KS1100 CS Insulated Panels for Temperature Controlled & Hygiene Safe Building Applications

Transcription

1 Insulated Panels CI/SfB (4-) Rh2 November 2008 CONTROLLED ENVIRONMENT SYSTEMS KS1100 CS Insulated Panels for Temperature Controlled & Hygiene Safe Building Applications Approved to LPS 1208 Certificate No. 260b

2 The paper we have printed on is from 80% postconsumer waste and the remaining 20% pulp is TCF (Totally Chlorine Free). This fibre is FSC certified (see fsc.org for details). In recognition, the range has been awarded both the NAPM and Eugropa recycled marks, two of the most prestigious and recognisable recycled certificates available. The ink we have used is vegetable based, allowing the document to be recycled. Sustainable Forest Recyclable Vegetable Based 2

3 Contents Contents Introduction, Benefits & Product Range 4 Construction Solutions & Selection Data 6 Product Data 8 Construction Details 12 3

4 Introduction Insulated Panels manufactures, hygienic and PIR insulated panel solutions for internal and external walls, roofs and ceilings. KS1100 CS insulated panel systems are suitable for use within temperature controlled and hygiene safe environments including: Food Processing Controlling food processing areas is easy with KS1100 CS insulated panel systems. Temperatures within the building can be managed and most importantly the surfaces have hygiene safe coatings, which resist moisture ingress and eliminate any risk of toxic mould or bacterial growth. Cold & Chill Store KS1100 CS insulated panel systems offer temperature controlled environments from -50 C to +60 C. The panels are available in different thicknesses which allow for a range of temperatures to be maintained. Clean Room KS1100 CS insulated panel systems are and therefore provide a controlled sterile environment minimising airborne particles and micro-organisms. Benefits KS1100 CS insulated panel systems: Are designed to withstand internal/external temperature differences of up to 80 C. Are suitable for cold and chill stores and food processing applications, with an internal temperature range of -50 C to +60 C. Incorporate a panel joint that achieves excellent thermal performance and can accommodate vapour and hygiene safe seals. Are available in a range of profiles, coatings and insulation core thicknesses to meet project specific demands. Are hygiene safe, resisting moisture ingress and any risk of toxic mould and bacterial growth. Are - No threat of loose fibres into the internal environment. Have an environmentally sustainable PIR insulation core. Have a long lifecycle durability (up to 30 years to first maintenance and up to 40 years overall life). Can be fully recycled at the end of their useful life through shredder plants. Are anticipated to achieve an A+ / A rating according to the 2008 Green Guide to Specification. have considerable and proven knowledge in these sectors, which is supported by successfully completed projects for some of the largest brand names who operate in the retail, food supply chain, confectionery, distribution and logistic sectors. 4

5 Product Range KS1100 CS insulated panel systems are available in a wide range of profiles, thicknesses, colours and finishes. These quality products are factory manufactured and delivered to site ready for immediate and rapid assembly. KS1100 CS Equi-Bead Internal Application - Internal Wall or Ceiling External Wall Application - Vertically or Horizontally Installed KS1100 CS Mini-Bead Internal Application - Internal Wall or Ceiling External Wall Application - Vertically or Horizontally Installed 1100mm cover width 1100mm cover width Introduction, Benefits & Product Range KS1100 CS Flat Internal Application - Internal Wall or Ceiling External Wall Application - Vertically or Horizontally Installed External Roof Application - External Roof with Site Applied Single Ply Membrane Weathering System 1100mm cover width KS1100 CS Micro-Rib External Wall Application - Vertically or Horizontally Installed 1100mm cover width KS1100 CS Equi-Bead KS1100 CS Mini-Bead KS1100 CS Flat KS1100 CS Micro-Rib 5

