Our goal is to provide the highest quality materials at affordable prices!

Polyiso is the best insulation money can buy. 

this page is to help you understand why.

How is Polyiso Made?

Manufacturing Process of Polyiso Insulation Products

Polyiso insulation is produced in manufacturing facilities across North America by PIMA member companies. While specific operations may vary by manufacturer, the general production process follows these key steps:

Manufacturing Process Overview

1. Raw Material Unloading & Storage

  • Raw materials are delivered via bulk shipments, such as rail cars or large totes.
  • Materials are unloaded and stored in on-site tanks or totes for processing.

2. Facer Unwind

  • Rolls of facer material are loaded onto the lamination line.
  • Two layers of facer material are unwound and fed into the laminator, forming the top and bottom surfaces of the final product.

3. Compounding

  • Raw materials are blended and heated to create the polyol (B-side) component of the formulation.
  • Isocyanate (A-side) components are separately heated and transferred for mixing.

4. Mixing & Pouring

  • The A-side and B-side components are combined with a blowing agent in the mixing head.
  • The mixture is applied onto the bottom facer layer, initiating the chemical reaction.
  • The top facer layer is introduced as the material enters the laminator.

5. Laminator Process

  • The chemical reaction converts the liquid mixture into a rigid foam core.
  • The laminator controls thickness, cell formation, curing, and facer adhesion.
  • Adjustments can be made to create tapered boards for specific applications.

6. Trimming & Cutting

  • After exiting the laminator, the continuous foam board is trimmed and cut to the desired dimensions using cross-cut and gang saws.

7. Stacking & Initial Quality Check

  • A conveyor moves the cut boards to a robotic stacker.
  • A preliminary quality check is performed as boards are bundled together.

8. Packaging

  • Stacked bundles are transferred to a hooding machine, where they are securely wrapped in plastic film for storage and transport.

9. Warehousing & Final Curing

  • Product identification labels are applied to each bundle.
  • Bundles are moved to warehouse storage, where the boards complete the curing process.

10. Quality Assurance & Control

  Samples undergo rigorous quality assurance testing, including:

  • Initial R-value verification
  • Compressive strength analysis
  • Dimensional stability checks

11. Loading & Shipping

  • Once approved through QA/QC, bundles are transported to the loading dock.
  • Products are loaded onto flatbed trucks and secured for delivery to job sites or distribution centers.


Why Choose Polyiso?

Summary of Polyiso Benefits and Attributes:

Polyiso insulation offers a range of advantages across various domains:

  1. Energy Efficiency:
  • High R-value per inch compared to alternative insulation materials.
  • Enables thinner wall assemblies, reducing material use and associated costs.
  • Contributes to energy savings potential up to 47 times the product’s embodied energy.
  1. Fire Performance:
  • Inherent fire resistance due to unique chemical bonds.
  • Thermoset material that withstands flame exposure without melting or dripping (ASTM E84).
  • Reduces the risk of fire-related incidents.
  1. Environmental:
  • Contains blowing agents with zero ozone depletion potential (ODP) and low global warming potential (GWP).
  • Recyclable where permitted and incorporates recycled content (varies by product).
  • Industry-wide Environmental Product Declaration reports available.
  1. Ease of Use:
  • Lightweight and easy-to-cut boards reduce labor costs and installation time.
  • Compatible with various roof and wall coverings, adhesives, and attachment systems.
  • Offers direct-to-deck attachment option for steel deck roofs (FM 4450/UL 1256).
  1. Economic:
  • Meets current code-required R-values without the need for additional layers or thicker assemblies, minimizing costs.
  • Available in a variety of thicknesses and dimensions to suit different project needs.
  • Reduces the potential for problems associated with air and moisture intrusion, contributing to long-term cost savings.
  1. Other Attributes:
  • Published Long-Term Thermal Resistance (LTTR) values for roof insulation products.
  • Third-party testing approvals for a wide range of assemblies and applications.
  • Versatile insulation solution for NFPA 285-compliant wall assemblies.
  • Reduces thermal bridges in roofs and walls compared to cavity insulation alone.
  • Contributes to overall assembly durability and long service life.
  • Offers continuous insulation solution for the entire building envelope.
  • Wall insulation can replace the need for separate air and water barrier products.
  • HD cover boards protect the investment and may reduce maintenance costs.
  • Regionally available through a nationwide network of manufacturing plants.


History of Polyiso

Polyisocyanurate (polyiso) insulation emerged in the late 1970s, a time when its production involved chlorofluorocarbons (CFCs), notably CFC-11, as blowing agents. However, concerns arose globally about Ozone Damaging Substances (ODS), fearing their impact on the ozone layer, which shields us from harmful UV radiation. In 1985, the Vienna Convention addressed this, leading to the 1987 Montreal Protocol, aiming to phase out ODS production. By 1996, CFC production ceased in developed nations, and thanks to such efforts, ozone layer recovery is projected by the mid-21st century.

For polyiso and the roofing industry, this posed challenges, leading to the formation of the Polyisocyanurate Insulation Manufacturers Association (PIMA) in a collaborative effort to find CFC alternatives. Transitioning away from ozone-depleting substances became a priority, and by 2002, the industry embraced non-ozone depleting alternatives.

Benefits and Uses:

Polyiso became a favored choice in commercial roofing insulation and building envelopes, offering numerous advantages:

  • High R-value per inch, making it efficient in commercial construction.
  • Cost-effectiveness, achieving required R-values while minimizing space, material, and labor costs.
  • Strong fire performance, especially evident in products like IKOThermTM III.
  • User-friendly, with a wide range of tested, approved, and code-compliant applications.
  • Stable across temperatures (-100°F to +250°F), suitable for various roof systems.
  • High compressive strength, low water absorption, and vapor transmission, ensuring durability.
  • Compatible with most construction adhesives, facilitating ease of installation.

