4✔ Insulation Boards Compared | Q3 2024 | [Infographic]

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Insulation boards are the best and most convenient form of insulating our home. Board doesn't come loose and never compresses after installation. Instead, it's a solid, hard foam material. Boards are simply a better solution, enabling greater savings and better thermal insulation than standard insulation roll. They come in specific dimensions, they are easy to cut and most importantly, they are very easy to carry on site. 
In this article, you will learn about the pros and cons of each of them. Of course, each insulation board will include a price per m2. Below, you will also find information of the most common insulation panels, together with their applications and main points of concerns. By the end of this article you should be able to see what the best performing materials are likely to be for your application. Let&#;s take a closer look and discuss all types of insulation boards.

 TABLE OF CONTENTS

 

The amount of money you spend on insulation boards can vary greatly depending on the type, so it's important to know what you're getting before you buy.

When building or renovating there are 4&#; main kinds of rigid foam panels you are going to have to choose from:

1. Polyisocyanurate known as Polyiso (

   PIR

   ),

2. Phenolic foam (

   PF

   ),

3. Extruded Polystyrene (

   XPS

   ) - often called Styrofoam,

4. Expanded Polystyrene (

   EPS

   ).

Here's how they compare. The green highlights show where each insulation board type is the best. Phenolic foam is the top performer in most aspects, but it's pricey. Another good option seems to be PIR insulation board. It's not as expensive and has aluminum foil on both sides. Plus, it has one of the best balances between price and thermal conductivity.

PIR vs Phenolic Board vs EPS vs XPS 

 

INSULATION BOARDS BACKSTAGE

PIR insulation board, short for PolyIsocyanuRate (PIR), is one of the most capable and valuable heat resistant material used in UK constructions that can be used to insulate buildings for energy conservation. Its rigid core is usually sandwiched between two aluminium foil facings that are high performance, thus creating a tough, hard wearing yet lightweight insulation board. It is ideal for in-between and under rafters in a pitched roof or for under-slab concrete floors and also for internal stud wall applications and wall lining to existing walls, roof, wall, timber frame, loft, floor and caravan applications. The major advantage of PIR compared to other insulation materials is the insulation value. The Lambda value of PIR is situated between 0.021 to 0.032 W/mK. This means that PIR offers superior insulation with the same thickness. PIR insulation boards combine thermal efficiency with an economical price point, although the slightly better thermal performance of phenolic foam may justify the increased cost if depth in the floor construction is at a premium. PIR is used in the majority of cases as a higher thermal performance can be achieved with less material.

PIR insulation board is often associated with market leader Celotex company as they began producing rigid polyisocyanurate foam as first. In fact, Celotex invented the thinnest thickness of PIR insulation measuring as little as 12mm. Many PIR insulation brands, such as Celotex, Unilin, Kingspan or Recticel come with a grid marked on, which can act as a guide to help ensure the thermal insulation board is cut in a straight line. 

Depending of thickness and brand, rigid insulation boards come in multiple name options, including:

Thinner insulation boards, ranging from 12mm to 50mm are offered by Unilin, Celotex, IKO Enertherm, Ecotherm and Kingspan. PIR insulation boards are available in a range of thicknesses such as 12mm, 15mm, 20mm, 25mm, 30mm, 35mm, 40mm, 45mm, 50mm, 55mm, 60mm, 65mm, 70mm, 75mm, 80mm, 90mm, 100mm, 110mm, 120mm, 125mm, 130mm, 140mm, 150mm, 165mm, 180mm and 200mm.

However, the most commonly used thicknesses are 12mm, 15mm, 20mm, 25mm, 50mm and 100mm.

APPLICATION

• Cavity wall, 

• Underfloor heating,

• SIP panels,

• In-between and under rafters, 

• Under-slab concrete floors, 

• Wall lining to existing walls,

• Roof,  

• Caravan applications, 

• Beam and block floors,

• Balconies and terraces, 

• Timber frame wall lining, 

• Timber frame walls sheathing ,

• Suspended timber floors, 

• Steel stud frame walls,

• Single timber frame wall lining, 

• Rain-screen cladding, 

• Pitched roof sarking, 

• Concrete slab floors,

• Loft and attic insulation,

• Garage conversions.

