23/2722 PV Brochure V2:2010 - Kingspan PowerPanel

Insulated Panels
Insulate&Generate
CI/SfB
(4-) Rh2
August 2010

2
Contents
Introduction 3
Kingspan PowerPanel
Systems 7
The paper we have printed on is from 80% postconsumer
waste and the remaining 20% pulp is TCF
(Totally Chlorine Free). This fibre is FSC certified (see
fsc.org for details). In recognition, the range has been
awarded both the NAPM and Eugropa recycled marks,
two of the most prestigious and recognisable recycled
certificates available. The ink we have used is vegetable
based, allowing the document to be recycled.
Sustainable Forest Recyclable Vegetable Based
Front cover images of photovoltaic projects courtesy of Romag Ltd

Introduction
Energy security is now up there with the climate change debate.
Some energy analysts1 have even suggested that securing the country’s
supply of energy is more important than tackling climate change,
because, they have warned, the UK’s economy could be wrecked if
there is no action to plug the energy shortfall predicted for the next
decade. This echoes the stark realities of escalating costs outlined in
the Stern Review on the Economics of Climate Change, published in
October 2006, not to mention the human cost as extremes of weather
continue to take their toll. But whether our main drivers are the
economy or the environment, what is clear is that strong and definitive
action needs to be taken to improve the current situation.
1 Ian Fells report, University of Newcastle, September 2008
Castle College Technology Centre, Nottingham. Photograph courtesy of Redshift Photography
The good news is that solutions are already available. All that is
needed is a clear long term strategy and sound investment in our
building stock and infrastructure, so that we can fully utilise the
technology and make a real difference.
The Trias Energetica model provides a logical approach to tackling
the key issues of energy security and climate change by promoting
three steps towards sustainable energy production: reduce use;
use renewables; be efficient with the remaining resources.
3
Introduction

4
Step One – Energy Efficient Buildings
The first step is clearly to reduce energy demand, and one of the
simplest ways to do this for both new build and refurbishment projects
is to use insulated panel systems, which offer high thermal
performance and low air leakage.
Over the past 30 years insulated panels have evolved as a particularly
thermal efficient and economic method of constructing the roofs and
walls of buildings, and have been extensively used in refurbishment as
they are ideal for re-cladding walls and roofs. Insulated panels offer the
best long term insulation performance for lowest thickness and weight
and can transform the energy efficiency of a building to current
standards with immediate payback on investment.
The reason they are so effective is that high performance insulation is
an integral part of the panel system, so excellent U-values are
guaranteed. For example, many older buildings have U-values of
0.6 W/m².K or worse, so over-cladding with an insulated panel system
that provides a U-value of 0.25 W/m².K, will offer a huge energy
saving, and rapid payback on investment, as well as improving the
aesthetics of the building and providing a more economic and
environmentally sound solution than demolition.
Research commissioned by Kingspan shows that upgrading all of the
UK’s public sector non-domestic buildings to meet level C of the
Display Energy Certificate (EPC) rating would deliver £10.42bn of
energy cost savings between 2010 and 2022.
Air tightness also has a significant impact on energy efficiency –
heat can escape with air, so the more air leaking out of a building,
the more heat goes with it. Insulated panels can achieve a rate of at
least 5m³/hr/m², with some projects having tested at rates below
2m³/hr/m², markedly improving energy efficiency and well below
what is currently required by the building regulations for either
refurbishment or new build.
Step Two – Renewable Energy
The development of sources of renewable energy is a crucial part
of the strategy to cut carbon emissions, but for these to work
they also have to be economically viable. As the technology evolves
and becomes more widespread the economies will improve.
However, it is initiatives such as the feed-in tariff which present
massive opportunities to move renewable energy out of the niche
and into the mainstream market in readiness to meet the target for
zero carbon buildings in 2016.
One of the key aspects for the success of integrating sources of
renewable energy into our construction programmes will be the ease
with which they can be incorporated into building design. Kingspan
Insulated Panels has a number of solutions which meet this criterion,
starting with the building envelope itself.
A combination of Kingspan’s KS1000 TS Tile Support System and the
KS1000 ZIP Kingzip Standing Seam were used during the building of a
£65m Oncology and Haematology Unit at Castle Hill Hospital, Hull.

