Core Range. ROCKWOOL FLEXI, Cavity TCB, ROCKFLOOR, Fire Barrier and Rollbatt 600 & 400. July 2009 Fifth Edition

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1 Core Range ROCKWOOL FLEXI, Cavity TCB, ROCKFLOOR, Fire Barrier and Rollbatt 600 & 400 July 2009 Fifth Edition

2 Intro Welcome to the ROCKWOOL Core Range: 6 products for all major applications The edge for performance We ve harnessed the awesome power of nature to bring you the exceptional performance of our unique insulation. ROCKWOOL is made from molten volcanic rock to bring you naturally efficient energy saving, unbeatable sound proofing and a level of fire safety that no other general insulation can match. The edge for convenience Walls, Partitions & Floors. Unlike other insulation, ROCKWOOL is suitable for acoustic, fire and thermal applications. The key to ROCKWOOL is its flexibility. There are products in the core range to cover all common applications. We have the correct ROCKWOOL solution to meet your system needs. 6 products for all major applications 2 The use of ROCKWOOL can not only help protect the planet, but also provides safe and comfortable living and working environments.

3 Superb fit - superior performance ROCKWOOL FLEXI fits perfectly every time - wherever you use it - delivering all-round superior insulation performance: Thermally effective Providing a perfect friction fit against frames, joists and studs, ROCKWOOL FLEXI delivers high levels of insulation, minimising cold bridging through the frame Superior sound performance Snug fit against frames, studs and joists eliminates gaps Non combustable insulation Acts as a Firestop A1 European reaction to fire classification Withstands temperatures over 1,000 C Environment ROCKWOOL insulation relies on entrapped air for its thermal properties; air is not a VOC and it does not have Global Warming Potential (GWP) or Ozone Depleting Potential (ODP) ROCKWOOL Cavity TCB Cavity ROCKFLOOR Fire Barrier Rollbatt FLEXI Barriers Partitions Timber frame walls Party walls Ceiling overlay Cavity walls Dry lining Lofts Rafters Thermal floors Acoustic/fire floors Cavity fire stops Fire & acoustic curtains 3

4 ROCKWOOL FLEXI Gives you the edge ROCKWOOL FLEXI - the ingenious volcanic rock slab with the patented flexi-edge that makes installation so easy. The flexi-edge is unique and ensures a perfect fit every time, within floor joists, between rafters, metal and timber studs and metal and timber frame buildings. Unlike rigid insulants, ROCKWOOL FLEXI will hold itself within the stud centres required, first time, every time. Timber expands and contracts, ROCKWOOL FLEXI can be fitted between damp timber and will expand into the wider space created when the timber has dried out and shrunk back. Other rigid or very flimsy insulants may fall out or be displaced, resulting in cold spots and poor acoustics. Advantages Timber Frame Cavity Wall ROCKWOOL a) Using Standard b) Using Tywek FLEXI Breather Reflex Breather thickness Membrane* Membrane* * U-values (W/m 2 K) Reduced installation time Tested solutions to meet thermal, acoustic and fire regulations Unique flexi edge offers accurate fit to all widths Multi-application, fits all typical metal and timber frame spacing No waste Excellent thermal, acoustic and fire properties Easy to handle and install without gaps U-values allow for 15% timber bridging 1hr Fire Resistant Floor (refurbishment) 4 ROCKWOOL FLEXI - the ingenious stone wool slab with the patented flexi-edge that makes installation so easy!

5 Suspended Timber Joisted Floor The P/A on the next page indicates the ROCKWOOL FLEXI thickness required to achieve an elemental U-values of 0.25 & 0.20 U-Values (PA) Ratio ROCKWOOL FLEXI (mm) None ROCKWOOL FLEXI (mm) Full Fill Rafter with Breather Membrane ROCKWOOL FLEXI thickness (mm) 38mm 600mm Centres* 38mm 400mm Centres* 200 ( ) ( ) ( ) * U-values (W/m 2 K) 5

