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Description:

The top and bottom sheets of metal are securely clamped onto the plant's unwinding unit, allowing them to be fed seamlessly into the machinery. The process begins with the "corona system," which cleanses both reverse sides of the metal sheets using high-frequency energy. This step removes oils, greases, and any debris to ensure optimal adhesion in subsequent stages between the foam and the sheet metal. Following this, protective films are applied to the exterior surfaces of both metal sheets.

Once the protective layers are in place, the two sheets are aligned. At this stage, the lower sheet undergoes a foaming process where a swinging foam head evenly distributes foam over its surface. Simultaneously, the top sheet is mechanically stabilized to maintain alignment. Immediately after, the composite sheets, now coated with foam, are fed into a continuous heated drying tunnel. Inside the tunnel, the foam expands to its full volume, adheres to the sheets, and binds them together, forming a sturdy, shear-resistant composite structural panel. Upon exiting the tunnel, these panels are cut to specific dimensions using a flying saw or cutter according to the customer's specifications.

Specifications

Thermal Performance & Strength:
When measured at a mean temperature of 25°C, the thermal conductivity of these panels ranges from 0.031 W/mK to 0.036 W/mK, depending on the density of the material. This ensures efficient thermal insulation in various applications.

Acoustic Performance:
The Alpha panels excel in sound absorption, boasting a Noise Reduction Coefficient (NRC) that falls between 0.80 and 0.95. This makes them ideal for noise-sensitive environments, enhancing comfort and acoustic control.

Fire Performance:
These panels significantly enhance fire safety. They are non-combustible, meaning they do not contribute to the spread of fire, nor do they shrink, stretch, or deform when exposed to high temperatures. Additionally, they do not produce smoke or harmful burning droplets in the event of a fire, making them an excellent choice for fire-prone environments.

Moisture Resistance:
The panels demonstrate excellent resistance to moisture. When partially immersed, they absorb just 0.5 kg/m² of water. Under full immersion, water absorption is limited to between 10% and 11.5% of the panel’s total weight, according to BS2972 standards.

Storage Recommendations:
For long-term storage, Alpha panels should be kept indoors. If outdoor storage is unavoidable, they must be stacked off the ground and covered with a securely anchored weatherproof sheet. Exposing the panels to prolonged weather conditions without protection is not advisable.

Non-Toxic:
Alpha panels pose no risk to health as they do not contain asbestos or other hazardous substances. Their composition ensures they are safe for use in various environments.

Environmental Impact:
The panels are environmentally friendly, free from harmful substances such as CFCs, HFCs, and HCFs. They contain phenol resins within permissible limits, ensuring they align with modern environmental standards.

Advantages

1. Fire Retardant: Provides enhanced fire safety by not contributing to the spread of fire.
2. Thermal Insulation: Offers long-lasting and efficient thermal insulation, significantly reducing energy costs.
3. Energy Efficiency: Helps in saving energy, especially in environments with temperature-sensitive applications.
4. Ease of Installation: Can be easily installed even in challenging weather conditions, reducing construction downtime.
5. Simple Repair & Maintenance: Panels are designed for easy repair or replacement, minimizing maintenance costs over their lifespan.
6. Sound Insulation: Provides excellent noise reduction, making them suitable for environments requiring acoustic control.
7. Design Flexibility: Available in various designs and vivid colors, allowing for customization based on aesthetic or functional needs.
8. Lightweight & Durable: Despite their low weight, they offer high load-bearing capacity, making them structurally sound.
9. Fast Assembly: The lightweight nature and design allow for quick assembly without needing heavy lifting equipment.
10. Aesthetic Appeal: Hidden self-tapping screws give the panels a neat, aesthetically pleasing finish.
11. Fire Resistance: Reasonable resistance to fire ensures they meet essential safety standards.
12. Space Efficiency: Their compact design allows for space-saving installations, ideal for tight spaces.
13. Cost Savings: Overall low cost of installation, maintenance, and energy use makes them a cost-effective solution.

Applications

• Industrial buildings, offering durable and fire-resistant structural elements.
• Partition walls, including semi-glazed partitions for interior spaces.
• Retail spaces such as malls and departmental stores.
• Poultry farms, where insulation and durability are critical.
• Warehouses and storage facilities, providing cost-effective and energy-efficient solutions.
• Cold storage units and blast freezers, ideal for maintaining consistent internal temperatures.
• Pharmaceutical production facilities, ensuring a controlled environment.
• Air handling units, where thermal and acoustic control is essential.
• Commercial buildings that require aesthetic, durable, and energy-efficient materials.
• The dairy industry, ensuring sanitary and temperature-controlled environments.