2.3 URETHANE & POLYISOCYANURATE FOAM Urethane and polyisocyanurate are closed-cell plastic foams where the cells contain Freon, a low-conductivity CFC gas. Since polyisocyanurate and urethane are chemically similar, their properties and characteristics are used interchangeably in this report (Andrews 1992a, p. 20). These foams have one of the highest R-values of all building materials (Andrews 1992a, p. 31). Winter Panel, a manufacturer of urethane foam panels, expects to convert to a less destructive hydro-CFC foaming agent within two years. The agent is still ozone depleting, but to a lesser extent. Under international treaty, all ozone depleting substances are being phased out of production due to their suspected effect on the Earth’s stratospheric ozone layer (Eneray Design Update 1993 p. 12). 2.3.1 Urethane & Polyisocyanurate Manufacturing Process The urethane and polyisocyanurate foam manufacturing process is complex. The chemicals must be properly formulated, properly mixed, and sufficiently cured under continuous pressure in a controlled temperature range. This results in higher cost. The average foam density is 2.0 Ibs/f (Andrews 1992a p. 31). Urethane and polyisocyanurate panels are either foamed-in-place or glue-bonded. The foamed-in- place process involves injecting the foam between the panel facings which are held apart by spacers. The liquid foam expands to fill the cavity and will adhere to the facings, resulting in a strong bond. This panel fabrication process requires the foam to be manufactured on-site. Glue-bonded panel fabrication is identical to the EPS process where an adhesive is applied to a precut foam block, which is then pressed between the facing materials. The foam can be either formed on-site or bought from a manufacturer. The foamed-in-place procedure is predominant (Andrews 1992a, p. 32). 2.3.2 Urethane & Polyisocyanurate Thermal Properties Initially, the thermal resistance of urethane and polyisocyanurate is approximately R-7.0 per inch. However, these foams suffer from “thermal drift" which, over time, causes a decrease in R-value. Thermal drift is caused by air permeating into the foam cells. This dilutes the Freon gas, which is responsible for the high thermal resistance, causing a drop in the R-value. In combination with the Freon gas dilution there is a slow *outgassing’ of Freon, which also decreases the R-value. Unfortunately, limited data exist concerning the magnitude of the R-value reduction and the duration of the aging period (Andrews 1992a p. 33). 25