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Sustainable Solutions for Thermal, Fire & Sound Control – Roxul

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  • 1. Stone Wool Insulation Sustainable Solutions forThermal, Fire, and Sound Control
  • 2. Roxul® Inc. NA division of Rockwool® InternationalRockwool International (Denmark, 1909) - world’s largestproducer of stone wool - 23 facilities in 14 countriesRoxul NA headquarters in Milton, ON (1988) and facilityin Grand Forks, BC (1999)Over 8,000 employees worldwide with 400 in NA
  • 3. Best PracticeRoxul is a Registered Provider with The American Institute ofArchitects Continuing Education Systems. Credit earned oncompletion of this program will be reported to CES Records for AIAmembers. Certificates of Completion for non-AIA members areavailable on request.This program is registered with AIA/CES for continuingprofessional education. As such, it does not include content thatmay be deemed or construed to be an approval or endorsement bythe AIA of any material of construction or any method or manner ofhandling, using, distributing, or dealing in any material or product.Questions related to specific materials, methods, and services willbe addressed at the conclusion of this presentation.
  • 4. Copyright Materials This presentation is protected by US and International copyright laws.Reproduction, distribution, display and use of the presentation without written permission of the speaker is prohibited. © Roxul 2008
  • 5. Learning ObjectivesDefine stone wool insulationIdentify the difference between stone wool, glass fiber,and foam insulationKey features of stone wool – more than just R-ValueSustainable aspects of stone wool and LEED creditsavailableApplications for stone wool in commercial buildings
  • 6. Commercial Insulation TypesFibrous Plastic Foams Glass Fiber Extruded Polystyrene Stone Wool Expanded Polystyrene Slag Wool Polyisocyanurate Polyurethane (SPUF)
  • 7. What Is Stone Wool?
  • 8. What Is Stone Wool? Recycled And Natural MaterialsProduced from natural and abundant basalt rock and blast furnaceslag (residue of the smelting of metallic ore).Spun-blown and has a variety of forms such as batt, board, blanketand pipe insulationBinders (resins and oils) can be added for rigidity, less dust andwater repellency Basalt Slag
  • 9. Production Process
  • 10. The Big PictureThe Facts On Energy Consumption Buildings consume over 40% of all fossil fuels and contribute 40% of 1 all CO2 emissions in the world 2 AIA target is a 50% reduction by 2010 Further 10% reductions every 5 years Carbon neutral in 2030 1. DOE (US Department of Energy), AIA, Architecture 2030 2. AIA HPB Position Statement
  • 11. Why Specify Stone Wool?The Top 6 Reasons1.Fire Resistance2.Water Resistance3.Sound Resistance4.Thermal Resistance5.Dimensional Stability6.Vapor Permeability
  • 12. Why Specify Stone Wool?The Top 6 Reasons1. Fire Resistance2.Water Resistance3.Sound Resistance4.Thermal Resistance5.Dimensional Stability6.Vapor Permeability
  • 13. FIRE CONCERNS 1. Research Project On The Noise Insulation Provided By Exterior Walls In Wood Construction, CMHC Technical Series 99-124
  • 14. Monday Nov 15, fire in Shanghai, China kills 58 people. The fire may have been caused by the accidental ignition of polyurethane foam insulation used on the buildings outer walls. -Shanghai Daily Local Authorities said two apartments next to the destroyed building would be renovated as well, and the foam cladding on the exteriors would be replaced in favor of fire resistant materials. -China Daily
  • 15. Why Specify Stone Wool?1. Fire Resistance Flame Spread1: 0 Smoke Development: 0 Non-combustible2 with a melting point of ~ 2150°F 1. ASTM E84 2. ASTM E136
