{"id":208304,"date":"2024-02-23T16:26:18","date_gmt":"2024-02-23T21:26:18","guid":{"rendered":"https:\/\/www.constructionspecifier.com\/?p=208304"},"modified":"2024-09-24T16:40:15","modified_gmt":"2024-09-24T20:40:15","slug":"evolving-foam-plastics-decoding-thermal-barrier-compliance","status":"publish","type":"post","link":"https:\/\/www.constructionspecifier.com\/evolving-foam-plastics-decoding-thermal-barrier-compliance\/","title":{"rendered":"Evolving foam plastics: Decoding thermal barrier compliance"},"content":{"rendered":"<figure id=\"attachment_208306\" aria-describedby=\"caption-attachment-208306\" style=\"width: 344px\" class=\"wp-caption alignright\"><a href=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/Texas-metal-building-using-Firestable-2.0.jpg\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-208306\" src=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/Texas-metal-building-using-Firestable-2.0-300x179.jpg\" alt=\"The picture shows foam plastics used as thermal barrier in an industrial facility.\" width=\"344\" height=\"205\" srcset=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/Texas-metal-building-using-Firestable-2.0-300x179.jpg 300w, https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/Texas-metal-building-using-Firestable-2.0-500x298.jpg 500w, https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/Texas-metal-building-using-Firestable-2.0-768x457.jpg 768w, https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/Texas-metal-building-using-Firestable-2.0.jpg 800w\" sizes=\"auto, (max-width: 344px) 100vw, 344px\" \/><\/a><figcaption id=\"caption-attachment-208306\" class=\"wp-caption-text\"><span style=\"font-size: 9pt; font-family: arial, helvetica, sans-serif;\">An industrial facility which uses foam plastics as thermal barrier. <\/span><span style=\"font-size: 9pt; font-family: arial, helvetica, sans-serif;\"><em>Photo courtesy Richard Barone <\/em><\/span><\/figcaption><\/figure>\n<p><strong>By Richard Barone<\/strong><\/p>\n<p>Over the past several decades, plastic has been increasingly used in the construction industry, and with more plastics in buildings, the <em>International Building Code<\/em> (<em>IBC<\/em>) has updated its requirements to address the flammability of these plastics.<\/p>\n<p>Regarding the proliferation of plastics and composites, the thermal barrier section of the <em>IBC<\/em> (chapter 26, specifically) came into existence. However, \u201cthermal barrier\u201d is a term used specifically for the fire rating of a building element. It can be confused with terms such as \u201cthermal insulation\u201d or \u201cthermal bridging,\u201d both of which relate to the transfer of heat or cold through building materials. A thermal barrier, however, as defined by the <em>IBC<\/em>, is very specific to heat and fire.<\/p>\n<p>The Underwriters Laboratories (UL) defines thermal barriers as \u201ca material or product that prevents or delays the ignition of a flammable surface, such as foam plastic insulation or metal composite material, in the event of a fire.\u201d<sup>1<\/sup><\/p>\n<p><strong>The requirements for thermal barriers<\/strong><\/p>\n<p>The <em>IBC<\/em> and the <em>International Residential Code <\/em>(<em>IRC<\/em>) define approved thermal barriers (\u201c15-minute thermal barriers\u201d) as:<\/p>\n<ul>\n<li>\u202812.7-mm (0.5-in.) gypsum wallboards.<\/li>\n<li>\u202818.2-mm (0.71-in.) wood structural panel (<em>IRC<\/em> only).<\/li>\n<li>\u2028A material that is tested in accordance with, and meets, the acceptance criteria of both the temperature transmission fire test and the integrity fire test of NFPA 275.<\/li>\n<\/ul>\n<figure id=\"attachment_208308\" aria-describedby=\"caption-attachment-208308\" style=\"width: 500px\" class=\"wp-caption aligncenter\"><a href=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/11.29.23-Figure-1-Hi-Res-copy.jpg\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-208308 size-large\" src=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/11.29.23-Figure-1-Hi-Res-copy-500x250.jpg\" alt=\"The photo shows the definition of Thermal Barrier as per 2018 IBC CODE and COMMENTARY.