High-density polyurethane (PUR/PIR) rigid foam core insulation panels engineered specifically for residential roof systems. Designed for installation above, between, or beneath rafters in pitched roofs, as well as continuous insulation decks for flat residential roofs. Features a closed-cell matrix (>95%) that delivers superior thermal resistance per inch compared to mineral wool or EPS alternatives, reducing structural dead load while meeting strict energy code requirements (IECC / ASHRAE 90.1 / Part L).
Technical Specifications
|
Property |
Typical Value / Metric |
Test Standard |
|
Core Material |
Rigid Polyurethane (PUR) / Polyisocyanurate (PIR) |
EN 13165 / ASTM C1289 |
|
Thermal Conductivity (lambda) |
0.022 - 0.024 W/(m·K) |
EN 12667 / ASTM C518 |
|
Compressive Strength |
>= 150 kPa (at 10% deformation) |
EN 826 / ASTM D1621 |
|
Closed-Cell Content |
>= 95% |
ISO 4590 |
|
Water Vapor Transmission |
<= 60 ng/(Pa·s·m²) |
EN 12086 |
|
Density |
32 - 40 kg/m³ (Core) |
ISO 845 |
|
Standard Thickness |
30 mm - 150 mm (Customizable) |
- |
|
Standard Width / Length |
Width: 1200 mm |
Length: 2400 mm (or cut-to-size) |
|
Facing Options |
Embossed Aluminum Foil, Glass Fleece, Kraft Paper |
- |
Key Features
High Thermal Resistance (R-Value): Minimizes roof thickness profile while achieving target thermal performance, preserving interior ceiling height in attic conversions.
Moisture Barrier Integrity: Low water vapor permeance prevents internal condensation within timber rafter cavities, mitigating structural rot risks.
Dimensional Stability: Maintains structural and thermal integrity across temperature extremes from -40°C to +100°C.
Lightweight Load Reduction: Reduces dead weight on roof trusses compared to concrete or heavy fiberboards, lowering structural engineering overhead.
Applications
Pitched Roofs (Above Rafters): Continuous insulation layer placed over timber decking to eliminate thermal bridging across framing members.
Pitched Roofs (Between Rafters): Cut-to-fit friction fit panels installed directly into rafter bays for retrofit and attic insulation upgrades.
Flat Residential Roofs: Insulation substrate beneath single-ply membranes (EPDM, TPO, PVC) or modified bitumen roofing systems.
Prefabricated Timber & Steel Frame Homes: Factory-integrated insulation component for modular wall and roof cassette elements.
Surface & Finish Options
Facings are selected based on specific vapor control and installation exposure requirements:
Multi-Layer Kraft / PE Foil: Acts as an effective vapor control layer for internal warm-roof applications.
Embossed Aluminum Foil (50 um): Reflective surface providing enhanced radiant heat barrier properties and weather-resistant temporary exposure during construction.
Mineral Coated Glass Fleece: Optimized for direct bonding with liquid-applied waterproofing membranes or adhered single-ply systems on flat decks.
Customization Capabilities
Dimensional Tolerances: Length and width cut to +/- 1.5 mm precision CNC routing to eliminate on-site trimming.
Edge Profiles: Available in Square Edge, Shiplap (Rabbet), or Tongue & Groove to prevent thermal bridging at panel joints.
Thickness Increments: Custom thickness scaling from 20 mm up to 200 mm in 5 mm increments for specific thermal calculation requirements (U-value targets).
Manufacturing & Quality Control
Continuous Lamination Line: High-pressure foaming injection coupled with dual-belt continuous laminators ensures uniform foam density, thickness consistency, and strong interfacial bond strength between core and facings.
Curing Process: Panels undergo controlled thermal curing cycles to eliminate post-expansion warping and ensure complete chemical reaction of polyols and isocyanates.
Quality Assurance Protocols:
In-line density and thickness laser scanning sensors.
Destructive batch testing daily for compressive strength and peel adhesion per EN/ASTM standards.
Traceability labeling on every panel package indicating production shift, batch number, and raw material lot.
Installation & Joint System
Joint Configuration: Shiplap or tongue-and-groove edges interlock to create a continuous thermal barrier, restricting air leakage.
Fixing Method: Mechanical fastening using specialized insulated screws and stress plates directly into timber decks or concrete substrates, adhering to local wind uplift design standards (e.g., ASCE 7 or Eurocode 1).
Vapor Sealing: Foil-faced joints sealed using high-tack acrylic aluminum tape to maintain continuous vapor control layer (VCL) continuity.
Packaging & Logistics
Palletization: Stacked in protective polyethylene film wrapping, strapped to heat-treated wooden pallets (ISPM 15 compliant) with edge protectors to prevent transit damage.
Logistics Optimization: Standardized bundle heights engineered to maximize 40-foot High Cube (40'HC) container utilization or standard European tautliner truck volume, reducing freight cost per square meter.
FAQ
Q: Are these panels compatible with water-based or solvent-based waterproofing adhesives?
A: Compatibility depends on the facing. Glass fleece-faced panels are fully compatible with most cold-applied liquid waterproofing and bitumen adhesives. For solvent-based adhesives, verify chemical resistance with our technical team prior to application.
Q: What is the fire performance rating of the PIR core panels?
A: Standard PIR formulations achieve Euroclass E rating according to EN 13501-1 (equivalent to Class B2 under DIN 4102). Specific fire-retardant additive packages can be adjusted based on project regulatory requirements.
Q: Can these panels be walked on during roof installation?
A: Yes, panels with standard compressive strength (>= 150 kPa) support normal foot traffic during installation, provided temporary load distribution boards are used over thin-gauge panels.
Q: What documentation is provided for commercial customs clearance and engineering sign-off?
A: Each shipment includes a comprehensive Technical Data Sheet (TDS), Declaration of Performance (DoP), Certificate of Analysis (CoA) per batch, and Mill Test Reports.
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