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ARMORTHANE PROTECTING YOUR WORLD

PROTECTING YOUR WORLD

ARMORTHANE PROTECTING YOUR WORLD

spray foam
INSULATION

Faster, Stronger, Better – Spray
Polyurethane Foam Insulation
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35+

Years in Business

500+

Active Dealers

#1

Rated Coatings

50+

Countries Served

Max R-Value Per Inch
.0
Energy Savings
20 %
Year Lifespan
30 +
Air Seal Rate
80 %

Table of Contents

WHAT IS SPRAY FOAM INSULATION

Spray foam insulation is a polyurethane-based insulation material applied as a liquid that expands into a rigid foam, creating an airtight thermal barrier with R-values ranging from R-3.5 to R-7.0 per inch.

Spray foam insulation, sometimes just abbreviated SPF, is a highly effective insulation technology that uses sprayable polymer materials like polyurethane to insulate buildings and seal cracks and gaps. Spray foam insulation can be used for both new and existing structures, and can help save big on energy bills, easily covering the cost of installation in only a matter of months. It can also help reinforce structural elements, and serves as an effective solution for achieving quieter homes and offices. It’s the most effective insulation available on the market, and provides the strongest airtight seal for cozier, quieter days, whatever the season.

According to the U.S. Department of Energy, proper insulation is one of the most cost-effective ways to make a building more energy-efficient and comfortable.

SPRAY FOAM INSULATION

Insulation R-Value Comparison

R-Value Per Inch (Higher = Better Insulation)

Closed-Cell Spray Foam R-6.0 to R-7.0
Open-Cell Spray Foam R-3.5 to R-3.8
Fiberglass Batts R-2.9 to R-3.8
Cellulose (Blown-In) R-3.1 to R-3.8
Mineral Wool R-3.0 to R-3.3
Closed-Cell Spray Foam
Open-Cell Spray Foam
Fiberglass
Cellulose
Mineral Wool
Source: U.S. Department of Energy & International Energy Conservation Code (IECC)

why choose spray
foam insulation?

Spray foam insulation is the ultimate four-in-one insulation technology, serving first and foremost as a highly robust type of insulation. It’s far more effective at reducing unwanted heat transfer compared to traditional insulation materials like fiberglass or cellulose, possessing spray foam R-values of R-6.5 per inch or higher for closed-cell foams, which is more than double that of conventional alternatives that typically range from R-2.0 per inch to R-3.5 per inch. Secondly, spray foam insulation is also an effective sealant, condensing the traditional two-step process into one consolidated effort. Like its thermal insulation, spray foams are also sound insulating, greatly reducing unwanted noise at frequencies common in everyday life like in speaking or loud music. Lastly, spray foam insulation also offers structural reinforcement, strengthening insulated building elements to reduce the risk of weathering or damage. Altogether, this means that rain or shine, summer heat waves or record low winters, noisy neighbors or inhabitants, and and buildings insulated with polyurethane spray foam can enjoy better temperature control and more comfortable living and working environments year-round, anywhere in the world.

The Spray Polyurethane Foam Alliance (SPFA) recognizes spray foam as one of the most versatile and energy-efficient insulation systems available for both residential and commercial applications.
Spray foam insulation

Open-Cell vs. Closed-Cell Spray Foam

Click to compare the two types of spray foam insulation
Best-in-Class

R-Value Per Inch

R-6.0 - R-7.0

Thermal Resistance

The highest R-value of any insulation type, meaning superior thermal performance in thinner applications.

Moisture Barrier

Class II

Vapor Retarder

Acts as its own vapor barrier at 1.5 inches or greater, eliminating the need for separate moisture protection.

Structural Support

+300%

Racking Strength

Adds significant structural rigidity to walls and roofs, improving overall building strength.

Cost Per Board Foot

$1.00 - $2.50

Installed Price

Higher upfront cost offset by superior energy savings, moisture protection, and structural benefits.

Good Value

R-Value Per Inch

R-3.5 - R-3.8

Thermal Resistance

Comparable to fiberglass but with superior air sealing. Excellent for interior walls and attics.

Sound Dampening

Excellent

Noise Reduction

Open-cell structure absorbs sound waves, making it ideal for media rooms, bedrooms, and shared walls.

Expansion Rate

100x

Original Volume

Expands to 100 times its original volume, filling every gap, crack, and void in the building envelope.

Cost Per Board Foot

$0.50 - $1.50

Installed Price

More affordable option for budget-conscious projects while still providing excellent air sealing.

