N.Y.C. Admin. Code § BC 2603: Section BC 2603: Foam Plastic Insulation

2603.1 General.

The provisions of this section shall govern the requirements and uses of foam plastic insulation in buildings and structures.

2603.2 Labeling and identification.

Packages and containers of foam plastic insulation and foam plastic insulation components delivered to the job site shall bear the label of an approved agency showing the manufacturer's name, product listing, product identification and information sufficient to determine that the end use will comply with the code requirements.

2603.3 Surface-burning characteristics.

Unless otherwise indicated in this section, foam plastic insulation and foam plastic cores of manufactured assemblies shall have a flame spread index of not more than 75 and a smoke-developed index of not more than 450 where tested in the maximum thickness intended for use in accordance with ASTM E 84 or UL 723. Loose fill-type foam plastic insulation shall be tested as board stock for the flame spread and smoke-developed indexes.

Exceptions:

1. Foam plastic interior trim shall comply with the flame spread and smoke-developed indexes as provided for in Section 2604.2.

2. In cold storage buildings, ice plants, food plants, food processing rooms and similar areas, foam plastic insulation where tested in a thickness of 4 inches (102 mm) shall be permitted in a thickness up to 10 inches (254 mm) where the building is equipped throughout with an automatic fire sprinkler system in accordance with Section 903.3.1.1. The approved automatic sprinkler system shall be provided in both the room and that part of the building in which the room is located.

3. Foam plastic insulation that is a part of a Class A, B or C roof-covering assembly shall be exempt from the flame spread requirements of this section provided the assembly with the foam plastic insulation satisfactorily passes NFPA 276 or UL 1256. The smoke-developed index shall not be limited for roof applications.

4. Foam plastic insulation greater than 4 inches (102 mm) in thickness shall have a maximum flame spread index of 75 and a smoke-developed index of 450 where tested at a minimum thickness of 4 inches (102 mm), provided the end use is approved in accordance with Section 2603.9 using the thickness and density intended for use.

5. Foam plastic interior signs in covered mall buildings shall not be required to comply with the flame spread and smoke-developed indexes of this section, provided the signs comply with Section 402.6.4.

2603.4 Thermal barrier.

Except as provided for in Sections 2603.4.1 and 2603.9, foam plastic shall be separated from the interior of a building by an approved thermal barrier of 1/2-inch (12.7 mm) gypsum wallboard or equivalent thermal barrier material that will limit the average temperature rise of the unexposed surface to not more than 250°F (120°C) after 15 minutes of fire exposure, complying with the standard time-temperature curve of ASTM E 119 or UL 263. The thermal barrier shall be installed in such a manner that it will remain in place for 15 minutes based on FM 4880, UL 1040, NFPA 286 or UL 1715. Combustible concealed spaces shall comply with Section 719 of this code.

Exception: Thermal barriers for exterior walls shall comply with Section 2603.5.2.

2603.4.1 Thermal barrier not required.

The thermal barrier specified in Section 2603.4 is not required under the conditions set forth in Sections 2603.4.1.1 through 2603.4.1.14.

2603.4.1.1 Masonry or concrete construction.

A thermal barrier is not required for foam plastic insulation installed in a masonry or concrete wall, floor or roof system where the foam plastic insulation is covered on each face by not less than 1 inch (25 mm) thickness of masonry or concrete.

2603.4.1.2 Cooler and freezer walls.

Foam plastic installed in a maximum thickness of 10 inches (254 mm) in cooler and freezer walls shall be permitted without thermal barrier, provided that the walls:

1. Have a flame spread index of 25 or less and a smoke-developed index of not more than 450, where tested in a minimum 4-inch (102 mm) thickness.

2. Have flash ignition and self-ignition temperatures of not less than 600°F and 800°F (316°C and 427°C), respectively.

3. Have a covering of not less than 0.032-inch (0.8 mm) aluminum or corrosion-resistant steel having a base metal thickness not less than 0.0160 inch (0.4 mm) at any point.

4. Be protected by an automatic sprinkler system in accordance with Section 903.3.1.1. Where the cooler or freezer is within a building, both the cooler or freezer and that part of the building in which it is located shall be sprinklered.

