An AeroBarrier Installation is a nonconventional construction process. A nonconventional process often requires detailed descriptions and unique terminology to accurately explain how a particular system works, as well as the nuances associated with it.
Over-spray is a term that has been a topic of discussion for us over the past year, but am I even talking about over-spray half of the time? This question has led me define the term as it relates to AeroBarrier Applications, which has resulted in a couple of new denominations.
AeroBarrier Over-spray = sealant that collects on vertical surfaces. This occurrence is rare and is caused only by turbulence around the injection point/the fan, or by a sealing station that was set up too close to a vertical surface.
AeroBarrier Settle-spray = sealant that settles on the horizontal surfaces below. AKA sealant that isn’t pushed to gaps and cracks by the Blower Door Directed Air Sealing.
AeroBarrier Exit-spray = sealant that escapes the building or unit envelope through large bypasses.
Exit-spray is generally a topic of discussion when it comes to Retrofit AeroBarrier Applications due to accessibility challenges. Accessibility to tape, caulk, or spray foam gaps, cracks, and holes in the air control layer that exceed a half of an inch.
New construction projects are less likely to experience exit-spray as most large bypasses are usually sealed up prior to our arrival. This is mainly because construction management teams and framing crews have become more adept in ensuring their air control layer is continuous. Design teams deserve credit for these improvements too, as their drawings are more detailed, clearly calling out air controlling materials in the building assembly.
In this case, we dealt with some exit-spray during the early stages of the AeroBarrier Installation due to the inadequate flash coat of spray foam. Primarily in and around the dormers and soffits, both of which are hard to reach areas for a spray foam crew even if mix issues or cold substrates aren’t present.
Given the existing conditions, we expected this to be the case, and were stoked to see the exit-spray diminish throughout the duration of the Seal. As the building envelope became more airtight, the exit-spray soon became nonexistent. Aside from monitoring the equipment via the SmartSeal Software, routine exterior observations are one aspect of our standard operating procedure.
To be continued…
