INSTALL INSTRUCTIONS GreenStuf® Thermal Soffit Liner

ASL THERMAL SOFFIT LINER

Installation Instructions

GreenStuf® Thermal Soffit Liner is engineered to improve the thermal performance and energy efficiency of the building envelope and assist in the control of reverberant noise. Thermal Soffit Liner is intended for direct-fixing to masonry soffit and ceiling constructions, including composite steel floor systems. These instructions are general and designed to assist suitably experienced tradesmen in achieving a high standard of installation in typical use situations. For further support, contact your GreenStuf account manager before starting.

Manufacturer's Documents

GreenStuf recommends installers have full knowledge of product and installation procedures from the most recent manufacturer's documents. Relevant documents include:

Thermal Soffit Liner Datasheet
GreenStuf Manufacturer's Guarantee
Thermal Soffit Liner Install Instructions
Insulation and Downlights Facts Sheet

Copies are available on request or from the GreenStuf website.

AS/NZS 4859.1 Labelling Compliance

Thermal Soffit Liner complies with AS/NZS 4859.1 labelling requirements. Initial performance may be reduced if stored compressed for too long; the product will recover its nominal thickness and R-Value within 72 hours after installation. The total R-Value of the building system depends on materials, design, and installation.

Other Trades

Consult with HVAC, plumbing, and electrical trades prior to installation to establish an optimal order of works.

Transportation, Storage & Handling

Handle Thermal Soffit Liner with care. Transport and store on a flat, clean, dry surface. Avoid abrasion, delamination, distortion, and crushing of edges. Avoid harsh rubbing or bending panels, and do not drop panels on corners. Keep the work area clean and free from dirt and contaminants. Do not accept damaged product; note any damage on freight documents and contact GreenStuf immediately. Goods signed for as 'good condition' are not GreenStuf's responsibility.

Inspection

Before installation, verify materials are as ordered and free from damage or faults. Ensure all product is from a single batch to avoid colour variation. Report any variations to GreenStuf before commencing installation. Claims will not be accepted for jobs proceeding with obvious faults without prior consultation. Cutting or installing the product signifies acceptance of its quality.

Safety Instructions

GreenStuf 100% polyester insulation is safe and user-friendly, requiring no protective clothing or specialist equipment. It is non-irritant, non-toxic, and non-allergenic, preventing skin, throat, or lung irritation.

CAUTION: Electric cables and equipment partially or completely surrounded by bulk thermal insulation may overheat and fail. Ensure this risk is avoided by following guidance in AS/NZS 3000:2018 Wiring Rules. Understand your responsibility before installation.

Lights and Electrical Appliances

High temperatures from some lighting (especially halogen bulbs) can pose a fire risk and may require clear ventilation space. Careful selection and correct installation of light fittings/appliances and surrounding insulation are critical. Check manufacturer requirements for minimum clearances to bulk insulation. Appliances, including recessed lights and transformers, should not be covered unless permitted by the manufacturer. If in doubt, leave a clear 50mm space between the fitting/appliance and insulation. Consult a registered electrician for guidance.

Product Format

Thermal Soffit Liner is supplied in standard 1200mm (+5/-0mm) x 2400mm (+10/-0mm) sheets in Flint (light grey) colour. Custom sizes and colours may be available on request, subject to minimum order quantities. The non-woven nature means some colour blending variation is typical batch-to-batch and throughout production lots; this is an inherent feature and not a manufacturing fault.

Insulation Fasteners

Install using mechanical fixings such as shot-fired insulation anchors (e.g., Hilti) or insulation pin style anchors with a washer/dome. Fastener length must match the insulation panel thickness to prevent compression and pillowing. Use fixings according to manufacturer's technical information and instructions.

Adhesives

In certain applications, Thermal Soffit Liner can be direct-fixed using adhesives. GreenStuf recommends contact-type or full curing panel adhesive for most common substrates. Contact your adhesive supplier with product samples and substrate specifications before commencing work. The installer is responsible for ensuring adhesive and substrate suitability. Contact your GreenStuf account manager for adhesive supplier information.

