2018 irc - spray foam & thermal & ignition barriers rt ......• foam insulationcan be...

Spray Foam

“The Lo‐Down on Spray Foam:

Including Thermal & Ignition Barriers”

Russell Thornburg507.413.2027russell.thornburg1@gmail.com

Background:Building Contractor 1984 _ over 30 yearsBuilding Inspector Technician ‐ 1997 ‐ 1999 Field Inspector – 1998 _ presentPlans Examiner – 1999 _ presentCode Development Committee – 2006 _ presentCode Trainer – 2001 _ presentCode Consultant – 2008 _ present

INSTRUCTOR:

Course Approval

• The opinions expressed in this presentation are the opinions of the presenter, Russell Thornburg, and do not represent the official opinion of the International Code Council (ICC) or that of the administrative authority of any jurisdiction, county or State. As always, the Building Official of the Jurisdiction is the final authority.

• This handout is used as a guideline for the instructor and no part of this work may be reproduced, distributed or transmitted in any form or by any means, including, without limitation, electronic, optical or mechanical, without advance written permission from Russell Thornburg.

“Disclaimer” The text in this presentation does not necessarily represent actual code language. The presented text may be summarize, highlight or generalize the code section. Additional provisions or exceptions may be included in the actual code section. General references to the code sections are given for the purpose of verifying the complete provisions of the code section for your further review.

Spray Foam Requirements for thermal barriers and ignition barriers in the IRC

Agenda

1. What about it…

2. Are thing different than before?

3. Prescriptive requirements.

4. Quick review of requirements.

5. Foam Plastics – specific approvals.

6. Test Reports and Evaluation Reports.

Background

• Background:• “The U.S. market for polyurethane foam used for building and construction has grown steadily since 2002. Professional contractors and consumers have increasingly purchased foam‐based insulation products for a multitude of energy‐saving renovation projects that could offset the rising cost of heating commercial and residential properties.

8H C Fennell Consulting

Background

• In 2004, 1.5 billion pounds of polyurethane foam was processed in the United States in the construction industry alone, with accelerating growth since then. Demand is expected to increase by a global average of 9.8% per year between 2007 and 2012, creating a potential market of nearly 654,000 tons by 2012."1

1 World Insulation to 2014 ‐ Demand and Sales Forecasts, Market Share, Market Size, Market Leaders; 2011, The Freedonia Group, Inc.

H C Fennell Consulting

“Quote”

• It has taken lots and lots of studying to understand foam. Air movement, vapor diffusion, toxicity, spraying techniques, shelf life, types, pressures, temperatures of the feed lines, correct mixing, indoor and outdoor temperatures, etc, all are all monsters that will surface their ugly head if anything is out of balance.

• I have found the only way to control foam is be on site 100% of the time while the sprayers are spraying.

• Study, study, study, and then some more. Job site control, job site control, and more job site control.

MN Contractor comments

Open Cell / Close Cell

Additional Information About SPFOpen‐Cell Spray Foam• “½‐lb” density

– Semi‐rigid spray foam– Low density

• Fills up the wall cavity– High expansion– Shaving required

• Water blowing agent– Expands & leaves open air

pockets• R‐value = 3.4‐3.9/inch• No structural value

Closed‐cell Spray Foam• “2‐lb.” density

– Rigid SPF– High/medium density

• Not full wall thickness– Controlled expansion– Hybrid system applications

• Non‐ozone depleting (HFC) blowing agent– Millions of tiny closed‐cells trap

this high‐efficiency gas• R‐value = 6.0‐7.0 per inch• Offers up to 300% increased

structural value (over 2”)

Additional Information About SPFOpen‐Cell Foam• Air Barrier at 3.5”

Meets sealant requirement of IECC

• Vapor retarder typically required in cold climates5” application = 10 perms

• Water can absorb (up to 40% by volume)Do not use below grade or on

ductwork• Offers sound absorption and

barrier

Closed‐Cell Foam• Air Barrier at 1”

