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. Insulation Spray Coating
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 Coating
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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

HVOF coatings may be as thick as 12 mm (1/2"). It is typically used to deposit wear and corrosion resistant coatings on materials, such as ceramic and metallic layers. Common powders include WC-Co, chromium carbide, MCrAlY, and alumina. The process has been most successful for depositing cermet materials (WC–Co, etc.) and other corrosion-resistant alloys (stainless steels, nickel-based alloys, aluminium, hydroxyapatite for medical implants, etc.).[1] Spray Coating
Building code regulations typically call for the use of thermal barriers when spray polyurethane foam is installed. The code requires that the foam is separated from any living spaces by a layer of 1/2-inch drywall. As discussed earlier, any material that has been approved as being as equally fire resistant as the gypsum drywall can be substituted as a thermal barrier.
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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. 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] Spray Coating Services
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Combustion spraying guns use oxygen and fuel gases. The fuel gases are potentially explosive. In particular, acetylene may only be used under approved conditions. Oxygen, while not explosive, will sustain combustion, and many materials will spontaneously ignite, if excessive oxygen levels are present. Care must be taken to avoid leakage, and to isolate oxygen and fuel gas supplies, when not in use.[6] Spray Coating Services

Steve: If your spray foam installer leaves the vents open, he will be committing the 2nd of the 4 problems I described above. You will most likely have comfort and efficiency problems. You may well have condensation problems. You will be spending a lot of money on a product that likely won't perform as it should. Don't let him leave the vents open. If the installer you've chosen doesn't understand this, you may want to choose someone else. 


The deposits consist of a multitude of pancake-like 'splats' called lamellae, formed by flattening of the liquid droplets. As the feedstock powders typically have sizes from micrometers to above 100 micrometers, the lamellae have thickness in the micrometer range and lateral dimension from several to hundreds of micrometers. Between these lamellae, there are small voids, such as pores, cracks and regions of incomplete bonding. As a result of this unique structure, the deposits can have properties significantly different from bulk materials. These are generally mechanical properties, such as lower strength and modulus, higher strain tolerance, and lower thermal and electrical conductivity. Also, due to the rapid solidification, metastable phases can be present in the deposits.
Fiberglass is the giant in the insulation industry, and the R rating to which it conforms is ingrained in the minds of contractors, builders, and code inspectors. Insulating ceramic coatings offer an alternative to traditional batt insulation. “Fiberglass insulation is tested and rated at 73 degrees Fahrenheit, which is the ideal temperature for fiberglass,” says Pritchett. Under harsher conditions, Pritchett suggests that fiberglass doesn’t perform as well as its ratings predict.
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
Thermal barriers come in the form of 1/2-inch gypsum drywall or any material that is proven to have an equal fire resistance to gypsum wallboard. Additionally, alternate assemblies can be used if they have been tested in a laboratory and approved. Ignition barriers are a lower standard to meet, and can be satisfied with a number of different materials. Like thermal barriers, they can be substituted with equivalent fire resistant materials and alternate assemblies, such as an intumescent coating. Coating Services
Condensation - It can seem like a tropical rain forest inside an unprotected metal building. It's worse on those days where there is a greater contrast between temperatures at night vs. day. The morning sun hitting the cool sheeting will create a drip. A temperature difference between outside and inside your building creates condensation - Similar to what happens when you leave a cold can of beer outside on a hot day. 
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
Synavax™ thermal insulation coatings help organizations improve energy efficiency. They are nano-engineered patented cutting-edge thermal paint coatings that provide next generation performance beyond older, non-patented ceramic insulation products.  Additionally, our products are eco-friendly and provide mold-resistant and anti-condensation properties without harmful biocides and other harsh chemicals, which is a significant plus for sustainably-minded companies. Insulation Spray Coating
PPG Coatings Services has protective coatings production facilities, sales offices and a network of representatives strategically located around the world. That means you can reap the benefits of working with one of the world’s largest and most innovative coatings companies while enjoying the personalized service of a smaller organization focused on meeting the needs of your business.
Simple – we’ve seen experienced contractors work with the separate nitrogen tanks and spray foam rigs and have one heck of a time. These spray foam insulation kits are quick to learn and simple to use. They’re designed to be easy so you get results the very first time you spray. Thorough Instructions, 24/7 Product Support, and videos make it easy to install. Spray Coating Services
Fiberglass is the giant in the insulation industry, and the R rating to which it conforms is ingrained in the minds of contractors, builders, and code inspectors. Insulating ceramic coatings offer an alternative to traditional batt insulation. “Fiberglass insulation is tested and rated at 73 degrees Fahrenheit, which is the ideal temperature for fiberglass,” says Pritchett. Under harsher conditions, Pritchett suggests that fiberglass doesn’t perform as well as its ratings predict.
I have been looking to have closed cell insulation added through out my attic space. I cant seam to find a installed that wants to install no more than 2 inches, and thats not near my R-valve for South Carolina (Lake Greenwood)please send any advice that will help me to see what installer will perform the correct job. This is a expense that i can only afford to do once. Sandi
Enjoy year round use of your garage with Enjoy year round use of your garage with the MATADOR Garage Door Insulation Kit. Easily transform your garage space into a workshop rec room or exercise area - in less than 1 hour. The same OEM - grade product used by garage door manufacturers. Panels are a bright white with ...  More + Product Details Close Spray Coating
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