Europe’s green insulation

Styrodur®C

Load Bearing and Floor Insulation

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1 Styrodur® C thermal Insulation 3

2 Advantages of Styrodur® C 4

3 Load Bearing Applications and Floor Insulation 4

4 Applications 5

4.1 Styrodur® C below Foundation Slabs 5

4.2 Load Bearing Applications on Roofs 5

4.3 Styrodur® C in Road Construction 6

4.4 Styrodur® C in Ceilings against Unheated Attics 7

4.5 Styrodur® C in Floors 7

4.6 Styrodur® C in Floors above Unheated Basements without Subsonic Noise Protection 8

4.7 Styrodur® C in Floors with Subsonic Noise Insulation and Floor Heating above Unheated Basements 9

4.8 Styrodur® C Insulation against the Ground with Floor Heating 9

4.9 Styrodur® C for Top-Side Insulation of Floor Slab in Industrial Construction 10

5 Technical Data Styrodur® C 11

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n1. Styrodur® C Thermal Insulation

Styrodur® C is BASF’s environmentally friendly, extru-ded polystyrene rigid foam. It is free of CFC, HCFC and HFC and makes an important contribution towards reducing emissions of carbon dioxide (CO2).

Due to its high compressive strength, low moisture absorption, long working life and its resistance to decay, Styrodur® C has become synonymous with XPS in Europe. The compressive strength is the main dis-tinction between the various Styrodur® C-types.

Effective thermal insulation with Styrodur® C reduces energy consumption with the result that the investment in thermal insulation can be recouped within a short period of time. It makes for healthy and comfortable living and protects the building from the effects of moisture as well as high and low temperature.

Styrodur® C is manufactured according to the require-ments of the European norm DIN EN 13 164 and its reaction to fire has been classified as Euro Class-E according to DIN EN 13501-1. It is subject to extensive assurance tests from “Wärmeschutz e.V.” and has been granted the approval no. Z-23.15-1481 from the “DIBt”, the Institute of the Federal and Länder Governments for a uniform fulfillment of technical tasks in the field of public law.

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2. Advantages of Styrodur® C

Styrodur® C is used for the reduction of heat losses, to increase your comfort of living and to protect buildings from damages. Among other conditions it is oftentimes subject to heavy loads.

Examples for such heavy loads are: Earth thrust Structural loads (furniture, superstructural parts,

merchandise) Dynamic load (vehicles e. g. for transport)

and Greening and patio surfaces

For many applications, compressive strength is the crucial factor in choosing the right insulation. For con-struction purposes it is also important that the insulation is not subject to brittle fracture when used on uneven or inhomogeneous ground. Despite its high compres-sive load, Styrodur® C is elastic to such extend that it adjusts to any unevenness and reacts to peak loads with plastic deformations rather than with material dam-age.

If the load, the type of load and the extension and duration of the load effect is known, the existing com-pressive strength within the insulation board can be calculated. There are various types of Styrodur® C for all different strains.

For choosing the right type of insulation it is important to know whether the strain is short-term or permanent. The existing compressive strength must not exceed the maximum strength allowable for the insulation. For more than 40 years, Styrodur® C has proven valuable when it comes to load bearing insulation.

3. Load Bearing Applications

Why you need heat insulation

Floors protect living-, working- and common areas against surrounding air, colder rooms or directly against the ground. In a single family detached house the heat loss of the floors against the basement or the ground are up to 20 % of the total heat loss of the house.

Minimum heat insulation

DIN 4108-2 determines the minimum insulation values for living areas heated to the average indoor tempera-ture (≥ 19 °C).

Regulating the minimum heat insulation shall protect the residents from health problems caused by low tem-peratures of the perimeter walls and structural damages caused by condensation.

The Energy Saving Ordinance (Energieeinsparvordnung – EnEV)

The Energy Saving Ordinance is a basic element of today’s climate protection policy. In requiring the con-sideration of heat insulation when calculating the annual demand for thermal heat and the annual demand for primary energy the EnEV makes way for an economic combination of constructional heat insulation as well as industrial and building systems.

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Fig.1: The parking roof – a load bearing application of Styrodur® C.

Fig.2: Attic insulation with Styrodur® C.

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4. Applications

4.1 Styrodur® C below Foundation Slabs

Styrodur® C meets every requirement for heat insulation in cellar rooms. It provides high compressive strength, resistance to decay and low moisture absorption. It has been state-of-the-art building insulation for many years now.

