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.
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:
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 Coating
Introducing Mothers CMX Ceramic Spray Coating, an affordable, user-friendly, professional grade, ultra-durable, super-hydrophobic protection formula. Just spray on and wipe off, with this game-changing SiO2 (Silicon Dioxide) and TiO2 (Titanium Dioxide) blend. This powerhouse combo provides ultra long-term protection from the elements and relentless water beading, without sacrificing true optical clarity, extreme depth and that signature ceramic glass-like liquid-gloss appearance. Use as a stand-alone product, or as a booster over your existing sealant or ceramic coating. Washing and caring for your vehicle has never been easier. Cures in 24 hours (do not get vehicle wet during curing period). Coating Services
Ignition barriers include six permissible materials. An ignition barrier can be 1/4-inch plywood or structural panels, 1 1/2-inch mineral fiber insulation, 1/4 inch hardboard, corrosion resistant steel at least .016 inches thick, 3/8-inch gypsum board, or 3/8- inch particle board. These sizes are the minimum; code officials will approve of thicker versions of any of these six materials as ignition barriers. Like thermal barriers, equivalent materials that have been shown to have equivalent fire resistance are acceptable. Additionally, an alternate assembly can be used if the assembly has been tested by a laboratory and meets certain criteria.

The fluid pressure is provided by an airless pump, which allows much heavier materials to be sprayed than is possible with an airspray gun. Compressed air is introduced into the spray via an air nozzle (sometimes called air cap) similar to a standard conventional spray gun. The addition of compressed air improves the fineness of atomization. Additionally unlike a pure airless spray gun, an AA gun has some control over fan spray to round spray. Some electric airless sprayers (Wagner and Graco) are fitted with a compressor to allow the use of an air-assisted airless gun in situations where portability is important.
At Praxair Surface Technologies, it’s our goal to help you get more protection, more customization and more performance from your parts. To do that, we work with you to select or develop coatings based on your operating environment and production requirements. Then we combine advanced preparation services, the right application technology and post-coating operations to create optimal coating performance for any component. Coating Services

Car was washed with Carpro reset and wiped down with Griots garage paint prep to ensure a clean surface for first application of CMX. Week one CMX had a nice gloss with small tight beads after getting rained on (typical Si02 protection). Week two the beads were large and flat (low contact angle) so product was on it's way out. Week three the water was sheeting with no beading at all. That's complete failure in three weeks. Also I didn't like the white crystals that developed in the bottle. I'm concerned that if I used the product again that I'd mar my Audi's Mythos black paint. My car is parked outside driven only about 50 miles per week and is washed weekly with Megs gold class car wash. . Won't apply it again. Moving on.... Coating Services
Due to a wide range of nozzle shapes and sizes, the consistency of the paint can be varied. The shape of the workpiece and the desired paint consistency and pattern are important factors when choosing a nozzle. The three most common nozzles are the full cone, hollow cone, and flat stream.[6] There are two types of air-gun spraying processes. In a manual operation method the air-gun sprayer is held by a skilled operator, about 6 to 10 inches (15–25 cm) from the object, and moved back and forth over the surface, each stroke overlapping the previous to ensure a continuous coat.[7] In an automatic process the gun head is attached to a mounting block and delivers the stream of paint from that position. The object being painted is usually placed on rollers or a turntable to ensure overall equal coverage of all sides. 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.
Prodex eliminates the moisture (condensation) from forming on the metal sheeting. It does it by making the temperature of the metal sheeting on the building approximately the same on the inside as the outside. When the heat or cold from outside comes through the metal skin it hits the outside aluminum facing of Prodex and is reflected back upwards through the underside of the metal sheeting. This process keeps the metal sheeting temperature consistent on both sides. In addition, the inside layer of aluminum in Prodex reflects away the heat (heater) or cold (air-conditioning) from inside the building, from getting to the metal skin. This also helps in preventing condensation.  Spray Coating Services
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
Independent reviews at Site Jabber. Site Jabber is the leading community of online business reviewers. The community helps consumers find great online business and avoid scams. The community has grown to over 850,000 members and has reviewed over 58,000 online businesses. Site Jabber was developed in part with a grant from the National Science Foundation. Spray 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. Insulation Spray Coating

