Spray Foam Insulation

Spray foam is the highest-performing insulation a home can get, and the most unforgiving to install. Done right, it air-seals and insulates in a single application, turns a leaky attic into a conditioned space, and outperforms anything blown or batted. Done wrong — bad mix ratio, off-spec thickness, missing thermal barrier — it's an expensive, permanent problem. Prime Chimney Experts installs spray foam to a controlled, code-correct standard, because this is precisely the kind of high-stakes craftsmanship our brand was built to deliver.

What makes foam different: it's not just R-value, it's an air barrier and an insulator at once. Open-cell (half-pound) foam expands to fill cavities and the roof deck, sealing air leaks while delivering about R-3.7 per inch. Closed-cell (two-pound) foam is rigid and dense, giving roughly R-6.5 per inch plus a vapor and air barrier in one — the choice where space is tight, structural rigidity helps, or moisture control matters. The premium application is choosing the right foam for the assembly and the climate, and applying it to the correct thickness with a correct mix, every time. That's a process-control job, and process control is exactly what separates a premium installer from a sprayer with a rig.

We install it deliberately. For cavity and roof-deck work, we prep and protect the space, verify the rig's temperature and mix ratio before a single pass, and apply in controlled lifts to the engineered thickness — never the rushed thick pass that traps heat and cures badly. The signature application is the unvented-attic conversion: foaming the underside of the roof deck to bring the attic inside the conditioned envelope, which tames a brutal hot-climate attic, protects ductwork sitting in that space, and dramatically cuts the HVAC load. We also do injection-foam and dense-pack retrofits into existing closed walls — insulating without tearing out drywall — and rim-and-band-joist foaming to seal one of the biggest hidden air-leak paths in a house.

The PCE difference is code-correctness and finish. Exposed foam requires an ignition or thermal barrier by code, and we install it — an intumescent coating or a drywall thermal barrier — rather than leaving bare foam that fails inspection and creates a fire-code violation. We protect the rest of the home from overspray, ventilate the cure correctly, and document the application thickness and the assembly. When an unvented attic changes how the house breathes, we account for the ventilation and moisture consequences instead of creating a new problem. That building-science completeness is what a premium client is paying for.

This hub covers open-cell and closed-cell spray foam installs, spray-foam roof-deck and unvented-attic conversions, injection-foam and dense-pack wall retrofits, rim-and-band-joist air-sealing foam, and the code-required thermal/ignition barrier over exposed foam. For homes where foam is the wrong call, we'll say so and point you to the blown or batt approach in hub E1 — premium means the right system, not the most expensive one on every job.

Because PCE is national and standards-driven, the mix-control, thickness verification, and code-barrier discipline are identical in every market and tuned to the local climate zone. A foamed roof deck in Atlanta is applied to the same controlled standard as one in Dallas. You're not gambling on whether the local rig was calibrated; you're getting the brand standard from a company that earned its name on exacting work. The premium is the process control and the code-correct finish: foam that performs for the life of the house and passes every inspection.

For an engineered, code-correct spray-foam install or attic conversion, call (682) 226-6257.