By NOMAD | Van Demon

Van insulation can be the most confusing first purchase in any campervan conversion.

Most people end up buying products from multiple brands, in the wrong order, or in the wrong quantities. Not because they didn't research it, but because nobody has ever explained it clearly.

This guide does exactly that. What you need, in what order, how much, and why, for your specific van. By the end of it, ordering should feel straightforward.

Why Van Insulation Is a Three-Layer Job

A panel van is essentially a metal box. Metal conducts vibration and transfers heat very efficiently, neither of which you want when you're trying to build a comfortable space inside one. A single product cannot solve both problems. Neither can two.

The correct system has three distinct layers, each doing a specific job the others can't. Here's what each one does and why it matters.

Layer 1: Sound Deadening

Applied to: bare metal panels - doors, floor, wheel arches, side panels

This is the first thing that goes in, and the last thing you ever want to redo. Once your build is over it, it's inaccessible, so it's worth getting right first time.

The job of sound deadening is to stop the van's metal panels acting like drum membranes. Without it, road noise, engine vibration, and wind all resonate through the bodywork into the cabin. It's structural vibration amplified by large flat panels with nothing to interrupt it.

Butyl deadening is a visco-elastic material. When a panel vibrates, the butyl converts that mechanical energy into heat, damping the resonance before it becomes sound. The thicker the butyl, the more mass, and more mass means better damping. This is the mass law of acoustics: performance scales directly with material weight.

NOMAD Sound Deadening is 2mm butyl rubber, which matters because not all deadening is the same.

Thinner asphalt-based alternatives go brittle in cold weather and develop an unpleasant smell when the van heats up in summer. Butyl is odourless, stays flexible from -40°C to 100°C, and maintains a far more reliable long-term bond to bare metal.

How much coverage do you need?

One of the biggest misconceptions is that adding more sound deadening will always make your van quieter. In reality, there comes a point where adding extra material makes very little difference to noise levels. Beyond that, you're just adding unnecessary weight and cost without any noticeable improvement.

The target is 40-50% coverage per panel.

That means covering roughly half the surface area of each panel rather than every square centimetre of it. Prioritise the areas that vibrate most - door inners, floor panels, and the lower side panels, and work from there. This is the same principle car manufacturers use. OEM engineers don't cover the entire interior of a vehicle with deadening. They identify the panels that vibrate most and treat them to a target coverage level. Beyond that, the foam layer handles the rest.

Deadening quantity guide by van size:

Van size Examples Recommended pack

Small VW Caddy, Ford Transit Connect, Citroën Berlingo 1x 20-sheet pack (1.875 m2)

Medium VW T5/T6, Ford Transit Custom, Vauxhall Vivaro 1-2x 20-sheet packs

Large Mercedes Sprinter MWB, Ford Transit MWB/LWB 1x 40-sheet pack (3.75 m2)

XL Sprinter LWB, Fiat Ducato L4, VW Crafter XLWB 1-2x 40-sheet packs

Every NOMAD deadening product clearly states its total coverage - the 20-sheet pack covers 1.875 m2, the 40-sheet pack covers 3.75 m2, and the 500mm x 5m roll covers 2.5 m2. So there’s no need to work backwards from sheet counts.

Layer 2: Foil-Backed Foam

Applied to: walls, ceiling, and floor - over the deadening layer

This layer does three jobs at once: thermal insulation, vapour control, and airborne noise absorption. It's the most important layer in terms of keeping the van comfortable and protecting the build long-term.

Condensation - why the foam layer matters beyond thermal performance

When warm, humid air inside the van comes into contact with the cold metal skin, it condenses. This is normal physics and it happens in every van - the difference is whether your insulation system is designed to stop it.

The foil face on NOMAD Foam acts as a vapour barrier. It sits between the warm cabin air and the cold metal, preventing condensation from forming behind your cladding. The result is a van that stays dry inside the walls and stays in good condition for longer.

The key thing to remember is that the vapour barrier only works if it forms one continuous, sealed layer. Every cut, overlap and join needs to be carefully sealed with aluminium tape, as even the smallest gap can let moisture through. That's why aluminium tape is an essential part of the NOMAD system, not just an optional extra.

