Tag Archives: thermal break

Dead Air as an Insulator

Dead Air as an Insulator

Are you considering building a climate controlled post-frame building? If so, then proper insulation is (or should be) at the top of your list.

Reflective InsulationIf you have not seen ridiculous claims of double digit R-values from reflective radiant barriers yet (aka ‘bubble wrap insulation”) you will. Read more about these claims here: https://www.hansenpolebuildings.com/2014/04/reflective-insulation-wars/

Reflective radiant barrier manufacturers base their R-value claims upon an assembly including a 100% sealed dead air space on one or both sides of their products. In all reality, it is impossible to achieve this in real world construction.

For many years buildings have been built with an air space between building cladding and batt insulation in wall cavities. This air space did, in fact, help circulate air inside the wall and ventilate humidity through the wall. Now, as we increase wall air tightness quality and increase insulation levels, this air space no longer serves a ventilating function. Being on modern heavy insulation outside, it is too cold to help much with ventilation, and convection currents in this air space can actually make condensation problems worse. In addition, this air space is not a very good insulator. It is now recommended that all space between inside wall finishes (such as gypsum wall board) and outside cladding be filled with insulation, leaving no air space. Again – when insulating an exterior wall, don’t leave any air space.

Improper installation techniques with batt insulation can cost you 20% of an exterior wall’s insulating value from air spaces in hidden corners. This radically increases thermal bridging through framing members.  If, on these same walls, you have an accidental space between insulation and vapor barrier, an air current can loop around insulation taking heat directly from warm interior finishes to cold cladding.

For an air space between wall insulation and interior finishes, vapor barrier location is critical.  If an air space is between insulation and vapor barrier, air will rise because of building warmth.  This air movement will find its way through or around insulation to cold side, where it will fall due to cladding’s colder surface.  When insulation completely fills space between wall girts this looping is minimal.  When insulation is installed less than perfectly, this looping force will accelerate.  If there are open triangular corner spaces as mentioned above, this becomes a pump moving heat from interior finish to cladding as if there was no insulation there at all. 

When there is an air space between vapor barrier and interior finish, nothing happens.  Temperature goes from cool on bottom to warm on top but air in this space has no access to cold exterior cladding.  It may circulate but it has no more effect than room air circulation. 

Years ago walls were constructed to leave an air space between exterior wall framing and interior finishes.  This was enough thermal break to stop condensation from forming on interior finishes in line with wall girts.  With modern construction and heavier insulation, there is no longer a condensation problem on interior finishes caused by girts being cold.  (There still is heat loss and in some climate zones building codes now actually require sheet insulation over all wall girts, either inside, or outside.)  An air space’s insulating value is very small compared to the same thickness of any insulation. 

Trapped air is an excellent insulator. Air moving freely carries heat. Circulating air, such as in a wall cavity, is effective at pumping heat from warm side to cold side. Not an insulator, in other words.

To be effective at isolating heat, air must be confined, trapped in tiny spaces, like in fibers of fiberglass, rock wool, or cellulose. Foam is particularly good at trapping air. So you take a not a very good heat conductor product and arrange for it to have many tiny cells able to capture air.

Condensation Control, Ventilation or Insulation

Most Builders Do Not Understand Condensation Control, Ventilation or Insulation

Crucial to proper performance of climate controlled buildings of any sort is condensation control, adequate ventilation and insulation. Sadly, most builders do not understand how to come up with a proper design solution.

Reader AARON in WISCONSIN DELLS writes:

“Hello, I was wondering if you had a minute for a quick question ? I have read posts for countless hours regarding vapor barrier between trusses and roof steel and I can’t find the answer I’m looking for. I’m building a 44×96 that will have in floor heat in South central Wisconsin (by Madison) so we have cold winters and humid summers. Walls will be spray foamed. I will be applying a vapor barrier (poly) to the bottom of roof trusses and then putting a metal ceiling on and spraying fiberglass insulation above the ceiling. Fully vented ridge cap and 2’ overhangs with vented soffits around the entire building. The builder did not put any vapor barrier down between the roof steel and the trusses so the steel is directly on the trusses. Could this end up creating a moisture issue or will I have enough air flow in the attic space that I do not need the vapor barrier between the roof metal and trusses ? Thank you very much for your time.”

