PIR Sandwich Panel, B1 Fire Rate Cold Room Insulation ...
PIR Sandwich Panel, B1 Fire Rate Cold Room Insulation ...
PIR Sandwich Panel: Your Essential Guide
Understanding PIR in Sandwich Panels
PIR, or Polyisocyanurate, represents a fire-resistant thermal insulation material derived from polyurethane. This material is known for its exceptional thermal insulation capabilities.
Key Characteristics of Zonsteel PIR Foam
- Density: 40-42 kg/m3
- Compression strength (thickness direction): 162Kpa
- Bonding strength: 141Kpa
- Size stability: ±1.5%
- Cell closure rate: 290%
- Water absorption rate: ≤3%
- K-value: 0.020W/(m·K)
Given its K-value, PIR foam stands out as an excellent insulating material, widely utilized for insulating walls and roofs in various structures, as well as cold storage facilities.
Defining a PIR Sandwich Panel
A PIR sandwich panel consists of metal sheets affixed to both sides, with a core made from PIR foam, offering rigid thermal insulation. It's often referred to as Sandwich panel PIR or PIR panel sandwich. This panel is produced via a one-shot foaming continuous process, making it renowned for its superior thermal efficiency. Its applications range from cold storage facilities to chillers, walk-in fridges, and modular walls and ceilings.
The thermal conductivity of Zonsteel PIR sandwich panels generally measures around 0.020 W/(m·K).
Figure 1PIR Sandwich Panel
Core Specifications of PIR Sandwich Panels
- Thickness: 50mm, 75mm, 100mm, 120mm, 150mm, 175mm, 200mm, 250mm
- Core material: PIR (Polyisocyanurate) foam
- PIR density: 40-42kg/m3
- Skin material: Pre-painted steel (0.4-0.8mm), Aluminum (0.5-3mm), Stainless steel (0.4-0.8mm)
- Length: Less than 11.93m
- Width: Various options available
Figure 2PIR Sandwich Panel Specification
PIR Sandwich Panel Joint Details
For walls and ceilings constructed with 50mm thick PIR sandwich panels, options include using either a sealant or spray foam to ensure maximum insulation effectiveness.
Figure 350mm PIR Sandwich Panel Joint
For panels thicker than 50mm, from 75mm to 250mm, it is recommended to utilize both sealant and spray foam together at the joints. This combination is crucial for enhancing the airtightness of cold storage environments, coolers, and freezers.
Figure 4Greater than 50mm PIR Sandwich Panel Joint
Cost of PIR Sandwich Panels
The cost of PIR sandwich panels varies based on the thickness of the panel and the thickness of the surface skin. Other considerations impacting the price include the type of surface skin and the type of paint used on the surface.
PIR sandwich panels with PE paint are less expensive than those with PVC coating, aluminum sheets, or stainless steel. While color does not significantly affect pricing, it may impact delivery times, with standard white panels leading to a 12-day wait compared to over 15 days for custom colors.
PIR Sandwich Panel Fire Rating Explained
PIR sandwich panels boast a B1 fire rating, signifying that they are highly resistant to flames. In accordance with Germany's DIN-1 standard, materials rated B1 are deemed flame-retardant. Although they can catch fire, they extinguish themselves and burn at a slower rate.
Comparative fire ratings include:
- Rock wool panels: rated A
- PU panels: rated B2
- EPS panels: rated B1
- Aluminum honeycomb sandwich panels: rated B
Figure 5PIR Sandwich Panel Fire-rating B1
Operating Temperature Range of PIR Sandwich Panels
PIR sandwiches can be employed at sustained temperatures between -196°C and +160°C with a size change rate of ±1.5%.
