Spray Foam Retrofit Project in Old Winchester, VA Farm House

Challenge

This Winchester, VA farm house was over 100 years old and drafty.  The homeowners wanted to make the house more energy efficient.  The owners were very educated and knew exactly what they wanted to accomplish.  They also had an excellent contractor who was going to re-side their house.  

The project goal was to convert the attic into conditioned space and to insulate the walls.

We chose a combination of Open Cell Spray Polyurethane Foam for the attic conversion, and Injection Wall Foam Gaco Profill system for the walls.  This material selection allowed for maximum cavity fill while eliminating clean up from overspray.

Our technical representative from Gaco Western, Kevin Beck, was extrememely helpful in developing this project and getting it completed quickly.

Solution

The exterior of the house was removed by Charlie Decourcy Contracting so that we could see the skeleton of the home from the outside.  We then found and plugged all holes that would have allowed foam to travel to places we did not want it to go. 

A membrane was then stapled to the outside of the house to contain the Gaco Western Profill Injection Foam.  Foam was injected to fill the cavity completely.  Personnel were stationed inside the house to find and clean all foam that expanded into the home where we did not want it to go.  We collaborated with C&R Insulation to install this project as they had some expertise that would lead to a more professional and timely installation.

Charlie Decourcy Contracting then sheathed the outside of the home with 2 inch foam board, preventing any thermal bridging through the framing of the home. This foam board also provided a water barrier to the outside of the home. 

Later, they returned and completed the project by siding the home with Hardy Plank siding for a durable siding solution that will last another 100 years on this beautiful country home.

Project Summary

Engineer: John W. LeVan Snr

Consultant: Scott Beers