K15 Rainscreen Board

K15Rainscreen BoardProduct specifi c method statement

InsulationGreat Britain

Second Issue | 09/2021

2

Contents

Sections Page

General 3

Product overview 4Component items used 4Equipment and tools needed 4Practicability of installation 4 Survey and preparation for existing buildings 4Property survey 5Pre installation checklist 5Handling, storage and daily working practices 6Helping hand brackets / top hat profiles support system 6Cavity barriers 6Installation of Kingspan Kooltherm® K15 7Recommended fixing patterns 7Brickwork outer leaf 8Flue penetrations 8Quality Control 9Overall installation quality checks 9Key stages 9Hand over manual 9

Kingspan Insulation Limited reserves the right to amend this document without prior notice. The information and guidance included within this document is given in good faith and applies only to the uses described.

Recommendations for use should be verified for suitability and compliance with actual requirements, specifications and any applicable laws and regulations.

This product specific method statement is for the Quality Control and Installation of the Kingspan Kooltherm® premium performance insulation for use behind Rainscreen or masonry façade systems.

This Product Specific Method Statement is to be reviewed and amended on a regular basis to ensure compliance with current obligations and any changes to circumstances.

3

General

This document is applicable to the Kingspan Kooltherm® K15 and is to be read with the appropriate Agrément certificate, manufacturer’s literature and the project specific contract documents.

This is a method statement for the installation of the product rather than a project specific method statement. Project specific method statements and risk assessments, which encompass the relevant information from this product specific method assessment, should be produced by the installer company for every project insulated with Kingspan Kooltherm® K15.

Rainscreen façade systems are proprietary, resulting in a wide variation of possible system build-ups, material combinations and mechanisms that are used to fix and support the external cladding to the wall structure.

There are potential restrictions placed upon this product which vary dependant on building type, height, construction and location. For guidance regarding the routes to compliance for meeting the fire safety requirements of the Building Regulations / Standards, refer to the relevant Technical Bulletins and links to Government websites at www.kingspaninsulation.co.uk/fireregulations.

Please seek guidance for suitability of use for the intended façade build–up and building type prior to commencement of any work. Kingspan Kooltherm® K15 achieves Euroclass C-s2,d0.

Kingspan Kooltherm® K15 in specific constructions has been successfully tested to BS 8414-1: 2015 + A1: 2017 (Fire performance of external cladding systems. Test method for non-loadbearing external cladding systems applied to the masonry face of a building), BS 8414-2: 2005 and BS 8414-2: 2015 + A1: 2017 (Fire performance of external cladding systems. Test method for non-loadbearing external cladding systems fixed to and supported by a structural steel frame), in accordance with the performance criteria set out in BR 135 (Fire performance of external thermal insulation for walls of multi-storey buildings). These specific constructions must be followed when using the performance-based route as a route to compliance in England, Wales and Scotland. The end use design needs to be carefully considered to replicate the design details used in the tested constructions.

Test reports owned by Kingspan Insulation, detailing these constructions, are available for download at www.kingspan.com/gb/bs-8414-systems or further information can be provided by emailing [email protected].

The product produced at Kingspan Insulation’s Pembridge, Herefordshire (in thicknesses of 25 - 120 mm) and Castleblayney (in thicknesses of 25 - 150 mm) manufacturing facilities has been assessed by the British Board of Agrément (BBA) as being fit for its intended use, provided the product is installed, used and maintained as set out in certificate number 14/5134, information which is reiterated within this document.

NB Kingspan require complete traceability of where Kingspan Kooltherm® K15 is being installed. Sales will not be released without information on, but not limited to, the project details, construction build-up and relevant contact details. The purchaser will be asked to fill out a form detailing these pieces of information. Without the required information and return of the form, the sale will not be processed. For more information please contact your local sales representative (see back cover for details).

