PIR sandwich panel manufacturer

Many cold storage experience frequent problems after being put into use, such as frost buildup, water leakage, slow cooling, soaring electricity bills, and panel deformation. These are not equipment malfunctions, but rather hidden problems created during the construction phase. Today, we summarize some of the most common mistakes in cold storage construction and provide practical solutions to help you avoid these pitfalls and build a durable, low-consumption standard cold storage facility.   I. Blindly Choosing Low-Priced Materials: Incompatible Panel Thickness and Density with Operating Conditions This is the most common problem. Many people, in an effort to cut costs, choose thin, low-density, inferior insulation panels, or use generic panels regardless of temperature range. Using thin panels in low-temperature cold storage will result in severe cold leakage and thermal bridging, leading to long-term frost buildup and a gradual decline in insulation performance. Furthermore, neglecting flame retardant ratings poses a significant fire safety hazard.   Solution: Select materials precisely according to the storage temperature. For cold storage above freezing, use 50–75mm PU composite panels; for freezing below freezing, use 100–150mm high-density PU composite panels; and for ultra-low temperature quick-freezing, prioritize 150–200mm B1-grade PIR composite panels. Before construction, verify the density, thermal conductivity, and flame retardant rating of the boards to prevent the use of inferior materials.   II. Neglecting Construction Details: Inadequate Sealing and Ground Treatment. Incomplete sealing of board joints, missing seams, and lack of edge reinforcement are major causes of cold air leakage. Furthermore, many small cold storage facilities neglect ground insulation and moisture protection, making them highly susceptible to frost heave, cracking, and arching under low-temperature conditions, directly leading to deformation of the storage structure and door jamming.   Prevention Methods: Ensure thorough sealing of board joints and proper edge reinforcement; low-temperature cold storage floors must be covered with a moisture-proof membrane and a pressure-resistant insulation layer, combined with frost-resistant concrete pouring, and maintain ground flatness to prevent frost damage at its source.   III. Mismatch Between Refrigeration Equipment and Storage Structure. Either pursuing high-power units results in energy waste, or prioritizing low-power units to save money leads to slow cooling, 24-hour full-load operation of units, rapid equipment aging, and high electricity costs. Meanwhile, improper installation of temperature control probes can lead to inaccurate temperature readings and large temperature fluctuations.   Solution: Accurately match the unit model to the cold storage area, storage temperature, and frequency of goods entering and leaving the warehouse, and install temperature control equipment according to regulations to ensure uniform and stable temperature and reduce equipment operating load.   IV. Neglecting Compliance Design and Acceptance Testing Some cold storage facilities are haphazardly laid out, lacking evacuation routes and fire compartments, failing to meet fire safety regulations, resulting in extremely high rectification costs later. Furthermore, many projects are put into use directly after completion, omitting no-load testing and hiding numerous operational hazards.   Solution: Plan the layout in accordance with regulations before construction, reserving safety passages and implementing fire compartments. After completion, conduct a 72-hour no-load temperature measurement and defrosting test to ensure stable temperature and normal equipment operation before putting the facility into use.   Summary: Cold storage construction should prioritize details over low prices. Reasonable material selection, standardized construction, and precise configuration are essential to effectively reduce later maintenance costs, extend the lifespan of the cold storage, and achieve long-term stable and low-cost operation.

