Spray Foam Insulation in Bunker Hill, IN

Cost is driven by foam chemistry (open-cell vs. closed-cell), total board footage, required thickness to meet target R-value, and site access conditions. Open-cell ranges from $0.50–0.65/board foot, typically applied at 3.5–5.5 inches to achieve R-13 through R-20. Closed-cell ranges from $1.15–1.35/board foot and reaches R-13 at just 2 inches of applied thickness. Residential projects generally fall between $1,500 and $4,000. Elite Spray Foam Kokomo provides itemized quotes broken out by material, labor, and prep based on your project specifications.

Elite Spray Foam Kokomo has completed insulation projects spanning metal buildings, pole barns, warehouses, manufacturing facilities, cold-storage environments, multi-unit residential, office retrofits, and ground-up commercial construction. We work from architectural specs and coordinate with GCs and project managers on sequencing, vapor profile requirements, and fire-rating compliance. Commercial and industrial envelopes typically present higher infiltration rates due to larger penetration counts and unsealed metal panel joints. Spray foam addresses both thermal performance and air barrier continuity in a single application.

A standard residential cavity (attic, crawl space, or rim joist) runs 4–6 hours including masking, multi-pass application, thickness verification with depth gauges, trimming, and cleanup. Whole-home projects typically complete in 1–2 days. Larger commercial applications with 5,000+ square feet of coverage may require 2–3 days to allow for proper lift scheduling and curing between passes. We provide a detailed project timeline based on measured square footage and target R-values.

All surfaces outside the spray zone are masked with 6-mil poly sheeting and blue painter's tape. HVAC registers, electrical panels, and finished surfaces are sealed off to prevent overspray contact. The two-component foam reaches tack-free cure within 8–10 seconds of leaving the gun, which limits aerosol drift. Excess material is trimmed flush to the stud face using a reciprocating saw with a foam-cutting blade. We perform a walkthrough inspection and full debris removal before clearing the site.

Open-cell (0.5 lb/ft3 density) delivers R-3.6 per inch and is vapor-open — typically 10–16 perms at 3.5 inches installed thickness. Suited for interior cavities where drying potential to the interior is desirable. Closed-cell (2.0 lb/ft3 density) delivers R-6.5 per inch, functions as a Class II vapor retarder below 1.5 inches and a vapor barrier above 2 inches, and contributes racking strength to framed walls. Material selection depends on the assembly's vapor profile, required R-value, structural loading, and moisture exposure. We specify based on the building science of each application.

All installations carry a workmanship guarantee covering application quality, adhesion, and specified thickness. The underlying material performance is indefinite. Spray polyurethane foam does not lose R-value over time because its cellular structure is dimensionally stable. It does not absorb moisture, support mold growth, or compress under its own weight the way fibrous insulation does. In practice, the foam outlasts every other building component it contacts.

Full slab replacement involves saw-cutting, demolition, haul-off, sub-grade compaction, formwork, a 4-inch minimum pour with fiber mesh or rebar, and a 7-day cure before full loading. That process runs $3,000–$8,000 for a typical driveway. Polyurethane foam injection achieves the same grade correction for $800–$3,000 with same-day load bearing. The injected material is closed-cell polyurethane with a compressive strength of 40+ psi. It will not erode, wash out, or deform under sustained load.

Any slab-on-grade that is structurally intact (no through-cracking, major spalling, or rebar corrosion) is a candidate. That includes driveways, sidewalks, garage slabs, patios, pool decks, porch slabs, and stoops. We drill 5/8-inch injection ports on a grid pattern, inject expanding polyurethane into sub-slab voids, and hydraulically raise the slab to target elevation. Settlement caused by soil washout, organic decomposition, or poor initial compaction all respond well to this method. Each slab is evaluated individually for structural soundness before we proceed.

We drill 5/8-inch injection ports at calculated intervals across the slab, insert the injection gun, and pump two-component high-density polyurethane beneath the concrete. The foam expands to fill sub-slab voids, displaces loose material, and generates hydraulic pressure that raises the slab. We monitor elevation in real time using a rotary laser level and adjust injection volume per port to control lift precision. The foam reaches 90% compressive strength within 15 minutes. Most residential jobs complete in 2–4 hours, and the surface is traffic-ready the same day.