cwi masonry system manual - energystoreltd.com · cwi masonry system manual august 2016 - revised...

cwi masonry system manual

AUGUST 2016 - REVISED JANUARY 2018

energystore • system manual 3

Contents

Introduction

energystore background information

energystore’s responsibilities

Bonded bead product range

Adhesive product range

Building regulations

Buildings under construction

Agrément certificates

Installation equipment

Quality checks

Health & safety

Drilling operation

Full fill

Partial fill

Borescope

Cavity Wall Insulation

Pre-Installation building assessment and survey

Pre-Installation property checks - external

Pre-Installation Property checks - internal

Cavity barrier fitting

Filling the cavity: Full fill

Filling the cavity: Partial fill

Installed bead density

Making good

Post installation internal checks

Post installation external checks

Customer care

energystore thermal lanceNB The energystore Thermal Lance is only to be used in conjunction with BDA agrément® BAW 18-070/02/A

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4 energystore • system manual

The installer’s relationship with KIWA BDAKIWA BDA agrément certificate: 18-070/02/A

CIGA & GDGC• Providing a 25 year insurance-backed guarantee.

energystore’s responsibilitiesIt is energystore’s responsibility – as the system supplier

– to advise, support and develop a working relationship

with all installers in order to help them provide the safest

and best quality service to all customers at all times.

energystore will provide the approved and certified

system methodologies, support and updates on an

on-going basis to all approved installer companies from

inception of agreement to termination.

energystore undertakes to:

• Provide training, approval and on-going

monitoring of technicians.

• Issue identity cards to approved installers,

valid for 2 years

• Ensure that all approved installation companies and

their technicians comply with all certification and all

other industry requirements.

• Undertake agreed inspections either with or without

notice. (This will usually be on a frequency of between

10 to 15 week cycles, and usually four per annum, or

as necessary).

Bonded bead product rangeenergystore superbead Cavity Wall Insulation - 0.033 ʎ

IMPORTANT HEALTH NOTICE:

Pentane is heavier than air and will settle at lower levels

e.g. walking/head height in a silo area. It is therefore

essential to ensure the silo area is well ventilated at all

times.

As a precaution we would suggest that if you have had a

delivery say on a Friday, and the store is closed up for

the weekend, you make sure on Monday morning to

open all doors and switch on fans to circulate fresh air as

quickly as possible. Should you feel ill or unwell vacate

the area immediately. And remember to inform others.

Adhesive product rangeThe range of energystore adhesives are individually

designed to work with each of the bonded bead types

available. Installers are required to use only the adhesive

supplied by energystore.

To get an effective bond it is essential you use the

correct adhesive designed specifically for the bead

product you order.

Storage of adhesives anddirections for use:• Do not allow the adhesive to freeze.

• Keep out of direct sunlight.

• Store all adhesive at between 5-25˚C.

• Only use approved adhesive.

• Adhesives come in two types, one to be diluted and

one that should not be diluted. Follow the instructions

on the drum carefully, and if in doubt contact

energystore prior to commencement of work.

• Filter all adhesive before use.

Introduction

energystore has been a manufacturer and supplier of

insulation to the building trade for 50 years and holds

many accreditations for its products.

energystore is the ‘system designer’ and in being so, is

the sole supplier of insulation materials to you – as a

licensed installer – under our signed agreement.

energystore company background


• Specialised adhesives are available for use in winter

and extreme cold conditions.

• Adhesive must not be allowed to freeze or sit in

sunlight, precautions must be taken to store materials in

a frost free environment. Batch numbers must be taken

and noted to allow for accurate traceability and the

expiry date must not be exceeded.

Building regulationsReference: CIGA manual: Installing Cavity Wall Insulation.

(Page 3).

Building notices - Northern Ireland, England & Wales:

All installers are now legally obliged to submit a building

notice to the Building Control Office of the appropriate

Local Authority at least 48 hours before installation (or as

specified). Failure to submit is a criminal offence which

carries the risk of fine and/or Imprisonment.

UK regional building regulations:

• The Building Regulations (England and Wales)

• The Building Standards Regulations (Scotland)

• The Building Regulations (Northern Ireland).

Buildings under constructionNEW BUILD SURVEY FORM

• A New Build Survey Form is to be completed before

any install works and must detail: services, cavity

closures, fire check barriers, boilers, fires and flues.

• Following installation, the entire wall cavity must be

sealed for weather proofing.

• It is essential that plastering is not started before the

CWI installation is complete.

• The drill pattern used will follow as per a brick pattern,

where all holes are drilled into the mortar joints

between the blocks

Reference: CIGA New Build Survey Form, within

Installing Cavity Wall Insulation (Page 33).

INSPECT OTHER BUILDINGS

Inspect other buildings and works on a new build site.

This will help familiarise you with more types of property

and build styles.

New build properties are not covered by a CIGA

warranty. Warrantees for new build properties are

usually supplied by the NHBC (National House Building

Council) and or from the architect responsible for the

build and its planning.

Agrément certificates: Certificate Number BAW 18-070/02/A

This Agrément Certificate Product Sheet

relates to energystore Superbead Cavity Wall

Insulation, expanded polystyrene material

injected in bead form with or without a

bonding agent, for use in external masonry

walls up to and including 12 metres in height,

with nominal cavity widths not less than

40mm.

Agrément certificates: Certificate Number 06/0168

This Agrément Certificate Product Sheet

relates to Graphite 27 Plus Cavity Wall

Insulation, expanded polystyrene material

injected in bead form with or without a

bonding agent, for use in external masonry

walls up to and including 12 metres in height,

with nominal cavity widths not less than

40mm.