\" width=\"500\" height=\"250\" srcset=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/11.29.23-Figure-1-Hi-Res-copy-500x250.jpg 500w, https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/11.29.23-Figure-1-Hi-Res-copy-300x150.jpg 300w, https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/11.29.23-Figure-1-Hi-Res-copy-768x384.jpg 768w, https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/11.29.23-Figure-1-Hi-Res-copy.jpg 800w\" sizes=\"auto, (max-width: 500px) 100vw, 500px\" \/><\/a><figcaption id=\"caption-attachment-208308\" class=\"wp-caption-text\"><span style=\"font-size: 9pt; font-family: arial, helvetica, sans-serif;\"><b>Figure 1<\/b> <em>The International Building Code<\/em> (<em>IBC<\/em>) section 2603.4, thermal barrier code requirements. <\/span><span style=\"font-size: 9pt; font-family: arial, helvetica, sans-serif;\">Images courtesy 2018 <em>International Building Code (<em>IBC<\/em>) <\/em><\/span><\/figcaption><\/figure>\n<p>According to the code, all plastics installed into the building envelope require thermal barrier material to be applied over them. <em>IBC<\/em> section 2603.4 defines thermal barrier, the various deviations and derivatives, and direct compliance approaches to allow plastics to be safely applied in the building envelope.<\/p>\n<p><strong>Addressing thermal barrier requirements<\/strong><\/p>\n<p>While the <em>IBC<\/em> defines three methods of permissible thermal barriers, the specific section of the code allows four different methods. These exist primarily due to the unavailability of all solutions and are allowed as deviations until technology catches up with the need for improved fire safety.<\/p>\n<p><!--nextpage--><\/p>\n<div class=\"wonderpluginslider-container\" id=\"wonderpluginslider-container-375\" style=\"max-width:950px;margin:0 auto;padding-left:0px;padding-right:0px;padding-top:84px;padding-bottom:0px;\"><div class=\"wonderpluginslider\" id=\"wonderpluginslider-375\" data-sliderid=\"375\" data-width=\"950\" data-height=\"850\" data-skin=\"topcarousel\" data-usejsforfullbrowserwidth=\"false\" data-fullbrowserwidth=\"false\" data-playmutedandinlinewhenautoplay=\"false\" data-addextraattributes=\"false\" data-autoplay=\"false\" data-randomplay=\"false\" data-loadimageondemand=\"false\" data-transitiononfirstslide=\"false\" data-autoplayvideo=\"false\" data-isresponsive=\"true\" data-fullwidth=\"false\" data-isfullscreen=\"false\" data-ratioresponsive=\"false\" data-showtext=\"true\" data-showtimer=\"true\" data-showbottomshadow=\"false\" data-navshowpreview=\"false\" data-textautohide=\"false\" data-pauseonmouseover=\"false\" data-lightboxresponsive=\"true\" data-lightboxshownavigation=\"false\" data-lightboxshowtitle=\"true\" data-lightboxshowdescription=\"false\" data-texteffectresponsive=\"true\" data-donotinit=\"false\" data-addinitscript=\"false\" data-lightboxfullscreenmode=\"false\" data-lightboxcloseonoverlay=\"true\" data-lightboxvideohidecontrols=\"false\" data-lightboxnogroup=\"false\" data-shownav=\"true\" data-navthumbresponsive=\"false\" data-navshowfeaturedarrow=\"true\" data-inityoutube=\"true\" data-initvimeo=\"true\" data-navshowplaypause=\"true\" data-navshowarrow=\"false\" data-navshowbuttons=\"false\" data-lightboxshowsocial=\"false\" data-lightboxshowfacebook=\"true\" data-lightboxshowtwitter=\"true\" data-lightboxshowpinterest=\"true\" data-lightboxsocialrotateeffect=\"true\" data-showsocial=\"false\" data-showfacebook=\"true\" data-showtwitter=\"true\" data-showpinterest=\"true\" data-socialrotateeffect=\"true\" data-disableinlinecss=\"false\" data-triggerresize=\"false\" data-lightboxautoslide=\"false\" data-lightboxshowtimer=\"true\" data-lightboxshowplaybutton=\"true\" data-lightboxalwaysshownavarrows=\"false\" data-lightboxshowtitleprefix=\"true\" data-titleusealt=\"false\" data-outputtext=\"false\" data-titletag=\"h1\" data-descriptiontag=\"h2\" data-scalemode=\"fit\" data-arrowstyle=\"mouseover\" data-transition=\"fade\" data-loop=\"0\" data-border=\"0\" data-slideinterval=\"8000\" data-arrowimage=\"arrows-48-48-4.png\" data-arrowwidth=\"48\" data-arrowheight=\"48\" data-arrowtop=\"50\" data-arrowmargin=\"0\" data-ga4account=\"\" data-googleanalyticsaccount=\"\" data-navplaypauseimage=\"navplaypause-48-48-0.png\" data-navarrowimage=\"navarrows-28-28-0.png\" data-navstyle=\"thumbnails\" data-navimage=\"bullet-24-24-5.png\" data-navwidth=\"109\" data-navheight=\"72\" data-navspacing=\"4\" data-navmarginx=\"16\" data-navmarginy=\"-84\" data-navposition=\"top\" data-navthumbnavigationstyle=\"arrowinside\" data-navthumbnavigationarrowimage=\"carouselarrows-32-32-3.png\" data-navthumbnavigationarrowimagewidth=\"32\" data-navthumbnavigationarrowimageheight=\"32\" data-playvideoimage=\"playvideo-64-64-0.png\" data-playvideoimagewidth=\"64\" data-playvideoimageheight=\"64\" data-lightboxthumbwidth=\"90\" data-lightboxthumbheight=\"60\" data-lightboxthumbtopmargin=\"12\" data-lightboxthumbbottommargin=\"4\" data-lightboxbarheight=\"64\" data-lightboxtitlebottomcss=\"color:#333; 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color:#333;\" data-descriptioncss=\"display:block; position:relative; font:14px