Surface Sheet Variants for PIR Sandwich Panels
There are several options for the outer layer of Zonsteel PIR sandwich panels:
- PPGI or PCGI on both sides with thicknesses ranging from 0.4-0.8mm available in any RAL color
- Both sides coated with PVC at 0.6mm or one side PVC coated
- Stainless steel sheets on either side ranging from 0.5-0.8mm or one side stainless steel
- Aluminum sheets on both sides at a thickness of 0.5mm to 3mm
- One side metal sheet, and the opposite side covered with aluminum foil
Figure 6 PIR Sandwich Panel Surface Sheet Options
Figure 6 PIR Sandwich Panel Surface Sheet Options 2 Big Groove
Figure 6 PIR Sandwich Panel Surface Sheet Options 3 Medium Groove
Figure 6 PIR Sandwich Panel Surface Sheet Options 4 Flat
Figure 6 PIR Sandwich Panel Surface Sheet Options 5 Small Wave
Figure 6 PIR Sandwich Panel Surface Sheet Options 6 Corrugated Roof
Are PIR Insulation Panels Available Without Surface Skin?
Zonsteel offers PIR insulation panels with minimal metal sheet thickness (down to 0.4mm) with the opposite side potentially using aluminum foil or geotextile.
We also produce polyurethane insulation panels that use budget-friendly geotextile on both sides, suitable for various insulation applications.
Figure 7PIR Sandwich Panel One Side Metal
Figure 7 PIR Sandwich Panel One Side Metal-Wall
Delivery Timeline for Zonsteel PIR Sandwich Panels
For standard white panels, delivery occurs within 12 days. Custom colors may require more than 15 days, depending on specific requests.
Figure 8PIR Sandwich Panel Loading
Certifications for Zonsteel PIR Sandwich Panels
Zonsteel sandwich panels hold certifications from ISO, CE, and SGS, with additional approval from FM. They come with a B1 fire test report and a mechanical properties test report. Our PIR sandwich panels are utilized in numerous countries including the USA, various EU member states, Australia, and Southeast Asian nations.
Applications of PIR Sandwich Panels
PIR sandwich panels serve as exceptional thermal insulated structures, being used as walls and roofs in diverse industrial buildings and refrigerated storage areas.
These panels are especially advantageous for cold storage facilities, helping to maintain low temperatures for preserving a variety of products such as:
- Fruits & Vegetables
- Meats
- Banana Ripening Rooms
- Mushroom Growing Rooms
- Pharmaceuticals
- Dairy Items
- Chocolate
- Floral Products
- Kirana Items
- Eggs
Our Zonsteel PIR sandwich panels can have one or both surfaces finished with stainless steel.
We also offer self-cleaning, anti-static, antibacterial, antiviral, and hydrogen peroxide-resistant PIR sandwich panels, with customizable surfaces for specific needs.
Figure 9PIR Sandwich Panel Application
Packaging of PIR Sandwich Panels
Zonsteel PIR sandwich panels are securely wrapped in film and placed on pallets, with XPS boards at the base for added protection. For longer panels, we suggest a width of mm for optimal support. Two pallets can be positioned together without any friction.
Figure 10PIR Sandwich Panel Packed on Pallet
Installing PIR Sandwich Panel Cold Room Walls
PIR sandwich panels feature a tongue-and-groove joint configuration. U or L-shaped profiles are installed at the base to support the panels, which are fastened into place. Sealant and spray foam secure the joints, while rivets secure the top and bottom. The installation method may vary based on the cold room's design, type, and height, and walls exceeding specified height may require additional support braces.
Figure 11PIR Sandwich Panel Wall Installation
Ceiling Installation for PIR Sandwich Panels
For ceiling installations, M12 steel rods are utilized to suspend PIR sandwich panels as false ceilings. An adjustable device is available to ensure proper ceiling height and leveling.
Figure 12PIR Sandwich Panel Ceiling Installation
Cold Room Installation Services Availability
We provide comprehensive overseas installation services or dispatch two engineers to supervise installations. Costs cover round-trip airfare, local lodging, and a daily wage for each engineer.
Accessories for PIR Sandwich Panel Installations
We offer a complete range of accessories for constructing PIR sandwich panel walls and roofs. Profiles can be crafted from aluminum or steel, with steel profiles designed to match the wall panel color. The accessories include:
- Aluminum U channels for wall panel floor tracks
- Aluminum or steel L channels to position wall panels
- Internal and external corner covers
- 18# C steel
- Hanging rods and kits
- PVC conduits
- Hanging rods joint fittings
- Nuts
- Aluminum beams
- Hanging mushroom screws
- M12 expansion bolts
- Adhesive
- PU spray foam
- M6 expansion bolts
- Rivets
Figure 13PIR Sandwich Panel Accessories
Are PIR Sandwich Panel Ceilings Walkable?
