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ISO 9001 :2008 CERTIFIED POLYFO

EXTRUDED POLYSTYRENE INSULATION BOARDS

QATAR INSULATION FACTORY

PROFILE

HISTORY

AI Mana companies are one of the distinguished and largest business group in Qatar since so many decades, from the beginning of Qatar started its development. AI Mana group companies are making a Significant contribution to the businesses in Qatar in various fields. Variety of AI Mana businesses, we have participated rapid economic development in Qatar as a business family. QATAR INSULATION FACTORY is one of companies of AI Mana Trading & Industrial Company, which is the biggest & oldest insulation manufacturing company in Qatar,

OVERVIEW

Qatar Insulation Factory (QJF) is a 100%Qatari owned company belongs to AI Mana Family. QJF was established in 1985 by producing and marketing of Thermal Insulation Boards. In the year 2001, we started to produce Extruded Insulation Boards under the

brand name ofPOLYFOAM. QJF is covering more than 80% of the local demand of polystyrene insulation and also exporting to Jordan, Bahrain, KSA and Dubai. Recently we expanded our export market to India, Lebanon, Egypt, Syria,Iraq, Hong Kong etc...

The distinction of QJF is, we use the latest technology from USA & Europe. Our products comply with US & European standards which are highly recommended international standards for the heat insulation. We have confidence in our team, who are well versed in using latest technology and maintaining the latest updates of the insulation manufacturing technology, which results to provide the best quality & improved efficiency of our product. Exceptional functional and technical expertise coupled with extensive industry knowledge makes QJF the ideal choice for the thermal insulations for your building constructions. Also we use latest chemical

formulas for achieving properties for required standards.

In 2009, we are proud to mention that QJF has entered to a new era,where the development of the business has

reached its

highest..In

the development of our business

started with huge demand which is increasing day by day for our products, not only in locally but also in overseas. The fulfilment of this demand driven us to increase our production capacity and go for the

expansion of production technology.

capacity with latest

As a result of the requirement of development, we have invested for new extruder plant with all the latest technology from USA, Italy & Germany. With our new plant, we are well confident of facing the demand in the market for insulation products not only in Qatar, but also in overseas.

VISION

Provide the most effectiveinsulation solution against the excessive heat & conserving energy with extended lifetime of the buildings.

MISSION

To provide the most effective insulation material to our customers and to be known as the leading, prominent and well established Insulation Company not only in Qatar, but in Gul£

PRODUCTS

INTRODUCTION

Producing thermal insulation rigid panels is justified by the high energy demand for airconditioning

and is

considered as one of the best ways to conserve energy and to increase building life.

NEED FOR THERMAL I SULATION

The cost of energy and rapid increase of usage have become very high in present days. This situation has emphasized

.:the need of energy conservation method. The concept of thermal insulation has been introduced to reduce the cost

of energy and conserve the buildings especially in hot climate.

Thermal insulation is used for the buildings for several reasons, but all are related to the main characteristics of

thermal insulation. Either in summer or winter, thermal insulation reduces the cost of energy In summer, thermal

insulation provides good resistance to the heat flow from roof, floor & walls and it will reduce the cost of cooling of

air conditioners.

The same way in winter, it will reduce the heat

loss and reduce heating cost.

PRODUCT DESCRIPTION

Polyfoam is extruded polystyrene boards manufactured from the best quality of general purpose polystyrene (GPPS).

It is manufactured as a closed cells by a continuous extrusion process in accordance with international standards of

DIN (German Standard) & ASTM (American Standard). In

order to achieve high standard quality, we have adopted

latest technology This process will guarantee unique properties such as high compressive strength, good resistance to

the diffusion of water vapour and water absorption, long term performance and high insulating value.

PRODUCT

SIZE (mm)

THICKNESS (rom) DENSITY KG/m3

DESCRIPTION

MAJOR

APPLICATION

Polyfoam

20,25,30,35,40,45,

Extruded Polystyrene

Roof

ormal (ND)

1250 x 600

50,55,60,65,70,75,

32-35

Rigid foam with &

Wall

 

80,85,90,95, 10O

without shiplap

Polyfoam

20,25,30,35,40,45,

Extruded Polystyrene

Roof

Normal (HD)

1250x600

50,55,60,65,70,75,

38-45

Rigid foam with high

WalJ

 

80,85,90,95, 10O

density & compressive

Floor

 

strength

Parking Decks

Polyfoam Super (ND)

