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This On-line Learning Seminar is
available through a professional
courtesy provided by:
Vita NonWovens
2215 Shore Street
High Point, NC 27263
Tel: (336) 431-7187
Fax: (336) 431-0693
Toll-Free: (877) 431-7171
Email: [email protected]
Web: http://enguardinsulation.com
An Overview of Glass-Free
Polyester Insulation Technology
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©2011 ∙ Table of Contents
©2011 Vita NonWovens. The material contained in this course was researched, assembled, and produced
by Vita NonWovens and remains its property. Questions or concerns about the content of this course
should be directed to the program instructor. ‘LEED’ and related logo is a trademark owned by the U.S.
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An Overview of Glass-Free Polyester Insulation Technology
Presented By: Vita NonWovens
2215 Shore Street
High Point, NC 27263
Description: Provides an overview of the sustainable manufacturing process, green features, and
characteristics of 100% polyester fiber batt insulation. This course also reviews the principles of heat
transfer and the factors related to the control of heat flow within the building envelope..
To ensure the accuracy of this program material, this course is valid only when listed on AEC Daily's
On-line Learning Center. Please click here to verify the status of this course.
If the course is not displayed on the above page, it is no longer offered.
The American Institute of Architects · Course No. AECXXX · This program qualifies for 1.0 HSW/SD/LU hour.
AEC Daily Corporation is a Registered Provider with The American Institute of Architects Continuing Education Systems (AIA/CES). Credit(s)
earned on completion of this program will be reported to AIA/CES for AIA members. Certificates of Completion for both AIA members and nonAIA members are available upon request. This program is registered with AIA/CES for continuing professional education. As such, it does not
include content that may be deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method
or manner of handling, using, distributing, or dealing in any material or product. Questions related to specific materials, methods, and services
will be addressed at the conclusion of this presentation.
This course is approved by other organizations. Please click here for details.
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AEC DAILY CORPORATION
is a USGBC Education Provider
committed to enhancing the
professional development of the
building industry and LEED
Professionals through high-quality
continuing education programs.
As a USGBC Education Provider,
we have agreed to abide by
USGBC-established operational
and educational criteria, and are
subject to course reviews and
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How to use this On-line Learning Course
• To view this course, use the arrows at the bottom of each slide or the up and down
arrow keys on your keyboard.
• To print or exit the course at any time, press the ESC key on your keyboard. This will
minimize the full-screen presentation and display the menu bar.
• Within this course is an exam password that you will be required to enter in order to
proceed with the on-line examination. Please be sure to remember or write down this
exam password so that you have it available for the test.
• To receive a certificate indicating course completion, refer to the instructions at the end
of the course.
• For additional information and post-seminar assistance, click on any of the logos and
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Learning Objectives
At the end of this program, participants will be able to:
•
discuss the composition, characteristics, and uses of polyester fiber
•
define the principles of heat transfer and the role of insulation as it relates to energy
efficiency
•
state the green characteristics and benefits of glass-free insulation, and
•
explain the sustainable manufacturing process of polyester fiber insulation.
©2011 ∙ Table of Contents
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Table of Contents
Polyester Fiber
7
Heat Flow & Insulation
12
The Role & Types of Insulation
23
Polyester Fiber Insulation
36
Sustainable Manufacturing
50
Click on title to view
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Polyester Fiber
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Introduction
This course begins with a review of polyester fiber, including its composition,
characteristics, and uses, followed by a discussion on the principles of heat flow and the
role of insulation.
In the last section of the presentation, we examine the role of polyester fiber batt
insulation as part of a sustainable building strategy.
To begin, what is Polyester Fiber?
Defined by the Federal Trade Commission, polyester fiber is “a manufactured fiber in
which the fiber forming substance is any long-chain synthetic polymer composed of at
least 85% by weight of an ester of a substituted aromatic carboxylic acid.” The history of
its use dates back to 1953, the year DuPont Company began the first U.S. commercial
polyester fiber production.
