Q: Describe the product.

A: Polyphen® is a combination of expanded polystyrene (EPS) and phenolic foam, combining the best qualities of each medium. The finished product is a rigid foam made from a matrix of EPS and Phenolic resin. EPS is renowned for its strong mechanical properties, thermal insulation and its ease of use and ability to be formed. However, EPS has a lower fire rating than phenolic foam. Phenolic foam, on the other hand, is brittle and difficult to work but its fire resistant properties are exceptional.

Q: What is Polyphen®?

A: Polyphen® is fire resistant insulation foam. As a sandwich panel with a 0.6 mm steel sheet, it has FM Class 1 approval as well as an official two-hour fire rating pursuant to Australian Standard 1530.4. Polyphen® is the first insulation product developed in Australia to be endorsed by Factory Mutual, the largest commercial insurance company in the world. Using Polyphen® presents a lower risk of fire damage and potential death, which can translate into lower premiums for the life of the structure to be insured.

Q: How does Polyphen® work?

A: In a non-fire situation, the EPS and phenolic matrix provides strength and insulation, making it suitable for cool room panels and cladding for domestic and commercial building cladding (RMAX ThermaPhen™). In a scenario where a fire is in close proximity to the Polyphen® foam, the phenolic part of the matrix does not burn and maintains its shape and structure, even when the EPS melts. The phenolic structure remains in a honeycomb shape and acts as a fire buffer.

Q: What are its applications?

A: Polyphen® can be used as part of a panel system to provide a two-hour fire rating. It is ideal in the construction of party walls where it slows the spread of fire. Brewing companies have used the technology as fire protection in their wine tank storage farms, whilst major engineering and manufacturing companies have used Polyphen® to protect their manufacturing facilities.

From an architectural perspective, fire-rated design now doesn't need to be compromised because of fire rating regulations. Polyphen® can be installed in sheet or laminated form and can be profile cut to +/- 0.5 mm. This opens up design opportunities that have been denied in the past.

Q: Does it have any unique features?

A: Yes. The product has been developed in Australia. The product is protected by International Patent in 82 countries. Polyphen® can be manufactured in panels or on a continuous line and is capable of producing 500m of laminated product per hour.

Q: Will Polyphen® conform to the new Victorian bushfire standards?

A: Yes. The two-hour fire rating for Polyphen® steel coated panels means it has been proven to withstand sustained temperatures of 1,000°C for two hours, which is far longer than the usual fire attack in bushfires where high temperatures last a matter of minutes. RMAX ThermaPhen™ is expected to comply with the BCA requirements for Fire Rating (FRL) with a 60- minute rating for structural adequacy, integrity and insulation as determined in Australian Standard 1530 part 4.

Q: What official testing and ratings does Polyphen® have?

A: Polyphen® in a steel clad sandwich panel has been assessed by the CSIRO MIT Fire Science and Technology Laboratory and achieves a Group 1 classification, which is the highest criteria for fire hazard properties of building materials and assemblies under the BCA, as tested pursuant to the ISO9705 Room Corner Test. The CSIRO report states there was no excessive flame spread or smoke production and the test room did not reach a flashover condition, unlike other insulation products. Tests using Polyphen® as a rendered product - RMAX ThermaPhen™ - are now being undertaken to meet AS1530 part 4.

Q: Can you demonstrate the effectiveness of Polyphen®?

A: The temperature of the flame in the blowtorch picture is over 1,000°C. At that temperature it will melt brass and copper and turn steel white hot. At that temperature Polyphen® has only just started to deteriorate. After 5 minutes the temperature remains ambient on the reverse side of the 75 mm Polyphen® sheet.

Q: What environmental credentials does Polyphen® have?

A: The energy saved over a lifetime of a Polyphen® insulation panel in reduced heating more than compensates for the raw material used in its construction.

Q: How does the product compare with similar products?

A: In reality there is nothing to compare it to. It is truly unique because of its combination of fire- rating, strength, weight, cost and ease of application, including the manufacturing process. Polyphen® insulation foam is currently manufactured in Australia, New Zealand and South Africa. RMAX ThermaPhen™, utilising Polyphen®, is made in Melbourne and once testing and approval is complete, will be able to be shipped to all areas of Australia.

Q: At what stage is the product at now?

A: Polyphen® fire resistant insulation foam has been commercially available for over four years and has undertaken many tests relating to the building industry. Tests on rendered RMAX ThermaPhen™ are awaiting final approvals, at which time the product will be commercially released.

Stephanie McDonald

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