Meets sealant requirement of IECC

• Code defined vapor retarder at 2” or greater2” application = 0.95 perms

• Difficult for water to absorb(less than 4% water absorption) ‐ HydrophobicFEMA Flood Resistant

Offers sound barrier performance only (will not absorb noise)

R‐value Calculation

14BASF Polyurethane Foam Enterprises LLC

FTC R-value DisclaimerRead Before You Buy: The data contained in this document shows the R-value of this insulation. “R” means the resistance to heat flow. The higher the R-value, the greater the insulating power. Compare insulation R-values before you buy. There are other factors to consider. The amount of insulation will depend upon the climate, the type and size of your house, and the fuel use patterns and family size. If you buy too much insulation, it will cost you more that what you will save on fuel. To achieve proper R-values, it is essential that insulations be installed properly.

Industry Comment

Ductwork2009 IRC/IECC Changes on Duct Insulation –• Duct Insulation Materials: Now allows for SPF to be used in direct contact with ductwork, with conditions:– Foam plastic must be Class 1 (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 all requirements of R316• Eliminates need for additional vapor retarder• Eliminates need for additional joint sealing/caulking

Mixing / Feed Lines

Foam Product as a System

Substrate Temperature

Ice Dams

Building Thermal Envelope

Definition• Unvented attics, also known as conditioned or cathedralized attics, are created by applying insulation directly to the underside of the roof deck and omitting or sealing all ventilation paths against air leakage (soffits, ridge and gable vents).

22SPFA AY‐141 December 2008

R806.5

• The unvented attic space is completely contained within the building thermal envelope.– The SPF insulation applied to the underside of the roof deck and to gable‐end walls instead of the attic floor.

– The SPF must be continuous and tied into the top plates of exterior walls.

– The thermal conditioning of the attic depends on heat transfer through the attic floor, therefore the attic floor should be left uninsulated.

– SPF must be applied as to prevent any air leakage between the attic and the exterior.

Building Thermal Envelope

SPFA AY‐141 December 2008

Under the Floor ‐ Continuity

Pressure Can Claps Air Chutes

Thickness

ASTM E 84NFPA 286.

AC377‐3.2

Thickness/Voids

Energy Code Requirement

Air Movement / Vapor Diffusion

Ratings on Air Tightness

Roof Leak Detection

• Insulation applied under a roof deck may hinder roof leak detection.

Vapor retarder coating or film

• A vapor retarder coating or film may be required for open‐cell foams in cold climates.

• Note: The application of a vapor retardant coating on SPF installed in attics changes the fire characteristics of the assembly. SPF’s coated in this manner must be covered with a thermal barrier, a prescriptive ignition barrier or should have full‐scale attic fire test data to support its use without a prescriptive ignition barrier or a thermal barrier.

32SPFA AY‐141 December 2008

Air Exchanges

• ES Report Insulation – Foam– Example: ESR #1383 revised in April of 2012. Section 4.4 ‐ C

• HVAC• Recess Light • Opening in Floor / Ceiling• BTU’s burn testing

– Oak– Foam Products

• Foam insulation can be applied by a professional using special equipment to meter, mix, and spray the foam into place. Polyisocyanurate and polyurethane foam insulation can be produced in two forms: open‐cell and closed‐cell. In general, open‐celled foam allows water vapor to move through the material more easily than closed‐cell foam. However, open‐celled foams usually have a lower R‐value for a given thickness compared to closed‐cell foams. So, some of the closed‐cell foams are able to provide a greater R‐value where space is limited.

34Department of Energy; Assistant SecretaryEnergy Efficiency and Renewable Energy

“Unvented Attic Assemblies”• Date: February 8, 2011• From: Donald J Sivigny; Sr. Bldg. Code Representative/Energy

Specialist• Subject: Staff opinion on the use of the 2009 International

Residential Code (IRC) Section R806.4 “Unvented Attic Assemblies” as an alternate method in accordance with MN Rules Chapter 1300 Section 1300.0110 Subp. 13 “Alternate materials, design and methods of construction and equipment”….

