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ThyssenKrupp DAVEX and ems Isoliersysteme: New approach to cold room construction

ThyssenKrupp Steel : 12 July, 2007  (Company News)
Ems Isoliersysteme GmbH and ThyssenKrupp DAVEX GmbH are demonstrating a new approach to cold room construction at Bau, using a walk-in freezer as an example. On the ThyssenKrupp Steel booth the two companies will be showing how cold storage rooms can be built at lower cost using continuously manufactured insulating panels. The concept is based on using innovative roll-joined DAVEX profiles as connecting elements for insulating panels manufactured by ems.
The two companies have developed the new concept for large freestanding cold storage units in buildings such as supermarkets, hotels and hospitals. Such units are built using steel insulating panels with a rigid polyurethane foam core and interlocking devices at the edges. Using the interlocks the panels can be joined together to form a self-supporting, virtually hermitically sealed structure.

The disadvantage of this solution is cost. Because the interlocks have to be embedded in the polyurethane core, panels for cold rooms cannot be produced in a continuous process but have to be manufactured individually. Continuously manufactured insulating panels without interlocks cost up to 60 percent less. In the past, however, they were unsuitable for cold rooms because they require a substructure on which they can be bolted so that the tongue and groove joints at the edges can be pushed firmly together. For this reason, continuously produced insulating panels are primarily used for cold storage facilities with their own structural system.

The new solution developed by ThyssenKrupp DAVEX and ems Isoliersysteme involves fitting continuously produced insulating panels into a frame structure made of DAVEX profiles. The profiles form the edges of the respective refrigerating unit and can be bolted together so that they press the panels in the frame together with the required force. The DAVEX profiles used are so-called hybrid profiles in which the flanges are made of carbon steel and the webs of perforated stainless steel. Because stainless steel has only low thermal conductivity, which is further reduced by the holes in the web, thermal bridges, which would impair refrigerating capacity, cannot occur.

The ability to combine carbon steel and stainless steel is provided by the innovative roll joining technology used to manufacture DAVEX profiles. In this process a special tool first rolls a groove into the flange material. The edges of the web material are contoured and inserted in the flange groove. A locking groove is then rolled into the flanges on either side of the web, causing material to flow into the contours on the web edges. The result is a firm friction/positive joint produced in a continuous, high-speed process. One of the advantages of this patented ThyssenKrupp DAVEX technology is that dissimilar materials such as carbon steel, stainless steel or plastic can be processed into beams.

DAVEX profiles have previously been used in the building industry in areas such as facade construction. Manufacturers of high-bay storage systems and containers also use DAVEX lightweight profiles. ems Isoliersysteme GmbH manufactures polyurethane sandwich panels as well as hinged and sliding doors with excellent insulating properties. Its wall and ceiling systems including a full range of accessories are used mainly in cold room construction as well as in industrial and commercial building construction.
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