Complete Wall & Façade System
Kingspan Thermastone
CI/SfB(4-) Rh2
November 2008
I nsu la ted Pane ls
Approved to LPS 1181Certificate No. 186a & 260a
I N S U L A T E D W A L L & F A Ç A D E S Y S T E M
2
The paper we have printed on is from 80% post-consumerwaste and the remaining 20% pulp is TCF (Totally ChlorineFree). This fibre is FSC certified (see fsc.org for details). In recognition, the range has been awarded both theNAPM and Eugropa recycled marks, two of the mostprestigious and recognisable recycled certificates available.The ink we have used is vegetable based, allowing thedocument to be recycled.
Sustainable Forest Recyclable Vegetable Based
3
Contents
Introduction, Benefits& Colour Range 4
Product Data 6
Construction Details 10
Cont
ents
4
IntroductionKingspan Thermastone is a unique system that combines all the benefits of insulated panel construction, with the aesthetics of a ceramic granite façade.
The Kingspan Thermastone complete wall & facade system offers theideal solution for all projects such as apartments, offices, retail, leisure,education and healthcare projects and is suitable for both refurbishmentand new build projects.
BenefitsComplete Wall & Façade SystemThe Kingspan Thermastone complete wall & façade system provides astrong, aesthetically pleasing finish with regulation compliant insulationbuilt-in. Benefits include:
• Design flexibility - all the Kingspan Complete Wall & Façade Systemscan be easily integrated with each other.
• Single point responsibility - one contractor installing wall and façade.
• Fast installation, allowing other services to gain access sooner.
• Removes ceramic granite façade from the critical path.
• Clear simple pricing structure providing a cost effective solution.
• Property & Business Protection - Loss Prevention Certification Board(LPCB) LPS 1181 certified insurer approved systemsdeliver certainty of performance and insurability.
• Grade EXT-B & EXT-A30, certified for 70mm and above insulationcore, providing 35 minutes insulation and 73 minutes integrity.
• , environmentally sustainable PIR insulation core, lowGWP (Global Warming Potential) and non-deleterious.
• Full system available with the Kingspan Total Panel Guarantee, offeringup to 25 years thermal and structural performance guarantee.
• Simple detailing to maximise air leakage performance.
• Full installation training and technical support available.
• System fully tested to the Centre for Window and CladdingTechnology (CWCT) standards.
• Easily integrates with other elements such as doors, apertures, brick,stonework and glazing.
• - No threat of loose fibres into internal environment.
5
Toscana T03 OP
Venezia VZ6 BC
Liguria LG 2 Prel
Pisa PIS 03 Nat.
Volcado HonedLazio LZ 6 Nat.
Please Note: The printed colours are as accurate as possible but are for guidance purposes only. Samples can be requested from the Kingspan Marketing Department on 01352 717251.
Colour RangeWhere a natural stone finish is required, the Kingspan Thermastone
complete wall & façade system offers a range of ceramic granite
cladding, which can reproduce all the beauty and variation of naturally
hewn stone. The ceramic granite is completely free from fissures, flaws
and other weak points which reduce the strength and versatility of
quarried materials in their original state.
The Kingspan Thermastone complete wall & façade system can be
supplied in a range of colours providing the specifier with an
exceptionally versatile way to enhance the appearance of any building.
Intr
oduc
tion
, Ben
efits
& C
olou
r R
ange
Kingspan Thermastone FaçadeUnlike natural stone, the Kingspan Thermastone façade requires nocutting and can be installed without traditional masonry skills. A patentedmanufacturing process achieves individual veining on the tiles, replicatingthat of quarried stone. Benefits include:
• The ceramic granite offers exceptional building protection.
• Loadings on the substrate and building exterior are reduced incomparison with naturally quarried stone.
• The ceramic granite is completely impermeable and resistant to lightand UV radiation.
• The ceramic granite is highly resistant to algae growth and does notabsorb dust.
• Virtually maintenance free.
• Easily used to ‘dress’ elevations to secure inner city planning approvals.
• Individual panels can be removed and replaced if necessary.