PRICE (m2): 100mm &#; £25
SIZE: mm x mm (8' x 4') (2.88m2)
THERMAL CONDUCTIVITY (λ&#;value): 0.022 W/mk
COMPRESSIVE STRENGTH: 120kPa
ADVANTAGES: wide applicability, provided with a vapour barrier on both sides, not corrosive to metal over time. 
DISADVANTAGES: needs a nice, tight fit (for more information on how to cut PIR insulation click here).

PF phenolic insulation boards (Phenolic Foam) are the most expensive but also most productive type of insulation boards. They are lightweight but strong thermosetting plastics and are considered to be one of the best rigid, closed-cell structure materials for thermal insulation at present being up to 50% more effective than other common insulation materials such as PIR. Boards are mainly intended for investors who want to achieve the standard of an energy-saving or passive house. Panels have a slightly higher R-value and a slightly thinner profile than PIR boards due to the manufacturing process. While PIR offers the lambda value of 0.022 W/mK, phenolic closed cell foam offers 0.018W/mK. In fact, that is only 10% better than PIR.

The term rigid insulation typically refers to the large pre-formed sheets of insulation which can be bought in mm x mm (8&#; x 4&#;) size. The most popular thicknesses are 25mm, 50mm and 100mm.  Phenolic board called Kingspan K5 brakes this magic point offering 0.28W/m²K with just 70mm board thickness. For this reason it is ideal for applications where space is at a premium. For instance, achieving a U-value of 0.28 W/m2K would require only 70mm of phenolic floor board while EPS polystyrene needs 200mm. As they&#;re closed cells they shouldn&#;t absorb moisture or water vapour, unlike partially open cell products (EPS). 
High density boards have a good compressive strength and are suitable even for floors.
Boards with high density boast strong compressive strength, making them ideal for flooring. Phenolic foams, crafted with densities up to 160 kg/m³, find utility in areas with high moisture, like bathrooms and toilets. They are also effective for insulation above rafters and as thermal insulation boards placed between and beneath rafters, particularly in pitched roofs with tiles or slates.
It can be used in a variety of wall and floor applications, which makes it a great solution for a range of constructions. Used extensively in the building industry for a number of application areas including roofing (Xtratherm Safe-R SR/PR), cavity board (Xtratherm SR/CW), external wall board (Kingspan K5), plasterboard dry linings systems (Xtratherm Safe-R SR/TB or Kingspan K118) and floor insulation (Kingspan K103 or Xtratherm SR/UF Safe-R). Phenolic foam is also used in a number of highly specialised applications including fire doors, highly fire resistant panels and for insulation in surface ships, off-shore installations and submarines. It has also been used in heating, ventilating and air conditioning applications for many years.

Phenolic boards will likely be the most expensive of all the rigid foam insulation options available on the UK market, however being low thermal conductivity insulation enables high levels of thermal performance to be achieved utilising thinner sections of insulation. The exceptionally low thermal conductivity of closed cell phenolic foam boards means that appropriate insulation efficiency can be achieved with the thinnest possible material. 

Depending on the design, you can choose from 2 brands. The only players on the market are - Kingspan® followed by Xtratherm®. While Kingspan offers only Kooltherm K-range, Xtratherm seems to offer a bit more. Xtratherm has products for specific projects. Depending on the application, you can choose between:

Soffit phenolic boards | Dry Lining | Cavity wall phenolic boards | Flooring Phenolic boards | Rainscreen phenolic boards | Roofing Phenolic boards | Steel and timber frame

APPLICATION:

• Dry lining, 

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• Cavity wall,

• Floor,

• Rainscreen insulation,

• Roofing,

• Steel and timber frame wall,

• Suspended floors, 

• Ground supported floors, 

• Underfloor heating systems.

