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CREATE And pRoTECT

Building and constructionThe RockShell wall system is an innovative, low energy solution for the construction of load bearing walls in low-rise buildings.

ROCKSHellWaLL system®

Let’s start a brand new tradition todayThe race for energy-efficient solutions has begun

The race against timeThe UK has a big challenge. The Climate Change Act of 2008 set the target to reduce greenhouse gas emissions by 80% from 1990 levels by 2050.

One of the key methods of achieving this goal is to improve the energy efficiency of our buildings. In Europe and the US, our buildings account for up to 40% of our total energy consumption. By improving the ef-ficiency of our buildings through better materials and design, there is huge potential to reduce CO2 output.

Technology is currently available to build energy efficiently and reduce the energy usage to a fraction of the current average consumption. The government’s drive towards energy efficient and ultimately zero carbon homes, is making these technologies more of a priority. This was a fac-tor behind the development of the RockShell wall system.

At Rockwool we identified a need in the marketplace for an alternative construction method. A wall system that allowed the use of traditional finishes combined with ease of installation and high energy efficiency. From this idea RockShell was born.

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A poorly insulated house can use up to 10 times as much energy for heating as a well-insulated house.

Y = The images within this brochure are taken from a European installation. They are shown for illustra-tion purposes only and are indicative of the methods used during a RockShell construction. The images are not intended to illustrate UK best practice and personnel shown do not comply with UK health and safety regulations.

Insulation is a key climate technologyHeating and cooling are the main sources of energy consumption in buildings. Together they account for more than two thirds of a build-ing’s energy usage. At present most of this energy is wasted due to inadequate insulation.

During its lifetime, a typical Rockwool insulation product will save 100 times the amount of energy and CO2 emissions than it takes to pro-duce, distribute and recycle it. This makes Rockwool insulation one of the most effective solutions that can be utilised to help reduce climate change.

Low energy houses do not need to distinguish themselves from tradi-tional buildings in terms of appearance, but they do require intelligent design.

Incorporating high performing insulation as an integral part of the building structure is one of the most important design elements to en-able low energy buildings.

As the external wall is typically the largest ”element” in a building, it offers the potential for the largest energy loss. As authorities impose ever stricter requirements concerning energy losses and reduced CO2 emissions, the race for energy efficient solutions has begun. To meet these needs the construction industry must address the challenges faced in relation to building design, structural changes and energy efficiency, whilst retaining economic advantage.

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Tomorrow’s energy efficiency delivered today

Minimal energy loss with optimal construction methods RockShell is an innovative system for constructing the load bearing walls of low-rise buildings. The RockShell wall system is a patented modular system, that meets future energy efficiency requirements, today.

The RockShell wall system combines the requirements for sustainable lightweight constructions with optimal energy performance, efficient in-stallation processes, technical support and end user benefits. In other words: The RockShell wall system is the ideal all-in-one construction system.

Minimising building costs and installation timeThe RockShell system has been designed to interface with standard build-ing components. Allowing flexibility of design for door, window, roof and exterior finishes.

The modular design also decreases the risk of making mistakes on the building site. For all interfaces between the RockShell wall system and other building solutions a suggested detail with minimised thermal bridg-es has been created. Due to the modularity of the system, very few adjust-ments are needed between different house designs. As a result, details could be used for different house designs.

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The RockShell solution is delivered on-site to fit the specific house de-sign. As no adjustments or modifications are necessary on-site, the time spent on modifications and material waste is minimal. If adjustments are needed, the system can be modified using hand tools.

Costs associated with waste and disposal are not included in the table. In general, however, waste and disposal costs are considerably greater with a traditional solu-tion than with a RockShell solution. The RockShell wall system is supplied as a complete, customised system, delivered for each particular building. This results in only minimal adaptation and waste in the construction process itself.

Installed cost comparison:The RockShell wall system and a standard timber solution.

Designphase

planning material costs

installation costs

stanDarD timber solutionrockshellwall system

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The RockShell wall system is a unique combination of steel -profiles, dense Rockwool insulation and interior OSB lining. This system results in a pioneering low energy wall system comprising minimal components and a slim profile.

U-value:

600

9400

5400

2700

RockShell wool elements

-shaped steel profiles

OSB boards

RockShell benefits: Suitable for use in low energy buildings Flexibility of final finish Free project assistance On-site technical support Passivhaus certified Free calculation tools Free e-learning modules Interfaces with most standard building components Minimises thermal bridges Increased air-tightness Reduces wall thickness Lower install costs Reduced installation risks Fitted by Rockwool certified installers Competitive material costs Excellent fire properties Good acoustic properties Minimal on-site waste

Thermal calculations have been made by the consultancy company Belenos.

*) The U-value can be improved by increasing the thickness of the service wall.

