Abstract: A non-wicking underlayment board and methods for forming the same. The non-wicking underlayment board includes a foam core formed of closed cell foam with reinforcement layers encapsulated within the foam core. Outer facings formed of mineral coated nonwoven fibers are positioned on opposite faces of the non-wicking underlayment panel. The non-wicking underlayment board is useful for efficient and cost effective installation of barriers and surfaces in water-resistant and waterproof environments.

Abstract: A non-wicking underlayment board and methods for forming the same. The non-wicking underlayment board includes a foam core formed of closed cell foam with reinforcement layers encapsulated within the foam core. Outer facings formed of mineral coated nonwoven fibers are positioned on opposite faces of the non-wicking underlayment panel. The non-wicking underlayment board is useful for efficient and cost effective installation of barriers and surfaces in water-resistant and waterproof environments.

Abstract: Apparatus and methods for constructing a shower pan. The shower pan is constructed from wedge panels having a foam core and facers on major surfaces of the wedge panels. The wedge panels are cut into portions that fit regions of the shower pan area. The wedge panel portions are placed in the regions such that the sloped upper surfaces of the wedge panel portions collectively form a continuous surface that at all locations slopes downward toward the drain of the shower. Pans for a wide variety of shower shapes and sizes can be constructed. The shower pan may be efficiently constructed on-site, often using common tools and techniques.

Abstract: Apparatus and methods for constructing a shower pan. The shower pan is constructed from wedge panels having a foam core and facers on major surfaces of the wedge panels. The wedge panels are cut into portions that fit regions of the shower pan area. The wedge panel portions are placed in the regions such that the sloped upper surfaces of the wedge panel portions collectively form a continuous surface that at all locations slopes downward toward the drain of the shower. Pans for a wide variety of shower shapes and sizes can be constructed. The shower pan may be efficiently constructed on-site, often using common tools and techniques.

Abstract: Apparatus and methods for constructing a shower pan. The shower pan is constructed from wedge panels having a foam core and facers on major surfaces of the wedge panels. The wedge panels are cut into portions that fit regions of the shower pan area. The wedge panel portions are placed in the regions such that the sloped upper surfaces of the wedge panel portions collectively form a continuous surface that at all locations slopes downward toward the drain of the shower. Pans for a wide variety of shower shapes and sizes can be constructed. The shower pan may be efficiently constructed on-site, often using common tools and techniques.

Abstract: A non-wicking underlayment board and methods for forming the same. The non-wicking underlayment board includes a foam core formed of closed cell foam with reinforcement layers encapsulated within the foam core. Outer facings formed of mineral coated nonwoven fibers are positioned on opposite faces of the non-wicking underlayment panel. The non-wicking underlayment board is useful for efficient and cost effective installation of barriers and surfaces in water-resistant and waterproof environments.

Abstract: A non-wicking underlayment board and methods for forming the same. The non-wicking underlayment board includes a foam core formed of closed cell foam with reinforcement layers encapsulated within the foam core. Outer facings formed of mineral coated nonwoven fibers are positioned on opposite faces of the non-wicking underlayment panel. The non-wicking underlayment board is useful for efficient and cost effective installation of barriers and surfaces in water-resistant and waterproof environments.

Abstract: Systems and methods for making a waterproofed concrete wall assembly, such as for a basement wall. A form is constructed. At least a first side of the form is made of one or more boards having a polymer foam and a fibrous facer. At least some of the boards have perimeter edges shaped such that some adjacent boards overlap at the shaped perimeter edges. Concrete is poured into the gap between the sides of the form, and is allowed to harden. The other side of the form may be removed, while leaving the boards of the first side of the form in place adjacent the hardened concrete. Some of the concrete is infused into the fibrous facers of at least some of the boards.

Abstract: Apparatus and methods for constructing a shower pan. The shower pan is constructed from wedge panels having a foam core and facers on major surfaces of the wedge panels. The wedge panels are cut into portions that fit regions of the shower pan area. The wedge panel portions are placed in the regions such that the sloped upper surfaces of the wedge panel portions collectively form a continuous surface that at all locations slopes downward toward the drain of the shower. Pans for a wide variety of shower shapes and sizes can be constructed. The shower pan may be efficiently constructed on-site, often using common tools and techniques.

Abstract: Embodiments of the invention provide roofing boards and roofing systems having improved fire resistance properties and methods related to the same. According to one aspect, a roofing system is provided. The roofing system includes roofing panels positioned atop structural support members to form a roof deck. Roofing boards are positioned atop the roof deck and coupled thereto and a roofing membrane is positioned atop the roofing boards and coupled therewith. The roofing boards include a coating of a mineral based material applied to one or more surfaces in an amount between the range of about 0.10 lbs/ft2 and about 0.70 lbs/ft2. The mineral based material coating enables the roofing boards to pass the UL 790 class A tests, such as the burning brand test.

Abstract: Systems and methods for making a waterproofed concrete wall assembly, such as for a basement wall. A form is constructed. At least a first side of the form is made of one or more boards having a polymer foam and a fibrous facer. At least some of the boards have perimeter edges shaped such that some adjacent boards overlap at the shaped perimeter edges. Concrete is poured into the gap between the sides of the form, and is allowed to harden. The other side of the form may be removed, while leaving the boards of the first side of the form in place adjacent the hardened concrete. Some of the concrete is infused into the fibrous facers of at least some of the boards.

