Spray foam insulation is used in select industrial settings to reduce energy loss and create a continuous air seal around complex geometries and equipment. Fire safety comes first in these environments.
This guide explains how spray foam assemblies are made safe, what thermal and ignition barriers are, how intumescent coatings are selected and applied, and which steps help you pass inspections with confidence.
Industrial facilities face higher fire risks than typical buildings, so every insulation system must be designed with fire resistance in mind. When paired with approved protective barriers, spray foam can deliver efficiency while meeting strict safety standards.
Why Fire Safety Comes First In Industrial Buildings
Industrial buildings concentrate people, equipment, and valuable inventory. If fire protection is weak, a small incident can grow into a major loss in minutes. Spray foam insulation is a foam plastic, which means it can burn when exposed to sufficient heat.
Building codes, therefore, require spray foam to be separated from the interior by approved protective layers. Getting these layers right is the key to safe, code-compliant projects.
The Basics Of Spray Foam And Fire
Foam Plastics Need Protection
Spray foam insulation can ignite if directly exposed to a sustained flame or very high heat. That is why codes require a tested protective layer between the foam and the occupied space. The goal is to slow heat transfer to the foam so it does not ignite early in a fire event.
What A Compliant Assembly Looks Like
A compliant assembly pairs spray foam with either a thermal barrier, such as gypsum board, or an approved intumescent coating that has been tested over that specific foam and at the specified thickness. Proper surface prep, film build, and curing are essential parts of that assembly.
Thermal Barriers And Ignition Barriers
Thermal Barriers
A thermal barrier is the primary line of defence on walls and ceilings that face occupied areas. Gypsum board is the most common choice. In many industrial contexts, a board layer is feasible and often preferred because it is familiar to inspectors and easy to document.
Ignition Barriers
In low-access service areas, an ignition barrier can be permitted by code. These products are not the same as thermal barriers. They are intended to reduce the chance that incidental sparks or brief heat exposure start a fire.
Only use an ignition barrier where the code allows it and only with products that are listed for that role.
Using Intumescent Coatings Over Spray Foam
What An Intumescent Coating Does
An intumescent coating swells and forms a protective char when heated. Applied at the correct wet film thickness and allowed to cure as directed, it can serve as the barrier layer over spray foam when a board layer is not practical.
DC315 Within A Compliant System
DC315 is a well-known intumescent coating that is commonly specified over spray foam. For Classic Spray Foam projects, we follow a strict rule. DC315 is not approved for over half-pound open-cell foam in the fire protection roles we discuss here.
We only specify DC315 within assemblies and use cases that match published approvals and testing. If an assembly requires a different coating or a board layer, we choose that instead.
Seven Steps To A Safer Industrial Spray Foam Assembly
Define The Occupancy And Use Of Each Area
Confirm whether a thermal barrier or an ignition barrier is allowed. Treat mechanical rooms, mezzanines, process lines, and storage differently if the code requires it.
Select The Foam Type And Thickness
Specify the exact product and installed thickness required by the design. Keep a written record of product data sheets and evaluation documents.
Choose The Barrier Method
Prefer a board layer where practical. If geometry or access prevents that, use a listed intumescent coating that has been tested over the exact foam type and thickness you plan to install.
Prepare The Surface
Surfaces must be clean, dry to the manufacturer’s threshold, and free of oils and release agents. Follow the installer guide for temperature and humidity limits.
Apply To The Tested Film Build
Record wet film thickness during application and dry film thickness after cure using the manufacturer’s method. Uneven or thin areas must be corrected before turnover.
Protect From Damage
Barriers must be protected from abrasion during operations. Set a maintenance plan so any gouges or cuts are repaired promptly.
Document And Inspect
Keep datasheets, application logs, photos, and thickness checks in one packet. Share with the authority having jurisdiction and the owner. This speeds approvals and reduces costly rework.
Common Pitfalls And How To Avoid Them
Assuming Any Coating Will Work
Only use a coating that is specifically tested and listed for the exact foam product and thickness you plan to use. If the tested system calls for two coats at a given coverage, follow that instruction exactly.
Missing Film Thickness Targets
Intumescent protection depends on coating build. Use wet film gauges during application and verify dry film after cure. Record readings at multiple points on each surface.
Treating Ignition Barriers Like Thermal Barriers
These two roles are not interchangeable. If a space requires a thermal barrier, do not substitute an ignition barrier. Ask for clarification from the authority having jurisdiction before you mobilize.
Overlooking Access, Traffic, And Future Work
Industrial walls and ceilings see frequent maintenance. Plan for guards, sacrificial panels, or protective cladding in high traffic zones so the barrier layer is not damaged by carts or tools.
Where Spray Foam With Proper Protection Shines
Large volume spaces
Open floor warehouses and light manufacturing benefit from the continuous seal that spray foam provides around structural steel and complex penetrations. When paired with a proper barrier, the result is efficient and code-compliant.
Retrofit projects
Older buildings often have uneven substrates and mixed materials. Intumescent coatings can make a compliant barrier possible where board layers would be difficult to install.
Complex mechanical zones
Around ducts and equipment, spray foam can seal irregular gaps quickly. The barrier strategy must be planned early so clearances, labels, and access panels remain safe and visible.
About Classic Spray Foam
Classic Spray Foam serves Edmonton and nearby communities with professional spray foam insulation services for custom-built homes and select industrial projects where specifications demand high-performance results.
Our priority is safe, code-aligned installations with proven products and barrier systems. Our team handles planning, application, and documentation from start to finish so you can move forward with confidence.
Contact us to discuss your project and request a detailed quote through the website.