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SPRAY POLYURETHANE FOAMS -PROPER APPLICATIONS AND

CODE COMPLIANCE

MWBO Association Westborough, MA5/16/17

WELCOME

Presenters from BASF Corporation Jim Derrigan, PE - Territory Sales Manager25 years in construction industry

Kelly Frauenkron, LEED BD+C - National Account Manager18 years in spray polyurethane foam industry

Expertise in residential and light commercial insulation applications

Code compliance, building science, and proper applications

BASF CorporationWorld’s largest chemical company with chemistry in nearly every industry

Globally over 112K employees with over 17K in North America

Thank you to MWBOA for supporting and coordinating this event.

LEARNING OBJECTIVES

After completing today’s course, you should be able to identify: Different types and physical/performance properties of spray polyurethane foam (SPF) used in residential and commercial construction (including open & closed-cell)

Benefits and features of using SPF for residential and commercial construction, including sustainable attributes and compliance to stringent energy efficiency requirements

Various areas of the residential and commercial building envelope where SPF is best used and discuss the preferred type of SPF for each area.

Building code requirements of foam plastics and how these products meet compliance, for construction and safety practices

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SAFETY FIRST - RESPONSIBLE CARE POLICY

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SPRAY POLYURETHANE FOAM:BASIC CHEMISTRY & PROPERTIES

Basic Facts – What you need to know!

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WHAT IS SPRAY POLYURETHANE FOAM (SPF)?

High-performance spray applied polyurethane foam insulationProvides an air seal, moisture and condensation control, plus other potential benefits depending on the type of SPF material

Foam expands away from the substrate creating foam insulation, air sealing, and moisture resistance, in a single application in 5-10 seconds

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A & B COMPOSITION = 1 SET/KIT

A-Side aka “Iso” aka “MDI” B-Side aka “Resin” aka “Polyol Blend”

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Polymeric methylene diphenyl diisocyanate (MDI)

SPRAY FOAM BLOWING AGENTS DETERMINE PHYSICAL PROPERTY

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Low Density Open-Cell Foam:• Uses water as blowing agent which

reacts with A-side to release heat & CO2 gas

Medium/High Density Closed-Cell Foam:• Typically uses HFC-245fa gas

• Non-ozone depleting/EPA-approved material

• 245fa is twice as efficient as a thermal insulator as air with millions of cell structures to form rigid bond

TYPES OF SPRAY POLYURETHANE FOAM

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Low-Density Open-cell (0.5-1.0pcf) Foam

Medium-Density Closed-cell (2.0pcf) Foam

High-Density Closed-cell (2.5-3.0pcf) Foam

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WHAT YOU NEED TO KNOW ABOUT SPF

Closed-cell Spray Foam “2-lb.” density Rigid SPF

High/medium density

Not full wall thickness – difficult to cut Controlled expansion (30:1)

Hybrid system applications

Non-ozone depleting (HFC) chemical blowing agent Millions of tiny closed-cells trap this high-

efficiency gas

R-value = 6.5-7.0 per inch

Offers up to 300% increased structural value (over 2”)

Open-Cell Spray Foam “½-lb” density Semi-rigid spray foam

Low density

Fills up the wall cavity High expansion (100:1)

Shaving required

Water blowing agent Expands & leaves open air pockets

R-value = 3.5-4.0/inch

No structural value

WHAT YOU NEED TO KNOW ABOUT SPF

Closed-cell Spray Foam Air Barrier at 1”

Usually qualified as code defined vapor retarder 1”-2” application = Less than 1 perm

(Class II VR)

Hydrophobic - Difficult for water to absorb (less than 4% water absorption) Water barrier- FEMA Flood Resistant

Offers sound barrier performance only (will not absorb noise)

Open-Cell Spray Foam Air Barrier at 3.5”

Vapor retarder typically required in cold climates 5.5” application = Greater than 10

perms (Not Class II OR Class III VR)

Hydrophobic But can absorb water, up to 40%

Offers sound absorption and barrier performance

OPEN VS. CLOSED-CELL SPRAY FOAM PROPERTIES

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Closed-Cell Foam Open-Cell Foam

Density 2-3 lb. density, rigid foam ½ lb. density, semi-rigid foam

Expansion Controlled expansion (30:1), without full wall thickness, and difficult to cut

High expansion (100:1) filling wall cavity, requiring shaving

R-Value 6.5 – 7.0 per inch 3.5 – 4.0 per inch

Application Pass Multiple pass application(1.5-2” per pass)

Single pass application(up to 6” per pass)

Structural Value Increases racking strength by 300% (over 2”)

None

Vapor Retarder (VR) Class II VR at 2” (1.5” applied = 0.95 perms)

Does not perform as VR(5” applied = 10-15 perms)*VR typically req’d in cold climates*

Air Barrier Air Barrier at 1” Air Barrier at 3.5”

Hydrophobic Less than 4% absorption (approved FEMA Water Barrier)

Can absorb up to 40% water

Sound Barrier/Absorption

Offers sound barrier only Offers sound absorption & barrier

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FROM CHEMICAL MANUFACTURER TO APPLICATOR

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Chemical Manufacturer – A Side & B Side (e.g.,

BASF)

1 “set/kit” =1 drum of A & 1 drum of B

Insulation or Roofing

Contractor/ Distributor

Field Installation & Application

SPRAY FOAM PHYSICAL ATTRIBUTES

Closed-Cell Foam (ccSPF) Less expansion, with a more even surface than OCF

Firm to the touch; will not compress easily

Will not fill full stud cavity when thickness meets R-value

Various colors including: green, purple, dark/light yellow white

Open-Cell Foam (ocSPF) High expansion, with more high & low spots than CCF

Soft & spongy to the touch; can push in to it

Will fill full stud thickness

Will be shaved flush with studs

Typically white or light yellow color, some for attics now tinted

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CODE COMPLIANCEFire Protection, Thermal Performance, Moisture Control, Termite Control

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CODE COMPLIANCE:FOCUS AREAS FOR SPF INSULATION

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Fire Characteristics

Thermal Barrier Requirements/

Exceptions

Ignition Barrier Requirements/

Exceptions

Full-Scale End-Use Fire

Testing

Thermal Performance &

Moisture Control

Unvented Attics

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SPF AND THE INTERNATIONAL CODES International Codes are the baseline code language for Massachusetts State Code IRC = Int’l Residential Code, IBC = Int’l Building Code, IECC = Int’l Energy