6 Flexi-edge makes installation so easy Simply squeeze the patented ROCKWOOL FLEXI into the space required and let go, it will spring back for a perfect fit every time. Even if the studs are not plumb ROCKWOOL FLEXI will fit the space between the studs perfectly without the need for cutting or waste. ROCKWOOL FLEXI Application for Timber Stud Walls ROCKWOOL FLEXI thickness 50mm, plasterboard 1 x 12.5mm (mass 11kg/m2) each side, stud size 38 x 75, fire resistance 30 minutes, sound reduction Rw 40 db As above using 2 x12.5mm layers of 11kg/m2 plasterboard each side, fire resistance 60 minutes, sound reduction Rw 46dB Timber Joist Domestic Internal Floor To meet part E2 Rw 40 db ROCKWOOL guidance specification Standard 18mm t&g flooring chipboard, mass per unit area 12.4kg/m² Timber 400mm ctrs 100mm thick ROCKWOOL FLEXI between joists Single layer of 12.5mm plasterboard ceiling mass per unit area 8kg/m² Acoustic Metal Studs ROCKWOOL FLEXI thickness 50mm, plasterboard 1 x 12.5mm plasterboard (8.0kg/m2) each side, stud size 50mm, fire resistance 30 minutes, sound reduction Rw 41dB As above using 70mm ROCKWOOL FLEXI, stud size 70mm, 2 x 12.5mm plasterboard (8.0 kg/m2) each side, fire resistance 60 minutes, sound reduction Rw 55dB Timber joist domestic internal floor Rw 40dB 6 The ROCKWOOL FLEXI -edge is unique and ensures a perfect fit every time.

7 Size and usage information Size (Length & Width) 1200 x 600mm Size (Length & Width) 1200 x 400mm Thickness (mm) Coverage per pack (m2) Thickness (mm) Coverage per pack (m2) x 75mm timber studs at 600mm centres 50 X 600mm wide ROCKWOOL FLEXI One layer of 12.5mm plasterboard both sides (Mass 8Kg/m2) 12.5 plasterboard both sides (Mass 11Kg/m2) mm Flexi ROCKWOOL FLEXI Application for timber stud walls Rw 40dB Acoustic metal studs Rw 41dB 7

8 Proven over 40 years Easier to cut, no slump, no gaps, water resistant and fits tightly to internal block work ROCKWOOL Cavity showing ROCKWOOL edge and floor insulation 8

9 Cavity Fully filled and fully proven ROCKWOOL Cavity provides a completely reliable and cost effective method of insulating new masonry cavity walls. The lightweight insulation batts considerably reduce heat loss without permitting water transmission from the outer to the inner leaf. The risk of condensation is also reduced and intermittent heating systems will be more effective. Advantages BBA certified for all exposure zones Acts as a cavity barrier Water repellent Excellent thermal and fire insulation Superior fit against blockwork Installation guide The installation of the batts should commence below the DPC* to minimise cold bridging. The bottom row of ties should be at 450 mm centres. If necessary, the width of the first course of batts can be cut to suit the height of the next row of wall ties. The width of cut batts should always be 5mm greater than the width to be insulated,eg wall tie centres. Fit ROCKWOOL Cavity by compressing between the two rows of wall ties to form a clean and tight butt jointed course. Wall tie drips should be located centrally in the Batts. Ties must be inclined downwards towards the outer leaf. It is essential that all joints between ROCKWOOL Cavity batts are clean and tightly butted. Raise the second leaf to the same level as the batts. * preferably by at least 150mm Clean mortar from block wall 9

10 The as-built cavity width must not exceed the following dimensions: Nominal Batt thickness (mm) Maximum as-built clear cavity width (mm) Dimensions Size (Length & Width) 1200mm x 455mm m ²/pack m m m m m m m m2 Prevent mortar dropping onto slabs or wall ties 10

11 Masonry Full Fill Cavity Wall 102mm facing brick outer skin, ROCKWOOL Cavity Full Fill, internal concrete block 100mm, plasterboard on dabs Internal BlockBlock K ValueInsulation Thickness Dense W/mk U -value Medium/Light W/mk U -value Aircrete W/mk U -value 65mm mm mm mm Building regulations requirements Part L 2006 for England and Wales U -value Extensions 0.30 Renovation & Repair 0.35 New build dwelling The lightweight insulation batts considerably reduce heat loss without permitting water transmission from the outer to the inner leaf. 11

12 TCB Fire safety for cavities Part of the ROCKWOOL FIREPRO range ROCKWOOL TCB Cavity Barrier is a polyethylene sleeved ROCKWOOL strip engineered to provide fire safety for timber frames, metal frames and traditional masonry cavities. Standard TCB Cavity Barrier comprises a strip of ROCKWOOL inserted into a translucent red polyethylene sleeve incorporating two flanges designed for fixing. ROCKWOOL TCB s have been fire tested to 60 minutes integrity and 30 minutes insulation and is used to provide a half hour cavity barrier as defined in Section 33 of the Building Regulations Technical Guidance Document B. Advantages Reduced installation time Meets Building Regulations requirements Simple to install and fix Water repellent Maintenance free Backed by Fire Test information TCB Length (mm) To suit cavity width TCB size x x x x x x

