On this episode of the Build Show, Travis Brungardt walks through a high-performance roof assembly on a unique build in Silver Lake, Kansas, alongside guest Randy Williams. The roof features reclaimed expanded polystyrene (EPS) insulation — salvaged blanks hot-wire cut to a uniform four inches — installed in three layers with deliberately offset joints to eliminate thermal bridging and air pathways. Zip sheathing sits both beneath and above the foam, handling air control and providing a nail base for the finish roofing. Randy explains how unbroken seams in exterior foam can cause visible melt patterns and condensation issues, a lesson rooted in real-world building science.

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