Georgia,serif,Arial; color:#333; margin-top:8px;\" data-buttoncss=\"display:block; position:relative; margin-top:8px;\" data-titlecssresponsive=\"font-size:12px;\" data-descriptioncssresponsive=\"display:none !important;\" data-buttoncssresponsive=\"\" data-jsfolder=\"https:\/\/www.constructionspecifier.com\/wp-content\/plugins\/wonderplugin-slider\/engine\/\" style=\"display:none;\" ><ul class=\"amazingslider-slides\"  style=\"display:none;\"><li><img decoding=\"async\" class=\"amazingslider-img-elem amazingsliderimg\" src=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/11.29.23-Figure-2-Hi-Res-copy.jpg\" alt=\"The photo highlights prescriptive and exception methods for plastics compliance in 2018 IBC CODE and COMMENTARY.\" title=\"\" data-description=\"&lt;b&gt;Figure 2&lt;\/b&gt; Prescriptive and exception methods for plastics compliance.\" \/><\/li><li><img decoding=\"async\" class=\"amazingslider-img-elem amazingsliderimg\" src=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/11.29.23-Figure-3-Hi-Res-copy.jpg\" alt=\"The photo highlights the text in 2018 International Building Code (IBC) to show the use of any material which meets certain requirements as thermal barrier.\" title=\"\" data-description=\"&lt;b&gt;Figure 3&lt;\/b&gt; Equivalent thermal barrier for plastics compliance.\" \/><\/li><li><img decoding=\"async\" class=\"amazingslider-img-elem amazingsliderimg\" src=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/11.19.23-Figure4-V2-Hi-Res-copy.jpg\" alt=\"This graphic represents some of the multitude of tollgates\/authorities specifiers might need to comply with., including government, national, state, and global organizations.\" title=\"\" data-description=\"&lt;b&gt;Figure 4&lt;\/b&gt; This graphic represents some of the multitude of tollgates\/authorities specifiers might need to comply with.\" \/><\/li><li><img decoding=\"async\" class=\"amazingslider-img-elem amazingsliderimg\" src=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/11.29.23-Figure-5-Hi-Res-copy.jpg\" alt=\"An example of the Unified Facilities Guide Specifications (UFGS) stretch fire safety requirement, highlighted in 2018 IBC Code.\" title=\"\" data-description=\"&lt;b&gt;Figure 5&lt;\/b&gt; An example of the Unified Facilities Guide Specifications (UFGS) stretch fire safety requirement. Image courtesy Unified Facilities Guide Specifications (UFGS)\" \/><\/li><\/ul><ul class=\"amazingslider-thumbnails\"  style=\"display:none;\"><li><img decoding=\"async\" class=\"amazingslider-thumbnail-elem amazingsliderthumbnailimg\" src=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/11.29.23-Figure-2-Hi-Res-copy-300x191.jpg\" alt=\"The photo highlights prescriptive and exception methods for plastics compliance in 2018 IBC CODE and COMMENTARY.\" title=\"\" data-description=\"&lt;b&gt;Figure 2&lt;\/b&gt; Prescriptive and exception methods for plastics compliance.\" \/><\/li><li><img decoding=\"async\" class=\"amazingslider-thumbnail-elem amazingsliderthumbnailimg\" src=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/11.29.23-Figure-3-Hi-Res-copy-300x109.jpg\" alt=\"The photo highlights the text in 2018 International Building Code (IBC) to show the use of any material which meets certain requirements as thermal barrier.\" title=\"\" data-description=\"&lt;b&gt;Figure 3&lt;\/b&gt; Equivalent thermal barrier for plastics compliance.\" \/><\/li><li><img decoding=\"async\" class=\"amazingslider-thumbnail-elem amazingsliderthumbnailimg\" src=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/11.19.23-Figure4-V2-Hi-Res-copy-300x147.jpg\" alt=\"This graphic represents some of the multitude of tollgates\/authorities specifiers might need to comply with., including government, national, state, and global organizations.\" title=\"\" data-description=\"&lt;b&gt;Figure 4&lt;\/b&gt; This graphic represents some of the multitude of tollgates\/authorities specifiers might need to comply with.\" \/><\/li><li><img decoding=\"async\" class=\"amazingslider-thumbnail-elem amazingsliderthumbnailimg\" src=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/11.29.23-Figure-5-Hi-Res-copy-300x113.jpg\" alt=\"An example of the Unified Facilities Guide Specifications (UFGS) stretch fire safety requirement, highlighted in 2018 IBC Code.