Unpolished Surfaces
Phlegethon PHG 05 LEV
BasilicataBS 22 LEV
Polished Surfaces
HeapeyHP 01
CoppiceCP 02
Metallic Surfaces
6
Product Data
1000mm cover width
Cor
e th
ickn
ess
Core Thickness (mm) 45 60 70 80 100
Weight kg/m2* 11.5 12.1 12.5 12.9 13.7
* Weight indicated is for the panel only and not the completed system.
KS1000 ST Insulated Panel
ApplicationKS1000 ST is a high specification insulated panel which, when laid
vertically acts as a carrier panel for the Kingspan Thermastone façade.
Dimensions & Weight
Available LengthsStandard lengths 1.8 to 12 metres. Panels less than 1.8m long can be
supplied and are subject to an extra charge.
Panel length
These panels cannot be end lapped.
MaterialsSubstrate
Standard external and internal sheets are hot dipped S220GD + ZA
zinc/aluminium coated metal to BS EN 10326: 2004 (Continuously
hot-dip coated strip and sheet of structural steels. Technical delivery
conditions).
Coatings - External Weather Sheet
KS1000 ST external side coating is a strong, organic coating system,
Kingspan XL FortéTM, standard colour Merlin Grey. Reverse side of
sheet coated with a light grey polyester coating.
Coatings - Internal Liner Sheet
A variety of finishes are available to suit the internal conditions of the
building. The standard liner is bright white polyester and is suitable for
typical internal environments. Where internal conditions are more
demanding, such as high internal humidity or clean room conditions,
Kingspan Aquasafe or Kingspan Cleansafe coatings are available
subject to minimum quantities. Reverse side of sheet coated with a
light grey polyester coating.
Cut to Length (mm) –5 +5
Cover Width (mm) –2 +2
Thickness (mm) –2 +2
End Square (mm) –3 +3
Flatness per metre (mm) –2 +2
Product Tolerances
Insulation CoreThe core of KS1000 ST is an , environmentally sustainable
PIR insulation which is non-deleterious with zero Ozone Depletion
Potential (zero ODP).
7
Specification
NBS Specifications are available from Kingspan envirocare®
Technical Services.
Tel: 0800 587 0090 (UK) & +353 (0) 42 96 98529 (Ireland)
Email: [email protected]
QualityKS1000 ST insulated panels are manufactured from the highest quality
materials, using state of the art production equipment to rigorous
quality control standards, approved to BS EN ISO 9001: 2000 (Quality
management systems. Requirements). Kingspan manufacturing plants
are BS EN ISO 14001: 2004 (Environmental management systems.
Requirements with guidance for use) and BS OHSAS 18001: 2007
(Occupational health and safety management systems. Requirements)
accredited.
GuaranteesKS1000 ST insulated panels are available with the Kingspan Total
Panel Guarantee, offering up to 25 years thermal and structural
performance guarantee.
DeliveryAll deliveries (unless indicated otherwise) are by road transport to
project site. Off-loading is the responsibility of the cladding contractor
or installer.
PerformanceThermal Insulation
Panel Thickness (mm) U-value* (W/m2K)
45 0.46
60 0.38
70 0.35**
80 0.30**
100 0.23**
*Thermal transmittance W/m²K**Recommended thicknesses to allow compliance with Building RegulationsApproved Documents L2A & L2B (England & Wales), Technical HandbooksDomestic and Non-domestic Sections 6 (Scotland), Part F2 (Northern Ireland)and Part L (Republic of Ireland – based on the Overall Heat Loss Method).
Biological
KS1000 ST insulated panels are resistant to attack from mould, fungi,
mildew and vermin. No urea formaldehyde is used in the manufacture
of the panels.
Fire
KS1000 ST insulated panels and overall system is
approved by the Loss Prevention
Certification Board (LPCB) to LPS 1181 Grade
EXT-B. It also achieves a Grade EXT-A30 certified
to BS 476-22: 1987 (Fire tests on building materials
and structures. Methods for determination of the fire resistance of
non-loadbearing elements of construction), for 70mm and above
insulation core, providing 35 minutes insulation and 73 minutes integrity.
