Norwegian Shadowline roof sandwich panel with PUR or PIR polyurethane insulation

Double sheet sizes

(x) (mm)	20,30,40,50,60,70,80,90,100,120,150
effective width (mm)	1120
ineffective width (mm)	1210
maximum length	in desired length up to 14 m (longer than 14 m depends on transportation method)

The shape and size of the trapezoidal profile, as well as the number of trapezoids across the panel and the top sheet, determine the compressive strength of a roof sandwich panel.

In proportion to the distance of the foundation supports from each other and the slope of the roof and the amount of snowfall and maximum wind pressure in the area as well as the pressure of other loads on the roof, the appropriate roof sandwich panel should be calculated and specified.

For example, in areas where it never snows or in projects where the distance between the support bases of the panels is close to each other, the use of sandwich panels with large trapezoids only leads to unnecessary weighting of the roof and unnecessary costs. Or when the slope of the roof is steep, even in snowy areas, it is not economical to use large trapezoidal steps.

For this reason, all reputable European and even Turkish manufacturers produce several types of roof sandwich panels with different sizes of trapezoids so that the buyer can always select and buy the desired sandwich panel based on technical calculations.

1.2-meter-wide panels have less overlap joints, lower screw consumption, lower transportation costs, and a higher installation speed than the traditional narrow-width panels, and do not weigh down the roof unnecessarily while it will be more cost-effective for the buyer.

Arya Baron for the first time in Iran and almost simultaneously with European manufacturers started to produce 1.2-meter wide panels, plus several ceiling models with different trapezoidal profiles for different roofs and in different climatic conditions have been a part of the Arya Baron product basket.

Insulation layer material

density	41±2kg/m³ (density 30kg/m³ to 50kg/m³ based on customer's order)
Heat transfer coefficient	0.0159 W/(m.K)
foam type	PUR (B1,B2,B3) + PIR

Top layer material

Top and bottom sheet	Pre-painted galvanized - Self-painted pre-painted aluzinc - Self-painted pre-painted aluminum - Self-painted stainless steel (matt or bright)
sheet thickness	0.3 to 0.7 mm
Forming type	cold rolling

According to the type of application and requirements and needs of the ceiling, the top sheet can be chosen of pre-painted or self-painted galvanized, pre-painted or self-painted aluzinc, pre-painted or self-painted aluminium, matt or bright self-painted stainless steel or copper in different thicknesses that each has their own features explained below.

Galvanized sheet: The base or core layer of these sheets is made of steel or iron, and to prevent rapid rusting due to the high affinity of iron in compounding with oxygen in the air, both sides of the iron sheet with a galvanized layer by Chemical plating method is coated, to better protect the base iron sheet from compounding with air and rust on the galvanized surface with several layers of different colors to suit the type of use. As long as the surface of the paint layers of these sheets are not scratched and the base iron is not in exposed to the oxygen in the air, there is a good resistance to the rusting however, it should be noted that drilling holes to close the connection screws also cause kerogen, rust and rot and its progression according to the intensity of moisture and salt of the air in the environment.

Aluminium sheets: The best superiority of the aluminium sheets is because of the resistance of the top and bottom layer of them in exposure of rust and rot in the worst, even in the equatorial climate. Sandwich panel with bottom aluminium sheet is the best option for the production halls with high humidity or needing a lot of washing, such as: hen houses, kitchens, food factories or the production of pastes, beverages. Due to its polish, aluminum shows very good light reflection that if it is used as a bottom casing sheet, it causes more light in the environment and less energy consumption, and if it is used as a top casing sheet, it reduces radiant energy and heat entry into the environment. Another advantage of aluminum sheets is that they are recyclable. In other words, after decades, if the structure is demolished for renovation, bottom and surface aluminum sheets can be sold as desirable recycled materials. Another advantage of these sheets in sandwich panels is their light weight, but in the past, considering due to the problems of adhesion of polyurethane foam to aluminum, fewer manufacturers were able to produce this product, but today, relying on modern technical knowledge and modern machinery, the production of this sandwich panel with excellent adhesion of foam to aluminum sheet is easily possible.

Common colors and designs of top layer Arya Baron products.

RAL

Bottom layer material

Type of bottom sheet rolling

The top and the bottom sheets are rolled in various forms in the roll forming machine and are selected in accordance with the expected pressure tolerance and the appearance of the rolling type.

Arya Baron can produce a wide range of rolling forms for the top and bottom of sandwich panels with the help of very modern machines and C.N.C. production lines.

Common colors and designs of bottom layer Arya Baron products.

Parameters affecting quality

1- The quality of the top layer and the bottom layer and its proper selection:

The Top and the Bottom layers are either stainless steel, aluminum, copper, PVC, fiberglass, galvanized or pre-painted aluzinc, based on the usage that as the Galvanized and Aluzinc sheets are more common to be used, we bring more details about them at this section. As you can see in the following image, the sheet is made of multiple layers that we call the whole thickness (thickness of all layers together) the sheet thickness. The thickness of a top and bottom layer sheet of an appropriate sandwich panel with expected stability is between 0.3 to 0.7 mm though 0.5 mm is more common and consumed much more.