Styrodur® C can also be used as thermal insulation for foundation slabs (Fig. 3).

In more and more houses and office buildings, founda-tion slabs from reinforced concrete are being used for the foundation. In order to avoid thermal bridges, it is advisable to lay Styrodur® C below the foundation slabs and directly attach the perimeter insulation of the base-ment wall.

Lohr Elemente E. Schneider GmbH from Gemünden (Germany) offers prefabricated elements of Styrodur® C for the production of round formwork for foundation slabs and anti frost heave constructions. For such an application the thermal insulation is extended into the ground beyond the foundation slab to prevent frost heaves below the foundation (Fig. 5).

4.2 Load Bearing Applications on Roofs

Styrodur® C is used for the following applications: Roof terrace Green roof Parking roof

In order to increase the housing quality of a building many flat-roofs are being converted into roof gardens. On inverted flat roofs, Styrodur® C can protect the roof sealing from mechanical damages and high thermal strain. It can handle heavy loads without difficulty due to its high compressive strength.

Styrodur® C is also applicable with point loads e. g. from stilted pavement slabs, distributed loads e. g. from storing the slabs in coarse gravel or for the conversion into a roof garden.

Fig.3: Insulation of a foundation slab with Styrodur® C.

Fig. 4: Laying of Styrodur® C boards.

Styrodur® C below Foundation Slabs n Load Bearing Applications on Roofs

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Fig. 6: Vegetated accessible roof terrace with irrigation system from ponds on an inverted roof construction with a full gravel drainage course.

Fig. 5: The frost protection layer is put into the ground below the frost line.

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Load Bearing Applications and Floor Insulation n Styrodur® C for Road Construction

Due to the increase of inner-city traffic, parking places become scarce. Therefore, many roofs of public build-ings and large department stores are converted into parking roofs. To compensate for any heat loss of the heated top levels against the surrounding air, the roof is being insulated with Styrodur® C following the inverted roof concept (Fig. 7). The high compressive strength of Styrodur® C guarantees limitless stability under the load of parked or driving vehicles.

4.3 Styrodur® C in Road Construction

Applications in Road Construction: Track beds Road beds Airports

If the ground is exposed to frost heave its lifting and sinking can lead to uncontrolled deformation of the tracks. For such cases, Styrodur® C can avoid the pen-etration of the frost into the material and the creation of ice lenses within the substructure (Fig. 8).

The subgrade protection layer can be significantly reduced when using Styrodur® C. Heavy dynamic loads caused by rail traffic constitute the utmost quality requirements for Styrodur® C.

Applied in road beds, Styrodur® C prevents the pen-etration of frost into the ground thus avoiding frost heaves as well as deformations of the road. In addition it reduces the necessary depths of the road bed, which leads to fewer construction and maintenance costs.

Styrodur® C also demonstrates its outstanding proper-ties when it comes to heavy loads: If the ground is insu-lated with Styrodur® C it can sustain the heaviest load being inserted into the ground via the props of a tripod construction.

Fig. 8: Frost protection for track beds with high compressive-strength Styrodur® C.

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Fig. 7: Parking roof with concrete slab pavement on inverted roof with Styrodur® C.

Fig. 9: Laying of Styrodur® C into track bed.

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Fig.12 Ground of an airplane hangar with floor heating on Styrodur® C.

Styrodur® C for Ceilings in Unheated Attics nStyrodur® C in Floors

4.4 Styrodur® C Ceilings against Unheated Attics

A lot of energy is saved if the upper side of a building’s top floor above the living areas is insulated. The Styrodur® C boards can be topped with running boards, hardboards or floor pavement depending on how the room is being used.

In order to achieve a thermal transmission coefficient of approx. 0.22 W/(m2·K) one needs an insulation layer of approx. 14 cm.

Since the attic and any chimneys therein are no longer heated, it is necessary to check for the possible danger of condensation from the fumes within the chimney.

Fig. 10: Insulation of an attic with Styrodur® C.

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Surface courseFloor heatingPrestressed and untensioned concretePolyethylene, two layersGravel/SoilThermal insulation Styrodur® CBlinding layer B 15Subgrade

Fig. 11: Insulation of an airplane hangar with Styrodur® C.

