Building & Construction Brochure

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ROCKSHELL WALL SYSTEM速

Building and construction The RockShell wall system is an innovative, low energy solution for the construction of load bearing walls in low-rise buildings.

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Create and protect

Let’s start a brand new tradition today The race for energy-efficient solutions has begun

The race against time The UK has a big challenge. The Climate Change Act of 2008 set the target to reduce greenhouse gas emissions by 80% from 1990 levels by 2050.

One of the key methods of achieving this goal is to improve the energy efficiency of our buildings. In Europe and the US, our buildings account for up to 40% of our total energy consumption. By improving the efficiency of our buildings through better materials and design, there is huge potential to reduce CO2 output.

A poorly insulated house can use up to 10 times as much energy for heating as a well-insulated house.

Y = The images within this brochure are taken from a European installation. They are shown for illustration purposes only and are indicative of the methods used during a RockShell construction. The images are not intended to illustrate UK best practice and personnel shown do not comply with UK health and safety regulations.

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Technology is currently available to build energy efficiently and reduce the energy usage to a fraction of the current average consumption. The government’s drive towards energy efficient and ultimately zero carbon homes, is making these technologies more of a priority. This was a factor behind the development of the RockShell wall system.

At Rockwool we identified a need in the marketplace for an alternative construction method. A wall system that allowed the use of traditional finishes combined with ease of installation and high energy efficiency.

From this idea RockShell was born.

Insulation is a key climate technology Heating and cooling are the main sources of energy consumption in buildings. Together they account for more than two thirds of a building’s energy usage. At present most of this energy is wasted due to inadequate insulation.

During its lifetime, a typical Rockwool insulation product will save 100 times the amount of energy and CO2 emissions than it takes to produce, distribute and recycle it. This makes Rockwool insulation one of the most effective solutions that can be utilised to help reduce climate change.

Low energy houses do not need to distinguish themselves from traditional buildings in terms of appearance, but they do require intelligent design.

Incorporating high performing insulation as an integral part of the building structure is one of the most important design elements to enable low energy buildings.

As the external wall is typically the largest �element� in a building, it offers the potential for the largest energy loss. As authorities impose ever stricter requirements concerning energy losses and reduced CO2 emissions, the race for energy efficient solutions has begun. To meet these needs the construction industry must address the challenges faced in relation to building design, structural changes and energy efficiency, whilst retaining economic advantage.

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Tomorrow’s energy efficiency delivered today

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Minimal energy loss with optimal construction methods RockShell is an innovative system for constructing the load bearing walls of low-rise buildings. The RockShell wall system is a patented modular system, that meets future energy efficiency requirements, today.

The RockShell wall system combines the requirements for sustainable lightweight constructions with optimal energy performance, efficient installation processes, technical support and end user benefits. In other words: The RockShell wall system is the ideal all-in-one construction system.

The RockShell solution is delivered on-site to fit the specific house design. As no adjustments or modifications are necessary on-site, the time spent on modifications and material waste is minimal. If adjustments are needed, the system can be modified using hand tools.

Installed cost comparison: The RockShell wall system and a standard timber solution.

Minimising building costs and installation time

Standard timber solution Rockshell wall system

The RockShell system has been designed to interface with standard building components. Allowing flexibility of design for door, window, roof and exterior finishes.

The modular design also decreases the risk of making mistakes on the building site. For all interfaces between the RockShell wall system and other building solutions a suggested detail with minimised thermal bridges has been created. Due to the modularity of the system, very few adjustments are needed between different house designs. As a result, details could be used for different house designs.

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Design phase

Planning

material costs

Installation costs

facade

Costs associated with waste and disposal are not included in the table. In general, however, waste and disposal costs are considerably greater with a traditional solution than with a RockShell solution. The RockShell wall system is supplied as a complete, customised system, delivered for each particular building. This results in only minimal adaptation and waste in the construction process itself.

9400 -shaped steel profiles

2700

5400

OSB boards

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600

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Faster understanding – improved results Y

The system comprises very few building components, which are easily assembled with just a power drill on-site. RockShell is quick and easy for installers to learn and understand. Actual installation is quick and simple versus other building solutions, meaning improved build times and less mistakes on-site.

RockShell wool elements The RockShell wall system is a unique combination of steel -profiles, dense Rockwool insulation and interior OSB lining. This system results in a pioneering low energy wall system comprising minimal components and a slim profile.

RockShell benefits:

U-value: Total Total U-value wall insulation W(m2K) thickness thickness 364.5 mm

295 mm

0.14*

*) The U-value can be improved by increasing the thickness of the service wall.

Thermal calculations have been made by the consultancy company Belenos.