4

Product overview

Kingspan Kooltherm® K15 is a premium performance insulation with a fibre-free rigid thermoset phenolic core, faced on both sides with a low emissivity composite foil, autohesively bonded to the insulation core during manufacture.

The core is a premium performance rigid thermoset fibre-free phenolic insulant manufactured with a blowing agent that has zero Ozone Depletion Potential (ODP) and low Global Warming Potential (GWP) supplied in a variety of thicknesses to suit different U-value requirements.

Kingspan Kooltherm® K15 is to be fixed by mechanical fixings only, for use as an insulated sheathing, to the outside of steel-framed walls clad with the appropriate sheathing board, and to the outside of masonry or concrete walls in existing and new dwellings or buildings of similar occupancy.

The Kingspan Kooltherm® K15 may also be used in pre-cast concrete construction where the board is fixed internally, however this application is outside the scope of this method statement and information should be sought from the pre-cast concrete panel designer / supplier.

Component items used with Kingspan Kooltherm® K15 only(does not include other components required to complete the façade / rainscreen)

For best practice, a total of 3.13 fixings per m² are required as a minimum, including 1 non-combustible fixing per m² and the remaining fixings (2.13 m²) can be plastic sheathed or equivalent. Please contact the fixing supplier and system designer to confirm the requirements for each project.

Appropriate self-adhesive foil tape.

Appropriate external grade mastic sealant and / or low expansion Fire Rated (FR) PU foam, used for sealing board ends, interfaces with brackets, sills or penetrations.

Fixing companies to contact: EJOT; SFS Intec; Fixfast; and Mak Fasteners.

Tape companies to contact 3M / Venture; and Bostik.

Sealant and foam companies to contact: SIKA; Everbuild; Hodgson Sealants; Firetherm; Illbruck; and Geocel.

Equipment and tools needed: 110v transformer (unless using battery powered

equipment); portable band–saw table or hand saw; pad Saw for cutting service penetrations; 110v power drill or battery drill; measuring tape; spirit level; laser level (if preferred); sealant or foam gun; core drill if preferred (for cylindrical service penetrations);

and rasp for smoothing foam edges.

Practicability of installationKingspan Kooltherm® K15 is to be installed by a competent contractor experienced with rainscreen or masonry façade systems.

Operatives, façade site managers and all involved in the façade works are to ensure the building survey (if an existing building) and design specification have been obtained and products are then installed as intended so that compliance with the various building regulations, standards, fire safety requirements etc. is achieved.

The project specific Method Statement and Risk Assessments, incorporating information from this product specific method statement, must also be read and understood prior to any works commencing.

Survey and preparation for existing buildingsFor existing buildings being re-developed, a detailed property survey followed by a pre installation checklist for the facade, which includes, but is not limited to the following points, must be carried out in order to assess what remedial works and design will be required in order to receive the new cladding system and if it can be achieved in practice.

5

Product overview

Pre installation check listThe installer company will assess the suitability of the substrate before the proposed works are commenced.

For best practice the installer company should provide their own pre installation checklist in order to agree the completeness of the building survey and that the design proposal supplied can be installed as intended.

This pre installation checklist should include a detailed examination of the external fabric of the building, which includes, but is not limited to the following items.

Removal of mould or contaminants from the existing substrate.

Condition of the substrate and that remedial works can be carried out according to plan. Pull out tests may be required.

Ensure existing windows and doors are fit for purpose and can remain, cavity barriers can be installed and the system can be installed as intended.

Ensure sills can be removed and / or extended to fit with the new cladding system.

Check existing services such as boiler flues, vents (for moisture extraction and to aid combustion of heating systems), fuel feed pipework (gas, oil) etc, satellite dishes, broadband, meter boxes, can be extended, removed and replaced.

Ascertain any necessary action to be taken prior to the installation for the repositioning of services, location for ductwork / alterations / extensions to services, prior to carrying out the new works.

Ensure gas, water, electric, telephone services and broadband services are removed and replaced by suitably qualified operatives / companies if it is required to extend or reposition services because of the new cladding system.