©2011 ∙ Table of Contents
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PET Fiber
Poly Ethylene Terephthalate (PET) is the most common polyester for fiber purposes. This
is also the same polymer used for many soft drink/water bottles and it is becoming
increasingly common to recycle these plastic bottles after use by remelting the PET and
extruding it as fiber.
Recycling PET saves valuable petroleum raw materials, reduces energy consumption,
and eliminates solid waste sent to landfills.
PET fiber is made by combining ethylene glycol with either terephthalic acid or its methyl
ester in the presence of an antimony catalyst. To achieve the high molecular weights
required to form useful fibers, the blending of the materials is carried out at high
temperatures.
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PET Fiber: Characteristics
Characteristics of PET fiber:
• extremely strong and very durable
• resistant to stretching, shrinking and wrinkling
• resistant to most chemicals
• easily washed and quick drying
• crisp and resilient when wet or dry
• mildew resistant
• abrasion resistant
The strength and tenacity of PET
fiber makes for a resilient polyester
fiber insulation.
©2011 ∙ Table of Contents
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PET Fiber: Uses
PET is used in a variety of products:
• apparel
• home furnishings, including carpets, curtains,
bedding, wall coverings, and upholstery
• fiberfill for various products, such as pillows and
furniture
• automotive
• health and hygiene
Lastly, PET is being used in the manufacture of batt
insulation, offering a reliable, green solution. Before
we discuss the benefits of using PET as a component
of insulation, let’s review the principles of heat flow
and the role of insulation in the building envelope.
©2011 ∙ Table of Contents
Batt insulation made from PET fiber
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Heat Flow & Insulation
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Heat Transfer
Heat transfer occurs by three primary mechanisms that act alone or in certain
combinations:
1. conduction
2. convection
3. radiation.
Conduction is defined as the flow of heat through a material by direct molecular contact.
This contact occurs within a material or through two materials in contact. Note that
conduction is the most important heat transport mode for solids.
Convection is the transfer of heat via the movement or flow of molecules (liquid or gas)
due to a change in their heat content. Convection is a significant heat transfer mode
between fluids and solids, or within fluids.
Radiation is the transfer of heat by electromagnetic waves through a gas or vacuum and
it is mostly of importance for heat transfer between solids and within highly porous solids.
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Heat Transfer
The mode of heat transfer frequently changes during the process of heat flow through
and within building systems. As an example, the sun transmits heat by radiation to the
earth, where it may be absorbed by a brick wall of a home. The heat is then transferred
by conduction through the brick, transferred via convection to the indoor air, and
transferred to the indoor surfaces by radiation.
Heat flows naturally from a warmer space to a cooler space. In cool climates, heat moves
from all heated living spaces to the outdoors and unheated spaces, such as attics,
garages and basements. Conversely, in warm climates, heat moves from outdoors to the
interior spaces.
To maintain comfort, occupants rely on a building’s HVAC system to replace heat loss in
the winter and remove heat gain in summer months. When combined with an efficient
HVAC system, properly insulated ceilings, walls and floors will decrease heating and
cooling requirements by providing an effective resistance to the flow of heat.
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R-Value
Insulation is rated in terms of thermal resistance, known as R-value, which indicates the
resistance to heat flow. The higher the R-value, the greater the insulating effectiveness.
The R-value of thermal insulation is dependant on three factors:
1. the type of material
2. the thickness of the material. and
3. the density of the material.
Whenever comparing insulation products, it is important that you base your comparison
on equal R-values.
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Effective Insulation Factors
The effectiveness of an insulated ceiling, wall or floor is dependant on how and where the
insulation is installed.
For example, insulation that is compressed will not provide its full rated R-value. This can
happen if denser insulation is added on top of lighter insulation in an attic. It also occurs if
batts rated for one thickness are placed into a thinner cavity.
