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HIGH PERFORMANCE CAVITY WALL INSULATION

HIGH PERFORMANCE

NZEB READY

SUSTAINABLE

NSAI CERTIFIED 

What is KORE Fill?

KORE Fill is a bonded bead, complete cavity wall insulation system for use in new and existing buildings with a cavity width of at least 40mm for KORE Fill Original, and 50mm for KORE Fill Diamond. Under our Agrement Certificate, KORE Fill is certified for use in cavities up to 225mm in width. Cavity walls over 225mm can be accommodated with the input of an engineer and are project specific. This makes KORE Fill the perfect solution to meet nZEB & Part L 2019 cost effectively.

KORE Fill Cavity Wall Insulation is Expanded Polystyrene (EPS) injected in bead form into a wall cavity to form an insulating mass. The cavity wall insulation bonds together in the cavity as it’s injected along with a special bonding agent called KORE Fill Glue. KORE Fill significantly reduces thermal transmittance across the cavity.

Filling the cavity with KORE Fill still allows the cavity to perform its function. The wall cavity can still breath, the bead does not absorb water or moisture, and water will not transfer across the cavity to the inner leaf.

The performance of KORE Fill is only limited by the width of the cavity, and can easily meet and exceed current building regulations, and is fully nZEB compliant as required by Part L 2019.

Meet nZEB with KORE Fill

KORE’s EPS cavity wall insulation has been designed to meet and exceed the requirements of Part L 2019 (nZEB-Ready). The required U-value for external walls in new builds is 0.18W/m2K. KORE Fill is certified for cavities of up to 225mm made with an external render or brick.

KORE Fill is available in Original, or lower thermal conductivity Diamond. Builders can easily meet the requirements of Part L 2019 with the following (relevant to both rendered and brick cavity walls):

Meet nZEB

Thermal Conductivity

Thickness

U-Value

KORE Fill Original

0.035W/mK

180mm

0.18W/m2K

KORE Fill Diamond

0.033W/mK

170mm

0.18W/m2K

Exceed nZEB

Thermal Conductivity

Thickness

U-Value

KORE Fill Original

0.035W/mK

200mm

0.16W/m2K

KORE Fill Diamond

0.033W/mK

200mm

0.15W/m2K

Find an Installer

Use our online interactive map to find a KORE Fill Approved installer in your area today. All KORE Approved installers are NSAI and SEAI certified.

Find an Installer

Why KORE Fill?

Many homes across Ireland and the UK are built utilising the cavity wall construction method. Cavity walls are built with an inner and outer leaf (wall) with a gap, or cavity, in between. Cavity walls are typically masonry construction made from concrete block or brick. Inside the wall, cavity wall ties are installed between the inner and outer leaf to connect the walls together.

KORE Fill supports larger cavity widths

KORE Fill is NSAI certified for use in rendered and brick cavity walls with a width of up to 225mm. There is no need for expensive wall ties even in larger cavities, and clear guidance from NSAI is provided within the KORE Fill NSAI Agrement Cert. At 225mm, KORE Fill exceeds Part L 2019 and nZEB requirements. Larger cavities can still be accommodated by working with an architect/engineer.

KORE Fill inherits the benefits of EPS

KORE Fill is made from Expanded Polystyrene, which offers builders and property owners a wide range of benefits:

  • EPS is versatile, lightweight and non-toxic 
  • EPS is completely moisture and water-resistant
  • EPS is made from 98% air and can be recycled at the end of its useful life
  • EPS is rot-proof, mould resistant and will not degrade over time unlike other insulation materials 

For more information on the benefits of switching to EPS, contact our sales or technical team.

KORE Fill supports lean construction methods

With KORE Fill, you only pay for the product that’s used. It is pumped into the wall (new build or retrofit) directly from the installation vehicle, which means we only supply the exact amount needed for each property. This also ensures there is no waste left on-site. KORE Fill installers provide all material, equipment and expertise. 

Depending on the width of the cavity, KORE Fill can usually be installed in just a few hours by our specially trained network of installers. The product will last the lifetime of the building and can be recycled at the end of its useful life.

KORE Fill is only installed by approved installers

While KORE manufacture KORE Fill Cavity Wall Insulation, we offer a nationwide network of KORE Approved Installers located in every county across Ireland and Northern Ireland. KORE Fill Approved Contractors are trained and licensed to install the product in new build and retrofit applications and are the only ones allowed to do so. This ensures a high quality installation each and every time. 

All KORE Fill contractors are SEAI and NSAI registered and are audited by KORE and the NSAI on a regular basis.

You can search for a KORE Approved Installer on our website, or contact us directly for more information on how to get started.

KORE Fill can be installed when insulation already exists in the cavity

KORE Fill Bonded Bead can be used in partial fill applications where another insulation material is already installed in the cavity. This includes EPS or foil-faced PIR, PUR or PF board, or mineral wool boards. The remaining cavity must be at least 40mm for EPS, PIR, PUR or PF board, and 50mm where mineral wool boards are installed. 

 

KORE Fill ensures a complete fill everytime

KORE Fill Cavity Wall Insulation ensures a complete cavity fill for every application. KORE Fill installers utilise the KORE Fill approved drilling pattern relevant to the construction of the building. This ensures the cavity is completely filled with insulation, leaving no air gaps or any part of the wall uninsulated. These drilling patterns have been tested and approved by the NSAI and BBA and are incorporated in our Agrement certificates.

