EL/MS/V3.0 – March 2015
MMM
METHOD STATEMENT
EL/MS/V3.0 – March 2015
METHOD STATEMENT
For the installation and quality control of the
EpsiLine Internal Wall Insulation System BBA
certificate [14/1567]
1.0 General
1.1 This document is to be read in conjunction with BBA Certificate [14/1567],
Wetherby’s EpsiLine literature and the project specific contract documents.
1.2 The products and installation of EpsiLine PIR plasterboard thermal laminate
(hereafter called “the system”) shall be as stated in the BBA Certificate and this
method statement.
1.3 This method statement is limited to the installation of the system and is not
construction project specific. The approved EpsiLine system installer shall provide a
project specific method statement to the construction client, which may include this
document as part of the submission.
2.0 The System Overview
2.1 The EpsiLine system comprises of a high performance PIR thermal insulation
board, in a range of thicknesses, which is supplied pre-bonded to a tapered edge,
standard plasterboard. The system also includes the EpsiLine Reveal Board, a thinner
PIR plasterboard thermal laminate to be used at reveals. All EpsiLine wallboards
feature a bi-laminate foil/kraft paper-facing to allow installation either by direct
bonding to the wall using plaster adhesive dabs, or by being mechanically fixed either
directly to the wall or onto timber battens or metal furring systems.
3.0 The System Components
3.1 EpsiLine Wall Board
• Rigid PIR foam ranging from 25 – 80mm in thickness bonded to 1200 x 2400
plasterboard of 9.5mm thickness.
3.2 EpsiLine Reveal Board
• Rigid PIR foam 15mm in thickness bonded to 1200 x 2400 plasterboard of 9.5mm
thickness.
EL/MS/V3.0 – March 2015
3.3 Ancillary items for use with the system:
•
IWI Bonding Compound
Gypsum-based dry lining adhesive compound (plaster dabs) to BS EN 14496: 2005
•
IWI Intumescent & Acoustic Sealant
•
IWF Hammer Fixings
Mechanical fixings (direct to masonry) to carry CE marking
3.4 Acceptable third party ancillary items for use with this system:
•
•
•
•
Metal component furring systems to BS EN 14195:2005
Mechanical fasteners including dry wall screws, plasterboard nails and nailable
plugs to BS EN 14566: 2008
Metal edge and corner beads to BS EN 14353:2007
Jointing materials including scrim tape and jointing compound to
BS EN 13963:2005
4.0 Recognised Contractor / Approved Installer
4.1 The installation of the system must be by a recognised contractor organisation,
using trained, suitable skilled and experienced operatives.
4.2 Installers must have been trained, assessed and approved by Wetherby Building
Systems or a body approved by them. All installers will be subject to a minimum of
two work in progress inspections per year by Wetherby Building Systems, as required
by the BBA Inspection Scheme Document.
4.3 Installers are to be fully responsible for the completion and accuracy detailed
within the initial Survey Form which must be completed on all individual properties
requiring a warranty.
5.0 Preparation of the Substrate
5.1 The installer should carry out a survey, prior to commencement of the installation,
to access the suitability of the substrate for use. The survey sheet must only be
completed by an Approved SWI Property Surveyor (a person who can satisfactorily
show competence in all aspects of GD PAS 2030 annexe B8, who is capable of
assessing defined types of buildings for their suitability for the application of internal
wall insulation, according to current SWIGA Scheme requirements).
5.2 All necessary repairs to the structure should be carried out by suitably qualified
contractors and completed prior to the application of any part of the EpsiLine system.
5.3 Where boilers are fixed to a wall requiring treatment, they should be removed
and reinstated by suitably qualified gas technicians. Identify all live / used balance
EL/MS/V3.0 – March 2015
flues, mechanical vents etc. The flue terminal / duct cowl should be carefully removed
and a suitable PVC sleeve / trunking be used to extend the flue / ducting beyond the
surface of the new insulation system. Securely reinstate the boiler on top of the new
EpsiLine IWI system taking care that all terminals, cowls etc. are properly re-fixed.
