Closed Cell Foam Insulation Causes Unintended Consequences

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I had Morton build our building. When I asked about Spray Foam Insulation they said they would not do it and advised against it.

I recall them mentioning something about putting Tyvek (or something similar) between the Panels and Pole Frame first then spray. The ceiling would have to be done at the deck not the roof.

I opted for their premium insulation package and have zero regrets.

Our house is all spray foam and we may hear 1 or 2 "nail pops" a year when it gets to -15° and colder.

 

[NUTTSGT]

Looking at my parents building that bare on the inside right now. I think I know what I would do if I was spray foaming.

I'd put 1.5 rigid foam between the girts, (maybe Tyvek) and put the metal siding on. On the inside if cost was no problem, I would spray foam right over the rigid foam panels and girts.

 

[Busted_Knuckles]

Improper mix can cause shrinkage and it will pull away. That could be what they were seeing.

While I can't offer assistance to the OPs issue here is my anecdotal experiences.
-the few pole barns I've built, or been involved with, set posts 8' OC, trusses 2' OC, OSB roof sheathing regardless if shingles, ribbed steel or standing seam.
-one shop has closes cell on the walls but has OSB sheathing and vinyl siding
-the one with closed cell sprayed to roof OSB has standing seam metal
-another metal sided barn used 8' wide PEBS fiberglass

In MY barns I won't use spray foam directly to metal.
The metal WILL move, period.

I'm a proponent of foam. Our entire living area has closed cell foam but it's applied to the OSB.

Have been around HUGE iron buildings around 30 yrs old and over time exposed screws back out or in some cases the heads snap off. That's one big advantage of standing seam, the fastener holes are slotted so it doesn't pull so hard on the fasteners.

Id concur, I did open cell foam on my last house ( contractor applied ) with a foil faced house wrap and a rain screen, it was a 1904 Farm house remodel/strip out to the studs on both sides, but I did NOT use it in my Morton building at that address. On the shop I used foil faced 2.25" Polyisco boards with fiberglass bats on the walls, with an air gap to the tin and I hung an insulated ceiling, and it was problem and noise free. Would do it again.

 

[danieldd]

I am pretty sure the cracking and popping noises are directly attributed to the 1 inch thermax panels that were originally on the underside of the roof. They sprayed over these with the closed cell foam. I've left a voice mail for the company that did the foam insulation to see if they have a remedy, but I seriously doubt there is a fix for this.

I'm moving on to planning the construction of another shop. The current one will be used to house the farm equipment.

 

[Toyomech]

Thats the best move. I don’t think there is anything long term you need to worry about as far as the structure but since you are concerned, a call to the installer and possibly a visit by the product technical rep is the way to go. Do you know the brand of spray foam used?

 

[danieldd]

Thats the best move. I don’t think there is anything long term you need to worry about as far as the structure but since you are concerned, a call to the installer and possibly a visit by the product technical rep is the way to go. Do you know the brand of spray foam used?

Installer called me this morning. They are coming out tomorrow to have a look. This is a good sign. Don't know what they can do, but we will see...

I don't know the brand of foam they used. If I remember to ask, I will.