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Sandwich Panels Division

 

"World's Best Manufacturing Process with continuous Production line for Sandwich PUF/PIR Panels."

 

Sandwich PUF Roof / Wall Panels

"World's Best Manufacturing Process with continuous Production line for Sandwich PUF/PIR Panels."

Metal-faced polyurethane Alfa sandwich panels are the system of choice of today for large industrial buildings refrigerated warehouses,office blocks,exhibition halls,fair pavilions,schools and sports halls.

The aluminium or steel facings themselves are surface coated and can be manufactured with profiles of various depths leading to a higher load bearing.

Polyurethane Alfa sandwich panels come complete with specially formed tongue-and -groove joints ensuring a perfect fit and maximum integrity,Assembly is fast,easy and cost effective.

The resultant Alfa sandwich panel has a load-bearing capability many times greater than the achieved by adding together the load-bearing capacities of the individual layers.As a result these thin,relatively lightweight Alfa sandwich panels can safely bridge wide spans. For Example,a panel just 100mm thick can easily bridge a clear span of some meters.

  1. Manufacturing Process
  2. Specification
  3. Advantages
  4. Application Area

The top and bottom coil (sheet metal) are clamped onto the plants unwinding unit and fed into the machine. In the first step, “corona system” cleans both reverse sides of the sheet metal using high frequency to remove greases and dirt and to guarantee the best possible subsequent full spread adhesion between foam and sheet metal. Thereafter the protective films are rolled onto outside of both metal sheets. The sheets are then brought together, the bottom sheet is foamed by the swinging foam head and the top sheet is mechanically steadied. Immediately thereafter, the panel is fed continuous line into the heated drying tunnel where the foam expands to its full volume, binds to the sheets and transforms both sheets to one robust, shear resistant composite structural panel. After leaving the tunnel the panels are cut according to your specification using flying saw/cutter.

Panel thickness available :     30mm, 40mm, 50mm, 60mm, 80mm, 100mm, 120mm
Panel width available :    1060mm
Panel length available :    2000mm-12000mm
Average density :   40± 2kg/m
Thermal conductivity :     0.024-0.03 W/m
Temperature range :    -40+800C
Free from CFC :    CFC free
Type of foam :    B1, B2, B3, PIR
Heat transfer co-efficient ::   -0.022W/M2*k
Pressure :    0.10Mpa
Cubic Area Change :    =1%(-30 C – 100 C/96h)

Panel Sheets specifications

Polyester primer :   5 micron Non-toxic food-graded STANDARD polyester
     finish paint.
RAL 9010 color :   20 micron
Back coat :   5 micron
Resistance to saline mist :   5 micron
>500h (ECCA TB) :   100 h (ASTM D 2247)

Effective width and length:

 WallRoof
Width1000 mm1000 mm
LengthUpto 12000 mm 12000 mm

Tongue and groove type joinery system.

Hidden self tapping screws for aesthetic appeal.

Great energy saver

Fast and easy installation

Light weight

Space saving

Various designs.vivid colours./p>

Energy conservation as per ECBC code.

Alfa sandwich panels have the following advantages over single skin/double skin field insulated panels.

High load bearing capacity at low weight.

Excellent and durable thermal insulation.

capacity for rapid erection without lifting equipments.Easier installation in hostile weather conditions.

Easy repair and replacement in case of damage.

Long life and very low maintenance cost

Good sound insulation

Reasonable fire reaction and resistance

Industrial Buildings

Roof

Walls

Partitions-Semi Glazed

False Ceiling

Walk-on False Ceiling

Commercial Buildings

facades/Elevation

Side wall panelling

Partitions-Semi Glazed

Warehouse/Godown

Roof

Walls

Partitions

Cold storage/Blast Freezers

insulated Ceiling

insulated Walls

Farm House

Decorative siding panels

Pharmaceutical Manufacturing units

clean Rooms

Walk-on False Ceiling

Return-Air Boxing

Air Handling Units

Insulated panels.

Poultry Form

Ceiling

Walls

Dairy industry

Ceiling

Walls

Malls/Departmental Stores

Facades

Partition

Walls

  1. Sandwich PUF Panel
  2. Manufacturing Process
  3. Specification
  4. Advantages
  5. Application Area

The top and bottom coil (sheet metal) are clamped onto the plants unwinding unit and fed into the machine. In the first step, “corona system” cleans both reverse sides of the sheet metal using high frequency to remove greases and dirt and to guarantee the best possible subsequent full spread adhesion between foam and sheet metal. Thereafter the protective films are rolled onto outside of both metal sheets. The sheets are then brought together, the bottom sheet is foamed by the swinging foam head and the top sheet is mechanically steadied. Immediately thereafter, the panel is fed continuous line into the heated drying tunnel where the foam expands to its full volume, binds to the sheets and transforms both sheets to one robust, shear resistant composite structural panel. After leaving the tunnel the panels are cut according to your specification using flying saw/cutter.

