Polyurethane edge-sealed rock wool sandwich metal composite panel

Product Definition

Polyurethane-Edge-Sealed Rock Wool Sandwich Metal Panels are high-performance building envelope panels. They combine the exceptional fire resistance, thermal insulation, and acoustic performance of a rock wool core with the high strength, superior thermal insulation, and airtight sealing provided by the polyurethane (PUR) edge-sealing technology. The core is fully protected by high-strength metal facings (typically pre-finished steel or aluminum). This innovative design synergizes the advantages of both core materials, overcoming the limitations of traditional rock wool panels in terms of strength, edge sealing, and thermal bridging at the edges.

Core Structure & Composition (From Outside to Inside)

1. Metal Facings:

• Material: High-quality Galvalume® (aluminum-zinc alloy coated steel), galvanized steel, or aluminum.

• Coating: Durable pre-painted finishes (Polyester (PE), Siliconized Polyester (SMP), Polyvinylidene Fluoride (PVDF)) offering excellent corrosion resistance, UV stability, color retention, and self-cleaning properties.

• Profiles: Available in various profiles (corrugated, micro-rib, concealed fastener systems) to suit architectural styles and functional requirements.

2. Core Material:

• Class A (A1) Non-Combustible: Highest fire safety rating. Does not ignite, contribute to fire spread, or release significant toxic smoke.

• Superior Thermal & Acoustic Insulation: Fibrous structure effectively blocks heat transfer and sound transmission, providing excellent thermal resistance and sound absorption.

• Hydrophobic: Treated to repel water, minimizing moisture absorption and maintaining long-term thermal performance.

• Chemically Stable: Resistant to corrosion and degradation.

• Primary Core: Rock Wool - Manufactured from molten basalt rock spun into fibers.

3. Edge Treatment: Polyurethane (PUR) Edge-Sealing (Key Innovation):

• Enhanced Structural Integrity: PUR foam bonds strongly to both metal facings and the rock wool core, significantly increasing the panel's overall stiffness, bending strength, and load-bearing capacity. Particularly reinforces the vulnerable edges for safer handling, transport, and installation.

• Elimination of Thermal Bridging: Creates a continuous, high-performance thermal barrier at the panel edges, completely preventing "thermal bridging" (heat/cold transfer through the facings at the joint). Dramatically improves the overall thermal efficiency of the building envelope, reducing energy loss and preventing condensation.

• Superior Airtightness & Weathertightness: Forms a dense, continuous seal, effectively blocking moisture vapor, rain, and air infiltration. Protects the rock wool core from moisture ingress and enhances the panel's air/water barrier performance.

• Robust & Clean Edges: Provides strong, smooth, and durable panel edges, resulting in tighter, cleaner joints and a more aesthetically pleasing installation.

• Material: Rigid polyurethane foam injected and bonded along the longitudinal edges of the panel.

• Critical Functions:

Key Advantages & Features

1. Exceptional Fire Safety (Class A/A1): Rock wool core provides top-tier fire performance, meeting stringent building code requirements.

2. High Thermal Efficiency: Rock wool core offers excellent baseline insulation, while PUR edge sealing completely eliminates edge thermal bridging. The overall thermal performance significantly surpasses traditional metal-edged rock wool panels and approaches that of pure PIR/PUR foam panels, leading to substantial building energy savings.

3. Excellent Acoustic Performance: Rock wool's fibrous structure effectively absorbs sound waves, reducing noise transmission.

4. High Strength & Stiffness: PUR edge sealing drastically improves panel integrity and edge strength, resulting in outstanding resistance to wind pressure (positive & negative), impact, and point loads. Suitable for large-span applications.

5. Superior Sealing & Moisture Resistance: PUR seal creates a perfect barrier against moisture ingress, protecting the rock wool core and ensuring stable long-term thermal performance. Prevents internal condensation and corrosion.

6. Durability & Longevity: High-quality facings resist corrosion and weathering. Stable PUR seal and non-aging rock wool ensure a long service life.

7. Fast & Efficient Installation: Reinforced edges minimize damage. Well-designed joint systems (e.g., tongue-and-groove, concealed clips) enable quick, secure, and high-quality installation.

8. Sustainable & Energy Efficient: Superior insulation reduces operational energy consumption. Rock wool and PUR are recyclable materials (subject to local regulations).

Primary Applications

• Industrial Buildings: Large factories, workshops, warehouses, logistics centers (high demands for fire safety, insulation, large spans).

• Public Buildings: Stadiums, exhibition halls, airports, theaters, hospitals, schools (emphasis on fire safety, energy efficiency, acoustics).

• Commercial Buildings: Shopping malls, supermarkets, cold storage facilities (require high insulation, moisture resistance).

• Clean Rooms: Pharmaceutical plants, electronics factories, food processing facilities (require high cleanliness, fire safety, insulation).

• Building Retrofit: Roof and wall upgrades for energy efficiency.

• Fire Compartmentation: Firewalls, fire-rated partitions.

Typical Specifications (Varies by manufacturer)

• Facing Thickness: 0.4mm - 0.8mm

• Core Thickness: 50mm, 75mm, 80mm, 100mm, 120mm, 150mm, 200mm (common)

• Rock Wool Density: Typically ≥ 120kg/m³ (ensures strength & fire performance)

• PUR Edge Seal Width: Covers the full edge profile, width optimized for performance.

• Effective Cover Width: 950mm, 1000mm, 1150mm, etc.

• Length: Customizable, typically ≤ 12 meters (transport limitations).

• Reaction to Fire: Class A (A1) Non-Combustible (core + edge system compliant).

• Thermal Conductivity (λ):

• Rock Wool Core: ≈ 0.040 W/(m·K)

• PUR Edge Seal: ≈ 0.022 - 0.024 W/(m·K)

• Overall Panel Performance: Superior to traditional metal-edged rock wool panels, approaching pure PIR/PUR foam panels.

• Bending Strength / Load Capacity: Significantly higher than same-thickness metal-edged rock wool panels.

• Standards Compliance: Typically conforms to relevant international standards (e.g., EN 14509, ASTM standards).