This is reallly not a new topic, and was discussed at length maybe two or three years ago.
Someone even talked about buildingarig to make PU pannels by simply building a cage
with rail way ties over it and chains to containit, then let the pu expand.

I don't remember the details, so you will need to search the archives.

What I am looking for now is a source for large eps sheets as close to central nevada as possible.
Idealy I would like 20' x 8' 8" sheets but I suspect that is too much to ask for. Hopefully someone
knows of an eps supplier who will sell a reasonable amout of eps sheets to a single buyer, and
ship them to Nevada.

Bruce

For non structural panels you could get the non or slow expanding pu.
Build some frames to keep your osb, or whatever kind of sheeting you want in place,
pour in the pu and let set. The pu is a two part process, so you will need to invest in some
equipment. It is either that or go with the Foam-o-foam kits, but those are a bit pricy.

This actually might be a better solution for you Chico. You can do all of your wiring and plumbing
in the open with suitable supports, provided you are careful about thermal bridging, and then
pour in the low expanding pu.

You still need to be careful about the necessary support, but nothing like it would be if you were pouring concrete walls.

Anyway, I hope this was helpfull,
Bruce

Dan;

you may want to try contacting some Canadian refrigerated panel mfgs. for "seconds" in steel or aluminum skins that would probably give you a better interior finish for your shop and could probably be had for 50 cents on the dollar

Eric,

Do you have any info on how to build the vacuum press? Where are you getting the foam?
If you get set up I'd be interested in doing that down here in southeren Ontario.
Your cost of $2.50 per sq ft is much more attractive than buying the foam in slabs.

I would build the panels for myself and therefore would not need certification.

This also goes out to anyone out there who could help on info on vacuum presses, where to buy foam and glue.

Chico

 

A technique used by skateboard and ski laminators is to use old firehouse, clamp off one end and fit a compressed air fitting to the other. Tho I think this much pressure would not be necessary. EPs has become such a common material I doubt You should have much trouble. A quick google search yielded this:

Plasti-Fab
The Largest Canadian EPS foam supplier
[b]1-88-THINK EPS
(1-888-446-5377)
[/b][u]Web Site: link[/u]

Nesdon,

I'm going to take a guess and say that the firehose would be used as a clamp.

I took a look at the Plasti-Fab website and I believe they're mainly supplying the ready made products. For now I'm investigating the idea of buying the liquid foam and making my own panels using a press. Any comments?

Chico

 

 

 

Chico,

This is Eric.  Please call me at 907-398-9231 and I'll go over with you what I know about the vacuum tents so far.  I don't have a perfect solution that I'm able to share with everyone yet but I'll tell you what I learned from talking with a guy who makes and sells them.

Later!

Eric

Petru,

Have you had any luck in finding a supplier of EPS foam here in Ontario. I contacted Plasti Fab and they directed me to Home Hardware and that's not really what I'd like to do.

Chico

 

Petru,

I have a quote from Home Hardware on the foam. 6" foam 4 by 9 ft is $64.00. R value is R22 (Type 1). Plastifab is the manufacturer. 7/16 OSB is $6.00 each. Total cost for a 4 by 9 ft panel 6 " thickness foam with OSB inside and out will be $76.00 or $2.11 per sq ft. This does'nt include taxes but should include delivery.

Chico

 

At that price Chico, does it include adhesive? Regardless, thats cheap enough that I would just fur out the interior with 2 by 4's and run wiringThrough there. ALso, that will give you something from which to hang cabinetry.
Also as far as the window and door jams, I would look in to getting C Channel or what I call track cut to size and to be screwed into the OSB. That eliminates wasting time and frustration of cutting out an 1.5" of foam out of the skins.
Way to investigate that process DIYer!

Charles

Hello Chico.
Have you tried contacting the EPS molders direct for a quote? You may as well cut out the middle men.
LINK

Which glue will you use?

Please keep us posted on your progress.

