KORE Fill Cavity Wall Insulation

Bonded Bead Cavity Wall Insulation

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.

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 solidifies in the cavity as its injected along with a special bonding agent (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 is still able to 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 Cavity Wall Insulation 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 the proposed Part L 2018.

Red Brick Wall

A COMPLETE FILL EVERY TIME

KORE Fill Bonded Bead ensures a complete cavity fill for every application, new build or retrofit. 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.

H20 in a water droplet

KORE FILL IS WATER AND MOISTURE RESISTANT

KORE Fill Bonded Bead is completely water resistant and will not absorb moisture. Any water that penetrates the outer leaf will drain down the cavity without any transfer to the inner leaf. KORE Fill will not retain moisture. This ensures that the insulation does not degrade over time, prevents mould growth and rot.

Irish Flag

NATIONWIDE KORE FILL INSTALLER NETWORK

KORE offers a nationwide network of KORE Fill Bonded Bead installers. Every installer is NSAI and SEAI registered to install KORE Fill Bonded Bead, along with a variety of other insulation and energy efficiency measures. Our KORE Fill Installers Register ensures the company you choose is certified and approved.

Green Recycle Symbol

MADE FROM SUSTAINABLE EPS

KORE Fill is made from Expanded Polystyrene, a sustainable material. KORE Fill Cavity Wall Insulation will last the entire lifetime of the building and can easily be recycled at the end of its useful life. Recycled EPS can be moulded into a variety of other products at the end of its life.

WHY CHOOSE 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.

Cavity walls are designed so that rain water and moisture do not transfer from the outer leaf to the inner leaf – especially wind-driven rain. Unfortunately, while cavity wall construction works very well at keeping rain and moisture out, many older homes were built without adequate levels of cavity wall insulation, if any at all!

KORE Fill Bonded Bead Cavity Wall Insulation easily fills cavity walls with a minimum width of at least 40mm (50mm for KORE Fill Diamond). As the insulation is pumped into the cavity from the exterior of the home, disruption to occupants is minimal and installation is completed very quickly.

MEET nZEB with KORE fill

KORE’ Fill Bonded Bead Cavity Wall Insulation has been designed to meet and exceed the U-value requirements of the proposed Part L 2018, and continues to meet the requirements of Part L 2011.

From 1st November 2019, the proposed U-value requirement for wall insulation in new builds is 0.18W/m2K.

KORE Fill is available in two different grades, KORE Fill Original with a thermal conductivity of 0.035W/mK, and our enhanced KORE Fill Diamond with a thermal conductivity of 0.033W/mK. 

Material Thickness Thermal Conductivity U-Value
KORE Fill Diamond 170mm 0.033W/mK 0.18W/m2K
KORE Fill Diamond 200mm 0.033W/mK 0.15W/m2K

For more information contact our technical team.

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.

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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 KORE Fill 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 KORE Fill Diamond 0.18 0.033 Wall ties are double triangle stainless steel, Best workmanship – Correction level 0 for air gaps
New Buildings: Cavity Wall Construction – Skim Internal Finish, Plasterboard, Block Inner and Outer Leaf

 
 
New Buildings
  Plasterboard, Block, Insulation, Block, Render
Cavity Width KORE Fill Original 0.035W/mK KORE Fill Diamond 0.033W/mK
  U-Value (W/m2K)
150mm 0.21 0.20
160mm 0.20 0.19
170mm 0.19 0.18
180mm 0.18 0.17
190mm 0.17 0.16
200mm 0.16 0.15
250mm 0.13 0.13
300mm 0.11 0.11
New Buildings: Cavity Wall Construction – Plasterboard and Skim Internal Finish, Block Inner, Brick Outer

New Buildings
  Plasterboard, Block, Insulation, Brick
Cavity Width KORE Fill Original 0.035W/mK KORE Fill Diamond 0.033W/mK
  U-Value W/m2K
150mm 0.21 0.20
160mm 0.20 0.19
170mm 0.19 0.18
180mm 0.18 0.17
190mm 0.17 0.16
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 Diamond 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
KORE Fill Bonded Bead

Properties Units
Thermal Conductivity
KORE Fill Original 0.035W/mK
KORE Fill Diamond 0.033W/mK
Density 12kg/m3
Bead Size 3mm-8mm

KORE Fill Glue

Properties Units
Density 1.10
Quality Free from impurities or lumps. Residue on 177 micron sieve max 20ppm
Form Liquid Suspension
Colour White
Odour Mild Sweet
Viscosity 20-30 cP @ 20C
Freezing Point 0C
Boiling Point 100C
Min Operating Temperature 5C
pH 8.5 – 9.5

KORE Fill Frequently Asked Questions

The following are the most frequently asked questions about KORE Fill Bonded Bead. For additional information please contact our sales or technical team.

How is cavity wall insulation installed?

KORE Fill may only be installed by certified and approved KORE Fill installers. KORE Fill is injected along with a bonding agent through the exterior walls of the structure. The bead, along with the bonding agent, solidifies and forms and insulating mass that significantly reduces the thermal transmittance across the cavity. 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.

