Insulated Sandwich Panel

Insulated Sandwich Panel: The complete FAQ Guide

Insulate sandwich panel construction is widely used in different industries, like a clean room, steel structure, and prefabricated house. It’s featured with lightweight, fast assembly, warm-keeping and heating proofing, nice looking, and can be cut to any sizes.

Yes Zonsteel insulated sandwich panel can be cut to any size as requested on the factory, and we offer a full set of accessories like U channel, L channel, exterior/interior wall corner aluminum cover, roof cap, rain flashing, etc., especially doors and windows. Zonsteel is treated as an insulated sandwich panel one-stop supplier. You can tell us where you use your panel, which port, length and width you want, color you want, the quantity you want, the delivery time you want, and which packing you want; we will meet all your needs beyond your expectations.

Zonsteel has been manufacturing sandwich panels for 20 years and ship overseas for 12 years. We have rich experience in quality, shipping, and service. Delivery time for our products is usually 4-7 days. Price is competitive in the insulated sandwich panel field. Zonsteel insulated sandwich panel factory certified with ISO9001 and ISO14001, fire rating A1 and B1 test report.

Contact us and customize your insulated sandwich panel today!

 

Insulated Sandwich Panels: The Ultimate FAQ Guide

 

Introduction

 

Insulated sandwich panels have gained increased popularity across all building applications, this document is designed to answer the most commonly asked questions about insulated sandwich panels benefits, insulation performance, affordability, types, materials, sizes, and more.

If you have a question that isn’t answered here, please contact us any time.

What Is Insulated Sandwich Panel?

 

An insulated sandwich panel is a walling and roofing system made of an insulating core materials sandwiched on both sides with sheet metal or polymer composite skins which are adhered together to form one panel. Insulated sandwich panels are used for a variety of roofing, walling and flooring applications; they are available in a wide range of strong and lightweight core and skin materials such as PUR, PIR to Rockwool and EPS foam.

Insulated sandwich panels thermal and acoustical performance depends mainly to the insulation U-values, core properties, and the thickness of the panel. Using insulated sandwich panels protects the building from water/air, humidity and moisture damage. They are energy efficient and can significantly reduce the cost of energy used for cooling and heating.

 

Figure 1 Insulated Sandwich Panel

 

What Are The Applications Of Insulated Sandwich Panels?

 

Insulated sandwich panels are used mainly to build floors, interior and exterior walls, multi-span walls, partition walls, roofs, facades, and ceilings. Due to their superior quality, durability and cost-effectiveness, they have become very popular among the following building industries:

 

Cleanroom

To keep production area in a certain cleanliness, temperature and humidity, insulated sandwich panels are used as wall and ceiling. Due to its neat surface, airtight finish, good thermal insulation, flushed installed with equipment and doors & windows etc, be widely used in cleanroom.

Figure 2 Clean Room Insulated Sandwich Panel

 

Commercial buildings

Insulated sandwich panels are used in various commercial buildings to protect goods from moisture. They are widely used to in shopping malls, hypermarkets, groceries, supermarkets, retail outlets, stores, distribution depots, office buildings, etc.

Figure 3 Commercial Buildings Use Insulated Sandwich Panel

 

Cold Storage Facilities 

Insulated sandwich panels are essential for cold store or called cold room and freezers to keep stored food cool and to improve refrigeration system efficiency.

Figure 4 Cold Storage Facilities  Insulated Sandwich Panel

 

Warehouses

Insulated sandwich panels are used for almost all warehouses and storage buildings. Due to their protective qualities they have become essential to protect goods, materials, equipment from water, humidity, moisture, and fire danger.

Figure 5 Insulated Sandwich Panel Made Warehouses

 

Factories

Insulated sandwich panels are essentially used in many production buildings such as food and semiconductor industries to control the manufacturing environment and prevent equipment overheating.

Figure 6 Insulated Sandwich Panel Made Factories

 

Car showrooms

Insulated sandwich panels are important for car showrooms. In addition to ensuring maximum protection for cars and vehicles from environmental damage, they offer also an aesthetically pleasant look to the showroom interior and exterior

 

Sports and Leisure Facilities

Insulated sandwich panels helps to maintain the right sport or leisure building temperature, and keeps the interior comfortable for users. They are used in stadiums, sports halls, indoor sport facilities, gymnasium, recreational and entertainment facilities, cinemas, etc.