Installation equipment

SYSTEM MANUALThis installer manual should be carried on site by all

installers and be available at all times. It sets down

measurable standards and routines to ensure quality and

professionalism.

CAVITY WALL INSULATION INJECTION MACHINERYThe cavity wall insulation injection machinery system has

to be regulated in order to achieve all relevant

certification body approval.

Any changes to the installation system used by a

registered installer must be approved before being put

into use on site.

All approved installation system machinery should bear a

registration plate which is specific to the install system

and cavity wall insulation product being used.

All cavity wall insulation systems and injection machines

must operate in strict accordance with the system

specification and KIWA BDA certification.

KIWA BDAThe preferred system of installation described in this

manual, together with all material recommended for

cavity wall insulation have been tested and approved by

KIWA BDA. The materials and\or system of installation

described should NOT be altered.

All approved operations and policies and their cautionary

procedures exist for the safety of the property occupier,

the customer, installers and members of the public.

COMPRESSORSCompressors should be of a suitable capacity to deliver

the required psi/bar as stated by the system designer.

This will vary depending on:

• the number of delivery hoses attached

to the compressor.

• the operating lengths.

• the height of the building and/or

its distance from the truck.

The compressor should operate at a working pressure of

7bar maximum.

ADHESIVEAdhesive must be fed through a flexible hose to the rear

of the injection gun, then through a jet sprayer which

sprays a fine coating of adhesive over the beads before

they are pumped directly into the cavity of the wall under

the suggested operating pressures as per the flow rate

chart opposite.

To find the Adhesive Flow Rate per Minute open valve to

jet and establish a fine, steady spray of adhesive and

collect in an accurately market measuring cylinder for a

period of one minute. Compare flow rate with chart and

adjust accordingly.

MATERIALS QUALITY CONTROLRecords must be kept of delivery of adhesive and bead

from the suppliers, and must include the following:

1. Date of receipt2. Batch/Product Number3. Quantity Delivered and Container Size4. Quality checks that were made on each product and any action required

BEAD DELIVERY HOSEThis is usually 38mm (internal) diameter with a coiled

Helix anti-static reinforcing, to earth any electrical

charges. The hose has a smooth inner facing.

AIRLINE HOSEAirline hoses are a 12mm reinforced piping and convey

high pressure air from the compressor to the regulators,

the control valves and the head of the gun (also known

as the venturi chamber).

ADHESIVE LINEThe adhesive line conveys the adhesive from the glue

chamber to the delivery gun. The line is usually between

6mm and 10mm in diameter.


It may be necessary to alter the jet size to achieve thecorrect adhesive flow rate.

Table of flow rates bead/adhesiveThe following is a comprehensive list of equipmentand accessories required by all installers of cavitywall insulation.

Bead flow(kg/min)

Cavities40-99mm(ml per min)

Cavities100mm +(ml per min)

Partial fill(ml per min)

Upward fill(ml per min)

0.6

0.7

0.8

0.9

1.0

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

2.0

140

155

190

205

220

245

265

285

310

330

340

360

380

400

420

155

165

180

195

220

240

260

280

300

320

340

360

380

400

420

140

155

170

185

200

220

240

260

280

300

320

340

360

380

400

100

110

120

130

140

150

160

170

180

190

200

210

220

230

240


DELIVERY GUNThe preferred internal construction of the delivery gun is

always of steel or aluminium. The delivery gun has a

diameter of 22mm or 26mm.

The pre delivery area is also known as the ‘Venturi’.

Essentially it is the area where the bead is mixed with the

adhesive to form a bonding blend which will then cure

and set in the cavity wall.

ADHESIVE FLOW/REGULATIONThe adhesive flow is controlled by adhesive injection

jets. These are available in a variety of sizes and can be

interchanged to regulate the adhesive flow without

compromising the air pressure flow.

OPERATING PRESSUREThe system is designed to operate at a safe maximum

pressure. Preset safety valves must also always be fitted

during operation.

The maximum pressure for delivering the two main

products is for:

• Bead delivery 7 bar

• Adhesive delivery 5 bar

(may be regulated to adjust flow rate)

Quality checksFACTORY QUALITY CONTROLFactory quality control is in place to ensure that the size

and density of all bead products matches the required

specification and that installers’ equipment is operational

in accordance with the energystore system manual.

This involves:

• Checking the diameter of bead by passing samples

through a graded series of sieves.

• Checking the density of bead by filling a vessel with

dry bead and then weighing the contents hourly during

production process.

Installation equipment tests

Installer equipment is inspected daily prior to

commencement of work and the results of these

inspections recorded – flow rate, bead weight/density.

Flow rates calculated by filling a hessian bag with dry

bead for 60 seconds, bead is then weighed and

recorded.

Select from the table the appropriate adhesive flow rate

(AFR) in accordance with the flow rate of the bead and

density (DBD) of the bead being used.

Ratio of adhesive to bead must be correct, to ensure this

a bead flow rate check should be carried out and the

flow rate of adhesive adjusted to suit, see energystore

table of flow rates bead/adhesive.

The pump is charged with adhesive and all

interconnecting lines and pipes are fitted. Compressor is

started and adhesive pump is pressurised to 5 bar.

Health & safetyIt is the responsibility of all installers and their employees

to ensure that they are working in accordance with the

Health and Safety at Work Act at all times.

It is the duty of every employer – as far as is reasonable

– to ensure the health and safety of every employee.

