FIRESHELL® (F10E) is a proprietary non-flammable, intumescing (expands up to 2000%) interior coating that provides oxygen starvation to fire. It is a non-toxic, water based, drain safe, no fuming GREEN product. FIRESHELL® passes full scale room corner over foam, NFPA 286 and E84 class A certified. Meets requirements for 15 minute thermal barrier. It is a water-based one part coating system that comes white but can be tinted different colors. This coating can be top-coated with either latex or oil based coating.
There have been a few mentions of intumescent coatingsabove, and it would be helpful to elaborate on them. Intumescent coating is a type of paint that will bubble when it is exposed to heat or flames. The bubbles act as a barrier that is relatively flame resistant. The bubbled coating delays the ignition of the spray foaminsulation. Because of this, intumescent coatings have become more common in building and construction.
In addition, it's difficult for an inexperienced installer to evenly spread the insulation foam over a surface. Miissing spots can leave holes and gaps for cold air to get through. Proceed with this project yourself only if you're doing a small insulation project -- such as installing foam in a crawl space or around your plumbing. Leave larger projects like the attic, basement or garage to the professional insulation contractors. Insulation professionals have the tools, equipment and background knowledge necessary. Moreover, they know how to accurately price insulation, whereas you could inaccurately budget for a DIY project and end up paying significantly more. Don't take the medical, physical or financial risks that come with pursuing this as a DIY project unless you're absolutely certain you have the skills.
4 years ago I applied Gaco Roof, coats to an Office Building flat roof and have zero leaks since that time. This saved me $30,000 compared to having a new roof installed. The roof itself was only 7 years old when I applied Gaco Roof. but due to ponding water and harsh Florida heat and UV, the roof already looked shot and was leaking. I have now used Gaco Roof on 4 flat roofs to great results. I also tried big hardware store lower cost substitutes on 2 flat roofs. Those product utterly failed 1 to 2 years. Yes, I pressure washed my roofs clean before using Gaco Roof and followed their simple installation instructions. Excellent product. Spray Coating Services
The problem you saw with the closed cell foam pulling away like that is due to the heat of the foam was to hot. It was actually curing out and making foam before it could adhere to the wood. The installer wasn't reading his foam correctly. He should of stopped and turned down the heat on his hose temp. Also installers have to be aware that as the sun rises and the temp in attics rises the subtrates get hotter as well. This will cause the installer to adjust his heat when installing the foam as the temp changes thru out the day.    Spray Coating Services

During the 1980s, a class of thermal spray processes called high velocity oxy-fuel spraying was developed. A mixture of gaseous or liquid fuel and oxygen is fed into a combustion chamber, where they are ignited and combusted continuously. The resultant hot gas at a pressure close to 1 MPa emanates through a converging–diverging nozzle and travels through a straight section. The fuels can be gases (hydrogen, methane, propane, propylene, acetylene, natural gas, etc.) or liquids (kerosene, etc.). The jet velocity at the exit of the barrel (>1000 m/s) exceeds the speed of sound. A powder feed stock is injected into the gas stream, which accelerates the powder up to 800 m/s. The stream of hot gas and powder is directed towards the surface to be coated. The powder partially melts in the stream, and deposits upon the substrate. The resulting coating has low porosity and high bond strength.[1]
Spray painting poses health hazards that affect the respiratory, nervous, and circulatory systems. Similarly, using solvents to clean one's hands of paint marks and residue may cause skin irritation or even more serious issues since many are carcinogenic or neurotoxic. There are risks involved in working with substances such as paint and thinner, which contain compounds that are potentially harmful to health, or even fatal.[9] Insulation Spray Coating
This technique is mostly used to produce coatings on structural materials. Such coatings provide protection against high temperatures (for example thermal barrier coatings for exhaust heat management), corrosion, erosion, wear; they can also change the appearance, electrical or tribological properties of the surface, replace worn material, etc. When sprayed on substrates of various shapes and removed, free-standing parts in the form of plates, tubes, shells, etc. can be produced. It can also be used for powder processing (spheroidization, homogenization, modification of chemistry, etc.). In this case, the substrate for deposition is absent and the particles solidify during flight or in a controlled environment (e.g., water). This technique with variation may also be used to create porous structures, suitable for bone ingrowth, as a coating for medical implants. A polymer dispersion aerosol can be injected into the plasma discharge in order to create a grafting of this polymer on to a substrate surface.[3] This application is mainly used to modify the surface chemistry of polymers. Coating Services

By heating the full-bodied paint to 60-80 °C, it is possible to apply a thicker coat. Originally the paint was recirculated, but as this caused bodying up, the system was changed to direct heating on line. Hot spraying was also used with Airless and Electrostatic Airless to decrease bounce-back. Two pack materials usually had premix before tip systems using dual pumps.
