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  • Partial fill

     

    The purpose of the air space in a cavity wall is as a barrier to the
    penetration of rainwater to the inside face of the wall. If the clear air space is to be effective as a barrier to rain penetration it should not be
    bridged by anything other than cavity ties. If the cavity is then filled with some insulating material, no matter how impermeable to water the material is, there will inevitably be narrow capillary paths around wall ties and between edges of insulation boards or slabs across which water may penetrate. As a clear air space is considered necessary as a barrier to rain penetration there is good reason to fix insulation material inside a cavity so that it only partly fills the cavity and a cavity is maintained between the outer leaf and the insulating mate¬rial. This construction, which is described as partial fill insulation of cavity, requires the use of some insulating material in the form of boards that are sufficiently rigid to be secured against the inner leaf of the cavity.
    In theory a 25 mm wide air space between the outer leaf and the cavity insulation should be adequate to resist the penetration of rain providing the air space is clear of all mortar droppings and other building debris that might serve as a path for water. In practice, it is difficult to maintain a clear 25 mm wide air gap because of protrusion of mortar from joints in the outer leaf and the difficulty of keeping so narrow a space clear of mortar droppings. Good practice, therefore, is to use a 50 mm wide air space between the outer leaf and the partial fill insulation.
    To meet insulation requirements and the use of a 100 mm cavity with partial fill insulation it may be economic to use a lightweight block inner leaf to augment the cavity insulation to bring the wall to the required U value.
    Usual practice is to build the inner leaf of the cavity wall first, up to the first horizontal row of wall ties, then place the insulation boards in position against the inner leaf. Then as the outer leaf is built, a batten may be suspended in the cavity air space and raised to the level of the first row of wall ties and the batten is then withdrawn and cleared of droppings. Insulation retaining wall ties are then bedded across the cavity to tie the leaves and retain the insulation in position and the sequence of operations is repeated at each level of wall ties.
    The suspension of a batten in the air space and its withdrawal and cleaning at each level of ties does considerably slow the process of brick and block laying.
    Insulation retaining ties are usually standard galvanised steel or stainless steel wall ties to which a plastic disc is clipped to retain the edges of the insulation, as illustrated in Fig. 83. The ties may be set in line one over the other at the edges of boards, so that the retaining clips retain the corners of four insulation boards.
    The materials used for partial fill insulation should be of boards, slabs or batts that are sufficiently rigid for ease of handling and to be retained in a vertical position against the inner leaf inside the cavity without sagging or losing shape, so that the edges of the boards remain close butted throughout the useful life of the building. For small dwellings the Building Regulations do not limit the use of combustible materials as partial fill insulation in a cavity in a cavity wall.
    To provide a clear air space of 50 mm inside the cavity as a barrier to rain penetration and to provide sufficient space to keep the cavity clear during building, an insulant with a low U value is of advantage if a nominal 75 mm wide cavity is formed between the outer and inner leaves.

    Fig. 83 Partial fill cavity insulation

    Insulation materials

    The materials used as insulation for the fabric of buildings may be

    grouped as inorganic and organic insulants.

    Inorganic insulants are made from naturally occurring materials that are formed into fibre, powder or cellular structures that have a high void content, as for example, glass fibre, mineral fibre (rock-wool), cellular glass beads, vermiculite, calcium silicate and magnesia or as compressed cork.

    Inorganic insulants are generally incombustible, do not support spread of flame, are rot and vermin proof and generally have a higher U value than organic insulants.

    The inorganic insulants most used in the fabric of buildings are glass fibre and rockwool in the form of loose fibres, mats and rolls of felted fibres and semi-rigid and rigid boards, batts and slabs of compressed fibres, cellular glass beads fused together as rigid boards, compressed cork boards and vermiculite grains.

    Organic insulants are based on hydrdocarbon polymers in the form of thermosetting or thermoplastic resins to form structures with a high void content, as for example polystyrene, polyurethane, iso-cyanurate and phenolic. Organic insulants generally have a lower U value than inorganic insulants, are combustible, support spread of flame more readily than inorganic insulants and have a comparatively low melting point.

