Then in 2002 the US Department of Energy created the Solar Decathlon. This international competition was designed to challenge up to twenty collegiate teams “to design, build and operate the most attractive, effective and energy efficient solar powered house.” Aside from those initial demands, the winner must also blend affordability, market appeal and a profound level of success in the design – all with an eye to the most efficient energy production. There are ten contests within the decathlon, each earning a maximum of 100 points. They are defined as architecture, market appeal, engineering, communications, affordability, comfort zone, hot water, appliances, home entertainment, and energy balance.

Judges are looking for excellence in each category, but the overall goal is to produce a house that can be appealing to the buyer, wholly powered via solar energy and be completely comfortable. In 2011 the winner of the Solar Decathlon was the University of Maryland with their ‘WaterShed’ house. The students reported their design was inspired by the Chesapeake Bay ecosystem. They illustrated their inspiration by managing water in four categories: potable water (drinking), rainwater, greywater (wastewater that does not contain biosolids) and blackwater (contains biosolids).

Each category is dealt with in a specified way and used to the maximum of its potential, unlike processes in most homes. Potable water is used only for consumption in WaterShed, while mainstream methods use potable water for irrigation and toilets. The difference in Watershed is 50% less potable water is consumed each day. Rainwater is used for irrigation and toilets, greywater is filtered and also used for irrigation, blackwater contains biosolids and therefore requires treatment before releasing to the environment. The significant use of rainwater in WaterShed’s use as a functional home means its collection has to be more efficient than just a rain barrel, without compromising the building envelope.

The University of Maryland Solar Decathlon team knew they had a challenge front of them: engineer a home that was ultra-energy efficient, but keep it warm and dry while maintaining affordability. Ultimately, their answer was a full integration of all systems. The building envelope was built multi-layered, each layer protecting against energy loss and negative infiltration of air or water. The team used a soy-based open cell SPF in the exterior walls, but closed cell SPF in the roof and floor. For the outer walls, the SPF was covered with wall sheathing, a liquid applied membrane, and then two inch thick polystyrene rigid insulation for extra protection against “thermal bridging”. Over top of the polystyrene are “thermo-treated wood” siding panels which purposely shed rainwater into collection apparatus’ via vent strips. Due to the special venting strips in the wood siding, an additional layer of ‘furring’ was needed to create a ventilated cavity.

The WaterShed home is anything but standard. The design is extremely interesting from various points of view, and does present some very intriguing ideas for home design and efficiency. However it is important to view the project for what it is, an experiment. For example, the addition of polystyrene panels to the building envelope while SPF was already in place is overkill. One must ask why an additional layer of SPF was not applied instead of the polystyrene. Nevertheless, for the standard residential building, open or closed cell SPF (whether it is soy based or polyurethane based) will do the job just as efficiently without those polystyrene panels. Which means if the future of the typical family home lies along the lines of the WaterShed, then we can happily report that SPF has a bright and useful future!

The Recovery Act or ARRA was signed into law in February of 2009 and designed to make “supplemental appropriations for job preservation and creation, infrastructure investment, energy efficiency and science…etc”. The Act allocated $27.2 billion to “energy efficiency and renewable energy research and investment”, which was broken down into detailed allotments. For example, $3.1 billion was set aside for State Energy Program aimed at investing in energy efficiency and renewable energy. A further $5 billion was provisioned for weatherizing modest-income homes, $300 million for energy efficient appliance rebates, and $250 million for increasing energy efficiency in low-income housing.

Out of the $30 million share Maine got from the $3.1 billion for State Energy Programs, lawmakers created the Property Assessed Clean Energy (PACE) program. That meant the Dudley’s could attain a loan of up to $15000 and repay it over 15 years at an annual interest rate of 4.99%, well below the existing bank rates. The family opted for a two inch layer of closed cell polyurethane spray foam insulation throughout the entire basement floors and walls. By giving the building a sort of ‘sock’ made from state of the art insulation, the building would better be able to hold its ambient heat. For some reason the rest of the home was insulated with cellulose. The Dudley’s used their loan to make sweeping changes in the efficiency of heating and cooling of their house, including upgrades to windows and thermal outer doors. The family reported that after all changes were made, their heating costs during the following winter season were reduced by a whopping 30%. One can only imagine the further reductions in utilities costs if the entire house was insulated with SPF.

