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Sandwich Panel Assembly Guide: Introduction and Preparation for Installation (vol.1)

In the vast world of construction, the Sandwich Panel stands out for its performance, sustainability, and ease of assembly. In this first volume of our Sandwich Panel Assembly Guide (a three-part series),we will explore the importance of sandwich panels in modern architecture and begin detailing the essential preparations for a successful installation.

Introduction to Sandwich Panel

Today, the construction industry often faces challenges when trying to find solutions that combine performance, sustainability, and economy. Constructed with a double layer of steel that encases the core, the sandwich panel provides thermal and acoustic insulation, as well as structural strength and ease of assembly. Due to its incredible performance, sandwich panels have become an important part of modern construction.

Materials

To ensure that sandwich panels offer maximum performance and consumers can take advantage of all the benefits they offer, we advise you to read through to the end of this post to ensure that the installation is done correctly. Below, we detail the essential materials for this process:

  • Panels: They are the heart of the installation. Composed of two sheets (an internal and an external one),generally made of galvanized steel, aluminum, or even composite materials, and an insulating core that can be made of polyurethane, rock wool, EPS, or XPS. Your choice depends on the specific use (roofs, facades, etc.) and the needs for thermal, acoustic, or fire insulation. It is crucial to consider the environment in which they will be installed, such as areas with high humidity or places with fire resistance requirements.
  • Screws and Fasteners: The choice of screws is vital for the safety and durability of the installation. Self-drilling screws with anti-corrosive treatment and suitable heads for the type of panel are the most commonly used. The length of the screw must be sufficient to penetrate the panel and firmly attach it to the supporting structure. In addition, elements such as sealing washers should be considered to prevent water leakage.
  • Profiles and Flashings: These metallic elements not only provide an esthetic finish but also protect the cut edges of the panels, which are vulnerable to moisture and deterioration. The profiles must be made of materials compatible with the panels to prevent galvanic corrosion and designed to fit perfectly with the thickness and shape of the panels.
  • Cutting Tools: To cut sandwich panels, you need tools that allow clean and precise cutting without damaging the internal layers or the coating. Circular saws with appropriate discs for metal or composite materials, jigsaws with specific blades, or sandwich panel cutters are some of the options. It is important to ensure that the tools are sharp and in good condition to avoid damage to the panels and irregularities.
  • Measuring and Leveling Equipment: Precise installation is key to the success of the project. Tools such as laser levels, tape measures, squares, and plumb bobs are essential to ensure that the panels are perfectly aligned, leveled, and of exact measurements.
  • Safety Equipment: Safety at the workplace is paramount. Helmets, work gloves, safety glasses, hearing protection, safety harnesses for work at heights, and safety footwear are advisable to minimize the risk of accidents.
  • Sealants and Polyurethane Foams: To ensure watertightness and improve insulation, sealants and polyurethane foams or butyl tapes and rolls are used in the joints between panels and at the joints with other construction elements. These materials must be compatible with the panels and capable of withstanding the environmental conditions of the location.
  • Scaffolding or Aerial Platforms: For work at heights, you should have certified scaffolding or aerial platforms that allow you to safely access all installation areas.
Successful Installation of Insulated Wall PanelSuccessful Installation of Insulated Roof Panels

Pre-Installation Tips

Choosing Appropriate Materials and Measurements

Make sure you have enough material to build your project correctly. On more than one occasion, customers have started panel installation and once anchored, they have seen that the requested measurements were not suitable for their structure. Therefore, even though we sometimes overlook this first step, it is really essential to review the material we have before starting to prevent surprises halfway through the project.

Avoiding Windy Days

Depending on the climatic zone where the Sandwich Panel installation is to be carried out, wind action must be considered because it can be a factor that works against us. It is recommended to avoid starting the assembly process in adverse situations like this to prevent possible detachments. However, once the panels are installed, their tightness and protection against weather agents will be complete, guaranteeing greater tightness and insulation against wind and water.

Safety Measures

Before starting with the handling and installation of the panels, it is necessary to rigorously check whether the main safety measures are met. Especially for large projects, it is necessary to confirm, first of all, that the slope of the structure is completely ready and reinforced to receive the sandwich panels. All edges that protrude into the void must be provided with perimeter protections, that is, safety lines or lifelines to which the people in charge of the work must anchor with their fall protection devices to prevent falls into the void. On the other hand, it is important that you can safely traverse the roof at the time of panel handling using a decking as a pedestrian walkway.


Now that we have established a solid foundation for effective, safe, and durable installation of our products, stay tuned for our next volume, where we will detail the specific installation steps. Make sure not to miss this vital information to ensure the effectiveness and efficiency of your project! Additionally, if you have any questions, feel free to contact our team of experts. One of our advisors will be happy to assist you. Alternatively, you can call us directly at +1 904 512-3122.