QuadCore KS Flat

QuadCore KS Flat is an insulated wall and ceiling panel in Kingspan's KS Series of controlled environment panels. It is built with The QuadCore insulation core, a hybrid core technology that forms microcells. The panel has a flat face on the exterior and a Shadowline profile on the interior.

Recorded interior wall and ceiling uses are in food and life science, pharmaceutical and biotechnology laboratories, research and advanced technology facilities. The flat, non-porous surface aids cleaning and resists bacterial growth. Exterior controlled-environment walls are also a recorded application.

The published specification for KS Flat is as follows.

• Insulation core: QuadCore Technology
• Profile: exterior Flat, interior Shadowline
• Embossing: stucco or non-embossed on both faces
• Gauge: 26, 24 or 22 ga on both the exterior and interior face
• Width: 42 inches, shown as 42-inch coverage (1,067 mm)
• Thickness: 2, 2.5, 3, 4, 5 or 6 inches
• Length: 8 feet to 53 feet
• Standard reveal option: vertical 1/8 inch or 3/8 inch, horizontal 3/8 inch
• Orientation: vertical or horizontal

KS Flat uses the KS joint, which forms a tight vapor barrier in enclosures of any size. Panels are made with stucco embossed or smooth faces on both sides. The CAD detail set for KS Series vertical installation includes an expanded joint, an engaged joint, standard fastening, a thermal cut at the joint and in the field, and numbered fastening patterns from 1A through 8A and 1B through 5B.

Those drawings also cover joint fastening to steel framing, to hat channel on masonry and directly to masonry, base details at insulated slabs and partitions, inside and outside corners with flat or profiled trim, framed openings, stack joints, rakes against a membrane roof, and low and high eaves. Ceiling details include ceiling channel, ceiling tee, hidden clips and a seismic or lateral brace plate.

The core has an R-value of about 8 per inch at a 75 degree F mean temperature and about 9 per inch at 35 degrees F, tested to ASTM C518. Panels reach R-values of up to R-9 per inch, and QuadCore is rated R-8.0 per inch at 75 degrees F.

Published panel R-values by thickness at 35 degrees F mean temperature are R-18 at 2 inches, R-22.5 at 2.5 inches, R-27 at 3 inches, R-36 at 4 inches, R-45 at 5 inches and R-54 at 6 inches. At 75 degrees F they are R-16, R-20, R-24, R-32, R-40 and R-48 for the same thicknesses.

Published test results are as follows.

• FM 4880: Class 1 fire rating of building panels or interior finish materials
• FM 4882: smoke sensitive occupancies, interior and exterior use
• FM 4881: passed for exterior wall systems
• ASTM E84: flame spread 25 or less, smoke developed 90 or less
• CAN/ULC-S101: fire endurance of 10 minutes
• CAN/ULC-S102: flame spread 20, smoke developed 45 for the panel insulation core
• CAN/ULC S138 and CAN/ULC-S134: passed
• NFPA 259: tested for potential heat of building materials
• NFPA 285: passed
• ASTM E72: vacuum chamber tested

Allowable uniform load span tables are published for KS Shadowline and KS Flat at a 42-inch panel width and an interior design load of plus or minus 5 psf, in six facer gauge combinations from 26 ga exterior with 26 ga interior up to 22 ga on both faces. Spans are for negative uniform loads on a single span, at L/180 and L/120 deflection.

With 26 ga facers and no temperature differential, a 2-inch panel spans 18 feet 7 inches at L/180 and 21 feet 7 inches at L/120. A 6-inch panel spans 39 feet 6 inches and 40 feet 3 inches. With a 24 ga exterior and 26 ga interior, the 2-inch panel spans 19 feet 1 inch and 22 feet 3 inches. The tables also give values for temperature differentials of 50, 75 and 100 degrees F. For example, the 2-inch 26 ga panel at a 100 degree F differential spans 9 feet 3 inches at L/180 and 12 feet 8 inches at L/120.

A custom color can be selected. For interior heavy wash down environments, plastisol (PVC) coatings and stainless steel facings are available for interior applications only. CLEAN safe 120 coating is offered for corrosion protection and for exposure to secondary food contact and corrosive cleaning agents.

A UL GREENGUARD Gold certificate (UL 2818, certificate number 86747-420) covers Kingspan insulated wall and roof panel systems for the period 31 Aug 2017 to 31 Aug 2026.

The Kingspan QuadCore 30-year limited thermal warranty provides that, for thirty years from the date of sale, the R-value of the foam in the product will not vary by more than 10 percent from the average R-value published for the product on its sale date. The warranty applies to products purchased on or after June 1, 2018, and is available only on QuadCore-equipped panels.

KS Flat sits beside KS Shadowline, KS Azteco and KS Micro-Rib in the Kingspan controlled environment portfolio. The same panel type is used in insulated metal panel wall and roof work.