    The organic insulants most used for the fabric of buildings are expanded polystyrene in the form of beads or boards, extruded polystyrene in the form of boards and polyurethane, isocyanurate and phenolic foams in the form of preformed boards or spray coatings.

    The materials that are cheapest, most readily available and used for cavity insulation are glass fibre, rockwool and EPS (expanded poly­styrene), in the form of slabs or boards, in sizes to suit cavity tie spacing. With the recent increase in requirements for the insulation of walls it may well be advantageous to use one of the somewhat more expensive organic insulants such as XPS (extruded polystyrene), PIR (polyisocyanurate) or PUR (polyurethane) because of their lower U value, where a 50 mm clear air space is to be maintained in the cavity, without greatly increasing the overall width of the cavity.

    Table 4 gives details of insulants made for use as partial fill to cavity walls.

    Insulation thickness

    A rough guide to determine the required thickness of insulation for a wall to achieve a U value of 0.45 W/m2K is to assume the insulant provides the whole or a major part of the insulation by using 30 mm thickness with a U value of 0.02, 46 with 0.03, 61 with 0.04, 76 with 0.05 and 92 with 0.06W/m2K.

    Table 4 Insulating materials Insulation thickness

    Total fill

    The thermal insulation of external walls by totally filling the cavity

    has been in use for many years. There have been remarkably few reported incidents of penetration of water through the total fill of cavities to the inside face of walls and the system of total fill has become an accepted method of insulating cavity walls.

    The method of totally filling cavities with an insulant was developed after the steep increase in the price of oil and other fuels in the mid-1960s, as being the most practical way to improve the thermal insulation of existing cavity walls. Small particles of glass or rock wool fibre or foaming organic materials were blown through holes drilled in the outer leaf of existing walls to completely fill the cavity.

    This system of totally filling the cavity of existing walls has been very extensively and successfully used. The few reported failures due to penetration of rainwater to the inside face were due to poor workmanship in the construction of the walls. Water penetrated across wall ties sloping down into the inside face of the wall, across mortar droppings bridging the cavity or from mortar protruding into the cavity from the outer leaf.

    From the few failures due to rain penetration it would seem likely that the cavity in existing walls that have been totally filled was of little, if any, critical importance in resisting rain penetration in the position of exposure in which the walls were situated. None the less it is wise to provide a clear air space in a cavity wherever practical, against the possibility of rain penetration.

    Where insulation is used to fill totally a nominal 50 mm wide cavity there is no need to use insulation retaining wall ties.

    With a brick outer and block inner leaf it is preferable to raise the outer brick leaf first so that mortar protrusions from the joints, sometimes called snots, can be cleaned off before the insulation is placed in position and the inner block leaf, with its more widely spaced joints is built, to minimise the number of mortar snots that may stick into the cavity. This sequence of opera­tions will require scaffolding on both sides of the wall and so add to the cost.

    Insulation that is built in as the cavity walls are raised, to fill the cavity totally, will to an extent be held in position by the wall ties and the two leaves of the cavity wall. Rolls or mats of loosely felted glass fibre or rockwool are often used. There is some likelihood that these materials may sink inside the cavity and gaps may open up in the insulation and so form cold bridges across the wall. To maintain a continuous, vertical layer of insulation inside the cavity one of the mineral fibre semi-rigid batts or slabs should be used. Fibre glass and rockwool semi-rigid batts or slabs in sizes suited to cavity tie spacing are made specifically for this purpose.

    As the materials are made in widths to suit vertical wall tie spacing there is no need to push them down into the cavity after the wall is built, as is often the procedure with loose fibre rolls and mats, and so displace freshly laid brick or blockwork. There is no advantage in using one of the more expensive organic insulants such as XPS, PIR or PUR that have a lower U value than mineral fibre materials for the total cavity fill, as the width of the cavity can be adjusted to suit the required thickness of insulation.

