Spray Foam is Not the Answer – Part III: Better Alternatives for Masonry
Over the past few weeks we’ve been looking at cases where spray foam has been installed for purposes for which it is not intended. We’ve shown many examples of the improper use of spray foam, today we’re going to look at additional examples but we’re also going to talk about some of the alternatives to spray foam and better methodologies for sealing up the exterior of buildings without using polyurethane spray foams or exposed insulation which are not intended to be a part of the exterior most part of building envelope.
In the picture below, you can see the pipe that runs, as a PVC drain line coming from the inside of the building to the exterior, goes through the brick wall, when this pipe was installed the opening was not with a round core drill, instead it was cut in a rectilinear or near rectilinear shape. Core drills generally work much better for clean and appropriately sized pipe penetration openings, but often the people installing the pipework are not the same people who would be cutting the core openings and often, particularly in home flipping, low quality contractors lack the ability to coordinate between different trade disciplines. Here though, the problem has been well remediated by the masonry contractor. Even though the whole or opening was very poorly made by the plumber, the masonry contractor applied a clean repair.
Lime mortar, used in historic masonry, cures very slowly. This is an issue or challenge that comes up often when doing large scale or whole scale facade repointing or tuck pointing. In most cases, you’re not able to provide or apply latex or acrylic paints on top of lime mortar at the same time of installation, Generally, you have to wait until the curing is near or mostly complete. There are exceptions and often the weather will work in favor of expediting the schedule, but these two steps shouldn’t happen at the same time.
You can see, in the picture below, that the joint between the pipe and the masonry has not been overlaid with an elastomeric or similar type of gun applied sealant. 
Interstitial space, inside of the exterior side of the partition can be filled with insulation. Especially where there is a void, insulation will help with R-value and thermal resistance. The exterior most parts of the walls should be filled with materials that are resistant to transmission of moisture. A brick facade is a long-lasting durable assembly of materials that is proven, over centuries of time, to resist moisture infiltration. In this case, around the perimeter of the pipe, a cementitious material has been applied to create a moisture barrier.
The next picture shows a location where an electrical cable and a refrigerant line-set enter into the building. At least at the location of the pipe penetration, they have as well applied an elastomeric sealant to allow a degree of resiliency where the piping passes through the cementitious materials.
In the next picture below, a different type of assembly of materials is shown where a light box or high hat type of rough-in device is installed to later connect to an exterior recessed lighting fixture. After the picture was taken, our company went and filled in the area around the perimeter of that light to create a seal between the exposed exterior ceiling and the edge of the recessed light fixture.
The next picture below shows a pair of air exhaust grilles. The original builders or prior workers used a spray foam to seal at this location. Our company later removed the excess spray foam and applied an elastomeric sealant to the perimeter of those louvers to seal those edges.
The next picture below shows a hose spigot where the original 3/4 inch or half inch copper pipe passes through the brick exterior to a spigot valve. After the picture was taken, our company also went and sealed that penetration with an elastomeric sealant. Applying a sealant at that location allows resiliency which tolerates or permits a degree of flexibility with natural movement in the piping. The sealant also creates a seal to prevent critters and rodents from entering from the outside and also prevents moisture infiltration or precipitation water from entering from the exterior of the building.
We can Help
Our company focuses on historic restoration more than modern building upkeep, maintenance, and construction, but our company understands both types of construction very well and a full picture well-rounded approach is needed in any niche in the construction industry. Although we focus on historic restoration, repointing, tuckpointing and historic brick repair, our company also has technical knowledge and competencies in the areas of modern and contemporary construction as well as we become one of the leaders in that area of the market today. Understanding both historic and modern or contemporary construction is useful because both aspects help understand the challenges and potential solutions for challenges in building science and construction.
We can help with a variety of historic masonry restoration needs and upkeep, from modest tuckpointing and or repointing to complicated and extensive historic masonry restoration. Infinity Design Solutions is a historic restoration specialist contractor specializing in both historic masonry restoration such as tuckpointing our repointing, and brick repair. If you have questions about the architectural details or facade of your historic building in Washington DC, reach out and say hello and if we can help we’ll be glad to assist you. You can email us or call us on the telephone at the following link: contact us here.
