Furnace Test Method,"

Test No. T-3832, Hardwood Plywood Manufacturers

Association, Reston, VA (January 6, 1983).

21. "Results of Sample Analysis Report, Formaldehyde Content,"

F-805-3387, Consumer Product Safety Commission, New York,

NY (June 22, 1983).

22. State of Maryland, Department of Health and Mental Hygiene,

No. 000484 (January 31, 1983).

23. Test No. F-623, Hardwood Plywood Manufacturers Association,

Reston, VA (May 2, 1983).

24. "Analysis Report," Sample No. 12183, Calocerinos & Spina,

Liverpool, NY (January 10, 1984).

25. "Smoke Density Characteristics Determined by NBS-Aminco

Smoke Density Chamber," Test No. S-426, Hardwood Plywood

Manufacturers Association, Reston, VA (January 6, 1983).

29
26. Weidt, John L., Saxler, Robert J. , and Rossiter, Walter J.

,

Jr., "Field Investigation of the Performance of Residential

Retrofit Insulation," National Bureau of Standards (U.S.),

Technical Note 1131 (September 1980), 67 pages.

27. Cole, W.F. and Demediuk, T. , "X-Ray, Thermal, and Dehydration

Studies on Magnesium Oxychlorides," Australian Journal

of Chemistry, Vol . 8, No. 2 (1955), pp. 234-251.

28. "Practice for Developing Accelerated Tests to Aid Prediction

of the Service Life of Building Components and Materials,"

ASTM E 632, 1985 Annual Book of ASTM Standards, Vol. 04.07,

ASTM , Philadelphia, Pa (1983), pp. 645-652.

29. Rossiter, Walter J. , Jr., and Mathey, Robert G., "Weatherization of Residences: Criteria for Retrofit Materials and

Products," National Bureau of Standards (U.S.), Technical

Note 1201 (August 1984), p. 7.

30
Table

1.

Reported

Properties

of

Magnesium

Oxychloride

Cement-Based

Foam

Insulation

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The

asterisk

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reported.
Table

1.

Reported*

Properties

of

Magnesium

Oxychloride

Cement-Based

Foam

Insulation

(Continued)

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Table

1.

Reported*

Properties

of

Magnesium

Oxychloride

Cement-Based

Foam

Insulation

(Continued)

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LO rH CM
Table 2. Preliminary List of Performance Characteristics for

In-Situ Foam Insulations: A Comparison With the

Availability of Information Regarding the Properties

and Performance of Magnesium Oxych 1 or i de Foam Insulation

Performance Characteristic Availability of Informati on Cavity-Filling No

Cell Structure/Composition No

Density Limited Availability

Durability No

- freeze-thaw resistance No

- temperature and humidity effects No

- temperature effects Limited Availability

Effect on Other Building Materials

- gypsum plaster and wall board No

- metals (corrosiveness) No

- paints, coatings No

- wood No

Electrical Resistivity (fresh wet foam) No

F 1 ammab i 1 i ty/Combu s t i b i 1 i ty Limited Availability

Fri abi 1 i ty No

Fungus Resistance No

Offgassing/Release of Particulates Limited Availability

Shrinkage No

Specific Heat No

Strength No

Thermal Conductivity Limited Av ai lability

Water Absorption No

Water Penetration No

Water Transmission No

T~. This table refers to information available from test reports

from independent laboratories.

2. The comments on the availability of information given here for the

listed performance characteristics are based on the information in

Table 1 of the present report.
NBS-114A (rev. 2-ac) U.S. DEPT. OF COMM.

BIBLIOGRAPHIC DATA

SHEET (See instructions)

4. TITLE AND SUBTITLE

PUBLICATION OR

REPORT NO.

86-3326

2. Performing Organ. Report NoJ 3.

Magnesium Oxychloride Cement~Based Foam Insulation i A Review of

and Identification of Research Needs

Publication Date

JULY 1986

Available Information

5. AUTHOR(S)

Walter J. Rossiter, Jr. and Robert G. Mathey

6. PERFORMING ORGANIZATION (If joint or other than NBS. see instructions) 7. Contract/Grant No.

NATIONAL BUREAU OF STANDARDS _

DEPARTMENT OF COMMERCE 3. Type of Report & Period Covered

WASHINGTON, D.C. 20234

9.

SPONSORING ORGANI ZATION NAME AND COMPLETE ADDRESS (Street. City. State, ZIP)

U.S. Department of Energy

Office of Conservation and Renewable Energy

1000 Independence Avenue S.W.

Washington, DC 20585

10.

SUPPLEMENTARY NOTES

| | Document describes a computer program; SF-185, FIPS Software Summary, is attached.

11.

ABSTRACT (A 200-word or less factual summary of most significant information. If document includes a significant

bibliography or literature survey, mention it here)

This report reviews available information concerning the properties, performance, and

use of magnesium oxychloride foam insulation. Laboratory testing was not included in

the scope of the study, and data summarized were not developed based on NBS testing.

These insulations are produced at the job site from formulations based on the reaction

of magnesium oxide and magnesium chloride to form magnesium oxychloride cement. The

low-density foams have been available in the U.S. for insulating walls of buildings for

about three years.

This review indicates that data are not complete regarding the characterization of this

thermal insulation. One density and one thermal resistance value have been reported,

in addition to some properties that concern the safe use of the insulation. Additional

properties such as composition and structure, durability, effect on other building

materials including corrosiveness, heat of combustion, shrinkage, strength properties,

and water absorption and moisture transfer, that affect its performance as thermal

insulation in buildings, have not been reported in the archival literature. It is recommended that more data be developed through laboratory research and field observations

to provide for the characterization of the insulation.

It is also recommended that caution be exercised when applying magnesium oxychloride

foam insulation in wall cavities that contain metal objects. The available evidence

describing the corrosiveness of magnesium oxychloride products is not definitive.

As a matter of caution, the foam insulation should not be installed in wall cavities

which have iron, steel, or aluminum objects such as studs, wall ties, or pipes without

evaluation of the potential corrosiveness of the foam on such metallic components.

12.

KEY WORDS (Six to twelve entries; alphabetical order; capitalize only proper names; and separate key words by semi.colon s) cement; foam; energy conservation; magnesium oxychloride; performance; properties;

thermal insulation; walls

13. AVAILABILITY 14. NO. OF

PRINTED PAGES

| | Unlimited

| X.)(For Official Distribution. Do Not Release to NTIS 40

1 1 Order From Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402. 15. Price

| 1 Order From National Technical Information Service (NTIS), Springfield, VA. 22161

U S COMM- DC 6043-P80
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