Sandwich Panel Installation

Sandwich Panel Installation: The Complete Guide

After sandwich panel be shipped, Zonsteel will also send you an installation tools list. This allows you to get them before the sandwich panels arrive to the destination. Such installation tools include lifting machines, sandwich board suction cups, leveling instruments, electric operation riveting gun, electric hand drill, silicone gun, etc.

Since sandwich panel be cut to size in manufacturing factory, you can avoid re-cutting on site. This greatly reduces the installation time and keeps job site clean.

For PIR sandwich panel installation, for cold room, the special place must be cutting a line on surface steel sheet to break cold bridge, and between two panels must spray FU foam to strength the connection, no need bolt anymore.

For EPS panel, its the lightest among PIR sandwich panel, PU panel, and rock wool panel. The best part is that its thermal insulation and price are still good. As such, the panel is widely used in industry buildings. The density is usually between 12kg/m3 to 28kg/m3.

The rock wool panel has the best fire rating of grade A. It is why it is widely used as thermal and sound insulation material for a drying room, a painting room, and for industrial equipment and buildings. Also, it can be used for partitioning the wall and ceiling of an electronic clean room, purification room, explosion-proof, and fireproof workshop.

Rock wool panel has high density between ranging from 80kg/m3 to 120kg/m3, so the length is usually less than 4m. Considering the panels will be heavy, the installation can be labor intensive.

Zonsteel has finished projects in IT, Pharmaceuticals, food, new energy, labs, and many other industries. This has made the company acquire rich experience in sandwich panel installation.

Contact us today to complete your project!

Sandwich Panel Installation: The complete FAQs Guide

Sandwich panels are awesome as they can be quite versatile. When you get the right sandwich panels for the job, then the sandwich panel installation will not be hard.

If you are new to sandwich panel installation, this is the guide for you. We look at some of the frequently asked questions on sandwich panels and the installation process. Well, keep reading to learn more about sandwich panels.

What is a Sandwich Panel?

Figure 1 Sandwich Panels Ready for Transportation

A sandwich panel is a material used for cladding walls and roofs of different types of buildings. The panel would have a thermal insulating core with metal sheet on both sides. You can take sandwich panels as being enclosure materials or structural materials. That is why they would have specific applications based on where you want to use them.

Depending on the applications, it is best to look at the different types of sandwich panels. The most common types include EPS, rock wool, PIR, and more.

The types of sandwich panels largely vary based on the thermal insulating performance, resistance to fire, weight, and sound insulating performance.

It is best to check out the different types of sandwich panels and compare their features before making up your mind.

Why Should You Use Sandwich Panels?

Figure 2 Joining Two Sandwich Panels

Maybe it is the first time you are coming across sandwich panels. The common question you would have in your mind would be, why should you even use them? Well, before you can start to get into the sandwich panel installation process, here are some of the reasons to consider getting the panels.

Easy and Fast Sandwich Panel Installation

The first thing that should be interesting to many people is the amount of effort that goes into the sandwich panel installation process.

Unlike the traditional materials, the sandwich panels are easy to assemble and install. So long as they are cut to the right size, the sandwich panel installation can be done quickly.

You might need someone and equipment to help in lifting and putting the panels into position, but on overall, the sandwich panel installation process is simple and fast. It should be why some people find it being simple and generally easy to handle.

Thermal Insulation

Another reason for getting the sandwich panel installation done is that the panels offer perfect thermal insulation.

As much as the thermal insulation varies from one panel type to another, the insulation is generally good.

Depending on where you live, the sandwich panel insulation can come in handy for keeping you warm during winter and cool during summer.

Having good thermal insulation also prevents cases of mold and humidity that result from condensation and heat movements. The best part is that the thermal insulation remains good for years to come.

Aesthetics

Anyone who is seeking sandwich panel installation services would want to know just how good such panels look. Well, the aesthetics are good. Whenever you use the sandwich panels, you will notice that the building’s aesthetics gets better.

People often play around with the orientation of the panels to come up with different patterns. The aim is to ensure that the sandwich panels leave you with a better look than before.

It is still possible to get the sandwich panels designed in different colors. The colors will determine how good they look depending on the existing décor. Always talk to the manufacturer to see if you can get the panel in different colors.

Fire Resistance

For a long time, sandwich panel installation has been done mostly because of fire resistance of the panels.

Due to fire resistance, the sandwich panels have found various uses in different applications. It is why you would find a lot more people going for them as they know they can help protect their machines and other stuff in case of a fire breakout.