\" title=\"\" data-description=\"&lt;b&gt;Figure 5&lt;\/b&gt; An example of the Unified Facilities Guide Specifications (UFGS) stretch fire safety requirement. Image courtesy Unified Facilities Guide Specifications (UFGS)\" \/><\/li><\/ul><\/div><\/div><div id=\"amazingslider_customtexteffect_375\" style=\"display:none;\" data-texteffect=\"{&quot;Underneath center&quot;:{&quot;textstyle&quot;:&quot;static&quot;,&quot;textpositionstatic&quot;:&quot;bottomoutside&quot;,&quot;textautohide&quot;:false,&quot;textpositionmarginstatic&quot;:0,&quot;textpositiondynamic&quot;:&quot;bottomleft&quot;,&quot;textpositionmarginleft&quot;:24,&quot;textpositionmarginright&quot;:24,&quot;textpositionmargintop&quot;:24,&quot;textpositionmarginbottom&quot;:24,&quot;texteffect&quot;:&quot;slide&quot;,&quot;texteffecteasing&quot;:&quot;easeOutCubic&quot;,&quot;texteffectduration&quot;:600,&quot;texteffectslidedirection&quot;:&quot;left&quot;,&quot;texteffectslidedistance&quot;:30,&quot;texteffectdelay&quot;:500,&quot;texteffectseparate&quot;:false,&quot;texteffect1&quot;:&quot;slide&quot;,&quot;texteffectslidedirection1&quot;:&quot;right&quot;,&quot;texteffectslidedistance1&quot;:120,&quot;texteffecteasing1&quot;:&quot;easeOutCubic&quot;,&quot;texteffectduration1&quot;:600,&quot;texteffectdelay1&quot;:1000,&quot;texteffect2&quot;:&quot;slide&quot;,&quot;texteffectslidedirection2&quot;:&quot;right&quot;,&quot;texteffectslidedistance2&quot;:120,&quot;texteffecteasing2&quot;:&quot;easeOutCubic&quot;,&quot;texteffectduration2&quot;:600,&quot;texteffectdelay2&quot;:1500,&quot;textcss&quot;:&quot;display:block; padding:12px 0px; text-align:center; margin-top:4px;&quot;,&quot;textbgcss&quot;:&quot;display:none;&quot;,&quot;titlecss&quot;:&quot;display:block; position:relative; font:bold 16px Georgia,serif,Arial; color:#333;&quot;,&quot;descriptioncss&quot;:&quot;display:block; position:relative; font:14px Georgia,serif,Arial; color:#333; margin-top:8px;&quot;,&quot;buttoncss&quot;:&quot;display:block; position:relative; margin-top:8px;&quot;,&quot;texteffectresponsive&quot;:true,&quot;texteffectresponsivesize&quot;:640,&quot;titlecssresponsive&quot;:&quot;font-size:12px;&quot;,&quot;descriptioncssresponsive&quot;:&quot;display:none !important;&quot;,&quot;buttoncssresponsive&quot;:&quot;&quot;,&quot;addgooglefonts&quot;:false,&quot;googlefonts&quot;:&quot;&quot;,&quot;textleftrightpercentforstatic&quot;:40}}\"><\/div><script>function wonderslider_375_appendcss(csscode) {var head=document.head || document.getElementsByTagName(\"head\")[0];var style=document.createElement(\"style\");head.appendChild(style);style.type=\"text\/css\";if (style.styleSheet){style.styleSheet.cssText=csscode;} else {style.appendChild(document.createTextNode(csscode));}};wonderslider_375_appendcss(\"#wonderpluginslider-375 .star-rating { \tdisplay: inline-block; }\");<\/script>\n<p>There are four methods in which a plastic (and spray polyurethane foam [SPF]) can comply with the code. Figure 2 illustrates three of the four methods: the prescriptive (grandfathered) method in black and two exceptions (deviations) in blue. These exceptions are permitted for specific approaches to meet the code without direct compliance to 2603.4.<\/p>\n<p>The fourth method, the equivalent compliance method, identifies a multi-test protocol (National Fire Protection Association [NFPA] 275) for achieving an equivalent rating to gypsum (Figure 3). Any product that strives to be equivalent to 12.7 mm \u2028(0.5 in.) gypsum must meet this protocol of tests.<\/p>\n<p><strong>Governing organizations<\/strong><\/p>\n<p>When one gains an understanding of these four compliance\/approval avenues defined in <em>IBC<\/em>, another layer of complexity forms. There are many governing groups, including global and national organizations, the federal government, and even states that mandate initiatives. Figure 4 (page 36) is an example of the organizations that govern insulation in buildings. Some allow direct interpretation of the <em>IBC<\/em> and others require stiffer requirements than the <em>IBC<\/em> or <em>IRC<\/em>. In many cases, the <em>IBC<\/em> and <em>IRC<\/em> are the \u201cminimum required approvals\u201d to be used in the building industry.<\/p>\n<p><strong>\u2018Alphabet soup\u2019: Construction compliance-related acronyms<\/strong><\/p>\n<p>In Figure 5, the alphabet soup of requirements is sometimes conflicting, as section Unified Facilities Guide Specifications (UFGS) 07 27 36 describes. This confuses even the most experienced construction participants. Thus, the information presented here focuses on <em>IBC<\/em> and <em>IRC<\/em> code needs only.<\/p>\n<p><strong>Understanding code requirements<\/strong><\/p>\n<p>Understanding code requirements can be quite overwhelming and even confusing for inspectors and fire marshals, as more complex layers of code are added to the sections around plastics. Keep in mind, the sprayfoam industry is relatively new in the world of construction. Equipment to sprayfoam insulation was only invented in the late 60s (Gusmer created the sprayer in 1962) and its growth and acceptance by construction codes did not exist until the 1970s.