Building and Modernizing with Neopor

Transcription

1 Building and Modernizing with Neopor

2 Building and Modernizing with Neopor Contents 03 > Neopor Material 04 > Quality Products from BASF 05 > Neopor Performance 06 > Thermal Insulation and Thermal Conductivity 07 > Technical Data Neopor > Ecoefficiency and Passive House > Application Overview Neopor 12 > Advantages of Insulation Materials Made of Neopor 13 > Exterior Insulation (ETICS) Interior Insulation 14 > Cavity Insulation / Loose Beads Insulation behind Curtain Walls 15 > Attic Insulation Ceiling Insulation (Basement) 16 > Flat Roof Insulation Above-rafter Insulation 17 > Between-/Under-rafter Insulation Insulating Concrete Forms ( ICF ) > References in Europe

3 Small, Round, Black One Material, Many Applications Neopor is composed of small black beads of polystyrene (EPS) containing blowing agent, which makes it expandable. BASF produces this unique material, which is processed by foam manufacturers into insulating materials for a wide range of different applications. up to r t e t i n s u l a t e s b e These black beads are foamed by converters on conventional EPS machines and processed into silver-gray foam blocks and molded parts with up to 20 percent better insulating performance than conventional EPS. The blocks are then cut into boards of different thicknesses. Neopor insulating materials offer greater insulating performance and up to 50 percent lower use of materials than conventional EPS, helping environmental conservation and saving money. Environmentally friendly Neopor insulating materials contain air as cell gas, which guarantees the preservation of the thermal conductivity throughout the life of the construction. Neopor insulating materials therefore represent a modern, environmentally aware lifestyle. We call it: Innovation in Insulation. 3

4 Quality Products from BASF The Benchmark in Polystyrene For Over 50 years Styropor Behind this name lies a success story that is everyone s goal. BASF discovered a classic over 50 years ago in expandable polystyrene (EPS). Under the tradename Styropor, EPS is now the solution for efficient insulation and safe packaging worldwide. With Neopor, BASF has taken the classic Styropor a step further. This new material for modern insulating materials is foamed just like Styropor and processed to boards and molded parts. The vital difference can be seen with the naked eye in the silver-gray color. In Neopor, graphite is added to the material, absorbing and reflecting heat radiation and improving the insulating performance of EPS by up to 20 percent. Products made from BASF s Neopor are an economic investment in the future and add to the value of a property Neopor Patent for the polymerization of monostyrene Patent on Neopor Styropor Patent for expandable polystyrene (EPS, Styropor ) 4 Neopor > Quality Products from BASF

5 up to i n s u l a t e s t b e t e r Neopor Insulation Materials with Performance Plus Up to 20 Percent More Performance for the Same Panel Thickness The special product properties provide insulation boards made of this material with up to twenty percent more performance than conventional EPS, which is due to the fine graphite particles in Neopor that act as infrared absorbers or reflectors. Builders and planers can take advantage of this benefit. With insulation materials made of Neopor, they achieve a significantly higher insulation performance and thus further reduce energy consumption. Insulation materials made of Neopor stand out thanks to their higher insulation performance compared to conventional EPS. They also provide other significant advantages: Water-repellent Open to diffusion Firm and dimensionally stable Environmentally friendly through high ecoefficiency Resistant to aging and decay Easier handling through weight advantage Dust-free and fast laying Installation independent of weather conditions No skin-irritant effects 5

6 Thermal Insulation is Quality of Life Optimized Insulation Performance with Neopor The excellent efficacy of insulation materials made of Neopor provides architects, engineers, craftsmen, and builders with convincing benefits in building practice. The infrared absorbers or reflectors in Neopor significantly reduce the thermal conductivity. The heat permeability of the material is lower than with conventional insulation boards. With Neopor, considerably improved insulation performance is achieved particularly for insulation materials with very low densities. The figure shows that insulation materials made of Neopor with a density of 15 kg /m 3, for example, achieves a thermal conductivity of W/(m K). For conventional EPS of the same density, the thermal conductivity is W/(m K ). Thermal conductivity [W/(m K)] EPS Average value curve of the measured values in accordance with EN (measurement at 10 C) Neopor Density [kg/m 3 ] The infrared absorbers and reflectors extensively prevent heat losses caused by radiation. 6 Neopor > Thermal Insulation and Thermal Conductivity