Existing masonry or steel framed walls will need to be structurally sound in order to support the new façade system. All friable or unsound surfaces to be made good prior to installation.

Ensure any leaking external pipework and blocked gutters are made good. Check efficiency and continuity of existing damp proof course materials for solid walled structures.

Ensure adequate ventilation provision through walls and the suitability of heating installation works internally to ensure elimination of condensation and mould growth.

Property survey Property type, year originally constructed.

Identify building regulations, planning consent, listed or other status requiring special permissions / requirements before work commences.

Height of the building and number of storeys. If a high rise building, then does the building have a habitable storey 18 metres, or greater, above ground level. If so, greater overall fire safety strategy of the building must be considered and then implemented.

Construction type i.e. concrete, steel-framed, solid masonry infill etc.

Existing finishes e.g. render, cladding.

Condition of the substrate and if any remedial works are required i.e. mortar or concrete repairs, corroded steel in need of replacement, etc. Are walls in a good state of repair with no evidence of rain penetration, damp, contamination or frost damage? If not, what work will be required to repair the damage?

Will the windows and doors need replacing in order to receive the new cladding system? Window / door reveals should also be insulated.

Ensure there is an adequate ventilation provision for the wet rooms, kitchens and utility rooms.

Some heating systems require permanently open air vents.

Where airbricks are present, for example to aid the combustion of a heating system, consider if these are still required.

The heating system may have changed over the years so ventilation of this kind may no longer be required. If they are still required then this will need taking into account in the design stage so ad hoc solutions are avoided when installation takes place.

Adding insulation to an existing building can improve airtightness dramatically, therefore it is very important to ensure the building, apartment etc. is adequately ventilated via controlled routes.

Identify standard and non-standard obstacles, which will require specific detailing (flues, vents, risers, pipework etc.) to overcome thermal bridging and air leakage. This can include issues with frontage, position of meters and distribution boards, service cables, pipes or ducts.

Rainwater goods and drainage, identify if repairs are needed (ensure no leakages or water accumulation on the walls).

Identify where cavity barriers, fire stopping, fire dampers, fire sleeving are required in order to satisfy the required provisions and compartmentation.

6

Product overview

Works may be interrupted for many reasons such as weekends, public holidays and programming considerations. Weather can also be a crucial factor.

Therefore to protect boards during a break in works, or from on-going adverse weather conditions, temporary weather protection may be required to protect installed components which are not yet fully weatherproofed.

The precise nature of this protection will vary depending on the cause of the requirement for the temporary protection (e.g. to provide shading in hot climates, or to protect from precipitation in colder climates), the area of system required to be protected and the expected timescale over which it would be expected to be in place.

This may typically include the use of items such as opaque tarpaulin / damp proof membranes / breather membranes or rolls of nylon-reinforced polyethylene plastic temporarily restrained to the structure or scaffolding.

In practical terms the actual protection provided will vary based upon the specific nature of the project and construction site, and responsibility in this regard should be managed by the project team in consultation with the façade designer / supplier.

Helping hand brackets / top hat profiles support system Before installing Kingspan Kooltherm® K15 to the substrate (masonry or sheathed steel studding with or without breather membrane), breather membranes (if specified / required), top hats and / or cladding brackets, firestops and cavity barriers must all be installed first.

Advice on these components and their installation must be sought from the appropriate manufacturer and / or system designer & supplier. The requirement for a breather membrane should be determined by the system designer and warranty provider.

Handling, storage and daily working practicesCare is to be taken in offloading, distribution and storage of all materials. Products should be protected until ready to use, by maintaining the wrappings and protection afforded since factory dispatch.

Kingspan Kooltherm® K15 is delivered shrink-wrapped in polyethylene. Each board has the manufacturing code printed on the surface and each pack carries a label with the product description and characteristics, manufacturers’ name and the BBA certificate number.