Thank you for reaching out to me Aaron, I am always available to answer questions.

Your builder sadly did you no favors in not having a means to prevent condensation on your roof steel underside. It also requires having an actual thermal break, not just a vapor barrier. Your best solution now is to have two inches of closed cell spray foam applied directly to the underside of your roof steel, making certain they do not block ridge vents. Without this thermal break, expect to end up with damp insulation.

If your builder installed vented soffits on your building’s end overhangs, you need to find a method to block them off – otherwise your attic will not vent properly.

In regards to ceiling vapor barriers, Joe Lstiburek (building scientist and founding principal of Building Science Corporation) says plastic vapor barriers should only be installed in vented attics in climates with more than 8,000 heating degree days. Even in South central Wisconsin, you are not to this point.

You’ll want to verify a correct ratio of air intake from soffits to air exhaust at ridge (chances are good your builder did not). At least 40% and no more than 50% of your attic’s net free ventilating area (NFVA) should be at the ridge. You may need to block off some of your sidewall eave vents to get the ratio correct.

I would also recommend you blow in rockwool insulation in your attic rather than fiberglass. Fiberglass insulation loses R value when outside (attic) air temperatures are low and is also affected by even small amounts of moisture.

Meeting IRC Slab Edge Thermal Breaks With Post Frame

Meeting IRC Slab Edge Thermal Breaks With Post Frame

Reader CHUCK in MUNCIE writes:

“Morning sir, I read your link in your post about post frame buildings for barn houses… one thing I am wondering, is how does the building pass energy code for residential construction, plus the IRC talks about a building being used for residential occupancy needs a thermal break at the foundation wall…. in a conventional post frame building the posts are on footings, and a slab on grade is poured, so how do you provide the thermal break to meet the building code?”

Mike the Pole Barn Guru says:

 

Post frame construction for residences has no appearance of going away at any time according to my crystal ball. And why should it? Post frame is more economical than stick frame, very DIY user friendly and can be readily super insulated. Here, I previously expounded upon post frame’s residential virtues: https://www.hansenpolebuildings.com/2022/01/why-your-new-barndominium-should-be-post-frame/

Slab edge thermal breaks (slab perimeter insulation) is only required in Climate Zones 3 and greater. You can look up your Climate Zone at codes.iccsafe.org/content/IECC2021P2/chapter-3-re-general-requirements When required, it must be a minimum of R-10 and down two feet (Climate Zones 4 & higher adds a horizontal R-10 component or becomes down four feet).

A common question with rigid foam insulations is how well it resists water. A number of studies show EPS retains less moisture than XPS. A case in point is a side-by-side analysis of these two rigid foam types installed on a commercial building foundation in St. Paul, MN. When extracted and tested after 15 years in service, EPS had 4.8% moisture content by volume, compared to 18.9% for XPS (a four-fold difference). A testing lab also found  XPS holds water longer than EPS. After 30 days of drying time, XPS still had elevated moisture of 15.7%, while EPS had dried to 0.7%.

For installations where insulation will be exposed to large amounts of water or frequent wetting, rigid foam insulation is available with water-resistant facers or pre-cut drainage grooves. Insulation with polymeric laminate facers keep water from entering insulation and also provide an added barrier to water wicking or diffusing through.

Moisture resistance is also important for below grade and under-slab insulation, since wet products provide much lower thermal resistance. Side-by-side insulation comparison found EPS retained 94% of its specified R-value, while XPS lost nearly half of its insulating capability over 15 years.

In addition to higher moisture resistance, EPS also is not subject to thermal drift. This means its R-value stays same over time. By comparison, XPS’s manufacturing process uses blowing agents diffusing from foam’s cellular structure over product life, thereby reducing its thermal performance. EPS manufacturers typically warrant 100% of published R-value for 20 years or more, while common XPS warranties cover just 90% of published R-value.