PRICE  (m2): 100mm - £39
SIZE: mm x mm (8' x 4') (2.88m2)
THERMAL CONDUCTIVITY (λ&#;value): 0.018 W/mk
COMPRESSIVE STRENGTH: 120kPa-160kPa
ADVANTAGES: highest fire rating among many organic insulation materials, highly resistant to water penetration, resist attack by mould and microbial growth, thinnest possible insulation board.
DISADVANTAGES: most expensive, causes pipework corrosion when it gets wet, easily crushes when walked on.

 

The XPS (EXtruded PolyStyrene) foam called &#;polyfoam floorboard&#; or &#;styrofoam blue board&#; is a fully closed cell, high density, upgrade extrusion skin panel designed especially for floor applications. Product is actually fairly inexpensive non organic styrofoam material. Chemically it&#;s made up of the same as EPS polystyrene but rather than being formed into droplets and then expanded, it is foamed up. Just like EPS, XPS is made of 98% air and just 2 % plastic. 
XPS board has no thermal drift or loss of R-Value over time. It remains waterproof over the decades. As a rule of thumb, the lower the thermal conductivity the better, because the material conducts less heat energy. For XPS polystyrene, its thermal conductivity ranges from 0.035 W/mK, which is &#; higher compared to phenolic insulation boards. On the other hand, as for the price, XPS is cheaper than Phenolic boards but more expensive than EPS polystyrene.

XPS polystyrene has excellent compressive strength which means it can easily cope with different flooring loads in different grades. Due to this fact, XPS is regularly used in applications where it is going to be under some strain, such as car park decks. It&#;s also great for use in basements or overlay roofs. XPS boards have a compressive strength of 30 tonnes per square metre, making them a lasting component for underfloor heating too. However, XPS can attract ants and termites even though it is not an organic material. XPS foam insulation is capable of withstanding over freeze/thaw cycles. Since the cells of XPS are so tightly packed, it is more moisture resistant and mildew resistant then EPS. So it is often selected in water environments.

The compressive strength of XPS is also greater than the EPS reaching 300-500 kPa. Similar to EPS there is no thermal drift or loss of R-Value over time. The thermal insulation performance of EPS and XPS in identical densities is quite close. However, EPS with the same level of density is less expensive. For more information of differences between EPS and XPS click here

Brands of XPS are generally recognizable by the colour of the insulation. XPS is typically supplied as blue, pink, green or yellow colored boards. XPS is made by Styrofoam and Dow Company, green XPS called GreenGuard is made by Kingspan and yellow XPS is made by Soprema. While they are all the same, the colour helps distinguish manufacturing companies on job sites.

APPLICATION:

• Underfloor heating,

• Garages,

• Car park,

• Commercial floor,

• Below DPC level application.

PRICE  (m2): 100mm - £25
SIZE: x 600, x 615,  x 600
THERMAL CONDUCTIVITY (λ&#;value): 035 W/mk
COMPRESSIVE STRENGTH: 300kPa
ADVANTAGES: can withstand over freeze/thaw cycles, excellent compressive strength, below DPC level application.
DISADVANTAGES: can attract ants and termites, breaks easily, fairly expensive product.

If your budget is tight and you are looking for the cheapest insulation board, Expanded polystyrene called EPS is the product to go for. This budget-friendly material has a high percentage of trapped air inside which makes it an excellent premier insulator. However, unlike XPS insulation boards, EPS panels have partially closed cells which may retain water and reduce its thermal properties. It is therefore irreplaceable in applications such as External Insulation Systems (EWI) or as a fill material. Micro cellular closed cell construction provides EPS with its excellent insulating and shock absorbing characteristics.
In fact, EPS leads the other insulation products when it comes to R-value per £. Therefore, manufacturing costs of EPS are generally lower compared to other insulating materials like PIR or Phenolic Boards. While still offering a high thermal performance, EPS board requires slightly thicker levels to achieve the same thermal performance as PIR or Phenolic board. For example, while a project may call for 120mm of white EPS, the same thermal performance can be achieved with 70mm of PIR. On the other hand EPS polystyrene is said to be slightly easier to work with when cut. For more information on how to cut styrofoam click here.
Polystyrene board is a very practical, economic and efficient insulation product which can be applied to all areas of building construction to provide superior standards of thermal insulation.