<sup>2<\/sup><\/p>\n<p>As expected with so many governing organizations, many of which overlap and cover different domains in the construction industry, SPF serves many masters. Compliance gets quite complicated, trying to supply all the documentation required, especially for the two exception-based compliance methods.<\/p>\n<p>Direct compliance with gypsum, where feasible, is a much easier and cost-effective execution. Historically, equivalent thermal barriers were \u201cadd-ons\u201d to the SPF and inherently added cost, labor, and inspection\/documentation steps. As codes have changed, the challenges for compliance with these approval methods are continually tested. Specific examples of how each of these entities drive different compliance requirement challenges include:<\/p>\n<p><!--nextpage--><\/p>\n<ul>\n<li>Some states are now requiring the installation of R-30 in walls and R-60 in ceilings, which requires almost 508 mm (20 in.) of fiberglass or mineral wool insulation.<sup>3<\/sup> Some buildings cannot even support the depth of bays required.<\/li>\n<li>The National Flood Insurance Program (and FEMA) require only closed-cell SPF in any cavity which might be exposed to water.<sup>4<\/sup><\/li>\n<\/ul>\n<p>The good news is there are other energy-based codes addressing more sustainable and energy-friendly solutions such as closed-cell sprayfoam, and specifically, a new generation of single-step thermal barrier SPF technologies. One example is the <em>International Energy Conservation Code<\/em> (<em>IECC<\/em>), which provides for significantly less continuous insulation (c.i.) material when using an energy performance\/savings measure for insulation and building envelope challenges.<\/p>\n<p><strong>\u2018Add-on\u2019 products over plastics<\/strong><\/p>\n<p>SPF has historically met the code by being applied behind gypsum or covered with approved, add-on thermal barriers such as cellulosic and cementitious materials. SPF could also comply with code through \u201cexception\u201d methods using the lower-level ignition barrier approval (method two) or special approval testing (method three) via intumescent coatings as well.<\/p>\n<p>When choosing one of these methods, commonly asked questions are:<\/p>\n<ul>\n<li>Which test(s) should be used?<\/li>\n<li>\u2028Which combination of coatings or cellulose \u2028or cementitious materials should be used?<\/li>\n<li>Over which foams?<\/li>\n<li>At which thickness?<\/li>\n<li>In which densities?<\/li>\n<\/ul>\n<p>Addressing all the combinations of SPF\/coating\/cellulose\/cementitious solutions and the appropriate paperwork needed for building officials is a separate topic in and of itself, requiring further discussion and explanation. However, understanding the add-on solutions is crucial and does need to be taught, as each skilled trade bears the responsibility for the safety of the construction process and the end-result.<\/p>\n<p>One overriding thought to keep in mind is that manufacturers who supply plastics for the building envelope often claim their products are \u201cfire-rated,\u201d and although overly vague and misleading, they are partially correct. All plastics require a minimal level of fire rating to even be allowed for use in buildings. The problem is the robustness of the test procedures they reference.<\/p>\n<p>Figure 6 shows a range of common fire tests that companies reference. A company could claim a \u201cfire rating\u201d from a simple Bunson burner test lasting only seconds, to full wall assemblies and ceilings that have achieved multi-hour ratings. Tests lasting mere seconds or claiming \u201cself-extinguishing\u201d properties with low-level heat or flame impingement provide less than acceptable protection for life safety.<\/p>\n<p>Even when companies claim adequate fire approvals within the jurisdiction of 2603.4 (usually as a function of time), the test behind the measure can be confusing and\/or inaccurately communicated, creating confusion and potential safety violations. A clear example of this confusion is the pass\/fail time requirements (Figure 7) of exception tests (method three) versus the gypsum approval (method one) versus the equivalent thermal barriers (method four).<\/p>\n<p>Prescriptive method one (gypsum) follows historical performance results and fire ratings are 15 minutes long, based on ASTM E119, <em>Standard Test Methods for Fire Tests of Building Construction and Materials<\/em>. This is also sometimes called the compartmentalization of the fire test. It tracks and defines the time it takes for extreme heat to pass through a wall or ceiling to create a fire-risk situation in adjacent rooms to the space that have been compromised by fire.