Modular Wall Systems: Comparing Steel and Gypsum Panels for Strength, Durability, and Performance

When choosing a modular wall system, the material inside each panel defines everything from appearance and sound control to insulation and impact resistance. For most modular buildings, the choice comes down to two primary materials: steel panels or gypsum panels.

At Panel Built, Inc., we engineer both types for superior performance in modular offices, inplant buildings, and industrial enclosures. While gypsum wall panels are cost-effective and widely used for interior environments, steel modular panels excel in durability and protection. The best option depends on your facility’s environment, durability requirements, and long-term maintenance goals.

This guide breaks down the differences between steel vs. gypsum modular wall systems, including strength, insulation, and sound performance, to help you make the right choice for your modular building.

Modular wall panels form the structural and aesthetic core of any prefabricated or modular building. Each panel is made from a combination of facing materials (such as gypsum board or galvanized steel) and a core material (typically polystyrene or another insulative medium).

Panel Built’s modular wall systems are manufactured to exact specifications in a controlled factory environment, allowing us to tailor each wall to the desired thickness, sound transmission class (STC), and R-value (insulation).

Common applications include:

• Inplant offices and modular workspaces
• Cleanrooms and controlled environments
• Equipment enclosures and machine rooms
• Guard booths and security buildings

What Is a Gypsum Modular Panel?

Panel Built’s standard gypsum wall panel features vinyl-covered gypsum boards on both sides of a 3-inch polystyrene core. This configuration delivers a clean, professional look with excellent sound and thermal performance for most interior modular applications.

Key Advantages of Gypsum Panels

1. Strong Insulation Performance

• A standard R-value of 11 ensures reliable insulation for inplant offices and warehouse interiors.
• The insulation can be increased by adjusting panel thickness or core materials.

2. Effective Sound Control

• Standard gypsum panels offer a Sound Transmission Class (STC) rating of 30.
• For louder environments, optional Sound Dampening Board layers can boost the STC to 40–42, ideal for facilities exceeding 80–100 decibels.
• Enhanced acoustics contribute to employee comfort, focus, and compliance with OSHA noise guidelines.

3. Cost Efficiency and Ease of Maintenance

• Gypsum modular walls are among the most cost-effective options available.
• The vinyl finish provides a durable, easy-to-clean surface that resists scuffs, stains, and moisture.
• Panels are easily replaced or reconfigured if the modular building layout changes.

Best Uses for Gypsum Panels

• Inplant offices and conference rooms
• Warehouse enclosures
• Temperature-controlled rooms
• Light-duty industrial or commercial interiors

What Is a Steel Modular Panel?

Panel Built’s steel modular wall system features two 26-gauge galvanized, stucco-embossed steel sheets around a 2.875-inch polystyrene core. This configuration matches the thermal performance of gypsum but adds significant strength and impact resistance.

Key Advantages of Steel Panels

1. Equal Insulation, Enhanced Durability

• Steel panels share the same R-value of 11 as gypsum panels.
• The rigid exterior shields the wall from dents, abrasions, and equipment impact, making it ideal for high-traffic or industrial areas.

2. Strength Options: Steel-Gypsum Hybrid Panels

• The Steel-Gypsum (SG) or Gypsum-Steel (GS) configuration combines the resilience of metal with the sound absorption of gypsum.
• These hybrid panels deliver an STC rating of around 32, balancing toughness with better acoustic performance than all-steel walls.

3. Reduced Long-Term Maintenance Costs

• Steel wall panels withstand forklift traffic, tool contact, and material handling impacts that would easily damage gypsum.
• Over time, this translates to lower repair and replacement costs, especially in harsh industrial settings.

Best Uses for Steel Panels

• Heavy-duty manufacturing environments
• Exterior or semi-exterior structures
• Security enclosures and equipment rooms
• Areas with high traffic or moving machinery

Both steel and gypsum modular walls are engineered for exceptional performance. The key difference lies in the type of strength needed:

• Gypsum modular panels excel in providing structural rigidity, sound absorption, and thermal efficiency in climate-controlled settings.
• Steel modular panels offer superior impact resistance and surface strength, protecting against dents, scratches, and physical wear.

Panel Built’s modular walls are designed to meet or exceed IBC, OSHA, and industry safety standards, ensuring long-term reliability and performance regardless of material.

Choosing the Right Wall Panel System

When deciding between gypsum and steel modular wall systems, consider these factors:

1. Environment: Is the building interior, exterior, or semi-exposed?

2. Traffic: Will forklifts or equipment operate nearby?

3. Sound Requirements: Do you need additional noise reduction or acoustic control?

4. Budget: Are you prioritizing upfront cost or long-term durability?

Panel Built’s modular specialists can help evaluate your project requirements and recommend a wall system that balances performance, aesthetics, and cost efficiency.

Whether you need a durable steel-gypsum hybrid wall system for a high-traffic facility or a cost-efficient gypsum modular office, Panel Built delivers precision-engineered modular wall systems built to your specifications.

With decades of experience in modular construction, we provide custom solutions that combine strength, flexibility, and design versatility for every industrial and commercial environment.

Contact us at 1-800-636-3873, email info@panelbuilt.com, or request a quote online to get started on your next modular project.