Spray Foam Solutions for Canadian Designers

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Spray Foam Solutions Spray Foam Solutions for Canadian Designersfor Canadian Designers

By Paul Duffy, P. Eng.

Vice President, Engineering

Icynene Inc.

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Biography - Paul Duffy, P.Eng.

• B.A.Sc. (1981), M.A.Sc.(1983) Construction and Building Science,U of Toronto

• Chairs Spray Foam Coalition for ACC-CPI• Sits on several Standards Committees, for RESNET, BPI, Energy

Star, etc.• More than 20 years Consulting Engineering experience in both

residential and commercial construction.• In his three years at Icynene, he has spearheaded the expansion

of approvals for new products and the push into Commercial markets for the key products offered by the company.


A Canadian Success Story

• Icynene Inc. is a Canadian company with manufacturing and operations located in Mississauga, Ontario.

• Icynene is generally credited with developing and commercializing the first Low Density SPF Product for insulating and air sealing buildings.

• Incorporated 25 years ago.• Icynene now has dealers in over 30 countries around the

world• One of the 1st Canadian Companies to hold a CCMC report

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Icynene - Canadian Success Story

• Over 100 employees• Executive and Managers hold or have held positions on

the Board and committees of HBA’s in both Canada and the USA (NAHB, BILD, EEBA , CSA, BEC’s, SPFA etc.) as well as on Energy Service Organizations with a building science focus

• Professional Engineering Staff including design review, energy modeling and intense dealer support

• Credible, reliable field experience and support


Canadian Sales Team

• Alison Scott Bull, VP Sales – Canada• Brian Pedersen, Eastern Canada Territory Manager• Len Siminowski, Western Canada Territory Manager• Scott Ruffett, Commercial Sales Representative• Over 50 dealers coast to coast – they are part of our

team!!


Strategic Alignment

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Outline of Presentation

• Introduction to Icynene Products• Industry Trends and Implications for New

and Existing Products• Spray Foam Application and Details• Overcoming Barriers to Innovation


Icynene® North AmericaSpray Foam Products for Building Applications

Low Density

a. LD-C-50 (*+)b. LD-R-50 (*+)

Medium Density

a. MD-C-200 CDN ( x)b. MD-C-200 ( x)c. MD-R-200 (*+)

Note:Green- Products Available in US in the US market only.

* Open Cell + Water Blown x Captive Blowing Agent


Open or Closed Cell????

• Icynene MD-R-200• Water blown, open cell, SPF

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Trends

1. Increased Concern for Environment– Green Building Standards (LEED, Built Green,

Green Globes, NAHB Green)– Increased Concern for Energy Efficiency– Formulation adjustment & revision focus:

• Blowing agents• Recycled content• Rapidly renewable content



Energy Efficiency Opportunities

• Air leakage can represent up to 40% of heat loss/gain

• When added to the reduction in conductive heat losses, the energy efficiency opportunities provided by Spray Foam are HUGE!!!

Air Leakage

Conductive Heat Losses

Non Heating Energy Use

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Energy and Environmental Programs

• Even in Environmental Programs such as LEED, Energy Efficiency represents 50% or more of points available in

• Because foam provides both R-value and air barrier it tends to contribute many points

• Typical concerns include: non renewable, non recyclable content, ozone depletion potential, global warming potential


Formulation Trends

a. Substitution of Rapidly Renewable Raw Materials (Castor Oil and Soy)

• Tends to increase smoke in fires

• Tends to produce less desirable properties

• There are practical limits to what can be done and how much can be substituted.


Formulation Trends

b. New Blowing Agents • Todays BA’s have Zero Ozone Depletion Potential (ODP)

• Global Warming Potential (GWP) still high (950 to 1050)

• Water Blown products Generate CO2

• CO2 has a GWP of 1

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Formulation Trends

c. New Polyols, Catalysts and Fire Retardants

• Some focus on environmental issues but more on better properties.


