What is Polyurethane Sandwich Panel
A Polyurethane Sandwich Panel, also known as PU Panel, is a composite material composed of three layers of polyurethane foam sandwiched between two metal side skins. This material is extremely durable, lightweight, and resistant to extreme weather conditions.
Thermal Insulation
Polyurethane foam has excellent thermal insulation properties, making PU sandwich panels effective in maintaining indoor temperatures and reducing energy consumption for heating or cooling.
Lightweight
PU sandwich panels are lightweight, which makes them easier to handle, transport, and install compared to other construction materials. This feature can help reduce construction time and costs.
Structural Strength
Despite being lightweight, polyurethane sandwich panels offer good structural strength and rigidity. They can provide structural support and withstand various loads, making them suitable for both wall and roof applications.
Fire Resistance
Polyurethane sandwich panels can be manufactured with fire-resistant properties, which helps improve fire safety in buildings. The foam core can be treated with fire-retardant additives to enhance its fire resistance.
Sound Insulation
The dense structure of polyurethane foam contributes to sound absorption and insulation. PU sandwich panels can reduce noise transmission, providing acoustic comfort in buildings.
Moisture and Weather Resistance
The outer layers of PU sandwich panels, typically made of steel or aluminum, offer protection against moisture, corrosion, and weather elements. This helps maintain the integrity and longevity of the panels.
Versatility
Polyurethane sandwich panels are versatile and can be used in a wide range of applications, including commercial buildings, industrial facilities, cold storage warehouses, residential construction, and more.
Polyurethane cold room panels offer exceptional insulation, ensuring temperature stability for cold storage facilities. With a seamless interlocking design, they provide airtight construction, preventing energy loss and maintaining optimal storage conditions. These panels are durable, lightweight, and easy to install, making them ideal for various cold room applications in industries such as food storage, pharmaceuticals, and logistics.
1: Polyurethane sandwich panels offer exceptional thermal insulation, reducing energy costs.
2: It's strong yet lightweight, making installation and transportation easier.
3: Polyurethane sandwich panels are highly resistant to moisture and corrosion.
4: Available in various surfaces and colors to suit diverse architectural needs.
5: Speedy and hassle-free installation reduces project time and labor costs.
1: PU Cold Room Panels offer exceptional thermal insulation, maintaining consistent temperatures.
2: It reduce energy consumption, leading to cost savings.
3: Highly resistant to moisture and corrosion, ensuring product integrity.
4: Speedy assembly reduces labor costs and project time.
5: Panels can be tailored to specific design and insulation requirements.
1.Outstanding Insulation: PU wall panels offer excellent thermal insulation.
2.Versatility: They suit various construction types and design aesthetics.
3.Durability: Resistant to moisture, corrosion, and wear, ensuring long-lasting performance.
4.Quick Installation: Speedy assembly reduces construction time and labor costs.
5.Cost-Effective: Energy efficiency and minimal maintenance.
1.Excellent Insulation: 75mm insulation boards offer high thermal efficiency, reducing energy consumption.
2.Space Efficiency: Thinner profile maximizes interior space in construction.
3.Lightweight: Their lightweight design simplifies handling and installation.
4.Cost-Effective: Reduced material and labor costs make them economical.
5.Versatility: Suitable for various applications, from walls to roofs and floors.
1.Excellent Insulation: pu sandwich panel for wall offer high thermal efficiency, reducing energy consumption.
2.Space Efficiency: Thinner profile maximizes interior space in construction.
3.Lightweight: Their lightweight design simplifies handling and installation.
4.Cost-Effective: Reduced material and labor costs make them economical.
5.Versatility: Suitable for various applications, from walls to roofs and floors.
Polyurethane Insulation Panels
1: Polyurethane insulation panels offer high thermal efficiency, reducing energy consumption.
2: They are lightweight yet strong, facilitating easy installation and ensuring long-term durability.
3: These panels are highly resistant to moisture and corrosion.