It is also the responsibility of every employee to take

reasonable care of their own safety.

All employees must make themselves aware of the

company’s Health & Safety policies and procedures at all

times.

PROTECTIVE CLOTHING & EQUIPMENTInstallers are required to have the following available to

them at all times on site:

• Gloves (anti-white finger gloves for drillers)• Hard hat• Reflective tabard/Jacket/Coat leggings• Appropriate dust mask• Ear defenders• Disposable gloves• Hand wash/barrier cream• Protective footwear• Harness • Ladder lanyard assembly• Securing brace/hook

INSTALLATION EQUIPMENT• Ensure all those operating any equipment on site have had the appropriate training.

• Take special care when moving equipment and materials in order not to put yourself or others at risk.

• Be sure to disconnect the power supply when not using electrical equipment.

ACCESS EQUIPMENT

• Make sure all access equipment is securely connected, joints are secure and in good order,bolts and couplings are not damaged and correctspanners are used in order to prevent ringing boltheads.

• Make sure access equipment is securely attached to the building with the correct harness straps andbolts in place.

• Check that all walkways on scaffolding and towers are secure and with the correct planked walkways and side kick boards fitted.


EMPLOYERS RESPONSIBILITYIt is the employer’s responsibility to ensure all staff are

trained and have a good working knowledge of any

equipment they are required to operate.

Also that all staff have had adequate Health & Safety

training to protect their wellbeing and that of other team

members, other trades persons and customers.

Also CIGA: Working at Height in the Retrofit CWI Industry

(Sections 6 to 9).

BODY HARNESSES AND PERSONNELBODY PROTECTION EQUIPMENTAll staff – without exception – are required to wear

protective harnesses at all times while working.

Failure can result in dismissal and the employer being

fined or receiving a custodial sentence.

HANDLING MATERIALS• Wear protective clothing at all times when handling materials.

• Never strain or expect others to risk injury.• Whenever possible spread the load with colleagues when moving heavy materials or equipment.

DRILLING• Secure drills to lanyard or secure line whenever possible.

• All drilling must be undertaken in a safe manner and with due care to the property, making sure the inner section of walling is not shattered by drilling with excessive force.

• Care must also be taken to make sure you do not drill through any single sectional walling.

• Check that no cables are present to prevent drilling through the power supply.

COMPRESSED AIR• Ensure the compressed air is controlled and conveyed through the recommended equipment.

• Make sure all hoses are in good order, free of cracks, splits and fractures.

• Replace any damaged hoses and/or connections immediately.

• Check safety valves at least once a week.• Check the compressor’s operation every week.• Use only correctly sized couplings/connections.• Only qualified employees should operate the equipment.

• Only operate the equipment in line within the safe or recommended maximum pressure.

LADDERS• Before commencing works, check that ladders are the correct grade for heavy trade use and are in

good order. If there are any signs of wear ordamage the ladders should be replacedimmediately.

• Use ladders at the recommended angle.• When using restraints make sure not to over tighten the ladder to the angle of the wall, as this will cause metal fatigue and weaken the ladder.

Ref: CIGA: Working at Height in the Retrofit CWI Industry

(Sections 5 & 6).

HOSES & CABLESWhere hoses and cables cross the public footpath,display warning notices and make a simple footbridge to avoid leaving a trip hazard.

Drilling operationTypes of Drill: Electric/air powered drills. Drill holes must be sized between 22-26mm

• Always avoid drilling into a chimney stack or flue.• Do not drill in line with the first floor joists or ceiling levels.

• Usually drill 200mm below ceiling joist height.• Always use quality sharp drill bits.• Drill with light pressure to minimise debris falling into cavity.

• Drill holes horizontally – not at angles.• Allow 600-700mm of space between drill holes at top of elevation. Any further horizontal holes required 2m apart.

• Drill between 200-300mm below windows or any obstruction through the cavity.

• Drill between 100-250mm in from the edge of the wall.

• All drilling should only go to a depth of 110mm into the cavity space to create access.

• Polypropylene Cavity Brushes must be fitted, all vents sleeved and vent covers replaced.

DRILL POINTS

• Drill holes should be made at the bottom of the perpend in mortar joints.

• Consider the building features when drilling; be sympathetic to the cosmetic appearance of allproperties at all times

• Take care around building features without causing damage to bricks.

• Always discuss and explain the drilling pattern with/to customers.

• Keep customers well informed at all times.• Remember: Good communication is key to customer satisfaction.


Drill patternsFULL FILL DRILL PATTERN

• Gable ends: fill or omit? Check what has been agreed with the customer. Is the area occupied? If it is, it has to be filled.

Filling must not commence until such time that the

elevation has been completely drilled out, to avoid falling

debris etc. bridging the wall cavities.


The energystore Certificate covers the use of our

products to fill partial filled cavities where the existing

insulation is either mineral wool (MW) batts, expanded

polystyrene (EPS) boards or foil faced insulation boards.

The minimum residual cavity width must not be less than

40mm for energystore superbead.

Additional holes should be drilled at 1000mm and

1100mm apart at 1.5m above DPC and another series of

holes are drilled 1000mm to 1100mm similar apart at 3m

from the DPC level. A series of drill holes is drilled below

windows and obstructions.

Our KIWA BDA & NSAI certificates give details on

Partial Fill allowable omitted areas.

• KIWA BDA agrément certificate: 18-070/02/A

• NISAI agrément certificate: 06/0166

Further details for Partial Fill are provided in thismanual, see pages 14 &15.

