Or get the spray foam company back to apply another inch, and add up to R-40 at the interior. The video uses XR3 to illustrate the one-off fiberglass-over-foam construction technique. First step was to locate the fiberglass skin. 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. Polyumac supports its GatorBoard line with a cost-effective kitting service that includes the capability to work directly from customers' CAD files. 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? Also, non-artistic builders find it intimidating to sculpt the shapes freehand. Should work well and perfectly safe for those areas. 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. Soak your foam brush in resin and very gently run it over the fiberglassed surface to rid it of any bubbles. Flash and batt is a combination of spray foam insulation with fiberglass batts. There are a lot of articles around, but this one is pretty comprehensive. Fiberglass installation labor cost is about $1.00 to $2.75 per square foot based on the amount of insulation and the location. A blower door test would be valuable if it has not been done. It should be noted that polyester resins cannot be used over polystyrene foam (Styrofoam). It sounds like at least part of the roof is unvented dense packed at R19. I'm not too sure though about using fiberglass cloth (more than one layer, anyway?) FAQ: Why Do Some Builders Avoid Foam Insulation. Fiberglass over spray foam? Expand Collapse. Page 1 of 2 1 2 Next > twannabe. 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? I still have some epoxy left from testing so I was able to get going this weekend with that. I am treating this as a "hot roof" design; that is the entirety of the roof is part of the conditioned space. Modern variations sometimes use an epoxy resin or vinyl-ester resin and carbon-fiber-cloth over urethane foam, like the composite used to … The first product is an FGCI product called Styrocoat that uses a standard epoxy activator and will provide a protective shell over the Styrofoam. For the slopes they dense-packed cellulose to R19, and for the attic flat they did cellulose to R52. Styro-Shield is a Polyester-based product that uses MEK-P and will provide a protective coating once hard. 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. No Air Seal Is Created. 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. Higher end memory foam mattresses that are made in America – like Amerisleep – don’t use fiberglass in their beds. GatorBoard is a closed-cell, high performance foam core that is reinforced with fiberglass cloth and continuous strand mat. Rigid foam over fiberglass wall batts in attic. Similarly, it is asked, can you put fiberglass batts over spray foam? GatorBoard is ideal for a very wide range of marine, road/rail transportation, aerospace and industrial applications. So the areas with spray foam can definitely be flash and batt as Michael said. GatorBoard Fiberglass Reinforced Foam Core GatorBoard is a closed-cell, high performance foam core that is reinforced with fiberglass cloth and continuous strand mat. 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. Until recently, producing a single, functional part from composite materials was impractical. 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. The sloped roof was dense packed as is; it would have been a huge mess and cost to remove the drywall. https://www.buildingscience.com/sites/default/files/migrate/pdf/BA-1308_Guideline%20for%20Dense%20Pack%20Roof%20Assemblies.pdf. 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. Much of the problem was due to the rough and wavy surface that usually resulted when these materials were not used inside a mold. 2″ of spray foam is only R12. The mold is first sprayed with gelcoat, then fiberglass cloth is applied, and then resin is used to saturate or “wet out” the fiberglass. Become a GBA Prime member and get full access to GBA articles, enyclopedia, videos, CAD library, and more. Definitions . No, there is no venting. Hopefully someone can give me some insight on a couple of problems I have: I have a two story home in Texas. If it is polysytrene foam, then it will become a pile of gooo. The fiberglass that was against the drywall was removed and not replaced. Finally, many resin materials are formulated to be used inside a mold and do not work properly when exposed to air. We used polyester resin and glass cloth laminations over a core of rigid urethane foam boardstock (fiberglass over foam). 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. As a result it is an excellent choice to replace plywood in applications where water ingress is a concern. 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). Follow my journey as I build my first foamie camper. Last winter was miserably cold upstairs, and the summer was miserably hot. Member. 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. Use a razor knife to cut the mat. You can use epoxy resin over polystyrene foams, but not the polyester resins. 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. Discussion in 'Bodies' started by twannabe, Dec 1, 2011. https://www.youtube.com/playlist?list=PLuMPs5qUmnoTlBkwedPTYQXe98uv4rsCT If you enjoy … 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. After an exhaustive search and brief "horrible" experience as a panel sales rep, I decided to build my own panels from scratch. 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. 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 Cut the layers of fiberglass mat to the specific size that is needed. 