4: Available in various finishes and colors, they adapt to diverse architectural needs.
5: Quick and hassle-free installation lowers project time and labor costs.
1: PIR sandwich panels offer exceptional thermal insulation, reducing energy costs.
2: They are strong yet lightweight, making installation and transportation easier.
3: PIR sandwich panels have excellent fire-resistant properties.
4: Highly resistant to moisture and corrosion.
5: Quick and hassle-free installation reduces project time and labor costs.
1.Superior Insulation: Polyurethane insulated panels offer excellent thermal efficiency.
2.Energy Cost Savings: They reduce heating and cooling expenses.
3.Lightweight: Easy handling and installation.
4.Durable: Resistant to moisture and corrosion.
5.Versatile: Suitable for various applications, from cold storage to construction.
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The roof plays a vital role in both residential and commercial structures as it acts as the first line of defense against external threats and risks. Roofs have been known to exist since man realized the importance of having a shelter to protect them from the elements. Cavemen used earth and vegetation as roofs. Though they were excellent protection from heat and cold, these natural roofing materials could not keep them safe from animals and would easily break due to rains. Over time, man would use different materials as roofing. In the 12th Century, Europeans used wood shingles as roofs. Today, roofs are made of different materials like concrete and metal. These transitions were often dictated by man's desire to come up with the best materials for the protection over their head. And now, thanks to modern technology, more materials or a combination of different materials are being used as roofs. An example is a roof made of Polyurethane Sandwich Panel. But what exactly is it.
Polyurethane may be unfamiliar to you, but it is used in common things around you, like your appliances, cars, shoes, and beds. Polyurethane is a synthetic plastic material with a wide range of uses. Perhaps one of the most familiar items made of this is the flexible foam used in mattresses. It is also used in shoe soles, tires, and as cushioning for furniture.
Polyurethane is popular for the many benefits it offers flexibility, high load capacity, strong bonding ability, range of hardness, and economical manufacturing process. It is also known for its resistance to abrasion and tear as well as water, oil and grease, mold, mildew, and fungus. Because of these qualities, it is widely used in different consumer and industrial products that make our lives comfortable. In construction, it can be used as roofing, particularly as Polyurethane Sandwich Panel.
Polyurethane Sandwich Panel or PU Panel is a structure made of polyurethane foam "sandwiched" between two side skins made of another material such as metal. The foam in between provides thermal insulation. The combination of the materials offers benefits such as its lightweight, durability, and resistance to corrosion and weather elements. All these benefits make the Polyurethane Sandwich Panel ideal for roofing.
Important Features & Applications of Polyurethane Sandwich Panel
A Polyurethane Sandwich Panel, also known as PU Panel, is a composite material composed of three layers of polyurethane foam sandwiched between two metal side skins. This material is extremely durable, lightweight, and resistant to extreme weather conditions. Its strength is further enhanced by its ability to retain its structural rigidity even when the temperature rises and falls. Its applications range from prefabricated buildings to portable cabins and stadiums.
Features of Polyurethane Sandwich Panel
PU Sandwich Panels are available in different thicknesses. The best part about this type of material is that it has the highest density of all insulation panels. PU Sandwich Panels are an excellent choice for cold rooms, freezers, and cooling facilities. They are also a perfect choice for building roofing. Moreover, this type of material is also ideal for modular buildings and construction enclosures.
A Polyurethane Sandwich Panel can be a good choice for buildings that require a fire-resistant structure. Since it is highly complex, it's crucial to find a supplier that manufactures these panels. This way, you'll get reliable technical support and can ensure that the panels meet your specific needs.
A Polyurethane Sandwich Panel is an attractive alternative to traditional construction methods and is used by many construction companies. Neer Enterprises is one of the leading manufacturers of PU sandwich panels. A PU sandwich panel is a superb alternative to traditional building methods due to its extremely adaptable and robust features. Due to the weight of PU sandwich panels, it's vital to choose a company that specializes in this type of material.
