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RockShield External Wall Insulation System Système d isolation pour murs extérieurs Wärmedämmung für Außenwand - PDF
RockShield External Wall Insulation System Système d isolation pour murs extérieurs Wärmedämmung für Außenwand
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1 CI/SfB 21.9 Rn7 (M2) IRISH AGRÉMENT BOARD CERTIFICATE NO. 10/0355 Rockwool Limited Unit 11, Northwood Court, Santry, Dublin 9 Tel Fax Website: RockShield External Wall Insulation System Système d isolation pour murs extérieurs Wärmedämmung für Außenwand NSAI Agrément (Irish Agrément Board) is designated by Government to issue European Technical Approvals. NSAI Agrément Certificates establish proof that the certified products are proper materials suitable for their intended use under Irish site conditions, and in accordance with the Building Regulations 1997 to PRODUCT DESCRIPTION: This Certificate relates to the RockShield External Wall Insulation System, an external wall insulation system comprising of: Surface preparation of masonry or concrete substrate. Base profile and corner profile. Adhesive Mortar. Rockwool dual density mineral wool insulation board (manufactured from molten rock). Mechanical fixings. Base coat with reinforcement. Glass fibre mesh. Primer coat. Finishing coat. Weather-tight joints. Movement joints. Provision for limiting cold bridging at external wall/floor junctions in compliance with Acceptable Construction Details published by the DoEHLG (Department of the Environment, Heritage and Local Government). Rockwool is responsible for the design, manufacture supply and installation of the system and for the integration of the design into the building. The installation of each system is carried out by installers who have been trained by Rockwool and are approved by Rockwool and NSAI Agrément to install the system. This Certificate certifies compliance with the requirements of the Building Regulations 1997 to USE: The RockShield External Wall Insulation System is suitable for use as an external insulation for refurbishment/retrofit of existing masonry or concrete buildings, up to a maximum of six storeys (18 metres) in height in purpose groups 1(a), 1(b), 1(c), 2(a), 2(b), 3, 4(a) and 4(b) as defined in Technical Guidance Document (TGD) to Part B of the Building Regulations 1997 to Readers are advised to check that this Certificate has not been withdrawn or superseded by a later issue by contacting NSAI Agrément, NSAI, Santry, Dublin 9 or online at
2 The systems have not been assessed for use with timber frame or steel frame construction. Rockshield External Wall Insulation System, achieved Category II impact resistance when tested with a single layer of glass fibre mesh 160g/m 2. In an Irish context, Category II Impact Resistance excludes any wall at ground level adjacent to a public footpath, but includes one with its own private, walled in garden. MANUFACTURE, DESIGN AND MARKETING: The system is designed and distributed in Ireland by: Rockwool Limited Unit 11, Northwood Court, Santry, Dublin 9 With the Insulation manufactured at the Rockwool facility in: Pencoed, Bridgend, Wales, CF35 6NY Rockwool is responsible for the design, and supply of all components to approved specifications, in accordance with the Rockwool approved supplier system. Certificate No. 10/0355 / RockShield External Wall Insulation System 2
3 Part One / Certification ASSESSMENT In the opinion of NSAI Agrément, the RockShield External Wall Insulation System, if used in accordance with this Certificate can meet the requirements of the Building Regulations 1997 to 2009, as indicated in Section 1.2 of this Agrément Certificate. 1.2 BUILDING REGULATIONS 1997 to 2009 REQUIREMENTS: Part D Materials and Workmanship D3 Proper Materials The RockShield External Wall Insulation System, as certified in this Certificate, is comprised of proper materials fit for their intended use (see Part 3 and 4 of this Certificate). D1 Materials & Workmanship The RockShield External Wall Insulation System, as certified in this Certificate, meets the requirements for workmanship. Part A - Structure A1 Loading The RockShield External Wall Insulation System once appropriately detailed, designed and installed has adequate strength and stability to meet the requirements of this Regulation (see Part 3 of this Certificate). A2 Ground Movement The RockShield External Wall Insulation System can be incorporated into structures that will meet this requirement (see Parts 3 and 4 of this Certificate). Part C Site Preparation and Resistance to Moisture C4 Resistance to Weather and Ground Moisture External walls has adequate weather resistance in all exposures to prevent the passage of moisture from the external atmosphere into the building as specified in Part 3 and 4 of this Certificate. Part F Ventilation F2 - Condensation in Roofs The RockShield External Wall Insulation System can be incorporated into structures that will meet this requirement (see Parts 3 and 4 of this Certificate). Part J Heat Producing Appliances J3 Protection of Building When the RockShield External Wall Insulation System is used in accordance with this Certificate, wall lining, insulation and separation distances meet this requirement. See Part 4 of this Certificate. Part L Conservation of Fuel and Energy L1 Conservation of Fuel and Energy The walls of the RockShield External Wall Insulation System can be readily designed to incorporate the required thickness of insulation to meet the Elemental Heat Loss method calculations for walls as recommended in TGD to Part L of the Building Regulations 1997 to 2009 (see Table 3, Part 4 of this Certificate). Part B Fire Safety B4 External Fire Spread The RockShield External Wall Insulation System can be incorporated into structures that will meet this requirement (see Part 4 of this Certificate). Certificate No. 10/0355 / RockShield External Wall Insulation System 3
