Annex 65, Long-Term Performance of Super-Insulating-Materials in Building Components and Systems. Report of Subtask III: Practical Applications – Retrofitting at the Building Scale – Field scale

Report, 2020

More than 80% of the energy consumption will be influenced by the existing building stock. Accordingly, building renovation has a high priority in many countries. Furthermore, several studies have shown that the most efficient way to curb the energy consumption in the building sector (new & existing) remain the reduction of the heat loss by improving the insulation of the building envelope (roof, floor, wall & windows). All since the first oil crisis in 1973-1974, the national building regulations require improvement of the thermal performance of the building envelope to significantly reduce the energy use for space heating. Following the regulations, the energy efficiency of new buildings has improved. In Europe, targeting to an average U-value close to 0.2 W/m2·K is optimal. Using traditional insulation materials this means an insulation thickness of about 20 cm. Thus, the thickness of internal and/or external insulation layers becomes a major issue of concern for retrofitting projects and even for new building projects in cities. Therefore, there is a growing interest in the so-called super-insulating materials (SIM). The scope of the present work covers two different types of SIMs:
• Advanced Porous Materials (APM), where the gaseous heat transfer is hindered significantly by the fine structure in the sub-micrometre range, and
• Vacuum Insulation Panels (VIP), where the contribution of gaseous conductivity to the total heat transfer is suppressed by evacuation.
For Advanced Porous Materials (APM) one might distinguish between
• porous silica e.g. based on fumed silica, and
• aerogels.
For Vacuum Insulation Panels (VIP) one might distinguish between:
• different core materials: fumed silica, glass fibre, PU, EPS, others;
• different envelopes: metalized film, aluminium laminate, stainless steel, glass, or combinations;
• with or without a getter and/or a desiccant.
The objective of this Annex 65 Subtask 3 report is to define the application areas of SIM and to describe the conditions of the intended use of the products. Indeed, it’s clear that the requested performance of the SIM will strongly depend on the temperature, humidity and load conditions. For building applications, storage, handling and implementation requirements are also described. Common and specific numerical calculations will be performed at the building scale to assess the impact of SIM on the performance of the building envelope.
SIM was used in almost all building components with different environmental condition (boundary condition) and in different climate zone. The moisture and temperature conditions in building components can cause moisture/temperature induced stresses and the stresses can cause damage in sensitive super insulation material e.g. VIPs. Thus, to convince the conservative market of construction, it needs, in addition to laboratory measurements, real condition/environmental measurements of commercially realized objects (new buildings as well as refurbishments) under several years of operation.
The long-term performance of super insulation materials has to be determined based on case studies in field and laboratory. Full scale experiments provide knowledge of practical and technical difficulties as well as data for service life estimation. For certain conclusions to be drawn from the case studies, monitoring is essential. Unfortunately, monitoring is only performed in few case studies. In this report these experiences are gathered and evaluated from a long-term performance perspective.
APMs have been commercially successful in the building industry in niche applications typically with space restrictions since the early 2000s. Therefore, over the last years, a number of state-of-the-art reviews have focused on applications of advanced porous materials, such as aerogels, used as thermal insulation in buildings. VIPs, on the other hand, have also been used in other applications than buildings, such as refrigerators and transport boxes. The different applications areas have been identified by numerous researchers. However, in most studies of VIPs available in the literature, it was only the thermal performance of the assembly that was investigated. However, also the moisture performance is important to consider since changes to existing structures will influence the risk for moisture damages.
In the Annex, the gathered case studies cover a wider range of SIM i.e. aerogel blankets, AB, (7 case studies), silica-based boards, SB, (3 case studies) and VIP (22 case studies). The aim was to gather information from projects where SIMs were used in different assemblies. Some of the projects have been monitored, i.e. sensors were installed to monitor the temperature, relative humidity or heat flux through the assemblies, while only three have been followed up, i.e. where a third party have analysed the results of the monitoring. The case studies are presented and specific and general conclusions from each application are made.
The case studies showed that aerogel blankets are possible to install in up to five layers (50 mm) without too much difficulty. The evaluations showed that the performance of the aerogel blankets was maintained over the evaluation period. For VIPs, it is difficult to evaluate the performance when installed in the wall. In one of the case studies in the report, the external air space made it impossible to identify the different panels by thermography. Only indirect methods, like evaluation of the measured temperatures in the wall, can be used to follow the long-term performance of the panels. In another case study, hybrid insulated district heating pipes were installed at two locations in a district heating system with temperatures up to 90°C. Measurements during the period 2012 to 2015 showed no sign of deterioration of the VIPs and the temperature profile over the pipes was constant. An existing masonry wall was insulated with VIP-foam sandwich (XPS-VIP-XPS). It showed satisfactory and promising performance for a period of six years (2011-present). The analysis of the data obtained from continuous temperature monitoring across each insulation layer indicated the aging of VIP remains insignificant.
In the framework of IEA EBC Annex 65 a common simulation-based procedure was introduced with the scope to identify potential critical hygrothermal working conditions of the SIM, which were identified as main drivers of the ageing effect. The study highlights that some physical phenomena (such as thermal bridging effects, the influence of temperature on the thermal conductivity and the decay of performance over time depending on the severity of the boundaryconditions) should be carefully evaluated during the design phase in order to prevent the mismatch between expected/predicted and the actual thermal performance.
As general guidelines to mitigate the severity of the operating conditions of VIP, a list of recommendation are in the following summarised:
• For the external wall insulation with VIP in solar exposed façade, the adoption of ventilated air layer could dramatically reduce the severity of the VIP operating conditions. Alternatively, light finishing colour are warmly encouraged to mitigate the surface temperature.
• The protection of VIP with thin traditional insulation layer is always encouraged.
• The application of VIP behind heater determines high value of surface temperature field which could potentially lead to a fast degradation of the panel. A possible solution to mitigate the severity of the boundary conditions could be the coupling of VIP with a radiant barrier, or the protection of VIP with thin insulation layer when it is possible.
• In roof application, light colour (cool roof), performant water proof membrane, ventilated airspace and gravel covering layer (flat roof) represent effective solutions to mitigate the severe exposure.
• In presence of wall subjected to high driving rain, it is preferable to adopt ventilated façade working as rain-screen to prevent the water absorption.
Furthermore, to provide designers, engineers, contractors and builders with guidelines for the applications of vacuum insulation panels (VIPs) and Advanced Porous Materials (APMs) examples are given of methods that may be used to verify the quality and thermal performance of SIMs after installation. A comprehensive account of transport, handling, installation and quality check precures are presented. The main purpose of the descriptions is to promote safe transport, handling and installation. In the case of VIPs the primary issue is that of protecting the panels whereas the main concern for APMs is the safety in handling of the material.
During the work of the Annex several questions regarding the long-term performance of SIMs on the building scale have been identified and discussed. Four main challenges were identified:
• Knowledge and awareness among designers concerning using SIM
• Conservative construction market
• Cost versus performance
• Long-term performance of SIMs
Finally, SIMs for building applications have been developed in the recent decades. Theoretical considerations and first practical tests showed that VIP, especially those with fumed silica core, are expected to fulfil the requirements on durability in building applications for more than 25 years. Both VIPs and APMs have been successfully installed over the past 15 years in buildings. However, real experience from practical applications exceeding 15 years is still lacking, especially when considering third-party monitoring and follow up of demonstrations.