EPS Core Insulated Panel
Fire Rated Systems
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Panel Specification Documents
  • Core

    Panel cores are self-extinguishing grade expanded polystyrene Class SL, manufactured to Australian standards. Steel skins are bonded to the core under pressure using a two-part thermosetting polyurethane adhesive.

    EPS Panel cores are also available with a thermal link finger joint on vertical panel joints for freezers and CA storage applications. This finger joint is used for panels between 150 and 200mm thickness; these panels are called Thermalink ®.

    Other specialised cores are also available on request.

    Skins

    Sheet thickness can range from 0.40mm to 0.60mm for either surface skin. Panel skins are available with a choice of steel:

    • Colorbond® Permagard™ steel, incorporating Microban® antibacterial technology in its coating to provide durable, food-safe performance that will not wash off. This steel is available in Permagard™ White only.
    • Colorbond® standard grade steel comes in a wide range of designer colours.
    • There are other skin materials available on request,including Stainless Steel, Aluminium and Printech™ printed steel.

    Colour

    The many colours available in Colorbond® range from traditional to modern. For Prestige Applications there is Colorbond® Metallic steel. Generally, the lighter colours are preferred for external use, because they reflect solar radiation. The various surfaces and colour choice can influence the price per square metre.

    Dimensions

    • Width: 1200mm as a modular standard.
    • Thickness: 38mm and 50 to 300mm in multiples of 25mm.
    • As required, determined by handling, design and transportation.

    SECTION PROPERTIES

    Section properties and mass for unit (1000mm) width of panel, together with the recommended maximum design skin stresses have been determined for panels of varying panel thickness and these are shown below.

    0.40mm Steel Skin
    Thickness(mm)

    View
    50
    75
    100
    150
    Section Modulus(mm2)
    View
    21230
    32020
    42800
    64370
    Maximum Design Skin Stress (MPa)
    View
    97
    90
    75
    63
    Weight(kg/m2)

    View
    7.7
    8.1
    8.4
    9.1

    0.60mm Steel Skin
    Thickness(mm)

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    50
    75
    100
    150
    200
    250
    300
    Section Modulus(mm2)
    View
    31590
    47770
    63940
    96300
    128660
    161020
    193380
    Maximum Design Skin Stress (MPa)
    View
    66
    66
    66
    66
    66
    66
    66
    Weight(kg/m2)

    View
    10.9
    11.2
    11.6
    12.2
    12.9
    13.6
    14.4

    THERMAL PERFORMANCE

    (SL Grade EPS core)
    Panel Thickness(mm)
    View
    50
    75
    100
    150
    200
    250
    300
    R value(m2K/W)
    View
    1.32
    1.97
    2.63
    3.95
    5.26
    6.58
    7.90
    U factor(W/m2K)
    View
    0.76
    0.51
    0.38
    0.25
    0.19
    0.15
    0.13

    Profiles


    PROPERTIES - ULTIMATE LIMIT STATE

    DESIGN LOAD CAPACITY Steel Thickness 0.60mm
    Nominal Panel Thickness Ultimate Limit State Uniform Design Load Capacity kN/sqm
    Single Span - Length in metres
    (mm) 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 9.0
    50 2.41 1.93 1.61 1.37 1.06 0.83 0.67 0.55 0.46 0.40 0.34 0.30 0.26 0.21
    75 3.64 2.90 2.42 2.08 1.59 1.25 1.02 0.84 0.70 0.60 0.52 0.45 0.39 0.31
    100 4.87 3.89 3.25 2.78 2.14 1.68 1.37 1.13 0.95 0.80 0.70 0.61 0.53 0.42
    150 7.34 5.88 4.90 4.19 3.22 2.53 2.05 1.69 1.43 1.22 1.04 0.91 0.80 0.63
    200 9.81 7.84 6.53 5.61 4.30 3.40 2.75 2.27 1.91 1.62 1.40 1.22 1.07 0.85
    250 12.30 9.83 8.19 7.02 5.38 4.25 3.44 2.85 2.39 2.03 1.75 1.53 1.34 1.06
    300 12.79 10.23 8.53 7.29 6.38 5.04 4.08 3.38 2.84 2.42 2.08 1.82 1.60 1.26

    Slip-joint© male/female main profile, 1200mm wide Wall Panels, 0.40mm Base Metal Thickness Colorband© ,raised profile at 50mm spacing on both sides of an SL Grade Polystyrene core.

