Feb 3, 2025
Phillip Scearce of Florida was looking for ways to make his home safer and more energy efficient. He had spray foam insulation installed by American Residential Products, and it was great for several years. But recently, he's been plagued with a foul-smelling odor and worries about his and his wife's health.
“You could walk in the clothes closet and it was, like, thick. I mean, it was definitely a gas. It was strong.” Scearce told reporters with Boston 25 News. The culprit? A flawed installation process left his spray foam insulation uneven and odorous.
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"I think it’s an excellent product," said John Lapotaire, a building envelope and indoor environmental consultant who has inspected homes with spray foam insulation across the country. He believes the insulation is effective, but warns that improper installation or exposure during application can make people sick.
“And that bell can’t be unrung. They’re going to be sick, probably forever. Nobody really knows,” he told Boston 25 News.
What caused the intense smell?
The nightmare started when a strong, fishy odor started seeping through Scearce's home, making even his clothing closet unbearable. A professional inspection revealed that instead of the closed-cell spray foam he had paid for — known for its dense, moisture-resistant properties — his attic was lined with a mixture of cheaper open-cell foam covered with a thin layer of closed-cell foam. This caused the insulation to off-gas improperly, creating an overpowering stench.
Lapotaire explained that spray foam insulation must be carefully mixed and installed under specific conditions.
"If you get somebody that is more concerned with selling the foam and getting in and out, and not protecting the home while they’re installing, then yes, it could be your biggest nightmare," he said.
Another issue is ventilation. Even when installed correctly, spray foam can create a nearly airtight seal. However, if a home’s HVAC system isn’t upgraded to account for reduced airflow, indoor pollutants — including lingering fumes from the foam — can become trapped inside.
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To make matters worse, removing spray foam can be costly. Unlike fiberglass or cellulose insulation, spray foam adheres tightly to surfaces, meaning complete removal often requires tearing out drywall, roofing materials or entire sections of a home’s structure.
In Phillip Scearce’s case, an inspection also found that “the foam exhibits an uncharacteristic odor.” After suing, Scearce reached a settlement with American Residential Products.
Scearce said, “I’d read the horror stories and I never thought, just like a lot of people, it would happen to me.”
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How to avoid similar issues with spray foam
While spray foam insulation can be a popular choice for improving energy efficiency, Scearce's situation serves as a warning: bad installation can cost you more money and maybe also your health. If you're considering spray foam insulation, here are some ways to protect yourself:
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Choose a good company and ask questions. Opt for an installation company that has a long history of positive reviews. Look for companies that are certified by the manufacturers to install the spray foam. Avoid contractors who push lower prices or a quick turnaround — competent installers follow strict protocols. Pay attention to the foam they install, and don't be afraid to ask questions.
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Don't stay home during installation. Make sure you have plans to be out of the house during installation. Spray foam installers wear safety gear during installation because the fumes can be dangerous, so take steps to protect yourself. There is an ‘off-gas’ period of up to 48 hours when the air quality in your home will be very poor. Most companies suggest staying out of the house for at least 24 hours, but it may be smart to plan for two nights away from home.
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Get your air quality checked after installation. Hire an independent inspector to test the air quality in your home a few days after installation. They'll be able to tell if the off-gassing period is over and whether the air in your home is safe to breathe. Consider using an indoor air purifier if you're still concerned.
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Assess your home's ventilation system. Spray foam insulation works by helping create an airtight seal, which is great for energy efficiency but can also lock in air pollutants. Have your heating, ventilation and air-conditioning (HVAC) system inspected to help ensure airborne contaminants — such as fumes from the foam, carbon monoxide, humidity and even mold spores and dust mites — aren’t being trapped in your home. Depending on your current system, you may need to install an air exchanger or add a whole-house dehumidifier.
Spray foam insulation can drastically improve a home's energy efficiency, but as Scearce's story shows, it can carry risks.
Doing your homework and making sure your HVAC system is compatible can make the difference between a comfortable home and a potentially dangerous one.
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Danielle is a personal finance writer based in Ohio. Her work has appeared in numerous publications including Motley Fool and Business Insider. She believes financial literacy key to helping people build a life they love.
