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5 big problems with spray foam insulation

Tom Gill
Written By
Maximilian Schwerdtfeger
Reviewed By
Updated on 24 April 2025
  • Getting spray foam insulation presents problems for homeowners
  • It can damage roofs, the environment, and impact health
  • While an effective insulator, it might be better to get a less damaging alternative
  • Spray foam insulation can last up to 80 years with the right maintenance

Spray foam insulation comes with numerous problems, the biggest of which are:

  • It’s not eco-friendly
  • It can damage your roof
  • It’s possibly bad for your health
  • It causes bad smells
  • It can create mould and mildew

It’s not particularly environmentally friendly, for example, and it can make it difficult (if not impossible) to remortgage your home (more on that later).

We’ve examined the 5 key problems with spray foam insulation and, more importantly, how to solve them.

If you’re ready to get spray foam insulation, just fill in this simple form to start. All you need to do is put in a few details about your home. We’ll connect you with our trusted suppliers, and they’ll get back to you with obligation-free quotes for you to compare.

What is spray foam insulation?

Spray foam insulation, also known as spray polyurethane foam, is a liquid insulation. You can get a professional to use spray foam to insulate your floors, loft, roof, or walls. After taking the appropriate safety measures, they’ll spray the substance – made of isocyanate and polyol resin – onto your chosen location, and it’ll expand to at least 30 times its size, forming a solid layer of insulation that looks like a cloud. Otto Bayer created polyurethane in 1937, and it quickly became a common material in all kinds of products, from car seats and baby mattresses to bungee cords. 20.5 million tonnes of polyurethane goods are now exported across the world per year, to the tune of £4.8 billion.

Even though spray foam insulation helps homes stop wasting energy (in turn, helping the environment), you can’t escape the fact that the majority of spray foam material insulation is just not eco-friendly.

In fact, it’s overwhelmingly made from nonsustainable materials, so it’s difficult to see it as the catchall solution for insulating our homes in the long run.

Older spray foam insulation is also a petroleum-based product, and as the world moves away from fossil fuels, it will inevitably become a thing of the past. However, more modern products are more sustainable (like recycled materials) and even bio-based options as an alternative. 

It isn’t just what spray foam is made from either – applying it has big environmental risks that are hard to ignore.

When you apply spray foam, you need to use a ‘blowing agent.’ These are commonly made from a mixture of hydrofluorocarbons, and therein lies the problem.

Hydrofluorocarbons have an incredibly high ‘Global Warming Potential’ (GWP). GWP is measured from a base level of 1, with carbon dioxide (CO2) from burning fuel defined as the start of the scale.

Methane (CH4) is well-known as being a good deal worse for the atmosphere than carbon dioxide. Its GWP level is 28, which means it is 28 times worse for the environment than carbon dioxide.

How bad are hydrofluorocarbons then? Really, really bad – hydrofluorocarbons have an astonishingly high GWP level of 3,400, which would make releasing just 1 kilogram of the stuff into the atmosphere the equivalent of releasing 3.4 tonnes of carbon dioxide.

It is important to note, however, that the spray foam insulation industry has been moving towards low-GWP alternatives, such as hydrofluoroolefins (HFOs), in recent years. These materials have significantly lower GWPs, often less than 1, making them more environmentally friendly.

Some older types of spray foam insulation also contain volatile organic compounds (VOCs), which can harm the environment and human health. This is primarily an issue during the application, as “set” spray foam releases very low to zero amounts.

From a recycling point of view, spray foam insulation is pretty dreadful because of how it clings to roofing materials. This makes recycling any parts of your roof (for example, during renovation or even a full roof replacement) very difficult.

Like other types of insulation, spray foam insulation can be installed in the attic or roof, under the floors, or in the walls.

When done correctly, spray foam insulation shouldn’t cause significant damage to your roof. However, if you’ve opted for “closed-cell” spray foam in your roof, you run certain risks.

Closed-cell foam is less porous than open-cell spray foam. This means that once it dissipates into your loft, the warmth will have nowhere to go. This might not sound like a problem, but the greater warmth has a hidden danger—expansion and contraction.

