Problem
- BioMed Realty Trust planned to add new office and lab space to an existing facility
- Use of common insulation would hamper the construction process
BioMed Realty Trust, a real estate investment trust specializing in providing real estate to the life sciences industry, wanted to add an additional 194,000 sq. ft. of office and laboratory space to their Landmark at Eastview property in Greenburgh, NewYork. Because field installed wall components were cost prohibitive, the builders, Sanford Contracting of North Billerica, Massachusetts, planned to use prefabricated truss-
supported granite panels for the exterior of the building. Assembled off-site, they offered both aesthetic value and cost savings. However, according to Tom Sanford, a principal of Sanford Contracting, “the use of common insulation would cause our fabrication process to be less efficient and so it was not an option. ”With energy costs rising, energy efficiency was a primary concern, and an alternative insulation needed to be found that would provide the required energy savings without hampering the construction process.
Solution
- InsulStar is used on prefabricated granite panels
- Applying InsulStar off-site allows the project to come in on time and on budget
- InsulStar will provide energy savings for years to come
Sanford decided that InsulStar spray foam insulation would be the answer. “We had used spray foam on a smaller scale for other projects and felt this was the best cost benefit ratio for this project,”he says. Working with Paul Dion of Closed Cell Structures, Sanford had InsulStar applied off-site to granites labs after they had been assembled in their support system. According to Sanford, using a factory controlled environment to install the InsulStar resulted in a better insulation job. What’s more, he says ,“the use of InsulStar sped up the manufacturing process and allowed for increased production to meet the aggressive job schedule. We fabricated and installed 90,000 sq. ft. ofexterior wall using 180,000 board feet of InsulStar in just 7 months. ”Paul Dion says the arrangement also benefited him. Because the insulation was being applied off-site, his applicators could work at night, freeing the mup for other on-site projects during the day. Using InsulStar also resulted in cost savings, according to Sanford. “Although the foam costs more per square foot than traditional board foam, InsulStar acted as both an insulator and an air/vaporbarrier. It saved manufacturingsteps,too,andthat
Finally, InsulStar will provide the energy efficiency the building needs.“ InsulStar is a better insulator than specified, so there will be an energy savings the owner will realize," Sanford says.
Results
- Adding foam insulation to prefabricated walls could be the wave of the future
The Bio Med project came in on time and on budget, and Tom Sanford believes that using spray foam on prefabricated walls, the insulation applied off-site in controlled conditions for maximum effectiveness, could be the wave of the future. “If we can market the wall assembly as an energy efficient alternative that is cost effective, I believe more architects will select it, ”he says. That’s sure to be the case as more architects, builders and building owners become aware that common insulation simply cannot provide the same uncommonly good benefits as spray foam.
AboutInsulStar®
InsulStar is a nominal 2.0 lb/cu ft high density, closed-cell spray polyurethane foam (SPF) from NCFI Polyurethanes. It is a two-part liquid system that is sprayed in place and quickly expands to fill all gaps and voids. It then cures to form a fully adhered, solid, monolithic insulation envelope.
- 2.0 lb/cu ft high density, closed-cell spray polyurethane foam
- R-value above R 6 per inch
- Saves an estimated 40% on energy bills
- Environmentally friendly
- Forms seal that blocks air infiltration, noise, dust and pollen
- Blended with anti-microbial to inhibit mold, mildew and bacterial growth
- Adds structural rigidity
Efficiency
InsulStar’s R-value is above R6.4 per inch, compared to fiberglass batt at R-3.5. Its ability to stop air in filtration an deliminate convective
looping saves the homeowner an estimated 40% on energy bills.
Green
In addition to its dramatic energy savings, InsulStar is formulated with renewable agricultural resources and uses a state-of-the-art, environmentally friendly blowing agent with zero Ozone Depletion Potential. NCFI Polyurethanes was awarded the 2004 Stratospheric Ozone Protection Award, an international award from the EPA for their work in developing environmentally friendly SPFsystems.
Comfort
The closed-cell, fully adhered structure of InsulStar forms an air seal that blocks air infiltration, noise pollution, dust and pollen. The low moisture vapor permeance eliminates the need for any additional vapor retarders. This low permeance works to control moisture vapor movement, there by eliminating the moisture accumulation necessary to support mold growth. Additionally, InsulStar is blended with an anti-microbial to inhibit mold, mildew and bacterial growth.
Structural Rigidity
InsulStar also adds structural rigidity to the home. In a test conducted by the National Association of Home Builders Research Center, it was concluded that a 2x4 wall sprayed with polyurethane foam insulation had two times the racking strength of a wall filled with fiberglass batt insulation.
About NCFI
From the carpet you walk on, to the warmth of your home in winter, to the sofa you and your family watch television on, NCFI Polyurethanes has been working hard since 1964 to make your world a more comfortable, secure, affordable place to be. You may not be aware of us, but our products touch millions of lives, and you can rest assured that we’re constantly working to make life easier and better for you and your family.