Conservation Code

Prescriptive requirements for “foam plastics” are included in each code, separate from “traditional” insulations

Code Sections relevant to SPF in the “I-codes”: State of MA Residential Code uses 2009 IRC currently

Section R316 Foam Plastic in Building Planning (Chapter 3), R318 Protection Against Termites, R806.5 Unvented Attics

State of MA Commercial Code uses 2009 IBC

Chapter 26 Section 2603 Foam Plastic Insulation

State of MA Energy Codes uses 2015 IECC with Stretch code in local municipalities

2015 IRC, IBC, IMC are to be adopted July 2017 with full implementation Jan 2018

ICCInternational Code

Council

CODE COMPLIANCE: ICC EVALUATION SERVICES (ICC-ES)

ICC-Evaluation Services (ICC-ES) ICC-ES has developed Acceptance Criteria (AC-377) for many classes of building products that describe the required material properties.

Evaluates alternative or special approval tests if outside the prescriptive code requirements

Each ICC-ES Report specifies which I-code the product is in compliance with (multiple code versions may be referenced)

AC-377 SPF is listed in AC-377 “Acceptance Criteria for Spray-Applied Foam Plastic Insulation”

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CODE COMPLIANCE:ALTERNATIVE COMPLIANCE REPORTS

All Companies are fully accredited under ISO/IEC Guide 65, General Requirements for Bodies Operating Product Certification Systems, by International Accreditation Service (IAS), an International Code Council (ICC) Subsidiary, and by ANSI International All programs are compliant to Section 1703 of the International Building Code

Each report specifies which I-code version the product is in compliance with Intertek Code Evaluation Services

Produces: Code Compliance Research Reports (CCRR)

IAPMO Uniform Evaluation Services

Produces: Evaluation Reports (ER)

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CODE FOCUS AREA:SURFACE BURNING CHARACTERISTICS I-Code: IBC 2603.3, IRC R314.3ASTM E84 / UL 723 Steiner Tunnel TestHorizontal, massive burner flame for 10 minutes limited to 4” specimen thickness on tunnel ceiling measures: Flame Spread Index (FSI) –speed of flame

Smoke Developed Index (SDI) –optical smoke

Baselines:

Fiber Cement: FSI/SDI is 0/0

Red Oak: FSI/SDI is 100/10020

Class FSI SDI

A (I) ≤ 25 ≤ 450

B (II) ≤ 75 ≤ 450

C (III) ≤ 200 ≤ 450Exterior Roofing

≤ 75 unlimited

CODE FOCUS AREA:THERMAL BARRIER FIRE PROTECTION

I-Code: Thermal Barriers [IBC 2603.4.1.13, IRC R316.4]

All state and model building codes require fire protection (an approved (15-minute) thermal barrier) between foam plastic and the interior occupied space in a building (with special exceptions also listed in the code).

WHY? To allow sufficient time for occupants to escape during a fireAlthough burning SPF will form a char-like layer, initial burning can produce combustible gases which can accumulate & result in a flashover fire involving other combustibles

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CODE FOCUS AREA:THERMAL BARRIERS

What is a thermal barrier? A material, applied between foam plastics (including SPF) and interior spaces designed to delay the temperature rise of the foam during a fire situation and to delay or prevent the foam's involvement in a fire.

Prescriptive Thermal Barrier

Defined as ½ inch gypsum wallboard or (in 2015 IRC) 23/32” wood structural panel or material equal in fire resistance

Approved equivalents/Non-prescriptive thermal barriers

Must perform as well as or better than ½-inch gypsum wallboard in oneof the following fire tests:

Temp. transmission test (ASTM E119), NFPA 275, a fire integrity test (NFPA 286) or by one of the approved full-scale fire tests in IRC Section R316.6 - Special Approval

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FULL-SCALE FIRE TESTS FOR THERMAL BARRIER ALTERNATIVE ASSEMBLIES

Special Approval Tests for Thermal Barriers [IBC 2603.9 / IRC R316.6] NFPA 286 - Contribution of Wall and Ceiling Interior Finish to Room Fire Growth (with the acceptance criteria of Section 803.2/R315.4)

FM 4880 - Fire Rating of Insulated Wall or Wall and Roof/Ceiling Panels, Interior Finish Materials or Coatings, and Exterior Wall Systems

UL 1040 - Safety Fire Test of Insulated Wall Construction

UL 1715 – Fire test of interior finish material

End-use fire tests to allow alternative thermal barriers

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CODE FOCUS AREA:COMMERCIAL THERMAL BARRIER EXCEPTIONS

Commercial SPF Use Requirement and Exceptions: See Chapter 26 – Section 2603.4 for full details of the exceptions

Masonry/Concrete Walls – Certain specific assembliesCooler/Freezer Walls – Certain specific assemblies, limited by size and use of sprinkler systems. Laminated Metal-Wall Panels (one story) Roofing Assembly (passing UL1256) Entry, garage doors

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CODE FOCUS AREA:THERMAL BARRIER EXCEPTIONS

I-Code: Sill Plates and Headers

[IBC 2603.4.1.13, IRC R316.5.11]

Not required to install fire protection barriers in the rim joist area when: Limited to Type V construction, with three requirements:

Class I (Less than 25 Flame Spread) Foam

Max thickness 3.25”

Medium density (2 lb) foam or low density (½ lb) foam – as of 2009 IRC

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CODE FOCUS AREA:THERMAL BARRIER EXCEPTIONS

I-Code: Attics & Crawl Spaces (limited-access)

[IBC 2603.4.1.6, IRC R316.5.4]In unvented attics or where SPF is sprayed on flat ceiling “where entry is made for service of utilities only” (no storage)

As an alternative (lesser requirement) to the thermal barrier, an ignition barrier is allowed to separate attic/crawl space from foam

Thermal barrier (i.e. gypsum) still required between attic/crawl space and occupied space

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CODE FOCUS AREA: IGNITION BARRIER REQUIREMENTS In limited-access, non-storage attics or crawlspaces, a thermal barrier may be replaced by a barrier to ignition, used to protect the foam from accidental ignition, with one of the following prescriptive materials….

