Continuous Spray Foam Insulation & Weather Barriers

www.icynene.com

Continuous Insulation And Weather Barriers

http://www.icynene.com/

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SECTION 1• Section 1: Codes Evolution – Building Envelope

• Section 2: Thermal And Moisture Control Requirements

• Section 3: Fire Safety

• Section 4: Integrated Solutions

• Section 5: Commercial Fire Testing

• Section 6: Health And Safety

• Section 7: Applications

1. Thermal / Moisture Control Requirements• IRC (Section 806.5 & Chapter 11)• IECC• ASHRAE 90.1

2. Fire Safety Requirements• IRC Section 3.16• IBC Section Chapter 26

Code Requirements








• Introduction of 8 climate zones (simplifies need for Vapor Retarders)• Introduction of Classes of Vapor Diffusion Retarder (I,II,III)• Class I or II VDR required on the interior in Climate Zones 5 thru 8• HERS Target = 100• Mechanical System Trade-offs allowed

ICC/IECC 2006/7

IRC/IBC Climate Zone

• Airtightness targets introduced (7 ACH)

• Insulation levels increased• Mechanical system trade-offs

not allowed• Insulation levels in Zones 7 & 8

contain proprietary insulation R-values (e.g. R-21 walls)

• HERS Target = 85

Required R-

Values

Zone Ceiling Walls Bsmt.

1 30 13 0

2 30 13 0

3 30 13 5/13

4 38 13 10/13

5 38 20 or 13+5 10/13

6 49 20 or 13+5 15/19

7 49 21 15/19

8 49 21 15/19

ICC 2009 is REQUIRED for States to get ARRA funds.

Feature of ICC 2009

• Airtightness levels decreasing (3-5 ACH)

• Airtightness test being introduced (required on all houses)

• Insulation levels increasing• No proprietary insulation levels• Requirement for continuous

insulation in Colder Zones (Zones 6-8)

• Mechanical system trade-offs not allowed

• HERS Target = 70

Required R-Values


1 30 13 0

2 30 13 0

3 38 20 or 13+5 5/13

4 49 20 or 13+5 10/13

5 49 20 or 13+5 15/19

6 49 20+5 or 13+10 15/19

7 49 20+5 or 13+10 15/19

8 49 20+5 or 13+10 15/19

Effect of Moving ICC 2012

• Airtightness levels decreasing (3-5 ACH)

• Airtightness test being introduced (required on all houses)

• Insulation levels unchanged• HERS Target = 70• Trade-offs allowed provided

performance:

Climate Zone Energy Rating Index1/2 52

3 51

4 545 556 547/8 53

Required R-Values


1 30 13 0

2 30 13 0

3 38 20 or 13+5 5/13

4 49 20 or 13+5 10/13

5 49 20 or 13+5 15/19

6 49 20+5 or 13+10 15/19

7 49 20+5 or 13+10 15/19

8 49 20+5 or 13+10 15/19

Effect of Moving ICC 2015

Higher Insulation LevelsContinuous Insulation Layer

Air Barrier

Commercial 2015 IECC Requirements

Higher Insulation LevelsContinuous Insulation LayerAir Barrier

Required R-

Values

Zone Attic Above Grade WallsBelow Grade

Wall

1 30 20 or 13+3.8 c.i. 0

2 30 20 or 13+3.8 c.i. 0

3 38 20 or 13+3.8 c.i. 7.5 c.i.

4 38 20 or 13+3.8 c.i. 7.5 c.i.

5 4920+3.8 or 13+7.5 c.i. 7.5 c.i.

6 4920+3.8 or 13+7.5 c.i. 7.5 c.i.

7 4920+3.8 or 13+7.5 c.i. 10 c.i.

8 4920+3.8 or 13+7.5 c.i. 10 c.i.


Air Barrier Material Options include most board stock materials along with a variety of proprietary membranes, parging, spray foam, sheet steel or aluminum and other materials that have an air permeability of 0.004 cfm/ft2 (0.02 L/s) @ 75 pa. when tested to ASTM E2178. (IECC Sentence C402.5.1.2.1)

Assemblies must also test with an air leakage not greater than 0.04 cfm/ft2 (0.2 L/s) @ 75 pa. when tested to ASTM E2357, ASTM E1677, or ASTM E 283. (IECC Sentence C402.5.1.2.2)

Joints must be sealed with materials meeting IECC Sentence C402.5.1.2.2.


Section 1403.2 calls for a Water Resistive Barrier. Some building science experts refer to also refer to this as a

“drainage plane” or “Weather Barrier”

Concept is relatively simple—provide a barrier system designed to prevent the ingress of wind-driven rain. In practice this requires a variety of materials, systematically lapped in a shingle fashion to keep inner walls dry and allow outer walls to drain.


