Neopor Application brochure: Wall insulation
Wall insulation
TABLE OF CONTENTS Editorial Neopor® – Innovation in Insulation Overview of applications for Neopor® Interior insulation Exterior insulation (EFIS) Insulating concrete forms (ICF)
2 3 4 5 6 6
Cavity insulation Insulation behind curtain walls Building and Construction Regulation Properties of Neopor® Example
1930:
1995:
Patent for the polymerization of monostyrene
Patent for Neopor®
1920
1925 1930
1940
1951:
1950
1960
1970
7 7 8 9 10 11
Neopor®
1980
1990
2000
2005
Styropor®
Patent for expandable polystyrene (EPS, Styropor®)
BASF – THE CHEMICAL COMPANY IN KOREA
Editorial
BASF is the world´s leading chemical company: The Chemical Company. As a reliable partner to virtually all industries, BASF´s high-value products and intelligent system solutions help its customers to be more successful.
Korea and BASF enjoy a progressive working relationship spanning over half a century. BASF, as a responsible partner, is committed to the development of the economy and chemical industry in Korea while enhancing the environment, promoting safety and health activities, transferring advanced managerial techniques, and introducing an innovative corporate culture to Korea. BASF will greatly contribute to the future development of the Korean economy through continuous investment.
BASF supplies highest quality of products at competitive prices to domestic and overseas customers, and its vigorous export activities in Korea doubtless help gain foreign currency. Workers and management at BASF together with the regional society take responsibility as good corporate citizens by helping create a safe and environmentally friendly operation of plants. BASF Company Ltd is one of biggest foreign invested companies in Korea as well as Top ten chemical company in Korea.
SMALL, ROUND, BLACK – ONE RAW MATERIAL, MANY APPLICATIONS
THESE BLACK BEADS are expanded by processors on conventional EPS machines and made into silver-grey foam blocks, panels and molded parts. The blocks are then cut into panels of different thicknesses.
INSULATING MATERIALS MADE OF NEOPOR® offer a higher insulating capacity using less raw material. They are gentle on the environment and on the wallet. Neopor® insulating materials symbolize a modern, ecologically sound life style. And this is what we call “Innovation in Insulation”.
Neopor ® – Innovation in Insulation
NEOPOR® – small black beads in the form of polystyrene granules that contain blowing agents and consequently can be expanded. BASF produces this unique raw material, which foam manufacturers then turn into insulating materials for a wide array of applications.
3
flat roof insulation insulating concrete forms (ICF) cavity insulation encasements for shutters
impact sound insulation
pitched roof insulation attic insulation
Overview of applications for Neopor®
interior insulation
exterior insulation (EFIS)
floor and ceiling insulation
INSULATION FOR THE FUTURE Before the backdrop of climate and environmental protection aspects as well as exploding energy prices, thermal protection of buildings has become indispensable. Excellent thermal insulation of roofs, exterior walls, floors and basements is the cornerstone of low energy consumption. When it comes to new construction and to the renovation of existing buildings, Neopor® offers ideal insulation solutions for almost all components.
insulation behind curtain walls insulated frame structure
INTERIOR INSULATION
The foamed Neopor® insulation panels are located and protected between the exterior concrete wall and the interior non-flammable gypsum board as the finishing materials, and the Neopor is attached to the concrete wall with cement adhesive. Foamed Neopor® insulation panels are very easy to produce, transport and handle by every player in the value chain in Korea. Composite panels made of Neopor®, which can be installed all the way up to the ceiling, are particularly convenient. When professionally sealed, they form an ideal substrate for painting and wallpapering work as well as for laying tiles. An assessment of the physical structure of the outer wall is recommended. Window soffits, floors and interior wall joints should likewise be insulated in order to reduce the formation of thermal bridges. The additional elasticity brought about up by Neopor® can also improve sound insulation.
Interior wall insulation is the predominant form of thermal insulation in Korea. It offers a clear-cut advantage for spaces that have to be heated up or cooled down quickly or only for brief periods of time. In addition, it makes restoration and renovation work easier (the facade can be retained) and it simplifies the work process when homeowners choose to remove walls or to move them to a different location.
Concrete wall Cement bond Neopor®
rooms heat up or cool down quickly less energy consumption
Gypsum Board
simple and cost-effective installation higher surface temperature
INTERIOR INSULATION
EXTERIOR INSULATION (EFIS)
INSULATING CONCRETE FORMS (ICF)
CAVITY INSULATION
INSULATION BEHIND CURTAIN WALLS
Interior insulation with Neopor®
Gypsum bond
5
Applications for Neopor® 6
EXTERIOR INSULATION (EFIS)
INSULATING CONCRETE FORMS (ICF)
Exterior wall insulation is used in smaller structures such as single-family homes, schools and commercial buildings. In the winter, the cold is kept out, while in the summer, the heat cannot get in. This type of insulation protects the load-bearing inner shell or the existing exterior wall against thermal loads and it also provides protection against the weather.