When choosing the best sandwich panel for fire proofing, make sure you understand its overall fire resistance and the duration it will remain fire resistant.

The different panels are made of varied materials. So, their fire resistance performance will largely vary from one panel type to another.

Water and Air Tightness

Because of how the sandwich panels are designed and installed, they are also good at preventing water and air leakages. The joints are done well to a point that even when two panels are joined, there will be continued thermal insulation. You are likely to find that there will be no heat loss from the building.

Having a watertight structure means that the panels will work well in areas with snow and rain. They will also be good at preventing humidity and mold. Since the outer surfaces are made of color steel, they are also good at remaining corrosion-resistant.

Sound Absorption

Another reason for sandwich panel installation is to provide sound insulation and absorption. It all depends on the type of sandwich panel you decide to use.

Sound insulation is great, especially when you live in an area likely to have a lot of noise outdoors. When you have the panels installed, they will be good at absorbing the sound leaving you feeling comfortable.

For most people, rock wool panels stand out for being the best in sound insulation. Their core material is good at breaking and absorbing the sound waves, making them even better.

What Are the Applications of Sandwich Panels?

Figure 3 PIR Sandwich Panel for Cold Room

As explained earlier, the sandwich panel installation process will provide your building with a better thermal insulator. It is for this reason; you will find that the sandwich panels have many applications today.

Some of the most common applications of sandwich panels include:

– Storage facilities

– Logistics centers

– Sports facilities

– Cold stores and freezers

– Office buildings

– Production halls

– Large retail stores

Well, the applications can be even more depending on your use. There are some that use them in their housing development products. Such include garage designs, room partitioning, and so much more.

What Are the Common Types of Sandwich Panels?

Figure 4 Two Sandwich Panels Ready for Joining

Now that you know more about the uses and features of the sandwich panels, it is also good to know about the various types before embarking on sandwich panel installation.

The common types include the following

Polyurethane (PUR) Sandwich Panels

The polyurethane sandwich panel has the rigid polyurethane foam as its core material. This material uses polyol and isocynate in addition with a catalyst to form the sandwich panel. The reaction takes place under a high pressure and other special production conditions.

Polyurethane sandwich panels are known for having a high dimensional stability. This makes it good at being water resistant as you keep using it in different areas.

The material is also good at remaining free from bacteria, since there is no nutritional value in them that would make bacteria consider living in the panel.

As for the mechanical performance, many people find this sandwich panel being good. This is because of the high compressive strength.

Polyisocyanurate (PIR) Sandwich Panels

Another top choice as a sandwich panel is the PIR panels. These panels have the polyisocyanurate material as its core. This is where the main components of polyurethane foam are further mixed with other materials to form a rigid foam.

Since there is the use of other materials, the overall rigidity is even better. It will also have better fire resistance and water resistance compared to when using polyurethane sandwich panels.

Rockwool Sandwich Panels

You might also want to consider using the rock wool sandwich panels. They get the name since the core materials are fibers obtained from inorganic rocks and other types of inorganic oxides. The fibrous open cell structure makes it the perfect choice for those that might need to use the panels for various applications.

The core materials of these panels make them good at thermal insulation, fire resistance, and sound absorption. If you ever want the best sound insulation, then consider this type of sandwich panel installation.

Expanded Polystyrene (EPS) Sandwich Panels

The expanded polystyrene (EPS) sandwich panel is another top choice for anyone who needs the best sandwich panel for various applications.

The raw materials of this sandwich panels are derivatives of petroleum. They are first heated and then expanded using water vapor. Pentane gas is then used for inflating the granules and that is how you end up with different shapes depending on the mold used.

Because of the production method, the EPS sandwich panels stand out for being the most economic. You can always end up with various applications for the EPS sandwich panel.

What Is the Process of Sandwich Panel Installation?

Figure 5 Installed Sandwich Panels to A Construction Element

Sandwich panel installation does not have to be hard when you have the right tools and people working on the project. Below are some of the general steps involved in sandwich panel installation process.

1. Transportation of the Panels to the Construction Site

For panels that are around 6 meters in length, consider unloading manually or using a forklift. If you have to use a forklift, make sure it has the option of adjusting the width so that you can pick up more panels and handle them at the right width.

If you have to deal with panels with more than six meters in length, the considering using conveyor belts and spreader booms. Follow the manufacturer instructions on how to attach the transport belts so that the panels can be unloaded properly without snapping.

2. Check the Overall Quality of the Panels

The next thing would be to check the overall quality of your panels before proceeding with sandwich panel installation. In case the joints are not right, then you might end up with leaks in the future. Luckily, most panels will stand up to the transportation strains and remain functional even at the construction site.