Thermal performance and strength

At 25C mean temperature thermal conductivity of varies between 0.031 W/mK and 0.036W depending upon the density of the material.

Acoustic Performance

Alfa panels offers excellent sound absorption.The Noise Reduction Cofficient (NRC) range is from 0.80 to 0.95

File Performance

Alfa panels does not contribute in any way to spreading of fire.It does not Shrink,stretch or deform when exposed to fire.It does not cause smoke or any burning droplets in case of fire.It significantly contributes to improved fire safety.

Resistance to moisture

Storage

To Store for long duration,Alfa panels should be stored indoor.If stored outside,the panels should be0stacked clear of ground and covered with a securely anchored weather proof sheet.the panels should not be left exposed to weather.

Non Toxic

Alfa panels are not hazardous to health and do not contain asbestos.

Environmental impact

Alfa panels are free from CFCs,HFCs and HCFs and contain phenol resins within the permissible limits.

Tongue and groove type joinery system.

Hidden self tapping screws for aesthetic appeal.

Great energy saver

Fast and easy installation

Light weight

Space saving

Various designs.vivid colours./p>

Energy conservation as per ECBC code.

Alfa sandwich panels have the following advantages over single skin/double skin field insulated panels.

High load bearing capacity at low weight.

Excellent and durable thermal insulation.

capacity for rapid erection without lifting equipments.Easier installation in hostile weather conditions.

Easy repair and replacement in case of damage.

Long life and very low maintenance cost

Good sound insulation

Reasonable fire reaction and resistance

Industrial Buildings

Roof

Walls

Partitions-Semi Glazed

False Ceiling

Walk-on False Ceiling

Commercial Buildings

facades/Elevation

Side wall panelling

Partitions-Semi Glazed

Warehouse/Godown

Roof

Walls

Partitions

Cold storage/Blast Freezers

insulated Ceiling

insulated Walls

Farm House

Decorative siding panels

Pharmaceutical Manufacturing units

clean Rooms

Walk-on False Ceiling

Return-Air Boxing

Air Handling Units

Insulated panels.

Poultry Form

Ceiling

Walls

Dairy industry

Ceiling

Walls

Malls/Departmental Stores

Facades

Partition

Walls

Energy efficiency

with 80 mm thick Alfa sandwich panels with polyurethane rigid foam, the U value is 0.297 W/(m K).In comparison, asolid wall with 24 cm thick masonry and 2 cm plaster walls has a U value of 1.85 W/(m K).

THERMAL CONDUCTIVITY*
EXPANDED CLAY
 
 
0.100
STRAW
 
 
0.090
WOOD WOOL  
 
0.060
COCONUT FIBER  
 
0.050
CORK SHEET
 
 
0.045
MINERAL WOOL  
 
0.040
POLYSTYRENE
 
 
0.035
POLYURETHANE  
 
0.024
* IN WATTS PER METER AND KELVIN(W/mK).THE LOWER THE VALUE THE BETTER THE INSULATION
35mm PUF is equal to
 
 
35 mm EPS(Thermocol)
 
 
55 mm Glass Wool
 
 
60 mm Mineral Wool
 
 
80 mm Fiber board
 
 
175 mm Wood
 
 
475 mm concrete
1075 mm Thick Brick Work
 

Rigid polyurethane foam combines excellent thermal insulation properties with good mechanical strength,making it an outstanding construction material that does not rot,mold-resistant,odorless and non-toxic for all conceivable applications,The foam is resistant to the chemicals typically used in construction and is compatible with most solvent-containing adhesives,paints and wood preservatives.

polyurethane rigid foam is extremely durable and can be installed easily and securely,ensuring cost-effective,efficient construction.

SANDWICH PIR PANELS

Alfa Sandwich PIR panels’ roof panels are combining low thermal conductivity ratio and good fire performance, this energy efficient PIR core panel both saves on heating costs and increases fire safety. Thanks to low weight this panel also offers savings on supporting structures as well as on freight and assembly costs. Ideal way to insulate any home or industrial premises and give higher thermal resistance is to have it insulated through particular roof insulation material. It can give you multiple benefits including applying it over the roof as well as under roof insulation. The process of applying insulation material is comparatively easy as most of the housing roof as well as industrial ceilings have some access for caring insulation work.

