PET Foams

Lightweight Cores for

Strong Structures
 Armacell – a global market leader
and pioneer in sustainability
Climate protection and sustainability are shaping the This is second nature to Armacell. Since our company
political agenda worldwide. Embracing responsibility for was founded back in 1860 as Armstrong Cork, we have
future generations means to focus on the need for been serving markets with products that promote
sustainable construction using materials and structures sustainable building concepts. But also in internal
which offer long-term performance. Buildings today are procedures, environmental stewardship is a day-to-day
responsible for more than 40% of global energy concern. Every industrial company has an unavoidable
consumption and account for 1/3 of the greenhouse gas impact on the environment; our operating principles
emissions into our planet's atmos­ phere. By observing prescribe that we reduce that impact to a minimum.
environmental needs more carefully in building planning Combining this legacy with decades of research and
and construction, decision makers at all levels can promote experience in polymeric foaming have made us what we
the transformation of our building environment towards are today, a leading innovator in our markets and a pioneer
greater energy efficiency and climate friendliness. in sustainability.

Facts and Figures

The company: Armacell International S.A. Established brands:
• ArmaForm® (PET foams, which are used as a
Founded: In 1860 the first activity started of core material in sandwich constructions)
Amacell‘s former parent company Armstrong Cork, • Armaflex® (highly flexible, closed-cell elastomeric
which later became Armstrong World Industries. insulation)
In 2000 Armstrong‘s insulation product division • Tubolit® (thermoplastic pipe insulation)
becomes independent under the name of Armacell. • OKA® products (covering systems made of PVC
and metal)
Total net sales (2017): 603.2 million euros • Arma-Chek® (highly flexible, non-metal cladding
system)
Headquarters: Capellen (Luxembourg) • ArmaSound® (acoustic insulation products and
systems)
Global presence: 3,000 employees, • Ensolite® (closed-cell foams in continuous rolls)
27 production plants in 17 countries • Monarch® (microcellular block foams)
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dedicated years to developing production technologies
resource-optimised production process. ArmaForm is
inno­vative, energy-efficient structural PET foam cores for
ArmaForm is a continuation of this success. Our

100% recycled products. Armacell scientists have

fully recyclable and – more importantly – is made out of
the composites industry are manufactured according to a

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post-consumer containers and packaging Franklin Associates, January 2011.

a m r aS
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Life cycle inventory of 100% post-consumer HDPE and PET recycled resin from

c o e ad h a p
Study (2011) results show that for every pound of recycled
it is a truly sustainable solution. The Life Cycle Inventory
material to produce ArmaForm. It is not only green in color,

PET flake used, energy use is reduced by 84% and

using post-consumer PET packaging waste as raw
and special recipes that allow a stable production process

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3
 Our PET foam product range
ArmaForm® Core
Structural lightweight PET foam cores made of 100% recycled PET.

ArmaForm® MultiCore - combines different densities in one foam core,

improving impact and point load resistance, keeping the weight to a minimum.
ArmaForm® Eco - combines strength, stiffness and thermal insulation with
process versatility, design flexibility, and outstanding sustainability.

ArmaForm® Foil
The first fully recyclable and thermoplastic foil product, entirely made
of recycled PET, with an outstanding operating temperature window.
Designed for thermoforming applications and sandwich structures
with very thin cores.

ArmaShape
Loose PET beads for large-scale production of ready-to-use 3D shaped foam
cores. The high mechanical properties of structural foam cores combined
with the advantages of particle foams offering a lightweight but strong
product, producable in any shape.

The sandwich concept

Tension

Applied Core
bending sheer
forces
Core
Compression

Compression

A sandwich structure consists of two relatively thin, yet over a larger area, while maintaining the skins at a fixed
strong and stiff, skins or facings on both sides of a distance.
thick, yet lightweight, core material. The skins take up The result is a greatly improved bending strength and
the normal stresses in-plane and give the structure a rigidity compared to monolithic materials. If you double
hard-wearing surface. The core material absorbs the the core thickness further, the weight increase is
shear forces generated by out-of-plane loads, negligible, while the stiffness is multiplied by a factor of
distri­buting between the skins and spreading them 4 and the strength is doubled.

4
Unique characteristics of ArmaForm® Core

Superior mechanical properties, excellent compression strength

and high shear modulus.

Outstanding fatigue resistance (threshold > 60%) for maximum lifespan.

Easy to shape by thermoforming (3D), offering freedom in design.