The steel outer and inner facings have a Class 1 fire rating to
BS 476-7: 1997 (Fire tests on building materials and structures.
Method of test to determine the classification of the surface spread of
flame of products) and are Class 0 as defined by Building Regulations.
Acoustics
All KS1000 ST insulated panels have a single figure weighted sound
reduction Rw = 24dB.
Sound Reduction Index (SRI) Tested
Frequency (Hz) SRI (dB)
63 20
125 15
250 17
500 23
1000 18
2000 25
4000 40
8000 46
Pro
duct
Dat
a
Approved to LPS 1181Certificate No. 186a
& 260a
8
Span Core Load Uniformly Distributed Loads (kN/m2)Condition Thickness Type Span L in Metres
(mm) 2.0 2.2 2.4 2.6 2.8 3.0 3.2 3.4 3.6 3.8 4.0
Single Span 45 Pressure 2.71 2.19 1.86 1.53 1.31 1.09 0.94 0.79 0.69 0.59 0.52Suction 2.32 1.83 1.53 1.22 1.03 0.83 0.69 0.54 0.44 0.33 0.27
60 Pressure 4.05 3.35 2.89 2.42 2.11 1.79 1.57 1.35 1.19 1.03 0.91L Suction 3.63 2.95 2.52 2.08 1.79 1.49 1.29 1.08 0.94 0.79 0.69
70 Pressure 4.83 4.12 3.58 3.03 2.66 2.28 2.01 1.74 1.55 1.35 1.21Suction 4.43 3.60 3.09 2.58 2.26 1.94 1.70 1.46 1.28 1.10 0.97
80 Pressure 5.39 4.85 4.26 3.64 3.21 2.78 2.47 2.15 1.92 1.69 1.52Suction 4.98 4.03 3.46 2.88 2.53 2.17 1.93 1.69 1.52 1.35 1.23
100 Pressure 5.39 4.85 4.48 4.10 3.83 3.56 3.35 2.96 2.67 2.37 2.15Suction 5.36 4.78 4.10 3.42 3.00 2.57 2.29 2.00 1.80 1.60 1.46
Double Span 45 Pressure 3.45 2.95 2.61 2.27 1.95 1.63 1.42 1.20 1.06 0.92 0.83Suction 3.05 2.45 2.10 1.75 1.54 1.32 1.17 1.02 0.92 0.82 0.75
60 Pressure 4.64 4.11 3.67 3.22 2.76 2.29 1.98 1.66 1.46 1.26 1.13L L Suction 3.93 3.15 2.71 2.26 1.98 1.69 1.51 1.32 1.19 1.06 0.96
70 Pressure 5.05 4.54 4.19 3.84 3.30 2.75 2.36 1.97 1.73 1.48 1.32Suction 4.49 3.60 3.09 2.58 2.26 1.94 1.73 1.51 1.36 1.21 1.10
80 Pressure 5.39 4.85 4.48 4.10 3.67 3.23 2.77 2.30 2.01 1.71 1.52Suction 4.98 4.03 3.46 2.88 2.53 2.17 1.93 1.69 1.52 1.35 1.23
100 Pressure 5.39 4.85 4.48 4.10 3.83 3.56 3.28 2.99 2.60 2.20 1.94Suction 5.36 4.78 4.10 3.42 3.00 2.57 2.29 2.00 1.80 1.60 1.46
Notes:1. Values have been calculated using the limit state method described in the “European Recommendations for the Design of Sandwich Panels”
(ECCS document No.115 2001), taking imposed loads, temperature and creep into account.
2. For each value individual and combined load cases with appropriate load factors and temperatures have been considered. These are detailed under “StructuralPerformance” in the Building Design Section of the Kingspan Design and Construction Guide.
3. The table is for dark coloured panels.
4. The following deflection limits have been used:
Downward loading L/100
Suction loading L/100
5. For intermediate values linear interpolation may be used.
6. The actual wind suction load resisted by the panel is dependant upon the number of fasteners used.The fastener calculation should be carried out in accordance with the appropriate standard, a minimum of two fasteners per support is required.For further advise please contact Kingspan envirocare® Technical Services.
