Condensation in GRP cold rooms

Fibre-reinforced plastic (FRP) is a versatile material that is used in numerous industries. In addition to the well-known advantages such as maximum hygiene, high stability, low weight, and corrosion resistance, condensation also needs to be considered. Thanks to their special material properties, LAMILUX wall and ceiling panels offer decisive functional advantages and help to ensure hygiene, efficiency, and safety in the long term.

Cold rooms usually have constantly cold, dry air due to the cooling system, which is usually installed in form of an evaporator. When the door is opened, warm, humid outside air flows into the room. Once this humid warm air hits a cold surface with high thermal conductivity (e.g. metal), the air cools down very quickly, falls below the dew point and condensation forms on the surface. In contrast, on a surface with low thermal conductivity such as LAMILUX FRP, the warm air cools down only slowly. This gives it enough time to mix with the colder air in the room without falling below the dew point. The result: little or no condensation on the wall and ceiling cladding.

1. Surface temperature and thermal conductivity of the material

2. Humidity

3. Air temperature

In cold rooms, the air temperature and humidity are fixed due to operational requirements. Only the choice of wall and ceiling material can be specifically influenced. This is where LAMILUX offers decisive advantages.

FRP has a very low thermal conductivity of only 0.21 W/mK. By comparison, stainless steel has a thermal conductivity of 45 W/mK, aluminum as high as 237 W/mK, and tiles between 1.0 and 1.4 W/mK. Metal surfaces cool down extremely quickly, causing warm air to immediately reach the dew point and moisture to condense. Although tiles offer slightly better insulation than metal, they have another major weakness: joints. Moisture can penetrate these joints and lead to mold growth or hygiene problems. FRP, on the other hand, keeps the surface temperature more stable, allowing the air to equalize and virtually prevents condensation.

The insulating effect of LAMILUX FRP is particularly effective in combination with sandwich panels. Thanks to the use of a PU foam core in combination with FRP cover layers, these panels offer very high insulation performance with a low overall height. A LAMILUX FRP sandwich element with a thickness of just 5.4 cm achieves the same insulating effect as a 40 cm thick brick wall.
This high insulation performance not only ensures optimum energy efficiency in cold room operation but also reduces the risk of cold bridges – and thus the formation of condensation. For planners and owners, this means lower operating costs, less energy loss, and long-term stable temperature control.

The consequences of condensation can be serious:

Water dripping onto food or packaging: The risk of microbial contamination increases.
Puddles on the floor: The risk of slipping and accidents is increased.
Increased humidity: Mold formation and bacterial growth are promoted.
Surfaces that dry poorly: Biofilms can form.
Additional cleaning and drying effort: Disruptions to the production process are likely.

Condensation can pose significant risks to quality, safety, and efficiency, especially in hygiene-sensitive areas such as the food industry. If condensation from steel panels enters production areas, there is a risk of rust formation. Rust particles can compromise hygiene, enter food products, and cause high safety risks. These risks can be effectively minimized with FRP wall and ceiling cladding.

Wall and ceiling cladding made of steel or aluminum is subject to heavy wear and tear in cold rooms and poses several potential problems:

Condensation-related corrosion: If moisture penetrates damaged or aged coatings, the material begins to rust.
Peeling paint layers: Rust beneath the surface can cause coatings to peel off, which is problematic from both a hygiene and visual perspective.
Oxidation in aluminum: This often causes unsightly discoloration that is difficult to remove.

Contact corrosion: When different metals encounter each other, the material can be further damaged.
Structural weakening: Corrosion reduces stability, necessitating maintenance and replacement measures.

These risks are problematic for cold rooms, especially in the food industry, as corrosion spots are difficult to clean and often lead to complaints during audits.

Tiles are also only suitable to a limited extent as wall or ceiling materials in cold rooms:

High proportion of joints: Joints absorb moisture, especially silicone or cement joints.
Mold growth: Damp joints and connection areas are ideal breeding grounds for mold.
Microcracks and leaks: These provide perfect hiding places for germs and bacteria.
Laborious cleaning: Dirty joints and deposits are difficult to remove.
Hygiene issues: Tile joints are often a problem during audits or official inspections, as residues and germs can be detected.

In comparison, LAMILUX FRP wall and ceiling cladding is completely jointless, hygienically safe, and much easier to clean.

LAMILUX FRP combines functional properties that are crucial for cold rooms:

Very low impact sensitivity – robust even under mechanical stress
Good scratch resistance – durable, resistant surface
Excellent corrosion resistance – no rust, even in the event of damage or cut edges
Very good repairability – minor damage can be repaired easily and permanently
No flaking coatings – the optional gelcoat is chemically bonded to the material and permanently stable
Pore-free, seamless surface – hygienic, moisture-resistant, and easy to clean
Excellent insulating properties – significantly reduce the risk of condensation
Resistant to aggressive cleaning agents – meets the highest hygiene requirements
Low maintenance and durability – reduce long-term operating and maintenance costs

With these properties, LAMILUX FRP meets the highest standards in terms of hygiene, material resistance, and efficiency, clearly setting itself apart from conventional solutions such as steel panels or tiles.

From a strictly physical point of view, condensation in cold rooms can never be completely prevented. However, choosing the right material can significantly reduce it. With its low thermal conductivity, corrosion resistance, hygienic surface, and high durability, LAMILUX FRP offers decisive advantages over conventional materials such as steel. Those who rely on LAMILUX right from the planning stage minimize long-term damage, reduce cleaning costs, and ensure long-term efficient and safe operation.