Above Grade Wall Systems by Dow

Dow Building Solutions

United States | R E S I D E N T I A L

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Energy Efficiency: A Top PrioritySecond only to the mortgage, a family’s home heating and cooling payments represent the largest portion of most household budgets. So it isn’t surprising that 72 percent of homebuyers indicate that a home’s energy efficiency features most influence their purchase decision. In fact, they would pay almost $9,000 up front to save on utility costs.* Many families are also combining the search for cost savings with a growing desire for “greener” homes that reduce a family’s footprint or impact on the environment.

With rigid and spray foam insulation, and integrated system components from Dow Building Solutions, homebuyers can benefit from value-added, proven, greener solutions that can help reduce energy loss and save money. And homebuilders and re-siding professionals can offer their customers enhanced energy efficiency.

For example, STYROFOAM™ Brand Extruded Polystyrene Foam Insulation and polyisocyanurate insulation from Dow cover the entire exterior wall surface – helping to alleviate conditions that can lead to energy loss, including:• Air infiltration• Moisture intrusion• Thermal bridging through wood framing• Air convection in the wall cavity• Wood frame and mechanical detailing that reduce the amount of

cavity insulation

Demand for High Quality Insulation

The Right Product for the Right Job

Dow offers one of the broadest arrays of rigid foam insulation and other integrated building envelope solutions to fit the specific needs of above-grade applications, regardless of climate conditions.

For new construction and re-siding applications, STYROFOAM™ Brand Extruded Polystyrene Foam Insulation combines exceptional moisture resistance with long-term, stable R-values (R-5.0 per 1”). Polyisocyanurate insulation from Dow offers a higher R-value (R-6.5), with special laminated facers that enhance its resistance to moisture and damage. STYROFOAM™ Brand Spray Polyurethane Foam (SPF) Insulation (RS Series)** creates a solid layer of thermal, air and moisture protection in stud cavities.

For a tight build, it is crucial to consider the home as an overall system that should be insulated and sealed against air infiltration through major areas (walls, floors, and roofs) as well as gaps, cracks and penetrations. In addition to these key insulation products, a host of integrated system components from Dow work together to help protect the home from air and moisture intrusion: GREAT STUFF PRO™ Insulating Foam Sealants and FROTH-PAK™ Foam Insulation kits**, and WEATHERMATE™ Flashings, to name a few.

*Based on 2008 National Association of Home Builders Consumer Preferences Study **Consult the label/instructions and Material Safety Data Sheets carefully before use.

Why Care About Air Infiltration?Air infiltration accounts for 25-40 percent of the energy used for heating and cooling a typical home.* Rigid foam sheathing, such as STYROFOAM Brand XPS™ Brand Structural Insulated Sheathing directly over the studs, can reduce air leakage through walls three times better than housewrap typically installed over OSB sheathing (Figure 1).

Based on ASTM E283 testing detailed in “Tech Solutions 217.0: Air Barrier Performance of STYROFOAM SIS™ Brand Structural Insulated Sheathing vs. OSB and Housewrap” – available at www.insulateyourhome.com

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Bare OSBsheathing

STYROFOAM™ Brand XPS as typically installed

Housewrap as typically installed over

OSB

The Science Behind Air Infiltration

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Understand and Control Energy Loss and MoistureThree flows to remember when insulating and air sealing a home: 1. Heat moves from hot to cold. 2. Air moves from high pressure to low pressure – even through the walls of a house. 3. Moisture moves from high concentration to low concentration – including through the walls of a house.

Air at higher pressure tries to move to areas of lower air pressure. The wind outside, stack effect and the operation of a home’s mechanical heating/cooling equipment can create pressure differences, which cause air movement between the inside and outside of a home.

Effective Solutions from Dow

• Rigid Foam Insulation

• STYROFOAM™ Brand Spray Polyurethane Foam Insulation

• WEATHERMATE™ Housewrap

• WEATHERMATE™ Plus Housewrap

• FROTH-PAK™ Foam Sealant

• FROTH-PAK™ Foam Insulation

• GREAT STUFF PRO™ Gaps & Cracks Insulating Foam Sealant

• GREAT STUFF PRO™ Window & Door Insulating Foam Sealant

Water vapor is similar – moving from areas of high water vapor concentration to areas of low water vapor concentration. Since warm air holds more moisture, water vapor tends to move from warm areas to cooler areas. Air movement also carries water vapor along the air leakage paths in a wall. As it moves through the wall area, water vapor may meet a surface with a temperature lower than the vapor’s dew point. Condensation can result and accumulate in the cavity – compromising the cavity insulation’s performance and causing (initially) unseen damage to drywall, wood framing, and OSB or plywood sheathing.

