Auburn University Poultry Study: Spray Foam Energy Savings Validated
Air leakage ruins profit margins. In older poultry barns, uncontrolled drafts force heaters to work harder while simultaneously stripping heat from the flock. This inefficiency c
Validating Energy Savings in Poultry Production
Air leakage ruins profit margins. In older poultry barns, uncontrolled drafts force heaters to work harder while simultaneously stripping heat from the flock. This inefficiency creates a cycle of high propane bills and inconsistent bird growth.
The Auburn University spray foam study provides the technical proof that sealing these leaks works. By applying specialized sealants to existing structures, producers can stabilize barn environments. This isn’t about adding thick insulation; it is about stopping air movement.
The Auburn University Study Results
Researchers at Auburn University tested the effectiveness of Ag-Tite products in real-world broiler barns. They focused on how sealing gaps affects energy consumption and house pressure. The results were definitive.
When using AireBarrier Black or White applied via the SprayPod 2.0, broiler barns saw energy savings between 25% and 40%. These numbers are not estimates. They represent measured reductions in fuel consumption caused by improved thermal envelopes.
The study also addressed house pressure. Before sealing, the houses had a static pressure range of .10 to .12. After the application, that pressure doubled to a range of .20 to .24. Higher static pressure allows ventilation systems to move air more efficiently through the building.
Addressing Structural Deficiencies
Most poultry houses older than five years suffer from significant structural gaps. In the specific Auburn study case, the walls consisted of 2”x4” boards. These boards were warped. Large gaps existed between every piece of lumber.
Only the south side of each house retained a curtain opening, measuring 13’ wide. These openings act as massive thermal leaks. We use Soy Bio Sealant and AireBarrier to bridge these gaps without requiring a full rebuild.
The application process is straightforward. We apply the sealant over the entire wall surface. The goal is twofold: seal every individual joint and provide a thin, continuous coat over the boards. Most applications require only 1/4” to 1/2” of coverage.
Density and Performance Metrics
Standard polyurethane foams often lack the structural integrity needed for agricultural environments. Ag-Tite products are different. Our Auburn-tested density is approximately 1.5 lb/ft³. This is twice the density of many competing polyurethane products on the market.
Because the product is so dense, a thin coat provides a complete air barrier. One 24 oz can yields approximately 3,000 linear feet of a 1/4” bead. For larger projects, a 16 lb canister is equivalent to about ten of those 24 oz cans.
This density ensures the material adheres to lumber, metal, concrete, or plastics. It creates a hard, smooth surface that does not degrade under heavy ventilation use.
Pest Control and Biosecurity
Energy savings are only one part of the equation. A sealed barn is also a cleaner barn. The University of Georgia published a newsletter in November 2005 regarding darkling beetle penetration tests. Their findings showed that traditional gaps in wall construction provide perfect harborages for pests.
Ag-Tite sealants cure in minutes once applied to a smooth surface. This rapid cure time prevents beetles from finding shelter within the material itself. In the Auburn study, even when the air barrier was sprayed down to the litter line, beetle damage remained minimal over several years.
Effective biosecurity requires a two-part approach. You must seal the physical gaps with Ag-Tite Spray Sealants, but you must also maintain a strict management program. Combining our sealant with an Ivesco pest control program provides the best defense against darkling beetles and rodents.
Return on Investment and Long-Term Value
Farmers often ask about the payback period for these upgrades. If propane costs are near $2.00 per gallon, the return on investment can occur in as little as two years.
The sealant also helps extend the life of your current infrastructure. Many producers want to keep their existing houses in production for another 15 to 20 years. Sealing the walls stabilizes the structure and improves moisture control. Better moisture management prevents wood rot and metal corrosion, which are common in poorly ventilated barns.
To help offset these capital improvements, look into the USDA REAP grant. This program can provide up to a 50% cost-share for energy efficiency upgrades. Application windows typically open on March 31, June 30, and September 30.
Summary of Technical Specifications
| Metric | Value/Result |
|---|---|
| Auburn Energy Savings | 25% - 40% |
| Post-Seal Static Pressure | .20 - .24 |
| Product Density | ~1.5 lb/ft³ |
| AireBarrier Coverage | ~16 board-feet per gallon (at 1” thick) |
If you are ready to stabilize your barn environment, contact us today to discuss your specific application needs or to request a technical data sheet.
FAQ
How much energy can I actually save?
The Auburn University study validated energy savings of 25% to 40% for broiler barns using AireBarrier. Actual savings depend on your current leakage rates and local fuel costs.
Is this product fire-rated?
Yes. Ag-Tite is the only agricultural sealant tested to meet ASTM E-84 standards for flame spread and smoke development.
Can I apply this to my existing barn?
You can. Our technology is designed specifically to improve the “barnseal” capabilities of existing buildings, including those with warped lumber or concrete walls.
What is the USDA REAP grant?
The Rural Energy for America Program (REAP) provides cost-share opportunities of up to 50% for energy efficiency improvements. Be sure to check the application windows on March 31, June 30, and September 30.