PARTIAL FILL

Additional holes should be drilled at 1000mm and 1100mm apart at 1.5m


BorescopeBorescope inspections must be carried out to verify the

existence of insulation products within the cavity. For

new build properties one borescope inspection must be

done per elevation.

A minimum of three borescope inspections per elevation

must be carried out for Partial Fill or Extraction including

one just above DPC level and recorded clearly on the

survey sheet. For an empty cavity 1 inspection per

elevation must be carried out and clearly recorded.

Further information on borescope will be provided in this manual for Full Fill and Partial Fill Jobs.

DPC line

BORESCOPE INSPECTION

Minimum survey sites per wall


For further details please refer to theenergystore Survey Manual

Pre-installation buildingassessment and survey The following checks must be made prior to thecommencement of all CWI works:

• Building must be surveyed to ascertain its suitability for CWI.

• A minimum of 3 borescope inspections per elevation must be carried out and recorded clearlyon the survey sheet.

• The Installing team must also make the same checks before the installation commences.

• Flues, Chimneys and combustion air ventilators must be both pre- and post-inspected and tested inaccordance with: CIGA Flues, Chimneys andCombustion Air Ventilators Manual (Pages 13-16).

• Always check that the details on the survey form are accurate and have described the cavity wallsaccurately.

• Go through all the details of the property inspection report with the customer explainingprocedures, checks and tests required.

• Complete an assessment form and explain to the customer all the internal and external checks to becarried out.

Reference: CIGA Manual: Suitability of External Walls for

Filling with Cavity Wall Insulation. (Pages 2.4 to 2.6.2).

Identifying the construction of properties and site conditions

• Is the external wall of cavity construction?• Is each leaf of masonry construction?• Is the height of the wall less than 12m?• Is the construction appropriate to the locality including its exposure

Are the following within normal expectations:

The exposure to wind and driven rain

The nature of the site

The form of construction

Properties above 12m in heightProperties that are taller than 12m in height require a

height restriction waiver. As a certificate holder

energystore has a programme for assessing these

buildings as approved and maintained under surveillance

by all relevant certification bodies. Each installation

above 12m must be individually assessed against the

agreed assessment programme and documented

approval given before work commences

Pre-installation property checks: external

Why are external checks necessary?

• To ensure the installation is carried out to an acceptable and approved specification withoutdamage to the property or exposing any individualsto health and safety risks.

• To confirm the property is suitable to for cavity wall insulation.

Installers on site, prior to commencement of theinstallation works must:

• double check the initial assessment. Is there anything unusual or different from the initialassessor’s report?

• carry out a hazard awareness assessment; even if one has already been undertaken - conditions mayhave changed.

CHECK garage roofs

• Examine the support structures ensuring it is safe to access without damage.

• Only use approved safe working practices.• Use scaffolding boards for walking, remembering to check that the pitch is not too steep or slippery.

• Make sure the roof is properly supported.• Use scaffolding boards with a canvas sheet below them, this is to maximise grip and prevent slippingor moving.

• Check that the roof pitch is not too steep.• Use access equipment such as a hydraulic tower unit, a scaffolding tower and/or platformframework

Reference: CIGA manual - Installing Cavity Wall

Insulation. (Pages 9-13). Also: CIGA manual - Working at

Height in the Retrofit CWI Industry. (Sections 2, 3, 4, 5,6).

In conjunction with: CIGA - Ladder restraint / Fall

Protection Systems. (Pages 1-9).

CHECK glass and plastic roofs

• Generally fragile structures which can be easily damaged. Glass and plastic roofs are not suitableto bear or carry the weight of a person and can beslippy

• Check that support structures are suitable to bare weight and take special care by spreading weight across a wide area with supports below.

CHECK flues, chimneys & combustion air ventilators

It is vital these are checked before and after the

installation is completed. There are four types of vent

within the external wall of property, these are; Fresh food

larder Vents, Primary air/room Vents, Combustion Vents

and Floor Vents.

Cavity wall insulation


The blocking of a combustion air ventilator or flue of a

fuel burning appliance during the works would risk

exposing the customer to carbon monoxide poisoning

which can prove fatal. If in doubt seek advice.

Reference: CIGA Flues, Chimneys & Combustion Air

Ventilators Manual - Pages 10.

Locate ALL boiler flues, chimneys and combustionair ventilators.

• Check other ventilators. The function and operation must be checked, this must include anyunder floor vents, cavity, roof and room ventilators.Air supply must also be checked to larders andstore cupboards.

• Check Baxi Ducting System• Obsolete Cavity Ventilators must be checked. These must be sealed with an appropriate materialto prevent water ingress and infestation.

Reference: CIGA Flues, Chimneys & Combustion Air

Ventilators Manual - Pages 13 to16).

CHECK cavities with a polypropylene cavity brush...

at adjoining properties which may not be in the

ownership of the customer (e.g. semidetached and

terraced properties). This may also isolate any electrical

cables within the wall of the property.

CHECK condition of external walls

Check mortar joints. Look for settlement cracks, spalling

masonry and render. A fine, crazed effect though the

outer render would suggest poor adhesion of outer

render and possible water seepage into the walling.

This may also be internal where the vibration of the drill

may cause plasterwork to fall away.

CHECK weathering details including:

• Gutters, downpipes and damp proof courses.• Cavity trays and weep holes• CWI must not commence unless all gutters are in perfect condition. If gutters are failing they must belined first.

Reference: CIGA Manual - Installing Cavity Wall

Insulation - Pages 9 to13).

Exposure zonesExposure zone maps were designed many years ago to

assist the construction industry calculate the rate at

which local weather affects water penetration into

properties.