• …. These changes have been reviewed and scrutinized in the 2012 national code adoption process and the 2012 IRC is consistent with the language in the 2009 IRC.

• … It is the opinion of this Construction Codes and Licensing Division (CCLD) Staff, that this could be considered by the Building Official in determining compliance with MN Rules Chapter 1300 Section 1300.0110 Subp. 13 “Alternate materials, design and methods of construction and equipment”. 35

Density of Spray Foam

36BSD‐149: Unvented Roof Assemblies for All ClimatesBy Christopher Schumacher Pg.3

The Caution

• In building fires, smoke inhalation and asphyxiation are the two main causes of fatalities.

• Many of the stipulation placed on spray foam often seem illogical or overly cumbersome.

• Regulations have challenged the foam plastic industry to create better building products & testing.

Approach

• Is the submitted document and construction project a Code compliant method?

• Does SPF meet the intent of the Codes for this application?

History…….

What about it….

• Spray polyurethane foam (SPF)– Organic materials and it is combustible

• It has been formulated with flame retardants to decrease the flame spread

• ASTM E 84 (Test for Surface Burning Characteristics for Building Materials) – Solely to measure and describes properties of products in response to heat and flame

What about it….

• ASTM E 84 (Test for Surface Burning Characteristics for Building Materials)– Set the limits on flame spread index and smoke development

– Only class A and B ratings are acceptable• Flame spread rating Class A is 25 and Class B is 75• Smoke development index same for both ratings

In your research you may notice that the smoke development index is also relatively high at 450 compared with other insulation materials.

What about it ‐ SPF

• When SPF exposed to fire sources unprotected SPF can ignite and may result in a flash fire.

• Although burning SPF will form a surface layer of less flammable char, the initial burning can produce combustible gases and black smoke.

• In confined interiors, these combustible gases can accumulate and ignite resulting in flashover, a dangerous fire situation.

What about it ‐ Flashover

• Five parameters to determine flashover– Flames exit doorway– Auto‐ignition of paper targets on floor– Avg. upper layer temp exceeds 1112⁰F– Heat Release Rate exceeds 1MW– Heat flux on floor exceeds 25 kW/m2

• NFPA 286 – Flashover occurs when any two of the parameters are attained

Testing ‐ Scale

• small‐scale: such as cone calorimeter• medium scale: room corner tests• large‐scale: mock‐up of unvented attic

Fire Test

• Shortly after ignition45

Fire Test

• Impinging on ceiling

Fire Test

• Flames outdoorway

What about it ‐ SPF• Under these conditions, additional foam and/or other combustibles can become involved in the fire creating additional combustible gases and feeding the fire.

• Note 1: These fire scenarios depend on the accumulation of combustible gases.

• Exterior applications of SPF, such as roof systems, where combustible gases can dissipate, are less likely to become involved in flash fires and are subject to different requirements under the model building codes.

What is a Thermal Barrier?

• A thermal barrier is a material– Applied between(for example: foam)– It is designed to delay the temperature rise

• During fire situation and to delay or prevent the product (foam) involvement in a fire

– Approved prescriptive thermal barrier by code is define as ½” gypsum (wallboard)

– Non‐prescriptive thermal barrier has to meet the same standard as prescriptive or exceed the requirements

Non‐prescriptive Thermal Barrier

• Shall undergo temperature transmission fire test.

• ASTM E 119 ( Test Methods for Fire of Building Construction Materials)

• Wherein the temperature rise of polyurethane foam is limited to not more than 121o C (250oF) after 15 minutes of fire exposure without the foam becoming involved.

• Additionally, equivalent thermal barriers must undergo a fire integrity test:– to establish that they will sufficiently remain in place during a fire scenario by passing a large‐scale, 15‐minute fire test

• Equivalent thermal barriers meeting this criterion are termed a “15 minute thermal barrier” or classified as having an “index of 15”

• Equivalent thermal barriers shall undergo two fire tests:1) A temperature transmission test (such as a modified

ASTM E 119, the actual thermal barrier test apparatus being smaller than the typical large‐scale wall or roof/ceiling test assemblies); and

2) A fire integrity test ( a large‐scale fire test such as NFPA 286 [with a specific acceptance criteria defined within the IBC or IRC], UL 1040, UL 1715, or FM4880).

