Spray foam insulation might seem to be an affordable option, but it can create serious long-term issues. Over time, spray foam can trap moisture, corrode panels, and ruin your van’s cooling efficiency, thus reducing efficiency and shortening lifespan.
The Costly Shortcut:
Spray foams appear to be an efficient solution as these are:
- Widely available, and
- Cheaper than professional rigid panel systems
However, the initial savings often hide expensive long-term consequences. Over time, spray foam traps moisture behind the walls, leading to rust, mold, and hidden corrosion that only show up during resale or deep maintenance. By then, repairs can reach $4,000–$10,000 per van.
The Science behind Condensation
Refrigerated vans operate under constant thermal contrast, resulting in condensation within the wall cavities. Spray foam traps moisture, leading to corrosion, mold, and long-term structural decay. It stays trapped behind the panels, slowly soaking the metal. Over time, that trapped water leads to metal corrosion, panel rust, and insulation failure.
Condition | What Happens | Result |
Temperature fluctuation | Moisture forms behind insulation | Hidden condensation pockets |
Foam expansion | Uneven curing creates air bubbles | Gaps and weak bonding |
Road vibration | Foam pulls away from van walls | Reduced thermal efficiency |
Trapped humidity | No ventilation path | Rust, mold, and corrosion |
The Hidden Risks of Spray Foam in Reefer Vans
1. Condensation Traps
Your van moves, flexes, and vibrates daily. That movement causes tiny cracks in the foam, letting in humid air that can’t escape, leading to moisture buildup behind panels. This results in unseen corrosion and long-term damage.
2. It Can Bend Your Panels
Spray foam expands under significant pressure - sometimes exceeding 2,000 PSI, which can ruin your work van’s structural accuracy. This can result in twisted doors and misaligned panels, and costly rework.
3. Mold & Hygiene Concerns
Trapped moisture spreads fast, which is not just unsanitary but a compliance risk. It can affect certifications and contracts.
4. Lower Resale Value
Evidence of hidden rust, corrosion, or odor can reduce resale value by 20–25%, or worse, make the van unsellable.
A Smarter Solution: Reefervan Insulated Liner Kits
Built with rigid composite cargo insulation panels, these kits feature a 3-inch foam core and FRP (fiberglass reinforced plastic) surface, and deliver precise, durable, and hygienic performance. 3-inch insulated core and a fiberglass-reinforced plastic finish can easily handle the daily grind of refrigerated transport.
- CNC precision fit means no gaps and no guesswork
- Even insulation across every wall and ceiling
- No warping, no cracking
- Resistant to moisture, rust, and mold
- Simple to wash down, service, or upgrade
- Meets HACCP, FDA, and transport compliance standards
Factor | Reefervan Kits | Spray Foam |
Insulation Consistency | Uniform 3” thickness, high R-value | Thickness varies with manual application |
Installation Fit | CNC-cut for perfect fit | Hand-sprayed, can miss or overspray areas |
Van Body Impact | No pressure distortion | High PSI can warp van walls |
Hygiene & Cleanability | Seamless, food-safe, easy to clean | Uneven surface, hard to clean |
Durability & Moisture | Moisture-proof and corrosion-resistant | Can absorb moisture and degrade over time |
Retrofit & Maintenance | Modular panels easily replaced | Hard to repair once cured |
Weight Efficiency | Lightweight composite structure | Can add heavy, uneven weight |
Long-Term ROI | Lower maintenance, better resale | Higher repair costs, lower resale |
The Serious Impact of Mold Contamination in Reefer Vans
In refrigerated vans, black mold can spread fast through air ducts, insulation layers, and cargo zones. In many cases, it can result in a complete van interior teardown, requiring a full strip-out and rebuild to make things safe again.
Watch for These Early Signs:
- A musty smell every time the fridge unit runs
- Discolored or darkened areas near vents or corners
- Soft wall panels that feel damp or spongy
- Corroded fasteners or stains along interior joints and edges
Action Plan for Fleet Managers
1. Audit Existing Fleet Insulation
Identify the insulation materials used in each vehicle. A quick audit can prevent future surprises.
2. Inspect for Early Warning Signs
Check for musty smells, soft or damp walls, and rust spots around doors - these are early clues that moisture is trapped behind the liner.
3. Factor Insulation into Total Cost of Ownership (TCO)
Include insulation lifespan, repair expenses, and resale value when assessing the total cost of ownership.
4. Eliminate Spray Foam From Fleet Builds
If your vans carry food, flowers, or pharmaceuticals, spray foam is a no-go as it traps moisture and fails hygiene tests.
5. Maintain Clear Documentation
Keep detailed insulation specifications and installation records for warranty validation and resale assurance.
6. Schedule Regular Checkups
Schedule semi-annual inspections to catch moisture intrusion or mold before it spreads.
Invest in Smarter Insulation
While spray foam may appear cost-effective upfront, its long-term risks. Hidden moisture, mold, and metal warping can quietly eat away at your vans. It can cost you far more for rebuilds in the long run. In contrast, rigid insulated panel systems from Reefervan provide consistent insulation performance, hygienic compliance, and a longer service life. These provide cleaner interiors, better efficiency, and a lower lifetime cost for every van in your fleet.
Volition Components partners with builders, upfitters, and fleet managers to design durable, compliant, and high-efficiency refrigerated vans.
If you’re looking to safeguard your fleet investment, our team is here to help you transition to smarter, safer insulation solutions that perform mile after mile. We at Volition Components can help you make the smart insulation choice that keeps your fleet strong for years to come.