2603.4.1.3 Walk-in coolers.

In nonsprinklered buildings, foam plastic having a thickness that does not exceed 4 inches (102 mm) and a maximum flame spread index of 75 is permitted without thermal barrier in walk-in coolers or freezer units where the aggregate floor area does not exceed 400 square feet (37 m

2

) and the foam plastic is covered by a metal facing not less than 0.032-inch-thick (0.81 mm) aluminum or corrosion-resistant steel having a minimum base metal thickness of 0.016 inch (0.41 mm). A thickness of up to 10 inches (254 mm) is permitted where protected by a thermal barrier.

2603.4.1.4 Exterior walls – one-story buildings.

For one-story buildings, foam plastic having a flame spread index of 25 or less, and a smoke-developed index of not more than 450, shall be permitted without thermal barriers in or on exterior walls in a thickness not more than 4 inches (102 mm) where the foam plastic is covered by a thickness of not less than 0.032-inch-thick (0.81 mm) aluminum or corrosion-resistant steel having a base metal thickness of 0.0160 inch (0.41 mm) and the building is equipped throughout with an automatic sprinkler system in accordance with Section 903.3.1.1.

2603.4.1.5 Roofing.

A thermal barrier is not required for foam plastic insulation that is a part of a Class A, B or C roof-covering assembly that is installed in accordance with the code and the manufacturer's instructions and is either constructed as described in Item 1 or tested as described in Item 2.

1. The roof assembly is separated from the interior of the building by wood structural panel sheathing not less than 0.47 inch (11.9 mm) in thickness bonded with exterior glue, with edges supported by blocking, tongue-and-groove joints or other approved type of edge support, or an equivalent material.

2. The assembly with the foam plastic insulation satisfactorily passes NFPA 276 or UL 1256.

2603.4.1.6 Attics and crawl spaces.

Within an attic or crawl space where entry is made only for service of utilities, foam plastic insulation shall be permitted without thermal barrier if protected against ignition by 1 1/2-inch-thick (38 mm) mineral fiber insulation; 1/4-inch-thick (6.4 mm) wood structural panel, particleboard or hardboard; 3/8-inch (9.5 mm) gypsum wallboard, corrosion-resistant steel having a base metal thickness of 0.016 inch (0.4 mm); 1 1/2-inch thick (38 mm) self-supported spray-applied cellulose insulation in attic spaces only or other approved material installed in such a manner that the foam plastic insulation is not exposed. The protective covering shall be consistent with the requirements for the type of construction.

2603.4.1.7 Doors not required to have a fire protection rating.

Where pivoted or side-hinged doors are permitted without a fire protection rating, foam plastic insulation, having a flame spread index of 75 or less and a smoke-developed index of not more than 450, shall be permitted as a core material without a thermal barrier where the door facing is of metal having a minimum thickness of 0.032-inch (0.8 mm) aluminum or steel having a base metal thickness of not less than 0.016 inch (0.4 mm) at any point.

2603.4.1.8 Exterior doors in buildings of Group R-2 or R-3.

In occupancies classified as Group R-2 or R-3, foam-filled exterior entrance doors to individual dwelling units that do not require a fire-resistance rating shall be permitted without a thermal barrier, provided that the doors are faced with aluminum, steel, fiberglass, wood or other approved materials.

2603.4.1.9 Garage doors.

Where garage doors are permitted without a fire-resistance rating and foam plastic is permitted as a core material, provided that the door facing shall be metal having a minimum thickness of 0.032-inch (0.8 mm) aluminum or 0.010-inch (0.25 mm) steel or the facing shall be minimum 0.125-inch-thick (3.2 mm) wood. Garage doors having facings other than those described above shall be tested in accordance with, and meet the acceptance criteria of DASMA 107.

2603.4.1.9.1 Garage doors in one- and two-family dwellings.

Garage doors using foam plastic insulation complying with Section 2603.3 in detached and attached garages associated with one- and two-family dwellings need not be provided with a thermal barrier.

2603.4.1.10 Siding backer board.

Foam plastic insulation of not more than 2,000 British thermal units per square foot (Btu/sq. ft.) (22.7 MJ/m

2

) as determined by NFPA 259 shall be permitted as a siding backer board with a maximum thickness of 1/2-inch (12.7 mm) without a thermal barrier, provided it is separated from the interior of the building by not less than 2 inches (51 mm) of mineral fiber insulation or equivalent or where applied as insulation over existing wall construction.

