INSULATED SANDWICH PANEL

WHAT IS SANDWICH PANEL?

Sandwich panels (sometimes referred to as Composite Panels or Structural Insulating Panels or Insulated Sandwich Panel consists of two layers of a rigid material bonded (zyncalume) to either side of a lightweight core. The three compressed components act together as a composite. The lightweight core keeps the two faces in the correct position, resists shear forces, and provides insulation, while the two faces provide durability, weather and impact resistance, and resist in-plane forces of tension and compression.  Insulated Sandwich Panel is a light material in a modular shapes which is easily applicable to meet project specific demands, so that workmanship is shorter than the conventional building construction. Insulated Sandwich Panel is known of its high thermal efficiency and maintenance cost saving, which is suitable for use within temperature controlled and hygiene safe environment.

STEEL SKIN

CLEAN TECH

POLY TECH

ECO TECH

The standard external and internal sheets are made from zincform, pre-painted galvanized steel that consist of zincalum base metal with corrosion resistant alloy.
Coating of the steel skin usually are the modified polyester or acrylic paint that are finished with food-grade coatings based on the usage of the panel.
The skin thickness ranges from 0,5mm to 0,6 mm TCT, with 0,15mm plastic film that laminated to protect the panel skin.
There are some key differences between the panel core types. Typical types of the core include:
1. Expanded Polystyrene (EPS),
2. Polyurethane (PU),
3. Paper/Alumunium Honey Comb, and
4. Rockwool.

Each core performs differently in fire.

The standard external and internal sheets are made from colorbond zincform, pre-painted galvanized steel consist of zincalum base metal with corrosion resistant alloy compromising of 55% alumunium, 43,5% zinc, and 1,5% silicone.
Coatings of the steel skin usually are the modified polyester or acrylic paint that are finished with an antibacterial or food grade coating based on the usage of the panel.
The other type of the coating is CRP, a zinc coated cold room panel steel specifically designed for cold and chill store construction.
The skin thickness is 0,68mm TCT, with 0,15 mm plastic film that laminated to protect the panel skin.
There are some key differences between the panel core types.

Typical types of the core include:
1. Expanded Polystyrene (EPS)
2. Polyurethane (PU)
3. Non-approved Polyisocyanurate (PIR)
4. Rockwool

Each core performs differently in fire.

The standard external and internal sheets are made from zincform, pre-painted galvanized steel that consist of zincalum base metal with corrosion resistant alloy.
Coatings of the steel skin usually are the modified polyester or acrylic paint that are finished with food-grade coatings based on the usage of the panel.
The skin thickness ranges from 0,5mm to 0,6mm TCT, with 0,15 mm plastic film that laminated to protect the panel skin.

There are some key differences between panel core types. Typical types of the core include:
1. Expanded Polystyrene (EPS)
2. Polyurethane (PU),
3. more recently Non-Approved Polyisocyanurate (PIR)
4. Rockwool

Each core performs differently in fire

THE CORE

o EXPANDED POLYSTYRENE (EPS)

Expanded Polystyrene is light weight CFC free, non-brittle closed cell foam with consistent thermal insulation performance, high dimensional stability and low water vapor transmission.

Density : 15 kg/m3 – 20 kg/m3

EPS Foam is manufactured from 100% virgin bead with low density (15 kg/m3 – 20 kg/m3), oven-cured after manufactured to ensure the block make it self-extinguish fire retardant.

Manufactured with a fire retardant grade of EPS, it is traditional and cost-effective panel depending on construction detail.

o POLYURETHANE (PU)

Polyurethane is rigid foam material injected to the core with CFC free blowing agent to a high density (up to 38 Kg/m3 – 42 Kg/m3).

Like EPS, PU contains no residual pentanes as it is self-extinguished fire retardant.

