Meeting Code Requirements With Open Cell Foam Paul Duffy, M.A.Sc., P.Eng. Vice President, Engineering Icynene Inc.
Agenda Introduction Background Foam Basics Code Requirements Design Options Applications Summary
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
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)
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
STRATEGIC ALIGNMENT
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.
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
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
SPRAY FOAM DIFFERENCES (ICC-ES AC 377) Low Density Open Cell (<90%) Half pound (0.5-1.5 lb/cu.ft.) Water 100%??? (+blowing agent???) R 3.7-4.5 per inch Medium Density Closed Cell (>90%) Two pound (1.5-2.5 lb/cu.ft) Captive blowing agent (low ODP but high GWP) R 6.2-7.0 per inch
SPRAY FOAM DIFFERENCES 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
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.
APPLICATIONS High Pressure Foam Truck Based Spray Rigs Product sold in sets two 55 gallon drums (A-side ISO, B-side Resin )
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.
WHICH FOAM IS BEST? Depends on: Design objectives Application Available space Needed R-value Cost etc.
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.
SPRAY FOAM AND CODES
SPRAY FOAM CODE REQUIREMENTS 1. Thermal / Moisture Control Requirements IRC (Section 806.5 & Chapter 11) IECC ASHRAE 90.1 2. Fire Safety Requirements IRC Section 3.16 IBC Section Chapter 26
THERMAL AND MOISTURE CONTROL REQUIRMENTS
www.bcap-energy.org
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
IRC / IBC Climate Zones
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. 1 30 13 0 2 30 13 0 3 30 13 5/13 4 38 13 10/13 5 38 20 or 13+5 10/13 6 49 20 or 13+5 15/19 7 49 21 15/19 8 49 21 15/19 ICC 2009 is REQUIRED for States to get ARRA funds.
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. 1 30 13 0 2 30 13 0 3 38 20 or 13+5 5/13 4 49 20 or 13+5 10/13 5 49 20 or 13+5 15/19 6 49 20+5 or 13+10 15/19 7 49 20+5 or 13+10 15/19 8 49 20+5 or 13+10 15/19
COMMERCIAL IBC Energy Req. Based on ASHRAE 90.1 (2010) Requires: Higher Insulation Levels Air Impermeable Insulation Continuous Insulation Layer
VAPOR CONTROL REQUIREMENTS International Residential Code 2009 Section 601.3 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 601.1 Class III Vapor Retarders Class III Vapor Retarders shall be permitted where any one of the conditions in Table R601.3.1 is met.
EXCEPTIONS TO THE VDR REQUIREMENTS
ICYNENE DEALER TRAINING Spray Foam Fundamentals Icynene Products Building Science Codes Technical Training and Troubleshooting
FOAM AND FIRE SAFETY
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.
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 2603.4] prescribes: ½ gypsum board Ignition Barriers Code [IRC Sections 316.5.3-4, IBC Section 2603.4.1.6] prescribes: 1 ½ mineral fiber ¼ plywood/particle board/hardboard 3/8 gypsum board 0.016 thick sheet metal
ALTERNATE IGNITION AND THERMAL BARRIERS CODE REFERENCES Thermal Barriers Code [IRC Section R316.6, IBC Section 2603.9] prescribes four tests for alternate thermal barriers: NFPA 286 FM 4880 UL 1040, or UL 1715 ICC-ES Acceptance Criteria -- AC 377 qualifies the approval allowing: Minimum thickness of coating Maximum thickness of foam Based on thicknesses tested. Ignition Barriers Code [IRC Section 316.6, IBC Section 2603.9] prescribes no specific tests for alternate ignition barriers only testing based on actual end use configurations ICC-ES AC 377 provides: Appendix X test (attics and crawlspaces) ASTM E-970 (attic floor) Appendix E (crawlspaces) Actual end use configurations
THERMAL BARRIERS ON ES-REPORTS 1. One prescribed solution [IRC Section R316.4, IBC Section 2603.4] 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 2603.4] 4. If it has only been demonstrated to remain in place during the room-size testing, the approval is SPECIFIC to the FOAM TESTED. [IRC Section R316.6, IBC Section 2603.4]
IGNITION BARRIERS ON ES-REPORTS 1. Several prescribed solutions [IRC Section R316.4, IBC Section 2603.4.1.6] 1 1/2 mineral fiber ¼ plywood/particle board/hardboard 3/8 gypsum board 0.016 thick sheet metal 2. Non-prescriptive (equivalent) IB s must be approved by testing based on actual end use configurations. [IRC Section R316.6, IBC Section 2603.9] Attic: AC 377 Appendix X or other end use configurations Floor of Attic: ASTM E-970 or other end use configurations Crawlspace: AC377 Appendix X or Appendix E or other end use configuration tests 3. Approval is specific to the foam and coating tested. Maximum thickness of foam Minimum thickness of coating
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
COMMERCIAL FIRE TESTING
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
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
ICYNENE PROSEAL ECO ASTM E119 Test for Hourly Rated Assemblies: Assembly Configuration: Interior 2 @ 5/8 Gypsum Type X 6 ProSeal Eco ½ DensGlass Gold 4 Brick Exterior Result: PASSED 3 Hour Rating
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.
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.
CONTINUOUS INSULATION
CAVITY + CONTINUOUS INSULATION
CAVITY + CONTINOUS INSULATION Icynene Interior - Exterior
HEALTH AND SAFETY
SPRAY FOAM SAFETY High Pressure Equipment (1000 psi +) Reactive Components Aerosolized particles Trace VOC s Unique Product Characteristics
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
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.
APPLICATIONS
BASEMENT WALLS Thermal Barrier Required (e.g. ½ gypsum drywall) IRC R316.4, IBC 2603.4 Vapor Retarder not required IRC R601.3
CRAWLSPACES Ignition Barrier Required IRC R316.5.4, IBC 2603.4.1.6 Thermal Barrier may be required (for example if used as a return air plenum) No VDR required IRC R601.3
SILLS & HEADERS No ignition or thermal barrier required if less than 3 ¼ sprayed. IRC R316.5.11, IBC 2603.4.1.13
EXTERIOR WALLS ABOVE GRADE Thermal Barrier required on interior IRC R316.4, IBC 2603.4 Foam in wall cavity tested to NFPA 259 IBC 2603.5.3 Types I-IV More than one storey wall assemblies must be tested to NFPA 285 and ASTM E119 IBC 2603.5.1-5
CANTILEVERED FLOORS (E.G. BONUS ROOM) Floor sheathing provides TB on interior IBC Table 721.6.2(1) TB may be required in garage Keep plumbing and mechanicals within the conditioned boundary (heating climates)
COMPLEX CONSTRUCTION
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.
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.
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
VENTED ATTIC Ignition Barrier required on floor of attic IRC R316.5.3 IB not required if foam passes ASTM E-870 VDR may be required on interior surface (Zones 5-8 + Marine 4) IRC R601.3 SOURCE: SPFA. 2011 SPRAY POLYURETHANE FOAM ALLIANCE
UNVENTED ATTIC Ignition Barrier required on floor of attic IRC R316.5.3 IB not required if foam passes ASTM E-970 VDR may be required on interior surface (Zones 5-8 + Marine 4) IRC R601.3 SOURCE: SPFA. 2011 SPRAY POLYURETHANE FOAM ALLIANCE
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
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
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 1406-03 provides additional information that goes beyond the scope of the ICC ESR
QUESTIONS Paul Duffy, M.A.Sc. P. Eng. Vice President, Engineering Icynene Inc. (905) 363-4040 x 209 pduffy@icynene.com icynene.com