Mineral Wool Insulation: A Sustainable Value Proposition for the Building Industry

Mohammad Aldabbas Business Development Manager Specialized Thermal And Acoustical Insulation Company

Agenda
Introduction Alghanim-KIMMCO

Mineral wool vs Other insulants Insulating material. Performance comparison: thermal, acoustic, fire, LCA

Building Codes & Sustainability

KIMMCO product range

AI: Alghanim Industries

AIIG: Alghanim Industries Insulation Group
Kuwait Insulation Material Manufacturing Company
1 plant, 35,000 MT Glasswool capacity

Rockwool India Limited

2 plants, 50,000 MT Rockwool capacity

JV with Saint-Gobain, in Turkey

5 plants, GW, RW, EPS, XPS, nitril rubber, PUR panels

All plants are ISO 9001 & 14001, certified

Regional Presence of KIMMCO- RIL

Primary markets =

GCC and India

Secondary markets = North Africa, Levant, South East Asia

Leading Technology - TEL process for Glasswool

Sand and cullet

Melting 1,450C

Fibre forming and binder injection

recycled waste Forming section White glasswool Curing oven Binder becomes yellow Edge trim cutting Cross cutting

Confidential

Leading Technology - REX process for Rockwool

Slag and basalt

1,600C Melting

Fibre forming and Binder injection Forming section Grey stone wool Curing oven Binder becomes grey / brown Edge trim cuttin Cross cuttin Recycled waste

Confidential

GlassWool

RockWool

AIIG
Product Range

Nitril Rubber

Sandwich Panel

EPS / XPS Foam

Insulation Application-Segmentation

Glasswool + Rockwool

Mostly Glasswool Mostly Rockwool

Agenda
Introduction Alghanim-KIMMCO

Mineral wool vs Other insulants Insulating material. Performance comparison: thermal, acoustic, fire, LCA

Building Codes & Sustainability

KIMMCO product range

Insulating Products Classification

Mineral based Glasswool Organic based PUR (polyurethane)

Stonewool
Foam glass Aerogel

PIR (polyisocyanurate)
EPS (expanded polystyrene) XPS (extruded polystyrene)

fibre foam powder

PHE (phenolic) NR (nitril rubber) PE (polyethylene)

PET (polyester)

1. Thermal insulation
Three ways of thermal transmittance
Conduction

Conduction
Convection

Convection
Radiation

Radiation

Total lambda (k-value) calculation

_cond (solids + gas) + _rad + _conv

30
25 20 15 10 5 0 8 9 11 11 13 16 26

synthetic foams

mineral fiber

ODP & GWP values of Blowing Agents

ODP
CFC: HCFC: HFC: HC:

GWP (100)

Chloro-Fluoro-Carbons Freon 11, Freon 12 Hydro-Chloro-Fluoro-Carbons 141b (PUR) Hydro-Fluoro-Carbons 245, 365, 134 etc (XPS) Hydro-Carbons methane, ethane, propane etc. n,i,c- pentane for (PUR/PIR/EPS) clean?

1 (def)
0,1

4000 / 8500

630

950 / 890 / 1300

0 0 0

20 <1

CO2 / H2O:

1 (def) 0

Air:

Mineral wool

Lambda performance of Glasswool

50

Lambda values allways have to be compared at the same temperature In Europe values are measured and declared at 10C In the US at 24C , in Japan at 25C ...

T : 10C T : 24C

45

40

35

32
30 0 10 20 30 40 50 60 70 80 90 100 DENSITY (kg/m3)

Lambda Ageing of PU boards!

Comparative K-values (@ 25 C) of most common insulants

160 140 120 100 80 60 40 20 0 maximum minimum

Lambda, R-value, U-value

Material constant: insulating capacity Lambda: W/m. K The lower the better

Application parameter Thermal resistivity, R = d/ (m2.K/W) d = thickness of insulating product

The rmal transmittance U = 1/R (W/m2.K)

U-value calculation for building facade

U0 = ((U

x A w)

+ (U

x A f)

U = component U value A = surface, m2 w = wall f = fenestration d = doors t = total

Uw =

1
n

R i
1

2. Acoustics
Too much noise outside the building entering the space

Too much noise from adjacent spaces

Too much noise generated within a specific space

Sound level vs. Sound frequency

Different acoustic attenuation mechanisms

1 sound absorption porous media

2 sound transmission mass-spring-mass

3 sound impact floating floors

a) Sound absorption - air flow resistivity

Air flow
P1 (Pa)
V (m/s)

P2 (Pa)

r (kPa.s/m)

Mineral wool, in contrast to foams, is a porous medium, capable of attenuating air pressure (sound). Influencing parameters are: fibre fineness, fibre orientation and density. The best result is obtained with an air flow resistivity r between 5 and 10 kPa.s/m2.