5.4 Reference is to be made to CIGA’s Technician’s Best Practice Guide to Flues,
Chimneys and Combustion Air Ventilators, or similar, so that the performance and
safety of fuel burning appliances is not compromised by the installation of the IWI
measure.
• The combustion air supply must be isolated and the air ventilator continuously
sleeved through the wall.
• Flueless gas fires require a ventilator that provides a free air area of 10,000mm².
Under PAS 2030, both surveyor and installer have strict responsibilities placed upon
them when it comes to the identification and safeguarding of essential ventilation
requirements. Failure to comply will result in PAS 2030 revocation. Please refer to
Wetherby document WBS-VENTINFO-01.
5.5 Where carbon monoxide (CO) or other safety alarm(s) have been already installed
at the designated location, the surveyor shall ascertain whether or not they have
been tested within the past twelve months and record the outcome on the survey
record. Where the system to be installed requires the installation of safety monitoring
as part of the specification, the surveyor shall in addition assess whether or not any
pre-existing alarms will be sufficient to cover the new installation and include the
result of this assessment in the survey record.
5.6 In the event that species (e.g. bats, birds, butterflies, dormice) or plants that could
be subject to special protection are found to be present at the designated location,
the surveyor shall report of that presence in the survey record and make the presence
known to the funder and installer.
5.7 The flatness of the surface must be checked and excessive irregularities
(deviations greater than 20mm in 1m) made good prior to installation.
5.8 In circumstances of building neglect, it may be necessary to affect repairs to the
building fabric prior to the installation of the system.
5.9 All associated builder’s works such as removal of fixtures and fittings, alterations
to services, are to be carried out prior to commencement of installation of the
system.
5.10 Services which will penetrate the internal wall insulation system, e.g. light
switches and power outlets, should be kept to a minimum to limit damage to vapour
checks.
5.11 It is important to ensure the wall is sound, free from contaminants and dry.
The system is not intended to offer resistance to rain penetration, therefore walls
must already be rain resistant and show no signs of water ingress, rain penetration or
damp from ground moisture.
EL/MS/V3.0 – March 2015
5.12 If present, mould, algae and fungal growth should be treated prior to the
application of the system.
5.13 Wallpaper, gloss paint, skirting, picture rails and projecting window boards
should be removed and made good as necessary.
5.14 De-rating of any electrical cables in areas where the system restricts the flow of
air should be considered. Works to be carried out by a suitably qualified technician.
5.15 The pull out strength of the fixings in the substrate walls is determined and the
number and depth of fixings required for that substrate calculated.
5.16 Some post installation builders works may be necessary, to reinstate services,
fixtures and fittings etc.
6.0 Storage and Handling
6.1 The boards are delivered to site in polythene wrapped packs. Each pack contains a
label bearing the name of the manufacturer, product type and thickness, board
dimensions, CE marking and the BBA logo incorporating the BBA Certificate number.
Care should be taken in offloading, distribution and storage of the materials. The
boards must be protected from prolonged exposure to sunlight and moisture and
should be stored flat inside, under cover and protected with opaque polythene
sheeting. The boards should be stacked flat and raised above ground level, and not in
contact with ground moisture.
6.2 Care must be taken when handling the boards to avoid crushing the edges or
corners, and to avoid contact with solvents or bitumen products. The boards must not
be exposed to open flame or other ignition sources.
6.3 The installer is to provide their own risk assessment for the handling, distribution
and use of and disposal of the products and resultant packaging.
6.4 Any mechanical lifting of materials from preparation area to work face must be
carried out only after a full risk assessment and method statement has been
approved.
6.5 If the system is damaged during use, it can be readily removed and replaced.
The durability of the materials is satisfactory. Provided the system is fixed to
satisfactory stable and durable backgrounds the system should have a life
equal to the building in which it is installed.
7.0 Adverse Weather
7.1 The EpsiLine system must not be installed to frozen substrates, frost bound
surfaces, or when the materials are or have been affected by frost or become frozen.