APPLICATION:
External wall insulation,
Attic applications,
Void former,
Floor Pile collars, 
Column formers, 
Insulated foundation systems,
Concrete floor, 
Structural insulated panels (SIPs)

PRICE (m2): 100mm - £20
SIZE: x , x 500, x 600
THERMAL CONDUCTIVITY (λ&#;value): 0.038 W/mk
COMPRESSIVE STRENGTH: 70kPa
ADVANTAGES: 100% recyclable, cheap to buy, easy to cut.
DISADVANTAGES: can attract ants and termites, fire class-E-F.

 

Related articles:

How to cut PIR?

How to cut Styrofoam?

Difference between EPS and XPS polystyrene boards

What is Filcor?

Thinnest Insulation

An exceptional performance of rigid phenolic foam

Feel the difference with XPS boards

Energy saver insulation

12mm Celotex TB vs 15mm Xtratherm Thin-r

 

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Phenolic Insulation Board Overview

Phenolic insulation boards, known for their versatility, are widely used in construction projects for roof, wall and floor applications. These boards offer exceptional thermal insulation and are considered one of the most effective types of rigid insulation available. In fact, they outperform other commonly used insulation materials by up to 50%!

At Workplace Interior Shop, we understand the importance of choosing the right insulation for your project. That&#;s why we offer a diverse range of phenolic foam insulation products, including the popular Kooltherm insulation. If you need help determining the most suitable product for your project or require additional information on insulation solutions, please feel free to get in touch.

Types of Phenolic Insulation Boards

Phenolic insulation boards come in various types and forms to cater to different insulation needs. The most common type is phenolic foam boards. These are rigid yet lightweight, offering excellent thermal properties to buildings across the UK. Rigid phenolic foam boards are often used for insulating ceilings, walls and floors in both residential and commercial buildings.

Phenolic Cavity Wall Insulation

Phenolic insulation boards can be installed within partitions and wall cavities to provide thermal insulation. This type of insulation helps improve energy efficiency by reducing the volume of heat lost through the walls, resulting in lower heating costs and a more comfortable indoor environment.

Phenolic Roof Insulation

For flat roofs, phenolic roof insulation boards are specifically designed to offer high compressive strength and excellent thermal performance. These boards are commonly used in commercial and industrial roofing applications, providing effective insulation and contributing to energy savings.

Phenolic Floor Insulation

Phenolic floor insulation boards are a highly effective solution for insulating floors, catering to both ground floors and intermediate floors in buildings. They&#;re designed to minimise heat transfer, ensuring that your space remains warm during the colder months.

Benefits of Phenolic Insulation Boards

Phenolic insulation boards offer a range of benefits that make them a popular choice for various insulation applications.

1. Thermal Efficiency

   One of the key advantages of phenolic insulation boards is their high thermal efficiency. These boards have low thermal conductivity, which helps to reduce heat loss and energy consumption within your building. This, in turn, helps to maintain a stable and comfortable indoor temperature.

2. Fire Resistance

   Phenolic boards can help you meet certain safety regulations as they are able to withstand continuous temperatures of up to 120 °C. Better yet, phenolic boards combine zero or very low flame spread with negligible smoke emissions and a very low level of toxic gas emissions. When it comes to fire safety, we always advise you to seek the advice of professionals.

3. Moisture Resistance

   Thanks to their close cell structure, phenolic boards don&#;t absorb moisture or water vapour, ensuring the structural integrity of your product. Additionally, they exhibit resistance to certain types of fungus and mould growth, further enhancing their durability and keeping your space hygienic.

