Case Study: Municipal Control Room Insulation

Location: Arizona

Industry: Municipal Utilities / Water & Wastewater

Contractor: Spray Foam Arizona

Website: https://www.sprayfoam-arizona.com/Phone: 520-252-3823

ROC #: 331359

🏛️ The Problem

A municipal wastewater treatment facility in Arizona was experiencing serious environmental control issues inside its main operations control room. This room housed:

• SCADA systems

• PLC panels

• Network servers

• Monitoring and alarm equipment

The building was constructed with CMU block walls and a low-slope metal roof assembly. Over time, the facility began noticing:

• Extreme temperature swings (summer interior temps exceeding 95°F)

• Condensation forming on walls and conduit

• High HVAC runtime and energy consumption

• Dust infiltration affecting sensitive electronics

• Employee discomfort during peak summer months

  

The city’s maintenance team had already replaced HVAC units twice in 10 years due to overwork and overheating. They needed a permanent building envelope solution, not another mechanical band-aid.

Complicating factors included:

• Active operations (no shutdown allowed)

• Sensitive electronics requiring protection during install

• Humidity control requirements

• Compliance with municipal fire and building codes

🛠️ The Solution

Spray Foam Arizona performed a full building envelope assessment and recommended a closed-cell spray polyurethane foam (SPF) insulation system applied to:

• Underside of metal roof deck

• Interior CMU walls

• Penetrations and mechanical transitions

Scope of Work:

1. Surface Prep & Protection

   • Containment barriers installed around equipment

   • Negative air machines deployed

   • Electronics fully masked and protected

2. Closed-Cell SPF Application

   • 2–3 inches of closed-cell foam on roof deck

   • 2 inches on CMU walls

   • Full air-sealing at penetrations

3. Ignition Barrier Coating

   • Code-compliant intumescent coating applied

   • Met municipal fire requirements

4. Air-Sealing & Moisture Control

   • Eliminated infiltration pathways

   • Created a continuous thermal and vapor barrier

Closed-cell foam was selected because it:

• Provides high R-value per inch

• Acts as both insulation and vapor barrier

• Strengthens the building assembly

• Prevents condensation in high-humidity environments

Installation was completed in phases to maintain uninterrupted plant operations.

📈 The Outcome

Within 30 days of completion, the facility documented:

✅ 28% Reduction in HVAC Runtime

Mechanical systems cycled less frequently, reducing strain and extending equipment life.

✅ Interior Temperature Stabilized

Control room maintained 72–75°F even during 110°F Arizona summer days.

✅ Condensation Eliminated

No further moisture accumulation on conduit, walls, or electrical enclosures.

✅ Improved Equipment Reliability

SCADA and PLC systems experienced fewer overheating alarms.

✅ Energy Cost Savings

Projected annual savings of approximately $9,800.

✅ Improved Employee Comfort & Productivity

Operators reported significantly improved working conditions.

🔎 Why It Matters

Municipal control rooms are mission-critical environments. When insulation and air sealing are overlooked:

• Electronics fail prematurely

• Energy costs skyrocket

• Condensation creates corrosion risks

• Staff morale declines

By addressing the building envelope instead of just mechanical equipment, this municipality achieved a durable, long-term solution.

🧱 Key Takeaways for Municipal Facilities

• Insulation is infrastructure.

• Air sealing is as important as R-value.

• Closed-cell SPF is ideal for high-performance, high-humidity control environments.

• Envelope upgrades reduce lifecycle costs far beyond energy savings alone.

If your municipal building, pump station, or control room is struggling with heat, condensation, or high energy use, let’s talk.

Spray Foam ArizonaArizona-Grown. Family-Built. Foam Strong.📞 520-252-3823🌐 https://www.sprayfoam-arizona.com/ROC #33135