ISO 9001 :2008

POLYFO
CERTIFIED

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
 VISION
formulas for achieving properties for required Provide the most effective insulation solution against
standards. the excessive heat & conserving energy with
extended lifetime of the buildings.
In 2009, we are proud to mention that QJF has entered
to a new era, where the development of the business has
MISSION
reached its highest..In the development of our business
started with huge demand which is increasing day by To provide the most effective insulation material to
day for our products, not only in locally but also in our customers and to be known as the leading,
overseas. The fulfilment of this demand driven us to prominent and well established Insulation Company
increase our production capacity and go for the not only in Qatar, but in Gul£
expansion of production capacity with latest
technology.

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.
 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.

DENSITY DESCRIPTION MAJOR

PRODUCT SIZE (mm) THICKNESS (rom) KG/m3 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 45,
J 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 (50oP) 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 when tested DIN 53421 or 43 psi as per
ASTMD 1621-95.

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 (50oP) 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

( Gravel layer

POLYFOANI

Waterproofing membrane

Roof Slab

IN-SITU CONCRETE LAYER

Reinforces in-situ concrete )

Separation Layer )

PO LYF OAM )

Waterproofing membrane )

Roofslab )

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 Up to 50 65 75 80 100

Required gravel layer depth 50 65 65 70 80

Required paving thickness 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 .tela: (---- Gravel Layer <I> 15-30 mm

( POLYFOAM ( POLYFOAM
( Waterproof .,...._ir-· ( Waterproofing membrane
~ Membrane (-
- Roof Slab ----- Roof Slab

FLOOR INSULATION
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 flow of heat through the floor to air conditioned building and this will
conserve the energy
POLYFOAM (HD) has the special variety Forparticularly For floor insulation with;
Low thermal conductivity
High compressive strength
High resistance to water absorption and moisture penetration

POLYFOAM (HD) boards can be POLYFOAM (HD) can be laid over the
used as a working slab concrete slab also
1. Floor finish 1. Floor finish

2. Concrete screed 2. Concrete screed

3. Vapour barrier
3. Concrete slab
4. POLYFOAM layer
4. Roof membrane (if required)
5. Roof membrane (if required)
5. POLYFOAM layer
6. Concrete slab
6. Well compacted soil
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 an exterior brick finish is required, and for both periodically and
permanently airconditioned buildings.

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

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,

0.050
U
0.040
~
C 0.030
:~
u
;::l 0.027
"0
.:: 0.016
0
u
c;;
S•...
OJ

P 0 5 LO 15 20 25 30 35 40 45 50

MEAN TEMPERATURE °C

2. COMPRESSIVE STRENGTH
111e compressive 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 polysterene panels contains a flame retardant material, it is classified as B2 building
material when tested in accordance with DIN 4102.

\ ..5'
1M
•r
,
=
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 TECHNICAL
SPECIFICATIONS

4. RESISTANCE TO WATER AND VAPOUR PENETRATION

POLYFOAM absorbs negligible amounts ofwater because of its structure which consist of small size closed cells
and outer foam. skin of denser material on both sides.Therefore POLYFOAM will remain dry in the high relative
humidity and high ambient temperatures of the Middle East

S. CHEMICAL RESISTANCE
'POLYFOAM is stable and has good resistance to acids basis, cold bitumen, silicon oil. But is unstable to tars,
organic solvents, hydrocarbon gasoline and oil based paints.

6. CUTTING AND FIXING

POLYFOAM can be easily cut with wood working tools and can also be cut by hot wire and can be bonded with
suitable hot bitumen and with special adhesive suitable for polysterene foams.

7. STORAGE AND HANDLING

POLYFOAM should be stored in a clean flat area and kept away from open flames and other sources of ignition.
When longer outdoor storage is forces, boards must be protected from ultra violet light by covering with brightly
collored plastic sheets properly anchored down against 'wind effect
SPECIAL PRODUCTS

BLOCK INSERT (MOULDED INSULATION INSERT)

POLYFOAM Block inserts are a special product, coming with a special shape for insulating cement block
bricks. These insulated cement blocks can accommodate many walls in a home. The cores are filled with
insulation (except for those cells required structural steel reinforcing and concrete inhll), which raises the
average wall R value. The better concrete masonry units reduce the area of connecting webs as much as
possible.

111ehollow cores of cement blocks can be accommodated with POLYFOAM Block In ert.
With this pre-insulated block bricks, the building construction is simple, just staking the blocks. There is no
need of insulating the wall separately.

Block Inserts basically coming with Extruded or Expanded Polystyrene insulations. Based on the properties of
each insulation material, block inserts can be selected.