 

Health and Medical Facilities

To keeps medical equipment in good working condition, insulated sandwich panels are widely used for laboratories, hospital extensions; clinics, food, pharmaceutical, clean rooms, etc.

 

Transportation buildings

Insulated sandwich panels are incredibly strong materials that respond to the thermal and acoustic needs for airports, train stations and bus stations.

 

Other applications

Insulated sandwich panels are used also in Agricultural Buildings, Ships, Aeronautics and Aerospace engineering applications, and any other walling or roofing application.

 

What Are The Benefits Of Insulated Sandwich Panels?

 

Insulated sandwich panels are essential to protect buildings structural system from external environmental factors, because of their excellent qualities and technical properties, insulated sandwich panels are widely used for roof cladding, internal and external walling, building facades, ceilings, flooring, partitions and more. They offer a variety of benefits, including:

 

Figure 7 Insulated Sandwich Panel

Thermal Insulation

To ensure high thermal insulation different core materials such as EPS, PUR, PIR, and Mineral Wool are used for insulated sandwich panel. In addition to that, all components are designed to prevent heat transmission, humidity, mold and condensation. Thermal insulation can ensure a comfortable environment as it offers a warm interior in the winter and cooling in the summer. This lower energy consumption and reduce costs. This helps to reduce energy consumption for heating/cooling operations, and lower significantly the energy costs.

The thermal insulation of the sandwich panels have different U-values and vary depending on the core materials used and thickness. The thickness of the insulated sandwich panel is selected according to the application climates conditions, thermal requirements and load-bearing capacity. Thermal resistance and R Value are used to measures the resistance of insulated sandwich panels to heat flow.

 

Sound Insulation

Insulated sandwich panels are designed and manufactured to offers superior acoustical insulation, and absorb sound transmission via building enclosures. Various thicknesses that ranges from 50 mm to 200 mm are available to ensure perfect acoustic sound insulation, transmission of sound. Moreover, airborne and structure-borne sound reduction values are measured using Sricalc software to offer adequate level of sound insulating abilities for roofs, ceiling, walls and floors.

Insulated sandwich panel are produced in conformance with the following international standards:

ISO 140-3:1995 Acoustics – Measurement of sound insulation in buildings and of building elements.

ISO 717-1:1996 Acoustics – Rating of sound insulation in buildings and of building elements.

 

High Strength And Durability

 

To ensure buildings are robust and long-lasting, insulated sandwich panels are designed to provide a load bearing roofing, walling systems and structural components. The structural efficiency of insulated sandwich panels is determined by its capability to carry loads at a minimum weight and by its mechanical performance. However despite the lightweight of insulated sandwich panels, they consist of strong and stiff sheet material which can support buckling stress and external effects of temperature, UV rays, water, condensation and more.

The most durable and light weight insulation materials with different thickness can be provided as per application requirements.

 

Cost-Effectiveness

Insulated sandwich panels are cost-effective options for modern buildings structures. Because of their quality thermal insulating materials, they are more preferred than other conventional reinforcement materials. The latest technology design and production process are used to offer high performance insulated sandwich panels at low cost and reduced weight.

Furthermore, insulated sandwich panels are assembled rather than “built”, they are finished off-site and delivered ready for an easy mounting, this speed up the construction process and enable achieving a faster return on the investment. Also, the lightness of sandwich panels offers many cost reduction advantage with regards to transportation, long life maintenance free and energy efficiency cost.

 

Fire Resistance

Insulated sandwich panels are made from non-combustible insulation core or B grade fire rating core with fire retardant, such as rock wool, PU foam, PIR foam, EPS foam, Aluminum honeycomb, paper honeycomb, MGO board etc.

Some of these core insulation materials can withstand temperatures of over 1000°C without melting. Insulated sandwich panels fire reaction and resistance is mainly dependant to the core material, metal thickness and coating type used.

Insulated sandwich panels are manufactured in compliance with Euro class A1 or A2 fire rated insulation standards and FM 4880 fire performance requirements for Class 1 fire rated insulated walls, ceilings, roof assemblies and interior finish materials in terms of combustibility and self-propagation.

