Polystyrene EPS Grafit 160 mm — Graphite Insulation Board for Deep Renovation, λ 0.031 W/mK

Genderka EPS 031 Fasada Extra Plus 160 mm is a graphite-enhanced expanded polystyrene insulation board delivering a declared thermal conductivity of λD 0.031 W/mK and thermal resistance of R 5.15 m²K/W — the deep-renovation thickness for projects that exceed standard Part L compliance and target the enhanced fabric performance demanded by PAS 2035 whole-house retrofit, Passive House pre-certification, and local authority decarbonisation programmes. Each board measures 1000 × 500 mm and is supplied in packs of 3 boards covering 1.5 m², keeping individual pack dimensions manageable even at this substantial board depth. Browse the full selection of graphite EPS insulation boards to match every zone of your façade build-up to the right thickness.

Certified to EN 13163:2012+A1:2015 with the classification string T1-L2-W2-Sb2-P5-BS100-DS(N)2-DS(70,-)2-TR100, this board shares the same graphite bead technology and mechanical properties as every variant in the Genderka EPS 031 Fasada Extra Plus family. At 160 mm the board delivers wall-assembly U-values of approximately 0.17–0.19 W/m²K on standard 215 mm solid brick — well below the 0.26 W/m²K new-build elemental target in Approved Document L and firmly within the territory required by the Future Homes Standard 2026. The additional 10 mm over the 150 mm variant provides a meaningful thermal gain for projects where every fraction of a U-value point contributes to SAP rating headroom or Passive House energy-balance calculations.

Key Benefits and Performance Advantages

Enhanced Performance Beyond Standard Compliance

• R 5.15 m²K/W — Beyond Part L Into Deep-Renovation Territory: On a typical 215 mm solid brick wall, 160 mm of graphite EPS brings the assembly U-value to approximately 0.17–0.19 W/m²K. This exceeds the Approved Document L new-build elemental target of 0.26 W/m²K by over 30 % and positions the wall element for Passive House fabric targets where the overall building envelope typically needs to achieve ≤ 0.15 W/m²K.
• Graphite-Enhanced λ 0.031 W/mK: Integrated graphite particles reflect infrared radiation within each cell, delivering approximately 20 % better insulation than standard white EPS of the same thickness. A 160 mm graphite board matches the thermal performance of roughly 200 mm of white EPS, saving 40 mm of build-up depth on every square metre of wall — a significant advantage on deep-renovation projects where total façade projection affects planning and architectural proportions.

Purpose-Built for Whole-House and Near-Zero Retrofit

• PAS 2035 Deep Renovation Pathway: The 160 mm thickness supports the medium-term and long-term improvement plans required under PAS 2035 whole-house retrofit assessments, providing the wall-element thermal resistance needed to move a dwelling towards EPC band A when combined with coordinated loft, floor, and glazing upgrades.
• Near-Zero and Passive House Projects: Projects pursuing Passive House pre-certification or the near-zero energy standard benefit from the substantial R-value that 160 mm delivers, reducing the heating demand contribution from external walls to the lowest practical level achievable with graphite EPS before stepping up to 180 mm or 200 mm thicknesses.

Rigid and Self-Supporting at Depth

• Bending Strength BS100 (≥ 100 kPa): Each board maintains its shape during handling and positioning at scaffold height. At 160 mm the board is rigid and self-supporting, resisting flex when carried flat or leant against the wall face between adhesive application and mechanical fixing.
• Tensile Strength TR100 (≥ 100 kPa): Adhesive bonds securely to the graphite-EPS surface, and the board's tensile integrity ensures that the long mechanical fixing shanks required at this depth transfer wind loads evenly without localised pull-through around the fixing head.

Compact Packs for Controlled Site Logistics

• 3 Boards per Pack (1.5 m²): Despite the 160 mm depth, each pack remains physically manageable for two-person lift onto scaffold platforms. At 15 kg/m³ density each board weighs approximately 1.2 kg, keeping single-handed positioning straightforward once packs are broken down at working height.

