Caparol Application Guidelines

Transcription

1 Caparol Application Guidelines Insulation with inspiration

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3 Caparol application guidelines Contents Introduction to Caparol... 4 Caparol external wall insulation systems... 5 Caparol System PRO Caparol System CARBON Caparol System ELEMENTS Preliminary work... 8 Substrate treatments Substrate preparation Storage and application temperatures System installation...10 Primer application Base rail installation Adhesive application expanded polystyrene insulation Board laying techniques Fire protection Fire breaks Adhesive application mineral wool insulation Board laying techniques Connections, edges & joints Window sills Mechanical fi xings Reinforcing layer Top coat application Special finishes...17 Brick slip application Technical contacts...18 Service and support 3

4 Introduction to Caparol About Caparol Insulating more than 23 million square metres annually at Caparol we certainly know what we are talking about when it comes to external wall insulation. The External Thermal Insulation Composite Systems (ETICS) designed and manufactured by Caparol are fully tested and have been acknowledged by the British Board of Agrement for the following: Mechanical strength. Safety in use. Stability. Fire protection. Energy saving. Caparol Carbon Partners General application requirements The minimum application temperature of +5 C must be complied with during both the application and drying of the system components. Protection may have to be provided in the event of rain, wind and direct sunlight to ensure that the system can be applied correctly. A basic requirement for carrying out insulation work is that the structure of the building must be sound, clean and dry. When erecting scaffold, please ensure that it is sufficiently far from the building to allow room to work. The current product data sheets, safety data sheets and information printed on the packaging applies in each case. Please consult Caparol who will be pleased to provide any required information on request. Only Caparol Carbon Partners can install Caparol Systems. It is important to work with a partner with the correct experience and expertise. Caparol will work with you from start to finish, offering technical and design support. A full range of technical services is available, from colour choice and design elements, through to project reports and ongoing maintenance and care. To achieve Caparol Carbon Partner status all installers must have attended a Caparol accredited training course. This can be done at our training centre in Stone, Staffordshire or through one of our satellite training centres throughout the UK. Design requirements The requirements for fixing external wall insulation systems must be taken into account when planning façade insulation. Details must be carefully and comprehensively planned, especially when renovating a building and a thorough assessment of the substrate must be completed. Façade weatherproofing is of particular importance with regards to the long-term maintenance of the fabric of the building. Eaves, overhangs and flashings should be of sufficient width and length to avoid staining on the system. Joints which surround windows and doors, window sills, penetrations, roof edging, and balconies must be carefully sealed so that no moisture can penetrate behind the external wall insulation system. For the Caparol Carbon Partner, an important part of approval is the stipulation that all components of an external wall insulation system must be supplied by Caparol. Only the application of compatible and tested system components can guarantee the desired outcome. This is particularly important with regard to the warranty. 4

5 Caparol external wall insulation systems Caparol System PRO Substrate Caparol System Fixing Caparol System Pro Base Caparol System Adhesive Caparol Darkside Board Caparol System Mesh Caparol System Top Primer P Caparol System Pro Plaster Caparol System Pro Finish Caparol System PRO Caparol System PRO provides a cost effective solution utilising proven technology in conjunction with excellent detailing options. It offers reliable protection and crack resistance. The mineralic system meets all the requirements of modern, commercially available systems and has the innovative technology of Darkside EPS insulation with a thermal conductivity of W/mK. System features Expanded polystyrene insulation. Cost effective solution. Darkside insulation board The Darkside insulation board is the core of the system. It not only looks good but its thermal performance is second to none: It consists of expanded polystyrene with a graphite additive that brings a high level of thermal performance. Nano-Quartz Technology The 3-D Nano-Quartz Technology in Caparol exterior paints and renders keeps the walls clean and colour-fast for longer. The extremely hard surface stabilises the paint layer and prevents dirt particles from attaching to the wall. Excellent detailing options. Proven technology. High vapour permeability. Reliable protection and crack resistance. 5