4 Part Two / Technical Specification and Control Data PRODUCT DESCRIPTION This Certificate relates to the RockShield External Wall Insulation System which employs Rockwool dual density mineral wall (MW) insulation (manufactured from molten rock), with glass-fibre reinforcement mesh and render finishes. It is suitable for use as an external insulation for refurbishment/retrofit of existing masonry or concrete building up to 18m (6 stories) in height. 2.2 MANUFACTURE, SUPPLY AND INSTALLATION Rockwool is responsible for the design manufacture and supply of all components to approved specifications, in accordance with the Rockwool approved supplier system. Rockwool are responsible for: Project specific design in accordance with approved design process. Training, monitoring and review of licensed applicators in accordance with approved training and assessment procedures. Product supply. Technical support. Sales and marketing. The installation of each system is carried out by the Certificate Holder s trained and approved installers in accordance with the Certificate Holder s project specific specifications and method statements. Installers must also be approved and registered by NSAI Agrément as part of the NSAI Agrément Approval Scheme for installers of External Thermal Insulating Composite Systems (ETICS). See Cl Quality Control The management systems of Rockwool have been assessed and registered as meeting the requirements of ISO 9001:2000 and a quality plan is in place for system manufacture, design and installation. 2.3 DELIVERY, STORAGE AND MARKING The insulation is delivered to site in packs. Each pack is marked with the manufacturer s details, product identification marks and batch numbers. Insulation should be stored on a firm, clean, dry and level base, which is off the ground. The insulation should be protected from prolonged exposure to sunlight by storing opened packs under cover in dry conditions or by re-covering with opaque polythene sheeting. Each container for other components, e.g. mesh cloth, primers, renders etc., bears the manufacturer s and product s identification marks, batch number and the NSAI Agrément logo incorporating the Certificate number. These components must be stored in accordance with the manufacturer s instructions, in dry conditions, and at the required storage temperatures. They should be used within the stated shelf life, where applicable. 2.4 INSTALLATION Approved installers Installation shall be carried out by the Certificate Holder s trained applicators who: 1) Are required to meet the requirements of an initial site installation check by NSAI Agrément prior to approval and are subject to the NSAI Agrément ETICS Approval Scheme. 2) Are approved by the Certificate Holder and NSAI Agrément to install the product. 3) Have undertaken to comply with the Certificate Holders installation Procedure. 4) Are employing Supervisors and Operatives who have been issued with appropriate identity cards by the Certificate Holder. Each team must consist of at least one ETICS Operative and ETICS Supervisor (can be the same person). 5) Are subject to supervision by the Certificate Holder including unannounced site and/or office inspections by both the Certificate Holder and NSAI Agrément, in accordance with the NSAI Agrément ETICS Approval Scheme General The Certificate Holder prepares a bespoke site package for each project, including U-value calculations, requirements for materials handling and storage, method statements for installation, building details, fixing requirements, provision for impact resistance, maintenance requirements etc. Certificate No. 10/0355 / RockShield External Wall Insulation System 4
5 Substrate Preparation Adhesives Insulation Below DPC Insulation Table 1 Component Specification Rockshield Prim Silicate - Potassium silicate based primer. - Consumption: 0,15 0,8L per m² depending on substrate - Application: For highly absorbent substrates and for equalising the absorption of different substrates. For consolidating sandy surfaced substrates. - Diluted by up to 1:1 with clean water depending on the absorbency of the substrate RockShield Adhesive Mortar - Mineral adhesive and reinforcing mortar to EN 998-1, - Dry powder prepared by mixing with clean water, Powder:Water = 4:1 parts per weight. - Application time: at 20 C approx. 45min RockShield Flexyl adhesive (only for use below DPC) - Organic leveller for sealing at plinth / ground level. Liquid water transmission rate w acc. EN ,: 0,005 kg/(m²/h) - For use as a primer, adhesive and base coat. - Mixing procedure: Mix 1:1 with Portland cement CEM I 32,5 to EN using mixer, open time 60min. - Drying/curing time 24-48hours. Extended in high humidity conditions. Rockwool External Wall DD slab Grade: MW-EN T5-DS(TH)-WL(P)-TR5-MU1 CFC/HCFC free. - A dual density mineral wool board (manufactured from molten rock), with 15mm higher density upper layer; RtF Classification to EN :A1 - MW Panel & MW Lamella HD EPS External Insulation Plinth Board Grade: EPS-EN T2-P4-DS(70,-)2-TR80, CFC/HFC-free, FRA Aged - Panels to be protected from UV radiation and not exposed to high temperature (>80 C). The product shall have a bonding strength >30 kpa - Must always be covered with RockShield Flexyl + mesh as a base coat for plinth/below DPC Dimensions / Quality 10L 25kg 18kg 1200x600x (50-200mm) (panel) 1200x200x (20-30mm) (lamella) Thickness mm Container Can Bag Bucket Polythene shrink wrapped package Anchors RockShield TID Anchors - mechanical fixings. Varies Boxes Base coat Glass fibre mesh Sealer/key coat Finishing coats Ancillary materials RockShield TC mortar -Dry powder prepared by mixing with clean water (6 litres approximately for each 25kg bag) - Reinforcement base coat layer 5 6 mm in thickness. - Drying/curing time hours (at +15 C and max. 70% air humidity). Quick drying (at high temperatures) to be avoided - (sprinkle with water as required). RockShield Universal Reinforcement Mesh - Alkali-resistant reinforcement mesh 6x6mm - Mesh to be located in upper third of the reinforcement base coat material and must be completely covered. - Mesh to overlapped approx. 10cm. At building openings, diagonal reinforcement with mesh stripe (approx. 20x30cm) to be applied. - Tensile strength acc. ETAG 004, EN ISO > 1000 [N/50mm] RockShield Masonry Sealer - A premixed acrylic resin primer base (water based alkali resistant) for use on mineral substrates prior application of finish coat. - Ready for use (max. 10% water can be added, depending on substrate). To be well mixed before application. - Consumption approx. 0,3 kg/m² - Application by brush roller - Drying/curing time 12 hours, at +20 C temperature (air and substrate) and 65% relative humidity. Second coat can be applied after full curing. RockShield Siloplast Top Coat - Premixed through coloured resin plaster (cement free), with film preservation, stippled texture. To be well mixed before application. Application with a hard plastic trowel - Available In grain sizes 1.5mm. 2.5mm and 3.5mm - Grain sizes 3,0 mm should be textured using a wooden float - Touch dry in 6 hours at 20 c and 65% relative humidity - Can be over-coated after approx. 24 hrs. - Completely dry after 14 days. Ancillary materials and decorative coatings must be approved by the Certificate holder. 25kg Bag 160g/m 2 Rolls 23kg Bucket 25kg Bucket - - Certificate No. 10/0355 / RockShield External Wall Insulation System 5