According to the US government’s official database of allocations made by the ARRA, a number of states have created similar programs to the one in Maine. The database lists each program, the date of initiation, and audit reports outlining the specific spending taking place. Some of the states taking advantage of the funding are: Ohio, Georgia, Pennsylvania, Tennessee, West Virginia, Commonwealth of Virginia, Indiana, Missouri, Idaho, New Jersey, Massachusetts, Arizona, Illinois, Michigan, and Louisiana. Of course each state’s program will be tailored to the specific needs of the housing demographics, yet it is still in the best interest of every homeowner to investigate their own eligibility for taking advantage of the government funding. By coming together in a common goal to reduce nationwide energy costs, and along with other initiatives, the economy will grow stronger.

Let’s begin with the basics. We know SPF is composed of polyurethane foam, and is present in a multitude of applications including: furniture padding, vehicle insulation, aircraft insulation, carpet under padding, soles of shoes, and protective cases for electronics. Knowing the difference between each of those applications, it is easy to see polyurethane foam can be created in all manner of densities and thicknesses. The demands of each application dictate the type of formula used to create the foam, but they all begin with polymer units held together by urethane links. When that solution is poured by itself, it becomes a solid plastic. When it is mixed with a secondary binary unit, and depending on measurements, foam is formed.

For the purposes of thermal insulation, there are two main varieties of polyurethane foam: open cell and closed cell. Open cell contains pores which are interconnected, and therefore not fully closed. Closed cell SPF has pores which are completed closed. The latter is far denser, can be used for structural strength and is an excellent air, sound and water vapor barrier. Open cell is also an effective air and sound barrier, but when it comes to moisture there is a chance it can enter the open pores. If there are bacteria in the moisture or the pores, then mold grows. However, when the open cell SPF has been treated with an antimicrobial agent the prospect of mold growth has been removed. Not all open cell SPF’s are treated with these agents.

Another important aspect of SPF insulation, and indeed any insulation, is its fire rating. At the minimum, an insulating material in the home should be tested and have earned an E-84 Class 1 fire rating. What that means is the product has been tested under specific guidelines, passed and is now considered to reduce the risk of flashover in a major fire. Flashover occurs when the heat emitting from a fire in the immediate surrounding area is so high, it causes surface to ignite spontaneously. An E-84 Class 1 fire retardant insulation has proven to show it will not ignite up to a particular heat in a major fire. This sort of protection means the difference between fires spreading throughout a building unchecked, and being held off long enough for firefighters to subdue it before the insulation has reached its maximum point of resistance.

To recap, we have closed cell SPF that is able to provide a competent barrier against air, moisture, pests and flashover with an antimicrobial agent. We also have open cell SPF, able to do all the same things and with an antimicrobial agent. So why use open cell at all? In most situations, open cell SPF requires a smaller amount of ‘ingredients’ hence it is usually less expensive compared to closed cell SPF.

Polyurethane spray foam insulation, whether it is open or closed cell, has the potential for saving billions of dollars in home energy costs every year. The US Department of Energy has released several figures estimating the potential savings if homeowners were to make their homes energy efficient. The most popular figure for cost reduction is 40%, a significant amount to be sure. Yet to the average homeowner, the concern is not energy savings on a national scale but the ease of converting their own home. It can be done, and it can be done easily. Start small, perhaps with energy efficient light bulbs. Then move on to shorter showers and less use of the clothes dryer. As spring approaches, begin an energy audit on the home. Those are the first steps to reducing your utilities costs and keeping your home cost effective.

Together with the Spray Polyurethane Foam Alliance (SPFA), CEC Commissioners spent several months studying the attributes of SPF in terms of building science and energy savings. Since closed cell SPF was already a part of the 2008 Energy Code, the CEC team was well aware of the R-value potential in SPF. But the specifications of open cell SPF reassured Commissioners that it was just as efficient as closed cell. Traditional fiberglass batt insulation bears an average R-value of 3 per square inch, does not fill in small gaps or crevices, and does not repel moisture, mold or pests. Open cell SPF has a minimum R-value of 4 per square inch and closed cell has an R-value of 7. They both provide a tight air barrier in even the smallest crevices, resistant to moisture, and of course are fire rated. There may only be one R-value point between pink batt and open cell, but consider how much of an impact it would make on utilities bills to have zero drafts entering the home.