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7.2 The system shall not be applied when the room temperature is below 5°C, nor
when the room temperature or surface temperature is above 30°C.
7.3 Any coatings that have been affected by frost or precipitation must be removed,
the substrate checked for integrity, repaired as necessary and the finishes reapplied.
8.0 Protection of Adjacent Surfaces
8.1 All adjacent surfaces should be fully protected during the installation of the
system and all protection is to be carefully removed and disposed of after completion
of the works. Any residue must be carefully removed from finished surfaces in a nonabrasive manner.
8.2 Adequate protection to the adjacent ground surfaces is to be provided, to prevent
damage from the application and from potential spills.
8.3 Protection to local surfaces, both internally and externally, is also required when
mixing bagged products and tubs in a preparation area.
9.0 Quality Control
9.1 Main system components are to be ordered directly from Wetherby Building
Systems Limited 01942 717100. Project specific quotation numbers must be quoted
on all orders to allow traceability to the project in question. Additional ancillary
components may be sourced locally, however it is essential that each component
carries the necessary British Standards marking as detailed in section 3.4 and CE
marking where required.
9.2 All work is to be carried out in compliance with this method statement, the
contract documents, the BBA Certificate and project specific details.
9.3 All installation works are to be fully monitored by the installing organisation, with
Installation Check Lists completed for each property and discipline, checked, signed
and dated for record purposes as required by the BBA Scheme Document. These
records are to be held on site, with full copies issued to Wetherby Building Systems
Technical Department and ultimately retained on the project files at the installer’s
office. Any deviation from approved and accepted installation practice must be
corrected before further disciplines or work locations commence. Failure to adhere to
this requirement may invalidate any guarantees / warranties.
10. Installation of the System
10.1 General:
10.1.1 The system should only be installed by tradespersons who have been trained,
carded and approved by Wetherby Building Systems. Applicator cards must carry a
EL/MS/V3.0 – March 2015
valid date and evidence must be provided before a warranty for the works can be
issued.
10.1.2 The insulation is to be EpsiLine Wall Board and EpsiLine Reveal Board, as
described in 2.1 and 3.1, to the thickness as specified in the contract documents.
10.1.3 The system is to be installed as an insulated dry lining system on internal solid
walls of existing dwellings and non-dwellings or buildings of similar occupancy, type
and conditions.
10.1.4 The boards may be installed on a masonry wall construction including clay and
calcium silicate bricks, concrete blocks, and natural and reconstituted stone blocks.
10.1.5 Installation must be in accordance with BS 8212: 1995. Before fixing the system
sufficient time must be allowed for damp proofing treatments, where applied, to dry
out (see also BS 6576: 2005 for dry lining in conjunction with a chemical DPC
application).
10.1.6 EpsiLine Wall Board and EpsiLine Reveal Boards feature PIR insulation with
bilaminate facings, allowing them to be installed by either direct bonding to the wall
using plaster adhesive dabs, or mechanically fixed either directly to the wall or onto
timber battens or metal furring systems. Typical installation methods are shown in
Figures 2 and 3 of the BBA Certificate.
10.1.7 The system can be cut using a fine-toothed saw, to fit around windows, doors
and air bricks. It is essential that cut pieces completely fill the spaces for which they
are intended and are adequately secured.
10.1.8 Vertical guidelines on the wall should be marked at 1200mm centres to
indicate the positioning of the boards.
10.1.9 The installation should always start from an internal corner or a window or
door reveal.
10.2. Direct bonding using plaster adhesive dabs
10.2.1 The direct bonding method allows for variable flatness of the wall. In all
instances, the background should be plumbed for alignment, making allowances for
high spots on the masonry. Chalk lines are marked on the floor and ceiling to establish
the new wall plane. Vertical guidelines on the wall should be marked at 1200m
centres to indicate the positioning of the boards. Fixing positions are determined by
lining system type.
10.2.2 IWI Bonding Compound – A gypsum-based dry-lining adhesive compound
(plaster dabs) conforming to BS EN 14496: 2005. Please refer to shelf life date on
individual bags.
