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Montreal Protocol and Third Generation Blowing Agents: The Road to Zero Ozone Depletion Developed by Richard Roe, RRC, CCPR, LEED AP Atlas Roofing Corporation
Montreal Protocol and Third Generation Blowing Agents: The Road to Zero Ozone Depletion What Is the Ozone Layer? What Is the Montreal Protocol? What Is a Blowing Agent? Available Blowing Agents Industry Status for Conversion Comparison of Physical Properties HCFC Expanded Foam HC Expanded Foam
Montreal Protocol on Substances that Deplete the Ozone Layer 1970 s: Ozone Depletion Recognized CFC Propellants In Spray Cans Banned In USA 1980 s: Antarctica Ozone Hole Discovered, Linked to CFC Release 1985: Vienna Convention for the Protection of the Ozone Layer 1987: Montreal Protocol: Ratification Begins 1989: Montreal Protocol Effective Date To Date, 175 Countries Ratified
Controlled Substances Class I: ODP above.2 Chlorofluorocarbons CFC-11 ODP: 1.0 (highest ODP) GWP: 4000 (carbon dioxide = 1.0) USA Phaseout 12/31/93
Controlled Substances Class II: ODP below.2 Hydrochlorofluorocarbons HCFC-141b ODP:.1 (10 % of CFC-11) GWP: 630 (16% of CFC-11) USA Phaseout 12/31/02
What Is A Blowing Agent? Low Boiling Point Liquid Exothermic Chemical Reaction Low Conductivity Gas Expands the Foam; Creates Cells Filled With Blowing Agent Accounts For Low K-value, High R-value
Desirable Characteristics of Third Generation Blowing Agents Non-Toxic 0.0 ODP 0.0 GWP Low Thermal Conductivity Economically Feasible Chemically Unreactive With Other Components Readily Available
Potential Third Generation Blowing Agents Hydrocarbons HC (Cyclo) CH 2 CH 2 CH 2 CH 2 CH 2 HC (Normal) CH 3 CH 2 CH 2 CH 2 CH 3 HC (Iso) CH 3 CH 2 CH 2 CH 3 Hydrofluorocarbons HFC-245fa CF 3 CH 2 CHF 2 HFC-365mfc CF 3 CH 2 CF 2 CH 3 Carbon Dioxide CO 2
Blowing Agent Finalists HC: HFC-245fa: HC Blends: 0.0 ODP; 0.0 GWP 0.0 ODP; 790 GWP 0.0 ODP; 0.0 GWP Blends of HC and HFC-245fa HC: Apparent Winner
ACUltra DEVELOPMENT April, 1994 Atlas Roofing Corporation researchers produce first prototype hydrocarbon blown laminate boards on European laminator.
ACUltra DEVELOPMENT October, 1994 Bayer researchers report on n-pentane/water coblown laminate foams with low thermal conductivity values.* 2 Month K-factor =.148 (BTU in./hr F ft2) 32 Month K-factor =.166 (BTU in./hr F ft2) *Nicola, Weber 35th SPI Conference October, 1994
ACUltra DEVELOPMENT November 1994 Atlas develops explosion proof hydrocarbon pilot machine capability in Meridian, MS.
ACUltra DEVELOPMENT March 1995 Atlas develops small-scale explosion proof hydrocarbon laminator capability in Mesa, AZ
ACUltra DEVELOPMENT November 1995 Atlas installs first ACUltra Technology roof on Camp Hill, PA foam plant. 1 Month K-factor = 0.159 36 Month K-factor = 0.179 Initial Comp Str. = 21.236 36 Month Comp. Str. = 23.5 Initial Density = 1.98 36 Month Density = 2.06 Initial Dim. Stab. (Width) = 1.15 36 Month Dim. Stab. (Width)= 1.09
ACUltra DEVELOPMENT October 1996 Atlas begins intensive formulations development program for ACUltra Technology in Mesa, AZ.
ACUltra DEVELOPMENT November 1996 Atlas installs ACUltra Technology roof on Meridian, MS felt mill. 1 Month K-factor = 0.159 (BTU in/hr F ft2) 24 Month K-factor = 0.179 (BTU in/hr F ft2) Initial Comp Str. = 23.93 24 Month Comp. Str. = 24.02 Initial Density = 1.98 24 Month Density = 1.92 Initial Dim. Stab. (Width) = 0.96 24 Month Dim. Stab. (Width)= 1.13
ACUltra DEVELOPMENT September 1997 ICI Researchers report on long term thermal performance of rigid foams blown with nonhcfc blowing agents* *G. Biesmans, et. al., Polyurethanes World Congress. 1997
RELATIVE DIFFUSION COEFFICIENTS OF HCFC-141b and HYDROCARBONS
Blowing Agent Uptake for HCFC-141b and Hydrocarbons
ACUltra DEVELOPMENT February 1998 Atlas introduces ACUltra Technology at NRCA trade show and limited availability from Mesa, AZ Plant
ACUltra DEVELOPMENT August 1998 Atlas completes conversion of LaGrange, GA, Plant to ACUltra Technology and begins first full-time hydrocarbon production facility in North America.
