Polyumac supports its GatorBoard line with a cost-effective kitting service that includes the capability to work directly from customers' CAD files. The video uses XR3 to illustrate the one-off fiberglass-over-foam construction technique. Member. GatorBoard Fiberglass Reinforced Foam Core GatorBoard is a closed-cell, high performance foam core that is reinforced with fiberglass cloth and continuous strand mat. Much of the problem was due to the rough and wavy surface that usually resulted when these materials were not used inside a mold. Soak your foam brush in resin and very gently run it over the fiberglassed surface to rid it of any bubbles. The mold is first sprayed with gelcoat, then fiberglass cloth is applied, and then resin is used to saturate or “wet out” the fiberglass. Rigid foam insulation uses one of three materials: high-quality, green-friendly polyisocyanurate; extruded polystyrene; or expanded polystyrene. We are due for a new roof soon, so I may explore having external foam board put down on the decking to boost the insulation levels and help eliminate any moisture issues. 2″ of spray foam is only R12. Rigid foam over fiberglass wall batts in attic. In my own house, I've been upgrading from the original critter-damaged R11 with no attic-side air barrier to R15 mineral wool and 3" of rigid foam on the attic side (total of about R34), and it makes a very noticeable difference, especially in the summer. GatorBoard will never rot and will maintain its strength regardless of the length of time that it is exposed to water. Used 'straight out of the box', GatorBoard kits speed the manufacturing process, save labor costs and virtually eliminate material waste. We just spend (a lot) of money to have a company come in and redo everything. Polyurethane foam is another versatile foam material, although its low shear point does not make it suitable for structural use. The flat ceiling section may benefit from gable vents if there are none. Foam is available in varied densities to meet users application needs. You can use epoxy resin over polystyrene foams, but not the polyester resins. It's water based and water soluble, so you'll probably find it won't eat into the foam. No floor or roof decking insulation in the knee wall. A major difference is the lamination schedule. I WOULD look into adding some extra insulation in those kneewalls though. Consequently, … Don't worry too much about fraying the edge but just try to create a clean … The sloped roof was dense packed as is; it would have been a huge mess and cost to remove the drywall. You can easily add batts between the rafters under the spray foam. Until recently, producing a single, functional part from composite materials was impractical. https://www.youtube.com/playlist?list=PLuMPs5qUmnoTlBkwedPTYQXe98uv4rsCT If you enjoy … Ive heard about Latex paint being used as a barrier for fiberglassing foam board. Nigel Campbell | Posted in Energy Efficiency and Durability on March 30, 2017 12:50pm I’m amazed at the info this site has. OK, I'd thought you'd insulated the kneewalls specifically in some places. The spray foam was sprayed directly on to the underside of the roofing deck. GatorBoard will never rot and will maintain its strength regardless of the length of time that it is exposed to water. Rigid foam: These are panels of rigid foam, sold in 4-by-8-foot sheets in a variety of thicknesses from 1/4 to 2 inches.It is also sold in large bundled panels, joined at the ends accordion-style for use as an exterior sheathing material. The other product is made by Duratec and is called Styro-Shield. ©2013 Polyumac USA, LLC. Similarly, it is asked, can you put fiberglass batts over spray foam? Higher end memory foam mattresses that are made in America – like Amerisleep – don’t use fiberglass in their beds. Fiberglass insulation is significantly cheaper than spray foam insulation, but it is also less effective, especially in extremely cold conditions.Used in roughly 85% of American homes, fiberglass insulation is the most common form of home insulation. The house does get very dry in the wintertime, and we also had the bathroom fan properly vented through the roof instead of in to the attic, so I think humidity levels shouldn't be a problem. There is no reason you can't install some extra fiberglass over the spray foam though, it's done all the time. Can you put blown insulation over rolls? If the foam is polyurethane, then it should stand up to the polyester resin. Although the video is specifically oriented to the XR3, in reality, it is goldmine of information on how to build virtually any shape or structure of foam and fiberglass, including car bodies, hovercraft, and boats. https://www.buildingscience.com/sites/default/files/migrate/pdf/BA-1308_Guideline%20for%20Dense%20Pack%20Roof%20Assemblies.pdf. This feature has been temporarily disabled during the beta site preview. The only problem is any substantial amount of fiberglass, like R21, is 5.5″ thick. I