Regards,
Nolan

Chico

Talked to the rep for Plasti Fab. You were right, they don’t deal with the public. They gave me some info on the product. They have EPS type 1, R value 3.75 / inch, type 2, R value 4.04 / inch and type 3, R value 4.27 / inch. They custom slice orders from 24” blocks. Your quote appears to be type 1.

Petru

No it does'nt include the adhesive, so add maybe $10 bucks per panel.

I was planning on putting the gyproc straight onto the OSB so i don't think I'll add the 2 by 4's. I'm contemplating putting the gyproc on before I tilt the panels into place as I think this would speed the process up. Less joints in the gyproc to tape because the posts would hide them.
I'd rather route out a channel for the wiring

Chico

Nolan,

Thanks for the link buddy. I was hoping someone could provide me names. There's even a supplier in my hometown of Barrie in Ontario. Before I get too excited I'll contact them tomorrow and let you know what they say.

I have'nt decided on the glue and it'll probably depend on what's available locally.

Chico

Petru,

I've got good news. Thanks to the link Nolan sent me I was able to find a supplier in Toronto.www.legerlite.ca 416 335-0192. They gave me a quote of $38.40 per panel, 4 X 8 ft X 6" thick. Type 1, EPS. Total R value will be 22.5.
I calculate $12 for 2 sheets OSB, $38.40 for the EPS, $10.00 for adhesive for a total of $60.40 per 4 by 8 ft panel finished. Which makes it $1.88 per sq ft.
They custom slice from 30" blocks.
They don't deliver, but I'd be happy to pick it up at that price.

Chico

Chico

That is good news! That’s half price compared to Plasti Fab. I found EPS adhesive at Rona. It’s made by Dural. They are discontinuing the product and liquidating it at $36.56 per 5 gallon pales. Regular price is $73.00. You can cover approximately 250 sq.ft with one 5 gallon pale. For a panel with glue on both sides you are looking at $0.30/ sq.ft.. The only problem that may be with this product is it sets in 10 minutes. You have to work fast to apply the glue on both sides and set it in a press. The advantage is not having to wait too long between panels. I purchased a small can today and will test it to see how it will work Will let you know what I think.

Dan

Chico

I have an idea for pressing the OSB’s to the foam. I am installing the panels over a existing timber frame structure therefore they don’t have to structural. I only have a 1,200 square foot shop to enclose. I am not interested in making this panels other than for this structure therefore I am not looking to invest in expensive equipment. I think you may be in the same situation. Got to keep that cost down. Hear is my idea. I am going to use 2 x 12” pine beams to make a press. I will build a platform using 2 x 12s cut at 4’ long. Use the jointer to make sure they have a straight edge. Set them on edge on a perfectly flat surface. I am thinking of setting one every 10” or so. Once you have a perfectly flat surface nail couple of 2 x 4s on the ends to hold them in place. Repeat the process and make an identical platform. Set one platform a foot or so off the ground. After you lay the OSB’s and the foam on top of the platform place the second platform on top. Tighten the platforms using pipe clams at each end of the 2 x 12s. If you have enough time you could try making two panels at once. You can also make couple of presses to speed the process. Let me know what you think.

Dan

Dan,

So it looks like the glue from Rona works out to $10 per panel. As far as your press, I'm having a hard time picturing it but I think since we don't need much pressure for the application we'll be using the panels for then your idea should work because pipe clamps would supply enough of the pressure you would need to allow the glue to bond.
In the mean time I'll try to come up with another idea.

Chico

 

Hi, I've been following this thread for a while... thanks for all the great info.
I found a source of reclaimed styrofoam roof panels, 4" thick, R20 value. My panels do not have to be structural either.
I am thinking of using this material, double layer it and use it as roof insulation. Placed between two pieces of osb, would this still have to be be glued together?

is anyone interested in ones made in china for US $25.00 ex shipping - skin is made of 5mm mgo (magnisium oxinde) with 75mm eps. zsize is 1.2m x 2.5m .soory i live in australia and all is metric here