The problem was that the installer was doing his first spray foam job ever, and the thickness of the insulation varied from zero (visible roof deck) to about 9". Unfortunately, good average thickness doesn't cut it. The coverage needs to be uniform because a lot of heat will go through the under-insulated areas. (See my article on flat or lumpy insulation performance.)

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Barrier’s specially-trained technicians have applied over 5 million square feet of coatings in a wide variety of commercial, industrial and residential settings throughout the United States. With our experience, product knowledge and long list of satisfied customers, Barrier is uniquely qualified to give your enterprise the protection it deserves.  

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Tucson Rubberized Coatings is on the cutting edge of technological advancement in the coating industry. From driveways to walls and rooftops, our products have you covered. Established in 1992, we have decades of research that has not only led us to create the best products of today, but is also providing the foresight in the formulation of the products for tomorrow. 

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Polyurethane Spray Foam Insulation is used in industries ranging from mining to movies, from cold storage to marine flotation. Spray Foam Insulation’s ability to seal out air and insulate quickly means it’s always in high demand for residential and commercial applications. Spray Foam Insulation is critical for solving our nation’s energy challenges because it dramatically reduces the energy needed to heat and cool our homes and offices. http://m.youtube.com/watch?feature=player_embedded&v=ggLAUsiuI_o
You probably have some familiarity with spray foam insulation, and you may have even used the foam that comes in pressured spray cans at home improvement retailers. This foam is know as one-part foam, meaning that it is one continuous mixture that is simply applied to the area in need. One-part foam is frequently used for sealing small gaps and cracks.

Thanks for asking for our input. I have enjoyed the 'Future House' episodes that you folks have created. And, I think that the amount of segments-per-season seems just about right - any more and it might begin to take the shows into an area that moves away from their core meaning (i.e. - home repair/rehab/construction, etc). Though, it's easy to understand how new and upcoming technologies fit well into TOH/ATOH's overall picture. Also, Ross Trethewey is a good sement host - very knoledgable and enthusiastic - and, as well, he gives the TOH/ATOH audience some 'younger blood' to continue forward with the show's traditions. My thoughts are to stick with 'Future House' segments.And, thanks for all of the good work you folks do in continuing to present to us each year such wonderful productions as TOH and ATOH, which we get to enjoy and benefit so greatly from!
Before filling the wall cavity, spray the perimeter with a 1/2-in. layer, which will expand to a 1-in. layer. These layers are called “lifts.” This will ensure that the foam penetrates any voids where the studs meet the sheathing. This also reduces the risk of bulges in the sheathing. If foam is sprayed into a large gap between the stud and the sheathing and is immediately covered by a thick layer, the pressure of the expanding foam can actually push out any sheathing that isn’t securely fastened. Wait a few minutes after picture-framing the cavity before you go back and lay down the first layer in the center of the wall. https://www.youtube.com/v/ggLAUsiuI_o&feature=share

I don't know if it's common or uncommon, but installing a layer of rigid foam above your roof sheathing in order to interrupt thermal bridging is always a good idea, and is preferable in all respects to a roof assembly without any rigid foam above the sheathing. If you decide to install rigid foam above the roof sheathing, you shouldn't use closed-cell spray foam under the sheathing; either use open-cell spray foam (which is vapor-permeable) or a fluffy insulation like cellulose, mineral wool, or fiberglass (any of which will allow the roof sheathing to dry to the interior).

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Spray foam insulation, also known as foaming insulation or sprayed insulation, is a two-part liquid insulation material that insulates and air seals wherever it is applied. The material comes in two large 55 gallon drums – an iso and a resin. These two liquids are kept separate until applied at the jobsite by a qualified, licensed spray foam installer. The two liquids travel up through a heated hose to the spray gun where they are combined to create the foam. The foam expands within seconds to fill the cavity surface.  Depending on the type of sprayed-in foam insulation used, closed-cell or open-cell, the foam expands between 40 and 100 times its size upon application. 
I've seen this only once, and it was with closed cell foam, but I've heard of it happening with open cell foam, too. I don't know the details, but I've heard it could result from a bad batch of chemicals, improper mixing, or too high a temperature. Whatever the cause, it's not a good thing. The photo below shows how the spray foam pulled away from the studs. A little bit of uninsulated area like that adds up to a lot of heat loss/gain when the whole house has that problem, as it did here.

