Knauf expands its thermal insulation range with new molded EPS solutions

Certified by ACERMI and with verified FDES, the new molded ranges presented by Knauf all claim particular and differentiating advantages on the market, both in terms of installation ergonomics and thermal performance.

As with all Knauf EPS, clean offcuts from construction sites are recyclable via Knauf Circular®, the Knauf service that allows their revaluation into new products.

A closer look at the technology of "molded" EPS, an even more "high-tech" form of EPS

There are two types of EPS products: cut and molded. For the former, a master block of EPS is cut in the factory using a hot wire, after stabilization, to obtain insulating panels with or without a specific shape. This is the most common EPS technology at Knauf.

For the second, the expansion of material is carried out in custom molds to obtain the final part; a more expensive but highly qualitative process in terms of the complexity of shape or die-making of the insulators obtained.

The 3 new products presented here are manufactured in France by Knauf Industries, a division of Knauf specializing in the production of molded EPS technical parts for various sectors of activity.

Molded EPS infill blocks: 3 new products for beam and block floors that complement an already established Knauf range

This new range of flooring solutions includes molded EPS formwork and insulation options for truss and prestressed beams. The range comprises COFFRABOX, HOURDIBOX, and TOPBOX. Their molded interlocking system makes installation even faster and more ergonomic. The insulated versions also allow for optimized thermal bridge management.

COFFRABOX PT (truss beams) and COFFRABOX PP (prestressed beams) formwork infill blocks are available in 1200 x 550 mm dimensions. Thanks to the lightweight EPS (expanded polystyrene), they reduce the floor's self-weight, while allowing for better structural design in relation to permissible live loads. They share the common features of lightness and ease of handling and cutting, while providing the essential strength for floor formwork; true guarantees of structural reliability and safety for professionals on site. Both models are available in M1 and M4 versions, with a formwork height of 120 mm for COFFRABOX PT and two formwork heights (120 and 150 mm) for COFFRABOX PP. COFFRABOX PT has a 600 mm installation center-to-center spacing for compatibility with all truss beams with a 600 mm center-to-center spacing, with a 40 or 45 mm flange. COFFRABOX PP, on the other hand, has certified compatibility with all prestressed beams (100, 103, 105 and 110 mm for center-to-center spacings of 600, 603, 605 and 610 mm) specified in their NF547 certificate.

The HOURDIBOX PT NEO 600 and HOURDIBOX PP NEO insulating infill blocks are lightweight and easy to handle and install, thanks to their integrated markings (designed for easy on-site cutting) and their tongue-and-groove joints for joining the ends. The former are used for thermal insulation of floors with T40 and T45 truss beams. The latter, with their markings facilitating staggered span installation or installation on twin beams and their two possible formwork heights (120 and 150 mm), are intended for thermal insulation of floors on prestressed beams.

All are available in M4 versions (recessed base for insulation over inaccessible crawl spaces in residential buildings of 1^re and 2th^e families) or M1 (flat base under decorative face for insulation on inaccessible crawl spaces in public access buildings, garage ceilings, basements and intermediate floors of residential buildings of 1^re and 2th^e families). In terms of thermal performance, HOURDIBOX PT NEO 600 displays Up values ​​between 0,14 and 0,33 and HOURDIBOX PP NEO, Up values ​​from 0,14 to 0,36.

Knauf also offers clip-on risers compatible with HOURDIBOX PT NEO (M1 and M4 joists): the TOPBOX SMART PT NEO, and with HOURDIBOX PP NEO: the TOPBOX SMART PP NEO. The former, after being cut according to the embossed markings, ingeniously transform into correctors for transverse and longitudinal thermal bridges. Both allow for adjusting the formwork height, limiting the concrete load on the floors, reducing installation time, and addressing linear thermal bridges in residential floors. Their optimized packaging in compact bundles ensures easy handling on site. Similarly, their installation using self-locking clips is easy and secure, as is their marking system, which allows for quick identification of anchor points. Finally, another advantage is that these two products eliminate the need for fir tree anchors during installation.

