Insulation industry news from Global Insulation

UK: The six-year public inquiry into the Grenfell Tower fire, which claimed 72 lives in 2017, has issued its final report, finding fault with ‘dishonest’ companies, as well as former governments and a disorganised response from the fire service. The inquiry criticised the role of cladding manufacturers, notably US-based Arconic, for its ‘systematic dishonesty’ in concealing the true fire hazards of its products. Arconic, which produced the Reynobond 55 polyethylene cladding used on Grenfell Tower, was accused of having hidden ‘very poor’ fire safety test results from the public and certification bodies. In the report, the cladding is described as ‘extremely dangerous’ when used in folded cassette form, and was ‘by far the largest contributor’ to the Grenfell fire.

The inquiry also named both Celotex and Kingspan as contributors to the incident. Celotex was accused of making ‘false and misleading claims’ by presenting its product to cladding contractor Harley Facades as being safe and suitable for Grenfell, even though ‘it knew that was not the case.’ Insulation producer Kingspan reportedly ‘misled the market’ by not revealing the limitations of its product, which was used on a small section of the building. In response to these findings, the inquiry has called for a revision in testing materials and designs for fire safety, advocating for transparency by making these test results publicly accessible. The findings of this inquiry lay the groundwork for potential criminal charges, with police and prosecutors indicating that investigations will continue until the end of 2025, and decisions on criminal charges expected by the end of 2026, according to a report by the BBC.

Kingspan said in a statement “We welcome the publication of today’s report which is crucial to a public understanding of what went wrong and why. It explains clearly and unambiguously that the type of insulation (whether combustible or non-combustible) was immaterial, and that the principal reason for the fire spread was the PE ACM cladding, which was not made by Kingspan. Kingspan has long acknowledged the wholly unacceptable historical failings that occurred in part of our UK insulation business. These were in no way reflective of how we conduct ourselves as a Group, then or now. While deeply regrettable, they were not found to be causative of the tragedy and Kingspan has already emphatically addressed these issues.”

A spokesperson for Celotex said “The publication of the Grenfell Tower Inquiry report marks the conclusion of the inquiry’s work and we are considering its contents with care. This review was a significant and thorough undertaking, and the results of that work were disclosed promptly and proactively to relevant stakeholders, including the Grenfell Tower Inquiry. Independent testing commissioned following the review demonstrated that the cladding system described in the Celotex RS5000 marketing literature met the relevant safety criteria. That system was substantially different to that used at Grenfell Tower. Decisions about design, construction and the selection of materials for the Tower were made by construction industry professionals.”

A spokesperson for Arconic subsidiary Arconic Architectural Products (AAP), which Building News reports supplied aluminium composite material used for the rainscreen at Grenfell Tower, said “The company respects the Inquiry process. AAP cooperated fully with the work of the Inquiry and will continue to engage with further legal processes. Together with other parties, AAP has made financial contributions to settlements for those affected, as well as to the restorative justice fund. Throughout the Inquiry, AAP has maintained a number of points: AAP sold sheets of aluminium composite material as specified in the design process. This product was safe to use as a building material, and legal to sell in the UK as well as the more than 30 other countries in which AAP customers purchased the product. We reject any claim that AAP sold an unsafe product. AAP regularly conducted tests of its materials using third-party testing bodies. Reports on these results were all publicly available, and AAP made these reports available to its customers. AAP did not conceal information from or mislead any certification body, customer, or the public.”

New Zealand: Germany-based building products and systems producer Sto has concluded a deal to acquire its New Zealand distribution partner Stoanz. Sto says that it expects to complete the acquisition on 1 April 2024.

Sto is the market leader in external wall insulation systems in New Zealand. Its other products and services include façade elements and concrete repairs.

UK: Insulation and cladding companies have blamed each other in a public inquiry investigating the Grenfell Tower Fire that took place in 2017 that led to 72 deaths. During closing statements to the inquiry the Press Association reports that the legal representation for Ireland-based Kingspan said, "In its phase one report the inquiry concluded that the cladding system on Grenfell Tower did not comply with the building regulations and that the PE ACM [polyethylene cladding] manufactured by Arconic was the principal reason for the rapid fire spread." The lawyer went on to summarise that Kingspan’s Kooltherm K15 phenolic insulation product was safe when used appropriately and not relevant to the nature and speed of the spread of the fire in this instance.

In a written statement though Arconic blamed the cause of the fire upon the failure by those involved in the refurbishment of the tower in assessing the fire performance of the building materials used and their configuration. It added, "A failure which was in significant part the result of the efforts made by the manufacturers of the insulation, Celotex and Kingspan, to hide or downplay the combustible and hence (under the prevailing regulatory regime) non-compliant nature of their product, an awareness of which would otherwise and in any event have led inexorably to the choice and configuration of the components being re-visited and amended."

The majority of the insulation purchased for use in a refurbishment of Grenfell Tower prior to the fire in June 2017 was Celotex’s RS5000 polyisocyanurate foam (PIR) insulation board. However, Kingspan confirmed in July 2017 that a small amount of its Kooltherm K15 product had also been used without its knowledge and that it had no involvement in the design or specification of the refurbishment.

