QUALITY CONTROL MANUAL


Jan 3, 2012 - ...

16 downloads 256 Views 4MB Size

TABLE OF CONTENTS SECTION

Part I 1.0 1.1 1.2 Figure 1.1 Figure 1.2

1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.1 Appendix – I Figure A1-2.0 Figure A1-2.0A A1-1.0 A1-1.1 A1-1.2 Table A1-A A1-1.3 A1-1.4 A1-1.5 A1-1.6

Figure A1-2.1 Table A1-B

TITLE

PAGE

Statement Quality Control Title Page Scope Quality Assurance Organization Organizational Chart Responsibility and Authority 1.2.1 Authority 1.2.2 Qualifications 1.2.3 Personnel Changes Administration Process and Documentation Receiving Inspection In-Process Inspection 1.6.1 Third-Party Inspection Discrepant Product 1.7.1 Recycled Materials Product Marking Manual Revisions List of Process Equipment Calibration and Frequency of Test Equipment Plant-Specific Information Plant Location Plant Layout Process Receiving Pre-Expansion Approved Raw Material Suppliers Molding Storage / Curing Cutting Marking and Packaging A1-1.6.1 IEG and EIFS Boards A1-1.6.2 Types I, VIII, II, and IX Boards A1-1.6.3 Bundles Process Flow List of Process Equipment i

1 2 3 3 3 4 5 7 7 7 7 8 8 8 9 9 9 9 9 9 9 10 11 12 13 13 13 14 15 15 15 15 15 15 15 16 17 Issued 7/92 Rev. 8/03

SECTION A1-2.0 A1-2.1 A1-2.2 A1-2.3 A1-2.4 A1-2.5

Figure A1-2.3 Form 2.0 Form 2.1 Form 2.2 Form 2.3 A1-3.0 A1-3.1 A1-3.2 A1-3.3 A1-4.0 Form 3.2 (I-4.10C) Appendix II

Figure A2-1.1 Figure A2-1.2

A2-1.0 A2-2.0

TITLE

PAGE

Inspections Receiving Pre-Expansion Block Molding Wire Cutting Marking and Packaging A. IEG Boards B. Types I, VIII, II, and IX C. R-TECH Test Sample Selection Batch I.D. Log Expansion Report Daily Block Molding Cutting Report Tests Density Flexural Small Scale Burn Test Dimensional Tolerance QA Test Report Product Performance Standards Type I Certified/Code Listed IEG Type I Certified/Code Listed Type I Certified/Code Listed Premier Panel Core Type VIII Certified/Code Listed Type II Certified/Code Listed Type IX Certified/Code Listed Type IX Certified/Code Listed Premier Panels Marking Diagram – PII-1 Marking Diagram – PII-1 Marking Diagram – PII-5 Type I - Certified Type VIII - Certified Type II - Certified Type IX - Certified Major and Minor Defects Test Instructions Small Scale Burn Test ii

18 18 18 18 18 19 19 19 19 20 21 22 24 25 26 26 26 26 26 27 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Issued 7/92 Rev. 8/03

SECTION

TITLE

PAGE

A2-3.0 Figure A2-4.2 Appendix III Chart A3-1.0 Appendix IV Appendix V

Flexural Test Flexural Test Apparatus EPS RCM Process Procedure Recycled EPS Process Procedural Path R-TECH Manufacturing/QC Procedures Poly-Gard 136 Tape

47 48 49 51 52 63

Part II

QAA Procedure

69

iii

Issued 7/92 Rev. 8/03

STATEMENT This manual is provided by the Quality Assurance Group. The manual's purpose is to set forth procedures for the Company's Quality Assurance functions. The manual is distributed, maintained, and controlled by the Quality Assurance Group, with manual holders receiving copies of new or revised material as it is issued. It is the Quality Assurance Department's responsibility to see that the procedures of this manual are followed and to conduct audits to ensure compliance. This manual has been developed as a guideline and requirement for use by Premier Industries, Inc. (PII)/Insulfoam (IF) in supplying expanded polystyrene board to ASTM C578 requirements for EPS boards Types I, II, VIII, and IX; Insulfoam's EIF Systems Grade (IEG); Premier Panel Core; and Exterior Insulation Finish Systems (EIFS) and R-TECH™. The procedures in this manual are the minimum necessary to satisfy requirements imposed through the PII/IF Certification Program and applicable Code Compliance; Evaluation Reports issued to Premier Industries as the proponent; or a report issued to a specific EIFS manufacturer. IF plants supplying the products listed under this program are required to have a follow-up thirdparty inspection program under a NVLAP-accredited Quality Assurance Agency (QAA).

1

Issued 7/92 Rev. 9/01

PART I QUALITY CONTROL TITLE PAGE

Insulfoam

1057 Sunburst Lane Mead, Nebraska 68041-9726

Plant I-41

Used in the Production of IF EPS PRODUCTS Types I, VIII, II, IX, IEG, PREMIER PANEL CORES, EIFS BOARDS and R-TECH™

2

Issued 7/92 Rev. 9/01

PART I QUALITY CONTROL TITLE PAGE

Insulfoam 12601 East 33rd Ave. Unit 114 Aurora, Colorado 80011-1839

Plant I-42

Used in the Production of IF EPS PRODUCTS Types I, VIII, II, IX, IEG, PREMIER PANEL CORES, EIFS BOARDS and R-TECH™

2

Issued 7/92 Rev. 9/01

PART I QUALITY CONTROL TITLE PAGE

Insulfoam 1820 South 4370 West Salt Lake City, Utah 84104

Plant I-43

Used in the Production of IF EPS PRODUCTS Types I, VIII, II, IX, IEG, PREMIER PANEL CORES, EIFS BOARDS and R-TECH™

2

Issued 7/92 Rev. 9/01

PART I QUALITY CONTROL TITLE PAGE

Insulfoam 4849 Groveport Road Columbus, Ohio 43207

Plant I-44

Used in the Production of IF EPS PRODUCTS Types I, VIII, II, IX, IEG, PREMIER PANEL CORES, EIFS BOARDS and R-TECH™

2

Issued 7/92 Rev. 5/02

PART I QUALITY CONTROL TITLE PAGE

Insulfoam 4500 South Frontage Road Lakeland, Florida 33815

Plant I-46

Used in the Production of IF EPS PRODUCTS Types I, VIII, II, IX, IEG, PREMIER PANEL CORES, EIFS BOARDS and R-TECH™

2

Issued 7/92 Rev. 5/02

PART I QUALITY CONTROL TITLE PAGE

Insulfoam 109 Service Road Anderson, South Carolina 29625

Plant I-49

Used in the Production of IF EPS PRODUCTS Types I, VIII, II, IX, IEG, PREMIER PANEL CORES, EIFS BOARDS and R-TECH™

2

Issued 7/92 Rev. 5/02

PART I QUALITY CONTROL TITLE PAGE

Insulfoam 19041 80th Avenue South Kent, Washington 98032-1136

Plant I-61

Used in the Production of IF EPS PRODUCTS Types I, VIII, II, IX, IEG, PREMIER PANEL CORES, EIFS BOARDS and R-TECH™

2

Issued 7/92 Rev. 5/02

PART I QUALITY CONTROL TITLE PAGE

Insulfoam 628 Western Drive Anchorage, Alaska 99501-1185

Plant I-62

Used in the Production of IF EPS PRODUCTS Types I, VIII, II, IX, IEG, PREMIER PANEL CORES, EIFS BOARDS and R-TECH™

2

Issued 7/92 Rev. 5/02

PART I QUALITY CONTROL TITLE PAGE

Insulfoam 1155 Business Park Drive, Building A Dixon, California 95620-9666

Plant I-63

Used in the Production of IF EPS PRODUCTS Types I, VIII, II, IX, IEG, PREMIER PANEL CORES, EIFS BOARDS and R-TECH™

2

Issued 7/92 Rev. 9/01

PART I QUALITY CONTROL TITLE PAGE

Insulfoam 5635 Schaefer Avenue Chino, California 91710-9041

Plant I-64

Used in the Production of IF EPS PRODUCTS Types I, VIII, II, IX, IEG, PREMIER PANEL CORES, EIFS BOARDS and R-TECH™

2

Issued 7/92 Rev. 9/01

PART I QUALITY CONTROL TITLE PAGE

Insulfoam 3401 W. Cocopah Street Phoenix, Arizona 85009-6712

Plant I-65

Used in the Production of IF EPS PRODUCTS Types I, VIII, II, IX, IEG, PREMIER PANEL CORES, EIFS BOARDS and R-TECH™

2

Issued 7/92 Rev. 9/01

PART I QUALITY CONTROL TITLE PAGE

Insulfoam 10010 Trumbull Ave. S.E. Albuquerque, New Mexico 87123

Plant I-67

Used in the Production of IF EPS PRODUCTS Types I, VIII, II, IX, IEG, PREMIER PANEL CORES, EIFS BOARDS and R-TECH™

2

Issued 7/92 Rev. 9/01

1.0 SCOPE This Quality Control Manual outlines the systems, procedures, and policies followed by IF in the manufacture of EPS Types I, VIII, II, IX, IEG, Premier Panel Cores, EIFS boards, and R-TECH™ to meet the requirements of PII/IF Certification Program and applicable Code Compliance and Evaluation Reports. IF's products are classified by the designated QAA. Producing acceptable product to the requirements of PII/IF Certification Program and applicable Code Compliance and Evaluation Reports is the responsibility of IF. The in-plant Quality Control system is monitored, and on-going testing of the products is performed by a NVLAP-accredited and Code Listed Quality Assurance Agency in not less than four inspections per year (quarterly).

1.1 QUALITY ASSURANCE The management of Premier Industries (PII) / Insulfoam (IF) is dedicated to assuring that only products meeting the highest standards for safety, appearance, and durability will be distributed, and that the policies and procedures in this manual will be adhered to. Products shipped will be in compliance with the requirements outlined. IF Certified EPS and Certified/Code Listed EPS are produced per the requirements of the PII/IF Certification Program, and monitored by Underwriter’s Laboratories, Inc. (QAA) NER-403. IF plants are committed to the on-going inspection program. A maintained list of IF plants certified under this program will be communicated to the appropriate code agencies and other appropriate parties, by PII/IF. The list of IF plants can be confirmed by the QAA, upon request. The QAA will conduct unannounced inspections of IF plants at a minimum frequency of four times per year, for the purpose of verifying that the product and in-plant systems meet the requirements of the QAA, the PII/IF Certification Program, and applicable Code Compliance and Evaluation Reports, as they specifically relate to flame classification and physical properties covered in this manual. See Part II. The Quality Manual shall be reviewed at a minimum of once per year. Each revised page shall bear the revision month and year, and be noted with an asterisk (*) in the page’s margin.

1.2 ORGANIZATION The Quality organizational structure within the IF plant is shown in FIGURE 1.1. The Quality Control Technician operates under the direction of Premier Industries-Technical Center, and is responsible for testing and documenting results and for providing the follow-up investigations required to keep the process in control. Fabrication of the board to requirements is the responsibility of the Production Manager, who reports to the General Manager.

3

Issued 7/92 Rev. 9/01

ORGANIZATIONAL CHART

Premier Industries, Inc. PRESIDENT

Premier Industries, Inc.

Premier Industries Technical Center CORPORATE QC/QA MANAGER Premier Industries, Inc. VICE-PRESIDENT

Insulfoam GENERAL MANAGER

Quality Assurance Tech.

Production Manager

Shift 1

Shift 1 Foreman

Shift 2

Shift 2 Foreman

Shift 3

Sales

Shift 3 Foreman Shipping / Receiving

Fabrication

Figure 1.1

4

Issued 7/92 Rev. 4/01

RESPONSIBILITY AND AUTHORITY GENERAL MANAGER • • • • • •

Implement QC/QA process; Provide QC/QA tools and personnel; Audit the system; Follow up on corrective/preventative actions; Enforce final decisions concerning QC/QA issues; Make final decision concerning disposition of deficient product.

LOCATION QC/QA TECHNICIAN • • • • • • • •

Responsible for all QC/QA documentation; Report QC/QA issues and product deficiencies directly to General Manager, Production Manager; and if need be Premier Industries Technical Center Perform QC/QA inspection, measuring, and testing; Place on hold any deficient product; Review all QC/QA documentation for completeness; Follow up on corrective/preventative actions; Maintain QC/QA records – minimum of 3 years; Inspect, measure, and test equipment maintenance and calibration.

