Encapsulated fragile insulation materials

A process for encapsulating fragile insulation materials, the process comprising:

• (i) providing a coverboard, wherein the coverboard includes a foam layer characterized by a density of greater than 2.5 pounds per cubic foot and includes less than 1000 ppm of a physical blowing agent based on the weight of the foam layer, wherein the coverboard further includes opposed first and second glass facers and at least one interfacial layer disposed between at least one of said first and second glass facers and said foam layer, and wherein the at least one interfacial layer includes an intumescent material;
• (ii) positioning one or more fragile insulation materials on the coverboard;
• (iii) depositing a developing foam over the fragile insulation materials to at least partially cover the fragile insulation materials and at least partially mate the developing foam with the coverboard, wherein the developing foam is characterized by a density of less than 2.5 pounds per cubic foot;
• and
• (iv) applying a facer to the developing foam, where the facer includes a coating including a layer of an intumescent material, and where said step of applying a facer includes contacting the layer of an intumescent material to the developing foam.