Introduction Expanded Polystyrene is a polymer impregnated with a foaming agent which, when exposed to steam, creates a uniform closed cell structure highly resistant to heat flow and moisture penetration. This in-plant expansion process is fused into blocks which are cured for dimensional stability and cut into boards. Due to its low cost per board foot, EPS is an excellent material for all construction applications. Dependable Performance The foaming agent used in the manufacture of EPS foam is replaced by air during the curing process resulting in uniform, long-te rm , dependab le t he rm a l performance.

Advantages • Low material and installation

cost. • Easy to handle and apply • Provides an excellent surface

for plastic base. • Excellent bond with drywall and

other panel type adhesives. • Resists moisture penetration. • Available in wide range of

sizes. • Available in various densities. • EIFS approved. Specifications Expanded Polystyrene boards meet the product requirements established by current building c o d e s a n d t h e f o l l o w i n g specifications, Standards and Approvals • ASTM C578-01 • Factory Mutual (FM) 4651

• Underwriters Laboratories (UL) R-9699

• ICC-ES NER 667 Availability EPS foam is available in a wide variety of sizes and densities to accommodate all applications. Available Sizes Thickness: 1/2” to 37” Length: 2’ to 16’ Width: 2” to 72” Adequate Strength Under normal conditions the compressive strength provided by EPS boards usually exceeds most design requirements. When dictated by load conditions, board densities may be increased to meet allowable working stresses.

Typical Physical Properties of Thermal Foam EPS Board PROPERTY1 UNITS ASTM TEST TYPE XI TYPE I TYPE VIII TYPE II TYPE IX

Density Min lb/ft3 C-303 0.7 0.9 1.15 1.35 1.8 Thermal Resistance Min R for C-177 or C518 @ 25° F (-3.9° C) 1 inch 3.45 4.2 4.4 4.6 4.8 @ 40° F (4.4° C) thickness 3.3 4 4.2 4.4 4.6 @ 75° F (23.9° C) 3.1 3.6 3.8 4 4.2 @ 110° F (43.3° C) 2.9 3.25 3.45 3.65 3.85 Compressive Resistance Min psi D-1621 5 10 13 15 25 at Yield or 10% Deformation Flexural Strength Min psi C-203 10 25 30 35 50 Water Vapor Permeability Max perm-in E-96 5 5 3.5 3.5 2 Water Absorption % by Vol Max C272 4 4 3 3 2 Dimensional Stability Max % 2 2 2 2 2 Oxygen Index Min % D-2863 24 24 24 24 24 Flame Spread 2 20 20 20 20 20 Smoke Developed 2 150-300 150-300 150-300 150-300 150-300 1 See ASTM C578-01 Standard Specification for complete information. 2 See UL Certificate Thermal Foam 1 (R-9699) reference available from Thermal Foams, Inc. / Buffalo NY

Expanded Polystyrene (EPS)

* Warning: Thermal Foam EPS is combustible and will burn and should not be exposed to fire or flame. Thermal Foam EPS should be covered with an ignition barrier such as a minimum of 1/2” drywall and not used in exposed applications.

Vertical Application Thermal Foam Expanded Polystyrene foam is placed against the foundation wall. As work progresses, foam is held in place with back fill. A suitable adhesive can also be used.

Horizontal Application Thermal Foam is placed on a level, well drained, well tamped ground. The entire concrete s l a b i s t h e n p o u r e d . Polyethylene film should be used as a vapor barrier.

Block Masonry Fill To meet energy conservation s t a n d a r ds f o r m as on r y foundation walls, granulated Thermal Foam EPS Blockfill may be placed within the core of the concrete block.

Foundation Wall Applications

Winter degree days

Width of Insulation

EPS Thickness R/inch -- 4.2

4000 or less 24” 1”

4001 to 8000 24” 1-1/2”

8001 or more 24” 2”

Winter degree days

Width of Insulation

EPS Thickness R/inch -- 4.2

3001 to 5000 24” 1 1/2”

5001 to 8000 24” 2”

8001 or more 24” 2 1/2”

2001 to 3000 24” 1 1/4”

2000 or less 24” 1”

Heated Slabs Unheated Slabs

Perimeter Insulation Thermal Foam Expanded Polystyrene is excellent when used for perimeter and slab edge insulation. It is resistant to water and water vapors. It does not rot or decay. It does not support fungus. EPS provides long term dependable resistance to heat loss.

Foundation Wall Applications Drywall Base Thermal Foam Expanded Polystyrene Foam can be applied directly to any masonry surface. Due to it’s high resistance to moisture transmission, no vapor barrier is required for the EPS foam. Local codes should be followed for vapor barrier requirements. This type of installation eliminates costly furring and lathing. It’s excellent insulation properties help keep heating costs low in winter and cooling costs low in summer. Specially fabricated metal channels are available for attaching Thermal Foam EPS foam to masonry walls. Drywall is then easily screwed to metal channels. Minimum 1/2” drywall can be applied directly to the foam providing for a completely insulated interior.

