Large-Scale Coastal Insulation Project Powered By PolyCon
MELBOURNE, Florida, March 30, 2026. — PolyCon, a leading spray foam manufacturer, and Knowles Spray Foam Insulation, a professional spray foam contractor, partnered to deliver high-performance insulation for a 2,500-square-foot new construction home located along Florida’s Intracoastal Waterway. The custom, two-story home was designed with a strong emphasis on energy efficiency, sustainability, and long-term building performance, making spray foam insulation a critical component of the project.
Knowles Spray Foam Insulation professionally sprayed PolyCon 450 High-Yield, No-Mix Open Cell Spray Foam insulation, which was installed at 6 inches to achieve an R-30 value. The application included the underside of the roof deck, the attic, and the patio roof, creating a sealed and energy-efficient building envelope, improving thermal performance, enhancing air sealing, and increasing overall comfort throughout the home.
A key factor in selecting PolyCon 450 for this project was its compliance advantages. PolyCon 450 High-Yield, No-Mix Open Cell Spray Foam is certified to ICC-ES AC377 Appendix U, allowing it to be installed in unvented attics without the need for an additional ignition barrier. This certification helped streamline the installation process, reduce material and labor costs, and ensure code compliance, making it an ideal solution for this high-performance custom home.
Knowles Spray Foam Insulation, led by owner Bill Knowles, was brought onto the project through a trusted relationship with the general contractor. Known for specializing in custom homes, the company was tasked with meeting strict energy code requirements that could not be achieved using traditional insulation methods. As a result of evolving standards in the state of Florida and demanding internal credentialing requirements, spray foam insulation proved to be the only viable solution.
The installation was carried out by a seasoned crew at Knowles Spray Foam Insulation with over 15 years of spray foam expertise in the field. According to Bill Knowles, PolyCon 450 performed with a high level of consistency throughout the project. “PC 450 was very controllable and predictable. That level of consistency makes a big difference, especially on detailed custom builds like this.”
The project had performance requirements that went beyond standard insulation expectations. To meet Florida’s updated energy codes and internal credentialing requirements, the home needed a system capable of delivering superior air sealing and thermal efficiency-capabilities that traditional batt insulation does not provide. The result is a high-performance home built to reduce long-term energy consumption while maintaining comfort in Florida’s coastal climate. By insulating critical areas such as the roof deck and attic, the home benefits from a tighter building envelope that supports HVAC efficiency and overall durability.
In addition to code compliance, the builder and homeowner prioritized minimizing the home’s long-term environmental footprint. Every aspect of the project was designed with sustainability in mind, and spray foam insulation played a key role in achieving those goals. By reducing energy demand and improving overall efficiency, PolyCon 450 supports a more responsible, eco-friendly approach to modern residential construction.
This project highlights the value of combining experienced contractors with high-performance materials. Knowles Spray Foam Insulation’s expertise in custom applications, paired with PolyCon’s reliable and consistent spray foam system, resulted in a successful installation that meets the demands of current energy codes as well as the sustainability requirements of the future.
About PolyCon
PolyCon is a Houston-based manufacturer of high-performance spray foam insulation, offering open cell, closed-cell, and roofing systems designed for superior energy efficiency, moisture control, and long-term durability. Built by contractors for contractors, PolyCon combines industry expertise with advanced manufacturing to deliver reliable and sustainable insulation solutions. The company also supports professionals through training and technical resources to ensure quality installation and performance.
Contact PolyCon Today.
www.polyconsprayfoam.com
Email: info@polyconspf.com
Phone: 1-855-PC1-FOAM