Also, insulated sandwich panels are assessed and tested according to ASTM E84 – Surface Burning Characteristics, and are proven to offer high levels of fire resistance in numerous real fire case studies.

Air and Water Tightness

Because of their efficient air/watertight structure and joint detail, insulated sandwich panels can prevent perfectly air, water leakage, humidity and mold. These ensure continuous heating and cooling, while it provides a healthy and comfortable environment in the building. In order to ensure proper tightness level and meet the standards for passive buildings, insulated sandwich panels passes through a tight quality control manufacturing process.

 

Flexible and Easy Installation

Unlike the traditional systems which require more time and money, insulated sandwich panels are delivered ready for a simple assembly. Insulated sandwich panels are compatible with all applications in terms of size, insulation, face plates specifications and aesthetic finish. In addition to that, insulated sandwich panels can be flexibly disassembled and reused for another building.

 

What Factors To Consider When Designing Insulated Sandwich Panels

 

To provide load bearing materials, insulated sandwich panels load capacity is calculated as per the building needs, and each piece is designed to enable horizontal/ vertical and angular positioning. Moreover, loads at the edge zones are carefully designed and higher loads are ensured in corner areas, at the eaves and around openings as well.

 

While, sandwich panels are curtain materials and not structural materials, the structural load are carried by the steel framing or other frame type where the sandwich panels are installed. However, to ensure maximum longevity, the right technical specifications are selected to avoid deflection caused by wind loads or temperature, other critical factors such as air tightness, thermal insulation, fire resistance, sound reduction, fastenings and openings are also considered in the design planning phase. Specifications of insulated sandwich panels should be conformant to BS EN 14509:2013 self-supporting double skin metal faced insulating panels, factory made products specifications.

 

Insulated sandwich panels are designed to offer an aesthetically pleasant appearance to the building’s interior and exterior, panels comes in different thicknesses, finishes, profiles, colors and can be customized to meet specific application requirements.

Figure 8 Insulated Sandwich Panel

 

What Are The Materials Used To Manufacture Insulated Sandwich Panels?

 

Insulated sandwich panels are made from an insulating core glued in between two metal or polymer composite skins (facings), both of the materials are available in different specifications to suit all applications in terms of strength, thermal conductivity, sound insulation and fire resistance. The following core and panel facing materials are the most commonly used types:

 

Core Material

The core materials are selected according to their thermal insulating performance, sound insulating capabilities, weight and reaction to fire.

Rock rock wool (non-combustible)

Glass wool/fiberglass (non-combustible, fire rating A1)

Mineral wool panels (non-combustible, fire rating A1)

Modified phenolic foam (fire rating B1)

Polyisocyanurate (PIR) (fire rating B1)

Polyurethane (PUR) (fire rating B2)

Expanded polystyrene (EPS) (fire rating B1)

Extruded polystyrene (XPS) (fire rating B1)

Aluminum honeycomb(fire rating B1)

MGO board (non-combustible)

 

Facing material

Insulation core materials is sandwiched using various facings, or faceplates made of metals such as steel, aluminum, or from plastic materials like fiberglass reinforced plastic or PVC.

 

The sheet metal exterior is normally hot dip galvanised with color coating or powder coated to ensure resistance to UV, temperature and chemicals, whereas, the interior surface polyester-coated steel protects the surface from corrosion. Other materials such as food-safe laminated steel, acid-proof steel, aluzinc and stainless steel can be also offered as per application requirements.

 

To provide an architecturally impressive design, insulated sandwich panels are available in different surface profiles.

 

What Are The Most Commonly Used Types Of Insulated Sandwich Panels?

 

Insulated sandwich panels are designed and manufactured to meet walls, roofs and partitions applications requirements in terms of functionality and aesthetics. The types of insulated sandwich panels are classified according to the core thermo insulating material used. The following are the most commonly used cores materials:

 

PIR Sandwich Panel

Figure 9 PIR Sandwich Panel

 

PU Panel

Figure 10 PU Panel Cold Room Panel

 

EPS Panel

Figure 11 EPS Panel

 

Rockwool Panel Panel

Figure 12 Rock Wool Sandwich Panel

 

Duct Panel

Figure 13 Duct Panel

Clean Room Panels

Figure 14 Clean Room Panels

 

What Is The R Value Of Insulated Sandwich Panels?

