Advice on insulation for existing 1980s pole barn

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Hi all.

Having to make some quick adjustments as my warehouse lease is suddenly not being renewed, so moving my business back to my farm in central WI.

I need to store a lot of motorcycle parts (so a bunch of steel that can easily rust) in a 40'x50'x14' tall pole barn with no current ceiling) and keep it heated to 40 in winter in order to make it tolerable to pick parts for an hour in the morning (have lp available and package/ship in the house).

There is no insulation or vapor barrier under the slab or on the walls (I didn't build it, sorry). The roof leaks in a few small spots and I'm sure degradation of the neoprene washers and screws backing out will continue as time progresses.

Original plan was to do walls and roof with 2" of closed cell, but then I'm stuck heating the extra "attic" space. Quote to do all four walls and roof underside with 2" closed cell was just over $10,000.

Options I'm looking for opinions on:

Spray only 1" of foam on the roof to stop leaks/air infiltration, still do 2" on walls, then add a ceiling and blown in insulation to R-38 ~$3500. Would assumedly reduce heating costs, but not sure by how much.

Add another inch to the roof in spray foam for an extra $2000 and don't do a ceiling at all, get some ceiling fans to keep hotter air moving.

Stick with the 2" everywhere and see how we do this winter, then add ceiling/extra wall insulation next year if needed.

What would you suggest in my situation or something completely different?

 

[kbeefy]

Theres lots of insulation experts in here.
I think it's time to replace the neoprene washers on the roof.
I'm curious if spray foam under a leaking roof is acceptable or just a way to accelerate water damage and mold.

I'd bet Ceiling and blown in insulation along with appropriate attic venting (ridge and soffit or whatever) is going to be your best and most cost effective improvement. Vapor barrier under insulation.
Sealing walls and adding rockwool or Fiberglass would do pretty well for the walls.

Lets see what the experts recommend....

 

[mikedodge]

I wouldn't do anything with insulating the roof before fixing the leaks.
I've never been a fan of spray foam directly on the under side of roof.
I'd almost put up with the cold for that short amount of time. If there's decent air flow rust shouldn't be a problem. Its the insulated part of my pole barn that has humidity issues.

 

[i4ni]

Could you could frame out a make shift room inside just big enough to get by? I've worked on winter jobs where they would frame up a hooch, skin it with re-enforced poly and cover that with concrete blankets and have a warm place to take breaks. You could probably cook a deal to rent some concrete blankets from some local cat reasonable. Food for thought maybe

 

[PWC Repair]

How about nailing 4x8 sheets of 2" foil faced styrofoam to the purlins, tape the seams.

 

[Firebrick43]

I would never spray foam the underside of a roof, it will destroy it eventually. But I sure as hell wouldn't spray foam a roof with issues or some age.

Any leaks will saturate the foam and cause rust on the panels.

Use XPS or even better Poly iso due to its fire resistance and radiant barrier attached to the bottom of the trusses. It makes a world of difference. Just put purlins across the bottom of the trusses and use ring shank cap nails to install the foam.