4. Compressive Strength

   Due to their high compressive strength, phenolic insulation boards are suitable for load-bearing applications such as under floors and in roofing systems.

5. Lightweight

   Despite their strength, these boards are surprisingly lightweight. This simplifies handling and installation. This not only reduces labour costs but also speeds up the construction process.

6. Durability

   Phenolic insulation boards are known for their durability and long lifespan, offering sustained thermal performance over time. This ensures that the insulation maintains its effectiveness, providing excellent value for money.

7. Eco-Friendly

   While phenolic insulation is non-biodegradable, waste material can be put back into the manufacturing process for reuse. Its outstanding thermal properties can also help to reduce CO2 emissions.

8. Energy Savings

   The superior thermal performance of phenolic insulation boards leads to reduced energy consumption for both heating and cooling, resulting in lower utility bills and improved energy efficiency.

Phenolic Insulation Boards Buying Advice

When buying phenolic insulation boards, there are a few factors to consider. For example, you&#;ll need to ensure that the boards have the correct conductivity rating to meet your insulation needs. The lower the conductivity value, the better the insulation performance.

The thickness of your board is also very important. In general, thicker boards provide better insulation, however, they may also be more expensive. You&#;ll want to choose a thickness that meets your insulation requirements without exceeding your budget.

For further guidance on selecting the right phenolic insulation board for your project, please don&#;t hesitate to get in touch.

Phenolic Insulation Boards Installation Advice

Proper installation is key to maximising the effectiveness of your boards. We&#;ve collated some additional tips to consider during installation to help with the success of your project.

• Always prioritise safety by wearing the appropriate personal protective equipment (PPE), including gloves, safety glasses and dust masks. This precaution is especially crucial when cutting or handling the phenolic insulation boards.
• For a smooth and secure installation, prepare the surface where the insulation boards will be placed; ensure that it&#;s clean, dry and free from any dirt. This surface preparation is essential for adhesion and the long-term performance of your insulation.
• If you&#;re not experienced in installing insulation, we recommend considering hiring a professional contractor who&#;s familiar with phenolic insulation.
• Regular maintenance is key to preserving the condition and performance of your boards. Regular inspections mean that you can address potential issues promptly and extend the lifespan of your insulation, as well as its thermal performance.

Phenolic Insulation Board Aftercare & Service

Once installed, phenolic insulation boards require careful aftercare and regular servicing to ensure their longevity and optimal functionality. We recommend implementing regular inspections to assess the condition of your boards. Things to look out for include:

• General signs of wear and tear
• Moisture damage
• Cracks or chips

This, along with regular cleaning, will ensure that your boards continue to deliver the expected thermal performance and continue to contribute to the energy efficiency and comfort of your building.

What Our Experts Say

When it comes to insulation materials, our experts recommend phenolic foam insulation as a top choice for all construction projects. At Workplace Interior Shop, we proudly offer a diverse range of high quality phenolic boards. If you have any questions about these products or any of our insulation solutions, feel free to reach out to our knowledgeable and friendly team. We&#;re always happy to help.

Our Customers Also Ask

Find answers to the most commonly asked questions about insulation.

• How thick is phenolic foam insulation? phenolic foam boards should be based on the degree of insulation you want to achieve. In general, the thicker the phenolic board you use, the more thermal protection you&#;ll have.

  Phenolic foam insulation is available in various thicknesses to suit different insulation needs and project requirements. The thickness usually ranges from as thin as 20mm to 140mm. The choice of thickness forshould be based on the degree of insulation you want to achieve. In general, the thicker the phenolic board you use, the more thermal protection you&#;ll have.

• Does phenolic insulation have the highest R-value? PIR boards have an R-value of around R-4.5. The exceptional thermal performance of phenolic insulation is attributed to its fine cell structure and high closed cell content. This means that if you require highly efficient thermal insulation for your building, using phenolic foam insulation is an excellent choice.