2603.4.1.11 Interior trim.

Foam plastic used as interior trim in accordance with Section 2604 shall be permitted without a thermal barrier.

2603.4.1.12 Interior signs.

Foam plastic used for interior signs in covered mall buildings in accordance with Section 402.6.4 of this code shall be permitted without a thermal barrier. Foam plastic signs that are not affixed to interior building surfaces shall comply with Chapter 8 of the New York City Fire Code.

2603.4.1.13 Type V construction.

Foam plastic spray applied to a sill plate, joist header and rim joist in Type V construction is permitted without a thermal barrier, subject to all of the following:

1. The maximum thickness of the foam plastic shall be 3 1/4 inches (82.6 mm).

2. The density of the foam plastic shall be in the range of 1.5 to 2.0 pcf (24 to 32 kg/m

3

).

3. The foam plastic shall have a flame spread index of 25 or less and an accompanying smoke-developed index of 450 or less when tested in accordance with ASTM E 84 or UL 723.

2603.4.1.14 Floors.

The thermal barrier specified in Section 2603.4 is not required to be installed on the walking surface of a structural floor system that contains foam plastic insulation when the foam is covered by a minimum nominal 1/2-inch-thick (12.7 mm) wood structural panel or approved equivalent. The thermal barrier specified in Section 2603.4 is required on the underside of the structural floor system that contains foam plastic insulation when the underside of the structural floor system is exposed to the interior of the building.

Exception: Foam plastic used as part of an interior floor finish.

2603.5 Exterior walls of buildings of any height.

Exterior walls of buildings of Type I, II, III or IV construction of any height shall comply with 2603.5.1 through 2603.5.7. Exterior walls of cold storage buildings required to be constructed of noncombustible materials, where the building is more than one story in height, shall comply with the provisions of Sections 2603.5.1 through 2603.5.7. Exterior walls of buildings of Type V construction shall comply with Sections 2603.2, 2603.3 and 2603.4.

2603.5.1 Fire-resistance-rated walls.

Where the wall is required to have a fire-resistance rating, data based on tests conducted in accordance with ASTM E 119 or UL 263 shall be provided to substantiate that the fire-resistance rating is maintained.

2603.5.2 Thermal barrier.

Any foam plastic insulation shall be separated from the building interior by a thermal barrier meeting the following provisions, unless special approval is obtained on the basis of Section 2603.9. For exterior walls, foam plastic shall be separated from the interior of a building by an approved thermal barrier of 5/8-inch (15.9 mm) Type X gypsum wallboard or equivalent thermal barrier material that will limit the average temperature rise of the unexposed surface to not more than 250°F (120°C) after 20 minutes of fire exposure, complying with the standard time-temperature curve of ASTM E 119 or UL 263. The thermal barrier shall be installed in accordance with criteria established by testing performed in accordance with FM 4880, UL 1040, NFPA 286 or UL 1715, where the thermal barrier shall remain in place for 20 minutes. Combustible concealed spaces shall comply with Section 718 of this code.

Exception: One-story buildings complying with Section 2603.4.1.4.

2603.5.3 Potential heat.

The potential heat of foam plastic insulation in any portion of the wall or panel shall not exceed the potential heat expressed in Btu per square foot (mJ/m

2

) of the foam plastic insulation contained in the wall assembly tested in accordance with Section 2603.5.5. The potential heat of the foam plastic insulation shall be determined by tests conducted in accordance with NFPA 259 and the results shall be expressed in Btu per square foot (mJ/m

2

).

Exception: One-story buildings complying with Section 2603.4.1.4.

2603.5.4 Flame spread and smoke-developed indexes.

Foam plastic insulation, exterior coatings and facings shall be tested separately in the thickness intended for use, but not to exceed 4 inches (102 mm), and shall each have a flame spread index of 25 or less and a smoke-developed index of 450 or less as determined in accordance with ASTM E 84 or UL 723.

