PERLITE
BLOCK AND CAVITY FILL
SCHUNDLER

COVERAGE CHARTS
INSULATION VALUES
CONSTRUCTION GUIDE
The Schundler Company
150 Whitman Avenue
Edison, New Jersey 08817
732-287-2244 www.schundler.com



PERLITE BLOCK AND CAVITY FILL

MASONRY LOOSE FILL INSULATION


Perlite loose fill insulation is an inert volcanic glass expanded by a special heat process that can be treated with water repellent material when necessary. The resultant lightweight product is a white granular material, which handles and pours easily. It provides a quick, inexpensive and permanent method for efficiently insulating masonry walls. Depending on design conditions, reductions in heat transmission of 50 percent or more may be obtained when perlite loose fill is used in the hollow cores of concrete block or cavity type masonry walls.

Basic Product Properties:

Thermal Insulation--Perlite contains countless tiny air cells that account for its excellent thermal insulation and lightweight. Thermal conductivity factors at the recommended density range of 2-11 pcf (32-176 kg/m3) are normally 0.27 k to 0.42 k.

The efficiency and economy of perlite loose fill insulation has been proven many years in the insulation of storage tanks for liquid gases, such as oxygen, liquid natural gas and nitrogen at temperatures as low as -400 degrees F (-240 degrees C).

Thermal Resistance for All Types of Perlite Loose Fill Insulation for 1-inch (0.0254m) thickness,
given in both U.S. R-values of h.ft2.F/Btu and metric k-values (in parenthesis) (m2.K/W)


Mean TempDensity lb/ft3 (kg/m3)
oF (oC)2-4.1 (32-66)4.1-7.4 (66-118)7.4-11 (118-176)
-300 (-184)9.1-7.7 (1.6-1.4)7.7-6.3 (1.4-1.1)6.3-5.2 (1.1-0.92)
-200 (-129)6.5-5.7 (1.1-1.0)5.7-4.8 (1.0-0.85)4.8-4.0 (0.85-0.70)
-100 (-73)5.1-4.5 (0.90-0.79) 4.5-3.8(0.79-0.67)3.8-3.3 (0.67-0.58 )
0 (-18 )4.2-3.7 (0.74-0.65)3.7-3.2 (0.65-0.56)3.2-2.8 (0.56-0.49 )
40 (4 )3.9-3.5 (0.69-0.62)3.5-3.0 (0.62-0.53)3.0-2.6 (0.53-0.46 )
75 (24)3.7-3.3 (0.65-0.58)3.3-2.8 (0.58-0.49 )2.8-2.5 (0.49-0.44 )
100 (38 )3.6-3.2 (0.63-0.56)3.2-2.8 (0.56-0.49 )2.8-2.4 (0.49-0.42 )
Mean TempDensity lb/ft3 (kg/m3)
oF (oC)3 (48)8 (128)11(176)
200 (93)2.5 (0.44)3.0 (0.53 )2.3 (0.41 )
300 (149 )1.9 (0.33)2.5 (0.44 )2.0 (0.35 )
400 (204)1.6 (0.28)2.1 (0.37 )1.8 (0.32 )
500 (260 )1.3 (0.23)1.9 (0.33 )1.5 (0.26 )
600 (316 )1.1 (0.19)1.6 (0.28 )1.3 (0.23 )
700 (371 )0.96 (0.17)1.4 (0.25 )1.2 (0.21 )
800 (427 )0.84 (0.15)1.2 (0.21 )1.0 (0.18 )
1000 (538 )0.65 (0.11)0.96 (0.17 )0.81 (0.14 )
1200 (649 )0.52 (0.092)0.76 (0.13 )0.63 (0.11 )
1400 (760 )0.42 (0.074)0.60 (0.11 )0.49 (0.086 )



Water Repellency--Perlite loose fill insulation can be reated to minimize water transmission. Laboratory tests on water transmission by Structural Clay Products Research Foundation showed a cavity wall filled with treated perlite will not transmit water to the interior wythe even under the most severe conditions. Performance of overall wall was rated "excellent" in accordance with procedures established by the National Bureau of Standards in BMS 82. However, it should be noted that treated perlite insulation will not waterproof a poorly constructed masonry wall!

Permanency--Perlite is inorganic and therefore rot, vermin, and termite resistant and non-combustible with a fusion point of approximately 2300 degrees F (1260 degrees C). It is as permanent as the walls which contain it.