How long does cavity wall insulation take to install?

Depending on the size of the home, cavity wall insulation can usually be installed in one day. Larger homes or inclement weather may cause delays. All equipment and material is removed from the job site at the end of each working day. Since installation occurs from outside the home there will be minimal disruption to occupants. Any leftover material is cleaned up and removed from the site once works are complete. Please note that outdoor air temperatures 5 degrees and below are not suitable for the installation of KORE Fill.

Are all homes suitable for cavity wall insulation?

There are a number of home insulation systems available on the market. Cavity wall insulation is only suitable for houses constructed with a cavity wall made from block or brick. Timber or steel frame houses, hollow block, cavity block and solid block walls are not suitable for bonded bead cavity wall insulation from any manufacturer. The wall cavity must be at least 40mm for KORE Fill Original, or 50mm for our high performance KORE Fill Diamond. The cavity must also be free from defects and debris. There must be no signs of dampness in the inner leaf and mortar joints must be in good condition and free from defects which may allow water ingress. The home’s exposure is also taken into consideration. Normal exposure is considered 5m2/sec/year, while severe exposure is classified as above this requirement. Building sites may need to be assessed individually for classification as normal or severe exposure. Unrendered brickwork is not suitable for full fill cavity wall insulation in severe exposure zones.

An on-site survey is performed on every structure before the installation of KORE Fill Bonded Bead. This survey includes the use of a borescope to examine the internal wall structure. Every assessment will include:

  • Form of construction and site conditions
  • Age of the building
  • The structural condition of the building
  • The size of the wall cavity
  • The structure’s exposure zone to wind-driven rain

Existing home ventilation in the case of retrofit applications must also be assessed. This includes ventilation openings that provide combustion air, underfloor ventilation and flues in the cavity wall. Adequate sleeving must be present on all ventilation to ensure that these openings do not become blocked by the insulation. Structures with inadequate ventilation will need remedial works to meet the requirements of Part F of the building regulations before works begin.

What's the difference between KORE Fill Original & KORE Fill Diamond?

Both products are part of a bonded bead cavity wall insulation system that provides a complete fill every time. KORE Fill Diamond provides a lower thermal conductivity than Original (0.033W/mK compared to 0.035W/mK). This means you can achieve a lower U-value using the same amount of material. Due to the oval shape of the bead, KORE Fill Diamond is suitable for use in existing wall cavities with a width of at least 50mm. The dense packing of the beads within cavity walls may cause issues when installing KORE Fill Diamond in cavities smaller than 50mm. Please contact our technical team for more information or to discuss your project requirements.

Is KORE Fill nZEB compliant?

Yes. 170mm of KORE Fill Diamond will meet the proposed requirements of 0.18W/m2K in most buildings. The wider the cavity, the lower the U-values you can achieve with KORE Fill.

Is KORE Fill tested?

Yes. Flow rates of the blown bead and adhesive are tested by the installer prior to installation. A hessian bag is filled with dry bead for 60 seconds and then weighed. The weight of the bead is recorded and the proper amount of adhesive is applied to the bead to ensure proper bonding. This procedure helps ensure that the stated U-values are achieved after the bonded bead has been installed within a wall cavity.

Does KORE install KORE Fill directly?

No. You must contact a KORE Approved installer directly for installation services. We only sell KORE Fill directly to approved installers. This ensures consistent quality of the product.

Are all insulation installers approved to install KORE Fill?

No. KORE has a nationwide network of approved and certified KORE Fill Bonded Bead installers which can be found on our website. All our installers are:

  • Registered with the NSAI Agrement CWI Scheme
  • Approved by KORE and NSAI to install KORE Fill
  • Trained and registered with KORE to survey and install the product
  • Required to carry ID cards certifying the above
  • Supervised by KORE and subject to unannounced quality audits

While our network of installers are approved to install KORE Fill cavity wall insulation, many offer additional products and services in home insulation and energy efficiency. Check directly with your local installer for a full list of products and areas covered. Some installers may offer a nationwide service.

KORE Fill Downloads

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

  • Download the KORE Fill Insulation Design Guide – Part L 2011Download
  • Download the KORE Fill Insulation Design Guide – Part L 2019 New Build (nZEB-Ready)Download
  • Download the KORE Fill Insulation Design Guide – Part L 2019 Retrofit (nZEB-Ready)Download
  • Download the KORE Fill Insulation Brochure (Part L 2019)Download
  • Download the KORE Fill Insulation NSAI CertificateDownload
  • Download the KORE Fill Insulation BIM Object FilesDownload

Locate an Installer or View Available Grants & Incentives

You can request a quotation for KORE Fill Bonded Bead Cavity Wall Insulation through your local installer. Use our online map to find a local installer or view the grants and incentives available nationwide.

published:20 Sep 2018
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Join Ecological Building Systems and KORE Insulation for an nZEB and air tightness CPD seminar on the 22nd October in Athboy, Co. Meath

Join KORE at our next CPD roadshow event in Meath on 22nd October. Free tickets are available by clicking on the image above. Seating is limited so register quickly.