Thermal Insulation Cavity Slab 032 Bba Certificate 22 6335 Cavity Wall Insulation Full Fill Application
Thermal Insulation Cavity Slab 032 Bba Certificate 22 6335 Cavity Wall Insulation Full Fill Application
Wern Tarw
Pencoed
Bridgend CF35 6NY
CERTIFICATION INCLUDES:
• factors relating to compliance with Building Regulations
where applicable
• factors relating to additional non-regulatory information
where applicable
• independently verified technical specification
• assessment criteria and technical investigations
• design considerations
• installation guidance
• regular surveillance of production
• formal three-yearly review.
Page 1 of 14
Regulations
In the opinion of the BBA, Thermal Insulation Cavity Slab 032 for Full Fill Application, if installed, used and
maintained in accordance with this Certificate, can satisfy or contribute to satisfying the relevant requirements of
the following Building Regulations (the presence of a UK map indicates that the subject is related to the Building
Regulations in the region or regions of the UK depicted):
Page 2 of 14
Regulation: 9 Building standards applicable to construction
Standard: 2.4 Cavities
Comment: The product can contribute to a construction satisfying this Standard, with reference to
clauses 2.4.2(1)(2), 2.4.4(1) and 2.4.6(2). See section 9.1 of this Certificate.
Regulation: 29 Condensation
Comment: The product can contribute to satisfying this Regulation. See sections 8.1 and 8.2 of this
Certificate.
Page 3 of 14
Regulation: 35(4) Internal fire spread – structure
Comment: The product can contribute to satisfying this Regulation. See section 9.1 of this
Certificate.
Additional Information
UKCA marking
The Certificate holder has taken the responsibility of UKCA marking the product in accordance with Designated
Standard EN 13162 : 2012 + A1 : 2015.
CE marking
The Certificate holder has taken the responsibility of CE marking the product in accordance with harmonised European
Standard EN 13162 : 2012 + A1 : 2015.
Technical Specification
1 Description
Thermal Insulation Cavity Slab 032 for Full Fill Application consists of a water-repellent-treated stone mineral wool,
formed into slabs using a resin binder, with the nominal characteristics given in Table 1.
Page 4 of 14
2 Manufacture
2.1 Raw materials, mixed to a controlled formulation, are melted in a furnace to produce molten stone. Stone fibres
are produced from the molten stone using a rotary spinning process. The fibres are treated with a resin and formed
into a continuous length of insulation to the required thickness. The insulation then passes into an oven which cures
the resin. The insulation is then cut to the required dimensions to form the slabs.
2.2 As part of the assessment and ongoing surveillance of product quality, the BBA has:
• agreed with the manufacturer the quality control procedures and product testing to be undertaken
• assessed and agreed the quality control operated over batches of incoming materials
• monitored the production process and verified that it is in accordance with the documented process
• evaluated the process for management of nonconformities
• checked that equipment has been properly tested and calibrated
• undertaken to carry out the above measures on a regular basis through a surveillance process, to verify that the
specifications and quality control operated by the manufacturer are being maintained.
2.3 The management system of the manufacturer has been assessed and registered as meeting the requirements of
ISO 9001 : 2015 and ISO 14001 : 2015 by BSI (Certificates FM 02262 and EMS 70301 respectively).
3.2 The slabs should be stored clear of the ground, on a clean level surface and preferably under cover to protect them
from prolonged exposure to moisture or mechanical damage. Packs should be stored under cover until required for
use.
3.3 It is recommended that dust masks, gloves and long-sleeved clothing are worn during the cutting and handling of
the product.
3.4 Damaged or contaminated products must not be used. Wet slabs must be allowed to fully dry out before use.
Design Considerations
4 Use
4.1 Thermal Insulation Cavity Slab 032 for Full Fill Application is satisfactory for use as full fill cavity wall insulation and
is used to reduce the thermal transmittance (U value) of external cavity walls with masonry inner and outer leaves
(where masonry includes clay and calcium silicate bricks, concrete blocks, and natural and reconstituted stone blocks).
The product is for use in new domestic and non-domestic buildings up to and including 25 metres in height (although
additional requirements apply above 12 metres in height). It is essential that walls are designed and constructed to
incorporate the precautions given in this Certificate to prevent moisture penetration.
4.2 Two or three layers of slabs can also be installed if necessary, in order to achieve the required U values (see
section 6.2). In this case, vertical joints between the outer slabs must be staggered to those of the inner slabs.
4.3 This Certificate covers the use of the product for full fill in any exposure zone. However, use of the product does
not preclude the need to apply any external render coat or other suitable finish in severe, or very severe, exposure
zones where such application would be normal practice.
Page 5 of 14
4.4 As with other forms of cavity wall insulation, where buildings need to comply with NHBC Standards 2022, specifiers
should observe the requirements of that document.