Whether selecting EPS or XPS insulation, to ensure performance, confirm product was manufactured to meet requirements of ASTM C578, Standard Specification for Rigid, Cellular Polystyrene Thermal Insulation. This standard provides a key quality check on rigid insulation.

As insulation becomes increasingly common at slab edges, understanding performance and cost factors of these different materials is important. EPS offers a number of advantages over more commonly installed XPS, including having highest R-value per dollar among rigid insulations, making it a cost effective choice for many jobs.

Can No Longer Afford Spray Foam for a PEMB

Can no Longer Afford Spray Foam for a PEMB

Loyal reader CINDY in TYLER writes:

“I had a steel building (20×18)  built with steel frame and metal exterior. This is going to be my house. It will have a loft that is half the size of the building. Originally the builder talked me into spray foam and that’s what Ii planned to do. He said I had to use wood to frame inside the metal walls first, then run electrical and plumbing before the spray foam. That was a couple of years ago. Now that inflation has caused prices to soar, I am simply not able to afford the spray foam. My main concern is the condensation/moisture issue. i am doing the rest of the work by myself. Since I don’t have any help it’s not going to be feasible to remove wall panels to install house wrap or insulation. So I wanted to get your expert advice on how to handle this. Specifically I have a plan to run by you. So the idea is instead of building my framing inside the metal frame, move to the inside of the metal, attach wood frame to the inside edge of the metal frame. Insulate the inside of the wood frame and add a moisture barrier to the inside of the wood frame before drywall. I will lose 3.5″ of space all around the inside but i think that will take care of any moisture issues. Please tell me what you think about this plan and make any appropriate suggestions even if you don’t post this on your blog. Also I wanted to thank you for the wealth of knowledge you have readily available on your site. Can’t tell you how much help you have been.”

Mike the Pole Barn Guru responds:

Thank you for your kind words, they are greatly appreciated.

Normally (in your climate zone of 2A) I would be recommending closed cell spray foam as insulator of choice – due to a combination of heat and humidity. Your builder headed you in a correct direction.

Before we get into how to frame your interior, we need to address what is going to happen with your roof. With steel installed directly over framing (whether wood, or in your case steel), if there is no well-sealed thermal break, you are going to experience condensation issues. You are going to have to find a way to spring for two inches of closed cell spray foam sprayed directly to the underside of your roof steel. Steel frame and steel purlins should also be sprayed. If not, you are going to have condensation on them – steel is a wonderful conductor of heat and cold.

Now – on to your question at hand. For your walls, it appears most folks do exactly as you propose and build a 2×4 wood stud wall inside of their PEMB’s (pre-engineered metal building) steel wall girts. You will want to completely fill your wall cavity with insulation – I would recommend rock wool, as it is not affected by moisture (here is information on one particular product https://www.hansenpolebuildings.com/2013/03/roxul-insulation/). You want to make sure your interior vapor barrier is extremely well sealed, including outlets.

If you do not have a well-sealed vapor barrier under your slab on grade, please seal your concrete now. Your HVAC system should be designed to mechanically dehumidify, else condensation is going to haunt you forever.

When the Problem is Not the Problem

When The Problem, Is Not The Problem

Captain Jack Sparrow’s quote is close in this instance. Please read on…..

RYAN in MISSOURI writes:

Hi Mike – I spoke with Brenda at your office and she said you may be willing to help me out. I don’t expect you to just give me free advice though, so if you were willing to provide me with some feedback on my “project”, I would like to pay you via Venmo or maybe your office could work up an invoice and I can pay you guys with a credit card. 

I built a 36×48 pole barn 5 years ago and didn’t account for adequate ventilation and now I want to fix the problem (I’m sure you’ve heard that line countless times before). I read one of your blog posts to get a head start on working up a plan of attack to keep it dry in there. I’m hoping you could check my work and either take a phone call from me or provide guidance via email (again, I can shoot you some money for this, please just let me know what sounds acceptable to you). 

