Cold Room Panel, Cold Storage Panel PU Sandwich ...

Exploring the Variety of Cold Room Panels

When it comes to cold room panels, you have an extensive selection to choose from. The materials used for these panels typically include either PPGI or galvalume steel with a thickness range of 0.4 to 0.8mm. The density of these panels varies between 38 to 55 kg/m3, while their thickness can range from 50mm to 200mm. Standard widths are 980mm, but customization options are available.

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The length of cold room panels is flexible, allowing for customization based on project requirements. However, for logistics, orders must adhere to the maximum length restrictions imposed by a 40HQ shipping container, which is 11.85m.

A complete set of accessories is provided with cold room panels, including channel profiles and ceiling hanging equipment. The doors are designed for maximum airtightness, featuring both manual and electric options.

In the case of freezer installations, proper floor preparation is essential. This includes applying an anti-water film, XPS insulation, heating wires, a concrete base, and drainage channels to ensure cold air containment. Once installation is complete, cutting lines on the panels is necessary to eliminate thermal bridging.

Typically, cold room panels are delivered within a week of placing an order.

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Cold Room Panels: Comprehensive FAQ Guide

This guide aims to inform you about the R-value, structure, material types, features, components, and various uses of cold room panels.

To enhance your knowledge in the domain of cold room panels, continue reading.

Defining Cold Room Panels

Cold room panels are specialized structural insulated panels utilized in the construction of cold storage facilities with regulated temperatures.

The panels are superior in quality, providing better insulation compared to conventional insulation solutions.

Figure 1 Cold room storage unit

Reasons to Build a Cold Room

A cold room functions as a refrigeration chamber or storage facility for products requiring specific temperature control, typically below the ambient conditions.

Cold rooms are crucial for preserving goods that cannot last long under normal temperatures.

By storing these items at lower temperatures, the rates of biological or chemical activity—and consequently, deterioration—are significantly reduced.

Figure 2 Cold room panel

Industries That Benefit from Cold Rooms

Various sectors that require the storage of temperature-sensitive products necessitate cold rooms, including but not limited to:

• Chemical processing
• Slaughterhouses
• Pharmaceuticals
• Food and beverage industries
• Retail businesses such as supermarkets and restaurants
• Electronics and computing
• Fisheries
• Agriculture and horticulture

Materials for Constructing Cold Room Panels

Several materials can be chosen to fabricate cold room panels, with decisions based on specific applications and environmental circumstances.

Figure 3 Structure of cold room panel

Sandwich Panel Faces

The sandwich surfaces form the outer layer of the cold room panel, enclosing the core.

The following materials can be used to construct the sandwich panels:

Steel

Steel is the preferred choice due to its robust performance across various applications and environments. It is typically coated to resist rust and corrosion. In food storage contexts, stainless steel is often preferred for its non-rusting properties, although it comes at a premium cost.

For storing chemicals or salty substances, coatings can prevent corrosion. However, for interior sections of the panels, care must be taken as steel can be more fragile.

Aluminium

Aluminium is an excellent option for cold rooms that store agricultural products due to its resistance to salts and chemicals, although it has higher thermal expansion and can be more pricey than mild steel.

The Core

The core is essential for providing thermal insulation in cold room panels and can be made from various materials of differing thicknesses, aligning with the application’s needs.

Polyurethane (PU)

PU is a high-performance insulation material that results from combining an isocyanate with a polyol mixture. Its rigidity contributes to excellent insulation capabilities while being lightweight.

PU boasts low thermal conductivity and high thermal resistance (R-value), making it ideal for energy conservation and reducing CO2 emissions.

PU is recognized for its fire rating of B2 and a density of 40kg/m3.

Polyisocyanurate (PIR)

PIR is an upgraded version of PU, manufactured via a reaction involving MDI and polyol at elevated temperatures. This material offers superior thermal insulation properties and higher expense, being suitable for use in applications needing better thermal performance.

PIR has a fire classification of B1 and a density of 42kg/m3.

Categories of Cold Room Panels

Figure 4 Cold room panel structure

Cold room panels come in three main types:

• Ceiling/Roof panels
• Wall panels
• Floor panels

Characteristics of Quality Cold Room Panel Materials

Proper materials for cold room panel construction should exhibit the following traits:

• Lightweight
• Poor thermal conductivity
• High mechanical strength
• Excellent thermal resistance
• Dimensional stability across temperature variations
• Corrosion resistance
• Resistance to biodegradation
• High fire resistance ratings
• Prevention of mould growth
• Simple processing and coating
• Weather-resistant

Longevity of Cold Room Panels

A cold room panel’s lifespan can vary based on material quality, environmental factors, usage, and maintenance routines.

