Category Archives: Global

NIA Sites > Insulation Outlook Magazine > Global

Safety Matters: Raising the Industry to New Heights

Recently I was pondering, “What hazards are unique to the mechanical insulation industry?” As with any building trade, the list of potential hazards in the insulation trade is a lengthy one. Some insulation materials can be very dusty if not handled properly. Some can cause eye injuries or irritation. Insulator’s tools, metal jacketing, and banding can all have very sharp edges. Sometimes the work can be done in confined spaces or other dangerous areas. Surface temperatures of equipment may be very hot. Older insulation materials and coatings may contain hazardous materials harmful to your health.

But the biggest hazard in the insulation trade has nothing to do with the materials used or the work practices employed. The biggest hazard is simply getting to the area to be insulated, inspected, or repaired. Often, the piping, duct work, or other mechanical systems are high above the ground, exposing workers to a potential fall.

Falls are the leading cause of workplace fatalities every year (not counting transportation-related fatalities). Every year, falls cause hundreds of deaths and tens of thousands of injuries resulting in disability in the workplace. Falls from elevated surfaces tend to be more severe than other work-related injuries. Falls from height result in more days away from work, and often result in injury to multiple body parts. Data from a Nationwide Insurance report showed that 30% of workers’ compensation claims costs in the construction industry are due to falls from elevated surfaces.

On top of the human and financial toll of falls, the Occupational Safety and Health Administration (OSHA) issues more fall protection violations every year than any other workplace hazard. Fall hazards top the Most Frequently Cited list every year. In 2018, OSHA’s Fall Protection standard was the most frequently cited standard. The standard for the duty to provide fall protection was cited almost twice as many times as the next most frequently cited standard, Hazard Communication. Three other fall-related standards also made the Top-10 list, including the standards for Ladders, Scaffolds, and Fall Protection Training Requirements. It’s no coincidence that OSHA focuses its attention on fall hazards. They know that falls are one of the most serious workplace hazards.

Unfortunately, we can’t build all of the duct work at ground level and we can’t keep tanks and pipe racks under 7 feet high. The nature of our work requires us to work at heights; sometimes at very great heights. Safe access should be a primary consideration during any insulation project, whether it’s new construction, inspection, or maintenance. The question of how to access the work area is just as essential as what insulation materials will be needed and how will it be installed.

Depending on the task and location, some options include having a scaffold built, using aerial lifts, or working from a ladder. In some situations, employees may have to use a personal fall arrest system, which consists of a full body harness connected to an adequate anchorage point. All access and fall protection systems require employee training. Whether the solution is as simple as working from a step ladder, or as complex as installing a swing-stage scaffold, employee training is critical. Personal fall arrest in particular is highly technical and requires specialized training. Improper use of personal fall arrest equipment is one of the reasons the Fall Protection Training standard is on OSHA’s Top-10 Most Frequently Cited list. Scaffolds are also a very specialized field. Scaffolds must be designed and built in accordance with a qualified person’s design. Scaffold users need to be trained on the requirements to work safely on the scaffold.

Don’t let safe access be an afterthought. Or worse, don’t assume the workers in the field will figure it out. Nobody plans on getting hurt, and nobody plans on falling. Yet, falls remain one of the most common serious injuries in the workplace every year. Follow OSHA’s advice in their fall prevention campaign: Plan, Provide, Train. Plan ahead to access the work area safely. Provide the right equipment or materials to prevent falls. And train everyone to use the equipment safely. In addition to injury prevention, by making sure insulation workers have safe access to their work area, facility owners will recognize all the benefits of a properly installed and maintained insulation system.

 

 

Copyright Statement

This article was published in the February 2019 issue of Insulation Outlook magazine. Copyright © 2019 National Insulation Association. All rights reserved. The contents of this website and Insulation Outlook magazine may not be reproduced in any means, in whole or in part, without the prior written permission of the publisher and NIA. Any unauthorized duplication is strictly prohibited and would violate NIA’s copyright and may violate other copyright agreements that NIA has with authors and partners. Contact publisher@insulation.org to reprint or reproduce this content.

NIA Sites > Insulation Outlook Magazine > Global

Removable Covers in Below-Ambient Applications

In the mechanical insulation industry there has always been a conversation about whether to insulate certain items that may require periodic maintenance, such as paired flanges, flanged valves, pumps, strainers, and similar items. In the late 1970s and early 1980s, the industry started to use flexible removable insulation covers. These covers are normally composed of an inner and outer layer of a silicon- or Teflon-coated fiber glass mesh, and a middle layer or fiber glass blanket. They are usually 1” to 2” thick and the covers are either sewn or stapled together. There are a variety of methods used to hold them in place, including, wire, Velcro, and belt straps.

Flexible removable covers are a great solution for items that require maintenance while still providing companies with energy savings and personnel protection. Today’s products are resistant to dirt and weather and can be easily removed and reinstalled by maintenance workers. Unlike traditional insulation, some products are created to require no special insulation expertise and are designed for any maintenance professional to be able to remove and reinstall.

Removable covers can be incredibly useful since there is a long-standing problem of insulation not being replaced when it is removed for maintenance or repair. While removable covers are certainly useful for many systems, there has been a question within the industry as to the use of removable covers on below-ambient systems. Examples of below-ambient systems include chilled water, brine, ammonia, and liquid gasses such as natural gas and oxygen. These systems have many of the aforementioned items (paired flanges, flanged valves, pumps, strainers, etc.) that will require maintenance.

One of the main challenges on below-ambient systems is that the pipe or equipment will attract moisture. Imagine a glass of ice water outside on a hot day: the glass immediately attracts moisture, and condensation forms on the outside of the glass. Since below-ambient systems operate at a colder temperature than the air, the same process happens on the pipe or equipment, and they can begin to condensate. Depending on how cold the system is running, that condensation can turn into ice. Left unchecked, this moisture can severely damage the system.

This propensity for moisture means that a proper insulation system must be installed. The insulation system will need to be carefully installed so any gaps in the system are minimized. Moisture is a determined foe and will look for any cracks in the system. This may present a problem if removable covers are used in a below-ambient system, since the seams on the cover can be a place where moisture may penetrate. Also, there may be additional seams where multiple removable covers are used to insulate the system.

Depending on the temperature of the system, many times a butyl caulk or expanding foam will be used over the seams as an additional barrier to the moisture draw. Then, a vapor retarding film or mastic is installed over the insulation to keep the moisture from penetrating the insulation.

The difficulty with removable covers is that the seams where the materials connect to each other or to the attaching pipe may not be sufficiently tight enough to keep out the moisture and may allow condensation or ice to form underneath the cover. As with any installed insulation system, once there is moisture inside the system, the situation can worsen, and here the moisture is held inside and unable to dry out.

There are manufacturers who make flexible removable covers for below-ambient systems. They use a different exterior jacket and require the installer to apply a layer of latex foam or caulk to all the seams after the cover is installed. Whether this will solve the problem of moisture draw, I don’t have the experience to say. However, foaming all the seams makes them much more difficult to remove and replace. When the item being insulated requires maintenance and the cover is removed, the person now removing the cover is likely concerned with fixing the mechanical problem, not necessarily about being careful with the flexible removable cover. When it comes time to reinstall the cover, the person should have a higher level of skill to take the time to properly install the cover and then apply the foam to any gaps. If the cover is not properly reinstalled, you may end up with moisture and possibly ice, or even corrosion.

Based on these factors and my personal experience, I do not recommend the use of flexible removable covers on below-ambient systems. While they can be invaluable on certain systems and make it easier for maintenance personnel to install and re-install, they may not be ideal for below-ambient systems where moisture draw will be an ongoing problem. If you have decided that you still want to have these covers installed, I suggest you have an insulation company familiar with below-ambient insulation systems install the covers every time to try to mitigate any potential issues. Other manufacturers make
products for indoor commercial use in controlled environments. It is vital to evaluate 3 items: chilled water temperature, vapor drive, and ambient conditions. You should also consult a qualified engineer to discuss products or specifications.

 

Copyright Statement

This article was published in the February 2019 issue of Insulation Outlook magazine. Copyright © 2019 National Insulation Association. All rights reserved. The contents of this website and Insulation Outlook magazine may not be reproduced in any means, in whole or in part, without the prior written permission of the publisher and NIA. Any unauthorized duplication is strictly prohibited and would violate NIA’s copyright and may violate other copyright agreements that NIA has with authors and partners. Contact publisher@insulation.org to reprint or reproduce this content.

NIA Sites > Insulation Outlook Magazine > Global

Insulation: Where Science, Technology, and Innovation Meet

Hidden behind the walls of many buildings and facilities, a relatively unknown technology is at work, keeping temperatures steady, providing acoustical comfort, and keeping systems working at maximum efficiency. Perhaps the most well-kept secret in the world of energy efficiency tools, thermal insulation is a vital component of properly functioning buildings and facilities. While insulation may seem like a simple technology, it is wholly dependent on skills from the science, technology, engineering, and mathematics (STEM) disciplines. For insulation to perform its most basic function—to reduce energy flow—a great deal of science and engineering needs to take place.

