Everything you need to know about Phenolic Insulation

What is Phenolic insulation?

Phenolic insulation is manufactured by a process in which a plastic foam forms an insulating core between two flexible tissue faced layers. It has a high closed cell content and fine cell structure. Rigid phenolic insulation is produced by mixing high solids and phenolic resin with a surface acting agent.

Link to Langfang Clear Chemical

Is Phenolic insulation combustible?

The first indicative test looked at the behaviour of 25mm Xtratherm Safe-R SR Phenolic PIR, a phenolic, fibre-free rigid thermoset material, recognised as "combustible". The second test looked at the behaviour of a rock mineral fibre insulation with a density of 40kg/m3 + 100kg/m3, recognised as "non-combustible".

What is the difference between PIR and Phenolic insulation?

As with the PIR/PUR boards above, phenolic insulation boards also have a closed cell structure. Phenolic board has a slightly higher r-value (higher is better, unlike u-values) and a slightly thinner profile than PIR/PUR boards due to the manufacturing process.

How is phenolic made?

Phenolic sheet is a hard, dense material made by applying heat and pressure to layers of paper or glass cloth impregnated with synthetic resin. ... When heat and pressure are applied to the layers, a chemical reaction (polymerization) transforms the layers into a high-pressure thermosetting industrial laminated plastic.

What is Xtratherm Safe-R | Superior Performance Phenolic Insulation made of?

Xtratherm Safe-R is a superior performance phenolic insulation with a Euroclass B classification. It is faced with low emissivity foil facings on both sides and has a Lambda value as Low as 0.020 W/mK.

Partial Fill Cavity Wall SR/CW

Safe-R SR/CW Partial Fill cavity insulation for traditional masonry walls, achieves excellent U-Values whilst maintaining a residual cavity, offering protection from wind driven rain.

Product Features
Superior Performance Phenolic Insulation
Euroclass B -s1 d0 Fire Classification
Lower Lambda Values for improved U-Values
For New Build or Refurbishment
Fast Response Heating
BRE Green Guide A+ Rated

Key Facts

FIRE PERFORMANCE The fire performance of phenolic foam is exceptional. It combines zero or very low flame spread with negligible smoke emission and a very low level of toxic gas emission

ENVIRONMENT Phenolic foam has very low embodied energy per unit thermal performance compared to other insulation materials ' Significant CO2 savings can be achieved compared to other insulation materials

MOISTURE RESISTANCE Phenolic foam has been used successfully in insulation systems where moisture resistance is a key issue. The reasons for this excellent performance are: ' Phenolic foam has a low water vapour permeance and is therefore highly resistant to the passage of water vapour ' Phenolic foam has low water absorption which takes place predominantly in the cut/broken surface cells of the foam

STRUCTURAL STRENGTH Phenolic foams have an excellent strength/density relationship being lightweight but strong. Higher density phenolic foams are typically used for: ' Pipe supports ' Duct supports ' Steel faced composite panels (including walk-on ceilings

THERMAL PERFORMANCE Phenolic foams offer a range of thermal conductivity performance. The closed cell type offers the lowest thermal conductivity available from any insulation material resulting from: ' Closed cell structure ' Extremely small cell diameter ' Low thermal conductivity gas permanently encapsulated in cells.

Conclusion

Phenolic foam is used in many building applications, typically continuously laminated phenolic board is used in roofing, cavity board, external wall board, plasterboard dry lining systems, wall insulation, floor insulation and as a sarking board.

The superior fire performance of phenolic foam is being recognised and this is leading to increased market share in these areas. Phenolic foam is used in factory engineered composite panels. These composite panels comprise of a high density structural phenolic foam core with steel facings both sides and an appropriate jointing system. These panels are used in a range of applications including food processing factories, cold stores, semi conductor clean rooms and hospitals. These panels are structurally sound and fit for purpose for use in walk-on ceilings.

The excellent fire performance provided by the phenolic foam core gives both good insulation and integrity performance in the 3m furnace fire resistance test. Phenolic foam is used in process/petrochemical applications for the insulation of pipework, tanks, vessels etc. Phenolic foam is also used in a number of highly specialised applications including fire doors, highly fire resistant panels and for insulation in surface ships, off-shore installations and submarines.

It is clear that phenolic foam is a very versatile material being suitable for a large range of applications where thermal performance, moisture resistance, fire performance and in certain cases structural strength are key performance criteria. Phenolic foam is the only material that can provide this unique range of benefits.

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Why Phenolic Panels Are on the Rise

1. Cost-Effectiveness

Seasoned architects and designers know that it's important to look at more than just upfront prices when recommending materials. Calculating the total cost of ownership is a much better guide to making smart decisions and ultimately saving money by purchasing cost-effective materials.

The durability, longevity, and low maintenance of phenolic panels make them an incredibly cost-effective option. Rainscreen façades that use phenolic cladding panels offer longevity of both form and function.