    The most effective way of insulating an existing cavity wall is to fill the cavity with some insulating material that can be blown into the cavity through small holes drilled in the outer leaf of the wall. The injection of the cavity fill is a comparatively simple job. The complication arises in forming sleeves around air vents penetrating the wall and sealing gaps around openings.

    When filling the cavity of existing walls became common practice, a foamed organic insulant, ureaformaldehyde, was extensively used. The advantage of this material was that it could be blown, under pressure, through small holes in the outer leaf and as the con­stituents mixed they foamed and filled the cavity with an effective insulant. This material was extensively used, often by operatives ill trained in the sensible use of the material. The consequence was that through careless mixing of the components of the insulant and careless workmanship, the material gave off irritant fumes when used and later, when it was in place, these entered buildings and caused considerable distress to the occupants. Approved Document D of the Building Regulations details provisions for the use of this material in relation to the construction of the wall and its suitability, the composition of the materials, and control of those carrying out the work. As a result of past failures this material is less used than it was.

    Glass fibre, granulated rockwool of EPS beads are used for the injection of insulation for existing cavity walls. These materials can also be used for blowing into the cavity of newly built walls.

    Table 5 gives details of insulants for total cavity fill.

    The required thickness of insulation can be taken from the two methods suggested for partial fill. In a calculation for total fill, the thermal resistance of the cavity is omitted.

    Thermal bridge

    A thermal bridge, more commonly known as a cold bridge in cold climates, is caused by appreciably greater thermal conductivity through one part of a wall than the rest of the wall. Where the cavity in a wall is partially or totally filled with insulation and the cavity is bridged with solid filling at the head, jambs or cill of an opening, there will be considerably greater transfer of heat through the solid filling than through the rest of the wall. Because of the greater transfer of

    heat through the solid filling illustrated in Fig. 84, the inside face of the wall will be appreciably colder in winter than the rest of the wall and cause some loss of heat and encourage warm moist air to con­dense on the inside face of the wall on the inside of the cold bridge. This condensation water may cause unsightly stains around openings and encourage mould growth.

    Thermal bridges around openings can be minimised by continuing cavity insulation to the head of windows and doors and to the sides and bottom of doors and windows.

    Of late an inordinate fuss has been made about ‘cold bridges’ as though a cold bridge was some virulent disease or a heinous crime.

    Solid filling of cavities around openings will allow greater transfer of heat than the surrounding insulated wall and so will window glass, both single and double, and window frames. To minimise heat transfer, cavity insulation should continue up to the back of window and door frames.

    Where solid filling of cavities around openings is used the area of the solid filling should be included with that of the window and its frame for heat loss calculation.

    Fig. 84 Thermal bridge Table 5 Insulating materials

     

     

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  • In positions of severe exposure to wind driven rain, the outer leaf of a cavity wall may absorb water to the extent that rainwater penetrates to the cavity side of the outer leaf. It is unlikely, however, that water will enter the cavity unless there are faults in construction.

    Where the mortar joints in the outer leaf of a cavity wall are inadequately flushed up with mortar, or the bricks in the outer leaf are grossly porous and where the wall is subject to severe or very severe exposure, there is a possibility that wind driven rain may penetrate through the outer leaf to the cavity

    Where rain penetrates the outer leaf and enters the cavity, it is certain that either the construction of the wall is poorly executed, or the bricks have been unwisely chosen or the outer leaf is of inadequate thickness for the position of exposure in which it is built. The solution is to choose some alternative form of construction such as a thicker outer leaf, more suited to the position of exposure.

    Some consider it good practice to use some form of impermeable cavity tray above all horizontal breaks in a cavity wall against the possibility of rainwater penetrating the outer leaf. The dubious argument is that freely flowing water may enter the cavity in sufficient run down on to horizontal breaks in walls, such as carried down to openings, and cause damp staining. Having been persuaded that it is sense to accept this idea, it has become common practice to build

    in some form of damp-proof course or tray of flexible, impermeable material to direct freely flowing water out to the external face of walls. A strip of polymer based polythene, bitumen felt or sheet lead is used for the purpose. The dpc and tray shown in Fig. 82 is built in at the top of the inner lintel and dressed down to the underside of the outer lintel over the head of the window. As an alternative the dpc tray could be built in on top of the second block course and dressed down to the top of the outer lintel, with weep holes in the vertical brick joints.