Water ingress through walls, in areas of the country

regularly exposed to bad weather, isn’t always due to

high levels of rainfall alone, but often due to the extent

that the rainfall is ‘wind-driven’.

energystore superbead is regularly subjected to a ‘wet

wall’ test that attempts to replicate the conditions of

extreme, wind-driven rain over a period of three weeks.

superbead has been found to pass this test in cavities

only 40mm wide.

It is essential that surveyors fully understand the risks

posed by wind-driven rain before cavity wall insulation is

installed in properties located in severe exposure zones.

A good rule of thumb is the ‘line of sight’ principle. If a

building is facing the sea, or is in an elevated position

with nothing blocking its ‘line of sight’, or if the building

is at the end of an estate road, it is likely to be more

exposed to poor weather and more likely to suffer from

damp and water ingress.

Site specific assessment of exposure zones

British Standard BS8104:1992 provides a methodology

for calculating the specific exposure zone rating for an

individual location or property. As such, it is possible for

properties to have a lower (or higher) exposure rating

than the area’s overall rating.

The survey method is relatively simple to implement. It

takes into account factors such as wall orientation,

obstructions protecting the property from wind and the

local terrain. If the property appears to be in a very

severe exposure zone, the surveyor should consider the

assessment guidance of BS8104 to determine the

property’s suitability for cavity wall insulation.


Pre-installation property checks: internalRisk assessment

Locate any boilers, fires or combustion air ventilators,

both working and redundant. Inspect and carry out a flue

test. Anything unusual? Ask the customer if they know of

anything that would affect the CWI installation and/or if

they have any other works planned which may have an

impact on the install.

Reference: CIGA manual: Installing Cavity Wall Insulation.

(Pages 14 to 15).

CHECK ornaments, cabinets, fixtures & fittings

CHECK utilities. Locate electricity & gas supply, cavitywiring, freezers, etc.

CHECK • For any cracks in plaster• The cavity sealing. Check for large holes.• Check consumer boards, fuse boxes and waste and soil pipes.

• Sash windows.• Roof space: Seal gaps, holes and any area if single leaf etc.

CHECK for dampness and condensation

Reference: CIGA manual - Installing Cavity Wall

Insulation. (Pages 15 to16).

Check for rising damp, damp penetration and

condensation. Ask the customer about the history of the

property in relation to dampness and mould. Check for

routes for possible water ingress.

CHECK flues, chimneys & combustion air ventilators

Read through the CIGA manual: Flues, chimneys and

combustion air ventilators to check your responsibilities.

Note the install technician’s safety checklist on the back

cover.

• Locate and identify type of appliance and routes of all flues and chimneys.

• Run appliance and observe flame.• Confirm exit of combustion gasses.• Note position, type and size of combustion air ventilator.

• Check that combustion air ventilator meets current safety standards. Replace air ventilator if it does notmeet current requirements. If it meets currentrequirements however, ensure combustion airsupply is maintained.

• Perform a smoke/spillage test.

Cavity barrier fitting Cavity barriers are fitted between all properties that are

semidetached or part of a terrace. They are fitted inside

the centre line of a boundary wall, from top to bottom.

The only exceptions to this are if the adjoining property

already has CWI installed or is due to have CWI installed

at the same time as a combined job.

The cavity barrier is normally fitted between roof line and

base ground floor line. This is usually a matter of drilling a

22mm hole near the roof plate line (two - three courses of

brick down, and up from DPC) just above DPC line.

Working from the top of the building, lower a weighted

object (plumb line) attached to a cavity chain and lower

through the cavity until retrieved at base line. Withdraw

and adjust the length of cavity chain and brush until it is

in situ from top to bottom.

For a typical semi-detached house you will require two

full lengths of polypropylene cavity brush of a larger

diameter than the cavity space (ie a 50mm cavity requires

a 75mm brush/barrier and an 85mm cavity requires a

100mm brush).

Polypropylene Cavity Brushes are also required to be

inserted where sliding sash windows are fitted and

weights or other items (counterweights) which travel

inside the cavity area.

Reference: CIGA manual: Installing Cavity Wall Insulation

(Page 18).

REMOVAL & SLEEVING OF VENTILATORSRemove any sleeving, then ensure that there is an airtight

seal between both inner and outer ventilators to avoid

leakage both into and out from the cavity area.

Redundant cavity ventilators must be sealed with mortar,

silicone or other suitable material.

The safe operation or function of ventilators other than

cavity ventilators must be safeguarded by the fitting of

polypropylene cavity brush of appropriate size.

NB Only approved/regulatory ventilators and sleeving

methods must be used for the provision of primary

ventilation.

COMBUSTION AIR & PRIMARY VENTILATORSCheck each combustion air and primary air ventilator for

a good air flow/draw, both before and after installation. If

a failure is found then ensure warning notices are

attached and displayed.

Also, report to line manager and ensure remedial

treatment is undertaken as soon as possible.


(Page 19).

CIGA manual: Flues, chimneys and combustion air

ventilators (Page 5 to 8).

STAGGERED OR OFFSET VENTILATORSThe airflow in staggered or offset ventilators must be

protected and maintained. This may require the fitting of


a sleeved ducting system or the realignment of the vents

to leave a clear air passage.

Reference: CIGA manual: Staggered and Offset

ventilators (Pages 4 and 5).

Filling the cavity wall: Full fill

THE DRILLING OPERATIONThe drilling out of a property commences using the drill

pattern agreed – from the base line to the roof line

throughout the building or area to be insulated.