6 This document forms part of the contract documentation for circulation to the home owner and the installer. Installers will be expected to adhere to the specification. Deviations must be approved by a technical representative of the Certificate Holder. The Certificate Holders technical representatives will carry out site inspections on a regular basis to ensure that work is carried out in according with the project specific site package, including the Certificate holder s installation manual. The RockShield dual density rock mineral wool board must be protected from prolonged exposure to moisture prior to and during installation. It may be necessary to remove and replace any unsuitable/damaged material. External works that leave the external appearance of the building inconsistent with neighbouring buildings may require planning permission. The status of this requirement should be checked with the local planning authority as required Site Survey and Preliminary Work A pre-installation survey of the property shall be carried out and recorded to confirm suitability of substrate for application of the ETICS System including, modifications/repairs necessary, pullout resistance of proposed mechanical fixings etc. The substrate must be free of water repellents, dust, dirt, efflorescence and other harmful contaminants or materials that may interfere with the adhesive bond. Remove projecting mortar, concrete parts, or irregularities (i.e. greater than 20mm in 1m) mechanically as required. Loose or flaking elements should be removed and defects filled with RockShield Adhesive Mortar. Where weak, dusty or highly absorbent substrates are to be insulated, they should be first treated with RockShield Prim Silicate in accordance with the Certificate Holders instructions. See Table 1. Where necessary, tests are conducted on the walls of the building to determine the pull out strength of any fixings required. All external plumbing should be removed, and alterations made to underground drainage, where appropriate to accommodate its repositioning on the face of the external insulation system. Where discrepancies exist preventing the installation of the Rockshield External Wall Insulation System in accordance with this Certificate, these discrepancies should be discussed with the Certificate holder to identify the appropriate solution Application Procedure Prepare substrate in accordance with the project specific site package. This will include brushing down of walls, washing with clean water and treatment with a fungicidal wash as required. Weather conditions must be monitored by installers to ensure correct application and curing conditions. Application of coating materials should not be carried out below 5 o C or above 30 o C, nor if exposure to frost is likely. Until fully cured, the coatings must protected from rapid drying, precipitation, direct sunlight and strong wind. Refer to the site package for guidance on modifications of down pipes, soil and vent pipes, pipe extensions etc. Where possible, all pipe work should be relocated as required to accommodate the Insulation. Where pipe work can not be relocated and is to be housed in the depth of the system, access for maintenance must me maintained through the use of removable covers or alternative design to be approved by the Certificate holder. Base profile and corner profiles are fixed as specified in the site package. Existing structural expansion joints should be extended through to the surface of the ETICS system with full system expansion beads. See Figure 7. A plinth strip/starter track is mechanically fixed to the substrate level with DPC level. This provided a horizontal line for the installation the insulation panels as well as providing reinforcement to the lower edge of the system. Each end of profile is prepared for internal and external corners as required. High density EPS boards (minimum density 30kg/m 2 ) are used below DPC level to provide the necessary impact and moisture resistance. To minimise the effects of cold bridging the high density EPS should extend below ground level where possible as shown in Figure 2. Where this is not possible the first run of high density EPS insulation boards is positioned at ground level as shown in Figure 3. The EPS insulation boards are bonded to the wall by using RockShield Flexyl adhesive (premixed paste). The complete back face of the panel is coated with adhesive using a notched trowel to produce a coat 2-5 mm in thickness. The panel is immediately placed on the substrate, pressed into place and secured with mechanical fixings as detailed in the project specific design. A base coat of RockShield Flexyl (5 6mm in thickness) incorporating RockShield Universal reinforcement mesh is then applied to the outer faces of the board, overlapping the substrate or existing water barrier, as shown in Figure 2, to provide a complete moisture seal. Certificate No. 10/0355 / RockShield External Wall Insulation System 6
7 Subsequent rows of insulation boards are bonded to the substrate above DPC using RockShield adhesive mortar starting on top of the starter track and positioned so that the vertical board joints are staggered and overlapped at the building corners. RockShield Adhesive mortar is prepared by mixing with clean water (6 litres approximately for each 25kg bag) using an electrically driven paddle mixer to give a smooth workable consistency. Care should be taken not to over mix. After 5 min mixing, additional water may be added to obtain the correct consistency for trowel application. Mixed mortar must be used within 4 hours and hardener mortar must not be used. Adhesive is applied to the insulation slabs using the Combined Bed technique with a 10/12 notched trowel or using the dot and dab method for uneven substrates. The insulation slabs should be pressed firmly on to the substrate immediately after application of the adhesive. Any delay may result in a weak bond. To avoid thermal bridging, a tight, adhesive free joint connection between slabs shall be maintained. For gaps up to 5mm, where it is not possible to insert thin strips of the RockShield slab material, a foam filler, approved by the Certificate Holder (e.g. Illbruck / Hanno) shall be used. When used, the expanding foam should have a fire-rating of B2 or better and a maximum lambda value of 0,035 W/mK. At façade openings e.g. windows and doors, insulation boards must not be continued around the corner. Insulation boards should overlap at these locations and can be cut to size to facilitate this. Any projecting insulation boards should trimming as required. Window and door reveals should be insulated to minimise the affects of a cold bridging in accordance with the recommendations of the Acceptable Construction Details Document (published by the DoEHLG), Section 2 External Wall Insulation, Detail to achieve an R-value of 0.6m 2 K/W as shown in Figure 5 and 6. Where clearance is limited, strips of approved insulation (RockShield lamella slabs that can be rasped down as required for this purpose) should be installed to suit available margins and details recorded as detailed in Cl. 4.5 of this Certificate. Details of mechanical fixings (including their arrangement in the insulation boards) are specified in the project specific design requirements based on pullout test results, substrate type and wind loading data. Installation of mechanical fasteners shall commence no earlier than 24 hours after the insulation panels have been adhesively fixed. A minimum of 8 mechanical fixings per m 2 are installed unless otherwise specified in the project specific design. RockShield TID Anchors must be installed the required depth into the substrate, with the head fixed tightly to the insulation board to ensure there is no risk of pull off. See Figures 1 and 8. Purpose-made and Rockwool/RockShield approved powder aluminum window sills (complete with PVC sill end caps), are installed in accordance with the Certificate holders instructions. They are designed to prevent water ingress and incorporate drips to shed water clear of the system. See Figure 5. Movement joints shall be provided in accordance with the project specific site package. See Figure 7. At all locations where there is a risk of insulant exposure, e.g. window reveals or eaves, the system must be protected e.g. by an adequate overhang or by purpose made sub-sills, seals or flashing. Building corners, door and window heads and jambs are formed using angle beads bonded to the insulation in accordance with the manufacturer s instructions. To minimise the thermal bridge affect during the installation of components/structures imposing a pressure or tensile load (e.g. railings, exterior lighting, shutter guide rails, canopies, aerials /dishes etc.), the certificate holder offers a range of anchoring options, utilising high density polyurethane cylindrical blocks incorporated into the insulation. These anchors must be installed in accordance with the certificate holder s instruction (as defined in the project specific site package) during the installation of the insulation boards Prior to application of base coat and finish coat all necessary protective measures, such as taping off of existing timber window and covering of glass, should be in place. If it is not possible to install the EWIS system to all external walls, alternate forms of thermal upgrades, such as full fill cavity wall insulation or internal dry lining, should be provided where physically and economically feasible. There should be an adequate over lap at the junction between and EWIS system and the alternative insulation method selected to limit thermal bridging at this interface. Where the external insulation meets intersecting walls etc. and the abutting structure cannot be cut back, the edge of the insulation where it meets the wall should be protected using pvc universal stop-trim, followed by the application of a low modular silicone sealant between the top-coat and the abutting structure. Certificate No. 10/0355 / RockShield External Wall Insulation System 7
8 If unusual levels of movement are expected then the use of an expansion joint at the intersection is recommended and should be incorporated into the project-specific design provided by the Certificate holder. In the case of unheated lean-two buildings, the EWIS system should continue around the lean-two. The RockShield Base Coat is prepared by mixing with clean water (6 litres approximately for each 25kg bag) using an electrically driven paddle mixer to give a smooth workable consistency. Care should be taken not to over mix. After 5 min mixing, additional water may be added to obtain the correct consistency for trowel application. The mixed mortar must be used within 4 hours and hardener mortar must not be used. The basecoat is trowel applied to the insulation using a 10/12mm toothed trowel to a minimum thickness of 5 6 mm. RockShield Universal alkali-resisting glass-fibre reinforcement mesh (minimum nominal weight of 160g/m 2 ) is immediately applied in vertical strips with 100mm overlaps and smoothed to a level surface with a trowel to fully bed the mesh into the top surface of the basecoat. Mesh reinforcement must always be carried around corners - overlaps in quoins should be min. 150mm. The above base coat thickness / mesh reinforcement combination achieved a Category II impact classification (when assessed against requirements of ETAG 004). See of this Certificate for description of impact classifications. Additional pieces of reinforcing mesh are applied diagonally at the corners of openings to provide the necessary reinforcement in these areas. At affected locations apply, install 200x300mm mesh strips at a 45 o angle in relation to the lines determined by the reveal, embedded into basecoat in accordance with the Certificate holder s instructions. See Figure 8. Refer to the certificate holder s instructions and the project specific site package regarding the requirement of additional fixings to be provided at the rate of one per square metre above two stories. The fixing design should take account of the additional layers of mesh are also applied at these locations. The base coat must be allowed to dry/cure, 2-3 days approx. (depending on drying conditions) prior to the application of the RockShield masonry sealer. RockShield masonry Sealer (a premixed acrylic resin primer base) is applied by roller painting and should be allowed to dry for approximately 12 hours (minimum) prior to the application of the Finishing Coat. This sealer prevents penetration of impurities from the adhesive into the render, protects and reinforces the substrate, and increases the bond strength between the render and the substrate. The RockShield Silcoplast (Stippled) Finishing Coat is prepared by mixing with clean water per the manufacturers instructions using an electrically driven paddle mixer to give a smooth workable consistency. Finishing coats are through coloured renders (available in BS and NCS colours), available in 1.5, 2.5 and 3.5mm grain sizes with application rates of 2.8kg/m 2, 3.5kg/m 2 and 5.0kg/m 2 respectively. Finishing coats should not be applied when the air or wall temperature is below +5 o C or above 25 o C. In wet weather the finished walls should be protected to prevent wash-off. It is also advisable that protective covers remain in place as required to maximise the drying process. Site temperatures and weather forecasts should be monitored during the application of the ETICS system. The RockShield Silcoplast (Stippled) Finishing Coat is applied using a stainless steel trowel, and after a short time, a plastic float is used in applied in a circular motion to the part cured surface to create a textured finish. After