Other factors related to the effectiveness of insulation and control of heat flow include:
• thermal bridges
• heat loss to/from the ground
• air leakage
• solar radiation through windows, and
• interior heat gains.
Each of these factors will be discussed in subsequent slides.
©2011 ∙ Table of Contents
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Thermal Bridging
Thermal bridges can severely compromise thermal control and comfort in some building
types by causing cold spots within an assembly. If large enough or highly conductive,
thermal bridges can affect the total heat loss through the enclosure.
As an example, heat flow through steel stud walls and metal curtain walls is dominated
by heat flow through the metal components. Failure to break these thermal bridges can
reduce the R-value of the insulating components by 50 to 80%. For concrete masonry,
filling the voids is not very effective, because adding R-15 insulation to a 12” block will
increase the R-value of the wall by roughly only R-2. Wood-framed walls are not as
affected, but reductions in R-value of 10 to 20% are common.
To help eliminate thermal bridging, it is recommended that attic insulation cover the tops
of the joists and insulative sheathing is used on walls.
©2011 ∙ Table of Contents
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Heat Loss To / From The Ground
Less insulation is generally needed to
control heat flow to or from the ground.
In many instances, heat flow control for
slabs, crawlspaces, and basements is
limited by that needed for control of
moisture, not energy.
As per U.S. Department of Energy
(DOE), insulation is required in all
climate zones
Climate Zones – Source: U.S. Department of Energy
www.ornl.gov/sci/roofs+walls/insulation/ins_05.html
©2011 ∙ Table of Contents
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Air Leakage
The energy impact of air leakage is substantial and it is often an important heat loss/gain
component of modern buildings. In fact, in a well-insulated home, air leakage can
account for 30% of the thermal flow across the enclosure.
To prevent unintentional air leakage, a complete air barrier system should be
incorporated the building design.
Airflow can reduce or bypass thermal insulation in other ways than just by flowing across
the enclosure. For example, convective loops can form within highly air-permeable
insulation (low-density fibrous insulations). As well, small gaps can appear around rigid
board insulation or improperly installed batts.
It is important to note that intentional ventilation has the same energy penalty as the
equal quantity of unintentional air leakage. As a result, the amount of ventilation should
not exceed the minimum requirement (refer to ASHRAE standards for guidance).
©2011 ∙ Table of Contents
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Solar Radiation
Solar gain through windows exposed to either the direct sun, or reflected sun, can
radically affect the heat flow in a structure. Accordingly, the building energy flows must
account for the solar gain through windows. Note that the amount of heat can dominate
the performance of a building with relatively high window coverage (i.e., above 20 to 30%
window-to-wall ratio).
The Solar Heat Gain Coefficient (SHGC) is the window property used to rate the amount
of energy permitted through windows. The SHGC is expressed as the fraction of incident
solar radiation that passes through a window.
The lower the SHGC, the less solar heat that the window transmits.
©2011 ∙ Table of Contents
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Interior Heat Gains
The interior heat generated by a building’s occupants and activities within can be an
important factor in terms of a building’s energy efficiency.
In a well-insulated building, this interior heat offsets the heat required to warm the space
in cold weather. In warm climates, interior heat gains add to the cooling load.
Generally, interior heat gains are not significant in smaller buildings, such as housing or
buildings with a large enclosure surface area to interior floor area ratio. Only in very well
insulated homes or mild climates (i.e., approximately 10 ºC or 50 ºF) do interior heat
gains form a major proportion of heat flows in a small building.
Large box-type buildings (those with a small ratio of enclosure surface area to floor area)
are often dominated by internal heat gain. Thermal flow in properly insulated commercial
office buildings is generally led by heat gain and loss through windows at the perimeter
and by interior heat gains in the core.