Easy to process with most types of resin and production methods.

High processing temperature of + 150 ºC / + 302 ºF with short term

curing temperature up to + 180 ºC / + 356 ºF.

Excellent thermal insulation properties.

Closed-cell structure means extremely low water and resin absorption

(no corrosion and degradation over time).

Good screw retention.

100% recyclable.

Please find technical data sheets for download as well as further information on our website:
www.armacell-core-foams.com.

Your benefits with ArmaForm® as core material

Compared with other plastics such as PVC and PUR/PIR, ArmaForm is easier to recycle,
extremely resistant to temperatures, in combination with excellent fatigue properties.

ArmaForm Density variation

9
PVC 8 Fatigue
Sustainability properties
Balsa 7

6
PUR/PIR
5

2
Insulation Peel
1
properties strength

Processing Resin
versatility absorption

Temperature resistance Mechanical properties

5
 Stability and lightweight mean new possibilities
In an ever more complex world with fierce competition more and more popular in structural design. There are other
for market share, the demand for efficient products is benefits prompting design engineers to take a closer look at
increasing exponentially. Most of the current growth is sandwich composites: Low maintenance and repair costs,
driven by substitution. New and better products replace positive environmental aspects, ease of installation, design
existing solutions. Openness to new concepts, speed of flexibility and low thermal conductivity. These factors will
implementation and the willingness to innovate are indeed have a greater or lesser impact, also depending upon the
factors that set successful companies apart from those who strategic choice of the right core material. And that is where
are merely followers. Sandwich composites belong to the ArmaForm comes into play, offering tremen­dous benefits to
category of products with a huge substitution potential. a broad area of applications in Wind, Building & Construction,
It is mainly due to weight savings that they are becoming Transport and General Industry.

Wind Energy
Wind Energy is faced with the challenge of
achieving grid parity. This requires more effective
components at a lower cost. A challenge difficult to
meet. Since qualifying our first ArmaForm products for
wind turbine blades, we have continued to innovate in the
development of PET foam and will never rest in improving our
own production efficiencies. Supporting the OEMs in their
endeavour of delivering clean energy at an accep­table cost to the
world, we have always shared efficiency increases with our partners
and consistently improved our overall value propo­sition. 100% supervised
quality; superior fatigue properties and excellent strength to weight ratios
are just a few examples, besides attentive customer service, that have made
Armacell the supplier of choice for leading players in this industry.
Rotor Blades / Nacelles / Spinners / Housing

Transport
Used as a core material in composites, ArmaForm helps to
reduce the weight of rail and road vehicles by up to 50%,
compared with conventional metal components, thus reducing
fuel consumption and carbon emissions. Because of their excellent
water resistance, all ArmaForm foam cores are perfectly suited for boat
and ship building applications. Screw retention is an additional key benefit
for all markets. ArmaForm meets the most relevant international fire and
smoke regulations for rolling stock, as well as for the aviation market.
Rail & Road and Aviation: Body Structure / Interior Panelling / Floors /
Roofs / Cabin Modules
Marine: Boat Hulls / Cabin Interior / Decks / Superstructures / Furniture

6
 Building and Construction
Buildings are made to provide shelter. But they also
shape the landscape around us. Thermal formability is just
one benefit of ArmaForm in sandwich composites, allowing
exceptional freedom of design for architects. Other benefits like
low thermal conductivity, ease of installation, light weight and long
free spans, the possibility of combining with all types of decorative
surfaces, no corrosion and low maintenance and repair cost, make
ArmaForm in sandwich composites a preferred choice for architects
and engineers to substitute with existing building materials.
Roofs / Facades / Domes / Bridges / Radomes

General Industry
ArmaForm is ideal in any scenario where sandwich elements can
save money thanks to low weight, easy workability, low maintenance
and high durability. An early discussion with our specialists can help to
improve your design – and save money. We are happy to assist.
Water & Chemical Tanks / Food Trolleys /
Shower Pans / Industrial Ventilator

