Airtight Foam Core Panels for Dangerous Gas Containment in Chemical Works – Phosgene Enclosure

It is important to carefully monitor and control the production of chemical phosgene used for polycarbonate manufacture as phosgene is highly toxic in the gaseous state. Typically phosgene is processed in an unsheltered piping system. In case a leak takes place, a siren sounds and workers evacuate the area. Shutdown of operations is done until completion of inspection that may take hours.

Strongwell designed and fabricated the building for Dow Chemical using 3" thick x 24" wide foam core panels and EXTREN® structural shapes

Solution by Strongwell

Dow Chemical is making an attempt to protect workers and prevent costly shutdowns with the first attempt to completely contain the phosgene manufacturing process. The operation is enclosed in a 40' x 40' x 40' fiberglass foam core building in an airtight environment, which contains 200 pipe penetrations. All tests for superior performance were cleared by the structure when it went into service. Strongwell designed and fabricated the building for Dow Chemical using 3" thick x 24" wide foam core panels and EXTREN® structural shapes that provided a support system for the structure.

Foam core panels were chosen over corrugated fiberglass panels as the tongue and groove assembly provides a complete seal. Furthermore the insulating features of 3" foam core panels contain possible phosgene leaks much better when compared to alternative materials. In order to provide for pipe penetrations, holes were cut in the panels, with EXTREN® sheet, caulking and epoxy used to seal around pipes. Walkways of DURADEK fiberglass grating are provided on the fiberglass foam core panel roof to provide workers access to vessels atop the roof.

The foam core panels pultruded with fiberglass provide a corrosion resistant structure that is highly rigid and strong. It was designed for withstanding 140 miles/h hurricane winds on the Texas Gulf Coast.

foam core panels pultruded with fiberglass provide a corrosion resistant structure that is highly rigid and strong

Technical Data

Product: Phosgene Enclosure
Process: Pultrusion
Materials: DURASHIELD® Foam core building panels, fiberglass reinforced vinyl ester
EXTREN® Series 525 fiberglass reinforced polyester, fire retardant
Sizes: DURASHIELD® Panels:
1" thick x 12" wide & 3" thick x 24" wide
User: Dow Chemical

About Strongwell Corporation

Strongwell Corporation is the world’s largest pultruder of fiber reinforced polymer composites. Strongwell’s FRP products were chosen as solutions in many different markets. For the mining industry, the company offers operating platforms, conveyor drip pans and platforms & walkways.

Strongwell Corporation design, manufacture, fabrication and testing of molded or pultruded fiber reinforced polymer composite products for construction, commercial and industrial applications.

Strongwell has been pultruding fiber reinforced polymer composite structural products since 1956. Today, with more than 65 pultrusion machines and 647,000 square feet of manufacturing space in three plant locations, Strongwell has unequaled capacity, versatility and flexibility to meet the needs of its customers and allied partners. All Strongwell pultruded products are made in the USA. Click here to learn how Strongwell’s pultruded products out perform traditional materials.

The company is financially strong, quality oriented, technically advanced, and customer focused. Strongwell's customers include Fortune 500 industrial and commercial firms, major architectural and engineering firms, leading contractors and distributors, and many other companies - both large and small - in a variety of markets.

This information has been sourced, reviewed and adapted from materials provided by Strongwell Corporation.

For more information on this source, please visit Strongwell Corporation.

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