thermwall tw50 partial fill cavity wall...

● High performance rigid urethaneinsulation – thermal conductivity0.022–0.023 W/m.K

● Utilises traditional cavity wallconstruction methods

● Clear cavity is maintained –resists moisture penetration

● Low emissivity foil facings areresistant to the passage of watervapour and double the thermalresistance of the cavity

● Unaffected by air movement

● Easy to handle and install

● Non–deleterious material

● CFC/HCFC–free with zero OzoneDepletion Potential (ODP)

PARTIAL FILL CAVITY WALL INSULATION

CI/Sfb

Fifth Issue November 2005

(21.9) Rn7 M2

BBABRITISHBOARD OFAGRÉMENT

CERTIFICATE 94/2992

wall TW50

IAB No. 03/0196

I nsu la t ion

Specification ClauseKingspan Thermawall TW50 should be described inspecifications as:–

The wall insulation shall be Kingspan Thermawall TW50____mm thick comprising a CFC/HCFC–free rigid urethaneinsulation core with low emissivity composite foil facings on bothsides manufactured to the highest standards in accordance withboth the requirements of draft BS 4841–1 and quality controlsystems approved to BS EN ISO 9001: 2000/I.S. EN ISO 9001: 2000 by Kingspan Insulation Limited and shall beapplied in accordance with the instructions issued by them.

Details also available in NBS PLUS.NBS users should refer to clause(s):F30 151 (Standard and Intermediate)F30 12 (Minor Works)

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Figure 1

Figure 2

Kingspan ThermawallTW50

Typical Design Detail

Insulation retaining clipand wall tie

Outer leaf of masonry

wall TW50

Residual cavity minimum 25 mm (subject to designconsiderations on pages 3 & 4)

Insulation retaining clipand wall tie

Damp proof course level

Residual cavity minimum 25 mm (subject todesign considerations on pages 3 & 4)

Boards can commence below dpc level andoffer some thermal insulation to the floor slab


However, manufacturers should not rest on their laurels, it is amatter of social responsibility to be open and honest about theenvironmental impact of the manufacture of a product, and afull Life Cycle Analysis (LCA) based on a much wider basket ofenvironmental impacts, rather than embodied energy alone, isrecognised as the preferred tool to achieve this.

Kingspan Insulation was the first insulation manufacturer tocomplete and openly publish an independently certifiedEcoprofile (a type of LCA) on one of its product ranges. The Ecoprofile was carried out on the Therma zero ODP rangeof rigid urethane insulation products by the BuildingResearch Establishment (BRE). The productrange comfortably achieves a BRE Green GuideA rating.

But there is far more to sustainability than whether or not aproduct, process or company affects the environment in apositive or a negative way. A company can and shoulddemonstrate its financial viability and social responsibility, aswell as ensure that its materials and methods do not addunduly to the burden placed on the planet.

Kingspan Insulation has now put the manufacture of itsproducts at its Pembridge facility in Herefordshire through arigorous independent appraisal of its economic, social,environmental and natural resource impacts using Arup’sSPeAR® tool.

The results show a well balanced performance in terms ofsustainability, and that Kingspan Insulation is already meetinglegislation or best practice in most areas, even moving beyondbest practice in some. Kingspan Insulation is the first and onlyconstruction material manufacturer to have taken this boldmove and openly publish the results.

Design ConsiderationsSustainabilityIn the past, erroneously, the relative environmental sustainabilityof insulation materials has been compared on the basis ofembodied energy and ozone depletion potential. It is nowrecognised that a much wider basket of embodiedenvironmental impacts (including those caused by theirembodied energy), rather than embodied energy alone, is theonly credible tool of comparison. Time has also annulled ozonedepletion potential as an issue as all insulation materials arenow banned from using CFC and HCFC blowing agents by law.

For buildings designed to today’s Building Regulations energyuse standards it is now also known that the embodiedenvironmental impacts of all of the materials and labour usedto create a building are insignificant in comparison with thelifetime operational environmental impacts of that building andso are of very limited importance. Since it is operational energyuse that creates the vast majority of operational environmentalimpact, saving energy by specifying the lowest U-valuespossible is the most environmentally sustainable action to take.

