The Four-Question Framework for Choosing Panel Thickness
Choosing the wrong panel thickness is expensive in two ways: too thin and you pay more in energy costs every year for the building’s lifetime; too thick and you overpay upfront for insulation performance you don’t need. These four questions resolve the decision for 95% of projects.
Question 1: Is the building air-conditioned?
If no (uncooled warehouse, open-sided structure): 75mm PIR is typically sufficient. The goal is keeping the interior comfortable for workers and preventing stored goods from overheating — not maintaining a precise temperature.
If yes (air-conditioned manufacturing, offices, logistics with temperature-sensitive cargo): 100mm PIR minimum. The insulation is now doing economically measurable work — reducing cooling load directly reduces electricity cost.
Question 2: What is the local climate?
| Climate | Ambient Range | Minimum for AC Building |
|---|---|---|
| Tropical (SE Asia) | 28–36°C year-round | 100mm PIR |
| Desert / Gulf | 20–48°C seasonal | 100mm PIR (150mm preferred) |
| Mediterranean / mild | 10–35°C seasonal | 75mm PIR adequate for most uses |
Question 3: Are there local energy code requirements?
- UAE Estidama: Roof U-value ≤ 0.25 W/m²K → 100mm PIR (U = 0.22) ✓
- Saudi SASO 2093: Recommends R-value ≥ 3.0 m²K/W for roofs → 100mm PIR (R = 4.5) ✓
- Malaysia MS 1525:2019: Roof OTTV targets → 100mm PIR meets requirements ✓
- No local code: Use Question 2 climate guide above
Question 4: Is there a refrigeration requirement?
If the building maintains below +10°C interior temperature, standard warehouse insulation logic no longer applies — you’re now in cold storage territory where the insulation is preventing heat from entering a refrigerated space, not just moderating ambient conditions.
- +2°C to +10°C (chill/produce): 100mm PIR minimum
- -5°C to -18°C (frozen food): 150mm PIR
- -25°C to -30°C (blast freezer / ice cream): 200mm PIR
- Below -30°C (industrial freezing): 200mm PIR + additional external insulation layer
Quick Reference Decision Chart
| Building Type | Climate | Specify |
|---|---|---|
| Uncooled warehouse | Any | 75mm PIR |
| AC warehouse / logistics | SE Asia | 100mm PIR |
| AC warehouse / logistics | Gulf / Middle East | 100–150mm PIR |
| Cold storage (-18°C) | Any | 150mm PIR |
| Blast freezer (-30°C) | Any | 200mm PIR |
| Office / pharma | Gulf | 150mm PIR |
Further Reading
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