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Huntsman’s Reliability Excellence Center (REC) in Geismar, Louisiana, used HEATLOK XT High Yield closed-cell spray foam as part of a Gulf Coast building-envelope strategy. The reported 22,000-square-foot structural-steel facility combines a TPO roof, fluid-applied exterior waterproofing and spray foam installed beneath the roof deck and between exterior metal wall studs. Huntsman and the project team selected the system to address heat flow, air leakage, vapor movement and water exposure in a humid, hurricane- and flood-prone climate.
The project coverage does not report measured energy use, utility savings, payback, installed foam thickness or a complete construction-assembly specification. Those limits matter: the case study documents design intent and installation locations, not an independently verified post-occupancy performance study.
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What the Huntsman Reliability Excellence Center is
The Reliability Excellence Center is described in 2023 project coverage as a 22,000-square-foot building at Huntsman’s world-scale polyurethane production site in Geismar, Louisiana. It supports the company’s maintenance, reliability and operational-excellence teams. Building Enclosure’s description lists 21 private offices, two open cubicle areas, seven conference rooms and a large break room. The building was constructed around an existing live electrical room serving production units, which made continuity, protection and separation important envelope considerations.
There is a reporting distinction to keep in mind. The Building Enclosure project report presents the work as a new, ground-up office building. An Adhesive and Sealant Council account describes an expansion that added a maintenance workshop and workspace. These descriptions may reflect different project phases or editorial scopes; they should not be treated as a single, fully interchangeable floor-plan claim.
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- ALL-IN-ONE SPRAY FOAM INSULATION KIT — UP TO 240 BOARD FT: Get everything needed to start insulating in one box, including 12 spray foam cans, heavy-duty applicator gun, solvent-based cleaner, gloves, goggles and coverall for a complete DIY insulation setup.
- ADVANCED HYBRID FOAM WITH LOW WATER ABSORPTION: FullStop combines strength and controlled expansion for dependable gap filling, insulation and coverage. Its cured foam structure helps resist water absorption, with short-term water absorption tested under EN 1609.
- HELPS REDUCE AIR LEAKS & IMPROVE THERMAL COMFORT: FullStop expands consistently within the recommended 68–77°F application range to fill gaps, cracks and hard-to-reach spaces. Its insulating foam helps reduce unwanted air movement and heat transfer for improved year-round comfort.
- STRONG ADHESION TO COMMON BUILDING MATERIALS: The moisture-cured polyurethane formula bonds securely to wood, metal, drywall, concrete, brick and other common building surfaces. Once cured, the foam creates a durable insulating seal that helps reduce drafts while resisting water absorption.
Project participants
- Owner and product source: Huntsman, whose Geismar site manufactures polyurethane products.
- General contractor: Arkel Constructors.
- Architect: Grace Hebert Curtis Architects.
- Spray-foam installer: Lafayette-based Rader’s Insulation, engaged by Arkel.
The Building Enclosure article identifies Doug Brady, Huntsman Building Solutions’ chief strategy officer, as its author and says project photographs were supplied by Huntsman Building Solutions. That involvement makes the article useful for documenting the intended assembly and participants, but it is not an independent commissioning report.
What spray foam was used, and where was it installed?
The project account identifies Huntsman Building Solutions’ HEATLOK XT High Yield Spray Foam as the closed-cell insulation. Rader’s Insulation applied it in two principal locations:
- Underside of the roof deck: The foam was sprayed directly below the deck to create a continuous insulated layer inside the roof assembly.
- Exterior walls: The foam was installed on the exterior sheathing between metal wall studs.
The rest of the reported roof-and-wall strategy included a TPO roof membrane and fluid-applied waterproofing over the exterior. In other words, the foam was one layer in a coordinated enclosure, not a stand-alone roof or weatherproofing system.
Why the location matters
Spraying below the roof deck can reduce thermal bridging and uncontrolled air movement through roof joints, penetrations and service openings when the work is detailed continuously. Filling the stud bays at the exterior sheathing can improve continuity around the wall frame, although the final result depends on substrate preparation, lift thickness, transitions, fasteners, penetrations and how the foam meets windows, doors, roof edges and other materials.
