• Commercial Spray Part 1: What is Commercial Spray?
• Commercial Spray Part 2: What You Will Need
• Commercial Spray Part 3: How to Do It

Site Considerations:

Assure proper electrical power supply for machine and pump, clean water for mixing glue adhesive and sufficient lighting.

Ambient temperatures should be above freezing (34 degrees F. or 1 degree Celsius), during the spray application and curing time. If required, use a non-vapor producing heat and adequate ventilation to ensure proper drying and curing. (Note: in enclosed areas a minimum of 3 air changes per hour are required during installation until product is properly cured).

Substrate Preparation:

All surfaces and substrates must be evaluated to determine if they are suitable for this application. The surfaces must be free from loose paint, dust & dirt, oil, or other deteriorating substances that would affect a good bonding, adhesion and preventing bleed-thru or staining. Wood and painted surfaces require sealing.

Cleaning the substrate surfaces can be accomplished with pressure washing, sandblasting or vigorous scrubbing with manufacturers approved cleaning solutions (i.e. TSP/ tri-sodium phosphate).

Check adhesion with duct tape and/or actual sample of diluted adhesive by brushing on test area, allowing to dry and checking bond strength.

Equipment set-up:

1.) Locate machine, glue pump, mixing barrels, fiber supply, and adhesive concentrate within close proximity of application site to reduce long runs of fiber and pressure hose.

2.) Connect appropriate power supply to the machine and pump assembly. Note: the fiber machine will need a separate power supply from the pump.

3.) Set-up ¾ ‘intake hose’ to lower pump manifold quick-connect fitting and connect to ¾” PVC rigid pick-up tube with external filter attached. This ‘rigid’ pick-up tube assembly is mounted to the glue barrel lid so that this assembly can be quickly re-moved from glue barrel during spray-on process and inserted into the pre-mixed second barrel with minimal interruption to the spraying process.

4.) Connect by-pass hose to pump manifold quick-connect fitting (located above the intake hose connection) and insert into hole at top of barrel lid. This fluid by-pass hose will keep the glue mixture in a constant mixing and suspension state while performing the spraying process.

5.) Attach the high pressure glue hose to the upper connection on the pump manifold adjacent to the ball shut-off valve and pressure gauge. (Note: be sure to connect ‘thru-flow’ connection to fitting at pump and ‘auto shut-off’ connection to spray nozzle head. This feature allows for quick removal of spray head without shut-off at pump).

Equipment Clean-up & Storage:

1. Before disconnecting power from machine, remove fiber from machine by blowing out remaining fiber. Select ‘air only’ with blowers on high to clean out machine airlock and hoses.
2. Follow manufacturer’s recommendations for properly storage or disposal of un-used glue adhesive.
3. Insert glue pick-up tube into a 5 gallon bucket of warm soapy water or several gallons of soapy water mixture in the glue barrel. Circulate a few gallons of warm soapy mixture thru pump, pressure hose, and spray nozzle to thoroughly clean all glue residue from internal spray components.
4. Use compressed air to blow into the pick-up tube of pump while pump is running to completely discharge water solution from pump and hoses. Store the pump system and hoses in an area that is above freezing to avoid any potential damage from freezing moisture remaining inside spray components.
5. Use a soft bristled brush to clean all glue residue from the exterior surfaces of the glue barrels, pump assembly, hoses, and spray nozzle.
6. Store all hoses, remote cord, and power cords on hose reels or other appropriate means to extend life of hoses and power cords.

Machine and pump settings: Note: Machine models will have different settings depending on the fiber supplier’s recommendations.

General Settings:

1.) Feed gate setting is closed at least ½ of full production capacity to allow a slow metered control and saturation of the fiber/glue mixture.

2.) Blower speed control should be as high as tolerable (without deflection of fiber/glue mixture), to allow for maximum impact and adhesion to prepared surface. Air speed setting will be at 50% or higher depending on machine model and spraying speed. Higher velocity air will make the fiber feed pattern from spray nozzle more ‘fluid’ and provide a smoother surfaced spray. Excess air will cause the fiber/glue mixture to deflect from surface and create excessive fall-off and wasted product.

