Guide to energy retrofit of traditional buildings, published by Historic Environment Scotland in November , defines phenolic foam as: ‘A synthetic polymer made from thermosetting foam plastic and used in thermal insulation’

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Phenolic foam is considered one of the best material for thermal insulation.

• It has over 90% closed cell formation, giving it good stability.
• Phenolic foams come in varying densities in the range of 35 kg/m³ to 200 kg/m³. High density varieties such as insulation boards have good strength and are suitable for floor insulation.
• It has low thermal conductivity. The thermal conductivity of phenolic closed cell insulation material is generally between 0.018 W/m.K and 0.023 W/m.K.
• It has fire retardant properties and a low smoke level (even under pyrolysis).
• It is water resistant.
• It is lightweight and so is easy to transport and install.
• Closed cell phenolic insulation foam can resist almost all inorganic acidic erosion, organic solvents and acids. However, it under-performs in alkaline environments.
• When exposed to sunlight for long periods it does not show any noticeable ageing.
• Insulation boards show good sound absorption properties.

The most common blowing agent used in phenolic foam insulation is ‘Pentane’. This is used to comply with EC regulation, because it is CFC and HCFC free, has no ozone depletion potential and low global warming potential. Pentane is a hydrocarbon. In order to prevent the blowing agent escaping and being replaced by air, the insulation boards are covered with gas tight aluminium foil or glass tissue.

Illustrated Guide to Mechanical Building Services 3rd Edition (BG 31/), written by David Bleicher and published by BSRIA in May , suggests that phenolic foam is: ‘A solid foam insulation with good thermal performance that can be used on most systems. As with mineral wool insulation, if used on cold water, chilled water or refrigeration pipework, it must be vapour sealed to reduce the risk of condensation forming on the pipe surface.’

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What Is The Difference Between PIR and Phenolic Insulation? 

Phenolic foam is often confused with PIR insulation due to the fact that these two materials share a lot of similarities.

Both PIR and phenolic are rigid thermoset foams that function as insulating cores between two facings. The main difference between them is the materials and the manufacturing process.

PIR foam is made from isocyanate and polyol. PIR insulation boards are manufactured in much the same way as Kingspan Kooltherm insulation. The main difference is that PIR insulation has to be cured for much longer than phenolic insulation. 

Whereas phenolic boards are cured before they are packed, manufacturers cure PIR boards after they have already been packed. The boards cure in a temperature-controlled environment for one day per each 25mm of thickness. 

Whilst PIR has good thermal insulating properties, phenolic excels in thermal performance, reaching lows of 0.018 W/mK compared to the 0.022 W/mK of PIR. Despite the many rigid thermoset insulation materials on the market, you will not find a lower thermal resistance figure than phenolic insulation. 

Both phenolic and PIR foam have combustible properties. However, they do deliver excellent protection against moisture and are ideal for areas with high rainfalls. Rot or fungi growth won't be an issue when you invest in phenolic insulation. 

Are Kingspan Phenolic Insulation Boards Flammable?

When fire touches phenolic foam insulation it undergoes thermal decomposition, which is called pyrolysis. 

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There are two byproducts of pyrolysis: the first is pyrolysis gas and the second is a black char on the surface of the board. Pyrolysis gases are hot and combustible, meaning that phenolic insulation is not entirely anti-flammable. 

The fire resistance of insulation boards is measured against the Euroclass rating. Insulation materials undergo up to five different tests and get a rating that ranges from A (non-combustible) to F (very combustible). 

There are lots of Kingspan Kooltherm boards to choose from, which means that there are a few different ratings to consider when meeting thermal performance targets and building regulations.

Most Kooltherm boards have a rating of C on the Euroclass scale, meaning that they are classed as combustible materials with limited contribution to fire.

How Is Rigid Phenolic Insulation Made? 

To make phenolic insulation boards, Kingspan applies a layer of wet phenolic directly onto a facing. The plastic foam forms an insulating core and expands to meet the top layer, achieving the desired thickness. 

When phenolic dries, it becomes tacky. It adheres to the top and bottom facings to create thin sheet material. 

Kingspan cooks the resulting board under immense heat, then cures it in a second oven. Cooked and cured phenolic is a distinct pink colour, which is distinguishable from yellow PIR foam. 

The boards have very low thermal conductivity and provide the best thermal protection that you can buy. They can also withstand continuous temperatures of up to 120 degrees C, making them the ideal choice for high specification projects. 

Are you interested in learning more about floor phenolic foam board? Contact us today to secure an expert consultation!

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