If You`re Still Using Rigid Foam Board Insulation, We Have

If You’re Still Using Rigid
Foam Board Insulation,
We Have One Question
for You. WHY?
Read on to Learn How You Can Have:
Code-Compliant, Durable, Green Buildings
The Ultimate in Design Flexibility
Lowered Installed Cost
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BROUGHT TO YOU BY
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THE EVOLUTION OF INSULATION ™
Closed Cell Spray Foam: Super Efficient,
Highly Flexible, Proven Performance
Icynene closed cell spray foam insulation offers a superior
performance alternative to rigid foam board products at a
demonstrated lower installed cost. Read on for details on how to
get started using this time- and money-saving product today!
If you are an architect who designs commercial buildings,
take note: You now have the opportunity to maximize
energy savings options with a single product: mediumdensity, closed cell spray foam insulation.
Icynene ProSeal and Icynene ProSeal Eco provide a
high-performance wall assembly solution by combining
four functions in one material:
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continuous insulation
a continuous air barrier
a full water-resistive barrier
a vapor barrier
Further, closed cell spray foam has been shown to
produce a lower installed cost for a superior thermal, air,
and water barrier assembly with less labor and less waste
than systems relying on rigid board insulation.
The Advantages Add Up
When considering building materials for exterior
continuous insulation, the default for many is to rely on
Extruded Polystyrene (XPS) foam board rather than
consider spray foam insulation. There are numerous
differences between the two types of products, which
can affect every part of your build—from design flexibility
to construction schedules.
“The two products we offer commercial architects—
Icynene ProSeal and Icynene ProSeal Eco—are highperformance closed cell medium density spray foam
products,” says Paul Duffy, VP Engineering for Icynene
“These spray foam products have an equal or higher R
value than board stock products. In addition, spray foam
has features that board stock does not. Board products
are punctured for every fastener and every transition
membrane that deflects water to the outside, so you
need to use adhesive sealants and tapes for installation,
which may require prep surface cleaners that have to be
used effectively in order for these products to be
continuous air and water barriers.”
2
“When you consider there is
no compromise to going to
a spray foam product, the
question becomes: Why would
anyone use EPS? It’s a good
question; they should go ask
the growing number of people
now using spray foam.”
PAUL DUFFY
Conversely, spray foam, with a few accessories, provides
enhanced performance in one step. “This simplified process
is a huge step forward for the building industry,” Duffy says.
THE EVOLUTION OF INSULATION ™
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Here are nine comparison points you need to know
(for full details on these points, download the free
White Paper “The Performance Benefits of
FIGURE 4. A cold weather exterior continuous insulation
application of Icynene ProSeal Eco medium density spray foam
in Michigan - November 2014.
using Medium Density Spray Foam in Continuous
Insulation Applications.”
1. CODE COMPLIANCE
Energy codes are requiring higher thermal performance
values in walls, particularly in the form of exterior
continuous insulation. Using spray foam dramatically
increases the effective thermal performance of a wall
since most thermal bridging is eliminated, resulting in
increased wall energy efficiency and occupant comfort.
The notion of using spray foam stems from these more
stringent code changes, which have highlighted need for
three things: continuous insulation, a continuous air
barrier, and a water-resistant barrier.
“Yes, it’s possible to use other products for those things,
but it requires multiple products often with multiple
installation steps, with added cost when you can do it
with one product that accomplishes many steps in one,”
Duffy says. “That raises the possibility of efficiency,
reduced cost and shorter construction schedules, and
FIGURE 3. In this window head detail, the spray foam working in
conjunction with the thru wall flashing create a water resistive
barrier that facilitates any accumulated moisture in the wall
cavity to drain out via the weep and drip edge flashing systems.
allows some folks who don’t want to take full advantage
of the system the ability to add redundancy as a
supplemental water barrier.”
The proper use of an exterior continuous insulation
system would result in the elimination of large thermal
bridges that often plague a building, such as perimeter
concrete floor edges and exposed concrete and steel
structural columns and beams.