3.) Pump setting should be around 180 p.s.i. to 220 p.s.i., depending on desired spray speed, quantity and size of nozzle jets. The brass hexagon shaped handle adjacent to the pressure gauge can be rotated clockwise or counterclockwise to adjust pressure on gauge.

4.) Once a starting point adjustment has been established, the operator will need to evaluate settings for air, fiber feed rate, and adhesive volume. Consideration must be given to fiber characteristics, adhesive and speed of application. Consult a fiber/adhesive supplier (or Cool Machines) for more information on settings and on-site training.

Getting Started: (Important: All systems should be set-up and tested at home warehouse location before setting-up on job-site).

• Be sure all surface preparation and masking/covering of vital areas to be protected is completed. (i.e. sprinkler heads, electrical devices, sidewalls, windows, etc.)

• Be sure to have appropriate respirator masks, eye protection, gloves, hard hats, paper coveralls to protect clothing and other items that would meet job-site safety requirements.

• Outfitted tool box with tools for troubleshooting machine, pump, and accessories.

• Specialty items for jobsite use:

• Extra spray tips.
• Extra in-line glue filters.
• Lights, fans & heaters for ventilation and curing of sprayed fiber, scaffold & man-lifts for reaching ceiling areas.
• Power cords for machine, pump, glue mixer, lights, etc.
• Tooth-picks for unclogging nozzle tips.
• Long handle screwdriver or paint stick to remove fiber nozzle clogs.
• Wire depth gauge for checking sprayed fiber depth.
• Masking and covering materials (i.e. poly drop cloths) to protect unwanted glue adhesive from surfaces.

• Adjust machine fiber feed-rate, blower air, and pump pressure to recommended settings.

• Load hopper with first bag of fiber.

• Pre-mix first barrel with glue concentrate and water. (Consult manufacture’s recommendations). Let pump run for 5 mins. to help recirculation of glue mixture through bypass hose in barrel.

Adhesive Mixing: Mix the adhesive with clean, potable water according to the manufacturer’s recommendation. Manually or mechanically mix the solution briefly, then allow adhesive pump to recirculate the water/adhesive mixture for a few minutes before starting to spray.

• Prime pump with glue by running pump, opening and closing the spray nozzle ball valve a few times and getting pressure to proper level on the pressure gauge.

• Always turn on fiber machine first, then turn on glue pressure when fiber begins to exit nozzle in a steady stream.

• To check for proper amount of glue… grab a hand full of sprayed product from surface and squeeze tight. You should be able to get several drops of glue from fiber to assure proper saturation of fiber/glue mixture.

Spray Technique:

1. Hold the spray nozzle at a right angle (90 degrees) to the plane surface and about a distance of 18” to 24” from the sprayed surface.

Note: Nozzle ‘too close’ to surface will cause excessive fiber deflection from the surface. Nozzle ‘too far’ from surface will cause excessive fall-off, poor density and compaction resulting in premature product failure.

1. Move the spray nozzle in parallel strokes to the surface allowing the fiber to build up in one pass ‘or” multiple rapid passes moving the nozzle in small forward increments to allow total thickness build-up layer at trailing edge of nozzle. (spraying depth up to 2” maximum).

If greater depths of 4” to 5” inches are desired; a second layer will need to be sprayed after partial drying and curing of the first layer is accomplished.

Note: Thicker layers can be achieved in the first spraying application with highly experienced spray professionals and will require careful adjusting and monitoring of machine, and glue adhesive. This is not recommended for beginners!

1. An over-spraying of the recently sprayed area with the glue adhesive only (no fiber), may be preferred to reduce failures and seal the surface before moving the scaffold to a new area for spraying.