Alternative Assemblies by Special Approval Testing – End-Use Fire Tests listed in Specific Approval Section R316.6

Building code officials may accept end-use tests that allow alternative assemblies (such as intumescent coatings, or many foams without coating pass to be left exposed in these limited access areas). ICC-ES reports are typically required to show acceptance.

Material inches

mineral fiber or cellulose insulation 1.5

wood structural panel or hardboard, fiber-cement panel, soffit or backer board 0.25

gypsum wallboard or particleboard 0.375

corrosion resistant steel 0.016

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CODE FOCUS AREA: IGNITION BARRIER FIRE TEST ASSEMBLIES

Alternative Assemblies by Testing – End-Use Fire Tests listed in Specific Approval Section R316.6 Building code officials may accept alternative end-use tests. ICC-ES or Intertek / IAPMO reports are typically required to show acceptance for both alternatives to Thermal or Ignition Barrier applications.

Special Approval for Foam In Attics and Crawlspaces

Spray Polyurethane Foam Alliance (SPFA) committee was formed in 2009 at request of the ICC = raise the bar for testing standards

Established a new test protocol for testing exposed foam and/or ignition barrier coatings over SPF in limited-access attics and crawlspaces = Appendix X

APPENDIX X LIMITATIONS (OR OTHER ALTERNATIVE ASSEMBLIES)

Appendix X of AC377 Acceptance Criteria is generally accepted for alternative applications (exposed foam and/or coatings over foam) to the code-prescribed ignition barriers Limitations of use still exist in accordance with “limited access” restrictions within the ICC, for attics and crawl spaces only: Entry to the attic or crawl space is only to service utilities, and no storage is permitted There are no interconnected attic areas, or crawl space areas Air in the attic or crawl space is not circulated to other parts of the building

If any of the above conditions exist, a thermal barrier (gypsum or equivalent) must be used over ALL spray foam products to provide 15-minutes or equivalent protection.

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REVISIONS TO ICC EVALUATION REPORTS

Interim testing or revisions to ICC Evaluation Reports were no longer applicable and ESR’s would need to be re-issued (as of Feb. 1, 2011)

What to do: Find the most updated reports at www.icc-es.org

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COMBUSTIBILITY OF SPFSPF is an organic material – it will burn! Code requires thermal and ignition barriers in residential and commercial applications to reduce the risk of ignition and flash fire.

Other types of thermal barriers are available in addition to gypsum board: spray-applied cementitious and cellulose materials

portland cement plaster and other proprietary materials

Intumescent coatings (more than ignition barrier thicknesses!)

Thermal and ignition barrier materials should have an ESR or CCRR with report number and validity dates.

Code officials may accept thermal and ignition barriers that have not been evaluated by ICC-ES, on the basis of performance in those generally accepted full-scale, end-use tests.

CODE FOCUS AREA:SPF AS A COMBUSTIBLE MATERIAL

If SPF is a combustible material, then how can we use it in Type I, II, III, & IV commercial construction in exterior walls? IBC Section 603 permits combustible materials in specific applications in Type I & II construction, namely: Thermal and acoustical insulation Foam plastic complying with IBC Chapter 26 Roof coverings having a Class A, B or C classification

IBC Chapter 26 contains specific provisions for using Foam Plastic Insulation in Exterior Walls of Type I, II, III & IV construction Additional fire tests are necessary NFPA 259 & ASTM E84 (Class I) Assembly tests per NFPA 285 and, where applicable, ASTM E119 and NFPA 268

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CODE FOCUS AREA:COMMERCIAL FIRE REQUIREMENTS - NFPA 285

I-Code: Exterior walls of more than 1-story height in Types I-IV

[IBC 2603.5.1]

NFPA 285 is required on all assemblies containing foam plastic insulation, whether on interior or exterior of cavity wall Must be conducted with exact façade and framing, at maximum depth of SPF to be installed Only certain SPF products may be tested and approved in these uses.

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CODE FOCUS AREA:COMMERCIAL / MULTI-FAMILY FIRE REQUIREMENTSHOURLY-RATED ASSEMBLIES

I-Code: Fire-resistance-rated walls

[IBC 2603.5.1]

All code regulated fire-rated construction must comply with an hourly-rated assembly By default, fiberglass and cellulose insulation products ARE allowed to be used in any UL assembly

Foam plastics are NOT ALLOWED by default, and are REQUIRED to have been tested in that exact assembly to allow for use (in accordance with ASTM E 119 or UL 263), otherwise it is not compliant with the design or code

SPF has limited testing within most hourly-rated fire assemblies

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CODE FOCUS AREA:THERMAL PERFORMANCE

I-Code: IBC 1301, IECC 102.1.1, IRC N1102.1, 16CFR Part 460

Thermal performance must be measured by ASTM C518 or ASTM C177 at installed thickness or extrapolated from R-value at representative thickness per FTC rule; Refer to ICC-ESR or technical data sheet Note: R-value is not linear with thickness

AC-377 R-value must be tested at 1 inch and 3.5 inches (or greater, no less), with extrapolation to be allowed for thicker applications based on the maximum tested thickness

Note: Must be aged R-value for SPF, as applicable

GENERALLY - R-value of CCF increases with increased insulation thickness, and R-value of OCF decreases with increased insulation thickness

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CODE FOCUS AREA:MOISTURE RESISTANCE PERFORMANCE

I-Code: Moisture Vapor Retarder [IRC R601.3, IECC 402.5]

IECC and IRC require a Class 1 or Class II vapor retarder on the interior side of frame walls in climate zones to 5, and Marine Zone 4 Exception: Where conditions in Table R601.3.1 are met, Class III is allowed (see chart on next page)

Moisture Vapor Permeance is measured per ASTM E 96 dry cup (method A) Perm units indicate the rate of water vapor transmission through a material at a specified thickness;

Higher perm ratings indicate more water vapor transmission.