  • 16. Why Specify Stone Wool?1. Fire Resistance Temperature development in a standard fire (ASTM E119) 2192°F 1200°C stone wool melts 1832°F 1000°C 1472°F 800°C 1112°F 600°C fiberglass melts steel loses load bearing capacity 752°F 400°C polystyrene foam burns 392°F 200°C polyurethane foam burns 32°F 0°C Minutes
  • 17. Why Specify Stone Wool?The Top 6 Reasons1. Fire Resistance2. Water Resistance3. Sound Resistance4. Thermal Resistance5. Dimensional Stability6. Vapor Permeability
  • 18. Why Specify Stone Wool?2. Water Resistance Stone wool is hydrophobic (resins) ASTM C 1104 Moisture Sorption 0.03% Is unaffected by wet / dry cycles Effective drainage plane
  • 19. Why Specify Stone Wool?The Top 6 Reasons1. Fire Resistance2. Water Resistance3. Sound Resistance4. Thermal Resistance5. Dimensional Stability6. Vapor Permeability
  • 20. Why Specify Stone Wool?3. Sound Resistance STC1 ratings on over 15 commercial wall assemblies This example is 51 (RAL-TL96-269) ½” gypsum board, 3 5/8” steel studs 24” center, 3” AFB 1. Sound Transmission Class – tested to ASTM E413, E90
  • 21. Why Specify Stone Wool?3. Sound Resistance STC ratings are poor indicators of sound resistance at frequencies which are of most concern (below 125 Hz) Sources of low frequency sound include speech, audio/video, ventilation equipment, airplanes
  • 22. Why Specify Stone Wool?3. Sound Resistance Low frequency noise is best tested using the “Coefficients at Frequencies” method Stone Wool provides more low frequency absorption than glass fiber when tested to both normal and random incidents of noise Insulation Batt Thickness Avg. 1/3 Octave Band Center Frequency (Hz) (inches) 63 80 100 125 160 200 250 Glass Fiber 3.5 .15 .18 .20 .24 .30 .40 .50 Stone Wool 3.0 .18 .23 .29 .34 .41 .51 .64 HGC Engineering Compared Acoustical Testing At Low Frequencies
  • 23. Why Specify Stone Wool?3. Sound Resistance Higher density of stone wool delivers dramatically better airflow resistivity compared to glass fiber Higher air flow resistivity will deliver better sound attenuation Density (kg/m3) Airflow Resistivity Insulation Batt Thickness (mks rayls / m) (inches) Average Standard Average Standard Value Deviation Value Deviation 3.5 12.2 0.4 4,800 400 Glass Fiber 2 .5 11.7 1.0 3,600 200 Stone Wool 3.0 44.2 1.7 16,600 900 1.5 51.9 2.2 15,000 500 HGC Engineering Compared Acoustical Testing At Low Frequencies
  • 24. Why Specify Stone Wool?The Top 6 Reasons1. Fire Resistance2. Water Resistance3. Sound Resistance4. Thermal Resistance5. Dimensional Stability6. Vapor Permeability
  • 25. Why Specify Stone Wool?4. Thermal Resistance R-value for most products is 4.2 per inch. Unaffected over long- term The flexible nature of stone wool allows the material to conform to surface irregularities, preventing thermal short circuiting
  • 26. Thermal Drift Overtime 7 6 5 ?R-Value 4 ? 3 2 1 0 5 10 15 20 25 30 35 40 45 50 Years Stone Wool PolyIso XPS
  • 27. Why Specify Stone Wool?The Top 6 Reasons1. Fire Resistance2. Water Resistance3. Sound Resistance4. Thermal Resistance5. Dimensional Stability6. Vapor Permeability
  • 28. Why Specify Mineral Wool?5. Dimensional Stability Not affected by thermal cycling ASTM C356 Linear Shrinkage: 0.01% @ 350 °F (177 °C) Reduces long-term effects caused by the stress of thermal cycling
  • 29. Why Specify Stone Wool?5. Dimensional Stability Does not warp, curl or cup Minimizes thermal bridging Provides a flush fit for optimal performance
  • 30. Why Specify Stone Wool?The Top 6 Reasons1. Fire Resistance2. Water Resistance3. Sound Resistance4. Thermal Resistance5. Dimensional Stability6. Vapor Permeability
  • 31. Advantages of Stone Wool in a Cavity Wall Assembly6. Vapor Permeability Stone wool is not a vapor retarder Good wall design should never include 2 vapor barriers Vapor permeance exceeds 30 perms “Breathable insulation” will not trap vapor Excellent for walls with split insulation (i.e. batt + exterior) Does not support mold or fungus growth Maximizes drying potential Great for mixed climates
