What you need to know about insulated panels for walls ...

The following text about sandwich panels for walls and roofs is geared towards beginners. It aims to introduce the topic and provide valuable information on various aspects such as transport, relocation, etc. While this guide is helpful, it cannot replace specialized training. Therefore, it is crucial to have experts who understand the transport, storage, and assembly of sandwich panels ready to assist. Get professional insights on Warehouses Thermal Insulated Wall Panel by contacting us for more information.

1. The Basics: Understanding Insulated Panels

Insulated panels, also known as sandwich panels, are composed of multiple layers: typically two thin cover sheets and an insulating core in the middle. These panels are significantly more durable than the sandwiches they are named after. The layers are tightly bonded, forming a composite structure known for its strength and rigidity.

These panels vary in design, with most outer shells made of galvanized steel. The inner shell could be composed of galvanised steel sheet, thin aluminium sheets, stainless steel, or glass-reinforced plastic (GRP). The core usually consists of insulating materials like polyurethane (PUR), polyisocyanurate (PIR), or rock wool. The composite nature of these panels ensures the properties of the materials are synergistically utilized: the core mitigates surface bending or breaking, while the outer shell safeguards the core from environmental damage.

2. Applications of Insulated Panels

Insulated panels find usage across numerous industries, including aerospace, automotive, and construction. Their most common application, however, is within the construction industry as prefabricated elements. These panels are ideal for building projects, offering time savings, cost reductions, and weight efficiency. They are suitable for use as walls, ceilings, and roofs. When delivered directly from the factory, these panels can be immediately installed upon arrival, providing stable and well-insulated structures in a single step. As a result, insulated panels are now commonly used in building lightweight halls, residential roofs, and for soundproofing in drywall constructions. Additionally, panels with fireproof cores are utilized as fire protection barriers.

3. Types of Insulated Panels

3.1. Insulated Roof Panels

These panels fulfill two primary roles: providing roofing insulation and forming the roof itself. Characterized by their distinct raised profiles known as high ridges, they enhance the panel’s stiffness. This stability is particularly crucial as roofs bear their own weight and endure additional snow and wind loads. Between the high ridges, the core thickness is measured. Roof panels are designed for seamless integration with overlapping flaps on one side, and they come in a diverse palette of RAL colors.

3.2. ECO Roof Panels

ECO roof panels are a specialized variant, featuring an underside covered in aluminum foil instead of steel. This design classifies them as single-use products exempt from certain building regulations. Besides their regulatory benefits, ECO panels are environmentally friendly, resisting harm from substances like ammonia. Therefore, they are particularly well-suited for agricultural structures such as barns and stables.

3.3. Insulated Wall Panels

Instead of high ridges, wall panels boast lined profiles for added stability. These panels use a more pronounced tongue-and-groove joint system, or optionally, invisible fastening screws, to seamlessly connect each unit. Additionally, wall panels can also function as ceilings or floors.

3.4. Cold Room Panels

Cold room panels are a specialized type of wall panel, offering superior insulation and high-quality joints. These attributes make them perfect for constructing refrigerated cold rooms and walk-in coolers. Frequently, these panels also feature food-safe coatings.

4. Composition of Insulated Panels: The Exterior

The outer shell of an insulated panel is designed with various layers for protection against elements like UV radiation and corrosion. Depending on environmental exposure, different materials and coatings may be selected to suit either the exterior or interior side. For example, the external layer should always feature UV protection, while damp interior spaces might require enhanced corrosion resistance.

4.1. Exterior Materials

A range of materials are used for the outer shell of insulated panels, each offering unique properties:

Sheet thickness varies, with thinner materials being lighter and less expensive but less stable. Thicker materials allow walking on panels without damage, generally ranging in thickness from 0.4mm to 0.6mm. For corrosion protection, all panels are galvanised to high standards.

4.2. Exterior Coating

Coatings provide extra defenses against corrosion and UV rays. Enhanced quality is achievable via innovative materials, coating methods, or thicker layers. Our insulated wall and roof panels come with a standard 25 μm polyester coating, externally and internally, whereas competitors usually offer only 15 μm. Here are the available coatings:

We provide a decision aid based on EN 10169 to help you choose the right coating, suited for different environmental influences, both external and internal, such as:

External Environmental Influences:

Internal Environmental Influences:

Refer to our decision diagram to ensure you select the appropriate coating based on your project's specific environmental factors.

