Phenolic Insulation Board HVAC Panel

Phenolic foam air duct panels are widely used in central air conditioning ventilation system. Compared with the traditional air ducts, phenolic foam compound panels have the features of better insulation effect, noise elimination, light weight, long using life, extensive application,etc.

Specifications:

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Features: 
1. Excellent fire performance: Phenolic insulation board is not combustible in case of fire, and its combustion performance is up to grade A, and is capable of resisting high temperature of 180ºC (instantaneously 250ºC). The flame resistance ability of 100 mm thick phenolic foam can reach more than 1 hour without being penetrated. Under the direct action of the flame, only a carbonization layer appears on phenolic board, no drop, no deformation, no melting phenomenon. After the flame burning, its surface can form a layer of "graphite foam", effectively protect the foam structure within the board.
 

2. Excellent thermal insulation performance: low heat conductivity (<0.025W/m·K, much better than polystyrene, similar to polyurethane), good in heat preservation and heat insulation.
 

3. Corrosion resistance and aging resistance: can resist the erosion of inorganic acid, organic acid, organic solvent, no obvious aging phenomenon appears under long-term exposure to the sun. So it has good aging resistance.

4. Small density, light weight: phenolic insulation board's density is less than 100 kg/m3, about 50 kg/m3 or so. It can reduce the dead weight of the building, reduce the load of the building, reduce the structure cost of the structure, and features of simple and fast construction, and high work efficiency.

5. Sound absorption performance: phenolic insulation board has excellent sound absorption performance, and its closed cell foam structure is more conducive to sound resistance;6. Environmental protection: phenolic insulation board adopts non-fluorine foaming technology, no fiber, in line with the national and international environmental protection requirements.


 

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There are so many excellent choices for non-toxic, healthy, green insulation, there should be one to fit everyone’s needs.

Look Out For Greenwashing

There are many new options that claim to be “green” “soy-based” or are formaldehyde-free – this does not mean that they are VOC-free or safe.

Look very closely at what’s in it.

Also, flame retardants and mildewcides are not counted as VOCs.

Green Certified?

Certifications are not that useful here: almost every insulation now qualifies as GreenGuard Gold, which for sensitive folks is not enough information.

This article contains affiliate links, upon purchase I earn a commission at no extra cost to you.

Summary:

Batt Insulation for Walls

1. Fiberglass Insulation

Fiberglass is the most common insulation used in standard stick-framed houses in Canada and the US. For this reason, I am starting here.

It’s not actually my top pick in the batt category because it’s not a compression fit into the walls, and therefore may not guard against air currents as well as mineral wool and some other options.

You can use it between wood studs of a house, between floor joists, and in the attic.

It is used in many trailers, but I don’t recommend that.

This option has improved dramatically in recent years, and the many of the batt brands are now extremely low in VOCs.

Formaldehyde-Free Fiberglass Brands:

1. Knauf EcoBatt – They are formaldehyde-free and they use a starch-based binder listed on their Declare label. Other ingredients include ammonium sulfate (fire retardant), mineral oil (dedusting), and silane.

More brands in the book.

Are there Flame Retardants in Fiberglass?

Knauf lists ammonium sulfate which is used as a flame retardant, Owens Corning lists no flame retardant, Certainteed doesn’t list a flame retardant but they do have an undisclosed additive.

Blown-In Fiberglass

Blown-in fiberglass that I have looked at recently contains borates, soda ash, lime, siloxanes/silicates/silane, mineral oil, and an unknown anti-static additive.

Fiberglass Insulation Around Pipes

The fiberglass insulation for around pipes that I have seen is also formaldehyde-free.

• R-Value
  • 3.5 inches is R-11-R-15.
• Cost USD ()
  • Knaff Ecobatt is 0.49/sq ft and you can buy it at Home Depot or through your contractor.

2. Mineral Wool Insulation

Mineral wool is in widespread use by builders who build green or high-quality homes and it is the most obvious alternative to fiberglass.

It is also easy to source.