Asda, Sutton Courtenay, Didcot
Simple Renewable Energy Solutions 1 – EnergiPanel
Kingspan EnergiPanel is an innovative insulated solar air heating
system designed for roof and wall applications as a supplement to
the main heating system. The system comprises a modified version
of a standard Kingspan KS1000 FC Five Crown Box Profile panel.
Profiled hollows beneath the crowns allow air movement up through
the panel and the air is warmed by the simple process of using the
outer steel skin as a solar energy absorber. The darker the external
colour of the panel the greater the solar absorption.
The rate of airflow up through the panel is determined by the
temperature of incoming air. Temperature sensors constantly monitor
the external air temperature and varies the fan speed to ensure the
supply air temperature is above the required internal temperature of
the building. The regular circulation of warm fresh air drawn into the
building improves the overall quality of indoor air, making the working
environment healthier and more comfortable.
The system offers a low cost and reliable renewable energy source
which can provide a rapid payback on investment and can help to
deliver up to 3 credits in BREEAM 2008 assessments. Kingspan’s
large scale test facilities have shown that heating costs can be
reduced by as much as 20%, offering the potential to significantly
reduce a building’s carbon emission rate. The introduction of a
renewable source of energy into the building composition can also
increase the chances of achieving planning permission where Merton
pro-renewables planning policies are being implemented.
Because it is a single component system, Kingspan EnergiPanel
allows fast track construction, and with there being no additional steel;
solar absorber plate, supporting framework or additional fixings
involved, the overall carbon footprint associated with the installation is
minimised. It integrates seamlessly with other panel systems from the
Kingspan range, and is available in a range of colours. It uses
Kingspan’s existing high quality insulated panel technology coupled
together with a tested and proven solar air heating capability.
The EnergiPanel Solar Air Heating System has the flexibility of either
being integrated with the existing HVAC system or being utilised in a
standalone heating capacity. It is also available with the Kingspan Total
Guarantee, offering thermal and structural performance.
Free support from Kingspan envirocare ® Technical Services can
ensure the most efficient building design. To obtain computer modelled
indicative data for your building please contact the Kingspan
envirocare ® Technical Services team on (UK) 0800 587 0090 or
(Ireland) +353 (0) 42 9898529.
Case Study: Kingspan provides the Energi for Asda
Asda’s new £42 million ‘eco-depot’ at Sutton Courtenay, Didcot, was
designed by Architects Chetwoods and serves 33 stores across the
South of England. The new ‘eco-depot’ has replaced the former
distribution centre three miles away, providing an extra 250,000 sq ft
of space, making a total development of 424,000 sq ft, as well as a
whole host of energy saving technologies, including Kingspan
EnergiPanel, the only insulated panel able to generate renewable
energy in the form of solar air heating.
Nigel Hupfield of Chetwoods said “Kingspan EnergiPanel acted as a
cost-effective solution which helped to answer the sustainability
objectives of our client. The panels have the potential to cut running
costs and carbon emissions which is something that we will be
monitoring, and these advantages are enhanced by the competitive
pricing of the panels.”
The Kingspan EnergiPanel in Merlin Grey integrated easily with the
rest of the wall cladding of the depot which comprised Kingspan’s
KS1000 RW Trapezoidal System in Goosewing Grey, Merlin Grey
and Sapphire Blue. All of the panels were supplied in Kingspan’s
XL Forté colour range.
5
Introduction

