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Rendering Thermal Performance The Specifiers Guide to Externally Insulated Facade Systems CI/SfB Version 1 CAWS M21 (41) Pq4 (M2) Building with Conscience The History of Externally Insulated Facade Systems From Silo to Solar Construction for the New Millennium The first external insulation systems can be traced back to the late 1950’s in Germany where they were installed on sugar silos to prevent condensation from sticking the sugar granules together. The first domestic use of Externally Insulated Facade Systems (EIFS) was in the beginning of the 1960’s in Germany, where the advantages of improved thermal performance and crack bridging properties, made them especially beneficial for over-cladding leaky panellised buildings. Today in Germany where external wall insulation began, approximately 60% of all new constructions are built using external insulation systems. To date over 400 million m2 have been installed, with StoTherm Systems accounting for more than one quarter of this figure. But technology does not stand still and now there is a unique insulation system available which actually gives a net heat gain by using the pollution free energy from the sun: StoTherm Solar. It was at this time that Stotmeister KG developed a product which was to revolutionise the renders industry. The material was Stolit, a cement free acrylic, highly crack resistant render, with immense flexibility and strength. These properties made it the ideal material for coping with the thermal stresses encountered by Externally Insulated Facade Systems (EIFS). The result? In1963 the first StoTherm Insulation System was installed. Since then, the use of externally insulated facade systems has spread rapidly across the globe with systems being installed in all climatic zones from Siberia to Saudi Arabia. The oil crisis in the 1970’s underlined the need to save energy through more efficient insulation and together with increased awareness through the 1990’s of the environmental implications of burning fossil fuels, this has spawned more stringent legislation requiring better insulation values for all types of construction. Building with Conscience - A Philosophy for Building ‘Building with Conscience’ places emphasis on visible and invisible quality in architecture and construction. It is about creating buildings which are meaningful to use, but which recognise ecological and social needs. It acknowledges the requirement for durability and value in fulfilling ecological, functional and aesthetical requirements at a realistic price. And it stands for an attitude which critically examines that which has been achieved and uses it as a basis for improvement and further innovation. Building with Conscience - Bewußt Bauen 1 Why Insulate? - The Benefits 35% Energy Loss Through Walls The benefits of insulating properly are numerous. For this reason significant advances have been made through the years in insulating different elements of the building to try to reduce energy loss: roof insulation, double glazing and draught proofing to name but a few. As up to 35% of heat is lost through the walls, these are the areas where the greatest benefits can be achieved. Saving Energy and Protecting the Environment; That’s our mission... By using thick layers of insulation (e.g.>100mm) heat loss through the walls may be reduced by up to 80%, saving money which in some instances amortises the cost of the external insulation system in as little as 5 years. But it is not only money that is saved; The reduction in energy consumption helps preserve precious natural resources and plays an important part in decreasing CO2 and SO2 emissions. A Flexible Protective Skin By insulating externally, the structure of the building is protected from the elements in a weather-proof yet vapour permeable layer. The Sto cement free renders are designed to flex and absorb thermal movement and impact. And there is also flexibility in the choice of finish, with 14 different textures and over 390 colours being available. Improving the Comfort Factor Externally insulating improves the comfort factor - and not just in terms of warmer room temperatures: By keeping the external walls of the structure warmer, the living climate is improved and condensation eliminated, preventing damp and mould growth. In addition, warm walls prevent the unpleasant draughts created by the combination of warm air and cold surfaces; a feature of uninsulated walls. 