Sustainability in Ceilings
Transcript of Sustainability in Ceilings
Armstrong Suspended Ceilings Presented By: John Spicer Technical Sales Manager
Agenda
Recycling Manufacturing Process
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Product Performance - Acoustics
Innovation - New Products Fire Regulations
Q&A
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RECYCLING
Recycled materials
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Recycled materials used in the manufacture of ceiling tiles and grid systems are:
Waste wools
Newspaper
Glass
Steel
Aluminium
Chipboard
Cardboard
Plastic
Ceiling tiles
Packaging
Definition of recycled content (EN ISO 14021:2001) The proportion, by mass, of recycled material in a product or packaging. Only pre-consumer and post-consumer materials shall be considered as recycled content, consistent with the following usage of the terms.
Recycled content and raw materials
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The total recycled content will vary depending on the material…
Material generated by households or by commercial, industrial and institutional facilities in their role as end users of the product which can no longer be used for it’s intended purpose. This includes return of materials from the distribution chain.
2)Post Consumer material
Material diverted from the waste stream during a manufacturing process. Excluded is such as rework, regrind or scrap generated in a process and capable of being reclaimed within the same process that generated it.
1) Pre-consumer material Resin bonded (‘soft’) mineral fibre tiles ≈ 15 - 25% (rock wool) ≈ 40 - 70% (glass wool)
Wet felt (‘hard’) mineral fibre tiles ≈ 19 - 70%
Metal tiles ≈ 25%
Suspension systems ≈ 30% (steel) ≈ 50 - 85% (aluminium)
Wood tiles ≈ 20 - 68%
Bio-soluble wool Wet felt (‘hard’) mineral fibre tiles Resin bonded (‘soft’) mineral fibre tiles
Gauge Reduction Suspension systems
Perlite Wet felt (‘hard’) mineral fibre tiles
Chipboard Wood tiles
Acoustic Fleece Metal tiles
Recycled content and raw materials
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Changes to raw materials have had an effect on environmental performance…
Armstrong Recycling Programmes – End-of-Life and Off-Cut-Recycling
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Armstrong offers a free collection for refurbishment / strip out projects of 2000m2+, anywhere in the UK. Ceiling tiles are 100% recycled into the mix and are processed into new ceiling tiles
End of Life (EOL) Recycling Programme End of Life Projects:
Grays Inn Road
Farnborough Air show
Lancaster Court
Off-cut ceiling tiles from new ceiling installations are stored on site in specially supplied bags and collected by Armstrong to be recycled into new ceiling tiles
Off Cut Recycling Programme (OCR) Off Cut Projects:
University Hospital
Birmingham
Peterborough Hospital
Tameside Hospital
Salford Hospital
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MANUFACTURING PROCESS
Manufacturing Process
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Wet-Felt Mineral Fibre Tiles
The wet felt pulp is deposited on a ‘conveyor belt’ where water is removed by a variety of techniques:- free drainage (gravity), pressing, vacuum & steam before being rolled to a level sheet at the required thickness.
This pulp then goes into the gas fired drying ovens (approx 50-65% moisture content). The temperature of and time spent in the oven will depend on the formulation (starch especially affects the drying rate) and the thickness of the board.
At the end of the drying ovens the board has any fissures or perforations rolled or punched into the board, gets sawn into the correct board size and with the appropriate edge detail as necessary.
Tiles typically have a primer coat, one or two intermediate coats and a finishing coat. Calcite gets applied to tiles on the paint line as necessary. The number and application rate will vary depending on the finish (fissured, perforated or calcite).
Product is packed face-to-face / back-to-back with cardboard dunnage, then shrink-wrapped and put into DC stock.
Manufacturing Process
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Soft Fibre Mineral Fibre Tiles
Slag and basalt (rock wool) or sand, limestone, soda ash and recycled glass (glass wool) heated in furnace (approximately 1300-1500ºC), droplets fall onto spinners creating fibres.
A binding agent is then added to the fibres and then cured in an oven at approximately 200ºC.
The thickness and density is controlled by the speed of conveyor belts and the amount of compression.
The wool slabs are cut into boards and a rebated edge detail cut as necessary.
Decorative and reverse scrims are glued to the board.
Edges are painted as required.
Product is packed face-to-face / back-to-back with cardboard dunnage, then shrink-wrapped and put into DC stock.
Manufacturing Process
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Metal Tiles
The coil is then cut to the appropriate length and notched (depending on whether tile being made can be ‘notched on tool’) to create ‘blanks’. If perforated, the blanks need rolling to flatten out the curve induced during the perforating process.
The blanks are then formed into tiles by either a power press, an automated folding machine, roll forming or hand formed using a brake press. The formed tiles are then washed and degreased before being painted.
The coil of the appropriate width for the type and size of tile to be manufactured is selected, and if required, the coil is fed into the perforating booth for perforating.
