About Our Insulated Wall Panels
ThermaSteel uses patented composite joining technology that injects closed-cell EPS between dual opposing light-gauge steel studs, creating a single panel that serves as structural framing, continuous insulation, and vapor barrier at once.
About Our Insulated Wall Panels
Patented Technology
Closed-cell EPS injected between dual opposing steel studs
Non-Combustible Assembly
All panels meet non-combustible classification
No Vapor Barrier Required for Exterior Walls
Built-in moisture resistance eliminates the need for a separate vapor barrier in exterior wall applications.
THE TECHNOLOGY
What Are Insulated Wall Panels?
Insulated wall panels combine structural support and insulation into one integrated system. Rather than adding insulation after the framing is built, the insulation is injected directly into the panel, eliminating the need to install framing, vapor barriers, and insulation as separate trades and materials.
ThermaSteel uses patented technology that injects closed-cell EPS between dual opposing light-gauge steel frames, creating a super-strong assembly.
OUR PANEL SYSTEM
Manufacturing Panels for Any Applications
Each ThermaSteel panel type is precision-engineered for a specific structural role, and all of them share the same patented closed-cell EPS and steel stud technology, non-combustible classification, and superior R-values.
xPanel
R51–R61Exterior Wall
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✦Up to 42,000 plf load LRFD
4–5 structural studs per face at 16" or 12" o.c., with closed-cell EPS injected between dual opposing studs for exterior wall applications. No separate vapor barrier required for exterior wall applications.
Thickness: 5.5" or 7.5"
View xPanel Details →iPanel
R28Interior Wall / Tiny Homes
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✦16, 18, 20, 24 gauge steel, Track profile
Ideal for interior partitions and small-footprint structures. Available in 1.0 or 1.5 closed-cell EPS density.
Thickness: 3.5"
View iPanel Details →fPanel
R58Stay-in-Place Concrete Form: Floor & Roof
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✦Spans up to 40 ft clear
A stay-in-place concrete form for floor and roof applications. Reduces concrete usage by 40% and labor time by up to 60%, with rebar chairs included.
Thickness: 7.5"
View fPanel Details →rPanel
R51–R61Roof
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✦Reduces trusses by up to 2/3
Placed every 4–6 ft o.c. and engineered to carry diaphragm loads in roof applications.
Thickness: 5.5" or 7.5"
View rPanel Details →hPanel
R51–R61Hurricane Wall
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✦Certified to withstand 185 mph winds
Designed, tested, and certified to withstand 185 mph winds, including flying debris. 11 studs on the exterior face for projectile resistance.
Thickness: 5.5" or 7.5"
View hPanel Details →sPanel
R51–R61Shear Wall
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✦Up to 2,420 plf capacity
Features 6 horizontal bracings. Studs are oriented sideways to create a thermal break, and every panel functions as a shear panel.
Thickness: 5.5" or 7.5"
View sPanel Details →bPanel
R61Below Grade / Foundation
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- Used for foundation, knee walls, and retaining walls
- 7.5″ thick 1.5 density up to 4′ wide and 12′ tall
- Thermally broken with three sections and thermal performance of R61
- 4 or 5 structural studs on both faces of the panel (16″ or 12″ o.c.)
- Check the below grade manual for design guidelines and limitations
cPanel
R28–R61Ceiling
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✦18, 20, 24 gauge steel, CSJ or Track profile
A flexible ceiling panel system compatible with all ThermaSteel panel types. Full range of R-values available.
