After procuring Bondor™ Insulated Panel Systems, the next important step to do is to maintain it. Bondor™ Insulated Panel Systems are very easy to maintain, but like any other products, a countinous slip-up in either the use or maintenance will result in a faulty product. By following the recommendation we provide in the maintenance guide you can confidently expect a long and satisfactory performance of your purchase.
 
 
 
 
NEED FOR REGULAR MAINTENANCE INSPECTIONS
 
 
Regular building maintenance makes good sense. The following list summarises the major reasons for regular inspections and prompt rectification work:
 
 
 
 
  • Prevention is better (and less expensive) than cure.
  • The earlier any problems are detected and rectified, the sooner any “snowballing” effects are prevented.
  • Without prompt rectification work, sudden and catastrophic collapse is possible.
  • A building owner’s commitment to an organised maintenance program will undoubtedly increase the life of installations, end enhance safety.
 
 
 
 
TYPES OF INSPECTIONS
 
 
Regular maintenance inspection is a simple, straightforward process, that costs no more than a little time. Virtually all the common maintenance items can be detected visually, or by simple measuring techniques.
 
 
 
 
There are also more sophisticated and expensive methods of detecting some specific problems, (eg: foam core sampling and thermal profiling) although these will not be covered in this manual.
 
 
 
 
INSPECTION INTERVALS
 
 
Inspecting you facility for any problems is continuous process, and the frequency and type of inspections should conform to the requirements of appropriate regulatory authorities. Routine maintenance inspection would be a personal choice of the owner. We strongly recommended that a comprehensive maintenance inspection covering the items shown in this manual be conducted at least every 12 months.
 
 
 
 
For more corrosive environments or those exposed to industrial pollution, more frequent inspection and maintenance is recommended
 
 
 
 
INSPECTION RECORDS
 
 
PT. Bondor Indonesia recommends that records be maintained to show the frequency and details of inspection. Records should be kept of any maintenance work done as a result.
 
 
 
 
WASHING
 
 
All roofing and cladding products are subject to cummulative effects of weather, dust and other deposits. Normal rainwashing will remove most accumulated asmospheric contaminants, but manual washing is recommended for areas which do not receive adequate rainwashing such as soffits, wall cladding under eaves, and other sheltered areas.
 
 
 
  Regular washing of Bondor™ Insulated Panel Systems increases the durability by reducing attack from airborne salts and pollutants.  
     
 
The panel surfaces can be washed with water and a sponge or a soft nylon-bristled brush. For large areas it may be more appropriate to use waterblasting at pressure up to 20 MPa.
 
 
 
 
MAINTENANCE CHECKLIST
 
 
 
 
WALLS
 
 
 
Vapour Seal
Inspect the roof and all joints to make sure that a vapour barrier is maintained. Vapour sealing of all joints is essentials in cold storage applications. Vapour seals are made on the outside (warm side) of the building envelope.

IMPORTANT FOR COLD STORAGE: Look for ice build-up on the inside skin to show a vapour seal leak.

Wall Alignment
Check panel ends (particularly at floor) for dislocation due to damage impact. Check walls for straightness (discounting normal thermal bow due to inside / outside temperature differences).
Washdown
Thoroughly wash down wall panels every 12 months. This is particularly required in areas under eaves, etc. where the wall is not naturally washed by rain. Follow the recommendation set out under the “washdown” for roofs.
Panel Slip Joints
Check for corrosion, ice/sweating and inadequate seal.
Panel Corner Joints
Check panels/angles/rivets for corrosion, ice/sweating and inadequate seal between panel and angles.
Panel to Floor Joint
Check for corrosion, ice/sweating and inadequate seal.
Panel Buckling
Check for panel buckling of any kind (thermal or structural) particularly near fixings and at corners.
Wall Panel to Floor Coving Intersection
Check for corrosion, excess ice/sweating, and that the gap between the coving and the panel is adequate sealed.
Pressure Relief Ports
Check for corrosion, excess ice/sweating and inadequate seal around perimeter and make sure that the relief port vanes open freely.

Check that the heater is functioning and heater cables are not damaged.

Check that excess pressure differences are not occurring in the cold room, particularly after loading operations. (Difficulty in opening doors and excessive in-rush of air upon opening is evidence of insufficient pressure relief).
     