External cladding eg. 18 mm RockShell wall system 289 mm

Service wall 57.5 mm, 82.5 mm or 107.5 mm

Suitable for use in low energy buildings Flexibility of final finish Free project assistance On-site technical support Passivhaus certified Free calculation tools Free e-learning modules Interfaces with most standard building components Minimises thermal bridges Increased air-tightness Reduces wall thickness Lower install costs Reduced installation risks Fitted by Rockwool certified installers Competitive material costs Excellent fire properties Good acoustic properties Minimal on-site waste

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A simple and straight forward construction method 8

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Principles of the RockShell system RockShell is a modular wall system designed for ease of installation, whilst maximising safety throughout the build process. This is achieved without compromising on the end user benefits of energy performance, sustainability, indoor climate or building quality.

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The first house built using RockShell was in Flensburg, Germany. It was based on a standard design. This house type was utilised to show how easy it was to integrate the RockShell wall system into an existing design and also to prove that it is possible to build a standard house with excellent energy performance and low installation costs. The low-energy house was a KfW 70 energy-efficient house. Offering a 30% improvement in energy efficiency over traditional methods, in line with market requirements.

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1 Foundation

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2 The RockShell wall

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3 Doors and windows

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4 Corners

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5 The exterior face of the wall

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6 The interior face of the wall

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7 Intermediate floor

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8 Connecting to roof and gable

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A straightforward installation sequence...

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Foundation

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2

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The RockShell bottom profiles are mounted securely on the concrete foundation on a layer of bituminous roofing felt, adhered to the foundation with cold asphalt sealant. Bottom profiles are used to fix the wall to the foundation and brackets are used to fix the RockShell modules.

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The RockShell wall

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The unique slits on all four sides of the wool elements make them fit perfectly into the flanges of the steel profiles.

A further profile is mounted on top of the RockShell modules and fastened to the -profiles. Finally a laminated veneer lumber board is placed upon the top profile to complete the wall section.

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Doors and windows

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Openings for windows and doors are vertically framed by RockShell end columns and pre-fabricated RockShell lintels are used above door and window openings.

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Corners

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The unique RockShell corner insulation elements are set slantwise in position, the same way as the ordinary wool elements.

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... and cost effective to build 5

The exterior face of the wall

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Laminated ”nailers” are mounted onto the external face of the RockShell wall. The ”nailers” serve three basic functions. They cover and tighten joints between the RockShell wool elements, establish a ventilated cavity and create a secure mounting for the chosen external finish.

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The interior face of the wall

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OSB boards are mounted directly onto the interior face of the RockShell wall to create a secure mounting for the service wall and interior linings.

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Intermediate floor

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The intermediate floor is mounted to the RockShell wall system on the interior face of the OSB by securing into the laminated timber bearer and steel -profiles located behind the OSB boards.

Connecting to roof and gable

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Roofs are fixed to the laminated timber board on top of the RockShell wall. After the bearing roof construction is erected and fastened, gables are built up in the same way as wall modules.

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With you every step of the way‌ A comprehensive technical service and support partnership

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Support tools at www.rockshell.uk.com On our website, you will find a variety of resources from general system information to example CAD illustrations, installation videos, product and material information and much more.

We have also created a comprehensive e-learning module, providing answers to virtually all aspects relating to designing, constructing, and using the RockShell system.

Technical support at every stage

Support and service

RockShell is a completely new way of building lightweight load bearing walls. As a result we offer comprehensive technical advice and support, which will enable you to complete the entire construction process with confidence.

You are always welcome to call or e-mail our RockShell specialists if you have any questions regarding the system or a specific construction project.

The technical support consists of a wide range of services ranging from calculation and design assistance to on-site support, providing a fast response to any questions regarding your project.

Your RockShell specialist will partner with you to guide and advise you during the construction process to ensure that you always have the most rational work processes and achieve the best possible result.

Calculations and design assistance We’ll work with you from the outset. At design stage you can utilise our RockShell design and calculation team. By simply sending your outline drawings to us, we will then calculate the RockShell system required and prepare an outline bill of materials and project specification.

From this we will aim to work with you further by suggesting design adaptions and adjustments to minimise the projects costs, buildtime and optimise energy efficiency.

Detailed building manual The building manual is a detailed step-by-step installation guide explaining all aspects of the RockShell wall system, construction details and assembly methods.

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“The RockShell wall

system is, without doubt, one of the most innovative construction systems we have worked with.

“

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easy to get started with the system and installation is fast and simple.

RockShell is actually so simple to build with that even the customer – after expert guidance from an instructor – could build the house himself. It’s almost like working with a building set.

It is incredibly easy to get started with the system and installation is fast and simple. RockShell is also unbelievably easy to adjust and adapt. In other words, this is both a rational and economic construction system, which takes into account some commercial aspects that are important to our company.

Moreover, it is just as important to the customer that the finished system also has particularly good heat insulation properties.

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Another advantage is that as a result of the pre-fabricated parts and elements, we are able to constantly ensure a tidy and clean building site, which makes a particularly positive impression on visitors to the site and passers-by.