7
 Environmental Protection and
Corporate Social Responsibility
The insulation of technical equipment in buildings and been developed to utilise production waste. The majority
industry is one of the simplest and most efficient ways of of locations are certified in accordance with the
saving energy and reducing CO2 emissions. As a world international environmental standard ISO 14000 – and all
leader in flexible insulation foams for the equipment European plants are already certified today. Armacell is
insulation market as well as a leading provider of also a founder member of the European Industrial
engineered foam products that have been installed in Insulation Foundation (EiiF), whose purpose is to promote
millions of buildings and facilities around the globe, the use of optimised insulation systems in industrial plants.
Armacell makes a considerable contribution to abating
greenhouse-gas emissions. Armacell became in 2009 the world`s first manufacturer
of flexible technical insulation materials to present a
Environmental Commitment comprehensive ecobalance life-cycle assessment (LCA).
Besides making an important contribution to environmental
protection by manufacturing energy-saving products, Social Commitment
Armacell practices active environmental protection In recent years, Armacell has also been emphasising the
throughout the company. social dimension of sustainability to its management and
employees. In 2005, Armacell received the Ethics in
Environmental protection is one of the main pillars of Business Award for its outstanding commitment to
Armacell’s corporate philosophy. It is an integral part of environmental and social issues. In 2006, Armacell joined
the business strategy and ranks equally with other the UN Global Compact initiative, the world’s most
company objectives. The environmental guidelines oblige important business network for sustainable globalisation.
all Armacell employees worldwide to aim to protect the As a company with a global footprint, Armacell supports
environment and conserve natural resources. local good citizenship projects. In 2011, the company
adopted a specific code of conduct that obliges all
To use resources as efficiently as possible, Armacell is employees worldwide to act ethically. The Armacell Code
constantly searching for ways to reduce raw material use, of Conduct is based on values and principles that apply
energy consumption and waste. Intelligent systems have throughout the Armacell Group.

Armacell’s Environmental Protection Guidelines

Our aim is to gear all our business activities Using environmentally-friendly technology in research
towards protecting and conserving nature. Our and production. By doing so, we increase safety in the
environmental policy is based on the following workplace and protect our communities and the
principles: environment.

Manufacturing only products that pose no risk to the Avoiding and reducing waste; using recycling and
environment when they are used as intended by environmentally-friendly disposal systems.
customers and consumers.

Reducing risks to soil, air and water to the greatest

Supplying information on the correct storage, use and
disposal of our products. extent possible

Conserving natural resources by using raw materials Preparing for potential dangerous situations in order to
and energy responsibly. protect both people and the environment.

8
ArmaForm®
a truly sustainable concept
“Caring for Climate”, a UN Global Impact Initiative, r-PET bottles are considered a valuable raw material,
highlights the responsibility of businesses to reflect the Armacell has developed the capability to recycle a PET
needs of climate protection. A principle we have fully packaging waste stream, which to a large degree ends up on
endorsed as well in our PET production: the product is landfills or goes to incineration, but it is now used to produce
fully recyclable, we re-use 100% of our material process ArmaForm.
loss in internal recycling, and we do not use any ozone-
depleting HFH or CFC blowing agents. Making the post-consumer r-PET requires 70% less
energy and produces 80% less CO2 per unit than the
But we did not stop here and have made again a signifi­cant virgin PET resin 1). Using such r-PET as a raw material
contribution to sustainable growth: Scientists of the global for our foaming process, a 34% reduction of the carbon
R&D Team of Armacell have spent several years to develop a footprint is possible compared to the use of virgin PET
technology that enables the production of PET foam boards resin. The results of comprehensive LCA review 2) are
in consistent, reliable qualities made 100% from post- depicted in the chart below indicating the relative green­
consumer PET packaging materials (r-PET). While "cradle to house effect (CO2 emissions) of various foams, including
cradle" recycling of PET bottles is common practice and that of ArmaForm made of r-PET 3).

CO2 emission per kg foam

XPS
XPS 179%

PVC
PVC 209%

SAN
SAN 185%

PUR
PUR 260%

r-PET
r-PET

standard
PET 149%
PET
0%
0% 50%
50% 100%
100% 150%
150% 200%
200% 250%
250% 300%
300%

ArmaForm – Designed for a greener tomorrow

®

PET material Sorting, crushing, ... PET granulation Extrusion foaming Used in a variety ArmaForm can be
collection to flakes process process of applications 100% recycled

1)
Life cycle inventory of 100% post-consumer HDPE and PET recycled resin from 2)
Armacell LCA report, data from 2015.
post-consumer containers and packaging Franklin Associates, January 2011. 3)
SimaPro Database 7.3.0; method: CML 2001