With proper maintenance, cold room panels can last over a decade before needing replacement.

Understanding R-value

R-value, or resistance value, is a rating system for insulating materials based on thermal resistance.

Higher R-values indicate better insulation. Factors influencing R-value include material thickness, type, and density. In installations employing multiple layers, the total R-value is calculated through the addition of each layer’s R-value.

Explaining Thermal Bow

A thermal bow occurs due to temperature differences between the inner and outer surfaces of insulating materials. Proper installation is vital to distribute these forces evenly and avert undesired deformities.

It is advisable to consider the following precautions when panel lengths exceed 26 feet:

• Opt for thicker materials
• Design thermal cuts or expansion joints within the panels
• Select lighter-colored panels
• Utilize repetitive patterns on the exterior
• Reduce tension on screws to balance temperatures
• Construct panels in shaded areas

Specifications to Review Before Purchasing Cold Room Panels

Figure 5 Structure of cold room panel

Before acquiring cold room panels, specific requirements at the installation location should be considered:

Cold Room Dimensions

Dimensions will affect the length and thickness of the panels. Environmental temperature and humidity should inform your choice of thickness for the cold room.

Insulation Options

The core material can be PIR or PU based on the application's needs. The thickness will be determined by the environmental temperature, operational temperature, and heat influx.

Vapour Barrier Implementation

A vapour barrier should be installed on the cooler side of the cold room to prevent moisture-laden air from entering, which can cause ice build-up and degrade insulation.

Thermal Specifications

These depend on the core material properties and will guide the optimal panel thickness to be utilized.

Air Chamber Installation

This is crucial for protecting the panels around the cold room enclosure. Ensure the materials used for air chambers are durable and intact.

Joint Sealing

Sealing is necessary to inhibit heat loss and moisture entry on both sides of the panel. Options include silicone or butyl sealants, among others.

Essential Construction Specifications for Cold Room Panels

When ordering cold room panels, be equipped with the following details to ensure proper construction:

• Cold room location
• Type of materials for storage
• Cold room dimensions
• Total product capacity
• Incoming product temperatures
• Desired operating temperatures
• Timeframe required to reduce product temperature
• Cold room door dimensions

Maintenance Recommendations for Cold Room Panels

Regular maintenance is crucial for the durability and efficiency of cold room panels. Consider the following best practices:

• Inspect ceiling fastenings and adjust tension.
• Check the structural integrity of panel joints and address any issues promptly.
• Examine sealants to prevent water intrusion.
• Implement measures to mitigate potential panel damage during stock handling.
• Establish walkways for maneuvering during maintenance tasks.
• Clean panels at least twice annually, adhering to manufacturer guidance for appropriate cleaning solutions.
• Monitor for bulges, which indicate possible water ingress, and address immediately.

Water intrusion can occur through joint failures, panel damage, or gaps between panels and channels. Identify and repair these vulnerabilities promptly.

Cost Factors for Cold Room Panels

Cold room panel costs depend considerably on the materials used and their thickness. Typically, PIR panels will be more expensive than those constructed with PU, while stainless steel panels will incur higher costs compared to other materials.

Figure 6 PU Panel

Constructing a Cold Room with Cold Room Panels

Consider the following when constructing with cold room panels:

Wall and Roof Panel Assembly

Cold rooms can be assembled by interlocking various panels through male and female connections, cam locks, or hooked designs. For optimal insulation, ensure joints are sealed with suitable materials.

Floor Preparation

The flooring must be level prior to installation, with techniques tailored to the specific application. Freezer floors require careful anti-freezing measures, while general cold room floors should be structured methodically:

• Place hollow vaults made from bricks.
• Concrete filling follows.
• A vapour barrier is installed next.
• Insulating plates with sealants are added.
• To shield against water, apply an impermeable material.
• Finish with reinforced concrete, ensuring a resilient framework.
• Incorporate a retracting seal whose depth corresponds to the thickness of the concrete.
• Ensure smooth anti-vapour barriers are in place to prevent moisture ingress.

Factors Affecting Cold Room Panel Performance

Product preservation quality may be impacted by various aspects, including:

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• Properties of stored products and packaging.
• Storage organization and filling practices.
• Structure and surface area of evaporators.
• Temperature differentials between evaporators and room temperature.
• Air circulation within the cold room.
• Shape of the enclosure and designated temperature range.

Cleaning Procedures for Cold Room Panels

Regular cleaning of cold room panels is essential to maintain hygiene standards, particularly when storing food. Follow these guidelines:

• Rinse surfaces thoroughly with clean water from top to bottom to remove dirt and prevent microbial growth.
• Utilize mild cleaners and avoid harsh chemicals that could damage panel surfaces.

