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Fizzy Foam

Spray Foam Saves the Office Space of a Coca-Cola Distribution Facility


The Coca-Cola Company operates numerous facilities across the world that thrive through timely production, where an interruption can result in downtime that alters production and distribution schedules. To keep this proverbial well-oiled machine running, any facility-related issues must be remediated with haste.

After a pipe froze and burst above the ceiling of an office space inside a 70,000 sq. ft. Kentucky-based Coca-Cola distribution facility, management sought a quick and long-lasting solution. They learned that the freezing of the pipe was a direct result of ineffective batt insulation that had deteriorated over time, allowing cold air to infiltrate the space above the drop ceiling. Furthermore, outside air was entering into the building through the vented soffits, which gave way to condensation.

Management opted to act quickly and have the pipe fixed and the insulation replaced. Upon fixing the frozen pipe, it was discovered that the condensation had generated mold in the batt insulation and the drywall. Even though the mold was not around any of the consumable products, management had a mold remediation crew come on site and remove the ceiling and batt insulation immediately. Management decided to utilize spray foam insulation to prevent similar occurrences in the future.

Management contracted Purefoam Insulation for the project, which entailed installing a three-inch lift of foam to the roof deck of the 4,500 sq. ft. office space.

“The busted pipe was clearly a result of subpar insulation being installed to the roof sheathing,” said Purefoam’s Manuel Adler. “Spray foam was the perfect solution for leak prevention, not to mention immense energy savings.”

A three-man Purefoam crew came on site and prepared the spray area with safety and time–saving in mind. The Purefoam crew noticed that the room itself had a circular shape with a 22-foot peak that would require scaffolding for crewmembers to properly carry out the application.  They decided that they would install a protective coating as opposed to drywall after the SPF application in order to comply with local building code requirements and simultaneously save time. To mitigate SPF overspray damage, the crew covered the floor, windows, and sprinkler heads with plastic sheathing. The crew wore PPE consisting of Tyvek suits, boots, gloves, and supplied-air respirators.

With the scaffolding in place and 300 feet of hose connecting their spray rig to the spray area, the Purefoam crew was ready for the foam application. Using a Graco H-30 proportioner, the crew applied the foam to the underside of the roof using a Graco Fusion air-purge gun. The three inches of foam that were applied provided an R-21 value. Throughout the application, the crew used InsulStar, a 2 lb. closed-cell spray polyurethane foam product formulated by NCFI.

“Closed-cell spray foam was the obvious choice for this project,” said Adler. “Structural rigidity was necessary and the foam itself is non-porous, providing an air and vapor barrier, so that there’s no danger of history repeating itself.”

After the spray foam application, the crew utilized a Graco GH 833 hydraulic gas sprayer to apply to the underside of the roof 40 wet mils of DC-315, a thermal barrier protective coating formulated by IFTI.

The Purefoam crew finished up with the application of the materials in three days. They spent three hours cleaning up the site before they packed up and headed home. After the project’s completion, management called Adler and expressed their gratitude for a job well done. Management noted that the office space’s environment changed drastically, and that they no longer needed to adjust the thermostat as much as they previously had to.

“The owners were very impressed with how the foam had sealed every nook and cranny and how well insulated their building felt,” said Adler. “The spray foam on that roof will now stop all air infiltration, which is something the old batt insulation could not do. Spray foam insulation will never need to be replaced; it is the forever type of insulation.”

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