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A polystyrene sandwich panel is a type of prefabricated panel composed of two layers of metal sheet and an insulating core made of polystyrene foam. Due to its lightweight, affordable price, and thermal and sound insulation properties, this panel is widely used in the construction of warehouses, portable cabins, walls, and prefabricated roofs.
However, compared to polyurethane sandwich panels, it has lower thermal resistance and strength, making it more suitable for budget-conscious projects.
Applications of Polystyrene Sandwich Panels
• Industrial and Commercial Buildings:
o Walls and roofs of warehouses and industrial halls
o Cold storage facilities and clean rooms
o Portable cabins and prefabricated buildings
o Interior and exterior building walls
• Residential Buildings:
o Sloped and flat roofs
o Interior and exterior walls
o Insulation of basements and false ceilings
• Cold Storage Industry:
o Walls and ceilings of small and large cold storage units
• Food Industry:
o Walls and ceilings of food production workshops
• Transportation Industry:
o Insulation of refrigerated trucks
o Construction of guard and workshop cabins
Production Methods of Polystyrene Sandwich Panels
Generally, two methods are used to produce polystyrene sandwich panels:
Continuous Method
In the continuous (mechanized) method, machines and mechanical robots convert raw materials into finished sandwich panels. In other words, raw materials — galvanized steel rolls, polyurethane foam or polystyrene foam sheets, and adhesive — enter the machine on one end, and completed, cut-to-size, packaged panels come out the other end.
Polystyrene Continuous Machine
This type of machine was developed after the invention of polystyrene sandwich panels and, although relatively new, has become very popular today.
In this method, a continuous machine similar to a polyurethane continuous line is used. It includes two uncoiler rows — one for the top sheet and one for the bottom sheet — and two sets of rollers and roll-forming machines to shape the sheets.
An operator then places 2- or 3-meter polystyrene sheets between the shaped, adhesive-coated sheets. The machine presses and bonds the layers and finally cuts the panels into the desired sizes.
Discontinuous Production Line
In this method, operations are performed at different stations and assembled at the end. The galvanized sheet is roll-formed and cut to the desired size, while polystyrene foam is cut to the required thickness. Then, the foam is glued to the sheets using special adhesive, pressed, and allowed to dry completely.
Advantages of Polystyrene Sandwich Panels
• More affordable compared to other insulation materials given its quality and performance
• Thanks to the discontinuous production process, it can be produced in different densities (from 15 to 25 kg/m³, and even up to 30 kg/m³)
• Can be produced in various shapes (the foam is molded under steam press or cut with hot wires into desired forms)
• Thickness can be adjusted and customized in millimeters
• Lightweight panels make transportation and installation easier
• Good thermal insulation: the polystyrene layer prevents energy loss
• Moisture-resistant and inhibits mold and bacterial growth
• Quick and easy installation
Disadvantages of Polystyrene Sandwich Panels
• Lower density and not recommended for areas where high insulation is crucial, such as hot rooms or cold storage, unless used in greater thicknesses. This is because the foam particles are bonded less strongly compared to polyurethane foam.
• Earlier versions of this foam were highly flammable when exposed to heat or direct flame. However, with improvements in raw materials, current versions only shrink under direct flame and are marketed as "non-flammable," similar to polyurethane panels.
• Lower mechanical strength compared to some other types of sandwich panels
• Less fire-resistant than rock wool sandwich panels
• Higher thermal conductivity compared to polyurethane sandwich panels