This project summarized the insulation retrofit of an old church building. The church had issues with heat loss, lack of insulation, moisture damage, and inadequate ventilation. The goals of the project were to cut heating and cooling expenses by 50% and protect the structure from further damage. Various insulation methods were used including blown-in fiberglass and foam insulation installed in walls, attics, and roofs. Over 70 new roof vents and a total of 162 vents were added. Air sealing and insulation installation reduced air leakage by 58%, helping to significantly reduce energy costs.

1. Federated Insulation Project
This “leaky”
old church.

3. Beautiful natural wood ceiling in the sanctuary

4. Three views of
the Federated
Church icicle
show!

5. Old shingles
showing
signs of heat
loss.
Shingle
damage from
heat loss.
External view
Internal view

6. No insulation continuity
Some fiberglass batting insulation
Bare sheetrock
Open concrete block wall

7. Mold Under the Shingles.
Out of sight, out of mind.

8. Back Side of Sanctuary from attic
No Insulation on original assembly!

9. Condensation Staining on Roof deck From
Heat Loss, Lack of Ventilation, near sanctuary.

10. More Moisture/Mold on Roof Sheathing, near sanctuary.

11. Only five vents installed during previous construction

12. Interior water damage and air leaks

13. Why This Happened?
•Poor design for this climate Zone
•Previous contractors lacked Building Science
background to solve these complex and
layered problems.
•Complex Thermal Boundary.
•Hidden Thermal Boundaries.
Our Goal!
•Cut Heating and cooling Expenses by 50%
•Protect the Structure from further damage
resulting from heat loss due to:
1.Lack of ventilation
2.Poorly or non-insulated thermal boundaries.

14. Shingle removal and replacement

15. blown in bat insulation

16. External blown in bat insulation

17. Interior foam insulation

18. Retro foam installation in concrete block wall

19. Closed cell
polyurethane foam
Used over the sanctuary
on the outside of the
original roof
Open cell tripolymer resin
plus foam agent
Used to fill the hollow
concrete block walls along
the west side of the church

20. 2 x 6 stud installation for external foam

21. Exterior foam insulation – close up

22. Exterior foam insulation

23. Exterior foam installation

24. Roof sheeting over foam

25. 70 new roof vents!

26. 5 ineffective vents before
Total 162 vents after
70 roof vents
60 soffit vents
20 gable vents
12 window vents

27. Total 162 vents installed

28. Energy audit “leak
tests” before and after
insulation, ventilation,
and sealing showed a
58% reduction, a big
contributor to reducing
energy loss.

31. 42 years of energy loss and poor
ventilation corrected by creatively
retrofitting insulation saving about
$5000 per year in energy costs!