The Challenges of Insulating Old Buildings
The energy efficiency of old buildings is a hot topic nowadays. Unlike new buildings which are designed and built with adequate insulation in mind, the retrofit insulation of old and listed buildings – especially the ones with solid walls – poses significant challenges, as the materials used in this regard must satisfy multiple (often conflicting) requirements:
- Resist moisture: due to their construction, old walls are often affected by multiple moisture sources. Wind driven rain can easily saturate external walls. Temperature differences can be an ongoing source of condensation on external walls. Moreover, the base of old walls is often subject to rising damp resulting in ongoing moisture and salt damage.
- Breathable: in order to prevent the build-up of moisture behind the thermal insulation (which can seriously damage the building fabric long-term), the insulation MUST be breathable so the humidity can evaporate.Â
- Traditional look and feel: wherever possible, the use of traditional, building-friendly materials is recommended.
The vast majority of insulating solutions on the marketplace, however, have been developed for newer buildings. They offer good thermal insulation, but modern materials – foam, plastic, metal foil, cement etc. – are non breathable, they trap moisture which can lead to future dampness problems.
Due to increasing energy costs, government pressure as well as the need for greater comfort, breathability is often sacrificed, leading to severe dampness problems in old building years or decades later.
Using breathable insulation materials in old buildings, such as lime thermal insulation, is very important for the long-term health and the integrity of the building fabric.Â
Lime Thermal Insulation Plasters
Lime thermal plasters represent an attractive alternative not only to modern insulations, but also to wood fibre or solid insulation systems because they are:
- Breathable
- Traditionally looking
- Space savings: decorative plaster and thermal insulation in one, saving spaceÂ
- Eliminate thermal bridging and thermal leaks if applied in a continuous coatÂ
- Being flexible, they can be used to insulate difficult-to-insulate areas such as window sills Â
- Can be highly resistant to moisture (depending on composition)
- Have a high fire rating: being non-combustible they have very good (Class 'A') fire ratings in comparison to much more combustible foam and fibre insulations (Class 'D/E' fire rating).
- A much healthier option to many other alternatives
Good quality lime thermal plasters, if applied correctly, can last for many years.
The most common threat to their integrity, what can damage them over time, or shorten their life span significantly, or decrease their thermal performance is moisture - especially in the presence of salts. Here is why.
The Problem of Salts
Contrary to common belief it's not moisture that damages the wall fabric or the plastering. It's the salts. High moisture content alone does not damage old buildings. Salts do.
Although water can cause damages to lime plasters through flooding, longstanding water ingress or frost, in the vast majority of cases, clean rainwater evaporates without a trace without causing any damages. Thus, dampness caused by clean fresh water is fully reversible.
The real problem, however, is when dampness is combined with minerals or salts. In the presence of salts everything changes. Salts are hard, solid minerals that in the presence of water temporarily go liquid. However, when humidity evaporates the salts re-crystallize and expand in volume 5-10 times. The crystallization or mechanical expansion of salt crystals is what makes old masonries or plasters crumble, salts being responsible for far more damages than water ingress and frost. This is a very important technical point that needs to be understood.
On real buildings the effect of salts can be very difficult to assess, as dissolved salts become invisible to the eye and touch, only dampness being obviously present. However, under controlled laboratory conditions the effect of salts can be easily demonstrated, measured and understood.
Here is a lab experiment: when two identical bricks - one salty, the other one not - have been subjected to high air humidity variations for an extended period of time, the salty brick has crumbled badly while the non-salty brick stayed completely intact in a high humidity environment.
So salts are the real problem, however it's water that carries them everywhere, contributing to their damaging effects.
Addressing the Problem of Masonry Salts
Dealing with high humidity and the destructive effect of salts requires special lime plasters. These are ancient plaster mixes initially used by the Phoenicians and Greeks, then rediscovered and perfected by the Romans throughout the centuries. Being outstanding architects and builders, the Romans have observed that adding to lime certain volcanic sands and ashes (also known as natural pozzolans - highly porous and breathable lava materials), these can significantly alter the properties of lime while retaining its breathability.
Through the skilful use of different types of volcanic sands and ashes, the Romans have created many types of lime mortars with outstanding properties - some of them becoming waterproof or able to set underwater, or becoming highly resistant to salts resisting seawater.
These volcanic lime mortars have been extensively used by the Romans in very demanding environments including sewers, ports, spas and aqueducts and they have survived for many centuries. They have also been widely used in Venice, as they perform extremely well in the humid and aggressive environment of the Venetian lagoon.
Traditional pozzolanic Roman mortars differ significantly from today’s modern NHL (Natural hydraulic lime) mortars.
NHL mortars - a mix of lime and clay - need to be fired at higher temperatures than normal (air) limes for the lime and clay to react. The higher firing temperatures and more heat partially closes off the pores of NHL plasters, reducing their breathability. Thus, NHL plasters trade-off breathability for improved water resistance.
Roman mortars use lime and volcanic materials. These are mixed at room temperature without heat as the volcanic sands and ashes have already been pre-burnt by the volcano. This keeps the pores structure open resulting in high breathability. The volcanic ingredients make the plaster highly resistant to dampness and salts, making these Roman mortars perform extremely well in damp and salty environments.