    If there were a real need for these trays it would be common to observe the evidence of water seeping through these weep holes to the outer face of cavity walls. No such evidence exists where cavity walls are sensibly designed and soundly constructed. A disadvantage of the weep holes is that cold air may enter and cool the air space and increase thermal transmission.

    Where the cavity is solidly filled with insulation any water pene­trating the outer leaf will be trapped between closed cell insulation and the wall or saturate open cell insulation.

    Good sense dictates that the notion of the dpc trays in cavity walls be abandoned.

    Fig. 82 Dpc and tray

     

     

     

    Resistance to the passage of heat

    Because thin solid walls of brick or block may offer poor resistance to the penetration of wind driven rain, many loadbearing walls are built with two leaves of brick or block separated by a cavity, whose prime purpose is as a barrier to rain penetration.

    Because the resistance to the passage of heat of a cavity wall by itself is poor, it is necessary to introduce a material with high resistance to heat transfer to the wall construction.

    Most of the materials, thermal insulators, that afford high resistance to heat transfer are fibrous or cellular, lightweight, have comparatively poor mechanical strength and are not suitable by  themselves for use as part of the wall structure. The logical position for such material in a cavity wall, therefore, is inside the cavity.

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  • As an alternative to the use of steel lintels reinforced concrete lintels may be used to support the separate leaves over openings. This construction may be used where the appearance of a concrete lintel over openings in fairface brick is acceptable and where an outer leaf dense concrete 0f brick or block is to be rendered to enhance protection against rain  penetration or for appearance sake. insulation board ^ ranSe of precast reinforced concrete lintels is available to suit the in cavity carried widths of most standard door and window openings with adequate down to head anowance for building in ends of lintels each side of openings. For use with fairface brickwork the lintel depth should match the depth of brick course heights to avoid untidy cutting of bricks around lintel ends.

    penetration or for appearance sake. insulation board ^ ranSe of precast reinforced concrete lintels is available to suit the in cavity carried widths of most standard door and window openings with adequate down to head anowance for building in ends of lintels each side of openings. For use with fairface brickwork the lintel depth should match the depth of brick course heights to avoid untidy cutting of bricks around lintel ends.

    Fig. 81 Concrete lintels

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  • Most loadbearing brick or blockwork walls over openings, where the cavity insulation is continued down to the head of the window or door frame, are supported by steel section lintels. The advantage of these lintels is that they are comparatively lightweight and easy to handle, they provide adequate support for walling over openings in small buildings and once they are bedded in place the work can proceed without delay. Because of their ease of handling and use these lintels have largely replaced concrete lintels.

    The lintels are formed either from mild steel strip that is pressed to shape, and galvanised with a zinc coating to inhibit rust, or from stainless steel. The lintels for use in cavity walling are formed with either a splay to act as an integral damp-proof tray or as a top hat section over which a damp-proof tray is dressed. Typical sections are illustrated in Fig. 78.

    The splay section lintels are galvanised and coated with epoxy powder coating as corrosion protection and the top hat section with a galvanised coating. For insulation the splay section and top hat section lintels are filled with expanded polystyrene.

    The top hat section steel lintel is built into the jambs of both the inner and outer leaf to provide support for both leaves of the cavity wall, as illustrated in Fig. 79. The two wings at the bottom of the lintel provide support for the brick outer and block inner leaves over the comparatively narrow openings for windows and doors. Where the cavity is partly filled with insulation it is usual to dress a flexible dpc from the block inner leaf down to a lower brick course or down to the underside of the brick outer leaf. The purpose of the damp-proof course or tray is to collect any water that might penetrate the outer leaf and direct it to weep holes in the wall.