DIMENSIONS (L x W x T) (rnm)
400x200x75
400x200x60
 SPECIFICATIONS OF
POLYFOAM
POLYFOAM POLYFOAM POLYFOAM POLYFOAM
PROPERTY STANDARD Norma1(ND) Super(ND) Norma1(HD) Super(HD)
UNIT
Fire Retardant Fire Retardant

Density range DIN 53420 Kg/ml 32-35 32-35 38-45 38-45

ASTMD 1622 Lb/&J 2-2.2 2.4-2.8 2.4-2.8 2.4-2.8
Thermal Conductivity at 10°C (50°F) DIN 52612
Mean temparature of test DIN 52616 W/m.ok 0.Q28 0.Q28 0.027 - 0.026 0.027 - 0.026
Mean temperature 23.9°C (7SOF) ASTM C 177-97 or Btu-ln/Ft'hOF 0.20 0.20 0.19-0.18 0.19-0.18
ASTM C 518-98
Compressive strength at 10%deflection DIN 53421 kPa 300 300 500 -700 500-700
ASTMD 1621-95 psi 43 43 70- 100 70·100
Water absorption by submersion DIN 53428 % by Vol 0.2 0.2 0.2 0.2
ASTM D 2842 % by Vol ,,-I ,,-I <1 <I
(±I %by 1'01. precision)

Water vapour diffusion resistance factor ~l OJ 52165 !--l 100·200 100·200 150·220 150-220

"Vater vapour permeability ASTME96·00 perm· inch 0.4·0.6 0.4·0.6 0.6·0.4 0.6·0.4
20kPa,80nC
type 2.8 psi
Heat stability / compressive creep DIN 18164 176°F WD WD WD WD
40kPa70"C WS WS WS WS
Type
5.6 psi, 158°F
Linear coefficient of thermal "C 70x 10.6 70 x 106 70x 10'(' 70x 10.6
(1pansion and contractJ~l1 DIN 52328 of 39 x 106 39 x to 6 39 x 106 39 X 106
Heat soaking condition
Irreversible dimensional variation
(Result of laboratory test with % < 0.2 <0.2 < 0.2 < 0.2
temperature changes up to 60°C (140°F)

Fire Classification 011 4102 (BuJding BI B2 BI B2

Material class)
Underwrites Laboratory (UL)
classification according to ASTM-E 84 Flame spread
standard test method for surface smoke developed 5 5 5 5
bu.rnin~ characteristics ofbuiJding for max. 4 pcf 165 165 165 165
materia s under designation density and 4" max
ASTM C 578·95 thickness
POLYFOAM POLYFO~ POLYFOAM POLYFO~
Norma1(ND) S~ Norma1(HD) S~
APPLICATIO
DCIUity
FiR t Dauity
Fire t
(32-35) ••••'m· D~ kgj'm'
(32-35 (38-45)kg/m' D~ kglm'
(38-45
Concrete Flat Roofs & Steep Roofs ./ ./

Metal Roofs ./ ./

Exterior Walls ./ ./

CavityWalJs ./ ./

Floors ./ ./

Cold Store Floors ./ ./

Cold Store Walls ./ ./

Ice Ranks ./ ./

Packing Decks ./ ./

Airport Runways & 'Transport Routes ./ ./

Sandwich Panel & Concrete Precast ./ ./

DIMENSION OF POLYFOAM

Length (mm) 1250 to 3500

Width (mrn) 600

Thickness (mrn) -r- 10 to roo

. -.;:

N. B.:Thicknesses more that 100 rnm can be arranged on special request.

 .-

ISO 9001 :20081

CERTIFIED

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cujl2.J1 .:.IQ.o.lJ J b ij 6 i no • QATAR INSULATION FACTORY

cic lLcJ Iq 6 J L:;illJ 0-i W I Q::,J.ill0-0 E j.o
Branch of AI Mana Trading & Industrial Co.
(+QVo a:Ofl((Vl :l).J.DLD EEOfl(t"(l- EElfl·Voo {}~
Tel.:44680755 - 44582326 Fax:+974 - 44582276
)..hD - <i.:lqlll t"t"·EO:L,J·LP
P.O. Box: 33045 Doha - Qatar -.
www.qatar-insulation.com :~qJl.~J)JI cS1i~1 Website: www.qatar-insulation.com
polyfom@qatar.net.qa • qataUnsulation@yahoo.com :vjq~lJl ~J+l1 eMail: p-olyfomatar.net.a.gatarinsulation.ahoo.com