J250x600

20,25,30,35,40,45,

Extruded Polystyrene Rigid

Roof

(Fire Retardant)

50,55,60,65,70,75,

32-35

foam with & without shiplap Wall

80,85,90,95, 100

& Fire Retardant Properties

Polyfoam Super (HD)

1250x600

20,25,30,35, 40 J 45,

Extruded Polystyrene Rigid

Roof

(Fire Retardant)

50,55,60,65,70,75,

38 -45

foam with high density &

Wall

80,85,90,95, 100

compressive strength and

Floor

Fire Retardant Properties Parking

N. B.: Longer Boards can be produced up to 3000 mrn on special request.

SPECIFICATION

POLYFOAM NORMAL (ND) jPOLYFOAM SUPER (ND)

When tested at lOOC (50 o P) in accordance with

DIN 52612 or ASTM C 518, the thermal

conductivity of 0.028 W /rn. "K.

Compressive strength to be of 300 kPa average

ASTMD 1621-95.

when tested DIN 53421 or 43 psi as per

Water absorption is less than 1% when tested after 4 days of immersion at 23°C according to

ASTM D 2842 or 0.2% by vol., according to DIN 53428.

Water vapor permeability within a range of 0.4 - 0.6 per inch when tested in accordance with

ASTM E 96-00.

Polyfoam super (ND) is specially fire retardant material under B2 building material category.

POLYFOAM NORMAL (HD) j POLYFOAM SUPER (HD)

When tested 10°C (50 o P) in accordance with DIN 52612 or ASTM C 518, the thermal

conductivity of 0.026 - 0.027 WI m.

"K.

Compressive strength to be of 500 - 700 kPa average when tested DIN 53421 or 43 psi as per

ASTM 01621-95.

Water absorption is less than 1% when tested after 4 days of immersion at 23°C according to

ASTM 0 2842 or 0.2% by vol., according to DIN 53428.

Water vapor permeability within a range of 0.6 - 0.4 per inch when tested in accordance with

ASTM E96-00.

Polyfoam super (HD) is specially fire retardant material under B2 building material category.

APPLICATIONS

ROOF INSULATION

CONVENTIONAL ROOF INSTALLATION

The conventional roof insulation method is simple to apply. POLYFOAM layer is laid over the roof slab and then

waterproofing membrane layer on POLYFOAM and finally the gravel/terrace slab layer.

(

(

(

(

Gravel or terrace slab

Waterproofing membrane

POLYFOAM

Roof Slab

THE UPSIDE-DOWN ROOF CONCEPT.

Upside-down roof concept is as simple to use

as it is effective. In this method, the roofing membrane is laid directly to

the roof slab followed by POLYFOAM as the

insulation layer with separation layer such as terrace slab with tight join

or gravel layer or reinforced in-situ concrete. This method has proved the efficiency in extensive practical tests over

the long years in the world.

Terrace Slab with tight join

POLYFOAM ---

)

....)

.•

Waterproofing membrane ---~)

Roof Slab ---~)

UPSIDE-DOWN ROOF

(

Reinforces in-situ concrete

Separation Layer

POLYFOAM

Waterproofing membrane

Roofslab

Gravel layer

POLYFOANI

Waterproofing membrane

Roof Slab

IN-SITU CONCRETE LAYER

)

)

)

)

)

ADVANTAGES OF THE UPSIDE-DOWN ROOF CONCEPT

Simple application of this concept

Efficiency which is proven in most of the world countries.

The waterproofing membrane is protected from extreme thermal stress, high ultraviolet

exposure and from mechanical stresses occurring during construction and subsequent use.

The life expectancy of the waterproofing membrane is substantially increased.

Maintenance costs are Significantly reduced.

Roofing membrane reduces temperature variation, in the upside-down roof

APPLICATIONS

INSTALLATION

POLYFOAM panels can be worked with conventional wood working tools. The panels could be bound together

with hot bitumen, dispersion type structural or special adhesives. Instruction for use and safety precautions relating

to the adhesive must be observed.

WATERPROOFING MEMBRANE

Ensure

the concrete slab is clean and fairly smooth, then membrane can be laid directly on the slab. If the concrete

surface

can not be made smooth, it is required to lay a protection sheet below the

membrane.

PROTECTION LAYER

Protection layer against the wind uplift, buoyancy and ultraviolet degradation can either be of gravel or paving slabs.

When using pebble gravel it is necessary to use the round, washed type having a 15-30 mm size distribution, laid

dray on a synthetic, non fabric, rot proof felt filtering layer. To determine the quantity of pebble gravel paving slabs

to be laid, it is advisable to adopt the values indicated in the following table.