This PIR panel combines low thermal conductivity ratio and good fire resistance together with available thicknesses up to 200mm. Wall panels with PIR rigid foam core and steel shells in different structures and surfaces. It is an ideal solution for cold storages as well as for facades with ultimate requirements for energy efficiency and fire safety. Wall Alfa Sandwich Panels Division PIR by we are designed to fulfill several functions. The most important are: resistance to atmospheric factors, thermo insulation, aesthetics, durability, functionality and universality .The continuous core is an additional advantage, which improves aesthetic of the building.

  1. GENERAL SPECIFICATION
  2. FOAM CHARACTERISTICS
ALFA PEB LIMITED
GENERAL SPECIFICATION FOR PIR- SANDWICH PANEL
SL.No CHARECTERISTICS SPECIFICATION
1 PRODUCT NAME PPGI/PPGL-STEEL SHEETS COILS
2 REFERENCE STANDARDS ASTM,A 7555(JIS 63312,IS14236,ECCA)
3 STRIP THICKNESS(TCT)-mm 0.5 TOP/0.50 BOTTOM(OPTION AVAILABLE)
4 SUBSTRATE MATERIAL Galume(AJ-Zn Alloy)Coating as per ASTM A792/A 792M withsteel base as per ASTM Std.
5 SUBSTRATE COATING MASS Gms/m2,SUBSTRATE COATING MASS CLASS 120,AZM 150 as per ASTM Std.
6 GRADE DESIGNATION Gr80 / CS Type A,B as per ASTM Std.
7 YIELD STRENGTH -Mpa min. 240/550 for Gr80.
8 YIELD STRENGTH -Mpa min. 240/550 for Gr80.
9 PAINT TYPE RMP/SMP/PVDF(SMP&PVDF ON MOQ)
10 PAINT COATING THICKNESS(DFT) RMP COATED-Top coat 18 to 22microns(+5 microns primer),Back coat 5 to 8 microns(Including Primer).& SMP COATED
SL.No FOAM CHARACTERISTICS UNIT SPECIFICATION
11 TOTAL FOAM DENSITY Kg/m3 48+2
12 CORE FOAM DENSITY Kg/m3 44+2
13 COMPRESSIVE STRESS AT10% DEFORMATION kpa >100
14 YOUNG COMPRESSION MODULES kpa >2500
15 FOAM TENSILE STRENGTH(ADHESION) kpa >100
16 YOUNG TENSILE MODULE kpa >2500
17 SHEAR STRENGTH kpa/td> >90
18 THERMAL-CONDUCTIVITY-A@50C MEAN TEMP & B.@10C MEAN TEMP-MAX kpa A.0.03 &b.0.023
19 HORIZANTAL BURNING TEST mm <25
20 HOT DIMENSIONAL STABILITY AT 85+2C/100+2C FOR 24HRS-MAX % LENGH+2
% WIDTH+2
% THICKNESS+2
21 COLD DIMENSIONAL STABILITY AT -25+2C FOR 24HRS-MAX % LENGH+2
% WIDTH+2
% THICKNESS+2
22 WATER VAPOR TRANSMISION-Max ng/pasm 8.5
23 PANEL WIDTH ROOF mm 1060MM
24 PANEL WITH WALL mm 1000
25 REFERENCE PROFILE DRAWING
26 ROOF PANEL PROFILE
27 WALL PANEL PROFILE
28 HIDDEN WALL PANEL PROFILE

Sandwich Concealed Wall panel Fastening System

Alfa Sandwich PUF panel with a concealed-fixing method for high quality industrial and commercial buildings, where good aesthetics are paramount. The special double labyrinth joint of this panel, provides mechanical resistance and insulation superior to any other wall panel product of this kind, the panel external micro-V increases the aesthetic appeal of this panel, which can be orientated both vertically and horizontally as required.

If wind pressure on a wall Alfa sandwich panel is more than allowed limit of panels so it is needed to fix the Alfa sandwich panels with self-drilling screws on a metal net. On the ordinary panels these screws are visible but hidden screw wall panel are designed so that the drilling screw are operated under the notch and tab and cause tight and firm connection. Alfa hidden screw wall panels can be manufactured with various patterns and designed like fine, corrugated coarse corrugated. Beside the designs Alfa is presenting the hidden screw wall panel with water fall design to the market that has great insulator and firmness and can be assembled horizontally and vertically as well.

Eco Panels / Aluminium Foil Faced

The internal side of the insulated panel has a surface finish manufactured from aluminum foil of thickness 0.07mm.