ENERGY SAVING WITH

THERMAL INSULATION MORTAR (TIM)

Malik Jamal, Construction Polymers, June 2011

CREATING TOMORROW'S SOLUTIONS

CONTENTS

Welcome to WACKER
Need for Thermal Insulation Mortar
Characterization of Thermal Insulation Mortar
Thermal Insulation Mortar with VINNAPAS Powders

Energy efficiency
June 2011, Slide 1

WACKER CHEMIE AG
OVER 90 YEARS OF SUCCESS
Wacker Chemie AG
Founded in 1914 by Dr. Alexander Wacker
Headquartered in Munich

WACKER Group (2010)

Energy efficiency
June 2011, Slide 2

Sales:

4.75 billion

EBITDA:

1.19 million

R&D:

165.1 million

Investments:

695 million

Employees:

16,314

PRODUCTS AND SOLUTIONS FOR KEY INDUSTRIES

Automotive

Textile

2% 4%
Adhesives

9%

14%
Others

3%

5%

Sales
by
industries

Chemicals

Energy / Electronics

20%

Construction

33%
11%

Semiconductors

Energy efficiency
June 2011, Slide 3

Solar technology

WACKER POLYMERS - GLOBAL SETUP WITH REGIONAL

FOCUS
Global Network

Business Card WACKER POLYMERS 2010

Sales: EUR 810.0 million

Capital expenditures: EUR 13.1 million
EBITDA EUR 122.6 million
Moscow
Allentown

Burghausen
Nanjing

Calvert City

Beijing
Suwon
Shanghai

Dubai
Mumbai

Development of sales in million EUR*

+ APP
868

Singapore

744
560

Sao Paulo
382

386

425

810

633

474

Melbourne
Production

Technical center

Technical center & WACKER ACADEMY

2002 2003 2004 2005 2006 2007 2008 2009 2010

Energy efficiency
June 2011, Slide 4

WORLD MARKET LEADER CONSTRUCTION POLYMERS:

ADDING VALUE TO DRY-MIX MORTAR SYSTEMS
Products

Trademark

Co- and Terpolymers as

Dispersible Polymer
Powders
Dispersions

VINNAPAS

Main Industries
Construction Chemicals
Dry-Mortar

Applications of Dispersible Polymer Powders in Dry-Mix mortars

Tile adhesives
Grout mortars
Sealing slurries
Exterior Insulation and Finish Systems
Thermal Insulation Mortar
Primers
Cementitious surface coatings
Self-leveling compounds
Energy efficiency
June 2011, Slide 5

Adhesive slurries
Plasters
Concrete renovation
Gypsum applications
Skim coats
Powder paints
Troweling compounds

CONTENTS

Welcome to WACKER
Need for Thermal Insulation Mortar
Characterization of Thermal Insulation Mortar
Thermal Insulation Mortar with VINNAPAS Powders

Energy efficiency
June 2011, Slide 6

CLIMATE CHANGE IS OMNIPRESENT - SAVING ENERGY

IS CRUCIAL FOR STOPPING GLOBAL WARMING

Energy efficiency
June 2011, Slide 7

IN EUROPE BUILDINGS REPRESENT THE LARGEST ENERGYCONSUMING SECTOR

Source: DG TREN, European Commission

Energy efficiency
June 2011, Slide 8

EXTERIOR WALL INSULATION CONTRIBUTES THE

MAJOR PART OF SAVING ENERGY IN BUILDINGS

Source: DENA, graphics Wacker Chemie AG

Energy efficiency
June 2011, Slide 9

EXTERIOR WALL INSULATION OFFERS BENEFITS LIKE .

. . . saving energy (costs) for both

heating and cooling

. . . creating comfort and well

being in your home
Source: http://rohstoffe.onvista.de, Recknagel-Spengler

Energy efficiency
June 2011, Slide 10

THE THERMAL INSULATION RENDER IS PART OF

A THERMAL INSULATION MORTAR SYSTEM
Thermal insulation mortar:
Special renders/plasters for the thermal insulation of buildings
Internal
plastering

Have a high content of thermally insulating light-weight

components
Expanded Poly Styrene (EPS)
Mineral foam glass (e.g. based on perlite / recycled glass)

Brick work

Have very low thermal conductivity and a thickness of 20 100

mm

Thermal
insulation
mortar

Thermal insulation mortars systems are:

Composed of aligned heat-insulating base renders and waterrepellent top renders / top coats

External
Rendering

Top coats also serve to protect the system from mechanical

damage and weathering

Energy efficiency
June 2011, Slide 11

THERMAL INSULATION SYSTEMS ARE ALSO USED FOR

COMPLEX ARCHITECTURAL STRUCTURES

Exterior insulation for highly complex

architectural structures:

Building complex Les Grottes in Geneva, CH

Timbered house with infilling

Energy efficiency
June 2011, Slide 12

Highly structured facades

(curvatures, profiles)

Mixed brickwork

Preservation of valuable historical

architecture (e.g. timbered buildings
with infilling)

CONTENTS

Welcome to WACKER
Need for Thermal Insulation Mortar
Characterization of Thermal Insulation Mortar
Thermal Insulation Mortar with VINNAPAS Powders

Energy efficiency
June 2011, Slide 13

THE NEW DIN V 18550 IS THE MOST IMPORTANT

STANDARD FOR THERMAL INSULATION RENDERS
STANDARD
DIN EN 998-1

DIN 18550-3 (old)

DIN 18550-3 (new)