Neither published project account states the installed thickness, density, total board footage, substrate temperature, number of lifts or the exact wall and roof-layer sequence. Those details are necessary to calculate the project’s code compliance or effective whole-building R-value and should be obtained from the construction documents rather than inferred from the product name.
Why closed-cell foam fit the Gulf Coast design brief
Geismar has a humid, subtropical climate with high cooling loads, moisture exposure and recurring severe storms. The project team’s stated rationale was therefore broader than insulation alone. The case study presents the foam as a way to combine several control functions within the enclosure.
Thermal resistance
Closed-cell polyurethane foam has a rigid cellular structure and a high thermal resistance per inch compared with many low-density insulation types. In the project account, Simon Baker, global president of Huntsman Building Solutions, said: “HEATLOK XT High Yield Spray Foam enhances thermal resistance and serves as both an air barrier and vapor retarder.” This is a manufacturer-representative statement about the product’s intended capabilities, not a measured R-value for the REC.
Because the REC report does not provide installed thickness or field testing, it cannot establish the building’s completed thermal performance. A designer evaluating a similar project would need the product’s tested aged R-value at the specified thickness, framing geometry, thermal-bridge calculations and details for roof and wall continuity.
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- CLASS A SURFACE-BURNING PERFORMANCE + HIGH R-VALUE: BEEST FullStop was tested to ASTM E84 and achieved a Flame Spread Index of 0 and Smoke Developed Index of 120, meeting Class A surface-burning criteria. Delivers strong thermal insulation performance with an R-Value of 8.24 at 2" thickness.
- ALL-IN-ONE SPRAY FOAM INSULATION KIT — UP TO 480 BOARD FT: Get everything needed to start insulating in one box, including 24 spray foam cans, heavy-duty applicator gun, solvent-based cleaner, gloves, goggles and coverall for a complete DIY insulation setup.
- ADVANCED HYBRID FOAM WITH LOW WATER ABSORPTION: FullStop combines strength and controlled expansion for dependable gap filling, insulation and coverage. Its cured foam structure helps resist water absorption, with short-term water absorption tested under EN 1609.
- HELPS REDUCE AIR LEAKS & IMPROVE THERMAL COMFORT: FullStop expands consistently within the recommended 68–77°F application range to fill gaps, cracks and hard-to-reach spaces. Its insulating foam helps reduce unwanted air movement and heat transfer for improved year-round comfort.
- STRONG ADHESION TO COMMON BUILDING MATERIALS: The moisture-cured polyurethane formula bonds securely to wood, metal, drywall, concrete, brick and other common building surfaces. Once cured, the foam creates a durable insulating seal that helps reduce drafts while resisting water absorption.
Air control
Air leakage can carry heat and moisture through cracks at joints, penetrations and transitions. A sprayed membrane can reduce those pathways when it adheres to the substrate and is tied into the rest of the air-control layer. The project coverage describes HEATLOK XT as functioning as an air barrier, but it does not report blower-door results, leakage targets or a post-construction air-barrier inspection.
Vapor control
In a hot, humid climate, vapor movement and air-carried moisture can contribute to condensation risks as temperatures change across the assembly. Closed-cell foam is commonly used where a designer wants a more vapor-resistant layer, but the correct location depends on the complete wall and roof design. The REC report calls the foam a vapor retarder; it does not publish perm ratings, dew-point calculations or a hygrothermal analysis for the installed assembly.
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Huntsman’s representative also described the rigid foam as providing a water-resistive-barrier function. The association account says the product was NFPA 285 tested and ABAA evaluated, and reports Huntsman’s statement that it met FEMA Class 5 requirements for cleaning and drying after flooding. Those are manufacturer or project-coverage claims. They should not be read as an independent flood-performance test of the REC, nor as proof that the entire building can be restored after any flood without removing finishes or contaminated materials.
For a Gulf Coast facility, resilience still depends on the entire enclosure: roof attachment, flashing, drainage, openings, equipment curbs, sealants, flood elevation, interior finish selection and the ability to inspect and dry concealed spaces. Foam can support those objectives, but it cannot compensate for a failed roof membrane or an unsealed transition.