International Residential Code 2009

Section 601.3 Vapor RetardersClass I or II vapor retarders are required on the interior side of frame walls in Zones 5,6,7,8 and Marine 4. (so not needed in Zones 1,2,3,4)Exceptions

Basement wallsBelow grade portion of any wallConstruction where moisture or its freezing will not damage the materials

Section 601.1 Class III Vapor RetardersClass III Vapor Retarders shall be permitted where any one of the

conditions in Table R601.3.1 is met.

Vapor Control Requirements

Exceptions to the VDR Requirements








Foam is assumed to be combustible.

The fact that it contains Fire Retardants and other additives does not make it non-combustible.

Testing is required to prove the degree to which it or the assembly in which it is used is non-combustible.

Spray Polyurethane Foam is a Thermoset plastic. Unlike other foams that are Thermoplastics (e.g. Expanded or Extruded Polystyrene), it does not melt as temperature increases.

Fire Safety Basic Principles

Thermal Barriers

Code [IRC Section R316.4, IBC Section 2603.4] prescribes:

• ½” gypsum board

Ignition Barriers

Code [IRC Sections 316.5.3-4, IBC Section 2603.4.1.6] prescribes:

• 1 ½” mineral fiber• ¼” plywood/particle board/hardboard• 3/8” gypsum board• 0.016” thick sheet metal

1. The Code assumes combustible materials such as foam must be covered by a Thermal Barrier.

2. In some applications, not directly connected to the occupied zone, where access is limited, the Thermal Barrier can be omitted and the foam may be covered by an Ignition Barrier.

Code-Prescribed Ignition and Thermal Barriers

Thermal Barriers

Code [IRC Section R316.6, IBC Section 2603.9] prescribes four tests for alternate thermal barriers:– NFPA 286 – FM 4880 – UL 1040, or – UL 1715

ICC-ES Acceptance Criteria -- AC 377 qualifies the approval allowing:– Minimum thickness of coating– Maximum thickness of foam– Based on thicknesses tested.

Ignition Barriers

Code [IRC Section 316.6, IBC Section 2603.9] prescribes no specific tests for alternate ignition barriers only testing based on “actual end use configurations”

ICC-ES AC 377 provides:– Appendix X test (attics and

crawlspaces)– ASTM E-970 (attic floor)– Appendix E (crawlspaces)– Actual end use configurations

Code-Prescribed Ignition and Thermal BarriersCode References

One prescribed solution [IRC Section R316.4, IBC Section 2603.4] ½” gypsum board

Non-prescriptive (equivalent) TB’s must be approved by room-size fire testing (UL 1715, NFPA 286, FM 4880 or UL 1040). [IRC Section R316.6]

If the coating has been demonstrated to resist temperature rise (via ASTM E119) it can be applied over ANY foam. [IRC Section R316.4, IBC Section 2603.4]

If it has only been demonstrated to remain in place during the room-size testing, the approval is SPECIFIC to the FOAM TESTED. [IRC Section R316.6, IBC Section 2603.4]

Thermal Barriers on ES-Reports

1. Several prescribed solutions [IRC Section R316.4, IBC Section 2603.4.1.6]

• 1 1/2” mineral fiber• ¼” plywood/particle board/hardboard• 3/8” gypsum board• 0.016” thick sheet metal

2. Non-prescriptive (equivalent) IB’s must be approved by testing based on “actual end use configurations”. [IRC Section R316.6, IBC Section 2603.9]

• Attic: AC 377 Appendix X or other end use configurations• Floor of Attic: ASTM E-970 or other end use configurations• Crawlspace: AC377 Appendix X or Appendix E or other end use configuration tests

3. Approval is specific to the foam and coating tested.• Maximum thickness of foam• Minimum thickness of coating

Ignition Barriers on ES-Reports

1. Assembly must be tested and shown to be non-combustible.• NFPA 285: Standard Fire Test Method for Evaluation of Fire Propagation

Characteristics of Exterior Non-Load-Bearing Wall Assemblies Containing Combustible Components

2. Potential Heat of combustibles must be known.• NFPA 259: Standard Test Method for Potential Heat of Building Materials

3. If a fire rating is required across the assembly, the assembly must be assessed in terms of fire rating and temperature rise.

• ASTM E119 - 12a Standard Test Methods for Fire Tests of Building Construction and Materials

Used of Foam in Non-Combustible Assemblies








Formed-in-place: Liquid components that are poured or sprayed in place that expand into a foam plastic material that insulates and air seals.

What is Spray Foam?