However, one of the most neglected facts aboutenvironmentally sustainable buildings is that the longevity oftheir standards of operational energy use, and therefore thelongevity their operational environmental impacts, is critical.The performance of some insulants, such as mineral fibre, candeteriorate rapidly if exposed to water penetration, airmovement or compression. This may increase operationalenergy use and hence compromise the environmentalsustainability of the finished building to an alarming degree.Other insulation materials, such as rigid phenolic or rigidurethane, are not vulnerable to any of these problems.

In summary, designers should:

(a) specify the lowest possible U-value regardless of insulation type;

(b) design out the risk of their chosen insulant not performingas specified; and (c) if the latter is not possible, choose aninsulant that is at low risk of failure e.g. a cellular plasticinsulation material.

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wall TW50

Typical U–valuesThe following examples have been calculated using thecombined method for compliance with Building Regulations/Standards revised after the year 2002. These examples arebased on the use Kingspan Thermawall TW50 fixed to theouter face of the inner leaf of a masonry cavity wall with aminimum 25 mm clear cavity between the face of the Kingspan Thermawall TW50 and the outer leaf of brickwork.For reasons of comparison the internal wall finish is taken as12.5 mm plasterboard on dabs. The U–values quoted takeaccount of the low emissivity cavity created by the foil–facedinsulation. If your construction is any different, please contactthe Kingspan Insulation Technical Services Department (seerear cover).

Combined Method – U–values were calculated using themethod which has been adopted to bring National standardsin line with the European Standard calculation method, BS/I.S. EN ISO 6946: 1997 (Building components and buildingelements. Thermal resistance and thermal transmittance.Calculation method).

NB when calculating U–values to BS/I.S. EN ISO 6946: 1997, the type of wall tie used may change the thickness of insulation required. These calculations assume a stainless steel double triangle tie 3.7 mm diameter giving a cross sectional area of 10.75 mm2. Please contact the Kingspan Insulation Technical Services Department (see rear cover) forproject calculations.

NB for the purposes of these calculations the standard of workmanship has been assumedgood and therefore the correction factor for air gaps has been ignored.

The figures quoted are for guidance only. A detailed U–value calculation together with acondensation risk analysis should be completed for each individual project. Please call theKingspan Insulation Technical Services Department for assistance (see rear cover).

Residual Cavity Width*For wall heights up to 12 m a minimum 25 mm cavity isrecommended, and a minimum 50 mm cavity for wall heightgreater than 12 m, and up to and including 25 m after theinstallation of Kingspan Thermawall TW50 irrespective of thethickness specified. By maintaining a clear cavity, problemsassociated with fully filled cavities can be avoided. For furtherdetails please refer to our current BBA Certificate No. 94/2992.

*A residual cavity width of 50 mm nominal will be required by the NHBC where nominalstandards of tolerance and workmanship are accepted. In Ireland a residual cavity not lessthan 40 mm should be maintained in accordance with Technical Guidance document C.

Design StandardsBS 5628–1: 1992 (Code of practice for use of masonry.Structural use of unreinforced masonry) and BS 5628–2: 2000(Code of practice for use of masonry. Structural use ofreinforced and prestressed masonry) should be consultedregarding the construction of insulated cavity walls.

Wall TiesWall ties should have a retaining clip for securing the insulantto the masonry plane and be of a double drip type. Ideally theyshould be BBA approved and conform to BS EN 845–1: 2003(Specification for ancillary components for masonry. Ties,tension straps, hangers and brackets).

Severe Exposure ZonesIn severe exposure zones only stainless steel or copper alloywall ties should be used. BS 5628–3: 2001 (Code of practicefor use of masonry. Materials and components, design andworkmanship) refers to this.