6 Construction Solutions Internal Insulated System with Purpose Built Support Framing Application: Coldstore/Chillstore/Food Processing or Preparation Main Structure: Portal or Truss Construction insulated roof panels insulated wall panels Suspension system Ceiling Wall KS1100 CS insulated panels used to form walls and ceiling, supported from purpose built frame Internal Insulated System Self-Supporting Application: Coldstore/Chillstore/Food Processing or Preparation Main Structure: Portal or Truss Construction insulated roof panels insulated wall panels Suspension system Ceiling Wall KS1100 CS insulated panels used to form walls and ceiling Internal Insulated System with Partial External Wall Cladding Application: Coldstore/Chillstore/Food Processing or Preparation Main Structure: Portal or Truss Construction insulated roof panels insulated wall panels Suspension system Ceiling Wall KS1100 CS insulated panels used to form walls and ceiling, supported from structure External Insulated System Application: Coldstore/Chillstore/Food Processing or Preparation Main Structure: Portal or Truss Construction KS1100 CS insulated panels and single ply membrane external weathering system KS1100 CS insulated panels (exposed wall cladding) Structural frame within KS1100 CS external insulated panel envelope 6

7 Selection Data KS1100 CS insulated panel systems can be used for cold and chill stores and food processing or preparation applications within an internal temperature range of -50 C to +60 C. KS1100 CS Wall & Partition Panel System Product Reference Application Description Temp Range Max Wall Height* KS1100 CS 50mm 25 C 5.16m KS1100 CS 80mm 40 C 6.40m KS1100 CS 100mm 50 C 9.10m KS1100 CS 125mm 60 C 10.00m KS1100 CS 150mm 70 C 12.15m KS1100 CS 175mm 80 C 12.90m * Heights stated are for single span internal walls and partitions with a maximum load of 0.3kN/m 2, deflection limit of L /150 and temperature gradient over panel of 0 C. KS1100 CS Ceiling Panel System Product Reference Application Description Temp Range Max Span KS1100 CS 50mm 25 C 3.66m KS1100 CS 80mm 40 C 4.50m KS1100 CS 100mm 50 C 6.00m KS1100 CS 125mm 60 C 7.50m KS1100 CS 150mm 70 C 9.12m KS1100 CS 175mm 80 C 9.98m Maximum span for ceilings takes into account panel dead weight, a point load of 0.9kN and a uniform distributed load of 0.25kN/m 2 as BS 6399: Part 1: The maximum deflection is L /200 and the temperature gradient over panel is 0 C Product Specification Data Core Thickness U-value 0.5/0.5 Steel Temp. Range Wall Max. Height* Ceiling Span* Product (mm) (W/m 2 K) Weight (Kg/m 2 ) ( C) (m) (m) KS1100 CS KS1100 CS KS1100 CS KS1100 CS KS1100 CS KS1100 CS U-value Thermal transmittance W/m 2 K * Single spans for internal walls and ceilings only. Please consult envirocare Technical Services for external load/span tables. Construction Solutions & Selection Data Popular External & Internal Facing Combinations Flat Flat External Internal Equi-Bead Equi-Bead Flat Equi-Bead Equi-Bead Flat External Internal External Internal External Internal These are just a few of the many combinations of external and internal facings available. For further details please contact envirocare Technical Services 7