4.5 Buildings subject to the national Building Regulations should be constructed in accordance with the relevant
recommendations of:
• BS EN 1996-1-1 : 2005, BS EN 1996-1-2 : 2005, BS EN 1996-2 : 2006 and BS EN 1996-3 : 2006, and their UK National
Annexes
• BS EN 845-1 : 2013 and BS 8000-3 : 2020.
4.6 New buildings not subject to regulatory requirements should also be built in accordance with the Standards
identified in section 4.5.
4.7 Cavity wall ties and, if required, any additional ties to BS EN 845-1 : 2013 and PD 6697 : 2019 should be used for
structural stability in accordance with BS EN 1996-1-1 : 2005, BS EN 1996-2 : 2006 and BS EN 1996-3 : 2006.
4.8 Care must be taken in the overall design and construction of walls incorporating the product to ensure the
provision of appropriate:
4.10 Where the walls of a building are between 12 and 25 metres high, the following requirements also apply:
• from ground level, the maximum height of a continuous cavity must not exceed 12 metres. Above 12 metres, the
maximum height of a continuous cavity must not exceed 7 metres. In both cases, breaks should be in the form of
continuous horizontal cavity trays and weepholes discharging to the outside
• the Certificate holder, in association with the architect, must carry out a detailed programme of assessment of the
project including an examination of the quality of installation as work progresses. Above average site supervision is
recommended during installation.
5 Practicability of installation
The product is designed to be installed by a competent general builder, or a contractor, experienced with this type
of product.
6 Thermal performance
6.1 Calculations of the thermal transmittance (U value) of specific external wall constructions should be
carried out in accordance with BS EN ISO 6946 : 2017 and BRE Report BR 443 : 2019, using the declared
thermal conductivity (λD) of 0.032 W·m–1·K–1.
Page 6 of 14
6.2 The U value of a completed wall will depend on the insulation thickness, number and type of fixings, and the
insulating value of the substrate masonry and its internal finish. Calculated U values for example constructions are
given in Table 2.
Junctions
6.3 The product can contribute to maintaining continuity of thermal insulation at junctions with other elements and
minimise thermal bridges and air infiltration. Detailed guidance can be found in the documents supporting the national
Building Regulations.
7 Water resistance
7.1 The product may be used in situations where it bridges the dpc in walls; dampness from the ground
will not pass through to the inner leaf provided the wall is detailed in accordance with the requirements
and provisions of the national Building Regulations.
7.2 Constructions incorporating the product and built in accordance with the Standards listed in section 4.5, will
resist the transfer of precipitation to the inner leaf and satisfy the national Building Regulations.
• installation is carried out to the highest level on each wall, or the top edge of the insulation is protected by a cavity
tray
• cavity trays are used with appropriate stop ends and weep holes at lintel level
• cavity battens and/or boards are used during construction to prevent bridging by mortar droppings
• wall ties are installed correctly and are thoroughly clean
• excess mortar is cleaned from the cavity face of the leading leaf and any debris removed from the cavity
• mortar droppings are cleaned from the exposed edges of installed slabs
• the dpc at ground level does not project into the cavity as it can form a trap for mortar bridging
• insulation slabs are properly installed and butt-jointed
• raked or recessed mortar joints are avoided in very severe exposure areas.
7.4 Window and door opening reveals should be constructed incorporating a cavity barrier/closer/dpc, as required.
Page 7 of 14
8 Condensation
Interstitial condensation
8.1 Walls will adequately limit the risk of interstitial condensation when they are designed and
constructed in accordance with BS 5250 : 2021, and the relevant guidance.
8.2 For the purposes of assessing the risk of interstitial condensation, the insulation vapour resistivity
may be taken as approximately 5 MN·s·g–1·m–1.
8.3 If the product is to be used in the external walls of rooms expected to have high humidity, care must be taken to
provide adequate ventilation to avoid possible problems from the formation of interstitial condensation.
Surface condensation
8.4 Walls will adequately limit the risk of surface condensation when the thermal transmittance
(U value) does not exceed 0.7 W·m–2·K–1 at any point and the junctions with other elements are designed
in accordance with the guidance referred to in section 6.3.
8.5 For buildings in Scotland, constructions will be acceptable where the thermal transmittance
(U value) does not exceed 1.2 W·m–2·K–1 at any point and the junctions with other elements are designed
in accordance with the guidance referred to in BS 5250 : 2021. Further guidance may be obtained from
BRE Report BR 262 : 2002 and section 6.3 of this Certificate.
(1) MPA NRW report No. 231001026-3, dated 9 November 2020, is available from the Certificate holder on request.
9.2 Designers should refer to the relevant national Building Regulations and guidance for detailed conditions of use,
particularly in respect of requirements for substrate fire performance, cavity closers and barriers, fire stopping of
service penetrations and combustibility limitations for other materials and components used in the overall wall
construction.
