Industry Insights & Newsworthy Articles


The Vapor Armor System Install Process: Part I



Here at Vapor Armour, we are recognized as experts in our field. The Cold Storage industry has recognized our company as the leading eliminator of vapor drive. We’ve even taught it to others, leading classes for RETA, CEBA, and the GCCA addressing the problems associated with Vapor Barrier Discontinuity.

But even as government recognized experts, with the only patented solution for eliminating vapor drive in cold storage facilities, none of it matters if we don’t get it right when we show up at your facility to install our patented system. That’s why we only trust our in-house trained Vapor Armour technicians. We train, equip, and pay them to be the best at stopping air, and combined with the system itself, we represent your best hope against Vapor Barrier Discontinuity.

Over the next two blog posts, we’re going to go in depth into the installation process for our patented Vapor Barrier Compression Seal system. We find that when warehouse operators understand the detail we put into every installation, it helps them visualize the benefits to them and their business.


Free Forensic Evaluation


Our work begins before our installation teams ever load a toolbox and prepare to head your way. Before we can know what solutions to offer, we come out and inspect your facility to make sure we’re a good fit. That starts with our Free Forensic Evaluation of your buildings to assess what needs, if any, you have for our patented Vapor Barriers.

These Vapor Armour “audits” are designed to meet compliance with the USDA, FDA and all FSMA regulations, as well as being sufficient for most insurance audits. Over the pandemic, we also developed a method for conducting offsite virtual assessments. In situations where this is still the best option, we’re happy to provide the free service.

Every Invasive Forensic Assessment includes a proposal for remediation of any problems we find which Vapor Armour can solve. At every facility we tour, we conduct our assessment as follows:

First, we document your current situation, using standard and thermal imaging photography, focusing areas of concern for ice and condensation. This gives us a clear picture of the visible, and heat picture of your facilities in their existing condition.

Next, we do a visual examination of the perimeter of your building on the exterior, to document any visible signs of damage, or areas of potential Vapor Barrier Discontinuation, followed by a careful visual inspection of the interior of your cooler and freezer interiors. Our teams are trained to note and document any areas of concern, or things we want the client, or our install team to be aware of.

Thirdly, if we find thermal evidence that the roof insulation has been compromised, we will take core samples of in order to determine the extent of the contamination. In about one half of the structures we visit, we find some or all the roofing system has sustained damage, including condensation collecting in the roof insulation, which can lead to freezing and a loss of R value.

These core samples give us a clear picture of what we cannot see between the interior ceiling and the exterior roof membrane. In some cases, as many as 40 cores are required to get a clear picture of how the contamination has spread.

Next, after we’ve made a thorough inspection, we talk with you and your facilities team about areas of concern you’ve had, and things that we see in our initial investigation. We will typically be able to show you where your Vapor Barrier has been breached and give you a general idea of the conditions inside your roof.

From there, we study the data we’ve gathered and reach a conclusion on what solutions we feel are best warranted in each situation. The report generated from this study then becomes the basis for a conference with you about the findings, and the dimensions of the issue within each facility. This allows us to create a scope of work and a project budget for remediation of the issues we find.

Lastly, Vapor Armour will supply you with a current image of your facility from Google Earth. This imaging highlights ice and condensation concerns related to Vapor Barrier discontinuation, or other problems that may be present in your facility from an aerial exterior view.

Finally, using all this documentation, a proposal is then generated including a budget for the remediation of the issues.


Our exterior compression seals


In our experience, building movement is the #1 cause of all Vapor Barrier Discontinuation, and breeches. There are several possible contributing causes.

  • The first is simply the expansion and contraction of the building itself. Due to the thermal dynamics of a cold storage facility, this can be severe.
  • Another major contributor is wind, also known as the “Venturi Effect.” Outside air currents are a powerful force which can cause shifting, even in stable construction.
  • One cause that can be overlooked, is building usage itself. Heavy machinery and cargo loads can shift concrete and steel structures enough to cause a problem.
  • Finally, the earth itself is never completely still. Settling, and shifts in surrounding terrain, even if not visible, can cause your building to move.

Since building movement is a fact, architects and contractors use expansion joints in roofs covering large buildings to account for the expansion and contraction in these materials. This allows for shifts in the roof deck to not destroy the structure but does nothing to help maintain the vapor barrier seal.

Since the edge of the wall is where most of the action happens, that’s where we start with our installation. Before we can start our process, we must excavate about 2 feet from the outside wall into the roof and remove all insulation down to the roof deck. This requires cutting down through the existing roof membrane, and removing all old insulation, roofing material, mastic, and other debris in a channel about two feet wide, parallel to the edge of the roof on exterior walls, and on one side of interior dividing walls.

Once demolition of the area is complete, we’re ready to start the installation process. We work to cause as little interruption to the course of your business as possible. The demolition is never more than 50 feet per crew at a time and the installation is complete on those 50 feet before any further demolition occurs. The beauty of this entire system is that it does not require you to shut down your facility, or even unload your freezer and cooler space.

In the next post, we’ll go into detail on the installation of the system. We think once you understand the lengths we go to in building in protection for your facility, your client’s inventory, and your inventory, you’ll find that Vapor Armour is the only solution you’re prepared to accept.

If you’ve heard enough already, give us a call and we’ll schedule a time to come out and get started with the free Invasive Forensic Assessment. We think you’ll like what you see.



We offer the industry’s only 15 year ‘No Ice. No Condensation. No Cost.’ Warranty for all thermal-controlled building that install Vapor Armour™, DOW Deckmate™ Plus Insulation and a roofing system installed by Royalty Roofing