Pros:

• The batts can be used between wood studs anywhere in the house.
• It’s very good at staying in place with compression fitting, so it fits well between framing.
• It fits and holds up well in ceiling joists.
• Blown in mineral wool can be used in the attic floors.
• It can be used on basement walls.

Non-Toxic Mineral Wool Brands

1. Rockwool is the most common and accessible mineral wool insulation.

They have a newer version, called AFB evo, that does not contain formaldehyde. The binder appears to be starch-based. It also contains mineral oil.

It’s much harder to source than their standard batts.

Rockwool ComfortBatt is the type for perimeter exterior walls, Safe N Sound, their soundproofing version is for interior walls, and ComfortBoard is exterior insulation (outside of the sheathing).

All three contain the same binders/additives: <3% phenol-formaldehyde, <1% starch, and <0.2% mineral oil source.

I look closer at the metals found in Rockwool in my book.

They have a blown-in option, though it’s not available in North America in late .

2. Thermafiber by Owens Corning is a brand that has a regular phenol-formaldehyde line and a formaldehyde-free line (you will see the letters FF), the latter usually has to be special ordered through a store.

A blown-in option is mentioned in the book.

Other Info

An easy way to cut through mineral wool is with an electric carving knife.

This insulation has good soundproofing qualities. The Safe N Sound version can be used on interior walls for soundproofing between rooms.

The fibers are not safe to breathe in and can cause a contact allergy if you are not using gloves.

• R-Value
  • 3.5 inches is R-15.
• Cost USD () 
  • $0.95/ sq ft for Rockwool (Comfortbatt, 3.5 inch)
• Where to Buy
  •  Rockwool and Thermafiber at hardware stores across the US and Canada, or through your contractor.

3. Wool Batt (and Blow-In) Insulation

Wool batting can be used between wood-framed walls and in the attic floor.

It’s more expensive than fiberglass and mineral wool above.

Top Brands of Wool Insulation

1. Havelock Wool has no synthetic fibers and no binders. It’s only wool and boric acid. They provide a Declare Label for all of their ingredients. This is the purest of the wool options (and one of the most natural insulation types all around).

You can buy it online which makes it the most accessible wool brand.

Borates are low-toxicity compounds, explains Dr. Mudgal, Toxicologist, but can cause irritation or harm if inhaled or ingested in large amounts. The risk is negligible once the material is installed and enclosed, as exposure pathways are blocked, she says.

More brands in the book.

Blown-in Wool Insulation

While none of them claim organic certification, wool is one of the purest options.

Borates are low-toxicity compounds, explains Dr. Mudgal, Toxicologist, but can cause irritation or harm if inhaled or ingested in large amounts.

The risk is negligible once the material is installed and enclosed, as exposure pathways are blocked, she says.

• R-Value
  • Wool in batts has R-13.7 in 3.5 inches
    Blow in dense-pack R-value: can be 15.3 in 3.5 inches
• Cost USD ()
  • Havelock Loose Fill is $1.97/sq ft
    Havelock Batts is $1.62/sq ft
• Where to Buy
  • Buy through local green building supply shops or buy Havelock online.

4. Recycled Cotton Batt

Ultratouch Insulation is what my builder used in my chemical-free tiny home (I later removed it).

It used to be made from new denim scraps, but they have moved to recycled denim now.

It does contain boric and ammonium sulfate and an olefin-binding fiber (polypropylene or polyethylene).

My opinion on this insulation can be found in the book on healthy building materials.

• Other Info
  • Wear an N95 mask while cutting and installing as it does get extremely dusty when working with it.
• R-Value 
  • For the 3.5” thickness, you get an R-value of 13
• Cost USD () 
  • $0.79/sq ft
• Where to Buy
  • Check online stores, it’s no longer listed on Home Depot or Lowes websites.

5. Hemp Insulation

Hemp insulation is the newest alternative insulation in the North American market.

It’s been used for much longer in Europe.

I think it is very promising.

