What's All the Fuss About Flute-Fill Roof Insulation?

The channels of a metal roof add a level of complexity for work crews, making it difficult to establish a smooth surface for a new roof membrane system.

A metal re-roof also poses challenges for many types of rigid insulation. For metal roofs, standing seams create additional obstacles for crews to work around. The channels require multiple pieces of insulation to be cut and fitted in order to create a smooth surface over the metal deck. Establishing a smooth, stable surface for a new single-ply or recover roof system is critical.

Flute-Fill is Insulfoam’s EPS insulation panel designed to fit seamlessly within existing metal roof deck channels and around raised seams, while delivering the required thermal R-values. The advantages of Flute-Fill go far beyond just R-value. The metal roof pictured to the right shows Insulfoam EPS being installed over a standing seam metal deck in New Mexico by Progressive Roofing.

One of the biggest advantages is cost. These custom solutions are often more affordable than alternative fill options. Insulfoam EPS can be produced in thicknesses up to 40 inches (far exceeding typical Flute-Fill needs), allowing for a single layer installation. The custom profile cutting is automated and precision-programmed, and large panels (typically 4' x 8') create a continuous, engineered flat surface over the metal deck. This eliminates the need to cut and fit multiple smaller pieces or layers of insulation.

Insulfoam Flute-Fill delivers simplified, continuous roof insulation, along with labor savings, cost efficiency, and reliable, value-added performance for metal roof recover assemblies.

Simplify Your Next Metal Roof Recover

See how Insulfoam Flute-Fill can create a smooth, continuous surface while reducing labor and installation time. Fill out the form below to get in touch with an Insulfoam product specialist.