ThermalShell Technologies, Inc.
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Panel Specs


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Panel Weight

Concrete/Steel Panels: 22.5 lbs./Sq.ft.
Steel/Steel Panels: 2.5 lbs./Sq.ft.

Panel Dimensions

All standard modular panels are 6 feet wide, and can be produced in variable lengths up to 48 feet long.  Standard concrete/steel wall panels are 8 inches thick, and steel/steel panels are 6 inches thick.  Thickness can vary depending on the amount of insulation required

Insulation Values

All standard modular panels (walls and roof) are insulated to R-30. Steel/steel panels can be made up to 10 inches thick and insulated to R-65.

Structural Requirements

ThermalShell panels, when attached to structural steel framing, require steel attachment angles anchored to the footing, slab or foundation wall. Wall sections up to 25 feet tall do not require mid-span attachment to horizontal girders. Roof sections require joists spaced up to 10 feet apart, depending on load requirements.

Panel Connections

To attach the panels to the bottom of the foundation, slab or footing, the manufacturer creates a void at the bottom of each panel (between the steel and foam). The panel is then placed over an attachment angle (previously anchored to the foundation) and is secured from the inside of the building with self-drilling screws (see Sheet #1, detail item #6). The top of the panel is affixed to the attachment angle (welded to the bottom of the girder) using stainless steel Fab-lok molly fasteners (see Sheet #1, detail item #1). Overlapping sections of interior steel are connected with steel stitch screws.

Roof panels are connected to each joist with structural screws on one side of the panel and stainless steel Fab-lok molly fasteners at multiple points underneath each panel.

Sealants and Flashing

Depending on the connection type and location different sealants are employed. All exterior concrete joints use a standard backer rod and exterior pre-cast caulk. Window and door jambs mounted to concrete panels are caulked as well. Roof panels use a sealant tape or silicon caulk to reinforce their triple seal mechanism.