Schweitzer Spray Coatings is a family owned and operated business, located in West Bend WI. Our company serves a wide variety of roof coatings to Agriculture/Farms, Commercial/Industrial and Residential Accounts. We specialize in coating buildings, pole sheds, barns, and trailers. If you are experiencing any leaks, rust, or just need a new paint coating, contact us today for your rubber roof solution. Spray Coating Services
For over a decade, Synavax™ has served as the preferred industrial thermal barrier insulation, energy saving, surface protection and asset protection coating, meeting the needs of multiple industries around the world, including pulp and paper manufacturing, food and beverage manufacturing, U.S. military, oil and gas, textile manufacturing and many others. Insulation Spray Coating
If your foam pulled away just a little bit, Jamie, and they were able to fix it with just a little bit of touching up, then it wasn't as bad as the house where I saw this problem. As the last photo above shows, it had pulled away significantly from the studs and rafters, and it was all over the house. This was closed cell foam, and interestingly, it didn't pull away from the horizontal framing members, just the vertical and sloped ones. They did some touch up, but that wasn't enough. I don't know how this one ended up getting resolved. I think maybe the contractor came back and sprayed cellulose on top of the foam. Spray Coating
RE: my June 12 post...We went ahead and had the attic sprayed with a Soy-based product. Stayed in a hotel for 3 nites. Still smelled a little bad but that's gone away over time. I'm very glad we didn't use the other foam as even that much outgassing of a petrochemical could have sent my wife to the hospital. Unfortunately, the spray crew didn't speak English(at least not to me) and were kinda lazy, so they ended up spraying over some can fixtures from the kitchen below that were not insulation-contact rated. So I hired an electrician to come out, pull down the cans, pull out what he thought was an appropriate amount of foam to create a big enough air space and then re-install the cans. I billed the firm for the electrician plus an extra night we had to stay in the hotel and they paid, no questions asked. Guess they knew they had screwed up.   Spray Coating Services

This is more common with closed cell foam, but it happens with open cell foam, too. Since closed cell foam has a higher R-value per inch, installers generally spray 2" in walls and 3" in rooflines to meet the energy code requirements of R-13 and R-19, respectively. (I'm not going to dive into the energy code here, but these numbers apply to many climate zones, the latter being allowed under the UA tradeoffs rule. See the Energy Nerd's blog on this topic if you want to argue.)
The local foam installer that I used here in Hilton Head told me he looked for some peeling back of the foam. This was ensuring that it was at the perfect temperature which helped them maximize their yield (profit). I have open cell foam and it pulled away a little, and did so immediately (within minutes). They went back after they were done to any spots that pulled away too much and filled them with the touch up kit; they were looking for the top edge to roll just a little bit.  Coating Services
Thank you, Allison. We have a split system unit (actually 5) with the heat being propane. The foam guy said that it needed ventilation, so completely sealing the attic wouldn't be a good idea. It sounds like you are saying that the systems need to be vented out of the attic or replaced with some type of closed system. But I shouldn't bother spraying if the plan is to leave the soffet vents open. Is that correct?
As an ISO certified company, we have a robust quality management system to ensure that everything, from incoming raw materials to the final product, meets or exceeds customer requirements. We measure and inspect characteristics such as coating thickness, coating weight, residual solvents/water, and bond strength to ensure your products perform as expected. Agile and efficient, we can process most work within a two- to four-week timeframe and have the flexibility to manage rush orders for situations where time is a critical factor. Spray Coating Services
E/M Coating Services has over 40 years of experience in applying critical tolerance coatings, and is a pioneer in the development and application of solid film lubricant (SFL) coatings. With its network of five U.S. facilities, E/M Coating Services is the largest applicator of solid film lubricant coatings in North America. Additional facilities in Evesham, U.K.; Unna, Germany and Tianjin & Suzhou, China apply a broad range of SFL and other coatings to steel, titanium and aluminum substrates. Spray Coating Services
Good article, but it seems like you can chalk up almost all of those problems to the experience level of whomever is spraying the foam. Spray foam isn't an inherently bad product, but it's pretty easy to botch if the hired company is inexperienced. Fiberglass may be foolproof to install, but then again it has a terrible R-Value compared to a good spray foam. People just need to get referrals and do their homework whenever they research a spray foam contractor.