6 Caparol external wall insulation systems Caparol System CARBON Substrate Caparol System Fixing Caparol System Carbon Base Caparol System Adhesive Caparol Darkside Board Caparol System Mesh Caparol System Top Primer SC Caparol System Carbon Plaster Finish Caparol System CARBON In addition to the benefits of the Caparol System Pro, Caparol System CARBON offers Nano-Quartz Technology in a state of the art silicone based topcoat render. System features Expanded polystyrene insulation. Cost effective solution. Excellent detailing options. Proven technology. Wide variety of colours. Reliable protection and crack resistance. Enhanced protection against algae and fungal growth. High vapour permeability. Darkside insulation board The Darkside insulation board is the core of the system. It not only looks good but its thermal performance is second to none: It consists of expanded polystyrene with a graphite additive that brings a high level of thermal performance. Nano-Quartz Technology The 3-D Nano-Quartz Technology in Caparol exterior paints and renders keeps the walls clean and colour-fast for longer. The extremely hard surface stabilises the finish layer and prevents the dirt particles from attaching to the wall. The quick-drying façade reduces the colonisation of algae and lichens because the moisture has been removed. At the same time, the Nano- Quartz Technology offers maximum protection from the weather; for example moisture from heavy rain cannot penetrate the outer layer but the vapour can still escape unhindered from the inside. The façade will simply retain a just applied appearance for years. 6

7 Caparol external wall insulation systems Caparol System ELEMENTS Substrate Caparol System Fixing Caparol System Elements Base Caparol System Adhesive Caparol Eco Fibre Caparol System Mesh Caparol System Top Primer SC Caparol System Elements Plaster Finish Caparol System ELEMENTS Caparol System Elements is the premium external wall insulation system. As with other systems the technology ensures safety, durability and longevity, but with the added benefi t of increased fi re resistance provided by the mineral wool insulation core. As well as ensuring increased levels of fi re resistance, this high performance mineral wool insulation has a thermal conductivity of W/mK. System features A rated fi re protection. Effi cient application. Nano-Quartz Technology The 3-D Nano-Quartz Technology in Caparol exterior paints and renders keeps the walls clean and colour-fast for longer. The extremely hard surface stabilises the fi nish layer and prevents the dirt particles from attaching to the wall. The quick-drying façade reduces the colonisation of algae and lichens because the moisture has been removed. At the same time, the Nano- Quartz Technology offers maximum protection from the weather; for example moisture from heavy rain cannot penetrate the outer layer but the vapour can still escape unhindered from the inside. The façade will simply retain a just applied appearance for years. Enhanced protection against algae and fungal growth. Maximum level of crack resistance. Optimum performance. High vapour permeability. Excellent detailing options. 7

8 Preliminary work Substrate treatments Before fixing an external insulation system with adhesive and mechanical fixings, it is generally advisable to check that the substrate is suitable for bonding. If necessary, the substrate should be pre-treated as indicated in the table below. Substrate Dusty, dirty Efflorescence Moss, algae, fungus Mortar ridges Greasy, forming oily residue Brittle, unsound plaster Damaged plaster Synthetic-resin plaster Chalking coat of paint Flaking coat of paint Absorbent Bitumen paint Thick bitumen coating Unidentified Treatment Sweep, brush, steam-clean Eliminate the cause Sweep, brush Remove Knock off Steam-clean with added cleaning agent Rinse off with water Remove mechanically Knock off blistering Clean Clean and prime Remove Clean and prime Please contact the technical department Remove Check adhesion on substrates that have not been identified 8

9 Preliminary work Substrate preparation Assess substrate. Conduct mechanical fi xing pull out test on substrate. Set the scaffolding anchors according to the selected insulation layer thickness. The scaffolding anchors must be tilted so that rain water cannot penetrate. After dismantling the scaffolding, ensure the holes are protected from moisture. The façade may be exposed to sunlight during warmer weather and therefore shading/protection may be necessary during application and drying. Clean substrate. Remove loose particles. Remove peeling paint or render. Close open or bearing joints in the masonry with mortar. In rooms with high humidity (swimming pool, sauna, or similar) an inside damp barrier must be installed. Check substrate for strength by performing a pull out test Clean soiled surfaces with highpressure cleaner and then apply an appropriate Caparol primer Storage and application temperatures Store polystyrene and mineral wool insulation boards in a dry environment and protect from sunlight. Store buckets in frost-free environment. Store sacks in a dry, frost free environment. Installation and drying temperatures should not be below +5 C. Thermal insulation work should not be carried out under damp conditions. Note: relative humidity may have an effect on drying periods. 9

