Sandwich wall panel with rock wool insulation and foam injection at both edges


The advantages of 1.2-meter wide sandwich panels over traditional narrow-panel made many European manufacturers to research technically to know how the machines are manufactured. Arya Baron also succeeded in producing these wide sandwich panels for the first time in Iran and almost simultaneously with some reputable global manufacturers.

Advantages of 1.2 m wide wall sandwich panel compared to traditional narrow type:

  • More installation speed
  • Less shipping cost
  • Better sealing is due to fewer joints and less screw consumption.
(x) (mm) 40,50,60,70,80,90,100,120,150
effective width (mm) 945 , 1020 , 1185
maximum lengthin desired length up to 14 m

insulation layer material

Rock wool
density 100kg/m³ - 120kg/m³
Heat transfer coefficient 0.03-0.04 W/(m.K)

top and bottom layer material

top and bottom sheet Pre-painted galvanized - self-painted / pre-painted aluzinc - self-painted / pre-painted aluminum - self-painted - matt or glossy stainless steel
sheet thickness 0.3 to 0.7 mm
foaming type cold rolling

The color and design of the common sheets in Arya Baron products


rolling type of top and bottom layer

Rolling type of top and bottom sheet

The top and the bottom sheets are rolled in various forms in the roll forming machine and are selected in accordance with the expected pressure tolerance and the appearance of the rolling type.

Arya Baron can produce a wide range of rolling forms for the top and bottom of sandwich panels with the help of very modern machines and C.N.C. production lines.

Parameters affecting quality

1- The quality of the top layer and the bottom layer and its proper selection:

The Top and the Bottom layers are either stainless steel, aluminum, copper, PVC, fiberglass, galvanized or pre-painted aluzinc, based on the usage that as the Galvanized and Aluzinc sheets are more common to be used, we bring more details about them at this section. As you can see in the following image, the sheet is made of multiple layers that we call the whole thickness (thickness of all layers together) the sheet thickness. The thickness of a top and bottom layer sheet of an appropriate sandwich panel with expected stability  is between 0.3 to 0.7 mm though 0.5 mm is more common and consumed much more.

It is worth noting that when it comes to the thickness of the sheet, for example considering 0.5 mm, t is necessary that the thickness of each layer would be standard and suitable, never use a thinner than standard range base sheet which is responsible for the main stability in order to reduce the costs and try to compensate the lack of thickness by using cheap painting layers. 

The quality of the paint used to color the sheet, the condition of the production lines and methods of painting, washing and degreasing have an impressive effect on the quality of the pre-painted sheet.
In order to make sure the desired quality and standard of the input sheet is fulfilled in the production lines, Arya Baron prepare the sheets directly from reliable companies such as Mobarakeh Steel Factory besides, all the quality control standard tests are done on every product before it enters to the company such as: salt spray test, paint thickness measurement and paint resistance to bending and crashes. 
2- Quality of rock wool

Rock wool is one of the best thermal and acoustic insulators that is currently used around the world for insulation. Rock wool has thermal stability up to 750 ° C.

The main raw material for the production of this insulation is basalt, a group of igneous rocks that is a remnant of volcanic activity.

The fibrous structure of rock wool provides excellent acoustic properties and sound absorption for this type of insulation. Also, very high temperature resistance and no fire and no smoke feature, this type of insulation is among the fireproof insulation.

In some rock wools, slag from steel furnaces and some other molts are used instead of basalt, and to compensate for the shortcomings caused by this work, unauthorized incendiary resins are used in excess of the standard. .

These rock wools have a much lower resistance to fire.

3- Production method and machinery

Because rock wool is made up of layered interwoven fibers, it is inherently soft and easily breakable in layers, therefore, the two sheets are arranged in cubes of brick rectangles. This way not only there would be a gap between the joints, but also the parts of the plugs and the tongue or the overlaps won’t have the necessary strength even during the installation stage.

For a long time, we have been looking to eliminate these two major disadvantages of rock wool sandwich panels so that we can enjoy the many advantages of these panels without any worries. In this regard, and to eliminate these two shortcomings, Arya Baron sandwich panels with PIR injection in both edges were launched to the market.

In this type of special panels, polyurethane injected in the two edges, firstly, compresses the rock wool blocks together and eliminates the distance between them, and secondly, in the plugs and tongue part or overlap of insulation and creates high strength between the top and bottom sheets.

In the continuous automatic production line (Continuous), the rock wool sandwich panel first opens the pre-painted sheets on the top and bottom and then each passes through the electric discharge device separately. The electric discharge device prepares the sheet for better adhesion and has a great effect on the quality of rock wool adhesion to the sheet.

The sheets then enter the final pre-heater and heater with a controlled atmosphere to reach the desired temperature for a good adhesive reaction on the sheet. The quality of the adhesive in terms of fire resistance and insolubility in water has a great effect on the final sandwich panel and if it has a poor quality fire-retardant adhesives are used, fire resistance, which is a main feature of this type of panel, will be lost, and water-soluble refractory adhesives will lose their adhesion over time against moisture, and the sheets made of wool would be separated from the rocks. Then the wool of the rocks, which are cut into rectangular cubes, are automatically placed on the sheets and the two sides of the sandwich panel are injected with PIR or (B1 / B2) insulation materials for better strength. Finally, this sandwich panel enters the rotary press machine for baking and after performing the process of chemical reactions, it leaves the rotary press as a finished product.

4-Efficient, specialized and trained personnel with up-to-date technical knowledge

Skill is a mixture of expertise and experience. And the necessary condition for the optimal use of modern machinery and quality raw materials is the presence of skilled workers in the production cycle. Arya Baron  in order to lead the company’s operators and production staff to produce quality and durable products with desirable raw materials and using modern and sophisticated machines at appropriate intervals has considered foreign and domestic training courses and seminars in the company as well as inviting foreign and internal professors and put it in the program of the company.