I applied the Gaco 100% Silicone Roof coating to a slightly-sloped, metal porch roof.  My leaks have stopped, and it looks like they are gone for good.  I followed the instructions, and it appears the product made a perfect bond to the roof.  What a terrific product!  I'm glad I made this purchase, and that I didn't settle for a cheap, metal coating from the local outlet store. Spray Coating
4 years ago I applied Gaco Roof, coats to an Office Building flat roof and have zero leaks since that time. This saved me $30,000 compared to having a new roof installed. The roof itself was only 7 years old when I applied Gaco Roof. but due to ponding water and harsh Florida heat and UV, the roof already looked shot and was leaking. I have now used Gaco Roof on 4 flat roofs to great results. I also tried big hardware store lower cost substitutes on 2 flat roofs. Those product utterly failed 1 to 2 years. Yes, I pressure washed my roofs clean before using Gaco Roof and followed their simple installation instructions. Excellent product.
Hydraulic or air powered airless provide a more uniform pressure control since the paint piston moves at a constant speed except when it changes direction. In most direct drive piston pumps, the piston is crankshaft driven in which the piston will be constantly changing speed. The linear motors of hydraulic or compressed air drive pumps, are more efficient in converting engine power to material power, than crankshaft driven units. All types of paint can be painted by using airless method. Coating Services
Are you tired of dealing with insulation jackets or insulation covers that don’t fit? Spray-on thermal insulating coatings by Synavax™ fit any shape of equipment and do not require any exterior jacketing. You can spray apply this technology easily while equipment is in-service and our concentrated insulation coatings will work diligently for 5-10 years or more without degrading. Spray Coating Services
In addition, it's difficult for an inexperienced installer to evenly spread the insulation foam over a surface. Miissing spots can leave holes and gaps for cold air to get through. Proceed with this project yourself only if you're doing a small insulation project -- such as installing foam in a crawl space or around your plumbing. Leave larger projects like the attic, basement or garage to the professional insulation contractors. Insulation professionals have the tools, equipment and background knowledge necessary. Moreover, they know how to accurately price insulation, whereas you could inaccurately budget for a DIY project and end up paying significantly more. Don't take the medical, physical or financial risks that come with pursuing this as a DIY project unless you're absolutely certain you have the skills. Spray Coating Services
We live in middle TN and had our house foamed last year. We noticed recently that some of the foam was shrinking and seperating from the floor joists. We contacted the installer and he informed us that the manufacturer had a problem with a batch of foam during the time frame we had our house sprayed. The contractor wasn't sure if we had the recalled batch installed in our house or not. He said he would check the batch numbers and let us know. He seems like a nice guy promising to do whatever it takes to fix any problems. Do we trust him, however, to be truthful about the batch number? Do we have any options for finding out the information ourselves? I inspected the entire crawl space of the house and noticed approximately (5) areas that were seperating and a couple areas where the foam didn't adhere to the block. Do I assume by it being so infrequent that it is nothing to be concerned about? My concern is the walls that are not capable of being visually inspected because of sheetrock. Coating Services
The standard prescriptive material that can be used as a thermal barrier is 1/2" gypsum board (a.k.a. drywall or sheetrock). Anything else has to be approved as an 'equivalent thermal barrier' by undergoing tests for temperature transmission and fire integrity. In some cases, however, you need only one test. According to the Spray Polyurethane Foam Alliance (SPFA), "Under specific conditions, the temperature transmission test can be waived if approved by building code authorities on the basis of large-scale fire testing representing actual uses." (See their pdf document, Thermal and Ignition Barriers For The SPF Industry.) Coating Services
This is more common with closed cell foam, but it happens with open cell foam, too. Since closed cell foam has a higher R-value per inch, installers generally spray 2" in walls and 3" in rooflines to meet the energy code requirements of R-13 and R-19, respectively. (I'm not going to dive into the energy code here, but these numbers apply to many climate zones, the latter being allowed under the UA tradeoffs rule. See the Energy Nerd's blog on this topic if you want to argue.)