4.5 Styrodur® C in Floors

Styrodur® C is also used for: Perimeter insulation Industrial construction Warehouses Cold storage houses Ice rinks Airplane hangars

Depending on the way they are being used, floors are subject to various kinds of heavy loads. Warehouses for example, are subject to compressive stress caused by heavy storage goods or heavy vehicles such as forklift trucks. Additionally, in cold storage houses a consist-ently low temperature has to be kept at all times. With Styrodur® C you can achieve just that (Fig. 12, 14, 16 and 17).

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Styrodur® C in Floors nStyrodur® C in Floors above Unheated Basements without Subsonic Noise Protection

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4.6 Styrodur® C in Floors above Unheated Basements without Subsonic Noise Protection

For floors in rooms above unheated basements we sug-gest a thermal transmission coefficient of ≤ 0.35 W/(m2·K). You can achieve this e. g. with a 16 mm thick reinforced concrete floor slab with 50 mm of floor pavement and an insulation with 10 cm Styrodur® C.

The Styrodur® C boards are slotted on even ground (Fig. 19), covered with polyethylene and topped with floor pavement.

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Fig. 16: Styrodur® C under ice rink.

Fig. 17: Reference: The Steel Arena in Košice (Slovakia). Home of the 2011 Ice Hockey World Championship. The new hockey arena is insulated with Styrodur® C.

Fig. 18: Floor insulation with Styrodur® C.

Fig. 14: Forklift truck and heavy storage goods strain the heat insulated floor of the cold storage warehouse.

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Surface course Reinforced floor pavementPolyethylene sheet (sheet of drift and separationlayer)Thermal insulation Styrodur® C, two layersVapor barrierRadiant heating concreteBlinding layerSubgrade

Fig. 13: Thermal insulation with Styrodur® C in floor of cold storage warehouse.

Wheel load

Block pavingSandbed GeomembraneGravel layer 8/16Geomembrane Thermal insulation Styrodur® C SealingReinforced concrete floor

Fig. 15: Wheel load on floor insulation with Styrodur® C.

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4.7 Styrodur® C in Floors with Subsonic Noise Protection and Floor Heating above Unheated Basements

For floor heating we suggest a thermal transmission coefficient of ≤ 0.35 W/(m2·K) for the construction components between the heated floor and the unheated basement. Should a subsonic noise insulation be nec-essary, we recommend the combination of a soft sub-sonic noise insulation board and hard Styrodur® C boards. You need 8 cm of Styrodur® C for a 35/30 subsonic protection board (Fig. 20).

The subsonic noise insulation board adjusts to the unevenness of the slab and together with the edge-trim guarantees for the subsonic noise insulation. The hard Styrodur® C board offers the necessary additional thermal insulation while at the same time providing a solid ground for the pipes of the hydronic floor heating (Fig. 21).

Fig. 21: Thermal insulation with floor heating.

Fig. 20: Floor insulation with subsonic noise protection in living areas.

Fig. 19: Insulation of a basement floor.

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Styrodur® C in Floors with Subsonic Noise Insulation and Floor Heating above Unheated Basements nStyrodur® C Insulation against the Ground with Floor Heating

Fig. 22: Floor construction with Styrodur® C.

Insulated Insulated with floor heating

4.8 Styrodur® C Insulation against the Ground with Gloor Heating

For this application we also recommend a thermal transmission coefficient of ≤ 0.35 W/(m2·K) for the con-struction components between the heated floor and the ground. We suggest 12 cm of Styrodur® C.

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Note:

The information submitted in this publication is based on our current knowledge and experience and is referring only to our product

and its properties at the time of going into print. It does not imply any warranty or any legally binding assurance about the condition

of our product. Attention must be paid to the demand of specific applications, especially the physical and technological aspects of

construction and building regulations. All mechanical drawings are basic outlines and have to be adapted to each application.

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4.9 Styrodur® C for Top-Side Insulation of Floor Slab in Industrial Construction

The top side insulation of floor slabs is especially recommendable for subsequent thermal insulation of existing industrial floors and for the installation of a floor heating system (Fig. 23).

The Styrodur® C boards are conjoined on top of the floor slab and covered with polyethylene. On top, a concrete slab is installed in order to balance the load of e. g. forklift trucks or the feet of shelves.

Abb. 23: Insulation of industrial floor with Styrodur® C.

