Case Study: This “Leaky” Old Church

The Project

The Federated Church, built in 1972, stood as a cherished space for worship and community. Its natural wood sanctuary ceiling gave it a distinct charm, but it came with a hidden cost. Over the years, the building became notorious for its inefficiency—sky-high heating bills, mold creeping under shingles, and even icicles forming along its edges in winter. It was clear: this “leaky” old church needed serious attention.

When RetroGreen Energy stepped in, the mission was simple: make the church more energy-efficient, comfortable, and sustainable while preserving its architectural integrity. It was a challenge, but one we were excited to tackle.

The Problems

Let’s just say this church had been losing heat—and money—for decades. Here’s what we found:

• Poor Insulation: Hollow concrete block walls and sections of the roof had little to no insulation. Some areas relied on fiberglass batting, which wasn’t cutting it.
• Lack of Ventilation: With just five roof vents installed, the airflow was inadequate, causing condensation, mold growth, and roof deck staining.
• Heat Loss Damage: Years of escaping heat led to damaged shingles, mold buildup, and water stains inside the building.
• Climate Challenges: Built without proper consideration for Minnesota’s cold winters and humid summers, the design itself was working against efficiency.

The Solutions

To give this church a second life, we had to think creatively. Here’s how we turned things around:

1. Boosting Insulation:
   
   We installed blown-in batt insulation to improve the thermal envelope.
   Closed-cell polyurethane foam was applied to the roof exterior, sealing air leaks and preventing moisture infiltration.
   Using RetroFoam, we filled hollow concrete block walls to stop drafts and improve energy efficiency.
   Open-cell tri-polymer resin foam was added in critical areas to ensure a continuous thermal boundary.
   
   
2. Improving Ventilation:
   
   The ventilation system went from five vents to 162 total, including:
   
   70 roof vents.
   60 soffit vents.
   20 gable vents.
   12 window vents.
   
   
   This eliminated moisture buildup and balanced the airflow throughout the structure.
   
   
3. Reinforcing the Roof:
   
   Damaged shingles were removed and replaced to prevent further heat loss.
   We added new roof sheathing over foam insulation to enhance durability.
   
   
4. Energy-Saving Enhancements:
   
   A full energy audit was conducted to measure improvements and seal any remaining air leaks.
   
   

The Results

After RetroGreen Energy’s upgrades, the Federated Church was a whole new building. Here’s what we achieved:

• Energy Savings: Air leakage was reduced by 58%, cutting heating and cooling expenses by about $5,000 per year.
• Better Comfort: Worshippers now enjoy a more stable and comfortable indoor environment, no matter the season.
• Extended Lifespan: The new insulation and ventilation system protect the structure from moisture damage, ensuring it serves the community for years to come.
• Eco-Friendly Impact: With lower energy consumption, the church reduced its environmental footprint—a win for sustainability.

Moving Forward

The transformation of this “leaky” old church is more than just a project, it’s a testament to how building science and insulation can bring life back to an aging structure. With creative thinking and innovative solutions, we helped the Federated Church save money, protect its beautiful sanctuary, and become a more sustainable space for its community.

Do you have an old or new building, that could benefit from an energy makeover? At RetroGreen Energy, we’re ready to help. Contact us today for an energy audit, and let’s start your transformation!