ArmorFoam polyurethane SPRAY FOAM INSULATION

ArmorFoam is ArmorThane’s own spray foam insulation formulation, composed of the same robust polyurethane technology that’s made us an industry leader for over 35 years. ArmorFoam has been engineered to outperform traditional alternatives and even other polyurethane-based spray foam technologies. It offers one of the highest R-values of any commercially available insulation material, while creating an airtight seal, reducing unwanted noise, and reinforcing structures to minimize the risk of structural damage and the effects of weathering. If you’re interested in learning more about ArmorFoam or any of ArmorThane’s products and services, please give us a call or contact us using our online contact form.
ArmorFoam polyurethane SPRAY FOAM INSULATION

ArmorFoam Performance Ratings

How ArmorFoam scores across the metrics that matter most
98%

Thermal Seal

95%

Air Sealing

97%

Durability

92%

Sound Block

96%

Structural

Insulation Cost Comparison

Compare spray foam against traditional insulation methods for a 2,000 sq ft home
Insulation Type Cost Range R-Value/Inch Lifespan Air Sealing Moisture Barrier
Closed-Cell Spray Foam Recommended $5,000 - $10,000 R-6.0 - R-7.0 Lifetime
Open-Cell Spray Foam $3,000 - $6,000 R-3.5 - R-3.8 Lifetime
Fiberglass Batts $1,500 - $3,000 R-2.9 - R-3.8 15-25 yrs
Blown-In Cellulose $1,800 - $3,500 R-3.1 - R-3.8 20-30 yrs
Mineral Wool $2,000 - $4,000 R-3.0 - R-3.3 30+ yrs
Rigid Foam Board $2,500 - $5,000 R-3.8 - R-6.5 50+ yrs
Spray Foam Insulation

FAQ FREQUENTLY ASKED QUESTIONS​​

Just as spray foam insulation minimizes unwanted heat transfer, it also functions to absorb and dissipate sound waves. It creates an airtight seal that eliminates any gaps that might otherwise transfer acoustic waves, particularly in the high- frequency regime. Spray foam insulation is also highly effective at controlling mid-range frequencies that represent the majority of common noise, including human voices and loud music.
Spray foam insulation offers the best insulating properties of anything on the market, making it perfect for almost any building. It also doubles as a robust sealant, while simultaneously providing structural reinforcement to treated building elements. Unless you have a project with very minimal insulation requirements, spray foam insulation is worth their additional cost for lasting and highly effective insulation.
Spray foam insulation can last up to an incredible 100 years. The exact duration depends on many factors, including application quality, type of spray foam insulation, location, space, moisture, and many more. To help ensure spray foam insulation lasts as long as possible, only qualified professionals should be responsible for its safe and effective installation.
While spray foam insulation offers superior thermal performance, there are some considerations. The upfront cost is higher than fiberglass or cellulose, typically ranging from $1.50 to $3.50 per square foot for open-cell and $2.00 to $5.00 for closed- cell foam. Professional installation is required because improper application can lead to issues like off-gassing or incomplete curing. During installation, isocyanate vapors require proper ventilation and protective equipment. Some homeowners also report difficulty with future renovations since cured spray foam is harder to remove than traditional insulation. Despite these factors, the long-term energy savings and superior air sealing typically offset the initial investment within a few years.
Open-cell and closed-cell are the two main types of spray polyurethane foam (SPF) insulation, and they differ in density, R- value, and application. Closed-cell spray foam has a higher density (approximately 2 lbs per cubic foot) and delivers R-values of R-6.0 to R-7.0 per inch. Its rigid structure also acts as a vapor barrier and adds structural strength to walls and roofs. Open-cell spray foam is lighter (about 0.5 lbs per cubic foot), expands more, and provides R-values of R-3.5 to R-4.0 per inch. It excels at sound dampening and is more cost-effective for interior applications. Closed-cell is ideal for exterior walls, roofing, and areas exposed to moisture, while open-cell works well in interior walls, attics, and soundproofing applications.
Spray foam insulation costs vary depending on the type and project scope. Open-cell spray foam typically costs between $0.50 and $1.50 per board foot installed, while closed-cell foam ranges from $1.00 to $2.50 per board foot. For an average 2,000-square-foot home, total insulation costs generally fall between $3,000 and $10,000, depending on the areas insulated and local labor rates. While the upfront cost is higher than fiberglass or cellulose insulation, spray foam delivers 20% to 40% energy savings annually, with most homeowners recouping the investment within 3 to 5 years through lower utility bills.
Spray foam insulation can significantly reduce the risk of frozen pipes by maintaining consistent temperatures around plumbing. Closed-cell spray foam, with its high R-value of R-6.0 to R-7.0 per inch, provides an effective thermal barrier when applied directly around pipes in exterior walls, crawl spaces, and unheated areas. Its air-sealing properties also prevent cold drafts from reaching pipe surfaces. While spray foam greatly reduces freezing risk, it is not a guarantee in extreme cold, and additional measures like heat tape may be recommended for pipes in severely exposed locations.

Yes, spray foam insulation is an excellent choice for insulating around HVAC ductwork. Applying closed-cell or open-cell
spray foam around ducts in unconditioned spaces like attics, basements, and crawl spaces helps prevent energy loss and
condensation. Spray foam creates a seamless air barrier that eliminates gaps and seams common with traditional duct wrap
or fiberglass insulation. This can improve overall HVAC system efficiency by 20% to 30%, reducing energy waste from poorly
insulated ducts. For best results, ensure ducts are properly sealed at joints before spray foam is applied by a qualified
installer.