Non-Settling--Perlite loose fill supports its own weight in the wall without settling as verified by actual field measurements.

Flowability--Perlite consists of free flowing granules, which that seek out and completely fill the smallest crevices and mortar areas without bridging.

Fire Ratings--Underwriters' Laboratory Design No. U905 shows that a 2-hour rated 8,10, or 12-inch concrete block wall is improved to 4 hours when cores are filled with perlite. (Other four hour designs and ratings for 8-inch blocks are also described in U901 (upgrading 2 and 3 hours blocks to 4 hours), U904 (upgrading 3 hr block to 4 hour), and U907 (upgrading 3 hr block to 4 hour).)

Perlite loose fill has been tested in accordance with ASTM E-136 and was rated non-combustible.

Sound Reduction--Perlite loose fill insulation has the ability to fill all voids, mortar lines, and ear holes thus enabling it to reduce airborne sound transmission through walls. Lightweight 8 inch (20 cm) masonry block filled with perlite achieves an STC of approximately 51 which exceeds HUD sound transmission standards.

Benefits:

Perlite loose fill insulation functions as a permanent, non-toxic, non-combustible, rot-proof insulation which minimizes winter heat loss and summer heat gain. These properties allow for greater comfort at lower long-term cost.

Thermal performance tests using ASTM C-236 Guarded Hot Box Method have shown conclusively that perlite masonry loose fill insulation is the superior concrete block insulation when compared to expanded polystyrene (EPS) inserts, expanded polystyrene (EPS) beads, and vermiculite.

Other test conducted by independent laboratories also confirm the superior qualities of perlite loose fill insulation:


Test ASTM E84
Flame Spread
Fuel Contribution
Smoke Density


Results

0
0
0


Fed. Spec HH-1-515D
Critical Radiant Flux
Smoldering Combustion
Smoldering Combustion


Results
Greater than 1.07 Watts/cm20
Flaming Combustion: None
Weight Loss: Nil

Cost Savings:

Insulation is essential in all construction for energy conservation. The original cost of installing perlite loose fill insulation can be recovered quickly due to substantial reductions in heating and air condition energy consumption. In addition, perlite loose fill insulation cuts installation costs since it is lightweight and pours easily and quickly in place without need for special installation equipment or skills. The insulation may be poured directly into walls or emptied into a simply wood or metal hopper which can be slid along the wall to direct the free flowing perlite into cores of cavities thus insulating all voids and air pockets.


Concrete Block Walls---U-Values & R-Values

Block Only
Block Thickness in Inches
Density
of Block
UninsulatedInsulated
RURU
6
80pcf (Lightweight)
Unit wgt: 17 lbs
2.64*
.38*
6.75*
.15*
95 pcf
Unit wgt: 20
1.57
0.41*
4.86
.18*
105 pcf
Unit wgt:22
1.45
.44*
4.25
.20*
115 pcf
Unit wgt:24
1.34
.46*
3.69
.22*
125 pcf (Sand & Gravel)
Unit Wgt:26 lbs
2.05*
.49*
3.86*
.26*
135 pcf
Unit wgt:28
1.06
.52*
2.42
.31*
8
80 pcf (Lightweight)
Unit Wgt:22
2.86*
.35*
9.07*
.11*
95 pcf
Unit wgt:26
1.77
.38*
6.76
.13*
105 pcf
Unit wgt:29
1.63
.40*
5.91
.15*
115 pcf
Unit wgt:31
1.51
.42*
5.14
.17*
125 pcf (Sand & Gravel)
Unit wgt: 26
2.21*
.45*
5.06*
.20*
135 pcf
Unit wgt:37
1.21
.49*
3.37
.24*
10
80 pcf
Lightweight
3.00
.33
11.02
.09
125 pcf
Sand & Gravel
2.31
.43
5.95
.17
12
80 cf (Lightweight)
Unit Wgt: 33
3.12*
.32*
13.44*
.08*
95 pcf
Unit wgt:39
2.00
.35*
9.64
.10*
105 pcf
Unit wgt:43
1.84
.37*
8.36
.11*
115 pcf
Unit wgt:47
1.70
.39*
7.21
.12*
125 pcf
Sand & Gravel
2.38*
.42*
7.17*
.15*
135 pcf
Unit wgt:55
1.38
.45*
4.64
.18*