Several Advantages of Polyurethane Sandwich Panel
A PU sandwich panel is a particularly desirable material for industrial and commercial projects. Its poor heat conductivity allows a building's framework to be made thinner. This lower thermal conductivity can save money and energy. By keeping a building cool during the summer and cold during the winter, the PU sandwich panel can help to reduce energy bills. This material is an excellent choice for buildings that need to be resistant to rust.
Polyurethane Sandwich Panel is a durable, lightweight, and affordable material for roofing. It can also be used as a floor covering, as it is durable and easy to install. Unlike other materials, polyurethane is flammable, so make sure you have a plan to address the risk of fire and make sure you choose a suitable product. If you are considering using a Polyurethane Sandwich Panel, be sure to consider the safety of the building.
In addition to roof applications, PU Sandwich Panel is also an effective material for floors. Its flexibility makes it ideal for a variety of applications. Its flexibility means that it can be applied to both the exterior and interior of a building. A Polyurethane Sandwich Panel's consistent thermal conductance can help a building maintain its desired temperature while infusing energy with the surrounding environment. The panels are a highly efficient way to save money on energy.
Because of its lightweight and insulating properties, PU Sandwich Panel is a versatile material for any type of building. Its high thermal transmittance and elasticity make it an excellent choice for roofs and other structural applications. The panel's durability is unmatched, and its thermal-transmitting qualities make it a perfect choice for a wide range of construction projects. There are many benefits to choosing a Polyurethane Sandwich Panel for your building.
The price of a Polyurethane Sandwich Panel varies depending on the size, weight, and country of production. The price of a sandwich panel is dependent on the specifications and the country of origin. For example, PU Sandwich Panel is used as a roofing material, while PU slats are used for flooring.
There are different types of PU sandwich which can be manufactured with both continuous and discontinues sandwich panel line:
PU Wall Panel for Cold Rooms
Typical Size of Cold Room Sandwich Panel: 120, 150, 170, 200 mm
PU Roof Panels
The number of Grooves can be selected / Typical Size of Roof Sandwich Panel: 40, 50, 60, 70, 80, 90, 100, 120 mm
PU Wall Panels
Typical Size of Wall Sandwich Panel: 40, 50, 60, 70, 80, 90, 100, 120, 150, 170, 200 mm
Secret Fix Panels (hidden screw sandwich panel, boltless sandwich panel, and hidden joint sandwich panel)
Typical Size of Secret Fix Sandwich Panel: 40, 50, 60, 70, 80, 90, 100, 120, 150, 170, 200 mm
Solar Roof Panels
Typical Size of Roof Sandwich Panel: 40, 50, 60, 70, 80, 90, 100, 120 mm
Duct Panel
Typical Size of Duct Panel Sandwich Panel: 20, 30 mm
Board Panel
Typical Size of Board Panel Sandwich Panel: 20, 30, 40, 50, 70, 100, 120, 150, 200 mm
Weight And Length Of PU Sandwich Panel
The two factors which determine the sandwich panel weight are:
The thickness of skin, previously mentioned that the sheets could be PPGI (pre-painted Galvanized iron, also known as pre-coated steel, coil coated steel, color coated steel coated by a hot dip zinc substrate), PPGL (pre-painted Galvalume iron, coated by a hot dip zinc substrate), Aluminum sheets and paper foils.
The density of PU foam produced by metering or foam machine in the sandwich panel production line.
The length of the sandwich panel produced by continuous sandwich panel production depends on the usage requirements which could be a minimum of 0.5 meters to 22-meter long. Yet, sandwich panels are normally produced less than 12 meters for easier transportation and avoiding over-length cargo.
How Much Does It Cost
The two main factors which determine the sandwich panel prices:
The thickness of the sandwich panel
The type and thickness of the skin
Therefore, the price of the sandwich panel will be different with every single specification and request. There is of course one more factor in sandwich panel prices; the country in which sandwich panel is produced. The raw material of sandwich panel could be available in some countries, so sandwich panel manufacturer can easily access the raw material, and sandwich panel might be lower in those countries whereas in some countries raw material for sandwich panel production might be imported (associated import cost to be added) and locally not available. As a result, the sandwich panel price will be higher.
