Guys my roof leaked a little and the open-cell spray foam (Icynene) appears to have degraded as a result. I need your expert advice to proceed in a smart way that won't cost a fortune. The foam was installed well and was flawless when I installed the XPS boards over it in Dec 11. It now appears to have * larger fist size holes, *foam layers with gaps in-between. apparently the spray was re-applied during installation and now one layer is coming off * in other areas when you push gently the foam deflects like 1/4" to 1/2" you can tell it detached from the roof deck * at other places some gaps between rafters and foam emerged The water damage didn't appear to be that bad. I was told the foam would disintegrate if the leak was "really bad" but we didn't reach that level. Questions 1. What do we do now? Take down those areas and replace? Patch? I was planning to cut into the foam and stick a 2" XPS board into the gap, seal with 'great stuff foam to seal' 2. Can we leave it as is or is it going to be a problem? 3. Can I take the entire section off between rafters and take 3x XPS 2" cut to fit and then seal around with 'great stuff' cans? If yes, how about I take all the spray foam down and use XPS boards between rafters? Would the air gap behind the XPS (between XPS and roof deck) be a problem? In hindsight I wish I had done that instead of the spray foam... Note it's an unvented metal roof, no ventilation gaps no ridge or soffit vents. Thank you for your suggestions!

what does the manufacturer say?

The foam being in layers gaps in-between seems like they screwed up the initial installation.

Losing bond in places with the wood isn't unusual if the wood got pretty saturated or if the wood was wet when installed, but it sticks pretty well to dry wood.

Open cell foam that's bonded well can take a lot of water and still resume it's prior R-value once it dries.