The ThermaSteel System is a unique patented process utilizing the power of composite technology. A structural grade double steel frame with rigid, fire retarding EPS (Expanded Poly-Styrene) bonded to the steel frame with heat activated bonding agents, produces a light weight composite panel that provides structural framing, insulation, sheathing and vapor barrier in one fast, high-tech step.
ThermaSteel panels may be used for exterior and interior walls, floors, ceilings and roofs. Combinations of panels are screwed together to form a building system that is extremely fast, light-weight and structurally strong. Because the studs are oriented parallel to the face of the panel and the shiplap joints are utilized at the edges, the system has an almost complete thermal break providing superior thermal performance. Rough openings for doors and windows are formed during the manufacturing process. The panel also has a unique molded horizontal chase to accommodate electrical wiring. Other chases for plumbing and wiring are usually made with a hot knife at the construction site. Any type of cladding (i.e. siding, stucco, EIFS, brick, stone, drywall) may be field applied to the interior and exterior sides of the panel similar to traditional construction methods.
ThermaSteel panels provide a 34% higher effective R-value compared to theoretical stated values for EPS.—— 3 ½" = R-22
—— 5 ½" = R-30
—— 7 ½" = R-40
This is a direct result of:
- Reduction of air infiltration
- Elimination of thermal bridging
- Effects of shiplap joints
- Effective of the interior & exterior cladding
A 4'x12' panel weighs approximately 68 lbs, enabling timely installation and eliminating the need for any lifting equipment.
Standard studs are manufactured from 24 gauge, G-90 galvanized steel and are positioned at either 16'' or 24'' on center on both sides of the panel. This steel is also utilized as edge metal at the top and bottom of each panel. As some projects demand a higher threshold of structural support, our team of engineers will design every panel individually and increase gauge thickness as needed.
The modified Expanded Poly-Styrene (EPS) used in these panels has a density of 1.5 lb/cf for the 3 ½" panel and 1.0 lb/cf for 5 ½" and 7 ½" panels.
Fire Ratings & Coverings
The EPS insulation used already has a superior auto-ignition temperature to that of wood (904 degrees vs 500 degrees). However, our panels also have a fire retardant added to the EPS mixture during panel construction. This assures our customers the very best fire ratings for both code officials and insurance agencies.
Interiors must be covered with a minimum of ½" drywall or plaster for a minimum 15 minute fire rating. Assemblies are also available with a one-hour or two-hour ratings. Exterior may be clad with any type of construction cladding materials - no sheathing or wrap is required.
Panel Attachment System
Panels interlock with shiplap joints and self-tapping tech screws. The preferred method is to use metal track for the top and bottom plate. If wood plates are used, only single plates top and bottom are required. Plates are attached to the panel with 3" x 5" galvanized shear plates at each stud.
Horizontal chases are pre-molded in the panels. Additional horizontal and/or vertical chases may be added at customer request. A hot-knife is typically used on-site to create the majority of wire runs & plumbing cutouts.
Available Test Results
As with any premiere structural building system used around the world, international code compliance is crucial in order to assure public safety and structural integrity. This panel system has all of the documentation and testing results from the International Code Council (ICC) and other globally recognized standards. These reports such as the ICC-ES Legacy Report are available in the Technical Information portion of this website.
Laboratory test results are available for compressive, transverse, and racking shear using the standard ASTM E-72 to determine the strength of the system. This panel system passed the Florida Hurricane Test Lab requirements for both wind speed and large impact resistance. Air & water infiltration, fire and sound test results are also available.
Building Code and other standards compliance:
- BOCA 91-40
- ICBO PFC-4216
- HUD 1072, Rev. 2
- South Florida Code Compliance #HTL 98072
Level of Service
LeeCor Systems is dedicated to the highest quality of service and support for our customers. Our staff is very happy to assist you from the concept and design phases all the way through the construction phase of your project.
A technical representative is available at our office to review technical details and plans if needed. A detailed set of shop drawings, an assembly manual and all required fasteners will be provided for ease in assembly. In addition, a hot-knife for electrical & plumbing and a self-feeding screw-gun will be included for qualified first-time customers.
Certain designs and regions require a seal or letter of recommendation from a licensed structural engineer. LeeCor Systems, for an additional fee, can provide the additional engineering on a case by case basis.