It’s harder to source and more expensive than some of the other options in this category, but it could be really great for someone who wants something mostly natural and who hasn’t done well with the other options above.

Brands

HempWool is 90% hemp and 10% polyester. Order from Hempitecture.

More brands in the book.

Companies have been coming and going out of business rapidly in the hemp insulation industry.

Sodium carbonate (soda ash) can be used as a flame retardant.

Ask them what they add to it, apart from hemp: alternate fibers, binders, flame retardants, and if it’s organic. And always test a sample first! Note that Polyester is not biodegradable.

• R-Value
  • It is R-13 for 3.5 inches
    
• Where to Buy
  • Contact the companies on where to source it.

Blown-In Insulation

1. Cellulose

Recycled cellulose is a blown-in insulation made from mostly recycled paper that contains a fire-repellent like boric acid.

Newspapers are made with “soy-based” inks but they still contain many other chemicals in the inks apart from soy, plus many other paper sources are used now.

There are also additional additives in the insulation.

Dense-packed cellulose is often used in Passive House design, which has great attention to details around moisture management and green healthy materials.

It is used in both walls and attics.

Safe Brands of Cellulose Insulation

1. GreenFiber brand from Lowes and Home Depot is 85% recycled paper. They have a Declare Label which lists boric acid, sodium pentaborate pentahydrate, ammonium sulfate, mineral oil, monoammonium phosphate, calcium carbonate, and corn starch.

A closer look at the brands and what’s in them can be found in the book.

• R-Value 
  • 13.3 for 3.5 inches
• Cost USD ()
  • $0.32/sq ft

2. AirKrete Cementitious Insulation

AirKrete is a cementitious blown-in insulation that claims to be VOC-free.

It has passed the “sleep next to it test” of many chemically sensitive people.

The company, however, has declined to participate in the industry-standard VOC test as well as the proper R-value test last I checked, so there is some doubt around this product’s claims.

We don’t know what the undisclosed 2% of this product’s ingredients are, but many with severe chemical sensitivities have chosen to go with this option and have done well with it.

Some people have reported shrinking, crumbling, and trouble drying. Here is the source for the concerns.

Paula Baker-Laporte continues to recommend this insulation, so I’m assuming that many are still doing well with it.

It can be used in walls and roofs. (Consult with an architect when designing an unvented roof).

Non-organic options like AirKrete are more likely to be hypoallergenic.

I would not use this insulation myself.

• R-Value
  • R-13 for 3.5 inches
• Cost USD
  • Around $2.25/sq ft including installation costs
• Where to Source
  • You would have to check to see if you have a certified installer in your area before proceeding.

3. Real Wool, Mineral Wool, and Fiberglass Blown-In

These three insulation types can be blown in as well. Fiberglass (pictured) is the most common blown-in insulation, followed by cellulose.

Mineral wool and real wool blown-in are less common but are healthier choices.

Brand names can be found in those respective sections above.

Exterior Insulation for Houses 

1. Styrofoam/Rigid Foam

i. Polyisocyanurate “Polyiso” Foam Board Insulation

Polyiso is one of the insulation types that is used on the exterior side of sheathing.

Typical current blowing agents for polyiso are CO2 and pentane.

There is some “thermal drift”, meaning the blowing agents off-gas over time. The off-gassing is extremely minimal.

It can be used in trailers and metal structures as well. It’s not to be used under slabs.

Flame retardants are a bigger concern than trace pentane. The most common flame retardant is TCPP.

Dr Mudgal, Toxicologist explains “TCPP has documented high toxicity for reproductive and developmental health. It is now classified under REACH regulations as a Category 2 carcinogen (it is suspected of causing cancer based on animal studies or other evidence). It is also persistent in the environment. The aquatic toxicity is moderate, but it varies by concentration and exposure time.”

It’s best to look for brands that don’t use a halogenated flame retardant like TCPP. Newer and safer flame retardants are non-halogenated phosphorus-based.

Though the foil does block the FR, the edges are unsealed and it will never be perfect.