10.2.3 A continuous bed of adhesive should be applied around the perimeter of the
wall as well as around any services or other openings. This is especially important
EL/MS/V3.0 – March 2015
when considering the airtightness of the building. All conduits and piping should be
installed prior to commencement of all works. The insulating backing of the laminates
should not be removed to accommodate services.
10.2.4 Adhesive dabs should be applied in three columns with each dab
approximately 75mm by 250mm in dimension. Intermediate dabs at ceiling level
should be applied and individual dabs should not bridge boards. Typically, the
adhesive dabs should cover at least 20% of the board area.
10.2.5 The board should be cut approximately 15mm short of the floor to ceiling
height and positioned with the bottom edge resting on packing strips. The boards are
tapped into position with a straight-edge and alignment checked with the chalk lines.
10.2.6 Once positioned, the board should be lifted to the ceiling edge using a board
lifter and supported until the adhesive has set. Once the adhesive has set, a minimum
of two nailable fixings should be applied at the mid-point of the board and
approximately 25mm from the board edge. Nailable plugs should penetrate the
background through the dab by at least 65mm.
10.2.7 Other boards should be installed closely butted together using the same
technique.
10.3 Mechanically fixed direct to wall
10.3.1 The board should be cut approximately 15mm short of the floor to ceiling
height and positioned with the bottom edge resting on packing strips. The boards are
placed into position, and alignment checked with the chalk lines on the floor and
ceiling.
10.3.2 Once positioned, the board should be lifted to the ceiling edge using a board
lifter and supported with additional packing at the base of the board. The board
should be fixed to the wall using suitable stainless steel mechanical fixings at 300mm
centres from the vertical and horizontal board edges with a minimum of 12 fixings per
board.
10.3.3 Other boards should be installed closely butted together using the same
technique.
10.4. Mechanically fixed to timber battens or metal furring
10.4.1 Metal component furring systems must conform to BS EN 14195: 2005
10.4.2 Services can be incorporated behind the dry-lining, making the chasing of the
wall unnecessary. Where the services have a greater depth than the void, the wall
should be chased rather than the insulation.
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10.4.3 Voids may provide habitation for insects or vermin in areas already infested.
Care should be taken to ensure, wherever possible, that all voids are sealed, as any
infestation may be difficult to eradicate. There is no food value in the materials used.
10.4.4 Using suitable mechanical fixings install minimum 25mm by 47mm wide,
treated softwood timber battens or proprietary metal furrings vertically at a
maximum of 600mm centres, along with horizontal battens at the top and bottom of
the installation area. Additional lengths of timber batten or metal furring should be
installed to coincide with horizontal board joints and around services, doors and
windows. The framing must provide a minimum of 20mm bearing to each system at
joints and be of sufficient depth to accommodate the fixings for the system.
Metal furring systems can also be bonded to the wall in accordance with the
manufacturer’s recommendations, and the same preparation and setting out
procedure should be used. The adhesive dabs (approximately 75mm by 200mm)
should be applied at centres suitable for the system, typically from 450mm to
600mm.
10.4.5 The board should be cut approximately 15mm short of the floor to ceiling
height and positioned with the bottom edge resting on packing strips. The boards are
placed onto the timber or metal frame, and alignment checked with the position of
the timber batten or metal furring and chalk lines on the floor and ceiling.
10.4.6 Once positioned, the board should be lifted to the ceiling edge using a board
lifter and supported with additional packing at the base of the board. The board is
fixed to the timber battens or metal frame using appropriate dry wall screws. Fixings
should be installed at 300mm centres across the horizontal and vertical elements of
the frame.
10.4.7 Other boards should be installed closely butted together using the same
technique.
10.5. Mechanical fixings
10.5.1 All mechanical fixings must be to the specification given in the BBA Certificate
for the applicable substrate, and shall be at least 65mm longer than the insulation
thickness, and in accordance with the requirements of the site survey. Fixings must
penetrate the substrate by at least 65mm.