Since our founding in 1973, Dal-Bac Manufacturing Co., Inc. has grown and expanded to become one of the premier providers of coating services to customers in a diverse range of industries. We are capable of applying both solvent and water-borne coatings to a wide variety of substrates, including fabrics, films, foams, and papers. Our capabilities include both knife-over-roll and Meyer rod coating methods for roll goods up to 61” in width. With our custom built equipment, we process materials accurately and cost-effectively. Insulation Spray Coating
I applied this product on a rolled asphalt flat patio roof. It was over 90 degrees and I could not touch the roofing at all on the first coat. I was laying on layers of cardboard to apply the silicone under the gutters and then rolled the first coat. The next day I brought all the cardboard to apply the coating under the gutters. I accidentally touched the roof and it was cool‼️  I threw the cardboard off the roof, laid down to do the gutters and roll the second coat. I was amazed how well this sealed and cooled the patio. I am going to apply this to my other patio and covered parking which are metal. I can’t wait to apply for sealing and adding cooling to these areas. Roof Coating Supply answered all my question and they ship promptly - I had my order in 3 days. Thank you. Coating Services
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 Coating Services
Spray painting poses health hazards that affect the respiratory, nervous, and circulatory systems. Similarly, using solvents to clean one's hands of paint marks and residue may cause skin irritation or even more serious issues since many are carcinogenic or neurotoxic. There are risks involved in working with substances such as paint and thinner, which contain compounds that are potentially harmful to health, or even fatal.[9] Insulation Spray Coating
Heat Shield™ EPX-H2O is a complete thermal barrier insulation system for pipes, tanks, and other industrial equipment and can provide 100% insulation coverage of all odd-shaped configurations – no more expensive insulation jackets or insulated covers needed. This next generation heat insulating coating has you covered for all types of directives – energy savings, safe touch for employee safety, heat radiation reduction, and asset protection from chemicals and corrosion. Don’t leave uninsulated areas in your pipe and tank insulation system that will lead to heat and energy loss. Instead use an easy spray-on solution that can coat, protect, and insulate your entire heat process system, including valves, pipes, tanks, boilers, heat exchangers, and more. Synavax™ thermal insulating and protective coating is a technology you can trust to perform consistently for 10 years or more. Spray Coating
Spray painting poses health hazards that affect the respiratory, nervous, and circulatory systems. Similarly, using solvents to clean one's hands of paint marks and residue may cause skin irritation or even more serious issues since many are carcinogenic or neurotoxic. There are risks involved in working with substances such as paint and thinner, which contain compounds that are potentially harmful to health, or even fatal.[9] Insulation Spray Coating
In plasma spraying process, the material to be deposited (feedstock) — typically as a powder, sometimes as a liquid,[2] suspension [3] or wire — is introduced into the plasma jet, emanating from a plasma torch. In the jet, where the temperature is on the order of 10,000 K, the material is melted and propelled towards a substrate. There, the molten droplets flatten, rapidly solidify and form a deposit. Commonly, the deposits remain adherent to the substrate as coatings; free-standing parts can also be produced by removing the substrate. There are a large number of technological parameters that influence the interaction of the particles with the plasma jet and the substrate and therefore the deposit properties. These parameters include feedstock type, plasma gas composition and flow rate, energy input, torch offset distance, substrate cooling, etc. Spray Coating Services
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Spray painting poses health hazards that affect the respiratory, nervous, and circulatory systems. Similarly, using solvents to clean one's hands of paint marks and residue may cause skin irritation or even more serious issues since many are carcinogenic or neurotoxic. There are risks involved in working with substances such as paint and thinner, which contain compounds that are potentially harmful to health, or even fatal.[9]
Most electric powered airless pumps have an electric motor connected through a gear train to the paint piston pump. Pressure is achieved by stopping and starting the motor via a pressure sensor (also called a transducer); in more advanced units, this is done by digital control in which the speed of the motor varies with the demand and the difference from the pressure set-point, resulting in a very good pressure control. Some direct drive piston pumps are driven by a gasoline engine with pressure control via an electric clutch. In electric diaphragm pumps, the motor drives a hydraulic piston pump that transmits the oil displaced by the piston, to move the diaphragm.