©2011 ∙ Table of Contents
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Heat Flow Control
To summarize, the control of heat flow in
buildings requires:
•
properly installed insulation layers
penetrated with few thermal bridges
•
an effective air barrier system
•
good control of solar radiation, and
•
management of interior heat
generation.
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The Role & Types of Insulation
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Introduction
In the average American home, heating and cooling account for 50 to 70% of the energy
used.
The leading causes of energy waste in the majority of homes are air leakage and
inadequate insulation.
A properly insulated building:
• saves money and energy resources
• makes the interior more comfortable by helping to maintain a uniform temperature
throughout the structure, and
• makes walls, ceilings, and floors warmer in the winter and cooler in the summer.
©2011 ∙ Table of Contents
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Where to Insulate
This image indicates which building spaces should be insulated. It is important to ensure each of these spaces is properly
insulated to the R-values recommended by the DOE.
Source: U.S. Department of Energy, www.ornl.gov/sci/roofs+walls/insulation/ins_06.html
©2011 ∙ Table of Contents
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Climate Zones
Presented on the following slide is an illustration of the U.S. climate zones, followed by a
summary of the insulation recommendations for new and existing homes, as per the U.S.
DOE.
These recommendations are based on comparing future energy savings to the current
cost of installing insulation.
Note that a range of R-value’s is shown for many locations because:
• energy costs vary between each zone
• installed insulation costs differ over each zone, and
• heating and cooling equipment efficiency varies from house to house.
©2011 ∙ Table of Contents
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Climate Zones
Source: U.S. Department of Energy, www.ornl.gov/sci/roofs+walls/insulation/ins_05.html
©2011 ∙ Table of Contents
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U.S. DOE Insulation Recommendations
Insulation Recommendations: New Wood-Framed Houses
Source: U.S. Department of Energy, www.ornl.gov/sci/roofs+walls/insulation/ins_05.html
©2011 ∙ Table of Contents
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U.S. DOE Insulation Recommendations
Insulation Recommendations: Existing Wood-Framed Houses
Source: U.S. Department of Energy, www.ornl.gov/sci/roofs+walls/insulation/ins_05.html
©2011 ∙ Table of Contents
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Choosing Insulation
The U.S. Federal Trade Commission defines home insulation as "any material mainly
used to slow down heat flow" (16 CFR Part 460.2). With the range of different insulation
solutions available it is important to specify the right product for the application.
Therefore, regardless of what kind of insulation you select, it is important to check the
information on the product label to ensure that the product is suitable for the intended
application.
To protect consumers, the Federal Trade Commission has very specific rules governing
the R-value label. The label (which indicates the R-value and information related to
health, safety, and fire-hazard issues) must be placed on all residential insulation
products.
Some products have been developed to give higher R-values with less thickness.
Conversely, some materials require a greater initial thickness to offset eventual settling or
to ensure that you get the rated R-value under a range of temperature conditions. The
different types of insulation are presented in subsequent slides.
©2011 ∙ Table of Contents
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Mineral Fiber Blanket Insulation
Made from mineral fibers (fiberglass or rock wool) blanket insulation is available in the
form of batts or rolls.
It is a flexible insulation product and is sized in widths suited to standard spacing of wall
studs and attic or floor joists.
Blanket insulation must be hand cut and trimmed to fit wherever the joist spacing is nonstandard or where there are obstructions in the walls. Batts can be installed by
homeowners or professionals and are available with or without vapor-retarder facings.
For basement walls where the insulation will be left exposed, batts with a special flameresistant facing are available in various widths.
©2011 ∙ Table of Contents
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Blown-In Loose-Fill Insulation
Blown-in loose-fill insulation can be utilized in wall cavities, unfinished attic floors,
irregular-shaped spaces and for filling in around obstructions.
This type of insulation is comprised of loose fibers or fiber pellets made from cellulose,
fiberglass, or rock wool.
Generally, professional installers use pneumatic equipment to install blown-in insulation.