No Insulation

1” tk EPS 2” tk EPS

8” concrete U .41 .15 .09 Block R 6.66 14.28 12” Concrete U .39 .15 .09 Block R 6.66 14.28 4” Brick and U .35 .14 .09 8” Concrete Block R 7.14 14.28 4” Brick and U .29 .12 .08 8” Cinder Block R 8.33 16.66

Wall Construction

Cavity Wall Insulation The most important function of Thermal Foam Expanded Polystyrene Foam when used for cavity wall construction is controlling water vapor transmission and heat loss. Due to it’s superior thermal properties, Thermal Foam EPS can be used with excellent success. The insulation can be placed against the inner vertical surface and secured with wall ties or bonded with a suitable adhesive. For optimum resistance to moisture penetration from exterior sources, maintain a minimum 1/2” air space between the foam insulation and outer vertical surface.

Typical U and R Values

“U” -- BTU/hr - sq. ft. - °F “R” -- 1/U

Wall Construction No Insulation 1” tk EPS 2” tk EPS 8” concrete U .41 .15 .09 Block R 6.66 14.28 12” Concrete U .39 .15 .09 Block R 6.66 14.28 4” Brick and U .35 .14 .09 8” Concrete Block R 7.14 14.28

Typical U and R Values

“U” -- BTU/hr - sq. ft. - °F “R” -- 1/U

1/2”Drywall

Backers for Exterior Siding Remodeling of an existing residential or commercial buildings requires re-insulation of exterior walls to guard against rising fuel cost. Aluminum, Vinyl and Steel siding coupled with Thermal Foam EPS backer board has long been recognized as the industry standard. It absorbs shock which helps to reduce damage to siding. It’s low thermal conductivity factor (K Factor) offers superior insulation values at a low installed price. It is light in weight and easily installed at the job site.

R-Plus Exterior Sheathing Thermal Foam Type IX Sheathing is a non-structural insulation board widely used in residential construction. When used in place of conventional sheathing and construction of an interior studded wall insulated with fiberglass it will provide for a totally insulated house. The minor increase of material cost is offset by the overall comfort of the house plus conserving expensive energy consumption. Thermal Foam Sheathing offers excellent insulation values. It’s inexpensive to install and resists moisture absorption. Sizes available: 3/4” x 24” x 96” -- R 3.2 1” x 24” x 96” -- R 4.2 1 1/2” x 24” x 96” -- R 6.3 Construction Procedures 1. Framing must be braced to meet code

requirements. Diagonal let-in bracing and stud straps can be used because it provides a flush surface for foam sheathing.

2. Nails must be at least 1/2” longer than thickness of foam sheathing.

3. Sheathing must be applied horizontally with vertical joints meeting at studs.

4. Protect bottom edge of foam with wood nailer.

5. Cover foam sheathing with exterior finish as soon as possible. Foam should not be exposed to the sun’s rays for a long period of time.

Special Applications Roof Insulation Thermal Foam Expanded Polystyrene insulation is used in a wide range of roof applications. It is well suited to both new and re-roof systems. It is used in asphalt build-up systems, as well as single ply membrane systems. Thermal Foam closed cell structure prevents excessive moisture from entering the foam, thereby minimizing harmful blistering in build-up roofs. Its light weight speeds up installation and reduces roof load weight. Board sizes are 4 ft. x 4 ft. and 4 ft. x 8 ft. in thickness from 3/4” to 37”. Tapered Roof Insulation Systems or Saddle and Cricket Assemblies are our specialty. Thermal Foam is UL and FM approved and listed for various roofing assemblies. Please consult with a Thermal Foams representative or the current UL and FM approval guides.

Specified Conductance (C)

Resistance (R) Thickness

Thermal Foam (2)

Fiber Board Perlite Polyisocyanurate Glass

Fiber .05 20 4.8” - - 3.6” - .08 12.5 3” - - 2.2” - .12 8.33 2” 3-1/4” 3-1/4” 1.5” 2-1/4” .15 6.67 1-1/2” 2-1/2” 2-1/2” 1.2” 1-5/8” .19 5.6 1-1/4” 2” 2” 1” 1-5/16” .24 4.17 1” 1-1/2” 1-1/2” - 1-1/16”

Cold Storage When used in Cold storage applications Thermal Foam EPS offers advantages such as light weight, water resistance, and it will not rot or decay. A highly efficient foam insulation providing medium permeability and a porous interior finish is the ideal combination for low vapor flow and optimum condensation control. Various densities are available to support heavy floor loads. Pre-laminated, FRP Faced, SIP (Structural Insulated Panels) are available. Being light in weight and easily fabricated, column fittings and cut-outs can be made with simple hand tools. Cost is reduced because foam insulation can be easily applied to substrates in single or multi-layer construction. It permits direct application of plastic and other finishes. Costly furring can be eliminated. When Thermal Foam EPS insulation is installed in accordance with recommended practices long term performances and thermal efficiency will last for the life of the project.

Comparison Chart

Notes: Thermal Foam thickness based on typical “R” value range at 40°F mean temperature and 4.2 per inch per ASTM C578-01 Type I.