Holes approximately the size of a one Euro coin (22mm to 26mm) are drilled in an approved pattern along each of the exterior walls. These holes are normally spaced 600mm to 650mm apart horizontally and 200mm above the highest ceiling level. Two-storey buildings are also subject to a further series of holes spaced 2m apart drilled at the middle height to ensure a complete fill. The cavity wall bead is then pumped (with compressed air) using specialised equipment provided by the installer. The drilling pattern ensures that the cavity of the wall is completely filled with bead. After the walls have been pumped, the holes are filled with mortar and coloured to match the existing appearance of the home. KORE Fill may be installed from inside the home in new build applications. For more information please speak with your installer directly.

 

KORE Fill is tested prior to installation

In addition to our quality assurance methods during manufacturing, KORE Fill is tested before each installation. Flow rates of the bead and adhesive are tested by the installer. A hessian bag is filled with dry bead for 60 seconds and then weighed. The weight of the bag is recorded and the proper amount of adhesive is applied to the bead to ensure proper bonding. This procedure helps ensure the stated U-values are achieved after the bonded bead bas been installed with a cavity wall.

Other quality assurance checks include glue flow rate checks, temperature checks, boroscope surveys and mortar joint inspections. The installer must ensure that the home is suitable the installation of KORE Fill and that proper records are kept on file for each installation. 

KORE and the NSAI audit KORE Fill installers on a consistent basis to ensure all quality assurance checks are carried out before each installation.

 

KORE Fill can reduce your construction costs

KORE Fill is a cost-optimal solution for a wide variety of applications in both the new build and retrofit markets. Customers pay for the exact amount of product used. In addition, since builders aren’t relying on bricklayers to install the insulation, the cost of labour can be reduced. Installers remove any material not used during the installation, which can help reduce costs for waste removal while diverting product from landfill. Speak with your local KORE Fill installer today to learn more about the cost benefits of insulating with KORE Fill.

 

KORE Fill Technical Specifications

KORE Fill Cavity Wall Insulation is the perfect alternative to PIR insulation for cavity wall applications. The table below shows a comparison between full fill PIR insulation board and KORE Fill Bonded Bead Cavity Wall Insulation. While the table displays a cavity width of 150mm, you can achieve lower U-values by widening the width of the cavity or by combining KORE Thermal Board. Example U-value calculations are also shown below for new build and retrofit applications.

Corrections for air layers and mechanical fasteners penetrating the insulation layer were considered. Best practice in terms of workmanship was assumed and therefore the correction factor for air gaps were ignored in calculations for new buildings. A correction factor was applied to calculations for existing buildings. Mechanical fasteners were taken as double triangle stainless steel, number 2.5 per m/sq. These calculations should act as a guide only. Please contract our technical team for a detailed U-Value calculation and condensation risk analysis

Wallboard, Plasterboard, Dabs, Concrete Block, Insulation, Concrete Block, Render

Cavity Thickness

Material Thickness

Material

U-Value

Thermal Conductivity

Assumptions

150mm

90mm

PIR (with 50mm cavity)

0.21

0.022

Best workmanship – Correction level 0 for air gaps

150mm

150mm

Original

0.21

0.035

Wall ties are double triangle stainless steel, Best workmanship – Correction level 0 for air gaps

150mm

110mm

PIR (with 40mm cavity)

0.18

0.022

Best workmanship – Correction level 0 for air gaps

170mm

170mm

Diamond

0.18

0.033

Wall ties are double triangle stainless steel, Best workmanship – Correction level 0 for air gaps

New Build - Plasterboard, Block, Insulation, Block, Render

Original 0.035W/mK

Diamond 0.033W/mK

Cavity Width

U-Value W/m2K

170mm

X

0.18

180mm

0.18

0.17

200mm

0.16

0.15

250mm

0.13

0.13

300mm

0.11

0.11

New Build - Plasterboard, Block, Insulation, Brick

Original 0.035W/mK

Diamond 0.033W/mK

Cavity Width

U-Value W/m2K

170mm

X

0.18

180mm

0.18

0.17

200mm

0.16

0.15

250mm

0.13

0.12

300mm

0.11

0.10

Retrofit – Partial Fill: EPS Board (0.037W/mK) with KORE Fill Original (0.035w/mK)

Year House Was Built

Cavity Width

Expected Insulation Level in Cavity

U-Value

KORE Fill Original

New U-Value

1997-2002

100mm

60mm

0.44

40mm

0.34

1990 - 1997

100mm

50mm

0.50

50mm

0.34

1980's

80mm

40mm

0.58

40mm

0.37

1970's

40mm

None

1.56

40mm

0.62

Retrofit – Partial Fill: EPS Board (0.037W/mK) with KORE Fill Diamond (0.033W/mK)

Year House Was Built

Cavity Width

Expected Insulation Level in Cavity

U-Value

KORE Fill Original

New U-Value

1997-2002

100mm

60mm

0.44

40mm

0.30

1990 - 1997

100mm

50mm

0.50

50mm

0.30

1980's

80mm

40mm

0.58

40mm

0.36

1970's

40mm

None

1.56

40mm

0.60

Technical Downloads

The following is a sample of technical documents available for KORE Fill. For the complete library, please join the KORE Resource Centre.

KORE Fill Insulation Design Guide – Part L 2011

KORE Fill Insulation Design Guide – Part L 2019 (New Build)

KORE Fill Insulation Design Guide – Part L 2019 (Retrofit)

KORE Fill Insulation Brochure – Part L 2019

KORE Fill Insulation – NSAI Agrement Certificate

KORE Fill Insulation – Part L 2019 BIM Object Files

Request a Quote

Submit your plans and receive a free, no obligation quotation for KORE Fill Cavity Wall Insulation specific to your project requirements.

published:07 Aug 2020
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