Spray Polyurethane Foam (SPF) Insulation

Florida Commercial and Residential Since 2001

If you have any questions about your Spray Foam Insulation give us a call.  We can establish the origin of Spray Foam Insulation odors, the installed condition of the Spray Foam Insulation, and the determine if the design of your home and HVAC system are correct for Spray Foam Insulation.  We provide Spray Foam Insulation consulting throughout the country.

The first step of any product failure investigation would be to identify the product, and then the inspection of the applied product.  The actual inspection of the applied product is critical in establishing if the product has been installed in accordance with the manufactures installation specifications and/or industry standards.   Only then can there be a determination of correct or incorrect installation and/or product failure.

The American Chemistry Council Spray Foam Coalition published the guidance document titled “Spray Polyurethane Foam: Guidance on Sampling Techniques for the Inspection of Installed SPF” which should be used to inspect the current condition of the installed SPF.

Spray Polyurethane Foam SPF Insulation Inspections

IAQ Solutions will inspect the installed condition of the Spray Foam Insulation in accordance with the manufacturer’s specifications and the SPFA Inspection Criteria.

  • The investigation of SPF or Spray Foam Insulation Inspection for occupant complaints must begin with the identification of the installed SPF Insulation and then
  • The physical inspection of the installed Spray Polyurethane Foam SPF Insulation
    • The physical inspection of the applied Spray Foam Insulation is to establish if the applied SPF Insulation is installed correctly or misapplied and the possible cause and origin of the occupant complaint
  • The investigation must begin with the physical inspection of the Spray Foam Insulation
  • Has the applicator met the Project specifications and
  • The manufacturer’s installation requirements?
    • Is the Spray Foam Insulation, SPF Insulation Installed Correctly?
A potential case for product failure or product defect where the product may be negatively impacting the occupants must begin with the establishment of correct product installation and performance.

Spray Polyurethane Foam SPF Odor Investigations

When it comes to the investigation of nuisance odors associated with the application of spray polyurethane foam SPF insulation, we’ve found that most of the investigations typically involve little more than varied attempts at trying to chemically associate the odor with the off-gassing of the Spray Foam Insulation.


We’ve been assessing spray polyurethane foam insulation SPF for over 20 years and on too many properties to list. We’ve assessed a dozen or so product lines both closed and open cell for manufactures, builders, homeowners, and applicators. The properties ranged from universities, community centers, offices, homes, both new construction and retrofit applications.


In my experience, Spray Foam Insulation investigations can be categorized in three distinct categories. The first two seem to be the primary areas of Spray Foam Insulation investigations. The first category is simply misapplied Spray Foam Insulation, the second is presence of pre-existing or recently introduced contaminants and the third would be occupant exposure and sensitization during Spray Foam Insulation application.

The 1st Category – Misapplied SPF

These nuisance odors are directly associated with incorrectly applied SPFI and can be addressed by either correcting the areas of misapplied foam or by removing and re-insulating the areas. Misapplied includes improper ventilation during the application, incomplete application, off ratio application, and also includes the Spray Foam Insulation in direct contact with recessed can lights in the attic, keyless light fixtures bulbs, dryer vents, and/or chimney flues, all of which can heat the Spray Foam Insulation and cause a tremendous amount of chemical odors.


Category 1 is relatively cut and dry and requires the onsite inspection of the Spray Foam Insulation and the collection of no air samples.  The inspection of the foam and the determination of correct and complete installation is a critical first step.

The 2nd Category - Pre-existing Contributors

This category cannot be stressed enough to the professionals that are investigating SPF.  This category is extensive and can include some rather odd contributors to occupant discomfort and nuisance odors that become much more concentrated when the SPFI is installed.   These include the HVAC system, air exchange rate, storage of materials in the now sealed attic space, insect and or rodent activity, routine pest control applications, the previous insulation condition and material, proper ducting of kitchen and bath fans.  The possibilities are endless and all must be considered.  Remember, what has accumulated in the attic is now conditioned air that is shared between the attic and living space of the home.