Formwork blocks are hollow foam forms installed at the construction site and filled with concrete. Formwork elements and molded parts made of Neopor® are suitable for all kinds of components that require thermal insulation and ease of processing. They are employed as wall and floor elements for single-family houses as well as multi-storey buildings.
thinner insulation material, higher insulation coefficient
no thermal bridges
exterior components free of thermal bridges
low weight
non-glare work in case of direct sunlight
simple and fast handling
simple handling, ease of processing
high degree of thermal insulation
Thanks to the outstanding thermal insulating properties of panels made of Neopor®, better insulation coefficients can be achieved with thinner insulation materials. The exterior insulation made of Neopor® is installed on the outside of the wall and coated with a reinforced special stucco. Mineral-based as well as dispersionbonded stucco systems can be used.
Formwork elements made of Neopor® make it possible to build and insulate exterior walls at the same time. The elements are available in various wall thicknesses and designs. Thanks to their good thermal-insulating properties, double-sided ICFs (insulating concrete forms) made of Neopor® are well-suited for the construction of lowenergy and passive houses.
Plaster
Stucco
Structure, for example, masonry, concrete, etc.
Reinforcement
Adhesive Exterior insulation (EFIS made of Neopor®)
Formwork element (outside) made of Neopor® Concrete core
Reinforcement
Formwork element (inside) made of Neopor®
Stucco
Cladding
CAVITY INSULATION
INSULATION BEHIND CURTAIN WALLS
In new construction, double outer walls provide ideal possibilities from an architectural and physical standpoint. Panels made of Neopor® can be employed for frost-resistant back-ventilated masonry as well as purely for cavity insulation that is not back-ventilated.
Back-ventilated curtain walls consist of a substructure, insulating material, an air layer and facade covering. They are used for design reasons and also due to safety considerations of a technical nature. The exterior walls can be tailor-made to match the characteristics of a given building.
permanently dry thermal insulation
durable and dimensionally stable
individualized facade design
high heat-storing capacity
good weather protection
good weathering protection
quick and dry installation
In double-wall masonry, the space between the outer frost-resistant masonry shell and the inner load-bearing structure is limited. Owing to the low thermal conductivity of insulating materials made of Neopor®, a relatively higher insulating effect can be achieved. Retrofitting a wall with cavity insulation can be done by blowing expanded beads made of Neopor® into the existing cavities.
Outer skin (Air layer) Cavity insulation made of Neopor®
The two-layer system of a back-ventilated curtain wall systematically separates the functions of weather protection and insulation, thus ensuring thermal insulation that is permanently dry and functional. The back-ventilation reliably eliminates any moisture stemming from the structure itself or from the utilization of the building. Thanks to its outstanding insulating capacity, Neopor® is the material of choice for use in this facade system.
Weather protection (facade covering) Back-ventilation
Anchoring Wall structure Plaster
Thermal insulation made of Neopor® Construction, for example, masonry, concrete, etc.
Applications for Neopor®
low water absorption
7
BUILDING AND CONSTRUCTION SCOPE This specification applies to the installation of Neopor® thermal insulation, which is foamed expandable polystyrene.
KOREA INDUSTRIAL STRANDARDS (KS) KS F 2271 KS M 3808 KS L 9016
Interior materials of building and Testing method for incombustibility Foamed polystyrene for thermal insulation materials Testing method for thermal transmission of insulating materials
TRANSPORTATION, STORAGE AND HANDLING Upon transporting and storing materials, be careful not to damage the edges. The product name and the quality mark must appear on the outer packaging. The following information must be provided on the labeling: manufacturer name, KS quality mark, CE mark, Neopor® certification logo. Neopor® thermal insulation should not be exposed to direct sunlight, rain or wind. It must be stored in dry and airy conditions according to use and type. When thermal insulation is stored and transported in plastic wrap, make sure both sides are open to let air through. Also, use colored wrap film to prevent long-term exposure to direct sunlight. Do not place heavy objects on Neopor® thermal insulation.
Building and Construction
QUALITY
The product must comply with KS M 3808. A product that is below 15 g/l, the lowest grade, is considered defective. Moreover, the minimum level of thermal transmission is set at less than 0.034 W/(m²·K).