2 Where should It is now generally accepted, that some form of efficient in be seen, the vari Interior Insulation General Attributes Benefits Drawbacks 1. Increased thermal performance. ✗ 1. Significant loss of space within room. ✓ 2. Rooms can be heated quickly from cold. ✗ 2. Installation is expensive and disruptive in refurbishment. Occupants must be moved out. ✗ 3. Heat storing capabilities of substrate not used - building will cool quickly when not heated. benefits ✓ ✗ Technical Implications inside outside ✗ +20°C ✗ ✗ 0°C -10°C ✗ ✗ 4. Cold bridging will occur between rooms and floors 5. The load-bearing structure will be in the frost zone; potential freeze - thaw damage. 6. Interstitial condensation will occur in the wall if a vapour barrier is not installed. 7. Wall subject to high thermal stress due to temperature fluctuation. 8. Neither weather protection nor aesthetics of outer leaf is improved by renovation. 9. Pipework in walls must be protected from frost. Summary: Many technical drawbacks, system offers no protection for the substrate. Only suitable for buildings which are infrequently used and need to be heated quickly. 3 For further technical information or queries, please contact Sto. the Wall Insulation go? Internal Insulation v Cavity Insulation v Exter nsulant must be used to obtain the required U - Value and desired levels of warmth. But does it matter where the insulation is situated? The three areas where insulation may be placed ar ous options each have significant impact on the construction physics of the building and the general effect on the occupants. Below is a synopsis of the advantages and disadvantages of Cavity Wall Insulation General Attributes Benefits ✓ ✓ ✓ ✗ 1. Increased thermal performance ( although limited by width of cavity ). 2. A cheap way of remedially insulating a building. ✗ benefits ✓ Drawbacks 3. Little disturbance to occupants during renovation. 1 Building process is slower and more expensive with 2 leaves of block / brick. 2. New build cavity insulated walls tend to be very thick, reducing available space. 4. Heat storing properties of inner leaf of wall are used. ✗ Technical Implications inside outside ✗ +20°C ✗ 0°C -10°C ✗ ✗ ✗ 3. Due to the position of the insulation between the 2 brick leaves, interstitial condensation is likely. 4. The outer leaf of brick is in the frost zone and may be subject to freeze - thaw damage. 5. Wind driven rain absorbed by outer leaf, may cross a completely filled cavity (e.g. with remedial insulation ). 6. Wall subject to high thermal stress due to temperature fluctuation. 7. Neither weather protection of outer leaf nor aesthetics are improved by renovation. 8. Some thermal bridging will occur. Summary: A cheap way of renovating cavity wall constructions. Not the best solution for the construction due to a number of technical drawbacks. The protection of the outer wall is not enhanced and may suffer in the long term from constant damp. 4 For further technical information or queries, please contact Sto. rnal Insulation re: inside the structure, in the cavity and externally. As can the alternatives. External Insulation General Attributes Benefits ✓ ✓ ✓ ✓ ✗ 1 Increased thermal performance without reducing internal space. 2. A cost effective way of renovating old buildings. 3.Aesthetic improvement of facade through colour fast, lime bloom free organic coatings. 4.Cost and space savings by using single leaf construction for new build. 5. Design freedom from special recycled profiles for creating cornices, features etc. ✓ 6. No additional expansion joints are ✓ ✓ ✓ ✓ ✓ ✓ ✓ required when cement free renders are used. 7. Insulating externally precludes cold bridging. 8. The wall acts as a thermal store, minimising temperature fluctuation. 9. The wall is kept out of the frost zone, there can be no freeze - thaw damage. 10. There is no thermal stress in the structure. 11. Condensation and mould will not occur under normal conditions. 12. Dense construction materials may be used giving improved sound insulation. 13. The entire structure is encapsulated in a protective weatherproof envelope. 