Thermal Insulation of PU Sandwich Panel
Thermal Transmittance or K-value is the rate of transfer of heat through a structure (which can be a single material or a composite), divided by the difference in temperature across that structure. The units of measurement are W/m²K. The K-value is determined by the thickness of the sandwich panel.
The below chart shows an example of approx. weight and K-value of the sandwich panel where 40 ± 2 (kg/m³) density of sandwich panel is considered consistent and PPGI for both sides of PU foam is 0.5 mm.
|
The thickness of the Sandwich panel line (mm) |
40 |
50 |
60 |
80 |
100 |
|
Weight of Sandwich Panel (kg/m2) |
10.1 |
10.6 |
11 |
11.9 |
12.8 |
|
Thermal Transmission K-Value of Sandwich Panel (w/m2 K) |
0.52 |
0.43 |
0.35 |
0.27 |
0.21 |
Polyurethane sandwich panels are widely used in various applications
Building construction: Used as wall and roof panels in commercial, industrial, and residential buildings.
Cold storage: Used as insulation in refrigerated warehouses and containers to maintain low temperatures.
Transport: Used as walls and roofs in trailers, truck bodies, and shipping containers.
Portable shelters: Used in the construction of mobile homes, cabins, and shelters.
Clean rooms: Used as walls and ceilings in controlled environment facilities, such as laboratories and electronics manufacturing plants.
Agricultural buildings: Used as roof and wall panels in barns, stables, and other agricultural structures.
Sports facilities: Used as walls and roofs in indoor sports facilities, such as gymnasiums and ice rinks.
Installation
1. Before installation, first of all, construction preparation should be carried out, including personnel and materials, everything should be prepared.
2. Before the installation of the wall panel, the verticality and level of the wall purlin installation should be checked to see if they meet the requirements, and the verticality of the wall frame column meets the requirements.
3. Before installing the polyurethane wall panel, the water barrier at the bottom of the board and the water barrier at the bottom of the window should be installed first, and the water barrier should be fixed with self-tapping screws for the connection between the water barrier and the wall frame beam.
4. Polyurethane wall panels are connected to the ground.
Horizontal link: The round hole between the fixed polyurethane sandwich panel and the other end of the ground is fixed with a steel frame, and the two board mouths are joined together; if cracks appear in the joint, insulation can be used to fill them.
Differences Between PU and PIR Sandwich Panel
Chemical properties
Rigid foam is formed by mixing four or more components in the metering machine or foam machine, main compensates of PU and PIR foam are Methylene Diphenyl Di-isocyanate (MDI, commonly known as isocyanate or ISO) and POLY.
There are two types of polyol
Polyethylene Glycol (PEG)
Polyester Polyol.
In simple terms: when ISO is mixed with Polyethylene Glycol (PEG), polyisocyanurate (PIR) rigid foam is created as a chemical reaction and when Polyester Polyol is mixed with ISO, polyurethane foam (PU). Of course, the presence of other components such blowing agent and catalyst are very vital in order to have a perfect closed-cell rigid foam with effective thermal insulation. Insulation is achieved by having almost 97% of the blowing agent gas contained in the cells of the foam. Rigid foams are used to prevent energy loss and minimise CO2 emissions applications that require thermic insulation.
Flame Resistance Properties
One of the most major difference between PU and PIR rigid foam in sandwich panel is in the flame resistance characteristic. PU foam is known for its limited fire resistibility, PU sandwich panel is normally produced with B2 and B3 fire classification of building materials:
Class B: Combustible materials (such as textiles, furniture and other interior)
Class B1: Flame Retardant
Class B2: Normal Flammability
Class B3: Easily Flammable (not usable in industrial Buildings)
On the other hand, PIR slows the spread of flames and reduces the smoke emitted from the fire when compared to PU products. Generally, PIR sandwich panels have excellent fire performance, reduced combustibility, and higher working temperature limits compared to PU. PIR sandwich panels are produced with B1 fire classification of building materials. Indeed, PIR sandwich panels pass compulsory fire tests without the addition of external flame retardants.
