Account for foam repairs in your estimate

Jan. 1, 2020
Make sure you thoroughly document and charge for all work done on foam.
Burrow estimates foam

Automotive engineers design vehicles in ways we may not understand. They have the knowledge and skills needed to determine how to build a vehicle and conform to various regulation, performance and marketing requirements.

For example, the deck lid trim panel on my car has exactly 14 clips attaching it. An engineer determined that 15 clips are too many and 12 or 13 clips are not enough. Reinstalling the trim panel, I put all 14 clips back in, exactly as designed, even though I don't know why 14 is the right number.

Trim clips, suspension bolts and lug nuts all have a specific type and number engineered for proper attachment of parts to the vehicle. When replacing parts, how many clips, bolts or nuts need to be re-installed to restore the vehicle's integrity and performance as designed? The answer is: all of them, even if we don't understand the engineering behind it. All of them also need to be installed properly.

Acoustic or structural foam inside of enclosed panels also has a specific type and amount engineered to meet certain requirements. Even if we don't understand why, that foam is there for a purpose. It may be needed for insulation, protection or structural reasons. If foam is damaged or removed during repair, all of it must be replaced with the same material and amount as designed. Automotive foam brings up several issues concerning the process, the estimate and its cost recovery with plenty of places for error.

During the initial damage inspection, can an estimator determine if there is foam, where it is, or what type it is? If a technician removes some foam, will it be replaced? When replaced, will the correct material and amount be used? Will the technician and shop be compensated for this operation?

During disassembly, the technician will discover any foam involved and remove it as needed. Note: A manager or estimator must be informed, specific information must be found and specific materials must be obtained and properly applied.

The estimate needs to reflect any foam applications done, however, the estimating systems do not have this information pre-stored. Audatex labor excludes "R&I of Injected/Structural foam" and states that body insulation (e.g. foams, pads) and sound deadener are not included. MOTORS (CCC) labor time does not include "sound insulate on paint inner areas" or "structural foam removal or application." Mitchell does not include labor for replacing sound deadening.

That means foam and body insulation materials with their labor must be estimated locally. Material costs won't be known until the correct product is purchased and the amount of that product needed is determined. Research with manufacturer body manuals, Web sites, or other repair information providers may be needed to find and document that information. Labor time involved can be estimated once the recommended procedures are known. Before the vehicle is delivered to the customer, not only does the process need to be done correctly, but the estimate must reflect this operation and associated costs. Communication is key here.

A foam application most likely will be discovered during repairs. Technicians must be aware of the importance of its replacement and communicate this. An estimator or manager must make sure the correct materials are purchased and recommended application procedures are done. The estimate must show this operation and recover the costs involved.

Automotive foam is there for a reason and must be replaced for the same reason. Technicians should be aware of what to look for and what to expect for replacing it. I-CAR's class (FOM01 Automotive Foams) is a good start. Communication processes or standard operating procedures should be in place to make sure this operation is performed when foam is encountered and that costs are recovered. Engineers determined this foam was necessary. We don't need to know why, just that it must be properly replaced.

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