Rigid and spray foam insulation products from Dow can reduce these flows to save heating and cooling costs and reduce moisture problems.

13% through plumbing penetration

Common Sources of Energy Loss

15% through ducts

31% through ceilings, walls and floors

10% through windows

11% through doors

Air infiltration

Air exfiltration

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Achieve a Tight SealFROTH-PAK™ Foam Insulation is a two-component, quickcure polyurethane foam that fills cavities, such as rim or band joists, for insulation and air sealing. The Class-A rating (flame spread of 25 or less) allows its use in residential wall and crawl space applications.

Designed to fill gaps up to 3”, GREAT STUFF PRO™ Gaps & Cracks Insulating Foam Sealant expands to take the shape of cracks and voids, forming a permanent, airtight and water-resistant bond to vinyl, wood and metal surfaces when applied properly. GREAT STUFF PRO™ Window & Door Insulating Foam Sealant is a one-component, minimal expanding, flexible polyurethane foam. It is exclusively formulated to air seal the gap between a window or door frame and its rough opening.

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In a wall insulated only with cavity insulation, heat moves easily through the studs and wood panel sheathing – lowering the effective R-value of the wall system.

Using rigid foam insulation from Dow covers thermal bridges to significantly improve R-value of the wall assembly – as much as 32 percent.**

Air Convection in WallsHot air rises, and cold air drops. In the wall cavity, air near the warm side of the wall rises, while air near the cool side falls. This rising and falling of air within the wall cavity sets up a circular motion of air called convective looping (Figure 2). This does not involve air leakage into the wall – just air movement within the hollow wall cavity. This circular motion of air in the wall cavity impacts energy efficiency. For instance, when the home is heated, convective looping moves cold air from behind the exterior sheathing to the back side of the drywall. Cold air from behind the drywall causes more heat to be lost through the wall, which causes the furnace to work harder. Convective looping steals heat from inside the house and releases it outside.

What is Thermal Bridging?Wood is a poor insulator. The wood framing in a home creates thermal bridges that allow heat to flow around insulation in stud cavities. In a typical home, thermal bridging through wood framing accounts for about 17 percent of energy loss.*

Rigid foam insulation from Dow is the primary insulation layer for the home to lessen the effects of thermal bridging. It provides a complete, solid layer of insulation on the walls and covers all of the thermal bridges that cannot be insulated by cavity insulation – reducing energy flow through the walls. And it significantly reduces air infiltration. Because it moderates the wall cavity temperature, rigid foam insulation reduces the potential for moisture condensation.

FIGURE 2: Convective Looping In A WallAir movement within the stud cavity reduces the wall’s thermal performance, contributing to energy loss.

WARMINTERIOR

Air near the inside

wall is heated

and rises.

WARMEXTERIORAir nearthe outside wall is heated and rises.

COLD EXTERIORAir nearthe outside wall is cooledand falls.

COLDINTERIOR

Air nearthe inside

wall iscooled

and falls.

Trapped air (insulation) becomes less efficient with movement.

Cool Conditions

Warm Conditions

WARMINTERIOR

Air near the inside

wall is heated

and rises.

WARMEXTERIORAir nearthe outside wall is heated and rises.

COLD EXTERIORAir nearthe outside wall is cooledand falls.

COLDINTERIOR

Air nearthe inside

wall iscooled

and falls.

Trapped air (insulation) becomes less efficient with movement.

Cool Conditions

Warm Conditions

The air convection displaces air trapped in cavity insulation (like fiberglass batts or cellulose), lowering the R-value. But a layer of rigid foam insulation over the wall moderates the temperature inside the cavity. This reduces convection energy loss and increases the insulation value of the wall system.

A layer of rigid foam insulation over the exterior of the wall warms the temperature inside the cavity and reduces the driving force for convective looping. This insulation layer:• Reduces convection energy loss• Increases the thermal performance of the wall system• Increases the home’s energy efficiency• Reduces heating costs

Cool Conditions

Warm Conditions

Warm InteriorAir near the inside wall is heated and rises

Cold InteriorAir near the inside wall is cooled and falls

Cold ExteriorAir near the outside wall is cooled and falls

Warm ExteriorAir near the outside wall is heated and rises

Studs account for 25 percent of the wall surface. Left uninsulated, the wood framing contributes significantly to energy loss known as thermal bridging.

*Dow calculation based on estimated heat loss from typical house.

**Wall assembly R-values calculated using parallel path from ASHRAE

Handbook – Fundamentals, pg. 27.3.