<\/p>\n<p>Exception method three (special approval) defines a 15-minute period where flame spread and smoke generation from a known fire source in a 2.4 x 3.6 m (8 x 12 ft) room cannot exceed certain critical safety levels of flame and smoke. The flame and smoke growth maximums over the 15-minute duration estimate a safe amount of time to evacuate the space. Method three almost always defines systems\u2019 \u2028(<em>e.g.<\/em> foam and coating together) capabilities which work in conjunction to achieve a exception level but \u201ccode-allowed\u201d solution to life safety, but does not show compliance to temperature transmission risk in a structure. Although both test programs have 15-minute durations, they certify two very different life-safety criteria that are not interchangeable.<\/p>\n<p><!--nextpage--><\/p>\n<p>Direct compliance, method four (NFPA 275, also known as \u201cequivalent thermal barriers\u201d), is a test protocol that requires both tests\u2014the temperature transmission test and the flame spread smoke generation test\u2014both over a period of 15 minutes. Method four establishes a combination of both the prescriptive solution and the special approval solution and defines an equivalent thermal barrier to the gypsum prescriptive method.<\/p>\n<p>All of these choices relate to a life-safety and liability issues; therefore, it is imperative for the builder, architect, or general contractor to understand the various fire-rating methods and what they mean in order to protect themselves. Alternatively, find a trusted compliance partner, a fire consultant, or a fire inspector.<\/p>\n<p>The SPF insulation industry has not been standing idly regarding the emerging requirements and changing code needs. It is finding ways to improve fire resistance. It is proving compliance to environmental\/sustainable\/planet-saving initiatives. SPF is the best solution for addressing the challenges of less CO2 emissions and less energy losses in buildings, which are one of the largest contributors to global warming.<sup>5<\/sup> Post-applied thermal barriers and cost increases associated with them have made the expansion of standard SPF into broader markets slowly. New, all-in-one thermal barrier sprayfoam technologies help solve many of these challenges, and effectively provide better value.<\/p>\n<p><strong>Emerging sprayfoam insulation technologies<\/strong><\/p>\n<p><em>Monolithic fire performance<\/em><\/p>\n<p>Some emerging SPF products are striving to achieve better fire performance, monolithically, in foam insulation. These new, monolithic SPF products pass NFPA-275 thermal barrier tests, thus being thermal barriers and c.i. Since the foam is a composite homogeneous solid, when it meets NFPA-275 requirements, it is a fire and thermal protective barrier throughout the complete volume of the insulation all-in-one. Having its fire characteristics throughout its complete volume means fewer added steps, cost, and risk, versus a thermal barrier coating, cellulose, etc.<\/p>\n<p>Post-applied \u201cexception-based\u201d thermal barriers become daunting when trying to ensure compliant, safe application. First and foremost, they need to be properly applied. Second, proper application requires third-party inspection. Next, they can only be used in what is referred to as \u201cconditioned spaces,\u201d which are dry, heated environments lest they are prone to field failures. Finally, as soon as the surface is breached in any way, shape, or form, the fire barrier characteristic of the flammable substrate is lost.<\/p>\n<p>A monolithic fire barrier material will also protect against fires from the outside in, as well as fires from the inside out. Topcoats only protect one face of flammable insulation; they cannot provide unilateral fire protection from wildfires (externally initiated fires), electrical shorts, wall fires, lightning strikes, etc.<\/p>\n<p><!--nextpage--><\/p>\n<figure id=\"attachment_208314\" aria-describedby=\"caption-attachment-208314\" style=\"width: 344px\" class=\"wp-caption alignright\"><a href=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/11.29.23-Figure-6-Hi-Res-copy.jpg\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-208314\" src=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/11.29.23-Figure-6-Hi-Res-copy-300x200.jpg\" alt=\"A flow diagram sowing evolution of spray foam fire testing from ul94 to wall assemblies.