  • 32. Why Specify Stone Wool?6. Vapor Permeability Stone wool insulation will not block vapor as it tries to escape through the exterior wall assembly Interior Exterior
  • 33. Why Specify Stone Wool?The Top 6 ReasonsM Fire ResistanceM Water ResistanceM Sound ResistanceM Thermal ResistanceM Dimensional StabilityM Vapor Permeability
  • 34. Where To Use Stone WoolCommercial Applications Cavity Walls Rain Screens Curtain Walls and Fire Safing Roofing Interior Stud Walls Ceilings
  • 35. Where To Use Stone WoolCavity Walls Fire resistant Water resistant Sound resistant Drainage capacity Flexible / conforming Vapor permeable
  • 36. Disadvantages of Foam Insulation in Cavity Wall Assemblies1. Thickness of wall vs. Batt Insul in Stud Wall • Added cost of construction • Reduction in floor space2. Poor Sound Control • Relatively low STC ratings for extruded Extruded Polystyrene polystyrene1. • Noise through hollow stud walls has been a common occupant complaint.3. Dimensional Stability of Extruded Polystyrene • Thermal expansion / contraction4. FIRE CONCERNS 1. Research Project On The Noise Insulation Provided By Exterior Walls In Wood Construction, CMHC Technical Series 99-124
  • 37. Disadvantages of Foam Insulation in Cavity Wall Assemblies FIRE CONCERNS1. Introducing a combustible material within the wall assembly.2. May be confined between non- Extruded Polystyrene combustible materials, but… • Weep holes, control joints, etc. • Plumbing and electrical penetrations Weep Holes • Gypsum sheathing joints3. Concerns and requirements of IBC Chapter 26 code 1. Research Project On The Noise Insulation Provided By Exterior Walls In Wood Construction, CMHC Technical Series 99-124
  • 38. IBC Chapter 26 on Plastic• Section 2603 - Foam Plastic Insulation 2603.5 Exterior Walls of buildings of Type I, II, III, or IV construction of any height need comply to the following: 1. 2603.5.1 Fire-resistance-rated walls to be tested according to ASTM E 119 to substantiate that the fire rating is maintained. 2. 2603.5.2 Requires a ½” gypsum thermal barrier separating foam plastic from the interior of the building. (some exceptions) 3. 2603.5.3 Potential heat of foam in any part of the wall shall not exceed the potential heat in the wall assembly tested in accordance with NFPA 285. 4. Flame Spread and Smoke Development less than 25 and 450 respectively, when tested at the thickness intended for use (4” max). 5. Wall assembly shall be tested and comply with the acceptance criteria of NFPA 285.
  • 39. 2006 International Building Codes – Adoption by State October 2009 – 36 States!! Alabama Mississippi Alaska Montana Arizona Nevada Alaska New Hampshire Arkansas New Jersey California New Mexico Colorado North Carolina District of Columbia Ohio Georgia Oklahoma Hawaii Oregon Illinois Rhode Island Indiana South Carolina Iowa Tennessee Kentucky Utah Louisiana Vermont Maryland Virginia Michigan Wisconsin Minnesota Washington
  • 40. Why Specify Stone Wool?One option to improve wall performance and EliminateFire Concerns is to Eliminate Combustible Materialsfrom the wall assembly:Use of Stone Wool Insulation in ExteriorCavity Walls
  • 41. Where To Use Stone WoolCavity Walls “Semi-rigid…has huge advantages over foam plastic insulation. It is extremely vapor permeable and will dry like gangbusters when it is on the exterior of the sheathing in a vented cavity. It also does not burn…It results in a huge improvement in performance compared to current practice…” Joe Lstiburek, PhD., Building Science Corp
  • 42. Where To Use Stone WoolCavity Walls
  • 43. Cavity Wall Applications
  • 44. Cavity Wall Applications
  • 45. Cavity Wall Applications
  • 46. Cavity Wall Applications