full curing of the Finishing Coat, sealants are applied per the project specific site package as per the Certificate holder s instructions. In sunny weather, work should commence on the shady side of the building and be continued, following the sun to prevent the rendering drying out too rapidly. To minimise colour shade variations and to avoid dry line jointing, continuous surfaces should be completed without a break. If breaks cannot be avoided they should be made where services or architectural features, such as reveals or lines of doors and windows, help mask cold joints. Where long uninterrupted runs are planned, containers of the Finishing Coat should be checked for batch numbers. Bags with different batch numbers should be checked for colour consistency. All rendering should follow best practice guidelines e.g. BS :1995 Workmanship on building sites Code of practice for plastering and rendering and IS EN :2005 Design, preparation and application of external rendering and internal plastering External rendering. On completion of the installation, external fittings, rainwater goods, removed wiring etc. are fixed through the system into the substrate in accordance with the Certificate holder s instructions. All necessary post-application inspections should be performed and the Rockwool RockShield documentation (check/sign-off sheets and provision of the Maintenance/Homeowners manual and project specific documentation to the client) completed accordingly. Certificate No. 10/0355 / RockShield External Wall Insulation System 8
9 Figure 1. ROCKSHIELD - External Thermal Insulation Composite System Soffit detail 1 Block work / Substrate 2 RockShield Adhesive Mortar 3 RockShield Dual Density MW Insulation (manufactured form molten rock) 4 RockShield TC mortar 5 RockShield Universal Reinforcement Mesh 6 RockShield Silcoplast Top Coat 7 Seal Tape 2D 15/ PVC Stop Bead 9 Ventilation to be maintained / replaced as required 10 RockShield TID Anchor Certificate No. 10/0355 / RockShield External Wall Insulation System 9
10 Figure 2. ROCKSHIELD - External Thermal Insulation Composite System Insulation below ground level 1 Blockwork / Substrate 2 RockShield Adhesive mortar 3 RockShield Dual Density Insulation 4 RockShield Silcoplast Top Coat 5 RockShield TC Mortar 6 RockShield Universal Reinforcement Mesh 7 RockShield Silcoplast Top Coat 8 Distance 150mm (minimum) 9 Distance 150mm approx. (to minimise thermal bridging) 10 Distance 100mm minimum (overlap of RockShield Flexyl water barrier on to substrate or existing water barrier) 11 Drainage stone (30cm x 60cm) 12 Existing DPC 13 RockShield Flexyl as primer and adhesive coat below DPC, (to act as water barrier) 14 HD EPS perimeter plinth board 15 RockShield Flexyl base coat below DPC, (to act as water barrier) Certificate No. 10/0355 / RockShield External Wall Insulation System 10
11 Figure 3. ROCKSHIELD - External Thermal Insulation Composite System Insulation to existing ground level 1 Block work / Substrate 2 Existing substrate render finish 3 RockShield Adhesive Mortar 4 RockShield Dual Density Insulation 5 RockShield Silcoplast Top Coat 6 RockShield TC mortar 7 RockShield Universal Reinforcement Mesh 8 RockShield Silcoplast Top Coat 9 RockShield starter profile 10 Existing DPC 11 Below DPC (original detail) 12 Seal Tape 2D 15/ Seal Tape 2D 15/ HD EPS Perimeter Plinth Board 15 RockShield Flexyl as base coat 16 RockShield Universal Reinforcement Mesh 17 Distance 150mm 18 Existing ground level 19 RockShield TID anchor 20 RockShield Aluminium starter 21 RockShield Flexyl as primer and adhesive (to act as water barrier) Certificate No. 10/0355 / RockShield External Wall Insulation System 11
12 Figure 4. ROCKSHIELD- External Thermal Insulation Composite System Aluminium sill detail 1 Block work / Substrate 2 Existing concrete sill, to be cut in line with existing substrate wall 3 Window Unit and aluminium sill to be compatible so as to provided a fully sealed, flush finished joint at interface 4 Window Seal tape 2D 20 5 Powder Coated Aluminium Sill profile with end caps. Sill have to have minimum fall of 10 degrees 6 RockShield Adhesive mortar 7 RockShield Dual Density Insulation 8 RockShield TC mortar 9 RockShield Universal Reinforcement Mesh 10 RockShield Silcoplast Top Coat 11 35mm minimum overhang 12 RockShield thermal bridge insulation 20mm min. (e.g. RW lamella) 13 RockShield Flexyl base coat below (to act as secondary water barrier) 14 Seal Tape 2D 15/ Sill End Cap Certificate No. 10/0355 / RockShield External Wall Insulation System 12
13 Figure 5. ROCKSHIELD - External Thermal Insulation Composite System Window reveal 1 Block work / Substrate 2 RockShield Adhesive Mortar 3 Air tightness foil stripe (interface between window frame and substrate) 4 RockShield thermal bridge insulation 20-30mm (e.g. RW lamella) to provided R-value of 0.6m 2 k/w 5 RockShield Dual Density Insulation 6 Window Frame 7 PVC Stop Bead with integrated compression foam strip 8 RockShield TC mortar 9 RockShield Universal Reinforcement Mesh 10 RockShield Silcoplast Top Coat Certificate No. 10/0355 / RockShield External Wall Insulation System 13
14 Figure 6. ROCKSHIELD - External Thermal Insulation Composite System Window / Door head detail 1 Block work / Substrate 2 RockShield Adhesive mortar 3 Air tightness foil strip (interface between window frame and substrate) 4 RockShield thermal bridge insulation 20-30mm (e.g. RW lamella) to provided minimum R-value of 0.6m 2 K/W 5 RockShield Dual Density Insulation 6 PVC stop bead with integrated compression foam strip 7 RockShield TC mortar 8 RockShield Universal Reinforcement Mesh 9 RockShield Masonry Sealer 10 RockShield Silcoplast Top Coat 11 Window Frame 12 RockShield TID anchor 12 RockShield PVC corner profile incorporating drips to shed water clear of the system Certificate No. 10/0355 / RockShield External Wall Insulation System 14
15 Figure 7. ROCKSHIELD - External Thermal Insulation Composite System Movement joint detail 1 Block work / Substrate 2 RockShield Adhesive Mortar 3 RockShield Dual Density Insulation 4 Rockwool Lamella or Slab to fill joint 5 RockShield TC mortar with RockShield Universal Reinforcement Mesh 6 RockShield Silcoplast Top Coat 7 PVC- Movement Joint Profile Certificate No. 10/0355 / RockShield External Wall Insulation System 15
16 Figure 8. ROCKSHIELD - External Thermal Insulation Composite System Arrangement of anchors and corner reinforcement mesh at openings 1 RockShield Dual Density Insulation 2 RockShield Universal mesh strips 200 x 300mm corner reinforcement at openings 3 RockShield PVC-edge corner profile with reinforcement mesh 4 RockShield TID-Anchors 5 RockShield Starter Profile 6 Below DPC per Figure 2 & 3 Certificate No. 10/0355 / RockShield External Wall Insulation System 16
