Rockwool Sandwich Panel Manufacturer

Rockwool Sandwich Panel Manufacturer Rockwool Sandwich Panel: The Ultimate FAQ Guide In this guide, I am going to answer all questions about the Rockwool sandwich panel. Whether you want to learn about fire resistance capability, design, insulation, thermal properties, limitations or characteristics, you’ll find everything here. Keep reading: What is the Rockwool Sandwich Panel? A Rock wool sandwich panel is an insulation material constructed from stone wool that is enclosed between two metal sheet surfaces. The stone wool has a high density with exceptional compression, and tensile strength which makes it suitable for constructing buildings. Figure 1 Rockwool sandwich panel Why use the Rockwool Sandwich Panel? Rockwool sandwich panel will offer you numerous advantages over other insulating materials. Some of the benefits of Rockwool sandwich panel include: Good Thermal Efficiency Rockwool has outstanding thermal resistance properties which will enable you to reduce the energy bills spent on heating, and cooling your building. Noise Insulation You can use Rockwool in places like meeting rooms or offices in busy towns to reduce noise nuisance. The material can trap sound waves, and deaden the vibration due to random fiber orientation, and high density. Non-combustible The material has good fire resistance properties and is suitable for constructing safety buildings that require fire protection. Using the Rockwool sandwich panel to construct your building will greatly improve its capability to protect life, and property in case of a fire outbreak. Breathability You can use Rockwool if you want to minimize risks of bacteria and mold infestation inside the building. This is because Rockwool provides room for moisture escape in the construction. Longevity Using Rockwool for constructing your buildings offers you a durable property that will serve you for a very longtime because of the unlimited lifetime of the material. The durability of the material reduces the cost of maintenance, replacements, and repairs. Resistance to Compression Rockwool sandwich panels are very firm, and not easily damaged through compression. This makes it suitable for constructing buildings whose layout or use may change with time, and require additional portions as well as thermal insulations for domestic buildings. Environmental Friendly The material reduces carbon footprints thanks to its natural origin and hazards free rating. Besides, using Rockwool sandwich panels reduces air pollution because you will not heavily rely on non-renewable energy sources like electricity, and gas. Sustainability The materials for making a Rockwool sandwich panel is naturally sourced and can be recycled over and over again. You can use old Rockwool sandwich panels to construct new panels when the building has served its purpose, and therefore reducing the cost of production. Fast Construction/Installation You can use fast to install Rockwool sandwich panels that are producedfollowing the layout of your building drawing. Hence, you will shorten the installation period with more than 40%. What are the Disadvantages of the Rockwool Sandwich Panel? The main disadvantages of a Rockwool sandwich panel include: The core material is heavier compared to core materials for other insulating sandwich metals Rockwool is non-biodegradable and will cause a huge environmental nuisance if carelessly disposed of. Handling the material can cause discomfort through skin irritations The dust from Rockwool can cause serious allergic reactions to people with compromised respiratory health issues. Wearing a dust mask is advisable. It takes longer to dry should it wet. Where can you use the Rockwool Sandwich Panel? Rockwool sandwich panels can be used in many industries for building the roofing, walls, modular buildings, and construction enclosures. You can also use Rockwool sandwich panels to: Construct storehouses Protect medium, and high-level buildings from fire Acoustic insulation in residential,commercial buildings, studios, offices, etc. However, the material is most suitable for the construction of cleanrooms, pharmaceutical and electronic industries most Is Rockwool Sandwich Panel Fire Resistant? Yes, Rockwool Sandwich panels can withstand temperatures above 1000°C, and the core material itself is non-combustible. The material’s high density will stop the fire from penetrating the fibers, prolonging the spread of fire to enable people to leave the building. Figure 2 Rockwool panel What are the Components of the Rockwool Sandwich Panel? The Rockwool sandwich is composed of surface material and the Rockwool filling material. Surface Material You can select Rockwool sandwich panels constructed from PPGI or galvalume steel Galvalume Steel Galvalume steel coating consists of aluminum, zinc, and silicon to protect the underlying metal (steel) from oxidation. The components ratio in galvalume steel is 50% zinc, just under 50% aluminum, and traces of silicon. It helps the metal resist rust, and offers enhanced long-term protection when exposed to a fluid which increases the speed of oxidation compared to normal galvanizing. This type of coating is best suited for metal paneling, and roofing for outdoor applications since it can withstand intense corrosion than standard galvanizing. However, you should not use galvalume steel in an alkaline environment because the aluminum in the