For example, if the home is a 60 year old ranch that had open cell SPF installed at the roof sheathing and the attic was not cleaned to help save a few bucks, the bath fans are ducted to the attic space, and the home once had a rodent issue that was treated with pesticides.  Well, to say the least you have a huge list of contributors to occupant discomfort and nuisance odors.  Most of the SPF insulation investigations I we're called in to review, all of these issues were overlooked simply because of the recent application of SPF.  


It’s not necessarily the SPF insulation that is producing the odor or contaminate that is causing occupant discomfort, but the SPF insulation eliminating the natural ventilation of the attic which prevented the odors and contaminants from entering the home.  The SPF insulation has now trapped the odors and contaminants within the semi-conditioned space.  In most cases, the home wont be meeting the minimum ventilation rate.  The now tightly sealed home will need outdoor air to meet the minimum ventilation rate and prevent the home from accumulating VOC’s from daily use products and activities.


This is a huge aspect of an SPF insulation investigation that I find all too often overlooked. As a professional investigating SPF insulation, you have to ask questions beyond the obvious, who was the demon SPF insulation manufacturer. 


You have to ask relevant questions such as;

  • “What is the condition of the new semi-conditioned space?”
  • “What have the occupants been sealed in with?”
  • “How is the air exchange rate being met?”
  • “How is the sealed attic space actually being conditioned and circulated?”

The 3rd Category – Sensitization Due to Exposure

This category includes all occupants who have become sensitized or allergic to the odors given off from Spray Foam Insulation. With sensitization, occupants have either re-entered the property shortly after the Spray Foam Insulation is applied, well before the manufacturer recommended re-occupancy time of 24 to 48 hours while the Spray Foam Insulation is still curing and off-gassing, or in the most severe cases of occupant sensitivity the exposure was actually took place during the application of the Spray Foam Insulation.


Sensitization of the occupants can be a result of many issues such as occupants that don’t want to spend the money for a hotel stay, early re-entry or occupancy, the curious application observer like the builder above.  However, occupant sensitization can also be the result of the lack of proper ventilation during the application. 


Venting the off-gassing of the SPF insulation during application is critical and often not conducted at all. In all cases of occupant sensitization that I have been involved with, the SPF insulation application was not properly vented to the exterior which created a substantial accumulation of the off-gassing chemicals within the property. These trapped volatile organic chemicals VOC’s are what sensitizes the occupants who have either re-occupied too early or were present during the SPFI application


Homes that have improper ventilation during the application process of the SPF insulation are also included in the misapplied category and almost always have identified areas of misapplied SPF insulation (SPFI).

This category is unique in that any attempt at reducing the occupant’s exposure to the SPF insulation that they are now sensitized to may not be of any relief.  I have had no luck in providing sensitized occupants relief from the home they are now sensitive to.  I have been involved in everything from the introduction of outdoor air through a pre-filter and dehumidifier to control the temperature, humidity, particles, path, and pressure to full removal of the SPF insulation. Unfortunately that bell can’t be un-rung.


Sensitization occurs when the occupants are overexposed to the trapped volatile organic chemicals VOC’s and become sensitized. From that point on, any exposure to even a minute amount of the chemical causes a reaction. The process of sensitization can make a home unlivable for people who become sensitized.


Homes that have improper ventilation during the application process of the SPF insulation are also included in the misapplied category and almost always have identified areas of misapplied SPF insulation (SPFI).


This category is unique in that any attempt at reducing the occupant’s exposure to the SPF insulation that they are now sensitized to may not be of any relief.  I have had no luck in providing sensitized occupants relief from the home they are now sensitive to.  I have been involved in everything from the introduction of outdoor air through a pre-filter and dehumidifier to control the temperature, humidity, particles, path, and pressure to full removal of the SPF insulation. Unfortunately that bell can’t be un-rung.