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B U I L D I N G

CELLULAR GLASS INSULATION

Ref. 2006/10/EN

PROJECT

INFO

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001

The name of the Phaeno conceals an experimental world under the heading of science and technology. The avant-garde architectural design of thebuilding by London architect Zaha Hadid moves away from conventional categories and is cast like a sculpture in the urban setting.Use of FOAMGLAS cellular glass as interior wall insulation is not to be considered as mere experiment it is the recipe for success in high stan-dard thermal insulation.

Phaeno Science Centrein Wolfsburg, Germany

FOAMGLAS interior insulationArchitects:

Zaha Hadid, LondonMayer-Bhrle, Lrrach

Phaeno building with foot bridge connecting to the north bank of the Mittelland Kanal,

the Volkswagen plant and Autostadt, the VW theme park. Photo Klaus Reichardt


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Learning by doing - this slogan by Robert Baden-Powell, the

founder of the scout movement was ori-

ginally characterising the social-educatio-

nal principles of the group and has inter-

nationally become a familiar quotation. It

has meanwhile become a valuable con-

cept in the scientific and research world,

where immediate results are claimed.

Technological know-how and the ability to

invent and do something can best be trai-

ned, when apparently difficult physical

and technical principles can be discovered

hands-on. This concept of learning is

the current approach of new Science

Centres that are opened all over the world

with growing success.

The first Science Centre, Exploratorium, ini-

tiated by Frank Oppenheimer as a hands-on

museum of science, art and human per-

ception, was opened in 1969 in San

Francisco. The desire to discover new

things and the fascination with the real phe-

nomenon is intended to open up for people

of all ages a new type of experience that is

clearly distinct from the classical museum.

Visitors are invited to touch the exhibits,

to make their own experiments and learn

about them. It goes without saying that

school classes like to have their Physics

lessons in Science Centres where they

can investigate and practically experiment

on the phenomenon.

The Phaeno building in Wolfsburg inter-

preted as a turbulent landscape is a fine

attraction that offers its visitors an adven-

tureland with 250 experimental stations.

T

he diverse world of shapes of the

Phaeno pushes the boundaries of

what is possible today. As the largest

building in Europe to have been construc-

ted in Self-Compacting Concrete. The

impressive structure of the building towers

high above the street. Various conical struc-

tures resembling truncated cones raise the

experimental hall above the public space at

ground level. The building is developed as a

spatial continuum that produces the effect

of a drifting, almost imperceptible transition

from outside to inside. Inside, the cones

become craters; there is no threshold, no

clearly defined boundary. Visitors arriving by

train and stepping outside the rather pro-vincial station are overwhelmed by the arti-

stic topography of the building that seams

to hover over a cushion of air.

Phno - THE EXPERIMENTAL LANDSCAPE

2

First sketch of the Phaeno

Science Centre

by Zaha Hadid


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The winning entry of the

2000 competition for

the new Science Centre in

Wolfsburg, Germany, was

the spectacular urban lands-

cape architecture of London

architect Zaha Hadid.

For the planning and execu-

tion of the Phaeno, Zaha

Hadid founded a team with

the architects Mayer-Bhrle

from Lrrach (D) and within

4 years the building was

constructed.

The German office had

already proved itself as a

most competent partner for

unusual projects and their

tenacity to find the best

technical solutions. Already

in 1999, the regional garden

exhibition pavilion in Weil

am Rhein made up for their

reputation.

3FOAMGLAS

Photo Mayer-Bhrle

10 conical structures support and penetrate into the building. They raise the experimental

hall at a level 7.5 m and open the area below it as a new urban space.

Zaha Hadid is indisputablyone of the greatest masters ofcontemporary architecture.

A building between futuristic sculpture and visual event


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It was a real challenge to meet the require-

ments of thermal insulation for this shape

of building and the specific use by choosing

adequate construction materials.