\" width=\"344\" height=\"229\" srcset=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/11.29.23-Figure-6-Hi-Res-copy-300x200.jpg 300w, https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/11.29.23-Figure-6-Hi-Res-copy-500x333.jpg 500w, https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/11.29.23-Figure-6-Hi-Res-copy-768x512.jpg 768w, https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/11.29.23-Figure-6-Hi-Res-copy.jpg 800w\" sizes=\"auto, (max-width: 344px) 100vw, 344px\" \/><\/a><figcaption id=\"caption-attachment-208314\" class=\"wp-caption-text\"><span style=\"font-size: 9pt; font-family: arial, helvetica, sans-serif;\"><b>Figure 6 <\/b>Evolution of large scale plastics testing. <\/span><span style=\"font-size: 9pt; font-family: arial, helvetica, sans-serif;\"><em> Image courtesy Richard Barone <\/em><\/span><\/figcaption><\/figure>\n<p>This technology is now presenting itself in the market. By taking a continuous sprayfoam and incorporating innovative, fire-addressing thermal barrier protective technologies within the foam, one can attain all the benefits of c.i., air barrier, moisture barrier, mold defense, structural rigidity, and high insulation value in their structures.<\/p>\n<p><em>Reducing risk window<\/em><\/p>\n<p>How does this benefit the owner, the general contractor, the architect, insurers, and\/or the spray application company? Sprayfoams react in the field through a two-component chemical reaction. The NFPA-275 fire barrier rating of the new foam becomes an effective fire barrier as soon as the chemical reaction finishes. Fire safety is \u201cbuilt-in\u201d as soon as the reaction is complete. This is what is known as a \u201czero risk window\u201d product and is very different from what happens currently when flammable plastic insulation materials, both panels and continuous, must wait for a thermal barrier to be applied.<\/p>\n<p>Often, the company providing the thermal\/fire barrier is not the same company applying the insulation. This presents the issue of who owns the liability during that in-between, safety risk window period. Also pertinent is who ensures the proper application methods of the post-added thermal barrier and which code requirements are being met. This risk affects everyone in the construction phase, from the architect to the contractor, sprayfoam applicator, insurance company, and owner\/end-user. The risk, added materials, labor, governance, and complexity are eliminated with NFPA-275 SPFs.<\/p>\n<p><em><a href=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/figure-7.jpg\"><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter wp-image-208315 size-large\" src=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/figure-7-500x191.jpg\" alt=\"Comparison Table showing the different methods for fire testing.\" width=\"500\" height=\"191\" srcset=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/figure-7-500x191.jpg 500w, https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/figure-7-300x115.jpg 300w, https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/figure-7-768x293.jpg 768w, https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/figure-7.jpg 1024w\" sizes=\"auto, (max-width: 500px) 100vw, 500px\" \/><\/a>Increasing fire resistance<\/em><\/p>\n<p>Another radically new and often overlooked paradigm credited to monolithic NFPA-275 SPFs is the ability to increase the fire resistance of a building wall or ceiling system. Historically, this has been reserved for non-combustible building elements such as brick, stucco, and concrete. With the achievement of method four (Figure 6), NFPA-275 SPF reduces the transmission of temperature through wall and ceiling assemblies. It passes the ASTM E119 temperature transmission tests described earlier (Figure 7), the method used to define wall ratings (<em>i.e.<\/em> when an inspector says a one-hour wall is needed between a garage and a house).<sup>6<\/sup> As the thickness of the monolithic fire barrier SPF increases, so does its ability to delay the transmission of heat and poisonous fumes, increasing the overall wall system\u2019s hour rating.<\/p>\n<p>This extends the thermal barrier SPF into the realm of fireproofing; something foam could never be used for in the past. That benefit has historically been reserved for gypsum, concrete, cementitious, brick, and stone. This new technology opens many new and creative avenues previously unattainable with foam insulation in concert with the non-combustible materials described above.<\/p>\n<p><!--nextpage--><strong>Embracing the benefits<\/strong><\/p>\n<p>At the end of the day, architects, builders, contractors, and even end-users care about better value. NFPA-275 thermal barrier high-R insulation products cost slightly more initially, but the total costs, including the speed of installation, the overall quality, and end-user impact generate significant value across the complete construction hierarchy, resulting in significant cost savings. As with any new, emerging technology, the costs will decrease as market penetration increases.