The Science Behind Insulation

The technology behind insulation is not well known, and it can often be relegated to a less important status on a building project. Far from being one-size-fits-all, each application calls for specific types of insulation based on the type of system, operating conditions, and goals desired. Physics is the basis of all insulation. Thermal dynamics, heat transfer/flow, fluid dynamics, wave theory, and acoustical dynamics, are critical science disciplines behind insulation. Insulation performs the functions of reducing energy transfer in the form of heat flow and reducing acoustical energy transmission. Understanding the physics behind these occurrences is critical in the development and design of insulation products and installation. Developing a finished insulation product also relies on the use of inorganic and organic chemistry, which are highly significant in the formulation of base materials for insulation products.

Polymer science plays a major role in the formation of elastomeric insulation, polyolefin insulation, polyisocyanurate insulation, polystyrene insulation, and melamine insulation. Polymer science is employed to create coatings and jacketings with many different desired properties, like durability in weather, high and low temperature durability, resistance to vapor transmission, and resistance to liquid penetration. Ceramic chemistry is used to produce formulations for alkaline earth silicate, calcium silicate, rock fiber, glass fiber, and refractory ceramic insulation materials. Metallurgical engineering is employed to produce jacketings and fasteners for insulation systems that can withstand mild to harsh conditions in chemical facilities, refining facilities, and food-production facilities for both outdoor and indoor environments.

Many of those who join the insulation industry in a research and development capacity hold a Masters or PhD in their areas of expertise. As an example, corrosion engineering is a growing field that looks at the mechanics and chemistry behind industrial corrosion, as well as the impact of insulation of corrosion. Some companies will even pay for their employees to obtain these higher degrees as a benefit of employment. If you’re a student and find yourself with an interest in these disciplines, you may want to consider a position in the insulation industry.

Similarly, those with an aptitude for math will find any number of applications in the insulation industry that can make use of those skills. As insulation is heavily dependent on science and engineering, math—the language of science—is naturally involved. Algebra, calculus, and geometry are all heavily employed in the development, production, and installation of insulation and insulation systems. Extensive calculations of many kinds go into all aspects of the insulation industry. Thermal savings calculations use heavy algebra to arrive at the best system design or economic thickness of insulation. Geometry is used every day in the estimating world when determining the amount of insulation needed in a project, or how an installer needs to cut the basic insulation material to form around a particular shape like a tank head, a large valve, or a pipe elbow. Calculus is also used in design of production lines or new facilities to calculated stresses to avoid failures.

Engineering and the Insulation Industry

Mechanical and electrical engineering are widely applicable disciplines within the insulation world. The industry is constantly investigating ways to improve processes used to produce insulation materials, design installed systems, and for the next best material or technology. The insulation industry has developed mass insulations that inhibit conduction, reflective insulation products that inhibit radiant heat transfer, and even insulations that employ vacuum technology to stop conduction. Nanoparticle technology is also being employed to produce highly efficient insulation materials. Some of the world’s largest companies have invested in ongoing projects to develop cutting-edge insulation technology.

Engineering disciplines used in insulation formulation, production, and installation include:

  • Ceramic engineering
  • Chemical engineering
  • Mechanical engineering
  • Electrical engineering
  • Civil engineering
  • Corrosion engineering
  • Metallurgical engineering
  • Acoustical engineering
  • Structural engineering
  • Information technology/systems development
  • Robotics/Plant Automation

Plants have to be built, machinery designed and tested, product development work conducted, computer systems for both business and manufacturing applications have to be designed and implemented, factory automation created and developed from concept to implementation, lab applications created for purposes ranging from basic research to quality control functions, and numerous other objectives. The industry uses a wide range of engineering disciplines in wide ranging set of applications. In the development of the uses and application of insulation materials, Civil Engineering, Mechanical Engineering, Construction Engineering, Safety Engineering, Energy Engineering, Structural Engineering, and Acoustical Engineering are very typical disciplines employed. Engineered solutions are required to address problems that insulation can address, like thermal and acoustical control. When non-engineered application of insulation technology is implemented or employed, it will likely result in an inferior product that will have ongoing repercussions for system operations.

Technology in the Insulation Industry

Technological tools have become ubiquitous in nearly every sector, and insulation is no different. From smart-sensors that can give updates on the current state of a mechanical system, to 3D-modeling and virtual reality, there are endless avenues where technology and insulation intersect. Insulation professionals in the future may find themselves wearing virtual headsets to experience BIM models in real time or working on an interactive computer animation for a new build. The time is ripe for innovators who are looking to make a real impact.

The Future of the Industry

Though insulation may seem like a simple or old-fashioned technology, nothing could be further from the truth. The insulation industry draws on a wide range of mathematic and scientific principles, as well as the expertise of highly skilled engineers. While many industries are contracting or experiencing downturns, the insulation industry is projected to keep growing in 2019 and beyond. Specializing in insulation allows you to utilize your expertise to make a lasting difference for not only a building or facility, but the larger building industry. The innovations possible in this industry have the potential to affect significant long-term change in energy needs and consumption of the built environment, the costs associated with meeting those needs, and extending the life of the resource pool for meeting those needs. If you have the right set of skills and interests, consider whether an insulation focus might be for you. Those who enter the industry will join a vibrant community of professionals who play a pivotal role in the ongoing integrity of the built environment across the globe.

 

Copyright Statement

This article was published in the February 2019 issue of Insulation Outlook magazine. Copyright © 2019 National Insulation Association. All rights reserved. The contents of this website and Insulation Outlook magazine may not be reproduced in any means, in whole or in part, without the prior written permission of the publisher and NIA. Any unauthorized duplication is strictly prohibited and would violate NIA’s copyright and may violate other copyright agreements that NIA has with authors and partners. Contact publisher@insulation.org to reprint or reproduce this content.

NIA Sites > Insulation Outlook Magazine > Global

Quick Contractor Questions: Insulation Outlook Interview Series

Insulation Outlook staff recently sat down with some NIA members for a conversation about what’s going on in the world of contractors.

1. What is your top priority for 2019?

2. Is the worker shortage an issue for your company?

3. Have you ever used NIA’s resources for your business?

4. What is your perspective of the insulation industry in 2019?

5. What do you think the industry should focus on achieving in 2019?

6. Anything else to add about the unique perspective of an insulation
contractor in this day and age?

Laura Dover

1. What is your top priority for 2019?

Same priority since 1965: Taking care of our customers, safely and with integrity.

2. Is the worker shortage an issue for your company?

The construction business is very “feast or famine” in nature, so when we have the next surge of immediate labor needs, it will be very difficult to find additional skilled workers, or even people with little or no experience. Those people just are not out there. There is no question that this shortage affects all trades in the construction industry, and is one of the biggest challenges we face going forward. We are really focusing on taking care of the employees we have, and doing more with less.

3. Have you ever used NIA’s resources for your business?

We travel a lot, so we use NIA’s Buyer’s Guide: Insulation Products & Providers directory to find suppliers and distributors throughout the country. We have Certified Insulation Appraisers on staff, which helps us take better care of our customers by giving them additional information about how our work can benefit their organization. Also, I really appreciate having access to other insulation contractors, who I can call if I need to bounce off ideas or ask questions.

4. What is your perspective of the insulation industry in 2019?

Insulation is still relevant and important to industry and construction, and 2019 will be a good year.

5. What do you think the industry should focus on achieving in 2019?

We should be focusing on coming together as insulation contractors and suppliers, regardless of size or type of business, to raise awareness of the importance of what we do. The vast majority of NIA members are small contractors, and I would like to see a focus on continuing to prioritize small companies and create additional resources for them.

Joe Leo

1. What is your top priority for 2019?

To get to 2020! Also, to grow the business in an ever-changing union environment.

2. Is the worker shortage an issue for your company?

Yes, we have seen erosion in production and manpower flexibility. Part of how we are handling this is having meetings at the local, regional, and national levels with the union to come up with creative ways to increase manpower in certain locations. The industry is struggling and the market share is shrinking because of the shortages.

It’s a serious problem.

3. Have you ever used NIA’s resources for your business?

Insulation Outlook magazine is a great resource, it’s always out at all of our branches and something our guys are regularly reading.

4. What is your perspective of the insulation industry in 2019?

Booming until 2021, when we’re anticipating a slowdown.

5. What do you think the industry should focus on achieving in 2019?

I think it’s important for NIA to help grow the industry and help educate industry members on the new laws and ever-changing business conditions. Things like mandatory paid leave, or other new regulations, can have a really serious impact, so it’s good to get ahead of what’s happening so you can be prepared.

