customized fireproof sound insulation sandwich panels factory: Specification, Ordering and Quality Notes

Where Cheaper Alternatives Fall Short

Unit price and service life diverge when core density drops below 100 kg/m³; the panel loses its fire rating after a single exposure cycle and the acoustic seal degrades at the joint.

Buyers who select a 30 mm polyurethane core to save freight cost typically face delamination at the steel‑to‑core interface within 18 months, especially in humid climates.

Size, Weight and Specification Range

Standard panel widths run 1000 mm and 1200 mm; lengths are cut to order up to 12 000 mm. Weight ranges from 18 kg/m² for a 50 mm mineral wool core with 0.5 mm steel skins to 28 kg/m² for a 100 mm core with 0.7 mm aluminum facings.

Option Comparison by Usage Level

Two core materials dominate the spec sheet; the choice hinges on fire rating versus weight budget.

Mineral Wool Core (120 kg/m³)

Fire rating: 120 min at 50 mm. STC: 42‑45 depending on facing. Weight: 22‑26 kg/m². Handles temperatures up to 800 °C without structural loss.

Best for: fire‑rated walls, ceiling plenums, industrial enclosures.

Polyurethane Core (40 kg/m³)

Fire rating: 30 min at 50 mm (with intumescent coating). STC: 35‑38. Weight: 14‑18 kg/m². Excellent thermal insulation (λ = 0.022 W/m·K).

Best for: cold‑storage partitions, non‑fire‑rated acoustic barriers, weight‑sensitive retrofits.

Assumptions Buyers Should Stop Making

Thinking that a higher STC number automatically guarantees better in‑situ performance ignores flanking paths.

• Assuming the same panel thickness works for both fire and acoustic specs without checking core density.
• Believing that a standard powder coat survives repeated chemical washdowns in food‑processing zones.
• Expecting zero dimensional change when panels are stored flat for six months in an unheated warehouse.

Each of these assumptions has triggered warranty claims on repeat orders; the fix is a tighter spec, not a thicker panel.

Working as a Production Partner, Not a Catalogue Supplier

We tool the line for your profile: custom width, pre‑cut service penetrations, and factory‑applied perimeter sealant. That eliminates on‑site cutting errors that cause 12 % of installation callbacks.

A private‑label buyer can supply their own coil colour masterbatch; we run a pilot batch of 200 m², run the full fire and acoustic test suite, and ship the approved lot under your branding.

Inspection Items and Test Methods

Core‑to‑skin adhesion

Peel test per ASTM D1781; minimum 1.5 N/mm width at 23 °C. Failure mode: cohesive break in adhesive indicates proper cure.

Fire resistance verification

Full‑scale furnace test (ASTM E119) on a 3 m × 3 m sample; thermocouples at mid‑core and unexposed face. Pass criteria: temperature rise < 140 °C average, < 180 °C max at 120 min.

Sound transmission loss

Two‑room method (ASTM E90) with flanking limit; STC calculated per ASTM E413. Target STC ±2 of spec.

Dimensional and flatness check

Laser scan across 2 m length; flatness tolerance ±2 mm, length ±3 mm, width ±2 mm.

Corrosion resistance

Salt spray (ASTM B117) 1000 h for coated steel; no red rust > 5 % of surface.

Capacity, Tooling and Scheduling

Two continuous laminating lines run 1200 mm wide at 8 m/min; a third line dedicated to 1000 mm width for smaller runs. Changeover between core types takes 4 h. Standard lead time: 3 weeks from approved drawing to first shipment; expedited 10 days if tooling is already set.

Monthly capacity: 45 000 m² mineral wool, 30 000 m² polyurethane. We hold 200 t of mineral wool and 80 t of PU in climate‑controlled storage to avoid moisture pickup.

Care, Storage and Service Life

Store panels flat on timber bearers spaced 600 mm apart; cover with breathable tarp to prevent condensation. Do not stack more than 1.5 m high. Edge protection strips must remain until installation.

Installed panels in interior partitions retain fire rating and STC for 25 years if the facing coating remains intact. Exterior façades with PVDF coating show < 5 % gloss loss after 15 years UV exposure per ASTM G154. Touch‑up of cut edges with matching coating restores barrier continuity.