In classical (developed between 1910 and 1920) but still widely used processes such as flame spraying and wire arc spraying, the particle velocities are generally low (< 150 m/s), and raw materials must be molten to be deposited. Plasma spraying, developed in the 1970s, uses a high-temperature plasma jet generated by arc discharge with typical temperatures >15,000 K, which makes it possible to spray refractory materials such as oxides, molybdenum, etc.[1]
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. Coating Services
Mass-produced material is loaded on a conveyor belt where it is fed into one of these flatline machines. Flatline machines are designed to specifically paint material that is less than 4 inches (10 cm) thick and complex in shape, for example a kitchen cabinet door or drawer front. Spray guns are aligned above the material and the guns are in motion in order to hit all the grooves of the material. The guns can be moved in a cycle, circle, or can be moved back and forth in order to apply paint evenly across the material. Flatline systems are typically large and can paint doors, kitchen cabinets, and other plastic or wooden products. Spray Coating Services
Sean, thanks for jumping in and answering John's questions. About choosing the right foam, I intentionally avoided the open cell vs. closed cell foam debate. I did this partly because it's worthy of an article all by itself, but mainly I didn't include it because, despite all the warnings the two sides issue about the other, I've never personally seen a problem caused by using open cell where they should've used closed cell or vice versa. I'm sure things like that happen; I just haven't seen it yet. Insulation Spray Coating
Spraying paint with compressed air can be traced back to its use on the Southern Pacific Railway in the early 1880s[1] In 1887 Joseph Binks, the maintenance supervisor at Chicago's Marshall Field's Wholesale Store developed a hand pumped cold-water paint spraying machine to apply whitewash to the subbasement walls of the store.[2][3] Francis Davis Millet, the decorations director for the World's Columbian Exposition in Chicago in 1893, used Binks and his spray painting system to apply whitewash consisting of a mix of oil and white lead to the buildings at the Exposition, taking considerably less time than traditional brush painting and tuning it into what has been called the White City.[4][1][3] In 1949, Edward Seymour developed a type of spray painting, aerosol paint, that could be delivered via a compressed aerosol in a can. Spray Coating Services
Wire arc spray is a form of thermal spraying where two consumable metal wires are fed independently into the spray gun. These wires are then charged and an arc is generated between them. The heat from this arc melts the incoming wire, which is then entrained in an air jet from the gun. This entrained molten feedstock is then deposited onto a substrate with the help of compressed air. This process is commonly used for metallic, heavy coatings.[1]
Combustion spraying equipment produces an intense flame, which may have a peak temperature more than 3,100 °C, and is very bright. Electric arc spraying produces ultra-violet light, which may damage delicate body tissues.Plasma also generates quite a lot of UV radiation, easily burning exposed skin and can also cause "flash burn" to the eyes. Spray booths, and enclosures, should be fitted with ultra-violet absorbent dark glass. Where this is not possible, operators, and others in the vicinity should wear protective goggles containing BS grade 6 green glass. Opaque screens should be placed around spraying areas. The nozzle of an arc pistol should never be viewed directly, unless it is certain that no power is available to the equipment.[6]
Personal protective equipment (PPE) use: PPE must be used when handling spray paint materials, particularly PPE that offers protection to the skin. Some of the essential personal protective equipment are overalls with a hood, protective goggles for the eyes, half-mask respirators, and single use nitrile gloves. One of the most essential types of PPE is respiratory protective equipment (RPE). Nevertheless, basic RPE does not offer ample protection from the negative effects of isocyanates in human tissue. Paint products containing isocyanates must be handled while donning an air-fed RPE that has a 20 or higher APF (assigned protection factor). Air-fed respiratory protective equipment needs extra attention since they provide breathable air to the user. When in use, measures must be implemented to prevent contamination of the air supply since there is a risk of harmful substances entering the intake valve if it is not positioned outside of the spray area.
A rule of thumb puts two thirds of the coating on the substrate and one third in the air. True HVLP guns use 8–20 cfm (13.6–34 m3/h), and an industrial compressor with a minimum of 5 horsepower (3.7 kW) output is required. HVLP spray systems are used in the automotive, decorative, marine, architectural coating, furniture finishing, scenic painting, and cosmetic industries. Spray Coating
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