Spraying Recommendations:

• On concrete and other porous surfaces; pre-wet an area with adhesive/water mixture (approx. 100 sq.ft.). Then begin the spray fiber application with smooth, even, side to side passes to required thickness.
• Tamping the surface with a board or pressing with a paint roller immediately after spraying an area will provide a smoother surface and better compaction. Over-spray surface with glue adhesive to provide a better seal.
• To check for proper amount of glue… grab a hand full of sprayed product from the surface and squeeze tight. You should be able to get several drops of glue from fiber to assure proper saturation of fiber/glue mixture.

Troubleshooting:

Fiber hose clog: If a fiber clog occurs at spray nozzle, shut-off adhesive at the ball valve on the spray nozzle. Remove the spray nozzle from end of a hose and use a long handle screwdriver or paint stick and ram-rod fiber from the nozzle. (Reverse direction as fiber enters the nozzle). Turn the machine ‘air only’ on to purge the hose of any further clogs and re-attach spray nozzle. Note: The fiber feed gate on the machine may have to be closed slightly to prevent further clogging at the nozzle.

Check for ‘crusty’ fiber that may have been exposed to moisture while in storage.

Spray Tip Clog: Turn off glue at the ball valve of spray nozzle and use a small ½” open end /box wrench to remove the spray tip. Back-blow the tip with compressed air to remove the clog. If compressed air is not available, use a wooden tooth-pick or a bristle from a corn broom to press the clog from the tip. Be sure to press from the front of the tip to rear to (reverse direction as clog entered tip), to effectively remove. Note: ‘Do not’ use metal items (i.e. wire brush, paper clips etc.) to remove tip clogs. This will destroy the smooth spray tip pattern.

Check for a missing, worn or defective in-line filter. Additional filters may be needed at the end of the pick-up tube, or at the spray nozzle. Old or expired shelf life of adhesive can cause frequent clogging of the filter.

Fiber Waste on Floor: There should only be a light fiber coating on the floor from a properly sprayed application. If this amount is excessive, check the following:

• Faulty spray pattern from spray tips. (Must be an evenly dispersed flat spray pattern).
• Nozzle too close to surface causing excessive fiber deflection.
• Nozzle too far from surface causing poor adhesion and excessive fiber fall-off before fiber impacts surface.
• Air setting too high causing excessive fiber deflection.
• Air setting too low causing poor adhesion and excessive fiber fall-off before fiber impacts surface.
• Uneven fiber metering pattern from spray nozzle caused by faulty airlock seals, low air setting, or fiber feed gate setting too high.
• Poor spraying technique, requiring additional in-field training from certified professionals.

Pump Problems:

• Pump does not prime or maintain constant pressure… check in-line filter, missing gasket or loose filter housing, sucking air from loose intake hose fittings. All connections in the pick-up hose line ‘must’ be air-tight.
• Check for debris stuck in the pressure relief valve assembly. Disassemble the valve assembly and clean. (Be sure to properly assemble all internal components in proper order). This problem can be caused from improper cleaning of pump after each use or faulty or damaged in-line filter.
• Check for faulty or damaged diaphragm seals. Allowing pump to freeze can cause this condition.

• Commercial Spray Part 1: What is Commercial Spray?
• Commercial Spray Part 2: What You Will Need
• Commercial Spray Part 3: How to Do It

Training:

The Commercial spray-on process, like many other acquired trade skills (i.e. spray painting, welding, masonry work), requires training from experienced professionals. To be successful and ‘positively’ promote this industry, we highly recommend on-site training or manufacturer’s sponsored certification before attempting this venture on your own. Various time-saving procedures, surface preparation processes and application skills can be effectively conveyed with proper instruction. This will result in reduced labor costs, prevent the possibilities of product or equipment failure and promote good will with your customer.

Contact Cool Machines for information on qualified trainers.