Same System, Longer Plug

• Compatible With All Standard EWI Adhesives and Finishes: Bond this board using cement-based or polyurethane foam adhesives from the EPS adhesives and basecoats range, then complete with basecoat, mesh, and render following the same build-up sequence as thinner primary insulation thicknesses. The installation method is identical to the rest of the range — only the fixing plug length changes to accommodate the deeper board profile.

Technical Specifications

Physical Properties

Property	Value
Manufacturer	Genderka Sp. z o.o.
Product Range	EPS 031 Fasada Extra Plus
Thickness	160 mm
Board Dimensions	1000 mm × 500 mm
Coverage per Board	0.50 m²
Boards per Pack	3
Pack Coverage	1.5 m²
Density	15 kg/m³
Colour	Steel grey (graphite)
Compressive Strength (CS)	≥ 70 kPa
Bending Strength (BS)	≥ 100 kPa (BS100)
Tensile Strength (TR)	≥ 100 kPa (TR100)
Dimensional Stability — Normal	± 0.2 % (DS(N)2)
Dimensional Stability — 70 °C	≤ 2 % (DS(70,-)2)
Reaction to Fire	Class E (EN 13501-1)
Standard	EN 13163:2012+A1:2015

Thermal Performance

Property	Value
Declared Thermal Conductivity (λD)	0.031 W/mK
Thermal Resistance (RD) at 160 mm	5.15 m²K/W
Classification String	EPS EN 13163 T1-L2-W2-Sb2-P5-BS100-DS(N)2-DS(70,-)2-TR100

Best Use Scenarios

Ideal Applications

• PAS 2035 Whole-House Deep Renovation: The primary use case for this thickness. Properties undergoing a coordinated whole-house retrofit to EPC band A benefit from the R 5.15 m²K/W that 160 mm provides, contributing the wall-element thermal performance needed to meet the enhanced fabric targets set by retrofit coordinators within medium-term and long-term improvement plans.
• Passive House and Near-Zero Energy Builds: The 160 mm board is a strong specification for projects pursuing Passive House pre-certification or near-zero energy performance, delivering wall U-values of 0.17–0.19 W/m²K that contribute meaningfully towards the overall ≤ 0.15 W/m²K building-envelope target when combined with thermally broken fixings and optimised junction detailing.
• New-Build Fabric-First Design With Future-Proofing: Architects and developers specifying beyond the current Part L minimum benefit from the compliance headroom that 160 mm provides. The resulting U-value sits well below both the current new-build threshold and the tighter targets anticipated under the Future Homes Standard, protecting the building specification against regulatory tightening during the design-to-completion timeline.
• Social Housing Decarbonisation Fund Projects: Local authority and housing association programmes targeting maximum fabric improvement under the Social Housing Decarbonisation Fund benefit from the 160 mm board's substantial R-value, supporting the ambitious EPC band C-to-A upgrade pathways required by many funding criteria.

When an Alternative Fits Better

• Standard Part L Compliance or Budget-Driven Retrofit: Where the specification calls for Part L retrofit or new-build compliance without exceeding the minimum, the 150 mm Grafit board at R 4.80 m²K/W delivers U-values of 0.18–0.21 W/m²K on standard masonry — comfortably exceeding both targets at a reduced material cost and slimmer 150 mm profile.
• Maximum Insulation Depth for Passive House Fabric: For projects where the energy-balance calculation demands every additional millimetre of insulation, the 180 mm Grafit board at R 5.80 m²K/W provides the next step towards the lowest achievable wall U-values within the Genderka EPS 031 range before moving to the 200 mm maximum thickness.
• High-Rise or Non-Combustible Requirements: Where Euroclass A1 fire rating is mandated, the mineral wool insulation range provides non-combustible slabs compliant with Building Safety Act façade requirements for buildings above 18 metres.

System Integration

The 160 mm graphite EPS board forms the thermal core of an enhanced-performance EWI build-up on deep-renovation, near-zero, and Passive House projects. Apply adhesive from the adhesives and basecoats collection to the back face using the circumferential-and-spot method — aim for a minimum 40 % contact area between the adhesive and the substrate to satisfy wind-load design requirements under BS EN 1991-1-4. At 160 mm board depth, consistent adhesive application across the full board face is essential: maintain a continuous perimeter bead at least 30 mm wide and three central spots each at least 100 mm in diameter to prevent voids that could allow board deflection under negative wind pressure.

