Case Study: High-Efficiency Thermal Insulation and Heat Preservation Retrofit of Modernized Breeding Facility Roof
Project Overview
This project addresses temperature control challenges in large-scale, intensive chicken farms during hot and humid summer conditions through roof energy-saving retrofits. By introducing high-performance insulation systems and durable decorative facings, it effectively resolves key pain points of traditional color steel tile roofs, including significant thermal bridging and excessive energy consumption. The initiative aims to create a stable, comfortable breeding environment that enhances poultry survival rates and production efficiency, achieving dual goals of green energy savings and industrial upgrading while providing a model for modern livestock infrastructure development.
Project Challenges
Dense internal heat sources in poultry farms often cause roof surface temperatures to exceed 60°C in summer, leading to uncontrolled shed temperatures that severely impact flock growth and egg production. The existing single-layer color-coated steel roof has high thermal conductivity, lacks an effective heat barrier, and suffers from long-term ammonia corrosion, reducing its sealing integrity and creating leakage risks. Additionally, the farming environment demands materials with high corrosion resistance, fire ratings, and ease of installation. Traditional insulation materials tend to absorb moisture and lose effectiveness, failing to meet the requirements for long-term stable operation. A comprehensive solution offering superior thermal insulation and structural durability is urgently needed.
Solutions
The project adopts a "structural insulation integration" design, using high-density polyurethane sandwich panels as the core insulation layer to block heat conduction. The exterior facade features an innovative aluminum alloy Great Wall panel system; its unique grooved profile not only enhances structural rigidity but also creates an air convection layer for auxiliary heat dissipation. The Great Wall panels are finished with fluorocarbon coating, offering exceptional resistance to acid and alkali corrosion—ideal for farming environments. At connection points, specialized waterproof sealants and hidden fasteners ensure overall roof airtightness and watertightness, physically eliminating thermal bridges to achieve long-term insulation and protection.
Project Deliverables
After retrofitting, third-party testing showed that the average temperature inside the barn during summer afternoons dropped by 5-7°C, and air conditioning energy consumption decreased by more than 30% year-over-year. The peak temperature on the roof surface was significantly reduced, effectively alleviating heat stress, lowering chicken mortality rates, and steadily increasing egg production. The aluminum alloy Great Wall panels' superior weather resistance ensures the building's appearance remains like new for years while substantially reducing maintenance costs. This project successfully validated the value of new insulation materials in agricultural and industrial buildings, achieving a win-win outcome for both economic and environmental benefits, earning high praise from the client.
Use Product
Detailed introduction
Project Background and Requirements Analysis
With the advancement of large-scale breeding technologies, environmental control has become a critical factor determining farming profitability. Located in a temperate monsoon climate zone, our poultry farm experiences hot and humid summers. The original...factoryThe roof uses standard single-layer color steel sheets, which have very poor thermal performance. During hot seasons, solar heat rapidly penetrates the roof, causing a sharp rise in indoor temperatures. This forces ventilation and cooling systems to run at full capacity, increasing electricity costs and triggering respiratory diseases in poultry due to excessive temperature fluctuations. Therefore, it is essential to find an efficient, durable, and easy-to-install solution.InsulationThe plan becomes the project's top priority.
Technical Implementation Plan
After extensive comparison and technical validation, aluminum alloy was ultimately selected.Great Wall PanelA composite roofing system with an exterior finish and rigid polyurethane foam core. Implementation steps are as follows:
- Substrate Preparation and Reinforcement:Perform anti-corrosion and rust-proof treatment on existing steel purlins, inspect and reinforce loose connections to ensure load-bearing capacity meets the requirements of the new roof system.
- Insulation Layer Installation:Install precast polyurethane insulation boards with tongue-and-groove joints, filling gaps with expanding foam to create a continuous, seamless thermal barrier that eliminates all thermal bridges.
- Wall Panel Installation:Secure the aluminum alloy Great Wall panels using concealed fasteners. The panel's distinctive wave-shaped cross-section not only enhances roof drainage but also provides a secondary insulation buffer through its cavity structure, further increasing the overall thermal resistance.
- Seal details:Apply multi-layer sealing with weather-resistant silicone sealant at critical areas such as ridges, eaves, and fan openings to prevent heat infiltration and rainwater backflow.
Technical Highlights and Advantages
The core advantage of this solution lies in the synergistic effect of its materials. The aluminum alloy Great Wall panels offer superior reflectivity and emissivity, effectively reflecting solar radiant heat, while their lightweight yet high-strength nature reduces the load on the main structure. Combined with the extremely low thermal conductivity of polyurethane, this configuration achieves a dual insulation mechanism: "reflection + barrier." Additionally, the dense oxide layer on the panel surface resists corrosion from ammonia and hydrogen sulfide in aquaculture environments, extending the building's service life and lowering full-lifecycle O&M costs—making it an ideal choice for energy-efficient retrofitting of industrial facilities.
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