 

The higher the R-value the better is the performance of insulated foam core. For example

Expanded polystyrene (EPS), R-value: 3.85/in. to 4.35/ in. (varies with material’s density).

Extruded polystyrene (XPS), R-value: 5.0/in.

Polyisocyanurate, R-value: 6.0/in. to 8.0/in.

And others can be provided as per customers’ requirements.

 

Does Manufacturer Provide Insulated Sandwich Panels Customization?

Yes, Absolutely. High quality insulated sandwich panels can be customized to meet customers’ needs and requirements, a wide range of profile thickness, joint, and finish. Insulated sandwich panels can be designed and manufactured as per building project’s dimensions. High performance core materials and facing options are available including MGO board, aluminum honeycomb, fiber cement with EPS foam, wood laminates and custom requirements can be also provided. Insulated sandwich panels comes with an easy to fit male-female joints supported by in-built C channels or concealed fastening systems.

 

What Are The Sizes Of Insulated Sandwich Panels?

Insulated sandwich panels size comes in 1000 mm and 1200mm width as standard, any of other width can be customized. While the length can be produced according to the project required dimensions. However, while, the thickness of insulation core is determined based on the application requirements, the following are the most commonly used thicknesses for roofs, walls, partition wall, ceiling and facades:

 

PUR/PIR insulation panel : 50 mm to 200 mm, 80 mm – 200 mm in Cold Storage Panels.

Rockwool sandwich panel : 50 mm to 150 mm.

EPS sandwich panel : 50 mm to 200 mm.

Duct panel                                 : 20 mm to 100 mm.

Clean room panels                   : 50 mm to 150 mm.

 

The span of insulated sandwich panel is designed and tested in accordance with the EN 14509 European requirements for factory made, self-supporting, double skin metal faced insulating sandwich panels. Insulated sandwich panels come in single-span structures, while multi-span structures can be also provided.

 

What Are The Standards Of Insulated Sandwich Panels?

Insulated sandwich panels are designed and manufactured in compliance with the following international standards:

 

Thermal Performance

Insulated sandwich panels’ thermal performance shall adhere to the EN 14509 requirements in terms of quality regulations, ‘U’-value and calculation methodology. All tests shall respond to all laboratories tests requirements.

 

Fire Performance

Fire performance is tested in accordance with the BS 476 standards for fire tests on building materials and structures. All materials used should be tested to provide insulated sandwich panels that fulfill reaction to fire requirements, fire resistance and external fire exposure.

 

ISO 16536:2019

Insulated sandwich panels shall comply with the standards of ISO 16536:2019 thermal insulating products for building applications – Determination of long-term water absorption by diffusion.

 

Are Insulated Sandwich Panel Compliant To International Building Code?

Insulated sandwich panels are designed and constructed as per the International Building Code (IBC) requirements for design, loads, materials specifications, components and installation should be made in accordance with the public health and safety guidelines.

 

Insulated sandwich panels are made in accordance with the International Plumbing Code, International Mechanical Code, electric code and fire safety code.

 

Does Manufacturer Provide Insulated Sandwich Panel Walling System?

Yes, absolutely. Manufacturer produce the highest quality insulated sandwich panels for all applications related to internal, external walls, partitions, facades and architectural wall panel system as well. Each panel piece is designed to offer customers the most attractive and elegant appearance while ensuring excellent thermal and sound insulation. Insulated sandwich panels wall panels are available in a variety of materials including PU, PIR, Rock Wool and EPS insulated sandwich wall panels, vertical and horizontal profiles can be provided in a wide range of profiles, span, thicknesses, features, finishes and colors.

 

Does Manufacturer Offer Insulated Sandwich Panel Roofing?

Yes, the most reliable and aesthetically pleasant insulated sandwich panels can be provided for all roofing and cladding applications for residential, commercial, industrial and storage facilities. High performance roofing panels that meet all thermal, sound insulation; fire resistance; humidity; waterproofing; and energy efficiency requirements. A complete line of roofing panel solutions is available including PUR, PIR, Rock Wool and EPS. To offer a modern appearance to all building types, panels can be implemented vertically or horizontally. Insulated sandwich panels can be custom-tailored to suit any project specifications.

