Start With The Roof Deck
If you only do one thing, do the roof.
Heat rises and leaves through the roof, so that is where the loss is worst. It is also the surface where condensation forms and drips onto whatever is underneath.
Closed-cell foam sprayed to the underside of the deck deals with both at once. No gap behind it means no cold surface for water to form on.
For a lot of shops, roof deck only is the sensible first phase, with walls following later. We are happy to quote it that way.
Why Pole Barn Framing Suits Foam
Girts and purlins create a lot of irregular cavity. Batt insulation has to be cut and fitted around all of it, and every imperfect fit is a gap.
Spray foam is applied wet and expands into whatever shape it finds. Bracing, fasteners, odd corners and penetrations all get sealed as a matter of course.
On steel buildings, foam bonds directly to the cladding, which is the whole point when condensation is the problem.
It also stays where it is put. Blanket systems sag, tear and get pulled down over time, especially where birds get behind them.
Heated Bays And Cold Ends
Very few shops need the whole building at the same temperature.
A common arrangement is a heated repair or workshop bay foamed properly, with the cold storage end left alone or done to a lower spec.
That split needs a real air barrier at the division, not just a stud wall, or you are heating the cold end through the partition.
We will spec the divide as part of the job rather than treating it as somebody else's problem.
Durability And Covering
A working shop is a rough environment. Equipment gets moved, things get knocked, and sparks happen during fabrication.
Foam in occupied space has to be covered to satisfy the building code, and half-inch drywall is the standard accepted assembly. Approved intumescent coatings are an alternative under OBC 9.29.4 to 9.29.9.
That covering also protects the foam insulation from impact, so it is doing two jobs.
We build thickness with the actual use in mind and tell you plainly what the covering requirement will be before you commit.