8 Product Data Application KS1100 CS is an insulated panel system which can be laid vertically or horizontally. It is suitable for use within temperature controlled and hygiene safe environments. Dimensions & Weight 1100mm A = Core Thickness (mm) Weight kg/m 2 0.5/0.5 steel Product Tolerances Length (mm) 3 +3 Width (mm) 1 +1 Thickness (mm) 2 +2 End Squareness (mm) 2 +2 Flatness (per metre) (mm) 2 +2 Thermal Break Panels can be manufactured with a thermal break cut to one side at base to provide insulation continuity at floor slab level if required. Dimension D = Max. 300mm D Panel Rebate Panels can be manufactured with a rebate cut to one side at the head if required. Dimension B: Unless otherwise stated, the depth will be 50% of the panel thickness. Dimension C: Unless otherwise stated, the depth will be 50mm; 80mm; 100mm; 125mm; 150mm and 175mm. B Available Lengths Standard lengths are from 1.8 to 12 metres. 12 to 16.5 metres can be supplied but are subject to additional transport surcharge. Materials Substrate S220GD+ZA hot-dip zinc/aluminium coated metal to BS EN 10214: Standard external sheet thickness nominal 0.5mm, standard internal sheet thickness nominal 0.5mm. Other thicknesses can be supplied for specific orders Coatings - Internal Application Polyester: Fully foodsafe coating although not recommended for prolonged contact with moist or wet food. 25 micron thick standard organic coating standard colour white. Polyester is not suitable for external roof or wall cladding applications. Foodsafe Laminate: Safe for continuous contact with food. 120 micron thick chemically inert polymer film bonded to steel suitable for cladding the interior of cold and chill stores and food processing and other hygienic applications. The standard colour is white. Foodsafe laminate is not suitable for external roof and wall cladding applications. Standard Liner: Bright white polyester. Coatings - External Application XL Forté, Spectrum and other coated steels are available on request. Insulation Core The core of KS1100 CS is an, environmentally sustainable PIR insulation which is non-deleterious with zero Ozone Depletion Potential (zero ODP). C NB. Rebates and thermal breaks are subject to manufacturing tolerances. Details available upon request. 8

9 Panel Joint The tongue and groove joint interfit achieves excellent thermal performance. The panel side joint can accommodate vapour or hygiene safe seals. Air Leakage KS1100 CS insulated panel systems can achieve airtightness below 0.5m 3 /hr/m 50Pa when installed to s recommendations. Performance Thermal Insulation KS1100 CS insulated panel systems have a thermal transmittance (U-value) of: Panel Thickness (mm) U-value (W/m 2 K) Fire The KS1100 CS insulated panel system is both LPCB and FM approved. LPCB certified to LPS 1208 up to 60 minutes. Specifications are available on request from envirocare Technical Services. FM approved to FMRC 4880 Class 1 Fire Classification (no height restriction i.e. - Unlimited Height). The steel outer and inner facings have Class 1 surface spread of flame to BS 476-7: 1987 (Fire tests on building materials and structures. Method of test to determine the classification of the surface spread of flame of products) and are Class 0, as defined by Building Regulations. Approved to LPS 1208 Certificate No. 260b Acoustics KS1100 CS insulated panel systems have a predicted single figure weighted sound reduction Rw = 24dB. Sound Reduction Index (SRI) Frequency (Hz) SRI (db) Biological KS1100 CS insulated panel systems are resistant to attack from mould, fungi, mildew and vermin. No urea formaldehyde is used in the manufacture of the panels. KS1100 CS insulated panel systems can incorporate project specific hygiene safe, wash and clean down facings. Quality KS1100 CS insulated panel systems are manufactured from the highest quality materials, using state of the art production equipment to rigorous quality control standards, approved to BS EN ISO 9001: 2000 (Quality management systems. Requirements). manufacturing plants are BS EN ISO 14001: 2004 (Environmental management systems. Requirements with guidance for use) and BS OHSAS 18001: 2007 (Occupational health and safety management systems. Requirements) accredited. Guarantees KS1100 CS insulated panel systems are available with the Total Panel Guarantee offering up to 25 years thermal and structural performance guarantee. Packing Standard Packing KS1100 CS insulated panel systems are stacked horizontally with facing sheets upward. The entire pack is wrapped in polythene. The number of panels in each pack depends on panel length, weight and thickness. Typical pack height is 1200mm. Maximum pack weight 1500kg. Core Thickness (mm) Panels per pack Sea Freight Fully timber crated packs are available on projects requiring delivery by sea freight shipping, at additional cost. Alternatively, steel containers can be used. Special loading charges apply. Delivery All deliveries (unless indicated otherwise) are by road transport to project site. Off loading is the responsibility of the client. Support envirocare Technical Services offer technical advice and support throughout the design and construction process. From the undertaking of Energy Performance Calculations to the creation of project specific NBS specifications, envirocare Technical Services can help to ensure that your building complies with the building regulations. 's Field Service Engineers offer free contractor training on the installation of new and existing products at our specially designed energi centre in Holywell, North Wales and at Kingscourt, Ireland. They also offer a site inspection service throughout the construction stage and can also offer advice on mechanical handling solutions. Product Data 9