Ceiling tiles: example of pure sound absorption effect

Room 1: Room 2:

69 dB 31 dB

NRC

0.75 - 1.0

4 Room 3: Room 2: 64 dB 20 dB

b) mass-spring-mass - effect

Maximise reflection of sound waves

Maximise dissipation of sound waves Minimise transmitted sound waves

Sound Reduction Index RW

Results ---- 190 mm full filling ---- 140 mm lw. glass wool ---- 45 mm lw. glass wool without insulation RW = 62 dB RW = 57 dB RW = 53 dB RW = 45 dB

414 kg/m

10:1

40 kg/m

c) Sound impact - floating floor

Typically reached with 1 to 2 inch thick glasswool layer

3. Fire & smoke

Al Wafra building, Kuwait, Feb 2010

Fire behaviour of building materials according to Euroclass system

Rockwool Glasswool

Glasswool & Rockwool are either A1 or A2, s2, d0 far outperforming any other insulating material

Product versus System performance

Insulant

Product fire rating Best system rating * Worst system rating *

Glasswool Stone wool Phenolic PUR PIR EPS/XPS

A1, A2
A1, A2 B F D,E F

A1
A1 B F E,F B,C B

* including facer (worst: Kraft / best: mineral coating, ALU, gypsum)

Smoke toxicity * comparison of foams & mineral wool

If we only consider the toxicity of the gases released from insulations materials (theoretical point of view), PUR is the most toxic product, followed by EPS and XPS. Mineral wools are not at the same level of toxicity compared to the other products.

LC50(g/m3)* PUR
(CO, CO2, HCN,)

IC50(g/m3)*
7.45

CO(mg/g)**
442

HCN(mg/g)**
38

Risk level

21.25

Strong

EPS
(CO, CO2, styrene,)

39.55

26.7

165

Intermediate

XPS
(CO, CO2, styrene,)

39.55

26.7

96

Intermediate

Mineral wool
(CO, CO2, HCN,)

21.25

7.45

17

0***

weak

*combined gases approach **test result according to standard: NF X 70100 @ 600C, see appendix slide 35 ***Glass wool can release about 10 ppm of HCN at the end of 60 minutes at 400C (see appendix slide 37 for more details)

* Courtesy of A.D. Little

Large scale fire testing movie

4. Sustainability - Use of Raw Material and Waste

Up to 80 % of raw material is recycled glass 20 % of raw material is sand, basalt, limestone: natural products abundantly available (in contrast to organic foams derived 100 % from oil) Liquid waste: Process water fully recycled Solid waste: none

Sustainability - CO2 emissions & savings

1 m3 raw material 150 m3 Glass wool CO2 emission to produce 1 m3 GW = 0,8 tons CO2 savings of 1 m3 GW in one year = 6 tons CO2 savings of 1 m3 GW over 50 years = 300 tons

Sustainability - Life Cycle Analysis

close the loop with MASDAR KIMMCO is registered vendor to Masdar project

Agenda
Introduction Alghanim-KIMMCO

Mineral wool vs Other insulants Insulating material. Performance comparison: thermal, acoustic, fire, LCA

Building Codes & Sustainability

KIMMCO product range

Estimated kWh consumption

Current Building Code in Syria

Wall Insulation

Cavity wall

Curtain wall

ETICS

Regional building requirements for U-wall values

low energy loss Passiv house new houses medium level

high energy losses

Building Code
2011 2010 2011

Energy savings
WUFI simulation
German IBP Institute for Building Physics

insert 5 cm of GW into a cavity

WUFI simulation

What is the optimum GW thickness in a wall?

100

Passiv House
80

15 cm GW will reduce energy loss through wall by ~ 85% 10 cm GW will reduce energy loss through wall by ~ 80%
solid brick wall

60

40

20

5 cm GW will reduce energy loss through wall by ~ 70%

concrete wall

10

15

20

25

30

35

cm of Glasswool

Do Not forget your windows!

Improved Shading coefficient Improved U-value Improved relative heat gain

Solar Control

Multi-function e-coating

Energy savings

estimated energy perdition

If wall + window + roof are properly insulated, total energy consumption for heating/cooling will reduce by 40 to 60 %.

