With superior air-sealing capability and manufacturer-claimed R-values as high as R-7 per in., spray polyure-thane foam insulation (SPFI) has become common in high-performing new and remodeled homes. So why isn't spray foam always the go-to insulation? Cost is certainly a factor-spray foam is more expensive than fiber insulation-but there's another side to the issue. An internet search reveals nightmare anecdotes about lingering odors, having to excavate badly installed foam, and health issues attributed to improperly applied foam. Some of my work as an engineer has been investigating such failures and testifying about them in court.
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