Specs on the barn (I’ve included some older pics from before I installed the gutters and the electric below):

  • Location: central Missouri
  • Dimensions: 36′ wide (gable and door end) x 48′ long
  • No overhangs or soffit 
  • Two 8 ft ridge vents
  • Gutters down the eave/length sides to push water away from the “foundation” 
  • Currently no vents on the eave/length or gable sides or anywhere really… just some gaps around the trim and the base of the building where you can see daylight. 
  • The barn has electricity and the floor is just gravel. I have a junction box run to the gable on the south side (over the door ready to accommodate a vent fan). No animals inside. Just old tractors, some tools, and four wheelers. I don’t plan on putting in concrete or any HVAC. Things out there can get hot or cold, I just don’t want it raining from the ceiling anymore. 

Using your blog post, I tried to calculate what I would need as far as the CFM rating of the fan and the square inches of vent space (table of numbers below)

Questions: 

  • Before installing a fan, I should ask: is a fan even necessary? Seeing as I don’t care about HVAC, temperature or even critters getting in there, could I get by with just strategically placed vents and wind? 
  • If I do need a fan to generate enough circulation, does my math below look ok? 
  • Would the Airlift T16 with a 3060 CFM adjustable fan speed and a humidity detector or something like it work ok? 
  • Where would you recommend I place the vents (and I’m happy to go overkill on them if needed) in order to achieve the best results? 

Thank you so much for your time!”

Mike the Pole Barn Guru writes:
Thank you for your generous offer of payment Ryan, however I answer all sorts of similar questions for free.

Now, the good news and bad news….

Good news is you do not have a ventilation problem, no reason to invest in any possibly expensive power ventilator fans.

Bad news – as you have found out, it rains from your ceiling. What you have is a condensation problem. Warm, moist air inside of your building is rising. It contacts with cooler roof steel, condenses and rains. This is much easier solved at time of construction than now (as well as less expensive). Roof steel ordered with an Integral Condensation Control factory applied would have been highly affordable, as well as easy to install.

Short of removing and reinstalling your roof steel to add a thermal break between purlins and steel (both costly and labor intensive), I would recommend having two inches of closed cell spray foam professionally applied to the underside of your roof steel.

When you do pour a concrete slab inside, be sure to add a well-sealed 6mil or thicker vapor barrier underneath.

Insulating a Partially Climate Controlled Building

Insulating a Partially Climate Controlled Post Frame Self-Storage Building

Reader KEVIN in HUMBOLDT writes:

“ I’m designing a post frame building for self-storage that will have non climate control units around the perimeter of my building with climate controlled units in the center, accessed via a hallway down the center of the building. The entire building will have a metal ceiling. The walls between the climate controlled area and the non-climatized units will be insulated with fiberglass with a vapor barrier between insulation and wall metal on climatized side. I’ll have fiberglass in the attic space above climatized area with vapor barrier between insulation and ceiling metal. If my math is correct on a 58×174 building, I need 4845 square inches in NFVA (net free ventilation area) exhaust and intake. My soffit and ridge vent combo will provide 6960 NFVA exhaust and intake. I have 2 questions. First, do I still need a thermal break under my roof steel? Second, I’ll have 2×6 purlins on edge, recessed btw trusses so, would it be advantageous to install a radiant barrier or house wrap to the bottom side of my purlins, simply for smooth airflow from my soffit vent to ridge vent? Just wondering if purlins blocking air path up the roof is anything to be concerned with. Thank you.”

Mike the Pole Barn Guru replies:

You need some provision for condensation control below roof steel – easiest would be to order roof steel with an Integral Condensation Control factory applied. In Tennessee you should not have a vapor barrier between steel ceiling liner panels and blown in fiberglass attic insulation. Placing a barrier on the underside of roof purlins does not appear to make a noticeable difference in performance of attic ventilation. Although you did not ask, you should have a well-sealed vapor barrier (6mil or greater) and R-10 EPS insulation under slabs (even in non-conditioned areas) to minimize potential for condensation on top of slab.