7. The allowable steelwork tolerance between bearing planes of adjacent supports is L/600, where L is the distance between the supports.
8. Load span tables for spans outside of those shown are available from the Kingspan envirocare® Technical Services.
StructuralUnfactored Load/Span Table(use calculated design windload values unfactored)
Typical Arrangement
Make up
Diagonaltie rod
Max
hei
ght =
=
=
Due to eccentricity of the extra load on the face ofthe insulated panel, it is important that the claddingrails are restrained from rotating, and that the rails aredesigned to resist this torsion load.
SW struts should be placed at max c/c of 1.5mequally spaced within the span of the side rails.
For cladding systems greater than 7m high, providean additional independent horizontal stucturalsupport member at 7m level. This member willreplace the sheeting rail.
Provide support to bottom cladding rail by means ofsupporting off the ground floor or introducing anadditional structural support member.
KingspanEaves Beam
KingspanMultibeamcladding rail
9
Kingspan Thermastone Façade
Dimensions & WeightDimensions: Maximum module 1206mm length x 606mm height
(inclusive of 8mm joint) and maximum actual panel size
1198mm length x 598mm height. Face panel 12mm thick.
Facade & Rail Weight: Nominally 27kg/m².
General CharacteristicsCeramic Granite
The ceramic granite is typically refined clays, quartz, feldspars and
metal oxides vitrified under high temperature and pressure, with mesh
reinforcement to rear face.
Product Tolerance
Thickness, sides straightness, rectangularity and surface flatness
are all in accordance with BS EN 14411: 2003 (Ceramic tiles Annex G
(Dry-pressed ceramic tiles with low water absorption group Bla)).
Aluminium Secondary Rail System
The extruded aluminium secondary rail system is tested to
BS 1474: 1987 (Specification for wrought aluminium and aluminium
alloys for general engineering purposes) in 6063/T6 grade alloy.
Powder coated black.
Attachment
The extruded aluminium straps tested to BS 1474 in 6063/T6 grade
alloy are secured to the ceramic granite facade panel using undercut
stainless steel expanding anchors. Straps are secured to the
aluminium secondary rail system using self-drilling / self-tapping
stainless steel fasteners. The secondary rail system is securely
fastened to the insulated wall panel with expanding self-fixing
aluminium and stainless steel fasteners.
Fire
The ceramic granite façade panels have Class 1 fire rating to
BS 476-7: 1997, and are Class 0 as defined by Building Regulations.
Ceramic granite largeformat façade panel
Typi
cally
606
mm
Typically 50mm
Pro
duct
Dat
a
10
Construction DetailsExternal Corner Detail
Eaves Detail
Note that the Kingspan Thermastone Façade isfixed to BX rails with 2 straps per façade panel
KSAFL6 fastener at 1000mm centres topand bottom, staggered at 500mm centres
Cleader angle
Foil backed PIB to seal off panel corner
Flat head fasteners at 500mm maximum centres
Undercut anchor
Kingspan Eaves Beam
Structural steel
Due to additional load from the KingspanThermastone Façade, panels must be fixed with a
minimum of 2 No. fasteners per panel per rail
‘D’ profile aluminium section
Kingspan Multibeam
Kingspan Thermastone Façade
KS1000 ST insulated panel
‘C’ profile aluminium section
Air seal - 6mm bead of gun-grade sealant
Air seal - gun-grade sealant at male jointHalter at side joint
Joint filler bed in scapa tapes 0100 grade non-curing mastic
Top sheet turned down on site for roof pitches below 4˚
Gutter and brackets by others
AWP joint filler and gun-grade sealant
Site applied fire rated canister insulation
Cover flashing with butt straps
Continuous horizontal 'J' rail with 1 No. full lengthisolation strip and 10mm expansion gap every 6m
Kingspan Thermastone Façade
KS1000 ST insulated panel
Undercut anchor
Note that the Kingspan Thermastone Façade isfixed to the BX rails with 2 straps per façade panel
KSAFL6 fastener at 500mm centres
Self-tap fixing
Drip Detail