In the open wall cavities of a new house, cellulose and fiberglass fibers can also be
sprayed after combining the fibers with an adhesive and water mixture. Diligent moisture
management and quality controls must be implemented to insure proper adhesion to
prevent settling.
©2011 ∙ Table of Contents
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Foam Insulation
Foam insulation is typically installed by a professional using special equipment to gauge,
mix, and spray the foam into place.
Polyisocyanurate and polyurethane foam insulation is produced in two forms: open-cell
and closed-cell.
Typically, open-celled foam allows water vapor to move through the material more easily
than closed-cell foam.
Since open-celled foams usually have a lower R-value for a particular thickness
compared to closed-cell foams, some closed-cell foams are able to provide a greater Rvalue where space is limited.
During the application, occupants must vacate the premises until the contractor deems
the area safe for re-entry.
©2011 ∙ Table of Contents
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Rigid Insulation
Rigid insulation, made from fibrous materials or plastic foams, is produced in board-type
forms and molded pipe coverings.
Rigid insulation is frequently used for foundations and as an insulative wall sheathing. It
provides full coverage with few heat loss paths and it is often able to provide a greater Rvalue where space is limited.
Some boards may be faced with a reflective foil that reduces heat flow when next to an
air space.
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Other Types of Insulation
Reflective Insulation:
This type of insulation system is made from aluminum foils with a range of backings,
including kraft paper, plastic film, polyethylene bubbles, or cardboard. Reflective
insulation is most effective in reducing downward heat flow and is generally installed
between roof rafters, floor joists, or wall studs. If a single reflective surface is solely
used and faces an open space (i.e. attic) it is referred to as a radiant barrier.
Polyester Fiber Insulation:
Safe and effective, polyester fiber insulation products offer an efficient and innovative
insulation solution. It is specifically engineered thermal/acoustic insulation that is
environmentally safe. The features, benefits and manufacturing process of polyester
fiber insulation are reviewed in the next section of the presentation.
Please remember the exam password INNOVATIVE. You will be required to enter it in order to proceed with
the on-line examination.
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Polyester Fiber Insulation
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Introduction
Glass-free insulation (also known as polyester fiber
batt insulation) is a sustainable product, providing an
ecologically-conscious insulation solution.
This insulation material maintains thermal resistance,
resulting in reduced energy consumption, lower
utilities, and a carbon footprint that is four times lower
than virgin PET fiber.
©2011 ∙ Table of Contents
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Composition
Glass-free insulation is a thermal-bonded non-woven
batting that has 50% total recycled content.
It is made from recycled plastic bottles, postconsumer material, and 100% polyester fibers. These
are the same fibers found in baby diapers, apparel,
bed linens, and upholstery, so polyester fiber
insulation is safe for direct contact to the skin.
©2011 ∙ Table of Contents
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Thermal Bonding
The matrix of glass-free insulation is bonded with high performance fibers through thermal
setting. Compared to chemical resin bonding, the thermal bonding process provides
increased strength, giving polyester batt insulation superior recovery ability.
Thermal bonding using low melt binder fibers as opposed to chemical resin bonding
©2011 ∙ Table of Contents
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Polyester Fiber Wall Insulation, 2”x 4”, R-13
Property
Unit
Test Method
Information
Thermal Resistance
R Value
ASTM C518
R-13 @ 3.5"
Thermal Conductivity
Btu *in/ft2
*hr* °F
ASTM C518
0.27
Water Vapor Sorption
% per cm3
ASTM C1104-06
0.20% -meets requirement
Flammability
(Surface Burn)
Flame Spread
ASTM E84
Class A- ≤ 25 Flame Spread:
≤ 450 Smoke @ 3.5"
Corrosion, Fungi, Odor
Tested
ASTM C665,
C1338, C1304
Does not promote corrosion,
fungi growth, or odor
Mold Growth
Scale 0 - 4
ASTM G21
0 - No mold growth
* Manufacturer does not undertake any liability for the results of usage of these products. The technical data set forth in
this data sheet reflect best knowledge at the time of issue. The data sheet is subject to changes pursuant to new
developments and findings, and a similar reservation applies to the properties of the products described.