6. Anything else to add about the unique perspective of an insulation contractor in this day and age?

The industry is ever evolving, there are constantly new advancements, technologies, and products. Some of the technological tools have allowed us to track projects more efficiently. Although, technological tools can be a double-edged sword—you now have so much capability to get and share information, it adds pressure to be reporting that information more frequently, which can leave less time for actually working on the project. Finding the right balance is key.

Matt Caldwell

1. What is your top priority for 2019?

I was thinking maybe work less and make more! In all seriousness, our top priority is going to be the addition of a new office in an adjacent state we’re not currently in. We have the people in place, and we’ve got a large job in the state.

2. Is the worker shortage an issue for your company?

Everyone in the nation is having a problem with that! Yes, we have a worker shortage problem and we’re doing 2 things to combat that: we’re working longer work weeks than normal and even though we’re a union contractor, we have taken in some of the responsibility for recruitment and recruiting our own workforce rather than waiting for the union to have them show up. Union or not, you’re having to go out and find your own people. We’ve had success working closely with the Department of Labor in each state. And we’re working with Helmets to Hardhats—we’re been working with them for a few years. It doesn’t matter where they’re coming from or even what they know—what you’re hiring for is work ethic and integrity, the industry training is going to have to come for everyone. Once we go out and solicit them, then make a determination that they have the right foundation, then we turn them over to the apprenticeship counsel for training.

3. Have you ever used NIA’s resources for your business?

We use some of NIA’s training manuals and resources for onboarding office staff. To kind of give them an idea what we do and do some surface level for the office staff to give them the 10,000-square-foot view.

4. What is your perspective of the insulation industry in 2019?

2019 is going to remain strong, at least in the southeast—and we work in every southeast state. We are seeing that there will be a slowdown mid-2020.

5. What do you think the industry should focus on achieving in 2019?

The industry is in growth mode and we’re going to be for the next decade—our biggest challenge is how we’re going to engage the younger workforce. That is currently the biggest challenge and is only going to get bigger. We need to figure out how we engage the younger generation to come into our industry—both office site and the field. It’s a promising industry that I would not hesitate to bring someone into at a young age. We just need to figure out how we can convince them it’s a good place to park their career.

6. Anything else to add about the unique perspective of an insulation contractor in this day and age?

The only thing I would say that is different than 40 years ago when we started is that we had a very defined scope of work and that has changed. We are now doing a broad scope of not only insulation, but pipe labels and heat tracing, sheet metal work—just a much broader scope of work. There’s a desire to see the insulation contractor handle more than just insulation. You’re seeing a lot of insulation companies that paint, do coatings, do scaffolding—there’s a lot of different things that are expected now.

A special thanks to the following NIA members for participating in this piece:

Laura Dover is the President of Dover Insulation (www.doverinsulation.com), and has been with the company for 17 years. Ms. Dover is the third generation of her family to work in the insulation industry. Dover Insulation is a merit contractor based in North Carolina, and has been in operation since 1965. She can be reached at lauradd@doverinsulation.com.

Joe Leo is the President of Atlantic Contracting & Specialties, LLC (www.atlanticcontracting.com) and Senior Vice President of IREX Contracting Group (www.irexcontracting.com). Mr. Leo has been in the commercial and industrial insulation business for 41 years. Atlantic Contracting services the New York/New England Market, as a full scaffolding, insulation, painting, and abatement contractor. He is President of the Insulation Contractor’s Association of New York City, Treasurer of the Insulation Contractor’s Association of Southern New York, and 1st Vice president of the Subcontractors Trade Association. He is also the Vice Chairman and former Co-Chair of the Building Trade Employer’s Association. He serves on the board of NIA, the Eastern States Insulation Contractor’s Association, and the National Union Insulation Contractor Alliance. He is Co-Chairman of the Trust Funds for both the Heat and Frost Insulators of New York City and Westchester, and sits as a Trustee on the Funds in Connecticut. He can be reached at JLeo@atlanticcontracting.com.

Matt Caldwell is the President of Caldwell Insulation Inc. (www.caldwellinsulation.com). The company is located in Atlanta, Georgia. He founded the company in early 1995 and has 27 years of experience in the mechanical insulation industry. Caldwell Insulation has a primary focus on commercial and industrial insulation in the southeastern U.S. market. Caldwell Insulation is a union shop and their specific area of focus is data centers and hospitals. He can be reached at matt@caldwellinsulation.com.

 

Copyright Statement

This article was published in the February 2019 issue of Insulation Outlook magazine. Copyright © 2019 National Insulation Association. All rights reserved. The contents of this website and Insulation Outlook magazine may not be reproduced in any means, in whole or in part, without the prior written permission of the publisher and NIA. Any unauthorized duplication is strictly prohibited and would violate NIA’s copyright and may violate other copyright agreements that NIA has with authors and partners. Contact publisher@insulation.org to reprint or reproduce this content.

NIA Sites > Insulation Outlook Magazine > Global

The Building Envelope: Codes, Codes, and More Codes

The metal building industry has witnessed a tremendous shift over the last several years. Increasingly stringent energy codes have propelled the industry toward more sustainable construction and innovation that we wouldn’t have imagined a few decades ago. An entirely new vocabulary is used when talking about metal buildings: “conditioned space,” “climate zones,” “air barriers,”—30 years ago this was all unheard of. Additionally, newer energy codes contain higher performance expectations, which not only require more insulation, but also call for more advanced systems, such as air barrier systems, liner systems, and more.

This metal building industry update is designed to cover the most recent building envelope changes within the latest code cycles and the specific insulation system innovations that meet the latest codes. Before that, I will briefly review some metal building energy code basics.

The Difference between ASHRAE and IECC

First, ASHRAE 90.1 is a minimum Standard of energy efficiency, not a code. The International Energy Conservation Code (IECC) is a model energy code that references the ASHRAE 90.1 Standard. Other differences include:

  • ASHRAE 90.1 and IECC have different 3-year cycles.
  • IECC follows behind ASHRAE 90.1 by 2 years. For example, IECC 2012 references ASHRAE 90.1-2010. IECC 2015 references ASHRAE 90.1-2013.
  • IECC adopts the latest ASHRAE Standard, plus any addendums and new data. This means that IECC is ultimately a more stringent code than the ASHRAE Standard.

What’s in an Energy Code?

There are 3 major components of an energy code:

  • Lighting;
  • HVAC; and
  • Envelope.

Additionally, there are many elements within the building envelope subject to energy code regulations:

  • Opaque roof and wall assemblies;
  • Windows;
  • Skylights;
  • Doors;
  • Foundation; and
  • Floor.

This article focuses on changes to roof and wall assembly code requirements, but remember that there are updates to other elements of the building envelope that you should also be aware of.

Code Adoption by State

The resources we use for state code changes include the Department of Energy (DOE), the Building Codes Assistance Project (BCAP), and the International Code Council (ICC). The chart above, which is a comprehensive list of codes adoptions in each state, is current as of December 2018. You can think of this as a guideline to help determine which adoptions have been made in your state.

The Newest Code Cycle: IECC 2018/ASHRAE 90.1-2016

In January, I attended the ASHRAE meeting in Atlanta, where we worked on the final stages of the 2019 ASHRAE 90.1 Standard. While that isn’t quite ready for publishing yet, the 2016 Standard is out and ready for adoption. Thus, we refer to IECC 2018/ASHRAE 90.1-2016 as the “newest” code cycle. While a handful of cities throughout the country have adopted it, no statewide adoptions have been made yet.

In terms of updates, you can expect to see the majority of changes in air sealing and blower door testing. Additionally, there’s a reduced BTU table for semi-heated space. This means that the maximum allowable heat output per climate zone has been reduced, thus making the semi-heated compliance path more difficult to use. Remember that these comparisons are based off of IECC 2015/ASHRAE 90.1-2013.

The Most Widely Adopted “New” Code: IECC 2015/ASHRAE 90.1-2013

The most widely adopted “new” code cycle is IECC 2015 and ASHRAE 90.1-2013. If your current state’s code is based on the IECC 2009/ASHRAE 90.1 2007 Standard, you’ll see the most significant envelope changes. Many states currently at the IECC 2009 code are bypassing IECC 2012 altogether (or have already done so) and are adopting IECC 2015. Pennsylvania and South Carolina are examples of this. On October 1, 2018, Pennsylvania changed from IECC 2009/ASHRAE 90.1-2007 to the IECC 2015/ASHRAE 90.1 2013 code. South Carolina did the same as of January 1, 2019. This is a huge jump, and many metal building contractors will feel the pressure. If you haven’t used Liner Systems or Filled Cavity/Long Tab Banded Systems in the past, you will need to start using them. Both options fulfill the metal building insulation requirements—it’s just a matter of preference. I detail the key differences between the systems later on in this article.

Highlights of the IECC 2015/ASHRAE 90.1-2013 cycle include:

  • Higher insulation values: IECC 2015 and ASHRAE 90.1-2013 have the most stringent envelope requirements based on “Conditioned Space” and “Non-Residential Space.” This means that, for the most part, contractors will need to use Banded Liner Systems or Long Tab Banded Systems in order to meet the stricter insulation requirements.

