Mawson Lakes Primary School
Kooltherm K12 Framing Board & AIR-CELL Permishield XV 70 featured in the school’s recent upgrade.
Case Study4 min read
The National Construction Code’s (NCC) energy efficiency requirements are driving energy improvements in the commercial and residential building sectors, and builders looking to improve the thermal properties of a new home need to consider building products that help meet these ever-evolving requirements.
A South Australian construction material supplier, Techtilt Building Systems, has used Kingspan’s Kooltherm, a rigid thermoset phenolic insulation, in a new and unconventional way to help a South Australian home builder significantly improve the thermal properties of their latest new build to achieve an 8.2 energy efficiency star rating.
LOCATIONSouth Australia
Using concrete's thermal properties to its advantage, Techtilt Building System's proprietary concrete panelling is embedded with Kooltherm, further enhancing the panels’ thermal properties and improving a home’s energy efficiency.
“Kooltherm’s R rating made it a clear choice for us to increase the thermal efficiency of our insulated concrete walling system in residential projects,” said Lou Gagliardi, owner of Techtilt. Kooltherm is a range of phenolic insulation boards, the most thermally efficient insulation commonly used, featuring a rigid thermoset foam as an insulating core between two facing elements, which helps slow thermal transfer and deliver an insulation rating of R2.30 in 50mm board. As a comparison, a 50mm traditional fibreglass insulation batt delivers an R rating of R1.40.
“Kooltherm is an amazing insulation product and one I have complete confidence in,” said Gagliardi. “Concrete walls without insulation can be uncomfortable for residential use, but with Kooltherm, temperatures take longer to transfer through the concrete, delivering a much more comfortable living environment all year round.”
The home’s concrete walls featured 50mm Kooltherm board embedded between 100mm and 75mm panels of concrete to deliver a concrete walling system achieving a Total R-value of RT2.5 in summer and RT2.6 in winter. Practically, this means the home provides comfortable indoor temperatures in both summer and winter, regardless of the external temperature.
“Modelling the whole house, including Techtilt’s Kooltherm-embedded concrete walling system and specified glazing, achieved an 8.2 star rating,” said David Burton, C & R Energy Consultants Pty Ltd, noting that Techtilt’s system was tested by an independent consultant who prepared a Computational Fluid Dynamics Modelling Report and the resistance value was then used in a theoretical software program developed by CSIRO to determine heating and cooling loads. “This was a great outcome for both client and energy assessor. I would expect this result to achieve a high level of comfort and ultimately, a significant reduction in heating and cooling expenses,” said David Burton.
These concrete insulated panels used for the external façade are custom-made for each home design using 1200mm x 2400mm Kooltherm boards, which can be custom cut to the required size. The benefits of using these panels include not needing a timber or steel frame, as Techtilt walls are load bearing and simply bolted together onsite. They also don’t require any external or internal cladding, with allowances for services and amenities included in the bespoke panels where required.
Gary Harvey, who bought the completed home, didn’t know about the home’s energy efficiency credentials when he made his initial enquiries, but was impressed by its solid construction. “I walked in to inspect the home for the first time in the middle of winter and immediately noticed the internal temperature,” said Harvey, describing the internal temperature as a stable environment. “Without heating or cooling, it is 18-20 degrees Celsius inside the home all year. Our energy bills decreased by up to 50 per cent from our previous home and if we need to warm or cool the house, we only need to turn the air conditioning on for an hour and not leave it running all night.”
Lou concludes, “Concerns about climate change, rising energy prices and building costs are challenging Australians to re-think how we design and construct our homes. Kooltherm helped achieve a 8.2 energy rating for the house, in which the home owner enjoys a comfortable internal temperature all year round.”
Kingspan conducted a thorough Indicative Condensation Risk Analysis as part of their comprehensive approach to the project. Through detailed modelling and analysis, Kingspan determined that positioning the Kooltherm insulation on the external side of the inner concrete skin effectively insulated it from external temperature fluctuations. This strategic insulation solution played a crucial role in maintaining a stable and regulated temperature within the concrete structure, akin to the conditions experienced inside the house. As a result, the risk of dew point formation on the concrete surface was significantly mitigated, ensuring enhanced durability and performance of the building envelope against moisture-related issues. This innovative application highlights Kingspan's commitment to integrating advanced insulation technologies to optimise building performance and comfort levels.
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