Operating Temperature F° Insulation Thickness U Factor BTU (Hr.) (Sq. Ft.) (F°)

50 2” - 3” .11 - .075 30 3” - 4” .075 - .060 15 4” - 5” .050 - .043 0 5” - 6” .043 - .037

-15 6” - 7” .037 - .032 -24 7” - 8” .031 - .027

Typical Thicknesses ~ Thermal Foam EPS Insulation

*Colder Temperatures not recommended

Note: Climatic conditions, local design temperature, building orientation, operating conditions, etc., can affect the insulation thickness required. It is therefore recommended that a study to determine the optimum thickness for each project be performed by a qualified professional.

Ceiling Tile Thermal Tile is a decorative, light weight, lay in panel for a suspended ceiling. It is approved by Factory Mutual when installed beneath an automatic sprinkler system. It’s high insulation value makes it an excellent energy saving installation. It’s decorative, economical and cost efficient. Thermal Tile is not recommended for residential applications. *See warning below. Sizes available: 1” x 23-3/4” x 47-3/4” -- 12 pcs. per ctn. -- 96 sq. ft. - Square Edge or Revealed Edge. 1/2” x 23-3/4” x 47-3/4” -- 24 pcs. per ctn. -- 192 sq. ft. - Square Edge or Revealed Edge.

Attic and Crawl Spaces Thermal Foam EPS boards are permitted to be used in attics and crawl spaces without protective coverings required under 2603.5.1.6 of the 1999 Standard Building Code©, Section 2603.4.1.4 of the BOCA National Building Code/1999, Section 2602.4 of the 1997 Uniform Building Code, Section 317.2.3 of the 1998 One- and Two-Familly Dwelling Code, Section 2603.4.1.6 of the 2000 International Building Code, and Section R318.2.3 of the 2000 International Residential Code.

Thermal Foam EPS Boards (2 inch maximum thickness and maximum 2.00 lb/ft3 density, or 5 inch maximum thickness and maximum 1.00 lb/ft3 density) are permitted to be installed exposed in attics or crawl spaces that are used only for service of utilities. Thermal Foam EPS boards as described above are permitted to be installed without the ignition protective coverings under the following conditions: • Entry to the attic or crawl space is limited to service of

utilities. • There are no interconnected attic or crawl space

areas. • Air in the attic or crawl space is not circulated to other

parts of the building. • The board thicknesses and densities are limited as

stated above. • Ventilation of the attic or crawl space is provided in

accordance with the applicable code.

Packaging Light weight, shock absorbent, strong, dust free, are just a few reasons why fabricated Thermal Foam Expanded polystyrene is widely used for packaging. It can be molded in densities as low as 0.8 PCF, and as high as 2.5 PCF. Because it is lighter than corrugated it saves on expensive shipping cost. Whether it’s simple squares or complicated cut outs, Thermal Foam EPS is an economical answer because there are minimal tooling costs compared to shape molding.

Insulating Properties Definition

K / Thermal Conductivity The measurement of heat flow through one-inch thickness of any single material per hour x square foot x °F K -- BTU/ (hr.) (sq. ft.) (°F/ inch) C / Thermal Conductance The measurement of heat flow through any single material that is more or less than one inch thick. C --K/ thickness R Factor / Thermal Resistance Reciprocal of the materials “C” R -- 1/C U Factor The measurement in BTU of heat flow, per hour - square foot (°F) through a combination of materials. U -- BTU/ (hr.) (sq. ft.) (°F) U -- 1/R

* Warning: Thermal Foam EPS is combustible and will burn and should not be exposed to fire or flame. Thermal Foam EPS should be covered with an ignition barrier such as a minimum of 1/2” drywall and not used in exposed applications.

2101 Kenmore Avenue Buffalo, NY 14207 Buffalo: (716) 874-6474 Rochester: (585) 247-0324 Fax: (716) 874-8180

Email: info@thermalfoams.com Website: www.thermalfoams.com

6173 South Bay Road PO BOX 1981 Cicero, NY 13039 (315) 699-8734 Fax: (315) 699-4969

* Warning: Thermal Foam EPS is combustible and will burn and should not be exposed to fire or flame. Thermal Foam EPS should be covered with a thermal barrier such as a minimum of 1/2” drywall and not used in exposed applications.

Though the information presented in this literature is offered in good faith and believed to be accurate, ALL STATEMENTS AND SUGGESTIONS ARE MADE WITHOUT WARRANTY, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTIES OF MERCHANTABILITY OF FITNESS FOR ANY PURPOSE. The typical values contained herein are properties believed to be representative of all EPS insulation meeting ASTM C578-01 specifications, and were obtained using test specimens prepared in the laboratories of NOVA Chemicals, Inc., Huntsman Corporation, Styrochem International, Inc., and BASF Corporation. Thermal Foams, Inc. or Thermal Foams/Syracuse Inc. should be consulted prior to using Thermal Foam EPS for any and all applications.

Copyright© Thermal Foams, Inc. 2002