    DESIGN LOAD CAPACITY Steel Thickness 0.40mm
    Nominal Panel Thickness Ultimate Limit State Uniform Design Load Capacity kN/sqm
    Single Span - Length in metres
    (mm) 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 9.0
    50 2.07 1.65 1.38 1.19 1.04 0.82 0.66 0.55 0.46 0.39 0.34 0.29 0 0
    75 2.88 2.31 1.92 1.65 1.44 1.14 0.92 0.76 0.64 0.55 0.47 0.41 0.36 0
    100 3.21 2.57 2.15 1.83 1.60 1.27 1.03 0.85 0.71 0.61 0.52 0.46 0.40 0.32
    150 4.06 3.25 2.71 2.32 2.03 1.60 1.30 1.07 0.90 0.77 0.66 0.58 0.51 0.40

    Notes

    • The tabulated design loads are factored maximum design loads. (In the assessment of the design loads, the designer should take into account the self weight of the Econotilt panel).
    • Compliance with these recommendations will ensure that deflections do not exceed span/90. Where more severe deflection restrictions are required, specific testing of deflection characteristics is recommended for the various span/thickness combinations.
    • A minimum design load of 0.68 kN/m2 is recommended for general applications. Design loads below the lightly shaded area satisfy Serviceability Limits on deflections. Circumstances may require different design loading.
    • Where panels are continuous across a support, it is recommended that stress cuts be made across the inside (or cold side) steel skin adjacent to the supports to prevent buckling of the outer (warm side) skin at the support. Fixings should be provided on both sides of the stress cut.

    POLYSTYRENE CORE BUTT JOINTS

    The butt joints between the ends of the polystyrene core material have been made by way of finger jointing providing a mechanical bond across the end faces of the core material. The finger joints of the polystyrene core material occur at every point.

    PROFILES

    Available with a surface finish or low profile of 0.75mm depth to either surface: 100mm Rib profile, 50mm Mesa Rib and Silkline. The Austral Slip-joint® is incorporated into the edges of both surface skins for easy installation.

  • Core

    Panel Cores are lightweight, fire-resistant composite insulation material manufactured to Australian standards. XFlam is both recyclable in itself and is capable of absorbing recycled foams such as EPS, PUR and PIR. Steel skins are bonded to the core under pressure

    Skins

    Sheet thickness can range from 0.40mm to 0.60mm for either surface skin. Panel skins are available with a choice of steel:

    • Colorbond® Permagard™ steel, incorporating Microban® antibacterial technology in its coating to provide durable, food-safe performance that will not wash off. This steel is available in Permagard™ White only.
    • Colorbond® standard grade steel comes in a wide range of designer colours.
    • There are other skin materials available on request,including Stainless Steel, Aluminium and Printech™ printed steel.

    Colour

    The many colours available in Colorbond® range from traditional to modern. For Prestige Applications there is Colorbond® Metalic steel. Generally, the lighter colours are preferred for external use, because they reflect solar radiation. The various surfaces and colour choice can influence the price per square metre.

    Dimensions

    • Width: 1200mm as a modular standard.
    • Thickness: 50 to 250mm in multiples of 25mm.li>
    • As required, determined by handling, design and transportation.

    Profiles

    Available with a flat surface finish or low profile of 0.75mm depth to either surface: 100mm Rib profile, 50mm Mesa Rib and Silkline. The Austral Slip-joint® is incorporated into the edges of both surface skins for easy installation.