About the foam material

Not all insulation foam performs the same. Many products use XPE (cross-linked polyethylene) foam, which is common across the industry, but it often has a fragile foil facing that can tear during installation when you're cutting and pressing it into a van interior. It's one of the most common frustrations people experience when installing van insulation.

NOMAD uses closed-cell rubber foam, which is more durable and thermally stable. The foil face handles cutting and fitting without tearing, and the adhesive maintains its bond at the temperatures a UK van interior actually reaches, including 85°C on a hot summer day. It's the material specification that stands up over time, which matters in a build that you won't want to pull apart and redo.

Which thickness?

5mm is the right choice for walls and ceiling. It delivers solid thermal and acoustic performance while keeping the insulation slim, so you don't sacrifice valuable interior space.

12mm is designed for the floor, where cold rises fastest and the thermal gap matters most. If you're planning a build for colder climates, or you simply want maximum thermal performance throughout, the 12mm can also be used on walls and ceiling for a thicker, warmer system throughout.

How much foam do you need?

Van size Examples 5mm (walls/ceiling) 12mm (floor)

Small VW Caddy, Transit Connect, Berlingo 1-2 rolls 1 roll

Medium VW T5/T6, Transit Custom, Vivaro 2 rolls 1 roll

Large Sprinter MWB, Transit MWB/LWB 3 rolls 1-2 rolls

XL Sprinter LWB, Ducato L4, Crafter XLWB 3-4 rolls 2 rolls

Each roll covers 5 m2.

Layer 3: Eco Fleece

Applied to: wall and roof cavities behind cladding

The fleece layer is the one most people skip - and once you understand what it does, you'll see why that's a mistake.

Even when sound deadening and foam are installed correctly, small air gaps can still remain behind cladding panels. Because warm air rises and cold air sinks, these spaces can create a slow circulation of air that gradually transfers heat through the wall, even though the foam is performing well and doing its job.

Filling those voids with fleece removes the air movement completely, helping to improve overall thermal performance.

Fleece plays a key role in absorbing mid and high-frequency airborne noise like rain on the roof or road texture - the kind of sound that tends to bounce around hard interior surfaces once a van is clad.

Each layer has a different job: deadening controls structural vibration, foam handles thermal transfer and lower-frequency noise, and fleece deals with the remaining airborne sound. When used together, the result isn’t just a reduction in noise, but a genuinely quiet-feeling space rather than one that simply sounds slightly improved.

NOMAD Eco Fleece comes as a roll that you cut to length and tuck into the cavities behind your cladding.

It's lightweight at 500g/m2 and conforms to the ribs and curves of the van interior without specialist tools.

One thing worth noting: NOMAD Eco Fleece has a water-resistant outer layer. Standard fleece from hardware shops does not. In a van environment, where condensation risk exists even in a well-insulated build, that matters.

Fleece quantity guide:

Van size Examples Eco Fleece

Small VW Caddy, Transit Connect, Berlingo 1 roll

Medium VW T5/T6, Transit Custom, Vivaro 1-2 rolls

Large Sprinter MWB, Transit MWB/LWB 2 rolls

XL Sprinter LWB, Ducato L4, Crafter XLWB 2-3 rolls

The System Finisher: Aluminium Tape

Every join, cut edge, and overlap in the foam needs to be fully sealed. The vapour barrier only works when it forms one continuous, unbroken layer, even small gaps can let moisture through.

NOMAD Aluminium Tape is designed to bond directly to the foil face and stay secure in real van conditions, from -10°C up to 85°C. One 45m roll is enough for a small or medium van. For large or XL vans, you’ll need two rolls.

Aluminium tape is included free with every NOMAD vehicle-specific kit.

The Roller

Butyl sound deadening is self-adhesive, but pressing it on by hand can leave small air pockets, especially around the edges. Over time, these can cause the sheets to lift.

Using a roller solves this. Firmly rolling each sheet from the centre outwards ensures full contact with the metal panel and a much stronger, longer-lasting bond. It’s a small step that makes a big difference to how well everything holds up over time.

A roller is included in all NOMAD vehicle-specific kits. If you’re buying products individually, it’s a worthwhile addition to your order.