Density : 38 kg/m3 – 42 kg/m3

o NON-APPROVED POLYISOCYANURATE (PIR)

Polyisocyanurate is rigid polyurethane foam made by mixing isocyanate and polyol with appropriate catalysts and HCFC free blowing agent to a high density (55 Kg/m3 – 60 Kg/m3).

In the event of fire, this core will simply chars. 

PIR panel are durable, providing high thermal resistance, mechanical resistance, and dimensional stability.

Density : 55 kg/m3 – 60 kg/m3

o ROCKWOOL

Rockwool panel is the ideal choice where a non-combustible core is required. 

Rockwool panel is not recommended for cold storage application, but is ideal near hot work area as it does not burn.

Density : 100 kg/m3 – 120 kg/m3

o HONEYCOMB PAPER / ALUMUNIUM

A revolutionary product that effectively replaces wood, PU, and EPS in a variety of applications is an environment friendly new-age alternative.

Can be used for a variety of applications to provide lightweight, strength, portability, durability, and environmentally friendly to the products.

The advantages of Alumunium / paper honeycomb are high fire resistant, low weight, high strength but higher cost, low thermal, and low noise insulation.

ACCESSORIES

DOOR & WINDOW

Door and window suitable for insulated sandwich panel system are powder coated finished aluminium frames with non-corrosive heavy duty components. Doors are electrically or manually operated with single action lever mechanism, while windows and other viewings are fixed with high quality laminated glass or acrylic as required.

There are wide ranges of doors and windows suitable for insulated panel systems applications. Horizontal  or vertical sliding, hinged or bi-parting are mostly available. For cleanroom applications, triple vacuum glass windows with slopes that are rounded with non-rivet frames are a good available choice.

ELECTRIC INTERLOCK

MAGNETIC INTERLOCK

ALUMINIUM EXTRUTION

Insulated sandwich panel system requires aluminium extrutions specifically designed for a wide range of applications. For cleanroom applications, the two-piece radius coving design is suitable to fulfill the requirements of hygiene, sanitation, cleanliness, and easy to maintain as required by the current Good Manufacturing Practices (cGMP).

The internal and external angles or channels used on the extrutions must be mill-finished or pre-finished with powder coated matched to the panel color.

MECHANICAL / ELECTRICAL FIXTURES

All type of mechanical and electrical fixtures can be applied in insulated sandwich panel system buildings. Wherever penetrations are made to accommodate those fixtures, they must be finished correctly with aluminium extrutions to ensure there is no exposure of the core. Such exposures are perceived to provide easy entry point for humidity or fire.

DOUBLE PLENUM

In pharmaceutical building construction, a plenum is a separate space provided for air circulation for heating, ventilation, and air-conditioning and typically provided in the space between the structural ceiling and a drop-down ceiling.

THE ADVANTAGES

Insulated Sandwich Panel can be easily customized to suit any project with minimum disturbances for installation of wall and ceiling partition or access wherever needed, and with its modular shapes it can be easily dismantled and reassembled when a renovation is needed. A simple and effective interlocking panel system provide fast and shorter erection time while ensuring the panels are joint strongly and tightly to each other, reducing the footing size and eliminating construction support structure. Insulated sandwich panel has smooth white surface that makes it hygienic, easy to clean and maintain

Insulated Sandwich Panel system comes with choices of core types, skin coatings, surface profiles and panel thickness which will suit your project needs and applications. Clean rooms for Pharmaceutical usually either Fire Retardant or Fire Resistant cores to protect against fire burns that might happen due to chemically reactions. Flat surfaces are also suitable for these areas as they need to be easily cleaned and dust free (cGMP) required by the National Agency of Drug and Food Control (BPOM). For the application in Food and Beverage Processing Facilities, more requirements will include food-safe coatings especially for designed Cold Room Panel (CRP) zinc coated steel, to ensure the foods or beverages stored in the room are not contaminated by the coil coatings or steel corrosions. Contact our Sales and Engineering Department for further assistant on how to choose insulated sandwich panel system that is appropriate for your project