The ceilings made from PIR sandwich panels can support foot traffic. It is advisable to walk on areas with rod support and to limit time spent in unsupported zones. For structures with walkable ceilings, beams should be limited to spans of less than 4 meters.
Figure 14Walkable PIR Sandwich Panel Ceiling
Cold Room Door Options Along with PIR Sandwich Panels
Cold room doors represent a fundamental product that complements PIR sandwich panels, ensuring complete functionality of the cold room. Available options include:
Electric Sliding Doors:
Utilizing a synchronous motor control system, these doors ensure smooth operation.
Suitable environments include cold storage and freezers maintained at -23 to -18°C, and cooling rooms at 0 to 5°C.
Figure 15Electric Sliding Doors Made of PIR Sandwich Panel
Manual Sliding Doors:
Characterized by a simplified structure, offering an attractive design, and featuring insulation made from one-shot PU foam, complete with a safety escape device.
Applicable in cold storage and freezers at -23 to -18°C and cooling rooms at 0 to 5°C.
Figure 16 Manual Sliding Door Made of PIR Sandwich Panel
Semi-Embedded/Swing Doors:
This door design partially slots into the frame, allowing for superior sealing and insulation capabilities.
Ideal for small cold storage and freezers at -23 to -18°C and cooling rooms maintained at 0 to 5°C.
Figure 17 Semi-Embedded Door(Swing Door) Made of PIR Sandwich Panel
Flush-Back/Embedded Doors:
Designed to be flush with walls, these doors are fitted with closers, ensuring they return to their position smoothly.
Best suited for small cold storage and freezers at -23 to -18°C and cooling rooms at 0 to 5°C.
Figure 18 Embedded and Fly-Back Door Made of PIR Sandwich Panel
Free Doors:
Featuring stainless steel 304 door panels with PUR foam insulation, these lightweight and sleek doors provide seamless operation.
Opening to 180 degrees, they are commonly utilized for entry and medium-temperature storage spaces.
Figure 19 Free Door
Electric Vertical Thermal Insulation Sliding Doors:
Sizes customizable.
Figure 20 Electric Vertical Thermal Insulation Sliding Door Made of PIR Sandwich Panel
Dock Doors:
Customizable dimensions.
Equipped with sponge door seals to minimize friction between the door and trucks, these seals remain flexible at temperatures below -40°C.
Features include an adjustable top that mitigates air circulation and temperature loss, promoting energy conservation. The adjustable range extends from 0 to 1.5m.
Compatible with 20FT, 40GP, 40HQ, 45HQ containers, and various trucks.
Figure 21 Dock Door
Thermal Folding Doors:
A crucial type of door for cold storage and food processing facilities.
These doors are known for their durability and safety, largely aided by high operational speed and being electrically operated.
Figure 22 Thermal Folding Door
High-speed Freezer Doors:
Zonsteel also provides high-speed freezer and cold storage doors designed to manage the environment, traffic, and expenses in refrigeration areas, featuring integrated thermal barriers.
Figure 23 High-speed Freezer Doors
PIR Sandwich Panels for Controlled Atmosphere Storage
Controlled atmosphere (CA) storage facilities are essential for keeping fruits and vegetables fresh, as they typically necessitate lower temperatures with high relative humidity to prolong storage life while maintaining optimal quality and flavor. By maintaining lower temperatures, respiration rates decrease, and metabolic processes that detract from produce quality slow down; however, excessive chilling can induce injury.
Figure 24 Controlled Atmosphere Storage Door
Utilizing PIR Sandwich Panels as Internal and External Cold Room Walls/Roofs
When deployed as interior walls or partitions, PIR sandwich panels emulate the joinery type of ceiling panels, incorporating tongue-and-groove methods. For external walls, a different joint type is used, with installation options being either vertical or horizontal. The roofs made with PIR sandwich panels feature a corrugated overlap joint, facilitating effective drainage of rainwater.