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Brands of Polyiso Foam Insulation

1. Johns Manville Foil Faced Polyiso has been the most popular brand among those who are sensitive, but they have discontinued Energy 3E, which was the one made without TCPP (all they have said is that it is phosphorus-based and is non-halogenated).

3. ZIP System R-Sheathing is the Huber Zip OSB sheathing, polyiso, and weather-resistant barrier all in one. Though you can use the above two brands as exterior insulation on the outside of the plywood or OSB, “ZIP-R”, as this type is normally called, is integrated with the sheathing, with the polyiso on the interior side. The flame retardant is TCPP.

My top brand is in my book.

2. GAF polyiso EnergyGuard-NH uses a halogen-free flame retardant (which is phosphorus-based, like the Energy 3E FR was). “Unlike TCPP, the flame retardant becomes part of the polymer backbone of the insulation—so there is no free flame retardant that can leach out”, according to GAF’s director of sustainability Martin Grohman. “TCPP, by contrast, is not chemically bonded to the polyiso polymer, so it can more readily escape.” Source

• R-Value 
  • Technically it’s R-6/ inch but it’s really about R-5.6/inch over its lifespan because it loses R-Value over time. It also loses R-value the colder it gets.
• Cost by R-Value (R6)
  • R-6 is $0.60 / sq ft

ii. Extruded Polystyrene (XPS)

XPS (extruded polystyrene) is another common exterior insulation outbound of the sheathing.

It is also used on exterior concrete basement walls, underneath the slab, and in trailers.

XPS, like polyiso, has some “thermal drift” i.e. some very slow off-gassing of the blowing agents over time. “Over a long period of time (50 to 75 years), the blowing agent slowly diffuses through the thickness of the foam” (source).

Typical blowing agents for XPS are CFC-12, HCFC-142b, and HFC-134a, but they change their formulas over time.

HFCs contribute to global warming.

Changes started January 1st, . Eleven states have banned foams blown with HFC-134a and other high-GWP blowing agents, including HFC-245fa as of January 1st, .

A ban on high-GWP blowing agents also went into effect in Canada on Jan. 1, . Canada did not ban HFC-134a but created maximum GWP for foam blowing agents.

Ownings Corning doesn’t use HFC-134a (GWP of ) anymore, they now uses a hydrofluoroolefin (HFO) blowing agent with a GWP of less than 80. And DuPont now offers a reduced GWP foam available in Canada and HFC-regulated U.S. states. The blowing agent is not disclosed. They say that the GWP was reduced by 20%+ (source, source, source).

XPS insulation was treated with the flame retardant hexabromocyclododecane (HBCD) until recently.

The two main brands no longer contain HBCD.

They are now using a butadiene styrene brominated copolymer as the flame retardant (source), this flame retardants is less bioavailable and has a lower toxicity profile, though its long-term effects are still being studied, says Dr. Mudgal, toxicologist. 

• R-Value
  • R-5/inch
• Cost by R-Value
  • R-5 is 0.60/ sq ft

2. Mineral Wool Board 

The other common and easy-to-source exterior insulation used in the US and Canada is Rockwool, in board form.

Rockwool Comfortboard is being used more and more as many codes across the US have shifted to requiring exterior insulation.

There are no flame retardants in Comfortboard and while it does contain formaldehyde this will be fairly quick to off-gas.

Foam and Rockwool will be the two main exterior insulation types to consider since they will be familiar to builders and easy to source.

The boards can also be used on interior basement walls. They are also used under the slab.

• R-Value 
  • R-4/inch
• Cost by R-Value (R6)
  • R-6 is $1. 24 sq ft

3. Cork

Thermacork insulation, unlike cork flooring, does not contain adhesives. It is held together by compressing it with heat which releases a natural binder in the cork.

The cork does give off a smoky smell that dissipates with time, as well as the natural odor of cork.

This is a newer product in North America and is more expensive than the more conventional options.