APPLICATION STANDARDS The following are the application standards for Neopor® thermal insulation, unless noted otherwise. Classification
Density (kg/m³)
Thermal Transmission (W/m·K)
Application
No. 1
30
0.031
Insulation of roof waterproofing layers, bottom of water tank
No. 2
25
0.032
Insulation of building shells using composite thermal insulation system, side walls
No. 3
20
0.033
Outer insulation of exterior and side walls
No. 4
15
0.034
Outer wall insulation, general wall information
GENERAL CONDITIONS FOR INSULATION INSTALLATION During installation at construction site, cut precisely in a straight line using a cutter. Work must be carried out with precision to ensure no gaps in convergence points and outer edges. In areas where thermal insulations come into contact with each other, seal the connecting area using tape. For double-layer thermal insulation, make sure the connecting areas intercross and tape the outer layer. For side walls, attach on the wall surface of the pertinent floor completely before moving on to the next process. When gaps appear, fill them with urethane foam.
CAVITY TREATMENT OF HOLLOW WALLS When installing Neopor® thermal insulation in the cavity of hollow walls, fix it in place via penetration with a connecting wire which is covered by the bricks, as is the case when giving air space during brick-laying.
INTERNAL WALLS The use of plasterboard bond provided by the plasterboard company is recommended when adhering thermal insulation to plasterboard. For stronger adhesion of Neopor® thermal insulation and plasterboard, apply primer to thermal insulation before the adhesion process.
GENERAL CONDITIONS FOR INSTALLING COMPOSITE THERMAL INSULATION SYSTEM In a composite thermal insulation system, a polypropylene surface layer or magnesium board is attached to Neopor® thermal insulation using a water-resistant adhesive for damage prevention. The system must provide insulation beyond that required for the applied area.
POLYPROPYLENE SURFACE LAYER An incombustible (grade 2) polypropylene board having a hollow space and measuring three mm in thickness. The exposed side should be coated to allow for easy wallpapering and maintenance and to prevent deformation. It must have a weight of over 800 g/m2.
MAGNESIUM BOARD An incombustible (grade 2) flat board made of a blend of magnesium, wood powder and pearlite measuring 3 mm in thickness that complies with KS F 2271. In accordance with KS L 5114 test methods, it should have an absorption rate of below 30 percent and a bending strength of over 14 N/mm2.
ADHESIVE Use an epoxy type adhesive to join Neopor® thermal insulation and surface board. All sides should be coated with the adhesive for areas within 50 mm of the surface board edge. The adhesive should be applied to more than 80 percent of the surface board.
regulation Korean regulators are increasingly focusing on high quality insulation materials and energy-saving when it comes to insulation-related construction law. Naturally, this trend can be observed on a global scale taking into account rising oil prices, global warming and limited resources of our eco-system.
Neopor®, the eco-efficient insulation solution by BASF, is clearly in line with these trends by means of its outstanding thermal performance, eco-friendliness and impact sound insulation properties. With Neopor®, you are prepared for the future!
Thermal transmittance for building thickness by location Application Internal wall
Middle area (W/m²·K)
South area (W/m²·K)
JeJu island (W/m²·K)
By face on external air directly
0.47
0.58
0.76
By face on external air indirectly
0.64
0.81
1.1
0.35
0.47
0.58
Location
Side wall of apartment housing
Thermal conductivity for building thickness by location Class
Conductivity
Specified material
(W/m·K)
(kcal/mh °C)
A
< 0.034
< 0.029
B
0.035 ~ 0.040
0.030 ~ 0.034
EPS board (KS-1, KS-2, KS-3), Rock wool board, Glass-wool board
C
0.041 ~ 0.046
0.035 ~ 0.039
EPS board (KS-4)
D
0.047 ~ 0.051
0.040 ~ 0.044
Others with 0.047~0.051 W/(m·k)
XPS board, Polyurethane foam board Neopor® board (KS-1, KS-2, KS-3, KS-4) Others below 0.034 W/(m·k)
Application
Seoul Area Southern Area Jeju Island
Description
A (mm)
B (mm)
C (mm)
D (mm)
By face on external air directly
65
75
85
100
By face on external air indirectly
45
50
55
65
By face on external air directly
50
60
70
75
By face on external air indirectly
30
35
40
45
By face on external air directly
35
45
50
55
By face on external air indirectly
20
25
30
30
Regulation
insulation thickness by material class for internal wall insulation
0.045
0.040
0.035 EPS 0.030
10
5
10
15
20
25
30
35
40
45 50 55 Density [kg/m3]
THERMAL PROTECTION
THERMAL CONDUCTIVITY
The outstanding effect of insulating materials made of Neopor® gives engineers and processors decisive advantages in actual construction projects. In comparison to conventional EPS, Neopor® allows more streamlined structures while providing a better insulating effect. Infrared absorbers or infrared reflectors make it possible to greatly reduce thermal conductivity. For instance, the permeability of the material to radiant heat is more restricted than with commonly employed insulating panels and the insulation effect is up to 20 percent higher than with conventional EPS panels.
The figure (diagram) shows that insulating materials made of Neopor having a density, for example, of 30 kg/m³, attain a thermal conductivity of 0.029 W/(m·K). Conventional EPS having the same density exhibits a thermal conductivity of 0.032 W/(m·K).
