Flute fill is rigid insulation cut to fill the open channels, called flutes, in a metal roof deck. It makes the surface flat so a new insulation board and roof membrane can go on top.
EPS Flute Fill Insulation for Metal Roof Decks
A flat, insulated deck for your metal roof retrofit
Flute fill is a rigid foam strip that sits in the flutes of an existing metal roof deck, so the new roof goes over a flat, even surface. Source Mountain Supply cuts EPS flute fill to match your roof profile and gets it to the jobsite.
Cellofoam EPS flute fill is cut with square or tapered edges, in lengths of 8, 10 and 12 feet, in ASTM C578 densities from 1.0 to 2.0 pounds per cubic foot and compressive strengths from 10 to 25 psi. Send us your deck profile and we will quote the fill. Planning the whole retrofit? See our EPS roof insulation, tapered roof insulation and polyiso roof boards.
Why Contractors Choose EPS Flute Fill
Lower material cost
Cellofoam reports that EPS flute fill can cost up to 40% less than polyiso flute fill, because EPS gives the most R-value per dollar.
Cut to your profile
The fill is CNC hot-wire cut to fit your flute profile, with square or tapered edges for nearly any metal deck or steel roof profile.
R-value that holds
EPS holds only air, so its R-value does not drift over time the way polyiso and XPS can as their blowing agents leave the foam.
Flute Fill Specifications
Typical values for the plain EPS used in flute fill, from the Cellofoam data sheet (ASTM C578). Pick the density and psi that match your roof system.
EPS properties by ASTM C578 type
| Property | Type I | Type VIII | Type II | Type IX |
|---|---|---|---|---|
| Nominal density (lb/ft³) | 1.0 | 1.25 | 1.5 | 2.0 |
| Compressive strength at 10% (psi) | 10–14 | 13–18 | 15–21 | 25–33 |
| Flexural strength (psi) | 25–30 | 30–38 | 40–50 | 50–75 |
| R-value per inch at 75°F | 3.85 | 3.92 | 4.17 | 4.35 |
| R-value per inch at 40°F | 4.17 | 4.25 | 4.55 | 4.76 |
| Water absorption (volume %) | < 1.5 | < 1.5 | < 1.5 | < 1.5 |
What we can cut
| Item | Options |
|---|---|
| Lengths | 8, 10 and 12 feet |
| Edges | Square or tapered |
| Densities | 1.0, 1.25, 1.5 and 2.0 lb/ft³ |
| Compressive strength | 10 to 25 psi |
| Cut | CNC hot wire, to your flute profile |
Typical values, not a specification. Confirm your assembly with your roofing manufacturer and local building code. Source: Cellofoam EPS flute fill and typical physical properties data sheets. Download the flute fill flyer and the flute fill order form.
Where Flute Fill Is Used
Metal roof recover
Fill the flutes of an existing metal roof, then add insulation board and a new membrane over a level surface.
Warehouses
Large low-slope metal roofs on warehouses and distribution buildings.
Manufacturing buildings
Metal-deck roofs on plants and industrial facilities.
Low-slope roof systems
Roof systems that need a flat, stable substrate over corrugated or ribbed steel.
Flute fill, cut to fit and ready for the job
Send us your deck profile and project size. We will quote the fill and talk through delivery.
Flute Fill Questions
EPS Flute Fill Flyer
EPS Flute Fill Order Form
EPS Typical Physical Properties
TS Flute Fill Brochure
What is flute fill?
Why use EPS flute fill instead of polyiso?
EPS costs less for the same R-value, and its R-value does not change over time. Cellofoam reports savings of up to 40% over polyiso flute fill. Polyiso boards still work well in the layer above the deck. See polyiso roof insulation.
What do you need to quote flute fill?
The deck profile (a photo or drawing of the flute shape works), the run lengths and quantity, the density or psi you need, and the delivery address. Call 920-382-0382 or send a request.
How is flute fill cut and shipped?
It is cut with a CNC hot wire to match your profile, in lengths of 8, 10 or 12 feet, with square or tapered edges. Delivery is arranged by order size and destination.
Is flute fill glued down or loose laid?
Cellofoam lists it as either loosely laid or mechanically attached, depending on the roof system. Follow your roofing manufacturer's instructions.
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