How the reported envelope layers work together
| Envelope element | Reported role at the REC | What the published accounts establish |
|---|---|---|
| HEATLOK XT High Yield closed-cell spray foam | Insulation, air-barrier and vapor-retarder layer; described by Huntsman as rigid and water-resistive | Installed under the roof deck and between exterior metal wall studs; thickness and field test results are not stated |
| TPO roof | Primary roof membrane and weather-shedding surface | Reported as part of the roof strategy; membrane manufacturer, attachment method and warranty details are not stated |
| Fluid-applied exterior waterproofing | Exterior water-management layer over the sheathing | Reported as part of the exterior system; product, film thickness and inspection records are not stated |
| Metal wall framing and sheathing | Structural and enclosure substrate receiving the spray foam and exterior waterproofing | Metal studs and exterior sheathing are identified; gauge, spacing and sheathing type are not stated |
The layers have different jobs. The TPO membrane sheds bulk rain at the roof. Fluid-applied waterproofing protects the exterior sheathing. Spray foam addresses heat flow and, where detailed and tested for the application, air and vapor movement. Treating these layers as substitutes would produce an incorrect design.
What Huntsman and the installers said
The project’s participants linked the product choice to efficiency and resilience. Mark Dearman, Huntsman’s senior operations director and Geismar general manager, said: “Not only is it important that the site’s Reliability Excellence Center be optimized for efficiency and resiliency but, in using our own spray foam in the building envelope, we are standing proudly behind its efficacy and long-term value.”
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Nick Rader, owner of Rader’s Insulation, said: “Using this particular spray foam will ensure long-term energy performance and savings, as well as protection against the risks associated with hurricanes and floods.” The wording reflects the installer’s expectation and project rationale. No published utility bills, modeled-versus-actual comparison, payback calculation or storm-loss record is supplied to verify those outcomes at this building.
Huntsman Building Solutions also states that more than 250 million PET single-use plastic water bottles are recycled annually into its products. That is a company-reported annual figure, not a quantity attributed to the REC and not an independently audited project statistic.
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- Efficient Thermal Performance & Draft Blocking – Delivers up to R-8 insulation at the recommended 2-inch thickness while expanding to fill gaps and cracks, helping stop drafts, reduce moisture intrusion and prevent heat loss—ideal for attics, walls, garages and whole-home use.Actual coverage may vary depending on application depth, surface condition, humidity, temperature, and technique.
- Advanced Hybrid Insulation Formula-Designed to outperform standard spray foam insulation, this advanced insulation foam combines the strength and moisture resistance of closed cell spray foam with the adaptive expansion of open-cell technology. The result is a high-performance spray insulation foam that fills gaps, seals cracks and delivers superior coverage on uneven surfaces. Ideal as a spray foam insulation kit, our foam insulation solution ensures long-lasting durability, maximum efficiency and professional-grade results with every spray.
- Energy-Efficient Spray Foam Insulation: Designed to perform where others fall short, this spray foam expands to seal gaps and cracks, creating an airtight barrier against energy loss. Its high thermal resistance delivers reliable, year-round insulation—apply between 60–90°F (15–32°C) for optimal performance, improved comfort, and lower energy costs.
- Strong Adhesion on All Surfaces-Adheres strongly to wood, concrete, metal, glass, brick, drywall and more, expanding to fill gaps and uneven areas. Recommended 2-inch application depth helps reduce airflow, limit moisture intrusion and minimize condensation for more efficient insulation.Adheres to many clean and dry building materials such as wood, concrete, brick, drywall, masonry, stone, and cool metal. Surfaces should be free from dust, oil, moisture, and loose debris before application.
Current Huntsman product information versus the 2022 project material
Huntsman’s current U.S. closed-cell product page lists Heatlok HFO Pro and Heatlok HFO High Lift. These current products provide useful context for how the manufacturer describes its technology, but they are not interchangeable evidence for the HEATLOK XT High Yield formulation installed at the REC.