6
Simple Renewable Energy Solutions 2 –
PowerPanel Systems
Photovoltaic (PV) Modules generate clean, inflation proof electricity,
reduce energy costs and can generate electricity to be fed into the
national grid, thereby allowing the building owner to benefit from
the feed-in tariff system. Even if the sky is overcast, PV are still
proven to produce electricity.
Every kW produced has zero carbon emissions, which significantly
reduces the carbon footprint. It reduces dependency on fossil or
nuclear fuels and helps to meet corporate social responsibility needs.
Such an investment could increase the saleable / rentable value of the
building and would enhance Energy Performance and Display Energy
Certificate ratings.
Kingspan design, manufacture and supply approximately 20 million m2 of insulated roof, wall and façade panels per annum, and work in close
conjunction with leading building investors, owners, developers,
designers and construction teams for the property market.
This capability has enabled us to introduce a range of fully
integrated solar photovoltaic solutions for roofs, walls and façades,
from a single, trusted provider, eliminating multi-sourcing, installation
and building envelope integration risks.
Kingspan PowerPanel Systems consist of three different product
offerings, including polycrystalline silicon modules for roofs and walls
and a thin film solar laminate for roofs. The advantages of these
systems are that there is a single-source integrated roof, wall, façade
Kingspan Optimo and KS1000 ZIP Kingzip Standing Seam were
specified to help meet required standards and strict regulations
during the building of St Thomas Primary School in Swansea.
and solar PV provider. Kingspan offers a full project analysis /
viability, design, supply, installation, testing, commissioning and
handover service and the systems are optimised and value-engineered
for rapid installation, providing maximised investment return and
‘feed-in tariff’ income.
Once installed the systems are virtually maintenance free, and
most importantly they are available with the comprehensive
Kingspan Total Guarantee.
The first Kingspan PowerPanel System project has recently been
commissioned by Sustainable Energy Systems for their new training
facility at Brook House, Great Eccleston. The installation was
completed by the 1st April 2010.
Research by Kingspan indicates that Government support for Building
Integrated Photovoltaic’s (solar panels integrated into building
materials) could deliver 6.4m tonnes of carbon savings by 2025.
Step 3 – Be Efficient
The remaining step is to be efficient with our remaining resources –
where fossil fuels have to make up the shortfall in energy supply this
should be done as cleanly and as sparingly as possible. The first and
most significant effort towards this will have already been made if we
have ensured that our buildings and appliances are constructed to
maximum efficiency; but even more important is the need to continue
educating people to safeguard our resources, to think about energy
security and to be environment savvy.

Kingspan PowerPanel Systems
The only complete system to offer a
comprehensive 25 year Guarantee.
Roof PowerPanel Module – Specific
Kingspan insulated panels with crystalline
module fixed directly to the crowns.
Roof PowerPanel Laminate – A range of
insulated roof panels manufactured with a thin film laminate adhered
directly to the surface.
Wall PowerPanel Module – A crystalline module fully integrated with
the façade of the building
Image courtesy of Romag Ltd
Benefits
Single-source integrated roof, wall, façade and solar PV provider.
PV modules are MCS certified and installed by MCS
approved contractors.
Optimised, value-engineered systems for rapid installation.
Project analysis / viability, design, supply, installation, testing,
commissioning and handover service.
Maximised annual rate of return of 8 – 12% on the initial investment.
Integrates with all Kingspan roof and wall products for
design flexibility.
Systems are maintenance free.
The only feasible renewable technology that guarantees onsite
electricity in an urban environment.
Available with the Kingspan Total Guarantee.
Photovoltaic (PV) Modules
Generates clean, inflation proof electricity – reduces energy costs.
Increases saleable / rentable value of the building.
Meets corporate social responsibility needs.
PV generated electricity eradicates the carbon contribution.
Not dependent on fossil or nuclear fuels.
Installed PV Systems produce zero CO 2 emissions.
Even if the sky is overcast, PV is still proven to produce electricity.
7
Kingspan PowerPanel
Systems

8
How PV Works
Overview
A Photovoltaic Cell (PV) is a semi-conductor device which converts
solar energy into electricity.
There are two main types of PV Cell Technology:
Crystalline PV - Monocrystalline or Polycrystalline
Thin film PV – amorphous Silicon, CIGS, CDTE, Dye Sensitised
or Organic
Modules, Strings & Arrays
Multiple PV Cells are interconnected and encapsulated to
produce a PV Module.
Modules are connected in series to form a string,
(Series connections increase system voltage).
A PV array is made up of modules connected in series and parallel,
(Parallel connections increase the current in the system).
Cell
Module
PV Array in Series Panel
Series String
Inverters
An inverter is used to convert the generated DC electricity from the PV
array to alternating current for use on site or for exporting to the grid.
Stand alone inverters are used for off grid systems.
Grid tie inverters are used when the installation is connected to a
utility supply. The grid tie inverter also synchronises the PV
generator with the grid.
Orientation, Pitch and Shading
For optimal performance of the photovoltaic array it should face
between south-east and south-west, at an elevation of about 30-40°.
However, in the UK even flat roofs receive 90% of the energy of an
optimum pitched system – see AC Output table below.
It is important to ensure that your PV system will not be shaded during
the day. Avoid placing the array where there will be significant shading
from surrounding buildings or trees, since this will decrease the output
from the system.
Although generally installed on a roof, PV systems can be installed
on any south facing elevation it can also be used for solar shading or
as a rain screen on a building wall – this is particularly suitable for
prestige buildings.
AC Outputs in kWh/KWp
Effect of Orientation and Pitch on Array Performance (% of Ideal)
Vert 80 70 60 50 40 30 20 10 Horiz
East 58 65 70 76 80 84 86 88 90 90
SE 69 77 84 89 93 96 96 96 94 90
South 71 80 87 93 97 100 100 98 96 90
SW 67 75 82 87 92 95 96 96 94 90
West 56 63 69 74 78 82 86 87 89 90
Solar Irradiance
Average annual solar radiation
(kWh/m²/day) for Great Britain
and Ireland.
< 850 900 950 1000 1050 1100 1150 1200 1250 1300
< 638 675 713 750 788 825 863 900 938 975
Yearly electricity generated by 1kWpeak with performance ratio 0.75 (kWh/kWpeak). Planning
The majority of buildings will not require planning permission for the
installation of PV systems. If however the building is in a conservation
area or is a listed building you may need to apply for full planning
permission. Kingspan recommend checking with your local council to
ascertain the planning requirement for your specific project / building.