Polyiso in Roofing:

Polyiso is widely used in low slope commercial roofing, offering versatility across modified bitumen, built-up, or single-ply roofing systems. Its features, including high strength facers and thermal properties, make it ideal for reducing heating and cooling costs. With continuous improvements, polyiso boasts extensive code approvals and remains the sole foam plastic insulation approved for direct application to steel decks without a thermal barrier. Additionally, it excels in fire performance tests, ensuring safety and reliability in roofing applications.

How can polyiso be used?

Polyisocyanurate (polyiso) insulation is a versatile material with a wide range of potential uses in various applications. Some of the common uses for polyiso include:

  1. Commercial Roofing Insulation: Polyiso is widely used as insulation for low-slope commercial roofs. It provides excellent thermal resistance, helping to reduce heating and cooling costs in buildings.
  2. Residential Roofing Insulation: Polyiso can also be used in residential roofing applications, providing effective insulation for pitched or sloped roofs.
  3. Wall Sheathing: Polyiso can serve as insulation for exterior walls, helping to improve energy efficiency and thermal comfort in buildings.
  4. Building Envelope Insulation: Polyiso can be used as part of the building envelope insulation system to provide thermal insulation and air barrier properties, enhancing the overall energy performance of a structure.
  5. Under Concrete Slabs: Polyiso insulation boards can be installed under concrete slabs to provide thermal insulation and moisture resistance in below-grade applications.
  6. Cavity Wall Insulation: Polyiso insulation can be installed within cavity walls to enhance thermal performance and reduce heat loss or gain through exterior walls.
  7. Pipe and Duct Insulation: Polyiso insulation can be used to insulate pipes and ducts in HVAC systems, helping to prevent heat loss or gain and improve system efficiency.
  8. Cold Storage Facilities: Polyiso insulation is suitable for use in cold storage facilities, helping to maintain consistent temperatures and reduce energy consumption.
  9. Industrial Applications: Polyiso insulation can be used in various industrial applications where thermal insulation is required, such as refrigeration units, tanks, and equipment enclosures.
  10. Transportation: Polyiso insulation panels can be used in the construction of refrigerated trucks, trailers, and shipping containers to maintain temperature control during transport of temperature-sensitive goods.
  11. Acoustic Insulation: In addition to thermal insulation, polyiso can also provide acoustic insulation benefits, reducing noise transmission between interior and exterior spaces.
  12. Green Building Projects: Polyiso insulation is often used in green building projects due to its energy efficiency properties and environmentally friendly manufacturing processes.

Overall, polyiso insulation offers versatility, durability, and excellent thermal performance, making it a preferred choice for a wide range of building and construction applications.

How is Polyiso Installed?

Certainly! There are several methods for installing polyisocyanurate (polyiso) insulation, depending on the specific application and requirements of the project. Here are some common installation methods:

  1. Mechanical Attachment: In this method, polyiso insulation boards are mechanically fastened to the substrate (such as roof deck or wall sheathing) using screws or nails. The fasteners penetrate through the insulation into the substrate to secure the insulation in place. Mechanical attachment is often used in roofing and wall applications where additional strength and stability are needed.
  2. Adhesive Attachment: Polyiso insulation can be adhered directly to the substrate using compatible construction adhesives. Adhesive attachment is a popular method for installing insulation in roofing and wall systems, providing a strong bond between the insulation and the substrate. It is particularly useful for irregular or uneven surfaces where mechanical attachment may be challenging.
  3. Ballasted Roofing System: In a ballasted roofing system, polyiso insulation boards are loose-laid on the roof deck and then covered with a ballast material such as gravel, pavers, or concrete tiles. The weight of the ballast holds the insulation in place and provides additional wind uplift resistance. Ballasted roofing systems are commonly used in commercial roofing applications.
  4. Fully Adhered Roofing System: In a fully adhered roofing system, polyiso insulation boards are adhered directly to the roof deck using a compatible adhesive. The roofing membrane is then fully adhered to the top surface of the insulation. Fully adhered roofing systems provide excellent wind uplift resistance and waterproofing, making them suitable for high-wind and low-slope roof applications.
  5. Hybrid Systems: Hybrid installation methods combine multiple techniques, such as mechanical attachment and adhesive attachment, to achieve specific performance requirements or address project constraints. For example, a hybrid roofing system may use mechanical attachment around the perimeter of the roof and adhesive attachment in the field of the roof.
  6. Roof Recover Installation: In roof recover applications, new polyiso insulation is installed over an existing roofing system without removing the old roof membrane. The insulation is typically mechanically attached or adhered to the existing roof surface, providing additional insulation and extending the life of the roof.
  7. Continuous Insulation: Polyiso insulation can also be used as continuous insulation in building envelope applications, where it is installed continuously across exterior walls or roofs to provide thermal insulation and air barrier properties. Continuous insulation helps to reduce thermal bridging and improve energy efficiency in buildings.

These are some of the main methods for installing polyiso insulation, each offering its own benefits and suitability for different applications. The choice of installation method will depend on factors such as project requirements, building codes, and environmental conditions. It's important to follow manufacturer recommendations and industry best practices when installing polyiso insulation to ensure proper performance and durability.


Where can I learn more?


Go to www.polyiso.org.