Cut Carbon with Reclaimed Foam Panel Insulation

When it comes to making buildings more sustainable, insulation plays a powerful role—not just in how much energy a building uses over time, but in the environmental cost of producing the materials themselves. While attention has often focused on operational energy efficiency, a growing body of research shows that embodied carbon—the greenhouse gas emissions from manufacturing, transporting, and installing building materials—represents a major share of a building’s climate impact, especially in the near term.

A recent report, Environmental Impact of Reclaimed Rigid Foam Insulation and Its Role in Reducing Embodied Carbon, offers clear insight into how reclaimed rigid foam insulation—including XPS, EPS, and polyiso—helps cut these emissions and aligns with circular economy goals.

What Is Embodied Carbon and Why Does It Matter?

Embodied carbon refers to the total greenhouse gas emissions generated over the lifecycle of a building material up to the point of installation. This includes extraction, processing, and manufacturing. According to the Rocky Mountain Institute, embodied carbon can account for up to 80% of emissions in new buildings constructed between now and 2030.

Traditional foam insulation products, while thermally effective, are energy-intensive to produce and often rely on high-global-warming-potential (GWP) blowing agents, such as HFCs used in XPS. AIA California notes that even small volumes of these foams can have outsized environmental impacts.

Why Reclaimed Foam Panels Are a Game Changer

Reclaimed foam boards avoid the need for new raw material extraction and manufacturing, eliminating the majority of emissions typically associated with insulation. As Insulation Depot points out, using reclaimed panels “radically reduces” embodied carbon by repurposing materials already produced.

One Harvard University study found that converting decommissioned polyurethane panels into recycled insulation resulted in a 98.4% reduction in embodied energy compared to new production. While that study focused on polyurethane, similar reductions apply to XPS, EPS, and polyiso foam when reclaimed.

To benchmark these savings, consider:

• New XPS: ~2.06 kg CO₂e per m² (SOPREMA EPD)
• New polyiso wall board: ~4.3 kg CO₂e per functional unit (PIMA EPD)
• New EPS (15–20 kg/m³): 47–60 kg CO₂e/m³ (EUMEPS EPD)

Blowing Agents: A Hidden Source of Emissions

Blowing agents are used to create the closed-cell structure of foam insulation. Traditional XPS often used HFC-134a or HFC-152a—chemicals with GWPs over 1,400 (EFCTC). EPS generally uses pentane, a far lower-GWP agent (around 7), and newer polyiso boards are increasingly made with HFOs (GWP <1), per PIMA.

By choosing reclaimed foam, builders avoid the manufacture and release of additional blowing agents altogether. The emissions from the original manufacturing process are “locked in,” and no new high-GWP chemicals are required.

Do Reclaimed Boards Still Perform Well?

Yes—thermal drift, or the loss of R-value over time, mostly occurs in the first few years after manufacture. Reclaimed insulation that has already aged tends to have a more stable R-value over the remainder of its life. According to the U.S. Department of Energy, the bulk of this drift occurs within two years of production. Boards that have been in service longer will typically offer consistent thermal performance over time.

Waste Reduction and the Circular Economy

Foam insulation is often landfilled after a building is deconstructed. Reclaiming and reusing these materials prevents them from becoming waste and aligns with the circular economy model—keeping resources in use longer and extracting maximum value. According to the Department of Energy, prioritizing reuse over recycling or disposal reduces environmental impact and promotes resource conservation.

Organizations like Covestro and EUMEPS are advancing foam recycling technologies, but reclamation generally uses less energy than recycling, making it the lower-carbon option when feasible.

Choose Reclaimed for Lower Carbon Construction

Reclaimed rigid foam insulation—XPS, EPS, and polyiso—offers a high-performance, cost-effective, and environmentally superior alternative to new foam products. It eliminates the need for new raw materials, avoids additional high-GWP blowing agents, and reduces the waste burden on landfills. It also retains strong thermal performance and aligns with both LEED v4.1 credits and circular economy goals.

Whether you’re a builder, architect, or homeowner pursuing a deep energy retrofit or simply looking to lower your project’s carbon footprint, reclaimed foam insulation is a proven and practical solution.

Learn more about sourcing high-quality reclaimed foam insulation panels for your next project from Green Insulation Group.