Table 3.2 (below), which is used for determining semi-heated space, has not changed from older code cycles to this one.

If semi-heated is not allowed based on the heating system or jurisdiction, then each climate zone will have major increases in thermal performance, which translates to increased insulation levels under the non-residential space. This is based on the ASHRAE 90.1-2013 Standard; however, the IECC 2015 code has, for the most part, the same values. For example, using ASHRAE 90.1-2013, climate zone 5a requires a roof U-Value of .037 and a wall U-value of .050. In order to obtain these U-values, a metal building would require either a Liner System or Filled Cavity/Long Tab Banded System for the roof, and a Liner System Filled Cavity for the walls.

  • Air barrier requirement: Both IECC 2015 and ASHRAE 90.1-2013 require an air barrier in the thermal envelope, and for it to be indicated in drawings. It can be placed on the interior side, exterior side, somewhere within assemblies composing the envelope, or any combination thereof.
    • In IECC 2015, this can be found in section C 402.5.1 and C 402.5.1.1. (exceptions = unheated buildings)
    • In ASHRAE 90.1-2013, it’s found in section 5.4.3, 5.4.3.1.1, and 5.4.3.1.2. (exceptions = semi-heated buildings in climate zones 1-6)

It is also mandatory to identify the air barrier and for it be continuous across joints and assemblies. Joints and seams must be sealed and securely installed. Penetrations and joints—and seals associated with penetrations—must be sealed in a manner compatible with construction material and location. These must be shown on the drawings submitted for permitting.

  • Compliance path: Under the IECC 2015 Code and ASHRAE 90.1-2013 Standard, it’s still the same choice. The designer decides to follow one of 3 paths: Materials, Assembly, or Whole Building. The materials path is just that—any material tested under ASTM E 2178.Assembly is a combination of envelope materials built and tested under ASTM E 2157, 1677, or 283. Whole building testing requires ASTM E 779. If this option is used, and the building fails, it must be brought in compliance with the leakage rate allowed. This means that you cannot opt out of this path once it’s chosen by the designer. ASHRAE 90.1-2013 does allow a lesser leakage rate if repairs are made.
  • States that have adopted IECC 2015/ASHRAE 90.1-2013 include: Alabama, California, Illinois, Maryland, Massachusetts, Michigan, New Jersey (adopted ASHRAE 90.1-2013), New York, Oregon, Utah, Texas, Vermont (state-specific code modeled after IECC 2015), and Washington. Georgia is also slated to adopt the code cycle over the next few months.

The Biggest Question to Answer in 2019: “What Do I Need to Meet Code?”

As we move toward more complexity in each code cycle, this longstanding question will only become even more common. As simple as the question is, it is very difficult to answer. In short, the compliance path I recommend most often is the prescriptive approach. Per the U.S. Department of Energy, the prescriptive approach includes “requirements that either must be met by every building design, or if the requirement is not met, a tradeoff must be made to make up for not meeting that requirement.” In other words, you must meet all U-values of the roof, walls, foundation, and fenestrations. If a tradeoff is indeed needed in the end, the quoted price has covered any changes.

Closing Remarks

In closing, the code cycle changes that are either here or coming soon to your state are, without a doubt, challenging to say the least. As insulation suppliers located throughout the country, we’ve had to attend meetings, learn, and be involved with the entire process of code development. This it to assure our customers are providing code-compliant envelopes to the their customers and, on a bigger level, the metal building industry. Overall, it’s been a good year for metal building construction. The newest code changes mean more efficient buildings and more innovative solutions that have greater potential to save end users money.

 

 

Copyright Statement

This article was published in the February 2019 issue of Insulation Outlook magazine. Copyright © 2019 National Insulation Association. All rights reserved. The contents of this website and Insulation Outlook magazine may not be reproduced in any means, in whole or in part, without the prior written permission of the publisher and NIA. Any unauthorized duplication is strictly prohibited and would violate NIA’s copyright and may violate other copyright agreements that NIA has with authors and partners. Contact publisher@insulation.org to reprint or reproduce this content.

 

NIA Sites > Insulation Outlook Magazine > Global

Affordable Worker Magnets

Whether as a result of a booming economy, tighter immigration laws, or an educational system gone astray, finding qualified job applicants has become increasingly more difficult for those in the construction and engineering industries. Even more troubling for many smaller businesses is the question of how they can compete for badly needed, qualified workers?

Fortunately, thanks to our unique tax laws, every construction company and engineering firm can afford to offer fringe benefits to their workers, and may even be able to benefit themselves. That’s right, our tax laws merely prevent employers from discriminating in favor of owners, key employees, or other highly-compensated individuals when setting up any benefits plan that is to be tax deductible by the business and tax free to the recipient.

Fringe Benefits

Fringe benefits are often defined as property and/or services whose benefit to employees frequently outweighs the cost to the employer. With a number of notable exceptions, fringe benefits are generally included in an employee’s gross, taxable income where they are subject to income tax withholding and employment taxes.

However, while some fringe benefits are included in an employees’ taxable wages, other fringe benefits aren’t taxable wages and, yet, remain deductible by the employer. Among these exceptions are nontaxable fringe benefits, so-called “qualified” fringe benefits such as health insurance, medical expense reimbursements, dental insurance, education assistance, and day-care assistance. Tax-qualified benefits are deductible by employers and totally free of federal and state income taxes as well as the employee’s Social Security and Medicare taxes.

These tax savings obviously make fringe benefits an attraction. However, thanks to last December’s Tax Cuts and Jobs Act, the array of tax-free fringe benefits that employers can provide employees is not quite as generous as it used to be.

Benefits to Attract and Retain Workers

Surprisingly, survey after survey shows that it is not money alone that attracts new workers and keeps existing employees on the job—the benefits are also a big pull. In fact, currently treasured by job seekers—and employees—are flexibility and the opportunity to balance work with other life responsibilities, interests, and issues. But, obviously, no engineering firm or construction business can be an employer of choice without a good benefits package. Job training, educational assistance, and employer-provided vehicles used for business are among the common working-condition fringe benefits for many small businesses.

Job Training and Educational Assistance

On-the-job training provided by an employer is a tax-free hiring incentive and functions well as an invaluable “perk” for current employees. Educational assistance and tuition reimbursement are also welcome fringe benefits.

A formal, written educational assistance plan doesn’t require immediate employer funding, only to provide reimbursement for an employee’s educational expenses—up to $5,250 per employee, per year and exempt from tax. Educational assistance doesn’t just include tuition assistance, but also payments for books, equipment, and other expenses related to continuing education.

Paying Better than the Competition

Job seekers and employees are increasingly looking for cafeteria-style benefit plans in which they can balance their choices with those of a working spouse or partner. Profit-sharing plans and bonuses that pay employees for measurable achievements and contributions are invaluable.

Every engineering firm principal and construction business owner should keep in mind that, in today’s job market, compensation remains an important factor. By surveying the local job market and the compensation offered by others in the construction and engineering industries, an employer can pay better than average to attract the best candidates.

Benefits offered by a construction company or engineering firm should also be above industry standards with new fringe benefits added—when they are affordable. Existing employees should be educated about the true dollar value of their benefits so they appreciate that their needs are being addressed.

Bonuses and Taxes

Bonuses and awards must, as mentioned, be included in an employee’s taxable income. Should the bonus or award be in the form of goods or services, employees must include the fair market value of those goods or services in their income. The same applies to holiday gifts. However, employees receiving turkeys, hams, or similar items of nominal value from their employers at Christmas or other holidays may exclude the value of the gift from their income.

Profit-Sharing Plans

A profit-sharing plan, often called a deferred profit-sharing plan (DPSP), is a plan that gives employees a share in the profits of the business. Under this type of plan, an employee receives a percentage of the operation’s profits based on its quarterly or annual earnings. This is a great incentive to attract new workers and a way to give employees a sense of ownership in the business. Not too surprisingly, however, there are restrictions as to when and how a person can withdraw these funds without a penalty.

The contribution limit for a engineering firm or construction company sharing its profits with an employee is the lesser of 25% of the employee’s compensation, or a maximum of $56,000 ($55,000 in 2018). In order to implement a profit-sharing plan, the business must file a Form 5500-series return/report and disclose all participants of the plan. Early withdrawals, just as with other retirement plans, are subject to penalties.

Employee Stock Ownership Plan

An Employee Stock Ownership Plan, or ESOP, is an employee-owner program that provides workers with an ownership interest in the business—tax free. An ESOP is a qualified defined contribution employee benefit plan designed to invest primarily in the stock of the employer.

In general, employees are provided with ownership with no upfront cost. The shares provided can be held in trust for safety and growth until the employee retires or resigns. At that time, the shares go back to the business for further redistribution or are completely voided.

What Do They Want?

