Flute Fillers are Roof Insulation

By: Jim Nugent, Regional Sales Manager

Walgreen's Distribution Center, Windsor, WI

Walgreen’s Distribution Center, Windsor, WI

Foam-Control® and Foam-Control® Plus+® roof insulation can be used in a variety of roof assemblies. Fully adhered, mechanically attached membranes. Also green roofs, inverted roofs, protected membranes and many others. Foam-Control® and Foam-Control® Plus+® is available in flat, tapered, fan fold, and as composite insulation with a fiberglass facer. One of the most common uses of Foam-Control® and Foam-Control® Plus+® roof insulation is filling flutes when re-roofing a metal roof, commonly known, the product is know as Flute Filler.

Because the EPS industry can offer Flute Filler in a wide range of sizes, material types, and configurations, EPS is the preferred material for this application, although polyiso is also used in this application.

The EPS industry is known to be able to produce material types with high recycled content that do not meet the code requirements for roof insulation, but can be used in industrial applications for packaging and dunnage. Some may consider Flute Filler a dunnage material to level a metal roof to receive a new roof, but make no mistake about it Flute Filler is a roof insulation and needs to meet code requirements.

1,175,625 Board Feet of Foam-Control® PLUS+® 250 Angle Cut EPS Flute Filler Roof Insulation.  Walgreen's Distribution Center.

1,175,625 Board Feet of Foam-Control® PLUS+® 250 Angle Cut EPS Flute Filler Roof Insulation. Walgreen’s Distribution Center.

The International Building Core requires that EPS roof insulation used above the deck (including metal roofs) must meet the physical properties of ASTM C-578 and must be labeled as such. EPS products with high recycled content may not meet all the physical properties of ASTM C-578. These high recycled content products may even have a UL label and be the right density but it will not meet the code.

At ACH Foam all our Foam-Control® and Foam-Control® Plus+® and Polar® products, including flute fillers, fully meet ASTM C-578 and fully meet the code requirements for roof insulation. For the roofing industry professionals reading this post, the next time you request pricing for EPS Flute Fillers you may want your supplier to provide documentation that their flute fillers meet ASTM C-578 and have the independent third party documentation to support that they are code compliant.

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ACH Foam Loose Fill Peanut Locations

By: Ryan Olson, Packaging Specialist


Did you know ACH Foam manufactures loose fill peanuts in Colorado, Kansas, and Utah? We manufacture anti-static loose fill and biodegradable loose fill.

Versatility is what comes to mind when our customers think about loose fill peanuts. They offer a cost effective solution of protection and flexibility.

Key Benefits of Loose Fill Peanuts

  • Lightweight
  • Economical
  • Prevents product migration
  • Anti-Static treated
  • Custom Bag size offerings
  • Bulk Shipments available

Recycling info for Loose Fill

Plastic Loose Fill Council (loosefillpackaging.com) offers drop off recycling centers in each state.  They also have a peanut hotline if you are trying to locate one of the many 1,500 collection centers.

In many instances, peanuts can be recycled at a UPS store. Contact your local UPS store for more information.

Contact ACH Foam Technologies for more info on loose fill packaging peanuts.

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What Does UL Classified Mean?

By: Tamara Middleton, Sales Representative – Architectural Products


UL, Underwriters Laboratories, is an American consulting company that provides certification on the safety and environmental claims of a product.  In order to be classified under UL a product must meet specific standards.  These standards are determined by risks such as fire or shock, performance under certain conditions, regulatory codes, and other standards set by UL.  In order for a product to be labeled with a UL Classified mark it must meet the standards determined specifically for the product.

For EPS, Expanded Polystyrene, the standards include surface burning characteristics, density, dimensional tolerance, flexural strength, thickness, trueness, and squareness to name a few.  EPS manufacturers must test regularly for these standards.  Every batch produced must be tested daily for its density, flexural strength, thickness, and trueness.  A batch is a number of pounds of bead (raw material) molded at one time of one density from one lot# from an approved bead manufacturer. Dimensional tolerance is tested one series per production run.  The testing is completed by the manufacturer with full reports maintained and audited by a UL representative.  A UL representative will also periodically audit the manufacturers testing equipment, processes, and procedures.

All products manufactured for ASTM D6817 must also meet a compressive resistance standard determined by its density.  Compressive resistance testing is completed by an independent lab, using samples collected by the manufacturer.  Samples for each lot, density and day must be collected.

An EPS board with a UL classified mark has met all standards required by either ASTM C578 for insulation, ASTM D6817 for geofoam and ASTM E2430 for WSG.