When things heat up, they expand, and subsequently, when they cool down, they contract. This process of expansion and contraction can damage roofs. Expansion and contraction cause gaps to appear in key parts of your roof, which decreases their structural integrity.

After a while of this process happening again and again, the likelihood of damage occurring increases.

Additionally, spray foam insulation can increase condensation in the winter, which can cause damage to untreated timbers. Damage to timbers can directly impact the structural integrity of your roof.

While other kinds of roof insulation, like fibreglass, can also cause similar issues, most other types of insulation don’t ‘stick’ to your roof the way spray foam does, making it harder to rectify once an issue is detected. For example, you can easily remove fibreglass insulation if you want, but spray foam insulation removal is difficult and potentially damaging.

One reason spray foam insulation can make your home difficult to mortgage (or remortgage) is the potential for damaging roofs. Of the 20 largest in the UK, TSB Bank, Skipton Building Society, Co-operative Bank, Principality, and equity release lender Aviva have publicly stated they will not lend if spray foam insulation is found in the roof space.

It is important to note, however, that most mortgage lenders do not have issues with spray foam insulation if installed correctly by certified professionals.

As the BBC reported, many (around one quarter, in fact) are reluctant due to concerns over poor fitting, which can lead to moisture buildup and roof timber decay. 

According to the Insulation Manufacturers Association (IMA), spray foam can be beneficial if properly installed. However, the IMA is concerned that homeowners could be needlessly driven to “cowboy” removal companies if mortgage companies refuse to provide finance because of these concerns. 

Property typeAverage property size (m²)*Average cost of 100mm-thick spray foam

House

97.5

£3,412.5

Bungalow

76.5

£2,677.5

Flat

41.5

£1,452.5

Maisonette

78.5

£2,747.5

Spray foam insulation is known to cause a few health issues, including: 

  • Asthma
  • Sensitisation
  • Lung damage
  • Other respiratory and breathing problems

There are chemicals found with some earlier spray foam types that contain carcinogenic properties (such as benzene), which can increase the chances of developing cancer. Some also contain toluene, which has been linked to neurological damage, and xylene, a substance that can irritate skin and eyes.

Additionally, the emissions released when applying spray foam can be damaging. We mentioned VOCs earlier, which react with chemicals in the air to form potentially dangerous compounds such as nitrogen dioxide.

This can lead to headaches and eye irritation if absorbed by someone over a long enough period. Again, however, it is important to note that most modern commercially available products must meet strict EU, UK, and US regulations, meaning they are highly unlikely to contain chemicals known to cause human health issues.d eye irritation if absorbed by someone over a long-enough period.

There’s a pretty unfortunate problem associated with spray foam insulation – bad smells, or more specifically, a fishy odour that seems to hang around for months after installation.

Whilst unpleasant, the issue is rare, especially if installed correctly by professionals. 

For those unlucky enough to suffer from this, the cause is usually the installer’s fault. If they’ve applied the spray foam either too thickly or too quickly, the reaction that causes the spray foam to expand properly is interrupted.

Applying it too quickly makes the exothermic reaction get too hot, meaning the next layer doesn’t react properly. When you apply it too thickly, the layer underneath cannot expand as it normally would, leaving gaps and causing the spray foam to react incorrectly again.

When the foam reacts in the wrong way, it gives off excess gas, which causes a nasty smell. Another reason for this is that the installer doesn’t use the correct mixture of chemicals.

This doesn’t automatically mean the installer is at fault because oftentimes, they just work with the chemical mix they’re given.

When you use closed-cell spray foam, you get a much tighter insulating seal, which keeps a lot more heat in than other forms of insulation.

The major potential downside of this is that, by keeping in so much warmth, you can create the perfect environment for mould and mildew to flourish.

Of course, mould and mildew are not guaranteed with spray foam insulation—in fact, they are more likely to appear with fibreglass and fabric insulation.