Among the more common, tax-free employee fringe benefits are the following:

  • Health benefits—Health benefits are by far the single most important fringe benefit. Health benefits include providing employees with health, dental, and vision insurance as well as paying health-related expenses.
  • Group term-life insurance—A business can provide up to $50,000 in group term life insurance to each employee tax-free.
  • Dependent care—Up to $5,000 in dependent care assistance can be provided to an employee tax free. Of course, many working parents may qualify for a tax credit for child and dependent care.
  • Working condition fringe benefits—Working condition fringe benefits are anything provided or paid for by an employer to help someone do their job. Local and long distrance travel for business, business-related meals and entertainment, professional publications, and company cars used for business driving are all good examples of tax-free working condition fringe benefits that are tax deductible by the employer and tax free to the employee/recipient. The former deduction of so-called “Employee Business Expenses” was eliminated by the Tax Cuts and Jobs Act, along with many other personal expenses previously allowed on individual tax returns. Disallowed were those expenses formerly deductible subject to a 2% floor.
  • Long-term care insurance—This insurance covers expenses such as the cost of nursing home care. While premiums are not taxable benefits, benefits received under the insurance may be partly taxable if they exceed certain limits.

The Cheapest May Be the Most Valuable

So-called “de minimis” benefits may be worth little or nothing in the eyes of our lawmakers, but go a long way toward making employees—and prospective employees—happy without an accompanying tax bill. De minimis fringe benefits refer to any property or service that is so small in value that accounting for it is unreasonable or administratively impractical.

Party Time

A business with happy workplace is often an attraction for job seekers. Whether it’s a nightclub affair or a buffet in the business’s break room, parties are a tried-and-true benefit. And, in addition to making employees feel valued and keeping them motivated, parties have tangible tax benefits.

The tax rules allow a business to throw a holiday party—even a relatively fancy one—with no tax consequences to the employees. Of course, in order to be deductible, the IRS requires the party cost to be “reasonable.” A construction company or engineering firm cannot deduct expenses for entertainment that are “lavish or extravagant.”

Tax Reform

Last December’s Tax Cut and Jobs Act included important changes to the tax treatment of employer-sponsored benefit programs. The new law restricts an employer’s ability to deduct many common business expenses, such as meals, entertainment, and employee moving expense reimbursements. On the upside, the law also included a new tax credit for employers who provide paid family and medical leave for their employees. The tax credit, a direct reduction in the tax bill rather than a deduction used to reduce taxable income, is available when compensation for employees is $72,000 or less.

The Bottom Line

In order to attract talented individuals to work for the engineering firm or construction business, as well as to retain qualified employees, today’s employer must offer fringe benefits and other perks. Once it has been determined what benefits will best attract badly needed workers in today’s job environment, which benefits employees would prefer, and which benefits the business can really afford, then and only then, will it be possible to make an informed choice of which benefits will attract job applicants, benefit your engineering firm or construction company and your employees the most.

Knowledge is essential when deciding which benefits work in today’s job market—as are the services of a qualified professional. But, wouldn’t it be wonderful if those benefits turned out to be the ones that cost your operation the least?

 

Copyright Statement

This article was published in the January 2019 issue of Insulation Outlook magazine. Copyright © 2019 National Insulation Association. All rights reserved. The contents of this website and Insulation Outlook magazine may not be reproduced in any means, in whole or in part, without the prior written permission of the publisher and NIA. Any unauthorized duplication is strictly prohibited and would violate NIA’s copyright and may violate other copyright agreements that NIA has with authors and partners. Contact publisher@insulation.org to reprint or reproduce this content.

NIA Sites > Insulation Outlook Magazine > Global

Safety Matters: Don’t Be Caught Sleeping on the Job

Still trying to pick a New Year’s Resolution? How about one that is easy and free and can make you healthier, smarter, less stressed, and happier? If the name of the column didn’t already give it away, we’re talking about getting more sleep in 2019. So why is Safety Matters concerned about how much sleep you get? Because, in addition to improving your overall wellbeing, getting the right amount of sleep makes you safer at work too. A report published by the National Safety Council estimates that 13% of workplace injuries can be attributed to fatigue. It’s an even bigger factor in fatal automobile accidents. Some of the biggest industrial accidents in history have been blamed, at least partly, on worker fatigue. Human error and fatigue factored into the partial meltdown of Three Mile Island, the Exxon Valdez oil spill, and the Union Carbide disaster in Bhopal, India.

The United States Department of Transportation (DOT) has long recognized that fatigue plays a critical role in workplace safety. The DOT addresses fatigue by limiting certain safety-sensitive positions to a certain number of acceptable hours that may be worked in a day, how many total hours in a week, and even how many hours they must have off between shifts. But it is not just truck drivers, airline pilots, and train engineers that are at risk. Impaired reaction time, poor judgement, poor decision making, and trouble paying attention are just some of the symptoms of fatigue that can affect any workplace. These are not the characteristics of a safe workforce. Worker fatigue should be considered in any company’s Health and Safety Program.

Most people know they should be getting 7 to 9 hours of sleep daily. But not many understand the consequences of sleep debt. Sleep debt is the difference between your sleep need (7–9 hours), and the actual hours of sleep you get. Each hour of sleep lost is added to your sleep debt. If each workday you add another 2 hours to your sleep debt, you would need to make up 10 extra hours of sleep over the weekend—over a full night’s sleep. Even if you did have that much extra time to make up the sleep, it would just throw off your regular sleep cycle and make it that much harder to sleep on Sunday night. For many people, that sleep debt continues to grow over weeks, months, and years. Chronic sleep debt raises your risk of weight gain, diabetes, heart disease, memory loss, and mood disorders. Short-term symptoms of sleep debt include fuzzy-headedness, fatigue, and irritability. Another dangerous side effect of sleep debt are microsleeps—momentarily nodding off during the middle of the day. Some people are in such a constant state of sleep debt, they forget what it feels like to be well-rested.

The National Sleep Foundation points out that it is not that big lunch, boring meeting, or the warm room that makes you sleepy in the afternoon—more likely it’s your sleep debt. A healthy person with a low sleep debt should not feel sleepy after lunch or during a meeting. A slight afternoon slump between 1:00 and 3:00 p.m. is normal due to your circadian rhythms, but you should not be fighting to keep your eyes open. Other signs you may have a sleep debt problem include difficulty getting out of bed in the morning, difficulty concentrating, low motivation, and being easily irritated.

The good news is that it is possible to get back on track with your sleep debt. The bad news is that it may take a while. Paying off your sleep debt requires a little extra sleep over a long time, not one big Rip Van Winkle–style slumber. One of the most important strategies is to gradually add to your sleep time and maintain a regular sleep and wake schedule, even on the weekends. Create a dark, quiet, comfortable, and cool sleep environment. Make your bedroom a sleep sanctuary—not a home office or TV viewing area. Also, avoid alcohol and caffeine before bed, both can disrupt your normal sleep cycles and result in poor sleep quality. You will also want to leave the cell phone on the bed side table (or even farther away). Apart from the mental stimulation of catching up on your social media feeds, the blue light from the smart phone screen can trick your brain into thinking it is daytime. Night shift workers can use blackout curtains or wear a sleep mask when sleeping during the day. A white noise machine can help block out the sounds of the day.

Almost all employers have strict policies against working while under the influence of alcohol, but few have policies on fatigue. Yet studies show an equivalent risk between the 2. Seventeen hours of sleeplessness is comparable to a 0.05 blood alcohol content (BAC). If you have been awake for over 24 hours, your impairment is equivalent to having a 0.1 BAC—above the legal limit to drive. In addition to contributing to workplace accidents, sleep deprivation is a productivity killer and an employee health issue. For these reasons, employers should have a vested interest in a well-rested workforce. Fatigue and the importance of good sleep should be included with other health and safety training for employees, supervisors, and managers. If your company has a wellness program, it should include healthy sleep practices and screenings for sleep disorders. Managers should also consider fatigue when developing schedules and manpower needs. When working long overtime hours, you may be paying premium rates for employees who are less productive, more error prone, and more likely to cause an accident. Poor lighting and excessive noise levels are 2 other workplace factors that have been identified as contributing to fatigue.

Don’t view sleep as a luxury to be indulged in only on the weekends. Sleep is an essential biological need that is necessary for your health, performance, safety, and quality of life. Sleep deprivation has serious negative consequences for all of these. Establishing healthy sleep practices is just as important as exercise and diet, so why not make it your New Year’s Resolution?

 

Copyright Statement

This article was published in the January 2019 issue of Insulation Outlook magazine. Copyright © 2019 National Insulation Association. All rights reserved. The contents of this website and Insulation Outlook magazine may not be reproduced in any means, in whole or in part, without the prior written permission of the publisher and NIA. Any unauthorized duplication is strictly prohibited and would violate NIA’s copyright and may violate other copyright agreements that NIA has with authors and partners. Contact publisher@insulation.org to reprint or reproduce this content.

