ICC-ES AC377 Spray Foam Insulation Testing

Third-party testing for spray polyurethane foam products seeking an ICC-ES Evaluation Report under AC377

Spray polyurethane foam (SPF) insulation products used in projects governed by the International Building Code (IBC) or the International Residential Code (IRC) require an ICC-ES Evaluation Report (ER) to demonstrate code compliance to building officials and specifiers.

QAI provides the third-party testing that manufacturers need to support their AC377 evaluation package, covering material properties, fire performance, and application-specific requirements including Appendix X testing for exposed foam installations. Whether your product is a closed-cell or open-cell formulation, QAI can support the testing work behind your ICC-ES ER from initial submission through final documentation.

What Is ICC-ES AC377 Testing?

ICC-ES Acceptance Criteria 377 (AC377) defines the test methods and performance requirements that spray polyurethane foam insulation products must satisfy to receive an ICC-ES Evaluation Report. An ICC-ES ER is the standard form of third-party evidence that building officials in IBC and IRC jurisdictions across the United States rely on when reviewing product approvals, and it is what most architects, contractors, and applicators look for when specifying an SPF product for a permitted project.

Testing scope under AC377 includes:

• Flame spread index and smoke developed index per ASTM E84
• Compressive strength per ASTM D1621
• Density per ASTM D1622
• Water absorption per ASTM D2842
• Dimensional stability per ASTM D2126
• Thermal resistance (R-value) per ASTM C518
• Vapor permeance per ASTM E96
• Closed-cell content per ASTM D6226
• Room corner fire performance per NFPA 286
• Fire-resistance assembly testing per ASTM E119 (where assemblies require it)
• Appendix X testing for applications installed without thermal or ignition barriers

Our Process Includes

• Sample conditioning and preparation per AC377 protocols
• Flame spread and smoke developed index testing per ASTM E84
• Physical and mechanical property testing: density, compressive strength, water absorption, and dimensional stability
• Thermal resistance testing to ASTM C518 for R-value determination
• Vapor permeance testing per ASTM E96
• Closed-cell content testing per ASTM D6226
• NFPA 286 room corner fire testing for interior finish and thermal barrier evaluations
• ASTM E119 fire-resistance assembly testing where the scope of your ICC-ES ER requires it
• Appendix X testing protocols for manufacturers targeting exposed foam applications without traditional thermal or ignition barriers
• Test report documentation formatted to support submission to ICC-ES for evaluation report issuance

Why It Matters

Without an ICC-ES Evaluation Report supported by AC377 testing, your spray foam product cannot be readily specified or approved for installation on IBC and IRC-governed projects in the United States. Code officials at the jurisdiction level treat the ICC-ES ER as the accepted form of third-party code compliance evidence, and building departments that are unfamiliar with a product will ask for it before issuing permits. Incomplete test packages, outdated test reports, or gaps in Appendix X documentation create delays at the point of product approval and create liability exposure for the applicators who install your product on permitted jobs.

How You Benefit from QAI

• Third-party testing from a lab accredited as an NRTL by OSHA, with testing accepted by ICC-ES for evaluation report submissions
• Coverage of both closed-cell and open-cell spray foam formulations under one testing program
• Appendix X testing for manufacturers targeting attic, crawl space, and wall installations where thermal or ignition barriers may not be used
• Test report packages structured to align with ICC-ES documentation requirements, reducing the back-and-forth during ER review
• Single-lab relationship for manufacturers who also need Canadian product listings under CAN/ULC-S705.1, with QAI holding SCC accreditation for Canadian compliance as well
• Rapid turnaround options available when your product launch or evaluation report renewal is time-sensitive

Typical Projects We Support

• New closed-cell and open-cell SPF formulations entering the US residential and commercial construction market
• Existing products requiring updated or expanded ICC-ES Evaluation Reports due to formula changes or component substitutions
• Manufacturers adding Appendix X documentation to cover exposed foam applications in attics, crawl spaces, and unvented roof assemblies
• Products targeting IRC-governed residential construction requiring insulation compliance documentation for permit review
• Canadian manufacturers expanding into US distribution who need an ICC-ES ER alongside their existing Canadian product listing
• SPF products used in fire-resistance-rated assembly applications requiring ASTM E119 testing data

New SPF product entering the US construction market

Exposed foam tested for attics and crawl spaces

Residential permit compliance for IRC-governed projects

Fire-rated assembly testing for commercial applications

Frequent Testing Methods and Standards

Accreditation and Recognition

QAI is recognized by OSHA as a Nationally Recognized Testing Laboratory (NRTL) and holds accreditations with IAS and the Standards Council of Canada (SCC). QAI’s testing is accepted by ICC-ES in support of evaluation report submissions under AC377.