 
CEILINGS (Suspended or Structurally Supported Ceilings)
 
 
 
Vapour Seal
Inspect the roof and all joints to make sure that a vapour barrier is maintained. Vapour sealing of all joints is essentials in cold storage applications. Vapour seals are made on the outside (warm side) of the building envelope.
Look for ice build-up on the inside skin to show a vapour seal leak.
Ceiling Levels
Check for excessive sagging using a string line or dumpy level. Sagging mau indicate a build-up of ice (and resultant weight) inside the ceiling and is a safety issue requiring prompt attention.
Cleaning of Ceilings
Clean or sweep ceilings of build-up of dust etc. Every 2 years maximum. Remove any loose metal or drilling swarf to prevent corrosion.
IMPORTANT: Ensure ceilings are never used for storage.
Panel End / Butt Joins
Check for corrosion, ice/sweating and inadequate seal.
Suspension/Anchorage
Check for corrosion, indentation into panel (on the underside) and excessive tightness. (Suspension cables or chains should be firm but not taut like piano wires).
Panel Buckling
Check for panel buckling of any kind (thermal or structural). This is particularly important as buckling signals a safety hazard.
Ceiling to Wall Intersection
Check panels/trim/rivets for corrosion, ice/sweating and any structural distress (sag, warping, etc.).
Ceiling Panel Penetrations
Check for proper seal on the top face of the panel. Check that loading is not being applied to the panel by the structure.
Structural Steel
It is worth checking the main roof steel work for corrosion etc. At the time of inspection. Moisture condensation in the space between roof and ceiling can cause corrosion.
Water Ponding
Check for water ponding on the ceiling perhaps caused by leaks or condensation from pipes above. Water ponding on ceilings is a serious defect which requires prompt attention.
     
 
DOORS
 
 
 
Door and Door Frame
Check for corrosion or damage, etc.
Heater Cables (where fitted)
Check door frame heaters are functioning and that heater cables are not damaged. Check that floor threshold is operating correctly.
Door Rollers and Tracks
Check for corrosion and wear and that wheels are running smoothly and freely. Check that the track is straight and that the fixing / support is adequate.
Door Actuators
Check door travel and limit switch.
Check all functions are operable. Ensure all moving parts are adequately greased (wormdrives, etc.). Ensure safety features are working (include safety reverse, warning bell, method of exit if electric power is lost, etc.).

Gaskets/Seals

Check seals are properly fitted and not damaged (ripped/torn/out of shape) and for inadequate seal (ice / sweating).
Do not use petroleum based products to lubricate seals and sealed faces with either talc powder or a silicon emulsion type lubricant.
Gasket may be cleaned using water based commercial detergents followed by flushing with water.
Do not use solvents for cleaning.
Door Safety Egress and Manual Override
Check door safety / emergency operation is functioning i.e.: manual override of powered actuator (where fitted).
Vertical Uplifting Doors
Check chains, sprockets and linkages for corrosion and inadequacy. (Safety considerations require fairly regular checking of operating components of vertical uplifting doors).
Swing Doors
Check door hinges, magnets and locking assembly for corrosion and inadequacy.
Check that all safety release mechanism(s) are working correctly.
Vapour Barrier
Check that the vapour barrier is maintained on the outer skin of doors. (Poor maintenance can contribute to ice build up inside freezer doors which reduces insulation efficiency and increases weight and subsequent wear of moving parts).
     
 
FLOORS (Bondor Panel Floors and Concrete Pan Floors)
 
 
 
Epoxy Coating (Where Used)
Check for wear/breakdown of coating.
Plywood (Where Used)
Check for swelling or any damage (cracking, splitting, warping, etc.).
Constructions Joints
Check for damage to concrete edges.
Floor Vent Pipes
Check for blockages, obstructions.
Heating Cables
Check for wear and damage
Heating Pipes
Check for blockages, leaks.
     
 
ROOFS
 
 
 
Vapour Seal
Inspect the roof and all joints to make sure that a vapour barrier is maintained. Vapour sealing of all joints is essentials in cold storage applications. Vapour seals are made on the outside (warm side) of the building envelope.

Look for ice build-up on the inside skin to show a vapour seal leak.

Ceiling Levels
Check for excessive sagging using a string line or dumpy level. Sagging mau indicate a build-up of ice (and resultant weight) inside the ceiling and is a safety issue requiring prompt attention.
Washdown
Throughly wash down the exterior of roof panels every 12 months using a mild solution of pure soap or non abrasive kitchen detergent and a soft bristle brush. (Wash down may be required more frequently in industrial areas where there are higher concentration of atmospheric pollutants). Pay particular attention to areas not washed by rain.
Thoroughly rinse the washed surfaces with clean water to remove traces of detergent.
Remove any loose metal items from the roof as these may contribute to corrosion. Always wear a soft soled shoes when walking on steel surface.
Weather Seals dan Panel Slip Joints (Underside)
Check for corrosion, ice/sweating and inadequate seal. Sealing of the SlipJoint is not normally required on the inside face of cold stores.
Panel Butt Joins / Expansion Joints
Check for corrosion, ice/sweating and inadequate seal.
Panel Buckling
Check for panel buckling of any kind (thermal or structural). The outside face generally requires the most attention.
Flashings / Trims
Check for corrosion, warping and water leaks. Check fixings.
Panel Anchorages / Fixing to Roof Structure
Check for corrosion and looseness/inadequacy. Check that vapour seal is intact on the external face of fixing penetrations.
Gutters and Downpipes
Check for corrosion, blockages and ponding.