Cellomur® Ultra ECA – a new generation of low carbon external thermal EPS insulation
Country of development/application:
France
Scope of innovation
☐ Office work
☒ Production / Service supply process
Sector-specific
☐ Yes / please, specify sector(s):
☒ No (relevant for all sectors)
Description of the needs
The impact on the environment of everyday materials is increasingly important if we are to reduce our carbon footprint and protect our natural heritage for future generations. Expanded Polystyrene (EPS) is an excellent material for packaging and for construction as it is a light yet rigid foam with good thermal insulation and high impact resistance.
EPS is a rigid cellular plastic, which is found in a multitude of shapes and applications. Among its commonly known uses are the food boxes, packaging for electrical consumer goods and for insulation panels for buildings.
The 1st stage of its production process is the pre-expansion. The raw material is heated in special machines called pre-expanders with steam at temperatures between 80°C and 100°C. The density of the material falls from some 630kg/m3 to values of between 10 and 35kg/m3. During this process of pre-expansion the raw material’s compact beads turn into cellular plastic beads with small closed cells that hold air in their interior.
The 2nd stage is intermediate maturing and stabilization. On cooling, the recently expanded particles form a vacuum in their interior which has to be compensated for by air diffusion. This process is carried out during the material’s intermediate maturing in aerated silos. The beads are dried at the same time. This is how the beads achieve greater mechanical elasticity and improve expansion capacity — very important in the following transformation stage.
The 3rd stage is expansion and final moulding. During this stage, the stabilised pre-expanded beads are transported to moulds where they are again subjected to steam so that the beads bind together. This way moulded shapes or large blocks are obtained and are later sectioned to the required shape.
EPS is widely used in construction. Its characteristics make it excellent for use as a lightweight filler, insulation, for decoration purposes, for facilitating land drainage, etc. The following properties are important for these applications:
• Low thermal conductivity – Due to its closed air-filled cell structure that inhibits the passage of heat or cold, a high capacity for thermal insulation is achieved.
• Low weight – Densities of between 10 and 35kg/m2 allow light and safe construction works.
• Mechanical resistance – EPS has excellent mechanical properties making it good choice for loadbearing roof insulation, sub-pavement flooring, loadbearing road construction insulation, etc.
• Low water absorption – EPS does not absorb moisture and its thermal and mechanical properties are unaffected by damp, humidity or moisture.
• Ease of handling and installation – The material can be handled in the usual way, guaranteeing a perfect finish. The low weight of EPS makes it easy to handle and to transport to site.
• Chemical resistance – EPS is completely compatible with other materials used in construction, including cements, plasters, salt, fresh water, etc.
• Versatility – EPS can be cut into the shape or size required by the construction project.
• Ageing resistance – All of the properties listed above are retained over the whole of the material’s life and will last as long as the building itself. EPS is not altered by external agents such as fungi or parasites as they find no nutritional value in the material.
EPS is obtained from oil. Using oil to manufacture products in EPS can be an efficient use of this natural resource, for example: Each kilogram of oil used to produce EPS insulation panels creates a saving of 150kg of oil used for heating residences and buildings (calculated over a 50 year period). Life cycle analyses have shown that EPS has far less negative impact on the environment than other competitive materials for the same use. Pentane, a non-CFC expansion agent is used during the EPS production process to expand the polystyrene granules into a cellular structure. Pentane is a slightly volatile liquid that is continually formed in natural processes. For example, it appears in the digestive systems of animals and in the anaerobic decomposition of vegetable matter by micro-organisms. It belongs to the same chemical family as other better known gases like methane, ethane, propane and butane which are used as heating fuel. Pentane released during the EPS manufacturing process quickly turns into carbon dioxide and water in a photochemical reaction. It does not contain chlorine and so does not harm the ozone layer like CFCs or HCFCs. Although the pentane released during the production and transformation of EPS does contribute to man-made emissions of volatile organic compounds (VOCs) – these are only found in the 0-0.2% range. Although pentane is not considered to be a substance hazardous to health by European health authorities, the EPS industry is researching new ways to reduce the levels of pentane used and to capturing and re-using pentane.
Description of the solution
Cellomur® Ultra ECA is a new generation of low carbon impact EPS insulation. Contributing to the use of renewable raw materials from biomass, Cellomur® Ultra ECA is developed to be used as external thermal insulation under thin coating. With high thermal, mechanical and environmental performances, it will find its place in any low carbon construction project, with 60% less CO2 impact than conventional EPS insulation. ACERMI and ISCC certified, Cellomur® Ultra ECA also offers all the advantages of expanded polystyrene in insulation: excellent durability, ease of installation, thermal performance and economy – an innovation that is worth to be discovered on any construction site.
Product characteristics:
• Dimensions : 1200 x 600 mm;
• Thickness : from 20 to 300 mm, every 10 mm;
• Thermal conductivity : 0.031 W/mK.
Installation recommendations:
• Recommended room temperature: 5° to 35° C;
• Recommended substrate temperature: >5°C;
• Should be kept away from rain, frost, humidity >80% RH and direct sunlight.
Description of the effect
Environmental benefits:
• CO2 impact reduced by 60% compared to conventional EPS insulation;
• Contributes to the use of renewable raw materials limiting the depletion of fossil resources and recovering green waste from other sectors;
• 100% recyclable;
• High thermal performance with λ = 0.031 W/mK;
• Thermal resistance up to 12,90 m².K/W;
• Excellent durability over the lifespan of the product;
• ACERMI and ISCC certified.
The Financial benefits
• About 5 years payback time for an overall external insulation;
• Up to 20% cheaper than bio-based equivalents.
Expanded polystyrene is the only 100% recyclable insulation. It can be recycled endlessly in different forms:
• Recovered on site by HIRSCH Insulation, it is directly reintegrated into the production process and is used in the composition of new insulation.
• Recovered by a company specializing in recycling (on site or in the waste collection centre), it will be crushed and then recycled in extruded form (in granules) to enter into the composition of commonly used plastic products.
Company/companies that developed/implemented/offer the innovation
Founded in 2019, HIRSCH Isolation is specialized in sustainable and responsible expanded polystyrene insulation. HIRSCH Isolation offers 100% recyclable insulation solutions with a low carbon footprint, manufactured on 5 sites in France, at the best price/performance/environmental impact ratio.
Head Office’s address: 164-174 rue Victor Hugo, 92300 Levallois-Perret, France
Website: https://hirschisolation.fr/
Additional information
Video Cellomur® Ultra ECA : the first insulation with an improved carbon footprint