The above comparison begs the question: why would anyone choose open cell over closed cell? Perhaps that single question is the reason CEC Commissioners waited almost four years to endorse open cell SPF. Let’s take a look at the overall benefits of each to help clarify differing advantages. Both are made from polyurethane foam, which is formed by a polymer – a chain of organic units linked by urethane groups. When the polyurethane is mixed with a binary unit, it becomes foam. Open cell SPF has interconnected pores, closed cell SPF does not. Because the pores in closed cell are not connected, there is more compression strength in the SPF, and therefore can be used for rigid structural support. However, closed cell also expands very quickly; in under a minute, and therefore is best used for cavities which are not yet enclosed (such as during construction) or exposed to dampness. Open cell foam is often ideal for adding r-value on top of a layer of closed cell foam instead of using full fill closed cell or fiberglass batts.

Another aspect of closed cell versus open cell is the issue of moisture. There are several sources recommending the disuse of open cell SPF due to a lack of water resistance. While moisture can enter the interconnected pores of open cell SPF, it does not absorb any and therefore is unlikely to grow mold. For those still fearful of mold growth, consider seeking out an open cell SPF that includes an anti-microbial agent, while still bearing an E84 Class 1 fire rating. This type of product gives the user the best of both worlds: significant energy savings, mold resistance, provides a sound barrier, and fire retardant.

As the development of the 2013 Energy Efficiency Standards for Residential and Nonresidential Buildings continues, California residents will see further assurances that SPF and roofing system efficiencies are addressed. And while other US states have begun to follow the same path, there is still a significant need for governmental bodies to provide solid incentives for pushing the use of energy efficient practices. SPF is just one component in building sciences, but it is a great place to start.

According to the United States Department of Veteran Affairs subordinate agency, the National Center for Post Traumatic Stress Disorder (PTSD), 11-20% of Iraq and Afghanistan war veterans will come home with PTSD. The number can’t properly be pinned down for many reasons. For example, often veterans are not aware their altered behaviour is a product of the trauma of war, or even a recognized medical condition. Additionally, PTSD is far more likely to afflict those who are under-educated, have little familial support, have experienced trauma prior to their service time, have endured stressful changes in their personal life, are under the age of 25, or are female. Obviously the presence of factors such as these is very common among military personnel, and therefore pushes the occurrence of PTSD further towards the 20% mark.

In the case of Sgt. Hill, during his time in Iraq he was almost killed when an Improvised Explosive Device (IED) detonated beneath his Humvee. During his rehabilitation from the physical wounds, it became very clear to Sgt. Hill’s medical team that psychological wounds ran deep. Several years of inpatient PTSD treatment were necessary for the veteran before he could return to his family, and even then life was hugely different than life before the explosion. Sgt. Hill had many triggers for his panic episodes, including dimly lit spaces, long dark hallways, loud and sudden noises, and vehicular sounds. His knee-jerk reaction to the triggers was to run, and run without regard for potential hazards, such as traffic.

To add to the situation, his family home was located right next to a rock quarry and train yard. Clearly Sgt. Hill could not return to the family home, if it were to remain in the same location. Alas, along comes the dramatic angel of mercy, Ty Pennington and his bag of sponsors. The rest of the story is familiar to us all; the Extreme Makeover team swoops in, builds a house in seven days, the family is welcomed back with momentous fanfare and tears of joy. Since that grey November day there have been dozens of articles written about the episode, each one covering a different angle of the event. Yet no one seems to have addressed the potential for helping veterans on a larger scale, using SPF. But first, let’s take a quick look at the details of the project.

The foam used in the Extreme Makeover case was open polyurethane foam, known for its sound dampening qualities. Quantitatively, it had a Sound Transmission Class (STC) rating of 41 per regular application thickness of two inches, but was applied in an eight inch layer. According to the International Standards Organization (ISO), an STC 41 rating sits squarely between the “onset of privacy” and “loud speech audible as a murmur”. When one of the occupants of the home is sensitive to environmental noise, an STC 41 rating is clearly not adequate. Applied at four times the thickness however, one could surmise the rating would sit at a little over 100. According to ISO, anything above 60 is “superior soundproofing; most sounds inaudible”. Clearly Sgt. Hill would now live in a home where he could enjoy the safety of quiet.