10.5.2 Fixings shall be installed in accordance with the substrate survey and the
system fixing pattern. The board should be fixed to the wall using suitable stainless
steel mechanical fixings at 300mm centres from the vertical and horizontal board
edges, with a minimum of 12 fixings per board.
10.6. Mesh angle beads
10.6.1 Any metal edge and corner beads to be used must be in accordance with BS EN
14353: 2008.
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10.6.2 Corner beads incorporating a reinforcing mesh, are to be fixed line and level
true to door, window, opening, order and reveal lines. Adhesive is to be applied to
both faces of the corner at nominal 300mm centres, into which the bead(s) shall be
firmly pressed, aligned and trowelled in.
10.7. Detailing
10.7.1 It is essential that proper care and attention is given to maintaining the
integrity/continuity of the insulation and facings.
10.7.2 The installation requires careful detailing around doors and windows to
achieve a satisfactory surface for finishing. In addition, every attempt should be made
to minimise the risk of thermal bridging at reveals, and where heavy separating walls
are attached to the external wall. EpsiLine Reveal Boards should be utilised
specifically for reveals. All work must be designed to accommodate the thickness of
the dry-lining, particularly at reveals, heads, cills and in relation to ceiling height.
Where the dimensions of fixtures are critical (e.g. bathrooms), these should be
checked before installation.
10.7.3 To help prevent thermal bridging at party walls, it is recommended that as well
as insulating the external wall, all separating walls should be insulated using the same
thickness of board as the main wall areas for a minimum distance of 400mm from the
external wall. This will help prevent excessive heat loss and keep the surface
temperature high enough to avoid the risk of surface condensation.
10.7.4 To help prevent thermal bridging at floor / ceiling / roof levels, please refer to
guidance given in the relevant EpsiLine detail drawings.
10.7.5 To reduce the risk of condensation, insulation shall be continued behind
ancillary items fixed to the wall, such as sinks and cupboards. Such ancillary items
should be fixed through the insulation to the underlying structural substrate.
10.7.6 Providing all joints in the system are sealed, they can offer a significant
resistance to water vapour transmission. This can be conducted by application of
either a skim coat or taping and filling of the tapered edges of the plasterboard.
Jointing materials such as scrim tape and jointing compound must conform to BS EN
13963: 2005.
10.7.7 Regardless of method used, additional consideration should be given for the
fixing of such features as cupboards and radiators. Any object fixed to the wall, other
than lightweight items, e.g. framed pictures, should be fixed through the lining board
into the wall behind, using recommended proprietary fixings. Please contact a
member of Wetherby’s Technical Support Team for advice.
10.7.8 Electrical cables that come into contact with the insulation component of the
thermal liner are not required to be protected by a suitable conduit or PVC-U
trunking. However, as with any other forms of insulation, de-rating of electrical cables
should be considered where the insulation restricts the air cooling of cables.
EL/MS/V3.0 – March 2015
10.8. Finishing
10.8.1 To avoid thermal bridging, the system should be used to line window reveals
and suitable provisions will also need to be adopted at junctions and other details
such as separating floors. Further guidance can be obtained from BRE Report (BR 262:
2002).
10.8.2 For windows, reveals and external angles, it is important to consider the
junction of the installation to avoid thermal bridges and boards should be extended
beyond the corner. The insulation should be cut back to form a neat junction with the
reveal board or wall lining. A bed of adhesive should be applied and the cut board
placed onto it. Once the adhesive has dried, two nailable fixings should be installed
half way up the board and 25mm from each edge.
10.8.3 EpsiLine Reveal Boards are available for specific use on door/window reveals.
10.8.4 For board joints, an appropriate joint filler should be firmly placed into the
tapered edge, with tape then set into the filler (VCL).
10.8.5 Two or three applications of jointing compound should be trowel applied,
allowing each to set before the next application. Each application should be feathered
out beyond the previous application. Screws and nails should receive the same
number of applications.
