Refrigeration
Cold stores, freezers, supermarkets. Operating temperature down to -40°C.
Sandwich panels in refrigeration — cold stores and freezers
The GS insPIRe® CH refrigeration sandwich panel and its enhanced-insulation version GS insPIRe® CH MAX are dedicated solutions for the construction and arrangement of temperature-controlled rooms. This includes both cold stores (t > 0°C) and freezers (t < 0°C), as well as other facilities where strict control of air temperature and humidity is required.
Scope of application
insPIRe® / GS MW sandwich panels — application in refrigeration
The GS insPIRe® CH / CH MAX refrigeration panel system is suitable for:
- construction of free-standing facilities — cold and freezer halls erected as stand-alone buildings,
- construction of cold and freezer chambers inside existing industrial, warehouse or production buildings,
- creation of temperature-controlled rooms in food, pharmaceutical, logistics and retail facilities,
- partition walls separating zones with different temperatures,
- ceilings and roofs of cold storage chambers.
The panels can be installed both vertically and horizontally, as single- and multi-span elements.
Panel construction and insulating core
The core of the panels is rigid polyisocyanurate foam (PIR) with a density of 40 kg/m³ (+/–10%). The design thermal conductivity coefficient is:
- λ = 0.022 W/m·K — standard GS insPIRe® CH version,
- λ = 0.019 W/m·K — GS insPIRe® CH MAX version (available from November 2020).
The facings are made of steel sheet galvanized on both sides in accordance with EN 10346, grade S220–S280GD, with an organic polyester coating of 25 μm thickness. Typical facing thicknesses are 0.5/0.5 mm or 0.5/0.4 mm; 0.6 and 0.7 mm facings are also available. The tightness of joints between panels is ensured by precisely manufactured refrigeration locks, filled during installation with polyurethane foam and permanently plastic sealant.
Available panel thicknesses
The product is available in four core thicknesses:
| Thickness [mm] | U [W/m²·K] — PIR | U [W/m²·K] — PIR MAX |
|---|---|---|
| 100 | 0.22 | 0.19 |
| 120 | 0.18 | 0.16 |
| 160 | 0.14 | 0.12 |
| 200 | 0.11 | 0.10 |
The panel thickness is selected by the designer depending on the temperature difference between the interior and the surroundings. The recommended maximum heat flux density for freezers is 10 W/m².
Example of thickness selection:
Internal temperature: –15°C, external temperature: +35°C → Δt = 50°C
The appropriate panel is GS insPIRe® CH / CH MAX with a thickness of 120 mm, for which the heat flux density is 9.24 W/m².
Technical parameters and certificates
- Reaction to fire: B-s1, d0 (without EPDM gasket) / B-s2, d0 (with EPDM gasket)
- Fire resistance: EI 30 (conditions per classification)
- Fire spread: NRO (non-fire-spreading)
- Acoustic insulation: Rw = 23 dB, Ra1 = 21 dB, Ra2 = 20 dB
- Atmospheric corrosivity category: C1, C2, C3 (per EN ISO 12944-2); coatings for C4 and C5 environments available on request
- Certificates: CE Declaration of Performance per EN 14509, Hygiene Certificate, Certificate of Constancy of Performance EN 14509, Fire Resistance Classification
The Hygiene Certificate permits the use of panels in food industry and refrigeration facilities, which is a key requirement for food producers, meat plants, dairies, pharmaceutical warehouses and cold logistics centres.
Modular widths and lengths
- Modular width: 1000 mm or 1140 mm (for L, M, F and P profiling)
- Standard panel length: from 2.0 m to 12.0 m
- On special order: panels shorter than 2.0 m and longer than 12.0 m, up to a maximum of 16.5 m
Facing profiling
External facing:
- L – Linear
- M – Microprofile
- F – Wave
Internal facing:
- L – Linear
- P – Flat
Installation details — cold stores (t > 0°C)
Cold store details — positive temperature
In cold rooms with positive temperature, panels are fixed to the supporting structure with stainless self-drilling fasteners. The minimum number of fasteners is 3 pcs per panel on each support (for full width). The joint between panels is sealed with PU foam and permanently plastic sealant, and PES tape is used at the contact with the substrate.