SOUND PROTECTION
FIRE PROTECTION Neopor® is a polystyrene rigid foam rated in Material Class B1, i.e. fire-resistant, and is categorized as non-burning dripping.
Insulating materials made of Neopor® not only account for energy savings but also considerably improve the sound protection of buildings. Studies have shown that the sound-insulating properties of thermal insulation composite systems with Neopor® bring about an improvement of the sound-insulation coefficient of up to 4 dB, depending on the solid wall, the panel thickness and the type of stucco or plaster.
ECO-EFFICIENt building with neopor® The eco-efficiency analysis looks at products and processes from an economic and environmental standpoint in order to find which ones are the most efficient. In comparison to alternative products, Neopor® offers a greater benefit at lower costs and with less impact on the environment. The huge advantage of Neopor® stems from the fact that it uses as much as 50 percent less raw material, as a result of which costs can be lowered and resources can be saved, all of which, in turn, alleviates the environmental burden. The same insulation effect is achieved with an insulating material that is 15 to 20 percent thinner. This translates into eco-efficient insulation solutions for modern thermal protection.
0.7
High eco-efficiency
Neopor® benefit obtained from using 1 m2 of the composite thermal insulation system
environmental burden (standardized)
Properties of Neopor®
0.025
Neopor®
1.0 Styropor®
alternatives examined: Neopor® Styropor® mineral wool
Mineral wool
1.3
Low eco-efficiency
1.3
1.0
0.7 costs (standardized)
Eco-efficiency analysis of thermal insulation composite systems used in the „Three-Liter House“ in the Brunck neighbourhood of Ludwigshafen, Germany in the year 2000, confirmed by the Öko-Institut in Freiburg and by the TÜV (German Technical Inspection Association).
The two-storey, 125 m² house is the first “Three-Liter House” in Korea and has been specially adapted to Korea’s housing environment. It introduces energy saving know-how and innovative housing technologies from BASF. The house was built by BASF Company Ltd., in collaboration with FuelCellPower Inc. and Daelim Industrial Co., Ltd. The “Three-Liter House” is a future-oriented, environmentally friendly house model, introduced by BASF in Europe. It maintains optimum temperatures with only three liters of fuel per m² per year, utilizing energy- efficient construction technologies, highly efficient insulation materials, and a fuel-cell system. It reduces energy consumption to one sixth or one seventh of existing houses and also reduces CO2 generation by 80 percent. This project is particularly significant because it forms the foundation for developing a new future-oriented housing concept - providing the infrastructure for innovative energy saving through collaboration between foreign business, a large local enterprise, and a venture business.
OTHER FEATURES – – – – –
Neopor® high efficiency insulation material Latent heat-retaining plaster (PCM-Micronal®) High-efficiency window system Thermal exchange ventilation system Fuel cell co-generation system
PROJECT BACKGROUND – – –
Efficient energy-saving in an era of high oil prices Active preparation for the climate change convention Creation of a new environmentally-friendly housing culture
Energy Award 2006 As a result of its outstanding insulation performance and contribution to energy-saving, BASF’s Neopor® was awarded the Energy Award for the year 2006 in the section Green Building on August 26, 2005 by the Citizen’s Alliance for Consumer Protection in Korea (CACPK). The National Energy Efficiency Award Programme (“Energy Winner”) is granted to producers who conserve energy by minimizing its use and maximizing its efficiency. It is sponsored by the Ministry of Commerce, Industry and Energy (MOCIE), Ministry of Environment, and Korea Energy Management Corporation (KEMCO) and supported by the United Nations Economic and Social Committee for Asia and the Pacific (UNESCAP).
Example
THREE LITER HOUSE in Yongin, Korea
11
Additional information about Neopor® Brochure: Neopor® – Innovation in Insulation Brochure: Neopor® – General information for the construction industry Application brochure: Wall insulation Neopor® film: Innovation in Insulation
BASF South East Asia Pte Ltd. 7 Temasek Boulevard, # 35-01 Suntec Tower One Singapore, 038987 Phone: +65 643 317 Fax: +65 643 379 E-Mail: [email protected] http://www.neopor.de http://www.basf.com
KTFN 0807 BKO – ENGLISH VERSION FOR ASIA – 1.008
Note The data contained in this publication are based on our current knowledge and experience. In view of the many factors that may affect processing and application of our product, these data do not relieve processors from carrying out own investigations and tests; neither do these data imply any guarantee of certain properties, nor the suitability of the product for a specifi c purpose. Any descriptions, drawings, photographs, data, proportions, weights etc. given herein may change without prior information and do not constitute the agreed contractual quality of the product. It is the responsibility of the recipient of our products to ensure that any proprietary rights and existing laws and legislation are observed. (December 008)
® = registered trademark of BASF SE
Website: www.neopor.de
TABLE OF CONTENTS Editorial Neopor® – Innovation in Insulation Overview of applications for Neopor® Interior insulation Exterior insulation (EFIS) Insulating concrete forms (ICF)
2 3 4 5 6 6
Cavity insulation Insulation behind curtain walls Building and Construction Regulation Properties of Neopor® Example
1930:
1995:
Patent for the polymerization of monostyrene
Patent for Neopor®
1920
1925 1930
1940
1951:
1950
1960
1970
7 7 8 9 10 11
Neopor®
1980
1990
2000
2005
Styropor®
Patent for expandable polystyrene (EPS, Styropor®)
BASF – THE CHEMICAL COMPANY IN KOREA
Editorial
BASF is the world´s leading chemical company: The Chemical Company. As a reliable partner to virtually all industries, BASF´s high-value products and intelligent system solutions help its customers to be more successful.