Abstract: According to one embodiment, a method of forming a facer includes forming a first layer of nonwoven glass fibers and positioning a second layer of reinforcement fibers atop the first layer of nonwoven glass fibers. The method also includes coating the first layer of nonwoven glass fibers and/or the second layer of reinforcement fibers with a binder composition and pressing the first layer of nonwoven glass fibers and the second layer of reinforcement fibers together between a pair of rollers. The binder composition is then dried to couple the first layer of nonwoven glass fibers and the second layer of reinforcement fibers to form the facer. The first layer of nonwoven glass fibers and/or the second layer of reinforcement fibers are free of a material coating prior to coating of the binder composition.

Abstract: A roofing system includes a plurality of insulation boards adapted for overlying a roof deck to form a layer of insulation, and a plurality of cover boards adapted for overlying the layer of insulation. Each of the plurality of insulation boards has opposing planar surfaces and has a facer on at least one planar surface, and each of the plurality of insulation boards includes polyisocyanurate foam having a first polyisocyanurate foam density. Each of the plurality of cover boards has opposing planar surfaces and has a facer on at least one planar surface, and each of the plurality of cover boards includes polyisocyanurate foam having a second polyisocyanurate foam density greater than the first polyisocyanurate foam density.

Abstract: A method includes providing a production line configured for continuous fabrication of polymer or predominantly polymer roofing boards by setting and expansion of precursor materials on a conveyor. A first polymer or predominantly polymer material foam precursor is dispensed to the production line, and allowed to rise and at least partially set to form a foam core layer for an insulation board, the foam core layer for the insulation board having a first density. A second polymer or predominantly polymer material foam precursor is dispensed to the production line and allowed to rise and set to form a core layer for a cover board, the foam core layer for the cover board having a second density greater than the first density. The combined thickness of the foam core layer for the insulation board and the core layer for the cover board is set by constraining the expansion of the combined foam precursors using a downstream forming conveyor disposed above the rising foam precursors.

Abstract: A method includes providing a production line configured for continuous fabrication of polymer or predominantly polymer roofing boards by setting and expansion of precursor materials on a conveyor. A first polymer or predominantly polymer material foam precursor is dispensed to the production line, and allowed to rise and at least partially set to form a foam core layer for an insulation board, the foam core layer for the insulation board having a first density. A second polymer or predominantly polymer material foam precursor is dispensed to the production line and allowed to rise and set to form a core layer for a cover board, the foam core layer for the cover board having a second density greater than the first density. The combined thickness of the foam core layer for the insulation board and the core layer for the cover board is set by constraining the expansion of the combined foam precursors using a downstream forming conveyor disposed above the rising foam precursors.

Abstract: According to one aspect, a roofing system comprises a plurality of insulation boards adapted for overlying a roof deck to form a layer of insulation. Each of the plurality of insulation boards has opposing planar surfaces and has a facer on at least one planar surface, and each of the plurality of insulation boards comprises polyisocyanurate foam having a first polyisocyanurate foam density. The roofing system further comprises a plurality of cover boards adapted for overlying the layer of insulation. Each of the plurality of cover boards has opposing planar surfaces and has a facer on at least one planar surface, and each of the plurality of cover boards comprises polyisocyanurate foam having a second polyisocyanurate foam density greater than the first polyisocyanurate foam density. The greater polyisocyanurate foam density provides for a compressive strength to resist deformation.

Abstract: According to one embodiment, a method of forming a facer includes forming a first layer of nonwoven glass fibers and positioning a second layer of reinforcement fibers atop the first layer of nonwoven glass fibers. The method also includes coating the first layer of nonwoven glass fibers and/or the second layer of reinforcement fibers with a binder composition and pressing the first layer of nonwoven glass fibers and the second layer of reinforcement fibers together between a pair of rollers. The binder composition is then dried to couple the first layer of nonwoven glass fibers and the second layer of reinforcement fibers to form the facer. The first layer of nonwoven glass fibers and/or the second layer of reinforcement fibers are free of a material coating prior to coating of the binder composition.

Abstract: According to one embodiment, a method of forming a facer includes forming a first layer of nonwoven glass fibers and positioning a second layer of reinforcement fibers atop the first layer of nonwoven glass fibers. The method also includes coating the first layer of nonwoven glass fibers and/or the second layer of reinforcement fibers with a binder composition and pressing the first layer of nonwoven glass fibers and the second layer of reinforcement fibers together between a pair of rollers. The binder composition is then dried to couple the first layer of nonwoven glass fibers and the second layer of reinforcement fibers to form the facer. The first layer of nonwoven glass fibers and/or the second layer of reinforcement fibers are free of a material coating prior to coating of the binder composition.

Abstract: Embodiments of the invention provide roofing boards and roofing systems having improved fire resistance properties and methods related to the same. According to one aspect, a roofing system is provided. The roofing system includes roofing panels positioned atop structural support members to form a roof deck. Roofing boards are positioned atop the roof deck and coupled thereto and a roofing membrane is positioned atop the roofing boards and coupled therewith. The roofing boards include a coating of a mineral based material applied to one or more surfaces in an amount between the range of about 0.10 lbs/ft2 and about 0.70 lbs/ft2. The mineral based material coating enables the roofing boards to pass the UL 790 class A tests, such as the burning brand test.

Abstract: Embodiments of the invention provide roofing boards and roofing systems having improved fire resistance properties and methods related to the same. According to one aspect, a roofing system is provided. The roofing system includes roofing panels positioned atop structural support members to form a roof deck. Roofing boards are positioned atop the roof deck and coupled thereto and a roofing membrane is positioned atop the roofing boards and coupled therewith. The roofing boards include a coating of a mineral based material applied to one or more surfaces in an amount between the range of about 0.10 lbs/ft2 and about 0.70 lbs/ft2. The mineral based material coating enables the roofing boards to pass the UL 790 class A tests, such as the burning brand test.