2009 IRC / IECC and beyond recognizes three classes of materials: Less than 0.1 perms – Class I vapor retarders = polyethylene Between 0.1 and 1.0 – Class II vapor retarders = kraft paper, ccSPF Between 1-10 perms – Class III vapor retarders = latex/enamel paint, ocSPF

Most closed-celled foams have less than 1 perm at thickness 2 inches (Class II VR)

Open-celled foams are about 4-16 perms at an installed thickness of 4 inches, and require the addition of a vapor retarder to comply with code in climate zones where one is required

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CODE FOCUS AREA:MOISTURE RESISTANCE PERFORMANCE

Moisture Vapor Permeance [IRC R601.3.1 Chart for Class III VR acceptance]

CODE FOCUS AREA:UNVENTED ATTICSI-Code: Attic Spaces and Ventilation [IRC R806.4 / IBC 1203.2 in 2015 I-code adoption]IRC allows unvented attics in all climate zones Air-impermeable insulation requirements (ASTM E283 or E2178) SPF insulation must be in direct contact with the underside of roof Subsequent insulation system must be in direct contact (next slide) SPF insulation must be a vapor retarder (2015 indicates Class II VR), or have one installed over it (Class II VR coating in case of OCF) in Climate Zones 5 or above No vapor retarder on attic floor or to interiorof insulation system Special ventilation for wood shingles Must have ½” air space above roof deck

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CODE FOCUS AREA:UNVENTED ATTIC ASSEMBLIES – COMBOS

I-Code: Attic Assemblies and Ventilation [IRC R806.4] Chart describes the amount of R-value required by the air-impermeable insulation when using a hybrid system with fibrous insulation underneath it Applicable fire protection is still required, with fibrous insulation possibly

providing ignition barrier protection ONLY

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Climate Zone 5: SPF thickness must meet minimum R-20, in a combination (foam/conventional) unvented attic application

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CODE COMPLIANCE: DUCTWORK REQUIREMENTS WITH SPF

I-Code: Duct Insulation Materials [M1601.3] Now allows for SPF to be used in direct contact with ductwork, with conditions:

Foam plastic must be Class1 (25 or less FS, 450 or less SD ratings)

Foam at installed thickness must be less than 3 perms to prevent moisture accumulation (means ccSPF ONLY!)

Foam plastic must be covered with ignition barriers per R316.5.3 / 5.4

Foam plastic must comply with requirements of R314

Eliminates need for additional vapor retarder

Eliminates need for additional joint sealing/caulking

CODE FOCUS AREA:TERMITE RESISTANCEI-Code: Termite Resistance [IRC R320.5] In areas determined to be “Very Heavy” with termite infestation, foam insulations (all types) shall not be used on the exterior of the foundation All foam plastics installed above grade must have a 6” clearance to exposed earth (this includes interior of crawlspaces!) Very Heavy areas include: Most of CA, East half of TX, LA, MS, AL, FL, GA, SC Exceptions for use: Interior applications below grade Where the entire building is built of non-combustible materials or pressure-positive treated wood When an approved method of protecting the foam & structure from damage is used

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SPF CODE COMPLIANCE: ON THE JOBSITE

Product Labeling [IBC 2603.2 / IRC R316.2]Containers on job site shall have manufacturer name, product ID, product listing, suitability for useAlternately,

Installation Certificate [IECC 102.1.1 / IRC N1101.8] – Provided by contractor to builder/homeowner Thickness, R-value and product listing or data sheet Placed on electric service panel or other conspicuous location

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CODE COMPLIANCE WITH INSULATION CARDS

I-Code: IRC N1101.8

Filled out and posted to comply with building code and FTC requirements identifying installed spray foam system

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ENERGY CODE CHANGE DETAILSInternational Code Council (ICC) energy code (IECC) made significant changes to the IECC 2015 vs. 2009 IECC including: 15% improved energy performance vs. IECC 2009

Increase insulation requirements in walls (R-20 or 13+5) and attics (R-49)

Added Air Barrier Requirements with reduction in air changes down to 3 ACH

Mandatory verification of infiltration and duct leakage, with HERS compliance option

Alternative compliance path called Energy Rating Index (ERI), can use HERS

The American Society of Heating, Refrigeration and Air Conditioning Engineers (ASHRAE) sets standards for the mechanical systems and also made significant changes to the ASHRAE 90.1-2010 and 2013 standards. 90.1-2010 requires a 30% energy savings vs. the 2004 version

90.1-2013 requires a 40% energy savings vs. the 2004 version

Cooling Energy Recovery required in CZ 3C, 4C, 5B, 5C, 6B, 7 and 8

CODE CHANGES TO HIGHER R-VALUES / AIR TIGHTNESSOpportunities and Challenges Find ways to bring solutions and other cost savings to your builders

Ensure they are working with a professional HVAC contractor who does the proper sizing (Manual J/S)

Consider closed-cell SPF and/or hybrid systems as a solution to maintaining 2x4 assemblies

Consider reviewing plans for advanced framing opportunities that allow less wood, more thermal and possibly a gain in saleable square footage

Considering utilizing U-factors for attics (continuous around rafters/framing) and/or Raised Heel/Energy Truss credit to drop overall attic R-values

SPF Thermal vs. Ignition Barrier – Code Requirements

SELL THERMAL BARRIERS AS THE SOLUTION!

“Get usable attic space”!

Or build a box of storage space with gypsum 48

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SPRAY FOAM MARKETS &APPLICATIONS

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Commercial

SPF MARKETPLACE & APPLICATIONS

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Low-slope Roofing

Commercial Air Barrier Residential

Commercial-Industrial-Agric.

