Quality Phenolic foam boards*

Not all insulation boards are the same. Compact phenolic panels are different. Phenolic foam is considered one of the best material for thermal insulation.
This post outlines Phenolic boards – the most effective type of rigid insulation boards used at present. Being up to 50% more effective than other common insulation materials. Phenolic insulation achieves a lambda value of just 0.018 W/m·K across all thicknesses. It can be used in a variety of roof, wall and floor applications, which makes it a great solution for a range of constructions.

Short history of phenolic insulation

Phenolic insulation became popular in the 1980s as a thin board that could meet the increased energy saving demands of the day and fit within the constrained spaces older buildings offered for insulation.
Kingspan, an Irish company has been producing and selling Kooltherm in Europe since 1992, introducing it in the U.S. in 2016. It was a response to the energy crisis, which called for greater insulation efficiency. As regulations required higher R-value insulation in roofs, a demand arose for material which offered both fire resistance and high R-value, while not requiring a full roofing re-build to accommodate its thickness.

Phenolic insulation. What is is made of ?

Phenolic insulation is made of high solids and phenolic resin with a surface acting agent. ‘Pentane’ is a blowing agent (straight chain alkane consisting of 5 carbon atoms).
Phenolic board is manufactured by a process in which a plastic foam forms an insulating core between two flexible tissue faced layers. It has a high closed cell content and fine cell structure.

How do I know which product to use?

There are only a few main players on the market - Kingspan® followed by Xtartherm®. Two of them started their activities in Ireland. Perhaps because many houses in Ireland, particularly those built prior to 1980, were not energy efficient and poorly insulated.

While Kingspan offers only Kooltherm K-range, Xtratherm seems to offer a bit more.  Xtratherm has products for specific projects. Depending on the application, you can choose between:

Soffit phenolic boards | Drylining  | Cavity wall phenolic boards | Florring phenolic boards | Rainscreen phenolic boards | Roofing phenolic boards | Steel and timber frame

XTRATHEM®

Xtratherm SR/CW Cavity Wall Insulation Board Xtratherm Safe-R - is a top-class phenolic foam rigid cavity insulation board with a low emissivity foil facings designed for use in traditional masonry walls.

Xtratherm Safe-R SR/TB Insulated Plasterboard is a combination of premium phenolic insulation core with a composite foil facing bonded to 12.5mm tapered edge plasterboard for drylining internal walls.

Xtratherm SR/UF Safe-R Phenolic Foam Underfloor Insulation Board -is a top-class rigid phenolic foam insulation board with a low emissivity aluminium foil facings designed for ground supported floors, suspended floors and underfloor heating (UFH).

Xtratherm Rainscreen Cladding Xtratherm Safe-R SR/RS is a high-class rigid phenolic insulation board with a low emissivity foil facings designed for ventilated rainscreen cladding applications in new build and refurbishment projects.

Xtratherm Safe-R SR/PR is a high-class rigid phenolic foam insulation board with a low emissivity foil facings designed for pitched roofs, sloped roofs, ventilated roofs, hybrid roofs and warm roofs.

Xtratherm Soffit Insulation Board Xtratherm Safe-R SR/ST is a high-class rigid phenolic insulation board with a low emissivity foil facings designed for structural ceiling applications.

Xtratherm Soffit Plus Insulation Panel Xtratherm Safe-R SR/STP (Decorative Finish) is a top-class two-in-one composite insulation board which provides an effective thermal and fire performance solution in structural ceiling applications for commercial and residential buildings.

Xtratherm Framing Board Xtratherm Safe-R SR/FB is a top-class rigid foam insulation board with a low emissivity foil facings designed for use with steel and timber frame applications up to 18m in height.

KINGSPAN®

The Kingspan Kooltherm K-range comprises the thinnest commonly used insulation products for any specific U-value. With a fibre-free rigid thermoset phenolic core, and a thermal conductivity of 0.018 - 0.023 W/mK, these are the most thermally efficient insulation products commonly used.

K103 Kingspan Kooltherm Floor - is an exceptional performance rigid phenolic foam floor insulation board with a glass tissue facings designed for suspended floors, ground supported floors and underfloor heating systems (UFH).

Kingspan Kooltherm K118 Insulated Plasterboard - Dry Lining Insulated Board is a top-class three-in-one product for internal wall insulation used as mechanically fixed and adhesively bonded 'dot and dab' insulated plasterboard.

Kingspan Kooltherm K5 Phenolic External Wall Insulation Board -  is a high-performance rigid thermal insulation board designed for external wall insulation behind traditional and lightweight polymer modified renders and dry cladding systems.

Phenolic Boards vs Compressive Strength

In addition to withstanding humidity, they are very hard and resistant. High density boards have a good compressive strength and are suitable for some floors. Phenolic foams are produced with densities in the range of 35 kg/m³ to 200 kg/m³. 

Phenolic insulation vs Moisture

Special coating gives phenolic panels special protection against moisture. Closed cell content makes it highly resistant to water penetration. Any moisture ingress is limited and confined to the punctured area. As they’re closed cells they shouldn’t absorb moisture or water vapour, unlike open cell products. Phenolic boards are often used in particularly damp environments such as bathrooms and toilets. 

Phenolic insulation vs Thermal Conductivity

The boards achieve a thermal conductivity (λ–value) of:

0.023 W/m.K (15–24 mm)
0.021 W/m.K (25–44 mm)
0.020 W/m.K (≥ 45 mm)

Is phenolic foam expensive?

Phenolic boards will likely be the most expensive of all the rigid foam insulation options available on market, however being low thermal conductivity insulation enables high levels of thermal performance to be achieved utilising thinner sections of insulation.

Phenolic insulation thermal conductivity

The thermal conductivity of phenolic closed cell insulation material is generally between 0.018 W/m.K and 0.023 W/m.K.

Phenolic application

Phenolic foam boards are available to suit most new buildings or refurbishment applications.
Used extensively in the building industry for a number of application areas including roofing, cavity board, external wall board, plaster board dry linings systems, floor insulation 
 

Space saver insulation

The exceptionally low thermal conductivity of closed cell phenolic foam boards means that appropriate insulation efficiency can be achieved with the thinnest possible material.

Timing is everything

Due to its firmness and water resistance, insulation will generally last 100 years or more.

Deterioration

Phenolic foam insulation will deteriorate if it is exposed to sunlight for extended periods of time.

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