Manufacturing Process
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Metal Tiles
The tiles are hung on the paint line ‘conveyor belt’ and painted by electrostatically applying the polyester paint powder to the tiles and curing in an ‘oven’. The temperature in the ‘oven’ is just sufficient to cause the paint to melt/soften and fuse together forming a hard durable finish.
Once painted, the tiles may have different types of acoustic infill applied…
• A black non-woven fleece impregnated with a hot-melt glue can be heat sealed onto the back face of the tile.
• For B15 acoustic infill, 15mm mineral fibre board is cut to size and glued to the back of the acoustic fleece.
• Aluminium foil wrapped, black tissue faced pads are either supplied separately or loose laid into the back of the tile. It is possible for the pads to be ‘cassetted’ but this is not a standard Armstrong solution.
Product is packed face-to-face / back-to-back with cardboard sheets between tiles and packed in a full cardboard carton, sealed and put into DC stock.
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INNOVATION - NEW PRODUCTS
Innovation - CoolZone
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How do PCM cassettes actually function
Partnership with BASF using Micronal encapsulated in the core of the cassette to be used in a suspended ceiling
Innovation - CoolZone
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26oC 22oC
A cooler surface temp. Also improves the thermal comfort of the space
26oC +/- 2.0oC Standard ceiling
22oC +/- 1.0oC PCM ceiling
Hour of the day
Surface 1 Ch11 [C]
Innovation – CoolZone
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In the hot afternoon, the PCM cassettes suck up the heat and keep the room pleasantly cool.
OUT IN IN
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OUT IN IN
Overnight, they release the energy throughout the room while using the cool night ventilation to change back to their solid state. the PCM cassettes are now fully reset and ready for the next day.
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PRODUCT PERFORMANCE - ACOUSTICS
Provides confidentiality
Improves attentiveness & performance
Reduces vocal stress
Helps meet BB93 regulation requirements
Aids speedier recovery
Aids confidentiality
Improved productivity
Reduces fatigue and stress
Benefits to users
Acoustic comfort
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Offices Healthcare Education
Reduces fatigue and stress
Acoustic comfort
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The intelligibility, concentration and confidentiality balance
MEETING ROOMS CONFERENCE ROOMS CLASSROOMS LECTURE THEATRES
Concentration
Confidentiality
Intelligibility
Combination of sound absorption and sound attenuation Medium density ceiling tiles
Acoustic comfort
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The intelligibility, concentration and confidentiality balance
INDIVIDUAL CLOSED OFFICE
CONSULTING ROOM
INDIVIDUAL BEDROOM
Concentration
Confidentiality
Higher levels of sound attenuation Higher density ceiling tiles
Acoustic comfort
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The intelligibility, concentration and confidentiality balance
(LARGE) OPEN PLAN AREA – ASSEMBLY / DINING / SPORTS HALL – 4+ BED WARD
Concentration
Confidentiality
Higher levels of sound absorption Lower density ceiling tiles
A WORD OF CAUTION: The same ceiling may have one type of room on one side of a partition, and another type on the other side. However, they may both have conflicting acoustic requirements.
Acoustic comfort
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The intelligibility, concentration and confidentiality balance
ACTIVE ACOUSTICS : FOR RETAIL BANKING, HEALTHCARE, OFFICE ENVIRONMENTS AND SCHOOLS
Concentration
Confidentiality
Intelligibility
Control background noise : overcome “occupational factor” with sound masking Active acoustics take into account all sound and noise sources on-site to guarantee levels of intelligibility, privacy and concentration.
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FIRE REGULATIONS
Fire safety
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“Designers are required to avoid foreseeable risks as far as is reasonably practicable, taking due account of other relevant design considerations. The greater the risk the greater the weight that must be given to eliminating or reducing it”
Euroclasses EN13501-1:
2007
Provide passive fire protection
Fire Resistance
Tests (BS/EN)
Escape routes or corridors
Larger rooms a greater distance to exit the room
Small rooms (≤ 30m2)
Fire reaction
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Legislation & regulations
Table 10 in Approved Document B (volume 2) specifies the minimum performance requirement for these categories...
For non-residential buildings these are…
Incre
asing
perfo
rman
ce EuroClass
rating (old) National classification
B-s3,d2 Class 0
C-s3,d2 Class 1
D-s3,d2 Class 3
EUROCLASSES
Fire safety
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UK
Class 0
Class 1
Class 3
B – s3, d2
C – s3, d2
D – s3, d2
Fire Reaction
Stability (R)
Integrity (E)
Insulation (I)
Fire Resistance
Fire reaction
The EuroClass is a fire reaction rating to EN 13501-1
Classification
Why is the ‘EuroClass’ rating?
Class 0 is defined in the Building Regulations whilst Class 1 and Class 3 are performances determined by British Standard test BS 476:part 7
What is Class 0 / Class 1 / Class 3?
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European harmonisation of testing for fire reaction of suspended ceilings requires Euroclass ratings to meet the Construction Products Directive
Why is Class 0 / Class 1 / Class 3 an old requirement?
Q & A