With a view to the entire military community, the sound dampening benefits of open cell SPF could be of great benefit to our nation’s veterans suffering from PTSD. After all, there are more than just Sgt. Hill seeking a quiet life of recovery after their service time. Approximately 165,000 military personnel were deployed to the Iraq war alone. If just 11% (the bottom of the PTSD scale of occurrence) of those troops suffered from PTSD, it would mean 18,150 veterans are in distress within their own homes. Those who deal with PTSD each day, and cannot handle the constant flashbacks, paranoia, anger, rage, fear triggers and so on, often resort to suicide or violent acts against themselves or family members. For Sgt. Hill, life is just a little more stable for him because he knows there is a quiet refuge available for him. For the minimum (and approximate) 18,149 veterans with PTSD, there may not be a retreat available.

This discussion begs the question: how can the SPF community reach out to the veterans’ community? How can careful education on SPF take place, so PTSD sufferers and their families can see the real-life benefits of open cell SPF? Extreme Makeover may be a show bent on drama, yet they have succeeded (albeit unknowingly) in making the first move between SPF companies and veterans. It is time for manufacturers, installers, even representatives, to approach veterans associations. Perhaps offer workshops or literature showing the role SPF can have in treating PTSD. Now that all those hundreds of thousands of veterans have helped their nation, it is time for us to help them.

Let’s start with the facts. Open-cell polyurethane foam insulation, in most forms, is an E84 class 1 fire retardant material. What that means is the open-cell SPF had to pass a specific flammability test to acquire a fire rating. Fire retardant doesn’t mean that it will not burn if flame is applied directly to the product. Having a fire retardant rating plus using the right ignition barrier means the product resists burning as a result of flashover. A flashover occurs when the surrounding fire and heat cause exposed surfaces to reach their autoignition temperature and ignite. If the fire directly touches the SPF, that is a different story.

The next logical question is, when does flashover typically occur? According to the National Fire Sprinkler Association, flashover occurs at about the eighth minute of a residential fire in which the fire growth has not been restricted. In other words, no fire department on site and no sprinklers are working. The average time for a fire department to respond to a residential fire is four minutes, less than half that of the time it takes for flashover to occur. Therefore, a home encased in open-cell fire-rated polyurethane spray foam insulation with a proper ignition barrier may have more than just those eight minutes because the SPF can have a significantly reduced role in supporting combustion.

In the case of the music room, the scenario is slightly different. Instead of the typical one, two or three inch layer of open-cell SPF, the music room was completely encased in an eight to ten inch layer. Apparently the homeowner enjoyed playing his guitars, and playing them loud. Thus one of his requests was for a soundproof room. Knowing the thermal benefits of open-cell SPF, its renewable based manufacture, sound attenuation benefits and fire rating, the homeowner commissioned its use for the music room.

When the devastating fire destroyed the rest of the building, firefighters were amazed by the still-standing structure that was the music room. It seemed to defy all flames, the heat and 6 million gallons of water. Upon further investigation (and when things cooled down), the homeowner discovered the heat of the fire had eaten through four inches of the SPF, but never actually ignited. Having the floor, ceiling and walls all encased in open-cell SPF with an ignition barrier like drywall or thermal barrier paint had saved $1 million dollars in rare art and musical instruments.

The case of the music room saved by SPF is unusual, there is no doubt. However there are some very important factors to consider. First of all, those four inches that melted away from the heat of the fire. They did not burn, they melted. Could it be there was no flashover on any outside surface of the music room, despite the rest of the home burning down around it? Also, the point of ignition was the result of a light

ning strike and thus from an outside force. Would the result have been the same if the ignition point came from inside the music room? All the valuable instruments would have been lost, but would the open-cell SPF have maintained such a strong level of integrity?

The article from which this story is drawn also describes how the homeowner went on to rebuild the home and encased the entire building this time in the same open-cell SPF. Obviously this homeowner wholly believes in the integrity of polyurethane insulation, for more than just its fire rating. Given his experience, who can blame him?