Low Density• Half pound (½ lb/cu.ft.)• Open Cell • Soft, flexible foam

Medium Density• Two pound (2 lb/cu.ft.)• Closed Cell • Hard, rigid foam

Spray Foam Differences

Low Density Medium Density

• Evaluated to AC 377 by ICC-ES• Can by used in Types I-V construction• Must be installed by trained installers

Spray Foam Approvals

Low Density• Open Cell (<90%)• Half pound (0.5-1.5 lb/cu.ft.)• Water 100%???

(+blowing agent???)• R 3.7- 4.5 per inch

Medium Density• Closed Cell (>90%)• Two pound (1.5-2.5 lb/cu.ft)• Captive blowing agent

(low ODP but high GWP)• R 6.2-7.0 per inch

Spray Foam Differences (ICC-ES AC 377)

Low Density• High expansion (80:1 or more)• Spray in one pass• Easy to trim• Full fill / scarf off excess in walls

Medium Density• More controlled

expansion (30-40:1)• Spray in 2”-3” layers• More difficult to trim• Typically under-fill cavities

to avoid trimming

Spray Foam Differences… The Rest of the Story

Depends on:

• Design objectives • Application• Available space• Needed R-value• Needed properties.• Cost etc.

Which Foam is Best?








The complete wall assembly needs to be tested for combustibility

Example Assembly Configuration:

Interior5/8” Gypsum Type X6” Open Cell spray foam or 6” closed cell spray foam insulation ½” DensGlass Gold

Exterior

Icynene ClassicNFPA 285 Test for Combustibility

Assembly configuration exampleAssembly Configuration:

Interior5/8” Gypsum Type X6” Open Cell spray foam or 6” Closed Cell ½” DensGlass Gold4” Brick

Exterior

Result: PASSED 1 Hour Rating

NFPA E119 Test for Hourly Rated Assemblies:

Continuous Insulation

Cavity and Continuous Insulation

Cavity and Continuous Insulation

Interior - Exterior

1. Can be used as a whole building insulation and Air Barrier Material. Controls air leakage, interstitial convection and can bond to adjacent framing to form an integral part of an Air Barrier System.

2. Can be used as part of design strategy to limit wetting and allow drying of assemblies as part of a Durability Plan.

3. Can be used as a Vapor Diffusion Retarder (VDR).

4. Can form a key element for a Water Resistant Barrier system.

Why Choose Spray Foam?








• High Pressure Foam• Truck Based Spray Rigs• Product sold in “sets”—two 55 gallon drums (A-side

“ISO”, B-side “Resin”)

Applications

• High Pressure Equipment (1000 psi +)

• Reactive Components• Aerosolized particles• Trace VOC’s• Unique Product Characteristics

Spray Foam Training / Safety

• All foams are not the same. The material selections on the B side make foam systems very different. ISO’s are not compatible from system to system or from one manufacturer to the next.

• Resin dictates physical properties (rise, yield, operating temps, water absorption etc.)

• Not only are formulations different, but also, approvals vary between manufacturers.

A-Side (ISO) B-Side (Resin)

Isocyanate

Polymeric MDI (pMDI)

Polyols

Catalysts

Surfactants

Flame Retardants

Water

Blowing Agent

Foam is NOT Foam

General:

1. Confine workspace.• Turn of HVAC• Block/seal inlets/outlets in

work area• Provide barriers to entry

2. Outfit workers with proper PPE.

3. Ventilate during and after spray application.

4. Protect occupants and their possessions.

5. Do work in accordance with best practices

Source: American Chemistry Council

What are We Trying to Achieve?

Important NEW Clarifications:1. If installer ventilates work area at a rate of 1 ACH,

unprotected workers can re-enter after 12 hours.2. If installer ventilates work area at a rate of 10 ACH,

unprotected workers can re-enter after 4 hours. 3. If installer ventilates work area at a rate of 40 ACH,

unprotected workers can re-enter after 1 hour.

Important NEW Clarifications:3. Specific manufacturers have approved products

that if used and work area is ventilated at 40 ACH, area can re-occupied after 2 hours. CHECK WITH THE MANUFACTURER

Spray Foam Safety –Installers

Spray Foam Safety –Everyone Else








LD OR MD FOAM IN CAVITY SPACESThermal Barrier required on interior IRC R316.4, IBC 2603.4• Foam in wall cavity tested to NFPA 259 IBC 2603.5.3• Types I-IV More than one storey wall assemblies must be

tested to NFPA 285 and ASTM E119 IBC 2603.5.1-5

Exterior Walls Above Grade

MD FOAM CONTINUOUS ON EXTERIOR• Transition membranes at windows, control

joints, thru-wall flashings, etc.• Sealants and single component foams at

penetrations and small gaps for touch-ups etc.

