Insulation industry news from Global Insulation

Ireland: Kingspan has reported a sales fall of 5% year-on-year in its 2020 nine-month trading update, to Euro3.27bn from Euro3.44bn in the first nine months of 2019. Its sales of insulation boards fell by 14% and by 5% year-on-year in the third quarter of 2020.

The group said that insulation board sales “performed well” in Ireland, the UK and parts of Continental Europe in the third quarter of 2020, while volumes “improved, with raw material-related price deflation in the earlier part of the period partially offsetting this” in total sales. The Asia Pacific region “consolidated the progress seen in the first half,” while activity in the US was “positive through the third quarter.” Only the Middle East proved “a more challenging environment.”

The company said, “Overall, our end markets are in reasonable shape bearing in mind the uncertain and evolving backdrop. In this environment it is difficult to see too far ahead and trading patterns can evolve quickly. Our raw material costs are on the rise at present and, with the customary lag anticipated, a challenging recovery effort is underway. Trading in the fourth quarter to date has been strong, helped to an extent by accelerated demand in the expectation of inflation-led price increases in the coming months. Whilst conscious that much of the seasonally variable fourth quarter is still at play, in what is an untypical year, we expect to deliver a full year trading profit marginally ahead of 2019.”

Ireland: Kingspan has written to the Building Research Establishment (BRE) to withdraw fire test reports on its rigid thermoset phenolic insulation Kooltherm K15. The Irish Times newspaper has reported that, speaking at the inquiry into the Grenfell tower fire in London, a representative of the company admitted that the fire test reports on Kooltherm K15 may not reflect the actual product. This was due to possible compositional changes arising from “process shortcomings” that “fell short of the high standards which Kingspan sets itself." In 2007 it failed a fire test in which it was reportedly tested with a cladding system that also failed subsequent testing with another company’s insulation.

The Grenfell inquiry has asked Kingspan why it had not previously withdrawn the Kooltherm K15 fire test reports with the BRE. A distributor supplied the insulation to contractors for use in the refurbishment of Grenfell in 2012 – 2016.

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: Italy-based Hennecke-OMS says that it has received an order for a 45m/min lamination line for Ballytherm UK’s upcoming 1.2Mm²/yr Herefordshire polyisocyanurate (PIR) and polyurethane (PUR) insulation plant. The plant consists of a continuous foaming line including a 38m double belt conveyor and foaming, mixing and distribution units for the PUR foam inside the two flexible facings, a cross cutting unit, a panel cooling section and stacking and packing equipment. The company said, “The entire plant in a fully automatic cycle and is controlled by a series of electric control panels based on an industrial Siemens S7 PLC and with relevant interface operator panels.”

The supplier added, “The choice of Hennecke-OMS as the supplier for Ballytherm’s second plant confirms the excellent co-operation between supplier and customer, as well as Hennecke-OMS’ leading position in continuous plant technology.”

Installation will commence in October 2020 and Ballytherm plans to commission the line in early 2021. It has future potential for expansion to 70m/min lamination capacity, according to the supplier.

UK: A public inquiry has heard that Grenfell Tower cladding subcontractor Harley Facades and staff of Saint-Gobain subsidiary Celotex discussed the use of Celotex’s RS5000 polyisocyanurate foam (PIR) insulation as a “case study” to determine “the U-value achieved by the product.” The insulation product was also sold to the contractor at a 48% discount. Ben Bailey, project manager at Harley Facades, denied that the price had anything to do with the final choice of product for the project. However, other documents showed that Harley Facades staff also enquired about the price of a Kingspan K15 insulation product.

In January 2020 Stephanie Barwise Q.C. told the inquiry that Celotex treated the 67m tall building as a "flagship" project for its RS5000 insulation product.

The Grenfell Tower fire in June 2017 killed 72 people. The inquiry continues.