7 Technical Data Neopor Properties Unit Key EN Key Features of Neopor Insulating Materials EPS 70 EPS 100 EPS 150 Standard Thermal conductivity, W/(m K) EN l D Thermal conductivity, rated value Compressive stress at 10 % compression Tensile strength perpendicular to panel surface W/(m K) German NTA* kpa CS (10) EN 826 kpa TR EN 1607 Flexural strength kpa BS EN Shear strength kpa t EN Dimensional stability 48 h, 70 C Deformation behavior 48 h, 20 kpa, 80 C Deformation behavior 168 h, 40 kpa, 70 C Water vapor diffusion resistance index m Thermal linear deformation coefficient % DS ( 70,-) EN 1604 % DLT (1) EN 1605 % DLT (2) EN EN K DIN Fire behavior Euroclass --- E E E EN Chemical resistance Biological behavior Insensitive to water, the majority of acids and alkalis, sensitive to organic solvents. Insensitive to microorganisms. Does not rot or decompose. Chemically neutral, not water-soluble. No harmful effects on health known. * NTA = national technical approval Note The technical and physical key data given in the table are standard values for insulation materials made of Neopor. The values and properties may vary depending on the processing. Neopor P is not provided with flame retardant. 7

8 More than 4,500 plants, shrubs, and trees from all regions of the world grow under the 3,000 m 2 glass structure of the BASF Construction Chemicals Competence Center in Trostberg, Germany. Insulation Materials Made of Neopor Sustainable and Efficient 50 Percent Less Use of Raw Materials Conserves Valuable Resources Compared to conventional EPS, about 50 percent less raw materials are used for the production of insulation boards made of Neopor. Neopor thus provides more efficiency with less environmental impact, and in consequence achieves top ratings in the ecoefficiency analysis. 0.7 High ecoefficiency Comparison of thermal insulations Greater benefits at lower costs Benefits when using 1 m 2 external thermal insulation composite system Environmental impact (standardized) 1.0 Stone fiber Neopor Styropor Low ecoefficiency ,7 Costs (standardized) Considered alternatives: Neopor Styropor Stone fiber Ecoefficiency analysis of external thermal insulation composite systems using the example of the three-liter house in the Brunck district in Ludwigshafen, Germany, in the year 2000, certified by the Öko-Institut in Freiburg, Germany, and by TÜV (German technical inspection authority). The ecoefficiency analysis considers products and methods both from an economic and an ecological perspective. The results of such an evaluation are shown in this figure, using the example of an external thermal insulation composite system ( ETICS ) with a U value of 0.29 W/(m² K). The tremendous advantage of insulation boards made of Neopor results from the up to 50 percent reduction of required raw materials, which leads to savings in costs and resources, and in turn benefits the environment. Compared to alternative products, insulation materials made of Neopor provide economic advantages along with less environmental impact, thereby offering ecoefficient solutions for modern thermal insulation. 8 Neopor > Ecoefficiency and Passive House

9 The Passive House An Active Contribution to Environmental Protection with Neopor The passive house this concept started its triumphant success only two decades ago. Its history began with a dissertation by two visionaries, Bo Andersen and Wolfgang Feist. Their answer to rising energy costs: a house without heating. At the time a vision, the passive house has garnered ever more acceptance as a construction method. The latest regulation files of the European Parliament from January 2008 see the passive house standard as the future, legally required energy standard for all new construction. Detached single-family passive house in Alsheim, Germany. A house without heating A passive house can do without conventional heating and air conditioning. Nevertheless, it remains cozy and warm in winter, but stays cool in summer. The energy expenditure, however, is exceptionally low, as the passive house has a remaining heat demand of only 15 kwh/(m 2 a) for heating. This corresponds to the heating value of 1.5 liters of heating oil per square meter of surface in one year. The U value of a passive house Maximum heat transfer coefficients are defined for all components of the passive house envelope. All opaque exterior building elements may not exceed a U value of 0.15 W/(m 2 K ). A particularly well-insulated building envelope is thus typical for passive houses. A passive house pays for itself When you invest in a building, the goal is to combine economic efficiency with climate protection. That s exactly what you get when opting for a passive house. The additional investment compared to buildings that are constructed in accordance with applicable energy standards (German Energy Saving Ordinance, EnEV ) amount to about 6-8 percent of the total construction cost of the building, based on well-founded calculations. These are offset by annual savings of approximately percent of the energy demand, which equates to a payback period of less than 15 years, depending on the development of energy prices. The quickest way to realize this return is through investment in insulation materials. 300 Primary energy demand heating [ kwh /(m² a ) ] German Heat Insulation Ordinance ( WSVO) 2 German Energy Saving Ordinance ( EnEV ) 15 kwh /(m² a) WSVO WSVO WSVO EnEV /2007 EnEV EnEV Passive house The road to passive house standards (Germany). 9