Korea and BASF enjoy a progressive working relationship spanning over half a century. BASF, as a responsible partner, is committed to the development of the economy and chemical industry in Korea while enhancing the environment, promoting safety and health activities, transferring advanced managerial techniques, and introducing an innovative corporate culture to Korea. BASF will greatly contribute to the future development of the Korean economy through continuous investment.
BASF supplies highest quality of products at competitive prices to domestic and overseas customers, and its vigorous export activities in Korea doubtless help gain foreign currency. Workers and management at BASF together with the regional society take responsibility as good corporate citizens by helping create a safe and environmentally friendly operation of plants. BASF Company Ltd is one of biggest foreign invested companies in Korea as well as Top ten chemical company in Korea.
SMALL, ROUND, BLACK – ONE RAW MATERIAL, MANY APPLICATIONS
THESE BLACK BEADS are expanded by processors on conventional EPS machines and made into silver-grey foam blocks, panels and molded parts. The blocks are then cut into panels of different thicknesses.
INSULATING MATERIALS MADE OF NEOPOR® offer a higher insulating capacity using less raw material. They are gentle on the environment and on the wallet. Neopor® insulating materials symbolize a modern, ecologically sound life style. And this is what we call “Innovation in Insulation”.
Neopor ® – Innovation in Insulation
NEOPOR® – small black beads in the form of polystyrene granules that contain blowing agents and consequently can be expanded. BASF produces this unique raw material, which foam manufacturers then turn into insulating materials for a wide array of applications.
3
flat roof insulation insulating concrete forms (ICF) cavity insulation encasements for shutters
impact sound insulation
pitched roof insulation attic insulation
Overview of applications for Neopor®
interior insulation
exterior insulation (EFIS)
floor and ceiling insulation
INSULATION FOR THE FUTURE Before the backdrop of climate and environmental protection aspects as well as exploding energy prices, thermal protection of buildings has become indispensable. Excellent thermal insulation of roofs, exterior walls, floors and basements is the cornerstone of low energy consumption. When it comes to new construction and to the renovation of existing buildings, Neopor® offers ideal insulation solutions for almost all components.
insulation behind curtain walls insulated frame structure
INTERIOR INSULATION
The foamed Neopor® insulation panels are located and protected between the exterior concrete wall and the interior non-flammable gypsum board as the finishing materials, and the Neopor is attached to the concrete wall with cement adhesive. Foamed Neopor® insulation panels are very easy to produce, transport and handle by every player in the value chain in Korea. Composite panels made of Neopor®, which can be installed all the way up to the ceiling, are particularly convenient. When professionally sealed, they form an ideal substrate for painting and wallpapering work as well as for laying tiles. An assessment of the physical structure of the outer wall is recommended. Window soffits, floors and interior wall joints should likewise be insulated in order to reduce the formation of thermal bridges. The additional elasticity brought about up by Neopor® can also improve sound insulation.
Interior wall insulation is the predominant form of thermal insulation in Korea. It offers a clear-cut advantage for spaces that have to be heated up or cooled down quickly or only for brief periods of time. In addition, it makes restoration and renovation work easier (the facade can be retained) and it simplifies the work process when homeowners choose to remove walls or to move them to a different location.
Concrete wall Cement bond Neopor®
rooms heat up or cool down quickly less energy consumption
Gypsum Board
simple and cost-effective installation higher surface temperature
INTERIOR INSULATION
EXTERIOR INSULATION (EFIS)
INSULATING CONCRETE FORMS (ICF)
CAVITY INSULATION
INSULATION BEHIND CURTAIN WALLS
Interior insulation with Neopor®
Gypsum bond
5
Applications for Neopor® 6
EXTERIOR INSULATION (EFIS)
INSULATING CONCRETE FORMS (ICF)
Exterior wall insulation is used in smaller structures such as single-family homes, schools and commercial buildings. In the winter, the cold is kept out, while in the summer, the heat cannot get in. This type of insulation protects the load-bearing inner shell or the existing exterior wall against thermal loads and it also provides protection against the weather.