It can be used as exterior insulation or even the facade of a house which serves the purpose of siding, insulation, and noise reduction.

See this post as an example of cork used as the facade.

• R-Value
  • R-4/inch
• Cost by R-Value (R8)
  • R-8 (doesn’t come in R-6) it’s $4.93/sq ft for the insulation type (rougher than the facade)
    R-8 in the facade grade, which covers your exterior insulation and your siding in one, is 10.77/sq ft
• Where to Buy
  • You can buy this through green building supply stores.

4. Wood Fiberboard Insulation

Wood fiberboard is often used in High Performance/Passive House designs as exterior insulation. It can be used closer to the interior as well.

One popular brand in North America is Gutex. It is 95% wood (spruce/fir, post-industrial, recycled, and new wood), 4% polyurethane, and about 1% paraffin. The total VOC level is 187 μg/m3.

• R-Value
  • R-3.7/inch
• Cost
  • R 5.8 is $1.81/sq ft
• Where to Source
  • You can buy this through 475.

Under the Slab Insulation

The most typical insulation for under the slab is XPS foam board. EPS foam board is sometimes used, both are mentioned above.

You can also use Rockwool Comfortboard under the slab, though it’s more common in Europe.

Glass Foam Blocks

One other unique insulation type for under the slab is foamed glass that comes in panels or chunks.

It is made by heating a mixture of crushed or granulated glass and a blowing agent (chemical foaming agent) such as carbon or limestone.

There is no need for flame retardants or other hazardous chemicals.

This has been used in Europe much longer than in the US.

This is what I would personally use under a slab.

I write more about this in the book.

Insulation Typically Used in Trailers, RVs, and Vans

1. Rigid Foam

EPS (Expanded Polystyrene aka Styrofoam)

EPS (expanded polystyrene) is often used in trailers and can be referred to as “block foam” by the companies.

It can also be used as exterior insulation, insulation over concrete basement walls on the interior, and under the slab. Though you are far more likely to see the XPS type of styrofoam under a slab.

Blowing Agents

EPS usually is made with pentane as a blowing agent, the final product has trace amounts of pentane which dissipates rather quickly and completely. Some butane can also be used as a blowing agent.

Sometimes the only blowing agent is carbon dioxide (based on DOW xnergy Declare label).

Zero-VOC

EPS, despite the name (polystyrene), does not off-gas styrene under normal conditions.

I have seen it listed as 0-VOC or very low VOC (with one SDS sheet listing 1.8% pentane, though that dissipates quickly).

What about Styrene?

The concerns over polystyrene (styrofoam) and styrene come from the following a) chemicals released during the manufacturing of the product b) the product is very toxic if you burn it and c) the styrene can leach if you drink beverages especially hot or acidic beverages out of styrofoam cups.

This is a very old product with a long track record. Here are a couple of links to back up the claims.

In the form of insulation, I would consider this product to be non-toxic, zero-VOC, odorless, and stable, with the only risk being the flame retardants.

Flame Retardants

EPS used to be treated with hexabromocyclododecane (HBCD), but luckily it no longer is. Polymeric FR (a copolymer of polystyrene and brominated polybutadiene) is now the most common FR.

The foil faces on these insulations block the flame retardants. However, the foil and plastic-backed versions can have some off-gassing odor. Some EPS is not backed with anything.

If using EPS in a living space I would recommend borate-treated foam to prevent ants from tunneling in.

R-14 for 3.4 inches EPS.

2. Reflectix and Prodex Insulation

Reflectix is a bubble foil made of aluminum over polyethylene bubble wrap.

It is flexible, very thin, and claims to have a very high R-value. The thicker version claims R-21 (which is higher than 5 inches of wool).

These claims are disputed by Green Building Advisor and the Government of Canada. The former states that the 3/8th-inch foil has an R-value of only 1 (the same as a single pane of glass).

This would hardly be useful anywhere unless it is in a curved trailer, RV, or vehicle where all other options have been ruled out. Sometimes it’s just used to insulate windows, which can be a great help.