9
 Complete monitoring for 100% safety
Our products and processes reflect the highest
quality standards for products and services in line with
ISO 9001:2015. We use state-of-the-art technology for
production, control and monitoring in the ArmaForm
manufacturing process. For instance, we have implemen­ted
fully integrated ERP and Six Sigma process monitoring sys­­
tems, which enable full 100% quality control of important
product properties relevant to the reliable performance of a
sandwich composite:

 Challenge No. 1: Density variation

The mechanical properties are all related directly to the Additionally, thickness variation in the interface between
density of the foam core. The physical properties of the two core sheets could result in local buckling or kinking
sandwich panel thus depend on close density control of of the sandwich face sheets.
the core.  The ArmaForm Solution:

 The ArmaForm Solution:  Automated, 100% in-line control measures every

 Density variation is kept at a very low level (< 5%), single board to ensure the precise thickness
because ArmaForm production features 100% tolerance range.
in-line control. Monitoring density information
continuously and using that information to adjust  Challenge No. 3: Surface damage or impurities
process parameters, prevents failures of the S urface damage and impurities can lead to delamination
sandwich due to uncontrolled density variations. of the sandwich skin and subsequent blistering in and
failure of the sandwich panels.
 Challenge No. 2: Thickness variation  The ArmaForm Solution:

S tiffness is an important characteristic of a sandwich All individual boards are subjected to in-line optical
composite that increases exponentially with the thickness scanning. Screening the foam core sheets for sur­face
of the core material. Small variations in core thickness damage and impurities ensures reliable adhe­ sion
already have a big impact. Reliable performance of the between the foam core and the FRP laminates and
sandwich depends heavily on compliance of the delivered prevents failure of the sandwich ele­ments. When the
core material board thickness with the requirements as system is outside the specified tolerances, the slicing
calculated and requested by the design engineer. line stops and an operator has to intervene.

The final product is continuously compared against the original approved material, including visual inspection and
packaging requirements. Above and beyond these in-line measurements and inspections, a series of additional tests
are performed regularly to guarantee the utmost quality and reliability.

Unique: 100% traceability

Every single ArmaForm board produced is identified by
a unique barcode. This allows the traceability from the
final product to the raw material used to manufacture
that product. It is also possible to access the archived
parameters of the entire product process, simply by
scanning the barcode.

10
Convenient PET foams
solutions worldwide

Armacell Canada Inc.

Brampton, Canada
E-mail: [email protected]
Armacell Benelux S.C.S.
Thimister-Clermont, Belgium
E-mail: [email protected]

Armacell (Guangzhou) Limited

Guangzhou, China
E-mail: [email protected]

There are not always standard solutions when it comes to using GRP Composite Sandwiches with
whatever kind of core material. Simply share with us your project ideas and we will guide you on how
it can be done. We will gladly work with you to develop a concept that offers you all the benefits of this
innovative foam core material and fulfils your particular industry requirements, worldwide,
no matter where you are.

Thanks to our close network of partners in all aspects of the composite industry, from engineering and
design to converting and manufacturing, we guarantee you a project involving close consultation and
support - exactly the way you need it.

We’ll show you what’s possible. Simply ask.

11
All data and technical information are based on results achieved under the specific conditions defined according to the
testing standards referenced. It is the customer’s responsibility to verify if the product is suitable for the intended appli-
cation. The responsibility for professional and correct installation and compliance with relevant building regulations lies
with the customer. Armacell takes every precaution to ensure the accuracy of the data provided in this document and all
statements, technical information and recommendations contained within are believed to be correct at the time of pub-
lication. By ordering/receiving product you accept the Armacell General Terms and Conditions of Sale applicable in the
region. Please request a copy if you have not received these.

As the inventors of flexible foam for equipment insulation and a leading provider of engineered foams, Armacell develops
innovative and safe thermal, acoustic and mechanical solutions that create sustainable value for its customers. Arma-
cell’s products significantly contribute to global energy efficiency making a difference around the world every day. With
3,000 employees and 25 production plants in 17 countries, the company operates two main businesses, Advanced In-
sulation and Engineered Foams. Armacell focuses on insulation materials for technical equipment, high-performance
foams for high-tech and lightweight applications and next generation aerogel blanket technology. For more information,
please visit: www.armacell.com.

Armacell Benelux S.C.S. · Rue des Trois Entités, 9

Z.l. Les Plenesses · 4890 Thimister-Clermont, Belgium
Phone: +32 (0) 87 32 50 70 · Fax: +32 (0) 87 32 50 71
[email protected]
www.armacell-core-foams.com

© Armacell Benelux S.C.S. IBWW-201901