Vapor Barrier for a Ceiling

Reader GEORGE in LOUISVILLE writes:

“I am looking to install tin on the ceiling of my 54 X 75 pole shed. I was wondering if 6 mil plastic sheeting with all seams taped would work for a vapor barrier? My concern is not to have it rain in my building after the tin is up and the heat is on.”

Mike the Pole Barn Guru:

Well George, this answer is not going to be nearly as simple as your question.

Prevention of internal rain (condensation) is going to be a function of several aspects.

#1 Controlling source – if there is not a well-sealed vapor barrier under your concrete slab on grade, you should be planning on two coats of a good sealant for it. If you do not know if there is a vapor barrier under it or not, leave a wrench on it overnight. Next day, pick the wrench up and if there is a dark place on the floor surface where the wrench was, you have no under slab vapor barrier.

#2 Source of heat – some heat sources add significant amounts of water vapor into your internal air (propane being a prime offender). Know what you are getting into before it becomes a challenge you do not want.

#3 How are you currently controlling condensation? If your building has a thermal break between purlins and steel roof – excellent. If not, your best solution is going to be two inches of closed cell spray foam applied to the underside of roof steel. This is not an inexpensive solution, but it is more practical than removing roofing, adding a thermal break, and reapplying roofing (plus roofing never goes back on as well as it was originally installed). Plan on $4000 to $4500 for closed cell spray foam.

vented-closure-strip#4 Ventilation – you are going to create a dead attic space above an insulated ceiling. If it is not adequately vented you are going to have problems. Best combination is vented eaves and ridge. Your building will require at least 1944 square inches of net free ventilation area (NFVA), distributed equally between eave and ridge. If this is not possible (building has no sidewall overhangs), then your choice is limited to gable vents and it will take many of them to provide adequate NFVA.

#5 You are in Climate Zone 5. This means a Class I or II vapor retarder is required for the interior side of framed walls. This could be 6 mil polyethylene (Visqueen) or Kraft-faced fiberglass batt insulation. For your ceiling a plastic vapor barrier should only be installed in vented attics in climates with more than 8,000 heating degree days. In Nebraska, heating degree days for a normal year is 6322.

Integral Condensation Control

With steel roofing for barndominiums, shouses and post frame (pole) buildings comes condensation.

When atmospheric conditions (in this case temperature and humidity) reach dew point, air’s vapor is able to condense to objects colder than surrounding air temperature. Once vapor condensing occurs, droplets are formed on cool surfaces. This is partly why warming a vehicle’s windshield with a defroster can prevent glass ‘fogging’.

When a building’s interior air meets these conditions, air vapor will condense to cool surfaces. Steel roofing cooled by exterior air temperature often provides this surface. Droplets formed will combine as they contact one another, continuing to do so until they are too large to be supported by surface tension. At this point, dripping will occur, essentially raining on your structure’s contents. 

Commonly (when addressed at all during construction) solutions to this problem have often involved creating a thermal break. A thermal break reduces contact between a structure’s warm interior air and cooler metal roofing, thereby reducing or eliminating overall condensation. Installing a reflective radiant barrier, often termed Vapor Barrier, involves laying rolls of faced ‘bubble wrap’ across your building’s purlins prior to roof steel installation. Ideal weather conditions are required for this as even a slight wind can make this a challenging or altogether impossible task. This can cause jobsite delays and may bring progress to a halt while a structure remains unprotected to weather. Even when ideal weather conditions are present, installing a reflective radiant barrier can be a very dangerous task, requiring builders to expose themselves to awkward material handling on a building’s bare roof framing. These risks and delays often generate additional costs for both owners and builders, but have often been necessary with reflective radiant barrier being the only relatively affordable option to prevent interior dripping. 

New materials and production methods offer a better solution. Utilizing polyester fabric’s absorption characteristics and their integral application during roll-forming, most better quality steel roofing roll formers offer a ready-to-install roofing panel with integral drip-protection. I.C.C. is a pre-applied solution reaching jobsites ready for immediate installation. Delays and increased jobsite workload caused by problems associated with radiant reflective barriers are eliminated by this product. Also, due to this solution’s simplicity, panels with I.C.C. install using the same methods, fasteners and time similar panel-only installations require. No changes to installation processes are necessary, with an exception of time and effort saved. 