Prodex is another similar material – foil and polyethylene-based – that also has a disputed R-value.

3. Aerogel Insulation

Aerogel is a fairly new product – unusual, extremely expensive, and harder to source.

The term itself can refer to a variety of materials from the original silica translucent product to polymer-based products that may include the addition of fibers.

The original Aerogel insulation was developed by NASA.

Aspen Aerogel collaborated with NASA to make their polymer-enhanced aerogel combined with fibers.

Some companies are selling insulation online that they claim is Aerogel. I would look closely at what’s really in it. Look for proper studies on the R-value of it.

They claim an extremely high R-value of R-10 to R-30 per inch.

This may be ideal for small, round, and difficult to insulate places, if you can source it.

4. Thinsulate Insulation

3M Thinsulate is an insulation used in vans, other vehicles, and RVs.

It is made of polyethylene terephthalate (a type of polyester) and polypropylene fibers which will be tolerable for most people. The backing is polypropylene.

One percent or less of the additives are proprietary and therefore unlisted. The health rating is 0 which is good.

What I don’t love about using this product in vehicles is that the insulation itself is vapor permeable and it is attached to the walls with 3M 90 Spray (GreenGuard certified, not GreenGuard Gold, not reported to be very tolerable by many chemically sensitive people).

R-value

5.2 for the 1.65-inch

NB. I have seen similar but more unusual insulation made from polyethylene and polyester for homes in batts. (It is more popular in some countries outside of North America.) It may be tolerable for sensitive folks depending on what is added to it.

5. Vacuum Insulation Panels 

Vacuum Insulation Panels have the highest insulation value of any of the insulation materials.

These Panasonic panels have an R-value of R-60 per inch. They were used in the latest Leaf House design (tiny house). This could allow you to build a tiny house for almost any climate. Though this introduces a tricky metallic vapor barrier which needs to be carefully thought out.

The foil vacuum pack will block any VOCs from migrating through, but your moisture management system would have to be planned carefully here.

These won’t work in most houses. You might consider them in some trailers or metal-framed homes.

They are very pricey and harder to source than almost all of the other options.

6. Non-Toxic Spray Foam Insulation?

Spray foam that is used to fill cavities of walls is two-part polyurethane. Some of it may have soy added, but it’s still mostly polyurethane foam.

This insulation has to be mixed perfectly, under the right conditions (there are many), and applied correctly.

When looking for a good spray foam you are looking for an excellent installer (the best one you can find) and not a specific brand.

The companies have claimed that it is no VOC, or close to that once cured, but many individual tests and many individual noses of those sensitive have shown otherwise.

I know moderately sensitive folks who have looked at many houses with spray foam and been able to pick up the odor for two years.

And that’s when it’s done right. When it’s done wrong it’s a massive disaster that can end in a lawsuit against the company, plus an expensive imperfect removal of all the foam.

If you are extremely sensitive you would lose the whole house if this goes wrong, as the VOCs will soak up into other materials. This has happened to two of my clients.

Brands:

Icynene and Demilic are both 2-part polyurethane spray foam.

Whether they have soy or castor oils in them is insignificant in my overall view.

Icynene OC No Mix is still a 2-part polyurethane foam and although it appears to mix in the gun, the installation still has to meet all of the other parameters.

One-part polyurethane:

One-part polyurethane, which is the canned stuff discussed below, is much easier to tolerate, it’s used in small quantities, and it doesn’t have the same challenges and risks as the 2-part foam.

Insulating Around Windows and Doors – Non-Toxic Options

Non-toxic insulation for the rough opening around windows that is mold preventative is in the book.

Corinne Segura is an InterNACHI-certified Healthy Homes Inspector with certifications in Building Biology, Healthier Materials and Sustainable Buildings, and more. She has 10 years of experience helping others create healthy homes. You can book a consult here.

Contact us to discuss your requirements of tunnel phenolic foam board(tr,uk,es). Our experienced sales team can help you identify the options that best suit your needs.