DECOBOX 36: a 2-in-1 solution (insulation/decoration) for renovating the undersides of floors in detached houses

DECOBOX 36 is a molded EPS panel designed for thermal insulation on the underside of slabs. Its manufacture uses raw materials certified by the LNE (National Laboratory of Metrology and Testing), as required by the Interior Insulation Guide. Compatible with all substrates (concrete, terracotta, or wood floors), it is lightweight, easy to cut, and easy to handle.

DECOBOX 36 is available in a 1200 x 600 mm format and, optionally, two thicknesses: 112 and 182 mm, for respective thermal resistances of 3,05 and 5,00 m².K/W, for a thermal conductivity of 0,037 W/(mK). A particular advantage of the molded technology is its tongue-and-groove edges on 4 sides, guaranteeing a perfect seal at the junction between panels and limiting thermal bridges.

Designed to be left exposed on ceilings, DECOBOX 36 stands out for its understated aesthetics, as well as for its speed of implementation (fixing by face under wooden supports or by gluing under masonry supports).

Intended for the renovation of insulation in ground floors (basements, crawl spaces, garages, etc.) of residential buildings.^re and 2th^e For families, DECOBOX 36 covers a very common and well-known insulation application for homeowners, an opportunity for building material suppliers and local stockists, both for their professional clientele and experienced individuals. It should be noted that this Acermi-certified solution is eligible for the main government renovation grants.

A new range of molded EPS insulation for External Thermal Insulation Composite Systems (ETICS-EPS)

For this key application in both new construction and renovation, Knauf is strengthening its External Thermal Insulation Composite Systems (ETICS-EPS) solutions with the integration of a comprehensive molded EPS range comprising three references. These innovations cover applications in residential buildings of all types.^re the 3^e families, ERP of the 1^er Specialized group and public access buildings, office buildings, and industrial buildings. Naturally, they have verified Environmental and Health Declarations (FDES). Like the molded ranges mentioned previously, these new Knauf solutions guarantee ease of installation thanks to markings on both sides and increased durability of the facade systems. Knauf has indeed treated these three products by shot blasting on each side, giving them a surface finish that optimizes the adhesion of the base coat and the mortar-adhesive pads to the panel.

Their applications cover both new and old substrates, with or without adhesion problems. They offer great flexibility in their installation, which can be carried out either by gluing or by anchoring with dowels.

Indeed, the panel size, the markings for the adhesive dots on the back, and the markings for the fixing plugs on the front greatly simplify installation. Knauf has also equipped them with corner markings on the front for easier identification of panel boundaries, as well as other guides for straight vertical and horizontal cuts. They feature markings at 200 mm intervals to facilitate cutting around specific points (such as corner joints or window corners). On the back, while grooves centered on the adhesive dots reinforce the bond, they are also equipped with various guides: some identify the location and boundaries of each adhesive dot, others indicate the adhesive application for bead bonding, and still others define the boundaries for full-surface bonding.

While ETIXX 37 panels are made of molded white EPS, ETIXX 31 panels are characterized by their high-performance gray EPS. ETIXXBOX panels (also made of high-performance molded gray EPS) are distinguished by their integrated anti-radiation front face made of molded white EPS. ETIXX 37 panels, with straight edges, are available in a 1200 x 600 mm format with thicknesses ranging from 40 to 250 mm, depending on the required thermal performance (from 1,05 to 6,65 m).².K/W), for a thermal conductivity of 0,038 W/(mK). As for the ETIXX 31 panels, with straight edges, identical formats and thicknesses, they exhibit higher thermal performance, ranging from 1,25 to 8,05 m².K/W for a thermal conductivity of 0,031 W/(mK). Finally, of similar sizes and thicknesses, the ETIXXBOX panels, with straight edges, boast thermal performance ranging from 1,20 to 8,00 m².K/W.