coating is less stable under such conditions. The cut edges of galvalume steel are more prone to corrosion given that the honeycomb structure of the coating of the steel provides insufficient protection to exposed edges. When corrosion occurs in galvalume steel, it will spread from the point of original contact whereas the corrosion remains localized in PPGI coating. You should also avoid using this type of steel in an application where the chances of damages, scratches, and indentation are high. PPGI Coating These are pre-painted galvanized iron steel. The coating has an evenly distributed layer of zinc cover which protects the underlying steel sheet from oxidation and rust. The steel that has this type of surface treatment is very durable and highly resistant to attack UV sunlight rays and weather. Insulating Core Material: Rockwool steel Rockwool is wool manufactured from molten rocks which include a mixture of anorthosite, basalt, and cemented briquettes. You can also make Rockwool through melting basalt, dolomite, diabase, and combining them with Bakelite. The rocks are subject to heat overabout 1600°C to melt the rock mixtures and spun them into fibers. The spun rock wool is stabilized through adding a mineral oil and a binder, which also makes it water repellant. What are the Characteristics of the Rockwool Sandwich Panel? A good Rockwool panel should possess the following features: Figure 3 Joining rockwool panel High fire resistance Anti-pressure, anti-impact, and anti-quake Waterproof and wet proof Eco friendly and energy saving Great sound insulation rating Lightweight God thermal properties Asbestos-free: Non-toxic Fast and easy to install Does Rockwool Sandwich Panel have Size Limitations? Yes, the length of the Rockwool sandwich panel is limited to the size of shipment vessels, which can only house 11.85 meters. The standard width of the panels is usually 1120mm while the thickness can vary from 40mm to 200mm. However, you should use panels that are less than 4 meters that are easy to handle and move around without bending. When your requirements exceed 4 meters, insert internal steel bars to reinforce against bending. How do you Install a Rockwool Sandwich Panel? When installing a Rockwool sandwich panel, you must take the following precautions to ensure good installation and safety to installing personnel. Check the suitability of the existing structures and ensure that the surface width is sufficient for installation. The installation personnel should wear rubber shoes to avoid damaging the panel surfaces and walk on roof ribs while mounting roof panels. Ensure that all the safety measures on the working site have been put in place as per the regulations. When installing roofing, follow the following steps: Lift the panels to points of installation using a U shaped hook or avacuum suction. Place the panels close to the main trusses on the roof purlins and distribute them across the roof length while considering the direction of installation. When working with log and heavy panels, you should use a crane and special lifting clamps to lift them one by one. Lift the loads using at least two clamps to move the panels to the desired location. Ensure that you remove all the protective films on the inside before installation. Similarly, partially remove the protectives on the panel edges and joints and remove the rest by the end of the installation shift. When installing the panels, place them in the opposite direction to that of the prevailing wind. Place the first panel in perfect alignment and square to the roof structure. You will fix the panel on the ‘valley’ found next to the first empty rib to secure it. Overlap the first empty rib on the second panel to the last full rib of the first panel and screw them together on the roof purlin. You should place the fixing elements centrally and perpendicularly to the surface of the panel. Use original saddle caps because they ensure that you correctly position the fixing and evenly distribute the pressure. Install the panels in strips where the length of the roof pitch has more than one-panel cover. Install the second panel by overlapping the first one longitudinally. You can apply secondary fixing elements along the joints to enhance the tightness of the joints and uniform distribution of the panel effects. Remove all the metal chippings that you produce in the course of installation with a vacuum cleaner to avoid scratching the panel surface. Figure 4 Rockwool panel For wall installation, observe the following: Place the first panel in perfect alignment with the wall structure. When installing the panels, insert a spacer between the base drip and steel-cut edges of the panel to prevent corrosion from starting and spreading from the edges. Fix the panels to the wall substructure using a screw with a gasket and a metal washer. Install the remaining panels by slightly inclining it towards the first one and gently pushing it against the first panel to get the best coupling. Inspect the panels verticals atleast once every 4 months to ensure that they are in good condition. You should install panels in bands where the height of the building requires more than a single panel. You should fix the panels using stainless steel screws if it is exposed to the weather. Perpendicularly fix the screw together with a metal washer and gasket to ensure water tightness of the fix. Use a jigsaw or a circular