Retrofit Residential

Residential Roof

SPF COMMERCIAL APPLICATIONS

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FRAME  WALLS

EXTERIOR WALLS

LOW‐SLOPE ROOFS

courtesy BaySystems

courtesy BaySystemscourtesy BASF

courtesy Honeywell/BSC

courtesy BASFcourtesy Honeywell

INTERIOR WALLS

METAL

BUILDINGMASONRY WALLS

courtesy Demilec courtesy Demilec

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SPF COMMERCIAL APPLICATIONS:MULTI-FAMILY STRUCTURES

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SPF COMMERCIAL APPLICATIONS:AIR BARRIERS & BUILDING ENVELOPE

Exterior Envelope Monolithic insulation, air barrier, weather resistant barrier (WRB) & vapor retarder all in a single application

Simpler, less labor

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SPF COMMERCIAL APPLICATIONS:AIR BARRIERS & BUILDING ENVELOPE

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SPF COMMERCIAL APPLICATIONS:CAVITY WALLS

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SPF COMMERCIAL APPLICATIONS:METAL BUILDING INSULATION

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SPF COMMERCIAL APPLICATIONS:SEALING DUCTS & HVAC UNITS

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SPF COMMERCIAL APPLICATIONS:AGRICULTURAL BUILDINGSHigh-density foam (often 7-10 lb. density) for use as interior insulation of livestock housing and other agricultural applications

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Photo Credit: Webster Insulation

Photo Credit: SPF.org

Photo Credit: SPF.org

2lb Foam Application

10lb Foam Application

SPF RESIDENTIAL APPLICATIONS

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UNVENTED CRAWLSPACES

FLOORS

BELOW GRADE WALLS

UNVENTED ATTICS

ATTIC FLOORS

CATHEDRALIZED CEILINGS

BASEMENT WALLS

GARAGE CEILINGS

EXTERIOR WALLS

INTERIOR WALLS

INTERIORWALLS

courtesy BASF

courtesy BASF

courtesy Honeywell

courtesy Honeywell courtesy Honeywell courtesy Honeywell

courtesy BASF

courtesy BASF

courtesy Honeywell

SPF RESIDENTIAL APPLICATIONS: INTERIOR WALLS

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Closed-cell Wall Application

Open-Cell Wall/Roof Application

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SPF RESIDENTIAL APPLICATIONS:CLOSED-CELL SPRAY FOAM IN WALLS

Closed-cell SPF (ccSPF) is a superior wall insulation when space is at a premium Provides ultimate thermal performance, air sealing and water vapor control

CCF can obtain R-21 walls using standard 2x4 framing

“Belt and Suspenders” approach to water intrusion helps to reduce mold risk

Offers structural enhancements –stronger, straighter walls

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ADDITIONAL CONSIDERATION:RACKING STRENGTH & MOISTURE RESISTANCE

Closed-cell SPF adds strength to the building envelope through its adhesion properties NAHB racking tests have shown – an average increase of 300%

NAHB bracing for wind resistance may not be required when using ccSPF in the walls, reducing construction cost

Alternative methods for gable wall bracing may be replaced by the use of SPF due to it’s enhanced racking capacity on these walls

Class II vapor retarder - ccSPF will provide a vapor retarder of 1 perm or less (1.5”-2.5”), helping to prevent water and moisture from permeating the home

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ADDITIONAL CONSIDERATION:FEMA RECOGNITIONFEMA recognizes closed-cell SPF as the only insulation material resistant to flood damage

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Source: FEMA, Flood Damage-

Resistant Materials Requirements,

Technical Bulletin 2, August 2008

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FEMA- CCSPF FLOOD RESISTANT MATERIAL

SPF APPLICATION: HYBRID/COMBO SYSTEMS – WALL APPLICATIONS

Hybrid System Considerations Can provide better thermal

performance than conventional insulations – allowing them to perform properly

Often combined with batts and loose-fill insulations

Combination Systems used in cold climates may still require a properly installed, interior vapor retarder

Adds air sealing and moisture resistance

Superior sound control package

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SPF RESIDENTIAL APPLICATIONS:OPEN-CELL SPRAY FOAM IN WALLS

Open-cell SPF (OCF) full cavity fill: (2x4) can obtain R-13 walls

(2x6) can obtain R-19 to R-21 walls

Excellent Wall Insulation Conforms to hard to insulate areas

Fills gaps and cracks

Provides efficient thermal performance and air sealing

Semi-vapor permeable

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ADDITIONAL CONSIDERATION:BUILD TIGHT, VENTILATE RIGHT!

To address air infiltration and related moisture concerns, Building Scientists have concluded that houses should be as tight and seamless as possible* and American Lung Association has recommended that homes need to be as tight as practical**

Random natural infiltration should be minimized and controlled mechanical ventilation should be employed***

Many states are considering implementing ACH (Air Change per Hour) rates and residential designers conclude they want either a heat-recovery ventilator (HRV) or an energy-recovery ventilator (ERV) to deliver fresh air to a home’s interior

As with all air-tight building approaches, homes built with spray foam should incorporate a method to manage indoor air quality

Fresh air should be introduced and exchanged within the home****

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*Arnie Katz, Director, Affordable Housing, Senior Building Science Consultant www.advancedenergy.org/buildings/about/specialists/arnie_katz.html

**American Lung Association www.healthhouse.org/build/TopTenQuestionsbooklet.pdf

***www.buildingscience.com

****Home Ventilating Institute www.hvi.org

Thermal barrier as required by use per code

1. Unvented-cathedralized attics: Where we’ve been and where we’re going, A. Rudd, J. Lstiburek and K. Ueno, Building Science Corporation.

2. Literature Review of the Impact and Need for Attic Ventilation in Florida Homes FSEC-CR-1496-05 31 May 2005

3. Attic and Crawlspace Ventilation: Implications for Homes in the Urban-Wildlife Interface, S.L. Quarles and A. TenWolde. Forest Products Society proceedings, 2005 ISBN I892529.

SPF ALTERNATIVE APPROACH - UNVENTED, SEMI-CONDITIONED ATTICSClosed-cell SPF is the best insulation for unvented, semi-conditioned attics and cathedral ceilings in cold climates

• Improved energy savings when HVAC equipment is in the attic1

• May reduce damage from rainwater intrusion in attic2

• Wrap around trusses to get thermal break

• May improve structural and uplift resistance to high winds and hurricane loads

SPF ALTERNATIVE APPROACH – SEMI-CONDITIONED ATTICS

Prescriptive U-factor Alternative [Energy R402.1.3] with R-49 requirements in 2015 IECC: “An assembly with a U-factor equal to or less than that specified in Table R402.1.3 shall be permitted as an alternative to the R-value in Table R402.1.1.” U-0.026 allowed in Zone 5

Equivalent to approximately 5.5” SPF or R-38

ccSPF installed continuously wrapping over rafters

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CLOSED-CELL SPF BENEFITS FOR HIGH WIND / STORM RESISTANT ROOF CONSTRUCTION

Closed-cell spray polyurethane foam (ccSPF) insulation - One of the best solutions for strengthening the connection between the roof deck and the trusses in both new and existing homes.