POLYFOAM

Thickness / mm

Required gravel layer depth

Required paving thickness

Up to 50

65

75

80

100

50

65

65

70

80

Min. 40

50

50

SS

6S

DRAINAGE

With the normal gravel-topped specification, water percolates down through the grave, over and between the

insulation boards, until it reached the waterproofing membrane where it then drains off to roof outlets. On terrace

decks, water will drain from the top surface of the terrace and POLYFOAM and from the roof membrane. The

draining outlet should, therefore, have a connection at the membrane level, and at the top terrace and POLYFOAM

top surface levels. The roof slab should be sloped towards the drainage outlet. Waterproofing membrane should be

properly installed around the drainage opening so that water drains off from the waterproofing membrane to the

roof outlet.

ROOF DRAINAGE

~

Paving Slab

(

POLYFOAM

(

Waterproof

~

Membrane

 

-

Roof Slab

FLOOR INSULATION

  • .tela:(---- Gravel Layer <I> 15-30 mm

 

(

POLYFOAM

.,...._ir-·

(

Waterproofing membrane

(-

  • ----- Roof Slab

Even at the depth of 3-4 meters, the soil temperature can reach 33°C specially in Middle East. Therefore floor

insulation is very important to reduce the

conserve the energy

flow of heat through the floor to air conditioned building and this will

POLYFOAM (HD) has the special variety Forparticularly Forfloor insulation with;

Low thermal conductivity

High compressive strength

High resistance to water absorption and moisture penetration

POLYFOAM (HD) boards can be

used as a working slab

  • 1. Floor finish

  • 2. Concrete screed

  • 3. Concrete slab

  • 4. Roof membrane (if required)

  • 5. POLYFOAM layer

  • 6. Well compacted soil

POLYFOAM (HD) can be laid over the

concrete slab also

  • 1. Floor finish

  • 2. Concrete screed

  • 3. Vapour barrier

  • 4. POLYFOAM layer

  • 5. Roof membrane (if required)

  • 6. Concrete slab

  • 7. Well compacted soil

APPLICATIONS

INTERIOR WALL INSULATION

INTERIOR THERMAL INSULATION OF ADVANTAGE FOR THE FOLLOWING:

*

Buildingwith special exterior finish

* Building with intermittent airconditioning

* Insulation for existing buildings

For the internal lining

POLYFOAM can be used either

with the help of adhesives or by mechanical fasteners.

Internal lining can be covered either by gypsum

plaster

boards or by wire mesh fixed

with fastener and normal plaster.

Structural Wall

POLYFOAM

Mesh & Normal

Plaster or Gypsum plasterboard

CAVITY WALL INSULATION

Cavity wall insulation is of advantage where

permanently airconditioned buildings.

an exterior brick finish is required, and for both

periodically and

Interior Plaster

Structural wall (usually bricks).

The wall should be smooth and clean

 

POLYFOAM

Outer brick wall and inner wall are connected

with

wall ties or bonded along the board joints

with a suitable adhesive

Wall ties

Concrete slab

'TECHNICAL

SPECIFICATIONS

PROPERTIES

Ihe properties ofPOLYFOAM

test procedures.

on page (13) are average figures obtained by ASTM & DIN

1. THERMAL CONDUCTIVITY

Due to its homogeneous

structure and high resistance to water & vapour diffUSion, the change in the cell gas

composition is retarded by the

above construction, thus aging phenomenon

is slowed down tremendously. This

leads to a stable, long term, low thermal conductivity of 0.03 W / mOK at 40°C mean temperature.

Relation of thermal conductivity against temperature,

U

0.050

0.040

~

C

0.030

:~

u

;::l

"0

0.027

.::

  • 0 0.016

u

c;;

S

...

OJ

P

0

5

LO

15

20

25

30

35

40

45

50

MEAN TEMPERATURE °C

  • 2. COMPRESSIVE STRENGTH

111ecompressive strength of thermal insulation materials is determined by short term standard test methods. The

data given in the table refer to a deflection of

10% or yield value within

10% deflection. For structural applications

involving continuous high compressive load, not uniform loads of high temperature, while designing, an adequate

safety factor in design stress levels should be provided to minim.ize deformation with time. These values are

reduced at higher temperatures but the mechanical properties are not affected adversely at lower temperatures

down to -40°C

  • 3. FIRE BEHAVIOUR

POLYFOAM SUPER extruded polys