Knowing these key points makes retrofitting a metal building a less daunting task
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| Photo: High-R Metal Building Insulation Solutions |
Making the choice to retrofit an existing metal building can be a daunting task that takes months or even years. With so many insulation options available and skilled labor shortages it takes a lot of patience and due diligence. Do you go for aesthetics, price point, increased R-value, cheap and quick, or do it right once?
Over the course of the most recent economic downturn, many companies have decided to stay in their existing spaces to cut costs and reduce their risk in the volatile markets. With that being said, the retrofit market has grown exponentially. Whether you have a 5,000-square-foot shop or a 100,000-squarefoot warehouse, each building brings the same challenges, some just on a larger scale.
Insulating a metal building, new or old, is a task meant to be dealt with by experts in their fields. They have studied their craft for years and more than likely have seen the good bad and the ugly. We will look at a few key points that need to be addressed when retrofitting a metal building.
Air Sealing
No matter what type of insulation system you decide to use when retrofitting your structure, if it is not properly air sealed you might as well light your wallet on fire. A little extreme analogy, but if air is moving into the insulation system, whether inside or outside, the value of the system is greatly diminished. With so many penetrations, brackets, windows and doors, it is always a tough task, but with the right products used in the right situations it can be done. For example, using spray foam around windows and doors to stop any drafts is a great way to get a proper air seal. Also, using the right sealant, adhesives and tapes are crucial to the integrity of the vapor barrier that is being used.
Cavity Insulation
Attempting to get a fiberglass batt to fit in an existing cavity with no air pockets for condensation to occur in is like finding a needle in a haystack. If the customer is going with a liner system, liner steel, fabric, foam board, etc., blowing insulation into the cavity can be the most effective way to insulate these areas. By pneumatically blowing insulation into these areas you can ensure every corner and rib of steel has adequate insulation. With typically a higher density than batting it can help reduce air movement through the system as well.
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| Photo: High-R Metal Building Insulation Solutions |
Retrofit Thermal Blocks?
With an existing building it is next to impossible to add a thermal block unless you address the topside of the roof in some manner. To help reduce thermal movements through the steel is and always will be a challenge. A possible option to rid a majority of the thermal movement would be using a fire-rated Polyiso foam board attached to the inside of the purlins or girts. With many more options today than even 10 years ago the market is competitive with many products and price points available to increase your energy efficiency.
Return on Investment
Getting the best bang for your buck is always front of mind. But how do you know if you are spending too little or too much? It’s a very fluid question depending on how long you expect to be in the facility, what you want your energy costs to be and what maintenance costs could incur with various systems over their lifetimes, etc. There is also a lot to be said for material R-values and installed Rvalues, a big misunderstanding by a lot of consumers and even some in our industry.
Choosing the Right Company
We all know there are many ‘trunk slammer experts’ in all industries that can talk the talk, but not necessarily walk the walk, so how do you choose the right company to perform the work on your facility? As I said before, retrofit insulation projects are much more complicated than new projects. With the hassle of working around existing equipment and mechanical units, limiting downtime or slowed production of your employees, it is just as important to choose the right company as it is to find the right product. Always ask for references and look for a BBB rating if possible, because no matter how high quality the product is, if not installed properly, it holds little-to-no value and you are back at square one with less money in your pocket.
Curtis Sturgill is national sales manager for High-R Metal Building Insulation Solutions, Ames, Iowa. To learn more about insulation options for your building, visit www.high-r.com or email Sturgill at info@high-r.com.