Care is taken with the laying of delivery hoses from the

delivery truck to the property. Where necessary,

step-over ramps are put in place to safeguard

pedestrians and/or customers and installers from falling.

HAZARD SIGNS are also deployed in order to make

people aware.

START THE FILLING OPERATIONPrime flow lines

Make sure any polypropylene cavity brushes and vents

are sleeved and sealed and then repeat the flow test

making sure the flow rate meets the required

specification.

Commence the installation starting at the lowest

injection point then follow the approved sequence.

When each cavity is full, back pressure will stop the flow

of bead (this is seen through the clear section of hosing

that connects directly to the gun). The adhesive valve

must now be immediately closed.

End of Operation: Once the adhesive valve is closed:

• Disconnect and remove all Hoses.• Tidy around the site.• Point all drill holes and vents as necessary.• Carry out flue tests ensuring that none are blocked or restricted.

• Remove all remaining equipment, signs etc.• All installers on-site should inspect the work and then make a final inspection with the customer.

• Invite the customer to sign off the completed job.• Make detailed notes including batch numbers for adhesive and bead.


(Page 23).

Filling the cavity wall: Partial fillKIWA BDA have approved energystore as a system

designer and the energystore approved installer network

to undertake the installation of cavity wall EPS bonded

bead installation into a partially filled cavity within

the following guidelines:

As a reference, the definition of Partial Fill is:• a minimum cavity width of 40mm must exist.

MINIMUM REQUIREMENTSIn addition to the site survey for a ‘standard or

conventional’ cavity, installers must as a part of the site

survey meet the minimum requirements as defined

below:

• The survey is only to be carried out by approved assessors in UK and Ireland

• A minimum of 3 borescope inspections are to be made for each elevation including one just abovedamp course level

• Additional borescope inspections must be carried out at each corner of the building, ie additionalholes per elevation

• Borescope inspections must be included that look along the length of a cavity, ie drill 120-150mm froma corner

• A drill depth stop must be used both during survey and installation

• The exact type of insulation present in the cavity must be identified and confirmed as acceptable

• Partial fill can only be carried out if the existinginsulation is EPS board, foil faced or fixed fibre batt board

• BONDED BEAD CANNOT BE USED to top up a home that has blown fibre insulation in the walls

• The condition of the insulation must be established and confirmed as suitable to allow further filling

• It must be confirmed that the existing insulation is not bridging the cavity

• The insulation board must not be dislodged or loose and must be securely fixed with suitable clipson all wall ties

• The insulation boards must not be overlapping each other in the cavity (see figures 1,2 and 3)

• No insulation should be missing, with particular reference to windows and at cavity heads

• There must not be excessive mortar on wall ties and at the base of cavities

• The cavity must not be restricted by excessive mortar squeeze between bricks in the outer leaf.

The above checks are particularly important where the

wall includes bridging features such as boiler flues,

service boxes, waste pipes etc. In these situations

additional documented borescope checks will be

required.

A clear record of all the findings should be recorded on

the pre install survey sheet.

The filling of all partially filled cavities can only be

undertaken to traditionally built properties, thus

excluding cavity block homes and timber framed homes.

If you are unsure you must contact the System Designer

for further clarification prior to commencement of any

work.


INSTALLATION GUIDELINES

When installing bead into a partially filled cavity the

installer MUST follow the revised drill pattern and use the

energystore Directional Nozzle. Only this drill pattern will

ensure that there is an adequacy of fill. After completion

of the cavity assessment and drilling plan for the building,

preparation for injection into the cavity is as follows:

• The drill should be fitted with a depth stop to prevent damaging the insulation material alreadypresent in the cavity.

• Holes of 22-26mm diameter are drilled in the outer leaf normally spaced 600-650mm horizontally apart and 200mm above the highest ceiling level.

• With respect to a two storey building a further series of holes are drilled 1000-1100mm apart at1.5m from the DPC level and another series of holesare drilled 1000-1100mm apart at 3m from the DPClevel.

• Care should be taken to ensure that these holes do not coincide with the intermediate suspendedtimber floor.

• A similar series of holes is drilled below windows and obstructions.

Where the apex of the gable end wall is to be insulated a

series of holes is drilled along the line of the eaves

approximately 600-650mm apart and 200mm below the

soffit line and also below any window in the gable in the

same way as described for other windows.

A further row of holes are drilled mid-level between the

top of the apex and the wall plate level, approximately

600-650mm apart.

All drill holes must be completed before drilling can

begin.

It is imperative that you carry out three borescopetests per elevation to establish that there are nobreaches in the cavity such as the existing insulationor rubble.

Existing insulation must not be bridging the cavity as in

Fig 1. The insulation must not be dislodged as in Fig 2 or

overlapping as in Fig 3.

INJECTING INSULATION MATERIAL• The injection nozzle is a specially designed directional nozzle which will not damage theexisting board when being installed.

• This nozzle will also be fitted with a depth stop to prevent damage to the rigid insulation board.

• The product is injected into the cavity (having determined the correct bead/bonding agent rationby test) though a flexible pipe.

• The material packs to a uniform density in the cavity and this is not affected by the injection equipment.

Holes beneath ground floor windows are injected first,

and filling then continues upward until a complete fill has

been achieved.


Installed bead density checkHow to calculate density:• measure the volume of materials used m3. (net

area of Walling x Width of Cavity).• Cavity widths can vary considerably, not only from

building to building, but also through the building

walls from base level to roof line.• at least 10 cavity widths should be recorded at

different points throughout the building in order to

obtain a mean average.• target install density is 12±2 kg/m3


(Page 29).