PRODUCTION MANAGER • • • • • • • • • • • •

Plan the production run for the product; Order the specified raw material; Provide receiving inspection for the raw material; Maintain a file for the Certificate of Analysis; Provide production instructions; Follow up and review production documentation; Audit the process and documentation; Make, and follow up on, corrective/preventative actions; Provide training for production personnel; Assist and train pre-expansion, molding, and cutting personnel; Maintain production records – minimum of 3 years; Assist in decisions for disposition of deficient product.

PRE-EXPANDER OPERATOR • • • • • •

Complete and maintain Batch I.D. Log; Record the pre-expansion weights, time, box nos., and bag nos.; Record settings and changes made during the I.D. run; Make pre-expander adjustments necessary to maintain the predetermined pre-expansion density; Check the pre-expansion scale for calibration; Complete the pre-expansion report.

5

Issued 7/92 Rev. 4/01

MOLD OPERATOR • • • •

Complete the required production report; Record mold settings and changes made during the I.D. run; Record billet/block weights, time, and bag nos.; Report below minimum average billet/block weights to the Production Manager and QA Technician for disposition decisions.

CUTTING LINE OPERATOR • • • •

Cut product to customer requirements; Record I.D. numbers and block numbers on yellow cut sheet of the bill of lading; Record length, width, thickness, and squareness measurements of 2 boards for each bill of lading; Package according to customer requirements.

SHIPPING AND RECEIVING • • • •

Perform receiving inspection of raw material; Provide the Production Manager with the COA’s when attached to shipping papers; Handle product with care, and store to prevent damage after production and inspections; Inspect for damage, and notify QC/QA and Production Manager of damage prior to shipping.

MAINTENANCE • • • •

Inspect all equipment on a periodic basis; Document findings; Schedule maintenance and repairs; Document work performed.

6

Issued 7/92 Rev. 4/01

The Location Quality Control Technician reports to the Location Manager, and is also responsible for assisting in visits to the IF Plant by the QAA and/or code body personnel in accordance with third-party agency procedures.

1.2.1

AUTHORITY The Location Quality Control Technician, in performing his/her responsibility to management for the assurance of acceptable quality, has the authority to interrupt and halt the production process at any time the requirements and quality objectives are out of control and are not being met.

1.2.2

QUALIFICATIONS The Location Quality Control Technician shall possess the experience and expertise necessary to conduct an internal quality program which complies with this manual. Training of Quality Control personnel in the use of proper procedures is the responsibility of Premier Industries-Technical Center.

1.2.3

PERSONNEL CHANGES Changes in Quality Control management will be immediately conveyed to the QAA.

1.3 ADMINISTRATION 1.3.1

The Quality Control system is designed to provide traceability of the product from the initial lot of raw materials to the point of shipment. This covers documentation of materials used, necessary process standards, and test results, which help management assure that the final product complies with PII/IF Certification Program and applicable Code Compliance and Evaluation Reports.

1.3.2

Production is responsible for making certain that the proper materials and processes are utilized. Documentation and use of the approved forms is the responsibility of production personnel, with inspection and follow-up provided by Quality Control personnel.

1.3.3

Sampling, evaluating, and testing is the responsibility of Quality Control personnel. Samples are to be selected from each B.I.D. number; identified, tests conducted, and documented. These documents will be maintained and made available at the time of the random QAA visitation. Completed products are to be checked prior to shipment for proper markings and verification of conformance to requirements.

1.3.4

Batch I.D. logs, pre-expansion reports, mold reports, QA test reports, cut sheets, test equipment calibration records, QAA inspection and test reports, FM inspection reports, Borate Analysis test reports, receiving inspection reports, certificates of analysis of EPS beads, and QA review reports shall be kept for a period equal to the current year plus the three previous years.

1.3.5

Copies of inspection reports conducted by the QAA indicating quality control variation(s) or marking/label withdrawal are to be forwarded to the Evaluation Service Agency within 10 days of the noted major deviation.

7

Issued 7/92 Rev. 5/02

1.3.6

The Evaluation Service Agency will be notified in writing if unannounced follow-up inspections have not been conducted in accordance with the approved Quality Manual.

1.3.7

Insulfoam and the QAA will promptly investigate and respond to the Evaluation Service Agency or a building official when apprised of field complaints concerning product performance.

1.3.8

Insulfoam will notify the QAA when production is halted for any extended period of time and when/if resumption is planned. Marking/labeling of products is not permitted until authorized by the QAA.

1.3.9

The Evaluation Service Agency shall be notified in writing prior to cancellation of the QAA inspection agreement.

1.3.10 The Evaluation Service report number will be affixed only to product(s) that is/are in

compliance with the published evaluation report. 1.3.11 The inspection agreement between Insulfoam and the QAA shall allow representatives of

the Evaluation Service Agency to examine at manufacturing plants or distribution points any of the product marked/labeled in conformance with the evaluation report. Such examination shall be conducted by individuals employed or retained by the Evaluation Service Agency to audit performance under the evaluation report. 1.3.12 The ICC-ES will be notified in writing if there is a change in the product from what was

originally recognized in the evaluation report.

1.4

PROCESS AND DOCUMENTATION

Plant information is outlined in the appendices to Section I of this manual. The information includes the production process followed, plant layout, inspection frequencies and methods, documentation processes, and markings.

1.5

RECEIVING INSPECTION

Receiving inspection is primarily visual. Material is to be checked for conformance and resin identification, and for accompanying documents. A file for certificates of analysis shall be maintained. Non-conforming material is to be segregated and set aside for action as determined by management. Non-conforming material is not to be used for products manufactured to the requirements of this manual. When necessary, the IF plant will notify the QAA to determine appropriate corrective action by the QAA.

1.6 IN-PROCESS INSPECTION Product in process is to be inspected for conformance. Non-conforming product is to be rejected, identified as such, and moved to a segregated area for disposition. Non-conformance uncovered at any point during processing will be cause for an investigation of the extent of the non-conformance for determination of any necessary corrective action.

8

Issued 7/92 Rev. 11/03

Samples processed before and after the non-conforming product will be checked for the same non-conformance to isolate the problem. Process corrections will be undertaken to prevent recurrences of the problem.

1.6.1 THIRD-PARTY INSPECTION Continuing noncompliance uncovered by the QAA inspection during inspection procedures will lead to increase frequency of inspection until problems are resolved. Decertification may result if satisfactory corrections are not made by the manufacturer. The QAA shall notify the Evaluation Service of any changes (physical, chemical or otherwise) to the products that are contained in the scope of the evaluation report.

1.7 DISCREPANT PRODUCT The Location Quality Control Technician, with the aid of the Production Manager shall establish and enforce procedures for the handling of discrepant product as identified in Sections 1.4 and 1.5. These procedures shall ensure that non-conforming product is neither labeled nor shipped, and that it is not recycled for use.

1.8 PRODUCT MARKING All acceptable B.I.D.s are to be marked in accordance with the procedures identified in this manual. Shipping documents, markings and/or wrappings are to provide the necessary trace-ability to the initial resin lot. Individual boards may also provide identification of the molder.

1.9 MANUAL REVISIONS All revisions to this manual are to be submitted to the QAA for review and for forwarding to code agencies for their appropriate action. PII/IF will notify code agencies of any QAA contractual changes. PII will also notify IF plants of systems utilizing code-recognized product produced under this manual, i.e. EIFS, roofing membrane manufacture, etc.

2.0 INSULFOAM LIST OF PROCESS EQUIPMENT All IF Plants “List of Process Equipment”, page 17 (Table A1-B) may change from date of the current approval of this manual. Manufacturer can remove and replace equipment as needed for production purposes. IF will forward updated lists on annual basis to UL for inclusion in the Q.C. manual. Third party inspection agency shall contact Premier Industries-Technical Center when reviewing IF plant equipment list for accuracy.

2.1 CALIBRATION AND FREQUENCY OF TEST EQUIPMENT All IF Plants shall conduct independent calibration of testing equipment on a bi-annual basis. Calibration of equipment shall comply to requirements of NIST standards. Records of Calibration and traceability shall be kept on file at all IF Plants.

9

Issued 7/92 Rev. 11/03

APPENDIX - I

Insulfoam

1057 Sunburst Lane Mead, Nebraska 68041-9726 (402) 624-6611 Larry Anderson-Production Manager

PLANT IDENTIFICATION I-41

PLANT LOCATION, PLANT LAYOUT AND PROCESS DESCRIPTION

10

Issued 7/92 Rev. 5/02

APPENDIX - I

Insulfoam

12601 East 33rd Ave., Unit 114 Aurora, Colorado 80011-1839 (303) 366-7730 Mark Alvarado-Production Manager

PLANT IDENTIFICATION I-42

PLANT LOCATION, PLANT LAYOUT AND PROCESS DESCRIPTION

10

Issued 7/92 Rev. 5/02

APPENDIX - I

Insulfoam

1820 South 4370 West Salt Lake City, Utah 84124 (801) 956-2808 Kim Higgins-Location Coordinator

PLANT IDENTIFICATION I-43

PLANT LOCATION, PLANT LAYOUT AND PROCESS DESCRIPTION

10

Issued 7/92 Rev. 5/02

APPENDIX - I

Insulfoam

4849 Groveport Road Columbus, Ohio 43207 (614) 409-4444 Tom Woods-Production Manager

PLANT IDENTIFICATION I-44

PLANT LOCATION, PLANT LAYOUT AND PROCESS DESCRIPTION

10

Issued 7/92 Rev. 5/02

APPENDIX - I

Insulfoam

4500 South Frontage Road Lakeland, Florida 33815 (863) 688-8879 Carlos Hernandez-Production Manager

PLANT IDENTIFICATION I-46

PLANT LOCATION, PLANT LAYOUT AND PROCESS DESCRIPTION

10

Issued 8/03

APPENDIX - I

Insulfoam

109 Service Road Anderson, South Carolina 29625 (864) 224-0900 Rob Watts - Production Manager

PLANT IDENTIFICATION I-49

PLANT LOCATION, PLANT LAYOUT AND PROCESS DESCRIPTION

10

Issued 7/04

APPENDIX - I

Insulfoam

19041 80th Avenue South Kent, Washington 98032-1136 (206) 242-9424 Chris Brown-Production Manager

PLANT IDENTIFICATION I-61

PLANT LOCATION, PLANT LAYOUT AND PROCESS DESCRIPTION

10

Issued 7/92 Rev. 5/02

APPENDIX - I

Insulfoam

628 Western Drive Anchorage, Alaska 99501-1185 (907) 279-9407 Monte Hagerty-Production Manager

PLANT IDENTIFICATION I-62

PLANT LOCATION, PLANT LAYOUT AND PROCESS DESCRIPTION

10

Issued 7/92 Rev. 5/02

APPENDIX - I

Insulfoam

1155 Business Park Drive, Building A Dixon, California 95620-9666 (707) 678-6900 Robert Bach-Production Manager

PLANT IDENTIFICATION I-63

PLANT LOCATION, PLANT LAYOUT AND PROCESS DESCRIPTION

10

Issued 7/92 Rev. 4/01

APPENDIX - I

Insulfoam

5635 Schaefer Avenue Chino, California 91710-9041 (909) 591-7425 Bill Seldenright-Production Manager

PLANT IDENTIFICATION I-64

PLANT LOCATION, PLANT LAYOUT AND PROCESS DESCRIPTION

10

Issued 7/92 Rev. 4/01

APPENDIX - I

Insulfoam

3401 W. Cocopah Street Phoenix, Arizona 85009-6712 (601) 269-2272 Harry Millard-Production Manager

PLANT IDENTIFICATION I-65

PLANT LOCATION, PLANT LAYOUT AND PROCESS DESCRIPTION

10

Issued 7/92 Rev. 4/01

PLANT LOCATION I-41

From Omaha Airport, go to I-80. Take I-80 westbound to State Hwy 92 (Dodge Street). Take State Hwy 92 West 25 miles to Mead, Nebraska. At Sinclair Service Station, take 78F Spur South 1.25 miles to Insulfoam sign. At Sign, take paved drive approximately .75 mile to plant.