With R-values for Icynene’s medium density products
ranging from R-4.9 to R-7 per inch of thickness, spray
foam typically meets or exceeds the thermal performance
of comparable thickness rigid foam insulation board
products. With its greater thermal resistance, the use of
spray foam insulation can lead to reductions in overall
wall thickness over foam board designs, thereby providing
a building owner with additional value.
Furthermore, because it is fully adhered to the substrate,
there are fewer opportunities for convection and/or air
leakage around the insulation to reduce its performance.
This advantage becomes even greater when walls are
non-rectangular/odd-shaped or the wall has penetrations
like anchors, attachments, fasteners or piping that board
products have a difficult time fitting around.
2. AIRTIGHTNESS
For an exterior insulation application, medium density
spray foam products have the advantage of creating a
continuous insulation and air barrier layer in one step.
With no board joints to tape, airtight performance
becomes much easier to deliver along with cost and
construction schedule savings that impress general
contractors and owners alike.
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THE EVOLUTION OF INSULATION ™
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All of Icynene’s medium density spray foam products
have been tested, evaluated and noted as air
impermeable, a key feature of air barrier materials, in their
ICC-ES evaluation reports. The thickness this
characteristic has achieved varies from 1” to 1.4”
according to the product. Icynene ProSeal has been
evaluated and listed by ABAA as an air barrier material
according to its air permeance (airtightness) test results
from ASTM E 2178. The testing of Icynene ProSeal Eco
according to ASTM E 2178 also found a high level of
airtightness that allows it too to be classified as “air
impermeable.”
educational-advertiseMent
Quick Facts:
Design Advantages
All photos courtesy of ICYNENE, Inc
Spray foam insulation can achieve
truly continuous insulation in
commercial buildings as required by
energy codes, particularly in curved
or irregular shaped walls.
3. AIR BARRIER ASSEMBLY PERFORMANCE
It is recognized by organizations such as ABAA that the
use of medium density spray foam (as well as rigid foam
insulation board) products in exterior continuous
insulation wall applications requires membrane materials
(self-adhered or liquid) to prove performance in key areas
such as through wall flashings, wall transitions and
control joints.
Continuous
Insulation:
Architects can achieve
total design flexibility in
commercial building projects when specifying Icynene
Spray Foam Compared
ProSeal and Icynene ProSeal Eco in continuous
to Rigid
insulationBoards
applications. Both offer design flexibility in
ConTinuinG eDuCaTion
EARN ONE AIA/CES HSW
lEARNINg uNIt (lu)
learning Objectives
after reading this article, you should be
able to:
1. identify the characteristics of highperformance continuously insulated
exterior wall assemblies.
2. compare the characteristics of rigid board
insulation with those of medium-density
spray foam insulation for use in exterior
wall assemblies.
3. investigate the use of spray foam
insulation to achieve multiple performance
traits in one product including thermal, air,
and water resistance.
4. assess the ability of spray foam insulation
to be installed with fewer steps and at a
lesser cost than assemblies using rigid
foam insulation.
Consequently, Icynene goes to great lengths to define the
Medium-density
spray foam insulation can provide
various ways:
components of such a system. Icynene ProSeal has been better results at less cost
for both cavity fill and continuous exterior
tested and listed by ABAA as the key component of an air Sponsored bySuitable
ICYNENE, Inc. | By Peter J. Arsenault, FAIA, NCARB, LEED AP
applications
barrier assembly. Icynene ProSeal Eco is also in the
board insulation located over the exterior
he design of exterior wall assemblies
structural face and behind exterior claddings.
has become increasingly focused on
Whileapproved
this may be a common
choice,assemblies
it is not
performance
for greaterin
energy
efficiency285
Tested
NFPA
wall
for
process of being recognized. Among the many rigid foam
the only one. In fact, closer review suggests that
and resistance to air and water penetration.
using field-applied spray foam insulation, of
Energy
Conservation
more
design
flexibility
insulation boards that exist in the marketplace, only four The 2015 International
a medium density, may be a better choice for
Code and ASHRAE 90.1 now require insulation
many situations. This has been found to be true
is continuous in wall assemblies (i.e. not
rigid foam insulation boards have currently received the that
Fireframing,
tested
building
types I, II, III, IV
when looked at in terms
of design flexibility,
interrupted by studs,
etc.) in for
all eightcommercial
performance, construction efficiency, and cost.
climate
zones
within
the
United
States.
