Spray foam insulation was a great breakthrough for the insulation industry, making it possible to insulate any number of things in a quicker, more efficient, and safer way. This type of insulation is made using different chemical compounds with polyurethane and urethane being the most common. In addition, spray on foam can be used for both residential and commercial purposes, a product available on a small scale such as a 12-ounce can, to a full application for larger spaces such as an attic.
We wanted to provide just a few of the thousands of applications for spray foam insulation to give you an idea of its incredible benefit. Although this type of insulation is an actual insulating material, it has many more uses. For instance, the foam could secure a pull knob that has loosened on a hollow core door, eliminate squeaky floors by filling gaps in floor joists, bond rocks for building an outdoor waterfall, and even fill open areas near the roof to keep critters out. Whether using the foam for soundproofing, padding, or insulation, it is an incredibly efficient product.
Polyurethane polymers were first discovered in 1937 in Germany by Otto Bayer. He was soon joined by David Eynon, together researching the integrity of the material and potential uses. However, things really took off when Eynon, the President of Mobay introduced the material to developers within the United States. Then, after some persuasion, the technology to develop and produce polymer was complete. However, it would take until 1953 for Walter Baughman of Blendometer to create polyurethane foam. Initially, the primary use was for the furniture industry but the earlier formula dried so hard it was near impossible to use.
Over time, the formula for spray foam insulation was modified. Today, the foam has a spongy feel when first applied, which then hardens to an appropriate level when dry. Another interesting fact is that the foam comes in two specific types – open cell and closed cell, depending on the chemical composition used. Open cell polyurethane is more formally known as “Flexible Polyurethane Foam” or FPF, which allows air and moisture to move through the tiny spaces of the cells. Applications would include padding, soundproofing, and loose insulation like that used for attics.
The second type is closed cell polyurethane, which is also referred to as “Sprayed Polyurethane Foam” or SPF. In this case, the foam dries exceptionally fast after being sprayed at which time it literally becomes a solid material that is waterproof plastic. As the name “closed cell” implies, air and moisture cannot pass through the foam. Because of the characteristics for SPF, it is most commonly used around water, such as a water barrier for an ocean or lakefront home and for roofing.
Although both types of spray foam insulation are beneficial, closed cell is actually more advantageous due to the higher R-value. This means the strength of the foam is greater than what the open cell offers and it is more resistant to water vapor and air leakage. However, closed cell foam does have one disadvantage. Because this material is denser than the open cell, more material is required for application, which means it cost more.
One note – as you shop around, the terms “urethane” and “polyurethane” are often interchanged. Although there are differences from a chemical compound standpoint, for spray foam insulation they work much the same. Therefore, do not be alarmed when seeing different brands using one or even both of these terms. The bottom line is that spray foam insulation is truly one of the most incredible discoveries of modern time. With such diversity, it can be used for small home DIY projects to major commercial construction projects with the same great results.