1. If cementitious renders are used these can be more prone to cracking and efflorescence. benefits ✓ Drawbacks Technical Implications ✗ outside inside +20°C 2. Projections through the insulation system will have to be lengthened e.g. flue pipes, vents, window sills ( refurbishment only ). 0°C -10°C Summary: Highly cost effective method for new build construction and also refurbishment works. Very low energy buildings may be created. The building is protected from the elements and the structure will not deteriorate over time. For further technical information or queries, please contact Sto. 5 Cost Effective Solutions for Modern Construction Single Leaf Wall Construction What is externally insulated single leaf wall construction? It is a method of building, used predominantly on mainland Europe since the 1950’s. There is no cavity, simply one externally insulated monolithic wall. Single skin wall externally insulated with a StoTherm System. 1. Substrate 2. Sto Adhesive 3. Sto EPS Insulation 4. Sto Reinforcing Coat 5. Sto Glass Fibre Mesh 6. Decorative Finish Render 1 2 3 4 5 4 6 Why is the cavity no longer required? What is the traditional purpose of the cavity? Firstly, the outer leaf acts as a rain screen, preventing water reaching the inside of the construction. Secondly, the shaft of still air in a sealed cavity acts as an insulating layer. A modern single leaf construction utilises either cast concrete or brick/block as the load bearing element and an external insulation system to do the job of the cavity: A far more efficient type of insulant replaces the still air as the thermal layer and complete weather protection is provided by Sto Synthetic Resin Renders which remain vapour permeable . On a building of perimeter 100m, an extra 15m2 floor space can be gained per storey simply by using single leaf construction and external insulation. Stud Wall Construction What is Stud Wall Construction ? Light-weight stud wall construction comprises of either metal or timber studs, clad internally with plasterboard and externally with either plywood or external wall boards. Insulation is placed externally using a StoTherm Insulation System to attain the desired U-Value and provide a weatherproof finish, It is usually necessary for a vapour barrier to be installed on the inside to prevent interstitial condensation. Stud wall externally insulated with StoTherm Classic 1. Structural framing 2. External Sheathing 3. Sto EPS Insulation 4. Sto Adhesive 5. Sto Reinforcing Coat 6. Sto Glass Fibre Mesh 7. Sto Decorative Finish Coat Complete weather protection is provided by Sto Synthetic Resin Materials 1 What are the advantages of single leaf construction? 1. Reduced Costs: With only one wall to build, material costs are reduced and construction is significantly faster than cavity wall, saving time and money. In one recent project in London, the money saved by the early off-hire of the tower crane virtually paid for the cost of the insulation. 2.Better U-values can be achieved by single leaf construction for the same space as a traditional cavity wall, saving money on heating bills. 3. Alternatively a better U value can be traded for more floor area within the same ‘footprint’ of a building. 4. A significantly lighter structure is possible than that which can be created with a cavity wall, providing the solution to difficult site conditions. 5. Dense concrete blockwork may be used, which has excellent sound insulating qualities. In addition, the dense blockwork also acts as a massive thermal store, keeping the building temperature constant i.e. cool in summer and warm in winter. 6 2 3 4 5 6 7 What are the advantages of Stud Wall Construction? 1. Extremely fast construction times. 2. Very light-weight type of construction. 3. Good thermal properties can easily be achieved. 