    The splay section lintel is built into the jambs of openings to provide support for the outer and inner leaf of the cavity wall over the

    brick outer leaf and openings, as illustrated in Fig. 80. Where the cavity is filled with 50 mm cavity filled insuiatjon there is no need to build in a damp-proof course or tray.

    block inner leaf Any water that might penetrate the outer leaf will be directed towards the outside by the splay of the lintel.

    Unless the window or door frame is built-in or fixed with its external face close to the outside face of the wall, the edge of the wing of the lintel will be exposed on the soffit of the opening. In handling and building in, there is a possibility that the edge of this wing might suffer damage to the protective galvanised coating. On the external face of a wall, water may penetrate the zinc coat and cause corrosion of the steel below. Rust very quickly spreads around the initial fracture of the protective coating. It is worthwhile making the comparatively small outlay on a stainless steel lintel as insurance against a possibly much larger expenditure on replacement of a corroded galvanised steel lintel.

    Fairface brickwork supported by steel lintels may be laid as horizontal course brickwork or as a flat brick on edge or end lintel.

    Fig. 79 Top hat lintel Fig. 80 Splay lintel

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  • The brickwork and blockwork over the head of openings in cavity walls has to be supported. Because of the bonding of brickwork and blockwork over the opening it is necessary to provide support for the weight of the brickwork or blockwork within a 45° isosceles triangle formed by the stretcher bond and the weight of floors and roofs carried by the wall over the opening.

    The comparatively small loads over small openings are carried by a lintel or arch. With the adoption of cavity insulation as a principal method of enhancing the resistance of walls to the transfer of heat and the need to continue cavity insulation up to the back of window and door frames to minimise cold bridges, it is practice today to use lintels to support the inner and outer leaves over openings.

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  • A cill is the horizontal finish to the wall below the lower edge of a window opening on to which wind driven rain will run from the hard, smooth, impermeable surface of window glass. The function of a cill is to protect the wall below a window. Cills are formed below the edge of a window and shaped or formed to slope out and project beyond the external face of the wall, so that water runs off. The cill should project at least 45 mm beyond the face of the wall below and have a drip on the underside of the projection.
    The cavity insulation shown in Fig. 77 is carried up behind the stone cill to avoid a cold bridge effect and a dpc is fixed behind the cill as a barrier to moisture penetration.
    A variety of materials may be used as a cill such as natural stone, cast stone, concrete, tile, brick and non-ferrous metals. The choice of a particular material for a cill depends on cost, availability and to a large extent on appearance. Details of the materials used and the construction of cills are given in Volume 2.
    As a barrier to the penetration of rain to the inside face of a cavity wall it is good practice to continue the cavity up and behind the cills as illustrated in Volume 2. Where cills of stone, cast stone and con¬crete are used the cill may extend across the cavity. As a barrier to rain penetration it has been practice to bed a dpc below these cills and extend it up behind the cill, as illustrated in Volume 2. Providing the cill has no joints in its length, its ends are built in at jambs and the material of the cill is sufficiently dense to cause most of the rainwater to run off, there seems little purpose in these under sill dpcs or trays.
    The threshold to door openings serves as a finish to protect a wall or concrete floor slab below the door, as illustrated in Volume 2. Thresholds are commonly formed as part of a step up to external doors as part of the concrete floor slab with the top surface of the threshold sloping out. Alternatively, a natural stone or cast stone threshold may be formed.

    Fig. 77 Jamb lining to wide cavity

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  • The practical guidance in Approved Document A in regard to openings in walls states that the number, size and position of openings should not impair the stability of a wall to the extent that the com­bined width of openings in walls between the centre line of buttressing walls or piers should not exceed two-thirds of the length of that wall together with more detailed requirements limiting the size of opening and recesses. There is a requirement that the bearing end of lintels with a clear span of 1200 mm or less may be 100 mm and above that span, 150 mm.