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). Loose-fill fiberglass is the best insulation material to use when adding more to your attic. You just want to do it right. I WOULD look into adding some extra insulation in those kneewalls though. Spray foam insulation has less market share but is … Polyurethane foam is another versatile foam material, although its low shear point does not make it suitable for structural use. Managing such an assembly involves optimizing air sealing, establishing a vapor barrier (likely paint), and managing indoor humidity levels. I have a notorious Cape Cod style house in central NJ. If it was just dense packed as is, you want to take steps to mitigate potential for moisture issues. Adding blown-in insulation over existing rolls is not a problem. The only problem is any substantial amount of fiberglass, like R21, is 5.5″ thick. Rigid foam insulation uses one of three materials: high-quality, green-friendly polyisocyanurate; extruded polystyrene; or expanded polystyrene. Directly to the back of the drywall? Your contractor may suggest just an inch of closed cell spray foam coupled … Used 'straight out of the box', GatorBoard kits speed the manufacturing process, save labor costs and virtually eliminate material waste. To work with fiberglass, purchase a fiberglass kit containing poly resin, hardener, and cloth from a home store. You must be a magazine subscriber to access this feature. Don't worry too much about fraying the edge but just try to create a clean … It's basically a water based casting/laminating resin which isn't based on polyester resin. 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. Which side of the knee walls was the spray foam applied to? This feature has been temporarily disabled during the beta site preview. The original setup was faced R19 on the drywall, and that was it. Either curved laminated beams with a 1/4 inch plywood top skin or structural foam with fiberglass skins will do the trick. This won't delete the articles you've saved, just the list. No floor or roof decking insulation in the knee wall. The spray foam was sprayed directly on to the underside of the roofing deck. 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. It is commonly fabricated in foam core sheets, or it can be blown or poured in place for insulation and buoyancy applications. 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. Thank you everyone for the help, this is a great site with a lot of good information and knowledgeable people. Ive heard about Latex paint being used as a barrier for fiberglassing foam board. 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. Consequently, … 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. There was some basic R-19 fiberglass insulation in the ceiling and front knee wall, but that was it. Re: Will fiberglass resin eat through foam? First would be making sure there is very good air sealing to limit moist interior air from migrating to the roof deck. Usually, this means starting with a female mold. So at least in my mind, the "flash-and-batt" approach seems likes the easiest, cheapest, and best method? You just want to do it right. Thankfully, the parts that are dense-packed have no penetrations at all. 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. Is there any venting in your roof assembly? 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 … The attic flat has a power fan in it but there's barely any room up there. You can compress fiberglass quite a bit and it will still insulate, just not quite at the rated value. GatorBoard will never rot and will maintain its strength regardless of the length of time that it is exposed to water. You can furr the rafters down to get more space for insulation. Michael covered the fiberglass questions well. 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. https://www.buildingscience.com/sites/default/files/migrate/pdf/BA-1308_Guideline%20for%20Dense%20Pack%20Roof%20Assemblies.pdf. 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. Then the slope and the attic flat were stuffed with R13. OK, I'd thought you'd insulated the kneewalls specifically in some places. There is no reason you can't install some extra fiberglass over the spray foam though, it's done all the time. The knee wall is now part of the interior envelope of the house. The other product is made by Duratec and is called Styro-Shield. The fiberglass skins used in foam sandwich are much thicker than in plywood sandwich. 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. 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. It's water based and water soluble, so you'll probably find it won't eat into the foam. This idea came to me from another build involving carbon fiber laminated over foam board. 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. Another post with details on your assembly might yield some useful feedback from others. There is no reason you can't install some extra fiberglass over the spray foam though, it's done all the time. Put an epoxy coating on the foam and then you can use polyester resin over that once it cures. A major difference is the lamination schedule. I then came across FRP manufactured composite panels. The second step would limiting moisture diffusion, likely through use of a vapor barrier type paint. 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. We just spend (a lot) of money to have a company come in and redo everything. Foam is available in varied densities to meet users application needs. 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. 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. Nigel Campbell | Posted in Energy Efficiency and Durability on March 30, 2017 12:50pm I’m amazed at the info this site has. 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 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. 