Knauf molded EPS insulation for floors and facades

A molded EPS product range adapted to construction systems

The new solutions developed by Knauf target several key building applications:

• joist floors with EPS infill blocks
• thermal insulation underside of floors
• systemsexternal thermal insulation (ETI) undercoat

These products are certified ACERMI and have FDES verified, thus meeting the requirements of the RE2020 in terms of energy performance and life cycle analysis.

Clean offcuts from the implementation process can be recycled via the service Knauf Circular®contributing to the management of construction site waste.

"The new ranges are distinguished by their ease of installation and thermal performance."

In practice, these solutions are integrated from the design phase by thermal design offices to optimize the building envelope performance.

Molded EPS technology and manufacturing precision

Molded EPS differs from cut EPS in its manufacturing process. The material is expanded directly in molds, allowing for the creation of parts with complex and precise shapes.

This technology offers several advantages:

• dimensional accuracy for better adjustment in progress
• integration of interlocking systems
• improvement of the treatment of thermal bridges

On the other hand, the process remains more expensive than conventional cutting, which may influence the choice during the specification phase depending on budgetary constraints.

EPS infill blocks for joist floors

Knauf completes its range with formwork and insulation infill blocks for floors on lattice and prestressed beams.

COFFRABOX, HOURDIBOX and TOPBOX

The proposed solutions combine structural and thermal functions:

• COFFRABOX PT and PP Lightweight formwork blocks facilitating the pouring of floors
• HOURDIBOX PT NEO 600 and PP NEO : insulating joists with markings to simplify installation
• TOPBOX SMART : clip-on accessories to limit thermal bridging

The advertised thermal performance varies depending on the configuration:

• Up 0,14 to 0,36 for insulating joists

Application example

In a multi-family dwelling, these systems allow for the creation of an intermediate floor while optimizing both:

• la mechanical resistance
• the continuity of thermal insulation

Implementation is generally carried out by structural engineering companies, with performance validation by a structural engineering firm.

Underside insulation with DECOBOX 36 panel

The panel DECOBOX 36 is intended for thermal insulation of the undersides of slabs, particularly in basements, crawl spaces or garages.

Its technical specifications include:

• format 1200 x 600 mm
• thicknesses of 112 and 182 mm
• thermal resistances of 3,05 to 5,00 m².K/W
• thermal conductivity of 0,037 W / (mK)

The tongue-and-groove edges ensure continuous insulation and limit the thermal losses.

"The product can be left exposed on the ceiling for quick installation."

This type of solution complies with the recommendations of the Guide to interior insulation and eligible for energy renovation grants.

Implementation

• mechanical fixing to a wooden support
• bonding to masonry support

Its lightness facilitates intervention by teams on site, particularly in renovation.

ETICS molded EPS for external thermal insulation

Knauf is also developing a new range for systems ETICS (External Thermal Insulation Composite System).

These panels are suitable:

• to residential buildings (1st to 3rd families)
• to public access buildings and commercial buildings
• to industrial works

Their design incorporates:

• markings for positioning the adhesive pads and dowels
• grooves to improve the adhesion of the coatings
• surface treatment by shot blasting

These elements facilitate compliance with the implementation rules defined in the Technical opinions (ATec) and Technical application documents (DTA).

ETIXX 37, ETIXX 31 and ETIXXBOX

Three key elements structure this range:

• ETIXX 37 : Molded white EPS
• ETIXX 31 High-performance grey EPS
• ETIXXBOX EPS with anti-radiation face

Thermal performance varies depending on the product:

• ETIXX 37: up to 6,65 m².K/W
• ETIXX 31: up to 8,05 m².K/W
• ETIXXBOX: up to 8,00 m².K/W

These solutions make it possible to adapt the insulation to the requirements of each project, whether new construction or renovation.

Integrated EPS solutions addressing regulatory and construction site challenges

The evolution of molded EPS solutions illustrates a search for balance between thermal performance, ease of installation and management of environmental impacts.

However, certain operational limitations must be taken into account:

• sensitivity of the PSE to mechanical constraints during storage
• need to protect the panels before plastering the facade
• dependency on rigorous implementation to guarantee performance

These products are part of a comprehensive approach led by the project management teams, in line with the requirements of RE2020 and energy performance objectives.

The industrialization of molded EPS thus confirms its role in optimizing insulation systems, particularly for floors and facades, where precision and speed of execution become determining criteria.