Sealing the venting with ccSPF to create an unvented attic has other benefits over improved fasteners and adhesives. Prevents unwanted internal pressurization of the roof during high winds

Blocks wind-blown rain from entering the home

Acts as a backup waterproofing layer that minimizes water entering the home

Stops water absorption – only FEMA approved cavity insulation for use in homes built in flood zones

CLOSED-CELL SPF STRENGTH - WIND UPLIFT RESISTANCE

Roof deck uplift testing per Miami Dade shows 3.5x the strength

Miami Dade Standard (-45.0 psf) Uplift Capacity

Roof Deck w/ SPRAYTITE® SPF(-157.5 psf) Uplift Capacity

FORTIFED HOME - CCSPF HELPS CONTRIBUTE TO HURRICANE RESISTANCE

Insurance Institute for Business & Home Safety (IBHS)

FORTIFIED Program for homes and buildings

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SPF RESIDENTIAL APPLICATIONS:CCSPF IN UNVENTED, CONDITIONED ATTIC

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SPF RESIDENTIAL APPLICATIONS:CATHEDRAL CEILINGS

Conforms to hard to insulate roof designs and fully seals areas

Unvented approach can also be used here, applied directly to the underside of the roof deck

Can be vented by installing SPF to rigid insulation or continuous chute vents to maintain air space

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SPF RESIDENTIAL APPLICATIONS:OPEN CELL IN UNVENTED, CONDITIONED ATTICS

Open-cell SPF offers excellent insulation and air sealing allowing for: Improved energy savings when HVAC equipment is in the attic*

Reduce ignition by wildfires**

Recommended to wrap around trusses

May allow for less total thickness using U-factor

Open-cell SPF is required to be protected by a thermal (storage) or ignition barrier (limited-access) depending on the use of the space

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ADDITIONAL CONSIDERATIONS:CATHEDRAL CEILINGS & UNVENTED ATTICS

Asphalt Shingle Manufacturers’ Warranties Check with all other manufacturers before proceeding with unvented roof assemblies Consider performance benefits with slight impact on shingle life Certainteed and a few manufacturers are supportive

Option to install continuous vent chutes in each bay, then install SPF over vents to create a sealed attic over a vented roof deck

Code required ignition barrier or thermal barrier coatings may be installed over SPF surface

Combustion air for appliances (especially retrofit applications) Consult with a qualified HVAC manufacturer (generally must be high efficiency, sealed combustion unit or vented to the exterior in a sealed space)

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SPF APPLICATION: HYBRID/COMBO SYSTEMS – VENTED ATTIC FLOORS

SPF can be used below other insulations to air seal and strengthen attic floors*

Covered with blown fiber glass or cellulose – To be determined by local building official what qualifies as ignition barrier per code requirement

It is ideally suited to seal crevices around recessed lighting**, vent pipes and wiring in the attic

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*Use caution when spraying onto sheetrock – ½”-1” initial passes

**Maintain 3” separation from all lights and fireplaces flues, per building code

SPF APPLICATION: HYBRID/COMBO SYSTEMS – VENTED ATTIC FLOORS

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SPF RESIDENTIAL APPLICATION – CRITICAL SEAL: HYBRID/COMBO SYSTEMS – SOFFIT & EAVES AREA

Applied near the eave/soffit area, the high R-value of ccSPF can provide the insulation needed to prevent excessive heat loss in cold climates and wind-washing of the blown insulation

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“In severe cold climates the critical air seal also applies to attic construction. Again, high-density spray foam [is the best]application to the exclusion of all other materials and approaches”Rigid Spray Foam Insulation: Residential and Low-Rise Commercial Construction – Joe Lstiburek, Building Science Corporation report, March 2006

RIGHT

InsulationWind intrusion

WRONG Insulation

Wind baffle

SPF Insulation

EASY

Unvented Attic

DEFEAT WIND INTRUSION

ALTERNATIVE APPROACH – SPF OR RAISED HEEL TRUSS IN CEILINGS WITH ATTIC SPACES

If insulation is full height (or full R-value) over exterior wall [Energy R402.2.1 – Prescriptive Alternative] R-30 allowed instead of R-38 wherever

the full height of uncompressed R-30 insulation extends over the wall top plate at the eaves (R-38 vs. R-49 in 2015 IECC)

ccSPF to full R‐value over top plate

Graphic and photo courtesy of Energy Star

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“In the retrofit area, Medium-density spray foam can do things no other insulation system can do with respect to both air-tightness and vapor control. … In such applications the Medium-density spray foam is not water sensitive, it provides both a thermal barrier and air barrier without creating a vapor barrier. A vapor retarder is provided to allow drying of the assembly in both directions.”

Rigid Spray Foam Insulation: Residential and Low-Rise Commercial Construction – Joe Lstiburek, Building Science Corporation report, March 2006

courtesy Honeywell

SPF ALTERNATIVE APPROACH – CRITICAL SEAL: UNDER HOUSES / GARAGE CEILINGS

SPF can be applied to the underside of the bonus rooms above garages

•Prevent or fix call back issues related to “hot floor” complaints

•Completely seals against air infiltration –reduces potential for other moisture concerns

•Covered with sheetrock – no exposed SPF in garages

SPF ALTERNATIVE - CRITICAL SEAL: CANTILEVER INSULATION COMBO

Applicators must use caution with thick foam applications in hard to reach areas due to excess heat build-up

SPF RESIDENTIAL APPLICATIONS:RIM JOISTSSPF seals and insulates rim (band) joists, overhangs and behind stairs Easily applied in hard-to-reach places that remains in place and does not

compress/sag like fiber glass batt insulation

Eliminates air infiltration and controls moisture at rim joist, mud-sill and masonry

In IRC, closed and open-cell SPF is allowed in this area with no fire protection necessary per Plastics code section, if meets criteria (3.25” max and Class 1).