PRODUCT APPLICATION

INSULATED SANDWICH PANEL FOR WALL, CEILING, AND ROOFING Our product range allows Architect, Developers, and Contractors to meet and exceed today's construction challenges and create functional buildings that are aesthetically pleasing, energy efficient, safe, cost effective and sustainable. Cleantech systems are manufactured to provide superior built quality, with rapid and safer on-site assembly. The panels are suitable for a range of different sectors including Pharmaceutical, Food, and Beverage Processing, Facade, and Hospital. They can also be used in temperature controlled and hygiene safe environments including cold storage, insuliving, and modular building.

PHARMACEUTICAL

Insulated sandwich panel system are fibre-free, hygiene safe, resisting moisture ingress, toxic mould and bacterial growth, that provides a controlled sterile environment, minimizes airborne particle and micro-organism in order to comply with BS EN ISO 14644-1, clean rooms, and Associated Controlled Environment

HOSPITAL

An operating room in a hospital equipped for the performance of surgical operation; “Great care is taken to keep the operating rooms aseptic.” to provide care patients with specific conditions.

Operating rooms are sterile environments.

FOOD & BEVERAGE PROCESSING

Controlling food processing areas is easy with insulated sandwich panel systems. Temperature within the building can be managed since the panels are designed to withstand internal or external temperature differences (up to 80 degrees Celcius for PIR panel).
The surfaces have hygiene safe coatings, which resist moisture ingress and eliminate any risk of toxic mould or bacterial growth.
Using the EPS, PU, or PIR cores, insulated panel systems have no threat of loose fibres into the internal environment which may harm the foods or beverage inside.

For food processing application, it is recommended to use CRP steel with food-safe / food grade inert polymer film coatings since it is safer for continuous contact with food

COLD STORAGE

Insulated sandwich panel systems are available in different types of cores and thickness which allow for a range temperatures to be maintained, offer temperature controlled environment from – 50 degrees celcius to +60 degrees celcius. Panel joining system achieve excellent thermal performance and can accommodate vapor and hygiene safe seals.

Airtight controlled temperature is mainly required for cold and chill store areas, and must also be applied in the walls, ceiling, floor, and door. Pressure relief ports are placed near doors to eliminate expansive room deformation, reducing ambient ingess that trigger the built-up of ice.

MODULAR BUILDING

Modular Building, also called prefabricated buildings, that consist of multiple sections called module, the module are six sided boxes constructed in a remote facility, then delivered to their intended site of use.

Using a crane, the modules are set onto the buildings foundation and joined together to make a single residential, or commercial building.

The module can be placed side by side, end-to-end, or stacked up to 6 stories in height, allowing a wide variety of configurations and styles in the building layout.

FACADES

Architectural walling offers design versatility, thermal efficiency and effective installation. Select from wide choices of the cores including: EPS, PU, PIR, and Rockwool.

The structural integrity of facade walling system is derived from its sandwich panel construction, making a cost-effective option to other facade materials.

ROOFING

The combination of roofing insulation and ceiling in one durable, functional and attractive panel is ideal to meet these extreme conditions.

Our roofing offers an efficient solution for the construction of today’s sustainable buildings. Apart from its superior thermal performance, construction offers the opportunity to reduce structural components, shortens installation time, and reduce overall construction costs.

Its outer “skins” are made from Bluescope Colorbond Steel, with the top sheet being high tensile steel, a standard upheld by all reputable steel roofing product manufacturers. Utilise an EPS (Expanded Polystyrene), PU (Polyurethane), and Rockwool core which has been used extensively.

INSTALLATION

Abadi Ario Sekawan Professional construction teams, install our insulated panel products throughout the length and breadth of Indonesia.

We have commitment doing it once, doing it right to specification, on time and on budget.

we provide national coverage for installation with the capacity to engage in building works from the subcontracting through to full design and build.