DESCRIPTION
Definition of rendering / plastering mortars for masonry
PART 1: Renders / Plasters
Thermal insulation renders with mortars made from mineral
binders and expanded polystyrene (EPS) as an additive
Renders and render systems
Sub-item 10: Thermal insulation renders

DIN 4108

Energy efficiency
June 2011, Slide 14

Measurement of R (thermal conductivity)

DIN V 18550 DEFINES BASIC REQUIREMENTS

General characteristics of a thermal insulation renders
Thermal conductivity:

0.2 W/(m.K)

Dry density:

600 kg / m3

Requirements for the thermal renders used as a basic render (base coat)
CHARACTERISTICS
Compressive Strength

Thermal Conductivity

Fire Behavior
Water Uptake
Energy efficiency
June 2011, Slide 15

REQUIREMENTS
0.40 N/mm2
(CS 1 as per DIN EN 998-1)
Class T1:

0.12 W/(m.K)

Class T2:

0.24 W/(m.K)

At least B1 (of low flammability)

(definition as per DIN EN 13501-1)
Water retardancy:

0.5 < w < 2.0 kg/(m2.h0.5)

DIN V 18550 DEFINES BASIC REQUIREMENTS

Requirements for a mortar used as top coat:
CHARACTERISTICS
Compressive Strength

REQUIREMENTS
0.80 N/mm2 and 3.0 N/mm2
Water repellency

Water Uptake

Sd 2 m
w 0.5 kg/(m2.h0.5)
Sd . w 0.2 kg/(m.h0.5)

Coating condition

Energy efficiency
June 2011, Slide 16

7 days after applying the base coat

THERMAL CONDUCTIVITY, THERMAL-TRANSFER

RESISTANCE AND U-VALUE
Thermal conductivity:

W/m.K

describe how much heat energy passes through one square meter of barrier when the
temperature differences between the 2 sides is 1C/ meter

Thermal-transfer resistance:

Rx = dx / x ;

m2.K/W

is calculated by dividing the thickness of the barrier by the thermal conductivity

various transfer-resistance values can be added: Rtotal = Rai + R1 + R2 ++ Rn + Rao
U-Value (Heat transfer):

U = 1 / Rtotal ;

W/ m2.K

is the heat transfer and describes the amount of energy lost per square meter for a
thermal barrier at a 1C temperature difference between inside and outside
The lower the U-Value, more energy can be saved!

Energy efficiency
June 2011, Slide 17

 VALUE COMPARISON OF VARIOUS MATERIALS

Material thickness needed to reach an R value of 1 mK/W

()
160

Concrete (1.6)
Full Clay Bricks
(0.56)

56
13

AAC blocks (0.13)

Thermal insulation
Mortar (0.07)

20

40

60

80

100

120

140

160

Source: FHG,WUFI: Material Data Base + own calculations

Energy efficiency
June 2011, Slide 18

APPLICATION
REGULATION AND RECOMMENDATIONS
Application with machines or manual (5-6 cm/working
step)
Drying time for TIM: 1 day per 5 mm thickness, but at
least 7days
Drying time for patching mortar: 1 day per 1 mm
thickness, but at least 6 days
If humidity is high or temperatures low: drying times
have to be extended
The substrate has to be dry, dust-free, free of loose
material and its temperature should be above 5 C.
In certain cases primer or plaster base (>5cm) are
essential/recommended
Crack delicate area (edges, openings) can be
protected by a fiber mesh
Dark colors for the finish coat should be avoided (high
temperatures -> shear stress)

Energy efficiency
June 2011, Slide 19

CONTENTS

Welcome to WACKER
Need for Thermal Insulation Mortar
Characterization of Thermal Insulation Mortar
Thermal Insulation Mortar with VINNAPAS Powders

Energy efficiency
June 2011, Slide 20

STEPS FOR DEVELOPMENT AND TESTING FOR

THERMAL INSULATION PLASTERS

Energy efficiency
June 2011, Slide 21

OBSERVATION:
STABILITY UNDER LOAD (WITH EPS BEADS)

Source: WACKER
Energy efficiency
June 2011, Slide 22

OBSERVATION:
STABILITY UNDER LOAD WITH PERLITE

Source: WACKER
Energy efficiency
June 2011, Slide 23

PERFORMANCE TEST:
THERMAL CONDUCTIVITY

Thermal Conductivity
(W/m.K)

Thermal Conductivity of Thermal Insulation Mortar

0.16
0.12
0.08
0.04
0
EPS (5 mm)

EPS (2 -3 mm)

Perlite

Requirements: T1: < 0.12 W/m.K

Source: WACKER
Energy efficiency
June 2011, Slide 24

ADDING VINNAPAS TO THERMAL INSULATION

MORTARS OFFERS CONSIDERABLE ADVANTAGES
Improved adhesion between the mineral
binder and the light-weight components
(EPS)
Improved adhesion to the substrate
Improved adhesion to the top render
Improved heat-insulation properties by
increasing the percentage of air voids
Higher flexibility
Optimized tensile adhesive strength and
flexural strength
Improved workability
On-demand water repellency and thixotropy
Energy efficiency
June 2011, Slide 25

VINNAPAS POWDERS FOR

THERMAL INSULATION MORTAR
Application

Recommended
VINNAPAS Polymer Powders

Base coat

5044 N
8031 H
8034 H
7031 H

Topcoat

8031 H
8034 H
7031 H

Energy efficiency
June 2011, Slide 26

THANK YOU FOR ATTENTION

Energy efficiency
June 2011, Slide 27

THANK YOU FOR YOUR ATTENTION !

CREATING TOMORROW'S SOLUTIONS