Equipment Requirements:

Blowing machine: An all-fiber ‘airlock’ blowing machine that provides a smooth, uniform spray pattern and sufficient air velocity to ‘stick’ the fibers to vertical and overhead surfaces. The texture, density/coverage and smoothness of spray can be affected by various features of the machine. A few examples are: fiber conditioning technology in the main hopper (‘scalping augers’), airlock feeder speed (r.p.m.), and the consideration of high speed shredders. Both the geometry of the high speed shredder blades, and direction or rotation can enhance the finished results when applying commercial spray fibers. Since diverse fibers have different responses to the spray-on machine operation, these elements along with the contractor’s budget are an important consideration in ‘the complete commercial spray-on machine’ that offers versatility and performance.

Pump system: A pump and motor assembly (typically diaphragm style), providing sufficient volume (3 g.p.m. or greater) and pressure (300 p.s.i. or greater), to spray a viscous glue adhesive in a smooth spray pattern thru a pressure hose up to 200 ft. in length. (Note: longer distance spray applications require higher pressure capabilities from pump and/or larger diameter glue hose to minimize pressure drop).

Commercial Spray Nozzle: A light-weight (aluminum or plastic) spray head nozzle that connects to the end of blowing hose and combines the blown dry fiber with pressurized spray adhesive. The ‘flat’ nozzle spray pattern for dry fibers allows maximum surface exposure of fibers and dispersal into the ‘flat’ liquid spray pattern from the surrounding glue tips. The nozzle and spray tip geometry assures a homogeneous mixing and encapsulation of the fibers as they impact the surface. (Note: The nozzle head should have multiple tip locations for mounting tips in a symmetrical and balanced spray pattern). Various sized tips are available to provide the required amount of glue adhesive for this application. (Consult a fiber and glue supplier for recommendations).

Glue/Water Barrels: A heavy duty plastic barrel (stackable for convenient shipping and storage), with sufficient capacity to allow un-interrupted spraying for 20 to 30 minutes. (45 gallon to 50 gallon capacity). A removable lid is needed to allow access at top of barrel for pre-mixing batches of glue concentrate and water. The lid provides a protection barrier from contamination of air borne fibers on the job-site. An externally accessible in-line filter is available with the hose kit (described below) to prevent clogging of the spray tips and allow for easy access and cleaning on job-site. Two (2) barrels with removable lids are recommended. One (1) to allow pre-mixing batches of adhesive while the other barrel is used for ‘in-process’ spraying. Quick-connect intake and bypass hoses are connected to the pump and lid assembly of barrel to accelerate set-up and troubleshooting time.

Hoses:

Fiber Hose:

An industry standard corrugated PVC hose up to 200 ft. in length. The hose should be reduced at machine to the desired inside diameter to connect with spray nozzle. (Common sizes are 2” or 2.5” hose diameter). Reducing the hose diameter at the machine promotes easier handling of the hoses over long distances. A larger hose can be reduced gradually to offer similar performance but may be heavier and more awkward to handle on lift platforms and scaffold.

Fiber Nozzle Connector Hose:

An appropriately sized hose (same as nozzle diameter and about 12 ft. long), that connects from the standard duty hose above and connects to the spray nozzle. This hose is designed for ultra light weight, maximum flexibility, for hours of easier handling (especially in overhead applications), by the spray contractor.

Pressure Hose:

High pressure (300 p.s.i. to 500 p.s.i. rated) durable glue/adhesive supply hose connecting from pump to spray nozzle. Thru-flow quick-connect fitting at pump and auto-shutoff quick-connect fitting at spray nozzle end of hose, offers easy set-up at the job-site along with quick access for nozzle removal and cleaning without a mess. Pressure hose is available in various lengths and diameter to provide adequate glue supply for long distance spraying (over 150 ft.) and assure minimal pressure drop at the spray nozzle for coating of fibers.

Hose Kit: (for glue barrel and pump hook-up)

Includes quick-connect fittings for attachment to pump and matching fittings for hose. This feature allows for speedy set-up of barrel/pump intake and bypass hoses, non-collapsible intake hose with rigid PVC stand pipe for insertion into barrel lid, bypass recirculation hose, and # 80 mesh in-line filter to prevent nozzle tip clogging caused by solid particles in the adhesive.