Brick/Aerated Concrete Block (λ–value0.11 W/m.K) Accounting for Mortar Joints

Insulant Thickness U–value (W/m2.K)(mm)

17 0.3820 0.3625 0.3330 0.3135 0.3040 0.2845 0.2650 0.2555 0.23

Rendered Block/Dense Concrete Block(λ–value 1.13 W/m.K)


17 0.5120 0.4725 0.4330 0.3935 0.3740 0.3445 0.3150 0.3055 0.2860 0.2665 0.2570 0.24

Rendered Block/Medium Density Concrete Block(λ–value 0.51 W/m.K)


17 0.4620 0.4325 0.3930 0.3635 0.3440 0.3245 0.3050 0.2855 0.2660 0.2565 0.24

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Brick/Dense Concrete Block (λ–value 1.13 W/m.K)


17 0.5020 0.4725 0.4330 0.3935 0.3740 0.3445 0.3150 0.3055 0.2860 0.2665 0.2570 0.24

Brick/Medium Density Concrete Block(λ–value 0.51 W/m.K)


17 0.4820 0.4525 0.4130 0.3735 0.3540 0.3345 0.3150 0.2955 0.2760 0.2565 0.24

Brick/Lightweight Concrete Block (λ–value 0.15 W/m.K)Accounting for Mortar Joints


17 0.4120 0.3825 0.3530 0.3335 0.3140 0.2945 0.2750 0.2655 0.2460 0.23

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wall TW50

Figure 5 Robust Cill Detail – UK

Residual cavity

External leafbrickwork

Vertical dpc

Inner leaf dense block

Concrete cill


Plasterboard finish

Figure 6 Robust Cill Detail – Ireland

Residual cavity

External leafbrickwork

Vertical dpc


Concrete cill


Plasterboard finish

Prevention of Thermal BridgingIn an effort to prevent a cold bridge detail at window cill andjamb details the designer may wish to adopt the followingdetails. The insulation is simply cut and returned to suit.

Figure 3 Robust Jamb Detail – UK

Residual cavity

External leaf brickwork

Vertical dpc

Door/window jamb


Plasterboard finish


Figure 4 Robust Jamb Detail – Ireland

Residual cavity

External leaf brickwork

Vertical dpc

Door/window jamb


Plasterboard finish


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Figure 7 Use of a cavity batten to protect the cavity

Figure 8 Use of a cavity board to protect the cavity

SiteworkWall Ties & Retaining ClipsKingspan Thermawall TW50 is normally held in position bythe wall ties used to tie the two skins of masonry togetherusing retaining clips. Walls are constructed in the conventionalmanner but with the first run of wall ties at least one coursebelow the damp–proof course and at approximately 600 mmhorizontal centres. A section of the inner or outer leaf of thewall is built up to the course below the next run of the wall tieswhich are situated at a spacing of 450 mm vertically and notexceeding 900 mm (750 mm in Ireland).

The Kingspan Thermawall TW50 boards are then placed inposition behind the retaining clips on the wall ties, andadditional wall ties and clips are used to retain the top of theboard. Additional ties may also be required at corners,junctions and cut board ends. Each board should be securedat a minimum of three points. The boards should form areasonable butt jointed row. The other leaf is then built up tothe level of the top of the boards and construction proceeds.

The first row of boards commencing below damp–proof courselevel also provides some edge insulation to the floor slab (seefigure 2). Successive sections of wall incorporating wall tiesand clips are constructed and Kingspan Thermawall TW50boards installed as work proceeds up to the required height.After raising each section of inner leaf, before installation,excess mortar should be removed and mortar droppingscleaned from exposed edges of the installed slabs. Use of acavity batten or cavity board, is recommended to protectboard edges and maintain a clear cavity (see Figures 7 & 8 orrefer to BBA Certificate 94/2992 or IAB Certificate 03/0196).

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wall TW50

Product DescriptionThe FacingsKingspan Thermawall TW50 is faced on both sides with a lowemissivity composite foil which is highly resistant to thetransmission of water vapour. This reflective, low emissivitysurface effectively doubles the thermal resistance of the residualcavity airspace in which the board is placed.