Exception: Prefabricated or factory-manufactured panels having minimum 0.020-inch (0.51 mm) aluminum facings and a total thickness of 1/4-inch (6.4 mm) or less are permitted to be tested as an assembly where the foam plastic core is not exposed in the course of construction.

2603.5.5 Vertical and lateral fire propagation.

The exterior wall assembly shall be tested in accordance with and comply with the acceptance criteria of NFPA 285. NFPA 285 design documentation of the tested exterior wall assembly shall be included on the submitted construction documents complying with Section 2601.2.1.

Exceptions:

1. One-story buildings complying with Section 2603.4.1.4.

2. Wall assemblies where the foam plastic insulation is covered on each face by not less than 1 inch (25 mm) thickness of masonry or concrete and meeting one of the following:

2.1. There is no airspace between the insulation and the concrete or masonry.

2.2. The insulation has a flame spread index of not more than 25 as determined in accordance with ASTM E 84 or UL 723 and the maximum airspace between the insulation and the concrete or masonry is not more than 1 inch (25 mm).

2603.5.5.1 Fireblocking.

Exterior wall coverings containing foam plastic insulation shall be fireblocked in accordance with Section 718.2.6.1.

2603.5.6 Label required.

The edge or face of each piece, package or container of foam plastic insulation shall bear the label of an approved agency. The label shall contain the manufacturer's or distributor's identification, model number, serial number or definitive information describing the product or materials' performance characteristics and approved agency's identification.

2603.5.7 Ignition.

Exterior walls shall not exhibit sustained flaming where tested in accordance with NFPA 268. Where a material is intended to be installed in more than one thickness, tests of the minimum and maximum thickness intended for use shall be performed.

Exception: Assemblies protected on the outside with one of the following:

1. A thermal barrier complying with Section 2603.5.2.

2. A minimum 1-inch (25 mm) thickness of concrete or masonry.

3. Glass-fiber-reinforced concrete panels of a minimum thickness of 3/8-inch (9.5 mm).

4. Metal-faced panels having minimum 0.019-inch-thick (0.48 mm) aluminum or 0.016-inch thick (0.41 mm) corrosion-resistant steel outer facings.

5. A minimum 7/8-inch (22.2 mm) thickness of stucco complying with Section 2510.

6. A minimum 1/4-inch (6.4 mm) thickness of fiber-cement lap, panel or shingle siding complying with Sections 1405.16 and 1405.16.1 or 1405.16.2.

2603.5.8 Special inspection.

Foam plastic insulation in exterior wall coverings shall be subject to special inspection in accordance with Chapter 17.

2603.6 Roofing assembly.

Foam plastic insulation meeting the requirements of Sections 2603.2, 2603.3 and 2603.4 shall be permitted as part of a roof-covering assembly, provided the assembly with the foam plastic insulation is a Class A, B or C roofing assembly where tested in accordance with ASTM E 108 or UL 790.

2603.7 Foam plastic insulation used as interior finish or interior trim in plenums.

Foam plastic insulation used as interior wall or ceiling finish or as interior trim in plenums shall exhibit a flame spread index of 75 or less and a smoke-developed index of 450 or less when tested in accordance with ASTM E 84 or UL 723 and shall comply with one or more of Sections 2603.7.1, 2603.7.2 and 2607.3.

2603.7.1 Separation required.

The foam plastic insulation shall be separated from the plenum by a thermal barrier complying with Section 2603.4 and shall exhibit a flame spread index of 75 or less and a smoke-developed index of 450 or less when tested in accordance with ASTM E 84 or UL 723 at the thickness and density intended for use.

2603.7.2 Approval.

The foam plastic insulation shall exhibit a flame spread index of 25 or less and a smoke-developed index of 50 or less when tested in accordance with ASTM E 84 or UL 723 at the thickness and density intended for use and shall meet the acceptance criteria of Section 803.1.2 when tested in accordance with NFPA 286. The foam plastic insulation shall be approved based on tests conducted in accordance with Section 2603.9.

2603.7.3 Covering.

The foam plastic insulation shall be covered by corrosion-resistant steel having a base metal thickness of not less than 0.0160 inch (0.4 mm) and shall exhibit a flame spread index of 75 or less and a smoke-developed index of 450 or less when tested in accordance with ASTM E 84 or UL 723 at the thickness and density intended for use.

