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25-063
Optimization of Engineering Design Parameters of
Injection Foams for Strengthening Purposes
Ataç Başçetin
Istanbul Technical University, Istanbul, Turkey
Kürşat Hasözdemir
Istanbul Technical University, Istanbul, Turkey
Hüseyin Onur Dönmez
Istanbul Technical University, Istanbul, Turkey
Hasan Çelt
Istanbul Technical University, Istanbul, Turkey
ABSTRACT
Phenolic foams, known for fire resistance, show broader
industrial potential, particularly in mining, through prop-
erty enhancements. Adjustments to the formaldehyde-to-
phenol (F/P) ratio, bio-based additives like lignin, and
nano-silica improve foam strength and thermal stability.
Density modifications allow foams to range from flexible,
low-density forms to rigid, high-density supports. In min-
ing, enhanced phenolic foams could reduce coal ignition
risks by acting as oxygen-blocking barriers. Current find-
ings suggest these foams offer viable, sustainable solutions
for safety in hazardous environments. Continued develop-
ment could make them essential for thermal and mechani-
cal applications under extreme conditions. This paper aims
to provide a comprehensive overview of the mechanical
characteristics of phenolic foams, current enhancement
strategies, and standardized testing methods used to evalu-
ate foam properties.
Keywords: Phenolic Foams, Underground Mining,
Spontaneous Combustion, Back-fill
INTRODUCTION
Phenolic foams are increasingly recognized for their supe-
rior thermal resistance and lightweight characteristics,
making them valuable materials in various industrial appli-
cations. Phenolic compounds are widely used in different
products like adhesives and foams. In general, polystyrene
and urethane foams are preferred because of their density
and thermal conductivity but the generation of toxic gases
during combustion has led to phenolic foams potentially
replacing these foams. In addition, phenolic foam is one
of the less expensive polymer foams commercially avail-
able. Phenolic foam is also thermally stable over a broad
temperature range, maintaining performance and stabil-
ity from –196 up to 200C. On the other hand, structural
applications of phenolic foam have been severely limited
because of the inherent brittleness and friability (Ni &
Pereira, 2000).
To enhance the mechanical and physical performance
of these foams, various methodologies have been explored,
including the incorporation of supplementary materials
into the foam’s formulation. Standardized testing protocols,
such as those outlined by ASTM, ISO, GB are utilized to
accurately assess these properties, thereby ensuring consis-
tency and reliability in performance evaluation.
This paper aims to provide a comprehensive overview
of the mechanical characteristics of phenolic foams, current
enhancement strategies, and standardized testing methods
used to evaluate foam properties. Special emphasis is placed
on the role of phenolic foams in the mining industry, par-
ticularly in addressing coal spontaneous combustion risks.
Production of Conventional Phenolic Foams
To understand the applications and properties of phenolic
foams, it is essential to first explore their fundamental com-
ponents and production methods, as these factors greatly
influence the final characteristics of the foam. Basic com-
ponents of phenolic foams can be listed as:
Resin (phenol-formaldehyde)
Surfactants
Blowing agents (for foam formation)
Curing agents (to solidify the foam)
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