Parsons

Brinckerhoff
Halsall

Putting the R (Value) in Roofing

Putting the R
(Value) in ofing
In This Presentation, We Will Cover:

• Brief History of Roof Insulation: The Rise of R Values

• Insulation Properties
• Insulation types:
– Characteristics
– Advantages, Disadvantages and Challenges
• Regulations
• The Future Rise of Insulation
 Brief History of Roof Insulation
• 19th century, wood roof
decks
• Steep slopes to shed water
• Early 1900s, evolution to
more diverse buildings
• Architectural needs =
Structural Engineer solutions
• Result of structural changes
= greater building design
flexibility
 The Advent of Low-Slope Roofing
• Steel and concrete
revolutionized building design
• Roof structures began to flatten
into low sloped roofs
• Weight of concrete decks
limited designs
• Introduction of lightweight deck
alternatives:
– lightweight gypsum
– fluted sheet metal decking
(most common)
 The Advent of Low-Slope Roofing
The roofing membrane needed to be supported over
the spans of fluted sheet metal decks. Low
performance insulation boards were introduced to
meet this need.
These include:
• Wood Fibreboard
• Perlite
• Vermiculite
• Glass fiber
 The 1970s Energy Crisis
• Over time, interior building climate needs and loads increased (air
conditioning and heating)

• OPEC oil embargo of the 1970s and energy crisis increased building
operating costs, forcing development of standards for buildings

• 1975: first version of ASHRAE model energy-efficiency standard for

buildings, Standard 90

• New insulations and solutions were introduced:

– Phenolic foam
– EPS
– Polyisocyanurate
– Lightweight insulated concrete
– Spray Polyurethane foam
 Insulation Properties
Per CRCA, roof insulation needs to have:

• Dimensional stability;

• Firmness to withstand installation traffic (compression

strength);

• Uniformity of thickness;

• Convenient, equal size panels;

• Shear strength; and

• Compatibility with other elements in the roof system.

 Other Insulation Properties
Consider also:

• Warping / cupping under field performance;

• Fire resistance / combustibility;

• Acoustical properties;

• Sustainability (manufacturing, field performance and beyond);

and

• Stability of R value performance in different climates

(temperature, humidity, etc.).
 Conventional Roof Assembly
• In conventional roof assemblies, the insulation is installed below the roof
membrane and can be exposed to different products and conditions which
may be detrimental to them during the construction phase. Examples of
these include:
– Solvent based adhesive and primers
– Hot mopping asphalt
– High temperature from torches

• The type of insulation chosen must be able to resist these conditions or a

suitable protection panel must be installed over the insulation before
installing the membrane.
 Inverted Roof Membrane Assembly (IRMA) or
Protected Membrane Roofs (PMR)
• In an IRMA/PMR system, the insulation will always be
exposed to water as the insulation is installed above the
roof membrane.

• The insulation needs to have minimal water absorption

characteristics.

• The only type of insulation suitable for this is extruded

polystyrene.

• Some hybrid roofs include insulation below the membrane

and above the membrane
 Insulation Types
Characteristics, Advantages, Disadvantages and Challenges

• Wood Fibreboard
• Perlite Board
• Glass Fibre
• Expanded Polystyrene
• Extruded Polystyrene
• Phenolic
• Cellular Glass
• Polyisocyanurate
• Stone Wool
• Spray Polyurethane Foam
• Lightweight Insulating Concrete
Wood Fibreboard
• Introduced in US markets in 1928

• Wood based product

• Interlocking cellulose fibers

bonded together by heat,
pressure and asphalt resin

• Boards limited to approximately

25 mm thickness; thicker boards
glued together
 Wood Fibreboard
Some Advantages:
• Economical
• Local manufacturing
• Relatively hard and can be
used as an overlay board layer
to protect the underlying
insulation
• Available in tapered boards
Some Disadvantages:
• Low R-value per thickness
• Vulnerable to moisture
• Risk for mould (organic
material)
• Manufacturing process with
high water contents = in-situ
roof membrane blistering
• Increased weight versus other
insulation boards: ISO, EPS
Perlite Board
• Introduced in US markets in
1958

• Composed primarily of
expanded perlite with
reinforcing cellulosic fibers
and selected binders

