9edc796c-2897-4200-8437-637e7070b4ebPolyisocyanurate rigid foam board roof insulation, R=10.2 (A1-A3)Cradle-to-gate production of polyisocyanurate rigid foam roof insulation boardIndustry average, multiple producers (at plant)R-value = 10.2, 1.8 inch thicknessPolyisoMaterials productionPlasticsThis process represents the North American cradle-to-gate production of polyiso roof insulation board, focusing on the main technologies and the legislative boundary conditions.503Primary energy and emissions data regarding manufacturing processes were collected through a plantby-plant survey of all PIMA member manufacturing plants in the United States and Canada. In addition, primary data was collected from all three polyeser polyol plants in the US.Polyisocyanurate (Polyiso) is a closed-cell, rigid foam board insulation consisting of a foam core sandwiched between two facers. The foam core is composed of closed-cell rigid Polyiso foam produced through the chemical reaction of an “A” side (MDI) and a “B” side (polyester polyol with various additives such as catalysts, surfactants, and flame retardant) plus a blowing agent (pentane). For roofing applications, the most common facer is a glass-reinforced fiber (GRF) material made from over 90% recycled post-consumer and post-industrial fiber.
The major raw materials at a Polyiso insulation manufacturing plant consist of chemical liquids stored in tanks onsite. The chemicals for the “A” side (MDI), the “B” side (polyester polyol plus catalysts, surfactants, and flame retardants) and the blowing agent (pentane) are pumped from storage into process tanks. The “B” side and blowing agent are then pumped to a mixer and then to a mix head where they are combined with the “A” side and injected between the top and bottom facers on the pour table. These chemicals combine on the pour table and react rapidly to form a closed-cell foam board that is sandwiched between the top and bottom facers. The rigid foam board then travels within a heated laminator on moving conveyor belts, which aids in cell formation and hardens the board. The board then exits the laminator and is fed through saws that trim the board to the desired width and then through a crosscut saw that cuts the board into desired lengths. The finished rigid boards are then stacked, packaged with plastic wrap,labeled, and moved via fork truck to a warehouse area for storage and eventual loading onto trucks for shipment.Tris(2-chloroisopropyl)phosphate (TCPP)Thermal energy from natural gasTap water from groundwaterTruck - Trailer, basic enclosed / 45,000 lb payload - 8bFoil FacerPolyethylene film (LDPE/PE-LD)Methylene Diphenyl Diisocyanate (MDI)Diesel mix at filling stationNon-ionic surfactant (fatty acid derivate)Rigid cellular Polyiso roof insulation board is the most widely used insulating material for above-deck commercial roof construction in North America. In commercial roofing assemblies, one or more layers of Polyiso are placed above the roof deck (typically steel, concrete, or wood) and beneath the roofing membrane. The Polyiso boards may be attached to the roof deck with various mechanical fasteners and construction adhesives or held in place with ballast stones or concrete pavers placed above the roofing membrane. The roofing membrane also may be mechanically attached through the Polyiso insulation, adhered to the top Polyiso facer or held in place with ballast. Additional common elements of this construction may include air retarders, vapor barriers, and thermal barriers placed beneath the Polyiso insulation and cover boards placed between the Polyiso insulation and the roofing membrane.LCI resultAttributionalnoneAllocation - market valueAllocation - net calorific valueAllocation - exergetic contentAllocation - massIf a flow is less than 1% of the cumulative mass of all inputs and outputs of the LCI model, it is excluded, provided its environmental relevance is not a concern. If a flow is less than 1% of the cumulative energy of all inputs and outputs of the LCI model, it is excluded, provided its environmental relevance is not a concern. The sum of all excluded material flows does not exceed 5% of mass, energy, or environmental relevance.Primary energy and emissions data regarding manufacturing processes were collected through a plantby-plant survey of all PIMA member manufacturing plants in the United States and Canada. The survey was conducted in January 2014 and reported annual values based on 2013 plant operations. In addition to energy use, the survey included information with regard to packaging, scrap/waste, and emissions rates associated with the manufacture of Polyiso roof insulation. In addition to data collected directly from PIMA member manufacturing operations, primary data was collected from the following sources:
• All three polyester polyol plants in the US
• Energy/emissions factors from one facer plant for glass reinforced fiber (GRF) facer
• Energy use for insulation installation on a building
Energy/emissions data from life cycle databases, studies in the literature, etc., were used for all other modeling of raw materials, transportation factors, and land disposal. In all cases, the data collected represented technologies currently in use, and all secondary data was not older than 10 years.Environmental Product Declaration: Polyiso Roof Insulation Boards95.02014No statementthinkstepthinkstep2019-02-01T00:00:00.000ILCD format 1.1thinkstep2019-02-01T00:00:00.00000.00.001Data set finalised; entirely publishedthinksteptrueFree of charge for all users and usesPolyiso Insulation Wrapped for ShipmentOutput0.1738058800748790.1738058800748790Mixed primary / secondaryUnknown derivationvaluable