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The photo is of an assembly of scrap foam cut offs and mis-cuts from a local manufacturer, glued to recycled pegboard sheets.
I am going to use these closed cell foam scrap pieces to create an insulated ceiling for my 14' x 20' work studio.
About three years ago I acquired 50-60 4 ft. x 3 ft. pegboard pieces when a local store moved their busines location. I had planned to limewash the pegboard and use it as ceiling cover in the studio anyway.
In the work studio there are 10 or 12 cross beams ( rafters) spaced 2 feet apart. The pegboard can be trimmed to fit the ceiling space.
PLAN A
I can lay the foam & pegboard ABOVE the rafters and let it rest on them, so the foam pieces can be of uneven height since they face upward to the roof.
On any small open areas or gaps on the pegboard I will stuff more of the odd foam bits to fill in, to keep a tight insulated surface.
I will attach a thin layer of cheesecloth over the foam pieces, limewashed heavily, which will face upward to the roof.
PLAN B
More practically I could also attach the peg board to the underside of the rafters like regular wallboard is used for a standard ceiling. I would lose 2" of height in the studio, but that is not of great concern. It will also allow me to still lay storage items across the rafters and use that space for all the odds and ends, and seldom needed items. Since the pegboard will be screwed to the rafters from below with drywall screws they will be easy to remove quickly if access is needed. Or, attaching small hinges on one side and a couple latches on the other of the pegboard piece allows me to swing down the square, and access above the rafters.
The foam pieces will be glued using a non-toxic PVA white glue, and the pegboard limewashed on both sides. Colored limewash tints and sponging techniques means any pattern can be created on the pegboard for an attractive look.
TOTAL COST: Elbow Grease and a package of drywall screws.
ABOUT THE FOAM
The closed cell foam used by the manufacturer for some products are made with PVC foam and also made with GAIA™ PVC-free foam.
In the photo, the
"greenish" colored foam is the Gaia foam, the pinkish is traditional closed cell PVC foam.
http://www.gaiafoam.com/gaia.htm -the light green scraps NOH-01
http://www.winboss.com/flotation.htm -the off-white scraps are PVC, KNV-201S
Other uses for Gaiafoam
I can get a 3' sq. box, ( a cubic foot) and much more, each week of scraps from this manufacturer. They are anxious to rcule, and not see scrap go direct to landfill either.
I wish I could find another taker/user for this scrap. Besides this use as ceiling insulation, It can be stuffed in walls as insulation too, or shredded, bagged and used in odd crannies and nooks where strawbale flakes or other insulation doesn't fit well.
Gluing the foam scrap to canvas can produce bed and camping mats, dog house bedding, or even to insulate the inside of an entire dog house, or an animal stall, making a "bouncy bin" for children to jum around in, and lots of ther uses. And as floatation aids or pool gear, as the foam is used in life vests primarily.
I personally also use the smaller pieces to pad shipping boxes for my customers DVDs and Videos. Customers, want a sample piece? ASK by email and I will ship it with your ORDER, as padding, so you get to see it, and maybe find a local maker with scrap also.
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