Proceed to remove the protective film so that the installation process can start. Some might opt for removing the film after installation, but consider removing it before installing your sandwich panel.

3. Sealing

You need the panel to have the best sealing. That is why you need to attach PES sealing tape to the surface before you can start attaching it.

Using seals is recommended so that there is no mechanical damage to the lining of the sandwich panel.

4. Installing the Sandwich Panels

Now that the sealing tape is in position, you can proceed to install the sandwich panels. Use vacuum lifts for transporting the panels into the right position for installation.

Use fasteners that can penetrate the entire thickness of the panel into the construction wall or element. This should hold the panel in position without it moving.

5. Install the Window Profiles, Door Profiles, and Skylights

Depending on where you are installing the panels, it might be necessary to also install the door profiles and window profiles.

In case you are doing roof panels, then skylights might be necessary.

You also need some simple tools for cutting the profiles into the sandwich panels. Use tools such as jig saws, nibblers, and reciprocal saws.

Do not use high temperature cutting tools such as angle grinders. This is because they are likely to damage the anti-corrosion coating on the sandwich panel.

6. Installation of Subsequent Panels

Whenever you are installing subsequent panels, you have to ensure that they are pressed down correctly. This ensures that you end up with maximum tightness of the fasteners too.

Each time to press down the panels correctly, you end up eliminating problems such as thermal bridges.

Finally, you can now install the masking treatments. This will mostly be applied to corners, joints, wind braces, ridges, and plinths. Once the masking treatments are done, you should end up with a clean wall or roof of sandwich panels.

It is easy to see that the sandwich panel installation process is not hard. With the right people, the installation can take less time and still be done correctly.

Why Are Sandwich Panels used for Insulation Applications?

Figure 6 Stacked Sandwich Panels Ready for Transportation

One thing is for sure, the main aim of sandwich panel installation would be to provide the user with thermal insulation. This might make some people wonder why sandwich panel thermal insulation is so important. Here are some of the reasons that should get you installing sandwich panels today.

– When the rooms have the panels installed, you end up with the best room comfort for years to come. This is because the thermal insulated rooms will stay warm during the winter and cool during the summer. That is why you would find a lot more people installing these panels in their houses.

– The sandwich panel insulation also helps in saving on heating and cooling. Since the panels can help maintain the best temperatures, you will not have to heat or cool the room all the time.

– If you have to deal with a lot of delicate surfaces, it is then best if you consider getting the EPS panels. They are lightweight and they will still give you the best thermal insulation. This is unlike when you have to use heavy materials such as bricks, wood, or concrete.

– The insulating sandwich panels are also recommended because they are versatile, reliable, and can remain structurally strong. Well, you should have the best sandwich panels to give you the best performance when want to have the right insulation while at the same time the panels remain strong.

– Another reason people would consider doing sandwich panel installation is because the panels are fire resistant. Make sure you understand what each of the panel can offer in terms of fire resistance before picking the right one. Some will have more fire resistance performance compared to the others.

How can You Properly Handle and Store Sandwich Panels Correctly?

Figure 7 Correctly Stored Sandwich Panels

Sandwich panels are great to use for different applications, then what is crucial to keep in mind is how to handle them during sandwich panel installation and storage. Here are a few tips to keep in mind always.

– You should place the panels away from fire hazards. As much as we have pointed out that sandwich panels are fire resistant, it does not mean you expose them to the hazard all the time. So, keep the panels from areas with welds or continuous burning work.

– When moving the sandwich panels, make sure that they are protected against abrasion. As much as the panels can handle abrasion, it does not mean you become careless when moving them around.

– The panel edges and corners are quite vulnerable. So, make sure that they remain protected each time you are moving them around.

– Consider lifting the panels using the ends rather than the edges. Keep in mind that the panels might have sharp edges, so wear protective gloves when handling the panels.

– When you have to store the panels out in the open, make sure they are stacked and off the ground. Protective UV proof sheeting can still be used to cover the panels so that you can have the best protection for your panels.

Conclusion

From the guide above, it is clear that sandwich panels are awesome. They are versatile, easy to install, good at thermal insulation, and many other features. So, it is easy to see how you would enjoy sandwich panel installation.

If you are not sure where to begin, Zonsteel is here to help. The company can provide you with the right technicians for the job. The aim is to help in correctly setting up the panels so that you can use them better.

If you have more questions, Zonsteel customer care team is available to help where possible. You will also be guided through the whole purchase process ensuring you end up with the right sandwich panel for your needs.