Grand Designs Container

WALLTITE® spray foam insulation has been used to provide wall and roof insulation to a house built from shipping containers as featured on TV’s Grand Designs. Described by presenter Kevin McCloud as the “right solution”, WALLTITE® spray foam was the only practical way to provide an airtight insulation envelope to Architect Patrick Bradley’s home and was used to insulate both the walls and roof areas. WALLTITE® spray foam is a high density spray applied insulation installed by trained and accredited contractors.

The foam insulation followed the contours of the metal containers that formed the basis of the construction. Gary applied 125mm of WALLTITE® spray foam to achieve airtight U-Value of 0.20 W/m2k. Patrick Bradley’s house has since won 2 RIBA awards (Royal Institute of British Architects).

BASF WALLTITE® is BBA certified and is available in both spray and injection formulations by Bright Home Renewables Insulation.

Stone Barn Upgrade

The development consist of a 19th century stone barn combined with two new build properties. The walls of the existing property consist of solid stone needing significant insulation improvement to bring to standard. WALLTITE® high density spray foam insulation was applied to the interior surface of the walls to achieve both the U-value and airtightness requirements. The new building consist of a 200mm clear cavity between two leaves of block. WALLTITE® injection grade foam was installed to achieve and airtight homogeneous layer with a U-value of 0.12 W/m2k. The final airtightness test recorded a result of 1 m3/m2/hr.@ 50 Pa.

Grand Designs Home

Michael Howe of 2020 Architects was recently featured on Kevin McCloud’s popular Grand Designs programme. Michael and his family have now completed their impressive home overlooking the Portrush peninsula with views of the Atlantic Ocean.

Michael decided on straw bales for his wall insulation and Foam-lok open cell spray foam insulation for the challenging roof shapes.

Channel 4’s Restoration Man

Converting a solid stone disused chapel into a warm and comfortable family home needed some heavy duty insulation – fortunately WALLTITE®  was able to cope with all the idiosyncrasies of the project, which has been featured on Channel 4’s Restoration Man. Owner Colin Clewes embarked on this ambitious conversion in order to create a dream home for his family. Taking a disused, unheated shell of building as a starting point, Colin, doing much of the work himself, was firmly in charge of the building process and insisted on the use of WALLTITE® spray foam insulation.

WALLTITE®is applied as a liquid that expands on contact to form a highly insulating rigid foam. This method of application means that it can cope with any substrate – no matter how uneven – and can easily be applied in restricted and difficult spaces. The external walls posed a particular challenge in this case. A Yorkshire stone facade is lined with brick and lime mortar – an inherently porous structure. WALLTITE® is resistant to moisture but the project architect, wanting complete assurance of water resistance, asked for a drainage mat to be fixed to the wall prior to application of WALLTITE®. Plasterboard was then used as an internal finish and base for the interior decoration.

The application of WALLTITE® was one of the first stages of the restoration project which includes a radical redesign of the interior space. A mezzanine floor built into the centre of the main space creates the master bedroom, while a modern family kitchen and open plan living area breathe vibrant new life into the building.

Condensation-busting insulation for mobile hotels

WALLTITE® spray insulation is being used on the construction of an innovative system of temporary hotel accommodation. Elements Europe in conjunction with Snoozebox are taking 40ft containers and turning them into high end accommodation. These can be moved and re-erected at events throughout Europe. WALLTITE® is applied directly to the internal metal surface prior to plasterboarding resulting in an airtight U-value of 0.20 W/m2k.

Cavity Wall Refurb

The existing wall 160mm wall cavity needed insulating in order to reduce the U-value in line with more recent regulation changes. The wall structure also had very few wall ties tying the inner block leaf to the outer brick skin. A decision was made to inject WALLTITE® cavity wall insulation to provide an airtight insulation layer and stabilise the cavity. Additional bracing was not required and the resulting U-value amounted to 0.15 W/m2k.

Fire Station – Refurb

The fire stations wall build up consists of a brick outer leaf with a 75mm cavity. BASF WALLTITE® proved to be the insulating material of choice as part of its Green Plan initiative and was installed by a registered Foam Master contractor. This has provided a high performance cavity wall insulation in terms of reducing heat loss by conduction and air infiltration / exfiltration.