  • 47. Cavity Wall Applications
  • 48. Cavity Wall ApplicationsUniversity of ChicagoResidence Hall
  • 49. Where To Use Stone WoolLightweight rain screencladding systems Superior water resistance Superior fire control Superior sound protection
  • 50. Where To Use Stone WoolCurtain Walls and Fire Safing Spandrel panels Fire safing Image courtesy of International Firestop Council (IFC)
  • 51. Where To Use Stone WoolCurtain Walls and Fire Safing Installed on site Installed in factories Multiple sizes to suit conditions Numerous UL listings
  • 52. Stone Wool Roof Insulation More Than Just An RNRCA Manual of Practice says an ideal Insulation would have the following properties; Provides a thermal requirement for the building and stable substrate for the membrane It would be incombustible, moisture resistant, impact resistant, resist deterioration, stable K (thermal conductivity), accommodate secure attachments, dimensionally stable under varying temperature and moisture conditions and compatible with the membrane
  • 53. Where To Use Stone WoolRoofing Dimensionally stability Fire Resistant Sound Absorbent Water Repellent Lasting R-value Conformation to minor deck irregularities Ease of installation Can be fabricated
  • 54. Where To Use Stone WoolRoofing Steel decks Concrete decks Wood decks Single-ply Tapered systems Torch and mop applications
  • 55. Stone Wool Roof Board A rigid mono-density stone wool board Coated with a bitumen layer that is compatible with a torch, mop and coldThe new leader in coverboard technology! applied membranes Dimensionally Stable Suitable for use as a coverboard, Water Repellent Fire Resistant re-coverboard and as a thermal barrier Vapor Permeable: 33 perms High R-Value A stable substrate for your roof membrane that has an R-value
  • 56. Stone Wool Roof Board A rigid mono-density stone wool board Designed specifically for single-ply membrane applications and compatible with all membranes and adhesive Suitable for use as a coverboard, re-coverboard and as a thermal barrier
  • 57. Where To Use Stone WoolInterior Walls Stays in place Friction fit Vibration resistant 1 hour fire rated walls UL listings, MEA, LARR Improves fire resistance by 54%.1 No other insulation material has this effect UL design No. U448 STC ratings 1. Sultan and Lougheed, National Research Council (NRC) Study A4051
  • 58. Where To Use Stone Wool Interior Walls Corridors Partitions Demising Walls 1. Sultan and Lougheed, National Research Council (NRC) Study A4051
  • 59. Where To Use Stone WoolCeilings Garage areas Mechanical rooms Utility rooms
  • 60. Sandwich Wall Panel Description An insulating stone fiber wool, bonded to metal skin on either side. Panel joints vary per manufacturer with tongue & groove edges which maintain the features & benefits of the SWP.Features & Benefits: Energy Efficient (High R-Value) Cost Effective (Lower Installation Costs) Fire Sound Moisture Wind Resistant Elimination of Thermal Bridging
  • 61. Sandwich Wall Panels Firewall Applications Sandwich Wall Panels can beused in Firewall applications asand alternative to: Concrete / Masonry Gypsum / Steel Stud Stone Fiber Sandwich WallPanels can achieve 1, 2 & 3 hourfire ratings.
  • 62. Where To Use Stone WoolCommercial Applications Cavity Walls Rain Screens Stud Walls Corridors Interior partitions Curtain Walls and Fire Safing Roofing Sandwich Wall Panel
  • 63. Sustainable Aspects of Stone WoolStone Wool Insulation saves 128 times more energyover the course of 50 years than was used for itsproduction, transport, and disposal.Energy balance becomes positive after only 5months after installation of the product.Natural and abundant basalt rock and slag (recycledcontent) is extracted within 75 miles ofmanufacturing plant.Cut waste is recycled back into new product. Zeromanufacturing waste going to landfills.