After a minimum of 24 hours' adhesive curing, secure each board with 6–8 mechanical fixings per m² from the fixing accessories range. The matching plug for this thickness is the LTX 200 mm polystyrene fixing plug, which provides the correct embedment depth into standard masonry substrates for a 160 mm board with adhesive layer. Once fixed, rasp or sand the outer face to create an adhesion key, then apply the reinforcing basecoat with embedded Atlas 150 g/m² fibreglass mesh for long-term crack resistance. The complete layer-by-layer build-up sequence — from substrate preparation through to the decorative render finish — is detailed in the EWI system build-up layers guide.

Comparison Table — Genderka EPS Grafit Range

Property	150 mm Grafit	160 mm Grafit (This Board)	180 mm Grafit
Thickness	150 mm	160 mm	180 mm
λD	0.031 W/mK	0.031 W/mK	0.031 W/mK
RD	4.80 m²K/W	5.15 m²K/W	5.80 m²K/W
Approx. Wall U-Value (215 mm solid brick)	0.18–0.21 W/m²K	0.17–0.19 W/m²K	0.15–0.17 W/m²K
Pack Coverage	2.0 m²	1.5 m²	1.5 m²
Boards per Pack	4	3	3
Typical Use	Part L 2025 / Future Homes pathway	Deep renovation	Part L compliance / near-Passive

UK Climate Performance Context

On a typical UK property with 215 mm solid brick walls (original U-value around 2.1 W/m²K), adding 160 mm of graphite EPS with λ 0.031 W/mK reduces the wall U-value to approximately 0.17–0.19 W/m²K — a reduction of over 91 % in heat flow through the wall. For a three-bedroom semi-detached home with roughly 80 m² of exposed wall area, this translates to an estimated annual heating energy saving of 7,000–8,500 kWh compared with the un-insulated baseline, depending on heating system efficiency and exposure zone. In SAP calculations, this level of wall insulation — when combined with insulated reveals, soffits, lintels, and a well-detailed base-track junction — can shift a property from EPC band D or E into band B or upper B, meeting the most ambitious decarbonisation targets set by local authorities, housing associations, and the Social Housing Decarbonisation Fund. The additional 10 mm over the 150 mm variant adds approximately 0.35 m²K/W of thermal resistance, which can contribute 1–2 extra SAP points — a margin that proves decisive in energy models where the building is borderline between EPC bands.

Trade Insight: Handling and Storage

At 160 mm the boards are the thickest that most installers encounter on routine deep-renovation projects. The boards are rigid and self-supporting — solid enough to stand upright against the wall face without bowing — but noticeably bulkier than the 80–100 mm retrofit thicknesses that make up the majority of domestic EWI work. Store packs flat on a level surface under opaque sheeting; the steel-grey graphite surface absorbs solar radiation quickly, and at this thickness the outer face can reach high temperatures in direct sunlight, softening the bead structure faster than thinner variants. When cutting boards to size, a long-blade hot-wire cutter is the fastest and cleanest option; a fine-tooth handsaw works but generates considerable EPS dust at 160 mm depth, so wear a dust mask and cut in a well-ventilated area. For best adhesive bond at this depth, rasp the bonding face lightly before application and apply adhesive immediately after rasping — the fresh surface provides the strongest mechanical key. One practical approach for deep-renovation projects with large wall areas: pre-stage full packs on each scaffold lift in fixing sequence before the adhesive operation begins. At 160 mm, boards take up significant platform space, so having packs positioned and ready to break open minimises repositioning at height and keeps the working area clear for adhesive and fixing tools.