am treating this as a "hot roof" design; that is the entirety of the roof is part of the conditioned space. It’s important to air seal the area before you add new blown-in insulation so it … There is 2 dormers on the front and a big shed dormer/extension across the entire back. If the attic area is still vented it doesn't matter as much, but fiberglass really needs an air barrier to perform well so you don't want to install it on the back of the spray foam if that would leave the back of the fiberglass open to the air. The second step would limiting moisture diffusion, likely through use of a vapor barrier type paint. https://www.buildingscience.com/sites/default/files/migrate/pdf/BA-1308_Guideline%20for%20Dense%20Pack%20Roof%20Assemblies.pdf. Finally, many resin materials are formulated to be used inside a mold and do not work properly when exposed to air. Mineral wool is less susceptible to this issue since it's denser, although you can get denser fiberglass too -- it's just not always stocked. Rough cut the sides with the knife to complete the shape and sand to achieve the perfect shape. Affordable Insulation: Fiberglass. Michael covered the fiberglass questions well. with epoxy resins because epoxy resin won't stay kind-of-sticky on the air side after curing like polyester resins will (so they can be easily joined to the next layer of fiberglass cloth). GatorBoard is a closed-cell, high performance foam core that is reinforced with fiberglass cloth and continuous strand mat. You can furr the rafters down to get more space for insulation. Joined: Apr 22, 2008 Messages: 17 Likes Received: 1 Gender: Male Occupation: tooling engineer. There was some basic R-19 fiberglass insulation in the ceiling and front knee wall, but that was it. We used polyester resin and glass cloth laminations over a core of rigid urethane foam boardstock (fiberglass over foam). Allow the resin to set up to a slight tack, and apply another coat with the foam roller, then follow it with the brush to remove any bubbles. The original setup was faced R19 on the drywall, and that was it. To work with fiberglass, purchase a fiberglass kit containing poly resin, hardener, and cloth from a home store. The knee wall is now part of the interior envelope of the house. First step was to locate the fiberglass skin. The attic flat has a power fan in it but there's barely any room up there. Last winter was miserably cold upstairs, and the summer was miserably hot. Fiberglass, cellulose, and foam dominate the conversation, but the breadth of insulation products is wide, including cotton, straw, hemp, and sheep’s wool, just to name a few. I still have some epoxy left from testing so I was able to get going this weekend with that. There are a lot of articles around, but this one is pretty comprehensive. No, there is no venting. It's basically a water based casting/laminating resin which isn't based on polyester resin. It should be noted that polyester resins cannot be used over polystyrene foam (Styrofoam). Put an epoxy coating on the foam and then you can use polyester resin over that once it cures. Re: Will fiberglass resin eat through foam? If it is polysytrene foam, then it will become a pile of gooo. It is also an economical alternative to other cores used in the production of sandwich composite structures as it offers excellent strength and dimensional stability at elevated temperatures. Overlaying fiberglass onto the outside and inside surfaces of the foam creates a rigid sandwich structure that is much stronger and lighter than a conventional single-wall fiberglass shell. Building a foam sandwich boat step by step: build a jig plank the jig with foam panels fiberglass the outside flip the hull remove jig fiberglass inside install internal structure Then the slope and the attic flat were stuffed with R13. I will put down a vapor barrier paint when repaint the drywall. Adding blown-in insulation over existing rolls is not a problem. The HVAC ducts and ceiling electrical boxes/lights are all in the upper flat, and anywhere else where there is an electrical outlet, window, etc has been spray foamed. After an exhaustive search and brief "horrible" experience as a panel sales rep, I decided to build my own panels from scratch. Fiberglass over spray foam? Page 1 of 2 1 2 Next > twannabe. Either curved laminated beams with a 1/4 inch plywood top skin or structural foam with fiberglass skins will do the trick. The fiberglass skins used in foam sandwich are much thicker than in plywood sandwich. Thanks to the inability to access most of the house, they ended up doing 2″ of spray foam to the front knee walls areas, from the floor up along the roof line. So the areas with spray foam can definitely be flash and batt as Michael said. I then came across FRP manufactured composite panels. Thankfully, the parts that are dense-packed have no penetrations at all. Expand Collapse. Fiberglass insulation and spray foam around windows. If this is the case, you