Closed-Cell Spray Polyurethane Foam Keeps The Heat Inside New Residential Construction

MOUNT AIRY, PA – April 3, 2014 – Harsh Northeast winters can certainly take tolls on residential homes’ energy consumption, with more energy being required to keep constant heat flowing through the house to maintain a comfortable, heated indoor environment. Air infiltration is a contributing factor to this high energy consumption, and not having effective insulation can result in an all-too-familiar cautionary tale that is reflected when the energy bill arrives in the mail. In hopes of avoiding this, a Pennsylvania resident who was having his new home constructed in the suburbs of Philadelphia decided he wanted the best insulation possible installed in his home. Calfayan Construction Associates, the builder of the home, specified an application of spray foam and turned the insulating process over to their sister company, Green Dog Foam Solutions.

“The client definitely sought comfort and energy efficiency,” said Green Dog’s Laura Calfayan. “He definitely understood the importance of having good insulation, especially through these brutal winters. Spray foam insulation inside the home allows for greater control of energy consumption.”

The two-story home had cathedral ceilings with a loft area that was open to the living room space below. Moreover, Calfayan pointed out that because there was this large space in between the two floors, spray foam insulation was crucial in ensuring temperature consistency throughout the home. The underside of the roof was 30 feet off the ground, so building scaffolding was absolutely necessary to be able to insulate it, especially since there were some areas that the crew would not be able to get to from the second floor.

"The space was significant and we knew it would be a challenge to insulate the attic because of how high off the ground it was," said Calfayan. "It was a bit nerve-wracking, but we knew it wouldn't be an issue if the crew communicated with each other. It had to be done right in order for the home to perform adequately."

 Aside from the underside of the roof, Green Dog’s spray foam project consisted of insulating the exterior walls and the home’s crawlspace. When the Green Dog crew arrived on site, the frame had just been sheathed with plywood, so there were no mechanical units or any type of obstructions, which facilitated the foaming process and reduced prep work. The two-man crew masked off the windows, floors, and ducts for overspray protection. They wore PPE that included full-face masks with fresh air returns, Tyvek suits, and gloves. The crew also had giant torpedo fans throughout their work area to ensure the home was well ventilated.

In order to ensure SPF adherence to the substrate while working through the intense cold, the Green Dog crew had three heaters on site, each pumping 50,000 BTU’s throughout the home at all times.

"We never turned our heaters off during the application because it was crucial to have the building conditioned," said Calfayan.

The Green Dog crew utilized Bayseal CC, a 2 lb. closed-cell spray polyurethane foam made by Bayer MaterialScience, during the application. They applied a 3-inch lift of SPF to the exterior walls and the crawlspace walls, and they applied two 2.5-inch lifts to the underside of the roof. The SPF provided an R-19 value for the crawlspace and exterior walls, and an R-30 for the underside of the roof. In total, there were six sets of foam applied throughout the project, which consisted of a total spray area of 7,800 square feet.

Calfayan noted that as the SPF application made headway, the temperature inside the home was maintained with less heat. She said that the heat retention got so effective that they had to use one heather instead of three, just so that crew could work comfortably. Calfayan added that even though she has been a long-time advocate of spray polyurethane foam, it's delightful to see its benefits at work every time.

"It's always great to see the proof in the pudding, it rekindles my belief that there is no better type of insulation than spray foam," said Calfayan. "It was surprising to see how comfortable and quiet it got inside the house, as more and more foam was installed. The siding had not even been installed and the house was already showing signs of optimal insulation."

After the SPF application was completed, drywall was installed on the first two floors of the home to cover the SPF. On the other hand, the crawlspace walls were covered with DC315, an intumescent coating made by International Fireproof Technology Inc. (IFTI), to separate the spray foam from the space.

The Green Dog crew worked with one rig on site, which was equipped with a Graco Reactor E-30 proportioner and a Graco Fusion air-purge gun. It took the crew eight days to complete the application.

Calfayan mentioned that the homeowner plans to retire in this home, and that opting for a spray foam application was an important step in providing a longterm life for the home.

"The spray foam really tightened up the house," said Calfayan. "It provides an air and vapor barrier, eliminating most of the issues that homes see in subsequent years. The homeowner will be able live comfortably for several years with minimal maintenance."

About Green Dog Foam Solutions: Green Dog Foam Solutions, based out Huntingdon Valley, PA, is an experienced leader in the insulation industry. Green Dog offers the finest insulation products, installation and service in the business. All of Green Dog's employees undergo extensive training and certification courses before being authorized to represent our company. Green Dog specializes in closed-cell and open-cell polyurethane foam. For more information about Green Dog, please use the contact details and links provided below.