©2011 ∙ Table of Contents
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Polyester Fiber Wall, Floor, & Ceiling Insulation
2”x 6”, R-19
Property
Unit
Test Method
Information
Thermal Resistance
R Value
ASTM C518
R-19 @ 5.5"
Thermal Conductivity
Btu *in/ft2
*hr* °F
ASTM C518
0.29 k Factor
Water Vapor Sorption
% per cm3
ASTM C1104-06
.20% -meets requirement
Flammability
(Surface Burn)
Flame Spread
ASTM E84
Class A – ≤ 25 Flame Spread:
≤ 450 Smoke @ 5.5"
Corrosion, Fungi, Odor
Tested
ASTM C665,
C1338, C1304
Does not promote corrosion,
fungi growth, or odor
Mold Growth
Scale 0 - 4
ASTM G21
0 - No mold growth
Indoor Air Quality
ppm
CA 1350
VOC 0 ppm, GG for C&S
compliant
* Manufacturer does not undertake any liability for the results of usage of these products. The technical data set forth in
this data sheet reflect best knowledge at the time of issue. The data sheet is subject to changes pursuant to new
developments and findings, and a similar reservation applies to the properties of the products described.
©2011 ∙ Table of Contents
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Properties: Polyester Fiber Wall, Floor, & Ceiling
Insulation 2”x 6”, R-21
Property
Unit
Test Method
Information
Thermal Resistance
R Value
ASTM C518
R-21 @ 5.5"
Thermal Conductivity
Btu *in/ft2
*hr* °F
ASTM C518
0.26 k Factor
Water Vapor Sorption
% per cm3
ASTM C1104-06
.20% -meets requirement
Flammability
(Surface Burn)
Flame Spread
ASTM E84
Class A – ≤ 25 Flame Spread:
≤ 450 Smoke @ 5.5"
Corrosion, Fungi, Odor
Tested
ASTM C665,
C1338, C1304
Does not promote corrosion,
fungi growth, or odor
Mold Growth
Scale 0 - 4
ASTM G21
0 - No mold growth
Indoor Air Quality
ppm
CA 1350
VOC 0 ppm, GG for C&S
compliant
* Manufacturer does not undertake any liability for the results of usage of these products. The technical data set forth in
this data sheet reflect best knowledge at the time of issue. The data sheet is subject to changes pursuant to new
developments and findings, and a similar reservation applies to the properties of the products described.
©2011 ∙ Table of Contents
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Polyester Fiber Insulation: Superior Acoustics
R-13, 3.5"
Random Incidence Sound Absorption Coefficients
in a Full-Size Reverberation Room
Sound Absorption Coefficient
Polyester Fiber Insulation
1/3 Octave Band Center Frequency - Hz
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Polyester Fiber Insulation: Superior Acoustics
R-13, 3.5"
Polyester Fiber
Insulation
STC Contour
©2011 ∙ Table of Contents
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Insulation Life Cycle: Polyester Fiber vs. Fiberglass
Accelerated Aging Test, 70C, 90% RH, R-13 Insulation
R -Value
Polyester Fiber
Insulation
Fiberglass B
Fiberglass A
Nominal
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Actual
4 weeks
6 weeks
(simulated 15 yrs.)
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Overview: LEED® Certification
The U.S. Green Building Council (USGBC) is a 501(c)(3) non profit organization composed
of leaders from every sector of the building industry working to promote buildings and
communities that are environmentally responsible, profitable and healthy places to live and
work. USGBC developed the LEED (Leadership in Energy and Environmental Design)
green building certification program, the nationally accepted benchmark for the design,
construction, and operation of high performance green buildings.