Styrodur® C for Top-Side Insulation of Floor Slab in Industrial Construction

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5. Technical Data Styrodur® C

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1) N/mm2 = 1 MPa = 1.000 kPa 2) dickenabhängig 3) ab 30 mm Plattendicke 4) Dicke 30 und 40 mm: 2510 x 610 mm

Property Unit1)

Codeaccording

to DIN EN 13164

2500 C 2800 C 3035 CS 3035 CN 4000 CS 5000 CSStan-dard

Edge profile

Surface skin embossed skin skin skin skin

Length x width mm 1250 x 600 1250 x 600 1265 x 615 2515 x 6154) 1265 x 615 1265 x 615

Density kg/m3 28 30 33 30 35 45DIN EN 1602

Thermal conductivity lD [W/(m.K)]

Thermal resistance RD [m2.K/W]

lD

RD

lD

RD

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RD

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RD

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DIN EN 13164

Thickness 20 mm30 mm

40 mm 50 mm 60 mm 80 mm 100 mm 120 mm 140 mm 160 mm 180 mm

–––––––––––

0.0320.032 0.0340.0340.034

––––––

0.650.951.251.501.80

––––––

0.0320.0320.0340.0340.0340.0360.0380.038

–––

0.650.951.251.501.802.302.803.20

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–0.0320.0340.0340.0340.0360.0380.0380.0380.0380.040

–0.951.251.501.802.302.803.203.654.204.45

–0.0320.0340.0340.0340.036

–––––

–0.951.251.501.802.30

–––––

–0.0320.0340.0340.0340.0360.0380.038

–––

–0.951.251.501.802.302.803.20

–––

––

0.0340.0340.0340.0360.038

––––

––

1.251.501.802.302.80

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Compressive stress or compressive strength at 10 % deformation kPa CS(10\Y) 150 – 2002) 200 – 3003) 300 250 500 700

DIN EN826

Compressive creep over 50 years at < 2 % deformation kPa CC(2/1,5/50) 60 – 802) 80 – 1003) 130 – 180 250

DIN EN1606

Certificated compressivestress under load bearing kPaloor slabsDIBT

– – – 130 – 180 250DIBT Z-23.34- 1325

Adhesive strength on concrete kPa TR 200 – > 200 – – – –

DIN EN 1607

Shear strength kPa SS > 300 > 300 > 300 > 300 > 300 > 300DIN EN 12090

Compressive modulus of elasticity kPa CM 10,000 15,000 20,000 15,000 30,000 40,000

DIN EN 826

Dimensional stability70 °C; 90 % r. h. % DS(TH) ≤ 5 % ≤ 5 % ≤ 5 % ≤ 5 % ≤ 5 % ≤ 5 %

DIN EN1604

Deformation behaviour: load 20 kPa; 80 °C % DLT(1)5 ≤ 5 % ≤ 5 % ≤ 5 % ≤ 5 % ≤ 5 % ≤ 5 %

DIN EN1605

Deformation behaviour:load 40 kPa; 70 °C % DLT(2)5 ≤ 5 % ≤ 5 % ≤ 5 % ≤ 5 % ≤ 5 % ≤ 5 %

DIN EN1605

Linear coefficient of thermal expansionLongitudinal mm/(m.K)Transverse

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0.080.06

0.080.06

0.080.06

0.080.06

0.080.06

0.080.06

DIN 53752

Reaction to fire Class – E E E E E EDIN EN 13501-1

Long term water absorption % v/vby immersion

WL(T)0.7 0.2 0.3 0.2 0.2 0.2 0.2 DIN EN 12087

Long term water absorptionby diffusion2 % v/v WD(V)3 2 – 4 – 2 – 4 2 – 4 2 – 4 2 – 4

DIN EN12088

Water vapour transmission2) MU 150 – 50 200 – 80 150 – 50 150 – 100 150 – 80 150 – 100 DIN EN 12086

Freeze-thaw-resistance % v/v FT2 ≤ 1 ≤ 1 ≤ 1 ≤ 1 ≤ 1 ≤ 1 DIN EN 12091

Maximum service temperature °C – 75 75 75 75 75 75 –

1) N/mm2 = 1 MPa = 1.000 kPa 2) Dependes on thickness 3) Thickness ≤ 30 mm 4) Thickness 30 and 40 mm: 2510 x 610 mm

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Information about Styrodur® C

n Product brochure: Europe’s green insulation

n Applications

Basement insulation

Load Bearing and Floor Insulation

Wall Insulation

Roof Insulation

Ceiling Insulation

Reconstruction

n Technical Data

Recommended Applications and Technical Data

Technical Data and Assistance data for dimensioning

n Chemical Resistance

n Styrodur® C-Movie: Europe’s green insulation

n Website: www.styrodur.com