Formwork blocks are hollow foam forms installed at the construction site and filled with concrete. Formwork elements and molded parts made of Neopor® are suitable for all kinds of components that require thermal insulation and ease of processing. They are employed as wall and floor elements for single-family houses as well as multi-storey buildings.
thinner insulation material, higher insulation coefficient
no thermal bridges
exterior components free of thermal bridges
low weight
non-glare work in case of direct sunlight
simple and fast handling
simple handling, ease of processing
high degree of thermal insulation
Thanks to the outstanding thermal insulating properties of panels made of Neopor®, better insulation coefficients can be achieved with thinner insulation materials. The exterior insulation made of Neopor® is installed on the outside of the wall and coated with a reinforced special stucco. Mineral-based as well as dispersionbonded stucco systems can be used.
Formwork elements made of Neopor® make it possible to build and insulate exterior walls at the same time. The elements are available in various wall thicknesses and designs. Thanks to their good thermal-insulating properties, double-sided ICFs (insulating concrete forms) made of Neopor® are well-suited for the construction of lowenergy and passive houses.
Plaster
Stucco
Structure, for example, masonry, concrete, etc.
Reinforcement
Adhesive Exterior insulation (EFIS made of Neopor®)
Formwork element (outside) made of Neopor® Concrete core
Reinforcement
Formwork element (inside) made of Neopor®
Stucco
Cladding
CAVITY INSULATION
INSULATION BEHIND CURTAIN WALLS
In new construction, double outer walls provide ideal possibilities from an architectural and physical standpoint. Panels made of Neopor® can be employed for frost-resistant back-ventilated masonry as well as purely for cavity insulation that is not back-ventilated.
Back-ventilated curtain walls consist of a substructure, insulating material, an air layer and facade covering. They are used for design reasons and also due to safety considerations of a technical nature. The exterior walls can be tailor-made to match the characteristics of a given building.
permanently dry thermal insulation
durable and dimensionally stable
individualized facade design
high heat-storing capacity
good weather protection
good weathering protection
quick and dry installation
In double-wall masonry, the space between the outer frost-resistant masonry shell and the inner load-bearing structure is limited. Owing to the low thermal conductivity of insulating materials made of Neopor®, a relatively higher insulating effect can be achieved. Retrofitting a wall with cavity insulation can be done by blowing expanded beads made of Neopor® into the existing cavities.
Outer skin (Air layer) Cavity insulation made of Neopor®
The two-layer system of a back-ventilated curtain wall systematically separates the functions of weather protection and insulation, thus ensuring thermal insulation that is permanently dry and functional. The back-ventilation reliably eliminates any moisture stemming from the structure itself or from the utilization of the building. Thanks to its outstanding insulating capacity, Neopor® is the material of choice for use in this facade system.
Weather protection (facade covering) Back-ventilation
Anchoring Wall structure Plaster
Thermal insulation made of Neopor® Construction, for example, masonry, concrete, etc.
Applications for Neopor®
low water absorption
7
BUILDING AND CONSTRUCTION SCOPE This specification applies to the installation of Neopor® thermal insulation, which is foamed expandable polystyrene.
KOREA INDUSTRIAL STRANDARDS (KS) KS F 2271 KS M 3808 KS L 9016
Interior materials of building and Testing method for incombustibility Foamed polystyrene for thermal insulation materials Testing method for thermal transmission of insulating materials
TRANSPORTATION, STORAGE AND HANDLING Upon transporting and storing materials, be careful not to damage the edges. The product name and the quality mark must appear on the outer packaging. The following information must be provided on the labeling: manufacturer name, KS quality mark, CE mark, Neopor® certification logo. Neopor® thermal insulation should not be exposed to direct sunlight, rain or wind. It must be stored in dry and airy conditions according to use and type. When thermal insulation is stored and transported in plastic wrap, make sure both sides are open to let air through. Also, use colored wrap film to prevent long-term exposure to direct sunlight. Do not place heavy objects on Neopor® thermal insulation.
Building and Construction
QUALITY
The product must comply with KS M 3808. A product that is below 15 g/l, the lowest grade, is considered defective. Moreover, the minimum level of thermal transmission is set at less than 0.034 W/(m²·K).
APPLICATION STANDARDS The following are the application standards for Neopor® thermal insulation, unless noted otherwise. Classification
Density (kg/m³)
Thermal Transmission (W/m·K)
Application
No. 1
30
0.031
Insulation of roof waterproofing layers, bottom of water tank
No. 2
25
0.032
Insulation of building shells using composite thermal insulation system, side walls
No. 3
20
0.033
Outer insulation of exterior and side walls
No. 4
15
0.034
Outer wall insulation, general wall information
GENERAL CONDITIONS FOR INSULATION INSTALLATION During installation at construction site, cut precisely in a straight line using a cutter. Work must be carried out with precision to ensure no gaps in convergence points and outer edges. In areas where thermal insulations come into contact with each other, seal the connecting area using tape. For double-layer thermal insulation, make sure the connecting areas intercross and tape the outer layer. For side walls, attach on the wall surface of the pertinent floor completely before moving on to the next process. When gaps appear, fill them with urethane foam.