    Figure 73 is an illustration of a window opening in a brick wall with the terms used to describe the parts noted.

    For strength and stability the brickwork in the jambs of openings has to be strengthened with more closely spaced ties and the wall over the head of the opening supported by an arch, lintels or beams. The term jamb derives from the French word jambe, meaning leg. From Fig. 73, it will be seen that the brickwork on either side of the opening acts like legs which support brickwork over the head of the opening. The term jamb is not used to describe a particular width either side of openings and is merely a general term for the brickwork for full height of opening either side of the window. The word ‘reveal’ is used more definitely to describe the thickness of the wall revealed by cutting the opening and the reveal is a surface of brickwork as long as the height of the opening. The lower part of the opening is a cill for windows or a threshold for doors.

    The jambs of openings may be plain or square into which the door or window frames are built or fixed or they may be rebated with a recess, behind which the door or window frame is built or fixed.

    The cavity in a cavity wall serves to prevent penetration of water to the inner leaf. In the construction of the conventional cavity wall, before the adoption of cavity insulation, it was considered wise to close the cavity at the jambs of openings to maintain comparatively still air in the cavity as insulation. It was practice to build in cut bricks or blocks as cavity closers. To prevent penetration of water through the solid closing of cavity walls at jambs, a vertical dpc was built in as illustrated in Fig. 74. Strips of bitumen felt or lead were nailed to the back of wood frames and bedded between the solid filling and the outer leaf as shown
    As an alternative to solidly filling the cavity at jambs with cavity
    closers, window or door frames were used to cover and seal the cavity.
    Pressed metal subframes to windows were specifically designed for
    jamb of steel this purpose, as illustrated in Fig. 75. With mastic pointing between
    su rame ^ metai subframe and the outer reveal, this is a satisfactory way of sealing cavities.
    At the time when it first became common practice to fill the cavity solidly at jambs, there was no requirement for the insulation of walls. When insulation first became a requirement it was met by the use of lightweight, insulating concrete blocks as the inner leaf and the practice of solid filling of cavity at jambs, with a vertical dpc continued.
    With the increasing requirement for insulation it has become practice to use cavity insulation as the most practical position for a layer of lightweight material. If the cavity insulation is to be effective for the whole of the wall it must be continued up to the back of window and door frames, as a solid filling of cavity at jambs would be a less effective insulator and act as a thermal or cold bridge.
    With the revision of the requirement of the Building Regulations for enhanced insulation down to a standard U value of 0.45 W/m2K window for the walls of dwellings it has become practice to use cavity insu-frame lation continued up to the frames of openings, as illustrated in Fig. 76, to avoid the cold bridge effect caused by solid filling. Door and window frames are set in position to overlap the outer leaf with a frame bedded resilient mastic pointing as a barrier to rain penetration between the m mo ar frame ancj the jamb. With a cavity 100 mm wide and cavity insulation as partial fill, it is necessary to cover that part of the cavity at jambs of openings, that is not covered by the frame. This can be effected by covering the cavity with plaster on metal lath or by the use of jamb linings of wood, as illustrated in Fig. 77.

    With this form of construction at the jambs of openings there is no purpose in forming a vertical dpc at jambs.
    The advantages of the wide cavity is that the benefit of the use of the cavity insulation can be combined with the cavity air space as resistance to the penetration of water to the inside face of the wall.

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  • The spacing of wall ties built across the cavity of a cavity wall is usually 900 mm horizontally and 450 mm vertically, or 2.47 ties per square metre, and staggered, as illustrated in Fig. 72, for the conventional 50 mm wide cavity, with the spacing reduced to 300 mm around the sides of openings. In Approved Document A to the Building Regulations, the practical guidance for the spacing of ties is given as 900 and 450 mm horizontally and vertically for 50 to 75 mm cavities, 750 and 450 mm horizontally and vertically for cavities from 76 to 100 mm wide and 300 mm vertically at unbonded jambs of all openings in cavity walls within 150 mm of openings to all widths of cavities.

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