Meeting Code Requirements With Open Cell Foam. Paul Duffy, M.A.Sc., P.Eng. Vice President, Engineering Icynene Inc.

Transcription

1 Meeting Code Requirements With Open Cell Foam Paul Duffy, M.A.Sc., P.Eng. Vice President, Engineering Icynene Inc.

2 Agenda Introduction Background Foam Basics Code Requirements Design Options Applications Summary

3 ICYNENE Manufacturing operations located in Mississauga, ON Distribution centers in: Memphis, TN Newark, NJ City of Industry, CA Icynene Classic (LD-C-50) was invented in Canada over 25 years ago. Icynene product portfolio includes light-density and medium- density water blown and blowing agent spray foams Dealers in 30+ countries globally

4 PAUL DUFFY, M.A.Sc., P.Eng. VP, Engineering at Icynene Previously a Consulting Engineer for more than 20 years Graduated from the University of Toronto, Construction and Building Science Program Past Chair of the Spray Foam Coalition for the American Chemistry Council (ACC), and chair of other ACC Committees. Active in various Codes and Standards committees, Building Envelope Councils (OBEC Past President), RESNET (Past President of Canadian Chapter)

5 U.S SALES TEAM Led by Randy Scott, VP and GM of North American Commercial Organization Five Regional Sales Managers More than 50 Territory Representatives and Manufacturer s Reps Over 400 Licensed Dealers coast to coast

6 STRATEGIC ALIGNMENT

7 WHAT IS SPRAY FOAM? Formed-in-place: Liquid components that are poured or sprayed in place that expand into a foam plastic material that insulates and air seals.

8 SPRAY FOAM DIFFERENCES 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

9 SPRAY FOAM APPROVALS. 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

10 SPRAY FOAM DIFFERENCES (ICC-ES AC 377) Low Density Open Cell (<90%) Half pound ( lb/cu.ft.) Water 100%??? (+blowing agent???) R per inch Medium Density Closed Cell (>90%) Two pound ( lb/cu.ft) Captive blowing agent (low ODP but high GWP) R per inch

11 SPRAY FOAM DIFFERENCES THE REST OF THE STORY... 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

12 WHY CHOOSE SPRAY FOAM? 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.

13 APPLICATIONS High Pressure Foam Truck Based Spray Rigs Product sold in sets two 55 gallon drums (A-side ISO, B-side Resin )

14 FOAM IS NOT FOAM A-Side (ISO) Isocyanate Polymeric MDI (pmdi) B-Side (Resin) Polyols Catalysts Surfactants Flame Retardants Water Blowing Agent 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.

15 WHICH FOAM IS BEST? Depends on: Design objectives Application Available space Needed R-value Cost etc.

16 ICYNENE SPRAY FOAM PRODUCTS Classic/Max/Eco (LD-C-50/LD- C-50 v2/ld-r-50) ICC-ESR 1826 LD/Open Cell/0.5 lb./cu.ft. R-3.7 per in. Air Barrier Vapor Permeable Breathes Rejects Water (Floats) Not for Exterior / WRB apps. Classic Plus (LD-C-70) ICC-ESR 1826 LD/Open Cell/0.7 lb./cu.ft. R-4.0 per in. Air Barrier Vapor Permeable Breathes Rejects Water (Floats) Not for Exterior / WRB applications.

17 SPRAY FOAM AND CODES

18 SPRAY FOAM CODE REQUIREMENTS 1. Thermal / Moisture Control Requirements IRC (Section & Chapter 11) IECC ASHRAE Fire Safety Requirements IRC Section 3.16 IBC Section Chapter 26

19 THERMAL AND MOISTURE CONTROL REQUIRMENTS

20

21 ICC/IECC 2006/7 Introduction of 8 climate zones (simplifies need for Vapor Retarders) Introduction of Classes of Vapor Retarder (I,II,III) Mechanical System Trade-offs allowed HERS Target = 100

22 IRC / IBC Climate Zones

23 Features of ICC 2009 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 / / or / or / / /19 ICC 2009 is REQUIRED for States to get ARRA funds.