10 Neopor One Material Many Attention must be paid to the requirements of specific applications, especially the physical and technological aspects of construction and building regulations. Insulating concrete forms (ICF) Special components Interior insulation Exterior insulation (ETICS) Floor insulation Ceiling insulation 10 Neopor > Application Overview Neopor

11 Applications Flat roof insulation Cavity insulation / Loose beads Attic insulation Steep roof insulation Insulation behind curtain walls Stud-frame insulation 11

12 Neopor Continuous Thermal Insulation from the Basement to the Roof up to With applications made of Neopor, you will achieve an integrated and coherent insulation concept for the whole house. From the basement to the roof, from the exterior insulation as an external thermal insulation composite system to the interior insulation, you can count on tried and tested applications made of a material that provides maximum efficiency. It provides optimal thermal insulation for new constructions and renovation projects, and effectively increases the value of the building fabric and of the property on the long term. i n s u l a t e s b e t e t r Insulation materials made of Neopor The advantages at a glance Versatile applications: Building constructions that require a limitation of the insulation thickness, for example in the case of modernization projects, can be easily realized with insulation boards that are thinner than conventional EPS, but provide the same insulation performance. The result: high savings in energy consumption. Handling: Insulation boards made of Neopor can be rapidly installed in any weather. They are easy to cut and grind, and do not blind in sunlight. They can be processed without dust generation or skinirritant effects. Quality: Insulation boards made of Neopor are resistant to aging and decay, and are also extremely sturdy and dimensionally stable. They are open to diffusion, strongly water-repellent, and are characterized by low water absorption. Sound insulation: In addition to energy savings, elasticized insulation boards made of Neopor also contribute to improving the sound insulation of buildings. Fire prevention: Insulation materials made of Neopor are manufactured in accordance with the requirements of the European standard EN 13163, and its fire behavior is classified as Euro Class E according to EN and B1 according to DIN Neopor P is not provided with flame retardant. Durability: The outstanding resistance properties to aging and decay of insulation materials made of Neopor ensure durable and reliable thermal insulation. 12 Neopor > Advantages of Insulation Materials Made of Neopor

13 Exterior Insulation (ETICS) Interior Insulation Exterior insulation with ETICS has excellent structuralphysical properties for the thermal insulation of facades. ETICS with EPS (Styropor ) have proved their worth in practice for more than 50 years. Insulation boards made of Neopor continue in this tradition. Internal thermal insulation achieves very good insulation results for new construction or renovation work wherever external thermal insulation is not an option. Spaces that have to be heated up quickly or only for brief periods of time definitely benefit from interior thermal insulation. Efficient thermal insulation Uncomplicated and economical Excellent for facade renovations Rooms heat up quickly Simple and cost-effective implementation Improved thermal and sound insulation ETICS with Neopor thermal insulation fulfills the thermal insulation requirements manifold and even up to the level of a zero heating energy house. Insulation boards made of Neopor are the most-used gray facade insulation board in Europe: more than 10 million laid square meters per year testify to the success of this BASF quality product. Because of the outstanding thermal insulation properties of Neopor insulating boards, better insulation performance is achieved with smaller thicknesses than with conventional EPS. This means less valuable interior space is lost. The additional elasticity brought about by insulating materials made of Neopor can also improve sound insulation. Exterior plaster Reinforcement (anchor bolt) Thermal insulation made of Neopor Adhesive mortar Brickwork Interior plaster Exterior plaster Concrete wall Adhesive Interior insulation made of Neopor (Condensation barrier) 13