Cold storage panel are typically composed of double-layer galvanized steel sheets and a layer of polyurethane (PU or PIR) insulation core material. Their thermal conductivity is only 0.024–0.041 W/m·K, providing excellent insulation performance. Common panel thicknesses include 50mm, 75mm, 100mm, 150mm, and 200mm. Thicker panels offer better insulation, lower refrigeration unit load, and more stable internal temperature.   The thickness of the cold storage panel directly determines the energy consumption, temperature control stability, and overall lifespan of the cold storage facility. Improper thickness selection can easily lead to temperature fluctuations, frost formation on the walls, increased power consumption, and panel deformation and damage. Storage temperature is the sole core factor in selecting panel thickness.   1. Fresh-keeping cold storage (+2℃ ~ +10℃) | 50–75mm is preferred. This temperature range is often used for preserving fruits and vegetables, fresh produce, dairy products, and in temperature-controlled food processing workshops. The temperature difference between the inside and outside is small, and the operating conditions are relatively simple. 50–75mm thick insulated cold storage panel fully meet the requirements, effectively blocking outdoor heat penetration and maintaining a stable internal temperature environment. This thickness offers high cost-effectiveness, balancing construction costs and long-term energy consumption, making it the optimal choice for above-zero cold storage.   2. Low-Temperature Cold Storage (-5℃ ~ 0℃) | 80–100mm is preferred This is primarily used for the low-temperature storage of cooked food, semi-finished meat products, and beverages. This temperature range already possesses low-temperature properties; using thin 50mm panels would result in insufficient insulation, leading to heat penetration, condensation on the panels, and dampness on the inner walls, damaging the storage environment.   80–100mm thick cold storage panel is the standard configuration for this scenario, significantly reducing hot and cold air exchange, eliminating condensation and frost problems, ensuring long-term stable operation of the cold storage, and effectively reducing energy consumption.   3. Conventional Cold Storage (-10℃ ~ -25℃) | 100–150mm is preferred  This temperature range is commonly used in commercial frozen goods, seafood, and meat cold storage warehouses, and is also the most frequently used freezing condition in cold chain engineering.   The industry prioritizes 100–150mm thick insulation panels. The high-density, thickened core material effectively locks in the low temperature, prevents cold air leakage, and reduces the frequency of refrigeration equipment start-ups and shutdowns.   4. Ultra-Low Temperature Quick-Freezing Storage (-30℃ ~ -55℃) | 150–200mm is preferred Quick-freezing workshops, deep-sea food storage, and medical low-temperature storage scenarios experience extreme temperature differences, requiring stringent insulation performance. Ordinary thickness panels are unsuitable.   150–200mm thick high-density cold storage panels are a mandatory standard for these projects. They can withstand extreme temperature shocks, preventing frost penetration, panel deformation, and temperature imbalances, protecting high-value goods. Although the initial investment is slightly higher, it ensures long-term stable operation of the cold storage and is a reliable solution for ultra-low temperature projects.   In conclusion, the appropriate thickness of the cold storage panel depends on the storage temperature of the cold storage facility. Selecting PU/PIR cold storage panel of different thicknesses based on varying temperature requirements can mitigate construction risks, reduce energy waste, and result in a cost-effective, stable, and durable high-quality cold storage unit.  

Cold storage panel installation is a core process in cold storage engineering, and the details of the construction directly determine the insulation effect, energy consumption, and service life of the cold storage. Many cold storage facilities experience problems such as cold leakage, frost formation, deformation, and water leakage later on, and 80% of these are caused by improper installation.   1. Pre-construction preparation. Verify the panel parameters in advance, confirm the panel thickness and flame retardant rating according to the temperature control requirements of the cold storage, and check the panel surface for dents, delamination, and damage. At the same time, clean the construction ground, ensuring it is flat, dry, and free of debris. For low-temperature cold storage, a moisture-proof layer must be laid in advance to prevent the floor from stretching the panels due to freezing. Prepare specialized sealant, angle aluminum, and pressure strips in advance; do not use ordinary household sealing materials.   2. The installation of the base plate and walls requires control over flatness and sealing. First, locate and mark the installation points of the panels accurately, ensuring overall horizontal and vertical alignment. When installing the bottom panels, ensure even gaps are left, and apply a full layer of special low-temperature sealant to all joints to prevent hollow gaps. This is a crucial step in preventing cold bridging and condensation. After the wall panels are assembled, reinforce them with strips and angle brackets immediately, paying special attention to sealing edges and corners to prevent cold air leakage. Continuously check verticality throughout the installation process; deviations must be kept within specifications.   3. Top panel installation is the most error-prone stage. Top panel joints must not have upward-facing gaps. All joints must face inwards, and the sealant must be full, dense, and free of breaks or air bubbles. Reinforcing brackets must be installed at load-bearing locations on the top panels to prevent them from being suspended and deformed or detached under long-term stress. Avoid drilling holes for pipes; ensure all openings are properly sealed to prevent cold air leakage.   4. Pay close attention to finishing details and acceptance procedures. Irregularly shaped areas such as doors, vents, and access panels require meticulous sealing to prevent air leakage from dead corners. After all panels are installed, apply a final coat of sealant, inspect all seams and edges, and repair any omissions or defects. Finally, conduct a no-load cooling test to observe for frost, water seepage, abnormal temperature differences, etc. Once everything is confirmed to be in order, the project is considered complete and ready for handover.   In summary, proper material selection, standardized splicing, and meticulous sealing are essential for cold storage panel installation. This not only improves the insulation stability of the cold storage and reduces future energy consumption but also minimizes rework and rectification, enhancing the project's delivery reputation.

