FOAM INSULATION - Continued
Foaming Panels of Full Height.
After removing the damaged panel, cut battens from the proper density foam block. The
battens should be 2 inches (50 mm) wide and exactly as deep as the original foam. Overall height of
the battens should be 12 inches (300 mm) shorter than the height of the cavity being filled. The
number of battens to be used depends on the width of the panel section repair. Battens should be on
12 inch (300 mm) centers (approximate).
Apply two component polyurethane adhesive full length to the 2 inch (50 mm) side of
each batten, and press into position against the inner panel on 12 inch (300 mm) centers, leaving 6
inches (150 mm) above and below.
Close the patch with prepared panel. Support the panel on both sides using plywood
sheets 1 inch (25 mm) thick cut to fit the panel. Use mechanical or hydraulic means to achieve the
Drill two 1/4 inch (6 mm) vent holes through the plywood and panel 3 inches (75 mm)
down from the top of the panel at the upper outside corners of the repair; drill one hole large enough
to fit the injection nozzle centrally between the two vent holes.
Prepare the proper density foam according to manufacturer's recommendations. Inject
the foam into the cavity until the foam escapes from the vent holes. Temporarily plug holes.
After curing in accordance with manufacturer's instructions, remove supports, clean the
surface and close holes by welding, riveting or filling, depending on material.
This task covers:
a. Straightening b. Partial Replacement
General Mechanics Tool Kit (Item 1, App B)
Polyurethane Adhesive (Item 1, App E)
Welding Shop, Trailer Mounted
Refrigeration unit shutdown (TM 9-4110-258-13)
The following limitations apply when repairing an aluminum "T" floor.
Cuts to remove damaged sections should be made with a disc cutter.
Longitudinal cuts should be made in the middle between "T" section webs.
Lateral cuts must cut through the base metal.
Wet and damaged foam must be removed down to the subfloor.
All welding must be MIG or TIG using appropriate filling material.