ACH Foam Technologies Foam-Control® expanded polystyrene (EPS) insulation and EPS geofoam, along with Foam-Control® PLUS+® architectural rigid foam insulation, are recognized by UL.

All-Spec’s Official Blog, ‘What is UL certification’ by Andy, September 27, 2011
Cabling Install, ‘UL’s Listed, Classified and Verified Marks explained’ August 1, 2012
GAPS Guidelines, ‘Definitions of “listed,” Classified,” “Recogonized,” Approved,” “Acceptable”
Posted in Geofoam, Roof Insulation | Tagged , , , , | 1 Comment

EPS Geofoam for Theater Conversion & Stadium Seating Applications

By: Terry Meier, Geofoam Specialist

Stadium Seating1 Stadium Seating2

Geofoam is the perfect solution for the construction of stadium seating. It has been used in a variety of projects (over 2,000 jobs nationwide), ranging in size from a small home theater to a 22,000 seat sports arena.

Blocks can be pre-fabricated by ACH Foam Technologies to the specified size and shape so that they are instantly ready to place after arrival. Each of the blocks are labeled as needed for easy installation. Plus, drawings can be provided to show where the blocks need to be placed.

Geofoam is available in a wide range of densities to ensure strength and structural integrity.

Cheaper and better… is that possible? When using Geofoam for stadium seating it is! Geofoam is much faster to install and much less expensive than steel metal framing. According to Dana Daniels (owner of Stadium Seating Conversions) “my experience has taught me that using metal framing takes twice the manpower as using EPS Geofoam”.

Stadium Seating3

Some examples of Geofoam Stadium Seating jobs are:

Home Theaters. (The Swensen Residence)

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Educational Classrooms   (Olympus High School)

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Cinema   (Thanksgiving Point Theaters)

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Corporate Auditoriums   (O.C. Tanner Building)

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Performing Arts Theaters   (Hale Theater)

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Concert Hall Auditoriums (Abravenel Hall)

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Sports Arenas (Romney Stadium)

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These are just a few examples of the many projects where our customers have benefited by using Geofoam for theater conversions and stadium seating applications.  Whether your job is a small home theater or a large sports arena, let EPS Geofoam help you with your stadium seating needs.

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Amenity Roof Decks

By: Jim Nugent, Regional Sales Manager


I have lived my entire life in the Chicago metro area, and while the city and state have had its political and fiscal issues in the past 10 years, I still have a hard time thinking of living anywhere else. One of the exciting developments in the past 10 years is the rapid growth of green roof construction in the City of Chicago. My excitement is purely selfish because Foam-Control® Geofoam and Foam-Control® PLUS+® rigid roof insulation has played an important role in the design of green roofs and in some cases green roof projects may not have been possible without these products.

Green roof design has grown in large metro areas for a few reasons. First large metro areas can experience a heat island effect from the concentration of buildings. A large metro area could see a 2-5 degree increase in temperature comparatively to surrounding rural areas. This heat island effect can lead to higher energy consumption and climate change. The other benefit of green roofs is slowing down water runoff during large rain events. Older cities can struggle to manage roof water runoff during a major storm.

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Another reason for the growth of green roof design is that it offers tenants of residential and commercial buildings a space with vegetation that can be used for entertainment that can be accessed without leaving their building. These have now become known as “Amenity Roof Decks”. Without question building owners, architects, and developers in the City of Chicago are embracing the amenity roof decks as a way of offer more options to their tenants and the results are visually amazing.hese amenity roof decks will include built-up areas with landscaping, ramps to access different elevations, terraced amphitheater seating, and hardscape or concrete walkways.  All of which are supported on Foam-Control® Geofoam and Foam-Control® PLUS+® rigid roof insulation.

So how does Foam-Control® Geofoam and Foam-Control® PLUS+® play a role in these projects? The light weight, high compressive strength, and stable high R-values all play a role in making these green roofs viable. Arguably some projects would not be possible without them. Some green areas are located over conditioned spaces inside the building and the high R-value of both products is an added benefit.

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Using granular material to build up landscape or hardscape areas would likely overload the decking. Moving a significant volume of these types of materials many stories in the air to access inner-city roofs is both expensive and dangerous. Moving lightweight Geofoam blocks or rigid insulation to the roof is quick and cost effective.

The future looks bright for the continued growth of green roofs and Amenity Roof Decks. Major metro areas like Chicago, Seattle, Washington DC, and New York City are providing incentives and in some cases, mandating owners, to build buildings with roofs that offer green space, which can greatly reduce heat island effect and rain water runoff. More and more major metro areas are going this direction. Foam-Control® Geofoam and Foam-Control® PLUS+® will continue to make these projects viable around the US.

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