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Ray-Core Panels

Walls, floors and roofs made of composite high density foam and stud panels

Contractors attach Ray-Core panels to wood framing.

Ray-Core Inc.®™ manufactures a patented Structural Insulated Panel (SIP) comprised of a high density polyurethane foam that is formed around pre-positioned wood or PVC studs with a radiant vapor barrier on both sides. These panels are used for walls, floors and roofs. The manufacturer states that the composite high density foam and stud panels are stronger than traditional wood and fiberglass construction and can cut heating and cooling costs by up to 50 percent.

The Ray-Core Building System combines foil-faced polyurethane foam panels with integrated wood or PVC studs into a 4' wide and up to 10' long lightweight highly insulated module. Top and bottom plates are dimensional 2x4 lumber and the skins are commonly an OSB exterior with a gypsum board interior that are installed on the job site by the builder.

Dimensional stability, rigidity, racking, creep and overall strength are provided by the foamed in-place studs placed 16" o.c. The manufacturer claims an R-value of 26 in the 3½" wall panel, and R-42 in the 5½" roof panel with 2" x 6" studs at 24 o.c.

Energy Efficiency

Wall panels are rated at R-26 and roof panels are rated at R-42.

Environmental Performance

Factory panelization makes efficient use of resources and often reduces waste compared to site-built construction.

Quality and Durability

The panelized walls are dimensionally stable, rigid, strong, and provide resistance to racking forces.


Ray-Core building panels are currently available nationwide.

Ray-Core panels are competitively priced with typical 2x6 construction (with comparable R-Values) and are priced competitive with other SIP panel systems on the market.


Component pieces are code approved: Foam - UL 15744R, Foil - UL R4461; Studs are SPF lumber or better, molded in the panel at 16" or 24" o.c.

Not Applicable

Installation steps for wall panels are as follows: 1) lay wall panels on floor deck and attach panels together with screws or nails using the "ship lap" joint on the edge of the panels. 2) After wall section of panels has been joined, place top and bottom plates as done with conventional framing. 3) Cut out window openings and frame with 2x4's. 4) Sheet the wall panels with OSB, plywood, or T-111. 5) Stand up the wall section and brace.

Insulated roof panels are used with open beam cathedral style construction typical in contemporary, log and timber frame homes.

Floors must be covered with plywood or OSB before installing any floor covering. Panels must be covered with a 15 minute fire-rated material (½" gypsum wall board), as required by code.

Not Applicable

Benefits of the system include its energy-saving design and speedy construction. The high insulation value of the panel results in lower heating and cooling loads, which translates into energy cost savings. The panels require no special tools and are environmentally friendly, having no formaldehyde or glass fibers. The panels are class 1 fire-rated, lightweight and easy to use. Using Ray-Core building panels results in a straight, impact-resistant composite wall with less air, dust, pollen and sound infiltration.

Ray-Core panels are competitively priced with typical 2x6 construction (with comparable R-Values) and are priced competitive with other SIP panel systems on the market.

Disclaimer: The information on the system, product or material presented herein is provided for informational purposes only. The technical descriptions, details, requirements, and limitations expressed do not constitute an endorsement, approval, or acceptance of the subject matter by the NAHB Research Center. There are no warranties, either expressed or implied, regarding the accuracy or completeness of this information. Full reproduction, without modification, is permissible.