Procuring polyiso

A decade ago, sustainable and energy-efficient construction were not central topics of conversation at construction industry trade shows; the price of oil had not hit an all-time high; most states did not have statewide energy codes; and the government had not yet mandated that federal buildings receive certifications through the U.S Green Building Council's (USGBC's) Leadership in Energy and Environmental Design (LEED) Green Building Rating System.®

As we enter 2005, energy-efficient and sustainable construction are influencing the current construction industry. Gov. Arnold Schwarzenegger (R-Calif.) has signed an executive order requiring LEED certification for state-owned buildings in California, and governors in Maine, North Carolina, Oregon and Washington have done so, as well. By the end of this decade, several LEED-certified high-rise buildings will grace the Manhattan skyline, including the new headquarters for The New York Times. The U.S. General Services Administration now requires all its buildings to receive certification through USGBC's LEED rating system. (For more information about LEED, see "Green buildings standard," September 2003 issue, page 30.)

Products such as polyisocyanurate insulation are meeting the increased demand for and interest in efficient, sustainable building products. However, this increased demand, especially in a growing global economy, sometimes is a mixed blessing for an industry that has prided itself on its ability to provide virtually next-day delivery to the roofing and related construction industries.

As the building industry continues to strive for more energy-efficient buildings, the demand from contractors, designers and building owners for polyisocyanurate insulation is driving a strong market. In fall 2004, polyisocyanurate insulation manufacturers completed their fourth consecutive quarter of double-digit growth compared with corresponding quarters in late 2002 through 2003. The Polyisocyanurate Insulation Manufacturers Association (PIMA) expects polyisocyanurate production numbers for 2004 to exceed historic levels and break the 5 billion board feet barrier.

Some background

Introduced more than 30 years ago, polyisocyanurate insulation gained the acceptance of the construction industry for two critical reasons: performance in fire tests and R-value. Polyisocyanurate insulation is the only foam insulation approved for Class I Roof Systems by FM Approvals for application directly to steel roof decks without the need for a thermal barrier or sprinklers. The product also is approved for direct-to-steel-deck application by Underwriters Laboratories Inc.

The growing demand from the contracting and design communities led polyisocyanurate insulation manufacturers who are members of PIMA to develop a groundbreaking initiative to validate polyisocyanurate's high R-value. PIMA's members instituted a rigorous certification program in 2004—the PIMA Quality Mark^cm Program. The voluntary program enables manufacturers to obtain third-party certification for long-term thermal resistance (LTTR) values of the permeable-faced polyisocyanurate roof insulation they produce. Professional Roofing has published several articles about LTTR; they are available at www.professionalroofing.net.

To further illustrate polyisocyanurate insulation's popularity, a study conducted by the Energy Services Provider Group and EBL Engineers, energy auditing and building systems analysis firms based in Baltimore, in November 2004 and December 2004 shows there are numerous benefits when increasing the thickness of polyisocyanurate by 1 inch (25 mm) or more beyond American Society of Heating, Refrigerating and Air-Conditioning Engineers standard 90.1-2002. These include:

• Significant rate of return to users for the financial investment of installing additional polyisocyanurate insulation
  
  
• Reduction of average heating and cooling costs to facilities per year
  
  
• Annual reduction in carbon dioxide emissions by thousands of pounds, sulfur dioxide emissions by thousands of grams and nitrogen oxide emissions by thousands of grams

In addition, it is important to note all polyisocyanurate insulation manufactured uses a U.S. Environmental Protection Agency-compliant hydrocarbon-based blowing agent that has zero ozone-depletion potential and virtually no global warming potential. Polyisocyanurate insulation is the answer to chlorofluorocarbon- and hydrochlorofluorocarbon-free specification requirements.

Current issues

As noted, strong performance of the U.S residential and commercial construction markets during the past few years is driving demand for construction materials during a worldwide shortfall in critical areas such as concrete, steel and related chemicals. In fact, raw-material costs are rising dramatically and, in some cases, chemical availability is affected.

Factors influencing the polyisocyanurate market most directly are the rising costs and limited availability of core raw materials. This includes petroleum products—polyisocyanurate is produced with compounds that primarily are petrochemical in nature.

The chemicals most affected by rising oil prices and decreasing availability are methylene diphenyl diisocyanate (MDI), polyol and pentane. MDI is a critical part of polyisocyanurate production and a significant component by volume. As a global product, 30 percent of all domestically produced MDI is exported. In addition to its use in roof insulation, MDI also is used as a binder in oriented strand board and in appliance insulation. As a global product, 30 percent of all domestically produced MDI is exported, and it is dramatically affected by construction trends and economic activity.

During 2001-03, global MDI production capacity has remained constant because of stable demand. However, in 2004, increased construction and economic upturns raised MDI demand in North America and abroad almost 18 percent while the anticipated growth rate of MDI production was 6 percent. This increased demand was particularly strong in the Far East. Additionally, prices for MDI rose significantly in 2004, and the current inventory of available MDI is at an all-time low.