17 Part Three / Design Data 3 3. GENERAL The system is designed by the Certificate Holder on a standard or project specific basis. The design will include for: a) The completion and recording of a site survey. b) Evaluation and preparation of substrate. c) Minimising risk of condensation in accordance with recommendations of BS 5250:2002 Code of practice for control of condensation in buildings. This includes the use of approved Rockwool/RockShield detailing as shown in Figures 1 8 incorporating the requirements of the Acceptable Construction Details published by the DoEHLG. d) Thermal insulation provision to TGD to Part L of the Building Regulations 1997 to e) Resistance to impact and abrasion. f) Resistance to thermal stresses. g) Resistance to wind loading. h) Design of fixings to withstand design wind loadings, using a safety factor of 3 (three) for mechanical fixings and a safety factor of 9 (nine) for adhesive. In addition, fixings around window and door openings shall be at a maximum of 400mm centres in each board or section of board so as to provide positive and robust restraint over the life of the system. i) The design for wind loading on building greater than two stories should be checked by a chartered engineer in accordance with Eurocode 1: I.S EN :2005 General actions- Wind actions. j) Design for fire resistance, fire spread and fire stopping. As defined in Cl. 4.2 and 4.3 of this Certificate. k) Design of a water management system to prevent ingress of water at movement joints, windows, doors, openings for services etc. Particular attention is required to ensure that window and sill design are coordinated to achieve a fully integrated design as shown in Figure 4. l) Movement joints. n) A site specific maintenance programme for inclusion in the home owner s documentation. o) Durability requirements. Detailing and construction must be to a high standard to prevent the ingress of water and to achieve the design thermal performance. Window details should be designed such that, where possible, they can be removed and replaced from within the building. Consideration should be given to maximising improvement of thermal insulation at window reveals, door openings etc. Adequate provision should be made at design and installation stage for the release of trapped moisture e.g. above window heads. When designed and installed in accordance with this Certificate, the systems will satisfy the requirements of TGD to Part L of the Building Regulations. The design shall include for the elimination/minimising of cold bridging at window and door reveals, eaves and at ground floor level in compliance with Acceptable Construction Details published by the DoEHLG; Seals to windows and doors shall be provided in accordance with the project specific site plan. Care should be taken to ensure that any ventilation or drainage openings are not obstructed. In areas where electric cables can come into contact with expanded polystyrene, in accordance with good construction practice, all PVC sheathed cables should be run through ducting or be re-routed. The durability of the render systems is influenced by the colour of the render used. The Certificate Holder recommend that where renders are used in thermal insulation systems, dark colors with a reflection coefficient of scattered light below 20% should be avoided. The use of dark color renders for such applications should not exceed 10% of facade surface. This should be considered when choosing the finishing coat to be used. Exceptions include north facing or shaded walls. In case of the doubt, the advice of the Certificate holder should be sought. Certificate No. 10/0355 / RockShield External Wall Insulation System 17
18 Part Four / Technical Investigations STRENGTH AND STABILITY Wind Loading. The Rockwool RockShield External Wall Insulation System can be designed to withstand the wind pressures (including suction) and thermal stresses in accordance with the Building Regulations 1997 to The design for wind loading on building greater than two stories should be checked by a chartered engineer in accordance with Eurocode 1 Actions on Structures: I.S EN :2005. General Actions- Wind Actions. A general factor of safety of 1.5 is applied to design wind loads Impact Resistance a/ The RockShield system (utilising a base coat thickness of 5-6mm, a single layer of Universal Reinforcing Mesh and a finishing coat of RockShield Siloplast has been tested to show a Category II Impact Resistance classification can be achieved. See Table 2. Impact Resistance Classifications are defined in ETAG 004 Cl Table 8, as follows: Category I: A zone readily accessible at ground level to the public and vulnerable to hard impacts but not subject to abnormally rough use. There are no restrictions on the use of Category I Systems. Category II: A zone liable to impacts from thrown or kicked objects, but in public locations where the height of the system will limit the size of the impact; or at lower levels where access to the building is primarily to those with some incentive to exercise care. Class II excludes use on wall at ground level adjacent to a public footpath, but includes use on properties with their own private, walled in garden. Category III: A zone not likely to be damaged by normal impacts caused by people or by thrown or kicked objects. Class III is taken to excluded the use on any wall at ground level. Note: The above classifications do not include acts of vandalism. b/ The design should include for preventing damage from impact by motor vehicles or other machinery. Preventative measures such a provision of protective barriers, or kerbs, should be considered. Table 2 Rockwool RockShield ETICS System Impact Resistance Rendering System: Insulation, Base Coat, and Finishing Coat indicated RockShield Dual Density MW panels + RockShield TC Mortar Base Coat (with mesh) + RockShield Siloplast Top Coat Impact Resistance Using one layer of RockShield Universal Reinforcement Mesh Category II 4.2 BEHAVIOUR IN RELATION TO FIRE a) The external surfaces of the system are classified as Class O as per Building Regulations Technical Guidance Document Part B 2006 Clause A12. b) The system as described has been assessed against the requirements of Building Regulations 2009 Technical Guidance Document B Fire Safety Cl 4.1.5, taking into consideration: - data from fire testing including fire testing in accordance with BS : 2005 Fire Performance of external cladding systems. Test methods for non-load bearing external cladding systems fixed to and supported by a structural steel frame. - the performance criteria set in BRE 135:2003 Fire performance of external thermal insulation for walls of multi-storey buildings. The systems are appropriate for the uses without restriction as described in Cl of Part B of TGD to the building regulations. 4.3 THERMAL INSULATION Assessments were carried out to verify that the requirements of Part L of the Building Regulations 1997 to 2009 can be achieved using the RockShield External Wall Insulation System. The manufacturer s declared thermal conductivity values (λ 90/90 ) for the RockShield dual density insulation is 0.036W/mK. Table 3 shows various insulation thickness on typical wall constructions and the corresponding U-Value (in W/m 2 K) that can be achieved. Calculation of U-Values will be required on individual projects to confirm a U-Value of 0.27 W/m 2 K has been achieved, based on the wall construction and the insulation used. Certificate No. 10/0355 / RockShield External Wall Insulation System 18
