Yellowknife (Mar 10/03) - When Manuel Jorge installed spray foam installation in the home of his first customer in 1996, the gas company called two weeks later to check whether the furnace had been turned off.

The Yellowknife-based company was so surprised by the drop in fuel consumption they couldn't believe it was simply a retrofit job.

Jorge, general manager of Energy Wall and Building Products, said spray foam has become a key tool in insulating homes because of its efficiency.

Instead of being crammed into place, it's sprayed and then expands into even the smallest cavities, reaching previously unreachable areas.

It's used below the floor in mobile homes to keep the walking surface warm.

"It's a strong business to be in," said Jorge. "You can do things with foam that you can't do with anything else. It's perfect for the North."

The foam acts as a wind and air barrier and can eliminate the need for caulking and creating a vapour barrier.

The 1996 pilot project house typically cost about $200 a month to heat in the winter, but after applying the spray foam, Jorge said the bill dropped to a total of $158 for three winter months.

"Spray foam" is actually a version of the polyurethane foam used in flotation devices, carpet cushioning and packaging.

It has been used in construction since the 1960s but recent improvements in its chemical composition make it a safe and environmentally friendly insulator, Jorge said. He figure's he's applied over half a million dollars worth of foam in Yellowknife.

Jorge said the foam should be installed in all new houses. It costs a little more per square foot than regular insulation but the extra investment pays for itself quickly.

"When you build you should look at the long-term costs, the long-term performance of the building," he said. "You pay for what you get."

He said it's impossible to say how long it will take you to recoup an investment in spray foam insulation. It depends on how robust your current insulation is, how big your house is and how much you're used to paying to heat it. He said a good retrofit will take 10 to 15 years to pay for itself. "But it will give you a comfortable home immediately," he said.