13 The ROCKWOOL TCB Cavity Barrier Compresses to a tight fit, is easy to install and maintenance free 13

14 Installation Fixing of the TCB Cavity Barrier to the inner leaf is carried out only at the flanges using non-corrosive staples or clout nails. These fixings should be located at maximum 150mm centres in both horizontal and vertical applications. Joints between TCB s must be closely butted. At door and window jambs, the horizontal barrier should overlap the vertical barrier to ensure a close butted joint is maintained between both barriers. TCB at door or window jamb Horizontal application of TCB TCB used as cavity closer 14

15 ROCKFLOOR Thermal & acoustic floor solutions Acoustic ROCKFLOOR is a tissue faced high compressive strength product designed as a mono density, rebated slab suitable for acoustic treatments of intermediate floors. Thermal ROCKFLOOR is a unique dual density, high compressive strength ROCKWOOL slab designed specifically for use as thermal insulation for floors. Advantages Excellent acoustic and thermal properties High compressive resistance Easy handling and fitting Fully tested Minimises thermal and acoustic bridging Dimensions ROCKFLOOR boards are manufactured to a standard size of 1000 mm x 600 mm, and in a range of thicknesses from 25 mm to 100 mm. 30 mm and 40 mm thick ROCKFLOOR boards have all four edges rebated (coverage area 980 mm x 580 mm, allowing for rebates). Laying method The ROCKFLOOR boards are laid lengthways to the longest wall, (the tongue on the first row being removed), in a staggered joint pattern, tissue face upwards. The offcut at one end of the first row is then used to start the next row and similarly with subsequent rows. Environment ROCKWOOL products rely on trapped air for their thermal properties, which has neither ozone depleting nor global warming potential. Specifically designed for use as thermal insulation for floors 15

16 Acoustic performance - separating floors For the first time a minimum airborne performance standard has been set for separating floors. Approved Document E describes a range of constructions that should achieve these standards if built correctly. Acoustic solutions for new build separating floors Single layer 12.5mm plasterboard fixed to resilient bars which are fixed to timber battens 50mm ROCKWOOL FLEXI between battens Thermal performance for ground floors part 'L' 2006 U-value Extensions 0.22 Renovation & Repairs 0.25 New Build mm t&g flooring grade chipboard on 15mm dbcheck wallboard on 30mm ROCKFLOOR resilient layer on 15mm OSB on 200 x 50mm timber joists at 400mm centres Resilient bars fixed at right angles to joists at 400mm Ceiling finish 2 layers of 15mm plasterboard mass 13kg/m² per board 65mm sand and cement screed on 40mm (min) propietary screed 30mm ROCKFLOOR resilient layer on Pre-cast concrete plank floor with all joints fully grouted (min/max per unit area 300 kg/m) 16 ROCKWOOL products rely on trapped air for their thermal properties, which has neither ozone depleting nor global warming potential.

17 Thermal performance U-values for ground floors are dependent upon size, shape, soil type and perimeter edge insulation etc., it is not possible to quote specific values. The following tables show insulation thickness required to suit the following exposed perimeter (P) and floor area (A) ratios. Concrete ground bearing slab 100mm concrete slab, insulation & 65mm screed P/A ratio U-value 0.25 U-value nil nil mm mm mm mm 120 Beam & block suspended floor 100mm concrete beam & block, insulation & 65mm screed P/A ratio U-value 0.25 U-value nil mm mm mm mm mm mm mm mm mm mm mm mm mm mm 145 Beam and block suspended floor Ground bearing concrete slab 17

18 Fire barrier Inhibiting the spread of fire and smoke As part of the comprehensive ROCKWOOL FIREPRO range of products, ROCKWOOL Fire Barrier systems offer labour-saving solutions to prevent fire and smoke spread within roof and ceiling voids for all general conditions encountered on site. Advantages Fixing solutions to concrete decks Fast patented angle and clamping plate system No nuts and bolts to fasten, simple hammer fix Simple angle support with stamped tongue One angle supports 2 barriers for 1 hour Excellent acoustic properties Fixing solutions to timber and steel No bolts required Standard no. 10 wood screws for timber fixing Fixings for clamping plate extended to 450mm Speed of installation increased Costs of installation reduced 18 The use of ROCKWOOL can not only help protect the planet, but also provides safe and comfortable living and working environments.