This
to receive aia/ces credit, you are required
air barrier assembly designation.
and
V construction
push for continuous
insulation
in exterior wall
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To make an air barrier system, these products typically
require sealants to be applied at all joints and
penetrations—a very laborious process. Furthermore, the
sealing tends to get applied on the exterior, which is the
most vulnerable location in terms of temperature and
humidity changes.
assemblies is also reflected in green building
standards and
the desires of building owners
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to reduce energy costs. The response by many
architects has often been to use rigid foam
4. DESIGN FLEXIBILITY
Spray foam can readily adhere to curved, irregular, or
unique shapes and conditions. “Spray foam provides
flexibility for designers,” Duffy emphasizes. “In fact, it’s the
flexibility of the product that they are often interested in,
which then becomes a springboard to them learning
about its other characteristics.”
5. WATER RESISTIVE BARRIER
All of Icynene’s medium density spray foam products are
considered as water resistive barriers since they have very
low water absorption per ASTM D 2842 and are capable
of shedding water. Consequently when used as exterior
continuous insulation, water that may have gotten past
the cladding system would meet the water resistive
4
Comparison of foam
insulaTion Types
to read the entire article and pass the test.
Go to ce.architecturalrecord.com for
complete text and to take the test for free.
Wide range of cost
effective ASTM E119 tests of
Plastic foam insulation has been in use for
decades on a range of applications from coffee
rated assemblies for
flexibility
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One hour, two hour as well as three hour fire ratings
appropriate for a greater range of structure types
One formulation with superior adhesion to
common building substrates under a wide range of
environmental conditions
Icynene ProSeal can be sprayed year round, even at
cold temperatures as low as 23°F while Icynene
ProSeal Eco can be sprayed year round in
temperatures as low as 5°F.
For more details, check out this video, which details
the performance advantages as well as the cost
savings of closed cell spray foam in steel frame and
CMU continuous insulation applications.
barrier at the foam’s exterior surface and drain down it
and not continue progressing into the wall assembly
where it could cause damage. Icynene ProSeal and
Icynene ProSeal Eco have been evaluated according to
THE EVOLUTION OF INSULATION ™
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AIA/CES COURSE #K1506C
Steel Framing for Exterior Walls
CLOSED CELL SPRAY FOAM
STEEL FRAMING (LGMF) WALLS
MAJOR COMPONENTS:
1/2” Gypsum
Wallboard
Taped
and Finished
RIGID XPS FOAM BOARD
STEEL FRAMING (LGMF) WALLS
MAJOR COMPONENTS:
Gypsum Sheathing
with Embedded
Glass Mats
1/2” Gypsum
Wallboard
Taped
and Finished
Polyethylene and
Rubberized Asphalt
Sheet Barrier
Joint Tape
VS
3” Closed-Cell
Spray
Polyurethane
Insulation
R-15
3-5/8” 25 Ga.
Metal Stud &
Track, 16” O.C.
Brick Veneer
3” Extruded
Polystyrene
(XPS)
Insulation
R-15
3-5/8” 25 Ga.
Metal Stud
& Track,
16” O.C.
Gypsum
Sheathing
with Embedded
Glass Mats
Brick Veneer
1/2” Gypsum Wallboard, Taped and Finished
$1.55
1/2” Gypsum Wallboard, Taped and Finished
$1.55
3-5/8” 25 Ga. Metal Stud & Track, 16” O.C.
$4.58
3-5/8” 25 Ga. Metal Stud & Track, 16” O.C.