10.8.6 In circumstances where square edges meet it will result in a raise profile. In
these situations, the secondary application of joint filler should be omitted and the
feathering extended to conceal the joint.
10.8.7 For internal angles, a jointing tape is creased into the corner and the same
procedure used as for board edges. On external angles, an appropriate corner tape
can be used or, where extra protection is required, an angle-bead used.
10.8.8 A finishing skim coat of 2mm of plaster should be applied to complete the
installation. Clean, non-contaminated tools should be used for this process.
10.8.9 Plaster should be applied to the boards and joints with firm pressure. The joint
adhesive should be firm but not quite set. Two applications should be used to achieve
the final thickness of 2mm the second coat is applied onto a wet primary coat and
trowelled to a smooth flat finish.
10.8.10 To help prevent cold bridging, it is important to ensure that the perimeter
joints of the floor and ceiling are sealed with a continuous 15mm bead of IWI
Intumescent & Acoustic Sealant, paying particular attention to the gap between the
flooring and wall, as well as the joint between the skirting board and flooring.
For further information, please consult the relevant EpsiLine detail drawing.
10.8.11 Once dry, the final surface is ready to be decorated. Consideration should be
given to the need to prime the surface prior to painting or papering.
EL/MS/V3.0 – March 2015
10.9 Installation Quality Checks
10.9.1 The installer will be responsible for undertaking regular site installation quality
control checks and recording the findings on the Installation Checklist. This shall be
based on visual inspections at key installation stages, to check on:
• Product compliance, i.e. correct products used at each stage
• Specification compliance, i.e. correct consumption, design compliant, technically
compliant
• Installation compliance i.e. line and level, smooth plane, even coverage
The key stages shall be:
• Before work commencement
• After preparation
• After installation of the insulation
• After completion of vapour control layer (taping and jointing)
• After decorative finishes
The submission of documented and photographic evidence at each of the above
stages will be required to ensure that strict levels of quality control are maintained.
Without this evidence, a guarantee cannot be issued.
10.9.2 A handover certificate should be issued to the client for each completed work
section, or building. This should be produced and presented to the building owner at
the completion of the works and should include the following information:
• The property address
• The building owner/manager
• The architect or designer
• The system name, supplier and all system components (project specific)
• The system installer, with full contact details
• The date of completion of the installation
• The location details of the installation(s)
11.0 Coverage Rates
Wetherby will not, under any circumstance, guarantee coverage rates for any of its
products. Any rates quoted either verbally of via online/printed guidance are
approximated, given in good faith and make no allowance for wastage or damages on
site. Rates can vary greatly dependent on the individual operative’s skill, site
conditions, weather conditions etc. Wetherby will not be liable for claims of any kind
made against it relating to material coverage rates.
EL/MS/V3.0 – March 2015
12.0 Materials for Application
All main components of the EpsiLine System are to be obtained from:
Wetherby Building Systems Limited
1 Kid Glove Road
Golborne Enterprise Park
Golborne
Greater Manchester
WA3 3GS
Main Tel:
Main Fax:
Email:
Web:
01942 717100
01942 717101
info@wbs-ltd.co.uk
www.wbs-ltd.co.uk/wetherby-iwi-systems
13.0 Technical Support
Technical Helpline: 08458 382380
EL/MS/V3.0 – March 2015
Dot & Dab Details
1. Isometric Build Up
2. Fixing Arrangement
3. Detail at Base
4. Door / Window Head
EL/MS/V3.0 – March 2015
Dot & Dab Details
5. Window Cill
6. Window Jamb
7. External Corner
8. Internal Corner
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Dot & Dab Details
9. Roof Abutment
10. IWI to EWI Interface
11. Party Wall
12. Timber Patress
EL/MS/V3.0 – March 2015
Wetherby Building Systems Ltd
1 Kid Glove Road | Golborne Enterprise Park | Golborne | Greater Manchester | WA3 3GS
Tel: 01942 717100 | Fax: 01942 717101 | www.wbs-ltd.co.uk | @wetherbyewi
Registered in England 3621726