2603.8 Protection against termites.

In areas where the probability of termite infestation is very heavy in accordance with Figure 2603.8, extruded and expanded polystyrene, polyisocyanurate and other foam plastics shall not be installed on the exterior face or under interior or exterior foundation walls or slab foundations located below grade. The clearance between foam plastics installed above grade and exposed earth shall be not less than 6 inches (152 mm).

Exceptions:

1. Buildings where the structural members of walls, floors, ceilings and roofs are entirely of noncombustible materials or preservative-treated wood;

2. An approved method of protecting the foam plastic and structure from subterranean termite damage is provided; or

3. On the interior side of basement and cellar walls.

Figure 2603.8 Termite Infestation Probability Map

2603.9 Special approval.

Foam plastic shall not be required to comply with the requirements of Sections 2603.4 or 2603.6 where specifically approved by the department based on large-scale tests such as, but not limited to, NFPA 286 (with the acceptance criteria of Section 803.1.2.1 of this code), FM 4880, UL 1040 or UL 1715. Such testing shall be related to the actual end-use configuration and be performed on the finished manufactured foam plastic assembly in the maximum thickness intended for use. Foam plastics that are used as interior finish on the basis of special tests shall also conform to the flame spread and smoke-developed index requirements of Chapter 8. Assemblies tested shall include seams, joints and other typical details used in the installation of the assembly and shall be tested in the manner intended for use.

2603.10 Wind resistance.

Foam plastic insulation complying with ASTM C 578 and ASTM C 1289 and used as exterior wall sheathing on framed wall assemblies shall comply with ANSI/FS 100 for wind pressure resistance and withstand the loads indicated in Chapter 16 of this code.

2603.11 Cladding attachment over foam sheathing to masonry or concrete wall construction.

Cladding shall be specified and installed in accordance with Chapter 14 and the cladding manufacturer's installation instructions or an approved design. Foam sheathing shall be attached to masonry or concrete construction in accordance with the insulation manufacturer's installation instructions or an approved design. Furring and furring attachments through foam sheathing shall be designed to resist design loads determined in accordance with Chapter 16, including support of cladding weight as applicable. Fasteners used to attach cladding or furring through foam sheathing to masonry or concrete substrates shall be approved for application into masonry or concrete material and shall be installed in accordance with the fastener manufacturer's installation instructions.

Exceptions:

1. Where the cladding manufacturer has provided approved installation instructions for application over foam sheathing and connection to a masonry or concrete substrate, those requirements shall apply.

2. For exterior insulation and finish systems, refer to Section 1408.

3. For anchored masonry or stone veneer installed over foam sheathing, refer to Section 1405.

2603.12 Cladding attachment over foam sheathing to cold-formed steel framing.

Cladding shall be specified and installed in accordance with Chapter 14 and the cladding manufacturer's approved installation instructions, including any limitations for use over foam plastic sheathing, or an approved design. Where used, furring and furring attachments shall be designed to resist design loads determined in accordance with Chapter 16. In addition, the cladding or furring attachments through foam sheathing to framing shall meet or exceed the minimum fastening requirements of Sections 2603.12.1 and 2603.12.2, or an approved design for support of cladding weight.

Exceptions:

1. Where the cladding manufacturer has provided approved installation instructions for application over foam sheathing, those requirements shall apply.

2. For exterior insulation and finish systems, refer to Section 1408.

3. For anchored masonry or stone veneer installed over foam sheathing, refer to Section 1405.

2603.12.1 Direct attachment.

Where cladding is installed directly over foam sheathing without the use of furring, cladding minimum fastening requirements to support the cladding weight shall be as specified in Table 2603.12.1.