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SPF RESIDENTIAL APPLICATIONS:BASEMENTS

The ccSPF water-resistance and vapor retarder properties are ideal for exterior or internally-insulated below-grade walls Best if used continuously between masonry walls and framing

Great for renovation/retrofit

IECC specifies R15 of continuous insulation (SPF on interior or exterior) to be equivalent to R19 of cavity insulation

Must be covered by drywall or 15 min. thermal barrier

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SPF RESIDENTIAL APPLICATIONS:CRAWL SPACES

ccSPF is an ideal answer for problem crawlspaces Can be applied between joists and to cover joists

Easily fits around obstructions and permanently remains in place

Offers great insulation alternative for unvented crawl spaces due to water resistance

Code requires it to be covered with ignition barrier – fiber / mineral glass or rigid board or approved alterative Open-cell not recommended for this application

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ADDITIONAL CONSIDERATIONS:APPLICATION/DESIGN LIMITATIONS FOR SPFClosed-cell 2lb foam is not designed for use in: Exterior roofing systems

Open-cell foam 0.5lb foam is not designed for use in: Under slab applications

Ductwork Vapor permeable insulation where condensation can occur

Exterior roofing systems

Exterior foundation applications

Use caution and well-installed vapor control in the following: Cold storage structures such as coolers and freezers

High humidity rooms, such as pools, demand special design considerations with regards to thermal insulation and moisture-vapor drive

Use caution in basement and crawlspace walls - high moisture potential areas: No soil contact – open-cell foam can wick water90

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SPF LOW-SLOPE EXTERIOR ROOF APPLICATIONS

1964:Spray Foam Southwest applies the first urethane foam roof in the United States

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EXTERIOR ROOF APPLICATIONS:LOW SLOPE COATED FOAM ROOF BENEFITS

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Attributes Coated Roof Foam

Weight Light weight and various densities available: 2.5, 2.8, 3.0 pcf

Application Seamless, monolithic, and able to conform to unusual substrates

R-value 6.3 per inch

Weather Hail, traffic, weather, UV-resistant, EnergyStar coatings available

UL & FM Ratings UL-790 Class A rated

Adhesion Fully-adhered, self-flashing membrane that does not use penetrating fasteners; which avoids holes/thermal breaks

Cost Impact Avoids costly tear-off and renewable process where existing roof removal generally not necessary; reduced disruption to existing businesses

EXTERIOR ROOF APPLICATIONS:POLYURETHANE ROOF ADHESIVE

Roof Adhesive Attributes: Low rise polyurethane foam adhesive for low slope roofing systems

Glues down board stock foam and membrane, eliminating fasteners to avoid thermal bridging

Ideal for small jobs and quick repairs with ease of handling and storage

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Covering/ Coating

Adhesive

Insulation BoardAdhesive

Non-nailableRoof Deck

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SPRAY FOAM MYTHS AND MYSTERIES

What foam is the best? Does it need to “breathe”?

Open cell or Closed cell is not the issue. It is: Air Permeance

Water Permeance

Home operating as a “system”

With a properly installed HVAC system with Air Exchangers and Humidity Controls, as well as fire protection as required by code, either SPF operates well within the “system”.

SPF MYTHS – UNVENTED ATTICS

Moisture and Vapor in attics – What foam is better? It is not about the type of foam – open vs. closed cell; it is about the design of the house, working as a system…

Unvented attic study – University of Waterloo and Building Science Corporation Conclusion for Zones 1-2 (Gulf Coast):

Full depth ocSPF (to code) works problem free in these zones (while it may start to accumulate diffusion driven moisture in Zones 3 and above).

Full depth ccSPF (to code) and ccSPF hybrids work problem free in all Climate Zones

SPF MYTHS - WHAT ABOUT ROOF LEAKS?

Closed-cell spray foam acts as a secondary rain barrier, ESPECIALLY valuable in a coastal zones and rain prone areas, to keep the elements out of the home prior to repairs during high wind events and damages

Open cell foam MAY let the water flow through, but can also retain moisture against the sheathing Water will also migrate within foam mass before showing up usually

Consider the BENEFITS of closed-cell SPF on the underside of your roof… Would you rather have water in your living room, or within one section of the roof sheathing? Easier to identify and repair… Damage is limited to a specific area, not allowed to move or create additional damage and mold potential

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SPF MYTHS – UNVENTED ATTICS & PLYWOOD ROOFS

Unvented attics with foam study on plywood / OSB roof decks – Building of America and Building Science Corporation

Based on the modeling done in this study, there are no known risks with using SPF insulation under plywood and OSB roof decks if the following requirements are met: The installation complies with the 2012 International Residential Code.

A fully adhered leak-free roof membrane is installed.

The roof sheathing and framing are dry below 18% before SPF installation.

When using open cell SPF, a low-perm Class II vapor retarder is installed where required.

Field investigations validated the modeling data used to achieve these results. However, damage could occur (with either foam system) where the volume of the leak, frequency of the leaks, or quantity of interior moisture driven into the system are more than modeled in this study. Bulk water control using a fully adhered membrane with proper gravity-lapped flashing details should be employed to help ensure leaks do not occur.

SPF MYTHS -WHAT ABOUT FLAMMABILITY AND FIRE?

Almost all spray foam systems for residential construction are Class 1 rated construction materials Contains fire retardants and smoke suppressants

Class 1 exceeds Class 2 requirements of International Residential Code

ALL FOAM INSULATION applications (open cell, closed-cell spray, rigid board, etc.) for interior use must be covered with thermal barriers, i.e. ½” Gypsum Board, for fire safety, with few exceptions (per IRC and IBC requirements) in SMALL OR LIMITED ACCESS areas98 5/16/2017

SPF MYTHS - WHAT ABOUT RIGIDITY AND LONG-TERM ADHESION?

