Insulation industry news from Global Insulation

UK: Denmark-based Rockwool has acquired external thermal insulation composite systems producer Wetherby Building Systems. Reuters has reported that the newly acquired company will now operate as part of Rockwool Wall Systems, under the name Wetherby Wall Systems. The integration parallels that of previous Rockwool acquisitions in other markets, like Fast Wall Systems in Poland and Heck Wall Systems in Germany.

Rockwool CEO Jes Munk Hansen said “The share of stone wool insulation in the Wetherby business has been growing steadily, and we will be completing this transition to a fully stone wool-based portfolio, as we have done in other markets in the past.” He added that this will advance Rockwool’s transformation of the construction sector towards non-combustible façades.

Wetherby Building Systems managing director Bob Deane said “There is a long-standing relationship between Wetherby and Rockwool, and the match is strong on all significant drivers.”

North America: Knauf Insulation has launched its new Knauf Performance+ range of glass wool insulation for heating, ventilation and air conditioning applications. The launch of the range, which is asthma and allergy friendly and formaldehyde-free, coincided with the start of Asthma and Allergy Awareness Month on 1 May 2024.

Knauf Insulation said “In a world where indoor air is two-to-five times more polluted than outdoor air, improving indoor air quality is critical.” Senior vice president sales, marketing and innovation Nathan Walker added “By the end of 2024, Knauf commits to eliminating formaldehyde from all its remaining products. This move sets a new standard in the production of high-performing building materials.”

US: Owens Corning has published its 2023 Sustainability Report, highlighting its advances in sustainability in the past year. These included a 59% share of revenues from reduced-CO₂ products, with a 25% share of revenues from 14 products certified as produced with 100% renewable electricity. Scope 1 and 2 emissions fell by 28% from 2018 levels, in line with the group’s 50% 2030 reduction target. It launched a pilot bitumen felt shingle recycling programme, aimed at recycling 2Mt/yr of shingles in the US by 2030. Further, Owens Corning reduced its generation of landfill waste by 14% from 2018 levels, and launched a Circular Economy Recycling Technology Innovation Laboratory in Granville, Ohio. In 2023, the group’s incident rate was 81% below the industry average, and it remains on track to meet its 2030 inclusion and diversity goals.

Senior vice president and chief sustainability officer David Rabuano said “Our 2030 sustainability goals are growing ever closer, and we believe that the targets we have set for ourselves are well within our reach. This confidence is the result of our employees’ unparalleled engagement and enthusiasm for our mission coupled with our investments in the innovation required to execute new solutions.”

Chair and CEO Brian Chambers said “Owens Corning demonstrated outstanding financial and sustainability results in 2023, showcasing the power of our company’s mission to build a sustainable future through material innovation. This report reflects the global scope of our people and our products and the many ways they work to make the world a better place.”

Owens Corning recorded net sales of US$9.68bn in 2023, down by 1% from US$9.76bn in 2022, while its adjusted earnings before interest and taxation, depreciation and amortisation (EBITDA) grew by 2% to US$2.31bn.

South Korea: The Ministry of Land, Infrastructure and Transport has suspended the Korea Foamed Plastic Industry Cooperative’s standard for expanded polystyrene (EPS) insulating sandwich panels. The standard had been certified by the Korea Institute of Civil Engineering and Building Technology. Maeil Business Newspaper has reported that the suspension is part of a regulatory revision in the interest of fire safety. The value of the South Korean EPS sandwich panel industry is US$1.37bn/yr.

The Korea Foamed Plastic Industry Cooperative said “With a severe shortage of certification agencies, it takes over a year to obtain certification. This is tantamount to telling small businesses to shut down.”

UK: Recticel says that new requirements following the UK’s exit from the EU have created estimated extra one-time costs of Euro464,000. Local press has reported that UK-based laboratory testing is estimated to cost Euro325,000 across eight products, while new fire tests for the same products will add a further Euro130,000.

Senior technical manager Simon Blackham said “It’s the same standards, to the same test method, the same everything - and it would have to be paid for, ultimately, by the customer.”

EU: The European Union (EU) is holding a consultation over possible changes to the limit on the use of hexabromocyclododecane, a brominated flame retardant (BFR) in consumer products. This includes expanded polystyrene (EPS) and extruded polystyrene (XPS) insulation. The consultation will run until 26 December 2023.

UK: Testing provider the Building Research Establishment (BRE) has informed Kingspan and Saint-Gobain subsidiary Celotex of its decision to break off its relationship with them due to perceived 'reputational risk.' Insulation supplied by Kingspan (Kooltherm K15 phenolic insulation) and Celotex (RS5000 polyisocyanurate insulation) was present in Grenfell Tower, London, when it burned down in June 2017. 72 people died in the fire. Both producers deny having contributed to the disaster. The Grenfell Tower Inquiry investigated the relationship between each company and the BRE during its inquest into the fire. A final report is currently in preparation following the conclusion of Phase 2 hearings in 2022.

The Grenfell Tower Inquiry heard that Kingspan had marketed its Kooltherm K15 panels for general use in high rise construction, relying on tests carried out at a BRE facility with a system involving external fibre cement panels, of a sort not used in Grenfell Tower. Subsequent tests of the product, carried out by Kingspan, included one which resulted in a 'raging inferno.' Meanwhile, Celotex added fire-resistant board to a rig used in testing in 2014, reportedly to increase its products' chances of passing.

Inside Housing News has reported that BRE said “BRE no longer accepts any new work on behalf of Kingspan or Celotex following evidence heard during the course of this inquiry.”

Kingspan clarified that "There is no product performance basis for [BRE's] decision,” adding that its panels had shown zero non-conformities in their most recent audit in December 2022. It said “Independently of BRE, whose certification is regionally focused on the UK and Ireland, Kingspan is certified by the globally recognised insurer testing regime FM Approvals, which carries out annual factory surveillance audits to verify our products comply with its global approval standards."

UK: Graffiti reading 'Grenfell' has appeared on walls and gates at the entrance to Ulster Rugby's Kingspan Stadium in Belfast in protest against Kingpan's indirect involvement in the Grenfell Tower fire in London on the night of 13 - 14 June 2017. Some insulation produced by Kingspan was present in the building envelope of the tower at that time.

The Belfast Telegraph newspaper has reported that local groups Act Now and Uplift in the Republic, in partnership with Britain-based 38 Degrees, previously erected a billboard in view of the Kingspan Stadium, expressing solidarity with victims of the Grenfell Tower disaster, in March 2022.

Germany: Knauf Insulation plans to increase the production capacity of its Bernburg, Saxony-Anhalt, glasswool insulation plant. The project will also modernise all of the plant’s equipment. The upgraded plant is scheduled for commissioning in 2023.

Central Europe regional managing director Michael Huesmann said "The market hunger for insulating materials necessitates the use all production resources as efficiently as possible. Operational safety has gained additional importance as we maximise capacity utilisation – a process which will likely continue in the future."

UK: Kingspan has recalled all uninstalled Kooltherm K15 phenolic insulation from UK customers pursuant to an order by the government’s Office for Product Safety and Standards. The company estimates the value of the affected stock to be Euro180,000. InsideHousing News has reported that the company hopes to resume its sale of Kooltherm K15 insulation following its suspension on 23 December 2021.

Kingspan says that recent tests have shown that Kooltherm K15 insulation is eligible for a C rating under European safety standards, which would enable it to be fitted in buildings of above 18m in heigth.