The key system details for cold stores include:
- Panel lock and joint — precise refrigeration lock profile with installation foam and plastic sealant,
- Cold store wall corner (Variant I and II) — with PVC corner profile and concealing sheet metal flashing,
- Connection of partition wall with external wall — with PVC corner profile,
- Wall and ceiling panel corner — with vapour barrier (bituminous tape or PE film),
- Connection of wall and ceiling panel — optional removal of facing where locks run perpendicularly,
- Partition wall at floor — with termPIR® insulation board in the floor, vapour barrier and PVC skirting,
- Protective profiles — PVC skirting + PVC bumper strip (~800 mm from floor),
- Cold store door installation — PVC insulating nut with steel insert, threaded rod Ø10, M10 nut with Ø21/Ø10.5 washer.
Installation details — freezers (t < 0°C)
Panel installation detail in freezer (negative temperature)
In freezer chambers, it is necessary to use thermally insulating fastening elements that eliminate thermal bridges and prevent condensation and freezing. The following are used:
- PVC fastening nuts with washer — M8, M10, M12,
- PVC nuts with steel insert and washer — M8, M10, M12,
- polyamide fastening screws — M10, M12.
Additional requirements for freezers:
- Vapour barrier at the wall-to-ceiling joint (bituminous tape or PE film),
- Floor with termPIR® insulation board, vapour barrier (roofing felt or PE film), cement levelling layer and concrete floor,
- Pressure equalisation valves — freezer chambers are airtight rooms; to prevent negative pressure during freezing and defrosting, equalisation valves must be installed,
- Freezer corners with sheet metal flashings (external and internal corner) without PVC profile — details different from those in cold stores,
- Connection of walls of chambers with different temperatures — detail with PVC corner profile on the cold store side and sheet metal flashings on the freezer side,
- Plinth at external wall (Variant I and II) — with termPIR® insulation under the floor, plinth flashing and PVC profile,
- Suspension of ceiling panels (Variant I and II) — using polyester T or Ω profiles with hanging steel threaded rods Ø10.
Packaging and logistics
Panels are packed in packages on pallets. Typical package height: 1000–1120 mm.
| Thickness [mm] | Typical number of panels per package |
|---|---|
| 100 | 11 |
| 120 | 9 |
| 160 | 7 |
| 200 | 5 |
Complementary system elements
The GS insPIRe® CH / CH MAX refrigeration system is a complete cladding system, which in addition to the panels includes:
- Sheet metal flashings (OB-01 external corner, OB-02 internal corner, OB-18 concealing, OB-36 panel-closing) in thicknesses 0.5; 0.7 and 1.0 mm, lengths 3.0 and 6.0 m,
- Self-adhesive gaskets: polyurethane (PUS, PURS), polyethylene (PES), butyl,
- PVC finishing strips: skirting, bumper, corner, plinth,
- Plastic suspension systems (T, Ω profiles) for installing freezer ceilings.
Key technical requirements
- Maximum heat flux density for freezers: 10 W/m²
- Hygiene Certificate required for food and pharmaceutical facilities
- Fire resistance EI 30 (conditions per classification)
- Reaction to fire B-s1/B-s2, d0
- Thermally insulating fastening elements mandatory in freezers (t < 0°C)
- Pressure equalisation valves mandatory in airtight freezer chambers
- Vapour barrier at wall and ceiling joints in freezers
Typical configurations and projects
- Free-standing cold store (t > 0°C) — 100 mm panel, U = 0.22 W/m²K, stainless self-drilling fasteners
- Warehouse freezer (t = –15°C, Δt = 50°C) — 120 mm panel, U = 0.18 W/m²K, PVC fasteners with steel insert
- Deep-frozen logistics chamber (t = –25°C, Δt ≥ 60°C) — 200 mm MAX panel, U = 0.10 W/m²K, Ω profile suspension
- Chamber inside production hall — vertical or horizontal panel layout, ceiling on T/Ω suspension
- Buffer zone between cold store and freezer — connection of walls of chambers with different temperatures using PVC corner profile
- Food processing plant — panel with Hygiene Certificate, flat P internal facing, PVC bumper strips
- Pharmaceutical distribution centre — controlled temperature and humidity, tight refrigeration lock with plastic sealant
Technical consultation
BOKKA advisors help select solutions for specific projects — from U-value analysis, through selection of panel variant and thickness, to support at the execution stage. Contact us via the form or by email to the sales department.