4. Durable, through coloured, low maintenance finish. Externally insulated studwork infill panels were used to achieve good U-values on the Piper Building in Fulham, London. Cost Effectiveness and Durability External Wall Insulation Systems Which Pay Their Way StoTherm insulation systems are cost effective in both new build projects, and refurbishment schemes. Consider a traditional uninsulated cavity wall; typically this may have a U-value of 1.19 W/m2K. By insulating with a 100mm thick StoTherm Classic System, the U-value is reduced to 0.29 W/m2K representing an energy saving of 76% or 84.08 KwH/m2. Depending on the heating type, the StoTherm System will pay for itself in approximately 9.25 years - or less if energy prices rise. If the necessary maintenance costs of a rendered facade are taken into account, the system will pay for itself in little over 6 3/4 years. From this point onwards, the owner can expect to profit from his investment. Durability from Exceptional Quality Since its beginnings over 130 years ago, Sto has sought to provide materials which offer good value for money. Value comes not from cheap materials, but from using the best quality raw materials and binders, to make products which provide highly durable long-term solutions, out-lasting cheaper alternatives and protecting the substrate for years to come. And the result is a building which is energy efficient and does not require over-painting to remain weather-proof, saving money in the long term. Durability - An Example from History Immendingen, Black Forest, Germany (Project completed in 1976, photographed in 1997) For an EIFS System, Feldkirch in Austria has one of the harshest climates in Europe. The harshness comes from the number of days per year when a freeze - thaw cycle occurs. When the temperature drops below 0°C any moisture present will freeze, causing damage to the substrate. In 1969 a StoTherm Classic external insulation system was installed on an 11 storey block of flats in Feldkirch. In 1991, the system was thoroughly inspected by independant materials testing authority MA39 of Vienna. The result? Fully functioning after 22 years. Now, nearly 30 years after installation, the system is still performing as intended and looks set to continue performing well into the new millenium. Sto cement free decorative renders do not require over-painting to maintain their weather-proof qualities. The environmental benefits of reduced consumption of fossil fuels and CO2 emissions are incalculable. It has been estimated that since 1973, the 400 million m2 of EIFS installed in Germany alone, has saved a quantity of energy comparable with over 15 billion litres of heating oil. Quality “ There is hardly anything in the world that some men cannot make a little worse and sell a little cheaper, and the people who consider price only are this man’s lawful prey.” John Ruskin 1819 - 1900 Feldkirch, Austria (Project completed1969, photographed in1991) 7 Designing for Lasting Performance Detailing: The Basis of Good Design Poor detailing can be the downfall of even the best system. For this reason, Sto has carefully developed standard details and specialist products to ensure maximum security and provide a solution for every eventuality. Typical details include: Partially insulated reveal Aluminium Window Sill Sto Aluminium Starter Track Unique Solutions to Construction Problems Fixing Systems for Uneven or Friable Substrates Sto has the solution; its own unique track fixing system which can be used to align uneven facades and safely fix to friable substrates without the expensive preparation required by adhesive fix systems. Cement Free Reinforcing Coats for Maximum Crack Resistance Sto has the solution; when combined with Sto Glass Fibre Mesh, the unique Sto-RFP cement free reinforcing plaster provides more than double the crack resistancy of even a modified conventional cementitious reinforcing coat. The result? No extra joints and maximum security against cracking. Colour without Over-Painting Cement Free Decorative Finishes Sto has the solution; through coloured, cement free decorative renders in a standard colour range of 390 shades with UV resistance factor 8 on the International Wool Scale. Stolit acrylic and StoSilco silicone resin renders are highly flexible, weather proof yet remain vapour permeable. Quick Set Materials - Winter Performance without Solvents Sto has the solution; its unique QS technology enables the water based Sto-RFP QS and QS grade Sto decorative renders to be applied in winter from +1°C without fear of frost or rain damage after the initial curing period of only 7 hrs. Architectural Features - Changing the Face of Buildings Sto has the solution; StoDeco Profiles are made from a unique recycled material, which is light-weight and available in a standard range of profiles which are fixed to StoTherm insulation systems to form string courses, window surrounds etc. Special profiles can be made to order. 