What do you mean by "our AC units require fresh air ventilation"? Fresh air doesn't come from the attic. If there's an atmospheric combustion appliance in the attic, such as an 80 AFUE furnace, then you shouldn't be encapsulating the attic anyway. If that's the case, you don't want spray foam on the roofline at all. You can either change out the furnace to a sealed combustion unit or do your insulating and air-sealing at the flat-ceiling level.
Synavax™ thermal insulation coatings are the top choice for a wide variety of thermal insulating paint applications over equipment like pipes, pipelines, tanks, ovens, processing vessels, heat exchangers and more. Synavax™ patented industrial thermal insulation paint solves corrosion-under-insulation (CUI) by both insulating and preventing corrosion with a single product. Our thermal paint coatings are multipurpose spray or paint applied products that are simple to deploy. Spray Coating Services

One of the most common applications we handle is the production of custom pressure sensitive adhesive tapes. We also process specialty coatings with job-specific characteristics, such as anti-fog coatings, laminating tapes, fabric appliques, and more. Custom coating formulations are also available to meet the unique requirements of virtually any application.
Allison--would be very interested in your take on the GHG issues of foams, which have received lots of smart commentary recently. To highlight a few: architect Jesse Thompson's comments on Tom's Good vs Bad post on Energy Circle, the very thorough piece by Alex Wilson on Green Building Advisor and Michael Anschel's cautionary diatribe on Remodeling. 

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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. Insulation Spray Coating
Thermal spraying can provide thick coatings (approx. thickness range is 20 microns to several mm, depending on the process and feedstock), over a large area at high deposition rate as compared to other coating processes such as electroplating, physical and chemical vapor deposition. Coating materials available for thermal spraying include metals, alloys, ceramics, plastics and composites. They are fed in powder or wire form, heated to a molten or semimolten state and accelerated towards substrates in the form of micrometer-size particles. Combustion or electrical arc discharge is usually used as the source of energy for thermal spraying. Resulting coatings are made by the accumulation of numerous sprayed particles. The surface may not heat up significantly, allowing the coating of flammable substances.
The CWST Thermal Spraying, FW Gartner and Bolts Metallizing business units in AZ, CT, MA, SC and TX apply HVOF, HVAF and plasma thermal spray coatings for flight and industrial gas turbine applications as well as tungsten and chrome carbide wear coatings utilized in Oil & Gas, Mining, Steel Mill and other demanding industrial markets. FW Gartner also provides Laser Cladding and PTA welding services on new and service run parts for components operating in severe service environments. Spray Coating

Open cell spray foams are less common and have a lower resistance to heat flow than closed cell spray does. Open cell spray foaminsulation expands when it is applied, which allows it to be installed in hard to reach areas, such as small wall and ceiling cavities. Open-cell spray foam is typically cheaper than closed cell foam is, but it is more permeable and vulnerable to fire hazards.
Plasmas affect materials at an atomic level. Techniques like X-ray photoelectron spectroscopy and scanning electron microscopy are used for surface analysis to identify the processes required and to judge their effects. As a simple indication of surface energy, and hence adhesion or wettability, often a water droplet contact angle test is used. The lower the contact angle, the higher the surface energy and more hydrophilic the material is.
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. Spray Coating
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.) Coating Services
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]
Whether you work on frame-up restorations in your garage, or projects like refinishing wheels, interior upgrades or maintaining the appearance of your everyday ride, Dupli-Color wants to be there with you. We have a heritage of providing only the best in automotive products since 1938, when we first started selling touch-up paint. This marked the beginning of “innovative firsts” which continues today with the automotive aftermarket’s largest array of DIY paints, primers and coatings.
The atomization of molten materials produces a large amount of dust and fumes made up of very fine particles (ca. 80–95% of the particles by number <100 nm).[8] Proper extraction facilities are vital, not only for personal safety, but to minimize entrapment of re-frozen particles in the sprayed coatings. The use of respirators, fitted with suitable filters, is strongly recommended, where equipment cannot be isolated.[8] Certain materials offer specific known hazards:[6] Insulation Spray Coating