11 Maintenance
As the product is confined within the wall cavity and has suitable durability (see section 12), maintenance is not
required.
12 Durability
The product is durable, rot proof, water resistant and sufficiently stable to remain effective as insulation
for the life of the building.
Page 8 of 14
Installation
13 General
13.1 The Certificate holder will provide on-site demonstrations on request, to ensure correct installation from the
outset.
13.2 Adequate supervision of the installation should be maintained and the Certificate holder must have right of access
to site to ensure correct installation.
13.3 It is recommended that the internal leaf is constructed ahead of the external leaf so that any mortar protruding
into the cavity space from the back of the external leaf can be cleaned off before installing the product. Slabs must not
be pushed into a completed cavity.
13.4 Vertical joints in the slabs must be staggered and all joints tightly butted. Where penetrations occur in the cavity,
the slabs should be carefully cut to fit.
13.5 If installation of the slabs is terminated below the highest level of the wall, the top edge of the insulation must be
protected by a cavity tray and alternate perpend joints raked out, to provide adequate drainage of water from the tray.
13.6 Where required, door and window reveals should incorporate a cavity barrier/closer. It is recommended that BBA-
approved cavity barriers/closers are used.
14 Procedure
14.1 The first run of slabs should start at least 150 mm below the dpc level to provide some edge insulation for the
floor. It is important that the slabs are not in contact with the ground. Slabs must fit flush against the internal leaf, with
a maximum 10 mm residual cavity if required, between the insulation slab and the external wall leaf.
Wall ties
14.2 Wall ties should be spaced at maximum 900 mm centres horizontally and 450 mm vertically. The width of the first
course of slabs can be cut to suit the height of the next row of wall ties. The width of cut slabs should always be 5 mm
greater than the width to be insulated.
14.3 Wall ties should be built in and not pushed into joints; they should be positioned so that they slope downwards
towards the outer leaf.
14.4 Additional ties may be required to satisfy the structural requirements and/or to ensure adequate retention of
slabs or cut pieces.
14.5 A complete section of the leading leaf is built to one course above the next row of wall ties spaced at a maximum
of 900 mm horizontally (Figure 1), to ensure that each slab is secured at a minimum of three points in accordance with
BS EN 1996-1-2 : 2005. All mortar joints must be properly filled, particularly the perpends (see Figure 1).
Page 9 of 14
Figure 1 Wall tie positioning
14.6 Slabs are compressed slightly and placed between the upper and lower wall ties to form a closely jointed run.
Mortar droppings
14.7 Before installing each course of slabs, excess mortar must be removed from the inside face of the leading leaf, and
mortar droppings cleaned from the exposed edges of the slabs. This is made easier using a cavity board (Figure 2). This
cleaning sequence should be maintained progressively until reaching the wall plate or cavity tray. It is important for the
insulation to be installed to the highest level of each wall, with all areas of the wall insulated (see section 13.5).
Corners
14.8 At corner joints, edges must be cut accurately to ensure close butting (see Figure 3).
Page 10 of 14
Figure 3 Slabs at corner detail
Wall openings
14.9 With openings such as doors and windows, it is recommended that a continuous lintel or cavity tray is used.
Individual lintels or cavity trays should have stopends and be adequately drained. Slabs should be cut to butt tightly
against the cavity barrier/closer/dpc or wall ties.
Cut pieces
14.10 The slabs must be cut cleanly, using a sharp, long-bladed knife and a straight edge. It is essential that cut pieces
of slab completely fill the spaces for which they are intended and are adequately secured; gaps must not be left in the
insulation.
14.11 It is essential that all the joints between the insulation slabs are clean and tightly butted.
14.12 The second leaf is built up to the same level as the slabs.
14.13 This sequence is repeated to the top of the wall. Alternatively, the top of the slabs can be protected by using a
cavity tray.
14.14 Where two or three layers of the insulation slabs are used, a similar procedure must be followed as for the single
layer (see sections 14.1 to 14.14). The first layer is fitted against the outer masonry leaf followed by the second and, if
relevant, third layer.
14.15 When multi layering, the vertical joints between the outer slabs must be staggered to those of the inner slabs.
14.16 For cavities exceeding 150 mm, the Certificate holder’s instructions must be followed regarding the type of ties
to be used, and the installation should be carried out in accordance with BS EN 1996-1-2 : 2005, BS EN 1996-2 : 2006
and BS EN 1996-3 : 2006.