The service life of sandwich panels is primarily determined by the facing material, facing coating, core material type, operating environment, and subsequent maintenance; lifespan varies significantly depending on the materials used and the application scenario.   The facing material is a key factor determining service life: in standard inland environments, panels featuring an Al-Zn (aluminum-zinc) alloy substrate (AZ100/AZ150) with a PE (polyester) coating typically last 12–15 years, whereas those with a PVDF (fluorocarbon) coating offer superior weather resistance, extending the lifespan to 20–25 years. In highly corrosive environments—such as coastal areas with salt spray or chemical industrial parks—standard Al-Zn panels are prone to rusting; in these cases, 304 stainless steel substrates with PVDF coatings are recommended, offering a service life of over 25 years with proper maintenance.   Performance also varies based on the core material: PIR and rock wool sandwich panels offer structural stability; closed-cell PIR sandwich panels provide excellent moisture and aging resistance, maintaining their shape over long-term use. Conversely, EPS sandwich panels are prone to shrinkage and degradation in high-temperature or humid environments, which can shorten their service life.   Additionally, proper installation and regular maintenance can effectively extend the lifespan of sandwich panels. Avoiding impact, promptly repairing coating damage, and ensuring effective joint sealing help minimize rust and core material damage. With appropriate material selection and maintenance, high-quality sandwich panels can achieve a service life of over 30 years in certain applications.

Sandwich panels are typically constructed by bonding two layers of facing material—such as color-coated galvanized steel sheets, aluminum sheets, or fiberglass cloth—with an insulating core. Depending on the core material, they are classified into PU, PIR, EPS, and rock wool sandwich panels. A comparative analysis of these types follows. Performance iIndex PU Sandwich Panel PIR Sandwich Panel EPS sandwich panel Rock wool Sandwich panel Thermal Conductivity（W/(m・K)） 0.022-0.028 0.018~0.023 0.038-0.042 0.040-0.048 Density(kg/m³） 36~45 kg/m³ 40~50 kg/m³ 10~18 kg/m³ 90~150 kg/m³ Hygroscopicity ≤ 3% ≤ 2% Low (closed-cell structure, water absorption rate ≤ 4%) High (porous structure, water absorption rate can reach 5%-10%) Fire Rating B2 B1 B2 Non-flammable (Class A), does not release toxic gases at high temperatures Sound insulation performance Moderate Moderate Lower High Weather Resistance Better (its UV resistance is superior to EPS, but still requires protection) Better than PU Poor (Subject to aging and deformation due to long-term exposure to ultraviolet rays) Excellent (resistant to high and low temperatures, anti-aging, unaffected by ultraviolet rays) Compressive / Flexural Strength Higher (with good toughness and strong impact resistance) Better than PU, more stable Medium (Susceptible to Impact Damage) High (strong in rigidity, but with high brittleness, prone to cracking) Cost Higher Highest Lowest Moderate   Based on the comparative analysis of the four types of core-material sandwich panels across various aspects: PIR sandwich panels offer the best thermal insulation and better fire resistance, delivering high overall cost-effectiveness, they are suitable for high- and low-temperature cold storage, blast-freezing facilities, cold-chain logistics warehouses, and EU-standard industrial plants. PU sandwich panels rank second in thermal insulation performance and are suitable for standard constant-temperature facilities, steel structure enclosures, temporary structures, and roofing or wall panels. EPS sandwich panels provide good thermal insulation at a low cost; being lightweight and easy to install, they are ideal for simple industrial buildings, temporary modular structures, construction site hoarding, and warehouses with lower specifications. Rock wool sandwich panels, distinguished by their superior fire resistance, are suitable for large shopping malls, office buildings, high-rise structures, hazardous chemical warehouses, explosion-proof workshops, and projects requiring Class A fire safety ratings.