Certifications and Compliance

• EN 13163:2012+A1:2015: Harmonised European standard for factory-made expanded polystyrene products used in buildings, covering declared thermal conductivity, dimensional tolerances, and mechanical strength properties.
• Reaction to Fire — Euroclass E: Suitable for use within EWI systems on buildings up to 18 m in height when combined with approved fire-barrier detailing at each floor level, in accordance with Approved Document B and Building Safety Act guidance.
• CE Marking and DoP: Each production batch carries a Declaration of Performance referencing the specific Genderka factory of origin (Bydgoszcz, Ostrów Mazowiecka, Oświęcim, Brzeziny, or Wschowa), supporting full traceability for Building Control inspections.
• Deep-Renovation and Passive House Contribution: At R 5.15 m²K/W, the 160 mm board forms part of a wall assembly that substantially exceeds current Approved Document L targets (0.30 W/m²K retrofit, 0.26 W/m²K new-build) and aligns with the enhanced fabric performance required by PAS 2035 whole-house retrofit assessments and Passive House pre-certification energy-balance calculations.

Technical Disclaimer

All thermal values stated are declared (λD, RD) per EN 13163 and manufacturer technical data sheet (Genderka karta techniczna nr W31FEP, July 2024). Actual installed U-values depend on wall construction, adhesive coverage, fixing thermal bridging, and the complete EWI system build-up. Always verify system-level U-value calculations with a competent energy assessor or building control body before specifying. Specifications are subject to manufacturer update; confirm current data at point of order.

Summary

The Genderka EPS Grafit 160 mm board delivers λ 0.031 W/mK and R 5.15 m²K/W — the deep-renovation thickness that brings typical UK masonry walls to approximately 0.17–0.19 W/m²K, substantially exceeding both current retrofit and new-build U-value targets. Each pack of 3 boards covers 1.5 m², sized for efficient ordering on deep-renovation and near-zero energy programmes. Where standard Part L compliance with comfortable headroom is sufficient, the 150 mm Grafit board delivers R 4.80 m²K/W within a marginally slimmer profile. For projects demanding the maximum insulation depth short of 200 mm, the 180 mm Grafit board steps up to R 5.80 m²K/W — approaching the Passive House fabric threshold on standard masonry constructions.

Frequently Asked Questions

How many 160 mm boards are in a pack, and how many packs do I need for a typical deep-renovation project?

Each pack contains 3 boards covering 1.5 m². A three-bedroom semi-detached property with approximately 80 m² of exposed wall area (after deducting windows and doors) requires roughly 55–60 packs, including 5–10 % for cutting waste around reveals, soffits, and service penetrations. For larger detached properties or multi-unit programmes, order quantities scale proportionally against the measured survey — early engagement with the Renders World team helps coordinate bulk delivery scheduling for deep-renovation timelines.

What is the environmental benefit of specifying 160 mm of graphite EPS on a deep renovation?

Graphite EPS is fully recyclable through specialist polystyrene recovery programmes, and off-cuts generated on site can be returned for granulation and re-expansion into new products. The primary environmental benefit is operational: achieving a wall U-value of 0.17–0.19 W/m²K cuts annual heating energy demand by an estimated 7,000–8,500 kWh on a typical semi-detached property compared with the un-insulated baseline. Over a 30-year design life, this translates to a substantial cumulative CO₂ reduction — with the embodied energy of manufacture typically paid back within the first one to two heating seasons at this insulation depth.

Is 160 mm of graphite EPS sufficient for Passive House wall U-value targets?

Passive House certification typically requires an overall building-envelope performance of ≤ 0.15 W/m²K, though individual wall elements may exceed this if compensated elsewhere in the fabric. On a standard 215 mm solid brick wall, 160 mm of graphite EPS delivers approximately 0.17–0.19 W/m²K — approaching but not quite reaching the 0.15 W/m²K threshold on the wall element alone. For projects where the wall element needs to meet 0.15 W/m²K independently, stepping up to 180 mm or 200 mm provides the additional resistance, while 160 mm performs well within a Passive House energy-balance model where the wall U-value is offset by high-performance glazing, airtightness, and mechanical ventilation with heat recovery.

What fixing plug length pairs with the 160 mm board on standard masonry?

The LTX 200 mm polystyrene fixing plug is the correct match for a 160 mm board on standard masonry substrates, providing approximately 30–40 mm of embedment beyond the board thickness and adhesive layer. Install 6–8 fixings per m² in the pattern recommended for the project's wind-load zone. At this board depth, accurate drilling depth is a step worth getting right — use a depth stop on the drill and verify embedment on the first few fixings before proceeding across the full elevation.