Page 11 of 14
Figure 4 Multi layering
Protection
14.17 Exposed areas of slabs should always be covered at the end of the day’s work or in driving rain.
14.18 All building involving the product, particularly interrupted work, must conform to BS EN 1996-2 : 2006, clauses
3.2 Acceptance, handling and storage of materials and 3.6 Curing and protective procedures during execution.
Technical Investigations
15 Tests
Results of tests were assessed to determine:
16 Investigations
16.1 Existing data on material safety, durability, and properties in relation to fire were evaluated.
16.4 Calculations were undertaken to confirm the thermal conductivity value (λD).
16.5 The manufacturing process was evaluated, including the methods adopted for quality control, and details were
obtained of the quality and composition of the materials used.
Page 12 of 14
Bibliography
BRE Report BR 262 : 2002 Thermal insulation : avoiding risks
BS EN 845-1 : 2013 + A1 : 2016 Specification for ancillary components for masonry — Wall ties, tension straps, hangers
and brackets
BS EN 1996-1-1 : 2005 + A1 : 2012 Eurocode 6 — Design of masonry structures — General rules for reinforced and
unreinforced masonry structures
NA to BS EN 1996-1-1 : 2005 + A1 : 2012 UK National Annex to Eurocode 6 — Design of masonry structures — General
rules for reinforced and unreinforced masonry structures
BS EN 1996-1-2 : 2005 Eurocode 6 — Design of masonry structures — General rules — Structural fire design
NA to BS EN 1996-1-2 : 2005 UK National Annex to Eurocode 6 — Design of masonry structures — General rules —
Structural fire design
BS EN 1996-2 : 2006 Eurocode 6 — Design of masonry structures — Design considerations, selection of materials and
execution of masonry
NA to BS EN 1996-2 : 2006 UK National Annex to Eurocode 6 — Design of masonry structures — Design considerations,
selection of materials and execution of masonry
BS EN 1996-3 : 2006 Eurocode 6 — Design of masonry structures — Simplified calculation methods for unreinforced
masonry structures
NA to BS EN 1996-3 : 2006 UK National Annex to Eurocode 6 — Design of masonry structures — Simplified calculation
methods for unreinforced masonry structures
BS EN 13501-1 : 2018 Fire classification of construction products and building elements — Classification using test data
from reaction to fire tests
BS EN ISO 6946 : 2017 Building components and building elements — Thermal resistance and thermal transmittance —
Calculation method
EN 13162 : 2012 + A1 : 2015 Thermal insulation products for buildings — Factory made mineral wool (MW) products –
Specification
ISO 14001 : 2015 Environmental Management systems — Requirements with guidance for use
PD 6697 : 2019 Recommendations for the design of masonry structures to BS EN 1996-1-1 and BS EN 1996-2
Page 13 of 14
Conditions of Certification
17 Conditions
17.1 This Certificate:
• relates only to the product/system that is named and described on the front page
• is issued only to the company, firm, organisation or person named on the front page – no other company, firm,
organisation or person may hold or claim that this Certificate has been issued to them
• is valid only within the UK
• has to be read, considered and used as a whole document – it may be misleading and will be incomplete to be
selective
• is copyright of the BBA
• is subject to English Law.
17.2 Publications, documents, specifications, legislation, regulations, standards and the like referenced in this
Certificate are those that were current and/or deemed relevant by the BBA at the date of issue or reissue of this
Certificate.
17.3 This Certificate will remain valid for an unlimited period provided that the product/system and its manufacture
and/or fabrication, including all related and relevant parts and processes thereof:
• are maintained at or above the levels which have been assessed and found to be satisfactory by the BBA
• continue to be checked as and when deemed appropriate by the BBA under arrangements that it will determine
• are reviewed by the BBA as and when it considers appropriate.
17.4 The BBA has used due skill, care and diligence in preparing this Certificate, but no warranty is provided.
17.5 In issuing this Certificate the BBA is not responsible and is excluded from any liability to any company, firm,
organisation or person, for any matters arising directly or indirectly from:
• the presence or absence of any patent, intellectual property or similar rights subsisting in the product/system or any
other product/system
• the right of the Certificate holder to manufacture, supply, install, maintain or market the product/system
• actual installations of the product/system, including their nature, design, methods, performance, workmanship and
maintenance
• any works and constructions in which the product/system is installed, including their nature, design, methods,
performance, workmanship and maintenance
• any loss or damage, including personal injury, howsoever caused by the product/system, including its manufacture,
supply, installation, use, maintenance and removal
• any claims by the manufacturer relating to CE marking.
17.6 Any information relating to the manufacture, supply, installation, use, maintenance and removal of this
product/system which is contained or referred to in this Certificate is the minimum required to be met when the
product/system is manufactured, supplied, installed, used, maintained and removed. It does not purport in any way to
restate the requirements of the Health and Safety at Work etc. Act 1974, or of any other statutory, common law or
other duty which may exist at the date of issue or reissue of this Certificate; nor is conformity with such information to
be taken as satisfying the requirements of the 1974 Act or of any statutory, common law or other duty of care.
Page 14 of 14