Installation Tools

A typical installation requires:

Appropriate access equipment for safe working conditions.
Measuring and marking out tools.
Insulation fastening system (anchors and equipment).
Pointed SDS chisel bit and battery drill, or appropriate hot-knife for anchor penetrations.
Cutting board, straight edge, and insulation knife/saw/cutter for trimming.
Knife and/or scissors for cutting and fitting foil tape (if required).

Insulation Anchor Penetrations

When using shot-fired insulation anchors, create penetrations for each anchor point before installing each sheet to ensure good anchor take and a tight, neat install. Penetrations can be formed using a hot-knife, insulation knife, or a pointed chisel drill bit. When using a drill, engage the clutch to minimize twist-up risk if the bit binds. Bring the drill to full speed before cutting and use light pressure.

Cutting Thermal Soffit Liner

Mechanical cutters like a straight knife cutting machine are ideal for cutting and trimming. Insulation knives and saws can also be used. Heavy-duty snap-off blade knives are useful for service holes. All cutting tools must be sharp for an easy, neat cut. Always cut slightly oversize for a tight friction fit. Follow manufacturer's use and safety instructions for all tools.

Clearances

Cut Thermal Soffit Liner to fit neatly around fire collars, pipes, and penetrations. Do not cover fire collars, as they must remain exposed to activate in a fire situation. Leave specified clearances for light fittings, ancillary equipment, and electrical accessories.

Diagram Description (Fig 1): Illustrates fixing points on a panel. Fixings should be set at no more than 600mm centres. Each fixing must be a minimum of 100mm and a maximum of 200mm from the edge of each panel. Approximately 11 fixings are recommended per standard panel.

Installation

Install GreenStuf® ASL according to these instructions and project specifications. Seek clarification if conflicting information arises. Plan installation before cutting. Recommended practice: "measure twice and cut once".

Thermal Soffit Liner is generally fixed with insulation fasteners. Fixings should be set out at no more than 600mm centres, with each fixing a minimum of 100mm and a maximum of 200mm from the panel edge. Fastener length must equal the insulation panel thickness to prevent compression and pillowing. Approximately 11 fixings per standard panel are recommended (refer to Fig 1). For fixing to corrugated/profiled steel floor composite systems, ensure fixings are installed securely against the trough of the corrugation. A staggered formation is recommended for installation speed and efficiency (refer to Fig 2).

Diagram Description (Fig 1): Shows a panel with recommended fixing points: max 600mm centres, 100-200mm from panel edge, with 11 fixings per panel.

Diagram Description (Fig 2): Depicts panels installed in a staggered pattern, which aids installation speed and efficiency.

Install the liner touching the slab/substrate, but do not compress it. Avoid uncontrolled airspace between the liner and the substrate, as this can affect thermal performance. Ensure tight joins to adjoining sheets and surfaces with no gaps. Do not compress the insulation, as this will affect thermal performance. While the soft nature allows some compression for butt joins, avoid visible folds and compression lines in the finish. Join panels width-to-width and length-to-length to prevent colour variation. Prepare the first sheet by creating penetrations for insulation anchors according to fixing locations. Install the panel by fixing from one corner, across the width, then down the length for a tight, flat install. Install successive panels with tight, neat joins. Insulate all areas as per plans and specifications, leaving no gaps.

E-Foil - Tape Joins

When using Thermal Soffit Liner with E-Foil, a 50mm wide foil tape can seal panel joins and penetrations. Refer to the tape manufacturer's instructions regarding climatic conditions and suitability. Ensure surfaces are free of dust, dirt, and oils. Apply tape over the centre of the join and press firmly to the E-Foil facing. Do not stretch the tape, as this can create buckles and voids. Wipe firmly to ensure adequate adhesion. Cut and fit tape with a knife or scissors as needed.

Completion

Ensure the work is secure, smooth, and free of wrinkles, gaps, stains, and blemishes, meeting the required standard. Remove waste and recycle where possible. Leave the site clean and tidy.

Service

For more information and installation support, please contact your GreenStuf account manager.