UK: Knauf Insulation has launched a new product in its Earthwool Soffit Linerboard range, intended for use in car parks, stadiums and commercial units. Rock mineral wool product manager Luke Davies said, “Specifications for non-combustible soffit insulation are likely to increase as building regulations evolve further and soffit applications become a focus for fire safety. We’ve improved Earthwool Soffit Linerboard to give customers the best possible solution to respond to this demand.”

The product uses tube washers instead of all-steel for ease of installation and each board has greater rigidity than previous products to reduce susceptibility to thermal bridging. Knauf Insulation says that its ECOSE Technology bio-based binder makes Earthwool Soffit Linerboard soft, durable, easy to handle and low in dust and volatile organic compounds (VOCs).

UK: Knauf Insulation has developed a tool that uses machine learning techniques to measure the energy performance of individual homes. The method can generate an assessment of fabric performance of a residential building within three months, according to BusinessGreen. The product is intended to provide evidence to support the building fabric component of a building's energy performance certificate (EPC) rating, as opposed to Standard Assessment Procedure (SAP) calculations. Such evidence could be used to support return on investment calculations for energy efficiency retrofit programmes.

UK: Recticel Insulation says that its production plant in Stoke-on-Trent is ‘Covid-19 Secure Certified.’ This confirmation is defined by the UK government and is designed to enhance safety and provide our staff with confidence in their workplace. Measures taken to meet this standard include conducting a risk assessment, implementing cleaning, handwashing and hygiene procedures in line with national guidance, encouraging remote working, maintaining social distancing in the workplace and minimising transmission risks where distancing is not possible.

The company also contracted an independent business risk management company to carry out an independent validation audit of its COVID-19 secure risk assessment. The insulation producer says it will, “continue to monitor the government’s advice, and will update measures as required to ensure safety is maintained for staff and visitors alike.”

UK: The Energy Efficiency Infrastructure Group (EEIG), a coalition of businesses and charities has published a report into the creation of jobs post-coronavirus lockdown, in which it concluded that 40,000 insulation jobs lie in modernising the UK’s energy-inefficient housing stock before mid-2022, and a further 110,000 jobs before 2030. BBC News has reported that each job will cost Euro65,800 to create, compared to Euro279,000 per job in road repairs, and will be evenly spread across all UK regions. Besides generating wealth, the EEIG says that the work will cut pollution, improve health and cut energy bills by Euro558/yr per household. EEIG chair Sarah Kostense-Winterton said, "Our country is in dire need of a green stimulus recovery. There could be no better time to future-proof our homes while providing buoyancy to our drained economy."

UK: SIG’s group revenue fell by 37% year-on-year to Euro154m during March and April 2020 due to disruption caused by the coronavirus outbreak. In its annual report for 2019 the insulation producer said that trading had returned to pre Covid-19 levels in most of its companies as it adapted social distancing measures. It also reported cash reserves of around Euro150m following the sale of its Air Handling division.

In 2019 the group‘s statutory revenue fell by 13% year-on-year to Euro2.4bn in 2019 from Euro2.7bn in 2018. It made an operating loss of Euro97m. This was blamed on loss of market share in the UK and Germany. In response the company’s board says it taken ‘decisive’ action including appointing a new leadership team and developing a new customer-centric strategy that reprioritises sales.

UK: SIG has appointed Ian Ashton as permanent group financial officer with effect from July 2020. He succeeds Kath Kearney‐Croft, who assumed the role of Interim chief financial officer (CFO) in late February 2020.

Ashton joins SIG from Low & Bonar, where he has served as group financial officer. Prior to that, he was CFO of Labviva, a US‐based technology company. He worked for 20 years at Smith & Nephew until late 2017, undertaking various financial roles of increasing seniority in the UK, the US and Asia. His last role was CFO, Global Operations, and prior to that Ashton served as CFO of their Advanced Surgical Devices Division. He is a qualified chartered accountant and began his career at Ernst & Young.

The building materials supplier has announced the appointment of Simon King as a non‐executive director. Recently King served on the Travis Perkins executive board and held the position of chief operating officer of Wickes. Prior to that he held various operational roles at Walmart, Savola Group and Tesco.