Section 2603 — FOAM PLASTIC INSULATION

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

2603.1.1 Spray-applied foam plastic. Single- and multiple-component spray-applied foam plastic insulation shall comply with the provisions of Section 2603 and ICC 1100.

2603.1.2 Insulating sheathing. Foam plastic materials used as insulating sheathing shall comply with the provisions of Section 2603 and the material standards in Table 2603.1.2.

TABLE 2603.1.2—MATERIAL STANDARDS FOR FOAM PLASTIC INSULATING SHEATHING

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.

2603.2.1 Labeling of polystyrene foam insulation without flame retardants . In addition to the requirements of Section 2603.2, polystyrene foam insulation boards manufactured with no flame retardants added shall be labeled in accordance with this section. 1. Each board shall be labeled on each face every 8 square feet in red [1] / 2 -inch text with the following information:

WARNING - FIRE HAZARD

This product is required to be installed below a minimum 3.5-inch-thick concrete slab on grade.

NOT FOR VERTICAL OR ABOVE-GRADE APPLICATIONS

This product contains NO flame retardants.

Not tested for flame spread or smoke development requirements of the model building codes 2. Each package shall be labeled on at least two sides in red [1] / 2 -text with the following information:

WARNING – COMBUSTIBLE MATERIAL

Keep away from ignition sources.

Maintain code required separation between product storage and structures under construction (minimum 30 feet).

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 E84 or UL 723. Loose fill-type foam plastic insulation shall be tested as board stock for the flame spread and smoke-developed indices.

Exceptions:

1. Smoke-developed index for interior trim as provided for in Section 2604.2.

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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 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 provided that 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 that the end use is approved in accordance with Section 2603.9 using the maximum thickness and density intended for use.

5. Flame spread and smoke-developed indices for foam plastic interior signs in covered and open mall buildings provided that the signs comply with Section 402.6.4. 6. Polystyrene foam insulation boards with a maximum thickness of 2 inches when installed below a minimum 3.5-inch-thick concrete slab on grade.

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, mass timber or heavy timber in accordance with Section 2304.11 or a material that is tested in accordance with and meets the acceptance criteria of both the Temperature Transmission Fire Test and the Integrity Fire Test of NFPA 275. Combustible concealed spaces shall comply with Section 718.

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 2603.4.1.15.

2603.4.1.1 Masonry or concrete construction. A thermal barrier is not required for foam plastic 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:

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 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.

mitted 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 exterior walls of one-story buildings constructed of insulated metal panels (IMP) with foam plastic insulation cores, the thermal barrier is not required when all of the following apply:

1. The foam plastic insulation thickness is not more than 4 inches (102 mm).
2. The foam plastic insulation core has a flame spread index of 25 or less and a smoke-developed index of 450 or less.
3. The foam plastic insulation is covered by 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).
4. 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, 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 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.

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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 where the door facing is of aluminum not less than 0.032 inch (0.8 mm) in thickness or steel having a base metal thickness of not less than 0.016 inch (0.4 mm) at any point.

ed 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 where the door facing is of aluminum not less than 0.032 inch (0.8 mm) in thickness 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 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 used as a core material, 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 in this section shall be tested in accordance with, and meet the acceptance criteria of, DASMA 107.

Exception: 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 feet (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), provided that 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 with re-siding 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 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 California 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 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 E84 or UL 723.

onstruction is 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 E84 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 where the foam plastic is covered by a minimum nominal [1] / 2 -inchthick (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 where 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.

2603.4.1.15 Separately controlled climate structures. In nonsprinklered buildings of Group U, foam plastic having a thickness that does not exceed 4 inches (102 mm) and a maximum flame spread index of 75 is permitted in separately controlled climate structures 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 (0.41mm). A thickness of up to 10 inches (254 mm) is permitted where protected by a thermal barrier.

Exterior walls of buildings of Type I, II, III or IV construction of any height shall comply with Sections 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. Fireblocking shall be in accordance with Section 718.2.

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 E119 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 provisions of Section 2603.4, unless special approval is obtained on the basis of Section 2603.9.

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 feet (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 feet (mJ/m [2] ).

Exception: One-story buildings complying with Section 2603.4.1.4.

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2603.5.4 Flame spread and smoke-developed indices. 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 E84 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.

Exceptions:

1. One-story buildings complying with Section 2603.4.1.4.
2. Exterior 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 E84 or UL 723 and the maximum airspace between the insulation and the concrete or masonry is not more than 1 inch (25 mm).

2603.5.6 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 2603.4.
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) corrosionresistant 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 Section 1404.17 and Section 1404.17.1 or 1404.17.2.

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 that the assembly with the foam plastic insulation is a Class A, B or C roofing assembly where tested in accordance with ASTM E108 or UL 790.

Foam plastic in plenums used as interior wall or ceiling finish, or interior trim, 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 E84 or UL 723 at the maximum thickness and density intended for use, and shall be tested in accordance with NFPA 286 and meet the acceptance criteria of Section 803.1.1. As an alternative to testing to NFPA 286, the foam plastic shall be approved based on tests conducted in accordance with Section 2603.9.

Exceptions:

1. Foam plastic in plenums used as interior wall or ceiling finish, or interior trim, 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 E84 or UL 723 at the maximum thickness and density intended for use, where it is separated from the airflow in the plenum by a thermal barrier complying with Section 2603.4.
2. Foam plastic in plenums used as interior wall or ceiling finish, or interior trim, 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 E84 or UL 723 at the maximum thickness and density intended for use, where it is separated from the airflow in the plenum by corrosion-resistant steel having a base metal thickness of not less than 0.0160 inch (0.4 mm).
3. Foam plastic in plenums used as interior wall or ceiling finish, or interior trim, 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 E84 or UL 723 at the maximum thickness and density intended for use, where it is separated from the airflow in the plenum by not less than a 1-inch (25 mm) thickness of masonry or concrete.

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.

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

3. On the interior side of basement walls.

FIGURE 2603.8—TERMITE INFESTATION PROBABILITY MAP

Foam plastic shall not be required to comply with the requirements of Section 2603.4 or those of Section 2603.6 where specifically approved based on one of the following large-scale tests:

1. NFPA 286 using the acceptance criteria of Section 803.1.1.1.

2. FM 4880.

3. UL 1040.

4. UL 1715.

Such testing shall 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 these tests shall also conform to the flame spread and smoke-developed 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.

[BS] 2603.10 Wind resistance. Foam plastic insulation complying with ASTM C578 and ASTM C1289 and used as exterior wall sheathing on framed wall assemblies shall comply with ANSI/SBCA FS 100 for wind pressure resistance.