This process has often been likened to a cotton candy machine spinning melted sugar into the fine, fluffy substance sold to kids at carnivals.Ī binding solution made from oils and resins holds these strands of rock fiber together and acts as an effective water repellant. This liquified basalt rock is then poured into a special spinning machine and spun into long, thin strands of Rockwool. Mineral wool manufacturers typically use a cupola furnace, but other gas or electric furnaces can also be used, including chamber, cyclone, and shaft furnaces. The entire operation is fueled by coke, a type of distilled coal. Soon, scientists found a way to replicate this natural process in factories to produce mineral wool for insulation.īatts of mineral wool are typically tucked between a framed wall’s studs to maximize thermal and acoustic insulation.īasalt rock, steel slag, dolomite, oil, and various resins are used during the manufacturing process. This insulating material was first invented more than 150 years ago when an erupting volcano made onlookers realize that strong winds could whip volcanic lava into wooly tufts. The mineral wool manufacturing process is unique and exciting. The Manufacturing Process of Mineral Wool This enhanced thermal performance can be attributed mainly to the unique manufacturing process of mineral wool insulation. Loose-fill Rockwool is not far behind, offering an R-value of 3.0 to 3.3 per inch of thickness. On the other hand, the batts made for 2×6 stud walls have an R-value of 23, which is significantly higher than the R-values of comparable insulation materials like fiberglass.Ĭlick here to learn more about the R-value of Rockwool insulation. For example, rockwool batts made for traditional 2×4 walls have an average R-value of 15 or higher. The thermal performance of mineral wool is quite impressive. The type of mineral wool insulation that is right for you will depend on the specific application, your budget, the kind of house you have, among other factors. Mineral wool generally comes in two forms-loose-fill and batt insulation. Mineral wool is also sometimes used to insulate the attic, although this application is rarer than the others. It can be used to insulate every part of a home, including the roof, walls, and floors. This insulation material is also very versatile. In addition, the minuscule waste generated during the manufacturing process of mineral wool has earned it an “A” rating from the BRE Group’s Green Guide to Specification. Hence, all the materials used to manufacture Rockwool insulation are eco-friendly and sustainable. Igneous or volcanic rocks form more than 15 percent of the planet’s entire land surface. As you probably know, rocks and stones are natural resources that are almost inexhaustible in quantity. Volcanic rocks are the other component of mineral wool. It makes excellent use of industrial waste that wouldn’t otherwise have been used for anything productive. The manufacturing process of mineral wool turns this waste material into effective and high-performing insulation. Typically, this waste material is sent off to landfills to clog the earth’s surface for centuries to come. Thousands of tons worth of slag is produced every year by the iron ore and steel industries. Hence, mineral wool is made almost entirely from raw materials that are recyclable, natural, and renewable. It also contains some recycled materials such as steel slag and iron-ore waste. Mineral wool insulation is typically made from volcanic rocks such as basalt, dolomite, or diabase. The Manufacturing Process of Mineral Wool.
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