“We can only

give the RockShell wall system our highest recommendation...

Overall, it has been an especially interesting task for our company to contribute to the development and testing of such an innovative construction system like the RockShell.

We can only give RockShell wall system our best recommendation and we look forward to using the system on other construction projects in the future.

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“It is incredibly

RockShell is, without doubt, one of the most innovative construction systems we have worked with.

Bernd Carstensen and Sven Hansen Carstensen Trockenbau GmbH & Co KG Drylining Contractors

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We’ve built the future...

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Rockwool means extra safety Guaranteed quality of every component in the RockShell wall system

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Documentation and approval

Quality and control

The RockShell system has been tested according to the requirements of European Technical Approval (ETA) and tests have been performed and certified at independent test facilities.

The RockShell wall system has been developed as a complete load bearing wall system, providing a construction system which meets the needs of the future for rational construction technology and energy-efficient buildings.

Fire from the outside: REI 90 minutes.

Performed by DBI in Denmark Fire from the inside: REI 60 minutes.

Performed by DBI in Denmark Sound reduction: Minimum 54 DB. Performed by DELTA in Denmark Load bearing capacity per profile (height 2.7 m): 53,3 kN. Performed by SP in Sweden Passivhaus approval.

The system has been certified by the Passivhaus Institute in Germany European Technical Approval.

Granted by ETA in Denmark. ETA-11/0013

Rockwool is one of the most Y thoroughly tested and welldocumented building materials, and it is a safe product to work with.

Conclusions regarding the properties of our products are based on extensive epidemiological studies, carried out in cooperation with external partners.

The RockShell wall system has been tried and tested at construction sites and is certified through independent laboratory tests. This guarantees the quality of every component in the system and ensures that the system functions in practice at the construction site and in the finished building.

Fire resistance

Durability

Moisture-repellent

Rockwool products withstand temperatures up to 1000° C, making them exceptionally resistant to fire. This resistance can slow a fire’s progress and buy precious time for rescue operations while helping to protect the building’s structure from unnecessary damage. Yet while heat and flames are bad enough in a fire, smoke is the serious danger. It can suffocate occupants, and it can incapacitate people who might otherwise have been able to escape.

Rockwool insulation keeps toxic smoke from insulation to a minimum for even greater safety.

Our products are built to perform over the long haul. Rockwool slabs and claddings remain stable over time, and they don’t allow cold bridges to form. But at Rockwool, it’s not just our products that are “rock solid”. So is our time-honoured name, and our reputation for delivering documented benefits and providing expert advice to architects, designers, contractors and building owners.

Rockwool is moisture-repellent. If the insulation is exposed to rain, only the outermost few millimetres will get wet. This will disappear rapidly when the rain stops. Rockwool is also breathable and allows water vapour to pass through the wool – without condensing.

Superior acoustics Buildings are noisier than many people think.

Traffic outside, ventilation systems, music, talking, doors opening and closing. So many sounds contribute to a typical room’s acoustic environment, we sometimes don’t even register them consciously. But we are affected by them.

Environments with a high noise level can be stressful and make it hard both to concentrate and relax. Rockwool insulation and acoustic ceiling panels dampen noise to improve comfort and quality of life both at home and at work.

Sustainability As producers of products and solutions made from reusable natural stone, and as acknowledged experts in designing buildings that maximise energy efficiency and minimise CO2 emissions, you could say that our very business is sustainability. Our products are eco-friendly, and we are happy to provide advice on energy efficiency in buildings of any size. We turn waste from our production process into new raw material, and we are developing systems for recycling our materials from building waste.

Comfort and indoor climate Insulation that provides an air-tight building envelope guarantees a pleasant and constant temperature all year round. Rockwool meets the strictest European requirements in relation to indoor climate, and is certified in the Finnish M1 emission class for construction materials.

All-in-o

system

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safet y

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Tailor-made courses – giving you the best start

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RockShell installation courses It is important that the many advantages of building with the RockShell wall system are utilised to the full. RockShell offer training courses for installers.

These courses help to ensure a rational and smooth construction process from start to finish.

The courses can be tailor-made to suit your company. Please feel free to contact us if you are interested or register your details at www.rockshell.uk.com

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proservice.dk

26-28 Hammersmith Grove London W6 7HA Tel: +44 (0) 845 241 2586

Unit 11 Northwood Court Santry Dublin 9 Ireland Tel.: +353 (0) 1 891 1055 E-mail: rockshell@rockwool.ie www.rockshell.ie

Brochure no.: ShellCon 01 Date: 01/09/2011

Rockwool Limited Registered Office Pencoed Bridgend CF35 6NY Tel.: +44 (0) 1656 868 400 E-mail: rockshell@rockwool.co.uk www.rockshell.uk.com