The Sustainability issue

The Advantages

Green Buildings - Rating system

Regional Priority Innovation in Design

Sustainable Sites

Water Efficiency

Indoor Environmental Quality

Energy & Atmosphere

Certified: Silver: 40 - 49 points 50 - 59 points 60 - 79 points 80 + points

Materials & Resources

Gold: Platinum:

Energy & Atmosphere Category (3 prerequisites, 6 Credits, 35 Points)

Materials & Resources Category (1 prerequisites, 7 Credits, 14 Points)

Indoor environmental quality Category (2 prerequisites, 9 Credits, 19 Points)

A proper insulation with mineral wool, focusing on walls and roof, (preventing thermal bridges, will contribute significantly to Green Building certification, with 20 to 25 credit points, (50 % of basic certification requirement)

Agenda
Introduction Alghanim-KIMMCO

Mineral wool vs Other insulants Insulating material. Performance comparison: thermal, acoustic, fire, LCA

Building Codes & Sustainability

KIMMCO product range

9KIMMCO BUILDING ROLL (KBR) 9KIMMCO BUILDING SLAB (KBS) 9KIMMCO RIGID PIPE COVERING (K450P) 9KIMMCO DUCT INSUL (KDI) 9KIMMCO DUCT INSUL PLUS (KDIP) 9KIMMCO DUCT LINER (KDL) 9KIMMCO CLEAN LINER (KCL) 9KIMMCO LAMELLA INSUL (KLI) 9KIMMCO ACOUSTIC FLOOR INSULATION (KAFI) 9KIMMCO KALINING (KKL 36) 9KIMMCO WHITE WOOL (KWW) 9KIMMCO MARINE BOARD (KMB) 9KIMMCO ENCAPSULATED BOARD (KEB) 9KIMMCO CURTAIN WALL (KCW) 9KIMMCO ALU DUCT (KAD) 9KIMMCO ALUGLASS DUCT SYSTEM (KADS) 9KIMMCO SOUND GUARD SYSTEM (KSGS)

KIMMCO PRODUCT RANGE

KIMMCO Building Roll KBR

Applications: for thermal or/and acoustic insulations of all building walls and roofs Description: Density: Ranging from 10 to 24

Facing:
Flexibility:

Unfaced FSK, Vinyl, Metallized Polyester, Kraft paper, Glass tissue

Flexible

Form:

Roll

KIMMCO Building Slab KBS

Applications:

All type of walls: Internal/ External/ Cavity/ Prefabricated Under Ceilings, Walls Solid Floors, External Roof Structures Industrial Applications: Boilers, Ovens, Refrigeration storage tanks, tankers

Density: Facing:
Flexibility: Form:

From 24 to 120 kg/m3 Unfaced, FSK, Unfaced, Vinyl, Glass tissue, Unfaced, FSK, ASJ, Canvas, Kraft paper Semi-rigid and rigid boards
Slab

KIMMCO Rigid Pipe K 450-plus

Applications:

Thermal Insulation of steel copper or plastic pipes in HVAC sector power plant, process industries Ranging from 64 -128 kg/m3 Unfaced, FSK, ASJ, Canvas, ALU Glass Rigid Roll

Density: Facing: Flexibility: Form:

KIMMCO Duct Insul KDI

Applications:

Thermal Insulation of Ducts in HVAC

Density: Facing: Flexibility: Form:

Ranges from 12 - 64 kg/m3 FSK, ASJ Flexible rolls, semi-rigid and rigid slabs Roll / Slabs

KIMMCO Duct Insul Plus KDI-P

Applications: Density: Facing: Flexibility: Form:

Thermal Insulation of ducts in HVAC system, no external weather protection required 24 - 64 kg/m3 Aluglass Semi-rigid or rigid Rolls/ Slabs

KIMMCO Alu Duct KAD

Applications: Density: Facing: Flexibility: Form:

Used for air distribution in HVAC systems operating at up to 120 C 72 - 96 kg/m3 On one side Aluglass - ASJ; other side FSK Rigid Slabs

KIMMCO Lamella Insul KLI

Applications: houses &

Density: Facing:

Thermal and Acoustical Insulation for walls or residential commercial buildings (New or Retrofit).
Ranges from 60 to 96 kg/m3 Kraft paper; glass reinforced aluminum foil/Kraft Paper laminate. (FSK) or reinforced white kraft / aluminum foil laminate (ASJ). Rigid

Flexibility:

KIMMCO Curtain Wall KCW

Applications: Density: Facing:

For thermal and acoustic insulation of the facade applied with in Curtain Wall spandrel systems. Range from 24 to 48 Unfaced / FSK / Black Glass Tissue (BGT)

Flexibility:
Form:

Semi-rigid
Slab

Conclusions
Insulation is a crucial element in todays new construction design

Energy savings are as high as 40 % if optimal thickness is applied Mineral wool offers across the board performance in thermal comfort, acoustical comfort & fire protection Mineral wool contributes highly to sustainable design, respectful of people and nature, and helping you get GB certification

National Assembly

Al Seef Hospital Kuwaiti Towers

New Metro, Dubai

Burj Khalifa, Dubai

City Center, Qatar

City Bank, Bahrain

Four Seasons, Damascus

For More Info please contact me: Mohammad Aldabbas

mdabbas@staic.com.jo