Kingspan Kooltherm® K15 should remain in its packaging, until ready to use.

The polyethylene packaging of Kingspan Insulation’s products, which is recyclable, should not be considered adequate for outside protection.

Ideally boards should be stored inside a building. If however, outside storage cannot be avoided the boards should be stacked clear of the ground and covered with an opaque polythene sheet or weatherproof tarpaulin. Boards that have been allowed to get wet should not be used.

During installation the insulation does have a degree of resistance against water as it is a “closed cell” insulation material. It is possible to tape all board joints and exposed edges of Kingspan Kooltherm® K15 in order to provide a reasonable weatherproof barrier until the external cladding can be installed.

Exposure of the insulation to UV light, in the short term (approximately 1 to 2 months) is less of a concern. Some foam colour change may be seen during installation, however, this is not detrimental to the performance of the product.

The precise nature of the protection methods to Kingspan Kooltherm® K15 will need to be assessed and managed by the project team for each specific project.

At the completion of each day’s work, or whenever work is interrupted for extended periods of time, Kingspan Kooltherm® K15 edges and joints should be protected from inclement weather.

7

Product overview

Installation of Kingspan Kooltherm® K15Since rainscreen façade systems are proprietary and use diff ering mechanisms to fi x and support the external cladding to the wall structure, installation guidance should be sought from the system manufacturer or supplier.

Some general guidelines are off ered in the previous section for the support system and cavity barriers, which are not project specifi c, however once the support system and cavity barriers are in place the Kingspan Kooltherm® K15 can be fi xed using the following installation guidelines.

Insulation boards should be installed break-bonded with board edges lightly butted and in such a manner to achieve a close fi t between the board and substrate interface so as to avoid gaps behind or between the boards.

Boards should be cut neatly around penetrations and brackets with a saw / pad saw, so as to avoid gaps. Where gaps are unavoidable, fi ll gaps with low expansion Fire Rated (FR) PU foam.

The number and type of mechanical fi xings required to fi x Kingspan Kooltherm® K15 will vary with the geographical location of the building, the local topography, the height and width of the wall concerned, the wall structure, and the type of mechanism being used to attach the cladding system.

However, as a minimum Kingspan Kooltherm® K15 should be installed in a stretcher bond pattern with a minimum 200 mm stagger, and fi xed using a minimum number of 3.13 fi xings per m² (of which 1 non-combustible fi xing per m² for best practice), the remaining fi xings (2.13 m²) can be plastic sheathed or equivalent. Please contact the fi xing supplier and system designer to confi rm the requirements for each project.

The fasteners are located along the edges or at corners between 50 mm and 150 mm from the board edge and should be evenly distributed over the whole area of the board.

The requirement for additional fi xings should be assessed in accordance with BS / I.S. EN 1991-1-4: 2005 + A1: 2010 Eurocode 1. Actions on structures. General Actions. Wind Actions).

In rainscreen cladding systems, Kingspan Kooltherm® K15 will often be cut down from 2400 mm x 1200 mm to fi t in-between the cladding brackets by the installer company, for example the board will be cut down to 2400 mm x 600 mm, 2400 mm x 300 mm, 2400 mm x 200 mm etc. Where the board has been cut down to fi t between the cladding brackets please see recommended fi xing pattern below for these smaller sizes:

Cavity barriers Cavity barriers should be provided to close the edges of cavities, including around openings. Cavity barriers must also be applied around all windows and doors.

Cavity barriers must also be provided at the junction between the external facade and every compartment wall or compartment fl oor, and at the junction between an internal wall and every compartment fl oor, compartment wall, or other wall or door assembly, which forms a fi re resisting barrier.

For extensive / undivided cavities which extend for 20 metres or more, cavity barriers are required at 20 metre intervals, in accordance with Approved Document B, or 10 metres, in accordance with Section 2 of the Scottish Technical Standards.

Once the cladding support system has been installed (tophats and / or brackets), install all vertical and open state horizontal cavity barriers at the required locations.

