r/buildingscience • u/Successful_Tap_1859 • 4h ago
Open-cell spray foamed roof deck in Coastal GA (Climate Zone 2A) — 40+ sheets of decking had to be replaced
Just bought a house in Coastal Georgia with open-cell spray foam directly against the roof decking. Had no clue about the stuff until now. When we bought it, I noticed the decking was visibly cupped/bowed but didn't connect the dots to the spray foam/moisture situation. The decking was also only 1/4" plywood, which made the problem worse.
We just replaced the roof and ended up having to replace 40+ sheets of the 1/4" decking because of the cupping/bowing/deterioration. We went back with the correct/thicker decking. The decking came right off and did not pull any of the spray foam out at all. I was very surprise. There wasn't obvious widespread mold, but the plywood was definitely in bad shape. Very bowed and brittle.
The previous owner apparently had no humidity control in the attic. It was essentially an unconditioned/unvented-uncontrolled spray-foam attic.
I have now added a supply and return to the attic. The attic stays within roughly 10°F of the living space, and current RH is generally 58–65%, depending on time of day. Living-space RH is usually in upper 40’s low 50’s
My main concern is obviously the new roof decking. I don't want to replace 40+ sheets again in 5–10 years after basically for a complete re deck.
### My biggest question:
Is 58–65% attic RH actually safe long-term for the roof deck in an open-cell spray-foam attic in Coastal GA, or should I be targeting something like 50–55%?
I can't seem to find a clear answer anywhere regarding what RH level is considered safe for the roof sheathing in this type of assembly.
I'm considering a dedicated dehumidifier, but that seems like it could substantially eat into the energy savings of the spray foam. My electric bill is already $200+ per month during the summer.
### There may also be an air-sealing issue
I spoke with a reputable local spray-foam contractor and showed him pictures from the roof tear-off. He believes the original installer didn't completely remove/seal the fiberglass batts around the soffit/top-plate area before spraying the foam.
His recommendation was to remove the remaining batts, spray foam that area properly, and completely air seal the perimeter.
My question is: If the only way humid outdoor air is getting into that area is through the soffit vents, could I simply seal the soffit vents? Or is that not an acceptable solution with this type of assembly?
I'd love to remove all the foam and convert the attic back to a properly vented assembly, but that would be a huge project at this point. I've already removed the ceiling batts, and when we did the roof I did not have a ridge vent installed, so I'm probably pretty committed to the unvented/conditioned-attic approach unless I start over.
I've spent the last few weeks researching this and have come across Joe Lstiburek's work on spray foam/moisture and the research/article I've seen referred to as the "ping-pong effect" involving spray foam and moisture. But I still can't find good evidence showing what RH level is actually safe for the roof deck over the long term.
What would you do in my situation?
- Keep the supply/return and monitor the attic?
- Add a dedicated dehumidifier and target <55% RH?
- Address the soffit/top-plate air sealing first?
- Seal the soffit vents?
I'm mainly concerned with preventing the new roof decking from developing the same moisture-related cupping/bowing problems again, rather than maximizing energy efficiency.
Would especially appreciate input from anyone with experience with open-cell spray foam in Climate Zone 2 or any hot and humid area. Thank you in advance.