• Mineral based insulation

• Top surface sealed with an

asphalt emulsion coating
 Perlite Board
Some Advantages:
• Economical
• Stable R-value and fire resistance
• Can be used as an overlay board
layer to protect the underlying
insulation
• Dimensional stability
• Could contain high recycled content
= environmental product
• High Density: install directly over a •
wide flute or metal deck application
for spans up to 2½" and resists
damage from construction and
maintenance
Some Disadvantages:
• Fewer manufacturers
• Low R-value
• Can collapse and rot when wet,
thus offering no more
protection to the insulation
below.
• Needs surface coating to
prevent excessive absorption of
asphalt during the installation
process
Could contain high recycled
content = unstable product?
Glass Fibre Insulation
• Composed of inorganic glass fibers

• Used in commercial roofing

systems since 1941

• Surfaces faced with a glass fiber

reinforced, asphalt kraft paper
 Glass Fiber Insulation
Some Advantages: Some Disadvantages:
• Stable R values • Not readily available

• Dimensionally stable • Costs: production, handling

• Will not expand with heat or swell • Manufacturing and transport costs
when exposed to moisture = less competitive than EPS / ISO

• Flexible and chemically inert • Soft underfoot = impression of wet

substrate = fools people
• Flexibility will allow the insulation
to conform to minor deck
irregularities

• Thermal barrier over steel roof

decks: adds fire-resistance

• Can manufacture tapered panels

Expanded Polystyrene (EPS)
• Rigid closed cell foam plastic

• Formed from plastic polymer

• Moulded into blocks, processed

into sheets (flat or tapered)

• Types 1, 2 and 3 from less dense

to denser materials.
 Expanded Polystyrene (EPS)
Some Advantages:
• Lightweight
• No chemical blowing agents (CFC,
HFC, HCFC) results in a more stable
R value over time
• Very cost competitive versus other
boards
• Cut easily to suit site conditions
• Non-nutritive: It has no food value
and will not support the growth of
insects, parasites or animal and
plant life
• Inert to a wide range of chemicals
Some Disadvantages:
• Will absorb water
• Vulnerable to petroleum products
(solvents, adhesives, coatings,
separation sheets, hot asphalt)
which will soften and collapse
boards
• Will shrink and warp when
exposed to high temperatures
(75C+/170F+)
• Susceptible to foot traffic damage
and damage during installation
• Combustible
Extruded Polystyrene (XPS)
• Rigid Closed cell foam

• Low water permeability

• Low vapour permeability

• Known as type 4 insulation

• Can be made more dense to support

greater weights for placement under
planters, high traffic areas etc.
 Extruded Polystyrene (XPS)
Some Advantages: Some Disadvantages:
• Resists water absorption = • Vulnerable to solvents, hot
Installation as part of a PMR asphalt, and high
/ IRMA roof assembly temperatures (early
installation underside BUR =
• Low water permeability major failures)

• Low vapour permeability • Costs = limited use above

roof membranes
• Can be made more dense to • Use in PMR roofs requires
support greater weights ballast = system weight
(beneath planters, etc.)
Phenolic Foam
• Manufactured from about
1974 to 1994

• Found in roofing systems

since 1982

• Catalyst blend of organic

sulfonic acids

• Phenol is a weak acid that is

soluble in water. It is the salts
that remain after its reaction
with water that may promote
more rapid corrosion of the
steel deck or steel
components (fasteners and
plates).
 Phenolic Foam and Corrosion
Some Advantages:
• Highest initial R values
• Very cost competitive during
the late 1980s, early 1990s.
• If dry and separated from
metal components, may
perform in the long term
(vapour retarder over metal
decks / adhered vs
mechanically fastened
systems).
Some Disadvantages:
• Increased risk of corrosion of metal
assembly components (white rust)
• Water can come into contact with
phenolic foam (similar to other
insulation) in a number of different
ways:
– Water is naturally entrapped in the foam
– From leaks
– From vapour entering the assembly
• Actual failures led to a phasing out of
the product in the 1990s
• Important information when carrying
out field testing
Cellular Glass Insulation
• Introduced in US markets
in 1943

• Manufactured from
crushed glass and carbon

• Not common in Canada

 Cellular Glass Insulation
Some Advantages:
• Impervious to moisture and water
• Vapor impermeable
• Fire protecting insulation: will not burn
or give toxic fumes or smoke.
• Rot, insect, vermin and acid proof.
• Does not support the growth of mold,
fungi or micro-organisms.
• Retains its original insulation value for
the life of the building.
• Can be made from recycling glass up to
66% content = environmental product;
May be a viable consideration for long-
term environmental product
Some Disadvantages:
• High Cost material and handling
• Brittle material may crack under
movement, shipping
• Limited manufacturer base
• Smaller panels 2’ x 4’ than other
insulations = more joints = more
handling
• Relative low R value as compared to
other commercial insulations
• Canadian contractor base unfamiliar
with technology, application and
performance
• Cold weather performance limitations
Polyisocyanurate
• Closed cell polyisocyanurate
foam core bonded to paper,
foil, or fiber glass reinforced
facers