ACUltra DEVELOPMENT September 1998 ICI researchers report on Hydrocarbon Blown Rigid Polyurethane Foam for the Boardstock Industry- A Novel Approach
CONFERENCE PAPER WD-546 Hydrocarbon Blown Rigid Polyurethane Foam for the Boardstock Industry - A Novel Approach CONCLUSIONS: Burn properties similar to HCFC-141b CP/IP gave best aged K-factors Polyol choice may impact K-factors Several routes to improved K-factors were identified
HC-Blown Polyiso vs. HCFC MICROGRAPHS ~ 175 MICRONS ~120 MICRONS
HCFC-Blown Polyiso vs HC MICROGRAPHS ~ 150 MICRONS ~200 MICRONS
Aged R-Value Curves for HCFC-141b Polyiso vs. HC Polyiso Initial 7 Months
COMPARISON OF TYPICAL INITIAL VS CONDITIONED K-FACTOR VALUES FOR HCFC-141b and HC-Blown Foams FOAM THICKNESS INITIAL K 6 MONTH K 141b 1.0 0.141 0.169 HC 1.0 0.153 0.167 141b 1.5 0.141 0.168 HC 1.5 0.155 0.164 141b 2.0 0.137 0.164 HC 2.0 0.155 0.163 141b 3.0 0.138 0.161 HC 3.0 0.150 0.161
ACUltra DEVELOPMENT October 1998 Atlas receives Stratospheric Ozone Protection Award from the U.S. Environmental Protection Agency for ACUltra Technology!
5-Year Sample Analysis Property November Initial Value 20005-yr. Value K-factor 0.159 0.176 Compressive Strength 21.2 23.5 Dimensional Stability (-40 C) -1.15-1.09 Board Density 1.98 pcf 2.06 pcf
HC-Blown Polyiso Typical Physical Properties PROPERTY TEST METHOD TYPICAL RESULT Dimensional Stability ASTM D 2126 Compressive Strength ASTM D 1621 Less than 2 % linear change 20psi Water Absorption ASTM C 209 Less than 1 % by Volume Moisture Vapor Transmission ASTM E 96 Less than 1 Perm Product Density ASTM D 1622 Nominal 2.0 pcf Service Temperature -100 F to +250 F max
Dimensional Stability NRC Test Program ASTM D 2126 Hot and Humid ACFoam -II: HC 50.8 mm (2") +.45% ACFoam -III:HC 27.9 mm (1.1") +.28% Cold ACFoam -II: HC 50.8 mm (2") -.02% ACFoam -III:HC 27.9 mm (1") -.04%
Dimensional Stability CCMC Test Program ASTM D 2126 Hot and Humid HCFC-blown +.56% HC-blown +.67% Cold HCFC-blown +.02% HC-blown +.02%
ACUltra DEVELOPMENT January 1999 Atlas begins construction of Canadian facility which will start up on ACUltra Technology. Target Start-Up Date May 1999
Testing, Approvals, and Listings UL 790: All Existing Class A, B,C Listings with Atlas Insulations UL 1256: Construction Nos. 120 and 123 UL 263: All Existing P Assemblies (hourly fire ratings) with Atlas Insulations FM 4450: All Existing Approvals; Full Equivalency J.I. 2D7A8.AM J.I. 3001900
Testing, Approvals, and Listings (continued) CCMC Evaluation Including Etobicoke Plant 12464-L: ACFoam-II, Vented-R, Nail Base 12423-L: ACFoam-III, Stucco-Shield, Rboard 12422-R: ACFoam Supreme, Energy Shield ULC Listings: Guide No. 360 O18, File CR 2339 ULI: File R13089, Roofing Systems Certified for Canada UL Wind Rating: 165 psf, ACFoam-II, fully adhered EPDM (SPRI sponsored)
Factory Mutual Class 1 Approval January 12, 1998 6.1-The test results obtained indicate that Atlas Roofing Corporation s proposed foam core formulation HC-500-X for their ACFoam II and ACFoam III roof insulation boards continues to meet FMRC Approved Standard 4450 requirements for Class 1 Fire and 1-60 and 1-90 Windstorm Classifications in insulated roof construction, when installed as outlined in the current edition of the FMRC Approval Guide and in previous FMRC Approval reports. Factory Mutual Approval Job Identification No. 3001900
Factory Mutual Class 1 Approval February 28, 2000 6.3 The testing conducted in this program confirms that any of the formulations identified in this report can be used interchangeably and still maintain the listings as shown in the current edition of the Factory Mutual Research Approval Guide. J.I. 3004929
UL Fire Test Report For this purpose, the results of the small-scale fire tests were compared to existing small and full scale fire test data. From this comparison, it was determined that the results of the tests on the assemblies incorporating Ultra II polyisocyanurate foamed plastic insulations compared favorably with the results of previous investigations incorporating other Classified polyisocyanurate insulations. UL Report Project 98NK33289
US Model Codes Chapter 26 Plastic SBCCI: Standard Building Code BOCA: National Building Code ICBO: Uniform Building Code IBC: International Building Code
Usage: General 730 Million Board Feet Shipped 2" average: 365.4 Million sq. ft. installed (3,654,000 squares) La Grange: 2,567,000 squares Etobicoke: 684,000 squares East Moline: 403,000 squares
By Roofing Membrane Types December 31, 2000 30% EPDM: 109.6 Million sq. ft. (1.1 million squares) 35% adhered: 38.4 Million sq. ft. (384,000 squares) 45% ballasted: 49.3 Million sq. ft. (493,000 squares) 20% mechanically fastened: 21.9 Million sq. ft. (219,000 squares) 60% BUR and Mod. Bit.: 219.2 Million sq. ft. (2.2 million squares) 10% Thermoplastics: 36.5 Million sq. ft. (365,000 squares)
Green Design U.S. Green Building Council (USGBC) Green Building Rating System, Leadership in Energy and Environmental Design (LEED) Energy and Atmosphere & Materials and Resources Energy and Atmosphere: eliminate HCFCs and reduce ozone depletion and early compliance with the Montreal Protocol (p. 12).
Results Seamless Market Entry Equal or Better Performance Excellent Claims History Improved Environment: GREEN
Montreal Protocol and Third Generation Blowing Agents: The Road to Zero Ozone Depletion Developed by Richard Roe, RRC, CCPR, LEED AP Atlas Roofing Corporation
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