NIA Sites > Insulation Outlook Magazine > Global

A Focus on Insulation and Surface-Burning Characteristics

Insulation materials are used in a variety of different applications in commercial and residential buildings. Depending on the installation, these materials are required by code and specifications to have minimum ratings established in accordance with specified fire tests and other standards. Identifying the governing code requirements, product specifications, and test standards that apply can be quite a challenge. However, understanding these specifications and regulations is of utmost importance to achieve the appropriate levels of product performance and enhance the likelihood of acceptance of the insulation products in the marketplace.

One of the common test methods applicable to insulation products in codes and specifications is ASTM E84 (UL 723), Standard Test Method for Surface Burning Characteristics of Building Materials. ASTM E84 (UL 723) includes a fire test method that evaluates the surface-burning characteristics of building materials, such as wall and ceiling surface finishes and insulation. The purpose of this test is to determine the relative burning behavior of the material by observing the flame spread along the specimen and the smoke developed during the test, and then documenting these using 2 ratings (the flame-spread index and the smoke-developed index). It is important to understand the intent of the test and the performance indexes in order to help end users and code authorities achieve code-compliant installations with minimal delays or problems.

This understanding is essential because all the model codes and installation standards listed below contain requirements for insulation products to achieve specific flame-spread and smoke-developed indexes when tested to ASTM E84 (UL 723).

  • International Building Code (IBC)
  • International Mechanical Code (IMC)
  • International Fire Code (IFC)
  • International Residential Code (IRC)
  • Uniform Mechanical Code (UMC)
  • NFPA 1—Fire Code
  • NFPA 101—Life Safety Code
  • NFPA 5000—Building Construction and Safety Code
  • NFPA 90A—Standard for the Installation of Air-Conditioning and Ventilating Systems

In addition to these common code and installation requirements, there are several specifications, such as ASTM, for insulation products that contain requirements for surface-burning characteristics, flame-spread, and smoke-developed indices. The National Insulation Association’s (NIA) Insulation Materials Specification Chart (https://tinyurl.com/spechart) is an excellent reference for the specific surface-burning characteristic values that apply to various insulation products.

In order to better understand the relevance of ASTM E84 (UL 723), it is important to understand the events that led to the development of the test and the code applications that require products to comply with this standard, as well as to know how the test is performed.

The Steiner Tunnel: Withstands the Test of Time

How It All Began

At the beginning of the twentieth century, major fires in U.S. buildings raised public concern and demonstrated the need to address and regulate the burning characteristics of building materials. Fires at the Boston Cocoanut Grove Nightclub, La Salle Hotel (Chicago), and Winecoff Hotel in Atlanta resulted in over 650 deaths. These 3 fires had a common theme: rapid flame progression along the surfaces of the interior finish greatly contributed to uncontrollable fire spread. There was a dire need to manage these types of building fires through passive fire protection and regulating material characteristics. By the 1940s, research work at UL resulted in this prevailing “reaction to fire” test method using a 25-foot-long tunnel to characterize the surface-burning fire and smoke characteristics of interior finish materials.

The 25-foot tunnel became known as the Steiner Tunnel, named in honor of the primary UL engineer, Albert J. Steiner. Its prominence in the fire-protection community was based on its ability to provide cost effective, repetitive testing and use of a sample size that could characterize interior finish materials used in actual installations. After a few refinements, the first formal test method was published as UL 723—Standard for Test for Surface Burning Characteristics of Building Materials by UL in 1950. The test method was formally adopted by American Society for Testing and Materials (now ASTM) in 1961. The National Fire Protection Association later adopted the method as NFPA No. 255 in 1955. Today, this method is currently described in the 11th edition of UL 723 and is also commonly known as ASTM E84.

The regulation of rapid progression of fire on interior finish materials is as relevant today as it was nearly 70 years ago, as the need for accurately assessing interior materials has not diminished. A more recent example of the need for interior material fire assessment is The Station nightclub fire that occurred in Rhode Island in 2003. In this fire, rapid progression of flames on the interior materials, which were not examined to proper standards, led to the building being engulfed within minutes.

Steiner Tunnel Apparatus

The tunnel apparatus is constructed such that materials under testing have an exposed area of 18 inches wide by 24 feet long, up to a thickness of approximately 5–6 inches, maximum. The test is conducted with the sample mounted in the “ceiling” position of an enclosed tunnel furnace measuring 18 inches wide by 12 inches deep by 25 feet long. Two burner outlets, spaced 8 inches apart, deliver a nominal 5000 BTU/min., 4 ½-foot flame to provide the ignition source to the underside of the mounted specimen. The test continues for a 10-minute duration. A controlled inlet draft of 240 feet per minute facilitates horizontal flame propagation throughout the test.

Test Procedure

With all of the controls set for the tunnel operation, the room is darkened and the gas burners are ignited. Observers record the distance and time of maximum flame-front travel through the tunnel observation windows. Flame-front advancement is recorded at the time of occurrence or at least every 30 seconds, if no advancement is noted. The test continues for a 10-minute period. A light and photoelectric cell, mounted in the exhaust duct, records smoke obscuration during the test. Flame-spread and smoke-developed indices are reported in comparison with calibration materials of red oak lumber and fiber-cement board. Red oak propagates flames to the end of the tunnel in approximately 5 ½ minutes and generates a flame-spread index of approximately 90. A smoke-developed index of 100 is assigned for red oak. Fiber-cement board generates flame spread and smoke developed indexes of 0.

Considerations for Sample Selection

It is important that the test specimens be representative of the materials that the test is intended to examine and representative of the products intended to be installed in the field. For sample selection, there are several considerations, such as sample composition, thickness, density, and joining characteristics.

Considerations for Sample Mounting

Products to be tested are mounted according to their product types. Sometimes the products are considered “self-supporting,” so they simply rest on the ledges of the tunnel. In other cases, the specimens are supported by rods and/or wire or secured from the back side. Several mounting practices listed below have been developed through the ASTM process to facilitate consistent mounting of various product types when testing to ASTM E84 (UL 723), including ASTM E2231 for pipe and duct insulation materials, ASTM E2599 for reflective insulation, and ASTM E2988 for flexible fibrous glass insulation for metal buildings.

Considerations for Testing of Composite Materials

This test method can provide data on composite materials, such as batt and blanket insulation products comprised of fiber glass insulation, adhesives, and facings, and the method is also capable of providing test results on the individual components of a composite product, such as the individual fiber glass insulation, adhesives, and facings. One misconception is that the individual component values can be used to represent the composite material for compliance with ASTM E84 (UL 723) regulation or specifications.

It is important to understand that products, such as batt and blanket insulation, are tested as a composite material. Experience and historical data has shown that as a rule, component values cannot be considered as worst case or additive to represent the composite product. In other words, 3 components with a flame spread of 5 will typically not yield a flame spread of 5 for the composite. Similarly, 3 components with a flame spread of 5 have not been shown to reliably predict a flame spread of 15 for the composite. This is an important distinction because combining materials can change the overall behavior of the final composite. This means that, even if the insulation itself were certified, the addition of adhesive and facing may change the behavior of the composite when exposed to fire. Only testing the composite product will demonstrate the actual values.

The requirement to test composite materials is reflected in ASTM E84 (UL 723), as well as the mounting procedures mentioned above. Often, the easiest way to avoid this issue is to look for finished materials with a reliable third-party certification.

Mitigating Flame Propagation Hazards for Decades

The Steiner Tunnel test method, as described in ASTM E84 (UL 723), is one of the most popular “reaction to fire” test methods within the U.S. This method has been used for decades with success to assess the comparative surface-burning characteristics of building materials. The selection of materials with appropriate, code-compliant results has proven to be a useful tool in mitigating the hazards associated with flame propagation on interior surfaces.

Code Requirements

We previously listed several model codes and installation standards that require insulation products to comply with surface-burning characteristics requirements determined in accordance with ASTM E84 (UL 723).

While we do not have the opportunity to explore all of the above codes, let’s explore some of the IBC applications that require insulation to have ratings established in accordance with ASTM E84 (UL 723).

IBC Section 720 covers a variety of thermal and sound-insulating materials, and requires compliance with the following requirements:

  • 720.2—Insulating materials in concealed spaces of buildings are required to have a flame-spread index of not more than 25 and a smoke-developed index of not more than 450, except for cellulosic fiber loose-fill insulation with a smoke-developed index of not more than 450 when tested in accordance with CAN/ULC S102.2. (Note S102.2 is a fire test that utilizes the Steiner Tunnel test apparatus but examines the material under test on the floor of the tunnel, rather than in the ceiling position.)
  • 720.3—Exposed insulating materials are also required to have a flame spread index of not more than 25 and a smoke-developed index of not more than 450, except for cellulosic fiber loose-fill insulation with a smoke-developed index of not more than 450 when tested in accordance with CAN/ULC S102.2.
  • 720.4—Loose-fill insulation, other than loose-fill cellulosic insulation, that cannot be mounted in the ASTM E84 or UL 723 apparatus without a screen or artificial supports, are required to have a flame spread index of not more than 25 and a smoke-developed index of not more than 450.

