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Insulated
panels used in controlled environments
A Controlled Environment
A controlled environment is an area that requires
precise internal environmental control, particularly temperature, hygiene,
thermal and fire safety. Such environments include food preparation
and processing, storage, distribution, chill rooms, cold stores and
clean rooms for pharmaceutical and bio-technological industries.
Buildings constructed with a controlled internal environment require
a holistic design, specification and build
approach. Considerations include practical, commercial, technical, performance,
sustainability, financial, regulatory, and more recently fire risk and
insurance cover issues.
Currently, PIR
rigid urethane core panels are the preferred choice for the construction
of controlled environments due to their proven thermal and performance
properties.
Types of Controlled
Environment Systems
There are two Controlled Environment systems available to cover internal
and external applications.
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Internal
Application: The internal walls and ceilings panel system
is known as a “box within a box” and is used for
chill/cold storage and clean room environments. A separate external
weathering roof and wall envelope is also required.
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External Application: The
external insulated roof and walls system is the envelope of the
building. Such buildings are ideal for food processing, distribution
and warehousing areas that require thermal performance and hygienic
standards. |
Insulated Panel Systems are suitable for use in new build sites,
extensions to existing sites or renovation projects. |
Why choose PIR rigid urethane
core panel? |
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PIR panels have been used in the UK for the
last two decades and have a proven durability. |
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They have excellent strength to weight ratio and spanning characteristics.
The lightweight materials mean less structural steel is required,
providing both cost and energy savings. Construction is made
quicker and safer through easier handling. |
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The unique male/female engineered and sealed joint ensures
no exposure of the core can occur. |
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PIR panels have a 95% closed cell insulation core, which prevents
interstitial condensation and other detrimental moisture effects. |
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The panels are completely fibre-free and are totally filled
with non-toxic, homogenous, closed cell insulation providing
a safer environment. |
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Sub zero temperatures can be reached, in fact as low as -40° putting
PIR in a unique position over other panel types. |
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PIR panels offer a greater thermal performance enabling a reduction
of thickness by up to 50%, which results in maximizing internal
space. |
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PIR panel have been tried and tested and are Insurer Approved
by the Loss Prevention Certification board, receiving the LPCB
Certification of Fire Performance. |
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PIR is suitable for internal and external walls, linings partitions
and ceilings. A range of profiles and foodsafe lining options
are available. |
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The panels are available in lengths of up to 18m.
This is longer than other core type panels and allows for greater
flexibility in the construction of walls, ceilings, and roofing sections. |
PIR rigid urethane core panels applications
Hygienic Environments:
In any food processing or storage location, or indeed buildings
that require a clean environment such as the electronic and pharmaceutical
industries, hygiene is of the utmost importance. The panels must
therefore be easily washed and cleaned and should not be prone
to surface or interstitial condensation, as this could lead to
the formation of bacteria and mould growth on the surface or within
the condensation.
Approved PIR rigid urethane core panels comply with Food and Hygiene
regulations. They are fully filled with non-toxic, homogenous, closed
cell insulation. They eliminate cold bridges by ensuring that both surfaces
are separated and condensation will not occur. The insulated panel system
eradicates the possibility of water or vapour ingress and therefore the
risk of mould and bacterial growth is eliminated. In fact, the insulated
panels are immune to attack from mould, fungi, mildew and vermin. No
urea formaldehyde is used in their construction. As PIR panels are also
fibre-free there are no risks of airborne, fugitive fibres that can also
lead to contamination.
For Temperature Control:
PIR rigid urethane core panels can reach temperatures of +40° to -40°.
It is in a unique position over many core types that cannot reach sub
zero temperatures or certainly not to -40°. The insulated panels
are available in different thicknesses which allow for a range of temperatures
to be managed. Thermal and airtight performance is also critical in these
environments. The insulated panels offer a high thermal performance and
low air leakage (typically0.5/m³/hr/m²) which significantly
reduces energy usage and running costs, while maintaining internal temperatures.
Insurance Industry
The use of insurer-approved products is increasingly being insisted upon
in all aspects of building construction to ensure that the products comply
with their requirements and are manufactured to controlled specifications.
Certified PIR rigid urethane core panels use a unique formulation that
gives a highly fire resistant product, which is capable of passing these
insurance industry tests. The most commonly requested certification is
the LPCB certification issued by the Loss Prevention Council.
Project examples
Distribution Centre – Thurrock |
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Example of ‘box-within-a-box’ construction
plus external envelope for completely controlled environment. |
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Selected for stringent hygiene requirements; quick and easy installation
due to tight construction programme; and fire performance. |
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Distribution Centre – Thurrock |
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Example of use of long length panels for rapid controlled installation
programme and less time working at height. |
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Overall project size 24,000
m². |
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Large freezer room |
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Example of large freezer room with racking
system – 5500
m². |
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Selected for at working temperature
of -25°C; stringent
hygiene requirements; quick and easy installation. |
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Ambient warehouse – refurbishment
project |
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Refurbishment and conversion of two existing ambient temperature
warehouses into controlled chilled distribution centre. |
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Project size 13,000 m². |
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Bakery – Falkirk |
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New food production facility – 4700 m². |
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Selected for hygiene (fibre-free) requirements; Structural performance;
quick and easy installation. |
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