The Science Behind Thermal Bridging

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How Does Dew Point Affect the Wall Cavity?Dew point temperature is determined by relative humidity of the air. Relative humidity is determined by the amount of water vapor in the air at a given temperature. When water vapor in the air meets a surface that is cooler than the dew point temperature, water vapor condenses into liquid. It is common during the year for some surfaces in the wall to be cooler than the dew point temperature. Therefore, it is not unusual for some condensation to occur on surfaces in a wall. Condensation leads to damage when the surface that is wet supports the growth of mold or decay organisms, and it stays wet long enough at the right temperature for the organisms to grow. For moisture to cause damage, three conditions must exist: 1. Prolonged exposure to wetness 2. Material that supports mold/decay organisms 3. Temperature that allows the growth of mold/decay organisms

Take away any one condition and mold/decay cannot occur. Insulated sheathing can take away two of the conditions for mold/decay. First, insulated sheathing can reduce the potential for condensation, which reduces moisture in the wall assembly. Second, insulated sheathing is made from water-resistant materials that do not support mold growth. Your Dow representative can help you determine the right thickness of insulated sheathing based on a dew point analysis.

Adding housewrap to the wood panel sheathing will provide a drainage plane that helps protect the wall cavity from bulk water intrusion.

Building with insulated sheathing not only provides a drainage plane to help protect the wall cavity, it also adds insulating value.

Wind Driven RainAll brick and exterior sidings leak. Behind siding or brick, a moisture-resistant product is needed to manage wind driven rain and other sources of exterior bulk water. When bulk water gets behind the exterior sheathing, it can penetrate the wall cavity. Pressure differentials and capillary forces compound the penetration of water into a wall system.

Insulated sheathing from Dow, installed over the studs, not only insulates the entire wall surface and moderates the stud cavity temperature to reduce condensation and convection, it also can qualify as a waterresistive barrier without the additional cost and labor of housewrap.

Moisture management solutions for windows include WEATHERMATE™ Flexible Flashing, WEATHERMATE™ Straight Flashing and WEATHERMATE™ Sill Pan.

Cool Conditions

Warm Conditions

WARMINTERIOR

COLD EXTERIOR

COLDINTERIOR

WARM EXTERIOR

VAPOUR

REDUCED CONDENSATIONREDUCED CONDENSATION

1 Rigid Foam Insulation’’

VAPOUR

Cool Conditions

Warm Conditions

WARMINTERIOR

COLD EXTERIOR

COLDINTERIOR

WARM EXTERIOR

VAPOUR

REDUCED CONDENSATIONREDUCED CONDENSATION

1 Rigid Foam Insulation’’

VAPOUR

Cool Conditions

Warm Conditions

CONDENSATION CONDENSATION

WARMINTERIOR

COLD EXTERIOR

COLDINTERIOR

WARM EXTERIOR

Plywood or OSB Sheathing

VAPOUR VAPOUR

Cool Conditions

Warm Conditions

CONDENSATION CONDENSATION

WARMINTERIOR

COLD EXTERIOR

COLDINTERIOR

WARM EXTERIOR

Plywood or OSB Sheathing

VAPOUR VAPOUR

Plywood or OSB Sheathing

1” Rigid Foam Insulation

COOL CONDITIONS

COOL CONDITIONS

WARM CONDITIONS

WARM CONDITIONS

The Science Behind Moisture and Condensation

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Control MoistureMoisture from wind-driven rain on the outside – and dew point condensation on the inside – can compromise the R-value of cavity insulation and lead to mold, deterioration and wood rot. Insulated sheathing on the exterior can help protect the home from these moisture sources. Rigid foam sheathings from Dow are closed-cell, and some have special laminated facers for exceptional moisture resistance. They meet the code requirements for water-resistive barriers when installed according to Dow installation instructions for this application. See ICC ESR-2142.

It takes only a small amount of consistent moisture to create problems in a wall.

Build the Right Way

Cavity insulation is most effective when it is installed properly. Even so, several factors can limit the effectiveness of cavity insulation no matter how well it is installed:• Structural requirements and wood framing• Plumbing, electrical junctions and wiring• HVAC ductwork

In contrast, rigid foam insulation over the entire exterior wall surface covers the framing and augments cavity insulation for an energy efficient wall. Insulated sheathing provides a continuous layer of insulation for the building envelope and, in many cases, is the only layer of thermal protection.

Structural requirements may necessitate wood framing more frequently than 16" or 24" on center. This “extra” framing restricts the use of cavity insulation. Insulated sheathing on the exterior reduces thermal bridging through these framing members.