The character of a building is largely influ-

enced not only by the choice and size of the

site, the specified function and ground-floor

plan, but also by the outward appearance,

i.e. the faade. It makes the first impres-

sion. The design of a building may show a

most conventional look a uniform or

inconspicuous form or be a clear manifest

of extravagance and head for an excitinglynew solution that makes curious to discov-

er its insides. In the case of the Phaeno

Science Centre, its attractive exterior form

and materials appeal to have a closer look

at the relations between space and paths in

the building and put the essentially banal

question When am I actually inside the

Phaeno?

The external world of forms invites to dis-

cover the mysterious landscape inside. Like

a casting and its mould, an exceptionally

close linking between outside and inside is

created by means of inversion. Inside the

building shapes into a covered artificial land-

scape, divided into sequences of roomsunpredictable by visitors.

Science, technology and the correspon-

ding experimental stations have found an

Public building passage - a town within a town

with access at ground level

4

The concrete cones create analmost cave-like atmosphere

for the passer-by at groundlevel. Spectacularly sloping

walls and directed viewsshape way through the

turbulent hilly landscape. Thebuilding is very easy to

access with several mostequal entrances from differ-

ent directions. The transitionfrom outside to inside is

most imperceptible. Physicalopenness and the opportuni-

ties for communication set aclear signal. The public build-ing passage is display win-dow of the Phaeno Science

Centre with the differentcones housing a shop, cafsand restaurants, the science

theatre, the ideas forum,a kiosk etc.

This emerging urban worldwith an original landscape is

to be used for the mostdiverse of events, a melting-

pot for commercial, educa-tional and cultural activities.

Coffee shop and entrance to

the restaurant at the upperfloor.


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adequate architectural representation, which

is constructed movement, constructed

inquisitiveness. Of course, the construction

materials emphasise this particular architec-

tural design.

Experiment as an integral component is

taken up in the light engineering, the win-

dow shapes, the non-transparent walls and

the sculptural, plastic shaping from one

piece which moves away from convention-

al categories of posts, lintels and ceilings.

The faade is a mix of geometrical and flow-

ing elements; a fascinating effect of driftingis produced by rows of windows cast in Self-

Compacting Concrete and metal walls, cre-

ating an interesting, dynamic pattern.

5FOAMGLAS

PhotoMayer-Bhrle

External view of Phaeno Science Centre during construction, a mix of geo-

metrical and flowing elements.

Entrance foyer for group visitors. The turbulent interior landscape arouses a

desire to discover. The 11,000 m2 area is divided into sequences of roomsunpredictable by visitors.

One of the 250 experimental stations.

A house designed to spark curiosity

Photo Klaus Reichardt

Photo Klaus Reichardt

The experimental hall, 9,000 m2, with

experimental stations.


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For the interior surfaces, on the bound-

aries with the outer climate and with

lower temperature locals, it is necessary to

eliminate physical interactions in the build-

ing, in view of an overall high standard

specified for the room temperature.

With the quantity of exposed concrete walls

and the required thermal insulation level,

this mission represented a real challenge,

further to the additional requirements listed

below:

Excellent ecological profile of theinsulation material.

Incombustibility of the insulant.

Highly resistant, without ageing

in the long-term.

High compressive strength.

Easy to work and fitting to all shapes.

Airtight.

Water- and vapour-proof;

no additional vapour-barrier required.

Constant thermal insulation, no conden-

sation within the build-up or wall section.

Surface suited for plasterwork.

Steady temperature level and comfor-

table interior climate under all weather-

conditions, for diverse use requirements

and a variable number of visitors inside

the Science Centre.

During the summer 2000 approx.

9 months before turning the first sod

different solutions for insulating relevant

construction elements at the interior were

discussed with the architects and engi-

neers. FOAMGLAS cellular glass insula-

tion, type T4-040, was identified to meet

the most stringent requirements of this

building. Imperative, workmanship and

execution of details required a great deal

of supervision and planning to optimise

the high product quality in application. This

becomes clear with a look at the photos

and plans (see page 10).

The shaping of the walls, with diverse

conical radius, was quite a difficult task for

the thermal insulation contractors. For cer-

tain sections the FOAMGLAS slabs had

to be cut into strips similar to the narrowpanels of the concretes wooden shutter-

ing - to follow the curved walls sloping at

different angles.

6

FOAMGLAS interior insulation systems -

meeting all the buildings performance demands


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7FOAMGLAS

On Self-Compacting

Concrete walls /

prefab concrete structures

In general, the interior insulation was laid

with the following build-up:

Structural wall

(Self-Compacting Concrete)

Bituminous primer, emulsion paint

PC EM

FOAMGLAS cellular glass insulation,fully adhered to the wall with

vapour-proof cold adhesive PC 56,

joints filled with adhesive

Above a certain height, mechanical

securing of the FOAMGLAS insula-

tion with ceiling fixing

Mineral mortar (base coat) PC 74 A2,

with reinforcement mesh PC 150

Prime coat PC 310

Decorative finish coat, retarded

hemihydrate plaster PC 140

(Class B p.; type of plaster of Paris)

and for execution in some parts:

Bituminous primer, emulsion paint

PC EM

FOAMGLAS cellular glass insulation,

fully adhered to the wall with

vapour-proof cold adhesive PC 56,

joints filled with adhesive

Above a certain height, mechanical

securing of the FOAMGLAS insula-

tion with ceiling fixing

Plasterboard finish.

On profiled metal walls

The build-up described above offered a

perfect substrate for installing the insula-

tion. However, where the substrate was

formed of profiled metal sheets, specific

sound insulation chipboard had to be

placed before application of the FOAMGLAS

slabs.

Placed on top of the crowns of the profiledmetal sheets, 10 mm thick fibre-rein-

forced PC sound insulation boards, fire

rating class A2, were screwed by means

Masonry/concrete

PC EM primer

Cold bituminous adhesive PC 56

Cellular glass insulation slabs FOAMGLAS T4-040

Mineral mortar (base coat) PC 74 A2

Reinforcement mesh PC 150

Mineral mortar (base coat) PC 74 A2 with prime coat PC 310

Finish coat, retarded hemihydrate plaster PC 140

PRINCIPLE DRAWING: Interior wall insulation system

with incombustible materials

Application of the FOAMGLAS insulation on metal walls (profiled metal

sheets).

Interior insulation


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vapour-proof FOAMGLAS insulation layer

is then bonded to the composite wall.

Details

Particular attention had to be paid to the

fixings of the sub-construction which had

to bear faade elements in some parts of

the building. FOAMGLAS insulation had

to be fitted around the fasteners in a way

to avoid all risks from condensation andthermal bridges. The adaptation of the insu-

lation slabs to these elements required a

great deal of precision and exceptional craft

skills from the contracting firms.

Connection joints which had to be made

impermeable to vapour and resistant to

movement stress were sealed with

Pittseal 444 N, a special mastic that is

fully vapour-proof and suited for the tem-

perature range from 50 C to + 80 C.

The joints between vapour-proof FOAM-

GLAS insulation and adjoining concrete

elements were bridged with self-adhesive

vapour seal tape.

FOAMGLAS interior insulation

8

of self-drilling screws; the number of

screws according to stability calculations.

In this way, the walls mass could be

increased to reduce the sound transmission

from one space to another; the sound insu-

lation value was improved by remarkable 5

to 10 dB. This is appreciable because 10 dB

means doubling of the sound insulation,

usually reached without any additional

measures. As described before, the proven

Interior works in the science cinema, bonding FOAMGLAS slabs to walls and ceiling. Finallythe insulation layer is coated with a finish coat of retarded hemihydrate plaster PC 140.

Bonding of FOAMGLAS slabs to follow the

curved walls sloping at different angles.

Thermal dilatation of materials

Concrete

Reinforced concrete

Steel

Cellular concrete

Aluminium

Titanium zinc

Copper

Styropor

Extruded polystyrene

Polyurethane

Phenol resin

PVC (hard)

WWLB Board **)

FOAMGLAS

**) Wood wool lightweight building board

Typeofmaterial

Source: Dr. Grunau, Thermal insulation materials

Dilatation (mm/ m x 100 K)


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Had to be taken into consideration the different thermal

dilatation of materials, for instance between FOAMGLAS

cellular glass, the bonding substrate (warming up of the

faade when exposed to the sun) and the adjoining con-

struction elements. Similar thermal dilatation values of the

materials are indicator for their compatibility.

9FOAMGLAS

Certainly of advantage is, that FOAMGLAS insulation is

dimensionally stable due to its cellular glass structure (it

will not swell or sag even when exposed to moisture) and

moreover, material tensions are avoided because its spe-

cific dilatation/contraction behaviour is in line with that of

steel and reinforced concrete (see figure, page 8:THERMAL

DILATATION OF MATERIALS).

Interior dcor with FOAMGLAS insulation slabs on the walls and a finish coat of retarded hemihydrate plaster PC 140.

Finish coat of retarded hemihydrate plaster

PC 140, quality fine.


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10

FOAMGLAS interior insulation

Plasterboard, 2 x 1.25 cm thick

CD profile 60 x 27 (Knauf - W 623)

U profile

Cellular glass, 8 cm thick;

sealed vapour-proof

Self-Compacting Concrete

wall, 25 cm thick

Concrete screed,

15 cm thick

Dampproofingat the bottom ofthe room

Thermal insulation

Structural

concrete

Sectional drawing Cone 1 & 2 FOAMGLAS interior insulation, in some parts with plasterboard finishStructural wall in Self-Compacting Concrete


11/16

11FOAMGLAS

Due to the great diversity of curved

walls sloping at different angles, the

contractors for the insulation had to work

with particular skill on the application of

FOAMGLAS slabs; in particular as FOAM-

GLAS insulation is incompressible, non-

flexible and deformation-free. The worker

had to be skilful, but nevertheless, with

common tools all levelling and fitting oper-

ations could be done without difficulties to

make the insulation double the most spec-

tacularly sloping walls.

By use of a scraper, pipe and cable con-

duits could be accommodated in the

FOAMGLAS insulation layer without cre-

ating thermal bridges or generating con-

densation problems.

A perfectly smooth insulation layer is

obtained by levelling out any unevenness

by abrasion.

Screwed connections to suspend light

weights could directly be screwed into the

cellular glass insulation, without risks of

thermal bridges or condensation. Fixing

through the insulation was thus reduced

to a strict minimum.

Wo rkmansh ip

Cutting grooves for cables in FOAM-

GLAS slab insulation with the help of

simple tools (e.g. a scraper).

Uneven insulation surfaces can be lev-

elled out by abrasion with conventional

tools.


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Certified safety

In order to control that state-of-the art workmanship would produce uncom-

promised thermal insulation performance on the inside of the structural walls

and offer best protection against condensation, the built-in thermal insulation

was checked at different spots. Upon request of the client, this control had

been made by Materialprfanstalt Braunschweig (MPA, material testing insti-

tute in Braunschweig). The results of the tests confirmed the excellent work-

manship regarding the insulation works and specified quality standards could

be certified.

The long path from the first consultance until completion of the project was a

great challenge for all participants. The history confirmed, however, that the

requirements regarding highly performing interior insulation did find a solution.

With regards to the expected service life, a durable technical solution for inte-

rior insulation was found using FOAMGLAS cellular glass, a material that is

cost-effective and offers large design liberties for the architect.

The main benefits are:

Constant thermal insulation value.

Vapour-proof cellular glass structure that prevents physical

interactions in buildings.

No need for additional vapour-barriers or airtight sheets on the

warm side of the insulation, which regularly show imperfections.

Full insulation performance, even under variable temperature

and moisture conditions on the room side.

No thermal bridges because of uninterrupted, fully bonded insulation

layer.

12

The FOAMGLAS insulation layer is the perfect, incompressible substrate

for the plasterwork. It protects the structure of the building without

need for fragile additional vapour-barriers, because closed cell cellular

glass material assumes the functions of vapour control layer

and thermal insulation in one.


13/16

13FOAMGLAS

Roof insulation

Compared to the wall insulation works,the roofing works were standardapplications; the proven FOAMGLAS

Compact Roof was installed fast-track on

concrete deck and on steel deck, using

hot bonded insulation slabs followed by a

two-ply waterproofing.

Meeting specified severe safety require-

Compact bonding of FOAMGLAS slabs

on steel deck using hot bitumen

1. Steel deck

2. FOAMGLAS slabs bonded with

hot bitumen

3. Hot bitumen flood coat

4. Two-ply waterproofing, 1st layer

5. Two-ply waterproofing, 2nd layer

Compact bonding of FOAMGLAS slabs

on concrete deck using hot bitumen

1. Concrete deck, structural concrete

2. Bituminous primer

3. FOAMGLAS slabs bonded with

hot bitumen

4. Hot bitumen flood coat

5. Two-ply waterproofing, 1st layer

6. Two-ply waterproofing, 2nd

layer7. Aggregate ballast, if required

Phaeno Science Centre

ON STEEL DECK ON CONCRETE DECK

ments, FOAMGLAS insulation systems

with compact bonding of all components

were applied. Rigid and high compressive

strength FOAMGLAS insulation forms a

supportive and resistant construction for

the waterproofing which is not subject to

settlement and shear in the joints.

FOAMGLAS cellular glass is the key ele-

ment of an exclusive all in one insulation

and waterproofing system with aqua-stop

and anti-leakage guarantee.

CONTRACTORS:

Fa. Jrg Zimmermann

Master painter

Potsdamerstrasse 8

D - 39114 MAGDEBURG

Fa. Werner Dohrendorf GmbH

Master painter

Mittelstrasse 12

D - 38527 MEINE

Fa. Rainer BodeBorsigstrasse 11

D - 38446 WOLFSBURG

Fa. Spoma

Parkett und Ausbau GmbH

Sallestrasse 43-44

D - 39126 MAGDEBURG

Fa. Opteam GmbH

Handwerkerring 1

D - 39326 WOLMIRSTEDT

Mnch Dachsysteme GmbH

Kleiweg 2a

D - 06484 QUEDLINBURG

see also:Technical Data, p.14

FOAMGLAS flat roof


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A retrospective look

In the middle of February 2006 about3 months after the opening of the PhaenoScience Centre in Wolfsburg the archi-

tect Peter Maximilian Bhrle from the

architect partnership Zaha Hadid Ltd. &

Mayer Bhrle met with Jrg Zimmer-

mann, contractor of the insulation works

for a summary of the works done.

Having chosen with FOAMGLAS sys-

tems a safe solution to meet all buildingphysics and design requirements of inte-

rior insulation, it was of crucial importance

for the architects that the insulation sup-

plier Deutsche FOAMGLAS GmbH could

offer excellent consultance services over

a long planning and execution period.

First pre-planning discussions started

halfway through the year 2000, in the

offices of Mayer-Bhrle architects in

Lrrach, Germany. More intensive consul-

tancies followed with the progress of the

construction. As Mr Zimmermann resumed

in his look back, the job-site assistance by

the FOAMGLAS supplier was excellent

and guaranteed that the most complicated

details on insulation and connection works

could be handled correctly; many of the

technical details having had their first edi-

tion in this demanding project.

