Problem
The service life of architectural coatings significantly impacts building maintenance costs.
Desired properties
Cost does not exceed that of currently available top-quality coatings (i.e. $0.30 per square foot)
Problem
Until today, the vast majority of building construction has utilized foam plastics (i.e. EPS and XPS) or mineral wool for thermal insulation. These materials are generally environmentally unsustainable, and low-cost competitors have commoditized the global market.
Desired properties
- Commercially available in 3 to 5 years
- Produced from biological / natural processes
- Drainable medium that can evacuate water quickly
- High water vapor permeability
Specifications
Category 4: Next-generation building insulation materials
Environmentally sustainable, noncombustible, and shapeable
Problem statement
Until today, the vast majority of building construction has utilized foam plastics (i.e. EPS and XPS) or mineral wool for thermal insulation. These materials are generally environmentally unsustainable, and low-cost competitors have commoditized the global market. Recently, catastrophic fires in London and the Middle East have caused architects and developers to move away foam plastic and other combustible insulation materials. Mineral wool, although noncombustible, is difficult to install and limits options for building design. The table below summarizes the properties of common insulation materials.
Properties of common insulation materials
| EPS | XPS | Mineral wool | Target | Stretch | |
|---|---|---|---|---|---|
| Thermal R-value | R-3.8 per in. | R-5.0 per in. | R-4.0 per in. | R-5. per in 0 | R-8.0 per in |
| Water absorption | 4% | 2% | > 20% | 20% or less | 5% or less |
| Combustibility | High | High | Low | Low | Meets E136 |
| Compressive strength | 10 psi | 25 psi | 4 psi | 25 psi | 50 psi |
| Weight density | 1 lb / ft³ | 1 lb / ft³ | 7 lb / ft³ | 6 lb / ft³ | 2-3 lb / ft³ |
| Installation | Easy | Easy | Difficult | Easy | Easy + |
| Cost per board-foot | $0.13 / bd. ft | $0.45 / bd. ft. | $0.78 / bd. ft. | $0.50 / bd. ft. | $0.25 / bd. ft. |
Possible approaches
Any materials that provide effective thermal insulation while being environmentally sustainable, noncombustible, shapeable, and easy to install will be considered. Example solutions include insulation beads fused together with resin, polymer-based insulation derived from sustainable materials using a low tech, low energy manufacturing process, and other noncombustible insulation materials.
Known approaches not of interest
Unless significant performance/cost breakthroughs or innovative applications can be achieved, the following materials represent known state-of-the-art and are thus not of interest:
- Foam plastics similar to EPS and XPS
- Mineral wool
- Wood-based insulation
Key success criteria
Required:
- Noncombustible
- Environmentally sustainable
- Non water-sensitive
- Dimensional stability
- Durability of masonry and high impact resistance (“woodpecker” and “golf ball” damage)
- Can be extruded, molded, formed, or compressed into shapes
- Can function as continuous insulation on the exterior of buildings
- Can be installed by the plastering, masonry, or carpentry trades
Desired:
- Commercially available in 3 to 5 years
- Produced from biological / natural processes
- Drainable medium that can evacuate water quickly
- High water vapor permeability
Technical specifications [Cat. 4]: Next-generation building insulation materials
| Property | Standard | Requirement |
|---|---|---|
| Thermal resistance | ASTM C518 | R-value 5 per inch or greater |
| Water absorption | ASTM C272 | Less than 5% |
| Water vapor transmission | ASTM E96, Method A | Greater than 10 perms |
| Surface burning | ASTM E84 | Flame spread: 0 Smoke developed: 0 |
| Combustibility | ASTM E136 or NFPA 220 | Noncombustible |
| Density (desired, not required) | ASTM D1622 | 2 lb/ft3 |
| Compressive strength (desired, not required) | ASTM D1621 | 25 psi or greater |