Batt insulation must maintain its full loft to deliver its stated R-value. Insulation that is compressed into tight spaces will deliver a lower R-value.

Plumbing, electric and HVAC ductwork limit the use and effectiveness of batt insulation.

2x6 R20 2x4 1” Foam

Studs $145.02 $84.35

Top Plates $41.89 $27.01

Bottom Plates $20.95 $13.51

OSB $89.30 $89.30

R13 FG -- $101.33

R20 FG $135.47 --

Foam Sheathing -- $153.00

Housewrap Material 38.40 --

Total $471.02 $468.50

Per Square Foot $1.47 $1.46

NOTICE: No freedom from any patent owned by Dow or others is to be inferred. Because use conditions and applicable laws may differ from one location to another and may change with time, Customer is responsible for determining whether products and the information in this document are appropriate for Customer’s use and for ensuring that Customer’s workplace and disposal practices are in compliance with applicable laws and other government enactments. The product shown in this literature may not be available for sale and/or available in all geographies where Dow is represented. The claims made may not have been approved for use in all countries or regions. Dow assumes no obligation or liability for the information in this document. References to “Dow” or the “Company” mean The Dow Chemical Company and its consolidated subsidiaries unless otherwise expressly noted. NO WARRANTIES ARE GIVEN; ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED.

The buyer assumes all risks as to the use of the material. Buyer’s exclusive remedy or any claim (including without limitations, negligence, strict liability, or tort) shall be limited to the refund of the purchase price of the material. Failure to strictly adhere to any recommended procedures shall release The Dow Chemical Company of all liability with respect to the materials or the use thereof. The information herein is not intended for use by non-professional designers, applicators or other persons who do not purchase or utilize this product in the normal course of their business.

NOTICE: Changes to the International Residential Code require the installation of a water-resistive barrier (WRB) within most exterior wall assemblies in residential construction. The following Dow insulated sheathing products qualify as a WRB when installed according to the installation instructions developed for “installation of foam sheathing as a weather-resistive barrier”: STYROFOAM™ DURAMATE™ Plus, STYROFOAM™ Resi-dential Sheathing, STYROFOAM™ Tongue and Groove, STYROFOAM SIS™, STYROFOAM™ Square Edge, STYROFOAM™ Residing Board, DOW™ High Performance Underlayment, THERMAX™ Sheathing, TUFF-R™ and Super TUFF-R™ and therefore do not require the use of a building paper or a housewrap as a WRB. When a WRB is not needed, these Dow foam sheathings may be installed according to standard installation instructions for foam sheathing from Dow. Be sure products and installation instructions meet code requirements for your particular location. Note: WEATHERMATE™ and WEATHERMATE™ Plus Housewraps have already qualified as water-resistive alternatives to the prescribed felt (see Evaluation Reports NER-593 and NER-640 for approved alternative).

STYROFOAM™ Brand Extruded Polystyrene Foam Insulation CAUTION: This product is combustible. Protect from high heat sources. A protective barrier or thermal barrier may be required as specified in the appropriate building code. For more information, consult MSDS, call Dow at 866-583-BLUE (2583) or contact your local building inspector. In an emergency, call 989-636-4400 in the US or 1-519-339-3711 in Canada.

Dow Polyisocyanurate Insulation CAUTION: This product is combustible and shall only be used as specified by the local building code with respect to flame spread classification and to the use of a suitable thermal barrier. For more information, consult MSDS, call Dow at 866-583-BLUE (2583) or contact your local building inspector. In an emergency, call 989-636-4400 in the US or 1-519-339-3711 in Canada.

WARNING: Rigid foam insulation does not constitute a working walkable surface or qualify as a fall protection product.

Dow Polyurethane Foam Insulation and Sealants CAUTION: These products are combustible and will burn if exposed to open flame or sparks from high-energy sources. Do not expose to temperatures above 240°F. For more information, consult MSDS, call Dow at 866-583-BLUE (2583) or contact your local building inspector. In an emergency, call 989-636-4400 in the US or 1-519-339-3711 in Canada.

STYROFOAM™ Brand Spray Polyurethane Foam contains isocyanate, hydrofluorocarbon blowing agent and polyol. Read the instructions and Material Safety Data Sheets carefully before use. Wear protective clothing (including long sleeves), gloves, goggles and proper respiratory protection. Supplied air or an approved air-purifying respirator equipped with an organic vapor sorbent and a P100 particulate filter is required to main-tain exposure levels below ACGIH, OSHA, WEEL or other applicable limits. Provide adequate ventilation. Contents under pressure. STYROFOAM™ Brand SPF should be installed by a trained SPF applicator.