<\/p>\n<p>To date, these new technologies are not optimized for all situations. However, they are already radically improving total costs and margins in several major areas of construction such as commercial, government, union, and prevailing wage projects. These benefits translate into other large fringe areas, which also need an increased focus in safety such as agriculture, commercial cold storage facilities, grow houses, outbuildings<span style=\"text-decoration: line-through;\">,<\/span> military, and aviation hangers.<\/p>\n<p>The elimination of steps in these larger, more complex initiatives translates to lower costs, better solutions, and most importantly, a lower risk for the loss of life and property\u2014a true trifecta of value. Remember what is really at stake. It is not just a code issue, it is a life safety issue.<\/p>\n<p><strong>Notes<\/strong><\/p>\n<p><sup>1 <\/sup>Refer to <a href=\"https:\/\/www.ul.com\/services\/thermal-barrier-testing-and-certification\" target=\"_blank\" rel=\"noopener\">www.ul.com\/services\/thermal-barrier-testing-and-certification<\/a>.<\/p>\n<p><sup>2<\/sup> See the polyurethanes timeline at <a href=\"https:\/\/www.polyurethanes.org\/what-is-it\/\" target=\"_blank\" rel=\"noopener\">www.polyurethanes.org\/what-is-it\/<\/a>.<\/p>\n<p><sup>3<\/sup> To learn more, read <a href=\"https:\/\/www.litchfieldbuilders.com\/the-importance-of-proper-insulation-in-connecticut-homes-and-how-to-achieve-it-through-renovation\" target=\"_blank\" rel=\"noopener\">litchfieldbuilders.com\/the-importance-of-proper-insulation-in-connecticut-homes-and-how-to-achieve-it-through-renovation<\/a>.<\/p>\n<p><sup>4 <\/sup>Visit <a href=\"https:\/\/www.fema.gov\/emergency-managers\/risk-management\/building-science\/national-flood-insurance-technical-bulletins,%20and%20see%20table%202%20at%20fema_tb_2_flood_damage_resistant_materials_requirements.pdf\" target=\"_blank\" rel=\"noopener\">www.fema.gov\/emergency-managers\/risk-management\/building-science\/national-flood-insurance-technical-bulletins, and see table 2 at fema_tb_2_flood_damage_resistant_materials_requirements.pdf<\/a>.<\/p>\n<p><sup>5<\/sup> Refer to <a href=\"https:\/\/www.weforum.org\/agenda\/2022\/02\/decarbonizing-buildings-climate-change-infrastructure\/\" target=\"_blank\" rel=\"noopener\">www.weforum.org\/agenda\/2022\/02\/decarbonizing-buildings-climate-change-infrastructure<\/a>.<\/p>\n<p><sup>6<\/sup> Learn more at <a href=\"https:\/\/codes.iccsafe.org\/content\/IBC2021P1\" target=\"_blank\" rel=\"noopener\">codes.iccsafe.org\/content\/IBC2021P1\/chapter-7-fire-and-smoke-protection-features, section 708<\/a>.<\/p>\n<p><strong><img loading=\"lazy\" decoding=\"async\" class=\"size-full wp-image-208318 alignleft\" src=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2024\/02\/Barone_Headshot-f.jpg\" alt=\"\" width=\"90\" height=\"90\" \/>Author<\/strong><\/p>\n<p>Richard Barone Jr. is co-founder and executive vice-president of operations for Firestable Insulation Co. As an entrepreneur and inventor, he has established several fire technology companies in his 20-plus years in fire protection.<\/p>\n<p>&nbsp;<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Regarding the proliferation of plastics and composites, the thermal barrier section of the <em>IBC<\/em> (chapter 26, specifically) came into existence. However, \u201cthermal barrier\u201d is a term used specifically for the fire rating of a building element. It can be confused with terms such as \u201cthermal insulation\u201d or \u201cthermal bridging.<\/p>\n","protected":false},"author":29853,"featured_media":208316,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[520,179,187,264,4008,265],"tags":[150,83,1195,735,70,9341,6807,7066],"class_list":["post-208304","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-features","category-masterformat","category-07-00-00-thermal-and-moisture-protection","category-07-20-00-thermal-protection","category-07-24-00-exterior-insulation-and-finish-systems","category-07-25-00-weather-barriers","tag-air-barrier","tag-continuous-insulation","tag-division-07","tag-firestopping","tag-insulation","tag-thermal-barrier","tag-vapour-barrier","tag-water-barrier","entry"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.8 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Evolving foam plastics: Decoding thermal barrier compliance - 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