• Fabrication: Liquid foam is

sprayed against a substrate
(paper facers, glass facers,
foil facers) and expands to
form a rigid panel

• Used in roofing since 1982

 Polyisocyanurate (ISO)
Some Advantages:
• Cost competitive
(manuf./transport)
• Handling (lightweight)
• Installation (cutting)
• Higher R-values (typically around
5.7, based on LTTR values)*
Some Disadvantages:
• R-Value stability in the long term
= design to lesser R values
(R5/inch per NRCA)
• Older insulations had
environmentally unfriendly
blowing agents (concern with
roofs in place prior to 2000s,
CFCs, pentenes, HCFC)
• Substrates originally consisted of
paper facers (subject to moisture
damage, mould, curling), but now
include foil, glass or other facers
 ASTM C1289 Standard Change
• Standard for polyisocyanurate products

• Long-Term Thermal Resistance (LTTR) value:

– 15-year weighted average of the thermal resistance

• Test method changed from CAN/ULC-S770-03 to CAN/ULC-

S770-09 to better represent long-term thermal behaviour

• This change was effective as of January 1, 2014 and

manufacturers have consequently updated their literature
Stone Wool Insulation
(Mineral Fibre)
• Production process: fusion of
volcanic rock, slag and coke at a
temperature of +-1600° C
(2732°F).
• Minor amounts of binder and oil
added.
• Spinning process to produce mass
of fine, intertwined fibres
• Structure and density of the wool
are adjusted before it enters the
curing oven
• Cured wool proceeds to cutting
saws and packing equipment or led
to off-line equipment for special
treatment
 Stone Wool Insulation (Mineral Fibre Insulation)
Some Advantages:
• R-value long term stability
• Dimensionally stable
• Vapour permeable
• Noncombustible product with a melting
point of approximately 2150°F (1177°C)
• Excellent fire resistance properties
• Water repellent yet vapor permeable
material.
Some Disadvantages:
• Weight in comparison to other rigid
boards
• Soft underfoot: impression of wet
substrate = fools people (denser
materials now on market)
• Cost. Some markets have higher
transport costs
• Handling may cause irritation to skin
• Should not be exposed to weather
during shipment, storage or
installation
• Not intended for use as a structural
roof deck or for use under heavy
traffic areas.
Spray Polyurethane Foam Insulated roofs (SPF) or (PUF)

• Early 1970's, urethane foams were

being specifically designed for
roofing applications.

• Functions as both structural

insulation and waterproofing

• Combination of chemicals sprayed

on roof surfaces in layers to create
monolithic surface

• Opened and closed cell

configuration

• Surface to be coated to protect

from UV degradation
Spray Polyurethane Foam Insulated roofs (SPF) or (PUF)

Some Advantages: Some Disadvantages:

• High fire resistance • Temperature, humidity
limitations for application
•R-value long term stability makes it difficult in some
climate zones

• Vapour permeable
•Degradation of coverings

•Some coatings were food

sources for seagulls
Lightweight Insulating Concrete
• Roof installations prior to the 1970s
in varying thicknesses without
integral insulations

• Early 1970s, constant layers of EPS

insulation integrated in assembly.

• Late 1970s, stepped layers of EPS

insulation introduced.

• Different types of lightweight

concrete mixes provide ranges of
compressive and tensile strengths to
suit project needs.

• System functions as both structural

insulation and sloped to drain system
 Lightweight Insulating Concrete
Some Advantages: Some Disadvantages:
• Durable claims • Weight (installation and
ongoing): structutal review
• Addresses ponding / pooling
water issues in existing roofs • Cost

• Air movement seals • Setup

• Replace membranes only • Limited applicators (better

over time = long term cost now)
savings
 The R-Value
• The R-value is an indication of the thermal
resistance of a material or assembly

• It can be represented as the thickness of a

material divided by its thermal conductivity:
=
Where
=
=
 The R-Value
• The R-value uses US units of (h*ft²*°F)/BTU

• The RSI value uses metric units of (K*m²)/W

• The R-values are roughly 5.67 times higher than

RSI values.