Feed-In Tariffs
The feed-in tariff (FITs) system is a government legislation, designed as
an incentive for domestic and non-domestic property owners to move
away from conventional fossil fuels to renewable energy sources.
The Department of Energy and Climate Change (DECC) has confirmed
that a feed-in tariff for solar installations up to 5 MW will be introduced
from 1st April this year in the UK, with a minimum lifetime of 25 years.
The feed-in tariff, which will be known as the ‘clean energy cash-back
scheme’, rewards households and businesses with a payment for
every kWh of electricity generated by a photovoltaic installation.
The incentive for solar PV is banded dependent on the size of the
system, whether it is retro-fit or new build and if it is building
integrated or standalone.
Examples of Revenue That Can Be Generated
Office
Commercial Building
Distribution Centre
In addition to the tariff for generation, where electricity is exported
back to the Grid users will receive a further payment of 3p per kWh.
The UK government is committed to reducing its carbon emissions
through the adoption of renewable energy sources, particularly in
regards to the generation of power in order to combat climate change.
The Energy Act of November 2008 sets out a series of provisions in
order to help the government meet its targets.
The FITs will incentivise and attract renewable investors, making solar
PV an increasingly cost effective energy providing solution.
The proposed UK tariff levels for photovoltaics (PV) are shown in the
table below. Tariffs will apply for 25 years.
Approx Array Size: 80m 2
PV System Size: 10kWp
Estimated Annual Revenue:
50% Usage on Site 50% Exported to Grid: £3,536 p.a.
100% Usuage on Site: £3,748.50 p.a.
Approx Array Size: 800m 2
PV System Size: 100kWp
Estimated Annual Revenue:
50% Usage on Site 50% Exported to Grid: £31,365 p.a.
100% Usuage on Site: £33,490 p.a.
Approx Array Size: 40000m 2
PV System Size: 5MWp
Estimated Annual Revenue:
50% Usage on Site 50% Exported to Grid: £1,479,000 p.a.
100% Usuage on Site: £1,572,500 p.a.
Assumptions:
Location is London. Orientation is South. Tilt 35˚. Solar irradiance 850kWh/m 2 /yr. Calculations assume £0.03 export tariff and cost of electricity at £0.08 per kW/h.
9
Kingspan PowerPanel
Systems

10
Product Range
Roof PowerPanel Module
Kingspan Roof PowerPanel Module consists of specific Kingspan
insulated roof panels with a frame mounted module. It is suitable for
pitched roof applications on new build or refurbishment projects.
Benefits
Complete roof and PV system with the Kingspan 25 year total
system guarantee.
Structurally designed specifically to facilitate installation onto
specific Kingspan insulated panels.
Integrated bypass diodes to minimise shading effects.
Available in approx 125 to 145Wp output per m2 installed
(Depending on power rating of module).
Quick and easy site connection using ‘push together’ connectors.
Kingspan Roof PowerPanel Modules
can be mounted on:
KS1000 RW Trapezoidal
Kingspan Lo-Pitch
Kingspan Kingzip – KS500 / KS1000
Kingspan Topdek
Kingspan Topspan
Roof PowerPanel Laminate
The Kingspan Roof Laminate systems are a range of insulated roof
panels manufactured with a thin film solar laminate adhered directly to
the surface of the panel to create a singular photovoltaic roof panel.
The systems offer the possibility to install modules over large roof
areas. They are lightweight and flexible, so they can be integrated into
most roof structures, while maintaining the main goal… generate
optimal energy output.
They offer long term high performance, roof integration and
environment friendliness at a competitive price.
Benefits
Quick to connect, lightweight and flexible, so they can be
integrated into most roof structures.
Available in two lengths, 2849mm and 5486mm.
Limited power output warranty: 92% at 10 years,
84% at 20 years, 80% at 25 years (of minimum power).
Integrated bypass diodes to minimise shading effects.
Kingspan Roof PowerPanel Modules
can be mounted on:
Kingspan Lo-Pitch
Kingspan Kingzip – KS500 / KS1000
Kingspan Topdek
Kingspan Topspan