Testing & Standards• ASTM E84 ‐ Standard Test Method for Surface Burning Characteristics of Building Materials

• ASTM E119 ‐ Standard Test Methods for Fire Tests of Building Construction and Materials

• ICC Acceptable Criteria 12 ‐ FOAM PLASTIC INSULATION

• NFPA 286• ICC Acceptable Criteria 377 ‐ SPRAY‐APPLIED FOAM PLASTIC INSULATION (supersedes AC12)

• NFPA 275And many, many more

CautionGenerally accepted diversified fire tests for building assemblies and thermal barriers include:

* UL 1715 Fire Test of Interior Finish Material* UL 1040 Insulated Wall Construction* FM 4880 Building Corner Fire Test* U.B.C. Standard 26‐2 Test Method for the Evaluation of Thermal Barriers.

Caution: Just because a material is advertised as a “thermal barrier” does not mean that it has been approved by a code agency or a local code official. Ask for test data and code body approvals, listings, or other written indications of acceptability under the code to be sure that the product selected offers the fire protection that the code demands.

Where is a Thermal Barrier Required?

• A thermal barrier is required between attic and crawlspace and living spaces when SPF is applied.

• Where there is interconnected attic or crawl space to (non & occupied space)

• All interior SPF applications are required to be covered with “approved thermal barrier.”

• “Unless Exception applies”

Exception Thermal Barriers

• Certain masonry or concrete constructions, R316.5.1;

• Exterior applications as part of certain tested & classified roof assemblies, R316.5.2 ;

• Certain attics & crawlspaces, R316.5.3 & R316.5.4

• Sill plates & headers, R316.5.11 (limited to certain SPF in Type V construction);

• And ….

Thermal Barrier Exceptions

• Attics and Crawl Spaces [IBC 2603.4.1.6 / IRC R316.5.3]– Entry is made for service of utilities

– Ignition barrier is required separating attic/crawlspace space from foam

– No storage area in the attic or crawl space

Ignition Barrier Requirements

• Ignition Barrier [IBC 2603.4.1.6 / IRC R316.5.3]– Prescriptive ignition barriers include:• 1.5” mineral fiber insulation• 0.25” wood structural panels• 0.375” particleboard• 0.25” hardboard• 0.375” gypsum board• Corrosion‐resistant steel having a base metal thickness of 0.016”

• 1.5” cellulose insulation• .25 fiber‐cement panel, soffit or backer board

– Alternative Assemblies by Special Approval Testing

Alternative Assemblies• Special Approval Tests [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/R302.9.4)

– 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

End‐Use Fire Testing

• Special Approval for Foam In Attics and Crawlspaces– ICC‐ES has issued ESRs for this application• Qualifies assembly with foam alone or foam with an alternate ignition barrier

More foam is being used… …and used in new ways.

1. The IRC requirements for foam have changed a lot over the past few code cycles. This has created a lot of confusion amongst builders, contractors, architects and code officials.

2. AC‐377 was in established 2008 to allow more accurate performance testing of SPF products.

– Applies jobsite installation of spray foam– Establishes testing procedures for qualifying

• Fire performance of foam ‐• Thermal Barrier• Ignition barrier – Appendix X

3. The SPF technology has advanced, especially with fire performance.

Foam plastic

R316.3 Surface Burning CharacteristicsR316.4 Thermal Barrier

R316.6 Specific Approval

R316.5 Specific RequirementsR316.5.1 Masonry ‐ Concrete ConstructionR316.5.2 RoofingR316.5.3 AtticsR316.5.4 Crawl SpacesR316.5.5 Foam‐filled doorsR316.5.7 Foam backer board

R316.5.8 Re‐sidingR316.5.9 Interior trimR316.5.10 Interior finishR316.5.11 Sill plates & headersR316.5.12 Sheathing

3 paths to compliance

3 IRC: R31662

Unless otherwise allowed in Section R316.5 or R316.6, all foam plastic shall have:

– flame‐spread index ≤ 75 (Other insulation ≤ 25)– smoke‐developed index ≤ 450

when tested in the max. thickness for use in accordance with ASTM E84. (foam plastic installed 4 inches or less)Exception: insulation greater than 4” thick:

– flame‐spread index ≤ 75 – smoke‐developed index ≤ 450, and….– the end use is approved in accordance with Section R316.6 using the thickness and density intended for use.