It works because this polyester membrane simply retains liquid until atmospheric conditions allow it to be re-evaporated. This is because polyester is hydrophilic, meaning water is attracted to it. It acts as a wick, harmlessly absorbing condensing vapor. Rather than preventing condensation, it provides an absorbent layer to detain condensing vapor until it can re-evaporate as temperatures increase and humidity decreases.

Installing Steel Liner Panels in an Existing Pole Barn

Installing Steel Liner Panels in an Existing Pole Barn

Reader JASON in WHITEHOUSE STATION writes:

“ Hello! I have a post frame 30X40 Pole Barn that was built prior to me owning the house. Currently, the shop is not insulated. I would really like to insulate it, as it’s quite unbearable in the summer and winter. The building has soffit vents, a ridge vent, and two gable vents. With the way the building is set up with all that ventilation (possibly too much?), is putting in a ceiling with insulation on top my best bet? I know there are many options when it comes to insulation, but I am trying to determine what is best for my application. I am leaning towards 6 mil poly on the bottom side of the truss, ceiling liner panel over that with blown in insulation on top. My truss is 8′ on center. Is there a recommended length of panel I should use? Thank you for your help with this. I’m sorry if I asked too many questions.”

Mike the Pole Barn Guru responds:

Provided your building has roof trusses designed to adequately support a ceiling load, your best bet will be to blow in insulation above a flat level ceiling. If you do not have original truss drawings available to determine if they have a bottom chord dead load (BCDL) of three or more, then you will need to find the manufacturer’s stamp placed on truss bottom chords and contact them with your site address. With this information they should be able to pull up records and give you a yes or no. If you are yet unable to make this determination, a Registered Professional Engineer should be retained to evaluate your trusses and advise as to if they are appropriate to carry a ceiling and if not, what upgrades will be required.

If your building does not have some sort of thermal break between roof framing and roof steel (a radiant reflective barrier, sheathing, etc.) you should have two inches of closed cell spray foam applied to the underside of roof steel, or else you will have condensation issues (even with the ventilation). With trusses every eight feet (again provided trusses can carry ceiling weight), I would add ceiling joists between truss bottom chords every four feet and run 30 foot long (verify from actual field measurements) steel panels from wall to wall.

You do not have too much ventilation – and be careful not to block off airflow at eaves. You can omit poly between liner panels and ceiling framing.

More Condensation Fun

Long time readers should be thoroughly drenched with solutions to condensation issues by now. As post frame construction has moved off farms and into suburbia, climate control has brought with it a plethora of condensation challenges.

Reader KRYSTA in SPOKANE writes:

“Hello! 

I have a pre-existing pole building that I am having a ton of trouble with. It is partitioned into two rooms, the back room is heated to around 50F. The attic space/loft space has a lot of condensation and I cannot seem to get this fixed. I have tried a lot of solutions, none of which have worked. I know that you build these types of buildings so I am hoping that you can recommend someone who might be able to come in and look at this issue and help me with a solution that works. I have no idea what to do next and I am a local business owner – my business is at a standstill right now until I can get this issue fixed. If you can recommend any general contractor, or anyone who might have expertise in pole buildings who I can contact I would greatly appreciate it. 

Thank you so much!”

Mike the Pole Barn Guru writes:

To control your condensation challenge you need to either remove warm moist air from inside your building, prevent this air from becoming in contact with surfaces at or below dew point, heat and/or ventilate. Here’s a brief summary, followed by solutions specific to your case: https://www.hansenpolebuildings.com/2019/02/how-to-reduce-condensation-in-post-frame-buildings/.

If you do not have some sort of thermal break below your pole building’s roof steel – two inches of closed cell spray foam should be applied. This process will be best done by a professional installer. Make certain to not block ventilation intake and exhaust points.