Wall PowerPanel Module
Kingspan Wall PowerPanel Module consists of a PV module, fully
integrated with the building’s facade. It is suitable for most wall
applications on new build or refurbishment projects. Kingspan Wall
PowerPanel Module has 21 enhanced efficiency crystalline silicon cells
in series, with 75 to 80 watts of nominal maximum power.
Benefits
Fully integrates with Kingspan’s insulated wall & façade systems.
Integrated bypass diodes to minimise shading effects.
Structurally bonded aluminium fixing straps for easy installation onto
façade structures.
Available in 100 to 115 Watts per m 2 .
Light aluminium frame for ease of installation, available in
silver or black.
11
Kingspan PowerPanel
Systems

Kingspan Insulated Roof, Wall & Façade Systems
Roof Systems
KS1000/2000
RW Trapezoidal
KS1000 FC
Box Profile
KS1000 SF
Secret Fix
Kingspan
Envirodek ®
Wall & Façade Systems
KS600, 900
& 1000
Optimo
KS600, 900
& 1000 PL
Plank
Kingspan
Thermastone
KS1100 CS
Equi-Bead
KS600, 900
& 1000 MR
Micro-Rib
KS1000 TL
Tramline
Kingspan
WoodTherm ®
KS1000/2000 TS
Slate & Tile
Support
Kingspan
Polycarb
Rooflight
KS600, 900 &
1000 EB
Euro-Box
KS1000 CW
CurveWall
Kingspan
Thermatile
Controlled Environment Systems
KS1100 CS
Mini-Bead
KS1100 CS
Flat
KS500/1000 ZIP
Kingzip ®
Standing Seam
Kingspan
Upstand
Rooflight
KS600, 900 &
1000
FL Flat
KS1000 LV
Louvre
Kingspan
Thermabrick
KS1100 CS
Micro-Rib
KS1000 LP
Lo-Pitch
KS1000 DR/DRC
Trapezoidal
KS600, 900
& 1000 FL-S
Stucco
KS600, 900
& 1000 LS
Longspan
Kingspan
Thermatallic
Kingspan
Modular Box
Kingspan Limited
Kingspan
EnergiPanel
KS1000 TD
Topdek
KS600, 900
& 1000 MM
Mini-Micro
KS1000/2000
RW Trapezoidal
Kingspan
Render Panel
KS1000 CR
Curved Roof
KS1000
Topspan
KS600, 900
& 1000 CX
Convex
KS1000 FC
Box Profile
Kingspan
Wall-Lite
Ancillaries
Gutters, Tophats
& Flashings
UK: Telephone: +44 (0) 1352 716100 Fax: +44 (0) 1352 710161 Email: pv@kingspanpanels.com
Ireland: Telephone: +353 (0) 42 96 98500 Fax: +353 (0) 42 96 98572 Email: sales.ire@kingspanpanels.com
Kingspan
Roof Tile
KS600, 900
& 1000 WV
Wave
Kingspan
EnergiPanel
KS1000 DR
Trapezoidal
Details for the following countries; Australia, Belgium, Czech Republic, France, Germany, Hungary, Netherlands, New Zealand, Norway, Poland, Romania, Singapore, Slovakia & Sweden
can be found by visiting our website www.kingspanpanels.com or our group website www.kingspan.com
Care has been taken to ensure that the contents of this publication are accurate, but Kingspan Limited and its subsidiary companies do not accept responsibility for errors or for information
that is found to be misleading. Suggestions for, or description of, the end use or application of products or methods of working are for information only and Kingspan Limited and its subsidiaries
accept no liability in respect thereof.