$4.58
Gypsum Sheathing with Embedded Glass Mats
$1.88
Gypsum Sheathing with Embedded Glass Mats
$1.88
3” Closed-Cell Spray Polyurethane Insulation (R-15)
$2.83
Polyethylene and Rubberized Asphalt Sheet Barrier
$2.78
Brick Veneer
$16.10
3” Extruded Polystyrene (XPS) Insulation (R-15)
$2.42
Brick Veneer
$16.10
TOTAL PER SQUARE FOOT
$29.31
TOTAL PER SQUARE FOOT
$26.94
INSTALLED COST SOURCE: R.S. MEANS 2014 BUILDING CONSTRUCTION COST DATA
The information detailed above is intended to provide a general cost comparison of commercial air barrier assemblies designed with foam plastic insulation materials of the
thickness. Figures do not include scaffolding costs, which can vary widely. R-Value performance will vary by product.
Additionally,
some rigid foam board
may
vapor
permeable
orproducts
impermeable
versions, so care is
ICC-ESsame
AC71,
the Acceptance Criteria for Foam Plastic
offer installation techniques allowing for the elimination of some of these generic assembly components such as Gypsum sheathing with embedded glass mats. Consult with
manufacturers for specific details.
needed to ensure that the correct product is chosen for
Sheathing Panels Used as Water-Resistive Barriers, and
TECHNICAL
/ ENGINEERING
SUPPORT
- CALLbarriers.
1.800.758.7325
the wall assembly as its drying potential will be affected.
are officially
designated
as water
resistive
(Figure 3 on page 3 is an example of a construction detail
For example, a very low water vapor permeance
that highlights the performance of the spray foam as a
membrane material (class I vapor retarder) used over an
water resistive barrier.)
entire wall surface, in conjunction with a rigid foam
insulation board application, would restrict the drying of
6. WATER VAPOR PERMEANCE
the wall much more than a medium density spray foam
Even though they can become a Class II vapor retarder (at
application of significantly greater thickness and thermal
noted thicknesses), all of Icynene’s medium density spray
performance.
foam products would allow an assembly to dry more
easily than equivalent thicknesses of all foil faced/skinned
7. DIMENSIONAL STABILITY
rigid foam insulation boards (either aluminum or foil
Both ProSeal and ProSeal Eco have tested for dimensional
based) and most unfaced foam boards. Therefore, spray
stability, which provides an indication how the foams
foam provides a wall with greater drying potential (to the
change dimensionally at different and severe temperature
outdoors) which should result in enhanced durability and
and humidity environments. Therefore, an architect can
longevity. If having a low water vapor permeance material
have confidence that their use will result in stable, long
on the exterior side of a wall assembly is a concern, note
term performance of the exterior continuous insulation
that the lesser the thickness of medium density spray
foil layer. Icynene design details provide solutions such as
foam, the greater the drying potential of the wall.
locking strips at key transitions to help ensure spray foam
bonds well to transition materials.
Also consider that membrane materials can be applied in
5
THE EVOLUTION OF INSULATION ™
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CMU Exterior Block Walls
CLOSED CELL SPRAY FOAM
MASONRY WALLS
MAJOR COMPONENTS:
1/2” Gypsum
Wallboard
Taped
and Finished
RIGID XPS FOAM BOARD
MASONRY WALLS
MAJOR COMPONENTS:
3” Closed-Cell Spray
Polyurethane
Insulation
R-15
Polyethylene and
Rubberized Asphalt
Sheet Barrier
1/2” Gypsum
Wallboard
Taped
and Finished
VS
Joint Tape
8” CMU
8” CMU
Brick Veneer
3” Extruded
Polystyrene
(XPS) Insulation R-15
Brick Veneer
1/2” Gypsum Wallboard, Taped and Finished
$1.55
1/2” Gypsum Wallboard, Taped and Finished
$1.55
8” CMU
$11.45
8” CMU
$11.45
3” Closed-Cell Spray Polyurethane Insulation (R-15)
$2.83
Polyethylene and Rubberized Asphalt Sheet Barrier
$2.78
Brick Veneer
$16.10
3” Extruded Polystyrene (XPS) Insulation (R-15)
$2.42
Brick Veneer
$16.10
TOTAL PER SQUARE FOOT
$34.30
(continued from page 6)
TOTAL PER SQUARE FOOT
$31.93
INSTALLED COST SOURCE: R.S. MEANS 2014 BUILDING CONSTRUCTION COST DATA
The information detailed above is intended to provide a general cost comparison of commercial air barrier assemblies designed with foam plastic insulation materials of the same
thickness. Figures do not include scaffolding costs, which can vary widely. R-Value performance will vary by product. Additionally, some rigid foam board products may offer
installation techniques allowing for the elimination of some of these generic assembly components. Consult with manufacturers for specific details.