Unless you know for certain a vapor barrier was placed under your building’s concrete slab, seal the floor. https://www.hansenpolebuildings.com/2019/02/how-to-properly-apply-post-frame-concrete-sealant/ and https://www.hansenpolebuildings.com/2018/11/siloxa-tek-8505-concrete-sealant/.

Vent any dead attic spaces. https://www.hansenpolebuildings.com/2018/03/adequate-eave-ridge-ventilation/.

Heating your building to a temperature above dew point will also solve this issue. Avoid heating with propane, as it adds moisture to the air.

Making Framing Work With Bookshelf Girts

Making Framing Work With Bookshelf Girts for Insulation

A most simple method to achieve a deep insulation cavity in post frame building walls is to use bookshelf girts, but how to make framing work?

Some quick background reading on commercial girts: https://www.hansenpolebuildings.com/2011/09/commercial-girts-what-are-they/.

Reader BRANDON in ST. JOE got today’s discussion going when he wrote:

“Hi there. I’m going to be building a post frame house and got a quote form Hansen for my building. Question is with the bookshelf Girts if they are 2x8s which measures 7 1/4” on 6×6 post that is 5 1/2” plus your 1 1/2” grade board will you notice the 1/4” difference.”

In an ideal dream world every 6×6 column would measure exactly 5-1/2 inches square. However lumber comes from trees, and trees are organic and tend to have a certain degree of variability. Rarely are timbers going to be dried after being milled, other than by nature. As such, they most usually start off being cut slightly over-sized in order to allow for shrinkage hopefully ending up with a 5-1/2 inch dimension.

I have seen builders attempt to use 2×6 bookshelf girts with 6×6 columns, if posts are perfect dimension then both sides can be set flush and surfaces for siding and interior finish are smooth. It does involve some extra work insetting things like splash planks, eave girts, headers, etc., as well.

I tried this in my own garage I had built in 1991. My posts were not perfect dimension, they were big! I had to stop drywall up against each column and then texture over posts. Trust me, it was a PITA (Pain In The Axx).

An easy fix – oversize girts by one dimension, using a 2×8 with a 6×6 column as an example. Chances are excellent columns will measure 5-3/4 inches in depth or less. If less, drywall (or other interior finish such as OSB or plywood) can be run directly across thinner columns with no adverse challenges.

I would recommend using closed cell rigid insulation sheets inside of framing, behind drywall, to create a thermal break.

Dear Guru: What Type of Insulation?

DEAR POLE BARN GURU: Good morning, Mike … I have a question for you.

I’m trying to decide between a 30×40 barn and a 60×40 barn. It would have a gambrel roof with a loft. 16′ wide sliding door in the center of the short ends.

All other things being equal, what is the cost difference between 30×40 and 60×40?

Or is there a size that’s more economical?

Thanks, Mike T. in Kershaw, SC

DEAR MIKE T.: Having to design the loft to support hay weight is not so much of a challenge as it is expensive. For sake of discussion the comparison was done a full loft, however it may be more practical to only have the loft in the center.

There is an economy of scale with pole buildings. For practical purposes, the price per square foot is going to decrease as the building footprint increases (until clearspans become very wide). I’ve also never had a client tell me their new building is “just too big”!

In your particular case, you could double the size of the building, while increasing the investment by only about 2/3.

Mike the Pole Barn Guru

DEAR POLE BARN GURU: Renovating our pole building arena is an undertaking.  We were quoted $70k (which included windows to replace the plastic) so we are doing it ourselves. I expect materials to run about $25k in the end.  The company that sold me the metal ceiling panels based out of Kentucky told me that people in his area do it all the time and that the best way to go is with blown insulation, as fiberglass batting is a lot more time consuming to install.  I decided against spray foam because it is toxic to begin with and then they put fire retardants in the mix which is even more toxic.  Plus it is expensive.

What will happen if we don’t have a “thermal break” on the underside of the metal roof? There will be a lot of condensation falling on the blown insulation?  We have a roof vent which I guess is correctly installed because we never have water coming in even during the most violent and heavy of rain storms. Isn’t this vent enough to prevent condensation?

