In this study - the Middle East’s first R&D initiative of its type and conducted by independent system house Pearl Polyurethane Systems LLC. - high index Poly-isocyanurate /Polyurethane rigid insulation foam systems were developed for continuous sandwich metal panel and insulation board applications. Effects of different sustainable blowing agents and their combinations were tested in reference formulation while keeping foam density, Isocyanate index and reactivity profile in same specifications. At the outset, this ground-breaking initiative’s goal was to research new solutions for continuous sandwich panel production to achieve an overall improvement in insulation performance of up to 20 per cent when compared to current industry standards in the Gulf region, as well as improving cost-effectiveness through experimenting with more affordable compositions of additives. of the research was also to develop alternative blends using more environmentally friendly, fourth-generation liquid blowing agents together with pentane derivatives as well as other nucleation additives.

Enrgy efficient poly-isocyanurate core chemistry allowed to pass most challenging fire test norms like FM Approval, NFPA, EN 13501-1 /The modern Single Burning Item (SBI) Test gives a good opportunity to distinguish between fire rated materials.Full room fire test with the possibility for predicting the expansion of the fire and the smoke
development. Latest high index PIR technology fulfills highest fire standards.

An innovative new core product together with potential for variations has been successfully developed from this R&D initiative. With continuous metal panel production and machine trial results now available, it was observed that up to 20 per cent improved insulation properties of panel insulation could be acheived when compared to other like-for-like board thicknesses.

These customised machine trials conducted as part of this R&D initiative have enabled Pearl Polyurethane to launch a portfolio of newly-branded EcoPearl Sandwich metal panel
systems. Results of this research has developed viable new methods for decreasing average continuous sandwich panel thickness, while maintaining insulation performance,
mechanical properties, fire resistancy and achieving lower smoke generation. These goals have been acheived while addressing the needs of MENA-based panel producers, as well as taking into account the numerous climatic and durability considerations influencing end user buying decisions in the Middle East region.