19 Installation guide Fixing system incorporates an angle support and clamping plate. For fixing to timber ROCKWOOL clamping plate is used, compressing the barrier to the timber, fixed at 450mm centres using No.10 woodscrews. Fixing to concrete soffits, the pre-punched angle support is fixed using Hilti DBZ or Ejot ECL 35 hammer set anchors at max. 750mm centres. Fixing to steel purlins, use Hilti SMD 02Z (5.5 x 70mm) self-tapping screws at max. 450mm centres. ROCKWOOL angle support system. Bend tongues out to 90O and impale barrier onto them. The slotted clamping plate is then fitted by pushing the tongues through the slots and these are then bent over the face of the clamping plate completing the process. The vertically hung Fire Barriers are capable of achieving both integrity and insulation fire protection periods from 15 to 120 minutes. It is ROCKWOOL s essential insulation performance that limits the heat transfer through the barriers, preventing ignition of combustible materials in adjacent areas. The new patented support system offers a quick, cost effective installation method for the Fire Barriers for periods up to 60 minutes. This focus on ease of construction and installation has the added benefit of reducing the risks of installation error. 120 minute systems are also available using the traditional support methods. Extended drops are easily catered for, with the system capable of maintaining its performance in void heights up to 10.5 metres. 19

20 Fire performance and specification Product 1/2 hour cavity barrier 1/2 hour fire barrier 1 hour fire barrier Fire performance Integrity (mins) Insulation Specification Report No. Notes layer 50mm plain faced layer 60mm fire barrier Fire barrier foil faced foil faced (overlapped joints 100mm) layers 50mm fire barrier Plain faced. Staggered vertical joints Acoustic performance The correct use of Fire Barrier within structural cavities and voids will reduce the level of transmitted sound. Room to room attenuation RW db 1. Typical lay-in grid suspended ceiling As above, with 50mm ROCKWOOL Fire Barrier Applied as 2, but ROCKWOOL Fire Barrier foil faced Applied as 2, but two thickness of 50mm ROCKWOOL Fire Barrier-both foil faced If ceiling is plasterboard, add between 2-3 db Note: values are approximate 20 ROCKWOOL Fire Barrier systems offer labour-saving solutions to prevent fire and smoke spread within roof and ceiling voids.

21 Rollbatt Nothing could be simpler than installing ROCKWOOL volcanic rock roll. It s designed to accurately fit between either 600mm or 400mm centre timbers. ROCKWOOL RollBatt is supplied in 2 x 600mm rolls or 3 x 400mm rolls dependent on your specific requirements. How much will you need Width (mm) Length (mm) Thickness (mm) Coverage per pack (m2) 2x600 or 3x x600 or 3x x600 or 3x Roll thermal performance First layer between joints, Additional layer over joists, Roll width to suit joist U-value (W/m2 K) (thickness mm) (thickness mm) centres (mm) 100 (+) (+) (+) (+) (+) (+) (+) (+) (+) (+)

22 Part L 2006 U-value requirement for Lofts (England & Wales) Extensions, renovation and repair work U-value 0.16 New build dwellings U-value Advantages Excellent thermal performance for a cosier home Higher density than lightweight glass fibre for superior fit Does not slump Best Fire and Sound performance available for a roll Installation guide Designed to fit accurately between joists Remove outer packaging Remove the inner wrap Lay insulation between joists, starting from the eaves Ensure eaves ventilation is maintained Lay top layer of Roll at right angles to the bottom layer Environment ROCKWOOL products rely on trapped air for their thermal properties, which has neither ozone depleting nor global warming potential. 22

23 This booklet is meant only as a guide If you require further information please refer to ROCKWOOL datasheets on the website at While we have endeavoured to make the information in this guide as accurate as possible, we cannot be held responsible for printing errors or changes to future building regulations. Precaution Product which has become wet should not be installed until it has thoroughly dried out. Safety When installing insulation in enclosed spaces a suitable face mask which bears the CE mark should be used. In applications such as lofts etc, a properly fitted disposable face mask to BS/EN149 is adequate. When handling, wear gloves. Should skin irritation be experienced it can be lessened by rinsing hands under cold running water before washing. For further information refer to guidance note EH46 published by HMSO and technical datasheets available from the ROCKWOOL website. ROCKWOOL Limited reserves the right to amend or alter the specification of their products without notice as their policy is one of constant improvement. The information contained in this booklet is believed to be correct at the time of publication. 23

24 ROCKWOOL Limited Pencoed, Bridgend South Wales, CF35 6NY T: E: