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The Group has defined five focus areas aimed at improving its CO2 efficiency by:
Sandwich Wall Panel
Residential New Construction has been an ongoing focus through 2010, where Roxul has begun to partner with “Green Builders”.
The launch of ComfortBoard FS is Roxul’s first product specifically designed for the new construction market.
We consume 3 times more oil and gas liquids than we discover. The gap between consumption and discovering is growing. Now 80% of the large oil producing countries are struggling with declining production.
This product does not develop smoke
or promote flame spread when exposed to flame, making CurtainRock® a critical line of defense in fire protection. CurtainRock40 and CurtainRock80 take fire protection one step further. When used with Roxul Safe, CurtainRock40 and CurtainRock80 become comprehensive fire-stopping systems specifically designed for fire-rated perimeter systems.
ROXULPlus® is a mineral wool insulation products for use in commercial or residential steel stud and metal building construction.
RockBoard 40, 60 , & 80 are:
These rigid mandrel wound pipe sections are
strong, preformed mineral wool insulation with
excellent thermal performance.
Techton® 1200 is ideal for steam and process
pipe systems operating at temperatures up to
1200°F (650°C), where energy conservation,
personnel protection and fire control are
concerns.
Techton® 1200 Marine is a rigid mandrel wound pipe product made of strong, preformed stone wool insulation. Designed for moisture intense applications, such as steam and process pipe systems operating at temperatures up to 1200°F (650°C), where energy conservation, personnel protection and fire control are concerns. Engineered for thermal and fire protection in marine applications.
The Roxul FabRock™ is a premium stone wool insulation board with low thermal conductivity. FabRock is a multi-purpose board designed to be fabricated to different dimensions and still retain fire, water and thermal properties.
FabRock™ comes in two different densities for different applications:
Roxul’s RHM® Marine series of non-combustible stone wool products are designed for thermal and fire protection in marine applications. Insulation is available in both board and blanket.
RHM is suitable for a full range of temperature applications including boilers, vessels, tanks, ducts, ovens, mufflers, and exhaust stacks.
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Emissions from melting, spinning,
curing and cooling are filtered and
incinerated in burners to remove binder rests and odor
All process and wool waste is collected and recycled back to spinning chamber or via briquette for zero waste to landfill
The white steam from the small stack is cooling water vapor from the melting process
Runoff water is collected and used for binder production
The WB is an artificial homemade “stone” produced from internal and external waste
The WB is charged back to the cupola together with basalt and slag for re-melting
The WB means zero waste to landfill and is approx. 40 to 50% of the charge
Basalt is a natural rock found in Ontario and is crushed to our specifications.
Basalt is app 30% of our charge
Steel Slag is a by-product or waste from steel mills in Hamilton
Slag is approx. 20 to 30% of our charge
When product is cut to size, online visual quality control is done before stacking
Defective products are diverted for recycling
All products are lab tested at production start and in set intervals during production
Each product can be traced back to the hour it was produced via label information
Coke is the fuel used in the cupola melting process; it’s combined with hot air and oxygen
Coke is made from coal and imported from the U.S.
Our raw-materials are fed into the cupola top in batches of 2,000 kg every 4 to 5 min
Temperature in the cupola top is app 175˚C and in the melting zone app 1,500˚C
Coke, combined with 700˚C hot air blown into the bottom of the cupola is the energy source for melting.
We have 2 cupolas in TOR, one electrical melter in GRF
The mixture of molten basalt rock and slag is fed to the spinners
It is spun at high speed to create stands of stone wool (like cotton candy)
Roxul uses a Pre-fab resin as a binding agent Resin is delivered weekly and is kept in storage tanks
Binder holds the fibres together and impacts different levels of rigidity
The pendulum process distributes the primary fleece in an even cross wise direction
TOR3 and GRF2 are both pendulum lines
TOR1 is a direct collection line
Product is compressed to its final thickness in the CO inlet
Product is cured at 240˚C
Hot air is blown through the wool and re-circulated as part of our energy saving program
To cut the product to size, we have 4 different types of saws
Orange piping is part of dust extraction, which recycled back into product
Our Plant in GRF uses an electrical melter
Raw materials are crushed to 1” size and fed into the melter
The electrical melter uses the same amount of power as the entire town of GRF with 3,500 residents
Before products can be cut and packaged, hot air inside the wool must be removed
A cooling zone sucks ambient air through the wool mat as it passes over a set of rollers.
The hot air is filtered before going to 75 m stack
All products are stacked before entering the packaging section Shrink tunnel is used for product where no compression can be applied Compression packaging is used for all lighter density products, e.g residential
Retail products are required to display actual R-value on each batt
Branding is done with gas burning wheels on the product surface, top and bottom if required
Minor amounts of binding agent and oil are added
The wool is collected on a belt conveyor in the spinning chamber
Daily production schedules are prepared based on customer orders
Production planning is done in Navision then exported to RockFact
Our 500 SKUs are categorized as A, B or C based on sales volume; only some A products are kept in inventory
Roxul employs 3rd Party Logistics Companies (3Pls) to arrange transportation (trucks, rail etc.) for the on-time delivery of customer orders
Roxul has a Traffic Supervisor overseeing 3rd Party Logistics provider East and West
Roxul RW® 40, 60, and 80 are flexible industrial blankets made of stone wool insulation. Designed for use where high temperature and fire resistance are concerns:
Roxul RW is avaliable in different densities and dimensions to meet various application requirements
Techton 1200 offers:
Roxul an official member of the
Committed to working with both USGBC and the CaGBC in a variety of ways including:
SturdiRock® is a rigid mandrel wound pipe ideal for steam and process pipe systems operating at temperatures up to 1400°F
(760°C), where energy conservation, personnel protection and fire control are concerns. The added density of SturdiRock® offers superior durability compared to other mineral wool products.
Virtually no dust to keep work environments cleaner
Fast easy installation
The ENERWRAP® 80 product is a flexible faced
industrial blanket mineral wool insulation that is
lightweight, water repellent, fire resistant and
sound absorbent.
ENERWRAP 80 is used to insulate surfaces
such as:
No need for band saw
Reduces waste and manpower hours
$150MM Plant Expansion completed: March 23, 2009
A focused Stone Wool manufacturing facility.
700,000 Sq. Ft. of manufacturing & warehousing (65,000 Sq.M). Triples existing manufacturing capacity in Milton.
Roxul FireWall™ 605 & 606 product is a non-combustible, rigid mineral wool insulation board that is lightweight, water repellent and designed for fire rated exterior non-load bearing sheet steel walls, where a one or two hour fire resistance rating is required.
The RockBoard™ is a semi-rigid and rigid mineral
wool insulation board that are non-combustible,
lightweight, water repellent, fire resistant and sound
absorbent.
Roxul RHT® products are rigid stone wool industrial insulation boards. Designed for use where high temperature, fire resistance, and moisture resistance are concerns.
RHT :
Ideal for applications such as:
Roxul Facility in Milton established as an environmental leader.
The Roxul DrainBoard® is a rigid mineral wool insulation board that is water repellent, durable and environmentally stable. Designed as a high-performance fibrous foundation drainage system, Roxul DrainBoard unique characteritics make it the ideal green exterior foundation insulation.
Roxul Insulation will save 128 times more primary energy and 162 times more C0 than was used for its production, transport and disposal.
Energy balance becomes positive in less than five months while C0 payback is less than 4 months.
Insulation of hot pipes, the energy and C0 payback can be less than 24 hours.
This product is designed for commercial, industrial, and residential buildings as a fire stopping insulation.
Ideal for filling:
Roxul SAFE® is used in conjunction with a fire sealant to prevent passage of fire and smoke.
SAFE
The 2009 edition of the International Energy Conservation Code (IECC) – the national model energy code of choice for states, citits and countries that adopt codes – is published and now available for adoption by jurisdictions.
New energy Efficient provisions in 2009 IECC include:
The American Recovery and Reinvestment Act of 2009 was signed by president Barack Obama. The Act allocates approximately 50 billion dollars for energy efficiency programs and incentives. This includes:
The Canadian stimulus budget will provide up to $7.8 billion of funding to help stimulate the housing sector and improve housing across the country.
There are a number of initiatives for enhancing the energy efficiency of homes, such as the ecoEnergy Program. There is also a new home renovation tax credit, which gives homeowners incentives to invest in their homes as well as helping to create local jobs.
On site briquette facility also ensures that we recycle our own waste.
Recycled content is balanced to ensure quality is never compromised.
Wall systems in today’s commercial and industrial buildings must do more than simply subdivide space. They need to:
Reduce unwanted transmission of noise
Increase safety against spread of fire.
Increased mass means better sound control
ROXUL is GreenGuard Certified.
ROXUL ConRock® is a board insulation product designed specifically for application in sandwich panel systems where excellent thermal and fire resistance properties are required.
CurtainRock® is a non-combustible, semi-rigid and
rigid mineral wool insulation board that designed specifically for use in curtain wall systems. CurtainRock’s excellent moisture resistance, and dimensional stability make it the ideal choice for backpan systems in curtain
wall applications.
“Energy efficiency is the most important key to a low-carbon society.
The Rockwool insulation that we produce this year will, in its lifetime,
save more than 200 million tonnes of CO2. That is three times more
than the emissions from Denmark,” says Thorkild Diness Jensen.
The Carbon Disclosure Project is an independent not-for-profit
organization holding the largest database of primary corporate climate
change information in the world.
Consistent with our Environment Focus Roxul products are CFC & HCFC Free
Dimensional Stability ensures product performance.
ROXUL TopRock® DD is a rigid mineral wool board insulation with a rigid upper surface for durability and enhanced strength. Intended for commercial and industrial roof insulation applications and is suitable for both new building and re-roofing applications.
High-density top layer of insulation
long-term performance of any roofing membrane
Recycled content is balanced to ensure quality is never compromised.
Roxul CavityRock® is a non-combustible, water repellent insulation board specifically engineered for cavity wall and rainscreen applications. As a continuous insulation (ci), CavityRock provides:
ROXUL MonoBoard™ Plus is a rigid, mono-density, dimensionally stable, mineral wool based insulating cover board. MonoBoard is intended for commercial and industrial roof insulation and is suitable for both new building and re-roofing applications.
MonoBoard™ is intended for use in tapered systems and fabrication.
MonoBoard™ Plus is impregnated with a bitumen layer which is compatible with torch or mop applied membrane.
ROXUL AFB® (Acoustical Fire Batt) is a batt
insulation product designed specifically for
application in wall/floor systems where
acoustical performance and fire resistance
are the primary concerns.
ConRock®
Mineral wool is hydrophobic and will not absorb moisture. It will not promote the growth of fungi or mildew and the R-value will be protected.
Comfortbatt is specifically engineered for use in exterior walls, cathedral ceilings, attics, basement walls, exposed floors, and heated crawl spaces.
In Canada
Roxul as part of the Rockwool Group must be the preferred supplier of products, systems and solutions for improved energy efficiency, acoustic performance and fire safety in buildings.
Roxul ComfortBatt™ is a stone wool insulation products for use in both new residential construction and renovations. This semi-rigid batt has a unique flexible edge designed to compress as the batt is inserted into walls, attics, ceiling and floor frames.
In USA
The Group’s Mission
Roxul ComfortBoard FS is a semi-rigid stone wool insulation boards ideal for firestopping in concealed spaces of multi-unit residential buildings.
Roxul® offers an innovative insulation board designed specifically for application in sandwich panel systems where excellent thermal and fire resistance properties are required. This rigid board has excellent acoustical dampening properties and is dimensionally stable which makes it ideal for installation in panel applications.
Why protect against fire ?
Protection of lives
Protection of property
Avoid company bankruptcies
Avoid contamination
Avoid loss of irreplaceable cultural assets
Stone Fiber/Wool is NON-COMBUSTABLE, with a melting point of about 1177°C (2150°F), providing excellent fire resistant properties to delay the spread of flames
TopRock®
MonoBoard™
ROXUL Safe‘n’Sound™ is a stone wool insulation product for use in interior wall partitions of residential wood and steel stud construction where superior fire resistance and acoustical performance are required.
non-combustible
Roofing
Roxul® offers two unique green roofing products designed for both new and retrofit roofing projects. Using patented technology and the unique properties of stone wool, Roxul® roofing products offer a Better alternative in roofing Insulation.
The unique properties stone wool make Roxul products ideal for use anywhere on a ship: A&H constructions, bulkheads & decks, engine rooms, pipe & air ducts, doors & panels, floating floors & sub sea pipelines
RHM
AFB®
Roxul Plus™ SS
RockBoard®
CavityRock®
CurtainRock®
FireWall™
Techton®1200
SturdiRock®
Enerwrap®
RHT
FabRock®
Roxul® blanket and board insulations add value to commercial & institutional buildings by enhancing the sound absorption, fire resistance and thermal resistance qualities of several types of wall systems
Roxul® industrial insulations offer consistent thermal, acoustical and fire safe performance on a variety of high temperature power & process systems
The first stone wool production started in Hedehusene near Copenhagen in 1937. By 1938 stone wool factories were established in Denmark, Sweden and Norway