Holey Board (EPS)
Creative Foam Products’ EPS (Expanded Polystyrene) Holey Board is a premium roof insulation engineered for lightweight insulating concrete (LWIC) roof deck systems. Unlike hot-wire-cut products, which are prone to wire burn and misaligned holes, CFP’s custom-built machine delivers precision-cut hole patterns for a stronger concrete bond and superior long-term performance. Available in a range of thicknesses, densities, and custom configurations to meet leading LWIC system specs.
Reach out today for a free quote on a precision-cut EPS Holey Board built to your LWIC system specs.
Why Creative Foam Products EPS Holey Board?
A Better Way to Cut Holey Board
What sets Creative Foam Products apart starts on the production floor. While most manufacturers rely on the hot wire method to cut hole patterns — a process prone to wire burn, overcutting, undercutting, and misaligned holes — we use a custom-built, drill-press-style machine that eliminates these issues entirely. The result is cleaner, more consistent hole geometry across every board, which directly supports the long-term performance of the LWIC assembly. Improperly cut holes from traditional hot wire equipment can compromise concrete encapsulation, bond integrity, and ultimately the durability of the finished roof. Our precision-cut process removes that risk from the equation.
Built to Spec, Built for the Job
No two LWIC roof projects are exactly alike, and our EPS Holey Board is manufactured with that in mind. Available in a wide range of thicknesses, densities, and custom hole configurations, our Holey Board is built to meet the specifications of leading LWIC system manufacturers — whether the job calls for a specific R-value, a particular compressive strength, or a hole pattern matched to a proprietary system. That flexibility makes it equally suited to new construction and reroofing across commercial, industrial, and institutional buildings, from warehouses and schools to hospitals and office complexes. When the spec is set, we manufacture to it.
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Details & Uses
EPS Holey Board is a critical component of LWIC roof deck systems, serving as the primary thermal insulation embedded within the lightweight concrete pour. The factory-applied holes — typically accounting for around 3% of board volume — allow the lightweight concrete to flow through and fully bond the upper and lower concrete layers to the EPS, creating a one-piece, monolithic roof assembly. By installing boards of varying thicknesses in a stair-stepped pattern, contractors can build positive slope-to-drain into the roof while delivering continuous, long-lasting insulation.
Suitable for both new construction and reroofing applications, Creative Foam’s Holey Board provides multiple advantages when specified in LWIC systems:
- Long-term, stable R-value of 3.9–4.6 per inch
- Compressive strengths from 10–60 PSI to meet system and project demands
- Closed-cell structure that resists moisture absorption
- Lightweight construction that’s easy to handle and install
- Custom hole patterns, sizes, and board configurations available
- Compatible with leading LWIC systems including Elastizell, Concrecel, Siplast, and Celcore
- Compatible with metal deck, precast concrete, poured-in-place slabs, and existing roof membranes
- Compatible with built-up, modified bitumen, and single-ply roof membranes
- Supports adhered or ballasted roof system designs
- 100% recyclable and may contain recycled material
- No CFCs, HCFCs, or harmful blowing agents
- Meets or exceeds requirements of ASTM C578, Standard Specification for Rigid, Cellular Polystyrene Thermal Insulation
LWIC Roof Insulation
Our EPS Holey Board is the primary insulation layer in lightweight insulating concrete roof systems. Cut to project specifications and embedded between a slurry coat and a top concrete pour, the board’s hole pattern allows the lightweight concrete to lock the assembly together — delivering a roof system that won’t lose R-value to moisture intrusion the way traditional rigid insulation can.
Benefits include:
- Custom-cut to project-specific thicknesses from 1″ to 16″ (and beyond when required)
- Standard 2′ x 4′ board size with custom dimensions available
- Nominal densities of 1.0 pcf, with higher densities (1.25, 1.5, and 2.0 pcf) available per LWIC system approval
- Stable R-value that doesn’t degrade over the life of the building
- Fully encapsulated in concrete for protection from thermal stress, moisture, and physical damage
- Lower installed cost compared to multi-layer polyiso tapered systems
- Manufactured to meet or exceed ASTM C578
Tapered & Stair-Step Slope Configurations
To meet roof drainage requirements, our Holey Board is custom-cut in varying thicknesses and installed in a stair-stepped pattern that creates positive slope-to-drain. This eliminates ponding water — a leading cause of premature roof membrane failure — without requiring multiple insulation layers.
Benefits include:
- Single-layer slope creation with EPS cut up to 16″ thick (compared to multi-layer polyiso assemblies)
- CAD-designed layouts engineered to project drainage specifications
- Faster installation than traditional tapered systems
- Reduced labor and material waste from custom cuts and penetrations
- Available in slopes designed to match LWIC system requirements
Custom Hole Patterns
Hole number, diameter, and placement vary by LWIC system manufacturer and project specification. We manufacture Holey Board to match the exact requirements of your specified system, ensuring proper concrete flow, bonding, and structural performance.
Benefits include:
- Factory-cut hole patterns matched to LWIC system manufacturer specifications
- Custom hole sizes and configurations available for special-order projects
- Consistent hole placement for predictable concrete flow and bonding
- Quality-controlled cutting tolerances for reliable field performance
Applications & Usage
Creative Foam’s EPS Holey Board is engineered for:
- Flat and low-slope LWIC roof systems
- New commercial, industrial, and institutional construction
- Reroofing projects pouring directly over existing roof assemblies
- Coastal and high-wind regions requiring strong wind uplift performance
- Buildings requiring Class A / FM Class I fire-rated assemblies
- Roofs over metal deck, precast concrete, poured-in-place slab, and existing built-up roofs
Our Products
EPS Foam Products
Foam questions?
We've got answers.
Learn more about the applications for our foam products.
What types of foam products do you manufacture?
Our specialties are expanded polystyrene (EPS), expanded polypropylene (EPP), and graphite polystyrene (GPS), These products have many applications, and can be used in roofing, insulation, landscaping, stabilization, exterior siding, and more.
Do you offer custom foam manufacturing?
We do have the capability to customize our products to your specific needs. In addition, we offer custom packaging, either to ensure your product arrives damage-free, or for your own shipping and packaging needs.
Which types of foam are best for each application?
Most of our applications can be made with multiple foam types, and we’ll guide you to choose the best one for your requirements. Here’s a list of what we manufacture:
- Custom packaging: EPS or EPP
- Insulated shipping containers: EPS or GPS
- Precast: EPS or GPS
- Garage doors and door cores: EPP, EPS, or GPS
- Sheathing: EPS or GPS
- EIFS: EPS or GPS
- Geofoam: EPS
- Roofing: EPS
- OEM: EPP, EPS, or GPS
Which type of foam is the best for my project?
If multiple foam types are able to be used in your project, we’ll discuss the benefits of each product and decide together what will be the best choice for your project.
Are your products sustainable or LEED-certified?
Many of our products can contribute to LEED points, depending on application and use.