10 Heat Transmission Thermal Conductivity (λ) W/mK. Panel Thickness (mm) U-value Temp. Difference (ºC) The recommended minimum insulation value for Coldstores is 10W/m 2 heat gain. (See Code of Practice for the Design of Coldstore Envelopes). KS1100 CS Panels Fire Test Results BS476: Part 22: 1987 Clause 5 - Walls Thickness (mm) Insulation (I) mins. Integrity (E) mins. Grading FR FR FR FR FR60 BS476: Part 22: 1987 Clause 9 - Ceilings Thickness (mm) Insulation (I) mins. Integrity (E) mins. Grading FR FR FR FR FR60 Notes: Specifications available on request. 10

11 Recommended Maximum Unsupported Wall & Ceiling Spans KS1100 CS 175mm Ceiling span 9.98m KS1100 CS 150mm Ceiling span 9.12m Ceiling span 7.50m KS1100 CS 125mm KS1100 CS 100mm Ceiling span 6.00m Wall height 12.90m Wall height 12.15m Wall height 10.00m Wall height 9.10m Wall height 6.40m KS1100 CS 80mm Wall height 5.16m Ceiling span 4.50m Ceiling span 3.66m KS1100 CS 50mm Maximum wall panel length 16500mm with intermediate restraint Operating Temperatures & KS1100 CS Panel Thicknesses External Ambient Operating Temperature ( C) Temperature 20 C KS1100 CS 50mm KS1100 CS 80mm KS1100 CS 100mm KS1100 CS 125mm KS1100 CS 150mm KS1100 CS 175mm Product Data Panel(s) should be selected to achieve a maximum thermal transmittance of 10W/m 2 11

12 Construction Details Coldstore Application: Vertically Laid Panel - Intermediate Wall Support Multibeam KS1100 CS insulated wall panel vertically laid Stainless steel fastener at maximum 450mm centres Base and Floor Detail Bird beak flashing with silicone pointing Infill by others DPM lapped and sealed over angle 50mm min Kerb by others KS1100 CS insulated wall panel vertically laid Concrete wearing floor Floor insulation Sand and cement screed 2mm 75 x 75 galvanised floor angle fixed at 600mm centres using hammer screws sealed using 2 runs of silicone Traditional heater mat by specialist 1000g polythene damp proof membrane joints lapped at 600mm centres minimum and sealed Thermal break 12

13 Coldstore Application: Ceiling Edge Support Steelwork by others Unistrut beam clamp type PZ785 P1000 unistrut Type TH53 unistrut swivel hanger M12 drop rod stainless steel or MS BZP Sleeve insulation by others: 300mm high insulation, taped and silicone sealed 2mm galvanised closer angle fixed at 300mm centres using steel rivets. Edge sealed with an intumescent mastic M12 nut and washer Foil faced PIB vapour seal KS1100 CS insulated ceiling panel KS1100 CS insulated wall panel vertically laid Canister applied fire rated insulation 2mm 40 x 40 galvanised closer angle fixed at 300mm centres using steel rivets 50mm min Canister applied fire rated insulation Modified A2 top hat support PPC white 13 Construction Details