24 Effect of Moving ICC 2012 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 Zone Ceiling Walls Bsmt or / or / or / or / or / or /19

25 COMMERCIAL IBC Energy Req. Based on ASHRAE 90.1 (2010) Requires: Higher Insulation Levels Air Impermeable Insulation Continuous Insulation Layer

26 VAPOR CONTROL REQUIREMENTS International Residential Code 2009 Section Vapor Retarders Class 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 walls Below grade portion of any wall Construction where moisture or its freezing will not damage the materials Section Class III Vapor Retarders Class III Vapor Retarders shall be permitted where any one of the conditions in Table R is met.

27 EXCEPTIONS TO THE VDR REQUIREMENTS

28 ICYNENE DEALER TRAINING Spray Foam Fundamentals Icynene Products Building Science Codes Technical Training and Troubleshooting

29 FOAM AND FIRE SAFETY

30 FIRE SAFETY BASIC PRINCIPLES 1. Foam is assumed to be combustible. 2. The fact that it contains Fire Retardants and other additives does not make it non-combustible. 3. Testing is required to prove the degree to which it is non combustible. 4. 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.

31 CODE-PRESCRIBED IGNITION AND THERMAL BARRIERS 1. The Code assumes foam is combustible 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. Thermal Barriers Code [IRC Section R316.4, IBC Section ] prescribes: ½ gypsum board Ignition Barriers Code [IRC Sections , IBC Section ] prescribes: 1 ½ mineral fiber ¼ plywood/particle board/hardboard 3/8 gypsum board thick sheet metal

32 ALTERNATE IGNITION AND THERMAL BARRIERS CODE REFERENCES Thermal Barriers Code [IRC Section R316.6, IBC Section ] 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 ] 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

33 THERMAL BARRIERS ON ES-REPORTS 1. One prescribed solution [IRC Section R316.4, IBC Section ] ½ gypsum board 2. 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] 3. 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 ] 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 ]

34 IGNITION BARRIERS ON ES-REPORTS 1. Several prescribed solutions [IRC Section R316.4, IBC Section ] 1 1/2 mineral fiber ¼ plywood/particle board/hardboard 3/8 gypsum board 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 ] 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

35 USE OF FOAM IN NON-COMBUSTIBLE ASSEMBLIES 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

36 COMMERCIAL FIRE TESTING

37 ICYNENE CLASSIC NFPA 285 Test for Combustibility Assembly Configuration: Interior 5/8 Gypsum Type X 6 Icynene Classic (LD-C-50) ½ DensGlass Gold Exterior Result: PASSED

38 ICYNENE CLASSIC ASTM E119 Test for Hourly Rated Assemblies: Assembly Configuration: Interior 5/8 Gypsum Type X 6 Icynene LD-C-50 Classic ½ DensGlass Gold 4 Brick Exterior Result: PASSED 1 Hour Rating

39 ICYNENE PROSEAL ECO ASTM E119 Test for Hourly Rated Assemblies: Assembly Configuration: Interior 5/8 Gypsum Type X 6 ProSeal Eco ½ DensGlass Gold 4 Brick Exterior Result: PASSED 3 Hour Rating

40 ICYNENE PROSEAL ECO Expanding Engineering Approvals Basic Principles: Decreasing amount of combustibles in the assembly improves performance. Adding in more non-combustible layers results in equal or better performance. Adding non-combustible layers of equal performance results in equal or better performance.

41 ICYNENE Expanding Engineering Approvals Basic Principles: Decreasing amount of combustibles in the assembly improves performance. Adding in more non-combustible layers results in equal or better performance. Adding non-combustible layers of equal performance results in equal or better performance.

42 CONTINUOUS INSULATION

43 CAVITY + CONTINUOUS INSULATION

44 CAVITY + CONTINOUS INSULATION Icynene Interior - Exterior

45 HEALTH AND SAFETY

46 SPRAY FOAM SAFETY High Pressure Equipment (1000 psi +) Reactive Components Aerosolized particles Trace VOC s Unique Product Characteristics

47 WHAT ARE WE TRYING TO ACHIEVE? 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. Source: American Chemistry Council 5. Do work in accordance with best practices

48 SPRAY FOAM SAFETY - INSTALLERS SPRAY FOAM SAFETY EVERYONE ELSE 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.

49 APPLICATIONS

50 BASEMENT WALLS Thermal Barrier Required (e.g. ½ gypsum drywall) IRC R316.4, IBC Vapor Retarder not required IRC R601.3