Making goodIt is of the utmost importance that ‘making good’ is done

to as high a standard as possible, leaving the property in

as good order as possible to minimise the impact of the

works on the customer.

Remember: Good practice is the best advertisementfor creating future business.

To make good render and mortar:• Colour match mortar, with bucket and water, trowel and hawk.

• Make sure customer understands a near match is the best that can ever be achieved.

• Clean down walls, windows and woodwork, paths and driveways to remove any loose insulationmaterial or drill dust.

• Mortar mix: mix one part cement to one part of lime, to six parts of sand.

• Mix one part cement to one part of sand. Plasticizers or surfactant should not be used.

• The mortar should be moulded into a sausage shape and then worked into the drill hole andfinished to match the surrounding walling.

• Make good any damaged bricks. Special plungers can be used if preferred.

--

BRICK-FACED PROPERTY

• Make the mortar match as close as possible.• Wet the wall to give a better colour match indication.

• Choose the type and colour of sand typical of the local area.

• Different parts of the building may require different variations of colour and sand/cement mix.

RENDER

Special care must be taken with rendered walls to match

colour, texture, local stone, chip or pebble used. The

making good or finish should be as close as is

reasonably practical to the existing facings.

If necessary colour matching can be achieved with the

use of coloured paints.

PEBBLE DASH OR CHIPPING FACE FINISHES

A white based cement may be useful when filling

white-rendered properties. Alternatively, in many cases

the debris from around the property can be used for

making good.

The mix may need to be wetter to allow the pebbles to

stick in the mix.

To find the cubic metres of bead and litres of adhesiverequired to complete a job you will need:• The average cavity width in mm• The wall area of the job in m2

Calculate bead useageFind the cavity width in the table above and read across to getthe figure for the wall area coverage.Divide the wall area of the job by the figure for wall areacoverage. The result is the quantity of bead required.

Calculate Adhesive UsageFind the cavity width in the table above and read across to getthe figure for the adhesive usage.Multiply the wall area of the job by the figure for the adhesiveusage. The result is the quantity of adhesive required.

Bead & adhesive useageCavity width Wall coverage area

m2 of wall per m3

of bonded bead

Adhesive usagelitres per m2

of wall area

40

45

50

55

60

65

70

75

80

85

90

95

100

125

150

175

200

28.75

25.56

23

20.91

19.17

17.69

16.43

15.33

14.38

13.53

12.78

12.11

11.50

9.20

7.67

6.13

5.75

0.09

0.10

0.11

0.13

0.14

0.15

0.16

0.17

0.18

0.20

0.21

0.22

90.23

0.29

0.34

0.43

0.46

Example:

Bead useage

Adhesive useage

Average cavity width = 60mmWall area of the job = 150m²

Therefore 150/19.17 = 7.82m³ of bead usedFrom the table 60mm cavity width = 0.14 litres ofadhesive per m² of wall area

Therefore 150 x 0.14 = 21 litres of adhesive usedFrom the table 60mm cavity width = 19.17 m² ofwall area per m³ of bonded bead

MANAGING CUSTOMER EXPECTATIONS

Prior to the installation works... If you envisage that a

colour match is not going to be possible, always advise

customers that a repainting of the property’s exterior is

going to be necessary following the install.

Record this observation on the survey and job sheets.

This will leave the customer in no doubt.

Installers can deliver exemplary works where the

customer is happy to accept that they have done their

best. This is the desired result.


(Pages 25-26).

Post installationinternal checks• Check and test all fuel burning appliances.• Check entire building – including roof space – for bead ingress. Remove any bead found immediately.

• Reinstate all electric circuits and appliances.• Check sash windows are operating correctly.• Rehang ornaments etc checking for damage.• Make sure sliding ventilators are open and clear.• Check with the customer that the installation has not caused any damage to their property orpossessions.

Reference: CIGA manual: Flues, chimneys and

combustion air ventilators (Pages 10 to 14)

Also: CIGA manual: Installing Cavity Wall

Insulation (Page 27).

Post installationexternal checks• Check that all drilled holes are re-pointed with mortar, sand and cement mix, that the mix fills and is firmly pressed into the holes.


(Page 28).

SATISFACTORY COLOUR MATCH• Check that the re-pointed drill holes are correctly colour matched (or as near as possible).

• Check that all ventilators are clear of any insulation materials, in the event of any bead being within a ventilation area this must be removed.

FINAL CHECKS• Check that all drill holes are filled, no tools remaining and that all vents and chimneys areworking and clear.

• Check that all dust has been blown down and cleared from paths and drive areas.

• Check that any cups, plates or other such items are removed.

• If any remedial treatment is required, ensure it is recorded and reported for action at the earliestopportunity.

• The site must be left clean and tidy as found.

CUSTOMER SIGN OFFCheck that your customer is totally happy and satisfied

with the installation work and then ensure that they sign

off the job as being complete.

Customer careCUSTOMERS ARE INDIVIDUALS

• Each customer has specific needs, desires, concerns and expectations which must berespected and handled with understanding andgood manners.

• Be sure you understand your customer’s expectations in order to avoid issues later.

• Be polite at all times. Do not be over familiar or too friendly, as this may cause offence.

• Be professional at all times.• Explain what you are doing and why, to keep the customer informed and happy.

• Give them the opportunity to air their concerns before commencing any works. It will save youtime and trouble later.

