ModuSec

Secure and efficient IT room solutions

Panel Systems Compared

Is your chosen panel system fit for purpose?

Panel systems are not all the same!
When it comes to accommodating critical IT systems, the first issue to look at is the environment
in which they are placed and the level of protection afforded by the construction system chosen.
Consider the consequences of loosing these systems in a fire, flood or forced entry situation.

Introduction............................................................................. 1
Comparison Table.................................................................. 2-3
Fire Rating................................................................................ 4
Structural Integrity. ................................................................ 5
Effects of Moisture Damage on Mineral Wool Panels.......... 6
 Panel Systems Compared
Foamed panels
Some foamed panels (e.g. PIR or PUR) produce a dense toxic smoke if the core is ignited, which can
happen very quickly in a fire. They add very significantly to the fire load (amount of combustible
ModuSec
material) of a building, can cause dangerous flashover and generally provide low fire ratings
(30 minutes max for a 100mm panel). Hence they are totally unsuitable for IT environments.

This is not the case for ModuSec’s Pyrofoam core panels. They have International Maritime
Organisation (IMO) approved smoke and toxicity levels, add no significant fire load to a building
and provide a 90 minute BS476 Pt 22 fire rating.

ModuSec (Pyrofoam Core) Mineral Wool Core Panels

Strength

Core material has high structural strength.
A complete room structure has been successfully
fire tested unsupported to the Enhanced LPS
1181 test. Hence wall panels support ceiling
panels without additional steel.
Ceiling can span up to 6m without intermediate
support with ‘walk on’ service access to BS6399.
Also strong enough to be used as base panels to
form a sealed six sided box.
Structural stability relies on the composite (steel
covers and core). The core provides virtually no
support on its own. Fire very quickly breaks down
this composite structure. To achieve LPS 1181
support is required from the test rig.
Wall panels should not support ceiling panels. To
maintain structural stability in a fire, they require
perimeter support independent of the wall panels.
This increases cost and can impede placement
of M & E equipment. A maximum ceiling span of
4m is usually recommended for 100mm panels
without intermediate support.

Service Loads & Conduits

Steel reinforcement channels are foamed in to No facility for internal reinforcement or conduits.
all ceiling panels to take heavy hanging loads
Heavy loads need supporting through the panels,
(pipes, cable trays, etc). Cable conduits or steel
increasing heat transfer, potential water leaks and
channels to hang heavy loads can be foamed in
the likelihood of ceiling panels sagging.
to walls as required. Light loads and conduits
can be fixed anywhere to the steel skin.

Panel Connection

Mechanical camlocks with interlinked Pushed together, generally fixed at top and
tongue and groove panels. Stronger, base only.
quicker to build, easier to extend or relocate,
better water protection.

Porosity

100% closed cell core.
Joints are sealed. However any water
penetrating a joint will NOT affect the structural
integrity of the panels.
The panels will not degrade over time.
Porous: Moisture can form and spread from
the dew point inside the panels, possibly
leading to redistribution of core density and
hence insulation values over time. Any water
penetrating a joint will also affect the integrity
of the panels. The additional weight of water can
lead to ceiling sag and possible collapse.

Page 2
 Panel Systems Compared

ModuSec (Pyrofoam Core) Mineral Wool Core Panels

Insulation
ModuSec
U value (rate of heat transfer) of just 0.18. U value of approx 0.38. i.e. half the insulation
This will keep the ‘Carbon Footprint’ of the value of ModuSec with reduced protection from
structure to a minimum. solar gain and environmental stability for air
handling (AC) equipment with the same panel
thickness.

Fire Rating

100mm: F90 to BS476 pt 22. Meets hardware/ 100mm: F60 or F90 depending on density,
media critical temperature criteria for 75 but quickly exceeds hardware/media critical
minutes. temperatures.

Marine Fire Testing

Panels and cable/pipe entry system Lloyds IMO Unaware of any IMO testing on mineral wool
approved to 60 minutes. panels or cable entry systems.

Service Entry

Tested pipe and cable entry systems. Unaware of any tested systems.

Contamination on Drilling

When panels are drilled or cut, heavy particles Light fibres float off, causing possible
drop locally, and are easily removed. contamination to hardware.

Security

Tested Class 2 or 3 options for additional Only standard panels available.

protection from forced attack and blast.

Rodent Protection

Unpalatable to rodents and provides no nesting Provides nesting material, encouraging rodents.
material.

Doors

Double rebated 65mm thick for additional Normally 40mm thick with a single smoke seal.
insulation and security with 2 smoke seals all
round. High security Class 3 doors available.

Overpressure Systems

Insulated overpressure and ventilation hatch Standard ‘off the shelf’

options. non insulated units only.