Figure A1-2.0

11

Issued 7/92 Rev. 4/01

PLANT LOCATION I-42

From Denver International Airport, take Pena Blvd to I-70 West. Once on I-70, travel west approximately 2 miles to the Peoria Street exit. Exit, turn left, and travel south on Peoria Street approximately ½ mile, across railroad tracks to Smith Rd. Turn left onto Smith Rd and travel east to Quentin Street (.25 mile). Turn right onto Quentin Street and go to 33rd Avenue. Turn left onto 33rd Avenue and travel east. Insulfoam is at the end of block on left, at 12601, Unit 114.

Figure A1-2.0

11

Issued 7/92 Rev. 5/02

PLANT LOCATION I-43

Figure A1-2.0

11

Issued 7/92 Rev. 5/02

PLANT LOCATION I-44

Insulfoam 4849 Groveport Rd. Columbus, Ohio

Leaving Columbus airport, go west onto International Gateway. Exit right to I270 towards Cleveland/Wheeling east. Follow I270 south towards Cincinnati approximately 16.4 miles to Obetz. Take Alum Creek Drive, exit 49 towards Obetz. Left onto Alum Creek Drive (0.4) miles. Turn right onto Groveport Rd. (0.2) miles. Turn left on Frusta drive and service road to enter parking lot. Total driving distance from airport 17.2 miles.

Figure A1-2.0

11

Issued 7/92 Rev. 4/01

PLANT LOCATION I-46

Insulfoam 4500 South Frontage Road Lakeland, FL 33815

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Start out going Northeast on Airport Entrance toward Parking Stay straight to go onto terminal Stay straight to go onto Red terminal Red terminal becomes Airport Exit Take the SR-60 ramp toward I-275/Downtown Merge onto N Memorial HWY/FL-60 E. Merge onto I275 N toward I-4 Merge onto I-4 E via exit number 45B toward Orlando Take the County Line Road Exit-number 25 Turn right onto County Line Road Turn Left onto US-92 Turn Left onto Clark Road Turn right onto Frontage Rd. S/Southside Frontage Rd.

Figure A1-2.0

11

.3 miles .2 miles .5 miles 1.6 miles .4 miles .5 miles 5.3 miles 25.2 miles .4 miles .5 miles 1.0 miles .2 miles .2 miles

Issued 9/03 Rev.7/04

PLANT LOCATION I-49

Insulfoam 109 Service Rd. Anderson, SC 29625

#1 Service Rd.

#1 – Texaco Station

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Start out going Southwest on Terminal Toward Short Term Parking .1 miles Turn slight Left onto Rental Car Return .1 miles Stay straight to go onto Airport Exit .1 miles Turn slight Right onto Aviation Dr. .5 miles Merge onto I-85 S. toward Greenville/Anderson 37.3 miles Exit number 19A Merge onto US-76 /Clemson Blvd. 1.9 miles Note: You will have to turnaround by Wendys to go south onto Clemson Blvd Take Clemson Blvd to SC Hwy 28 1.8 miles SC-28 to second light-past/Pearman Dairy Rd. N. to Whithall Rd-turn left 1.8 miles Turn Left onto Whitehall Rd. Past first light-Turn right-across from Texeco .8 miles Turn Right onto Service Rd. Follow to Dead End-Plant on right side .1 miles

Figure A1-2.0

11

Issued 7/04

PLANT LOCATION I-61

From airport, exit and turn left onto Hwy 99 (northbound) and go to 176th St. Turn right onto 176th and travel east. 176th will become 178th , then cross over I-5 and become 180th at Southcenter Pkwy. Continue east on 180th approximately 1.5 miles to 80th Ave. south. Turn right (south) onto 80th Ave. South and travel approximately .75 mile to 192nd St. Insulfoam is on the right at the intersection of 80th Ave. South and 192nd St..

Figure A1-2.0

11

Issued 7/04

PLANT LOCATION I-62

From airport, travel east on International Airport Rd to “C” St. Turn left onto “C” St. and travel north. “C” will divide and become a one-way north on “A” St. Continue north on “A” St. through town and across Dock Creek / R.R. viaduct. Turn left at end of viaduct, onto Ocean Dock Rd. Immediately turn left again, then right, onto Western Drive. Insulfoam is on the right at the intersection of Ocean Dock Rd and Western Dr., at 628 Western Drive.

Figure A1-2.0

11

Issued 6/98 Rev. 4/01

PLANT LOCATION I-63

From Sacramento Airport, head north on I-5 to Woodland, CA. Exit I-5 and travel west to downtown Woodland. Take State Hwy 113 south from Woodland to I-80 at Davis, CA. Take I-80 west to Hwy 113 / Curry Road exit on north side of Dixon, CA. Take State Hwy 113 south to Industrial Way (Ford dealership). Take Industrial Way east to Business Park Drive. Take Business Park Drive south to the cul-de-sac. To the right of the cul-de-sac is Premier Packaging at the rear of Insulfoam, at 1155 Business Park Drive, Building A.

Figure A1-2.0

11

Issued 6/98 Rev. 4/01

PLANT LOCATION I-64

Exit airport on Vinard Street, going north across railroad tracks to Holt Blvd. Turn left onto Hold Blvd. And travel west approximately 1.5 mile to Grove Ave. Turn left onto Grove Ave. and travel south approximately 5.5 miles to Schaefer Ave. Turn right onto Schaefer Ave. and travel west approximately 2.5 miles. Insulfoam is on the left (south side of the street), at 5635 Schaefer Avenue.

Figure A1-2.0

11

Issued 6/98 Rev. 4/01

PLANT LOCATION I-65

Exit airport and travel west on Buckeye Road approximately 6 miles to 35th Ave. Turn left onto 35th Ave. and travel south two (2) blocks to Cocopah Street. Turn left on Cocopah Street and travel east approximately one (1) block to Insulfoam, on the right at 3401 W. Cocopah.

Figure A1-2.0

11

Issued 6/98 Rev. 4/01

PLANT LAYOUT I-41

Figure A1-2.01A

12

Issued 7/92 Rev. 6/03

PLANT LAYOUT I-42

Figure A1-2.01A

12

Issued 7/92 Rev. 7/04

PLANT LAYOUT I-43

Figure A1-2.01A

12

Issued 7/92 Rev. 4/01

PLANT LAYOUT I-44

Figure A1-2.01A

12

Issued 7/92 Rev. 4/01

PLANT LAYOUT I-46

Figure A1-2.01A

12

Issued 9/03 Rev. 7/04

PLANT LAYOUT I-49

Figure A1-2.01A

12

Issued 7/04

PLANT LAYOUT I-61

Figure A1-2.01A

12

Issued 7/92 Rev. 4/01

PLANT LAYOUT I-62

Figure A1-2.01A

12

Issued 7/92 Rev. 4/01

PLANT LAYOUT I-63

Figure A1-2.01A

12

Issued 7/92 Rev. 10/01

PLANT LAYOUT I-64

Figure A1-2.01A

12

Issued 7/92 Rev. 2/03

PLANT LAYOUT I-65

Figure A1-2.01A

12

Issued 7/92 Rev. 7/04

PROCESS DESCRIPTION, QUALITY CONTROL PROCEDURES, INSPECTIONS, AND TESTING.

The following is a guide for use by each IF plant in completing this manual.

A1-1.0

PROCESS (See FIGURE A1-2.1)

The process description for fabricating Expanded Polystyrene Products to PII/IF’s requirements is as follows:

A1-1.1

RECEIVING

Raw materials (resin) are received in containers and are to meet one of the following types: (See U.L. File No. 14313; Vol. 1, Sec. 1, Page 1-2, Ingredients) (See approved supplier list, designated as Table A1-A.) Receiving inspection is to verify that the markings on the containers are in accordance with the above requirements. Containers are to be identified for traceability to date of receipt.

A1-1.2

PRE-EXPANSION

Raw material (resin) is moved to pre-expander area for expansion to meet density requirements of IF insulation board. Expansion is controlled through temperature and steam settings. Pre-expanded bead is checked for density during process as it is moved to storage bags. Pre-expanded beads not meeting density requirements are not utilized for Certified or Certified/Code Listed materials produced under this manual. Pre-expanded beads in storage bags are to be from one resin source, one resin lot number, and one bead size. Pre-expanded resins are stored in bags prior to molding.

13

Issued 7/92 Rev. 4/01

TABLE A1-A — APPROVED RAW MATERIAL SUPPLIERS

SUPPLIERS:

RESIN TYPES:

NOVA Chemical Co.

NOVA - M771, M971, 33M1, 35M1

BASF Corp.

BASF – BF-020 , BF-122, BF-134 , BF-222, BF-229, BF-329, BF-321 , BF-322, BF-326, BF-327, BF-422; BFL 020 , BFL 122, BFL 134 , BFL 222, BFL 322, BFL 327, BFL 422,

HUNTSMAN Corp.

HUNTSMAN – Grades 54, 40, 86

STYROCHEM U.S., LTD

STYROCHEM – MA-500, MB-500, MB-590, MC-500, MC-590, MA-550 , MB-550 , MC-550 , MA-590

POLIOLES, S.A. de C.V.

STYROPOR Types AF112, AF212, AF312, AF412, AF512 , F0305 , F0507 , F1015 , F1525

MITSUBISHI CHEMICAL/ BASF Ltd.

JF200

TAITA CHEMICAL CO. Ltd.

321 S & T Series

DONBU HANNONG CHEMICAL CO. Ltd.

250, 350, 450 “L” Series Note: Not to be used for code listed products 1

14

–ICBO Stamped product limited to Types I, VIII, II

Issued 7/92 Rev. 6/03

A1-1.3

MOLDING

After pre-expanded bead storage, beads are transferred to a mold for fusion. The bead transferred to the mold is to be of one type only. As the billets come out of the mold, they are identified by bead type, bead lot number, density and date of molding. Finished billet is weighed and the weight recorded.

A1-1.4

STORAGE/CURING

For stability requirements, material produced under the Certification Program shall be stabilized prior to cutting. Billets may be stored for longer periods as required for specific end uses. In all cases, spacing will be maintained between billets to allow for air circulation.

A1-1.5

CUTTING

After curing, the billets are moved to the cutting area, where they are prepared and cut to customer requirements. IEG and EIFS board is a minimum of 3/4" thick to a maximum of 4" thick. Type I, VIII, II and IX EPS board is limited to maximum thickness acceptable to applicable Compliance and Evaluation Reports. Roofing products produced under the "UL Roofing Systems Classification" are produced in any thickness.

A1-1.6

MARKING AND PACKAGING A1-1.6.1 IEG and EIFS Boards

Each board intended for an IEG job will be edge-marked per paragraph A1-2.5, or as specified by EIFS manufacturer. Within each package, one board will be stamped on both faces with the markings per paragraph A1-2.5, or as specified by the EIFS manufacturer. The boards are to be put in IEG plastic bags or plastic full wrap, or as specified by EIFS manufacturer and the applicable Classification Marking of the QAA applied on the outside of the bundle. A1-1.6.2 Types I, VIII, II AND IX Boards

Types I, VIII, II and IX EPS boards are shipped in bundles or packages as determined by IF. Each board carries the classification marking of the QAA as per paragraph A1-2.5. A1-1.6.3 BUNDLES

Each bundle of board molded for use in attic or crawl spaces is restricted to the use of BASF Styropor, BL or BFL, or Nova Dylite M77 or 33M beads in its manufacture. No recycled material is permitted. The board lot carries a minimum of one bundle label, as per paragraph A1-2.5, which shall include the applicable classification marking of the QAA, bead identification, and restrictions.