Kingspan Multibeam
Air seal - 6mm bead of gun-grade sealant
Air seal - gun-grade sealant at male joint
Kingspan Thermastone Façade
Brickwork
Drip flashing
Closure flashing
Air seal - Continuous bead of gun-grade sealant
Undercut anchor
Continuous horizontal BX rail with 2 No. fulllength isolation strip and 10mm expansion
gap every 6m
Compression pad
Note that the Kingspan Thermastone Façade is fixedto the BX rails with 2 straps per façade panel
KSAFL6 fastener at 1000mm centres top andbottom, staggered at 500mm centres
‘D’ profile aluminium section
‘C’ profile aluminium section
AWP joint filler and gun-grade sealant
Air seal - 6mm bead of gun-grade sealant
Due to additional load from the KingspanThermastone Façade, panels must be fixed with a
minimum of 2 No. fasteners per panel per rail
Horizontal BX rail
KS1000 ST insulated panel
Kingspan insulated roof panel
80mm thick PIR board insulation with canisterapplied fire rated insulation to fill gaps, if required
11
Recessed Window Head Detail
Note that the Kingspan Thermastone Façade isfixed to the BX rails with 2 straps per façade panel
Window fixed with ferrules
KSAFL6 fastener at 1000mm centres topand bottom, staggered at 500mm centres
Window head flashing
Air seal - gun-grade sealant at male joint
Air seal - 6mm bead of gun-grade sealant
External soffit flashing with no connection to internal flashing
Optional internal head flashing
Internal finish to architects designs
Internal head flashing
Window by others
Continuous horizontal BX rail with 2 No. full lengthisolation strip and 10mm expansion gap every 6m
Kingspan Thermastone Façade
PIR board insulation
PIR board insulation
Recessed Window Jamb Detail
Recessed Window Sill Detail
‘D’ profile aluminium section
KSAFL6 fastener at 1000mm centres topand bottom, staggered at 500mm centres
Internal finish to architects designs
Internal jamb flashing
External jamb flashing
Window and seal by others
Horizontal BX rail
Kingspan Thermastone Façade
KS1000 ST insulated panel
KS1000 ST insulated panel
PIR board insulation
Undercut anchor
‘C’ profile aluminium section
Cons
truc
tion
Det
ails
Due to additional load from the KingspanThermastone Façade, panels must be fixed with a
minimum of 2 No. fasteners per panel per rail
Flat headed fastener at 500mm maximum centres
Air seal - 6mm bead of gun-grade sealant
Window by others
Window fixed with ferrules
KS1000 ST insulated panel
Note that the Kingspan Thermastone Façade is fixedto the J rail with 2 straps per façade panel
Kingspan Thermastone Façade
Undercut anchor
KSAFL6 fastener at 500mm centres
Continuous horizontal 'J' rail with 1 No. full lengthisolation strip and 10mm expansion gap every 6m
Self-tapping fixing
Drip flashing
AWP joint filler and gun-grade sealant
Air seal - gun-grade sealant at male joint
Air seal - 6mm bead of gun-grade sealant
Site applied fire rated canister insulation
Internal finish to architects designs
Due to additional load from the KingspanThermastone Façade, panels must be fixed with
a minimum of 2 No. fastener per panel per rail
Kingspan LimitedUK: Telephone: +44 (0) 1352 716100 Fax: +44 (0) 1352 710161 Email: [email protected]
Ireland: Telephone: +353 (0) 42 96 98500 Fax: +353 (0) 42 96 98572 Email: [email protected]
Details for the following countries; Australia, Belgium, Czech Republic, France, Germany, Hungary, Netherlands, New Zealand, Norway, Poland, Romania, Slovakia & Sweden can be found by visiting our website www.kingspanpanels.com or our group website www.kingspan.com
Care has been taken to ensure that the contents of this publication are accurate, but Kingspan Limited and its subsidiary companies do not accept responsibility for errors or for informationthat is found to be misleading. Suggestions for, or description of, the end use or application of products or methods of working are for information only and Kingspan Limited and its subsidiaries
accept no liability in respect thereof.
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