10 System installation Primer application The surface must be clean, dry and free from dust, dirt, grease, oil and other adhesion reducing contaminants. Remove any loose or de-bonded materials by thoroughly dry brushing. The surface will need to be primed with an appropriate Caparol primer. Primer application Base rail installation Fix the base rail at DPC level ensuring it is aligned and level. Create corner links with mitres. Compensate for wall irregularities by using spacers. Insert connector pieces as appropriate. Secure the base rail every 30cm. Secure base rail with mechanical fixings Corner links are created with mitres Adhesive application expanded polystyrene insulation Mix Caparol System Adhesive and apply to back of insulation board using spot and continuous bead method. This involves applying a bead near the outside edge and dabs of adhesive which must cover at least 50% of the board/substrate unless detailed otherwise (typically bead and 3/4 no. spots per board). On flat and even substrates, the tooth and bed method of application can be used. 100% of board/substrate must be covered when using the tooth and bed method of application. Caparol System Adhesive to be applied at 4kg/m 2 minimum. Fire break Apply Caparol System Adhesive to Caparol System Fire Break using the tooth and bed method. Caparol System Adhesive to be applied at 4.5kg/m 2 minimum. Spot and continuous bead method Tooth and bed method Fire break installed with tooth and bed method 10

11 System installation Board laying techniques When laying boards, take care to avoid impact with the base rail. Lay insulation boards in combination and fl at on the surface (offset: 10 cm) from bottom to top. Be aware of detailing at corners and reveals. Align boards with straight edge and constantly tap with wooden board. Board joints and voids must not be fi lled with mortar. Joints of 2-10 mm may be fi lled with a suitable foam. For larger voids fi ll with insulation strips. Raised areas can be rasped after drying and then thoroughly cleaned. Fill larger voids with insulation strips Smooth out raised areas by rasping Fire protection Cut out window and door corners from full insulation boards and adhere What about fire? Approvals The requirements for fi re resistance and external wall insulation systems are clearly defi ned. They are regulated by building regulations and fi re regulations and graded according to the height of the building. Basically it can be assumed that the higher a building is, the higher requirements for fi re protection are. Caparol External wall insulation systems have been certifi ed by both British Board of Agrement (BBA) and the German Institute for Building Technology (DIBT). External wall insulation systems are among the most extensively tested. Tests are carried out both under laboratory conditions as well as complex large-scale experiments, carried out on fabricated walls. Fire breaks The purpose of the fi re breaks is to prevent fi re from spreading to higher storeys. Typically, where required, a 200mm high mineral wool strip will be adhered and mechanically fi xed around the circumference of the building at a minimum of every storey above the fi rst. By including solid, non-combustible components and adapting to different levels and varying heights, there are many possibilities of installing fi re breaks even on complex buildings. 11

12 System installation Adhesive application mineral wool insulation Mix Caparol System Adhesive and apply to back of insulation board using spot and continuous bead method. This involves applying a bead near the outside edge and dabs of adhesive which must cover at least 50% of the board/substrate unless detailed otherwise (typically bead and 3/4 no. spots per board). On flat and even substrates, the tooth and bed method of application can be used. 100% of board / substrate must be covered when using the tooth and bed method of application. The insulation boards should be positioned and pressed onto the wall immediately. Caparol System Adhesive to be applied at 4.5kg/m 2 minimum. Adhesive bead around the edge and dabs in the centre Layer full board with tooth and bed method Adhere insulation from bottom to top and beware of detailing on the corners Cut out window and door corners from full insulation boards and adhere Board laying techniques Avoid impact to the base rail. Lay insulation boards flat on surface in combination (offset: 10 cm). Do not fill voids with mortar, but fill with insulation strips. 12