8 StoTherm Classic StoTherm Classic, introduced in 1965 is proven as a tough and reliable system in extreme climates around the globe. Used in locations as diverse as Siberia and Texas, the systems flexibility and weather proof capabilities have shown it to be the durable long term answer for insulating and protecting buildings. SYSTEM Which is d StoTherm Classic is available with two types of fixing system: Adhesive Fixing System Suitable for: Friable, non load-bearing substrates Uneven / out of plumb substrates Bridging different substrates Suitable for: New build constructions ‘fair-faced’ tolerance blockwork Light-weight frame constructions 1 2 3 4 1 2 3 EPS ( Polystyrene ) CFC/HCFC free with Fire Retardant Additive INSULATION Mechanical Fixing System StoTherm Classic ( Class '0' Fire rating ) Is substrate load-bearing & level/even? 4 ... .. ... .. The principle features which have made StoTherm Classic popular over the years with Architects and Clients alike can be summarised as: Highly flexible anti-crack coatings Wide colour choice Class ‘0’ fire rating Curves, features and ashlar grooves possible Vapour permeable coatings Proven reliability over 30 years Completely weather proof system Low maintenance, painting is unnecessary Special details solve difficult design problems Light-weight system 10-12kg/m2 compared to 20-22kg/m2 for traditional heavy-weight systems No Adhesive Fix Mechanical Fix Sto-RFP and Sto Glass Fibre Mesh INTERMEDIATE COAT 1. Adhesively fixed EPS board with secondary fixings if required 2. Sto Glass Fibre Mesh embedded in 3. Cement free Sto-RFP reinforcing plaster 4. Cement free decorative render - see below Brick/Tile Finishes Stolit K/R & Sto-Rustic FINISHES 1. Mechanically fixed, track system EPS board 2. Sto Glass Fibre Mesh embedded in 3. Cement free Sto-RFP reinforcing plaster 4. Cement free decorative render - see below REINFORCING COAT FIXING Yes StoSuperlit StoSilco K/R/MP Sto Decorative Renders Stolit: Through coloured, ready to use, acrylic, cement free render. Completely impervious to driving rain yet remains vapour permeable. Immensely tough, and highly flexible. Available in range of 390 colours. Over 400 million m2 applied world-wide since 1955. Stolit is available in Quick Set (QS) winter grades. StoSilco: Through coloured ready to use, silicone resin, cement free render. Special properties include excellent vapour per- Stolit and StoSilco are available in a variety of textures including: A traditional style of finish is provided by Sto-Rustic or StoSilco MP with a fine grain and gently undulating texture. 9 smooth rilled coarse StoTherm Mineral StoTherm Mineral is the alternative for those who wish to use a mineral based insulation system. The insulation boards formed from basalt stone are slightly heavier than the EPS boards used in the Classic system, but have outstanding fire resistant properties and are used where a non-combustible insulant is preferred. The system shares the same finishes as StoTherm Classic and has proven to be tough and reliable over many decades of use. SELECTION Insulation desired? StoTherm Mineral is available with two types of fixing system Mineral Fibre Insulation StoTherm Mineral ( Class '0' Fire rating ) Mechanical Fixing System Lamella Adhesive Fixing System Suitable for: Friable, non load-bearing substrates Uneven / out of plumb substrates Bridging different substrates Suitable for: New build constructions ‘fair-faced’ tolerance blockwork Light-weight frame constructions Is substrate load-bearing & level/even? 1 2 3 4 2 1 3 4 No Yes Adhesive and Dowel Fix Mechanical Fix Sto Mineral Plaster and Sto Glass Fibre Mesh Sto Primer 1. Mechanically fixed, track system mineral fibre board 2. Sto Glass Fibre Mesh embedded in 3. Sto mineral reinforcing plaster 4. Cement free decorative render - see below 1. Adhesively fixed mineral lamella board 2. Sto Glass Fibre Mesh embedded in 3. Sto mineral reinforcing plaster 4. Cement free decorative render - see below Special features in addition to the shared advantages of StoTherm Classic which have made StoTherm Mineral popular over the years with Architects and Clients include: ... . Class ‘0’ non-combustible system Lamella board easy to install around curves Highly vapour permeable Completely weather-proof system ... Flexible render finishes Proven reliability over 30 years Low maintenance, painting is unnecessary Sto-Superlit: exposed aggregate style, through coloured acrylic render. Available in 24 colours and 2 aggregate sizes. Using variegated stone, Sto-Superlit is tough, flexible and especially suitable for use in plinth area’s. Sto-Superlit is available in 24 colours and 2 aggregate sizes. Sto-Superlit gives buildings a distinctive appearance. 