CAVITY TREATMENT OF HOLLOW WALLS When installing Neopor® thermal insulation in the cavity of hollow walls, fix it in place via penetration with a connecting wire which is covered by the bricks, as is the case when giving air space during brick-laying.
INTERNAL WALLS The use of plasterboard bond provided by the plasterboard company is recommended when adhering thermal insulation to plasterboard. For stronger adhesion of Neopor® thermal insulation and plasterboard, apply primer to thermal insulation before the adhesion process.
GENERAL CONDITIONS FOR INSTALLING COMPOSITE THERMAL INSULATION SYSTEM In a composite thermal insulation system, a polypropylene surface layer or magnesium board is attached to Neopor® thermal insulation using a water-resistant adhesive for damage prevention. The system must provide insulation beyond that required for the applied area.
POLYPROPYLENE SURFACE LAYER An incombustible (grade 2) polypropylene board having a hollow space and measuring three mm in thickness. The exposed side should be coated to allow for easy wallpapering and maintenance and to prevent deformation. It must have a weight of over 800 g/m2.
MAGNESIUM BOARD An incombustible (grade 2) flat board made of a blend of magnesium, wood powder and pearlite measuring 3 mm in thickness that complies with KS F 2271. In accordance with KS L 5114 test methods, it should have an absorption rate of below 30 percent and a bending strength of over 14 N/mm2.
ADHESIVE Use an epoxy type adhesive to join Neopor® thermal insulation and surface board. All sides should be coated with the adhesive for areas within 50 mm of the surface board edge. The adhesive should be applied to more than 80 percent of the surface board.
regulation Korean regulators are increasingly focusing on high quality insulation materials and energy-saving when it comes to insulation-related construction law. Naturally, this trend can be observed on a global scale taking into account rising oil prices, global warming and limited resources of our eco-system.
Neopor®, the eco-efficient insulation solution by BASF, is clearly in line with these trends by means of its outstanding thermal performance, eco-friendliness and impact sound insulation properties. With Neopor®, you are prepared for the future!
Thermal transmittance for building thickness by location Application Internal wall
Middle area (W/m²·K)
South area (W/m²·K)
JeJu island (W/m²·K)
By face on external air directly
0.47
0.58
0.76
By face on external air indirectly
0.64
0.81
1.1
0.35
0.47
0.58
Location
Side wall of apartment housing
Thermal conductivity for building thickness by location Class
Conductivity
Specified material
(W/m·K)
(kcal/mh °C)
A
< 0.034
< 0.029
B
0.035 ~ 0.040
0.030 ~ 0.034
EPS board (KS-1, KS-2, KS-3), Rock wool board, Glass-wool board
C
0.041 ~ 0.046
0.035 ~ 0.039
EPS board (KS-4)
D
0.047 ~ 0.051
0.040 ~ 0.044
Others with 0.047~0.051 W/(m·k)
XPS board, Polyurethane foam board Neopor® board (KS-1, KS-2, KS-3, KS-4) Others below 0.034 W/(m·k)
Application
Seoul Area Southern Area Jeju Island
Description
A (mm)
B (mm)
C (mm)
D (mm)
By face on external air directly
65
75
85
100
By face on external air indirectly
45
50
55
65
By face on external air directly
50
60
70
75
By face on external air indirectly
30
35
40
45
By face on external air directly
35
45
50
55
By face on external air indirectly
20
25
30
30
Regulation
insulation thickness by material class for internal wall insulation
0.045
0.040
0.035 EPS 0.030
10
5
10
15
20
25
30
35
40
45 50 55 Density [kg/m3]
THERMAL PROTECTION
THERMAL CONDUCTIVITY
The outstanding effect of insulating materials made of Neopor® gives engineers and processors decisive advantages in actual construction projects. In comparison to conventional EPS, Neopor® allows more streamlined structures while providing a better insulating effect. Infrared absorbers or infrared reflectors make it possible to greatly reduce thermal conductivity. For instance, the permeability of the material to radiant heat is more restricted than with commonly employed insulating panels and the insulation effect is up to 20 percent higher than with conventional EPS panels.
The figure (diagram) shows that insulating materials made of Neopor having a density, for example, of 30 kg/m³, attain a thermal conductivity of 0.029 W/(m·K). Conventional EPS having the same density exhibits a thermal conductivity of 0.032 W/(m·K).