13 System installation Connections, edges & joints All connections on windows, doors or adjacent components must be carefully planned. System seal Caparol System Seal can be applied at window/door interfaces to terminate the system. Note: This is deemed a secondary seal, the primary seal of the aperture is provided by the window/door specialist. Sealing strip As an alternative to Caparol System Seal being used around windows, Caparol System Sealing strip can be used, adhered with the adhesive side onto the adjacent component. Subsequently, the insulation boards will be laid onto it. The insulation boards are arranged so that the joint sealing strip is fl ush with the insulation board. Again the primary sealing of the aperture is by others. The reinforcing layer and top coat will then cover the Caparol System Sealing Strip. Detail for the application of Caparol System Seal Movement joints Existing structural expansion joints should be replicated in the insulation system with suitable expansion joint profi les. Expansion joint profi le corner. Expansion joint profi le straight. Please refer to the Caparol standard details for further guidance. Drip edge For protection of the façade balcony bases, lintels and horizontal drip edges a minimum overhang of 45mm is recommended. Sealing Caparol System Seal can be injected into joints/voids with a hand operated gun and smoothed over with a brush and water. Only as much sealant should be injected as can be smoothed over before it forms a skin. Application of Caparol System Sealing Strip Application of corner beads Caparol System Seal applied to joints and voids 13

14 System installation Window sills Recommendations Ensure window sills are the correct and sufficient length. Window sill overhang is the distance measured from the finished render face, recommended to be 45mm minimum. To minimise heat loss, the outer insulation should be a minimum of 30mm. Window sill detail Mechanical fixings Hammer fixing - NTU fixing/k fixing Only use approved hammer fixings appropriate for the façade substrate. Mechanical fixings have to be anchored to the required depth in the solid wall. Tiles, old plaster coatings and similar materials are not suitable anchoring substrates. If in doubt about the suitability of the substrate, the pull-out strength of the mechanical fixings has to be determined by tests conducted on site. Insulation boards require fixing with both adhesive and mechanical fixings. This procedure involves using suitable drills to prepare a hole for the fixings, inserting the fixings and driving them in. Hammer fixing Fixing patterns Standard fixing pattern is 7 mechanical fixings per square metre. Mechanical fixing EPS Mechanical fixing mineral wool 14

15 System installation Additions to façades MU set. To secure light objects a mechanical fi xing is inserted in a pre-drilled 8mm hole in the render, reinforcement layer and the insulation board followed by a wooden or a self-tapping screw. Recommended load: maximum 5kg per mounting point (MU set). Light objects such as sensor lights or signs are screwed directly onto an MU set. Use an MU cutter to create a recess in the insulation board. Apply adhesive on the back of the MU Set. MU set Push the MU Set onto the insulation layer until fl ush. Reinforce entire surface. For items heavier than 5kg please refer to or contact the technical department. Reinforcing layer The reinforcing layer is made with the system s basecoat, which is applied at the appropriate minimum thickness (see system data sheets). The reinforcing layer must not be applied until the adhesive has hardened and not less than 24 hours afterwards. Caparol System Pro Base apply basecoat using a stainless steel trowel. Level out using a plasterer s straight edge or by combing through with a 10 x 10 tooth trowel. Float Caparol System Mesh into the top third of the basecoat render ensuring a minimum horizontal and vertical overlap of 100mm. Caparol System Carbon Base apply basecoat using a stainless steel trowel. Level out using a plasterer s straight edge or by combing through with a 10 x 10 tooth trowel. Float Caparol System Mesh into the top third of the basecoat render ensuring a minimum horizontal and vertical overlap of 100mm. Caparol System Elements Base apply basecoat using a stainless steel trowel. Level out using a plasterer s straight edge or by combing through with a 10 x 10 tooth trowel. Float Caparol System Mesh into the top third of the basecoat render ensuring a minimum horizontal and vertical overlap of 100mm. Application of reinforced layer Priming 250 x 250mm stress patches applied to all corners at openings After the reinforcement has hardened, apply a system-specifi c primer, which will: Improve protection against moisture. Give excellent adhesion to the substrate for the topcoat render. All corners at openings must be additionally reinforced with 250 x 250mm stress patches embedded diagonally into the wet basecoat render. Immediately trowel the mesh into the basecoat while still wet and smooth off to fi nished thickness using a stainless steel trowel. Leave basecoat render to set for at least 2 to 3 days before applying top primer and topcoat. 15