51 CRAWLSPACES Ignition Barrier Required IRC R , IBC Thermal Barrier may be required (for example if used as a return air plenum) No VDR required IRC R601.3

52 SILLS & HEADERS No ignition or thermal barrier required if less than 3 ¼ sprayed. IRC R , IBC

53 EXTERIOR WALLS ABOVE GRADE Thermal Barrier required on interior IRC R316.4, IBC Foam in wall cavity tested to NFPA 259 IBC Types I-IV More than one storey wall assemblies must be tested to NFPA 285 and ASTM E119 IBC

54 CANTILEVERED FLOORS (E.G. BONUS ROOM) Floor sheathing provides TB on interior IBC Table (1) TB may be required in garage Keep plumbing and mechanicals within the conditioned boundary (heating climates)

55 COMPLEX CONSTRUCTION

56 CONTINUOUS MEDIUM DENSITY FOAM MD Foam sprayed continuously on exterior Transition membranes at windows, control joints, thruwall flashings, etc. Sealants and single component foams at penetrations and small gaps for touch-ups etc.

57 HYBRID ASSEMBLIES Continuous board stock foam or MD Foam sprayed continuously on exterior LD Foam in Cavity Transition membranes and/or sealants at windows, control joints, thru-wall flashings, etc. By sealing at the back plane of the board stock joints remain open on the exterior for drainage.

58 EXTERIOR WALLS ABOVE GRADE Current Approvals Thermal Barrier required on interior Up to 6 foam in wall cavity tested Up to 5 ½ foam continuous on exterior tested Non-combustible cladding

59 VENTED ATTIC Ignition Barrier required on floor of attic IRC R IB not required if foam passes ASTM E-870 VDR may be required on interior surface (Zones Marine 4) IRC R601.3 SOURCE: SPFA SPRAY POLYURETHANE FOAM ALLIANCE

60 UNVENTED ATTIC Ignition Barrier required on floor of attic IRC R IB not required if foam passes ASTM E-970 VDR may be required on interior surface (Zones Marine 4) IRC R601.3 SOURCE: SPFA SPRAY POLYURETHANE FOAM ALLIANCE

61 APPLICATION SUMMARY The Facts APPLICATION LOW DENSITY MEDIUM DENSITY COLD CLIMATES WALL CAVITIES PREFERRED PREFERRED UNVENTED ATTIC ACCEPTABLE PREFERRED CEILING / VENTED ATTIC PREFERRED ACCEPTABLE FOUNDATION AND BELOW GRADE PREFERRED PREFERRED BAND JOISTS / MUD SILLS PREFERRED PREFERRED CANTILEVERED FRAMING PREFERRED ACCEPTABLE DUCT INSULATION PREFERRED PREFERRED INSULATION SHEATHING/CONTINUOUS NOT ACCEPTABLE PREFERRED HOT CLIMATES WALL CAVITIES PREFERRED PREFERRED UNVENTED ATTIC PREFERRED ACCEPTABLE CEILING / VENTED ATTIC PREFERRED PREFERRED FOUNDATION AND BELOW GRADE ACCEPTABLE PREFERRED BAND JOISTS / MUD SILLS PREFERRED PREFERRED CANTILEVERED FRAMING PREFERRED ACCEPTABLE DUCT INSULATION ACCEPTABLE PREFERRED INSULATION SHEATHING/CONTINUOUS NOT ACCEPTABLE PREFERRED

62 SUMMARY Spray foam can help simplify details and designs for insulation and air barrier continuity Code compliant design details are available for most applications Testing and Engineering support is opening up new assembly options for designers and builders

63 SUMMARY LD foam is the workhorse of spray foam it s a proven performer that delivers cost effective solutions for many applications in today s buildings Spray foam has unique attributes that make it the best choice for many applications It is important to be aware of approvals permitted in ESR Reports not all foams are the same. DrJ Engineering TER provides additional information that goes beyond the scope of the ICC ESR

64 QUESTIONS Paul Duffy, M.A.Sc. P. Eng. Vice President, Engineering Icynene Inc. (905) x 209 pduffy@icynene.com icynene.com