14 Cavity Insulation / Loose Beads Insulation behind Curtain Walls Two-leaf masonry structures represent a rainproof wall structure even when subjected to heavy loading from driving rain. Insulating materials made of Neopor can be employed for frost-resistant, back-ventilated masonry as well as purely for cavity insulation that is not backventilated. Back-ventilated curtain walls consist of a substructure, insulating material, an air layer, and facade covering. They are used for design reasons and also because of safety considerations of a technical nature. The exterior walls can be tailor-made to match the characteristics of a given building. Best thermal insulation effect Water-repellent without hydrophobing Low setting behavior with Neopor beads Outstanding insulation performance Permanently dry thermal insulation Licensed systems 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. A wall can be retrofitted with cavity insulation by blowing expanded beads made of Neopor into the existing cavities. This provides complete and lasting thermal insulation. The two-layer system of a back-ventilated curtain wall systematically separates the functions of weather protection and insulation. The insulation can be used in any desired insulating material thickness. U values are thus achieved that are suited to low-energy and passive houses and comply with the current energy saving regulations. Thanks to its outstanding insulating capacity, Neopor is the material of choice for use in this facade system. Outer leaf (Air layer) Cavity insulation made of Neopor Anchoring Inner leaf Interior plaster Weather protection ( facade covering ) Back ventilation Thermal insulation made of Neopor Construction (e. g., masonry, concrete) Interior plaster 14 Neopor > Applications in Detail

15 Attic Insulation Ceiling Insulation (Basement) Regardless of the legal requirements, it is recommendable for all owners of old buildings to check the thermal insulation in the attic, which may help to significantly save costs. In many buildings, the ceiling of the top floor is poorly insulated or not insulated at all. The attic can be optimally insulated using insulation boards made of Neopor. Basement ceilings can be optimally insulated with insulation boards made of Neopor, the existing ceiling height is only minimally reduced, and as a result, the heating energy consumption is lowered thanks to Neopor s improved insulation performance compared to conventional EPS. Optimal insulation High energy cost savings Recommendable for old buildings Improved insulation performance Low installation height Cool basements, warm living spaces 15

16 Flat Roof Insulation Above-rafter Insulation Flat roofs are subject to high thermal stress and the resulting strains, which has an effect on the roof waterproofing and the building construction. Insulation boards made of Neopor protect the construction from the effects of temperature fluctuations and ensure reliable thermal insulation. From a structural-physical point of view, above-rafter insulation is an optimal construction, since the insulating layer is installed virtually without gaps above the roof construction. In doing so, the visible rafters are integrated as a decorative element in the interior design of the rooms. Reliable thermal insulation Economical constructions Installation independent of weather conditions Complete insulation layer Water-repellent and open to diffusion Easy handling Insulation boards made of Neopor are used for warm roof constructions. They are suitable for almost all conceivable sealing materials, as well as protective and top layers. Environmentally friendly and economical flat roofs are realized with insulation boards made of Neopor. An additional thermal insulation layer with insulation boards made of Neopor is used for roof renovations. This modernizes the flat roof to meet today s thermal insulation standards. In order to optimally fulfill the thermal insulation requirements, insulation materials made of Neopor are installed efficiently in form of panels or roof elements for above-rafter insulation and as a thermal roof. Professionally renovated areas under steep roofs offer valuable living space. The sufficiently dimensioned insulation layer made of Neopor is of special importance in this regard. In the summer, living spaces under the roof should not heat up unbearably, and in the winter, the thermal insulation must restrict the loss of expensive heating energy. Protective layer Roof waterproofing Thermal insulation made of Neopor Vapor barrier Concrete ceiling Interior plaster Attic insulation Battens ( Under-roof membrane ) Thermal insulation made of Neopor Airtightness layer Formwork Rafters 16 Neopor > Applications in Detail

17 Between-/ Under-rafter Insulation Insulating Concrete Forms ( ICF ) Slotted thermal insulation boards made of Neopor are ideal for between-rafter insulation. Special longitudinal slits make the insulation board flexible and elastic, which enables a perfect fit of the panels between the rafters. Formwork elements 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 highrise buildings. Enormous potential savings are available todo-it-yourselfers. Dust-free and fast laying No skin -irritant effects Firm and dimensionally stable No thermal bridges High degree of thermal insulation Simple and fast handling The combination of between- and under-rafter insulation with insulation boards made of Neopor provides increased thermal insulation with minimal installation height. The energetic restoration of the attic with insulation boards made of Neopor provides a healthy and cozy living space and contributes to the conservation of and increase in value of the building. 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 for example, lintel elements that are free ofthermal bridges, floor surrounds, roller shutter housings, or cantilevers. Thanks to their good thermal-insulating properties, formwork elements made of Neopor are well-suited for the construction of low-energy and passive houses. Attic insulation Battens Under-roof membrane Thermal insulation made of Neopor Airtightness layer Interior siding Exterior plaster Reinforcement Insulating concrete forms (outside) made of Neopor Concrete core Insulating concrete forms (inside) made of Neopor Lining on the inside 17