Page 3
 Fire Ratings
Combustibility and Fire Load
Whilst mineral wool is classed as being
‘non combustible’, composite mineral
ModuSec
wool panels contain combustible materials
(adhesives, surface materials, etc.) and hence
cannot be regarded as ‘non combustible’, any
more than Pyrofoam panels can be. Hence in
testing by the Association of British Insurers,
modified phenolic foam panels (Pyrofoam) are
in the highest safety class for ‘fire load’ with
mineral wool.
Foamed Panels vs ModuSec
Some foamed panels (e.g. PIR or PUR) produce a
dense toxic smoke if the core is ignited, which
can happen very quickly in a fire. They add
very significantly to the fire load (amount of
combustible material) of a building, can cause
dangerous flashover and generally provide
low fire ratings (30 minutes max for a 100mm
panel). Hence they are totally unsuitable for
IT environments.
This is not the case for ModuSec’s Pyrofoam
core panels. They have International Maritime
Organisation (IMO) approved smoke & toxicity
levels, add no significant fire load to a
building and provide a 90 minute BS476 Pt 22
fire rating.
A ModuSec panel last much longer against fire compared to plasterboard stud partitions
and mineral wool panels.
Mineral Wool vs ModuSec
Mineral wool panels etc. are rated under BS476/
EN1364 to protect escape routes or building
integrity to temperatures below 180°C for
the rating period. However, whilst they may
be rated for 60, 90 or even 120 minutes,
critical temperatures for hardware and media
will be very quickly exceeded, well within the
rating period.
The European standard for computer room
construction (EN1047-2) recommends a
maximum rise of 50°C measured 100mm away
from the protected face at 60 minutes.
ModuSec also has a ‘traditional’ 90 minute
rating, but more importantly, during a BS476
Pt 22 test with external temperatures rising
to 950°C over 90 minutes, the internal
temperature, measured on the protected face,
stayed within the critical temperature for media
for 75 minutes and hardware storage (50°C rise
from around 15°C) for 83 minutes.
In addition ModuSec has been fire tested to
LPS 1181 unsupported. This means that the
wall panels can support the ceiling panels
that can span up to 6m without intermediate
support and without a steel ring beam.
Mineral wool composite panels require a ring
beam all round to support the ceilings in a
serious fire situation, as the panels provide no
support if the steel skins come off (as they do
in a serious fire) and generally 100mm panels
should only span up to about 4m for without
intermediate support.
Page 4
 Structural Integrity
The diagram below highlights one of the basic differences in construction between ModuSec panels
and mineral wool panels. Mineral wool panels require extra steel supports within the room which
reduces the floor space and increases the cost. ModuSec panels can act as floor, wall and ceiling
ModuSec
panels and can span up to 6 metres without the need for any additional support.

Single piece core maintains structural integrity

in a fire within the test period.

Ceiling

Pyrofoam Panels

Tested as an unsupported structure to LPS

1181 & Lloyds IMO A 60 Marine Test.

Wall Hence ModuSec’s Pyrofoam core panels

require no perimeter steel support to
maintain structural integrity in a fire,
reducing costs and providing flexibility in
placing plant around the walls.

Mineral wool sections are bonded together and to

steel skins to provide strength.
The bond eventually breaks down under heat.

Ceiling

Mineral Wool Panels

Tested as a supported structure

only to LPS 1181. Hence mineral
wool panels require perimeter
steel support to maintain
Wall structural integrity in a fire.
This increases cost and restricts
placement of plant.

Steel Support

Page 5
 Effects of Water Damage on
Mineral Wool Panels
This diagram shows the possible effects over time from moisture in mineral wool panels. The meeting
Effect Of Moisture Over Time On Mineral Woo
ModuSec
of hot and cold air at the Dew Point may cause water to condense within the panels. Water may also
enter via unsealed or inadequate joint/penetration sealing, particularly if outer access is restricted.
This can significantly increase the weight of ceiling panels, possibly leading to sag or collapse or the
mineral wool may slump to the bottom of panels, reducing insulation and structural integrity.

Weakened
Hot from walls
Air

Porous Mineral Wool

Dew Cold Dew

Point Air Poin
Hot Cold Cold
Air Air
Over time moisture from
Air
condensation can form at the
‘dew point’ and spread
throughout the panels.

Effect Of Moisture Over Time On Mineral Wool Panels

Weakened support Ceiling sag,

Hot from walls Cold exacerbated by weight
Air Air of pipes & cables

ous Mineral Wool

Possible
ceiling
collapse
Cold Dew
Air Point Hot
Air
d Cold Hot
Over time moisture from
Air Air Top ceiling joints that are not sealed
condensation can form at the (if due to restricted access) or which
‘dew point’ and spread have small gaps in sealing may also
throughout the panels. allow water into the panels from
leaks above.

Soaked core reduces insulation &

structural integrity

Page 6