Fixing Foam Post-Occupancy
In occupied or late-stage construction, most wall-foam repairs stem from post-install trade activity such as cuts, penetrations, box moves, and retrofits. Emergency replacement/repair work represents 49% of improvement project spending by homeowners, and often reveals or creates penetrations that need to be air-sealed. This leaves insulation contractors who are called back to the home with the predicament of either sending back in the entire spray foam rig (expensive), using a 2-component spray foam kit (often leaving behind wasted material) or just suggesting that the homeowner patch the drywall and move on (thus leaving an air penetration).
This article will show that a reusable, one-component foam like Thermospray converts those damage events into same-day micro-repairs, reducing callbacks, cycle time, and air-leak paths without mobilizing an entire insulation rig.
Common Damage Types (where foam needs to be fixed)
New/Oversized Penetrations
There are several common repair project or additions where some new penetration is made in the wall and the homeowner is left trying to fix the spray foam. Consider the below statistics:
- In 2024, 45% of kitchen projects changed the layout and 39% modified walls – which forced supply/drain rerouting.
- In 2024, 38% of bathroom projects changed the layout, resulting in fixture and line relocations.
- In kitchens, 43% of renovators reported changing kitchen systems (electrical/plumbing/HVAC) – where piping gets moved.
- 59% of renovating homeowners said they added a ventilation fan, in the 2024 U.S. Houzz Bathroom trends study. This would result in a penetration in the bathroom ceiling that now needs to be insulated.
Wire Fishing & Device-Box Moves
Another common situation is where switches and lights are upgraded or moved:
- 29% of renovating homeowners report electrical system upgrades. In these cases, the spray foam needs to be scraped out so that the electrician can access the electrical lines.
- 94% of kitchen renovators upgrade lighting – thus requiring new switch locations.
Consider this image below of an light box being moved. In order to access the area around this light, the foam would have to be removed and then later replaced somehow:
Wall/Foundation Repairs
Wall and foundation-related repairs are also a common source of penetrations:
- Across 2019-2023, about 1 in 67 insured homeowners filed a water damage or freezing claim annually (this is the second most common cause after wind/hail). Such damage can result in increased humidity, mold, mildew, and hairline cracks in the home’s walls and foundation.
- Roofing/windows/doors/HVAC repairs (typically moisture/envelope fixes) – accounted for 49% of improvement spending 2023.
Consider the below example. This reddit user had a crack in their foundation and therefore had to remove the spray foam insulation for it to be repaired:
Why Return Trips Kill Margin
It probably goes without saying that these small repair projects are not profitable for the typical insulation contractor. Sending back the entire spray foam rig for a small repair will erase the majority (or possibly the entirety) of the margin from that project.
Return Trip Cost
Consider the labor cost and rig mobilization/maintenance cost for any spray foam project ($50/hour + $1000 just to get the rig out and clean it). Now shrink that down to a small repair. With the lower board feet size, your ability to make any margin on the project is tiny at best. What kind of homeowner or builder is going to want to pay the thousands necessary to even execute such a project?
But What If You Use a 2k Foam Kit?
Traditional 2-component foam kits still have a board foot cost of $1.50 to $2.50 (not including labor hours). The issue is that for the smaller repair projects listed above (say, 315 square feet), you are left with some amount of unused spray foam material after the project is over. Most times with frozen hoses and guns, you end up just throwing that material away instead of being able to use it later. So a project that theoretically costs $750 ends up costing $1000 just for the material.
Check out the below case study in this video:
Consider Tytan Professional Thermospray for Post-Occupancy Foam Fixes
Insulation contractors should consider TYTAN Thermospray for post-occupancy foam fixes.
Speed to Seal
Instead of bringing out the entire spray foam rig or crew, a single representative from the insulation company can come out and repair the foam in just seconds:
Easy To Use
Any spray foam tech from your crew can handle the punch-list and later surprises using Thermospray.
Check out the below guide that shows how easy it is to use:
Air Barrier Continuity
Each cut typically creates air leakage for the homeowner. Thermospray can replace and/or repair 2-component spray foam without breaking the air barrier (learn more here).
Cost
At a board foot cost of only $0.90, Thermospray is less than half the cost per board foot of traditional spray foam. This allows insulation crews to efficiently handle small repair projects and call-backs without having to break out a 2-component kit or the entire spray foam rig.
Sources
“Improving America’s Housing 2025” – Harvard Joint Center for Housing Studies
“How to repair spray foam insulated wall” – Reddit
5 Major Kitchen Renovation Trends for 2024
2024 U.S. Houzz Bathroom Trends Study
Houzz: Most Households Proceeding With Remodeling, Survey Finds
How to Move a Wall Light – Megan Taylor
Water Damage Statistics – This Old House