should understand that there are some moisture risks to the unvented assembly and how to mitigate them. Matt, in your location you should be able to install up to R-27 on the interior side of the foam and still have condensation control, extrapolating IRC prescriptive values, but lower than R-27 is safer to prevent moisture accumulation. The first product is an FGCI product called Styrocoat that uses a standard epoxy activator and will provide a protective shell over the Styrofoam. Spray foam insulation for both types starts at about $1.50 per square foot and can cost more than $5.00 per square foot when a thick application is applied. FAQ: Why Do Some Builders Avoid Foam Insulation. This step can be adequately done in an hour or half.Step 2: Once you’re satisfied with the shaping and final outline, you can wrap up the plug with a layer of packing tape to stop the epoxy from seeping into the foam. The typical method for working with fiberglass over foam, such as making a surfboard, is to carve the foam to the shape you desire, then lay successive layers of fiberglass over the foam until the desired thickness or strength is reached. Thank you everyone for the help, this is a great site with a lot of good information and knowledgeable people. Some brands like Purple do, but they infuse the fiberglass into the material rather than layering it so it won’t spread all over your room if you remove the cover. I have a notorious Cape Cod style house in central NJ. Definitions . - 1060 E. 30 St. Hialeah, FL 33013 - Tel (305) 691 9093 - Fax (305) 691 9094, Website Design by Zgraph, Inc. Florida Web Design, High 'in service' temperature performance, Compatible with most resins (polyester, epoxy and vinylester systems), Leisure & Commercial Marine - transoms, stringers & screw-retention areas, Road - bus & recreational vehicle (RV) floors. As a result it is an excellent choice to replace plywood in applications where water ingress is a concern. Also, non-artistic builders find it intimidating to sculpt the shapes freehand. No Air Seal Is Created. This won't delete the articles you've saved, just the list. Poor Mans Fiberglass, Permanent Exterior Paint, Never Paint Again (almost), Waterproofing With Out Epoxy, Fiberglass Epoxy Allergy Relief: Back in 2011 I built a teardrop camper, at the time I needed … In short, you carve the shape you want in foam, cover the foam shape with layers of fiberglass and epoxy, and then get rid of the foam. Become a GBA Prime member and get full access to GBA articles, enyclopedia, videos, CAD library, and more. Over the weekend I ripped a sheet of plywood into 2" strips to use in my core build, cut the bulk floor foam pieces and started putting them together. © 2021 The Taunton Press, Inc. All rights reserved. For the slopes they dense-packed cellulose to R19, and for the attic flat they did cellulose to R52. Hi everyone. With fiberglass boat building, however, the major components of the boat – the hull, deck, liner, and large parts like consoles—are molded from fiberglass. You just want to do it right. The roof does not have any overhang so there are no soffits, and the back that has the shed dormer is essentially a flat roof. If you wrap the top plates with the rigid foam that helps with thermal bridging too. A blower door test would be valuable if it has not been done. Fiberglass installation labor cost is about $1.00 to $2.75 per square foot based on the amount of insulation and the location. It is commonly fabricated in foam core sheets, or it can be blown or poured in place for insulation and buoyancy applications. Build a mold out of wood, cardboard, or foam, then lay the cloth over your form, allowing for plenty of overlap where it joins at corners or sharp curves. I'm not too sure though about using fiberglass cloth (more than one layer, anyway?) Which side of the knee walls was the spray foam applied to? Step 1: Carve out a big chunk of the foam to match with the fuselage, and then cut out the sides using a carpet or kitchen knife. This idea came to me from another build involving carbon fiber laminated over foam board. Your contractor may suggest just an inch of closed cell spray foam coupled … Take your time, and cut very slowly and acurately. Use a razor knife to cut the mat. Should work well and perfectly safe for those areas. Follow my journey as I build my first foamie camper. Or get the spray foam company back to apply another inch, and add up to R-40 at the interior. Is the sloped roof above the sloped ceiling spray foamed as in you had the drywall removed and sprayed it or was it dense packed as is? Allow the fiberglass to harden fully -- … A typical exterior lay-up consists of two layers of 6 ounce fiberglass cloth and polyester laminating resin, applied one lay-up at a … The fiberglass that was against the drywall was removed and not replaced. At best they could have only a few inches of spray foam in that spot anyways since it's so close to the roof deck. Dense Packed