Panel · 50–200 mm
Panelised — indicative fig. C·31
Fire MW core: Group 1 Non-combustibleEmbodied carbon Data pending Per-m² sourceCompressive PIR core: 100–150 kPa; MW core: 40–60 kPa (perpendicular to face)kPa StructuralDesign life 30yr
Factory sandwich panels with steel skins and PIR (lambda 0.022 W/mK, R2.3–R9.1) or mineral wool cores (lambda 0.033 W/mK, non-combustible Group 1/A1). Mineral wool mandated in Type A/B construction post-NCC 2022 amendments.
01 Physical
Density PIR core: 32–45 kg/m3; mineral wool core: 80–120 kg/m3; steel skins: ~7850 kg/m3; composite panel: 8–25 kg/m2 depending on core type and thicknesskg/m³
Specific gravity 0.010–0.035 (panel composite)
Porosity PIR: ~95 (closed-cell); MW: ~85–90 (open fibre)%
Water absorption PIR core: <3 (closed-cell); MW core: <5 (protected); exposed MW: can absorb significantly%
Hardness Steel skin Rockwell B ~60; PIR core Shore D 25–35Shore
UV resistance Excellent (Colorbond steel skins)
Chemical resistance Good (Colorbond skins); Excellent (MW core)
pH tolerance 5–9 (uncoated steel); Colorbond coating extends to 4–10pH
Surface roughness 0.8–3.5 (steel skin, profile dependent)μm Ra
02 Mechanical
Tensile strength 550–600 (steel skin); PIR core: 0.08–0.12 MPa perpendicularMPa
Compressive strength PIR core: 100–150 kPa; MW core: 40–60 kPa (perpendicular to face)kPa
Flexural strength Panel system — refer to manufacturer span tables per AS/NZS 1170.2kNm/m
Shear strength PIR core: 70–150 kPa; MW core: 40–80 kPakPa
Poisson's ratio 0.30 (steel skins, governing)
Impact resistance 10–30 J (Colorbond skin, thickness dependent)J
Creep resistance Good (steel skins); Moderate (PIR core under sustained load)
03 Thermal
Thermal conductivity PIR core: 0.022 W/mK (declared lambda); mineral wool core: 0.033 W/mKW/m·K
Specific heat 800–1400 (composite, component dependent)J/kgK
Thermal expansion 12–15 (panel, steel-skin governed)×10⁻⁶/K
04 Compliance & Fire First question
Combustibility class MW core: Group 1 (AS 1530.1), Euroclass A1 — non-combustible. PIR core: Group 2–3 (combustible), Euroclass B-s2,d0
Fire resistance level MW wall panels: up to FRL -/60/60 or -/90/90 (with tested linings); PIR panels: typically unrated without passive protectionminutes
Ignition temp PIR foam: 340–380; MW core and steel skins: non-igniting°C
Flame spread index MW core panels: FSI 0 (Group 1); PIR core panels: FSI 15–25 (exposed core)FSI
Smoke dev. index MW core panels: SDI ~0; PIR core (exposed): SDI 5–15 (significant smoke)SDI
Heat release rate PIR core (exposed): 50–200 kW/m2; MW core: near zerokW/m²
05 Sustainability & Health
Embodied carbon 18–35 kgCO2e/m2 (100mm panel, cradle-to-gate, core type dependent)kgCO2e/m²
Carbon footprint 18–35 kgCO2e/m2 (embodied); operational savings offset in 3–8 yearskgCO2e/m²
Embodied energy Panel total: ~150–500 MJ/m2 (thickness and core dependent)MJ/kg
Water footprint 200–500 L/m2 (100mm panel, manufacturing)L/m²
Recyclability Panel: ~40–55% recyclable by weight (steel skins); steel skins alone: ~100%%
Recycled content Steel skins: 50–85%; MW core: up to 70% recycled slag; PIR core: 0%%
Renewable content 0%
Circular score 5/10 (steel recyclable; foam core problematic)/10
VOC emissions Low in service; PIR fabrication/cutting releases isocyanate dust (occupational hazard)μg/m³h
Toxicity rating Low–moderate (MW core and steel skins in service); moderate concern for zinc runoff from steel skins
LEED contribution 3–7 credits (energy, recycled content, low-VOC)credits
06 Durability · Cost · Logistics
Expected lifespan 30–50years
Maintenance interval 6–12 (coastal); 12–24 (inland)months
Warranty period 10–25 (Colorbond paint); 36 (Zincalume substrate)years
Material cost (range) PIR wall panels: $55–95/m2; MW wall panels: $80–150/m2 (supply only, AUD, 2025)AUD/m²
Material cost (per unit) $55–150/m2 (supply only, core type and thickness dependent)AUD/m²
Lead time 2–12 (thickness, colour, and core type dependent)weeks
Lifecycle cost 15–25% lifecycle saving versus equivalent framed wall (30-year basis)AUD/m² LCC
Annual maintenance 0.50–2.00AUD/m²/year
Market availability PIR core: widely available; MW core: good availability (some lead time premium)
07 Assessment
Advantages
- Integrated building envelope — structure, insulation, weather barrier, and lining in one element
- High thermal performance: PIR panels achieve R2.3–R9.1 (50–200mm) in a single skin
- Mineral wool core is non-combustible (Group 1/A1) — compliant with NCC Type A and B walls
- Rapid installation: 3–5 times faster than equivalent framed-and-insulated wall construction
- Factory manufacture ensures consistent quality and dimensional precision
- Wide span capability (up to 8m wall, 6m roof unsupported) reduces secondary structure
- Colorbond steel skins provide 10–25 year paint warranty (Bluescope warranty conditions)
- Fire resistance ratings up to FRL 60/60/60 achievable with mineral wool panels and linings
- Acoustic STC 30–38 for mineral wool wall panels — suitable for industrial noise environments
- Fully recyclable steel skins; high recycled content in mineral wool core (up to 70% recycled slag)
Constraints
- PIR core is combustible — prohibited in Type A/B external walls above NCC thresholds
- Post-Grenfell regulatory scrutiny creates procurement and insurance complexity for PIR systems
- Mineral wool core adds 3–7 kg/m2 weight versus PIR equivalent
- Thermal bridging at fasteners and joints can reduce system R-value by 10–20%
- Specialist trade knowledge required — incorrect joint sealing causes condensation and corrosion
- Cut edges must be sealed to prevent moisture ingress into mineral wool and core corrosion
- Limited panel lengths (typically max 14m) may require mid-span joints on tall facades
- Colorbond steel skins susceptible to oil-canning (visual waviness) on flat profiles
- PIR combustion produces hydrogen cyanide (HCN) and isocyanate gases — high acute toxicity
- Lead times 4–12 weeks for non-stock thicknesses or special colours
08 Applications
A1 Commercial and industrial external wall cladding Warehouses, distribution centres, factories, cold storage — the dominant IMP application in Australia
A2 Low-pitch industrial roofing Long-span roof panels for industrial buildings, typically at 3–5 degree minimum pitch with PIR or MW core
A3 Cold storage and controlled environment rooms Food processing, pharmaceutical storage, and freezer rooms — primary driver of IMP technology development
A4 Commercial office and retail facades (Type B, MW core) Mineral wool core IMPs for compliant external walls on multi-storey Type B commercial buildings post-NCC 2019
A5 School and education buildings Rapidly deployable, highly insulated wall and roof systems for modular school buildings (MW core for NCC compliance)
A6 Healthcare facilities MW core IMPs for fire-compliant external walls in hospitals and aged care, with hygienic smooth liner panels
A7 Data centres Thermally efficient, airtight enclosure for temperature-controlled server environments
A8 Modular and transportable buildings Factory-assembled IMP modular units for rapid deployment — mining camps, site offices, emergency housing
A9 Agricultural buildings Insulated dairy sheds, piggeries, and poultry sheds where temperature control is critical
A10 Residential construction (Type C, single dwellings) PIR core IMPs permissible for Class 1 residential construction — used in energy-efficient and Passivhaus-inspired projects
09 Sources & Standards
Sources pending — citations for this material are not yet recorded. Verify all figures against manufacturer data and current standards before specifying.