saw for cutting the panels at the installation site. Before cutting the panel, use adhesive tape to protect the area you want to cut, mark it using a felt pen, cut, and then clean the chippings off the surface. You can also strengthen the cut area using angle braces since cutting will weaken the panels. Ensure that all possible leakages are sealed in heat preservation facilities. You can add a layer of waterproof material on the surface when installing under cold weather conditions. What is the Thickness of Rockwool Sandwich Panel? The thickness of surface galvalume steel or PPGI steel can range from 0.4 to 0.8 mm while that of the whole Rockwool sandwich panel will range from 40 to 200 mm. The thicker the Rockwool sandwich panel, the more efficient the insulation. Why is Rockwool Sandwich Panel Best of Acoustic Insulation? Noise insulation provided by Rockwool sandwich panels isdue to the structure of fibers. They possess a characteristic high sound absorption coefficient over a very wide range of frequencies. The fibers have an orthogonal arrangement towards the sheets. They are also very densely compacted to achieve monolithic blocks which are perfect for the absorption of sound. You can also include an internal steel sheet that has been micro-perforated to enhance the sound absorption properties and reduction of reverberation. When you lineyour room with a Rockwool sandwich panel, you can reduce the sound by more than 10Db and further reduction is dependent on other details of the room. When should you Choose Rockwool Sandwich Panel Insulation? You should use select Rockwool sandwich panels when your main aim is to insulate against fire and sound. Rockwool has the best fire performance of all the insulating materials and can achieve up to 4 hours of fire resistance, which is sufficient enough to allow people to leave the building. Similarly, it is perfect for insulation against sound and is fundamental for applications that need to be soundproof such as television and radio studios among others. What Determines Rockwool Sandwich Panel Price? Figure 5 Rockwool sandwich panel The price of a Rockwool Sandwich panel will vary to the following factors; The quality and thickness of the surface steel sheets The Thickness and density of Rockwool The number of ribs in the roof Type of fixation, that is, visible or hidden Aesthetic finishing, that is, type of paint, varnish material and it’s color How does PUF Insulation compare to Rockwool Sandwich Panel Insulation? PUF is an acronym for polyurethane foam insulation which you can construct through filling the void of the insulating material by an insulating gas/air. When you release the pressurized PUF sprays in the insulating region, they mix with air and solidifies, a process that traps numerous air pockets inside the solid. On the other hand, Rockwool is constructed from stone fibers. Rockwool is heavier and more densely packed than PUF insulation. As such, Rockwool offers higher fire resistance and more temperature tolerant compared to PUF. PUF insulation also has a high resistance to water absorption and low permeability to moisture compared to Rockwool. In terms of thermal insulation, PUF offers superior thermal insulation compared to Rockwool sandwich panels. How do you Manufacture Rockwool Sandwich Panel? Figure 6 Sandwich panel production Production of commercial Rockwool sandwich starts from heating basalt rocks and other raw materials at 1600°C. The molten rocks are then subjected to air or a current of steam. You can add oil to during the production process to reduce dust formation. The molten rock is then rotated in a spinning wheel at a very high speed, producing a finished fibrous product. An automatic machine uncoils the inner and outer sheet layers. The Roll forming machine designs the sheets to the desired shape for either roof or wall panels. You then cut slabs of Rockwool into filler strips and feed them between the sheets when making the sandwich panels. For roof panels, you cut the slabs into trapezoidal shapes that fit them. Run the sheet layer through a preheating station to obtain a uniform reaction. Apply the appropriate amounts of components using two or multi-component high-pressure metering machines. An oscillating coating gantry then evenly distributes the foam mix. The reacting foam moves to a double belt where the foam cures in a slat conveyor visible as a continuous moving mold. Using a cross cutter, cut the endless formed sandwich ribbon into the desired length and set it to cool in the conveyor. Stack the cooled panels on pallets and wrap them using a PVC foil then deliver it to the customer. The whole production unit should be automated and control systems configured to ensure uniform and constant product quality. What are the Quality Standards for Rockwool Sandwich Panel? A superior quality Rockwool sandwich panel should have ISO, TS EN, and CE quality certificates. The fire protection qualities of the Rockwool are tested and classified according to TS EN 13501-1, A2-s standards. Similarly, the product specification should meet the specifications of TS EN 14509 which deals with self-supporting double skin metal faced insulating panels. Are Rockwool Sandwich Panels Safe? Rockwool has been classified by the International Agency for Research on Cancer under materials that are not classifiable as to human carcinogenic. 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