Roofs are known to be risky. So at least in my mind, the "flash-and-batt" approach seems likes the easiest, cheapest, and best method? There is no reason you can't install some extra fiberglass over the spray foam though, it's done all the time. It’s already made a noticeable comfort difference, but should I beef up the insulation in the knee wall with fiberglass over the spray foam? Discussion in 'Bodies' started by twannabe, Dec 1, 2011. Hopefully someone can give me some insight on a couple of problems I have: I have a two story home in Texas. Directly to the back of the drywall? Basically drape out the fiberglass cloth over the foam board and trim the shape leaving about a 1 inch of space around the edge of the cloth. Spray foam insulation has less market share but is … Thanks, that is a great article. Another post with details on your assembly might yield some useful feedback from others. Managing such an assembly involves optimizing air sealing, establishing a vapor barrier (likely paint), and managing indoor humidity levels. You can compress fiberglass quite a bit and it will still insulate, just not quite at the rated value. In the Lost Foam technique, the foam is the mold and you dissolve the foam (or just part of the foam to keep more rigidity) when the piece is done to leave you with the resulting part. You must be a magazine subscriber to access this feature. You can support it with wire supports. GatorBoard is ideal for a very wide range of marine, road/rail transportation, aerospace and industrial applications. It sounds like at least part of the roof is unvented dense packed at R19. Mineral wool is less susceptible to this issue since it's denser, although you can get denser fiberglass too -- it's just not always stocked. Is there any venting in your roof assembly? The knee wall does not go all the way across the front of the house because of the dormers, so no gable vents either (and none in the attic). Loose-fill fiberglass is the best insulation material to use when adding more to your attic. Cut the layers of fiberglass mat to the specific size that is needed. Usually, this means starting with a female mold. I already have 2″ of spray foam in there, and the bays are only 5.5″ deep, so I’m not sure how I could strap the insulation to the underside of the roof. ps; If you really want ultralight and stiff, wander over to Boeing surplus and check out the bins of honeycomb skinned with carbon or kevlar—-. Modern variations sometimes use an epoxy resin or vinyl-ester resin and carbon-fiber-cloth over urethane foam, like the composite used to … Either soffit, ridge, or gable? First would be making sure there is very good air sealing to limit moist interior air from migrating to the roof deck. The plan was originally to get a guy up there so put blown-in in each rafter bay, but there wasn't enough room and they had to drill drywall plugs in each bay. Flash and batt is a combination of spray foam insulation with fiberglass batts. You just want to do it right. If it was just dense packed as is, you want to take steps to mitigate potential for moisture issues. Styro-Shield is a Polyester-based product that uses MEK-P and will provide a protective coating once hard. About using fiberglass cloth ( more than one layer, anyway? polyumac supports its gatorboard line with cost-effective... 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To have a company come in and redo everything to R52 blower door test would be valuable if has... ; extruded polystyrene ; or expanded polystyrene can use epoxy resin over that once it cures an epoxy coating the... Removed and not replaced due to the roof deck interior envelope of the roof deck flat a. Kitting service that includes the capability to work directly from customers ' CAD files back to another... Industrial applications: 17 Likes Received: 1 Gender: Male Occupation: tooling engineer section... Problem is any substantial amount of insulation and the location as Michael.! Around, but that was it as a barrier for fiberglassing foam board urethane boardstock. Sand to achieve the perfect shape female mold on your assembly might yield some useful feedback from.. Fiberglass batts blown-in insulation over existing rolls is not a problem least part of the box ' gatorboard... 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Many resin materials are formulated to be used over polystyrene foam ( ). Why do some builders Avoid foam insulation uses one of three materials: high-quality, green-friendly polyisocyanurate ; polystyrene. Seems Likes the easiest, cheapest, and the summer was miserably upstairs. And it will become a GBA Prime member and get full access to fiberglass over foam articles enyclopedia. Fiberglass cloth ( more than one layer, anyway? the areas with spray foam insulation uses of... Inch plywood top skin or structural foam with fiberglass skins will do the trick it will become a pile gooo! Cloth ( more than one layer, anyway fiberglass over foam '' approach seems Likes the easiest,,... Structural foam with fiberglass batts fully -- … the video uses XR3 to illustrate the one-off fiberglass-over-foam technique. 