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Styrotech/STYRO-STOP, Inc. selects BASF’s EPS for ‘direct-to-deck’ insulation
Foams made from Styropor® resins save costs, energy in metal roofing systems

WYANDOTTE, Mich., November 22, 2004 -- Styrotech/STYRO-STOP, Incorporated, Brooklyn Park, Minn., uses BASF’s Styropor resin to produce expanded polystyrene (EPS) foam for “direct-to-deck” metal roofing designs in commercial buildings because of the material’s consistency, performance and environmental benefits.

Historically, building codes have required a thermal barrier between the EPS insulation and the metal deck in roofing to achieve proper fire ratings. The issuance of ICC-ES Evaluation Report ESR-1025, held by Styrotech/STYRO-STOP, Inc., has eliminated the thermal barrier requirement, making EPS direct-to-deck installations easier, more efficient and less expensive.

“The direct-to-deck approach is very appealing to commercial roofers because it takes less time to install an effective insulation envelope, which reduces labor costs and increases the number of projects they can pursue,” said Scott Wehrmeyer, Marketing Coordinator for Styrotech. “Previously, the only insulation material feasible for direct-to-deck designs was polyisocyanurate foams.”

According to Wehrmeyer, the thickness of EPS foams became more comparable to the commonly used insulation materials after required formulation changes to remove HCFC blowing agents in polyisocyanurate were implemented. “Material costs for EPS are typically lower than polyisocyanurate. Now that Styropor EPS foam delivers the necessary thermal insulation at a similar thickness, it is has become a material of choice for commercial roofers who install direct-to-deck envelope systems,” he said.

Styrotech/STYRO-STOP, Inc., offers STYRO-STOP™ Direct EPS insulation over steel roof decks. In addition to being cost-efficient, the benefits delivered in this system include design flexibility, high R-Values for thermal insulation, superior dimensional stability, and resistance to moisture absorption and physical degradation, said Wehrmeyer. He added that STYRO-STOP Direct has undergone a thorough evaluation for fire-safety performance and can be installed directly over metal roof decks in ballasted, mechanically-fastened and fully-adhered roof assemblies.

“With winter fast approaching, rising energy costs to heat commercial structures are compelling building managers and owners to evaluate advanced insulation systems to help them save money by improving energy efficiency,” said Gene Zimmermann, Director of BASF’s Styropor EPS business in North America. “Because most heat loss occurs through the roof, selecting a technology to insulate this area is the most critical decision to make. Roofing systems that utilize Styropor EPS foams are a highly viable option by virtue of their performance and cost-effectiveness.”

According to Zimmermann, the positive attributes of plastic materials for direct-to-deck metal roofing insulation systems were further reinforced by an extensive study conducted by BASF that confirmed their eco-efficiency benefits. The study analyzed BASF’s Styropor EPS foam, spray polyurethane foam (SPF) and polyisocyanurate materials, as well as extruded polystyrene (XPS), which the company does not supply.

The findings of this eco-efficiency analysis indicate that EPS, SPF and polyisocyanurate supplied by BASF are comparable, and each has its own attributes and benefits for thermal insulation applications. What differs are the means in which they achieve eco-efficiency, such as material density, manufacturing processes and how they are installed.

“The specific environmental benefits Styropor EPS foam brings to direct-to-deck insulation systems include having the lowest air emissions, since it never used ozone-depleting hydrochlorofluoro-carbons (HCFCs) blowing agents, and requiring less materials and weight to meet the necessary insulation standards,” said Zimmermann.

More information on Styropor EPS is available on the Internet at or The Internet site for Styrotech is

Styrotech, Incorporated
Styrotech, Incorporated manufactures, designs and fabricates EPS foam for use as insulation, protective packaging and diverse custom applications. State-of-the-art process equipment and production techniques, coupled with third-party certification by Underwriters Laboratories, assure our customers of consistent product performance with every order. The company is based in Brooklyn Park, Minn.

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For more information, contact:
David A. Elliott
Tel: (734) 324-6148



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