16 System installation Topcoat application General Mineral and silicone renders should only be applied on mineral reinforcing compounds. When selecting colours, the warming of the façade in summer must be taken into consideration. Dark colours absorb more heat and therefore, provide a risk of thermal stress that can contribute to cracking. Not allowing the Brightness Reflectance Value to fall below 20 eliminates this risk. For corners and joints that are finished with sealing strip, a trowel cut is required. For mineral render, the necessary unique equalising paint provides a uniform and consistent colour. Mineral topcoat render as seen in Caparol System Pro, should be finished following application with Caparol System Pro Finish in two coats. Top primer P & SC The application of a product-specific primer is recommended, since it makes the subsequent final coat easier to apply. The primer is applied after the reinforcing layer has dried out. Applying the finishing plaster Apply specified topcoat render using a stainless steel trowel and immediately create the desired effect using a plastic finishing trowel. System PRO mineral based textured. System CARBON silicone based textured. System ELEMENTS silicone based textured. Example of finished project with textured top coat Top primer application Textured top coat applied to DPC level Application of top coat using stainless steel trowel Plastic finishing trowel used to create the desired effect 16

17 Special finishes???????????? Brick slip application Substrate Caparol System Fixing Caparol System Carbon Base Caparol System Adhesive Caparol Darkside Board Caparol System Mesh Caparol System Bonding Mortar Caparol System Brick Slips Façades need not necessarily be rendered, Caparol System Brick Slips give a decorative alternative. Brick slips can make the surfaces more attractive and emphasise defi ned areas e.g feature panels. Caparol System Brick Slips offer the possibility of maintaining the building style and renovating old buildings so that they can be an authentic and harmonious part of a growing architecture. Caparol System Brick Slips are available in the following 5 styles Hamburg, Betley Red, Foxfi eld, Swynnerton Rustic and Walton Red, see website for further details Joints Immediately after the fl at facing bricks have been applied, the mortar in the joint should be lightly brushed with a moistened 10mm fl at brush to spread it out evenly and to work in the edges of the bricks. The transition of the adhesive mortar onto the edge of the bricks must be tightly fi nished so that no water can get through. Leave excess material to dry out and then brush off with a hand brush or similar. In addition, for larger projects, bespoke brick slips are available in any desired colour and surface structure for the replication of existing façades. Installation To install the brick slips, mark the prepared surface with height markings at regular intervals. Bonding The brick slips are bonded using Caparol System Bonding Mortar from the top down, starting with the corner pieces. The adhesive mortar is always applied in stripe formation within the height markings and combed through with a notched trowel (tooth 4-6mm). The individual bricks are positioned with a pushing motion and pressed into the mortar. Only apply as much mortar as can be covered with fl at facing bricks before a skin forms. Brick slips are pressed into the bonding mortar A brush is used to seal the joints to prevent water ingress 17

18 Technical contacts Service and support Caparol Carbon Partners As a Caparol Carbon Partner, we can offer you training and technical and design support services. A range of technical services is offered from colour choice and design elements through to project specifi cations. Thermal insulation and U-value calculations Based on the information you supply we can calculate the insulation required for your EWI project in order to meet Building Regulations. Calculations are made on a project by project basis, however there is a useful U-value calculator tool on the website in the Carbon Partner section. This tool is to be used purely for general guidance and indication purposes only. Detail drawings We can supply system details or if necessary to address specifi c design requirements, we can provide project specifi c detail drawings. All standard details are available in the Carbon Partner section of the website Technical and testing documentation BBA certifi cates and system component data sheets are available to download in the Carbon Partner section of the website Technical team Our technical team are on hand to help with your project offering guidance and support. Technical team contact details: Tel: technical.support@caparol.co.uk 18

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