Curves and Spirals

Open cell spray foam insulation was successfully used in the construction of the renowned holistic architect Michael Rice’s new Timber Framed home. As most of us spend the majority of our lives indoors, the implications of how we live, eat, sleep in these spaces should be seriously considered. Michael uses natural geometries, shapes, forms and growth patterns to create perfect living spaces.

The choice of building materials is also an important element in any harmonious design but particularly in the construction of a unique new build such as this with many construction challenges and very few straight lines. Selecting open cell foam as the insulation of choice in this house was the right option for Michael as he could be guaranteed that it would form into every shape set out. Michael used an site fabricated 150mm stud for his external walls which was filled with open cell spray. His newly insulted roof consisted of sweeping truss work which was again hand made on site. Creating a warm comfortable environment in this large house was essential and Michael was extremely satisfied with the final installation of the spray material and continues to recommend the insulation to his clients.

Zero Carbon House

The breathable wall and roof build ups exceed passive standard in this house by utilising open cell spray foam insulation to a thickness of 400mm in a twin stud timber frame construction designed to reduce the effects of thermal bridging, giving excellent U-Values without compromising on wall or roof breathability. The external 140mm timber frame stud was finished on the outside with a rendered woodfibre board. Using an additional 89mm internal stud in conjunction with an internal cavity allowed for greater insulation thickness.

Open cell spray foam was applied to the full stud depth and was then shaved flush with the adjacent timbers to allow for fixing of the internal lining. By using this arrangement Patrick Daly managed to achieve a Q50 airtightness result of 0.37. Patrick has succeeded in designing and constructing a 250m2 house which has been rated ‘Energy Positive’ to the tune of 27kWh/m2/ annum meaning his house will generate excess energy.

Patrick sums up his achievement with these words:

“Its only 5 degrees outside but sun is shining and we are producing 4500 kW of electricity and 3000 kW of hot water…… and it’s a cosy 23 degrees inside. Buildings don’t need to gobble up tones of energy! Design and Build Positive!”

The Coldest Journey

In 2012  Sir Ranulph Fiennes and his team attempt a 4,000km expedition across the Antarctic in the winter: The Coldest Journey. It is the first time the feat has been attempted and the living and working quarters for the expedition members have been treated with WALLTITE® spray foam insulation.

The specially developed Cabooses (there are two) will be towed across the ice by tractors. With temperatures potentially reaching close to -90oc keeping the team warm is a top priority.

The Cabooses are constructed from adapted shipping containers. These are steel and the walls are of corrugated design. WALLTITE® has been used as an initial insulation layer, sprayed directly onto the steel shell where it fills the corrugations, providing a flat surface for further insulation layers and partitioning to be fixed as the interior layout is designed.

The conversion of shipping containers into living accommodation is increasingly common, and providing adequate insulation without causing condensation is always an immediate challenge. WALLTITE®sprayed directly onto the internal surface removes this condensation problem entirely and provides consistent and effective insulation across the area.

WALLTITE® is a closed cell polyurethane insulation spray foam, providing a highly versatile and effective insulation system suitable for roofs, walls or floors.

Photo credit: Harriet Wooltorton

Passivhaus project chooses WALLTITE® for airtight insulation

WALLTITE® spray foam insulation has been used in the roof of Dorset’s first Passivhaus dwelling to achieve the air-tight insulation required to meet the demanding standards required for Passivhaus certification.

The impressive five bedroom house in Poole is making maximum use of all interior space, with the roof space being used to accommodate an office and a bedroom with en-suite facilities.

Thermal insulation was obviously critical. The roof achieves its required U-value using a combination of PIR board above and a layer of WALLTITE® between the rafters.

WALLTITE® is a spray applied polyurethane foam applied in a continuous spray that is fast to apply and quick to cure, resulting in an airtight building envelope.

The property is a privately owned residence where the owner had made the decision to build to Passivhaus standards as a cost-effective way to achieve near-zero running costs for the house.

The WALLTITE® used in this project was applied to the 160m2 area of the roof in just two days.

Northcroft construction consultants acted as Project Manager, Employers Agent and Quantity Surveyors on the project. This was the organisation’s first experience of specifying the WALLTITE® product, but is unlikely to be their last. “We were very impressed by the speed of the installation: WALLTITE® was the best solution to combine thermal insulation with airtightness, particularly in hard to reach locations where traditional techniques would be unlikely to achieve the required standard” summarised Project Manager Jonathan Dronsfield.

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