Optional: (Time-Saving Accessories)

Wheel Dolly System: for convenient moving of spray pump and glue barrel to different job-site locations. (Note: Machines are also available with optional wheel dolly systems for easy moving and handling on job-site).

Glue hose: ¼”, 3/8”, or ½” diameter hose in varying lengths. (Note: long distance pressure hose applications, in excess of 150 ft. require a larger diameter hose considerations to reduce pressure drops from pump to spray nozzle). Length of hose and ease of handling need to be considered when selecting the diameter of hose. (Suggestions: 1/4” dia. up to 150 ft.; 3/8” dia. up to 200 ft., ½” dia. = 200 ft. and greater).

Hose Reels: A time-saving solution for the fiber and pressure hose set-up and disassembling on the job-site. The hose reels also prolong the life of the hoses by eliminating the twisting and mistreatment of the hose under normal handling and storage conditions.

Wireless Remote: For cordless control of the machine functions from over 300 ft. distance. This feature saves set-up and dismantling of the cord on the jobsite while offering more freedom of movement while on scaffold and lift platforms.

• Commercial Spray Part 1: What is Commercial Spray?
• Commercial Spray Part 2: What You Will Need
• Commercial Spray Part 3: How to Do It

Definition:

A blended spray-on application of dry fibers merging with a pre-mixed adhesive to a properly prepared surface. This spray application is a combination of fiber and glue adhesive providing a monolithic coating on vertical and horizontal (overhead) surfaces that will remain exposed without additional covering treatments. This application must be impacted in a steady, uniform spray pattern with sufficient blowing air velocity and glue pressure to assure a long lasting, durable and aesthetic appearance. The end result of this process provides a semi-hard, crusty, textured, durable surface treatment offering effectively designed attributes of sound attenuation & high ‘R’-factor insulation.

Properties:

A semi-hard interior surface coating or covering process that offers superior sound attenuation and thermal qualities. Preferred for coating un-even and non-linear interior surfaces difficult to cover with batt and board applications. (i.e. corrugated metal siding/decking, structural supports, wood, glass, masonry, etc.). An ideal solution for sound / movie studios, theaters, and noisy environments like offices, restaurants and public meeting halls. The resulting semi-smooth surface can be further improved by additional spray treatments to offer choices of color, texture, and enhanced sealing characteristics.

Product manufacturers and suppliers offer choices of materials in Fiberglass, Cellulose, Rockwool, and other specialty fibers for spray application to surfaces. These suppliers provide the fibers in combination with recommended adhesive products that have been tested and approved with their fibers and application techniques. (Note: Be sure to follow all manufacturers’ recommendations in the preparation and application of this commercial spray-on process. Proper surface cleaning and preparation is very important before proceeding with this spray-on application).

Product considerations when choosing a supplier: color, finished surface treatment, warranty, and quality/cost comparisons.

Contact Cool Machines for fiber/adhesive suppliers if needed.

Sometimes it can be difficult to provide the exact settings of machine and water pump pressure because the (air, feed rate, and water pressure), can change due to humidity, length of hoses, different manufacturers fiber characteristics, etc.

I will try to explain the "general concepts" when performing wall spray applications with the CM-1500 machine.

Important: Be certain "all floors" are swept very clean so that no objects pass thru machine when collecting the recycle from floor.

1.) Adjust pump pressure to 350 p.s.i (#25015 tips).

2.) Open the slidegate setting to 2/3 open (‘locking pin’ in 8th hole open).

3.) Turn both blowers to #6 or #7 on the blower control dial.

Note: these are approximate settings to start process. Further adjustments can be made after spraying the first 5 minutes or 3 to 4 wall cavities.

4.) Turn ‘on’ machine system and blow 1 bag of fiber on floor with water spray "on" to create some damp recycle. (Empty machine)

5.) Collect recycle in a 30 to 35 gallon plastic barrels (trash barrel) and return back to machine. (you will need some brooms and a large scoop shovel to do this).