  Phenolic insulation is known for having one of the highest R-values among insulation materials. The R-value measures the material&#;s thermal resistance, indicating how effectively it resists heat transfer. Phenolic insulation , particularly the Kooltherm range, boasts an R-value rating between R-5 to R-8+, whilehave an R-value of around R-4.5. The exceptional thermal performance of phenolic insulation is attributed to its fine cell structure and high closed cell content. This means that if you require highly efficient thermal insulation for your building, using phenolic foam insulation is an excellent choice.

• Does phenolic insulation absorb water?

  No, phenolic insulation boards do not absorb water. Phenolic insulation has a very slow water absorption rate - it&#;s one of the product&#;s most desirable selling points (alongside its exceptional thermal efficiency, of course). Phenolic insulation is both water and moisture resistant, preventing issues like mould and mildew growth, structural damage and a negative impact on its thermal performance. This will also help you to keep your space clean and sanitary with little maintenance. Although water will damage them with prolonged submersion in water, temporary leaks shouldn&#;t harm the phenolic board you install in your building.

• What&#;s the difference between PIR and phenolic insulation? PIR Insulation Phenolic Insulation PIR insulation is composed of polysiocyanurate foam. This has excellent thermal properties and is known for its ability to reduce heat transfer. Phenolic insulation is made from phenolic foam. This foam offers exceptional thermal performance and is renowned for its closed-cell content and fine-cell structure. PIR insulation requires a longer curing process during the manufacturing stage. This extended curing period can impact project timelines. Phenolic insulation achieves exceptional thermal efficiency without the need for an extended curing period, making it a more time-efficient choice. PIR insulation performs well in providing insulation and energy efficiency for various applications. Phenolic insulation is renowned for its outstanding thermal efficiency, making it the preferred choice for applications where top-tier insulation is essential. At Workplace Interior Shop, we supply a wide range of both

  PIR insulation boards have excellent thermal properties, but when compared to phenolic boards such as the Kooltherm range, they far exceed the performance of PIR boards. Out of the most rigid thermoset insulation materials you can choose from, you won&#;t find anything more thermally efficient than phenolic insulation boards. Some of the key differences include:At Workplace Interior Shop, we supply a wide range of both PIR and phenolic insulation boards to ensure your space is properly insulation. To discuss the best product for your building, don&#;t hesitate to ask our experts.

• Why choose a phenolic insulation board? phenolic insulation board is a more expensive form of insulation, its performance is unrivalled. For many, it&#;s regarded as one of the most thermally efficient insulation products currently used. This is due to a number of benefits:
  • Phenolic insulation boards are one of the thinnest insulation boards for a specific u-value, meaning they&#;re incredibly space efficient.
  • Phenolic insulation boards offer excellent moisture resistance. Their company cell structure prevents moisture absorption and water vapour penetration, ensuring that the insulation remains effective and durable over time.
  • The boards are also resistant to certain types of fungus and mould growth, further enhancing their longevity and structure integrity.
  • In terms of safety, phenolic boards are designed to withstand high temperatures. They can withstand continuous temperatures of up to 120 °C.
  • Phenolic boards have zero or very low flame spread, produce negligible smoke emissions and release a minimal amount of toxic gases when exposed to fire.
  • While phenolic insulation is non-biodegradable, you can put the waste material back into the manufacturing process for reuse, and its outstanding thermal properties help reduce CO2 emissions.

  While ais a more expensive form of insulation, its performance is unrivalled. For many, it&#;s regarded as one of the most thermally efficient insulation products currently used. This is due to a number of benefits:

• What is phenolic insulation? phenolic foam has a high closed cell content and fine cell structure, similar to

  Phenolic boards are manufactured from a plastic foam which forms an insulating core between two flexible facing layers. Thehas a high closed cell content and fine cell structure, similar to PIR boards . Rigid phenolic insulation is produced by mixing high solids and phenolic resin with a surface-acting agent. The heat created by the reaction makes a mass of tiny bubbles in the material. The phenolic foam is then cured and manufactured continuously to create thin sheet material laminated with various facings and cut into boards.