It is worth noting that when it comes to the thickness of the sheet, for example considering 0.5 mm, t is necessary that the thickness of each layer would be standard and suitable, never use a thinner than standard range base sheet which is responsible for the main stability in order to reduce the costs and try to compensate the lack of thickness by using cheap painting layers.

In order to make sure the desired quality and standard of the input sheet is fulfilled in the production lines, Arya Baron prepare the sheets directly from reliable companies such as Mobarakeh Steel Factory besides, all the quality control standard tests are done on every product before it enters to the company such as: salt spray test, paint thickness measurement and paint resistance to bending and crashes.

2-The quality of the polyurethane foam used in sandwich panels

Polyurethane foam is obtained from a combination of isocyanate, polyol and several other additives mixed with catalysts.

The quality of these raw materials has a direct and deep effect on the quality of polyurethane foam of the sandwich panels.

Polyisocyanates (PIR) are chemicals of the same family as polyurethanes, which are mostly used as insulation, and the percentage of MDI in this foam is higher than PUR foam. The insulation of PIR in equal conditions is more than PUR. PIR fire resistance is also higher than PUR (B1).
35 kg / m³ to 50 kg / m³ it is obtained, which according to experiments has been done. The best and most optimal density in the above range is compression or density of 41 kg / m³.

In many cases, density or volumetric mass with the same density of foam is considered a necessary and sufficient condition for a desirable and quality foam which is not correct.

As we know, polyurethane foam is an organic material and its main function is insulation. Now, if this organic matter is mixed with heavy minerals such as mill or rock powder, and even with polyurethane milling materials, the desired density can be easily achieved. However, the desired standard insulation has not been achieved and the level of insulation has decreased and preventing the exchange of cold and heat will no longer be at the standard and acceptable level.
The degree of insulation of the foam, which directly depends on its heat transfer coefficient, is an important quality parameter that should be paid special attention to. The heat transfer coefficient can be measured with the relevant device and the presence of unauthorized organic or mineral additives in the foam layers can be seen and detected with a laboratory microscope.
Another important feature of polyurethane foam is its fire resistance that neglecting to obey this, can lead to severe damage.

Arya Baron has equipped a modern laboratory for customers and provided them a free sample testing. This laboratory with standard fire resistance test device, microscope for ocular detection of polyurethane texture and the absence of unauthorized or mineral additives in the foam layers, standard devices for testing the adhesion of foam to sheet, panel bending test device, densification facilities and many Other devices are equipped.
Regarded customers can take the desired number of samples from each received product and test the samples for free by attending the laboratory.

3-The quality of machines in production line

Polyurethane foam production machines require a high level of technical knowledge, and even some European countries that have been working in the field of producing such machines for many years have not yet been able to achieve the details and tricks of the trade.
Arya Baron believes that the expensive production machines of number one European brands are due to their superior quality, and based on this, the company years ago with polyurethane foam machines from O.M.S. Italy has started its activity.

In the continuous automatic production line of polyurethane sandwich panel, the coils of the top and bottom sheet are opened separately and each of them enters the sheet electric discharge device so that the electrical energy of the sheet is discharged and the adhesion of foam to the sheet is done perfectly.

Then the discharged sheet enters the cold rolling machine (roll forming) so that the shutters are rolled on the top and the bottom sheets. If the rolling machine is not a quality one, the sheet paint will be crashed at the place of bending and over time, rust will start from the place of the same crashes. The sheet then enters the pre-heater with a specially controlled atmosphere and is heated to the desired temperature. Then the top and bottom sheets that have reached the desired temperature are taken out of the pre-heater and entered the heater, and after reaching the predetermined temperature and surface conditions, the foam materials prepared in the foam production machine with desired pressure, temperature and percentage mixture is sprayed on the sheet.
Pressure, temperature, mixing percentage and type of spraying are very important and qualitatively effective parameters. Now, the created sandwich panel enters the longitudinal rotary press machine and leaves it after finishing the baking process. Usually these longitudinal rotating presses are between 12 and 36 meters and Arya Baron lines are equipped with 36 meter presses to achieve the desired quality. The length of this press as well as the quality of the surface and its resistance to high pressures of foam are considered as effective parameters.

4-Efficient, specialized and trained personnel with up-to-date technical knowledge

Skill is a mixture of expertise and experience. And the necessary condition for the optimal use of modern machinery and quality raw materials is the presence of skilled workers in the production cycle. Arya Baron in order to lead the company’s operators and production staff to produce quality and durable products with desirable raw materials and using modern and sophisticated machines at appropriate intervals has considered foreign and domestic training courses and seminars in the company as well as inviting foreign and internal professors and put it in the program of the company.