What is the manufacturing process of Rockwool? | FUNAS Guide

What is the Manufacturing Process of Rockwool?

This article provides a clear, step-by-step overview of the manufacturing process of Rockwool, a cornerstone material for thermal insulation experts. Understanding how Rockwool is produced answers common technical questions and enhances product knowledge. Keywords: Rockwool manufacturing process, thermal insulation materials.

Overview: Rockwool as a Thermal Insulation Material

- Definition: Rockwool, also known as stone wool, is an inorganic product made from volcanic rocks.

- Key Properties: Exceptional thermal, acoustic, and fire resistance.

- Applications: Used widely in building envelopes, high-temperature systems, and industrial processes for insulation.

H2 How Is Rockwool Manufactured?

H3 Primary Raw Materials

- Basalt, diabase, and other natural rocks: Principal ingredients.

- Recycling: Incorporation of recycled stone wool and slag to optimize resources.

H3 Melting Process

- Temperature: Rocks heated to ~1,500°C (2,732°F) in a furnace.

- Equipment: Typically, a cupola furnace using coke as fuel.

- Molten State: Raw materials liquefy and homogenize.

H3 Fiber Formation

- Centrifugal Spinning: Molten rock is spun at high velocity via spinning wheels or a spinning chamber.

- Fiberizing: Rapid cooling forms fine, intertwining mineral fibers.

H3 Binder Application

- Resin Addition: Droplets of phenol-formaldehyde or bio-based resins are applied to bind fibers.

- Purpose: Enhances structural integrity and water repellency.

H3 Collection and Mat Formation

- Fiber Collection: Fibers are blown onto conveyor belts, forming a mat.

- Thickness Control: Layers are pressed and cut according to product specification.

H3 Curing and Finishing

- Curing Oven: Mats pass through an oven at 200–250°C, polymerizing the binder.

- Shaping and Cutting: Mats are further processed into boards, rolls, or customized products.

- Surface Treatments: Optional facings or coatings may be applied for specific applications.

H2 Quality Control and Industry Standards

- Compliance: Rockwool is produced to meet or exceed EN 13162, ASTM C612, and other global standards.

- Testing: Rigorous checks for density, compressive strength, thermal conductivity, and fire performance.

- Certifications: Many manufacturers attain ISO 9001 and CE marking for product quality assurance.

H2 Key Performance Advantages of Rockwool

- Superior Thermal Performance: Low thermal conductivity (~0.035-0.045 W/m·K).

- Fire Resilience: Non-combustibility with melting point above 1,000°C (EN 13501-1 Euroclass A1).

- Acoustic Control: High sound absorption coefficients.

- Sustainability: Up to 50% of input material from recycled content, with long service life.

H2 References

: European Insulation Manufacturers Association (EURIMA), Stone Wool Production, 2023.

: International Association for Testing Materials (ASTM), C612-14: Rock and Slag Wool Standards.

: Rockwool Group Sustainability Report, 2023.

For further technical details on the Rockwool manufacturing process or to discuss tailored insulation materials, our FUNAS thermal insulation expertise team is available to assist you.