Table 2603.12.1 Cladding Minimum Fastening Requirements for Direct Attachment over Foam Plastic Sheathing to Support Cladding Weight

a

Cladding Fastener Through Foam Sheathing Into:

Cladding Fastener Type and Minimum Size

b

Cladding Fastener Vertical Spacing (inches)

Maximum Thickness of Foam Sheathing

c

(inches)

16

2

o.c. fastener horizontal spacing

24

2

o.c. fastener horizontal spacing

Cladding weight

Cladding weight

3 psf

11 psf

25 psf

3 psf

11 psf

25 psf

Steel framing (minimum penetration of steel thickness plus 3 threads)

#8 screw into 33 mil steel or thicker

6

3

3

1.5

3

2

DR

8

3

2

0.5

3

1.5

DR

12

3

1.5

DR

3

0.75

DR

#10 screw into 33 mil steel

6

4

3

2

4

3

0.5

8

4

3

1

4

2

DR

12

4

2

DR

3

1

DR

#10 screw into 43 mil steel or thicker

6

4

4

3

4

4

2

8

4

4

2

4

3

1.5

12

4

3

1.5

4

3

DR

For SI: 1 inch = 25.4 mm; 1 pound per square foot (psf) = 0.0479 kPa, 1 pound per square inch = 0.00689 MPa.

DR = design required; o.c. = on center.

a. Steel framing shall be minimum 33 ksi steel for 33 mil and 43 mil steel and 50 ksi steel for 54 mil steel or thicker.

b. Screws shall comply with the requirements of AISI S240.

c. Foam sheathing shall have a minimum compressive strength of 15 pounds per square inch in accordance with ASTM C 578 or ASTM C 1289.

2603.12.2 Furred cladding attachment.

Where steel or wood furring is used to attach cladding over foam sheathing, furring minimum fastening requirements to support the cladding weight shall be as specified in Table 2603.12.2. Where placed horizontally, wood furring shall be preservative-treated wood in accordance with Section 2303.1.9 or naturally durable wood and fasteners shall be corrosion resistant in accordance Section 2304.10.5. Steel furring shall have a minimum G60 galvanized coating.

Table 2603.12.2 Furring Minimum Fastening Requirements for Application over Foam Plastic Sheathing to Support Cladding Weight

a

Furring Material

Framing Member

Fastener Type and Minimum Size

b

Minimum Penetration into Wall Framing (inches)

Fastener Spacing in Furring (inches)

Maximum Thickness of Foam Sheathing

4*

(inches)

16

2

o.c. furring

e

24

2

o.c. furring

e

Cladding weight

Cladding weight

3 psf

11 psf

25 psf

3 psf

11 psf

25 psf

Minimum 33 mil steel furring or minimum 1x wood furring

c

33 mil steel stud

#8 screw

Steel thickness plus 3 threads

12

3

1.5

DR

3

0.5

DR

16

3

1

DR

2

DR

DR

24

2

DR

DR

2

DR

DR

#10 screw

Steel thickness plus 3 threads

12

4

2

DR

4

1

DR

16

4

1.5

DR

3

DR

DR

24

3

DR

DR

2

DR

DR

43 mil or thicker steel stud

#8 screw

Steel thickness plus 3 threads

12

3

1.5

DR

3

0.5

DR

16

3

1

DR

2

DR

DR

24

2

DR

DR

2

DR

DR

#10 screw

Steel thickness plus 3 threads

12

4

3

1.5

4

3

DR

16

4

3

0.5

4

2

DR

24

4

2

DR

4

0.5

DR

For SI: 1 inch = 25.4 mm; 1 pound per square foot (psf) = 0.0479 kPa, 1 pound per square inch = 0.00689 MPa.

DR = design required; o.c. = on center.

a. Wood furring shall be Spruce-Pine fir or any softwood species with a specific gravity of 0.42 or greater. Steel furring shall be minimum 33 ksi steel. Steel studs shall be minimum 33 ksi steel for 33 mil and 43 mil thickness and 50 ksi steel for 54 mil steel or thicker.

b. Screws shall comply with the requirements of AISI S240.

c. Where the required cladding fastener penetration into wood material exceeds 3/4 inch and is not more than 1 1/2 inches, a minimum 2-inch nominal wood furring shall be used or an approved design.

d. Foam sheathing shall have a minimum compressive strength of 15 pounds per square inch in accordance with ASTM C 578 or ASTM C 1289.

e. Furring shall be spaced not more than 24 inches on center, in a vertical or horizontal orientation. In a vertical orientation, furring shall be located over wall studs and attached with the required fastener spacing. In a horizontal orientation, the indicated 8-inch and 12-inch fastener spacing in furring shall be achieved by use of two fasteners into studs at 16 inches and 24 inches on center, respectively.