RockShell wall system289 mm

Externalcladdingeg. 18 mm

Service wall57.5 mm,82.5 mm or107.5 mm

Total wall

thickness

364.5 mm

U-value W(m2K)

0.14*

Total insulation thickness

295 mm

Faster understanding – improved resultsThe system comprises very few building components, which are easily assembled with just a power drill on-site. RockShell is quick and easy for installers to learn and understand. Actual installation is quick and simple versus other building solutions, meaning improved build times and less mistakes on-site.

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Principles of the RockShell systemRockShell is a modular wall system designed for ease of installation, whilst maximising safety throughout the build process. This is achieved without compromising on the end user benefits of energy performance, sustainability, indoor climate or building quality.

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A simple and straight forward construction method

3 Doors and windows

6 The interior face of the wall

4 Corners

7 Intermediate floor

5 The exterior face of the wall

8 Connecting to roof and gable

2 The RockShell wall

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The first house built using RockShell was in Flensburg, Germany. It was based on a standard design. This house type was utilised to show how easy it was to integrate the RockShell

wall system into an existing design and also to prove that it is possible to build a standard house with excellent energy performance and low installa-

tion costs. The low-energy house was a KfW 70 energy-efficient house. Offering a 30% improvement in energy

efficiency over traditional methods, in line with market requirements.

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1 Foundation

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The RockShell bottom profiles are mounted securely on the con-crete foundation on a layer of bituminous roofing felt, adhered to the foundation with cold asphalt sealant. Bottom profiles are used to fix the wall to the foundation and brackets are used to fix the RockShell modules.

The unique slits on all four sides of the wool elements make them fit perfectly into the flanges of the steel profiles.

A further profile is mounted on top of the RockShell modules and fastened to the -profiles. Finally a laminated veneer lumber board is placed upon the top profile to complete the wall section.

A straightforward installation sequence...

Foundation The RockShell wall1 2

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Openings for windows and doors are vertically framed by Rock-Shell end columns and pre-fabricated RockShell lintels are used above door and window openings.

The unique RockShell corner insulation elements are set slantwise in position, the same way as the ordinary wool elements.

Doors and windows Corners3 4

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Laminated ”nailers” are mounted onto the external face of the RockShell wall. The ”nailers” serve three basic functions. They cover and tighten joints between the RockShell wool elements, establish a ventilated cavity and create a secure mounting for the chosen external finish.

OSB boards are mounted directly onto the interior face of the RockShell wall to create a secure mounting for the service wall and interior linings.

... and cost effective to build

The exterior face of the wall The interior face of the wall5 6

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The intermediate floor is mounted to the RockShell wall system on the interior face of the OSB by securing into the laminated timber bearer and steel -profiles located behind the OSB boards.

Roofs are fixed to the laminated timber board on top of the RockShell wall. After the bearing roof construction is erected and fastened, gables are built up in the same way as wall modules.

Intermediate floor Connecting to roof and gable7 8

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With you every step of the way…A comprehensive technical service and support partnership

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Support tools at www.rockshell.uk.comOn our website, you will find a variety of resources from general system information to example CAD illustrations, installation videos, product and material information and much more.

We have also created a comprehensive e-learning module, providing answers to virtually all aspects relating to designing, constructing, and using the RockShell system.

Technical support at every stageRockShell is a completely new way of building lightweight load bearing walls. As a result we offer comprehensive technical advice and support, which will enable you to complete the entire construction process with confidence.

The technical support consists of a wide range of services ranging from calculation and design assistance to on-site support, providing a fast response to any questions regarding your project.

Calculations and design assistanceWe’ll work with you from the outset. At design stage you can utilise our RockShell design and calculation team. By simply sending your outline drawings to us, we will then calculate the RockShell system required and prepare an outline bill of materials and project specification.

From this we will aim to work with you further by suggesting design adaptions and adjustments to minimise the projects costs, buildtime and optimise energy efficiency.

Support and serviceYou are always welcome to call or e-mail our RockShell specialists if you have any questions regarding the system or a specific construction project.

Your RockShell specialist will partner with you to guide and advise you during the construction process to ensure that you always have the most rational work processes and achieve the best possible result.

Detailed building manualThe building manual is a detailed step-by-step installation guide explaining all aspects of the RockShell wall system, construction details and assembly methods.

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RockShell is, without doubt, one of the most innovative construction systems we have worked with.

It is incredibly easy to get started with the system and installation is fast and simple. RockShell is also unbelievably easy to adjust and adapt. In other words, this is both a rational and economic construction system, which takes into account some commercial aspects that are important to our company.

Another advantage is that as a result of the pre-fabricated parts and elements, we are able to constantly ensure a tidy and clean building site, which makes a particularly positive impression on visitors to the site and passers-by.

Bernd Carstensen and Sven HansenCarstensen Trockenbau GmbH & Co KG

Drylining Contractors

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The RockShell wall system is, without doubt, one of the most innovative construc-tion systems we have worked with.