Continuous Medium Density Foam

• Foam in wall cavity tested to NFPA 259 IBC 2603.5.3

• Types I-IV More than one storey wall assemblies must be tested to NFPA 285 and ASTM E119 IBC 2603.5.1-5

Complex Construction

LD OR MD FOAM TO PROTECT STRUCTURE AND/OR SERVICES• TB may be required over garage• Keep plumbing and mechanicals

within the conditioned boundary (heating climates)

Cantilevered Floors

• Thermal Barrier required on interior (1/2” drywall minimum or 5/8” Type X for rated assemblies.)

• Wall Cavities – Up to 6” foam in wall tested/approved

• Continuous Exterior – Up to 5 ½” MD foam on ext. tested/approved

• Transition Membranes – tested for compatibility, detailing specific to products/manufacturer.

• Non-combustible cladding

Summary of Typical Components ofAbove Grade Commercial Assemblies

• Increasing Insulation Levels

• Use of Continuous Insulation in all Climate Zones

• Avoidance of the Need for Vapor Diffusion Retarders by choice of materials and / or details.

• Use of LD foam as Insulation, Air Barrier, Vapor Control (control of wetting/drying)

• Use of MD foam as Continuous Insulation, Air Barrier, Vapor Diffusion Retarder and Water Resistive Barrier.

Summary of Trends

Continuous Insulation And Weather Barriers

Questions?Thank You for Attending!

This concludes the American Institute of Architects Continuing Education System Program

www.icynene.com

AIA PRESENTATION IS NOW OVERThe AIA presentation is officially over and attendees are now allowed to leave. Credits will be posted and certificates will be emailed within one

week of today’s date.

We would like to welcome anyone to stay for a further presentation to learn more about Icynene.

Thank you for participating. The official AIA course is now complete.

So why choose Icynene spray foam insulation?

Why Icynene?Our challenge is to go beyond the building regulations and offer much more to our customers. Available in more than 30 countries, Icynene was the first manufacturer to offer innovative spray foam products that do not contain harmful gases or formaldehyde. Our commitment to quality and innovation is recognized globally.

• Multiple commercial products meet the performance criteria of ASHRAE 90.1• Commercial Fire Tested to meet a large variety of NFPA 285 Wall Assemblies• Three open cell and two closed cell SPF products to meet a variety of commercial applications. Unique new closed cell water blown product. • Closed-cell products are deemed water resistant for commercial applications as approved by FEMA.

Industry’s Finest Customer Service 400+ Installers In North America

Our Product PortfolioCLASSIC• Soft, flexible composition

maintains an air seal even after seasonal expansion/ contraction of building assembly

• Vapor permeable, supports bi-directional drying of assemblies

• Ideally suited for interior roof deck commercial applications.

• Approved for construction types: I, II, III, IV, V

• R-value of R3.7 per inch

Our Product Portfolio

• APortion of the polyol formula has been substituted with castor oil to reduce the need for petroleum-based polyol

• Vapor permeable, supports bi-directional drying of assemblies

• Approved for construction types: I, II, III, IV, V

• Open-cell, light density 0.5 lb. spray foam insulation material

• R-value of R3.7 per inch

• Offers the best in class R-Value: R-4 per inch

• Achieve R-22 in a 2 x 6 wall assembly

• Higher density foam - 0.7lbs/ft3• Ideal for use on a broad range of

substrates, temperatures, and humidity conditions

• No limitations of thickness per pass• Provides code compliant assemblies

for areas requiring higher R-value per inch as per local building codes

Our Product Portfolio

• Highest available R-value - R7 per inch

• One formulation suitable for year round use

• Improved yield for more coverage during application with an average yield of 4,750 board feet

• Higher initial pass of 3” to achieve R21 in one pass

• Standard ‘A Side’, allowing for better inventory control

• Approved for Types I-V Construction

• No ozone-depleting blowing agent, 100% water blown

• No hydrofluorocarbons or• polybrominated diphenyl ethers • Tested in NFPA 285 approved wall

assemblies for more design flexibility• Wide range of cost effective ASTM

E119 tests of rated assemblies for ultimate flexibility

• One hour, two hour as well as three hour fire ratings appropriate for a greater range of structure types

• One formulation with superior adhesion to common building substrates

LIVE BINDER• Comprehensive Architect

resource with:– CAD Details– CEU Courses– White Papers– LEED Details/Summary– Product Sell

Sheets/Specs– Technical Data Sheets

Engineering

Continuous Spray Foam Insulation & Weather Barriers