Automotive and electronics plants need to meet requirements for dust and explosion prevention, static electricity prevention, moisture control, and temperature control.   Different sandwich panels need to be selected according to different production areas within the workshop, as follows:   1. For power battery and electronic assembly workshops, we recommend high-density rock wool handmade panels with magnesium oxide edge sealing: The core material is basalt rock wool with a density ≥120kg/m³, double-sided corrugated steel plate covering + four-sided magnesium oxide sealing, A1 fire rating, fire resistance exceeding 60 minutes, fully meeting the fire protection requirements of new energy battery workshops and electronic workshops. The rock wool handmade panel is covered with a protective film, is dense and does not accumulate dust, is resistant to forklift scratches, and the protective film can be removed after assembly.   2. For temperature-controlled and temperature- and humidity-controlled clean workshops, we recommend PIR polyurethane sandwich panels: PIR sandwich panels have a thermal conductivity of only 0.023W/(m·K), excellent thermal insulation performance, a closed-cell rate higher than 95%, extremely low water absorption, and significantly better temperature control performance than other core material sandwich panels. Fire resistance reaches B1 flame-retardant level, suitable for electronic SMT assembly, automotive chip assembly, and temperature-controlled testing workshops for automotive parts.   3. Ultra-high precision clean rooms utilize silicon rock/aluminum honeycomb clean room panels: Silicon rock panels are Class A non-combustible, moisture-proof, and mildew-proof, with a dense surface that prevents dust shedding. Their cost-effectiveness surpasses that of aluminum honeycomb panels, making them suitable for clean room assembly of electronic and automotive modules. Aluminum honeycomb panels are lightweight, extremely flat, and possess excellent anti-static properties, but are more expensive. They are primarily used for ceilings and partitions in precision workshops for semiconductors and automotive radar, where large-span ceilings do not require dense joists. Both types of panels are easy to clean, corrosion-resistant, and suitable for clean rooms requiring high-frequency water washing, meeting ISO 7-8 clean room standards.   In summary, for high-risk production areas in automotive and electronics plants (batteries, painting, welding), Class A rock wool clean room panels with magnesium oxide edge sealing are preferred; PIR polyurethane sandwich panels are used in temperature-controlled clean rooms; aluminum honeycomb or handmade silica rock clean room panels can be selected for precision clean rooms; and ordinary machine-made rock wool sandwich panels can be used in storage aisles.

Coastal or rainy regions often experience high salt spray, high humidity, strong ultraviolet radiation, and frequent rainfall, which directly accelerate the corrosion, aging, core material moisture absorption, and sealant aging of sandwich panels.   The durability of sandwich panels with different core materials and coatings varies in coastal/rainy regions, as compared below: 1. Fluorocarbon coated high-zinc PIR sandwich panel: Service life 15-25 years, up to 25 years with regular maintenance; ideal for cold storage, industrial plants, and clean rooms in coastal high-salt-spray and tropical rainy areas; 2. Polyester coated ordinary galvanized PU sandwich panel: Service life 8-10 years, 10-15 years in inland rainy areas; suitable for ordinary factories and warehouses in inland rainy areas; 3. Polyester coated rock wool sandwich panel: Service life 5-8 years; insulation performance significantly decreases after 3-5 years in high humidity environments. This product is only suitable for ordinary factory buildings in dry areas and is not recommended for use in coastal or rainy areas.   In summary, for coastal and rainy regions, it is recommended to choose PIR sandwich panels with a high zinc layer and fluorocarbon coating. Their durability fully meets the needs of the building's entire life cycle, making them the optimal choice for steel structure building envelope systems, especially suitable for building scenarios in tropical coastal and rainy countries in Southeast Asia such as Indonesia.  

