The document discusses various options for board insulation, summarizing their pros and cons. It recommends mineral wool and polyisocyanurate foam boards but notes mineral wool uses formaldehyde resins and polyiso absorbs moisture. The document also recommends polyurethane-core structural insulated panels (SIPs) over expanded polystyrene-core SIPs due to hazards of EPS and styrene. Finally, it discusses cellular glass, phenolic foam, and natural options like cork and wood fiber boards as alternatives.

1. Board insulation
BuildingGreen does not recommend extruded and expanded polystyrene (XPS and EPS)
due to the number/volume of hazardous chemicals used in their production(s), including
benzene, styrene, and halogenated flame retardants (especially HBCD, a persistent,
bioaccumulative toxic chemical). XPS also uses the blowing agent HFC-134a, which has
a high global warming potential (over 1,400 x more powerful than CO2). If one has to use
XPS, Owens Corning has now replaced HBCD with a brominated polymeric flame
retardant, developed under the EPA Design for the Environment. It is supposed to be
much less of a pbt. They also have Cradle to Cradle Silver v3.1 Material Health
Certification
Here are some other board insulation options.
Most versatile EPS/XPS replacement is mineral wool, because some products can be
used below grade—an application typically dominated by XPS.
Mineral wool: Made from slag a byproduct of steel production and basalt. Products are
available in boards and batts; higher-density boards can be used below grade. Average
thermal performance < R-4.
Pros
 Made with high recycled content slag from steel production (70-90%) and
readily available basalt.
 Excellent flame resistance without flame retardants.
 Moisture resistant.
 Pest resistant, ants/termites don’t bore through it
 Higher density products can be used below grade, though they may require
verification/communication between engineers/manufacturers beforehand.
Cons
 Board products use urea-extended phenol formaldehyde resins (Batt
products from Roxul and Thermafiber are formaldehyde-free but those
resins are not appropriate for boards exposed to moisture)
 Though phenol formaldehyde resins crosslink into a plastic when
heated/cured, resulting in very little to no emissions, urea formaldehyde
resins do not crosslink so can break down and release formaldehyde under
certain conditions (heat/moisture). So, avoid using them on the building
interior when possible
 High-embodied energy

2. Best R-value goes to polyiso, though it absorbs moisture and cannot be used below
grade.
Polyiso/polyisocyanurate: Found in boards, polyiso (PIR) is a form of polyurethane
made from one part polyol and one part isocyanate.
Pros
 Highest R-value of any insulation, up to R-8/in (from factory) reducing to
R-6.5/in (after “aging.”) Foil facings can reduce loss of blowing agent.
 Low GWP blowing agent (pentane).
 Polyiso is available without the halogenated flame retardant TCPP, from
Johns Manville, GAF, and Kingspan (inside metal skinned panels). GAF’s
EnergyGuard NH is R-5.7/in
 A portion of the polyol component can contain biobased material
Cons
 Isocyanates, such as MDI and TDI, are toxic, and pose a risk to
manufacturer/workers during curing. Polyiso uses more MDI than
polyurethane (PUR) used in SIPs (see below) Minimal exposure risk to
end user, though possible during cutting.
 Again, can lose some performance over time, but the products “settle” into
consistent performance.
 Absorbs moisture so not for below grade use
 Most still use chlorinated flame retardants (TCPP)
 Made from fossil fuels
 Though pests do not use it as food, they can burrow through foam.
Best SIP: Those made with polyurethane cores rather than EPS
Polyurethane (PUR): Found in SIPs is similar to SPF. The foams are factory applied,
reducing potential exposure to isocyanates on the jobsite. Unlike EPS commonly found in
SIPs, PUR SIPs do not contain styrene or its associated hazards. There are a lot of PUR
SIPs now on the market, but none that use HFO blowing agents…yet.
Pro
 SIPs have excellent thermal performance. Murus SIPs, for example, have
an R-value of 27 for a 4.5 inch thick OSB/PUR SIP compared to R-15 for
a similar EPS SIP and R-17 for Neopor EPS.
 Potentially less construction waste
 A portion of the polyol component can contain biobased material
 Closed cell foams do not absorb moisture
 Those made with HFO blowing agents should be available in the future,
lowering GWP of the blowing agents from about 1000 to <10.
–

3.  Isocyanates, such as MDI and TDI, are toxic, and pose a risk to
manufacturer/workers during curing. Once cured, minimal risk.
 Most still use chlorinated flame retardants (TCPP)
 Most PURs in SIPs still use HFC-245fa as a blowing agent, with a GWP
of around 1000. See above.
 Made from fossil fuels
 Though pests do not use it as food, they can burrow through foam.
Intriguing belowgrade option: durable, water resistant, good compressive strength,
holds its R-value
Foamglas Cellular Glass: Recently purchased by Owens Corning, Foamglas board
insulation is made with sand (60%), limestone (20%), soda (15%), and trace minerals
(5%). 18" x 24" dimensions in thicknesses from 2" to 8". A bitumen-faced “Readyboard”
is available in 2' x 4' dimensions. A VT company is considering importing cellular glass
gravel that can be used in a number of applications.
Pros
 R-value 3.44 per inch.
 Contains no HCFCs or high GWP blowing agents
 No flame retardants necessary (of course)
 0 VOC, though it can give off hydrogen sulfide when scratched
 Extremely durable
 Can be used for insulating roofs, walls, and below-grade applications,
including beneath slabs.
 It is impervious to moisture, inert, resistant to insects and vermin, strong,
and has an R-value of R-3.44 per inch.
 High compressive strength makes it particularly appropriate for roof
decks, green roofs, and parking decks.
Cons
 Expensive
 Trades are probably not used to using it
 Takes significant energy to make
 Can give off hydrogen sulfide when scratched
Kooltherm: phenolic insulation with pentane blowing agent. Highest R-value of any
board product equivalent to polyiso. It is phenol formaldehyde, but it is also inherently
flame retardant. Interesting tradeoff.
Pros
 R-8 per inch.
 Contains no HCFCs or high GWP blowing agents

4.  Requires no flame retardants
Cons
 Is made from formaldehyde, but it is phenol formaldehyde so if they get
the manufacturing/crosslinking right, emissions should be very low
 Similar to polyiso, it is susceptible to water so not for below grade use.
There are also cork and wood (Agepan) board insulation options. Agepan is interesting
because it is moisture resistant yet breathes in both directions (it is not a food source for
insects (according to the company). Using it would require careful detailing and skinning
to make that work.