– NFPA 286 (foam plastic installed more than 4 inches)

Surface burning characteristics

IRC: R316.363

Unless otherwise allowed in:– Section R316.5 or – Section R316.6

foam plastic shall be separated from the interior of a building by an approved thermal barrier of minimum ½” gypsum wallboard…..

Thermal barrier IRC: R316.4

…. or tested in accordance with NFPA 275…..

Foam plastic

3 IRC: R31665

Specific Requirements

The following requirements shall apply to these uses of foam plastic…

– unless specifically approved in accordance with Section R316.6

– or by other sections of the code

– or the requirements of Section R316.2 through Section R316.4 have been met.

IRC: R316.5

No thermal barrier is required when foam plastic is incorporated into a roof assembly on the exterior side, over tongue and groove planks or wood structural panel sheathing 15/32

Smoke developed index of the foam plastic is not limited.

RoofingIRC: R316.5.2

Ignition Barrier

The reduced provision provides a barrier whose only purpose is to prevent the direct impingement of flame on the foam plastic insulation

Access

• Attic access: R807.1 Buildings with combustible ceiling or roof construction shall have an attic access

• Crawl Space access: R408.4Access shall be provided to all under‐floor spaces.

The thermal barrier specified in Section 316.4 is not required where access is required by Section R807.1 (R408.4) and where entry is made only for service of utilities and when the foam plastic insulation is protected against ignition using one of eight ignition barrier materials for Example:

• 1.5” thick mineral fiber insulation,• 0.25” thick wood structural panels,• 0.375” thick particleboard,• 0.25” thick hardboard,• 0.375” thick gypsum board, or• steel having thickness of 0.016 inch • ¼” fiber‐cement panel, soffit or backer board

The above ignition barrier is not required where the foam plastic insulation has been tested in accordance with Section R316.6.

Attics Crawl spacesIRC: R316.5.4IRC: R316.5.3

Access is required when attic is:> 30 ft2, and> 30″ high

Rough Opening size: 22″ x 30″Minimum

IRC: R807

Attic access for appliances

Foam plastic shall be permitted to be spray applied to a sill plate and header (AKA –band joist) without thermal barrier, subject to all of the following:

– The maximum thickness of the foam plastic shall be 3¼ inches

– The density of the foam plastic 0.5 to 2.0 pcf.

– The foam plastic shall • flame spread index ≤25 • smoke developed index ≤450

Sill plates and headers

IRC: R316.5.11

Lets review then look at some applications

Foam shall be separated from the interior of the building by thermal

barrier

Exception – Band joists/ headers – limited to 3¼” R316.5.11

Attics

No requirement No access (??) required R807< 30” high & < 30ft2

Attics

No requirement No access required R807< 30” high & < 30ft2

Ignition barrier Access required R807≥ 30” high & ≥ 30ft2

No Storage

78Ignition barrier – R316.5.3 & 4

Attics

No requirement No access required R807< 30” high & < 30ft2

Ignition barrier Access required R807required ≥ 30” high & ≥ 30ft2

No Storage

Thermal barrier Access required R807required ≥ 30” high & ≥ 30ft2

With Storage

Storage Attic

• What is declared on the plan?

• Is access required?

• Is the spaced accessed by stairs?