Figure 1: Rainscreen system utilising Kingspan Kooltherm® K15 with vertical and open state horizontal cavity barriers.

Current guidance to the Building Regulations should be considered with regard to the performance requirements for, and the provision of fi re stops and cavity barriers. For specialist advice, including confi guration and installation, refer to:Kingspan Technical Insulation Ltdwww.kingspanpassivefi reprotection.co.uk+44 (0) 1524 388 898

8

Installation

Recommended fi xing patterns

The images below show recommended fi xing patterns, the number of fi xings used and the resulting fi xing density (number of fi xings per m2).

9 No. per board(2.4 x 1.2 m board - 3.13 fi xings / m2)





If other shapes or sizes of insulation are used, ensure adequate fi xings are used based on above fi xing patterns and fi xing densities.





9

Installation

Once the insulation boards have been fixed in place, apply a self adhesive aluminium foil tape no less than 75 mm wide; the tape should be applied to all horizontal and vertical board joints and when abutting junction interfaces.

Exposed edges of the Kingspan Kooltherm® K15 should, in the absence of other protection, be protected by a suitable self-adhesive aluminium foil tape, with a 50 mm minimum wide overlap onto the insulation board face.

Brickwork outer leaf When installing Kingspan Kooltherm® K15 behind a brickwork outer leaf with a supporting channel and tie framework, there is no need for additional non-combustible / mushroom head fixings, provided the channels are at no greater than 600 mm centres, and if each channel has multiple fixing points through each insulation board back to the steel frame, as this would be sufficient to restrain the insulation.

Some fixings will be required to keep the boards in place prior to the installation of the channel and tie system. If boards are installed in smaller pieces that are not covered by the channel and tie system, these will require additional fixings.

Figure 2: Kingspan Kooltherm® K15 with self adhesive aluminium foil tape.

10

Flue penetrationsThe distance between Euroclass B - E rated materials, flues, chimneys and combustion appliances needs to be designed appropriately to prevent risk of ignition of vulnerable components. Distances will vary depending upon type of flue, appliance and fuel.

When undertaking the property survey determine the fuel type of any combustion appliances, its maximum power output ratings, and the specification for the associated flue.

A detailed design should be produced to follow the recommendations of Approved Document J in England and Wales or Section 3.17 - 3.24 of the Scottish Technical Standards, and any additional guidance from flue / combustion appliance manufacturer following the property survey.

The required separation distance between the Kingspan Kooltherm® K15 and flue will typically vary between 0 mm and 600 mm depending on type of flue, fuel supply, heating capacity etc.

For example, all flues serving oil fired boilers require 300 mm minimum clearance around the flue terminal free from combustible material.

Natural draft balanced flues (non condensing boiler) requires 600 mm all round clearances free from combustible materials.

Advice must be sought from the manufacturer of the flue / heating system in order to determine if clearance is required.

If no separation from the flue is required, holes should be core drilled or cut with a pad saw to provide a snug fit. Any damage caused to the Kingspan Kooltherm® K15 by service penetrations should be made good.

Once the insulation boards have been installed, seal around the perimeter of the Kingspan Kooltherm® K15 and penetration with an appropriate intumescent flexible mastic sealant or FR rated PU foam. Refer to the appliance manufacturer for guidance.

It is extremely important that ventilation requirements for certain combustion appliances are not compromised when installing a new cladding system onto an existing building.

Cladding panelOn completion of the Kingspan Kooltherm® K15 installation, rails are then attached to the cladding brackets or equivalent in order to receive the selected cladding panel.

If rails are to be fixed such that they are required to enter the insulation in order to maintain the chosen cavity depth, then boards should be scored with an appropriate tool, prior to fixing the rails.

Installation

Figure 3: BS 8414-1 test at BRE.

Quality controlKingspan Kooltherm® K15 must be ordered from Kingspan Insulation Ltd’s supply chain in order to maintain traceability, and orders are to be project specific and traceable to the project in question.