Essential Tools for Installing PIR Sandwich Panels
The basic tools needed for installation include:
- Pliers
- Electric hammer
- Electric hand drill
- Forklift
- Portable cutting machine
- Hydraulic elevator
- Riveting gun
- Adhesive gun
Differentiating PIR from PUR Sandwich Panels
PUR and PIR represent distinct types of foam technologies. Polyols are categorized into two groups: polyester-based and polyether-based. The formation of PUR results from a chemical reaction between polyether polyols and isocyanates, while PIR arises from the reaction between polyester polyols and isocyanates. Generally, the isocyanate index for PUR panels falls between 110 and 120, whereas PIR panels typically lock in a range of 200 to 300.
PIR Sandwich Panels in Walk-In Cooler Applications
Handling the storage of fruits and vegetables at temperatures between 0 and 5°C, walk-in coolers are ideal environments for PIR sandwich panels, with recommended thicknesses of 75mm, 100mm, or 120mm.
PIR core sandwich panels come from an automated continuous production line, limited to standard widths while allowing height modifications. Each wall may require panel adjustments at the ends. All essential profiles and accessories, including cold room doors and flooring elements, are provided and shipped together.
In contrast, cam-lock PUR sandwich panels have the advantage of being pre-cut for straightforward assembly. They also allow for hygienic elbow corners.
While PUR panels are rated B2 for fire, PIR panels enjoy a B1 rating, which is preferable for safety-conscious applications.
Figure 25 PIR Sandwich Panel Walk-In Cooler Panels
PIR Sandwich Panels for Walk-In Freezer Use
Storing goods at -23 to -18°C, walk-in freezers are perfectly complemented by PIR sandwich panels, with the recommended thicknesses being 150mm, 180mm, and 200mm.
Figure 26 PIR Sandwich Panel Walk-In Freezer Panels
Why Choose Zonsteel PIR Sandwich Panels?
Certified Quality for PIR Sandwich Panel Boards
Zonsteel PIR sandwich panels are certified to ISO standards, CE, SGS, and receive FM approvals.
Our manufacturing facility is also ISO certified.
Proven Quality Through Projects
Zonsteel’s PIR sandwich panels have been exported widely, particularly to the USA and various international markets, with over 90% of repeat orders confirming their quality.
Rapid Delivery Times
Many clients seek companies that can expedite the delivery of PIR sandwich panels. Zonsteel’s production capacity reaches 4.5 million square meters annually, with two continuous production lines ensuring prompt turnaround.
PIR sandwich panels in standard white can be delivered in just 12 days; custom colors may take 15 days or more.
Expertise and Experience
With a skilled workforce of over 300 employees and years of expertise in manufacturing PIR sandwich panels, Zonsteel ensures your orders are handled with excellence.
Our modernized production processes enable us to deliver high-quality products that meet your performance expectations.
Available Custom Sizes
Besides standard sizes, Zonsteel understands the need for custom dimensions and accommodates tailored specifications.
Width: adjustable between mm and mm.
Length: under mm (factoring in container limitations).
Options Tailored for Your Applications
Select among various surface skin options: stainless steel, colored steel, aluminum, or aluminum foil.
Color choices: any RAL color available.
Functionality choices include self-cleaning, anti-static, antibacterial, antiviral, and hydrogen peroxide-resistant PIR sandwich panels.
Surface pattern selections include flat, small groove, and big groove.
Commitment to Quality Panels
Zonsteel prioritizes quality. Having manufactured these panels for years, we acknowledge the significance of delivering durable products.Thus, they remain a top choice for a variety of applications without the worry of quality issues.
Affordable Options
Even on a budget, Zonsteel guarantees competitive pricing for PIR sandwich panels without sacrificing quality.
Installation Services Offered
For those unfamiliar with the installation process, Zonsteel provides professional installation services. Our technicians will also advise on maintaining your panels for optimal performance over time.
For further details on PIR Insulated Panels, please get in touch with us, and we will deliver expert insights.