5. Composition of Insulated Panels: The Core

The core materials contribute significantly to the panel's high insulation properties. The external shells of steel or aluminium protect this core, which varies in material and thickness:

5.1. Polyurethane (PU)

Polyurethane, a synthetic resin developed by Otto Bayer and his research team in the 1930s, is commonly known for its household use in sponges. It’s the most widely used insulation material for panels. Here are typical U-values according to core thickness for a standard-lined Eurobox type panel:

5.2. Polyisocyanurate (PIR)

Polyisocyanurate (PIR) offers superior insulation compared to polyurethane. It achieves the same insulation values at lower core thicknesses and provides enhanced fire resistance, enduring higher temperatures for more extended periods. Consequently, PIR core panels are more costly than their PUR counterparts.

5.3. Rock Wool

When stringent fire protection is needed, rock wool core panels are the preferred choice due to their non-combustibility, despite slightly lower insulation properties compared to polyurethane and polyisocyanurate. Here are the U-values for a standard-lined Eurobox profile:

6. Transporting Insulated Panels

After placing your order, the first step is transport. For panels up to 24 meters in length, adhere to these guidelines to prevent damage. Packages should be placed horizontally on plastic foam or wooden spacers and secured with straps across at least two cross-sections, spaced no more than 3 meters apart. Ensure the loading surface is empty and weatherproof.

7. Storing Insulated Panels

For logistics purposes, panels might need storage on a site or warehouse. Never place panels directly on the floor; always use timber or polystyrene spacers adapted to the panel's shape. If stacking, ensure the weights are considered and spacers are perfectly aligned across packages. Store in dry, dust-free, ventilated rooms, avoiding long-term outdoor storage to prevent moisture damage. Best storage periods should not exceed six months even under optimal conditions.

8. Lifting Insulated Panels

Despite being lightweight construction elements, panels can be cumbersome due to their length. When lifting via crane, use synthetic sling belts, ensuring they are placed at a minimum of two locations. Wooden or plastic spacers should be used to prevent damage. For hand lifting, always work in pairs and carry the panels with horizontal edges oriented upwards and downwards.

9. Cutting Insulated Panels

In situations requiring on-site modifications, panels should be cut on a firm base using a plunge saw, jigsaw, or circular saw. Avoid overheating the cutting surface to prevent damage to the galvanization. Angle or disc grinders should not be used due to potential spark damage.

10. Installing Roof Panels

Proper installation should always be performed by professionals. Panels are attached to substructures of timber, concrete, or steel. Ensure all weight calculations and regional factors such as snow and wind loads are considered for substructure design. Maintain a roof slope of at least 5° or 7° for roofs with crossbars or penetrations, as roof panels are not suitable for flat roofs.

10.1. Laying the Roof Panels

Begin installation opposite to the main weather direction to minimize wind impact on joins. Align the first panel carefully using a guideline, and secure it with screws equipped with rubber seals. Continue laying panels in a similar fashion, ensuring panels are held firmly together at the joints.

10.2. Overlapping the Short Joint

For vertical joint overlaps, remove the lower sheet and foam insulation based on the data sheet specifications. Lay the upper panel over the lower one to allow rainwater drainage, applying a self-adhesive seal for added protection.

10.3. Completing the Eaves Area

Protect exposed insulation from weather and animals by using waterproof coatings or flashings. Optionally, panels can be provided with a drip edge for added durability.

11. Approval as per EU Standard 14509

Insulated panels are compliant with EU Standard 14509, setting the requirements for factory-made self-supporting elements with metal sheets on both sides.

12. Fire Protection Classes and Regulations

Fire protection is critical in many applications of insulated panels. The European standard DIN EN 13501 specifies detailed fire resistance classes. The table provides a guideline for meeting various fire protection requirements based on the EU classification:

For more information on Rockwool Panels for Insulating Shipping Containers, please do not hesitate to contact us.

Insulated panels with a rock wool core achieve fire classes up to F120, meaning they can withstand exposure to fire for up to 120 minutes. They are made primarily of molten volcanic rock formed into fibrous structures, making them ideal for both internal fire walls and external walls, as well as ceilings, roofs, and building insulation.

Wall Panels - All Weather Insulated Panels

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