The commercially available material today is the Rinzaffo MGN lime plaster. It comes in 25 kg bags with all necessary ingredients pre-mixed, requiring only water. Once it hardens it becomes waterproof, extremely resistant to all salts (chlorides, nitrates, sulphates), yet thanks to its porous volcanic lava ingredients, it stays breathable allowing the wall fabric to breathe.
This plaster - depending on where it's used - performs several important functions:
- Liquid moisture barrier: as a result of its special pore structure, this plaster acts as a selective moisture barrier, stopping liquid water while allowing the passage of vapours.
- Salt barrier: this plaster acts a salt barrier, protecting subsequent lime coats from premature decay caused by dampness and salts. As a result the longevity of lime plastering increases by about 10 times.
- Consolidates the frail, crumbly masonry, providing a solid, dry, breathable surface to build on.Â
- Internal humidity regulator: by stopping liquid water it regulates the internal humidity, creating a drier, healthier, warmer, more comfortable climate.
- Improves the performance of thermal insulation by keeping any thermal plaster applied on it dry. A dry insulation performs thermally much better than a moist or damp insulation.
This lime plaster is made exclusively of natural materials. It contains no chemicals nor additives. All prime materials as well as the final product is certified.
Thus, the Rinzaffo MGN plaster is a lime plaster that acts as breathable water and salt filter. Due to its small pores it blocks liquid water. Due to its open pore structure allows the wall fabric to breathe. Having no salt content of its own, it does not introduce salts into the masonry. Being waterproof, it becomes impervious to salt penetration and crystallization, resulting in an extremely long service life even in very demanding and damp environments (e.g. basements).
An Improved, Longer-Lasting Thermal Insulation
Our thermal plasters can be applied directly onto any wall surface - brick, stone or concrete; old or new; dry or damp. However, to achieve best performance of the thermal insulation and maximum longevity, the use of the Rinzaffo MGN Roman salt-resistant base coat under the thermal plaster is highly recommended.
Omitting the Roman base coat will not make a difference short-term, but it will make a significant difference long-term. Lime being a porous material, it will take years for the crystallizing salts to fill up its pores, reaching a critical volume that starts causing damages. But given enough salt migration from the underlying masonry into the plaster, salts will eventually make the plastering fail. Using the Roman base coat, which completely blocks the migration of salts into the thermal plaster, will make any lime plastering last significantly longer - typically 5-10 times longer than without it.
The use of the Rinzaffo MGN Roman base coat is a simple, tried-and-tested, traditional, building-friendly solution to mitigate future problems, and ensures a top performance of the thermal insulation or any lime plastering.
So, the improved lime thermal insulation plastering schedule, that "ticks all boxes" - breathability, water and salt resistance, moisture control, improved thermal performance, long life expectancy - consists of the application of the following plaster coats:
- Base coat: the Rinzaffo MGN Roman salt-resistant base coat
- Thermal insulation coat(s): in one or several coats, depending on desired thermal performance (e.g. U-value)Â
- Finishing coat: a protective-decorative lime finish
This concept is very similar to the existing lime renovation concept, except it extends that by adding the Roman waterproof, salt-resistant base coat to the plastering schedule. This Roman coat does the "heavy lifting" in the background, protecting the other lime coats (the main and finishing coats) from premature decay from the combined effect of humidity and salts. Being a heritage-friendly material, it is extensively used in one of the most historic cities of the world - Venice - a World Heritage Site.Â
The renovation concept is detailed below.
Thermal Plaster Choices - Differences
We have several thermal plasters for different applications, including special applications. Although there is an overlap between these materials, there are also key differences between them.
Termointonaco 2020 MGN
This is an air-lime based, high-performance, medium granulation light thermal plaster, which can be built up in 20 mm passes to significant thicknesses if required. 100-160 mm thick thermal coats can be created if needed, however the common application thickness is about 20 - 60 mm.Â
Termorasante Aerogel MGN
This is an air-lime based aerogel-lime thermal plaster, classed as a super-insulating lime plaster. It has outstanding thermal performance, which is further improved by its excellent heat reflectance, reflecting the heat back into the room. It is a fine granulation plaster which can be applied up to about 30 mm thickness. Due to its outstanding thermal value, it can be used for the thermal insulation of difficult-to-insulate areas such as window reveals.Â
It is often combined with the Termointonaco 2020 MGN plaster. Although the Aerogel plaster offers a better thermal performance, depending on your application and target U-values, the mechanical properties and build-up of these materials also must be taken into consideration.
Coccioterm MGN
This is another air-lime based thermal plaster, a mix of air lime, natural perlite and traditional Roman cocciopesto (brick powder). The porosity of the lime and of the crushed terracotta give the product a high vapor permeability and an exceptional ability to regulate humidity. As a result it performs very well is high-humidity environments, such as basements or cellars.
As thermal lime plasters are light and soft, they require a protective-decorative finish. Although a common lime putty plaster can be applied for this purpose, we have dedicated, highly-breathable lime finishes that perform better and offer a better mechanical protection to the thermal plasters than regular putty plasters. Â
For more information, please see below a list of recommended MGN lime plasters for the implementation of this solution, as well as technical pages, projects, image galleries and videos related to this solution and materials.