Closed-Cell Spray Foam on an Arched Metal Barn in Onalaska, TX
This project involved applying closed-cell spray foam to a massive metal barn structure in Onalaska, TX. The building features an expansive, arched metal roof supported by heavy steel structural framing, alongside wood-framed lower exterior walls. Structures with this sheer volume and exposed metal surface area can easily become sweltering ovens during the summer if they lack a proper thermal barrier.
What the Building Needed
Bare metal roofs transfer an immense amount of radiant heat directly into the space below. Furthermore, the massive air volume inside this barn makes it incredibly difficult—and expensive—to condition if the building envelope isn’t completely airtight. Additionally, temperature swings often cause condensation to drip from uninsulated metal ceilings, which can damage equipment and tools stored below.
Traditional batts or blankets just don’t cut it for these large-scale arched structures. To permanently stop heat transfer, prevent condensation, and lock out uncontrolled air movement, high-performance metal building insulation via spray foam was the only logical solution.
The Application Process
Our crew applied a consistent, monolithic layer of closed-cell spray foam directly to the underside of the corrugated roof deck and upper wall panels. The foam expands and cures in seconds, adhering directly to the metal and filling every rib, seam, and gap.
As you can see in the project photo, our team worked meticulously around the heavy steel structural trusses, cross-bracing, and lighting conduit to ensure continuous, gap-free coverage. We sprayed the envelope continuously down to the top plate of the wood-framed lower section, bridging the gap between the metal upper shell and the lower walls. The large roll-up doors and lower wall sections were carefully masked and protected during the spray process to ensure a clean, professional finish.
The Finished Result
The transformation is immediate. The space went from a heat-absorbing steel shell to a heavily insulated, thermally controlled environment. By locking out the East Texas heat and sealing every air leak, spray foam insulation provides an airtight seal that will drastically reduce the workload on any future HVAC systems or exhaust fans.
Whether the owner intends to use this space for heavy equipment storage, a climate-controlled environment requiring shop insulation, or eventually finishes out portions of the interior, the envelope is now perfectly prepped.
If you have a large barn, shop, or metal building project in the Onalaska area at any stage of construction, we can help you get the thermal control you need.
Request a free estimate from Weeks Spray Foam. No pressure, straight answers on what the job takes and what it’ll cost.