Some mortgage lenders and surveyors have raised concerns about spray foam insulation in roof spaces, which can occasionally complicate home sales. The main issues include difficulty inspecting roof timbers beneath the foam, potential moisture trapping if improperly installed, and the challenge of removal if repairs are needed. However, these concerns primarily apply to poorly installed open-cell foam in roof decks. Professionally installed closed-cell spray foam with proper ventilation considerations rarely causes issues. To avoid complications, homeowners should keep installation documentation, use certified installers, and ensure the work meets current building codes and manufacturer specifications.

HDPE sheet liners are welded geomembranes used on large flat containment areas. They work well when a specialist crew can weld reliable seams and the geometry is simple. Polyurea is seamless, conforms to complex geometry, and installs faster on irregular terrain. For most industrial containment pads with tanks, piping, drains, and transition details, polyurea outperforms HDPE on both installation speed and long-term integrity.

Spray Foam Insulation Savings Calculator

Estimate your energy savings and ROI with spray foam insulation
-
Annual Savings
-
ROI Period
-
25-Year Savings
Estimated based on average energy savings of 20-40% with closed-cell spray foam insulation. Actual savings vary by home construction, HVAC efficiency, and local energy costs.

Get Your Detailed Savings Report

Enter your email to receive a personalized breakdown including recommended R-values for your climate zone, estimated installation costs, and available rebates in your area.

Check Your Inbox!

Your personalized spray foam insulation savings report is on its way. Want to speak with an insulation expert? Call us at 417.631.5090.

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The Complete Guide to Spray Foam Insulation

2026 Edition | 32 Pages

Free Download

The Homeowner's Guide to
Spray Foam Insulation

  • Open-cell vs. closed-cell: Which is right for your home
  • Complete cost breakdown by region and project size
  • R-value requirements by climate zone (with map)
  • How to vet and choose a qualified installer
  • Available federal and state rebates for 2026
  • Maintenance checklist to maximize insulation lifespan
  • 🔒 No spam, ever
  • ⚡ Instant delivery
  • ✓ 5,000+ downloads

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Business Opportunity

Start a Spray Foam Insulation
Business with ArmorThane

Join 500+ successful dealers worldwide. ArmorThane provides the training, equipment,
materials, and ongoing support to build a profitable spray foam business from day one.

$180K+

Avg. First Year Revenue

55%

Avg. Profit Margins

14%

Annual Market Growth

$3.2B

Market Size by 2030

Exclusive Territory Rights

Get protected territory rights so you can build your business without competition from other ArmorThane dealers in your area.

Complete Training Program

Comprehensive hands-on training covering spray foam application, safety protocols, equipment operation, and customer acquisition strategies.

Pro-Grade Equipment

Access ArmorThane professional spray foam equipment designed for maximum efficiency and reliability. Financing options available.

Ongoing Support & Marketing

Continuous technical support, marketing materials, lead generation, and a network of experienced dealers to help you succeed.

Spray Foam Insulation

Spray Foam Business Profit Calculator

See your earning potential as an ArmorThane dealer

$750,000
Annual Revenue
$300,000
Annual Profit
$25,000
Monthly Income
40%
Profit Margin

* Estimates based on industry averages. Actual results vary by market and operations.

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Spray Foam
Where Does Your Home Lose Heat?
Click each area to learn how spray foam insulation helps
100%
Heat Loss
Roof & Attic25%
Open-cell spray foam in attic spaces can reduce roof heat loss by up to 90%. R-38 to R-60 recommended for most climate zones.
Walls35%
Closed-cell spray foam in wall cavities provides R-6.0+ per inch with built-in air and moisture barrier. The biggest impact area.
Windows & Doors15%
Spray foam around window and door frames seals gaps that account for significant air infiltration.
Floors & Foundation10%
Spray foam on crawlspace ceilings and rim joists stops cold air infiltration from below the living space.
Air Leaks & Gaps15%
Spray foam expands to fill every crack and gap, eliminating air infiltration that traditional insulation misses entirely.

Spray foam insulation addresses 85% of home heat loss areas with a single application, making it the most comprehensive insulation solution available.

Tyler Gleckler - ArmorThane blast mitigation specialist author photo

ABOUT THE AUTHOR

TYLER GLECKLER

Tyler Gleckler is a coatings specialist with deep field expertise in polyurea, polyaspartic, and high-performance protective systems. His writing appears regularly in Polyurea Magazine, the American Polyurea Organization, ArmorThane’s technical library, and a range of industry publications. He focuses on translating laboratory chemistry into specifications that engineers, owners, and applicators can actually deploy.

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Mike from Texas just started his ArmorThane business
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Tyler Gleckler, Polymer Chemist
Tyler Gleckler — Polymer Chemist & Spray Foam Specialist
M.S. Applied Materials Chemistry | Expert in polyurethane foam formulation & SPF insulation systems | ArmorThane R&D
✓ Expert Review
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