15

Issued 7/92 Rev. 4/01

PROCESS FLOW

REFERENCE SECTION

Figure A1-2.1

Receiving

A1-1.1/2.1

Inspection

A1-1.1/2.1

Store Resins

A1-1.2/2.1

Pre-Expansion

A1-1.2/2.2

Inspection

A1-1.2/2.2

Storage

A1-1.2/2.2

Molding

A1-1.3/2.3

Inspection

A1-1.3/2.3

Curing/Storage

A1-1.4

Cutting

A1-1.5/2.4

Marking/Packaging

A1-1.6/2.5

Inspection

A1-2.4/3.0

16

Issued 7/92 Rev. 4/01

TABLE A1-B

LIST OF PROCESS EQUIPMENT

IF Equipment List - Mead, NE Boiler: Superior (2000), 600HP Model 6-X3000, Serial #14479 Boiler: Cleaver Brooks (1997), 350 HP Model CB 1200350150, Serial # OL096955 Dearator (2000):Superior Serial # B991066, for 600 HP boiler Dearator (1995): Spraymaster, Model SMP 15, Serial # DG-7203 Accumulator (1999): 500 Gal., 42” x 84” Accumulator (1995): 3,000 Gal., 6ft. dia. X 20 ft. long Accumulator (2001): 3,000 Gal., 72 x 240 - (24’ Idro) Mold (1998): Idropress 18’ – 5.6 x 1 x 1.3M Mold (2001): Idropress 24’ – 7.5 x 1 x 1.3M Block Scale: Model D630K Block Scale: Weigh-Tronix; Model WI-125 Serial # 008673, 2000 lb capacity Pre-Expander (1999): Hirsch, PREEX 12000 C14 PDVM Pre-Expander Scale: Weigh-Tronix; Model WI-130, Serial # 0022635 Horz. Cutting Line: Treffner; Model HWC20 Horz. Cutting Line: Mid America, Model HM 411 Horz. Cutting Line (Flat Line): Treffner, Model HWC20 Down Cutter: Gateway GP 2150, Serial # 488701-02 Down Cutter (2000): Gateway GP 2150, Serial #648601 Profile Cutter: PII HM #4111 Wrapper: PII HM# 4101 Wrapper: PII HM# 4102 Down Cutter: Mid-America; Model HM 414 Horz. Cutting Slabber: GP4000, Serial #648901-02 C/E Shape Cutter (1992): Gateway GP 5000, Serial # 2501-0388-0092 Electric Bander: Signode-Spirit, Serial # A3699BLI Mixing Station (1998): IDRO, Model M5C2, Serial #577 Dust Seperator (2000): IDRO, Model DPI, Serial #631

Laminator: Union Tool Fan Fold Machine: PII HM#4110 Pallet Wrapper: Orion, Model L66-12-5, Serial # 9039254 Down Cutter: Mid-America; Model HM 413 Horz. Cutting Line: Treffner , Model HWC20 Laminating Machine: Black Bros., Serial # 199858 Laminating Machine: Black Bros., Serial # 189664 Hot Melt Glue Pump: Graco C32429 Hot Melt Glue Pump: Graco C32194 Portable Electric Bander: Dynoric Inc., Model DF20, Serial # 2996 Wrapper: PII HM#4103 32” x 40” Wrapper: PII HM#4104 40” x 48” Bag Closer: Kwik Lock Model CKM57NRPR, Serial # 69324-2002 Lamination Scale: AND EK-12006 xlg OHD Groover: 3:20 / 17 CONB PII 4106 Groover: 24’ – PII HM #4105 Groover: 24’ – PII HM #4106 In-Line Groover: PII HM 4118 Heat Embosser (20’): Gateway, Model GP0506 Heat Embosser (10’): PII HM # 4107 Valley/Ridge Cutter: PII HM #417 Block Cuter/Tilter: PII HM#4109 4’ x 16’ Cricket Cutting Table: PII HM #448 QC Measuring & Testing Equipment QC Down Cutter: PII HM#4112 QC Lab Balance;OhausSC 6010 300gr Precision Steel Rule- 2ft & 1 ft Caliper-Mitutoyo-6” Leaf Thickness Gauge-Precision .001-.025” Pocket Square-Angle Square Flexural Test Apparatus Tape Measure-Stanley 16’

17

Issued 6/98 Rev. 11/03

TABLE-B

LIST OF PROCESS EQUIPMENT

IF Equipment List - Aurora, CO Boiler: Superior S-X-1750 Serial # 14017 / 1998

Door Groover #1: IF/HM

Mold: Nouva Idro 16-04-2003 Serial # 805

T & G Machine: IF/HM

Accumulator: National #31735 / 1998 Block Scale: Lumas Electronics Model TP 5010, Serial # E0192403 Pre-Expander: Hirsch, Model 12000A1 - Batch

Door Groover #2: IF/HM Hot Melt Laminator: Black Bros., Serial # 199857 Laminating Machine #1: Union Tool, R-TECH Line Laminating Machine #2: Union Tool, Fan Fold Line QC Measuring & Test Equipment

Pre-Expander Scale: Weigh-Tronix Model #QC3265

QC Down Cutter- PII MN#4112

Compressor: Quincy QSI-245 Model QST24ANA31C, Serial #94957H

Precision Steel Rule – 1", 2" Steel

QC Lab Balance-EK 1200g x 0.1g Caliper-Mitutoyo, Model CB-6" CS

Horizontal Cutting Line #1: Gateway # GP 4000

Leaf Thickness Gauge-Johnson

Horizontal Cutting Line #2: Tri-Mfg., Model 1122

Flexural Test Apparatus

Pocket Square-Angle Square Tape Measure-Stanley

Down Cutter #1: Gateway Model 2150, Serial #5508 Down Cutter #2: Gateway Model 2150, Serial # 4916 Down Cutter #3: Big W Industries, Model 4 x 10 DC-16’ Shape Cutter #1: Gateway GP 5000 Contour Cutter, Serial # 6204-01 Shape Cutter #2: Gateway #PC116708-01 Grinder: Nuova MUL-812, Serial #791 Separator: Idro Deduster # DP1 Wide Belt Sander: Ramo, Model 52TOPL, Serial #5585

17

Issued 6/98 Rev. 7/04

TABLE A1-B

LIST OF PROCESS EQUIPMENT

IF Equipment List - Salt Lake City, UT

17

Issued 6/98 Rev. 11/03

TABLE A1-B

LIST OF PROCESS EQUIPMENT

IF Equipment List - Columbus, OH

17

Issued 7/92 Rev. 11/03

TABLE A1-B

LIST OF PROCESS EQUIPMENT

IF Equipment List - Lakeland, FL Mold: Oyster MS1 Hirsch 24’Mold Serial # 0A5-YR 2000

Grinder: Nuova Idro – 2004 Mul 20- #831

Pre-Expander: Vacutrans Pre-ex 1200D Pre-Expander / D26D

Grinder: Nuova Idro – 2004 Mul 20- #832

MSC Vertilcle Lift Dump: Model 215000SP / Serial #16692

Foil Machine: 16’ Long Single side, A/IF HM

Boiler #1: Cleaver Brooks Model CB600-100 / Serial # L-77671 (12/5/83)

Compressor #3: Speedaire-Model # 52639A 80 gal.

Boiler #2: York-Shipley / FA 250 / Serial # 78-12012

Compressor #4: Manchester 100gal. / Serial # B212409

Compressor #1: Ingersoll Rand-Model SSR EP255E 25HP/95CFM / Serial # KE4929U97193

Holey Board Drilling Machine: A/IF HM

Compressor #2: Manchester-Model # WP200 (1986) A/IF #00047

QC Testing & Measuring Equipment QC Lab Balance: Mettler PJ 6000, serial # M24246 Precision Steel Rule-Starrett 12”

Depolverator: Nuova Idropress – Model # DP1-DP2

Caliper-Digit Cal Digital 6”/.001”

Cutting Line #1: 8’ Long Slabber/Down Cutter, Big Walley Industries – Model # CC54102

Stanley Pocket Square-10-3/16”

Cutting Line #2: 12’ Long Belt Slabber/Down Cutter A/IF HM

Leaf Thickness gage-.0015-.025” Flexural Test Apparatus Stanley Tape Measure

Cutting Line #3: 16’ Long Belt Slabber/Down Cutter TSI Cutting Line #4: 24’ Long Belt Slabber/Down Cutter TSI Model # 3055 Horizontal/Slabber: 16’ Treffner combination A/IF #00016 Contour Cutter #1: 12’ Big Walley Industries-Model #0054102 Serial # 2204-12-3088 Contour Cutter #2: 18’ Gateway Industries-GP 5000/Serial# 419301

TABLE A1-B TABLE A1-B

17 LIST OF PROCESS EQUIPMENT LIST OF PROCESS EQUIPMENT

Issued 8/03 Rev. 7/04

TABLE A1-B

LIST OF PROCESS EQUIPMENT

IF Equipment List - Anderson, SC Laminating Machine: Union Tool, Series 55-56, Serial # SO 3078/JO2100

Boiler: Industrial 250HP, Model IR3WB200CG0H6, Serial # R 200 16

De-Duster :

Mold : Weiser Vertical

Fan Fold Cutter: IF HM

Block Scale : Hirsch/Lenz AD4326A Serial # H7208627

QC Measuring & Test Equipment

Pre-Expander : Hirsh Model PREEX 12000 D28D

QC Down Cutter- IF; HM

Pre-Expander Scale:Hirsch NR1-0034B Accumulator : 3000 gal, Cert# 592202

QC Lab Balance-Scout Pro SP200, Serial # 7122100712

Steam Accumulator : 30515, 1996

Caliper-Westward 6”, #5LD57

Cooling Tower: Marley; Model NC8304F1GM, Serial# NC-240940-A1

Leaf Thickness Gauge-Blackhawk .0015”-.035” Angle Square-Johnson

Water Softner: Cleaver Brooks 3000 gal, Model SAB-300-2TW, Serial #C-0797011

Flexural Test Apparatus Tape Measure-Stanley 16’

Dearator: Dryer: Zeks 400cfm, Model 300NCGA400, Serial # 230410 204 Compressor: Quincy 50HP Model QS1245ANA31EE, Serial #95606J Water/Oil Separator: Model Q10W-0015, Serial # 1281589 Horz. Cutting Line #1: 16’ Down Cutter: EMF, 18’ Grinder:Treffner VARAG 8, Serial #966 Regrind Mixing Station: IF HM

17

TABLE A1-B

LIST OF PROCESS EQUIPMENT

Issued 7/04

IF Equipment List - Kent, WA

17

Issued 7/92 Rev. 11/03

TABLE A1-B

LIST OF PROCESS EQUIPMENT

IF Equipment List - Anchorage, AK

17

Issued 7/92 Rev. 11/03

TABLE A1-B

LIST OF PROCESS EQUIPMENT

IF Equipment List - Dixon, CA

17

Issued 7/92 Rev. 11/03

TABLE A1-B

LIST OF PROCESS EQUIPMENT

IF Equipment List - Chino, CA

17

Issued 7/92 Rev. 11/03

TABLE A1-B

LIST OF PROCESS EQUIPMENT

IF Equipment List - Phoenix, AZ Boiler: Cleaver Brooks, Model CB-LE 1997-300HP

Down Cutter: TRI

Mold #1: Nouva Idro Model 5.6 x 1 x 1.35 - 18’, 2001

Down Cutter: IF; Model HM652 (8’)

Mold #2: Kurtz, Nr 5-1-3-1-234, 16’, 1997

Grinder #1: EMF

Down Cutter: IF; Model HM651 (10’) Insulperm Machine: IF; Model HM653 Grinder #2 & #3: (2) Nuova Idro, Model MUL 20, 2003

Block Scale #1: Kurtz/Siemens Model OP25

C/E Shape Cutter: EMF; Model 852 Serial #5399-03

Block Scale #2: Idro AND, Model EQ-1200

Computer Cutter: Gateway; Serial #5890-02

Pre-Expander #1: Hirsh 12000 / Computer

T & G Machine (2’ x 8’): SMB-David; Model D135

Pre-Expander #2: Hirsh 12000 / Computer

T & G Machine (4’ x 8’): IF; Model HM652

Pre-Expander Scale: Weigh-Tronix, Model WI-130, Serial #043853

Laminating Machine: (2) Union Tool

Accumulator #1: Wheeler, 4000 gal. , Serial # 76036

Laminating Machine: Black Bros.

Accumulator #2: Wendlang mfg. , 4000 gal. , 1993

Mixing Station: IF; Model HM654

Accumulator #3: Wendlang mfg. , 4000 gal. , Serial # 33066

QC Measuring & Test Equipment

Dust Compactor: Dixon Y Machine Inc. QC Down Cutter- IF; HM

Cooling Tower: Marley; Model NC4201GM, GMP:980

QC Lab Balance-AND Model EK 1200g x 0.1g

Compressor #1: Quincy QSI-500, 125HP

Caliper-Mitutoyo, 6” Leaf Thickness Gauge-Precision .001”-.025”

Compressor #2: Qunicy 40HP Horz. Cutting Line #1: Nuova Idropress, 2002

Pocket Square-Angle Square

Horz. Cutting Line #2: TRI

Flexural Test Apparatus

Horz. Cutting Line #3 & #4: (2) IF, Model HM 650

Tape Measure-Stanley 16’

Down Cutter: (2) Gateway, 18’

17

Issued 7/92 Rev. 7/04

TABLE A1-B

LIST OF PROCESS EQUIPMENT

IF Equipment List - Albuquerque, NM

17

Issued 7/92 Rev. 4/01

A1-2.0

INSPECTIONS

The inspections and tests to be performed are as follows. The referenced forms that are to be utilized are included in this section.