8. COLD TEMPERATURE APPLICATIONS
TECHNICALmedium
/ ENGINEERING
SUPPORT
All of Icynene’s
density
spray- CALL
foam1.800.758.7325
products can
be applied in cold conditions and to cold substrate
materials in accordance with their installation guidelines.
ProSeal Eco is particularly useful for cold weather work
since it can be successfully applied to substrates as cold
as 5°F (-15°C). This capability makes it an industry leader
for winter time use as exterior continuous insulation.
ProSeal has cold temperature capabilities similar to or
better than other medium density spray foams with
substrates allowed to be as cold as 22°F (-5.5°C) for an
application.
9. FIRE RESISTANCE
Both spray foam and rigid foam insulation board products
are considered combustible and this installation is
allowed in non-combustible assemblies provided that the
assembly non-combustibility requirements in the Building
Code are met. All of Icynene’s medium density spray (and
low density) foam products have been evaluated for use
6
in fire-rated assemblies (per ASTM E 119 and NFPA 285)
for Code compliant walls.
Other fire-rated assemblies and NFPA 285 compliant
walls have been determined on a case by case basis
through our fire engineering consultant’s examination of
assembly construction details. Icynene medium density
spray foam’s fire performance characteristics are different
than extruded polystyrene foam boards in that they do
not melt at high temperatures. Furthermore, although
Icynene’s medium density spray foam products are
considered combustible according to the Code, they will
not sustain a fire once the fire-source is removed.
A Smart Option
Properly used and installed, all insulation will help reduce
the use of energy for heating and cooling in buildings,
which will help with sustainable and efficient building
performance. When comparing spray foam and board
insulation however, there are several notable differences.
THE EVOLUTION OF INSULATION ™
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First, spray foam can more completely and fully insulate
and seal a building without joints, gaps, or other
interruptions in the continuous insulation. The fact that it
adheres to surfaces helps ensure thermal performance.
Second, there is normally no waste associated with spray
foam compared to board insulation since only the
amount of material needed is used. Rigid XPS boards
often need to be cut to fit producing scraps and waste.
Third, since spray foam is delivered in liquid form, a
tractor trailer load of it can hold a significantly greater
amount of board feet of insulation than a truck load of
rigid foam insulation boards.
Fourth, the process for producing spray foam insulation
compared to board insulation is different not only in the
base material used but also in the type of blowing agents
used. Those blowing agents have been independently
rated and range widely in terms of Global Warming
Potential (GWP). Icynene ProSeal Eco with 100 percent
water blown technology offers the lowest rated GWP of 1.
By contrast, XPS chemical blowing agents carry a
dramatically higher GWP of over 1,000. It is easy to see
which one is more environmentally appropriate based on
those numbers.
Quick Facts: ProSeal
and ProSeal Eco
Icynene’s latest white paper “The Performance Benefits
of using Medium Density Spray Foam in Continuous
Insulation Applications” explains how medium density,
closed cell spray foam:
Meets or exceeds thermal performance of
comparable rigid foam insulation products due to
its high R-value, which can also lead to reductions
in overall wall thicknesses
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Creates a continuous insulation, water resistive
barrier and air barrier layer in one step
Delivers consistent system performance for cost
and construction schedule savings
Can cover the widest range of exposed surfaces to
prevent thermal bridging
Features an approach to air and water resistive
barrier creation that is not dependent on extensive
use of joint sealants in exposed situations
Has a much better ability to bond to the entire
length of wall penetrations, such as brick ties and
fasteners, thereby better ensuring thermal and
airtightness effectiveness
Is less likely to have air barrier discontinuity at
transitions and control joints
Has very low water absorption and is capable of
shedding water
Can be applied in cold temperatures as low as 5°F
(for Icynene ProSeal Eco)
Can be installed in wall assemblies that are firerated or part of non-combustible construction
Icynene’s story got even better when the company
introduced ProSeal Eco, an environmentally responsible
100% water blown closed-cell spray foam.