• U-value: overall thermal conductance. U-value is

equal to the inverse of the sum of the R-value in a
system (U=1/R total).
 The Rise of the R-Value
Industry practices in most parts of Canada for some commercial,
higher end buildings:

• Up to and including the 1960s: R-1 to R-5

• 1970s: R-5 to R-10
• 1980s: R-10 to R-15
• 1990s: R-10 to R-20
• 2000s: +- R-20
• 2010s: +- R-20 (not following OBC codes)
• 2020s: R-30 + ?
• November 2007 RCI Interface magazine article by Jared Blum
outlines the various ASHRAE proposals up until that time.
R-Value/inch of different types of insulation
Approximate Insulation Material R values per 1" thick boards
Based on room temperature values (colder and warmer conditions affect R values of different insulations)

Introduction in US Approx. R values

Roof market ** (inch thickness)
Snow Roughly R–1
Straw bales About R–1.5
Vermiculite R-2.13
Wood Fiberboard 1928** R-2.5** to R-2.78**
*Loose cellulose, fiber glass, rock wool R-2.5 to R-4
Perlite 1958** R-2.78**
Cellular Glass 1943** R-2.86** to 3.57
Open-cell polyurethane spray foam R-3.6
Moulded expanded polystyrene (EPS) low-density 1976** (1955**) R-3.85**
Dual density mineral wool board insulation R-3.8
Expanded polystyrene EPS Type 1 R-3.75
Rigid Glass Fiber (fiber glass) 1941** R-3.9 to R-4.2**
1937 (Europe)
Stone Wool insulation (Mineral fibre) 1990s (US/Canada) R-4
Lightweight Insulated Concrete (with EPS insulation) 1970s R-4
Expanded polystyrene EPS Type 2 R-4.04
Expanded polystyrene EPS Type 3 (High compressive strength) R-4.3
Extruded polystyrene XPS Type 4 1965 R–5
Spray polyurethane (closed cell) 1970s R–6
Polyisocyanurate (ISO) Regular densities 1982** (1972**) R5.7 (R–5***)
Polyisocyanurate (ISO) Higher densities R–5.7 plus
Phenolic foam Rigid panel 1982** - end 1992 R–7 to 8.3**
Aerogel 20xx? about R–10-30
Vacuum insulated panels 20xx? R–45

Notes:*blown & in batts ** NRCA 1991 data(Canada soon after) *** NRCA recommended design R values for northern
climates

Other R values taken from various manufacturers published data or other sources
 Which type of roof insulation to use?
• It does not only depend on the roofing system being used

• Consider R value requirements for the building use and location

• R value requirements also vary per the OBC*.

*2012 OBC code requirements for 2017 based on Energy Efficient Design
Requirements and on ASHRAE 90.1 standard or the Model National Energy
Code for Buildings (MNECB) plus supplementary standard SB-10 Energy
Efficiency Supplement July 1, 2011 update

• Requirements vary for new construction versus retrofit to

existing buildings and if building permits are required.
 Which type of roof insulation to use?
• Example Insulation Requirements (per SB-10 dated Sept. 14, 2012, in effect Jan. 1, 2014)

For a non-residential building within Part 9 scope in Ottawa, roof R-values will vary:

– New construction requirements:

• Prior to 2014 (per SB-10 Aug. 15, 2006, in effect Dec. 31, 2014) = R- 22 insulation
• Division 2 (permit application before January 1, 2017) = R-30 insulation
• Division 3 (permit application after December 31, 2016) = R-30 insulation

– Roof replacement, no permit:

• Replace with R-value to match or exceed existing per Division 11 (could be as low as R-5 !?)

– Roof replacement, permit required (not an Ottawa requirement now if project is purely roof
replacement):
• Considered as extensive renovation to meet parts of the building code (construct to meet
structural and fire-resistance compliance)
• GREY AREA: new roof system for roof replacement project needs to comply to fire-
resistance and structural requirements, but no mention of meeting minimum R-values.
Interpretation: Replace with R-value to match or exceed existing assembly per Division 11
(could be as low as R-5 !? but assembly must be fire rated). Local Building Officials may
have a different opinion.
 Roof Insulation Performance
The Drifting R Value
• Studies of insulation performance
• Paper presented by a Canadian consultant (RDH) at the 2013 RCI Building Envelope
Symposium - Monitored Field Performance of Conventional Roofing Assemblies –
Measuring the Benefit of Insulation Strategy (3 types of insulation assemblies
versus 3 roof surface colours)

