Marine Insulation Upgrade for Real Journeys' Milford Sound Vessels
Real Journeys in Milford Sound is a stunning experience, but in sometimes extreme weather conditions. Temperatures can drop to below zero in the wettest part of New Zealand – and one the wettest in the world.
Contract and Maintenance Engineer Bluff Workshop Team, who ensures a smooth sailing fleet, has begun an ongoing relationship with Rob Leach and the team at NZ Foam.
The application of spray foam has given a permanent insulation solution to the super structure interior wall lining, including between the ceiling and the deck.
The foam application ensured there were absolutely no gaps to let in moisture and dampness – and heat loss is greatly reduced.
Although NZ Foam was part of the all-round package for the upgrade, which included heating, carpet and upholstery, The Team says there has been a marked improvement with the five different vessels that have been upgraded so far – being namely warmer drier interior, that is more efficient to heat.
“When it came time to upgrade the boat it just made sense to upgrade the insulation at the same time. It will also definitively increase the longevity of the vehicle.”
He says most of vessels were insulated in the ’80s – but with only the poorer performing fibreglass and polystyrene. And this is the first time upgrading the insulation with a permanent solution.
“It was good to know the job was undertaken by a very professional contractor, such as Rob and the team. They took care of the entire project from beginning to end. It was great – I could just leave them to it.”
Dale who maintains a total of 12 vessels in the fleet, says: “Going forward foam insulation will be part of our regular maintenance. Each vessel undertakes a maintenance programme every two years.”
“We will always consider NZ Foam – it’s now our go to insulation for our refurbishment programme.”
Questions about this project
These are passenger vessels operating in Milford Sound, New Zealand, one of the country’s wettest and most challenging environments. The boats operate year-round, so maintaining a warm, dry and comfortable interior is essential for passengers and crew.
The main goals were to create a warm and comfortable experience for passengers and crew, while reducing heat loss and the energy required to heat the boats. Improving insulation also helped reduce ongoing running costs and create a more pleasant environment throughout the journey.
The vessels had previously been insulated with materials such as fibreglass and polystyrene. While these materials had served their purpose, the refurbishment provided an opportunity to install a more durable and permanent insulation solution. Spray foam was selected as the best option for the vessels and the challenging marine environment.
NZ Foam spray foam insulation was installed throughout the boat, including the interior walls of the superstructure and challenging areas such as the space between the ceiling and deck. The foam provided continuous coverage across areas where conventional insulation could be difficult to install effectively.
The project achieved 50 mm of spray foam insulation with an R-value of R2.20.
The existing insulation materials had served their purpose, but spray foam offered a more durable and permanent solution for the refurbishment. Its ability to create a continuous layer of insulation and reduce gaps made it particularly well suited to the boats and the demanding Milford Sound environment.
The project had several challenges, including a limited timeframe while the boats were out of the water, restricted and difficult-to-access spaces, and the cold working environment. NZ Foam overcame these challenges through careful organisation, efficient application processes and strong technical knowledge of how to install spray foam correctly in demanding conditions. This allowed the work to be completed efficiently while maintaining the required insulation performance.
The project demonstrates the importance of choosing an insulation system that suits the building environment, available installation space and long-term performance requirements. Spray foam can be particularly useful in complex or difficult-to-access areas because it creates a continuous insulation layer and helps minimise gaps and potential moisture pathways. The Milford Sound vessels also show that upgrading insulation during a wider refurbishment can improve comfort, energy efficiency, durability and long-term operating costs.