Thickness: 3.5"–7.5"
View cPanel Details →
Full Comparison
Panel Specification Table
| SPECIFICATION | xPanel | iPanel | fPanel | rPanel | hPanel | bPanel | sPanel | cPanel |
|---|---|---|---|---|---|---|---|---|
| Application | Exterior wall | Interior wall | Floor & roof (stay-in-place concrete form) | Roof | Hurricane wall | Below grade | Shear wall | Ceiling |
| Max Size | 4'×12' | 4'×12' | 4'×12' | 4'×12' | 4'×12' | 4'×12' | 4'×12' or 2'×12' | 4'×12' |
| Min Size | 1/8" changes | 1/8" changes | 1/8" changes | 1/8" changes | 2" changes | 1/8" changes | 2' or 4' wide | 1/8" changes |
| Thickness | 5.5" or 7.5" | 3.5" | 7.5" | 5.5" or 7.5" | 5.5" or 7.5" | 7.5" | 5.5" or 7.5" | 3.5"–7.5" |
| Thermal (R-Value) | R51–R61 | R28 | R58 | R51–R61 | R51–R61 | R61 | R51–R61 | R28–R61 |
| Closed-Cell EPS Density (psf) | 1.0 or 1.5 | 1.0 or 1.5 | 1.0 | 1.0 or 1.5 | 1.0 or 1.5 | 1.5 | 1.0 or 1.5 | 1.0 or 1.5 |
| Acoustic (STC) | Commercial | Residential | Commercial | Commercial | Commercial | Commercial | Commercial | Residential |
| Steel Gauge | 14, 16, 18, 20, 24 | 16, 18, 20, 24 | 24 | 14, 16, 18, 20, 24 | 14, 16, 18, 20, 24 | 16 | 14, 16, 18, 20 | 18, 20, 24 |
| Steel Profile | CSJ | Track | Track | CSJ | CSJ | CSJ | CSJ | CSJ or Track |
| Special Features | Connect 2 panels / tall walls | Connect 2 panels / tall walls | Rebar chairs included | Diaphragm loads | Certified projectile protocol | 10' limit | Works with every hold down | Ready for sheathing |
| Multi-Panel Connect | Yes | Yes | Yes | Yes | Yes | Yes | Yes | Yes |
| Thermally Broken | Yes | Yes | Yes | Yes | Yes | Yes | Yes | Yes |
| Energy Code Compliant | Yes | Yes | Yes | Yes | Yes | Yes | Yes | Yes |
| Mold Resistant | Yes | Yes | Yes | Yes | Yes | Yes | Yes | Yes |
| Fire / Smoke Resistant | Yes | Yes | Yes | Yes | Yes | Yes | Yes | Yes |
| Vapor Barrier Needed | No | No | No | No | No | No | No | No |
| Assembly Type | Non-combustible | Non-combustible | Non-combustible | Non-combustible | Non-combustible | Non-combustible | Non-combustible | Non-combustible |
| Off-Gassing / Allergens | No | No | No | No | No | No | No | No |
Steel Gauge & Profile Options by Panel
Each panel type is available in multiple steel gauges and stud profiles to meet project-specific structural and code requirements. ThermaSteel’s engineering team helps specify the right gauge and profile for every application.
| Panel | Steel Gauge | Steel Profile |
|---|---|---|
| xPanel, rPanel, hPanel | 14, 16, 18, 20, 24 | CSJ |
| iPanel | 16, 18, 20, 24 | Track |
| fPanel | 24 | Track |
| bPanel | 16 | CSJ |
| sPanel | 14, 16, 18, 20 | CSJ |
| cPanel | 18, 20, 24 | CSJ or Track |
Acoustic Ratings
STC Performance
ThermaSteel panels carry independent STC (Sound Transmission Class) ratings for both commercial and residential applications.
Panel Size Range
4' × 12'Maximum Size
1/8"Incremental Adjustment
PANEL PERFORMANCE
Notable Panel Highlights
fPanelStay-in-Place Form
40 ftClear span with minimal shoring
−40%Reduction in concrete usage
−60%Reduction in labor time
58 psfAverage section weight
hPanelHurricane Panel
185 mphCertified wind speed resistance
11Studs on exterior face
✓Flying debris certified
✓Impact tested & rated
sPanelShear Panel
2,420 plfShear capacity
6Horizontal bracings
✓Every panel acts as a shear wall
What Are Insulated Wall Panels?
Insulated wall panels are high-performance building components that combine structural support and insulation into one efficient wall system. Designed to streamline construction and boost energy efficiency, these panels consist of an insulating foam core—typically rigid foam insulation or fiberglass insulation—sandwiched between durable outer layers, often metal or structural sheathing.
Compared to traditional wall systems that require multiple layers of framing, insulation, vapor barriers, and exterior finishes, insulated wall panels simplify the process while delivering superior thermal performance. They reduce labor costs, speed up build times, and offer a cleaner, more consistent installation.
There are several types of insulated panels available to meet different performance requirements:
- Insulated Metal Panels (IMPs): Featuring metal facings and an insulating foam core, these panels are ideal for commercial and industrial buildings where strength and thermal efficiency are critical.
- Structural Insulated Panels (SIPs): These panels use rigid foam insulation between structural facings, offering excellent load-bearing capacity and air-tightness.
- Insulated Metal Wall Panels: A popular subset of IMPs designed specifically for wall applications, offering enhanced moisture resistance, fire protection, and long-term durability.
Together, these wall panel systems provide a smart, long-term building solution for a wide range of projects—from office buildings and warehouses to smart homes and cold storage facilities.