ThermalSafe® Fire-Resistant Panel

ThermalSafe is a Metl-Span insulated metal panel with a non-combustible mineral wool core. It is built to reach one-hour, two-hour or three-hour fire resistance ratings in walls and a two-hour rating in ceilings. The panel belongs to the Metl-Span wall panel range for commercial and industrial buildings and is used as an insulated metal panel wall and ceiling assembly in fire-rated construction.

The panel is offered in three profiles: Santa Fe, Striated and Ultra-Light Mesa.

The fire ratings are carried through Intertek and UL+ fire approval to ASTM E 119, CAN/ULC 101 and UL 263 in the United States and Canada. Walls reach one-, two- or three-hour ratings, depending on thickness. Ceilings reach a two-hour rating.

The 3 inch thickness carries no hourly rating. The hourly ratings apply to the 4, 5, 6, 7 and 8 inch thicknesses.

• High temperature: the mineral wool core resists high temperatures and does not burn or release gases in a fire
• Acoustics: the mineral wool provides sound reduction
• Moisture and movement: the core is water repellent and dimensionally stable
• Intended use: industrial and high fire-risk buildings

The core is made of non-combustible, rigid mineral wool lamellas. The mineral wool fibers are oriented perpendicular to the panel faces. The core has a K-Factor of 0.275 BTU in/ft²hr°F at 75°F (24°C) mean temperature.

The side joint is the LockGuard joint. It is a flush, double tongue-and-groove connection of the metal faces, with an integral spline that joins the mineral wool core.

Thermal values for the 42 inch panel width are:

• 3 inch: U-Factor 0.086, R-Value 10.9
• 4 inch: U-Factor 0.065, R-Value 14.5
• 5 inch: U-Factor 0.053, R-Value 18.2
• 6 inch: U-Factor 0.044, R-Value 21.8
• 7 inch: U-Factor 0.038, R-Value 25.5
• 8 inch: U-Factor 0.034, R-Value 29.1

U-Factor is in BTU/h·ft²·°F and R-Value is in h·ft²·°F/BTU.

Coverage width is 42 inches or 43 inches. The 43 inch width is offered only in the Ultra-Light Mesa profile. Nominal thicknesses are 3, 4, 5, 6, 7 and 8 inches. Lengths run from 8 feet to 40 feet, varying with thickness.

Panel weights in pounds per square foot, by exterior and interior gauge combination:

• 4 inch: 4.51 (26/26), 4.73 (24/26), 5.04 (24/24)
• 5 inch: 5.22 (26/26), 5.44 (24/26), 5.75 (24/24)
• 6 inch: 5.93 (26/26), 6.15 (24/26), 6.46 (24/24)
• 7 inch: 6.64 (26/26), 6.86 (24/26), 7.17 (24/24)
• 8 inch: 7.35 (26/26), 7.57 (24/26), 7.87 (24/24)

The exterior and interior faces are G-90 galvanized or AZ-50 aluminum-zinc coated steel in 26, 24 and 22 gauge. The 26 gauge exterior is offered only in the Ultra-Light Mesa and Striated profiles.

Finish systems are Fluropon, Fluropon Premier, Fluropon Classic, Flurothane, Flurothane Coastal, WeatherXL and Igloo White Polyester. Colors are formulated for solar reflectance. Metallic finishes can show color shift, shade variation, striations and longitudinal patterning. Light Stone in Tuff Cote does not match Light Stone in Standard SP.

The panel installs in one step and can be disassembled and reinstalled. Load span tables are based on Allowable Stress Design (ASD). For ASCE 7-10 LRFD loads, section 2.4.1 of ASCE 7-10 applies. ThermalSafe is specified under MasterFormat 2012 Section 07 42 13.19.

Published details include exterior sill and door head trim in 3 inch through 8 inch sizes, TS42 and TS43 through-fastener patterns (FP1 to FP3), ceiling joint details for suspended and direct-attached two- and three-hour joints, and panel joint, base, corner, eave, rake and transition details.

• The Ark at JFK: about 6,000 sq ft of 7 inch panels, three-hour rating
• Sofidel Centerville: about 500,000 sq ft of 6 inch wall panels, two-hour rating
• Fallsview Indoor Waterpark: two-hour firebreak ceiling panels on four parking levels
• Lander County Recreation Center: 972 sq ft of 24 gauge, 4 inch panels

A separate TCS series of details covers ThermalSafe cold storage walls, fastening patterns, joints, bases, corners, eaves and intermediate supports. Some of those details use Bulb-Tite and grit clips.