• Is floor sheathed >30”x 30” (min required for mechanical equipment M1305.1)

Crawlspace

Ignition Barrier Access required R408.4No Storage

Thermal Barrier Access required R408.4With Storage

1. What is declared on the plan2. Ease of access3. Is flooring provided – rat slab – etc. 81

Where is the access: Inside the dwelling or outside exterior wall

Is an ignition barrier or thermal barrier required? 82

Is an ignition barrier or thermal barrier required?83

Foam plastic

3 IRC: R31688

Foam plastic not meeting the requirements of Sections R316.3 through R316.5 shall be specifically approved on the basis of one of the approved tests.

The specific approval shall be based on the actual end use configuration (thickness, joints, etc.) and shall be performed on the finished foam plastic assembly in the maximum thickness intended for use.

Specific approval

Large Scale Testing

IRC: R316.6

Large Scale Tests

Examples of specific large scale tests, such as:FM 4880 Class 1 Insulated Wall or Wall & Roof/Ceiling Panels

NFPA 286 Standard Methods of Fire Tests for Evaluating Room Fire Growth Contribution of Wall and Ceiling Interior Finish

UL 723 Test for Surface Burning Characteristics of Building Materials

UL 1040 Fire Test of Insulated Wall Construction

UL 1715 Fire Test of Interior Finish Material

Other large scale fire tests related to actual end‐use configuration can be used. R316.5

FM 4880 Class 1 Insulated Wall or Wall & Roof/Ceiling Panels

91http://www.fmglobal.com/assets/pdf/fmapprovals/4880.pdf

Alternate test method

As an alternate … …wall and ceiling finishes shall be permitted to be tested in accordance with NFPA 286, and meet the meet the following criteria:

1. During the 40 kW exposure, flames shall not spread to the ceiling. (approx 150k BTU’s)

2. During the 160 kW exposure, the interior finish shall comply with the following: (500K BTU’s)2.1. Flame shall not spread to the outer extremity of the sample on

any wall or ceiling.2.2. Flashover, as defined in NFPA 286, shall not occur.

3. The total smoke released throughout the NFPA 286 test shall not exceed 1,000 m2.

IRC: R302.9.4

92IRC: R316.6

NFPA 286 Standard Methods of Fire Tests for Evaluating Room Fire Growth Contribution of Wall and Ceiling Interior Finish

Testing for Ignition Barrier

• 40 kW fire for 4:18 minutes • Flames can not reach the ceiling• Smoke released not exceed 1,000 m2

• 40 kW fire for 5:00 minutes • Flames can not reach the ceiling• 160 kW for total from 5:00 to 15 min• Smoke released not exceed 1,000 m2

Testing for Thermal Barrier

Intumescent Testing

It is the assembly that is evaluated

Product Thermal Barrier Ignition Barrier

Gaco WallFoam 183M

2 lb foam – close cell

TRR2 Fireshell F10E16 wet mils

None Required

DC3156 wet mil base, 22 wet mills top coat = 28 wet mils total

GacoGreen 052.5 lb foam – open cell

TRR2 Fireshell F10E26 wet mils

TPR2 IB414 wet mils

GacoFireStop 5500.5 lb foam – open cell

DC31522 wet mills

None Required

This is a system. All Spray Foam Co. have system to follow!!!

Coatings

Ways to show code compliance under Section R316.6

1. Provide the actual test report that contains a description of the assembly and test results showing that the foam plastic, in the end use application, has passed the test.

2. The second method is to obtain an evaluation report that covers the end‐use application. (ICC‐ES AC377)

IRC Commentary

Lapolla

https://icc‐es.org/evaluation‐report‐program/reports‐directory/

ESR 4322 ICC 2019 DC315 ER_0499

Intumescent testing

Evaluation Reports

• Confirm that products meet code requirements.

• Technical review of data by 3rd party.

GacoFireStop 5500

IAPMO ER‐0233

GacoFireStop 5500

IAPMO ER‐0233

References

• http://biobased.net• http://www.foam‐tech.com• http://www.gaco.com• www.iccsafe.org• http://www.nfpa.org• http://www.sprayfoam.com

https://www.youtube.com/watch?v=mUPp‐Ipt‐Pk

• Comments

• Questions

• Complaints

Short Cut

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