For pipes, non-combustible pipe shells made from mineral wool and laminated with an aluminum layer are the state-of-the-art. The fire-protected insulation of more complex system components is more complicated. Up until now, aluminum boxes have been used for this purpose: These are stuffed by hand with mineral wool on the construction site - a time-consuming process. Furthermore, subsequent non-destructive inspection is not possible. Foam-glass half shells are used as an alternative. These are, however, very odor-intensive to produce, are comparatively expensive and are difficult to work with.

Inexpensive and removable insulation boxes made from polymer foams (e.g. PU foams, PP foams) achieve at best the building-material class “flame-retardant”. The aim of the project is to achieve a comparably simple and economical solution that complies with building-material class “non-combustible” (A1). In a previous project (“A1 foam”), the project team had already successfully developed a non-combustible construction foam. In the new “FormHeat” project, the foam is being further developed and optimized for the production of insulation boxes. The adaptation of existing plant technology from the PU-foam sector is difficult, as the mineral-based A1 foam has a higher abrasiveness. A new process must therefore be developed.

At the Fraunhofer WKI, we are drawing up statistical test plans and characterizing the foam with regard to non-combustibility, mechanical and hygric properties, and emissions. Furthermore, we are investigating whether it is possible to grind the hardened foam and use it as a filler for the production of new insulation boxes. This would enable the high-quality recycling of production waste and disused insulation boxes and could reduce production costs.