  • 64. LEED Category & Credits Possible Points Using Stone WoolEnergy & Atmosphere Up to 10 pointsMaterials & Resources 1 to 6 pointsIndoor Environmental Quality 1 pointInnovation & Design Process 1 to 4 points Possible Total Points 21 points
  • 65. LEED ExamplesEnergy & Atmosphere Materials & ResourcesEA Credit 1: MR Credit 2.1 and 2.2:Stone Wool Insulation has higher R-Values Stone Wool products are dimensionallyfor superior thermal properties and energy stable and sag resistant. Whenefficiency. Overall contribution depends on removed undamaged Stone Wool mayR-Value used. be reused and recycled for other projects. Stone Wool Insulation products are sized for optimized fit, enhancing performance and limiting construction waste
  • 66. LEED EXAMPLESIndoor Environmental Quality Innovation & Design ProcessEQ Credit 7.1: ID Credit 1 to 1.4Stone Wool Insulation offer a higher R- Stone Wool Insulation provides superiorValue. This minimizes thermal cycling due to thermal performance and fire performance.external conditions, contributing to a morecomfortable thermal environment
  • 67. KROON HALL CASE STUDYProject Name: Yale School of Forestry & Environmental Studies, Kroon HallProject Size: 65,000 Sq FtLocation: new Haven, CTBuilding Use: Educational (Offices, Classrooms, Auditorium)Project Architect: Centerbrook & Hopkins ArchitectsDeveloper: Turner Construction CompanyConstruction Manager: Turner Construction CompanyInsulation Used: Stone WoolApplications Details: Roof & Cavity WallReasons for Stone Wool Insulation Use: Thermal Stability and Non-CombustibilityProject Completion: Early 2009LEED Certification Level Achieved: Platinum
  • 68. ReviewBuildings consume 40% of all fossil fuelsStone wool is sustainable Natural raw materials, high recycled contentThermal, fire, water, sound resistance, anddimensional stability Key value added benefitsMultiple uses in commercial structures Roofing, cavity wall, curtain wall and interior walls
  • 69. ABOUT ROXULRoxul recycles its own waste and delivers Ø waste to the landfillThe water from our production is collected and reusedStorm water is collected for use in our own productionRecycled heat from our process is used to augment heatingEnergy efficient lighting has been installed throughout the facilityA no-idling policy for vehicles minimizes pollution
  • 70. THANK YOU!
  • 71. ROXUL AFB® (Acoustical Fire Batt) Benefits Comfort, quiet and fire safe Cleaner, better handling and packaging reference Superior acoustical performance Four times the density of a glass batt Four times better airflow resistivity* Testing criteria * In situ sound transmission improves with density
  • 72. CavityRock DDApplications: CavityRock DD is specifically designed for use in cavity wall and rainscreen applications. The outer layer of CavityRock DD offers even better water repellency characteristics, while the lower density inner layer improves its capacity to conform to architectural features and minor wall irregularities.Compliance & Performance Test to ASTM C612 Flame Spread = 0 Smoke Development = 0
  • 73. ROXUL CurtainRock® 40/80 Various densities and dimensions available for various applications Numerous UL rated Curtainwall designs for approvals. Easily fabricated Choice product for application
  • 74. ROXUL DrainBoard® Description Designed for use with a damp proofing layer for both residential and commercial applications up to a depth of 12 ft (3.7m) below grade. Properly installed, Roxul DrainBoard® is a key ingredient in keeping basements dry and comfortable. Specification Density: 9.3 lbs/ft3 150 kg/m3 (Target) R-Value: 4.3 per inch Binder: High Compliance & Performance Test to CAN/ULC S702 Flame Spread = 0 Smoke Development = 5
  • 75. Roxul PlusApplications This product is designed specifically for exterior wall steel stud applications.Compliance & Performance Test to ASTM C665, ASTM C553 & CAN/ULC S702 Flame Spread = 0 Smoke Development = <5
  • 76. ROXUL RockBoard™ Description Is a semi-rigid/rigid commercial board, that is a general purpose board which has low thermal conductivity and superior compressive resistance which translates into good site durability. The product is measured in ACTUAL density with a recommended application temperature up to 232^C (450^F).
  • 77. RockBoard 40Specifications Density: 4.0 lbs/ft3 64 kg/m3 R-Value: 4.1 per inchApplications Mechanical rooms, parking garage underdecking
  • 78. RockBoard 60Specifications Density: 6.0 lbs/ft3 96 kg/m3 R-Value: 4.2 per inchApplication Metal roof requiringsnow load
  • 79. RockBoard 80Specifications Application Density: 8.0 lbs/ft3 Surfaces requiring wind load such as 128 kg/m3 substrate for stucco walls R-Value: 4.1 per inch
  • 80. Roxul SafeApplication Fire stop product for application at ceiling and floor juncture etc. Perimeter gaps between concrete floor slabs and exterior wall systems Around conduit pipe and duct openings through walls and floor slabs Between fire walls and ceiling slabs Used where non-combustible product is required. Approved for most applications. Minimum 4 lbs density required. Always used with a fire & smoke sealant.

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