If a herd of animals lived in the building, then I would worry about condensation, but there will be maximum 2-4 live beings in there at one time.   Removing the roof to install a reflective radiant barrier is not an option.  How about covering the underside with “Tyvek” the stuff houses are wrapped in?  Are you saying the blown insulation on the ceiling will not do its job without this thermal break on the roof, or is it the condensation you are concerned about?   What does the reflective radiant barrier need to reflect?  Cold coming from outside, or heat coming from outside?

We have blown insulation in our 14 year old house.  I guess it is newspaper.  It works a charm.  We’re on a hill and it can blow out there and we’re cozy inside.  One can buy cellulose from Lowe’s or Home Depot and they lend you a machine to install it.   I was worried that wind from the roof vent would blow it around.  I was also worried critters would nest in it, although we have covered such access with 1/2″ wire mesh.  Nonetheless, critters are very resourceful about getting into things.  I was worried that if it got wet it would get moldy.  My daughter is very sensitive to mold.  Best thing is it stays dry….and like I said, we never had rain come through that vent, although when the conditions were right, we’d get a bit of snow blown in.  We have a lot of snow now, and no snow in the arena.  So it has to be special conditions. I thought of covering the blown insulation with tarps to protect it from wind or moisture.  Is that a good or bad idea?

BTW, we have no intention of heating the arena.  The goal is to have it warmer in there than outside….hopefully a little above freezing.

I guess for the walls we will use fiberglass.  The plastic panels will be replaced with double glazed “picture” windows (they don’t open) and will run the length of about 2/3 of the arena at 2′ high.

A trainer we met from Maine said he insulated his riding arena and it really helped keep out the cold.

I’m wondering what will happen in summer.  Will it keep out the heat, or trap it?

It’s great communicating with someone who knows what they are talking about.  I’d be happy to compensate you for your expertise.

P.S.  Here’s a fiberglass story.  The owner of a horse boarded at our farm had a plumbing leak in her basement.  The plumber came and fixed the leak and left.  Several weeks later she developed itching sores all over her body.  She woke up one morning with arms so swollen she could not bend them and a face twice the size of normal.  She went to the ER and they told her a dust allergy, so she threw out all drapes and mattresses, etc. and cleaned the carpet and whole place.  However, it didn’t help and she landed in the ER again.  Meanwhile they found out that the plumber had pulled away fiberglass insulation from the broken pipe, and because of the leak it was all wet.  He didn’t remove the wet fiberglass and so mold developed, and with the furnace down there blowing hot air (with the mold) all over the living space it made her VERY sick.  She moved out immediately and had to take a lot of nasty drugs, and she is still not well.  Plus, inhaled fiberglass is a known carcinogen, as you probably know.

A GREAT thing to insulate with is wool.  But who can afford it?  They do make wool “bats” for the purpose though.  CINDY

 DEAR CINDY: Without the thermal break under the roof steel, there will be condensation on the underside of the roof steel, which will result in rain upon the attic insulation. Ventilation alone may cure some, but not all of the condensation problems.

The major source of the warm moist air rising is the ground under your building (evapotranspiration). According to www.ScienceDirect.com the average value of the moisture evaporation with uncovered ground is 0.33 to 0.53 gallons per hour per square foot. For a fairly typical 60 by 120 foot riding arena, this could be between 57 and 90 thousand gallons per day!!

Housewraps like Tyvek are not vapor barriers – they are designed to allow moisture to pass through.

Reflective radiant barriers just happens to be a very cost effective thermal break. The aluminum facing on the exterior reflects radiant heat in the summer, keeping the building cooler.

Insulating your building will keep it cooler in the summer, there is no question there. As to the effectiveness for keeping things warmer inside, without a heat source the air inside will be at or near the temperature on the outside.

And thank you very kindly for your offer of compensation. I do my best to provide quality information for the good of the industry as a whole. If you feel I have been of service, please feel free to share the link to this blog with others.

Mike the Pole Barn Guru