19 Table 3: Typical U-values (W/m 2 K) Existing Wall Structure Thickness of ECAP Insulation (mm) None mm Dense Block on Flat mm Medium Density Block on Flat mm Hollow Block Block Cavity Wall 100mm unventilated cavity (No insulation in cavity) Brick / Block Cavity Wall 100mm unventilated cavity (No insulation in cavity) Block 100mm Cavity Wall with Rockwool Energy Saver full fill CWI These values are based on the following construction (External to Internal): Render on existing concrete block work -19mm (not on brickwork) Block work, dense 2000kg/m³ (440x215x100) - 215mm Block work, medium dense 2000kg/m³ (440x215x100) -215mm Hollow block work -2000kg/m³ (440x215x100) -215mm Existing Render (BS5250) -19mm Existing Plaster, gypsum (BS5250) -13mm The thermal conductivity (λ) value of the insulation to be used in all U-value calculations must be the λ 90/90 value. When the ETICS system is to be applied to a masonry cavity wall construction, consideration should be given to the treatment of the ventilated cavity. In order to maximise the impact of the ETICS system on the U-Value of the wall, filling of the cavity, or sealing to ensure no airflow occurs should be considered. 4.4 LIMITING THERMAL BRIDGING The linear thermal transmittance ψ (Psi) describes the heat loss associated with junctions and around openings. Window and door reveal design used on the RockShield External Thermal Insulation Composite Systems have been assessed and when detailed in accordance with this certificate, can meet the requirements of Table D1 of Appendix D of TGD to Part L of the Building Regulations 1997 to When all bridged junctions within a building comply with the requirements of Table D1 of appendix D of TGD to Part L, the improved y factor of 0.08 can be entered into the Dwelling Energy Assessment Procedure (DEAP) Building Energy Rating (BER) calculation. Alternatively if all junctions can be shown to be equivalent or better than the Acceptable Construction Details, published by the DoEHLG then the improved y factor of 0.08 can be used i.e. R value = 0.6m 2 K/W for window/door reveals. Where either of the above options are shown to be valid, or when the required values can not be achieved, all relevant details should be recorded on the Certificate of Compliance for that project for use in future BER calculations. Ψ values for other junction outside the scope of this certificate should be assessed in accordance with the BRE IP1/06 Assessing the effects of thermal bridging at junctions and around openings and BRE Report BR 497 Conventions for calculating linear thermal transmittance and temperature factors in accordance with appendix D of TGD to Part L of the Building Regulations 1997 to CONDENSATION RISK Areas where there is a significant risk of condensation due to high levels of humidity should be identified during the initial site survey Internal Surface condensation. When improving the thermal performance of the external envelope of a building through the use of external wall insulation, designers need to consider the impact of these improvements on other untouched elements of the building. As discussed in section 4.5 of this certificate thermally bridged section of the envelope such as window jambs, sills and eves will experience a lower level of increased thermal performance. The degree of improvement to these junctions can be limited due to physical restrictions on site i.e. footpaths, soffit boards or hinges for windows. Certificate No. 10/0355 / RockShield External Wall Insulation System 19
20 When bridged junctions meet the requirements of TGP L appendix D table D1, the coldest internal surface temperature will satisfy the requirements of section D2, namely that the temperature factor shall be equal to or greater than As a result best practice will have been adopted in order to limit the risk of internal surface condensation which can result in dampness and mould growth. When site limiting factors give rise to substandard level of insulation at bridged junctions, guidance should be sought from the certificate holder as to acceptable minimum requirements Interstitial Condensation An interstitial condensation risk analysis will be carried out by the Certificate Holder in accordance with BS 5250:2002, and the design modified as appropriate to reduce the risk of interstitial condensation to acceptable levels. 4.6 MAINTENANCE Adequate provision should be made for access and maintenance over the life of the system. The system shall be inspected and maintained in accordance with the Certificate holder s instructions, as detailed in their Repair and Maintenance Method Statement, which is incorporated into the Home Owner s Manual. Necessary repairs should be effected immediately and should be carried out in accordance with the Certificate holder s instructions. Repairs to plumbing etc. should also be carried out as required to prevent deterioration or damage, and to protect the integrity of the system. Synthetic finishes may be subject to aesthetic deterioration due to exposure to UV light. They should be re-painted every 18 to 20 years to maintain appearance. Care should be taken to ensure that the synthetic finish used is compatible with the original system and that the water vapour transmission or fire characteristics are not adversely affected. Sealants shall be subject to regular inspection (at least annually). They should be replaced as required and fully replaced every 18 to 20 years to maintain performance. 