The CoreThe core of Kingspan Thermawall TW50is manufactured from trademarkedNilflam® technology (a high performance CFC/HCFC–freepolyisocyanurate (PIR) based formulation). KingspanThermawall TW50 has a typical density of 32 kg/m3.

CFC/HCFC–freeKingspan Thermawall TW50 is manufacturedwithout the use of CFCs/HCFCs and has zeroOzone Depletion Potential (ODP).

Product DataStandards and ApprovalsKingspan Thermawall TW50 is manufactured to the higheststandards in accordance with the requirements of draft BS 4841–1 (Rigid Polyurethane (PUR) and Polyisocyanurate(PIR) products for building end–use applications. Specificationfor laminated insulation boards for wall cavities).Kingspan Thermawall TW50 is manufactured to the higheststandards under quality control systems approved to BS EN ISO 9001: 2000/I.S. EN ISO 9001: 2000 (Qualitymanagement systems. Requirements). Its use is covered byBBA Certificate 94/2992 and IAB Certificate 03/0196.

007

Manufactured to BS EN ISO 9001: 2000Certificate No. 388

I.S. EN ISO 9001: 2000Registration No. 19.0633

BBABRITISHBOARD OFAGRÉMENT

CERTIFICATE 94/2992

IAB No. 03/0196

Daily Working PracticeInstalled Kingspan Thermawall TW50 boards should beprotected against inclement weather.

CuttingCutting should be carried out using a fine toothed saw or byscoring with a sharp knife and snapping the board over astraight edge and cutting the foil face on the other side. Ensure accurate trimming to achieve close butting joints andcontinuity of insulation.

AvailabilityKingspan Thermawall TW50 is available through specialistinsulation distributors and selected builders merchantsthroughout the UK, Ireland and Europe.

PackagingThe boards are supplied in labelled packs shrinkwrapped in polythene.

StorageThe packaging of Kingspan Thermawall TW50 should not beconsidered adequate for long term outside protection. Ideally,boards should be stored inside a building. However, if outsidestorage cannot be avoided, the boards should be stackedclear of the ground, and covered with a polythene sheet orweatherproof tarpaulin. Boards that have been allowed to getwet should not be used.

Health and SafetyKingspan Insulation products are chemically inert and safe touse. A leaflet on this topic which satisfies the requirements setout in the Control of Substances Hazardous to HealthRegulations 1988 (COSHH) is available from the KingspanInsulation Marketing Department (see rear cover).

Please note that the reflective surface on this product is designed to enhance its thermalperformance. As such, it will reflect light as well as heat, including ultraviolet light. Therefore, if this board is being installed during very bright or sunny weather, it is advisable to wear UV protective sunglasses or goggles, and if the skin is exposed for a significant periodof time, to protect the bare skin with a UV block sun cream.

The reflective facing used on this product can be slippery underfoot when wet. Therefore, it isrecommended that any excess material should be contained to avoid a slip hazard.

Warning - do not stand on or otherwise support your weight on this board unless it is fullysupported by a load bearing surface.

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Fire PerformanceKingspan Thermawall TW50, when subjected to BritishStandard fire tests, achieves the results given below.

Test Result

BS 476–7: 1997 Class 1 rating(Fire tests on building materials and structures. Method of test to determine the classification of the surface spread of flame of products)

Further details on the fire performance of Kingspan Insulationproducts may be obtained from the Kingspan InsulationTechnical Services Department (see rear cover).

The use of the product in the context of BBA Certificate94/2992 does not prejudice the fire resistance properties of thewall. It is unlikely to become ignited within the cavity. If firedoes penetrate into an unventilated cavity, the amount of airpresent will be insufficient to support combustion, and flamespread will be minimal.

Walls containing the product do not need cavity barriers inbuildings of any purpose group provided they are constructedin accordance with the provisions of BBA Certificate 94/2992.

Standard DimensionsKingspan Thermawall TW50 is available in the followingstandard sizes and thicknesses:

Nominal Dimension Availability

Length (m) 1.2Width (m) 0.45 (0.6)Insulant Thickness (mm) Refer to local distributor or

Kingspan Insulation price list forcurrent stock and non-stock sizes.