6.) (Very important):
Layer fiber in machine with about 1/3 barrel recycle (damp fiber), to 1/3 bag of dry compressed fiber from bag. ( The ratio is about 2 parts dry to 1 part recycle /by weight). As you load a few layers into the machine, it helps to perform a little ‘stirring’ action with your hand manually, to help the two materials (recycle & dry) to mix better. This is done in the upper section of hopper to keep hands away from moving parts of the lower hopper.

Note: this layering & mixing action is very important to create a homogeneous or constant blend when spraying the walls. If the fiber comes out of the nozzle for wet and dry intervals, the product will not stick to walls. You have to provide a very ‘even’ mixture at all times when spraying.

When person spraying fiber becomes ‘skilled’, there will be less recycle fiber to return thru the machine. You may have to increase the ‘dry-to -damp’ recycle ratio. With dryer mixture, increase the water pressure since the fiber will have less moisture in the sprayed mixture. Adjust machine to use the recycle you make when spraying. At end of job you should only have one or two barrels of damp recycle to be used on next job, or blown in the attic area.

In General:

Maintain fiber mixture as dry as possible with just enough moisture (water pressure) to make the fiber stick to the walls. The mixture should be slightly darker grey color than the dry fiber from the bag and slightly dusty. (If fiber mixture is a very dark color and heavy/ dense texture, it is probably too wet and the pressure at pump will need to be reduced in 20 p.s.i. to 30 p.s.i. increments.

The air pressure from blowers needs to be turned up as high as possible to provide the high speed and velocity to stick the fiber to the walls at a high density. (Use the air pressure to provide the high impact of the fiber hitting the walls not higher water pressure). If the air pressure is turned up ‘too’ high and the fiber bounces off the walls, reduce air pressure settings on the blower control slightly.

7.) Begin spraying the fiber mixture, as close to the surface of the wall studs as possible. If excess fiber is sprayed beyond the wall studs, this overhung weight can cause the fiber to fall from the wall cavity and generate excess recycle to be used on jobsite.

8.) Scrub walls immediately following the sprayer to generate recycle for the machine. All of this must be performed in an even rhythm to keep all aspects of this operation flowing in a constant pattern.

9.) After the project has been sprayed and scrubbed, the sprayer may have to go back and perform some ‘touch-up’ fiber spraying to fill in any gaps or low areas so that a high quality application is provided to the customer.

10.) Optional: As a final step, the sprayer can go back over all sprayed surfaces with water spray nozzle at 350 p.s.i. (water only/ no fiber), and quickly overspray all fiber surfaces. When dry, the surface will form a ‘crusty’ harder surface layer that looks good for the customer when pressed with hand into the fiber surface.

Note: The fiber moisture should not exceed 35% moisture content and should be left un-covered for as long as possible to allow the drying process. Usually; 2 to 3 days is sufficient, depending on the thickness of the sprayed walls. 20% to 25% before covering inner walls. Do not cover walls with plastic moisture barriers and avoid oil based paints on the drywall (gypsum board) inner walls. The walls need to ‘breath’ or allow moisture migration.

Spray technique or skill is very important also:

1.) The spray person will start at bottom of wall cavity, (position the spray nozzle 1/2 meter from wall surface at 90 degree angle (perpendicular to the wall plane), or directed slightly downward.
Make sure to hold the nozzle with the water hose on the bottom (not the top).
Move the nozzle back and forth in constant ‘stroke’ pattern (1 second intervals), and slowly step-up in upward increments as the cavity fills from lower section of the nozzle spray pattern.
Important: the sprayer must maintain a very constant spray pattern with a constant rhythm. (similar to spray painting an automobile). This constant 1 second interval stroke pattern will provide additional mixing and blending effect of the sprayed fiber as it contacts the wall.

2.) As sprayer advances to the top of wall cavity, the sprayer needs to change angle of nozzle, directed 45 degrees upward and move nozzle closer to wall to impact remaining crevice with high density packing effect. This will prevent the fiber from ‘sagging’ or forming a gap at the top of the wall cavity.

Hopefully this information offers better details to make your experience successful!

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