MDI manufacturing capacity is expected to increase in 2006. In the meantime, chemical suppliers are doing their best to facilitate their manufacturing processes to maximize production.

Working together

To help manufacturers meet their customers' needs, PIMA recommends contractors stay in close contact with suppliers. In addition, it is important to plan well so materials are ordered in a timely and accurate manner and arrive at job sites when needed.

It also is important to keep in mind a short-term decision can have long-term consequences. As the energy payback studies referenced in this article illustrate, there are many reasons polyisocyanurate insulation may be worth the additional effort contractors may need to take during the coming year to ensure their customers have the best possible roof system performance.

The following tips should help you plan for the coming year:

• Check with your polyisocyanurate insulation supplier frequently to ensure you are aware of the latest market developments.
  
  
• Order product as early in the contract and building process as possible to ensure timely delivery once the construction process is under way.
  
  
• Check PIMA's Web site, www.pima.org, for industry updates.

Your efforts to use the best available, high-performance thermal product will contribute to the long-term, sustainable performances of your projects.

Jared Blum is president and chief executive officer of PIMA.

Storage and handling recommendations

PIMA's recent technical bulletin about the storage and handling of polyisocyanurate roof insulation recently was discussed in "PIMA's advice about storage and handling," January issue, page 52. In the article, Mark Graham, NRCA's associate executive director of technical services, raised questions about this bulletin. The technical bulletin has been updated to attempt to address the issues Graham raises. PIMA intends for the recommendations to apply to distributors and contractors.

Following are highlights of the bulletin, as well as some additional information. The bulletin can be found on PIMA's Web site, www.pima.org.

Storage

Polyisocyanurate insulation typically is shipped to job sites and distribution centers protected by plastic wrap, plastic bags or both. This factory packaging is intended for handling the insulation in the manufacturing plant and during transit; it should not be relied on at job sites to protect the polyisocyanurate against the elements.

At distribution centers, polyisocyanurate always should be stored indoors in dry, well-ventilated warehouses and loaded onto trucks with proper equipment.

Following are steps you can take to keep insulation protected at job sites:

• Material delivery should be carefully coordinated with the roof application schedule to minimize job-site storage.
  
  
• In the event short-term job-site storage is necessary, whether at ground level or on a roof deck, place the package on raised pallets or platforms (at least 4 inches [102 mm] above ground) and store flat. If possible, the pallets should be placed on a finished surface rather than on dirt or grass. In addition, cover the package and pallet with a waterproof, breathable cover such as a canvas tarpaulin.

PIMA members do not recommend polyisocyanurate roof insulation be stored at job sites for extended periods. If polyisocyanurate insulation needs to be stored more than two weeks before installation, it should be stored indoors in a dry, well-ventilated warehouse.

Handling

Whether at job sites or distribution centers, proper handling of polyisocyanurate insulation will ensure a quality installation. Following are some points to remember:

• Exercise care when handling polyisocyanurate insulation to prevent breaking or crushing of the square edges and surfaces.
  
  
• Load and remove insulation bundles from trucks with proper equipment, such as a forklift or crane equipped with spreader bars and canvas lifting straps.
  
  
• Avoid other means of mishandling, such as pushing pallets off the edge of a truck or "rolling" a pallet across a roof deck or truck bed.

Application

Polyisocyanurate insulation always should be installed on dry, clean roof decks in dry conditions. In addition, follow manufacturers' recommendations regarding product application to ensure roof system performance. Make sure to apply only as much polyisocyanurate roof insulation as can be covered by roofing materials the same day.

Roof insulation that is wet, damaged, cupped or bowed must be replaced with solid, dry insulation.

Construction traffic

You should avoid excessive traffic during roof construction or on a completed roof surface. Although polyisocyanurate insulation is designed to withstand normal foot traffic, protection from damage by construction traffic and/or abuse is important. Roof surface protection, such as plywood, should be used in areas where storage and staging are planned and heavy or repeated traffic is anticipated during or after installation.

Some designers and membrane manufacturers specify the use of cover boards as a means of protecting insulation. If specified, ensure a cover board is compatible with all components of a roof system; is acceptable to the membrane manufacturer; and meets specified fire, wind and code requirements.

Safety

Polyisocyanurate insulation, similar to wood and other organic building materials, is combustible. Therefore, it should not be exposed to an ignition source of sufficient heat and intensity (such as flames, fire, sparks, etc.) during transit, storage or product application.

Consult the product label and/or material safety data sheets for specific safety instructions. In addition, follow all regulations from the Occupational Safety and Health Administration, National Fire Protection Agency and local fire authorities.

Polyisocyanurate roof insulation, similar to other roofing materials, requires a proper understanding of storage, handling and application to result in a well-constructed and satisfactorily performing roof system. For additional information about polyisocyanurate insulation, visit PIMA's Web site at www.pima.org.