Insulation Compressive StrengthTypically exceeds 140 kPa at 10% compression when testedto BS EN 826: 1996 (Thermal insulating products for buildingapplications. Determination of compression behaviour).

Water Vapour ResistanceModified to include board facings, the boards achieve aresistance far greater than 100 MN.s/g when tested inaccordance with BS 4370–2: 1993 (Methods of test for rigidcellular materials. Methods 7 to 9).

DurabilityIf correctly applied, Kingspan Thermawall TW50 has anindefinite life. Its durability depends on the supporting structureand the conditions of its use.

Resistance to Solvents, Fungi & RodentsThe insulation core is resistant to short-term contact withpetrol and with most dilute acids, alkalis and mineral oils.However, it is recommended that any spills be cleaned off fullybefore the boards are installed. Ensure that safe methods ofcleaning are used, as recommended by the suppliers of thespilled liquid. The insulation core is not resistant to somesolvent-based adhesive systems, particularly those containingmethyl ethyl ketone. Adhesives containing such solventsshould not be used in association with this product. Damagedboards or boards that have been in contact with harshsolvents or acids should not be used.

The insulation core and facings used in the manufacture ofKingspan Thermawall TW50 resist attack by mould andmicrobial growth and do not provide any food value to vermin.

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Thermal Properties

The λ–values and R–values quoted are in accordance with the Harmonised European StandardBS EN 13165: 2001 (Thermal insulation products for

buildings – Factory made rigid polyurethane foam (PUR)products – Specification) using so called 90/90

principles. Comparison with alternative products maynot be appropriate unless the same procedures have

been followed.

Thermal Conductivity The boards achieve a thermal conductivity (λ–value) of 0.022 W/m.K (insulant thickness ≤ 30 mm) and 0.023 W/m.K(insulant thickness ≥ 35 mm).

Thermal ResistancesThermal resistance (R–value) varies with thickness and iscalculated by dividing the thickness of the board (expressed in metres) by its thermal conductivity.

Insulant Thickness Thermal Resistance(mm) (m2.K/W)

17 0.7520 0.9025 1.1030 1.3535 1.5040 1.7045 1.9550 2.1555 2.3560 2.6065 2.80

Refer to local distributor or Kingspan Insulation price list for current stock and non-stock sizes.

wall TW50

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Kingspan InsulationKingspan Insulation offers an extensive range of premium and high performance insulation products, breathablemembranes and pre–fabricated/ pre–insulated systems for theconstruction industry. Following an extensive investmentprogramme, Kingspan Insulation is continuing to lead theinsulation industry by manufacturing its insulation productswith zero Ozone Depletion Potential (ODP) and quoting thermalperformance data in accordance with the new harmonisedEuropean Standards.

Kingspan Insulation Limited specialise in the solution ofinsulation problems. The Kingspan Insulation range ofinsulation products meet the exacting requirements of theconstruction industry are produced to the highest standards,including BS EN ISO 9001: 2000/I.S. EN ISO 9001: 2000.Each product has been designed to fulfil a specific need andhas been manufactured to precise standards and tolerances.

Insulation for:● Pitched Roofs

● Flat Roofs

● Cavity Walls

● Timber and Steel Framing

● Externally Insulated Cladding Systems

● Floors

● Soffits

Solutions:● Insulated Dry Lining

● Tapered Roofing Systems

● Kingspan KoolDuct® Pre–Insulated Ducting

● Kingspan nilvent ® Breathable Membranes

The Kingspan Insulation Product RangeThe Kingspan Kooltherm® K–range● With a thermal conductivity of 0.021–0.024 W/m.K

CFC/HCFC–free rigid phenolic insulation is the mostthermally efficient insulation product commonly available.

● Utilises the thinnest possible insulation board to achieverequired U–values.

● Fire performance can be equivalent to mineral fibre.

● Achieves a Class O fire rating to the Building Regulationsand Low Risk rating for the Technical Standards in Scotland.

