How to Install Sandwich Panel?

Here’s a guide to installing sandwich panels from Baikal.

What are sandwich panels intended for?

Sandwich panels for roofs and walls constitute a cladding material which acts as a thermal insulator. Thanks to the fast assembly process, such panels are commonly used in almost every type of industry.

It is estimated that the erecting of buildings using timber-frame technology (sandwich panels) can be completed even 6 months faster compared to the buildings constructed using standard technology, e.g. masonry.

Sandwich panels are most often used for erecting:

ㆍstorage facilities

ㆍlogistics centres

ㆍsports facilities

ㆍcold stores and freezers

ㆍlarge retail stores

ㆍproduction halls

ㆍoffice buildings

Sandwich panels are also used in housing development. For instance, garage designs and modern houses based on sandwich panels are very popular.


Small Brick Pattern Sandwich PanelHow much do sandwich panels cost?

It is very difficult to determine a universal price for the installation of sandwich panels, as many different components need to be included in the cost estimate for the construction, and the different scales of investment.

As a rough estimate, the following costs of material purchase can be assumed:

ㆍThe price of a sandwich panel with a foamed-polystyrene core — from PLN 50 per m2 net

ㆍThe price of a sandwich panel with a mineral-wool core — from PLN 79 per m2 net

ㆍThe price of a sandwich panel with a polyurethane core (PIR) — from PLN 58 per m2 net

In addition to the price of purchasing sandwich panels, the following must be taken into account in the cost estimate:

ㆍLabour costs

ㆍRental of basket and vacuum elevators

ㆍPurchase of accessories (fasteners, flashings, seals) — they account for approx. 10–15% of the purchase cost of all materials

ㆍTransport

Step-by-step installation instructions for sandwich panels



The installation of sandwich panels can be divided into a number of stages.

1. The transporting of panels to the construction site, and unloading

ㆍFor packages up to 6 metres in length

The panels can be unloaded manually or with a forklift. It is recommended to use forklifts with adjustable fork width — the minimum fork spacing should be 2m with a width of 150mm.

ㆍFor packages exceeding 6 metres in length

Such packages should be lifted using conveyor belts and spreader booms. The indicated spacing of belts for packages from 6m to 12m is 2–4m. For packages longer than 12m, the spacing of transport belts is 3.5–4.5m.

Avoid point supports when unloading panels. Otherwise there is a risk of damaging the lining of the lowest panel.

2. Quality control of the completed structure

Prior to the installation of panels, it is necessary to check whether the structure to which the sandwich panels will be fixed is straight. Even the slightest deviation in implementation can result in leaks occurring at the joints between panels, which produces the so-called “wave effect” (the panels are not on one plane).

3. Removal of the protective film

It is best to remove the film just before transporting the panel to the place of installation. It is not recommended to remove the foil after installing the panel.


Large Brick Pattern Sandwich Panel4. Sealing

Before fixing the panel, attach strips of PES sealing tape. It is to be fixed to the structure in places where it will be in contact with the internal lining of sandwich panels.

The use of seals effectively prevents from mechanical damage to the lining.

5. The installation of sandwich panels

The safest and most-recommended assembly solution is the use of vacuum lifts for the transporting of panels.

Install the first panel using fasteners penetrating the entire thickness of the panel, up to the construction element.

6. The installation of door profiles, window profiles, and skylights

The installation of door profiles and window profiles, i.e. windows, doors, gates, small windows, etc., requires a separate description.

In the case of roof panels, these also include skylights. The entire range of small windows supplied by Balex Metal features locks, which facilitate their fixing to sandwich panels, without the need to purchase and install additional elements to fit them.

It is not allowed to use any high-temperature cutting tools, e.g. angle grinders. This could damage the anti-corrosion coating.

7. Assembling subsequent panels

When installing subsequent panels, it is very important to make sure that the panels are pressed down correctly, in order to ensure the maximum tightness of the fasteners.

The locations where panels are joined without any fasteners (e.g. a horizontal joint between one panel and another, on a column, or a joint between a wall panel and a roof panel), must be additionally sealed, for example with low-pressure polyurethane foam or butyl.

8. Masking treatments

The last stage is the installation of masking treatments, e.g. joints, corners, wind braces, ridges, or plinths.

9. How to attach small elements, e.g. a company logo, lighting elements, or a monitoring system.

ㆍThe maximum load exerted by the fastened elements is 10kg/m2.

ㆍThe fasteners must penetrate the whole panel (the core and both linings; it is absolutely prohibited to fix them only to one lining).

ㆍApply a washer with a minimum diameter of 40mm to the opposite side of the fastened element (it is necessary to distribute the loads over as much area as possible).

The first stage in the investment process is the purchase of the right sandwich panels. It is worth putting trust in the biggest manufacturers with long years of experience — they are able to guarantee the reliability of sandwich panels, such as Baikal, short delivery times, and full support during the process of ordering. If you still have questions about sandwich panel, please contact us!

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