• Publication by BSC (U.S. Consultants): Information Sheet 502- Understanding the

Temperature Dependence of R-values for Polyisocyanurate Roof Insulation
•Similar conclusions from research
• Various types of insulations perform differently at different exterior temperatures,
with minimal impact from roof surface colour (cold weather performance
concerns)
• Using more stable insulations or hybrid insulation systems (different insulation
types) with more stable insulation layers on top will provide more consistent
results
Roof Insulations are Only as Good as Their Application
• It takes more than just insulation
to slow heat
• Importance of air and vapour
retarder substrates and detailing
• Insulation will not work in a
wind tunnel
– Still air is about R-6 per inch.
– Eliminate Gaps in insulation boards
(horizontally and vertically)

Case Study
- "Consolidation" of EPS insulation
towards low point.
- 1.5" gap created along the perimeter
- Thermal loss and ineffective insulation
 Installation Challenges
- Are Fastening patterns
ever followed?
- Are insulation joints
staggered?
- Does it matter?
 Roof Insulation Performance

Laying insulation on metal deck, offset joints horizontally and vertically

 Roof Insulation Performance

Gaps in phenolic insulation underside membrane, causing ridges to form above

 Roof Insulation Performance

Metal roof on an industrial building: Inverted roof on an office building:

Heat loss due to inadequate insulation Heat loss through insulation board joints.
between roof girts and metal roof
cladding.
The Future of Roof Insulation
Where is the market heading?
 The Future of Roof Insulation

Climate change impact on roofing and insulation requirements

 The Future of Roof Insulation
GOVERNMENTS WILL CONTINUE TO BE INVOLVED

• Regulations for thermal performance of buildings will drive

insulation development and costs (already has)

• Programs and Incentives Designed to Help Battle Climate

Change (Politicians react to climate change)

• Other regulations affecting insulation

– Safety: mechanically fastening through decks and conduits!
– Health: Will insulation types or adhesives used today be a
health risk tomorrow? (past history confirms this!)
 The Future of Roof Insulation
• Consultants have a responsibility in insulation selection
for sustainability
– Design to leave substrates in place, where practical
– Consider building airtightness in designs
– Consider designs of roofs that harvest energy
– Design to provide optimal system performance
– Design to provide long term health, safety, cost benefits
– Consider actual Thermal Performance of in-situ insulations. Are
they equal to claims made?
– Work with all parties in the construction team and provide the
needed Quality Assurance during all stages of roof system
installation
– Provide knowledgeable services (RCI Registered Roof
Consultants – RRCs and Registered Roof Observers – RROs)
 The Future of Roof Insulation
• Will insulation be thicker or thinner?

New products and innovations

• Vacuum Insulated Panel (VIP)
– Highest R values to date: R-30 to R-50 per inch = thinner systems =
construction cost savings
– Germany / Europe innovation
– Cost now prohibitive and production challenges: sealed units cannot
be cut (getting around this)
– NRC Research - Long-term performance of Vacuum Insulation Panels
(VIP) in the Canadian climate Volume 17, Number 3, September 2012

NRC Research
• Research Paper: Long-term performance of Vacuum Insulation Panels (VIP) in the
Canadian climate Volume 17, Number 3, September 2012
• Research Paper presented at the IVIS Symposium: APPLICATION OF VACCUM
INSULATION PANELS IN LOW SLOPE ADHESIVE APPLIED ROOFING SYSTEMS
 The Future of Roof Insulation
Silica Aerogel (Maerogel):
• Aerogel is almost a
product out of science
fiction. Nicknamed
“frozen smoke”

• R-10/inch

• Aerogel provides nearly

40 times the performance
Researcher: Prof. Dr. Halimaton Hamdan of fiberglass insulation
Malaysia
 Conclusion
• The selection of insulation types varies with building use, building code
interpretations, building location

• R-values drive the selection process (maybe too much), need to consider
other properties as well as installation challenges

• Long-term thermal performance and in-situ stability are a concern that

cannot be ignored

• Multiple insulation layers create redundancy and deal with air movement,
thermal bridging

• Multiple types of insulation within an assembly can deal with variances

and optimize total system performance

• More research is leading to better existing insulations and new

generations of “science fiction” insulations

• Maybe thinner will be the new normal, not thicker!

Thank You

Putting the R
(Value) in ofing