A1-2.1

RECEIVING

Incoming shipments are to be checked to verify that the resins are identified as modified resins as stated in paragraph A1-1.1 of Appendix I of this manual. Containers are to be marked for lot identification.

A1-2.2

PRE-EXPANSION (Use FORMS 2.0, 2.1, computer print out or similar forms )

Batch ID (B.I.D.) No. is assigned and recorded. Note

A batch is X-number of pounds, pre-expanded and molded at one time, of one density, from one lot number of one of the approved bead manufacturers.

Settings on steam pressure and air temperature are checked and recorded. Storage bag receiving expanded resins is referenced by distinguishing number associated with date of expansion and B.I.D. number. As resins leave pre-expander, samples are pulled to check density through use of: Container — 1/2 cu.ft. Scale Type — National Control Model 5788, WI-130, WI-127, or equal (nearest 0.1 lb.) Density, time of day, and B.I.D. number are also recorded on pre-expansion report.

A1-2.3

BLOCK MOLDING

(Use FORM 2.2 or similar daily and/or computer mold print-out)

Values for steam pressure, etc., are recorded. Size of block is specified (if applicable). Material type is recorded, as is bag identification and B.I.D. number on mold report. After molding, block is marked with identifying information (bead manufacturer, virgin, modified, B.I.D. number, date, and blk. no.).

A1-2.4

WIRE CUTTING

Billets are cut into boards to meet PII/IF and customer requirements. 1. Samples are to be selected for testing (see FIGURE A1-2.3). 2. Dimensions are to be checked. 3. B.I.D. nos. and blk. Nos. are recorded on yellow copy (cut sheet) of bill of lading. 18

Issued 7/92 Rev. 4/01

4. One board of each carries the B.I.D. no. on one end. 5. Traceability is through the B.I.D. No. – from bundle to cut sheet (bill of lading) to Mold Report to Pre-Expansion Report to B.I.D. Log.

A1-2.5

MARKING AND PACKAGING A.

IEG BOARDS 1.

IEG boards are to be edge-marked as per FIGURE A2-1.1.

2.

At least one board in each bundle ready for packaging is to be stamped on both faces with the marking as per FIGURE A2-1.1.

3.

The bundle is to be placed in a plastic bag or wrap that carries the applicable classification marking.

4.

The outside of the bag or wrap is to be marked with the bill of lading/order number.

5.

Comply with the requirements of individual EIFS manufacturers for marking and packaging, when different from this manual.

EPS supplied for individual EIFS manufacturers shall bear the minimum markings as per FIGURE A2-1.1. B. TYPES I, VIII, II, AND IX EPS BOARDS 1.

Types I, VIII, II and IX EPS boards shall be bundled for packaging in quantities determined by IF.

2.

The board is to be identified with a classification marking of the QAA on the product as per FIGURE A2-1.1.

3.

The EPS of board molded for use in exposed conditions for attic or crawl space is restricted to the use of BASF Styropor BL or BFL or NOVA Dylite M77 or M33 EPS beads. The board carries the applicable classification marking of the QAA as per FIGURE A2-1.1. No recycled material is permitted.

4.

EPS used as core material for Premier Building Panels will be edge-marked with the information shown in FIGURE A2-1.1. Minimum density shall be .95 lbs./cu.ft.

C. R-TECH 1. The EPS boards shall be bundled for packaging in quantities determined by IF. 2. The boards shall be edge-marked in accordance with (IAW) Figure A2-1.1, except that these markings may all be on the end edge of the board. 3. The board is to be identified with a classification marking of the QAA, and the Evaluation Service evaluation report number.

19

Issued 7/92 Rev. 9/01

TEST SAMPLE SELECTION

Figure A1-2.3

20

Issued 7/92 Rev. 4/01

FORM 2.0 BATCH I.D. LOG

Density B.I.D. NO.

DATE

TYPE

LOT

LBS

BAG

BOX NOS.

OPERATOR

Similar Form May Be Substituted

21

Issued 7/92 Rev. 4/01

FORM 2.1 EXPANSION REPORT

I.D. Number

Expanding Date

Density Read

Bead Type

Pounds Expanded

Bag Numbers

______

Lot Numbers Box Numbers

Operator :

Signature :

Similar Form May Be Substituted

22

Issued 7/92 Rev. 4/01

Door Used

Air Setting

Auger Speed

Temp.

By-Pass

Steam Setting

Density Net Weight

Box Number

Bag

Time Start

Door Used

Air Setting

Auger Speed

Temp.

By-Pass

Steam Setting

Density Net Weight

Box Number

Bag

Time Start

Plant # I-

Form 2.1

Expansion Report

Similar Form May Be Substituted

23

Issued 7/92 Rev. 4/01

Form 2.2 Daily Block Molding MOLDING RECORD

PLANT NO. I-XXXXXXX

I.D. Number : ________________________Bead Type : _______________________________

Bead Slide Number

Auger Setting Regrind

Dwell Seconds

Foam Pressure

Steam Pressure

Rinse Pressure

Rinse Seconds

Seconds Timer D3B

Steam Turn LIds

Main Stream Turns

Time

Shot No.

Bag No.

Date

Operator : ___________________________Signature : ________________________________

Comments

Similar Form May Be Substituted

24

Issued 7/92 Rev. 4/01

FORM 2.3 CUTTING REPORT

25

Issued 7/92 Rev. 4/01

A1-3.0

TESTS

Each manufacturing facility shall select samples from a minimum of one billet produced from one B.I.D. The following tests are to be performed by Quality Control at a minimum frequency as defined above, and using the methods outlined in the Follow-Up and Inspection Manual. See Part II.

A1-3.1

DENSITY

Finished board samples (12” x 12” x 1”) or (12” x 3” x 1”) are to be weighed in order to verify density.

A1-3.2

FLEXURAL

Finished board samples (12” x 3” x 1”) are to be subjected to flexural loading in order to verify fusion (use FORM I-4.10c).

A1-3.3

SMALL SCALE BURN TEST

This test is performed in order to verify that modified resins are being used. Samples are to be cut from larger pieces previously used for density and flexural testing. Tests are to be conducted at a minimum frequency as per instructions provided above (use FORM I-4.10c).

A1-4.0

DIMENSIONAL TOLERANCE

Dimensional tolerances are a function of cutting procedures. Manufacturers’ cutting schedules will indicate the type, B.I.D., length, width, and thickness. Production personnel shall be aware of tolerance limits on products being produced. Production personnel will periodically verify that the material complies with tolerance specifications. In addition, personnel will measure and record a minimum of two boards per order, but at least one of each size, to see that they comply with tolerances of individual customer specifications. See Appendix II of this manual for specifications.

26

Issued 7/92 Rev. 4/01

27

Issued 7/92 Rev. 1/02

28

Issued 7/92 Rev. 1/02

APPENDIX II

PRODUCT PERFORMANCE STANDARDS

THIS SECTION INCLUDES THE PRODUCT STANDARDS AND MARKINGS FOR ALL PRODUCTS COVERED UNDER THE LISTING AND FOLLOW-UP PROGRAM FOR

PII/IF EPS PRODUCTS.

29

Issued 7/92 Rev. 1/02

TYPE I CERTIFIED/CODE LISTED IF TYPE I BOARD .90 PCF minimum

ASTM C 578 STANDARD SPECIFICATION

Feature

Acceptance Limits

Density

.90 pcf minimum

Flexural

25 psi minimum

Thermal 75° F 40° F

3.6 minimum for 1" ASTM C 518 4.0 minimum for 1" ASTM C 518

Dimensional

Length Width Thickness Square within

Compressive

10 psi min. @ 10% def.

Oxygen Index

24.0 minimum

* Flame Spread and Smoke Density (max.)

+/- 1/32"/ft. +/- 1/16"/ft. +/- 1/16"/in. 1/16"/ft. of width and length

* 15 flame spread and 150-300 smoke developed as tested per ASTM E 84.

Special Requirements Resin

(See TABLE A1-A for suppliers.) Boards molded for use in exposed conditions in attics and crawl spaces are restricted to the use of BASF Styropor BL or BFL or NOVA Dylite M77 or 33M EPS beads in their manufacture.

Labeling

Certified/Code Listed material will be marked with the classification mar-king of the QAA and code listing number. See FIGURE A2-1.1 or A2-1.2.

NOTE : See FIGURE A2-1.1 for labeling format used for board intended for attic or crawl space. * Data reflects values while materials remained in their original test position. These ratings are not intended to reflect hazards in actual use.

30

Issued 7/92 Rev. 4/01

IEG TYPE I CERTIFIED/CODE LISTED IF INSULFOAM EIFS BOARD IEG TYPE I

ASTM C 578 STANDARD SPECIFICATION

Feature

Acceptance Limits

Density

.90 pcf minimum

Flexural

25 psi minimum

Thermal 75° F 40° F

3.6 minimum for 1" ASTM C 518 4.0 minimum for 1" ASTM C 518

Dimensional

Length +/- 1/32"/ft. Width +/- 1/16"/ft. Thickness +/- 1/16"/in. ¾” minimum to 4” maximum Square within 1/16"/ft. of width and length Flatness +/- 1/32" on length

Compressive

10 psi min. @ 10% def.

Oxygen Index

24.0 minimum

* Flame Spread and Smoke Density (max.)

* 15 flame spread and 150-300 smoke developed as tested per ASTM E 84.

Special Requirements Resin

(See TABLE A1-A for suppliers.)

Labeling & Packaging

Each IEG board will be edge-marked per paragraph A1-2.5. Each package will have one board with both faces stamped with marking. IEG will be packed in plastic bags or wrap. Classification markings will be per FIGURE A2-1.1 or A2-1.2.

* Data reflects values while materials remained in their original test position. These ratings are not intended to reflect hazards in actual use.

31

Issued 7/92 Rev. 4/01

TYPE I CERTIFIED/CODE LISTED PREMIER PANEL CORE

IF PREMIER BUILDING PANEL CORES .95 PCF minimum ASTM C 578 STANDARD SPECIFICATION

Feature

Acceptance Limits

Density

.90 pcf minimum

Flexural

25 psi minimum

Thermal 75° F 40° F

3.6 minimum for 1" ASTM C 518 4.0 minimum for 1" ASTM C 518

Dimensional

Length Width Thickness Square within

Compressive

10 psi min. @ 10% def.

Oxygen Index

24.0 minimum

* Flame Spread and Smoke Density (max.)

+/- 1/32"/ft. +/- 1/16"/ft. +/- 1/16"/in. 1/16"/ft. of width and length

* 15 flame spread and 150-300 smoke developed as tested per ASTM E 84.

Special Requirements Resin

(See TABLE A1-A for suppliers.)

Labeling

Certified/code listed material will be marked with the classification mar-king of the QAA and code listing number. See FIGURE A2-1.1 or A2-1.2.

* Data reflects values while materials remained in their original test position. These ratings are not intended to reflect hazards in actual use.

32

Issued 7/92 Rev. 4/01

Type VIII Certified/Code Listed IF TYPE VIII BOARD 1.15 PCF minimum ASTM C 578 STANDARD SPECIFICATION

Feature

Acceptance Limits

Density

1.15 pcf minimum

Flexural

30 psi minimum

Thermal 75° F 40° F

3.8 minimum for 1" ASTM C 518 4.2 minimum for 1" ASTM C 518

Dimensional

Length +/- 1/32"/ft. Width +/- 1/16"/ft. Thickness +/- 1/16"/in. Square within 1/16"/ft. of width and length

Compressive

13 psi min. @ 10% def.

Oxygen Index

24.0 minimum

* Flame Spread and Smoke Density (max.)

* 15 flame spread and 150-300 smoke developed as tested per ASTM E 84.

Special Requirements

*

Resin

(See TABLE A1-A for suppliers.)

Labeling

Certified/code listed material will be marked with the classification marking of the QAA and code listing number. See FIGURE A2-1.1 or A2-1.2.

Data reflects values while materials remained in their original test position. These ratings are not intended to reflect hazards in actual use.