When do you need an ignition barrier? According to the IRC and IBC, an attic or crawl space needs an ignition barrier over the spray foam if the space can be accessed but will not be used for storage or auxiliary living space. You don't need an ignition barrier if the space cannot be accessed without cutting into it, if it is not connected to other spaces, and if it does not communicate with other spaces. Spray Coating Services


While intumescent coating can be used instead of an ignition barrier or thermal barrier in some cases, the coating itself is not technically either. It does prevent or slow fires, so it has been approved to be used in conjunction with spray foaminsulation as an alternate assembly. The fact that it qualifies as an alternate assembly means that it can be used instead of a thermal barrier or ignition barrier.
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. Spray Coating
Yes, you're right that all of the problems mentioned above are related to the installer. I didn't try to hide that and even used the word 'installer' in two of the four headings. I can see how you'd think that the title is misleading, but in the end you can't separate spray foam insulation from its installation. Some people have the mistaken impression that if you get spray foam in your house, your home will outperform all others. My point here is that that's not true. Insulation Spray Coating
Note: The practice of foam insulating the attic has raised eyebrows in the building industry because "standard" roofing techniques call for the attic to be ventilated; however, in a vented attic situation it will become approximately 130 degrees in the summer. There's no reason for an air-conditioning and vent-ductwork to have to work in that type of severe conditions. By applying Icynene right on the underside of the roof deck, the severe temperatures no longer exist in the attic. In short, the attic is now a "conditioned" space of the house that is just as comfortable as any other room in the home. This is called a "Compact Roof", which means you can frame right up against it. The one drawback of using expanded foam on the inside of the roof is that this will cause the temperature of the shingles to rise, but how much is not yet known. And how much damage a rise in temperatures could cause is debatable. Coating Services
Spray foam comes in two flavors, open cell and closed cell, and provides both parts of the building envelope - the insulation and the air barrier. The building envelope should completely surround the conditioned space, and the insulation needs to be in contact with the air barrier. Since spray foam is both insulation and air barrier, proper alignment of insulation and air barrier is guaranteed.
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. Insulation Spray Coating
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.

If you're plagued with quality problems caused by uneven application of coatings or waste of costly coatings due to over-application, take a close look at our products for precision coating. You will find a wide range of nozzles, standard and heated spray headers and automated spray systems to apply all types of coatings – including thick slurries, chocolate, viscous oils and more – uniformly with minimal waste. Spray Coating
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
In cold spraying, particles are accelerated to very high speeds by the carrier gas forced through a converging–diverging de Laval type nozzle. Upon impact, solid particles with sufficient kinetic energy deform plastically and bond mechanically to the substrate to form a coating. The critical velocity needed to form bonding depends on the material's properties, powder size and temperature. Metals, polymers, ceramics, composite materials and nanocrystalline powders can be deposited using cold spraying.[4] Soft metals such as Cu and Al are best suited for cold spraying, but coating of other materials (W, Ta, Ti, MCrAlY, WC–Co, etc.) by cold spraying has been reported.[1]
I've had concerns with foam in walls with only 2-3" and the resulting air space & convective currents. spray foam for walls is not one of my recommendations to my clients. instead foam sheathing to exterior of walls caulked,taped & sealed. conventional insulation & air tight drywall approach. a better and affordable wall with no extremely long payback like spray foam in walls.  Insulation Spray Coating
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Kool Seal may be the best roof coating because it clings to your roof in all temperatures. It provides good protection against moisture, so it is suitable for humid areas.This product forms a thick barrier for the roof, which can reflect 90% of the sun’s rays. Whether in the hottest summer or in the coldest winter, this product maintains durable and protective. Spray Coating Services
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