LEED credit requirements cover the performance of materials in aggregate, not the
performance of individual products or brands. Therefore, products that meet the LEED
performance criteria can only contribute toward earning points needed for LEED
certification; they cannot earn points individually toward LEED certification.
For detailed information about the council, their principles
and programs, please visit www.usgbc.org.
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Polyester Fiber Insulation & LEED
As indicated in the table below, polyester fiber insulation can provide LEED certification
credits in the Materials Resource, Indoor Environmental Air Quality, and Innovation in
Design categories.
LEED Material Resource Credits
MR Credit 4.1
10% Recycled Content
MR Credit 4.2
20% Recycled Content
Value determined by weight:
15% Post-Consumer
35% Pre-Consumer
MR Credit 5.1
20% Material Manufactured in 500 Mile Radius
Value determined by weight.
MR Credit 5.2
10% Material Extracted in 500 Mile Radius
LEED Indoor Environmental Air Quality
IEQ Credit 3.2
Low-Emission Material
Product contains no formaldehyde, VOCs, other
harmful chemicals, or irritants.
LEED Innovation in Design
ID Credit 1
Contribute to Innovation in Design Credit
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Product features superior thermal properties and
resistance to degradation in energy efficiency so it
can be used in Green building designs that call for
non-glass, recyclable materials.
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Installation Advantages
Glass-free insulation technology facilitates simple and
effective installation for both professional contractors
and the “do-it-yourselfer”.
Since there are no respiratory or skin irritation issues,
no protective gear is needed during installation. The
blanket-like, non-irritating feel of polyester batt
insulation provides ease of handling, making the
product simple to cut for proper fit around
obstructions, such as electric receptacles and in-wall
plumbing.
The design features of polyester batt insulation allow compliance with the industry's
leading standards to eliminate voids, gaps and compression. The precut friction fit design
permits for uniform stud-to-stud installation. Furthermore, the fiber architecture and
resilience reduces compression with the ability to quickly recover to engineered thickness.
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Installation Advantages
Other installation advantages of polyester batt
insulation:
• no dusting
• waste materials can easily be recycled from
the job site.
Note that the proper installation of polyester batt
insulation is a crucial step in realizing superior
energy efficiency. It is recommended to follow
industry best practices and consult local building
and energy codes.
The U.S. Department of Energy recommends a comprehensive approach incorporating
proper air sealing, moisture control and ventilation techniques to complement the
insulation effort (refer to www.eere.energy.gov).
Once installed, the insulated framing can be covered with gypsum, drywall, or other
approved finishing wall material.
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Sustainable Manufacturing
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Introduction
By using recycled plastic bottles and other pre-consumer recycled content,
manufacturers of polyester batt insulation are helping to solve global environmental
challenges through sustainable manufacturing processes.
Recycling plastic saves twice as much energy versus incinerating it.
Additionally, since it takes up to 400 years for plastic to break down in landfills, combined
with the fact that Americans use 2.5 million plastic bottles every hour, recycling plastic
makes even more sense.
Furthermore, recycling one ton of plastic bottles saves 1.5 tons of C02/year – roughly a
150% positive return.
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The Great Pacific Garbage Patch
Worldwide, over 4.50 million tons of PET is recycled annually. Recycling PET plastic and
repurposing it into products, like polyester batt insulation, is a crucial step to address
many of the ecological problems we currently face, like The Great Pacific Garbage Patch.
The term “garbage patch,” coined by the media, refers to areas of marine debris
concentration in the North Pacific Ocean. Plastics are the main debris type found in these
patches, likely due to the abundance of plastics and the fact that some common types of
plastic float.
Although the name has led many to believe that this area is a sizable and continuous
patch of visible marine debris, this is simply not true. Although the reported size and
mass of these "patches" have differed from various media articles, there is really no
accurate estimate on the size or mass of the “garbage patch” or any other concentrations
of marine debris in the open ocean.