33

Issued 7/92 Rev. 4/01

TYPE II CERTIFIED/CODE LISTED

IF TYPE II BOARD 1.35 PCF MINIMUM ASTM C 578 STANDARD SPECIFICATION

Feature

Acceptance Limits

Density

1.35 pcf minimum

Flexural

35 psi minimum

Thermal 75° F 40° F

4.0 minimum for 1" ASTM C 518 4.4 minimum for 1" ASTM C 518

Dimensional

Length +/- 1/32"/ft. Width +/- 1/16"/ft. Thickness +/- 1/16"/in. Square within 1/16"/ft. of width and length

Compressive

15 psi min. @ 10% def.

Oxygen Index

24.0 minimum

* Flame Spread and Smoke Density (max.)

*

* 15 flame spread and 150-300 smoke developed as tested per ASTM E 84.

Special Requirements Resin

(See TABLE A1-A for suppliers.)

Labeling

Certified/code listed material will be marked with the classification marking of the QAA and code listing number. See FIGURE A2-1.1 or A2-1.2.

* Data reflects values while materials remained in their original test position. These ratings are not intended to reflect hazards in actual use.

34

Issued 7/92 Rev. 9/04

TYPE IX CERTIFIED/CODE LISTED IF TYPE IX BOARD 1.8 PCF minimum ASTM C 578 STANDARD SPECIFICATION

Feature

Acceptance Limits

Density

1.8 pcf minimum

Flexural

50 psi minimum

Thermal 75° F 40° F

4.2 minimum for 1" ASTM C 518 4.6 minimum for 1" ASTM C 518

Dimensional

Length +/- 1/32"/ft. Width +/- 1/16"/ft. Thickness +/- 1/16"/in. Square within 1/16"/ft. of width and length

Compressive

25 psi min. @ 10% def.

Oxygen Index

24.0 minimum

* Flame Spread and Smoke Density (max.)

* 15 flame spread and 150-300 smoke developed as tested per ASTM E 84.

Special Requirements Resin

(See TABLE A1-A for suppliers.)

Labeling

Certified/code listed material will be marked with the classification marking of the QAA and code listing number. See FIGURE A2-1.1 or A2-1.2.

* Data reflects values while materials remained in their original test position. These ratings are not intended to reflect hazards in actual use.

35

Issued 7/92 Rev. 4/01

TYPE IX CERTIFIED/CODE LISTED PREMIER PANELS IF TYPE IX BOARD PREMIER BUILDING PANEL CORES 1.8 PCF MINIMUM ASTM C 578 STANDARD SPECIFICATION

Feature

Acceptance Limits

Density

1.8 pcf minimum

Flexural

50 psi minimum

Thermal 75° F 40° F

4.2 minimum for 1" ASTM C 518 4.6 minimum for 1" ASTM C 518

Dimensional

Length Width Thickness Square within

Compressive

25 psi min. @ 10% def.

Oxygen Index

24.0 minimum

* Flame Spread and Smoke Density (max.)

+/- 1/32"/ft. +/- 1/16"/ft. +/- 1/16"/in. 1/16"/ft. of width and length

* 15 flame spread and 150-300 smoke developed as tested per ASTM E 84.

Special Requirements Resin

(See TABLE A1-A for suppliers.)

Labeling

Certified/code listed material will be marked with the classification mar-king of the QAA and code listing number. See FIGURE A2-1.1 or A2-1.2.

* Data reflects values while materials remained in their original test position. These ratings are not intended to reflect hazards in actual use.

36

Issued 7/92 Rev. 4/01

MARKING DIAGRAM

UL/PII/IF PRODUCT EDGE MARKING CERTIFICATE PII-1

All IF plants will display the following on each EPS board:

SHORT EDGE OF BOARD This mark will appear on all EPS board used as IEG, EIFS, FreeForm shapes, and all Type I, VIII, II, and IX EPS board. This includes Certified and Certified/Code Listed Material.

See Cert. PII-1

PII’s/IF’s QC Agency

LONG EDGE OF BOARD

Type I EPS

IF Code Report # **(ICBO)

I- ____ (Plant Identification Nos.)

Physical type of EPS provided. Meets minimum standards of ASTM C-578. ** Code compliance numbers of PII/IF ICBO ER3414

SPECIAL NOTE : Packages, bags, or wraps can bear this same reference to the UL/PII/IF Certificate PII-1.

Figure A2-1.1

37

Issued 7/92 Rev. 9/01

MARKING DIAGRAM UL/PII/IF PRODUCT EDGE MARKING CERTIFICATE PII-1

All plants will display the following on each EPS board: This mark will appear on all EPS board as described in the first paragraph, “Description”, of Sec. 2 and Sec. 3 of R14313, Vol. I. This includes Certified and Certified/Code Listed Material.

SHORT EDGE OF BOARD See Cert. PII-1

PII’s/IF’s QC Agency

LONG EDGE OF BOARD

Type I EPS

IF Code Report # **(ICBO)

I- ____ (Plant Identification Nos.)

Physical type of EPS provided. Meets minimum standards of ASTM C-578. ** Code compliance numbers of PII/IF ICBO ER3414

SPECIAL NOTE : Packages, bags, or wraps can bear this same reference to the UL/PII/IF Certificate PII-1.

Figure A2-1.2

38

Issued 7/92 Rev. 9/01

MARKING DIAGRAM UL/PII/IF PRODUCT EDGE MARKING CERTIFICATE PII- 5

All plants will display the following on each EPS board: This mark will appear on all EPS board as described in the first paragraph, “Description”, of Sec. 2 and Sec. 3 of R14313, Vol. I. This includes certified roofing material.

SHORT EDGE OF BOARD See Cert. PII-5 PII’s/IF’s QC Agency

LONG EDGE OF BOARD

Type I EPS

I- ____ (Plant Identification Nos.)

Physical type of EPS provided. Meets minimum standards of ASTM C-578.

SPECIAL NOTE : Packages, bags, or wraps can bear this same reference to the UL/PII/IF Certificate PII-5.

Figure A2-1.3

39

Issued 7/92 Rev. 9/01

TYPE I CERTIFIED IF TYPE I BOARD .90 PCF minimum

ASTM C 578 STANDARD SPECIFICATION

Feature

Acceptance Limits

Density

.90 pcf minimum

Flexural

25 psi minimum

Thermal 75° F 40° F

3.6 minimum for 1" ASTM C 518 4.0 minimum for 1" ASTM C 518

Dimensional

Length Width Thickness Square within

Compressive

10 psi min. @ 10% def.

Oxygen Index

24.0 minimum

* Flame Spread and Smoke Density (max.) Post Production Blend

+/- 1/32"/ft. +/- 1/16"/ft. +/- 1/16"/in. 1/16"/ft. of width and length

* 15 flame spread and 150-300 smoke developed as tested per ASTM E 84. ≤15% - PII-1

≤ 25% - PII-5

Special Requirements Labeling

Certified material will be marked with the classification marking of the QAA. See FIGURE A2-1.1 OR A2-1.2.

* Data reflects values while materials remained in their original test position. These ratings are not intended to reflect hazards in actual use.

40

Issued 7/92 Rev. 9/01

TYPE VIII CERTIFIED IF TYPE VIII BOARD 1.15 PCF minimum ASTM C 578 STANDARD SPECIFICATION

Feature

Acceptance Limits

Density

1.15 pcf minimum

Flexural

30 psi minimum

Thermal 75° F 40° F

3.8 minimum for 1" ASTM C 518 4.2 minimum for 1" ASTM C 518

Dimensional

Length Width Thickness Square within

Compressive

13 psi min. @ 10% def.

Oxygen Index

24.0 minimum

* Flame Spread and Smoke Density (max.) Post Production Blend

+/- 1/32"/ft. +/- 1/16"/ft. +/- 1/16"/in. 1/16"/ft. of width and length

* 15 flame spread and 150-300 smoke developed as tested per ASTM E 84. ≤15% - PII-1

≤ 25% - PII-5

Special Requirements Labeling

Certified material will be marked with the classification marking of the QAA. See FIGURE A2-1.1 OR A2-1.2.

* Data reflects values while materials remained in their original test position. These ratings are not intended to reflect hazards in actual use.

41

Issued 7/92 Rev. 9/01

TYPE II CERTIFIED IF TYPE II BOARD 1.35 PCF minimum ASTM C 578 STANDARD SPECIFICATION

Feature

Acceptance Limits

Density

1.35 pcf minimum

Flexural

35 psi minimum

Thermal 75° F 40° F

4.0 minimum for 1" ASTM C 518 4.4 minimum for 1" ASTM C 518

Dimensional

Length Width Thickness Square within

Compressive

15 psi min. @ 10% def.

Oxygen Index

24.0 minimum

* Flame Spread and Smoke Density (max.) Post Production Blend

*

+/- 1/32"/ft. +/- 1/16"/ft. +/- 1/16"/in. 1/16"/ft. of width and length

* 15 flame spread and 150-300 smoke developed as tested per ASTM E 84. ≤15% - PII-1

≤ 25% - PII-5

Special Requirements

Labeling

Certified material will be marked with the classification marking of the QAA. See FIGURE A2-1.1 OR A2-1.2.

* Data reflects values while materials remained in their original test position. These ratings are not intended to reflect hazards in actual use.

42

Issued 7/92 Rev. 9/04

TYPE IX CERTIFIED IF TYPE IX BOARD 1.8 PCF MINIMUM ASTM C 578 STANDARD SPECIFICATION

Feature

Acceptance Limits

Density

1.8 pcf minimum

Flexural

50 psi minimum

Thermal 75° F 40° F

4.2 minimum for 1" ASTM C 518 4.6 minimum for 1" ASTM C 518

Dimensional

Length +/- 1/32"/ft. Width +/- 1/16"/ft. Thickness +/- 1/16"/in. Square within 1/16"/ft. of width and length

Compressive

25 psi min. @ 10% def.

Oxygen Index

24.0 minimum

* Flame Spread and Smoke Density (max.) Post Production Blend

* 15 flame spread and 150-300 smoke developed as tested per ASTM E 84. ≤15% - PII-1

≤ 25% - PII-5

Special Requirements

Labeling

Certified material will be marked with the classification marking of the QAA. See FIGURE A2-1.1 OR A2-1.2.

* Data reflects values while materials remained in their original test position. These ratings are not intended to reflect hazards in actual use.

43

Issued 7/92 Rev. 9/01

A2-1.0

Major and Minor Defects

A2-1.1 Major defects are those that would cause the product not to meet the physical

requirements and the permissible dimensional variations of ASTM C-578, paragraphs 7.0 and 8.0. A2-1.2 Workmanship, finish, and appearance shall not be more or less than that specified in

paragraph 9.0 of ASTM C-578. A2-1.3 Anything more than the least or less than the most specified in paragraph 9.0 of ASTM

C-578 shall be considered minor defects.

44

Issued 7/92 Rev. 9/01

TEST INSTRUCTIONS (Also see Part II.)

A2-2.0 A2-2.1

SMALL SCALE BURN TEST TEST CRITERIA

Materials should be deemed acceptable on the basis of test results obtained on three small bar specimens selected from the samples when tested as described below: Flame shall self-extinguish before reaching the 4-inch mark on the sample. See FIGURE A2-4.1. Measure the most extreme point of burn. If more than one specimen fails to comply with the requirements, the lot is not acceptable. If only specimen from a set of three specimens fails to comply, another set of three specimens cut from three other samples shall be tested. All specimens from this second set shall comply with the above requirements in order for that lot to be accepted and labeled.

A2-2.2

APPARATUS

The recommended apparatus is to consist of the following: A2-2.2.1 Draft-free room or test chamber, enclosure, or laboratory hood; A2-2.2.2 Laboratory Burner: A Bunsen or Tirrill burner having a tube with a length of 4” (102mm)

and an inside diameter or 3/8” (9.5 mm). The tube shall not be equipped with end attachments such as a stabilizer; A2-2.2.3 Gas Supply: A supply of Technical Grade methane gas, natural gas, or propane gas

with suitable regulator and meter for uniform gas flow; A2-2.2.4 Ring Stand: A ring stand with clamps, or the equivalent, for positioning of the specimen.

A2-2.3

TEST SPECIMEN

The specimen shall comply with the following: A2-2.3.1

Maximum size is to be ½” x ½” x 5” (length may be any desirable length >5”).

A2-2.3.2

Edges are to be smooth, and radius on corners is not to exceed 0.05” (1.3 mm).