Concentration of cleaning solutions should be less than 5%, and pH range should be between 4 and 9. Use white spirit for removing grease, followed by rinsing with clean water.

• Exercise caution with high-pressure hoses, maintaining a distance of at least 30cm from the panel surface and a maximum pressure of 50 bars.

Adjust fluid temperatures between 30°C and 50°C, ensuring not to exceed 70°C to protect panel integrity.

• Direct the high-pressure stream downwards when cleaning joints to prevent water intrusion.

Utilize non-abrasive cleaners to remove residue.

• Immediately rinse cleaning agents off panel surfaces to avoid oxidation.

The general rule is to rinse any detergents within 5 minutes.

Quality Testing for Cold Room Panels

Quality assessment of cold room panels adheres to established procedures for testing thermal insulation materials. These tests vary by standard and requirement:

• Thermal conductivity assessments (EN).
• Dimensional stability evaluations (EN, EN, EN).
• Water performance scrutiny: Water absorption (EN, EN, EN), and vapour transmission (EN, EN).
• Mechanical evaluations: Compression (EN 826), bending (EN), shear (EN), creep (EN), and tensile testing (EN, EN).
• Acoustic evaluations: Dynamic stiffness (EN -1) and sound absorption (ISO 354).

Insulating Cold Room Panels

Figure 7 Insulated cold room panel

Insulating a cold room panel begins with selecting the most suitable core material, ensuring it is resistant to rot, odour, fire, and vermin while being impermeable to moisture. Options include polystyrene, polyurethane, or Styrofoam FR.

The thickness is determined by the desired operational temperature, thermal conductivity, and ambient dew points. Prevent thermal bridges during installation and insulate pipes carrying refrigerants at lower temperatures. Ensure all joints are sealed adequately and provide an effective vapour barrier to prevent water ingress.

The cold room door should be insulated similarly to the walls and fitted with a heating element to prevent ice formation on the seal.

Main Components of a Cold Room Panel

The two primary components of a cold room panel are its core and the exterior/sandwich board.

Figure 8 Parts of cold room

The Core

A variety of materials can comprise the cold room panel core, primarily focused on providing thermal insulation. Common materials include polyurethane (PUR) and polyisocyanurate (PIR) foams, differing in insulation efficiency and fire resistance.

Sandwich Board/Face

Depending on usage, different materials such as metal sheets or oriented strand boards can form the exterior of the cold room panel. Multi-layered outer shells offer protection against environmental influences and include:

• Topcoat
• Primer-coat
• Pre-treatment
• Galvanization
• Base material, such as steel
• Additional galvanization
• Pre-treatment
• Back-coat

Surface coatings should be tailored to protect against UV exposure or corrosion, depending on the application, especially in food storage where safe materials are required. Manufacturers often provide standard sizes or custom options based on specific needs.

Understanding SIPs Panels

Figure 9 SIP Wall

Structural insulated panels (SIPs) are utilized in constructing walls, ceilings, and roofs for both commercial and residential spaces. SIPs feature a rigid insulating core sandwiched between two structural boards, often leading to more cost-efficient, robust, and energy-efficient building solutions.

Preventing Mould Development in Cold Room Panels

The conditions within a cold room can facilitate mould proliferation, posing health risks and endangering product quality. To keep your cold room mould-free:

Cleaning Regularly

Establish a monthly cleaning routine utilizing proper disinfectants for surface sanitization. Avoid methods such as dusting or sweeping that can release spores into the environment.

Wet cleaning followed by drying with a cloth is recommended. Additionally, check for leaks and rectify immediately, and promptly clean up spills as these can accelerate mould growth.

Proper Material Storage

Organize items correctly within cold rooms, using plastic or metal containers for perishable or organic products. Avoid cardboard, which can promote mould growth. If using porous materials, ensure they are stored in non-porous containers.

Construct shelving from stainless steel or consider seasoned wire shelving that encourages airflow.

Always keep the cold room entrance closed to avert unwanted mould spores and moisture ingress.

Avoid storing items directly on the floor or against walls, and control access to authorized personnel.

Joining Cold Room Panels

Figure 10 Joining cold room panel

Joining techniques for panels depend on their interlocking design. For vertical and roof installations, panel types may include male and female interlocks, cam locks, or tongue and groove interlocks. For male and female options, press panels together, while hooked designs require rotating an eccentric hook to secure on the metal axle, employing two settings for proper alignment.

Properly joined panels ensure effective insulation around the joints. Sealing at the installation site can enhance insulation, utilizing materials like silicone for air and water sealing, butyl for moisture management, or foam for negative temperature retention.

As we conclude this guide, you may have further questions regarding cold room panels or wish to import panels for your projects.

For high-quality, competitively priced cold room panels, reach out to Sunnyda House.