Featured Case Study – Oak Hill

Here is the case study of a retirement home called Oak Hill located between Edgerton and Janesville at 6313 North River Road. Completed in 2002 by Ferguson Custom Homes, this unique residence is insulated with Dwyer’s advanced polyurethane foam. The home was designed to use renewable energy, featuring an outdoor wood furnace and a geothermal heating/cooling system. Photovoltaic panels will be installed on the large south-facing roof in the future to achieve energy independence.

Owners Kathie and Dave Brown are happy to show this unique home to visitors. Call (608) 756-4479 for an appointment

Most “superinsulated” homes rely on thick batts of paper-backed fiber-glass insulation stapled into the spaces between 2×6 studs and then covered with Visqueen. But this leaves gaps – especially around windows and in corners – where air can infiltrate. Effective insulating power is seldom more than R19. With Dwyer’s less expensive standard construction with 2×4
Oak Hill is foam insulated. The foundation is built with insulated concrete forms covered with natural fieldstone. The second level is constructed with standard 2×4 prebuilt sections and sided with vinyl. The unique tower has a real silo roof covered inside with Dwyer’s advanced polyurethane insulation.
studs on 16″ centers can be used. The polyurethane foam, sprayed to a depth of 3″ (completely filling the stud spaces and requiring no extra vapor barrier) is rated at R-21.
Sharon and Bruce Dwyer have a unique mixing and pumping system to apply polyurethane foam material. Three long hoses in a protective sheath carry the heated foam components and compressed air to the application site.
Pumping equipment stays outside. Dwyers have an equipment truck that contains the foam components and pumps. A long container sheath can be pulled to the site where foam is applied.
The Dwyer organization carefully prepares each worksite so the foam lands only where it is intended to go. Windows, floors, and stud surfaces are covered with plastic. Electric outlets and heat registers are protected. The sheeting and tape is removed after the foam hardens and
Tim Rowley protects windows and surfaces. Plastic sheeting and tape covers windows and stud faces so that sidespray can easily be removed.
cures. Where necessary, inside sufaces of the foam are shaved so that sheets of cement board or other wall covering can be mounted securely to the wall.
The services of an experienced installer are required to insure that the polyurethane foam is deposited without voids to a uniform thickness. Bruce Dwyer has been in the commercial insulation business for more than 20 years. He has perfected his application technique so that wall spaces are filled, but not overloaded. After
Bruce Dwyer applies polyurethane insulation. Heated chemicals and compressed air are fed through the hose bundle and mixed into a creamy foam that is sprayed into wall cavities. The foam hardens in a few seconds.
careful preparation, a typical 2000 sq. ft. residence usually can be foamed in one day.
The silo-like tower on Oak Hill was a challenge to insulate. To position the tower’s first floor on the same level as the main house, joists were set on a kneeler wall atop the foundation. The cavity was filled with polyurethane foam 8″ deep. This formed an excellent barrier against outside winds. Hot water circulating pipes are buried in the
Foam is especially effective around sill plates. Where wallboards, joists or trusses meet the top of a foundation, seams are uneven. Dwyer’s advanced insulation seals those openings to prevent heat loss and eliminate drafts.
tower’s basement concrete floor.
The tower’s 20 ft. diameter galvalum silo roof, left open and insulated from inside, promotes air convection and provides a dramatic arched ceiling over the observation deck. Bruce Dwyer demonstrated his experience and skill by building up the 3″ thickinsulation freehand, producing a smooth covering inside the silo roof. The resulting
Polyurethane foam sprayed inside the tower roof. This was a “first” for Ribstone Silos, Inc. and Dwyer’s Foam Systems.
liner is quiet, warm, and exceptionally sturdy.