08/02/2026
FROM PAPER-BACKED INSULATION TO CLOSED-CELL SPRAY FOAM: THE EVOLUTION OF THE CANADIAN VAPOUR BARRIER
The vapour barrier did not begin as the clear plastic sheet we recognize today.
Its development began when Canadian builders started placing insulation inside wood-framed walls. Insulation reduced heat loss, but it also made the outside portions of the wall colder. Warm, humid indoor air could then move into the wall, reach a cold surface and condense into water.
That hidden condensation could wet insulation, promote mould, stain finishes and eventually contribute to wood decay.
THE 1930s: RESEARCH IDENTIFIES THE PROBLEM
During the 1930s, Canadian researchers studied how water vapour moved through insulation and other building materials. They found that a material resistant to vapour movement could help prevent condensation when installed on the warm, interior side of the insulation.
By the mid-1940s, insulation, attic ventilation and vapour-retarding materials were already widely used in Canadian housing. The typical barrier was not polyethylene. It was usually asphalt-coated kraft paper attached to the face of an insulation batt or installed as a separate sheet. (Publications.gc.ca)
1941: THE VAPOUR BARRIER ENTERS THE NATIONAL CODE
Canada’s first National Building Code was published in 1941, and it contained an early vapour-barrier requirement.
The original requirement was more conditional than today’s rules. It addressed wall assemblies in which moisture could pass through the interior and become trapped against materials on the colder side of the wall.
The National Building Code is a model code, however. Provinces, territories and municipalities adopted and enforced national requirements at different times. There was never one single day when the same vapour-barrier rule became law everywhere in Canada. (NRC Publications Archive)
Ontario’s first province-wide building-code system took effect during the mid-1970s, with buildings throughout Ontario required to comply with the Ontario Building Code by December 31, 1975. (Environmental Registry of Ontario)
THE 1940s TO 1960s: PAPER-FACED INSULATION
Through the postwar building boom, mineral-wool and later fibreglass batts were commonly manufactured with a waxed or asphalt-coated kraft-paper facing.
The batts were fitted between the studs with the paper facing the heated interior. The paper edges were stapled to the framing to create a vapour-retarding layer.
This system was better than having no vapour control, but it was difficult to make continuous. Every stud, electrical box, pipe, seam and poorly stapled edge created a potential opening.
Homes from this period may also rely on wax paper, foil-backed material, layers of oil-based paint or other vapour-resistant finishes rather than a recognizable plastic membrane. (Publications.gc.ca)
A 1960 National Research Council publication described a sheet-type vapour barrier installed over the insulation and immediately beneath the interior finish as the simplest and most common approach in new construction. Code requirements continued evolving through the 1960 and 1965 National Building Code editions. (NRC Publications Archive)
THE 1970s: POLYETHYLENE TAKES OVER
By the end of the 1970s, polyethylene had largely replaced kraft paper as the vapour barrier in conventional Canadian wood-frame housing.
Early installations sometimes used approximately 2-mil polyethylene, stapled over mineral-wool or fibreglass insulation. As standards developed, heavier polyethylene became common, eventually leading to the familiar 6-mil polyethylene sheet used in modern construction. (Publications.gc.ca)
Polyethylene offered one major advantage: it could cover entire walls and ceilings as a continuous membrane.
When properly sealed at:
• seams and overlaps
• top and bottom plates
• windows and doors
• electrical boxes
• plumbing and wiring penetrations
• floor and ceiling transitions
the polyethylene could perform as both a vapour barrier and part of the home’s air-barrier system.
But simply hanging plastic over the insulation is not enough. A vapour barrier controls moisture movement by diffusion. An air-barrier system controls moisture carried through holes and cracks by moving air.
Air leakage can transport far more moisture into a wall than vapour diffusion alone. By the 1970s and 1980s, Canadian research increasingly recognized that homes needed both vapour control and a continuous air-barrier system. Beginning with the 1990 National Building Code, the code formally recognized that the vapour barrier and the airtight element could be provided by different materials. (Publications.gc.ca)
TODAY: CLOSED-CELL SPRAY FOAM CAN PERFORM SEVERAL JOBS
Modern medium- or high-density closed-cell polyurethane spray foam represents the next stage in this evolution.
When correctly specified and installed at the required thickness, closed-cell spray foam can provide:
• thermal insulation
• resistance to vapour diffusion
• air-leakage control
• adhesion to irregular surfaces
• sealing around framing and penetrations
National Research Council guidance recommends a minimum thickness of approximately 40 millimetres—about 1½ inches—when medium-density spray polyurethane foam is intended to serve as both the insulation and vapour barrier in a wall. The exact accepted thickness and assembly must still follow the product evaluation, applicable standard, manufacturer’s instructions and local building-code requirements. (NRC Publications Archive)
Natural Resources Canada also recognizes wall assemblies in which high-density closed-cell spray foam acts as the vapour barrier, eliminating the need for a separate interior polyethylene sheet. (Natural Resources Canada)
That does not mean all spray foam replaces polyethylene.
Open-cell and low-density foams generally allow more vapour movement and may still require a separate vapour-control layer. Even closed-cell foam must be installed continuously, at the correct thickness and by qualified installers. Poor mixing, incorrect temperature, inadequate thickness, gaps, shrinkage or loss of adhesion can compromise its performance.
The wall must also be designed so that moisture is not trapped between two highly vapour-resistant layers. A wall needs an intentional drying direction.
EVOLUTION—NOT COMPLETE REPLACEMENT
Six-mil polyethylene remains an economical and effective vapour-barrier material and continues to be widely used.
Closed-cell spray foam is gradually assuming the role of the vapour and air-control layer in certain basements, roof assemblies, renovations and high-performance walls, but it is not a universal one-for-one replacement for poly.
The progression has been:
Asphalt-coated paper → paper-faced insulation batts → separate polyethylene sheets → sealed air-and-vapour barrier systems → closed-cell spray foam and other integrated building-envelope assemblies.
The materials have changed, but the goal has remained the same:
Keep warm, moisture-laden indoor air from reaching cold surfaces inside the building envelope—and give the wall a safe way to stay dry.