45

Issued 7/92 Rev. 4/01

A2-2.4

TEST METHOD

The Burning Test is to be conducted in a draft-free area. Each specimen is to be marked across its width with a line 4” from one end of the specimen. The specimen is to be clamped at the end furthest from the 4-inch mark, with its longitudinal axis 45° from horizontal. See FIGURE A2-4.1. The burner is then to be placed remote from the specimen, ignited, and adjusted to produce a blue flame 1” high. The flame is to be obtained by adjusting the gas supply and the air ports of the burner until a 1” yellow-tipped blue flame is produced, and then the air supply is to be increased until the yellow tip disappears. The height of the flame is to be measured again and corrected if necessary. The flame is to be applied to the free end of the lower edge of the specimen. The center axis of the burner tube is to be in the same vertical plane as the longitudinal bottom edge of the specimen (and inclined toward the end of the specimen) at an angle of approximately 45° to the horizontal. The flame is to be applied so that the front edge of the specimen, to a depth of approximately ¼”, is subjected to the test flame. If the specimen does not burn to the maximum mark and the flame extinguishes, the specimen is considered to be acceptable. If the specimen continues to burn past the maximum mark, it is considered to have failed the test.

FIGURE A2-4.1

46

Issued 7/92 Rev. 4/01

A2-3.0

FLEXURAL TEST

The Flexural Test is performed a minimum of once per B.I.D. Each Flexural Test is composed of three specimens. The specimens are 1” x 3” x 12” or 1” x 4” x 12”. The specimens shall be taken from the locations in the billet as shown in figure A1-2.3 Testing will be done on an approved test fixtures shown in FIGURE A2-4.2. Minimum weights required for each density are shown below.

TYPE

MINIMUM DENSITY

MINIMUM FLEXURAL STRESS

WEIGHT

WEIGHT

1” X 3” X 12”

1” X 4” X 12”

I

0.90

25 psi

5.0 lbs

6.67 lbs

VIII

1.15

30 psi

6.0 lbs

8.00 lbs

II

1.35

35 psi

7.0 lbs

9.35 lbs

IX

1.80

50 psi

10.0 lbs

13.33 lbs

FLEXURAL TEST 47 APPARTUS

Issued 7/92 Rev. 7/04

*

Figure A2-4.2 APPENDIX – III

48 PROCESS PROCEDURE EPS RCM

Issued 3/98 Rev. 9/01

Process Procedure for Recycling Expanded Polystyrene (EPS) Material A3-1.0

PURPOSE

This procedure describes the process for recycling modified EPS product material trimmings and dimensional defects back into the product line, rather than letting them become a part of the environmental and landfill problem.

A3-1.1

APPLICATION

The procedure is applicable to all clean and dry modified portions of EPS product from job sites or our own cut-to-size and fabrication operations.

A3-1.2

PROCEDURE

A3-1.2.1

Product to be reclaimed shall be collected at a Premier Industries EPS Plant (Insulfoam or Premier Packaging).

A3-1.2.2

It shall be clean and dry.

A3-1.2.3

A Small Scale Burn Test shall be performed on the EPS material to be recycled in order to determine if it is modified or unmodified.

A3-1.2.4

The unmodified EPS material shall be separated and used as recycled regular grade material in shape molding or in other regular material products, or it shall be compacted and sent to a polystyrene recycle resin processor.

A3-1.2.5

Specimens from the recyclable modified EPS shall be cut to a convenient size, measured, weighed, and the density determined.

A3-1.2.6

Recyclable modified EPS material with a density <1.35 pcf shall be separated from that with a density ≥1.35 pcf.

A3-1.2.7

From this point forward, the <1.35 pcf and ≥1.35 pcf densities shall be kept separated in storage silos (bags); but the process for each density shall be the same.

A3-1.2.8

The recyclable EPS material shall be granulated.

A3-1.2.9

The granulated recyclable EPS material will proceed through a dust separator. The dust (fines) shall be melted into solid polystyrene, or disposed of in other appropriate ways.

A3-1.2.10

The two different densities will then be stored in separate silos after dust removal and be ready for use.

49

Issued 3/98 Rev. 9/01

A3-1.2.11

The modified EPS granules <1.35 pcf density shall be metered into virgin pre-expanded modified EPS material of 1.0 to 1.25 nominal density product.

A3-1.2.12

The modified EPS granules ≥1.35 pcf density shall be metered into virgin pre-expanded modified EPS material of 1.5 to 2.0 nominal density product.

A3-1.2.13

The modified EPS granules and the virgin EPS pre-puff shall be metered together through a metering station. The auger setting for each material shall be calibrated by measuring volume against time.

A3-1.2.14

The modified EPS granules shall not exceed allowable volume, of the total of RCM and Virgin EPS material.

A3-1.2.15

The molding report will reflect the cubic feet of virgin pre-puff used and the total cubic feet molded, the difference being the percent RCM.

A3-1.2.16

This product will be traceable by the Batch I.D. No. assigned to the virgin material at the time of pre-expansion.

A3-1.2.17

The QA tests performed after the material is cut for the job will be: (A) Density Determination; B) Flexural Strength Test; and C) Small Scale Burn Test. The Test Data Sheet reflects the Batch I.D. No. and Work Order No.

A3-1.2.18

After cutting, the product is marked, labeled, and packaged.

A3-1.2.19

The Bill of Lading and/or Batch I.D. No. are marked on the outside of the packaging.

A3-1.2.20

Traceability for the product shall be as follows:

A3-1.2.20.1

The Order No., Bill of Lading No., and Invoice No. are the same number in the system, and assigned by the computer.

A3-1.2.20.2

The Bill of Lading No. and/or the Batch I.D. No. is marked on the package.

A3-1.2.20.3

The Test Data Sheet has the Batch I.D. No. and the Order No. recorded on it.

A3-1.2.20.4

The back side of the yellow copy of the Bill of Lading is the cut sheet.

A3-1.2.20.5

The Batch I.D. No. and the block numbers of the molded EPS that are used to fill the order are recorded on the cut sheet.

A3-1.2.20.6

The Batch I.D. No., silo(s) number(s), billet number, and billet weights are recorded on the molding report. The volume of pre-puff and total volume molded is on this report.

A3-1.2.20.7

On the pre-expansion report are recorded the Batch I.D. No., Bead Type, Bead Lot No., Bead Box Nos., pre-expansion weights, and silo(s) number(s).

A3-1.2.20.8

On the Batch I.D. Log are recorded the Batch I.D. No., Bead Manufacturer, Bead Type, Bead Lot No., Number of Pounds Pre-Expanded, and Box Nos.

A3-1.2.20.9

There is traceability from the package on the job site, and through testing, cutting, molding, pre-expansion to bead manufacturer, bead type, lot number, and box number. 50

Issued 3/98 Rev. 9/01

Chart A3-1.0

51

Issued 7/92 Rev. 9/01

APPENDIX IV

MANUFACTURING PROCEDURES FOR

R-TECH™

52

Issued 3/98 Rev. 9/01

TABLE A4-1.0

55 55

EPS Polyethylene Polypropylene

56 56 56

HANDLING PROCEDURES A4-3.1

Receiving

A4-3.1.1

EPS

A4-3.1.2

Polyethylene

A4-3.1.3

Polypropylene

A4-3.2

A4-4.0

Purpose of this manual Administration

APPROVED RAW MATERIALS A4-2.1 A4-2.2 A4-2.3

A4-3.0

CONTENTS

INTRODUCTION A4-1.1 A4-1.2

A4-2.0

OF

57 57 57

Storage

A4-3.2.1

EPS

A4-3.2.2

Polyethylene

A4-3.2.3

Polypropylene

57 57 57

STAGING A4-4.1 A4-4.2 A4-4.3

EPS Polyethylene Polypropylene

53

58 58 58

Issued 3/98 Rev. 9/01

A4-5.0

LAMINATION A4-5.1

A4-6.0

A4-7.0

A4-8.0

Equipment

A4-5.1.1

Roll Coater Set-up

A4-5.1.2

Preparation to Run

A4-5.1.3

Cutting of Continuous Laminate

58 59 59

QUALITY CONTROL

60

A4-6.0

60

R-TECH Laminate QC Procedure

RAW MATERIAL SPECIFICATIONS

61

A4-7.1 A4-7.2 A4-7.3

61 61 62

Expanded Polystyrene Polyethylene Polypropylene

CUSTOMER SPECIFICATIONS

54

63

Issued 3/98 Rev. 9/01

A4-I.0 INTRODUCTION A4-1.1

The Purpose of this Manual This manual has been created to provide each of the Premier Industries, Inc. / Insulfoam manufacturing facilities with a standard operating procedure for the production of R-TECH laminate products. This manual has been developed using input from our manufacturing teams and suppliers. It will assist each of us in our production of R-TECH laminates, assuring that all product shipped meets Premier’s standards and, above all else, the customers’ expectations. This manual is to be a part of the Quality Control Manual for Insulfoam, and pertains only to R-TECH. This manual is designed as a living document, such that changes due to increased knowledge in our manufacturing process, raw materials, and new requirements by our customers will require that the manual be updated. Amendments or changes will be forwarded to each facility as changes are implemented. It is imperative that you up-date this manual as changes are received. This document is to be followed as the manufacturing guidelines for the manufacture of R-TECH laminates using polyethylene and polypropylene films. Deviations from the procedures in this manual must be documented and forwarded immediately to the Premier Technical Center. Deviations in raw material may not be made without written approval from the Technical Center. All raw materials must appear on the Approved Raw Materials list found in Section II of this manual. Vendors requesting approval should be forwarded to the Premier Technical Center for product evaluation.

A4-1.2

Administration Production personnel are responsible for making certain that proper material and processes are utilized. Production personnel must complete documentation and use the appropriate forms enclosed. Facility management will review production documentation on a weekly basis to ensure conformance.

55

Issued 3/98 Rev. 9/01

A4-2.0 APPROVED RAW MATERIALS A4-2.1

EPS Refer to table A1-A for acceptable resin types. Material must be U.L.-certified (see Appendix II). Refer to customer specifications found in A4-8.0 if applicable. All code listed board shall be manufactured with beads recognized in a current ICBO evaluation report as complying with ASTM C578.

A4-2.2

Polyethylene All polyethylene purchased must meet the specifications listed in the Appendix. Presently, the following manufacturers have demonstrated that they can meet the specifications. Please note that the specifications included in A4-8.0 must be forwarded to the supplier, and all purchase orders must reference specifications if applicable.

A4-2.3

Manufacturer

Product

Pliant Corporation

PE X3-419

Polypropylene All polypropylene purchased must meet the specifications listed in the Appendix. Presently, the following manufacturers have demonstrated that they can meet the specifications. Please note that the specifications included in A4-8.0 must be forwarded to the supplier, and all purchase orders must reference specifications if applicable. Manufacturer

Product

Pliant Corporation

LX 859-02

Sonoco Products

X85-902 Ins-4520 Ins-2425 Ins-4520T

56

*

Issued 3/98 Rev. 10/04

A4-3.0 HANDLING PROCEDURES A4-3.1

Receiving

A4-3.1.1

EPS – Receiving inspection is primarily visual. Check to ensure that corners are intact, that sheets do not contain severe wire chatter marks that will telegraph through the laminate, and that laminate is clean and dry. Material found to contain irregularities or not meeting visual inspection should be rejected and removed from lamination department. All material must be QC tested (Appendix I, 1A-3.0) and U.L. labeled. Note: Maximum recycled content is 15%.

A4-3.1.2

Polyethylene – Receiving inspection is primarily visual. Check material, as it is unloaded for rolls that are damaged or telescoping. Check rolls to assure that proper width has been shipped. Record data contained on manufacturer documents found with shipment of PE rolls. Damaged rolls should be set aside and the supplier notified immediately.

A4-3.1.3

Polypropylene – Receiving inspection is primarily visual. Check material, as it is unloaded for rolls that are damaged or telescoping. Check rolls to assure that proper width has been shipped. Record data contained on manufacturer documents found with shipment of PP rolls. Damaged rolls should be set aside and the supplier notified immediately.

A4-3.2

Storage

A4-3.2.1

EPS – Once received, EPS must be stored out of weather in an area that will protect the edges and corners.

A4-3.2.2

Polyethylene – Rolls of PE material are to be stored as received on shipping pallets, in original wrapper provided by supplier. Rolls should be stored out of the elements and in temperatures of 40º - 100ºF. In all cases, the rolls must be stabilized in staging at a minimum temperature of 40ºF. Furthermore, rolls must be stored flat, and care should be taken when handling in order to prevent damage from compression at the ends of the rolls.