IBC Chapter 8 contains the performance requirements for controlling fire growth and smoke propagation within buildings by restricting interior finish and decorative materials. The provisions of this chapter require materials used as interior finishes and decorations to meet a Class A, B, or C fire performance based on the relative fire hazard associated with the occupancy. The Class A, B, or C fire performance of the material is evaluated based on test standards ASTM E84 (UL 723). The required level of performance for a Class A, B, or C fire performance is defined in Chapter 8 of the IBC, shown below.

Plenum Applications

When used in exposed plenums the IMC, UMC, and NFPA 90A in general will require insulating materials to comply a flame-spread index of not more than 25 and a smoke-developed index of not more than 50.

Foam Plastics

Foam plastic insulation is governed separately by these codes (for example Chapter 26 of the IBC). In general, foam plastic insulation and foam plastic cores of manufactured assemblies shall be tested and labelled as having a flame spread index of not more than 75 and a smoke-developed index of not more than 450 when they are tested in the maximum thickness intended.

Throughout these codes, there are several more required fire response tests other than ASTM E84 (UL 723) for surface-burning characteristics. For example, just to name a few, insulation materials used in fire-resistive construction are required to be tested within the assemblies in accordance with UL 263 (ASTM E119); insulation materials used in roofing assemblies are evaluated in accordance with UL 790 (ASTM E108); insulation materials defined as noncombustible are examined by ASTM E136; and insulation products evaluated in exterior wall construction are tested in assemblies in accordance with NFPA 285.

Third-Party Certification

Code authorities rely on UL Product Certifications to show compliance with the ASTM E84 (UL 723) flame-spread index and smoke-developed index requirements.

This third-party certification demonstrates an ongoing commitment to safety and quality. For some specific products, such as faced blanket insulation, third-party certification can also prove beneficial because it demonstrates that the composite material— the insulation, adhesive, and facing—has been evaluated and certified rather than the individual components alone.

Certification by UL means a product has been evaluated, complies with UL’s requirements, and is manufactured under a Follow-Up system, meaning the certification extends beyond testing. This Follow-Up Program allows UL to verify that products remain compliant with requirements and are produced in a manner representative of the construction of the product that was originally evaluated and certified. UL’s Classification Mark on insulation products—“UL Classified” is the applicable term—is the manufacturer’s representation that samples of that product have been evaluated as to their surface-burning characteristics in accordance with ASTM E84 (UL 723).

Products certified for ASTM E84 (UL 723) surface-burning characteristics can be found online on in UL’s Product Spec database at http://productspec.ul.com by selecting Product Type, and entering surface burning. A link to this database is also available on NIA’s Specs and Codes page at https://tinyurl.com/ybdef8td. The many advantages of third-party certification lead some building material product manufacturers to make it company policy to obtain UL Classification for their products to minimize the possibility of non-acceptance by code authorities. Additionally, many purchasers, building designers and building owners understand UL-Certified materials can be counted on to perform as expected. Specifying UL-Classified building materials also means the materials will automatically come with third-party quality control which, in turn, means UL will establish a field report to determine the nature of the nonconformance and take appropriate corrective action should an issue occur.

 

 

Copyright Statement

This article was published in the January 2019 issue of Insulation Outlook magazine. Copyright © 2019 National Insulation Association. All rights reserved. The contents of this website and Insulation Outlook magazine may not be reproduced in any means, in whole or in part, without the prior written permission of the publisher and NIA. Any unauthorized duplication is strictly prohibited and would violate NIA’s copyright and may violate other copyright agreements that NIA has with authors and partners. Contact publisher@insulation.org to reprint or reproduce this content.

NIA Sites > Insulation Outlook Magazine > Global

Tariffs

The other day, a client called and said, “I’m going to change the classification on my product so I don’t have to pay tariffs.” I told him I don’t recommend it. For those facing new tariffs, it may be wise to consider reinventing your approach to your compliance strategy by reevaluating your supply chain and considering how you can reduce your risk.

U.S. tariffs against Chinese products remain a big story today. Here’s why:

  • List 1 tariffs on $34 billion of Chinese products went into effect on July 6.
  • List 2 tariffs on $16 billion of Chinese products went into effect on August 23.
  • List 3 tariffs on $200 billion of Chinese goods: the 10% duty effective on List 3 products went into effect on September 24, 2018; the 25% duty effective on List 3 product was initially intended to go into effect on January 1, 2019. However, on December 2, 2018, U.S. and China leaders met at the G-20 summit and agreed to a 90-day hold on the List 3 increase for January 1. If no deal is reached between the United States and China within 90 days, then tariffs could increase to 25% around March 1, 2019.

Why Compliance Is Worth the Effort

You can bet that U.S. Customs and Border Protection (CBP) will be watching closely for noncompliance, and the penalties for trade-related transgressions can be severe. For example, CBP imposes fines of up to $10,000 per entry for recordkeeping infractions. Nonfinancial costs such as shipment delays; the diversion of staff resources to correct problems; and in rare instances, the loss of trade privileges; can be detrimental to your business.

CBP maintains 2 penalty provisions: the loss of revenue provision and a non-loss of revenue provision. Each provision has 3 degrees of culpability that are predicated upon whether the violations that occurred are deemed negligent, gross negligent, or fraudulent. Compliance errors that result in the loss of revenue to the U.S. government are penalized based upon a percentage of the loss of revenue in correlation with the importer’s degree of culpability.

Even inaccuracies that do not pose a loss of revenue to the U.S. government, such as statistical errors or omissions, can potentially result in the administering of severe penalties to the importer. Inaccuracies that do not pose a loss of revenue incur culpable penalties based on a percentage of the entered value of the goods.

The typical import duty in America is estimated to be 1.2%; a penalty of half that amount can be imposed for basic-negligent mistakes—as high as 8% for a fraudulent infraction. Nonrevenue infractions—which do not affect the revenue the government would have received—begin at 5% and go to as high as 80% of the entered value of the goods based upon the degree of culpability. Since CBP invariably begins with the maximum penalties for wrongful filings, the actual fine can be quite substantial.

Ideas for Compliance

Here’s what you should consider doing now for your compliance program and the options that could be worth investigating.

1. Look at your customs bond sufficiency.

Importers must have a customs bond—generally 10% of the duties and taxes you expect to pay to CBP for import transactions throughout the year. Customs can shut down all imports if they discover you have an insufficient customs bond. Since tariffs (and duties) are increasing substantially, your bond may no longer be sufficient. Bond insufficiency will negatively impact your ability to conduct business, and will lead to additional costs and delays if not monitored or addressed in a timely manner. Even if you don’t require a new bond now, consider the increased duty amounts well before the bond renewal period comes up. If your bond will need to be significantly higher, the surety company may require additional documentation—including financial statements and possibly letters of credit—before they issue a new customs bond, all of which will take time to get into place.

2. Take advantage of duty drawback programs.

Duty drawback programs refund 99% of certain import duties, taxes, and fees for goods that are subsequently exported; this supports both U.S. manufacturing and foreign export sales.

Previous duties might only have been in the 1% to 2% range, and since there is paperwork to file to get the refund, many companies did not bother with it. Today, those 1.2% duties have jumped up to 25%, and duty drawback programs could be a game changer for your business.

The downside: you have to pay the duties up front, then wait for 1 to 2 years to receive the refund under the current drawback environment, which can become a cash flow issue for some companies (typically, it takes 4 to 6 weeks for a claimant to get paid under the Accelerated Payment program, but until the Drawback Modernization regulations are finalized, Accelerated Payment is suspended).

3. Use free trade zones (FTZs).

FTZs are secure areas located in or near CBP ports of entry under CBP supervision. Unlike duty drawback programs, you don’t have to pay duties when goods enter an FTZ. Instead, FTZs enable duty deferment; the duties are paid when the goods enter CBP territory for domestic consumption. At that point, the importer pays the duties at the rate of either the original foreign materials or the finished product (of course, with Section 301, you would still have to pay the 25% tariff from China when the cargo enters into the zone under Privileged Foreign Status).

4. File for exclusion requests.

If you think your product should be excluded from U.S. tariffs, you can request exclusion. However, be aware this is a painfully slow process at the moment. For example, after the steel and aluminum tariffs on List 1 went into effect, thousands of companies requested exclusions. So far, the Bureau of Industry and Security has approved a small number of exclusions for steel and aluminum; no exclusions have been approved by the U.S. Trade Representative for Section 301 China on List 1 or 2 yet. The U.S. Commerce Department hired 30 people to handle the exclusion requests, however, it will take them time to learn the ropes and process those requests, much less any future exclusion requests. The deadline for submission of List 1 exclusions is October 9; the deadline for List 2 exclusions is December 18. When filing an exclusion, make certain that the classification you are using is the best classification for your product. Also, work with a trade attorney who can help you navigate the law and apply it to your specific product so your exclusion isn’t rejected on a technicality.