Closed-cell spray foam has been used successfully for residential and commercial construction for over 30 years Exhibited dependable performance, when applied properly, in extreme weather

conditions, without loss of adhesion or bond

Properties that enhance it’s performance…

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Elasticity

Mechanical / Chemical Bond

Racking Strength

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SPF MYTHS - WHAT ABOUT OUTGASSING AND AIR QUALITY?No Urea Formaldehydes in SPF chemistry - Never had them, Never will

For closed-cell, HFC-245fa is a non-flammable that replaced HCFC and CFC blowing agents. Zero Ozone Depletion Potential (ODP)

Low Global Warming Potential (GWP)

Not considered a Volatile Organic Compound (VOC) in US

Inert Plastic Remains in place - No outgassing Studies by American Medical Association and others to prove no physical effect in

homes with fully cured polyurethanes

Used in American Lung Association (ALA) Health House Asthmatic daughter – benefited from a well-sealed assembly, reduced air leakage = less allergens and pathogens Non-fibrous insulation is a bonus

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ENVIRONMENT, HEALTH, & SAFETY (EHS)

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ENVIRONMENTAL HEALTH & SAFETY: JOBSITE SAFETY

Quality controls start at the design, estimation & bidding processes

Exposure controls such as ventilation and isolated work areas should be used. Standard industry practices is no reentry for 24 hours. Some manufacturers / products may allow faster reentry w/ventilation.

After SPF is sprayed on jobsite, use of ventilation and/or containment should be part of the risk management plan for each job with SPF Protect foam from accidental ignition by other trades “NO HOT WORK” signs should be posted Alert other trades of fire protection needed for open flames

All employees need to know the location and proper use of the required safety equipment.

Industry Guide (see right) on Ventilation available from ACC, Center for the Polyurethanes Industry, Spray Foam Coalition

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EHS: APPLICATION REQUIRED, PERSONAL PROTECTION EQUIPMENT (PPE)

Respiratory Protection Full Face Supplied Air Respirator for both

applicator and helper during application Clean up crews after installation - cartridge mask

can be utilize with approval by your respiratory program administrator (subject to change)

Body Protection (no visible skin) Chemical Resistant Suit (HOT!!!) Chemical Resistant Boots/Booties Nitrile Gloves to protect hands from absorbing

chemicals Head masks

Eyewear with Side Shields

Avoiding skin contact with proper coverage & using breathing equipment is a necessity when using SPF materials!

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SAFETY FOCUS AREA: OSHA’S NEW CONFINED SPACE RULE

The Occupational Safety and Health Administration (OSHA) has developed a new rule to protect workers in confined spaces, including residential attics and crawl spaces, that will impact the work of home performance contractors, notes the Building Performance Institute Inc. (BPI). Routine tasks such as installing spray-foam insulation in attics or installing plumbing in a crawlspace will require documented safety plans, and in some cases stationing an additional person outside the space to grant access.

Effective Aug. 3, 2015, the rule — which has long applied to confined spaces such as tunnels and manholes — now specifies crawl spaces and attics due to recent fatalities. The rule will apply to any space that meets the following three criteria: Is large enough for a worker to enter it Has limited means of entry or exit Is not designed for continuous occupancy.

Under the new rule (29 CFR 1926 Subpart AA), permits to access specific confined spaces are granted by the general contractor or lead contractor on each job.

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See more at: http://www.sprayfoam.com/foam-news/oshas-confined-spaces-rule-impacts-home-performance-contractors/2447#sthash.odeAag3m.dpuf

EHS: SUSTAINABILITY BENEFITS OF SPF

Minimizes energy usage Superior R-value for Maximum Energy Efficiency (ccSPF)

Reduced uncontrolled air leakage

Helps reduce fossil fuel usage, due to energy savings Helps consumers lower carbon footprint

Increased thermal comfort No drafts, consistent temperatures

Ozone protection Non-ozone depleting blowing agents

Low-emission materials Meets or exceeds VOC requirements for LEED – low / zero values

SPFs contain no urea formaldehydes

Many products Greenguard® listed, UL-approved or ICC SAVE verified105

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EHS: SUSTAINABILITY BENEFITS OF SPF

Recycled Content Most SPF contains 5-10% post-industrial and/or post-consumer recycled content

Agricultural-based content Typically sucrose-based or soy-based polyols, up to 10-15% by total volume

Applications create minimal debris and waste (ccSPF)

Advanced framing techniques – 24” ocf vs. 16” ocf or 2x4 vs. 2x6 (ccf) Less lumber usage

Life cycle assessment – long term performance Eco-efficiency analysis

Computer modeling shows SPF has lowest life-cycle cost/impact on environment than other insulations

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EHS: IS SPRAY FOAM A “GREEN” PRODUCT?“Green” or sustainable components only make a portion of only the polyols in the B drum. All other components remain fairly equal amongst spray foams

Based upon the total percentage of all polyols that have the capacity of being recycled or renewable in content, most spray foams contain no more than 15-20% of these materials total

Possible “green” components: Post-scrap plastics reprocessed (recycled soda &

water bottles)

Renewable or plant-grown materials (sugar beets, soy, cane products)

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EHS: LEED GREEN BUILDING RATING SYSTEM

Most polyurethane spray foams can contribute to LEED projects in many categories LEED Certificates showing points and percentages are available from most

manufacturers

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LEED CreditCommercial Insulation & Air

BarrierResidential Insulation & Air

Barrier

Material & Resource (MR) credits 4.1 & 4.2

Yes Yes

Material & Resource (MR) 6.0 Yes

Indoor Environmental Quality (EQ) Credit 4.1

Yes Yes

Energy & Atmosphere (EA) Prerequisite 2 & Credit 1

Yes Yes

Energy & Atmosphere (EA) Prerequisite 3

Yes Yes

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?QUESTIONS?

CODE COMPLIANCE? INTERPRETATION? APPLICATION?

Open Discussion on SPF

Thank you for your attention!

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ADDITIONAL RESOURCESAmerican Chemistry Council (ACC) Spray Foam Coalition (SFC)

www.Spraypolyurethane.org

Insulation Contractors Assoc. of America www.Insulate.org

Spray Polyurethane Foam Alliance (SPFA) www.Sprayfoam.org

Air Barrier Association of America (ABAA www.airbarrier.org

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THANK YOU!

BASF Corporation is committed to sustainable solutions

for construction applications.

www.spf.basf.com

888-900-FOAM

Kelly Frauenkron-National Accounts

Kelly.frauenkron@basf.com

612-840-6631 Mobile

Jim Derrigan - Northeast Territory Manager

Jim.Derrigan@basf.com

716-830-9741 Mobile

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