UK: Denmark-based Rockwool has appointed Hedley Thompson as Rockwool’s Recladding and Façades Sector Manager in the UK. The position is a newly created role in the company. Thompson’s appointment is the first step in the creation of a new team which will target housing associations, local authorities and housebuilders.

Hedley has worked for Rockwool UK since 2014 in the position of Technical Specification – Façades. Prior to this he held a variety of technical and operations roles with the construction sector.

Australia: The owners of potentially thousands of buildings in the Australian state of New South Wales (NSW) will have to replace their cladding after the government retrospectively banned aluminium panels with a core of more than 30% polyethylene. It is seeking to prevent fires such as those seen in Melbourne's Lacrosse building and Grenfell Tower in London, UK.
The ban, announced by Fair Trading Commissioner Rose Webb, goes further than previous announcements by state governments in Queensland and Victoria that banned the use of high-content polyethylene cladding, as it also affects existing buildings, rather than just those in planning or under construction.
"The building product is unsafe for use in any external cladding, external wall, external insulation, façade or rendered finish in buildings (as low as two storeys, depending on purpose), subject to specified exceptions," said Ms Webb in a communique. "I therefore decided to prohibit the use of the building product."

The number of buildings affected by the ban is unclear. In June 2018, the state government said Fire & Rescue NSW had assessed 2280 buildings and found 417 in need of closer scrutiny. A register of buildings with combustible cladding, drawn up in the wake of an audit conducted by the NSW Cladding Taskforce, is due to come into effect in 2018, but may not be made public.

Under the ban permitted under NSW cladding legislation passed in late 2017, local councils and other relevant authorities will be able to issue rectification orders for affected buildings.

UK: The British Rigid Urethane Foam Manufacturers’ Association (BRUFMA) has said that the materials tested so far by BRE Group, following the Grenfell fire in June 2017, do not meet building regulations and would never be recommended or approved for use by the members of BRUFMA in a real building.

The Department for Communities and Local Government (DCLG) has commissioned six BS 8414 tests using a combination of materials, including the make-up of the outer cladding system. The first aluminium composite material (ACM) cladding test, carried out by BRE combined an assembly of polyisocyanurate (PIR) insulation used in conjunction with an unmodified polyethylene filled ACM cladding panel. Both PIR foam and mineral wool are being tested with each cladding system.

BRUFMA described the situation as ‘worrying’ that a number of buildings have been identified with this combination, indicating a lack of compliance to existing rules and regulations. However, it has advised that all six tests should be completed satisfactorily before any analysis is drawn and remedial action is proposed by the government. It also highlighted that PIR insulation manufactured in the UK and Ireland that is recommended for use in high-rise buildings is tested with the BS 8414 fire test as part of a complete ventilated rainscreen system.

UK: Exterior cladding systems have come under scrutiny in the aftermath of a devastating fire at a tower block in west London that has killed at least 17 people. The system was retrofitted in 2016 to the 24-storey building that was originally built in the 1970s, according to Reuters. Concerns have been raised about the speed the fire spread. Suspicions have targeted the flammability of the insulation panels used in the façade and whether fireproof barriers were installed properly at the site. It is believed that wall fixings, exterior zinc panels and insulation panels were used in the cladding according to a planning document relating to the building that was published by the local government in 2012. It is unknown whether the insulation material included any fire retardant chemical additives.

“Without knowledge of the specific materials used we cannot say at this early stage if any of the conclusions above are relevant to this tragic incident, but the increasing use of combustible materials in construction needs to be addressed if further events are to be avoided,” said Jim Glockling, Technical Director at the Fire Protection Agency (FPA). He added that the FPA believes that local building regulations need to be updated to consider, “both the external envelope of the building and its resilience to fire ingress.”

Prime minister Theresa May has ordered a full public inquiry into the incident.

UK: MonolithUK, a new business in North Wales, is set to create 40 new jobs with its launch of an innovative external cladding product for the home insulation market Brick Plus, an alternative type of insulation for older properties, looks and feels like real brick, but it is not a structural product. It is ideally suited to conceal and cover external wall insulation while preserving the appearance of older brick properties. This also helps it to circumnavigate planning permission controls that apply to cavity insulation.

Made from a specialised natural lime product, Brick Plus are lighter than bricks, only 20mm deep and have a thin expanded polystyrene backing. They can be provided as individual bricks, on a mesh sheet and with or without thermal insulation attached.

Steven Waring, who has invested nearly Euro600,000 into the Brick Plus project since 2008, says that the new application is quicker, safer, less costly and lighter than alternative systems on the market. He highlighted that the potential market for Brick Plus was significant, with hundreds of thousands of older properties in the UK not able to install cavity wall insulation due to not having cavity walls.

"Brick Plus is the only system of its type available that can match all brick types and colours, including those that have been out of production for decades. Brick Plus provides a solution to the dilemma of having to finish externally insulated brick buildings with a render coat," said Waring, who also believes that his product will be an ideal product for use under the Green Deal, a UK Government initiative due to come into effect in the autumn of 2012 that is geared to making homes more efficient.