FLOORING PHENOLIC INSULATION BOARDS

Phenolic floor insulation board is a most effective, closed cell, lower lambda insulation material with a fibre-free rigid thermoset phenolic core that can be used on a wide range of floor applications such as concrete, beam & block and timber floors. The term rigid insulation typically refers to the large pre-formed sheets of insulation which can be bought in 2400mm x 1200mm (8’ x 4’) size. Phenolic panels are up to 50% more effective than other common insulation materials (such as PIR or EPS), however, boards will likely be the most expensive of all the floor insulation options. Being low thermal conductivity insulation enables high levels of thermal performance to be achieved utilising thinner floor sections of insulation. Moreover, phenolic closed cell content makes it highly resistant to water penetration. As they’re closed cells they shouldn’t absorb moisture or water vapour, unlike open cell products. The thermal conductivity of phenolic floor closed cell insulation material is generally between 0.018 W/m.K and 0.023 W/m.K. In addition to withstand humidity, they are very hard and resistant. High density boards have a good compressive strength and are ideal for floors. Phenolic foams are produced with densities in the range of 35kg/m³ to 150kg/m³. Those floor boards are more efficient and have lower U values than the PIR boards for the same level of thickness. This is particularly significant where space saving is important. For instance, achieving a U-value of 0.25 W/m2K would require only 70mm of phenolic floor board while EPS polystyrene needs 200mm.

PHENOLIC BOARDS APPLICATION

Floor phenolic boards such as K103 or Xtratherm SR/UF are designed to be used in suspended floors, ground supported floors and underfloor heating systems (UFH). It is also intended for use as flooring in work platforms, scaffolding, warehouses and other wet environments. While Kingspan Kooltherm offers compressive strength of 120 (kPa), Xtratherm and its SR/UF seems to be 30kPa stronger offering 150 kPa.

PHENOLIC FLOOR BOARDS MANUFACTURERS

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

KINGSPAN

Kingspan K103 Floorboard offers fibre-free rigid thermoset phenolic core with thermal conductivity of just 0.018 W/mK across all thicknesses. In fact, K103 is a premium product in terms of floor insulation. Product has been developed by Kingspan as a premium floor insulation board, providing high performing insulation with a thinner material than was possible before. K103 Kooltherm can be used on both solid concrete and suspending floors.

XTRATHERM

Kingspan is followed by Xtratherm brand with SR/UF Safe-R Phenolic Floor Insulation Board. Xtratherm phenolic board offers thermal conductivity of 0.020W/mK and compressive strength of 150 (kPa).

PHENOLIC FLOOR INSTALLATION

Boards should always be installed above the damp proof membrane (DPM). It is never recommended to lay them exposed directly to the ground. Long term exposure to moisture can result in facings – particularly composite ones featuring kraft paper layers – breaking down, to the detriment of the product.

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Video credit:https://www.youtube.com/watch?v=xzL0RS1luDY&t=118s