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Expanded Polystyrene - Insulfoam · PDF file Learning Objectives o Define and understand how...

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  • Expanded Polystyrene The Economical Choice for Roofing Insulation

    Provider K 031 Course EPS 104, 1 LU HSW/SD

  • AIA Continuing Education

    o Carlisle Construction Materials, Insulfoam, is a Registered Provider with the American Institute of Architects Continuing Education Systems. Credit earned on completion of this program will be reported to CES Records for AIA members. Certificates of Completion for non-AIA members are available on request.

    o This program is registered with the AIA/CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using, distributing or dealing in any material or product.

    o Questions related to specific materials, methods and services will be addressed at the conclusion of this presentation.

  • Copyright Materials This presentation is protected by USA and International

    copyright laws. Reproduction, distribution, display and use of the presentation without written permission of the

    publisher is prohibited.

    Copyright © 2012 Carlisle Construction Materials.

  • Learning Objectives

    o Define and understand how Expanded Polystyrene (EPS) is manufactured

    o Understand the environmental features and benefits of EPS insulation including recyclability, LEED, thermal performance, and energy efficiency.

    o Understanding key physical properties of the different EPS products used in Roofing applications.

    o Understand the features and benefits of the different EPS products: standard, faced, and composites and which roofing applications they are used in.

    o Understand the economic advantages when using EPS in different roofing applications than other insulations. Case Study examples sited.

    o Understand what key components to consider when preparing a specification for EPS vs another insulation product in a roofing application: R-Value, Compressive Strength, Codes, Product Performance, Labor Costs, LEED and Sustainability, Product Availability and Warranty.

  • EPS Industry Alliance www.epsindustry.org

    o Insulfoam

    o Cellofoam

    o Atlas

    o Plastifab

    o Carpenter

    o ACH

    o Many small local and regional companies

  • What is EPS?

    Expanded Polystyrene (EPS)

    o Closed cell rigid foam insulation

    o Manufactured using expandable polystyrene

    o Block-molded for most construction applications (vs. shape-molded)

    Physical Characteristics

    o Available faced and unfaced

    o Available in flat & tapered panels - 4’ x 4’, 4’ x 8’, custom sizes and as a fanfold bundle

    o Available in thicknesses of

    1/4” – 40”

    o Densities from 1.0 - 3.0 pcf

    o Compressive Resistances from 10 - 60 psi

    o Stable, non-degrading R- Values

  • Key Raw Material

    EPS is manufactured from a polystyrene resin…

    o Modified and unmodified

    o Varying pentane contents

    o Varying Sizes

  • EPS Market Segments

    Insulation Applications Roofing



    Wall Systems Sheathing

    EIFS and One-Coat

    Siding Backer & Profiles

    Cavity Walls


    Perimeter & Below Slab

    Pre-cast panels

    Radiant Heating

    Non-Insulation Applications Geofoam

    Highways & Bridges

    Lightweight Void Fill


    Garden Roofing

    Pools and Pool Decks

    Concrete Block-outs

    Theaters & Stadiums



  • EPS Manufacturing

    Cutting Finished GoodsLaminating

    Pre-Expansion Block Molding

  • Sustainability & Environmental Benefits

    o Environmentally friendly o Contains no HCFCs or formaldehyde o 100% recyclable from jobsites o Manufacturing option: contains up to 25%

    recycled content o Reduces global warming o Contributes towards LEED Certification

    credits o Manufacturing option: additives

    to resist insects and mold

  • Recyclability

    o If not contaminated, EPS can be removed from jobsites and used in future manufacturing

    o Can be introduced into the manufacturing of new product or returned to a styrene resin

  • Polystyrene Insulations Reduce Global Warming Insulation can return up to 200 times the amount of energy required to produce it, and reduce emissions by up to 100 times the volume produced during the manufacturing process

  • Expanded Polystyrene Insulations Reduce Global Warming

    o The use of foam insulation on a building significantly increases the R-Value of walls to save energy

    o Lower residential energy use translates into fewer emissions and reduced GWP

  • USGBC and LEED

    Materials and Resources (MR Credits) MR Credit 2.1 and 2.2 - Construction Waste Management: Divert 20% or 75% from Disposal, 2 points possible

