The Product

The key to our Structural Insulated Panels (SIPs) is our polyurethane foam that we use between the building panels. Through the process of manufacturing the SIPs, the enormous pressure created by the polyurethane foam when it forms and cures binds the outer layers of our panels resulting in a unique product that has been widely used industries for over 50 years. Polyurethane structural foam is a space age insulation that has been used in passenger jetliners for over 50 years that has allowed them to operate at great heights and extreme temperatures in excess of minus 50 degrees centigrade.

Polyurethane structural foam is inert and has a closed-cell homogenous structure that is fire retardant with no oxygen to carry flames, retaining its insulation values throughout its life, which to date has been checked at ages greater than 50 years without deterioration or delamination. It is used in domestic refrigerators where the freezer section is normally at minus 22ºC, of course, our insulation section is much thicker in our wall, roof and floor panels, giving exceptionally high insulation values.

Polyurethane structural foam should not be confused with the inferior expanded polystyrene foam.

Expanded polystyrene foam not only posses a fire risk but is also targeted by vermin and insects. It has been found in roof panels that ants have eaten holes in the core weakening the roof panel. It will also melt when exposed to a hydrocarbon (fuel, insect spray etc). This will not happen to polyurethane.

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Key features

  • Fire resistant

  • Excellent thermal qualities

  • Quick build

  • Simple joining installation

  • Noise reduction

  • Excellent air insulation

  • C4 cyclone coded

  • Structurally sound

  • 10 year guarantee

  • Available in all Colorbond finishes

Different Types of Panels

Structural Insulated Wall Panel

104mm Structural Insulated Panel (SIP) Wall product comprises of 2 x 6mm thick x 900mm wide cementitious sheets 92mm apart and core filled with Fire Retardant Polyurethane. The panels are formed with edge seals to allow the insertion of a 35x35x1.6mm SHS between the panels on construction. Lengths are made to 2550mm, 2700mm, 3000mm and 3600mm.

Structural Insulated Panel Roof & Floor

Structural Insulated Panel SIP Floor and Roofing products comprise of 2 x 760mm x 0.42mm Spandek metal sheets (700mm Span) with valleys opposing at 50mm apart and core filled with Fire retardant Polyurethane. Lengths can be any length up to 10000mm. The cementitious sheets, Chemicals cyclone rods, SHS steel, steel roofing, steel flashings and hardware are all sourced locally. The cementitious sheets, steel roofing and flashings are manufactured within Australia.

Compliance Testing

Our walls, roofing and floor panels have been re-tested in 2020 for the following:

  • Racking of walls

  • Cyclic testing of walls

  • Compression load testing of walls

  • Floor panel testing

  • Static tensile loading of glue joints

  • Roof panel testing

  • Thermal performance

  • Fire resistant rating

Manufacturing Process

The method of forming SIP panels is to place two outer skin layers in a press module. The skin layers are placed on opposed plates of the press module and seals are placed around the perimeter of the panels. The press module is then closed to a position where the skin layers are held in parallel planes. The seals keep the skin layers spaced apart, seal the perimeter of the panels and act as a mould, while defining a cavity between the skin layers.

The press module is then locked by tightening locking assemblies such that the plates are held rigidly in the closed position. A liquid foam polyurethane (fire retardant) is injected into the cavity through one or more conduits in the seal. The polyurethane foam expands in the cavity to a specified density, filling the cavity and bonding the two skin layers together.