  • The values with an asterick * are approximate values that include the effect of inside and outside air film resistances. The other values do not include inside and outside air film resistances.
  • The values in this table represent typical R values of concrete block. The actual R value ofa concrete block is influenced by the concrete constitutents and by moisture content. More accurate estimates of thermal performance can be made if the atual thermal conductivity k or thermal resistance R of the specific block has been determined by tests. Procedures to make calculations for blocks of known conductivity are described in the Perlite Institute's Technical Data Sheet No. 2-6

Resistance Values for Veneer and Cavity Wall Calculations:R-Values

R Values
(0 F . ft 2.h/ Btu)
R Values
(K.m2/W)
Outside Air Film0.170.03
Common Brick0.200.04
Face Brick0.440.08
Air Space in Cavity 3/4 to 4 in. (19-102mm)0.970.17
1 in. Cavity Filled with 5 PCF Perlite (80 kg/m 33.120.55
2 in. Cavity Filled with 5 PCF Perlite (80 kg/m 36.251.10
3 in. Cavity Filled with 5 PCF Perlite (80 kg/m 39.381.65
4 in. Cavity Filled with 5 PCF Perlite (80 kg/m 312.502.20
Reflective Air Space3.080.54
Furring (Nonreflective Air Space1.010.18
Gypsum or Plaster Board 0.5 in (13mm)0.450.08
Gypsum or Plaster Board 0.625 in (16mm)0.560.10
Inside Air Film0.680.12


Sample U factor caluculations for Veneer Walls

Veneer Wall of 4 in face brick, 8 inch 105 pcf block filled with 5 pcf perlite
inside air film 0.68
8 inch 105 pfc block filled with 5 pcf perlite5.91
face brick0.44
outside air film0.17
R Total 7.20
U Value= (1/R (total))0.14

Sample U factor caluculations for Cavity Walls

Cavity Wall of 4 in face brick, 3 inch cavity filled with 5 pcf perlite,
8 inch 105 pcf block filled with 5 pcf perlite
inside air film 0.68
8 inch 105 pfc block filled with 5 pcf perlite5.91
3 inch cavity filled with 5 pcf perlite9.38
face brick0.44
outside air film0.17
R Total 16.58
U Value= (1/R (total))0.06


Installation:

a-The insulation must be installed in the following locations:

  • In the cores of all exterior (and interior) hollow masonry units.
  • In the cavity between all exterior (and interior) masonry walls.
  • Between exterior masonry walls and interior furring.

b-The insulation shall be poured directly into the wall at any convenient internal. Wall sections under doors and windows shall e filled before sills are placed.

c-All holes and opening in the wall through which insulation can escape shall be permanently sealed or caulked prior to installation of the insulation. Copper, galvanized steel, or fiberglass screening shall be used in all weep holes.

(The inclusion of weep holes is considered good construction design practice to allow passage of any water that might penetrate the cavities or core spaces of wall construction.)


Approximate Coverage(a)
Sq. ft. of wall area(b)
1"
Cavity
2"
Cavity
3"
Cavity
6"
Block
8"
Block
12"
Block
100
2
4
6
5
7
12
500
10
21
31
23
33
58
1,000
21
42
62
46
65
118
2,000
42
84
124
96
130
236
3,000
63
126
186
138
195
354
5,000
105
210
310
230
325
590
7,000
147
294
434
322
455
826
10,000
210
420
620
460
650
1,180

(a) 4-cubic foot bags required to fill
(b) a standard 8"x16" block equals 0.89 sq.ft.
Multiply the number of blocks times 0.89
to calculate the total square footage needed.


Applicable Standards, Specifications, and References:

  • ASTM Specification C549 for Perlite Loose Fill Insulation
  • ASTM Specification C520 Density of Granular Loose Fill Insulation
  • ASTM Specification C236 Test Method for Steady-State Thermal
  • Performance of Building Assemblies by Means of a Guarded Hot Box
  • ASTM Specification E84 Test for Surface Burning Characteristics of Building Materials
  • FHA Use of Materials Bulletin UM-37
  • GSA Commercial Item Description A-A-903 Insulation, Thermal(Expanded Perlite)
  • Brick Institute of America Technical Notes No 21A
  • Federal Specification HH-I-515D


For more information, please call or contact:

The Schundler Company

150 Whitman Avenue
Edison, New Jersey 08817
732-287-2244 or www.schundler.com

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