When cured, these products are combustible and will burn if exposed to open flame or sparks from high-energy sources. Do not expose to temperatures above 240ºF (116ºC). For more information, consult MSDS, call Dow at 1-866-583-BLUE (2583) or contact your local building inspector. In an emergency, call 1-989-636-4400 in the U.S. or 1-519-339-3711 in Canada.

When air sealing buildings, ensure that combustion appliances, such as furnaces, water heaters, wood burning stoves, gas stoves and gas dryers are properly vented to the outside. See website: http://www.epa.gov/iaq/homes/hip-ventilation.html. In Canada visit: http://archive.nrc-cnrc.gc.ca/eng/ibp/irc/bsi/83-house-ventilation.html.

FROTH-PAK™ Polyurethane Spray Foam contains isocyanate, hydrofluorocarbon blowing agent and polyol. Read the instructions and Material Safety Data Sheets carefully before use. Wear protective clothing to cover all skin (including long sleeves and hood), gloves, goggles or safety glasses, and proper respiratory protection. Do not breathe vapor or mist. Use only with adequate ventilation per use instructions. The spray foam applicator and anyone within 25 feet of the applicator must use an approved air purifying respirator equipped with an organic vapor sorbent and a particle filter at a minimum. Increased ventilation significantly reduces the potential for isocyanate exposure; however, supplied air or an approved air-purifying respirator equipped with an organic vapor sorbent and a particulate filter may still be required to maintain exposure levels below ACGIH, OSHA, WEEL or other applicable limits. For situations where the atmospheric levels may exceed the level for which an air-purifying respirator is effective, use a positive-pressure, air-supplying respirator (air line or self-contained breathing apparatus). Spraying large amounts of foam indoors may require the use of a positive pressure, air-supplying respirator. Follow all applicable federal, state, local and employer regulations.

Dow Polyurethane Foam Insulation and Sealants

CAUTION: When cured, these products are combustible and will burn if exposed to open flame or sparks from high-energy sources. Do not expose to temperatures above 240ºF (116ºC). For more information, consult (Material) Safety Data Sheet ((M)SDS), call Dow at 1-866-583-BLUE (2583) or contact your local building inspector. In an emergency, call 1-989-636-4400 in the U.S. or 1-519-339-3711 in Canada. When air sealing buildings, ensure that combustion appliances, such as furnaces, water heaters, wood burning stoves, gas stoves and gas dryers are properly vented to the outside. See website: http://www.epa.gov/iaq/homes/hip-ventilation.html In Canada visit: http://archive.nrc-cnrc.gc.ca/eng/ibp/irc/bsi/83-house-ventilation.html.

GREAT STUFF PRO™ Insulating Foam Sealants contain isocyanate and a flammable blowing agent. Read the label and Material Safety Data Sheet carefully before use. Eliminate all sources of ignition before use. Wear long sleeves, gloves, and goggles or safety glasses. Provide adequate ventilation or wear proper respiratory protection. Contents under pressure.

Not to be used for filling closed cavities or voids such as behind walls and under tub surrounds; this improper use of the product could result in the accumulation of flammable vapors and/or uncured material. Failure to follow the warnings and instructions provided with the product, and/or all applicable rules and regulations, can result in injury or death.

Building and/or construction practices unrelated to building materials could greatly affect moisture and the potential for mold formation. No material supplier including

Dow can give assurance that mold will not develop in any specific system.

Printed in the U.S.A. ®TM Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow Form No. 178-00872-0815 CDP

www.insulateyourhome.comFor Technical Information: 1-866-583-BLUE (2583) (English)1-800-363-6210 (French)

For Sales Information: 1-800-232-2436 (English)1-800-565-1255 (French)

In the U.S. The Dow Chemical Company Dow Building Solutions200 Larkin CenterMidland, MI 48674

Maximize Your InvestmentWhen you add a layer of rigid foam insulation to the studs or over wood panel sheathings such as OSB or plywood, you can make the most of your investment. STYROFOAM™ Brand XPS provides three functions in one product: wall-bracing, insulation and a water-resistive barrier. Alternatively, rigid foam insulation from Dow is easy to install directly over studs using let-in bracing or metal strapping to provide the code-required lateral bracing. (Refer to applicable building code.)

Because it helps save energy costs, rigid foam insulation from Dow can pay for itself in the first two years. To add value to your investment, insulate the walls – and entire building envelope – with Dow Building Solutions products.

Installing insulated sheathing from Dow directly over the studs maximizes the wall’s insulation value and provides a level, even surface for the exterior finish.