What is Spray Foam Insulation?
Spray foam insulation is a modern insulation material made from polyurethane or polyisocyanurate chemicals that are reacted through a "spray" application. When the two components are sprayed together, they expand and adhere to the surface it is being applied to. Once dried, it turns into a seamless air barrier or insulating material. There are two main types of spray foam insulation - open-cell and closed-cell.
Open-Cell Spray Foam Insulation
Open-cell spray foam contains many small air pockets which act as an insulator. It has a density of about 0.5 pounds per cubic foot. Open-cell foam has a higher R-value per inch and allows more airflow, making it a better vapor barrier. it has a lower R-value per inch than closed-cell spray foam. It is often used for applications that require sound proofing capabilities like roof assemblies. Open-cell foam is less expensive than closed-cell foam.
Closed-Cell Spray Foam Insulation
Closed-cell spray foam has a higher density of about 1.5 pounds per cubic foot due to the smaller air pockets. Spray Foam Insulation gives it better insulation qualities with typical overall R-values of R-6.5 per inch. Closed-cell spray foam acts as both an air barrier and a vapor barrier. It is more resistant to damage from moisture and has higher flame-spread ratings than other insulation materials. However, closed-cell foam is more expensive than other insulation options. Common applications for closed-cell spray foam include basement walls, attics, crawl spaces and log homes.
How is Spray Foam Insulation Applied?
Spray foam insulation is applied by professional insulation contractors using specially designed spray foam machinery. The two-part spray foam components (resin and iso) are stored in separate heated tanks on the machine. They are then sprayed together through an attached mixing tube and gun onto the surface needing insulation.
The contractor will mask and protect any areas not requiring insulation such as electrical boxes. Thin layers are applied one after the other to build up to the desired thickness, usually around 1-2 inches thick. Within a few minutes the foam begins to rise and expand, conforming to all cracks and contours of the surface. It expands up to three times its original thickness. Within a day the foam is fully cured and hardened into place.
Energy Efficiency and Air Sealing Benefits
One of the biggest benefits of spray foam insulation is its ability to create an incredibly tight, air sealed barrier in the home. No other insulation material adheres and seals as well as spray foam to eliminate air gaps and leaks which account for up to 30% of a home's energy loss. Spray foam provides an air tight envelope that can reduce heating and cooling bills significantly.
Compared to fiberglass batts, a typical spray foamed home can save up to 23% on annual energy costs according to the U.S. Department of Energy. Spray foam also has higher R-values per inch than other insulation, allowing less material to be used to reach the same level of protection. This denser application maximizes the insulating power by filling all cracks, gaps and voids where air can penetrate.
Durability and Noise Reduction
The closed cell structure of spray foam makes it resistant to moisture, humidity, mold and mildew growth. It will not deteriorate or settle over time like loose fill cellulose or fiberglass. Homeowners gain durable lifelong insulation that will not have to be re-done. Additionally, spray foam acts as a sound barrier between floors, walls and ceilings for enhanced soundproofing in noise sensitive areas like home theaters.
Healthier Indoor Air Quality
Many spray foam formulations are formaldehyde-free and do not release VOCs (volatile organic compounds) that can off-gas from older fiberglass and cellulose options. This non-irritating material contributes to a healthier indoor air quality especially important for homeowners with asthma or chemical sensitivities. Spray foams may also qualify for green building points towards LEED certification.
Drawbacks of Spray Foam Insulation
The main downside is the higher upfront costs of spray foam insulation compared to cheaper fiberglass batts. Labor costs are higher for the skilled application process, and closed-cell foams use more expensive petroleum-based raw materials. However, energy savings generally recoup the higher costs within a few years. Accessibility may also be reduced in certain areas like attics until the foam cures. Specialty contractors with spray foam experience are also needed for proper installation.
Improving A Home's Efficiency
For both new construction and home remodels, closed-cell low-density spray polyurethane foam provides the best overall insulation, air sealing and moisture protection. It can upgrade older, drafty homes to achieve tight, well-insulated building envelopes worthy of an ENERGY STAR certification. With lower utility bills and improved comfort, homeowners realize the spray foam investment pays for itself in just a few years. Modern homes are now taking full advantage of this efficient, sustainable spray foam insulation solution.
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