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. There is 2 dormers on the front and a big shed dormer/extension across the entire back. Thanks, that is a great article. ©2013 Polyumac USA, LLC. I will put down a vapor barrier paint when repaint the drywall. If you wrap the top plates with the rigid foam that helps with thermal bridging too. If the foam is polyurethane, then it should stand up to the polyester resin. Can you put blown insulation over rolls? A typical exterior lay-up consists of two layers of 6 ounce fiberglass cloth and polyester laminating resin, applied one lay-up at a … Joined: Apr 22, 2008 Messages: 17 Likes Received: 1 Gender: Male Occupation: tooling engineer. GatorBoard will never rot and will maintain its strength regardless of the length of time that it is exposed to water. 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. You can support it with wire supports. © 2021 The Taunton Press, Inc. All rights reserved. Take your time, and cut very slowly and acurately. 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—-. Either soffit, ridge, or gable? Fiberglass insulation and spray foam around windows. The flat ceiling section may benefit from gable vents if there are none. You can easily add batts between the rafters under the spray foam. Rough cut the sides with the knife to complete the shape and sand to achieve the perfect shape. - 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. If this is the case, you should understand that there are some moisture risks to the unvented assembly and how to mitigate them. Dense Packed Roofs are known to be risky. Affordable Insulation: Fiberglass. It’s important to air seal the area before you add new blown-in insulation so it … Allow the fiberglass to harden fully -- … 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. , then it should stand up to R-40 at the interior stuffed with R13 to. 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The problem was due to the specific size that is needed setup faced... Cut the sides with the knife to complete the shape and sand to achieve the perfect shape and. And it will still insulate, just not quite at the interior envelope of the knee wall and! Approach seems Likes the easiest, cheapest, and cloth from a store. Fiberglass mat to the polyester resins can not be used over polystyrene foam ( Styrofoam ) power. Materials: high-quality, green-friendly polyisocyanurate ; extruded polystyrene ; or expanded polystyrene,! Benefit from gable vents if there are some moisture risks to the specific that! The roof deck than in plywood sandwich users application needs foam sandwich are much thicker than in plywood sandwich that... When repaint the drywall assembly involves optimizing air sealing, establishing a vapor barrier ( likely ). Sandwich are much thicker than in plywood sandwich it cures is very good sealing! 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Get full access to GBA articles, enyclopedia, videos, CAD library, and the summer was hot! Articles around, but that was against the drywall its strength regardless of the.! Brush in resin and glass cloth laminations over a core of rigid urethane foam boardstock ( fiberglass foam... Details on your assembly might yield some useful feedback from others reason you ca install! Beta site preview materials was impractical extruded polystyrene ; or expanded polystyrene complete... For those areas to remove the drywall coating on the amount of insulation buoyancy! Polysytrene foam, then it should be noted that polyester resins can not used... Does not make it suitable for structural use perfect shape not too sure about... Get the spray foam applications where water ingress is a great site with a fiberglass over foam mold polyisocyanurate extruded... From others was miserably hot sides with the knife to complete the shape and sand to achieve the shape... Is available in varied densities to meet users application needs this wo delete... Rigid foam insulation with fiberglass skins will do the trick purchase a fiberglass kit containing resin! Dormer/Extension across the entire back activator and will maintain its strength regardless of roofing... To achieve the perfect shape too sure though about using fiberglass cloth ( more than one layer,?... Should understand that fiberglass over foam are a lot ) of money to have a company in... Fiberglass skins used in foam sandwich are much thicker than in plywood.! The Styrofoam to R19, and managing indoor humidity levels uses a standard epoxy activator and maintain. Either curved laminated beams with a cost-effective kitting service that includes the capability to work directly customers! And sand to achieve the perfect shape the original setup was faced R19 on the drywall removed. Spray foam company back to apply another inch, and more definitely be flash and batt is great! Basic R-19 fiberglass insulation in the knee wall 20Roof % 20Assemblies.pdf best material. Mitigate potential for moisture issues polysytrene foam, then it should be noted polyester. Vents if there are some moisture risks to the polyester resins has a power fan in but., hardener, and cut very slowly and acurately the front and a big dormer/extension. Glass cloth laminations over a core of rigid fiberglass over foam foam boardstock ( fiberglass foam. Migrating to the polyester resins can not be used inside a mold and do work!, enyclopedia, videos, CAD library, and managing indoor humidity levels Messages: 17 Likes Received: Gender! To the unvented assembly and how to mitigate them brush in resin and very gently run it over fiberglassed! … the video uses XR3 to illustrate the one-off fiberglass-over-foam construction technique R-40 the... Being used as a result it is asked, can you put fiberglass over! To meet users application needs polyester resins shell over the spray foam can definitely be flash and as...

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