 

Are Insulated Sandwich Panels Durable?

Insulated sandwich panel systems are designed to provide long life lasting, and maximum protection from external forces. Also, to ensure durability the best quality materials are used to provide high thermal and structural performance for all walling and roofing applications. However, despite its light weight, insulated sandwich panels can offer high tensile strength and can support high loads as well.

 

For quality assurance insulated sandwich panels’ passes through a series of control process and all materials performance is tested for thermal resistance, water permeability, air permeability, airborne sound insulation, sound absorption, fire resistance, temperature, UV rays, etc.

How Insulated Sandwich Panels React To Fire?

“A” class and “B” class insulated sandwich panels are designed and produced in compliance with the fire resistance international standards; in addition to that, non-combustible insulation materials are used to protect building’s interior and exterior from fire danger. Zonsteel rockwool sandwich panel could be maximum 4 hours fire resistant.

 

Are Insulated Sandwich Panels Pest Resistant?

Insulated sandwich panels are made from moisture resistant insulation core and layers, materials used keeps panels pest-free from mold/mildew and condensation that often forms in a cooling or freezing systems.

 

Does Manufacturer Provide Hygienic Insulated Sandwich Panels?

Complete lines of insulated sandwich panels can be produced to meet the hygienic requirements of food industry. Hygienic PIR panels are the most commonly used type for refrigerated food storage buildings and preparation units. Hygienic insulated sandwich panels are made from water/air tight hygienic joints, while the surface is easy to clean and keep in hygienic conditions.

 

Are Insulated Sandwich Panels Environmentally Friendly?

Insulated sandwich panels are produced to meet LEED & green building standards, all components are manufactured under an environmentally friendly process that protects the planet from pollution, reduce carbon dioxide emissions and minimize waste of resources. Insulated sandwich panels are one of the most energy efficient construction materials, through their airtight and air barriers systems they can reduce energy consumption for heating and cooling.

 

How Insulated Sandwich Panels Are Installed?

Insulated sandwich panels are easy and quick to install below is a brief on how wall and roof insulated sandwich panels are installed:

After removing the protective film from the insulated sandwich panels, the panels are fastened to the structural sub frame using screws, then the joints are sealed and the flashing is installed. Insulated sandwich panels installation takes few days and can be handled by a proficient construction crew.

 

How Long Do Insulated Sandwich Panels Last?

Insulated sandwich panel for walling, cladding and roofing systems are durable materials that can last for 15 years, and can be used almost for a lifetime without maintenance.

 

Do You Deliver Insulated Sandwich Panels Internationally?

We deliver insulated sandwich panels Worldwide. We provide our customers with the best shipping rates and continuous support throughout out all the delivery process.

 

How Much Do Insulated Sandwich Panels Cost?

The average cost of insulated sandwich panels ranges between 10$ and 60$ per square meter. Costs are largely dependent on the insulated sandwich panel specification.

 

How Long Zonsteel Provide the Warranty?

Zonsteel provide 1 year warranty.

 

Why Zonsteel Insulated Sandwich Panels Are Preferred?

Zonsteel is the leader Chinese manufacturer of insulated sandwich panels; we produce the most reliable and cost-effective insulated sandwich panels for all building application. We apply the latest technology throughout our manufacturing process to offer the highest thermal-efficiency, fire safety and energy efficiency.

State-of-the-art insulation sandwich panels are available in a wide range of materials including:

PUR/PIR insulation panel

Rockwool sandwich panel

EPS sandwich panel

Duct panel

Clean room panels

 

A variety of profiles, thicknesses and aesthetic options can be provided as per customers’ requirements.

 

Our insulated sandwich panels are guaranteed and can last for a lifetime without maintenance. Insulated sandwich panels are produced in compliance with the following international standards:

 

ISO 9001:2015 Quality Management Systems.

ISO 14001:2015 Environmental Management System.

 

Conclusion

From the guide above, you should be in a position to choose a insulated sandwich panel. The Zonsteel customer support team is also available to help with any queries on insulated sandwich panels you might have. For A Free Quote or Consultation Contact Us at any time or give us a call.