Icynene ProSeal and Icynene ProSeal Eco create a continuous
insulation, water resistive barrier and air barrier layer in one step.
7
“The environmental advantage of Icynene ProSeal Eco
pulls heartstrings of specifiers because you don’t have to
worry about environmental issues like global warming or
about spraying at lower temperatures like 5°F,” says Duffy.
“Plus the product offers more flexibility in diverse weather.
The R value of ProSeal Eco is comparable to extruded
polystyrene foam, but not as high as ProSeal. When you
consider there is no compromise to going to a spray
foam product, the question becomes: Why would anyone
use XPS? It’s a good question; they should go ask the
growing number of people using spray foam.”
THE EVOLUTION OF INSULATION ™
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continuous water barrier. This is a straightforward way
to meet code requirements.”
There is also a misunderstanding surrounding the issue of
combustibility. According to Duffy, individual products
can be technically “combustible” as long as they are used
in a code-compliant “noncombustible” assembly.
For example, in electrical wiring, plastic foam insulation
which is combustible, is safely used within a
non-combustible electrical assembly.
Icynene ProSeal is applied to the exterior in a continuous
insulation application prior to brickwork being added over top.
For more information on all the testing and analysis
Icynene has done on combustibility of common wall
assemblies—you can request testing on one of your wall
assemblies from the Icynene Engineering Division—
Call 800-758-7325.
GET STARTED!
In terms of indoor air quality, Icynene just announced
(August 2015) that it has shortened building re-entry and
re-occupancy times through innovations in both
product formulation and environmental testing protocol
for its low VOC products Icynene ProSeal and Icynene
Classic Max. The revised allowances permit one hour
re-entry for trades and two hour re-occupancy for
homeowners. This is only applicable to applications of
Icynene ProSeal and Icynene Classic Max spray foam
insulation in the United States.
Get started using Icynene ProSeal or ProSeal Eco in your
next building. You can contact Icynene’s Building Science
team at 1-800-758-7325. In the meantime, take a quick
look at some handy references Icynene has already created
to get you planning.
“Shorter re-entry times allow builders in residential and
commercial projects to continue construction with
minimal impact on their schedules, while shorter reoccupancy times offer homeowners the opportunity to
return to their homes the same day, within hours, of
their spray foam installation,” says Icynene VP Marketing,
Betsy Cosper.
The online wall assembly tool allows you to build more
than 750 NFPA 285 compliant combinations. There are
many more options available that meet NFPA 285.
Icynene’s Engineering team can assist if your preferred
assembly is not listed within the tool itself.
What’s the Pushback?
The advantages of spray foam are so comprehensive, it is
hard to imagine why commercial architects wouldn’t take
advantage of it.
Duffy explains the common concerns. “In some cases
folks are trying to apply exterior claddings directly over
the surface of a material, so they like conventional
board type products because they are a consistent
thickness. Spray foam does have some variation in
thickness.” However, he adds, “Good architectural
design requires space behind the cladding material to
drain moisture away from the interior of the wall. With
proper details, spray foam’s lack of complete uniformity
doesn’t matter because what you end up with is an air
barrier that is fully adhered to sheathing with a
8
First, you can build your own NFPA 285 compliant wall
assemblies featuring Iynene spray foam insulation
products for your next design project with an online wall
assembly tool (click here).
Second, check out Icynene’s Architectural Resource
Binder online. This comprehensive resource is packed
with the valuable design information that you need to
specify Icynene spray foam insulation.
Continuing
Education
For years, Icynene has worked closely with the AIA
as an approved provider within their Continuing
Education System (CES). Icynene has completed more
than 3,500 live presentations in front of more than
40,000 architects throughout North America. Schedule
your next Continuing Education session by emailing
[email protected] today!
THE EVOLUTION OF INSULATION ™
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