• If you think you are going to have a procedural problem, bring it to the attention of the customeras soon as possible, discuss options and agree away forward, noting on the job card the deviationand agreement reached.

• Note all reasons for, and changes to, standard procedure taking photographs and recordingdetails of the agreement reached with thecustomer and the final outcome. Also include thetestimony of any colleagues present.

• Ensure that your actions are always in the customer’s best interest.

• Always encourage the customer to inspect and sign off completed installation work, noting anychanges, agreements and comments plus furtherworks agreed.

• Always get a customer signature of satisfaction.


(Page 31).


METHOD

Site AssessmentTh e lance system can only be used after a detailed

survey has been carried out by a qualified, competent

surveyor and in accordance with energystore training and

Agrément Certificate.

If the lance is required the surveyor must assess the hard

to reach area, identifying where and why on the survey

sheet no other alternative is possible. A risk assessment

must also be carried out and submitted at the time of the

survey along with a photograph of the elevation in

question.

When surveying a party wall it will probably not be

feasible to drill internal inspection sites. Therefore, a

borescope using a minimum of a one meter lens should

be used. This should be inspected from either end of the

party wall at higher and lower level.

The customer must be informed that the lance system is

being used and the reason why it is necessary.

OPERATING PROCEDURE

The following procedure must be used when installing

energystore superbead into a property with traditional

brick and block external cavity walls using the lance

system.

Before any work commences the installer must prepare

the site which includes performing a specific risk

assessment. Any existing services, balanced flues or air

vents should be checked to ensure functionality.

energystore thermal lance

When a survey is performed to install cavity wall insulation, in some instances a standard

drill pattern cannot be adopted. This may be due to (but not restricted to) there being a

car port, shed or conservatory on site, or if there are access or health & safety issues or

the need to fill additional walls – for example party walls.

To overcome these issues with a minimum of disruption or intrusion, the energystoreLance System may be used. As well as negating the requirement for costly access

equipment the lance system eliminates the necessity for drill holes on the face of the wall.

The energystore Thermal Lance in operation on site


In conjunction with BDA agrément® BAW 18-070/02/A

The lance can be telescopically extended, but all

sections must be checked thoroughly before use to

ensure each section is not damaged.

Before using the lance, the bead and glue must be

calibrated. In order to do this the following procedures

should be carried out:

• Use directed nozzle unless blowing upwards i.e.

between windows

• Determine the weight of the test sack

• Extend lance to maximum length required and blow

beads into the test sack for one minute

• Reduce lance to minimum length required and blow

beads into the test sack for one minute

• Weigh both sacks of dry bead and deduct the original

weight of the sack

• Multiply the two sack weights together and divide by

two. This will give the average bead flow rate per minute

• Set the air pressure at approximately 5 bar

• Ensure adhesive jet is clean

• Spray the adhesive into a measuring vessel for 30

seconds

• Double the amount of adhesive measured to give the

flow rate for one minute

• Compare the results to the energystore table of flow

rates and adjust accordingly

• Maximum length of lance is 4m.

DRILLING

1. Drill holes on each side of the wall at the top of ground

floor ceiling level and again at the top of first floor ceiling

level. Where possible holes should be located at the

junctions between the horizontal and vertical mortar

joints.

2. Depending on cavity width and height of the building,

adjustments may be made within these limits.

3. Drilling should always commence from the lowest

point and work upwards.

4. Holes of between 22-40mm are drilled in accordance

with the drill pattern (see diagram A). The holes are

spaced no further than 120-130mm from any edge of the

wall (see thermoscopic drill pattern diagram – figure 1).

5. Holes must be drilled no more than 450mm from the

top of the wall i.e. soffit height.

6. Installation should not start until all drilling is complete

to avoid debris falling on the insulation.

FILLING

7. The lance is then inserted into the cavity. When fully

inserted to the pre-measured length the filling may

commence. When the installer encounters a back

pressure of air this area is filled and the lance should be

retracted by 1m and the process repeated. This is

repeated until the final 1m of the lance has filled the

cavity. At this stage the lance should be removed and a

normal gun used to fill the last 1m of the cavity.

8. Installation should be conducted in accordance with

the correct drilling pattern, shown in figure 1. The

installation should begin at the lowest injection holes.

The upper holes should only be used after the lower

holes are filled with bead.

9. For difficult filling areas i.e between windows, the lance

should be completely retracted and the directional nozzle

should be changed to a nozzle with a 90º bend – see

below. The lance should then be extended between the

windows and the fill of this area should commence (See

diagram overleaf).

10. Chimneys and flues must be checked to ensure they

have not become obstructed by the installation of bead.

After completion of the installation, the correct

functioning of the chimneys and flues should be checked

in accordance with CIGA guides to best practice.

FINISHING

After filling is complete, the drill holes should be fully

filled with mortar to match the colour and texture of the

existing wall. Post installation of vents and flues,

including a smoke test if required, should be completed.

The site should be cleaned down and a final inspection of

the site should be completed with the customer before

the job is signed off.

CLEANING

The lance sections and injection equipment should be

thoroughly cleaned after use. It is important to keep the

sections of lance completely clean to avoid future

problems of blockages that may otherwise occur.

Figure 2 - 90º bend nozzle


Filling sequenceusing the Energystore Thermal Lanceif the loft is converted

Outlets when Energystore thermal lance retracted

Diagram A

120-130mm from the edge will find the centre of the cavity

Cavity

Energystore original drill pattern/holes

Energystore thermal lance drill pattern/holes

Figure 1

Front elevation Rear elevation

Side elevation Side elevation


Figure 2

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