One thing to note is that there is a conflict of interest between businesses promoting spray foam insulation and businesses promoting alternatives. The former insist that spray foam insulation is great for preventing mould and mildew, and the latter usually stresses the opposite.

It is also important to note that while this is a potential problem, it can be overcome with adequate ventilation and moisture control in the impacted areas. This could include something as simple as trickle vents or more sophisticated mechanical ventilation systems. 

Simply put, the best way to avoid spray foam problems is not to install it in the first place, and instead choose superior, safer options that will cut your energy bills, such as normal loft insulation or cavity wall insulation.

Insulation is a great thing to do, and you should absolutely consider doing so as part of any effort to cut your bills and reduce carbon emissions.

For more information on what type to choose, read our insulation cost guide.

  • Spray foam insulation is effective at reducing energy waste, but its traditional petroleum-based composition and high-GWP blowing agents raise environmental concerns, although modern alternatives are improving sustainability.
  • Newer spray foams use low-GWP hydrofluoroolefins (HFOs) and meet stringent safety regulations, significantly reducing environmental and health risks compared to older products.
  • Improper installation of spray foam, particularly closed-cell types, can lead to roof damage from expansion and contraction, increased condensation, and difficulties with repairs or mortgages.
  • Health risks during installation, such as exposure to VOCs and off-gassing, can be mitigated by evacuating homes for 24 hours and ensuring professional application with modern, compliant materials.
  • Bad smells caused by improper chemical reactions during application highlight the importance of hiring skilled, certified installers to avoid costly and challenging fixes.
  • Proper ventilation and moisture control, along with thorough pre-installation assessments, can prevent mould, mildew, and structural issues, ensuring the long-term benefits of spray foam insulation.

Before considering installing spray foam insulation, it is important to note that the Homeowners Alliance (HOA) does not recommend installing spray foam until issues with lenders and rogue traders are resolved.

That being said, if you are considering insuring your home but are unsure about spray foam or any other product, fill out our simple webform to get an idea of which insulation will be best for your home. Enter a few short details about your home, and we’ll connect you with our expert installers.

They’ll get back to you with obligation-free quotes for you to compare.

Written by

Tom Gill

Tom has been writing for The Eco Experts for nearly five years an in that time, he has calculated the carbon footprint of the Roman Empire, profiled the world’s largest solar farms, and investigated what a 100% renewable UK would look like.

He has a particular interest in the global energy market and how it works, including the future of hydrogen, and Cornwall’s growing lithium industry.

Tom also regularly attends Grand Designs Live as a Green Living Expert, where he provides expert solar panel advice to members of the public.

He frequently focuses on niche environmental topics such as the nurdle problem, clever ways to undo the effects of climate change, and whether sand batteries could store enough energy for clean heating in the winter.

If there’s an environmental niche to be covered, it’s a safe bet Tom’s already thinking of how to write about it.

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Reviewed By

Maximilian Schwerdtfeger

Max joined The Eco Experts as content manager in February 2024. He has written about sustainability issues across numerous industries, including maritime, supply chain, finance, mining, and retail. He has also written extensively for consumer titles like City AM, The Morning Star, and The Daily Express.

In 2020, he covered in detail the International Maritime Organisation’s (IMO) legislation on sulphur emissions and its effects on the global container shipping market as online editor of Port Technology International.

He also explored the initiatives major container ports and terminals have launched in order to ship vital goods across the world without polluting the environment.

Since then, he has reported heavily on the impact made by environmental, social, and governance (ESG) practices on the supply chain of minerals, with a particular focus on rare earth mining in Africa.

As part of this, in 2022 Max visited mines and ports in Angola to hone in on the challenges being faced by one of the world’s biggest producers of rare earth minerals.

His most recent sustainability-related work came much closer to home, as he investigated the eco-challenges faced by independent retailers in the UK, specifically looking at how they can cut emissions and continue to thrive.

Max lives in South London and is an avid reader of books on modern history and ghost stories. He has also recently learned to play the game Mahjong and takes every opportunity to do so. He is also yet to find a sport he doesn’t enjoy watching.

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