    MR Credit 3.1 & 3.2 - Materials Reuse: 5% or 10%, 2 points possible

    MR Credit 4.1 & 4.2 - Recycled Content: 10% or 20%, 2 points possible

    MR Credit 5.1 & 5.2 - Regional Materials: 2 points possible

    Sustainable Sites (SS Credits) SS Credit 7.2 – Heat Island Effect Roof, 1 point possible

    Energy and Atmosphere (EA Credits) EA Credit 1 - Optimize Energy Performance, 10 points possible

    EA Credit 5 – Measurement & Verification, 1 point possible

  • EPS Physical Properties ASTM C578

  • EPS Roofing Products

    Standard Products o EPS Plain Foam

    o EPS Holey Board

    o Metal Roof Flute-fill

    Premium Products o Fanfold Roof Underlayment

    o EPS with factory-laminated fiberglass facers

    o Tapered EPS

    o EPS Composites

  • Standard EPS Products

    Product Features o Densities from 1.0 – 3.0 pcf

    o Compressive Strengths from 10-60 psi

    o Custom panels and blocks

    o R-Value from 3.85 to 4.5 per inch

    o Flat or tapered

    o 3/8” – 40” thick

    Product Benefits o May contain recycled content (depending on

    the spec)

    o 100% recyclable

    o No HCFCs or dyes

    o Energy Star & LEED compliant

    o Building Code Compliant

    o UL and FM Listings

    o Provides the most R-Value per dollar

  • EPS Flute Fill

    Product Attributes

    o Any size, shape and length to 16’

    o Any density from 1.0 – 3.0 pcf

    o Able to completely fill the flutes

    o Can obtain a UL Class A rating

    o Compatible with all metal roof systems

    o Manufactured to meet ASTM C 578

  • Premium EPS Products facers, laminates, composites

    Factory-applied Materials o Polymeric facers (white, silver, printed) o Fiberglass facers o Assorted cover boards (OSB, Gypsum, etc.)

    Product Benefits o Added durability and job-site handling o Improved roof system fire resistance o Reduced material handling o Reduced field-applied insulation adhesives o Improved misuse, abuse and hail resistance

    Premium EPS Product Features are the same as Standard EPS

  • EPS Fanfold Roof Underlayment

    Lightweight, separator board for re-cover applications

  • EPS Fanfold – Product Attributes

    o A full 2-Sq. fanfold bundle (4‘ x 50‘ with

    o 25 - 2’ x 4’ individual panels)

    o Thicknesses of ⅜", ½" or ¾"

    o Typical nominal density of 1.25 pcf

    o Manufactured to meet or exceed ASTM C578

    o Also available in 4'x8' panels up to 5” thick

  • EPS Fanfold – Advantages

    o Compatible with PVC, TPO & EPDM membranes (verify with manufacturer)

    o Maintains existing roof system’s UL Classification (verify with manufacturer)

    o Lightweight – a full 2-square bundle weighs less than 11 pounds

    o 1 bundle = more than six 4' x 8' sheets

    o User friendly - lays flat, easy to install

    o Easy to ship – up to 800 SQ per T/L

  • Cost Comparison Re-cover System; Separator Board Required

    Labor Costs


    Man-hours/SQ to Install

    Typical hourly labor rate

    Labor cost/SQ

    Material Costs ($/SQ)

    1/2" Fanfold

    1/2" Wood fiber or perlite

    1/4" Gypsum Board

    Installed Cost/SQ








    Other Cover Boards

    1/4“ or 1/2"






    $48.20 - $62.20

    This means a $19.40 to $33.40/SQ advantage.

    That’s a $20,000 to $34,000 savings on a 1,000 SQ project!!

    $14.40 in

    labor savings!

  • EPS with a Fiberglass Facer

    Fiberglass facer is factory-laminated; developed specifically for mechanically attached single ply systems

  • EPS/ Fiberglass Facer – Product Attributes

    o Standard panel sizes of 4’x 8’

    or 4’x 4’; custom sizes available

    o Any thickness from 1” to 7”

    o Standard nominal density of

    1.25 pcf; custom densities available

    o Manufactured to meet ASTM C 578

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