5. Consider changing sourcing locations from China to another country.

It’s not always easy to change suppliers, but such are the times we live in that some companies are looking at it. Be aware that suppliers for some materials are only found in China, and even if you locate a source in another country, there can be issues. Can they supply at the level you need? How long will it take to test the new supplier to ensure they can meet your specs? The more complicated your product, the more challenging this process of switching will be. Also, keep in mind that you can’t just change the shipping location. If the cargo ships from Singapore but its origin is China, Section 301 tariffs still apply.

6. Take advantage of Section 321.

Low value entries that have a value of less than $800 are not subject to duties. That doesn’t mean you can break up your shipments to be less than $800 in value. But for certain companies that ship directly to consumers from overseas, this may be a viable option.

7. Consider the impact of your product.

Go back and review the basics of your supply chain. For instance, imagine that you are an importer of lunch bag coolers. There is a big difference in duties for lunch bag coolers that are all soft sided versus those that have a plastic coating. In that instance, the company could plan to import fewer high-duty bags. Likewise, there is a big difference in duties for a T-shirt that is 55% cotton/45% polyester versus a T-shirt that is 45% cotton/55% polyester. Consider how the tariffs will impact your products and your supply chain as a whole.

Not all of these ideas or options will fit or resonate with you or your business. The most important thing you can do right now is discuss the issues with an attorney or expert in customs compliance and learn which elements might be the most useful for you.

 

Copyright Statement

This article was published in the January 2019 issue of Insulation Outlook magazine. Copyright © 2019 National Insulation Association. All rights reserved. The contents of this website and Insulation Outlook magazine may not be reproduced in any means, in whole or in part, without the prior written permission of the publisher and NIA. Any unauthorized duplication is strictly prohibited and would violate NIA’s copyright and may violate other copyright agreements that NIA has with authors and partners. Contact publisher@insulation.org to reprint or reproduce this content.

NIA Sites > Insulation Outlook Magazine > Global

The Opioid Crisis: Waging Battle Against Deadly, Costly Problem

Last year, Pennsylvania Governor Tom Wolf declared opioids a statewide disaster emergency, marking the first time the commonwealth declared a disaster emergency for a public health crisis. The declaration suspends regulations hindering addiction care access, which Wolf hopes will help streamline treatment for the 90 days the declaration is in effect. Seven other states have taken similar steps in declaring the opioid crisis a disaster emergency.

Although the nationwide problem affects people across professions, construction industry workers are particularly prone to opioid addiction. With that in mind, it’s important to understand why opioids are a problem and the safety considerations as they relate to addiction in a high-risk profession. In December, we shared part one of this opioid report, which explored the whys and the safety concerns, as well as what legal and insurance protections are available.

Rather than turn a blind eye to at-risk employees or a worker who might be struggling, though, companies can take preventative measures and offer help—measures can mean the difference in accidents on a jobsite and hefty punitive damages.

Preventing Abuse

Prevention often is the best medicine, and that’s no different when looking at potential opioid abuse. David Pfeffer, Chair of the Construction Practice Group at New York-based law firm Tarter Krinsky & Drogin, has seen companies issue rewards to employees for maintaining safe work environments for themselves and others, and he also knows owners and contractors that hire third-party safety firms to regularly visit a jobsite to check for safety issues.

Another bonus of keeping a safe site—firms with safe work histories often can negotiate better premiums with their insurance carriers.

Jake Morin, Niche President of Construction at ProSight Specialty Insurance in Morristown, New Jersey, noted that some states have drug-free workplace credits for workers’ compensation, which necessitate having certain programs in place with random testing and non-discriminatory-type action. If someone does test positive, companies must look at how they want to address the problem. Some have zero-tolerance policies while unions, especially, offer some sort of rehabilitation program.

Ultimately, Morin said, “Employees on the jobsite with nothing in their systems is the best route, but I know this aging workforce is going to get hurt a little bit more and have more ailments than someone in their 20s. How do we work with them and help them? Talking about it is a first step.”

In 2012, several industry groups teamed to form the Construction Coalition for a Drug- and Alcohol-Free Workplace (CCDAFW). The coalition includes founding organizations Associated Builders and Contractors and The Associated General Contractors of America, and the Construction Industry Round Table, Construction Users Roundtable, Independent Electrical Contractors, and the National Center for Construction Education and Research. CCDAFW aims to establish industry-wide recognition of substance abuse, as well as advocating for implementation of substance abuse policies while providing best practices to work toward a goal of zero substance-abuse-related incidents on jobsites.

More than 5,100 companies and organizations—including general contractors, subcontractors, trade associations, insurance companies, regulatory/government agencies and employee representatives, and unions—have pledged their support to eliminating substance abuse. The pledge states “that my company will take reasonable action to create and maintain a workplace free from substance abuse. My company will work to increase awareness of the dangers of substance abuse within our workplace and throughout the construction industry.”

Drug Testing

The Occupational Safety and Health Administration (OSHA) has formal national standards for scaffolding and crane safety, but Morin thinks OSHA should also be involved in establishing national standards as they pertain to misuse of substances. Because companies work across state lines, the lawyer said, it’s important to have a federal standard in place rather than relying on state standards, which can vary.

Nevertheless, Pfeffer said it’s complicated to implement testing plans because of the sheer volume of individuals from myriad companies coming onto sites. “Some employers do have random testing, but they have not proven to be very useful at diminishing abuses on construction projects over the years,” he said. “It would be practically impossible to have a testing program where workers are coming in and being tested regularly. I don’t think that will fly well with owners who want their buildings done quickly or with the construction workers.”

Exploring Treatment

There are many treatment options available for opioid addicts. One specifically for laborers is from the British Columbia, Canada-based Construction Industry Rehabilitation Plan (CIRP), which was founded in the mid-1980s in response to the drug and alcohol crisis of the period. Although Executive Director Vicky Waldron wasn’t in Canada during that time, she said the construction industry in North America faces similar addiction issues today—mainly, a lack of resources.

“People were looking for help or treatment, and there wasn’t anywhere to send them,” she said.

That’s where CIRP came in. It began as a 12-step program, and Waldron evolved it to worldwide mental health industry standards so that today CIRP works within a harm-reduction framework. Services include individual counseling, as well as an outpatient day program, a residential program, a family program, and a telehealth program, which includes Skype, online support, telephone counseling, and text and instant messaging support.

Waldron emphasized the family program’s importance. “We don’t want to get a person clean only to put them back into a family that might have a lot of dysfunction,” she said. “You want to make sure you work not only with the individuals themselves, but with the family members as well to help them deal with the addiction and help them learn new ways of interacting with one another.”

CIRP began collecting data after Waldron realized there wasn’t a lot of information for the industry from the industry. Its inaugural report last July showed that nearly 83% of those addicted to substances who come through CIRP’s doors screen positive for moderate to severe underlying mental health issues.

More significant than that number, however, according to Waldron, is that most of those mental health problems are undiagnosed. About 90% of CIRP’s clients screen positive for a significant underlying early childhood trauma issue; about 70% of those also screen positive for moderate to severe post-traumatic stress disorder (PTSD).
“We have people that are really presenting with severe mental health and addiction issues,” she said.

Proper Training

Most people who seek treatment through CIRP are 30 to 40 years old. “That tells us we need to see people before they reach that age. For example, if we go in to talk to sheet metal workers, as part of the curriculum we talk about the correlation between mental health and addiction and do education and awareness training.”

Waldron attributes the growing crisis in part to contaminated fentanyl sweeping through the West Coast. “Fentanyl has completely changed the playing field,” she said. “Drugs are so contaminated at the source that we are seeing this huge spike and huge numbers of overdoses. As a result of that, demand for our services has more than doubled in the past year. That is directly related to the fentanyl crisis.”

Waldron has found employers and their staffs to be supportive of those who need help for substance abuse. “Nobody wants to lose a human life,” she said.

Although there is some concern that providing resources might be perceived as endorsing use, she said that the opposite is true—it saves lives.

“The mental health and addiction conversation needs to happen in the industry,” she said. “It’s a conversation that’s not always easy, especially when we have an industry that is so safety critical. It’s a very complicated conversation, but certainly we are starting to raise the topic. Employers have embraced training and that’s a very positive thing.”

 

Copyright Statement

This article was published in the January 2019 issue of Insulation Outlook magazine. Copyright © 2019 National Insulation Association. All rights reserved. The contents of this website and Insulation Outlook magazine may not be reproduced in any means, in whole or in part, without the prior written permission of the publisher and NIA. Any unauthorized duplication is strictly prohibited and would violate NIA’s copyright and may violate other copyright agreements that NIA has with authors and partners. Contact publisher@insulation.org to reprint or reproduce this content.