| Current product-page item | Published manufacturer information | How to interpret it for the REC |
|---|---|---|
| Heatlok HFO Pro | Described as continuous insulation addressing air, thermal, water and vapor control; aged thermal resistance listed as 7.4 per inch; NFPA 285 tested and approved behind multiple claddings, including aluminum and metal | Current product information only; it does not establish the REC’s product, thickness or installed R-value |
| Heatlok HFO High Lift | R-value stated as 7.4 per inch depending on installed thickness; maximum 6.5-inch lift per pass; NFPA 285 testing and a tested water-resistance barrier are described | Current product information only; these values are not specifications for HEATLOK XT High Yield |
| HEATLOK XT High Yield at the REC | Project coverage identifies the product and its intended control functions | Published accounts do not state installed thickness, aged R-value, yield, pass sequence or field verification |
Anyone specifying a current system should confirm the exact formulation, technical data sheet, safety documentation, approved substrates, cladding combinations, lift limits, ignition-barrier requirements and local code pathway with Huntsman and a qualified installer. A current product label should not be substituted for the project’s original submittal.
Fire, code and flood questions a similar project must resolve
NFPA 285 and cladding assemblies
The association account reports that the product was NFPA 285 tested. NFPA 285 is an assembly fire-propagation test; compliance depends on the tested combination of foam, sheathing, framing, membranes, cavity configuration and exterior cladding. A generic statement that a foam passed does not approve every wall build-up. The architect and code official must match the proposed assembly to an applicable tested or otherwise accepted design.
ABAA evaluation
The same account reports ABAA evaluation. Evaluation supports qualification of air-barrier materials and installation practices, but the project still needs compatible transitions, sealants, primers, detailing and inspection. The published accounts do not provide the REC’s inspection checklist or acceptance results.
Flood cleanup
The reported FEMA Class 5 claim concerns cleaning and drying after flooding. Flood recovery decisions are site-specific and can involve contaminated water, concealed cavities, electrical systems, interior finishes and health requirements. Building owners should follow current emergency-management, public-health and manufacturer guidance rather than assume that leaving all foam and finishes in place is acceptable.
What the case study does—and does not—prove about energy savings
The case study explains why the team expected better efficiency and resilience, but it does not publish project-specific energy savings. There is no reported baseline, weather normalization, utility interval data, modeled energy-use intensity, operating schedule, payback period or measured indoor-comfort study.
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That distinction is especially important for a 22,000-square-foot industrial-site office building. Energy use can be affected by HVAC sizing, controls, schedules, plug loads, lighting, ventilation, occupancy and adjacent production operations. Insulation and air control may contribute to lower loads, but the available project coverage cannot assign a savings percentage or dollar value to the foam.
How to evaluate a comparable Gulf Coast enclosure
- Define the control layers. Draw the thermal, air, vapor and water-control layers continuously from foundation to roof, including every opening and service penetration.
- Confirm climate and moisture assumptions. Use the project location, interior humidity, cooling strategy, flood exposure and wind design criteria rather than selecting foam solely by nominal R-value.
- Obtain assembly-specific documentation. Request the exact product data, aged thermal resistance, vapor permeance, water-resistance evidence, substrate limits and approved wall or roof assemblies.
- Check fire pathways. Match foam, membranes, sheathing and cladding to an applicable NFPA 285 or code-approved assembly. Confirm ignition and thermal barriers where required.
- Specify installation controls. Include substrate preparation, temperature and moisture limits, lift thickness, recoat windows, trimming, overspray protection, ventilation and inspection hold points.
- Detail transitions. Coordinate roof-to-wall edges, parapets, windows, doors, louvers, penetrations, electrical-room interfaces and movement joints before spraying begins.
- Verify the finished work. Use visual inspection and, where required, adhesion, thickness, continuity or air-leakage testing. Record repairs and concealed-condition approvals.
- Plan for storm and flood recovery. Coordinate drainage, equipment elevation, access for drying and documentation that tells responders which materials can be cleaned, removed or retained.
Bottom line for the Huntsman project
At the Geismar Reliability Excellence Center, HEATLOK XT High Yield closed-cell spray foam was reported as an integrated part of a TPO-roof and fluid-applied-waterproofing envelope. Rader’s Insulation installed it beneath the roof deck and between exterior metal wall studs. Huntsman’s representatives emphasized thermal resistance, air and vapor control, water resistance and Gulf Coast resilience.
The evidence supports those design intentions and identifies the project team. It does not establish a measured energy-savings result, a payback period, an installed R-value or independent flood performance. For designers and owners, the practical lesson is to evaluate the complete, tested assembly and verify installation details rather than treat the product name alone as proof of building performance.
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