How to Avoid Ordering Too Much or Too Little

One of the biggest concerns for first-time van converters is getting quantities right. The simplest way to avoid guesswork is to use a NOMAD vehicle-specific kit.

Each kit is tailored to a specific van model, with materials calculated from real interior measurements. You’ll receive the correct amount of each product, plus free aluminium tape, a free NOMAD roller, and a small amount of extra material to allow for trimming and offcuts. Everything you need arrives in one package, ready to go.

If you prefer to buy individually, each NOMAD product clearly states its coverage so you can plan your build accurately.

 

Full Van Kit Guide

Van size	Examples	Deadening	5mm Foam	12mm Foam	Eco Fleece	Tape	Roller
Small	VW Caddy, Transit Connect, Berlingo	1x 20-sheet pack	1–2 rolls	1 roll	1 roll	1 roll (free)	Included (free)
Medium	VW T5/T6, Transit Custom, Vivaro	1–2x 20-sheet packs	2 rolls	1 roll	1–2 rolls	1 roll (free)	Included (free)
Large	Sprinter MWB, Transit MWB/LWB	1x 40-sheet pack	3 rolls	1–2 rolls	2 rolls	2 rolls (free)	Included (free)
XL	Sprinter LWB, Ducato L4, Crafter XLWB	1–2x 40-sheet packs	3–4 rolls	2 rolls	2–3 rolls	2 rolls (free)	Included (free)

 

All kits include a small amount of extra material for trimming and offcuts.

The Certifications

Most van insulation products don’t publish independently verified manufacturing standards, NOMAD does.

IATF 16949:2016 (NQA T200356) is a globally recognised automotive manufacturing standard used by Tier 1 suppliers to brands like Ford, BMW, Toyota, and Volkswagen. It’s independently audited, not self-certified, and ensures consistent quality throughout production.

NOMAD is the only brand in this category that publicly shares this certification.

ISO 3795 is the EU automotive flammability standard. NOMAD foam achieves a result of 0mm/min, meaning it self-extinguishes when the flame is removed instead of continuing to burn. The full test certificate is available: EMTEK EGZ2306280178R00101R.

For materials used in a living space, independent testing like this provides important peace of mind.

 

Quick Reference

Layer	Product	Where it goes	What it does
1	Sound Deadening	Bare metal panels	Reduces vibration and road noise
2	5mm Foil Foam	Walls and ceiling	Thermal insulation, vapour control, airborne noise reduction
2	12mm Foil Foam	Floor (or full van for cold climates)	Higher thermal performance
3	Eco Fleece	Cavities behind panels	Reduces heat loss and absorbs residual noise
Finish	Aluminium Tape	All foam joins and edges	Seals vapour barrier
Tool	Roller	Sound deadening sheets	Ensures strong, lasting adhesion

 

Frequently Asked Questions

Do I really need all three layers?
Yes. Each layer has a different job. Sound deadening reduces vibration from the metal panels. Foam handles insulation and condensation control. Fleece deals with leftover air movement and noise. Together they create a properly finished system, leaving one out reduces overall performance.

Is 40–50% coverage of sound deadening really enough?
Yes. You only need to cover the main vibration areas of each panel. More than that adds weight and cost without meaningful improvement. This is the same approach used by vehicle manufacturers.

What happens if I don’t seal the foam properly?
If joins aren’t sealed, warm moist air can reach the cold metal skin and cause condensation behind your panels. Fully sealing the foam prevents this and protects the build long-term.

Can I skip sound deadening and just use foam?
You can, but performance will be noticeably reduced. Sound deadening reduces vibration in the metal itself, which foam alone can’t fully address. The best results come from using both in the correct order.

How do I know how much to order?
The easiest option is a vehicle-specific kit, which is pre-calculated for your van. If you’re buying individually, each product shows its coverage so you can work it out accurately.

 

Start Your Build Right

NOMAD Insulation is available as individual products or complete vehicle-specific kits for all major van sizes.

Browse at Van Demon or get in touch if you need help choosing the right setup for your van.

NOMAD Insulation is manufactured under IATF 16949:2016 certification (NQA T200356). Foam independently fire tested to ISO 3795 at 0mm/min combustion rate (EMTEK EGZ2306280178R00101R).