Regardless of the exact size and mass of the “garbage patch,” man-made debris does
not belong in our oceans and waterways.
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The Great Pacific Garbage Patch
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Recycling & Sustainable Insulation
With an abundance of plastic bottles, recycler capacity, and potential end uses,
successful recycling of PET plastics can lessen the “garbage patch” problem and
eliminate the environmental impact of landfill disposal.
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Manufacturing Process
The manufacturing process of polyester batt
insulation begins with recycling collection.
More than 7,000 communities in the United States
have curbside collection programs.
In some areas, drop-off bins are provided at
appropriate locations in the community and at retail
deposit sites.
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Manufacturing Process
Once collected, PET is taken to recycling centers,
known as materials recovery facilities, where it is run
through grinders that reduce the PET to flake form.
The flake then proceeds through a separation and
cleaning process that removes all foreign particles,
such as paper, metal, and other plastic materials.
Having been cleaned according to market
specifications, the recovered PET is converted to
fiber and baled. The process is illustrated on the
following slide.
These bales can be processed into a variety of useful
products, including polyester batt insulation.
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Manufacturing Process
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Manufacturing Process
Once the baled fiber is received, the insulation manufacturer begins the low energy
processing of the materials.
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Manufacturing Process
Next, the process of "carding" begins, where the fibers are combed and laid into a web.
Lastly, these fibers are bonded together in a natural gas oven.
Drylaid
Carded with binder impregnation
Wind up
Drying
Binder impregnation
Carding (combing fibres into web)
Staple fibre
from bale opener or blender
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Summary of Polyester Fiber Insulation Benefits
The green manufacturing process of polyester fiber insulation results in an innovative
insulation product that offers a myriad of benefits for the building and construction
industry.
Polyester fiber insulation:
• is manufactured using recycled plastic bottles and other pre-consumer recycled
polyester content
• contains no VOCs, formaldehyde, carcinogens, or any harmful chemicals
• requires low embodied energy to produce – from supply chain through consumer
• is hypo-allergenic and naturally hydrophobic, meaning it does not absorb moisture
• is resistant to long term degradation (no loss in energy efficiency)
• is a superior acoustic insulator
• requires no protective gear for installation - no respiratory or skin irritation issues
• is easy to cut/tear – friction fit installation
• has superior compression/recovery
• is 100% recyclable - waste materials can easily be recycled from the job site.
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References & Resources
•
buildingscience.com
http://www.buildingscience.com/documents/digests/bsd-011-thermal-control-inbuildings?topic=doctypes/digests
(date accessed Aug 2, 2011)
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U.S. Department of Energy Insulation Fact Sheet,
http://www.ornl.gov/sci/roofs+walls/insulation/ins_08.html
(date accessed Aug 2, 2011)
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Fibersource
http://www.afma.org/f-tutor/polyester.htm
(date accessed Aug 2, 2011)
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Course Evaluations
In order to maintain high-quality learning experiences, please access the evaluation for this
course by logging into CES Discovery and clicking on the Course Evaluation link on the left
side of the page.
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Conclusion
If you desire AIA/CES and/or state licensing
continuing education credits, please click on the
button below to commence your on-line
examination. Upon successful (80% or better)
completion of the exam, please print your
Certificate of Completion.
For additional knowledge and post-seminar
assistance, please visit the Ask an Expert forum
(click on the link above and bookmark it in your
browser).
©2011 Vita NonWovens. The material contained in this course was researched,
assembled, and produced by Vita NonWovens and remains its property.
Questions or concerns about the content of this course should be directed to the
program instructor. ‘LEED’ and related logo is a trademark owned by the U.S.
Green Building Council and is used by permission. Questions or concerns about
this course should be directed to the instructor.
If you have colleagues that might benefit from
this seminar, please let them know. Feel free to
revisit the AEC Daily web site to download
additional programs from the On-line Learning
Center.
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