When the reaction takes place bubbles form and the substance expands, almost like the process of baking a pound cake. Various measures of each ingredient or different methods of mixing will produce varied consistencies and densities of foam. Some forms are hard like plastic, others are extremely soft. Depending on the density and presence of elastomers, polyurethane foam foam is formed into everyday materials such as all manner of fabric coatings and synthetic fibers. The durability of the foam and ability to be impervious to moisture, translates into an excellent material for outsoles and midsoles of footwear. Low density and flexible foams are perfect for bedding and upholstery.

Rigid polyurethane foam that is so high in density it becomes a plastic, is used for casting structural parts for buildings. The small bezels in jewelry, watches and electronic instruments are made from more dense polyurethane foam. Foam that is rigid and reasonably compact can be easily formed into specific shapes using molds. Therefore polyurethane foam is very popular in the construction industry for use as structural foam, particularly for a building facade. The vehicle industry makes use of polyurethane foam in the vehicle fascia and the protective ‘skin’ of the interior surfaces, such as the dashboard. Let’s also not forget how polyurethane foam is used in a spray form and as a highly efficient insulating material in buildings and vehicles. Millions of dollars in energy costs are saved every year, but billions more may be saved by a wider use of spray foam insulation in residential and commercial applications.

Alright, so we know what polyurethane foam can be used for, but what about sustainability? Let us first address the insulation factor. By reducing the heating and cooling costs for every structure, in both residential and commercial buildings, permanent and modular greenhouse gases can be significantly diminished. Mining and transportation of fuel is reduced, as are all the activities related to energy consumption. As a moisture resistant material, polyurethane spray foam insulation also prevents mold and moisture damage to structures, thus reducing the unnecessary use of raw materials for repairs.

One of the largest misconceptions regarding polyurethane foam is in its manufacturing process. Since the end product is not an organic material, many believe the foam is created in an environmentally harmful manner. In truth, polyurethane foam is created through an exothermic reaction that requires very little energy or water. That means the polyol and the diisocyanate releases its own energy through the naturally occurring chemical reaction, negating the need for a further ‘push’ via mechanical means to produce the end product. This natural process also means there are no off-gasses from the cured foam.

Furthermore, polyurethane foam is sustainable in that it is recyclable. According to the Polyurethane Foam Association (PFA), all polyurethane foam products are used for recycling purposes. The association itself has created a collection and reuse program that is one of the most successful in the world to date. Hundreds of millions of pounds of post-consumer waste in the form of polyurethane foam is rerouted away from landfills and used as a bonded carpet cushion. Data from the PFA tells us about 80% of all carpet cushion used in the US is produced from recycled polyurethane foam.

Living green is not always as simple as organic foods and the complete abandonment of anything man-made. Living in an environmentally friendly manner means making smart choices for the earth and for society. True and lasting sustainability is only achievable through first educating oneself with balanced information from reputable sources, then using that information to make realistic changes in our everyday life. Not one of us can change the world by our self, yet we can do the small things that culminate in larger change. Begin with making your home more energy efficient. Change light bulbs to cost saving energy star lighting. Conduct an energy audit on your home, then block up all those drafts with spray foam insulation. You can make a difference with polyurethane foam!

According to the International Organization for Standardization (IOS) the term is too vague to be meaningful. The US Environmental Protection Agency (USEPA) agrees, but only to a point. The USEPA created the international Energy Star program in an attempt to provide the manufacturers of goods with a voluntary labeling system for promoting energy efficient products.

In the 1990′s when the program was started, it was only applied to appliances and electronics. However, today entire homes and home offices are able to gain Energy Star certification. The only criteria is the building must use 15% less energy than a standard home built to the 2004 International Residential Code. How does a home achieve that rating? The things at the top of the list for getting an Energy Star rating are not surprising: insulation, high performance windows, tight construction and ducting, energy efficient cooling and heating systems and Energy Star certified products (appliances, lighting, water heaters).