spray foam garage


I don't even want to ask this question but... several years ago we hired a local contractor to spray high density foam on the roof deck and walls of our unfinished 2nd floor. We realized that the job was done poorly and cut an access into the attic space to assess things. We realize now that they spray foamed directly to the chimney (no flashing). The chimney is currently used for a woodstove and DHW venting. The DHW will go away but wood stove will remain. My question is, how bad (unsafe) is this? I have found information on foam exposure to fire but have not been able to find anything about temperature ratings in general (i.e. what happens on prolonged exposure to high temperatures).
Spray foam insulation, when properly installed is both an air barrier and when closed cell foam is used at the proper depth a vapor barrier!  Before hiring any contractor you should establish the brand of foam being used and verify that with the named manufacture.  Please ask for ESR reports and MSDS sheets on any foam being installed in your home. A couple areas where you might consider spray foam insulation include:
Loctite TITE FOAM Window and Door is a Loctite TITE FOAM Window and Door is a new generation of polyurethane-based insulating foam sealant that expands to fill seal and insulate around window and door jambs. Loctite TITE FOAM is a minimal-expanding foam based on purified and concentrated ingredients that provides four times more density versus conventional window and ...  More + Product Details Close
Closed-cell (aka two-pound foam) is denser than open-cell at about 2 pounds per cubic foot. Its R-Value is between 6-6.5 per inch. As a result, this kind of foam is much more expensive than its counterpart. The reason closed-cell doesn't need a vapor retarder is because it already has one. It's permeance is 0.8 perm, which means it can handle cold climates without the use of an additional board or drywall. Closed-cell uses hydroflurocarbons (HFCs) as part of its makeup. However, this material has been known to have a high global warming effect. If you want a green insulation solution, this is not the material to use. A way to avoid this and still use closed-cell is by installing it alongside fiberglass batts.
Spray polyurethane foam, or SPF, is the main type of 2-part, closed-cell spray foam used by insulation contractors. Large-scale insulation jobs require special equipment as well as safety gear to protect the installer from chemical fumes during installation. When the foam cures and hardens just several minutes after application, it's completely safe for as long as it stays in place.

spray foam insulation cost


Loctite tite foam is a new generation of Loctite tite foam is a new generation of polyurethane-based insulating foam sealant that expands to fill seal and insulate gaps and cracks inside or out. It is white polymer foam based on purified and concentrated ingredients that provides 4 times more density versus conventional foams for better durability and insulation. ...  More + Product Details Close
Liquid Roof is a liquefied version of a synthetic rubber typically referred to as EPDM. The letters EPDM stand for ethylene, propylene, diene monomer and M class. Prior to the liquefied version emerging on to the market, rolls of the rubber were used for waterproofing roofs. The liquids are much easier to apply. Can fill cracks and crevices. Liquid EPDM can go where the sheet version could never effectively coat. The liquid roof coatings have more uses. They can be used on RV roofs and other vehicles. They can be applied to a wide range of roofing materials including metal, fiberglass and wood (although wood is not a warrantied application and require the use of the ProFlex primer first). Always consult your roofer to determine if aftermarket coatings are acceptable given the condition of your overall roof. The use of an undercoating means the liquid roof can be applied to built-up and asphalt-based coatings (with the use of the ProFlex primer).
Never spray foam on a surface with a moisture level of more than 20 percent—the foam won’t stick. If the surface you’re spraying hasn’t been exposed to water for a few weeks, it should be OK to spray. But if you’re patching a wall that recently sustained water damage, or was just assembled with new, wet lumber, you may want to test the moisture level before you spray. You can get a moisture meter here.
Thoroughly clean the roof surface. Roofs collect oils from asphalt, chimneys, and cars plus lots of dirt and dust. Coatings don’t stick well to any of these. We recommend cleaning with an inexpensive solution of TSP or TSP Substitute in a bucket of water (follow label instructions). Use a broom to scrub ponding areas and areas of peeling coatings. Work a section at a time and hose off the dirty water. Sweep away puddles to promote drying. Do not allow wash water to dry on walls, furniture, windows, and visible surfaces.  http://youtube.com/embed/ggLAUsiuI_o
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