01 April 2004

For companies in the region, particularly in the food and pharmaceutical sector, the ability to maintain a controlled internal environment within buildings is of paramount importance.

BRIAN Harrington (left) discusses on the benefits of innovative temperature-controlled integrated systems.

With a growing demand for larger industrial buildings that hold large amounts of stock, machinery and products, and with strict regulations governing environmental and safety legislation in place, there is a real need to use advanced construction materials and systems. One increasingly popular route is to take a totally integrated approach to the building envelope.
There are many construction methods that can be used to provide a temperature-controlled climate, notably internal “box within box” with external insulation systems or external clad rack systems where the panel is supported by the racking or frame.
While these methods do create effective controlled environments, they also require a large number of components. The problem lies in the fact that it could take the failure of just one element to compromise the temperature controlled function of the system as a whole.
The consequences of such an event could be disastrous as water, air and vapour ingress could result in thermal breakdown, product deterioration and hygienic failure. The danger is that it could seriously damage a company’s profitability and reputation, something which could take years to rebuild. 
Obviously, this is the worst-case scenario but it isn’t unrealistic. So what’s the alternative?
The introduction of fully integrated units, such as the KS1200 CS temperature-controlled wall and ceiling system from Kingspan Insulated Panels, removes these risks by coordinating the foundations, floor slabs, underfloor heating, cooler and chiller systems within the building fabric as a whole.
Apart from the fact that factory-engineered panels can maximise build quality and speed of construction, the KS1200 CS offers other significant advantages over traditional external cladding because it does away with the need for additional main or secondary steelwork.
The envelope can be designed such that it can be fixed directly to the mainframe – that is, the rafters and columns. The need for above-ceiling/roof void sprinklers and ventilation is also eliminated. In addition, the panels are available in lengths up to 16 m, accommodating the trend to build bigger and significantly reduce the number of components and on-site operations. It also eliminates concerns associated with insulation or thermal inconsistencies.
The result is a quick, cost-effective and airtight construction that also removes airborne fibres, which can be problematic within a clinically clean or food-safe environment.
Fire safety is one area for concern with many customers. Unlike the traditional polystyrene insulation core panel systems used for coldstore or food-processing applications, which perform badly in a fire, the insulation material within the KS1200 CS system is actually made of PIR, a rigid close-cell product that has a completely different reaction to fire as opposed to polystyrene.
PIR forms a protective char, which allows it to self-extinguish. The char expands and fills the space behind the steel sheet, reducing the core’s exposure and the likelihood of fire ingress. The KS1200 CS has, therefore, received LPCB FireSafe and FM accreditation – a key requirement from insurance companies.
Given that the whole purpose of a controlled temperature environment is to ensure the building maintains a reliable and consistent temperature, how does one sustain it with integrated systems such as the KS1200 CS system?
The answer lies in the effective coordination of the building elements and when applied it can accommodate a full range of temperatures from +40 deg C to minus-40 deg C. The interlocking tongue and groove panel joint provides an airtight construction, which enhances protection against common failures in the building envelope, such as water, air and vapour ingress.
Integrated systems offer a ‘peace of mind’ approach to coldstore applications and it is an advanced solution for temperature-controlled environments. The cost of installing internal chilling and cooling systems can be expensive and have a higher potential for failure.
Integrated systems on the other hand, provide a continuous barrier around the building envelope to create an airtight seal, allowing companies to truly take control of the internal environment in a safe, productive and cost-effective manner.
More information on Kingspan Insulated Panels and its products can be obtained from the company’s website at www.kingspanpanels.com

• Brian Harrington is the cold store manager for the UK-based Kingspan Insulated Panels.

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