Now, in reference to insulation specifically, its efficiency is measured according to R-value. An R-value is a mathematical calculation which produces the level of thermal resistance a building has. For the average North American home insulated with traditional fiberglass batts, R-value sits at between 3.1 and 4.3 per square inch. Blown in fiberglass insulation has a typical R-value between 2 and 4 per square inch. According to the US Department of Energy, the same home insulated with spray foam polyurethane insulation will have an R-value between 7 and 8 per square inch. Clearly a home insulated with spray foam would be well on its way to achieving an Energy Star rating, even without installing LED lighting and thermal windows.

When a building is insulated with polyurethane foam, the costs of heating and cooling will undoubtedly be vastly reduced. Many spray foam manufacturers report that energy costs can be reduced by up to 40%; a claim that is both highly likely and easily attainable. With such a diminished use of energy, there is less demand for petroleum-based products and fossil fuels, resulting in a smaller carbon footprint being left on our planet.

We are half way to answering our title question, is spray foam insulation really green? Now we know its immense potential for energy savings, but what about the manufacture of the foam itself? In the case of spray foam, the two substances that come together to produce the foam must remain separate until the time of application. Those two things are polyol (a naturally occurring alcohol) and diisocyanate (a group of organic compounds derived from plant and animal materials). When they are brought together with water, an exothermic reaction takes place producing the polyurethane foam. Although the foam is produced from organic substances, it does not breakdown over time – a good thing for insulation applications, but where does it go when it is no longer needed?

When the intended use of the polyurethane foam has been completed, it can be re-purposed and recycled. For example, the Polyurethane Foam Association has pioneered a program in the US in which spray foam insulation and products meant for the landfill are collected and made into carpet foam underlay. The program is so successful that 80% of all carpet underlay used in the US is made from recycled polyurethane foam. The reduction in waste going to landfills is incredible!

So, is spray foam insulation really ‘green’? Yes, it is. Polyurethane foam is produced in an environmentally friendly way in that it is created from organic compounds using very little energy or water, prevents the excess use of fuel in heating and cooling homes and is entirely recyclable for other uses.

Before you even think about moving forward, you should be thinking about safety. Protective safety goggles, full-cover clothing, a mask, and work gloves are a must for anyone applying spray foam insulation. Make absolutely sure that no skin is exposed during application, because the adhesiveness of spray foam is similar to that of permanent glue: it will stick to skin and will not come off. If this occurs, the insulation will remain on your skin until your outer epidermal layer peels off. For the record, the only substances known to remove spray foam are white spirit-based solvents – and only then if the insulation has not begun to set. Applying spray foam insulation also opens the possibility of the material getting into your lungs, which can cause respiratory problems. In short, get confident in your ability to apply spray foam properly.

Once you are ready to proceed, make sure the area where the spray foam is to be applied is between 65 and 80 degrees Fahrenheit. If it is not, either wait for the temperatures to decrease or warm the area using a bullet heater. Also, make sure the application area is clear of debris and dust in order to maximize adhesion. If there are holes or cracks in the walls or ceiling areas where you are spraying, make sure that you apply a sealant to insure a suitable air seal.

Once the area to be sprayed is ready, you must turn your attention to the areas that will not be sprayed. Windows, doors, floors, drywall, and other areas must be masked with cloth or plastic sheeting so they won’t be affected by over spraying. If there are any objects or structures that cannot be removed before spraying (such as air conditioners, plumbing piping, or heating units), then make sure they are completely covered as well. Again, one gap in your protective sheeting could result in a spot or stain which you may be unable to remove.

Now it’s time to turn your attention to the spray foam insulation equipment. Like the application area, the insulation kit tanks should also stay within the 65 to 80 degree range before and during spraying. Also, make sure the pressure settings on the tanks are set to the manufacturer’s specifications. Next, take the spray hose and check it to make sure there are no blockages of any kind. Fasten the hose to the insulation kit tank, using a wrench to properly tighten them together. When you are ready to begin spraying, open the valves by turning them counterclockwise.

The spraying process itself is much like applying spray paint, coating the area with smooth, broad strokes. Most spray foam home insulation manufacturers recommend spreading the product with a thickness of one inch. After it dries, the spray foam will keep your home better insulated than fiberglass, and you will start seeing some energy cost savings. But those savings will not appear if you don’t apply the spray foam correctly. It’s very important that you take the time to prepare for properly applying spray foam. Because, like most things, installing spray foam insulation in your home is easy – if you know how to do it right!