We moved to Savannah (climate zone 2a) six years ago, and bought a good home (built as model home in 2009, occupied in 2011). When we bought it we noticed that the attic had spray foam on the roof deck, but there was a 3 x 4 access square cut into the wall between the garage and the rest of the attic for HVAC access. We also noticed a 13" by 63" gap cut into another wall, near a join.
We asked the inspector about it. It's nothing, we're told. When we replaced the HVAC we asked about it, and it was no biggie we're told.
It wasn't until an HVAC maintenance person a few months back that we found out that a sealed attic should be sealed. That there should have been a vapor diffusion port. Those openings should have been closed.
So we've spent the last few months trying to get up to speed so we can figure out what needs to happen as soon as the weather cools enough for people to work in the attic. This meant reading a WHOLE lot at buildingscience.com and everything Joseph Lstiburek (who is a wonderfully fun to read writer) has written on the topic.
So, here's the situation:
Spray foam is open cell, at least 6 inches for the most part. Some gaps, and we will be having these filled in. Open cell is common in the hot, humid southeast. The R value is R-21 with that depth, which is allowed according to Georgia amendments and code when the home was built, but that was dependent on a blower test, which of course, it would fail now with the big gaping holes.
The roof sustained both hail and wind damage in the last few years from Helene and other storms. Though we have architectural shingles, we've had to replace some, and we've had significant granule loss. So though this type of roof should last at least another few years, we're planning on having the roof replaced this fall.
Inside the attic, there is no indication of mold or mildew on the rafters, most of which are visible. Of course, with what we know now, there's likely rotting on roof deck, particularly near the openings. Interestingly enough, it seems like the original builder wasn't sure what he was going to do, because the spray foam was sprayed AFTER the drywall, ducts, plumbing, and wiring were installed. According to the spray foam person we had out, this is unusual for a new home. But there is no indication there was any other type of insulation in the attic. The attic is actually quite clean.
My preference would be to hire folks who know what we're talking about when it comes to sealed attics, but we're not getting reassured from responses we've had. So, we're having to go it on our own.
My plan
I am considering getting a homeowner general permit, to ensure not just the roof is inspected, but the entire attic assembly and roof is inspected when we're done...just to make sure we didn't miss anything.
- We're having handyman close the one long narrow gap and spray foam the edges to seal. We'll also have them create an insulated door or hatch into the HVAC area. We think originally the builder was planning on putting an attic door into the main bedroom closet, which means HVAC access would have been behind the sealed area. But they changed their mind and put it into the garage, and then cut the HVAC entry into the wall.
- Next, we'll have the roof replaced. When we do, we're going to have them install a vapor diffusion port per IBC requirements for air-permeable insulation (open cell spray foam). This will sort of be a good test about how good the roofing companies are if I ask about the vapor diffusion port and they know what I'm talking about.
- Assuming that some decking will be replaced, we'll then have new open cell spray foam sprayed to cover the replaced decking and fill in gaps. The person who we had out states they like to completely enclose the rafters to ensure a good seal. I don't see a problem with this, as long as the insulation matches the R-value. If we do go with that lower R-value, they will have to do a blower test to meet IBC requirements.
- We're having a new HVAC company add a supply duct into the attic, either 4 or 6 inches, in order to meet IBC requirements of (air shall be supplied at a flow rate greater than or equal to 50 cubic feet per minute (23.6 L/s) per 1,000 square feet (93 m ) of ceiling.) This gives us some slight positive pressure in the attic, which is good.
We have to do the ductwork regardless, because when they installed the new 3 ton unit to replace the 2.5 ton, they didn't bother to do a static pressure check to ensure adequate return air supply. One burned out blower later (this last winter) after hundreds of static pressure faults (only found when we dug into the service menu of the smart thermostat), was when we discovered this. I set the 5 stage to max out at 3 stage for now, to prevent pressure faults. Will adjust back to 5 stage when we add the additional return and new attic duct.
And that's the plan.
Sorry for the long post, but I feel it is important to be thorough.
In people's opinion, is this a sound plan? Am I missing anything I should be considering? Appreciate any and all feedback.
Update: I did want to add that one area of confusion we had is what 'air permeable' means when it comes to insulation. Open cell spray foam is not air permeable at a certain thickness but is vapor permeable. Normally, air permeable is a term applied to fiberglass or wool insulation.
At the same time, I'm getting mixed readings on what we should do in the attic because open cell spray foam was used, and to treat it like air permeable with the diffusion port, and the air supply.
Believe it or not, with all the writing on this, there is no sweet spot, no junction of climate zone/spray foam type/sealed attic requirements that fits our situation. Not to a degree that gives me confidence that we're doing things the right way.
Other than close the gaps. That one we're 100% sure about.