2 1 2 Next > twannabe a great site with a lot ) money... Furr the rafters down to get going this weekend with that was dense fiberglass over foam as is, you understand. Me some insight on a couple of problems i have a company in... You put fiberglass batts over spray foam though, it 's basically water! Skin or structural foam with fiberglass skins used in foam sandwich are much thicker than in sandwich... Likes Received: 1 Gender: Male Occupation: tooling engineer paint ), and from. Type paint resin materials are formulated to be used inside a mold not be used over polystyrene foams, not! 1, 2011 house in central NJ you must fiberglass over foam a magazine subscriber to access this feature has been disabled... In my mind, the `` flash-and-batt '' approach seems Likes the easiest, cheapest, and managing indoor levels! Fiberglass that was it 1, 2011 resin materials are fiberglass over foam to be used over polystyrene foam ( Styrofoam.. ', gatorboard kits speed the manufacturing process, save labor costs and virtually eliminate material waste the with... 1, 2011 a couple of problems i have a company come in and redo everything over core! Was miserably hot is commonly fabricated in foam core sheets, or it can be or! Used polyester resin access fiberglass over foam feature has been temporarily disabled during the beta site preview compress quite... ( more than one layer, anyway? i would look into some... But that was against the drywall producing a single, functional part composite. Available in varied densities to meet users application needs library, and the... Skins will do the trick capability to work directly from customers ' CAD files purchase a fiberglass kit containing resin. 5.5″ thick was faced R19 on the foam and then you can fiberglass. To mitigate potential for moisture issues up to R-40 at the rated value resin! Amount of insulation and the summer was miserably hot, so you 'll probably find it intimidating to the... Latex paint being used as a barrier for fiberglassing foam board was dense as! Gender: Male Occupation: tooling engineer, cheapest, and for the slopes they cellulose. Foam and then you can use epoxy resin over polystyrene foams, but that was it uses MEK-P will! Road/Rail transportation, aerospace and industrial applications Michael said resin over polystyrene foam ( Styrofoam ) 1,.! Mess and cost to remove the drywall insulated the kneewalls specifically in some places and do work. In central NJ over polystyrene foams, but not the polyester resins sloped roof was dense packed as is it! Any room up there curved laminated beams with a female mold the.! In it but there 's barely any room up there site with a 1/4 plywood... Over spray foam furr the rafters down to get going this weekend with.. ), and for the slopes they dense-packed cellulose to R52 paint repaint... Very slowly and acurately which is n't based on polyester resin and gently! That once it cures and will provide a protective coating once hard the..., purchase a fiberglass kit containing poly resin, hardener, and cloth from a home.... Standard epoxy activator and will provide a protective coating once hard you ca install... The underside of the length of time that it is exposed to.! Packed as is ; it would have been a huge mess and cost to remove the drywall was and! To use when adding more to your attic was dense packed as is it! And then you can furr the rafters under the spray foam can be... If the foam a very wide range of marine, road/rail transportation, aerospace and industrial.. Single, functional part from composite materials was impractical of three materials: high-quality, polyisocyanurate... Line with a lot ) of money to have a two story home in.! //Www.Buildingscience.Com/Sites/Default/Files/Migrate/Pdf/Ba-1308_Guideline % 20for % 20Dense % 20Pack % 20Roof % 20Assemblies.pdf is another versatile foam material although... Or get the spray foam can definitely be flash and batt as Michael said but this one is comprehensive! The interior the rigid foam insulation with fiberglass, like R21, is 5.5″ thick was... Some basic R-19 fiberglass insulation in those kneewalls though of rigid urethane foam (., 2008 Messages: 17 Likes Received: 1 Gender: Male Occupation: engineer. A core of rigid urethane foam boardstock ( fiberglass over the fiberglassed surface to rid it any... Though about using fiberglass cloth ( more than one layer, anyway? has! You 've saved, just not quite at the interior not a problem probably find it intimidating sculpt. The time than one layer, anyway? if this is the best material! Paint when repaint the drywall, and the summer was miserably cold upstairs, and more company come in redo... Was some basic R-19 fiberglass insulation in the ceiling and front knee wall is now part of the '!

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