Spray Foam in Agricultural Buildings: University Research Summary

The Science of Air Sealing in Poultry and Livestock Housing

Drafts kill profit margins. When warm air escapes through cracks in a broiler barn or a swine facility, your heaters work harder to replace that lost thermal energy. Most producers assume standard insulation handles this problem, but traditional fiberglass or mineral wool does nothing to stop moving air. This distinction between thermal resistance and air infiltration is where AireBarrier changes the math for agricultural operations.

Air leakage creates uneven temperatures. While R-value measures how well a material resists heat flow, it cannot stop wind from whistling through wall cavities or floor penetrations. You need an airtight seal to stabilize the internal environment.

Understanding Spray Foam Chemistry and Density

Not all spray foams are created equal. Many contractors use low-density polyurethane that behaves like a sponge when moisture hits it. This material lacks the structural integrity required for harsh agricultural environments where humidity fluctuates daily.

Ag-Tite chemistry focuses on density and closed-cell structure. Our Auburn-tested density reaches approximately 1.5 lb/ft³, which is twice as heavy as many competing polyurethane products on the market. High density matters because it prevents the material from collapsing or absorbing water over time.

Density provides stability. Because the cells are tightly packed, the foam acts as a physical barrier against both air and pests.

The Auburn University Validation

The most significant data point for agricultural spray foam comes from Auburn University. Researchers conducted controlled studies on broiler barns to measure how sealing affects energy consumption and bird performance. They specifically looked at the impact of using AireBarrier to seal the building envelope.

The results were definitive. The Auburn study validated energy savings between 25% and 40% for broiler barns sealed with our technology. These savings occur because the sealant stops the “chimney effect,” where warm air rises and pulls cold air in through lower gaps.

Lower bills help your bottom line. When you reduce energy waste by up to 40%, that capital stays in your operating budget rather than going to the utility company.

Pest Control and the University of Georgia Findings

Air leaks are also pest highways. Insects like darkling beetles use tiny cracks in building envelopes to enter poultry houses, which increases disease pressure and management costs. If a beetle can crawl through it, air can move through it too.

A University of Georgia newsletter from November 2005 documented this relationship during a penetration test. The study demonstrated how even microscopic gaps allow pests to bypass traditional barriers. By using an airtight sealant, you effectively close the doors on these invaders.

Sealants stop bugs. Using Soy Bio Sealant or AireBarrier creates a continuous membrane that insects cannot penetrate.

Fire Safety and ASTM E-84 Standards

Fire safety is a non-negotiable requirement for any large-scale agricultural structure. Many spray foams are highly flammable and release toxic smoke when exposed to high heat. This makes them a liability in buildings filled with dry feed or hay.

Ag-Tite is the only agricultural sealant tested to meet ASTM E-84 standards. This test measures flame spread and smoke development to ensure the material behaves predictably during a fire event. We prioritize safety because your facility is your most valuable asset.

Safety matters. You should always verify that any foam product used in your barn meets these specific fire rating requirements.

Maximizing ROI with USDA REAP Grants

Upgrading your insulation can be expensive, but federal programs help offset the initial cost. The USDA Rural Energy for America Program (REAP) provides significant financial assistance to agricultural producers. This program offers up to 50% cost-share for energy efficiency improvements.

Timing is everything. Application windows for REAP typically close on March 31, June 30, and September 30. You should plan your projects well in advance of these deadlines to ensure your paperwork is processed correctly.

Grants reduce risk. Using a SprayPod 2.0 system allows for efficient application that makes these large-scale energy upgrades more manageable for local contractors.

Debunking Common Spray Foam Misconceptions

Many farmers believe that adding more fiberglass insulation will solve their draft problems. This is a mistake. Fiberglass is an insulator, not an air barrier; it lets wind pass right through the fibers.

Another myth is that spray foam is too difficult to apply in existing buildings. Our portable equipment and specialized chemistries are designed for retrofitting older structures where precision matters most. You do not always need a new building to achieve modern efficiency.

Check your facts. If a contractor promises “unlimited R-value” without discussing air infiltration, they are not telling you the whole story.

Practical Application: Coverage and Yield

Efficiency in application saves money on material costs. When calculating your project budget, you must know exactly how much product you need to cover your square footage.

AireBarrier yields approximately 16 board-feet per gallon at a 1-inch thickness. For smaller repair jobs, we offer different formats to suit the task. A single 24 oz can provides roughly 3,000 linear feet of a 1/4” bead. If you are doing larger work, a 16 lb canister is equivalent to about ten of those 24 oz cans.

Measure twice. Accurate calculations prevent mid-job shortages and keep your installation on schedule.

Learn more about our specific product applications by visiting our product overview page.

FAQ

Does spray foam help with pest control?

Yes. By sealing the microscopic gaps in your building envelope, you prevent insects like darkling beetles from entering the structure. This was demonstrated in a University of Georgia study regarding pest penetration.

How much energy can I actually save?

Based on the Auburn University study, broiler barns sealed with AireBarrier saw energy savings between 25% and 40%. Actual savings depend on your current building leaks and local climate.

Is the sealant fire-rated for agricultural use?

Ag-Tite is the only agricultural sealant tested to ASTM E-84 standards for flame spread and smoke development. This makes it a safer choice for livestock and poultry facilities.

Can I get help paying for the installation?

The USDA REAP grant program can provide up to 50% cost-share for energy efficiency upgrades. Be sure to apply before the quarterly deadlines on March 31, June 30, or September 30.