For all building professionals it was inter-

esting to discover that deformation-free

and high compressive strength FOAMGLAS

insulation could visually perfect be adapt-

ed to the surfaces of the curved walls

sloping at different angles, be it convex or

concave shapes.

The architect Peter Bhrle commented

that this building owes its uniqueness and

livelihood to the avant-garde architectural

design and an approach to construction

that is to be classified as pioneering work.

After all, a project that makes technical

history, with new design and thinking, in

terms of technical as well as spatial or

functional form.

It does not surprise that the Phaeno

Science Centre in Wolfsburg was officially

presented to the public twice, as an excit-

ing masterpiece of architecture: the day of

its inauguration and on the occasion of the

Open Doors Day of Architecture, on 25th of

June 2006. Incredible, a first run!

Planners, manufacturer and building trades -

a successful team

14

Basic principles and benefits ofcellular glass interior insulation

Constant thermal insulation value/Significant energy savings in the

long term.

Prevents cold bridges.

Creation of a barrier against con-densation and moisture migration

through the construction element.

Prevents mould growth andefflorescence.

Supportive and deformation-freelayer for plasterwork.

Safe detail handling.

Reduced number of componentsin the build-up.

Fits to all shapes.

No limits regarding use andinterior climate conditions.

Incombustible material, optimalsolution regarding fire safety.

I would not appreciate if somebody leaves this

house, full of admiration how intelligent somebody

else is. It is terribly important not only to be curious,but to have some confidence in your own ability tofind something out or to lean something. Quotesfrom Frank Oppenheimer, the founder of the first

Science Centre, Exploratorium, in San Francisco.

On the completion of theproject: red carpet forFOAMGLAS.

TECHNICAL DATA

Project:PHAENO Science Center WolfsburgWilly-Brandt-Platz

D - WOLFSBURG

www.phaeno.de

Client: Municipality of Wolfsburg

Architects:Zaha Hadid Ltd. &

Mayer Bhrle, freelance architects

www. zaha-hadid.comwww.mayer-baehrle.com

Technical consultant,thermal insulation:

Deutsche FOAMGLAS GmbH

www.foamglas.comWilfried Bhler, office Freiburg

Tel.: 0761-20272-0

Tel.: 0761-20272-12

Fax: 0761-20272-20Eckhardt Noack, office Hamburg

Tel.: 040-253051-0

Tel.: 040-253051-13Fax: 040-253051-20

FOAMGLAS insulation:Interior wall insulation: 9,500 m2

Primer PC EM: 400 kg

Vapour-proof adhesive PC 56:

36,000 kgVapour-proof adhesive PC 88:

1,200 kg

FOAMGLAS slabs T4-040;

thicknesses 40 / 80 / 100 mmPC ceiling fixing, type F: 9,000 pcs

Plasterworks:PC 74 A2: 21,000 kg

Finish coat, retarded hemihydrate

plaster PC 140: 8,000 kgPC sound insulation chipboards:

400 m2

Roof insulation: 1,300 m2

FOAMGLAS slabs T4-040;

140 mm thick

Construction period: 12/2003 - 07/2005


15/16


16/16

FOAMGLAS interior insulation - fits to all shapes

and controls the physical interactions in buildings.

An essential high-tech solution.

PITTSBURGHCORNINGhaschosenachlorine-freepapertosafeguardourenvironment.

The plateau of the experimental hall with FOAMGLAS insulation on

the interior walls and on the steel decks of the main ceiling.

FOAMGLAS

CELLULAR GLASS INSULATION

PI/PhaenoScienceCentre,

Wolfsburg-Germany/EN/10/06.2

006-

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DepartmentPITTSBURGH CORNING EUROPE SA

Belgium

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FOAMGLAS insulation

applications are detailed in

technical specifications

covering various projectstages: Design, Specification,

Tender and Installation.These specifications are

available on request from

any Pittsburgh Corning

subsidiary or their approvedrepresentatives.

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