In addition to their impact resistance, exterior phenolic wall panels are UV-resistant. Specifically, Fundermax's phenolic cladding panels have a greyscale rating of 4-5, indicating the material is reliably colorfast.

For more Phenolic Foam Decorative Panelsinformation, please contact us. We will provide professional answers.

There can also be significant savings over time on a building's heating and cooling costs when using a properly designed rainscreen system with continuous exterior insulation behind the Fundermax phenolic wall panel system.

2. Ease of Installation

Among a long list of popular features, ease of installation remains one of the most commonly mentioned benefits of phenolic panels.

With just three main factors to consider (substructure material, mounting direction, and fastening system), installing a  phenolic wall panel system is a fairly straightforward process.  Additionally, Fundermax's selection of fastening systems and variety of panel sizes (more than many other phenolic panel manufacturers) provide options to fit any budget or aesthetic.

3. Durability

Choosing durable materials that will hold up over time preserves not only the integrity of the design but also the client's investment. The importance of durability is multiplied when designing for high-traffic applications such as in airports, transit systems, cities, and schools. Phenolic panels are a solution that offers all of the durability you need while maintaining the design flexibility you really want.

Phenolic cladding panels are scratch-, impact-, weather-, and chemical-resistant. The hygienic, non-porous surfaces of Fundermax phenolic panels make for easy cleaning when necessary, (for more details on cleaning and chemical resistance, see here), and the acrylic surface of Fundermax's Max Compact Exterior phenolic wall panels is 5x thicker than comparable products from other phenolic panel manufacturers, making them exceptionally durable, even down to high-traffic, sidewalk level installations.

As a general rule, phenolic panels are strong building materials. But, in order to ensure you select the most durable phenolic panel system, be sure to work with highly reputable and globally trusted phenolic panel manufacturers like Fundermax, who go above and beyond the industry standard for durability.

4. Sustainability

Sustainable construction reduces the industry's overall impact on the environment -- not only during construction but also throughout the lifespan of the building. The benefits of Fundermax phenolic panels include both.

Fundermax has been making sustainable manufacturing choices for more than a century, and using Fundermax phenolic panels can contribute to a client's environmental goals in many ways.

Our exterior phenolic wall panels are FSC Certified and consist of 65% natural fibers, and some of our interior phenolic panels now utilize 100% recycled core paper. Fundermax also has several ISO certifications that demonstrate our company-wide commitment to operate in a responsible manner.

For more details, consider this article on Fundermax and LEED and Fundermax's Green Energy Manufacturing.

5. Code Compliance

Fire rating and code compliance are two important matters of safety when considering any building material, including phenolic panels, and Fundermax has consistently been ahead of the curve among phenolic panel manufacturers regarding code compliance.

While some phenolic panels have a standard Class B fire rating, all Fundermax exterior phenolic panels are Class A fire rated, and even before the code adoption of high-pressure laminates as a specific segment of IBC Chapter 14, Fundermax invested in a full ICC Evaluation Services Report for our Max Exterior Façade Cladding. As of , Fundermax now has a full Intertek Code Compliance Research Report for all of our commercial exterior façade systems.

The ICC AC92 Criteria remains far beyond the minimum IBC Code Requirements for High-Pressure Laminates.

Bottom line: Fundermax rigorously tests all products, offering architects the assurance and peace of mind that comes with local and national code compliance.

6. Versatility

Versatility is another of the most appealing benefits of phenolic panels. Architects appreciate the great flexibility of product applications without sacrificing the freedom of high-quality design capabilities.

Specifically, Fundermax offers a phenolic panel sheet program, a factory cut-to-size option, and a fully engineered package program, not to mention a variety of fastening options -- all of which uniquely allows Fundermax to provide innovation and design flexibility to architects and installers alike.

Phenolic panels provide architects the opportunity to make bold and creative choices, emphasizing architectural features with the durable, high-quality aesthetics of the material. Digitally printed phenolic panels are also available, allowing customization that will fit the unique specifications of any project.

Phenolic Panel Applications & Examples

Exterior

Exterior phenolic wall panels are an excellent material for rainscreen facades, balconies, soffits, sunshades/louvers, furniture, and/or signage. For these uses, Fundermax offers exterior architectural panels, digitally printed panels, and natural panels.

Interior

Phenolic panels are an exciting solution for interior wall lining, washroom partitions, lockers, and furniture. Fundermax offers interior architectural panels, digitally printed panels, and thin laminate panels for these applications.

Lab

Phenolic resin panels can also be used in laboratory applications including lab shelving, fume hood lining, wall lining, furniture, and work surfaces. Fundermax offers laboratory architectural panels, horizontal lab work surfaces, vertical lab work surfaces, and digitally printed panels.

The rise of phenolic panel system use in the United States is an exciting development for architects and designers.

From sustainability to versatility, the benefits of phenolic panels can add value to any project.

Contact us to discuss your requirements of Internal Wall Insulation. Our experienced sales team can help you identify the options that best suit your needs.