Thermocore Structural Insulated Panel Systems

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 Thermocore structural insulated panels are high-quality foam core panels suitable for exterior wall and roof systems in residential and commercial applications. Designed to enclose timber frame structures, log structures and conventional buildings, this one-piece product is completely structural and can substitute for conventional framing in most applications. Because they are custom-manufactured, Thermocore panels allow extensive design freedom.

Basic Composition

Each panel is composed of a polyurethane insulation core with interior and exterior skins of oriented strand board. Panels are precisely custom-manufactured to drawings through a foam injection process in which the polyurethane bonds directly to the skins. They include preinstalled corners, door bucks, window bucks, subfacia and electrical conduit boxes. Pre-engineered header and beam pockets are molded into panels.

Overall Thickness

Wall: 4.5″ or 6.5″

Roof: 6.5″

Inner/Outer Skin

OSB with options for plywood (note panel sizes are typically smaller with plywood)

Insulation Core

Polyurethane, 2.2 lb. density, Class 1, closed-cell foam. Contains no formaldehyde or CFCs. Self-adhering polyurethane foam is injected between the skins to ensure a consistent, superior bond and structural integrity.

The foam exhibits these properties:

  • Compressive Strength: 26 psi
  • Tensile Strength: 18 psi
  • Shear Strength/Modulus: 22/300 psi
  • Porosity: 95%
  • Does not promote the growth of mold.
  • Serves as its own vapor barrier.


  • Wall: R-28, R-40
  • Roof: R-40

Fire Safety

  • Foam Fire Rating: Class I
  • Flame Spread: 20 (ASTM E-84)
  • Smoke Developed: 300 (ASTM E-84)
  • Structural Integrity: Polyurethane foam is a thermoset plastic which does not melt and maintains structural integrity until consumed.

Informational Videos


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