18 References Low-energy Houses in Europe Testify to the Quality of BASF Technology for Thermal Insulation Social housing in Catalonia, Spain High energy efficiency for the construction of social housing BASF collaborated closely with the public administration in the construction of 54 ecoefficient housing units in Cerdanyola del Vallès. The project is part of the Policity program of the European Union, which is being implemented simultaneously in several member states. The buildings facades were insulated with insulation boards made of Neopor, and Styrodur was employed for the inverted roofs. In several of the housing units, suspended ceilings with Micronal PCM were installed to improve the regulation of the interior temperature. The insulation thicknesses of the housing units surpass the current applicable legal requirements by far. This is reflected in the energy savings, which are about 40 percent higher compared to buildings with conventional construction and insulation. Zero heating energy house in Ludwigshafen, Germany Energy consumption is reduced to a technicaleconomical ideal In view of increasing energy prices, a zero heating energy house can represent an ideal investment option. LUWOGE, BASF s housing company, developed a concept that reduces energy consumption to an economic ideal through energetic modernization measures. An external thermal insulation composite system with insulation boards made of Neopor is used to reduce the building s heating costs to a minimum. The energy required for electricity, warm water, and heating in the house is generated through regenerative sources of energy. The cost savings are used for refinancing. Costs for heating and warm water are thus no longer part of the running expenses. Bâtiment Génération E in Fontenay-sous-Bois, France Complete renovation significantly reduces energy consumption BASF s expertise in energy-efficient construction using innovative materials has also been put to the test in France. After its complete renovation, the Bâtiment Génération E, a city mansion in Fontenay-sous-Bois, only consumes less than 50 kwh per square meter instead of previously 400 kwh. This reduction in energy consumption was achieved for the most part by means of insulation materials made of Neopor, which were used to insulate the walls, floors, and ceilings. Styrodur C was employed for the perimeter insulation. 18 Neopor > References in Europe

19 BASF and its partners offer practical, well-tried, and easy-to-use solutions to increase the energy efficiency of buildings of all kinds. The high performance and energy efficiency, as well as the environmental benefits of the technologies of BASF and its construction industry partners are demonstrated by a variety of low-energy houses. Apartment building in Lucerne, Switzerland Heating energy consumption reduced by 90 percent Modern architecture, high comfort, and low energy consumption can be combined. Anliker AG from Lucerne testifies to this. In the Konstanz housing estate in Rothenburg / Lucerne, the company designed several apartment buildings according to passive house standards as a first in Switzerland, and were awarded with the first Swiss Building Award from the Swiss foundation Solar Agentur. BASF contributed to this success with insulation materials made of Neopor. The expandable polystyrene insulates the facades of all buildings in the housing development. Together with other measures, the heating energy consumption was reduced by 90 percent in comparison with a conventionally built house. Three-liter house in Rome, Italy Marketable low-energy solutions for Italy Although the building follows traditional Italian design, the annual heat consumption is at least 80 percent lower than the Italian average with only three liters of oil or 30 kwh per square meter. This was achieved with extensive Styrodur C perimeter insulation and insulation boards made of Neopor for the outside external thermal insulation composite system as well as for the roof and footfall sound insulation. The Micronal PCM plaster regulates the interior temperature, which remains comfortable even on the hottest days without using a cooling system. The result: a marketable low-energy solution for Italy, providing comfort 365 days a year. Prefabricated houses in London, Great Britain Impressive thin building elements and low thermal conductivity Ten prefabricated houses were built in a suburb of London within only a few weeks. The combination of steel frames and directly foamed-in insulation material used here only allowed limited material thicknesses. Hence, a thermal insulation material with particularly low thermal conductivity was required. Neopor fulfills the exacting demands for the limited building element thickness, and simultaneously provides outstanding thermal insulation. For example, the U value for the exterior wall elements of Fusion Building Solutions is at only 0.27 W/(m² K ). As a consequence, insulation materials made of Neopor are explicitly named the materials of choice for the authorization of innovative prefabricated houses. 19

20 Information on Neopor Brochure: Neopor Innovation in Insulation Brochure: Building and Modernizing with Neopor Brochure: Wall Insulation Website: Neopor: Product Sample Folder 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 specific 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 2011) = registered trademark of BASF SE KTFN 0831 BE GENERAL ENGLISH VERSION BASF SE Ludwigshafen Germany Find your local distribution partner on our homepage.