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      Case Studies — insulation repair

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      Case Study: How United Airlines Gave Their Newark Hangar a Brand-New Look with the BlueTex™ Cover System

      Posted by Edward Fritz ·

      Case Study: How United Airlines Gave Their Newark Hangar a Brand-New Look with the BlueTex™ Cover System

      Case Study: Covering Up Old Airplane Hangar Insulation with BlueTex™

      Old insulation has a way of aging a building. Whether it's been torn up over the years, stained, or has just faded into a dingy, uneven mess, worn insulation can make an otherwise solid facility look tired and unprofessional. The good news? You don't have to rip it all out to fix it. With the BlueTex™ cover system, you can install right over your existing insulation and create a fresh interior vapor barrier that's bright, clean, and built to impress. Below is a great example of that approach on a big scale.

      Background

      Many facilities are looking for a way to conceal outdated insulation that has become damaged, discolored, or worn over time—leaving the space looking unattractive and unprofessional. This customer, United Airlines, needed to refresh the interior of a massive 60,000 square-foot airplane hangar at their Newark, New Jersey location. The existing insulation was old and worn, and they were working against a tight timeline: the hangar would only be empty for a limited window, and the install had to be done before it was back in use.

      Project Details

      Type of Structure: 60,000 Sq Ft Airplane Hangar and Filming Studio

      Install Date: July/August 2026

      Location: Newark, New Jersey

      Goal: Cover old insulation without removing it, to create a fresh, clean interior surface — on a tight timeline

      Product Used: 2mm BlueTex™ Pro 50" Wide

      Install Details

      Because United Airlines needed to make the most of a short window when the hangar would be empty, speed was everything. We worked closely with their team to get them samples, create a custom quote for their facility, and help get their order placed and shipped out quickly so they could get to work right away and meet their deadline.

      Since they were covering over the old insulation rather than removing it, the prep work was minimal. The crew went right over the existing insulation with the BlueTex™ cover system, creating a brand-new interior vapor barrier across the walls without the time and mess of a full tear-out.

      Finish

      The BlueTex™ was installed creating a fresh interior vapor barrier with a clean, bright, professional appearance across the entire hangar. This space is used for filming so the improvements made a big impact. This Cover System method is great for large spaces like this—where the building needs to look presentable for crews, staff, and operations—and it gets the job done fast.

      Results

      By covering the old insulation instead of removing it, United Airlines transformed the look of their 60,000 square-foot hangar within their tight timeline and had the space ready to go when they needed it. The result is a bright, clean, professional interior that looks brand new. The hangar hosted United Airlines employees, executives, and media (including the company's CEO, Scott Kirby) for an unveiling ceremony showcasing their brand-new aircraft.

      That's a dramatic difference — the before/after that the BlueTex™ cover system delivers is unlike no other insulation out there.

      Interested in improving the look of your building's old insulation? If you have a project like this and are wanting to know how BlueTex™ can help, contact us for more info or fill out the form on the bottom of this page to get a quote fast.

      Case Study: Covering Up Damaged Warehouse Insulation with BlueTex™

      Posted by Edward Fritz ·

      BlueTex - Cover System - Before & After

      We hear from a lot of people who are trying to find a solution to cover up their old warehouse insulation that, over time, may have been damaged or just gotten stained and looks unsightly/unprofessional. Did you know BlueTex™ has a cover system application? You can use BlueTex™ to cover over old insulation (without removing it if you don't want to) and it creates a new interior vapor barrier that looks bright and clean! See below for some details from a customer who did just that. 

      Read more

      Case Study: Indoor Volleyball Court

      Posted by Edward Fritz ·

      Case Study: Indoor Volleyball Court

      Each case study offers unique conditions that make it especially interesting to discuss. In the case study we first identify the problem and the expected outcome. Then, after BlueTex™ is installed, we determine the ways it solved the problem.

      Background: This customer owns an indoor volleyball gym that is used for training, practice, and games. Over time the ceiling insulation faded, cracked and fell apart. In this particular building, the ceiling takes a beating when the building is in use, so the customer was looking for a strong material that could withstand being hit but also something that looked nice and brightened up the roofline. This customer was not looking for any heat-blocking benefit from BlueTex™, so creating an air gap between the roof and the foil side was not a requirement for this special application. 

      Type of Structure: red iron PEMB

      Install Date: October 2022

      Goal: Repair roofline of old, falling down insulation

      Product Used: 6mm 50" Wide BlueTex™ Supreme

      Install Details: First, all of the old insulation was pulled down and the roof was bare. This isn't always necessary when you're covering old insulation with BlueTex™, but because of how he was attaching it, our customer needed the roofline bare. After some trial and error he found that the Gorilla® brand construction adhesive worked best to adhere the thicker 6mm to the metal roof. He added lines of adhesive so that each piece of BlueTex™ would be glued in about 3 places (either end of the panel and in the middle). Then he installed 50" panels of BlueTex™ directly to the metal underside of the roof, in between the purlins, pressing for about 30-60 seconds to form the bond between the adhesive and the BlueTex™. Again, he was not looking for the radiant barrier benefit from our product, so the air gap between the metal and the foil was not needed.  The seams were taped with 3" wide vapor barrier foil seam tape.

      Finish: The white side was facing down, toward the inside of the volleyball training facility. The bright white finish made the space look new again and he chose to leave it uncovered and unpainted. Remember, you can cover or paint BlueTex™ if you're looking for a different interior aesthetic. 

      Results: The customer said even though it required some extra steps over a conventional installation, he was very pleased with how easy BlueTex™ was to work with and how strong, sturdy, and tear-proof it is. He also really likes the look of the white side of the BlueTex™ insulation inside and said it brightened up the space more than he imagined. The BlueTex™ continues to hold up well while the gym is in daily use!