All work is to be carried out in compliance with the design specification and contract documents, project specific method statements and risk assessments.

The installer company should provide appropriate supervision in order to monitor the installation. It would be advisable for the installer company to produce their own pre installation (as highlighted earlier), intermediate installation and post installation sign off sheets for each location / elevation and discipline, to be checked, signed and dated for record keeping purposes.

These sheets should also include a section for recording the materials and the components used along with their article numbers / batch numbers etc. in order to demonstrate the correct components / materials have actually been used.

A section for photographic evidence of the installation should also be incorporated into the intermediate and post installation quality control sheets.

These sheets would be one way of demonstrating the installation has met with the design specification, both in terms of materials used and installation detailing.

These records to be held on site, with full copies held at the installer company’s offices. Any deviation from approved and accepted installation practice must be corrected before further work is carried out.

11

Installation

Overall installation quality checksRegular site installation quality controls should be undertaken by the installer company. This is to be based on visual inspections at key installation stages, to check on:

product compliance, i.e. correct products / components used at each stage and recorded;

specification compliance, i.e. correct consumption, design compliant, technically compliant; and

installation compliance i.e. line and level, even coverage, brackets, insulation continuity, cavity barriers all installed as designed.

Key stages are: after services adjustment / alteration and preparation of

the wall face if applicable;

after framework installation, sheathing board and breather membrane (if required) installation;

after first fix mechanical and electrical services;

after cladding brackets, compartmentation / cavity barriers installed and the Kingspan Kooltherm® K15 installation;

after the rails and cladding have been fitted;

on completion and on re-commissioning of all adjusted services; and

a handover certificate and manual shall be issued to the client for each completed work section, or building.

Handover manualBest practice would be for the installer company to produce a handover manual, which should be presented to the building owner after the completion of the works and shall include the following information:

the property address; the building owner / manager; the Architect or Designer; the System name; the System supplier; the System installer, with full contact details; the date of completion of the installation; the System components (project specific); the location details of the installation/s; and the Kingspan Kooltherm® K15 guide and certification.

Contact details

KI\GB\MS\K15\002\Sept21a

The information contained in this brochure is believed to be correct at the date of publication. Kingspan Insulation Limited (“Kingspan Insulation”) reserves the right to alter or amend the product specifi cations without notice due to continuous improvement commitments. There may also be relevant changes between publications with regard to legislation, or other developments aff ecting the accuracy of the information contained in this brochure. Product thicknesses shown in this document should not be taken as being available ex-stock and reference should be made to the current Kingspan Insulation price-list or advice sought from Kingspan Insulation’s Customer Service Department. The information, technical details and fi xing instructions etc. included in this literature are given in good faith and apply to uses described. Kingspan Insulation does not accept responsibility for issues arising from using products in applications diff erent from those described within this brochure or failure to correctly follow the information or instructions as described within this brochure. Recommendations for use should be verifi ed with a suitable expert or professional for suitability and compliance with actual requirements, specifi cations and any applicable laws and regulations. For other applications or conditions of use, Kingspan Insulation off ers a technical advisory service (see above for contact details), the advice of which should be sought for uses of Kingspan Insulation products that are not specifi cally described herein. Please check that your copy of this literature is current by contacting the Kingspan Insulation Marketing Department.

® Kingspan, Kooltherm and the Lion Device are Registered Trademarks of the Kingspan Group plc in the UK, Ireland and other countries. All rights reserved.

Registered in England & Wales, No. 01882722. Registered Offi ce: Pembridge, Leominster,Herefordshire HR6 9LA UK. VAT GB428602456.

Kingspan Insulation LtdPembridge | LeominsterHerefordshire | HR6 9LA

T: +44 (0) 1544 388 601E: [email protected]

For individual department contact details please visitwww.kingspaninsulation.co.uk/contact

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K15 Rainscreen Board