Case Study: Spray Foam Cuts Energy Costs 40% in a Commercial Metal Building
- sprayfoamarizona
- Jan 22
- 2 min read
Project Overview
A commercial metal building in Arizona was experiencing extreme interior heat, high cooling costs, and inefficient HVAC performance — common challenges in metal structures exposed to desert sun.
The owner wanted a solution that would:
Reduce operating costs
Improve tenant and worker comfort
Lower HVAC strain
Deliver a clear return on investment
They selected spray foam insulation to upgrade the building envelope and control heat gain.
The Challenge
Before the upgrade, the facility struggled with:
Excessive heat transfer through the metal roof and walls
Large daily temperature swings
Long HVAC runtimes and high demand charges
Rising annual energy expenses
Productivity and comfort complaints from occupants
Baseline annual energy spend: approximately $40,000 per year
The Solution
Spray Foam Arizona installed closed-cell spray polyurethane foam (SPF) across critical heat-gain surfaces to create a sealed, insulated thermal envelope.
Scope of Work Included:
Spray foam applied to underside of metal roof panels
Sealing air leaks and penetrations
Thermal barrier to reduce conductive and radiant heat
Improved overall building airtightness
Total project cost: $55,000
The Results
Post-installation analysis showed an estimated 40% reduction in energy use tied to cooling and envelope performance.
Annual Energy Savings
Before: $40,000 per year
After: $24,000 per year
Annual savings: $16,000 per year
Payback Period
$55,000÷$16,000=3.4 years\$55,000 \div \$16,000 = \textbf{3.4 years}$55,000÷$16,000=3.4 years
The spray foam upgrade is expected to pay for itself in approximately 3.4 years, with continued savings every year after.
Operational Benefits Beyond Energy Savings
1. Improved Interior Comfort
More stable indoor temperatures
Reduced heat radiating from metal roof surfaces
Better working conditions for staff and tenants
2. HVAC Efficiency & Longevity
Reduced runtime and cycling
Less strain on compressors and blowers
Potential for downsized HVAC replacement in the future
3. Building Protection & Durability
Reduced condensation risk
Added structural rigidity from closed-cell foam
Lower long-term maintenance risk on metal panels
4. Productivity & Tenant Value
Cooler workspaces improve comfort and productivity
More attractive environment for tenants or customers
Stronger long-term property value
Why Spray Foam Works Especially Well in Metal Buildings
Metal buildings are highly conductive and prone to massive heat gain. Traditional insulation methods often leave gaps, thermal bridges, and air leaks.
Spray foam delivers three advantages at once:
Insulation (R-value)
Air sealing (energy control)
Moisture resistance & durability
In hot climates like Arizona, this creates one of the fastest payback timelines available for building envelope upgrades.
Owner Feedback
“The building is noticeably cooler, the HVAC doesn’t run nearly as hard, and our energy bills dropped fast. Seeing a payback in just over three years made this one of the smartest upgrades we’ve done.”
Financial Summary
Category | Value |
Building Type | Commercial Metal Building |
Project Cost | $55,000 |
Annual Energy Spend (Before) | $40,000 |
Estimated Energy Reduction | ~40% |
Annual Savings | $16,000 |
Payback Period | ~3.4 Years |
Ready to Calculate Savings for Your Facility?
Spray Foam Arizona can analyze your actual utility bills, square footage, and building type to estimate energy savings, ROI, and payback timeline before you commit.
Spray Foam ArizonaArizona-Grown. Family-Built. Foam Strong.🌐
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