SECTION 2603 FOAM PLASTIC INSULATION

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 0.5-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. 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 717.

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 2603.4.1.13.

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 a minimum of 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. 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 m2) 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. Foam plastic insulation under a roof assembly or roof covering that is installed in accordance with the code and the manufacturer’s instructions shall be 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. A thermal barrier is not required for foam plastic insulation that is a part of a Class A, B or C roof-covering assembly, provided the assembly with the foam plastic insulation satisfactorily passes FM 4450 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 1.5-inch-thick (38 mm) mineral fiber insulation; 0.25-inch-thick (6.4 mm) wood structural panel, particleboard or hardboard; 0.375-inch (9.5 mm) gypsum wallboard, corrosion-resistant steel having a base metal thickness of 0.016 inch (0.4 mm) 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 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 faced with 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 above 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/m2) as determined by NFPA 259 shall be permitted as a siding backer board with a maximum thickness of 0.5 inch (12.7 mm), 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 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 402.15 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 International Fire Code.

2603.4.1.13 Type V construction. Foam plastic spray applied to a sill plate and header of Type V construction is subject to all of the following:

1. The maximum thickness of the foam plastic shall be 31/4 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/m3).

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.

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