● Achieves the best possible rating of < 5% smokeobscuration when tested to BS 5111: Part 1: 1974.

● CFC/HCFC–free with zero Ozone Depletion Potential (ODP).

The Kingspan Therma Range● With a thermal conductivity of 0.022–0.028 W/m.K

CFC/HCFC–free rigid urethane insulation is one of the mostthermally efficient insulation products commonly available.

● Easily achieves required U–values with minimum boardthickness.

● Achieves the required fire performance for the intendedapplication.


The Kingspan Styrozone® & Purlcrete Ranges● Rigid extruded polystyrene insulation (XPS) has the highest

compressive strength of any commonly available insulant.

● Ideal for specialist applications such as inverted roofing andheavy–duty flooring.

● Easily achieves required U–values with minimum boardthickness.

● Achieves the required fire performance for the intendedapplication.


All Products● Their closed cell structure resists both moisture and water

vapour ingress – problems which can be associated withopen cell materials such as mineral fibre and which canresult in reduced thermal performance.

● Unaffected by air movement – problems that can beexperienced with mineral fibre and which can reducethermal performance.

● Safe and easy to install – non–fibrous

● Provide reliable long term thermal performance over thelifetime of the building.

Customer ServiceFor quotations, order placement and details of despatches pleasecontact the Kingspan Insulation Customer Services Department onthe numbers below:

UK – Telephone: +44 (0) 870 850 8555– Fax: +44 (0) 870 850 8666– email: [email protected]

Ireland – Telephone: +353 (0) 42 97 95000– Fax: +353 (0) 42 97 46129– email: [email protected]

Literature & SamplesKingspan Insulation produce a comprehensive range of technicalliterature for specifiers, contractors, stockists and end users. The literature contains clear ‘user friendly’ advice on typical design; design considerations; thermal properties; sitework and product data.

Available as a complete Design Manual or as individual productbrochures, Kingspan Insulation technical literature is an essentialspecification tool. For copies please contact the KingspanInsulation Marketing Department on the numbers below:



Tapered RoofingFor technical guidance, quotations, order placement and details of despatches please contact the Kingspan InsulationTapered Roofing Department on the numbers below:



Technical Advice/DesignKingspan Insulation Ltd support all of their products with acomprehensive Technical Advisory Service for specifiers, stockistsand contractors.

This includes a computer–aided service designed to give fast,accurate technical advice. Simply phone the Kingspan Insulation

with your project specification. Calculations can be carried out to provide U–values, condensation/dew pointrisk, required insulation thicknesses etc… Thereafter any numberof permutations can be provided to help you achieve your desired targets.

The Kingspan Insulation Technical Services Department can alsogive general application advice and advice on design detailing andfixing etc... Site surveys are also undertaken as appropriate.

Please contact the Kingspan Insulation Building Fabric InsulationTechnical Services Department on the numbersbelow:



General EnquiriesFor all other enquiries contact Kingspan Insulation on the numbers below:



Kingspan Insulation reserve the right to amend product specifications without prior notice.Product thicknesses shown in this document should not be taken as being available ex-stockand reference should be made to the current Kingspan Insulation price-list or advice soughtfrom Kingspan Insulation Sales Department. The information, technical details and fixinginstructions etc. included in this literature are given in good faith and apply to uses described.Recommendations for use should be verified as to the suitability and compliance with actualrequirements, specifications and any applicable laws and regulations. For other applications orconditions of use, Kingspan Insulation offers a Technical Advisory Service (see left) whoseadvice should be sought for uses of Kingspan Insulation products that are not specificallydescribed herein. Please check that your copy of the literature is current by contacting theKingspan Insulation Marketing Department (see above).

Contact Details

Kingspan Insulation LtdPembridge, Leominster, Herefordshire HR6 9LA, UK

Castleblayney, County Monaghan, Ireland

www.insulation.kingspan.com

® Kingspan, KoolDuct, Kooltherm, Nilflam, Nilvent, Styrozone, the zo Device and the Lion Device are Registered Trademarks of the Kingspan Group plc

thermwall tw50 partial fill cavity wall...

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