How Spray Foam Can Hide (or Worsen) Property Losses

Spray foam insulation can be an effective air and moisture barrier in basements, wall cavities, crawlspaces, and attics. However, it’s actually possible for spray foam to be too effective, trapping moisture and hiding long-term damage from view. Policyholders may not notice water intrusion for months or years – long enough to compound losses on top of losses.

What is Spray Foam Insulation?

Spray foam is an insulation material formed as the result of a reaction that occurs as its chemical components are exposed to air. It’s typically made of polyurethane, but other insulation materials include cementitious, phenolic, polyisocyanurate, icynene, and tripolymer foams.

While there are several different chemical compositions of spray foam available, they are essentially categorized as either open cell or closed cell foam. Open cell spray foam is filled with air, which makes it light and pliable. When manufactured and installed correctly, it has a spongy texture. Closed cell foam, on the other hand, is filled with heavier gasses, making it denser and more rigid. Both kinds of foam can be applied to areas that are hard to reach or oddly shaped.

They are injected into open spaces to improve a structure’s energy efficiency by increasing the R-value – the resistance to heat flow – of the floors, walls, and roof. As it reacts to oxygen, the foam expands to fill the space and hardens in place. This is how foam insulation can keep a property cool during warm weather and protect pipes from freezing conditions once temperatures drop. Closed cell foam insulation has a higher R-value than the open cell varieties, so it is best suited to parts of a structure close to the exterior. It’s especially useful in flood-prone areas.

Spray foam can go into many kinds of spaces and expand to fit them, from large wall cavities to small openings.

How Does Spray Foam Work as a Moisture Barrier?

Closed cell spray foams provide resistance to more than just heat flow – they also serve as a moisture barrier. This means that moisture doesn’t get through the layer of spray foam to damage whatever is beyond it, whether that’s drywall, wood framing, or other building materials. On the one hand, the foam stops the moisture in its tracks, preventing further losses. However, in some cases this can also contribute to a larger failure.

Moisture migrates toward dry air where it can evaporate, and this is also true when a material like drywall stands between water in a wall cavity and the dryer interior air. Moisture will diffuse through the drywall and make its way to the other side where it can evaporate – though it will likely damage the drywall in the process.

A strong vapor barrier like closed cell spray foam insulation impedes this process, trapping the moisture where the intrusion started, preventing it from drying out, and encouraging water damage and fungal growth. Some parts of a home are more likely to cause this problem than others, depending on the structure’s location and climate. Each region and climate zone has its own rules and guidelines for adding or replacing insulation. Disregarding or misunderstanding the best installation practices for a region can cause long-term moisture problems.

Spray foam insulation hardens to create a solid air and moisture barrier, and it can be difficult to determine if water intrusion is occurring on the other side.

Closed cell foam is such an effective moisture barrier that it effectively hides water intrusion from view, potentially allowing significant damage to occur before the water intrusion can be detected. Open cell spray foam’s properties allow it to absorb and retain moisture. Under these circumstances, water intrusion may be left unchecked for months or even years before the property owner is any the wiser, creating the ideal environment for mold/fungal growth or wood rot, which can compromise the building’s structural integrity. Unfortunately, if a homeowner suspects they may have water intrusion, they may not be able to confirm or locate the source without removing sections of the wall and insulation to find it.

Open cell foam’s ability to absorb moisture may contribute to water-intrusion damage in spaces below ground level or in the roof, if the roof covering is not fully water tight. Roofs are designed to shed water from the roof’s surface and preventing water damage in the home. However, if the roof covering becomes compromised and allows water to intrude, spray foam may hide the signs of water intrusion, and it may go unnoticed for many months.

Dark stains on spray foam insulation may indicate water intrusion.

What Can Adjusters Do?

Generally, the only way to prevent losses related to spray foam insulation is to make sure it’s manufactured and installed properly. This means a policyholder or homebuilder should consult a reputable contractor, choosing the right insulation and installation practices for the climate. If policyholders perform regular maintenance and inspect all parts of their properties, they may notice these failures early enough to address them and prevent significant losses.

All of this is beyond the scope of an insurance adjuster, but there are some essential questions adjusters can ask when making decisions regarding claims that involve spray foam insulation and water intrusion:

• What is the source of the water intrusion?
• Is the damage recent, or has it been sustained over time?
• Was the spray foam insulation installed in the correct locations, composition, and thickness?
• Was a thorough analysis of the location and climate performed before construction/installation?
• When was the home last inspected?

If spray foam insulation may have contributed to a water loss, the adjuster should determine whether the spray foam was installed correctly.

Adjusters should move as quickly as possible to mitigate any water exposure or mold growth. Time is also of the essence in choosing an assessment partner, as drywall and other affected materials should not be removed before the property has been evaluated by a licensed professional engineer.

Donan’s licensed forensic engineers are equipped with the experience and expertise required to answer tough questions about property damage. Our nationwide team is prepared to investigate industrial, commercial, and residential properties from the attic to the foundations.

Submit an assignment to Donan to see how our quick cycle times, exceptional customer service, and consistent reports can help you settle claims accurately.

Alpine Intel’s content is meant to inform and educate readers using general terms and descriptions. They do not replace expert evaluations that determine facts and details related to each unique claim.