Core-Fill 500™ Masonry Foam Insulation
Core-Fill 500™ is America’s leading foam insulation
for concrete block, precast concrete and hollow cavity brick walls
Core-Fill 500™ is a non-expanding aminoplast foam that looks like white shaving cream. The foam is injected under pressure into the empty cores of masonry walls. When insulating concrete block walls, pressure forces the foam from one core into adjacent cavities, flowing both vertically and horizontally, sealing even the smallest cracks and fissures.
The insulated block structure forms a protective envelope, preventing air leaks, dramatically reducing sound transmission and sealing out moisture, pollutants and allergens. A trace amount of boric acid—the active ingredient in some household cockroach baits—in the resin prevents mold, mildew and bacteria growth, and nesting by pests.
Core-Fill 500™ emits no toxic gases during or after installation, and is not a skin or mucous membrane irritant like fiberglass. The aminoplast foam biodegrades gracefully—primarily into nitrogen—in the presence water and sunlight. Because of the very high nitrogen content, hardened Core-Fill 500™ foam has actually been ground up and used as fertilizer.
Architects Prefer Core-Fill 500™.
Core-Fill 500™ is an essential part of any construction project that values energy savings, indoor air quality and acoustic shielding. Architects have specified Core-Fill 500™ for thousands of commercial projects, including buildings for Walmart, Fresh Market, Whole Foods, Publix, Kroger, Costco, PetSmart, Advanced Auto Parts and Lowes Home Improvement. Core-Fill 500™ has successfully insulated stadiums and arenas, colleges and universities, schools, churches, prisons, banks, hospitals and factories.
Core-Fill 500™ Application
Core-Fill 500™ has two components: an aminoplast resin and a catalyst foaming agent surfactant. Delivered with compressed air, the resulting foam mixture is a Class A building material for use in concrete masonry blocks, brick cavity wall systems and cavity spaces between brick and blocks. The foam mixture sets cold within 10 to 60 seconds of leaving the injection hose nozzle and does not expand, so enclosed spaces fill without pressure build-up. Before setting, the foam flows easily to fill an entire vertical cavity and adjacent cavities, regardless of cavity shape or obstructions like pipe, wire, conduit, electrical boxes or trash in the wall. No surface preparation is required.
Once set, Core-Fill 500™ foam has an R-value of 4.91 per inch, with a density of about 0.8 pounds per cubic foot. But unlike loose fill insulation products or dry mix foam products, Core-Fill 500™ won’t settle over time or experience the shrinkage of dry mix products.
One of the biggest advantages of Core-Fill 500™ is that the insulation can be injected after all masonry construction is completed. This allows masonry crews to work without interruption, shortening construction time and cost.
Project Application Notes
- Core-Fill 500™ masonry insulation is a thermal foam insulation product. It is not intended and should never be used to increase the fire rating of a concrete masonry unit.
- Although easily applied and lightweight, Core-Fill 500™ is not recommended for ceiling or attic applications.
- Core-Fill 500™ will not support compressive loads and should not be used to create bouyancy for flotation.
- Core-fill 500™ should not be used in any application environment likely to see sustained temperatures in excess of 190°F (88°C).
- Core-Fill 500™ should not be used in overhead applications or underground as a vapor barrier.
Exclusive Distribution Channel and Warranty
Core-Fill 500™ is manufactured and shipped from the factory as a liquid, in tanker trucks, to an exclusive network of factory-certified installation contractors. Keeping the foam in liquid form from raw ingredient manufacturing to finished installation preserves the foam’s plasticity and ensures consistent product quality as installed. Measured shrinkage of the hardened foam across tens of thousands of projects and millions of insulated concrete blocks is less than one percent.
Competing masonry foam insulation products ship as a bagged dry resin powder that must be mixed with water at the construction site. Several batches are usually required to complete a single project. Inconsistent batch quality can result in foam shrinkage after installation.
The manufacturer of Core-Fill 500™, Tailored Chemical Products, has so much confidence in the consistency of their product and the accuracy of our installation work that they do not just warrant the product. They also warrant our installation work. Tailored Chemical Products is the only masonry foam insulation manufacturer to warranty the quality of the installed insulation product.
Of course, any company can make a warranty promise. What makes this warranty truly impressive is that Tailored Chemical Products, headquartered in Hickory, North Carolina, has manufactured Core-Fill 500™ for over 30 years and is the largest producer of masonry foam insulation in the United States. State-of-the-art manufacturing facilities, obsessive focus on quality assurance and the most extensive certified dealer/insulation contractor network in the industry have made Core-Fill 500™ North America’s most commonly specified and installed thermal and acoustical masonry foam insulation. Core-Fill 500™ has been installed in over one million new and existing construction projects throughout the United States.
Core-Fill 500™ for Precast Concrete Panels
Core-Fill 500™ thermal and acoustic masonry foam insulation is also the preferred solution to insulate the cores of prestressed/precast hollow-core concrete panels, delivering the highest R-value per inch of any integral masonry insulation and also effectively deadening sound. And because Core-Fill 500™ fills the core space completely, condensation issues and air infiltration through the cores are virtually eliminated. These superior performance characteristics combined with ease of installation provide the ultimate precast hollow-core insulation system.