With the shuttle style configuration where components are stacked side-by-side, there will always be a risk that debris coming off one component could impact another. Even if you totally eliminate the foam insulation problem, there would still be lots of matter being shed. For instance, ice buildup on the fuel tank.
After the Apollo missions, NASA and the USA were at a crossroads and lacked direction. Since the cost of the booster rockets was considered a total waste, the concept of a totally reusable space transportation system appeared desirable. So was born the shuttle and the STS. The original ideas were simple and realistic. But the end result became an engineers nightmare, because it was designed by a committee.
Eventually the shuttle was built and flown into space. But it was built to service missions, to deliver people and/or cargo into space. But sadly, since the shuttle ate into NASA's budget so much, it became the mission. The shuttle was supposed to be the delivery truck, and just that alone. But instead, it morphed into the entire parade.
So what came of this was a transportation system without a clearly defined mission, such as Apollo's going to the moon. So NASA reinvented the shuttle and it was used in all kinds of missions, even some as public relations work. Only when a space station was decided on did the shuttle finally have a mission it could do.
But previous accidents have really changed NASA. In a lot of ways, for the better since safety is now taken seriously by all levels of management. For the worse because NASA is unwilling to take risks that could further erode public confidence (spelled money). The new hardware coming out is fundamentally the same as from the Apollo era. Heck, they are even using the same heat shield material as Apollo.
It all comes back to the political environment in the USA. For the lawmakers to approve money for a NASA budget requirement, it has to be appealing to the public. But for a public easily distracted by MTV, reality shows and youtube, it has to be something special. it has to entertain, be very interesting, and hold the public appeal for years.
Meanwhile the Russians built a reliable rocket to get into space, and have only refined the basic design. It isn't fancy, it doesn't do tricks, all it does is deliver people or cargo into space.
This is the real situation. The USA is retiring the shuttle and it will be a few years before they have the ability to laiunch man into space. Meanwhile the Russians will continue launching into space, continuing an unbroken sage of manned spaceflight that began with Gagarin. They and others will continue the exploration of space, and along with others reach the moon and Mars long before the USA.