Trends

2. Increased Competition– New Competitors– Outfall of US Market Collapse– Attractiveness of Canadian Market– Lack of Understanding of Canadian Market /

Codes / Standards


Spray Foam in Canada

• Many new product approvals• New SQAP providers

• Lots of confusing information from “American Suppliers”– Canadian Versions of Products– Code Approved Thermal Barriers– Ignition Barriers

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Canadian SPF StandardsMedium Density• CAN/ULC S705.1

(Material Standard) being updated

• CAN/ULC S705.2 (Application Standard) out for ballot

Low Density• CAN/ULC S712.1

(Material Standard) in print.

• CAN/ULC S712.2 (Application Standard) being printed

• Not Referenced in Code (yet)

• Current Reference is CCMC Evaluation Guide.


Icynene’s Canadian Spray Foams

LD-C-50(CCMC 12070-R)• Low Density• Open Cell• LTTR – R-3.7/in.• Vapour Permeable

MD-C-200 CDN(CCMC 13561-L)• Medium Density• Closed Cell• LTTR – R5.6/in.• Vapour Barrier @ 1.5”


Differences Between Canadian and US Product Standards

Low Density• Fire Testing• Open Cell %• Permeance• Dimensional Stability

Medium Density• Fire Testing• Closed Cell %• R-value Testing• Dimensional Stability• Permeance

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A Few Words about Quality Control


Icynene’s Quality Assurance Programs

• Plant is ISO 9001:2008 Registered –Audited Quarterly by ITS (Intertek)

• Site Quality Assurance Programs (SQAP) – Conform to CAN/ULC S705.2 and CAN/ULC S712.2 – Audited by ITS (Intertek)


Trends

3. Conversion of Other Insulation Types to Spray Foam– Better Performance– Easier to Achieve Better Air Tightness– Less Risk to Builders – Better Reliability

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Typical Product Cycle


Low / Medium Density Spray Foam Insulation Applications

17Designing for the Future: Understanding Light Density and Medium Density Open Cell and Closed Cell Spray Foam Insulation

PreferredNot RecommendedInsulation Sheathing / Continuous Exterior

PreferredPreferredDuct Insulation

AcceptablePreferredCantilevered Framing

PreferredPreferredBand Joists / Mud Sills

PreferredPreferredFoundation and Below

Grade

AcceptablePreferredCeiling / Vented Attic

PreferredAcceptableUnvented Attic

PreferredPreferredWall cavities

COLD CLIMATES

Closed Cell SPFOpen Cell SPFAPPLICATION


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Design Concept 1: LD Foam in wall cavity

• LD Foam in wall cavity• Single component foam

at windows etc.• Sealants at base of wall

plus built up framing• Transition membranes

at joints to other wall systems


Design Concept 2: Continuous MD Foam

• MD Foam sprayed continuously on exterior

• Transition membranes at windows, control joints, thru-wall flashings, etc.

• Sealants and single component foams at penetrations and small gaps for touch-ups etc.

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Design Concept 3: Hybrid Foam

• 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.

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Advantages of Using Spray Foam� Improves performance of insulated layer�Can provide redundancy in the design�Ability to test performance before subsequent

construction steps�Provides the opportunity to thermally protect

essential air barrier details� Improves performance of other materials� Integral air barrier and vapor permeance

characteristics can be used to avoid wetting and improve drying


Innovations with Spray Foam

1. Unvented Attic Designs2. “Continuous” Air Barrier / Continuous

Insulation3. Wall Energy Rating


1. Unvented Attics???

• Venting Required by Code?

• “Unless it can be shown that it is not required….”

Code Change is warranted

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2. Continuous Insulation and Air Barrier Systems

• ABAA Compliant• Tested to more

than 1000 pa. (ASTM E2178 and ASTM E2357)

• Both Low Density and Medium Density foam systems.


3. Wall Energy Rating

• More than R-value

• Includes Air Barrier and Insulation performance

Fiberglass LD Spray Foam

MD Spray Foam


Questions?

Paul Duffy

Icynene Inc.

6747 Campobello Road

Mississauga, ON

L5N 2L7

905-363-4040 x 209

www.icynene.com

[email protected]

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Spray Foam Solutions for Canadian Designers