    TECHNICAL SPECIFICATIONS AT A GLANCE

    Typical 100mm panel with XFlam core and nominal 0.60mm steel skins

    View
    Weight
    Span
    R-Value (100mm)
    View
    14.6kg/m2
    5.5m with 1.61kN/m2 design load
    3.23m2KW

    FIRE PERFORMANCE AT A GLANCE

    Result

    View
    FM Global Class 1
    -/120/15 (50mm)
    -/120/30 (100mm)
    -/120/115 (250mm)
    BCA Group 1
    Standard

    View
    FMG 4880
    AS 1530.4 1997


    ISO 9705:1993


    Description

    • XFLAM™ panels are a lightweight composit building system.
    • The system comprises of two sheets of Colorbond® steel, XFLAM™ core and bonded by special adhesives.
    • Panels are formed with the Austral Slip-joint® enabling effective and easy installation.

    Fire Safety Performance

    • BRANZ: ISO 9705 - exceeds 20mins which is the requirement for Group 1 Australian Building Code.
    • Factory Mutual: Meets fire resistance requirements of FM Global Class 1 (4880)
      “Subject to the conditions of Approvals as a Class 1 insulated wall & ceiling panel when installed as described in the current edition of the FM Approval Guide.”

    Panel Specification

    Width

    View
    1200mm cover
    Width

    View
    1200mm cover
    Core

    View
    XFlam™
    Length

    View
    Cut to order
    Min. 1000mm
    Max. 22000mm
    U-Value

    View
    1200mm cover
    Adhesive

    View
    Thermosetting two part mix of Polyurethane. CFC Free
    Finish

    View
    Flat, 100mm Rib, 50mm Mesa Rib, Silkline.
    Finish Thickness Metal Colour
    Colorbond® 0.60mm (BMT) BlueScope Steel Zinc coated with a corrosion inhibitive primer baked onto surface with durable top coat. Classic Cream, Surfmist, Paperbark, Dune,Shale Grey, Deep Ocean and Pale Eucalypt plus 3 Metallics and Permagard™ White
    Colorbond® Permagard™ steel has been successfully designed with antibacterial properties which provide excellent benets across many applications. Non-standard metals, colours and paint types may be negotiated subject to quantity and time considerations.

    Panel Properties

    Thickness (mm) 50mm 75mm 100mm 150mm 200mm 250mm
    Weight(kg/m2) based on panels with 0.59BMT steel wall & facade panels 12.7 13.7 14.6 16.5 18.4 20.3
    R-Value (m2KW) 1.61 2.42 3.22 4.84 6.45 8.06
    Compressive Strength 156.1 kpa
    Water Vapor Transmission Rate 180 µg/m2 s
    Water Absorption 1%

    Panel Span in Metres

    DESIGN LOAD CAPACITY Steel Thickness 0.40mm
    Nominal Panel Thickness Ultimate Limit State Uniform Design Load Capacity kN/sqm
    Single Span - Length in metres
    (mm) 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 9.0
    50 3.0 2.40 2.00 1.71 1.50 1.19 0.96 0.79 0.67 0.57 - - - -
    75 4.54 3.63 3.03 2.59 2.27 1.79 1.45 1.20 1.01 0.86 0.74 0.65 0.57 0.45
    100 6.07 4.86 4.05 3.47 3.04 2.40 1.94 1.61 1.35 1.15 0.99 0.86 0.76 0.60
    150 9.14 7.31 6.09 5.22 4.57 3.61 2.92 2.42 2.03 1.73 1.49 1.30 1.14 0.9
    200 10.9 8.72 7.27 6.23 5.45 4.31 3.49 2.88 2.42 2.06 1.78 1.55 1.36 1.08
    250 13.7 10.9 9.13 7.82 6.80 5.37 4.35 3.6 3.02 2.58 2.22 1.93 1.70 1.34

    Notes

    • The tabulated design loads are factored maximum design loads. (In the assessment of the design loads, the designer should take into account the self weight of the Econotilt panel).
    • Compliance with these recommendations will ensure that deflections do not exceed span/90. Where more severe deflection restrictions are required, specific testing of deflection characteristics is recommended for the various span/thickness combinations.
    • A minimum design load of 0.68 kN/m2 is recommended for general applications. Design loads below the lightly shaded area satisfy Serviceability Limits on deflections. Circumstances may require different design loading.
    • Where panels are continuous across a support, it is recommended that stress cuts be made across the inside (or cold side) steel skin adjacent to the supports to prevent buckling of the outer (warm side) skin at the support. Fixings should be provided on both sides of the stress cut.