Production Differences
For production of PIR sandwich panel with sandwich panel production line, same poly as PU sandwich panel cannot be used. The poly used in metering machine has to be specifically manufactured for PIR foam. In the production of PIR sandwich panel, the proportion of MDI is higher, and instead of polyols on ethers, a polyether polyol is used in the reaction. Thecatalysts and additives used to produce PIR are also different from those used in PUR.
Furthermore, heating in double belt of sandwich panel production line will be higher in PIR sandwich panel. Double belt in the production of PIR sandwich panel line will reach around 60 centigrade while for PU sandwich panel it will be around 40 centigrade.
In the production line of the sandwich panel, un-coiler, roll forming, double belt, cutting machine for sandwich panel, stacking sandwich panel cooling system of sandwich panel and packing of sandwich panel will be the same.
Structural differences of polyurethane sandwich panels and polystyrene
Polyurethane sandwich panels were used in construction. Polystyrene sandwich panels are a new phenomenon used in construction. This is a good replacement for this structure.
Differences between polyurethane and polystyrene
Polyurethane is one of the best insulators in the world and it is used in the manufacture of air conditioners, refrigerators, and freezers. Many home appliances are designed and made with polyurethane.
How to produce polyurethane and polystyrene
The production method of these two distinguishes between them. These are used as a material on both sides of the foam. Polyurethane is used in the industry as an adhesive. Some products are even designed and manufactured with three layers of polyurethane.
Polystyrene sandwich panels are used on both sides of the parquet. Polyurethane is also used for the same purpose. The size of the parquet matches the polystyrene sandwich panel. After gluing the sandwich panel, the polystyrene is subjected to mechanical pressure to dry the glue.
Moisture feature of polyurethane and polystyrene sandwich panels
Moisture resistance is one of the prominent features of polystyrene sandwich panels. A polyurethane sandwich panel is also equipped with this feature. Moisture resistance in polystyrene sandwich panels is 2 to 5% and this amount is 1.2 in polyurethane sandwich panels. Therefore, it turns out that the performance of urethane sandwich panels will be better than polystyrene.
Fireproof feature of polyurethane and polystyrene sandwich panels
The chemical polyurethane does not burn normally, it can even act as a fire extinguisher. This material catches fire at a temperature of 1000 degrees Celsius. Polystyrene is in good condition and softens at 180 ° C and melts at 240 ° C. Polyurethane has advantages in this property over polystyrene.
Compressibility of polystyrene and polyurethane sandwich panels
Density is one of the advantages of the product. The density of polyurethane is 2.2 pounds and polyurethane is 1, which again puts polyurethane in a better position.
Chemical resistance properties of polyurethane and polystyrene sandwich panels
Polyurethane is resistant to chemicals and polystyrene is neutral to petroleum products. The properties of both substances are similar in many ways.
Our Factory
Element insulation sandwich panels, along with overhead section door and cold storage door, have gained widespread adoption as building insulation in developed nations like Europe, the United States, and Japan, achieving an 80% penetration rate.Renowned for exceptional thermal insulation, fire resistance, and energy efficiency, Element's energy-saving sandwich panels consist of two layers of color-coated steel or alternative metal sheets bonded by flame-retardant polyurethane foam. Utilizing cutting-edge technology like high-pressure foaming and curing, these panels boast a sleek appearance, robustness, and superior properties in fireproofing, thermal insulation, waterproofing, soundproofing, and pest resistance. Recognized globally as a premier eco-friendly, energy-saving, and heat-insulating material, they provide a compelling solution to China's energy consumption challenges.
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