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Rocwall™ Fire-Rated Insulated Panels

Jan 20, 2014

ROCKWALL™ fire rated/non-combustible insulated panels are designed to provide building solutions where both fire resistance and thermal insulation are required. Its metal-skinned, mineral wool panel was developed specifically to meet demands for a fire resistant, aesthetic, high performance, steel- faced building or wall system.


This airtight panel system can be installed easily and quickly, producing an efficient thermal envelope unit that has superior fire resistance (1, 2 or 3 hours based on 4", 5" or 6" core thickness) and a small carbon footprint.


ROCKWALL provides protection from the spread of the fire, and permits egress from the building. ROCKWALL panels can help reduce insurance costs, protect against loss of business, and even save lives.

 

Typical Applications

ROCKWALL™ fire-resistant panels have been used in a wide-variety of applications including the following:

• Large commercial, industrial, and institutional buildings
• Exterior wall cladding, interior partitions, and liners with non-combustible requirements
• Machinery and equipment rooms
• Mezzanine fire separations
• Fire resistant enclosures for conveyors and elevators
• Corridors, hallways and links
• Containment rooms for chemical and flammable material storage
• Mining, oilfield, and milling operations
• Limiting distance applications
• Walls at lot lines
• Boundary and demising walls
• High occupancy areas
• Food production and processing
• Cold storage industry
• Coolers and freezers
• Clean rooms
• Small outbuilding applications

 

Features & Benefits

ROCKWALL™ is a stressed skin, sandwich panel with metal facings permanently bonded to Roxul Conrock® mineral wool core with a heat polymerizing adhesive. The panels are produced in a continuous in-line method for optimum uniformity and quality. The steel top and bottom are 26 gauge pre-painted silicone-polyester finish and profiled galvanized steel facings that are roll-formed and bonded continuously with thermosetting adhesive to mineral fiber insulation.


The core material is cut into lamella strips with perpendicular fiber orientation that provides additional strength, dimensional stability, and moisture resistance.


A tongue and groove interlocking edge is designed in both the core and the metal facing, producing an easy to install joint that is water tight. Optional sealant can be applied during installation. Panels are 46 inches wide and custom lengths cut up to 32 feet.


ROCKWALL and ISOWALL® panels have the same profile edge and facings so they can be seamlessly integrated for architectural agreement.

• Critical line of defense in fire protection: passive fire protection of 1, 2, or 3 hours (4”, 5”, 6”) non-combustible core (no sprinklers required) possesses excellent fire-stopping properties and does not develop smoke or promote flame spread when exposed to fire
• Available in core thickness from 2 to 10 inches
• High thermal barrier envelope and vapour resistance resulting in significant energy saving R-value (R4 per inch) for consistent thermal performance and thermal envelope. Energy cost savings of as much as 30% over traditional multi part building systems. LEEDS credits can contribute up to 22 points with mineral wool panel
• Enhanced sound containment for a quieter environment
• Esthetic flush exterior profile with a smooth, microrib, or shadow line surface in choices of standard colours
• Maintenance-free performance and long building lifecycles
• Installation process can cut construction costs in half: Tongue and grove edge enables ease of construction and edge harmonizes with ISOWALL panel system. Custom fabricated wall and ceiling building solutions in lengths of any transportable length
• Ratings - panels comply with industry standards and building safety codes, including CFIA acceptance for sanitary room requirements as well as Intertek Fire Resistance Rating for a non-load bearing wall [ASTM E119 Fire resistance rating 1, 2, and 3 hour Warnock Hersey Design No. SPI/FWP 180-01, CSI : Code 07 42 63]
• ROCKWALL mineral wool core  is made from natural basalt rock and recycled slag providing a lighter environmental footprint and LEED point credits that contribute to sustainable development

 

Specifications

ROCKWALL™ panels provide the highest Fire Resistance Rating of any fire rated panel on the market. Rockwall core is non-combustible with a melting point of 2150°F (1177°C). In addition to possessing fire-stopping properties, the core does not smoke or promote flame spread when exposed to fire. Our panel meets most current limiting distance standards and building envelope performance criteria stipulated in Canadian building codes. ROCKWALL™ panels have been tested per the following Intertek Standards:
 


Note 1: The wall panel assembly that achieved the air, water and win load ratings described above used silicone sealant around the perimeter and every vertical joint between panels. Refer to Intertek Design Listing SPI-FWPA 180-01 for steel girt placement when fire resistance rating is required.


Note 2: The ultimate loads achieved by each Rockwall panel configuration text for ASTM E72 transverse load are as described below.
 

 

Panel Properties

• Panel facings are permanently bonded to mineral wool core with a heat polymerizing adhesive
• Exterior facings are .020” minimum galvanized steel, G-90 hot dipped, conforming to ASTM A653-Grade 33 pre-coated with a nominal .001” thick modified silicone polyester finish (imperial white)
• CFIA accepted
• Plastic coated steel interior facings, where designated, shall be .020” minimum, galvanized steel, hot dipped, conforming to ASTM A653-Grade 33, pre-coated with .04” CFIA Acceptable White polyvinyl chloride plastisol. Plastic Coated Steel interior facings shall have continuously roll-formed configuration consisting of 0.06” deep grooves spaced approximately 6” apart
• Exterior facings have continuously roll formed rib/groove configuration consisting of 0.06” deep grooves spaced approximately 6” apart, a smooth finish or a micro rib finish

 

Panel Weights

 

26 gauge- 0.018 +/- .002 :   251/2 gauge- .019 :  25 gauge- 0.021 +/- 0.003
Dead load = 2.948psf + 2.948psf + 10.861 psf/panel coverage
SPI panel coverage= 3.9


ROCKWALL sandwich panels are a light fire wall but a heavy insulating panel. The core is much heavier than the EPS cores normally associated with sandwich panels. Vacuum lifters assist with installation.

 Handling Instructions
 Installation Manual


Source: http://structuralpanels.ca/rockwall_fire-rated_panel_system