10 StoTherm Solar Insulation for the New Millenium StoTherm Solar System Construction Reduce heat loss and gain free energy - these are the principles behind StoTherm Solar, the only external insulation system to make active use of solar energy. The theory is very simple: A transparent insulating layer lets solar rays pass through to a black solar absorber which also acts as an adhesive. The 95% efficient solar absorber then converts the solar rays to heat. After 6-8 hours, the heat energy permeates through the solid wall construction to the inside. The result? A net gain of up to 120KwH/m2 per annum for south facing facades. The transparent insulation layer, then effectively reduces heat loss at night. 1. Single leaf dense brick/blockwork 2. StoSolar Absorber 3. StoSolar Panel 4. Conventional adhesively fixed StoTherm EIFS 1 2 StoTherm Solar integrated in a conventional StoTherm EIFS. 3 4 Temperature Flow In winter, with an outside temperature of -10°C, temperatures of up to +60°C can be reached in the absorber StoTherm Solar: Temperature Change in Wall over Time 70 StoSolar Absorber 50 Middle of wall 30 Inner wall behind StoTherm Solar System Interior wall behind conventional EIFS 10 °C Time 7.00 1000 13.00 16.00 19.00 22.00 1.00 4.00 Data: Detached house, Bonndorf, Germany 1995 The wall heats up slowly during the course of the day and discharges the heat into the room after 6-8 hrs. Source: Test house in Germany, Winter 1995 Selective Solar Energy StoTherm Solar works selectively: In summer, when the sun is at its highest in the sky, the majority of the solar rays are reflected. By contrast, in winter when the sun is at its lowest in the sky, the majority of the solar rays are absorbed and turned into heat. The result? A self regulating system which does not require expensive shading systems to prevent over-heating. 11 .. . .. .. Technical Summary Substrate: Single leaf blockwork. Min.density 1200kg/m3 Not suitable for use on cavity wall constructions. Potential Energy Gain /m2/yr: South Facade: 120KwH West / East Facade: 80KwH North Facade: 30-40 KwH Insulation Thicknesses in mm: 80/100/120/140 Min / Max installation area’s: 10% 30% of facade StoTherm Solar standard panel formats: 7 no. The system does not require shading in summer. Sto Reference Projects 1 4 2 5 6 7 3 1 Project: Planet Hollywood, Chessy, France Architect: Rockwell Group, New York Products / Description: StoTherm Insulation System, StoSilco MP 5 Project: Premier Place, Isle of Dogs, London Architect: Chassay + Last Architects Products / Description: StoTherm Insulation System, (EWIA Award winner) 2 Project: Mercedes Benz U.S.A. Architect: Gresham, Smith and Partners Products / Description: StoTherm Insulation System 6 Project: Charlesworth House, Stanhope Gardens, London Architect: Chassay + Last Architects Products / Description: StoTherm Insulation System, StoDeco Profile 2001, StoSilco MP 3 Project: Feder Lechner, Germany Architect: Winkler and Bahm Products / Description: StoTherm Solar 7 Project: Rotel Inn, Passau, Germany Architect: Hans Hoffer, Austria Products / Description: StoTherm Insulation System, StoSilco Color 4 Project: Crescent House, Wiltshire Architect: Sir Norman Foster & Partners Products / Description: StoTherm Insulation System, StoDeco Profile 2000 12 . . . . . . High Performance Render Systems Externally Insulated Facade Systems Silicone Resin Paints Architectural Profiles Acoustic Ceilings Concrete Restoration Head Office: Sto Ltd Unit 3 Lyon Rd Linwood Industrial Estate Paisley Scotland PA3 3BQ Sto Ltd Unit 4 The Ringway Centre Edison Rd Basingstoke Hampshire RG21 6YH Tel: 01505 324262 Fax: 01505 323618 E-mail: [email protected] Tel: 01256 332770 Fax: 01256 810887 E-mail: [email protected]