Why Is Spray Foam Insulation So Expensive?

“Fifty dollars, for that little thing? I don’t think so!”

As buyers, we want to understand the value of products. When we see a high price tag, we need a logical reason for such a high number. If there isn’t a reasonable connection between product and price, we can’t rationalize buying it.

Spray foam is one of the most expensive insulation products on the market. While it may be worth the price, it's hard to justify the cost when you don't know what factors create that price. You want to understand what contributes to the hefty price tag of spray foam, and we want you to know that, too.

South Central Services has given quotes for and installed spray foam in hundreds of homes. This article will share all of the factors, both big and small, that impact the cost of spray foam insulation. By the end of this article, you will know:

• Why spray foam is a premium product
• The rates of spray foam insulation to install
• Every factor that could impact your quote
• What price can tell you about contractor expertise

How Much Does Spray Foam Cost, Anyway?

When we say spray foam insulation is expensive, how costly do we mean?

At South Central Services, we charge the following rates for open and closed cell spray foam.

• Open cell spray foam insulation: $0.25 to $0.75 per board foot
• Closed cell spray foam insulation: $1.15 to $1.75 per board foot

At first glance, those prices might not seem that high. These are prices per board foot, not per square foot. After calculating the board feet of your project, spray foam insulation will seem much pricier.

Looking for a quick estimating tool? Check out our retrofit insulation page, where you can get a rough estimate of the lowest, average, and highest cost for projects like basements, attics, and crawl spaces.

Compared to other insulations, which may cost only $1 to $2 per square foot, spray foam insulation is more expensive. Spray foam's cost per square foot varies by project type and foam type.

For example, open cell in an exterior wall may cost between $2.25 and $3.38 per square foot. In an attic application, open cell may cost between $5.00 and $7.50 per square foot. This difference is due to the quantity of foam.

Why Is Spray Foam A Premium Product?

Spray foam is often described as a premium product. Let's break down three factors that contribute to this high-quality label.

1. Product Performance

Spray foam insulation is a premium product because of its high performance. Structures insulated with spray foam have lower energy bills, increased comfort, and improved air quality. While some insulation products can offer these benefits, they offer them at a lower performance rate.

Not only does spray foam have a high R-value, but it also offers air-sealing capabilities.

By creating an airtight seal in the thermal envelope of a building, spray foam insulation slows both conductive and convection heat transfer. Other insulations only prevent conductive heat transfer.

2. Manufacturing Costs

The manufacturing costs of spray foam insulation are higher than those of other insulation products. The raw chemical materials are more expensive than recycled cellulose or glass fibers.

Chemical processing facilities are more expensive to build and maintain, with stricter safety protocols and testing protocols. There are fewer safety and testing costs associated with plants creating fiberglass and cellulose insulation because these industries do not manufacture chemicals.

3. Equipment

Most insulation products are manufactured, purchased, and then installed. Spray foam is both a product and a service, as it is manufactured and installed simultaneously on-site. Manufacturing spray foam correctly requires precision and control, which starts in a spray foam rig. A spray foam rig is the truck or trailer that travels to job locations, containing all the materials and equipment necessary to safely apply foam.

Spray foam rigs are filled with expensive equipment which monitors temperature, pressure, and ratio. A quality spray foam rig can cost anywhere between $60,000 and $100,000 for a contractor to build.

What Factors Will Impact My Specific Quote?

Numerous factors can impact a quote from a spray foam contractor, including:

• Quantity of raw materials
• Type of foam
• Accessibility
• Safety requirements
• Man-hours
• Travel time
• Contractor expertise

Let’s examine these factors to better understand how and why they influence price.

Quantity Of Raw Materials

A common misconception is that spray foam contractors charge by the 55-gallon drum for insulation. Many believe opening a spray foam drum is like opening a 2-liter bottle of soda. Soda will go flat, but spray foam components do not lose quality when opened or used. You will only be charged for a full drum if a project requires one.

How do contractors measure how many drums a project requires? Contractors calculate the liquid chemicals needed to create foam for a project's board feet.

A board foot is the measurement insulation contractors use for pricing. A board foot is 1 foot by 1 foot by 1-inch thickness. The square footage of the space being sprayed is multiplied by the depth it has to be sprayed.

Again, our rates are per board foot.

• Closed cell: $1.15 to $1.75 per board foot
• Open cell: $0.25 to $0.75 per board foot

Type Of Foam

You likely noticed the rates of open cell and closed cell spray foam are different. The difference in cost is primarily because of density. Open cell spray foam is less dense than closed cell spray foam. A 55-gallon drum of open cell will go farther than one of closed cell.

Your quote amount may be higher or lower, depending on whether your contractor recommends open or closed cell foam. The type of foam that will work best hinges on the application and the project details.

Generally speaking, open cell foam can be installed in above-grade places. These are locations above the ground like exterior walls, pole barns, garages, and roofs. Closed cell foam can be installed anywhere that open cell foam can be installed.

Closed cell spray foam is the only spray foam installed below-grade. Below-grade applications are any applications that are below ground level. Generally, below-grade includes basements and crawl spaces.

Accessibility

Have you ever been in a building that needed a giant ladder to change a lightbulb? Or, have you ever seen an entrance to a space so small that you weren't sure you could fit through the doorway?

Any structure that has accessibility issues can incur additional costs. Having to install scaffolding or provide man lifts costs time and money. Not only are there man-hours to set up these accommodations, but working with the accommodations can also slow down the work.

Safety Requirements

Some projects have safety requirements or building codes that require additional specialized equipment and impact the time it takes to do the job. Safety requirements are associated with more complex or commercial jobs. If your project is residential, this factor likely will not apply to your quote.

Man-Hours

Some spray foam quotes may break down labor cost, while others do not list man-hours. Contractors must consider this factor, whether a quote references man-hours or not.

Travel Time

Travel time is a factor that will vary by location and market.

For example, let's say you live in an area with several contractors within reasonable driving distance. These contractors may not include travel time in their quotes.

However, if the closest contractor to you is someone over four hours away, travel time may become a factor in their quote.

Contractor Expertise

Expertise is a factor in the cost of spray foam. However, it is not as simple as saying the highest quote means the most expertise. Higher quotes may come from contractors with more expertise. However, it is not a rule that the highest quote equals the greatest expertise.

You cannot choose a contractor solely based on price. It is vital to work with a company and contractor you trust, regardless of their quote amount.

The Bottom Line About Why Spray Foam Insulation Is So Expensive

Many factors contribute to the price of spray foam insulation. Not only is spray foam a premium product with higher manufacturing costs, but the details of every installation can impact the final price. Whether your project is a straightforward installation or a more complex job, you must work with a contractor who will deliver a high-quality finished product.

Now that you know why spray foam insulation is so expensive, you need to choose your next step.

• Calculate an estimate of spray foam for your project
• Determine if spray foam is worth investing in for your current home
• Learn how to save money on spray foam using a federal tax credit