14 Coldstore Application: Intermediate Ceiling Support Steelwork by others Unistrut beam clamp Type PZ785 P1000 unistrut Type TH53 unistrut swivel hanger M12 drop rod stainless steel or MS BZP Sleeve insulation by others: 300mm high insulation, taped and silicone sealed 0.7mm PE closer plate fixed at 300mm centres using steel rivets. Edge sealed with an intumescent mastic Foil faced PIB vapour seal M12 nut and washer KS1100 CS insulated ceiling panel A2 top hat support PPC white Canister applied fire rated insulation Coldstore Application: Corner - Wall to Wall 2mm PPC galvanised closer angle fixed at 300mm centres using steel rivets. Edge sealed with an intumescent mastic Minimum 600mm to vertical panel joint Foil faced PIB vapour seal KS1100 CS insulated wall panel vertically laid Canister applied fire rated insulation KS1100 CS insulated wall panel vertically laid Minimum 600mm to vertical panel joint 50mm min 2mm 40 x 40 PPC galvanised internal angle fixed at 300mm centres using steel rivets. Edge sealed with an intumescent mastic 14

15 Coldstore Application: Ceiling Partition Support Steelwork by others Unistrut beam clamp Type PZ785 P1000 unistrut Type TH53 unistrut swivel hanger M12 drop rod stainless steel or MS BZP 0.7mm PE closer plate fixed at 300mm centres using steel rivets. Edge seal with an intumescent mastic Foil faced PIB vapour seal Sleeve insulation by others: 300mm high insulation, taped and silicone sealed M12 nut and washer Canister applied fire rated insulation KS1100 CS insulated ceiling panel 2mm 50 x 100 galv. angle fixed at 300mm centres to ceiling using steel rivets and to wall with screws and washer through slotted hole KS1100 CS insulated wall panel vertically laid Coldstore Application: Base Detail Partition Wall Canister applied fire rated insulation A2 top hat support colour white PPC 2mm 50 x 100 galv. angle fixed at 300mm centres to ceiling using steel rivets and to wall with screws and washer through slotted hole Bird beak flashing with silicone pointing 2mm 75 x 75 galvanised floor angle fixed at 600mm centres using hammer screws sealed using 2 runs of silicone KS1100 CS insulated wall panel vertically laid Kerb by others 1000g polythene damp proof membrane joints lapped at 600mm centres minimum and sealed Traditional heater mat by specialist Thermal break 15 Construction Details

16 Insulated Roof, Wall & Façade Systems Roof Systems KS1000 RW Trapezoidal KS1000 SF Secret Fix KS1000 TS Slate & Tile Support KS500/1000 ZIP Kingzip Standing Seam KS1000 LP Lo-Pitch EnergiPanel KS1000 CR Curved Roof Roof Tile KS1000 FC Box Profile Envirodek Polycarb Rooflight Upstand Rooflight Wall & Façade Systems & 1000 Optimo & 1000 MR Micro-Rib & 1000 EB Euro-Box & 1000 FL Flat & 1000 FL-S Stucco & 1000 MM Mini-Micro & 1000 CX Convex & 1000 WV Wave & 1000 LS Longspan KS1000 RW Trapezoidal KS1000 FC Box Profile EnergiPanel Thermatile Thermabrick Thermastone WoodTherm Thermatallic Render Panel Wall-Lite Ancillaries Gutters, Tophats & Flashings Limited UK: Telephone: +44 (0) Fax: +44 (0) Ireland: Telephone: +353 (0) Fax: +353 (0) Details for the following countries; Australia, Belgium, Czech Republic, France, Germany, Hungary, Netherlands, New Zealand, Norway, Poland, Romania, Slovakia & Sweden can be found by visiting our website or our group website Care has been taken to ensure that the contents of this publication are accurate, but Limited and its subsidiary companies do not accept responsibility for errors or for information that is found to be misleading. Suggestions for, or description of, the end use or application of products or methods of working are for information only and Limited and its subsidiaries accept no liability in respect thereof.