A4-3.2.3

Polypropylene – Rolls of PP material are to be stored as received on shipping pallets, in original wrapper provided by supplier. Rolls should be stored out of the elements and in temperatures of 40º - 100ºF. In all cases, the rolls must be stabilized in staging at a minimum temperature of 40ºF. Furthermore, rolls must be stored flat, and care should be taken when handling in order to prevent damage from compression at the ends of the rolls.

57

Issued 3/98 Rev. 9/01

A4-4.0 STAGING A4-4.1

EPS

A4-4.1.1

EPS – EPS sheets should be brought into the lamination area one hour prior to lamination in order to allow for equilibration of temperature. Prior to use, the EPS must be checked to assure that the material meets the customer’s specifications outlined in the Appendix. Measure and record the thickness, width, and length of the EPS.

A4-4.1.2

Polyethylene – PE should be carefully placed into position next to laminator so that it can be lifted onto the roll coater. Remove the adhesive tape and any over-wrap from the roll. DO NOT USE OUT-OF-SPEC MATERIAL.

A4-4.1.3

Polypropylene – PP should be carefully placed into position next to laminator so that it can be lifted onto the roll coater. Remove the adhesive tape and any over-wrap from the roll. DO NOT USE OUT-OF-SPEC MATERIAL.

A4-5.0 LAMINATION A4-5.1 A4-5.1.1

Equipment Roll Coater Set-up – Prior to any start-up, roll coater should be checked to ensure that gauge distance between applicator rollers is equal along the length of the rollers. Rollers that do not exhibit even gauge distance must be adjusted. Uneven gauge distance will result in an inconsistent pinch that may cause poor lamination. The roll coater should be started a minimum of 30 minutes prior to use, and oil temperatures should be set to 245º - 275ºF. Film rolls should be placed on the spindles and loaded onto the roll coater. To load the rolls on the spindles, insert the cones into the ends of the rolls and then insert the pipe through the spindles. Care should be taken that the rolls will unwind as needed. The film has a bottom surface and a top surface; the bottom surface is the surface that is to be mated to the EPS. Placement of the rolls on the pipe will require that the cone collars be driven into the roll core. The rolls must be centered on the pipe assembly, and break pressure should be set to zero. Once the film rolls are in position on the machine, thread the film through the rollers and pull both films out onto the feed table. The rollers of the roll coater are heating, so care should be taken during the thread operation in order to avoid injury. Placement of kraft paper on the lead edge of the films may facilitate the threading process.

58

Issued 3/98 Rev. 9/01

A4-5.1.2

Preparation to Run – Check to make sure that no heat is being placed in the doctor rollers. Measure the thickness of the EPS to be laminated, and set roller height or pinch so that the distances between the top and bottom rollers are a minimum of 0.125” less than the thickness of the EPS. As an option, the roller distance may be set at 0.25” below the nominal thickness of the EPS to be laminated. Roller distances that are greater than 0.125” less than the thickness of the EPS may result in poor lamination. Next, make sure that the pinch rollers are opened. It is not necessary to run the pinch rollers when manufacturing R-Tech. Set the speed of the machine. EPS staging should be near roll coater. EPS must be placed so that the EPS is tight to guide fence and butted tightly to prior piece fed into roll coater. All EPS that has contamination, poor edges, or broken corners should be culled prior to insertion into the roll coater. EPS which exhibits severe wire chatter marks on the surface or unusual picture framing height differences (greater than 1/32”) should also be culled. EPS should be continuously loaded into the laminator so that the edges are butted tightly. Should it be necessary to stop operating for a period of time (i.e. lunch), turn the roller heat down to 150ºF in order to prevent melting of the film while keeping the rollers warm. Upon return to the machine, increase the roller temperature to 245ºF minimum, and continue the lamination order. During lamination, film tracking should be maintained so that the film is within 0.25” of the edge of the EPS. Near the end of a film roll, additional unwinding may be required to eliminate stretch in the film that will cause it to be placed short of the EPS edge.

A4-5.1.3

Cutting of Continuous Laminate – As the laminate exits the laminator, it will be necessary to cut the laminate to the appropriate size. This process can be accomplished either with the use of a fly-by cutter (saw or knife) or by hand with a knife. In either operation, care should be taken to ensure that clean edges are obtained. Fan-fold product should be fed into the fan-folding device and cut as needed for desired length. Check customer specifications for packaging requirements and prepare for proper packaging. Most customers request that the product be stacked to a specific height, or require x number of pieces per bundle. Also, review if additional markings on the ends of the laminate are required.

59

Issued 3/98 Rev. 9/01

A4-6.0 QUALITY CONTROL During the lamination process, a continuous visual examination is to take place. Product that has broken edges, missing EPS, or film placement >0.25” from the edge should be culled. A technique for checking the lamination is to remove a sample from the run. This sample should be subjected to hand peel test. The test should take place at start-up, at the beginning of each new roll of film, after each break, and a minimum of once every hour.

60

Issued 3/98 Rev. 9/01

RAW MATERIAL SPECIFICATIONS

A4-7.0 A4-7.1

EXPANDED POLYSTYRENE

DENSITY

:

Customer specification will mandate density requirements.

LENGTH

:

± 1/8”, based on customer specification.

WIDTH

:

± 1/32”, based on customer specification.

THICKNESS

:

± 1/16”, based on customer specification.

SQUARENESS

:

Shall not deviate from square by more than 0.06 in./ft of length.

DEFECTS

:

No defects that will affect appearance or quality of lamination are allowed. EPS shall have uniform texture and be free of foreign inclusions, broken edges, and corners.

Note : EPS material must undergo and pass U.L. QC tests. The material may contain no more than 15% recycled content. (See Appendix I, 3.0.)

A4-7.2

POLYETHYLENE

THICKNESS

:

.001”

WIDTH

:

48.5” ± 1/16”

ROLL TENSION

:

Roll must be tightly wound to withstand normal handling without telescoping.

ROLL TELESCOPE

:

Maximum ½” off square to core.

ROLL WEAVE

:

Maximum ½”

BELLED EDGE

:

Maximum ½”

COLOR

:

White; printed blue on white and metalized

PACKAGING

:

Flat stacking on pallets with separator sheet applied to top of pallet.

61

Issued 3/98 Rev. 9/01

A4-7.3

POLYPROPYLENE

THICKNESS

:

.0015”

WIDTH

: :

48.5” ± 1/16” [Pliant] 48.375 ± 1/16” [Sonoco]

ROLL TENSION

:

Roll must be tightly wound to withstand normal handling without telescoping.

ROLL TELESCOPE

:

Maximum ½” off square to core.

ROLL WEAVE

:

Maximum ½”

BELLED EDGE

:

Maximum ½”

COLOR

:

White; printed blue on white, blue, Teal and metalized

PACKAGING

:

Flat stacking on pallets with separator sheet applied to top of pallet.

62

*

Issued 3/98 Rev. 10/04

*

APPENDIX V

QUALITY INSPECTION PROCEDURES FOR

POLY-GARD 136

63

Issued 8/03

TABLE A5-1.0

Purpose of this manual Administration

65 65

APPROVED RAW MATERIALS A5-2.1 A5-2.2

A5-3.0

CONTENTS

INTRODUCTION A5-1.1 A5-1.2

A5-2.0

OF

Poly-Gard 136 Tape Polyethylene Tape Manufacturer

66 66

HANDLING PROCEDURES A5-3.1 A5-3.2

Receiving & Inspection Storage

66 66

A5-4.0

QUALITY CONTROL

67

A5-5.0

MATERIAL SPECIFICATIONS

67

A5-6.0

CUSTOMER SPECIFICATIONS

68

64

Issued 8/03

A5-1.0 A5-1.1

INTRODUCTION The Purpose of this Manual This manual has been created to provide each of the Premier Industries, Inc. / Insulfoam manufacturing facilities with a standard operating procedure for the quality inspection of Poly-Gard 136 Polyethylene tape. This manual has been developed using input from our manufacturing teams and supplier. It will assist each of us in our inspections, assuring that all product shipped meets Premier’s standards and, above all else, the customers’ expectations. This manual is to be a part of the Quality Control Manual for Insulfoam, and pertains only to the Poly-Gard 136 tape. This manual is designed as a living document, such that changes due to Increased knowledge in our manufacturing process, raw materials, and new Requirements by our customers and vendors will require the manual be up-dated. Amendments or changes will be forwarded to each facility as changes will be forwarded to each facility as changes are implemented. It is imperative that you up-date this manual as changes are received. This document is to be followed as the inspection guidelines for the inspection of the Insulfoam Poly-Gard 136 tape. Deviations from the Procedures in this manual must be documented and forwarded immediately to the Premier Technical Center. Deviations may not be made without written approval from the Technical Center.

A5-1.2

Administration Production personnel are responsible for making certain the received Material and processes are utilized. Production personnel must complete Documentation and use the appropriate forms upon receiving. Facility Management will review documentation on as received basis to ensure Conformance. Product received at the Insulfoam manufacturing facility will be responsible for conformance on received shipments.

65

Issued 8/03

APPROVED MATERIAL

A5-2.0 A5-2.1

Poly-Gard 136 Tape Material received shall be packaged 24 rolls per carton. Each roll shall measure 2.0 inches wide by 36 yards in length. Color shall be described as Teal Blue. Each box shall carry the manufactures lot number and date.

A5-2.2

Polyethylene Tape All polyethylene purchased must meet the specifications listed in the Appendix. Presently, the following manufacturers have demonstrated that they can meet the specifications. Manufacturer

Product

Scapa North America

Polyflex (Poly-Gard) 136

HANDLING PROCEDURES

A5-3.0 A5-3.1

Receiving & Inspection

A5-3.1.1 Poly-Gard 136 Carton - Receiving inspection is primarily visual. Check to ensure that the rolls have wax paper inserted between each roll. Material found to contain irregularities or not meeting visual inspection should be rejected and removed from the receiving area. A5-3.1.2 Poly-Gard 136 Roll – Receiving inspection is primarily visual. Check material for rolls that are damaged or telescoping. Check rolls to assure that proper width has been shipped. Record data contained on manufacturer documents found with shipment of tape. Damaged rolls and or cartons should be set aside and the supplier notified immediately. A5-3.1.3 Adhesive bond to laminated R-Tech film is conducted for visual examination. First a 6” long piece is adhered to the laminated film. The center of tape is measured and a 1” wide, and strip is cut and pulled. Result shall be failure of the laminated polyethylene R-Tech Film from the EPS substrate. A5-3.1.4 Nonconforming Product – Product that does not conform or is damaged from shipping will be tagged and put on QA hold. All nonconforming product will be reported to the supplier and processed per section 8.3 of the SNA Quality Systems Manual.

66

Issued 8/03

A5-3.2

Storage

A5-3.2.1 Tape – Once received, cartons must be stored out of weather in an area that will protect the polyethylene tape. Product is to be stored in a cool dry area below 80ºF. Cartons should be stored on end, no more than 5 boxes in height.

A5-4.0

QUALITY CONTROL During the inspection process, shipments received will be monitored for nonconformance and damage from shipping. The receiving Insulfoam facility will document inspection of product, corrective action and issues pertaining preventing recurrence. All corrective action measures will be forwarded to the supplier and entered into their preventative action electronic database. Management will notify the supplier on nonconformance or damage product resulting in a corrective action and credit issuance.

A5-5.0

POLY-GARD 136 MATERIAL SPECIFICATIONS Color:

Teal Blue

Width:

2.0in. ±1/32”, based on customer specification

Length:

108 ft/roll (36 yd/roll) ±1/2” based on customer specification

Thickness:

9.0 mils ±.5 mils, based on customer specification.

Roll Telescope:

Maximum 1/32” off square to core.

Packaging:

Flat stacking on pallets with separator sheet applied between rolls in cartons.

67

Issued 8/03

A5-6.0

CUSTOMER SPECIFICATIONS (To follow if applicable)

68

Issued 8/03

PART II – QAA PROCEDURE INSPECTION PROCEDURES FOR DESIGNATED QUALITY ASSURANCE AGENCY

(Attach QAA Standard Forms Describing Follow-Up Service and Quality Control Procedures.)

(U.L. Follow-Up Service Procedure R14313 is a part of the Insulfoam Quality Manual.)

69

Issued 7/92 Rev. 4/01