Walk-in Freezer primarily uses PU/PIR sandwich panels, which offer excellent thermal insulation and superior waterproofing and moisture resistance. Different panel thicknesses are suitable for different temperatures and application scenarios. Generally, the thicker the panel, the better the insulation performance.   For walk-in freezer units with different temperature requirements, different PU/PIR sandwich panels can be selected:   1. -18℃ ~ -25℃ cold storage: 150mm PIR sandwich panels can be used for storing various aquatic products, meat products, and frozen foods;   2. -25℃ ~ -30℃ deep-temperature cold storage: 180mm and above PIR sandwich panels can be used for long-term storage of high-end seafood and meat, as well as freezing of ice cream and dairy products;   3. -30℃ ~ -40℃ ultra-low temperature cold storage: PIR sandwich panels with a thickness of 200mm or more must be used for long-term storage of deep-sea aquatic products, high-end seafood, and high-end beef and mutton.   4. Deep cryogenic storage at -40℃ and below: Requires 250mm thick PIR sandwich panels for the long-term preservation of vaccines, plasma, biological samples, viral strains and other biomedical and research materials, special industrial materials (such as aerospace materials and chemicals) and rare agricultural and insect specimens.

There are many types of sandwich panels, and common mistakes when choosing industrial sandwich panels include:   1. Focusing solely on price and selecting panels incompatible with the core material. EPS sandwich panels are the cheapest and generally only used in ordinary factories. PU/PIR sandwich panels are chosen for cold storage, while rock wool sandwich panels are chosen for large logistics warehouses.   2.Confusing roofing and wall panels. Wall panels cannot be used directly for roofing. Roofing requires high-strength roofing panels with corrugated peaks to withstand strong winds and rain/snow.   3.Ignoring the density of the core material. Generally, EPS density ranges from 10kg/m³ to 20kg/m³, which can be selected based on different insulation requirements; Rock wool density ranges from 80kg/m³ to 140kg/m³. It is generally not recommended to use less than 90kg/m³ for walls and less than 100kg/m³ for roofs.   4.     Ignoring the thickness requirements of the sandwich panel steel plate The thickness of the top and bottom plates of the sandwich panel can be determined according to the strength requirements of the building. Common thicknesses are 0.4mm to 0.8mm.   5.Ignoring the zinc coating thickness requirements of the sandwich panel Generally, the thicker the zinc coating, the better the corrosion resistance. Industrial buildings typically require AZ100 or AZ150.   6.Ignoring the color coating requirements of the sandwich panel steel plate PE coating can be used in ordinary environments, while PVDF coating can be used in coastal or highly corrosive environments.   7.Incorrect calculation of sandwich panel length, leading to excessive splicing It is recommended to provide CAD drawings. Our technical engineers will calculate the accurate number and length of panels to avoid errors.   8.Ignoring panel load-bearing capacity and span The panel thickness needs to be calculated based on the purlin spacing, load, and wind force of the industrial building to avoid placing orders blindly.  

The fastest construction time for a standard single-story warehouse using sandwich panels can be reduced to 6 to 14 days. The higher the degree of prefabrication, the simpler the structure, and the more experienced the construction team, the shorter the construction period will be. Conversely, the construction period will be longer accordingly.   Sandwich panels are custom-made products according to the building design dimensions. On-site construction only requires splicing and installation. Compared to traditional concrete structures, this eliminates processes such as masonry and cementing, saving at least 40% of the construction time.   Furthermore, simpler building structures result in faster construction. For example, single-story warehouses without complex spans are the fastest to construct; while multi-story warehouses and workshops, or those requiring provisions for crane beams, will have a construction period of 15-25 days due to the need for additional steel frame structures.   A well-organized and skilled professional construction team can typically install at least 120 square meters of sandwich panels per day, further shortening the construction cycle.