4.7 WEATHERTIGHTNESS When designed and detailed in accordance with this Certificate, the system will prevent moisture from the ground coming in contact with the insulation. See Figures 2 and 3. The external render has adequate resistance to water penetration when applied in accordance with the Certificate holder s instructions. Joint designs, sealant specifications and recommendations for detailing at windows and doors were assessed and are considered adequate to ensure that water penetration will not occur, assuming that regular maintenance is carried out in accordance with the Certificate holder s instructions. See Figure DURABILITY Design Life An assessment of the life of the system was carried out. This included an assessment of: Design and installation controls; Proposed building heights; Render thickness and specification; Material specifications, including insulant, mesh, beading and fixings specifications; Joint design; Construction details; Maintenance requirements. The assessment indicates that the system should remain effective for at least 30 years, providing that it is designed, installed and maintained in accordance with this Certificate. Any damage to the surface finish shall be repaired immediately and regular maintenance shall be undertaken as outlined in Section 4.7 of this Certificate Aesthetic Performance As with traditional renders, the aesthetic performance of the systems, e.g. due to discolouration, soiling, staining, algal growth or lime bloom, is dependent on a range of factors such as: Type, colour and texture of surface finish; Water retaining properties of the finish; Architectural form and detailing; Building orientation/elevation; Local climate/atmospheric pollution. Adequate consideration should be given at the design stage to all of the above to ensure that the level of maintenance necessary to preserve the aesthetics of the building is acceptable. 4.9 PRACTICABILITY The practicability of construction and the adequacy of site supervision arrangements were assessed and considered adequate. The project specific designs and method statements for application, inspection and repair were reviewed and found to be satisfactory. Certificate No. 10/0355 / RockShield External Wall Insulation System 20
21 4.10 TESTS AND ASSESSMENTS WERE CARRIED OUT TO DETERMINE THE FOLLOWING Structural strength and stability. Behaviour in relation to fire. Impact resistance. Pull-out resistance of fixings. Thermal resistance. Hygrothermal Behaviour Condensation risk. Site erection controls. Durability of components. Dimensional stability of insulants OTHER INVESTIGATIONS (i) Existing data on product properties in relation for fire, toxicity, environmental impact and the effect on mechanical strength/stability and durability were assessed. (ii) The manufacturing process was examined including the methods adopted for quality control, and details were obtained of the quality and composition of the materials used. (iii) Special building details (e.g. ground level, window and door openings, window sill and movement joints) were assessed and approved for use in conjunction with this Certificate. (iv) Site visits were conducted to assess the practicability of installation the history of performance in use of the product. Certificate No. 10/0355 / RockShield External Wall Insulation System 21
22 Part Five / Conditions of Certification National Standards Authority of Ireland ("NSAI") following consultation with NSAI Agrément has assessed the performance and method of installation of the product/process and the quality of the materials used in its manufacture and certifies the product/process to be fit for the use for which it is certified provided that it is manufactured, installed, used and maintained in accordance with the descriptions and specifications set out in this Certificate and in accordance with the manufacturer's instructions and usual trade practice. This Certificate shall remain valid for five years from date of issue so long as: (a) the specification of the product is unchanged. (b) the Building Regulations 1997 to 2009 and any other regulation or standard applicable to the product/process, its use or installation remains unchanged. (c) the product continues to be assessed for the quality of its manufacture and marking by NSAI. (d) no new information becomes available which in the opinion of the NSAI, would preclude the granting of the Certificate. (e) the product or process continues to be manufactured, installed, used and maintained in accordance with the description, specifications and safety recommendations set out in this certificate. (f) the registration and/or surveillance fees due to NSAI Agrément are paid. 5.2 The NSAI Agrément mark and certification number may only be used on or in relation to product/processes in respect of which a valid Certificate exists. If the Certificate becomes invalid the Certificate holder must not use the NSAI Agrément mark and certification number and must remove them from the products already marked. 5.3 In granting Certification, the NSAI makes no representation as to; (a) the absence or presence of patent rights subsisting in the product/process; or (b) the legal right of the Certificate holder to market, install or maintain the product/process; or (c) whether individual products have been manufactured or installed by the Certificate holder in accordance with the descriptions and specifications set out in this Certificate. 5.4 This Certificate does not comprise installation instructions and does not replace the manufacturer's directions or any professional or trade advice relating to use and installation which may be appropriate. 5.5 Any recommendations contained in this Certificate relating to the safe use of the certified product/process are preconditions to the validity of the Certificate. However the NSAI does not certify that the manufacture or installation of the certified product or process in accordance with the descriptions and specifications set out in this Certificate will satisfy the requirements of the Safety, Health and Welfare at Work Act 2005, or of any other current or future common law duty of care owed by the manufacturer or by the Certificate holder. 5.6 The NSAI is not responsible to any person or body for loss or damage including personal injury arising as a direct or indirect result of the use of this product or process. 5.7 Where reference is made in this Certificate to any Act of the Oireachtas, Regulation made thereunder, Statutory Instrument, Code of Practice, National Standards, manufacturer's instructions, or similar publication, it shall be construed as reference to such publication in the form in which it is in force at the date of this Certification. Certificate No. 10/0355 / RockShield External Wall Insulation System 22
23 NSAI Agrément This Certificate No. 10/0355 is accordingly granted by the NSAI to Rockwool Limited on behalf of NSAI Agrément. Date of Issue: December 2010 Signed Seán Balfe Director of NSAI Agrément Readers may check that the status of this Certificate has not changed by contacting NSAI Agrément, NSAI, 1 Swift Square, Northwood, Santry, Dublin 9, Ireland. Telephone: (01) Fax: (01) Certificate No. 10/0355 / RockShield External Wall Insulation System 23
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