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It is incredibly easy to get started with the system and installa-tion is fast and simple.

RockShell is actually so simple to build with that even the customer – after expert guidance from an instructor – could build the house him-self. It’s almost like working with a building set.

Moreover, it is just as important to the customer that the finished sys-tem also has particularly good heat insulation properties.

Overall, it has been an especially interesting task for our company to contribute to the development and testing of such an innovative con-struction system like the RockShell. We can only give RockShell wall sys-tem our best recommendation and we look forward to using the system on other construction projects in the future.

“We can only give the Rock-Shell wall system our highest recommenda-tion...

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We’ve built the future...

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Rockwool means extra safetyGuaranteed quality of every component in the RockShell wall system

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Quality and controlThe RockShell wall system has been developed as a complete load bearing wall system, provid-ing a construction system which meets the needs of the future for rational construction technology and energy-efficient buildings.

Rockwool is one of the most thoroughly tested and well-documented building materials, and it is a safe product to work with. Conclusions regarding the properties of our products are based on ex-tensive epidemiological studies, carried out in cooperation with external partners.

The RockShell wall system has been tried and tested at construction sites and is certified through independent laboratory tests. This guaran-tees the quality of every component in the system and ensures that the system functions in practice at the construction site and in the finished building.

Documentation and approvalThe RockShell system has been tested according to the requirements of European Technical Approval (ETA) and tests have been performed and certified at independent test facilities.

Fire from the outside: REI 90 minutes.Performed by DBI in Denmark

Fire from the inside: REI 60 minutes.Performed by DBI in Denmark

Sound reduction: Minimum 54 DB.Performed by DELTA in Denmark

Load bearing capacity per profile (height 2.7 m): 53,3 kN.Performed by SP in Sweden

Passivhaus approval.The system has been certified by the Passivhaus Institute in Germany

European Technical Approval.Granted by ETA in Denmark. ETA-11/0013

Fire resistanceRockwool products withstand temperatures up to 1000° C, making them exceptionally resistant to fire. This resistance can slow a fire’s progress and buy precious time for rescue operations while helping to protect the build-ing’s structure from unnecessary damage. Yet while heat and flames are bad enough in a fire, smoke is the serious danger. It can suffocate occupants, and it can incapacitate people who might otherwise have been able to escape.Rockwool insulation keeps toxic smoke from insulation to a minimum for even greater safety.

Superior acousticsBuildings are noisier than many people think. Traffic outside, ventilation systems, music, talking, doors opening and closing. So many sounds contribute to a typical room’s acoustic environment, we sometimes don’t even register them consciously. But we are affected by them.Environments with a high noise level can be stressful and make it hard both to concentrate and relax. Rockwool insulation and acousticceiling panels dampen noise to improve comfort and quality of life both at home and at work.

DurabilityOur products are built to perform over the long haul. Rockwool slabs and claddings remain stable over time, and they don’t allow cold bridges to form. But at Rockwool, it’s not just our products that are “rock solid”. So is our time-honoured name, and our reputation for delivering documented benefits and providing expert advice to architects, designers, contrac-tors and building owners.

SustainabilityAs producers of products and solutions made from reusable natural stone, and as acknowl-edged experts in designing buildings that maximise energy efficiency and minimise CO2 emissions, you could say that our very business is sustainability. Our products are eco-friendly, and we are happy to provide advice on energy efficiency in buildings of any size. We turn waste from our production process into new raw material, and we are developing systems for recycling our materials from buildingwaste.

Moisture-repellentRockwool is moisture-repellent. If the insula-tion is exposed to rain, only the outermost few millimetres will get wet. This will disappear rapidly when the rain stops. Rockwool is also breathable and allows water vapour to pass through the wool – without condensing.

Comfort and indoor climateInsulation that provides an air-tight building envelope guarantees a pleasant and constant temperature all year round. Rockwool meets the strictest European requirements in relation to indoor climate, and is certified in the Finnish M1 emission class for construction materials.

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Tailor-made courses– giving you the best start

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RockShell installation coursesIt is important that the many advantages of building with the RockShell wall system are utilised to the full. RockShell offer training courses for installers. These courses help to ensure a rational and smooth construction process from start to finish.

The courses can be tailor-made to suit your company. Please feel free to con-tact us if you are interested or register your details at www.rockshell.uk.com

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ROckwOOl lImItedRegistered OfficePencoedBridgendCF35 6NYTel.: +44 (0) 1656 868 400E-mail: rockshell@rockwool.co.ukwww.rockshell.uk.com

26-28 Hammersmith GroveLondonW6 7HATel: +44 (0) 845 241 2586

Unit 11Northwood CourtSantryDublin 9IrelandTel.: +353 (0) 1 891 1055E-mail: rockshell@rockwool.iewww.rockshell.ie

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