SOUND PROTECTION
FIRE PROTECTION Neopor® is a polystyrene rigid foam rated in Material Class B1, i.e. fire-resistant, and is categorized as non-burning dripping.
Insulating materials made of Neopor® not only account for energy savings but also considerably improve the sound protection of buildings. Studies have shown that the sound-insulating properties of thermal insulation composite systems with Neopor® bring about an improvement of the sound-insulation coefficient of up to 4 dB, depending on the solid wall, the panel thickness and the type of stucco or plaster.
ECO-EFFICIENt building with neopor® The eco-efficiency analysis looks at products and processes from an economic and environmental standpoint in order to find which ones are the most efficient. In comparison to alternative products, Neopor® offers a greater benefit at lower costs and with less impact on the environment. The huge advantage of Neopor® stems from the fact that it uses as much as 50 percent less raw material, as a result of which costs can be lowered and resources can be saved, all of which, in turn, alleviates the environmental burden. The same insulation effect is achieved with an insulating material that is 15 to 20 percent thinner. This translates into eco-efficient insulation solutions for modern thermal protection.
0.7
High eco-efficiency
Neopor® benefit obtained from using 1 m2 of the composite thermal insulation system
environmental burden (standardized)
Properties of Neopor®
0.025
Neopor®
1.0 Styropor®
alternatives examined: Neopor® Styropor® mineral wool
Mineral wool
1.3
Low eco-efficiency
1.3
1.0
0.7 costs (standardized)
Eco-efficiency analysis of thermal insulation composite systems used in the „Three-Liter House“ in the Brunck neighbourhood of Ludwigshafen, Germany in the year 2000, confirmed by the Öko-Institut in Freiburg and by the TÜV (German Technical Inspection Association).
The two-storey, 125 m² house is the first “Three-Liter House” in Korea and has been specially adapted to Korea’s housing environment. It introduces energy saving know-how and innovative housing technologies from BASF. The house was built by BASF Company Ltd., in collaboration with FuelCellPower Inc. and Daelim Industrial Co., Ltd. The “Three-Liter House” is a future-oriented, environmentally friendly house model, introduced by BASF in Europe. It maintains optimum temperatures with only three liters of fuel per m² per year, utilizing energy- efficient construction technologies, highly efficient insulation materials, and a fuel-cell system. It reduces energy consumption to one sixth or one seventh of existing houses and also reduces CO2 generation by 80 percent. This project is particularly significant because it forms the foundation for developing a new future-oriented housing concept - providing the infrastructure for innovative energy saving through collaboration between foreign business, a large local enterprise, and a venture business.
OTHER FEATURES – – – – –
Neopor® high efficiency insulation material Latent heat-retaining plaster (PCM-Micronal®) High-efficiency window system Thermal exchange ventilation system Fuel cell co-generation system
PROJECT BACKGROUND – – –
Efficient energy-saving in an era of high oil prices Active preparation for the climate change convention Creation of a new environmentally-friendly housing culture
Energy Award 2006 As a result of its outstanding insulation performance and contribution to energy-saving, BASF’s Neopor® was awarded the Energy Award for the year 2006 in the section Green Building on August 26, 2005 by the Citizen’s Alliance for Consumer Protection in Korea (CACPK). The National Energy Efficiency Award Programme (“Energy Winner”) is granted to producers who conserve energy by minimizing its use and maximizing its efficiency. It is sponsored by the Ministry of Commerce, Industry and Energy (MOCIE), Ministry of Environment, and Korea Energy Management Corporation (KEMCO) and supported by the United Nations Economic and Social Committee for Asia and the Pacific (UNESCAP).
Example
THREE LITER HOUSE in Yongin, Korea
11
Additional information about Neopor® Brochure: Neopor® – Innovation in Insulation Brochure: Neopor® – General information for the construction industry Application brochure: Wall insulation Neopor® film: Innovation in Insulation
BASF South East Asia Pte Ltd. 7 Temasek Boulevard, # 35-01 Suntec Tower One Singapore, 038987 Phone: +65 643 317 Fax: +65 643 379 E-Mail: [email protected] http://www.neopor.de http://www.basf.com
KTFN 0807 BKO – ENGLISH VERSION FOR ASIA – 1.008
Note The data contained in this publication are based on our current knowledge and experience. In view of the many factors that may affect processing and application of our product, these data do not relieve processors from carrying out own investigations and tests; neither do these data imply any guarantee of certain properties, nor the suitability of the product for a specifi c purpose. Any descriptions, drawings, photographs, data, proportions, weights etc. given herein may change without prior information and do not constitute the agreed contractual quality of the product. It is the responsibility of the recipient of our products to ensure that any proprietary rights and existing laws and legislation are observed. (December 008)
® = registered trademark of BASF SE
Website: www.neopor.de
