What is a sandwich panel?
A sandwich panel is a building component with a steel outer layer and an insulating core.It is manufactured by compressing a core material between two metal sheets. Structurally, it resembles a sandwich. Whilst the top and bottom layers are made of metal, the centre contains a core material that provides thermal and acoustic insulation.
Sandwich panels are a building material that is used just as frequently on façades, in cold stores and in agricultural buildings as they are on roofs. There are three main reasons for their widespread adoption in the industrial sector:
- Their light weight
- Their quick installation
- Their thermal insulation properties
How are sandwich panels manufactured?
Steel coils pass through the paint shop, where they are coloured and treated to provide corrosion protection. Insulation is then injected between two sheets, which are pressed together and formed into a profile. When they leave the factory, they are ready for installation and require no further processing on site.
The type of gas used in production is important. Older plants used to employ gases that damage the ozone layer, and some small manufacturers still use these gases during the manufacturing process. Modern plants that run on pentane have eliminated this problem. Mekpan Panel manufactures its products using eco-friendly pentane technology with zero ozone depletion potential.
What are the different types of sandwich panels?
Roof panels
The roof is the most challenging part of a building. Snow, rain, wind and sun all come into contact with the roof surface at the same time.
3-ribbed roof panels are used in buildings with gentle slopes. They are relatively easy to install. 5-ribbed roof panels, on the other hand, are preferred in factories and warehouses with wide spans; as the number of ribs increases, so does the load-bearing capacity. In regions with heavy snowfall, five-ribbed panels are a safer choice; one should not rely on the load-bearing limit of 3-ribbed panels.
Polycarbonate-compatible roof panels provide natural light by incorporating transparent sheets between the rows of panels. They are frequently used in greenhouses and poultry houses, significantly reducing the cost of artificial lighting.
In solar-compatible roof panels with a ridge cap, the solar panel rails are attached directly to the ridge cap. Furthermore, no steel framework is required.
Membrane roof panels come with a factory-integrated waterproofing membrane. They provide additional protection against water accumulation on flat or gently sloping roofs.
Facade panels
In concealed screw systems, the screw heads do not protrude. This ensures both a clean appearance and protection of the screws from the elements; This dual benefit ensures both aesthetic value and long-term durability. The siding panels are installed horizontally, creating a simple, clean look. With their corrugated profile, sine wave facade panels are highly resistant to wind pressure, making a real difference in coastal areas and open countryside.
Cold room panels
Cold room panels are a distinct category from standard panels. The thickness and density of the insulation are much higher. The joints are sealed with an eccentric interlocking system, as even a small air leak would cause the compressor to run continuously, resulting in a significant increase in energy consumption.
Thermal insulation boards
Thermal insulation boards are used solely for insulation purposes, without a metal cladding. They are the preferred choice when insulation needs to be retrofitted to existing buildings or when filling voids.
Choice of insulation material
The insulation material determines both the thermal and fire performance of the panel.
Rock wool is non-combustible; mineral wool becomes mandatory in buildings subject to fire regulations or to meet insurance requirements. EPS is lightweight and economical, and is used in applications where load requirements are low.
Choosing the wrong core material leads to both a loss of performance and the cost of replacing the panels in later years. Rectifying the situation afterwards is always more expensive than making the right choice from the outset.
How should the thickness be chosen?
In standard commercial buildings, 40–60 mm is usually sufficient. For cold-room applications, 80 mm or more may be required. Thinner panels may seem cheaper at first, but when annual energy costs are taken into account, the difference is negated and, in many cases, the situation is reversed.
Advantages of sandwich panels
To achieve the same insulation performance using traditional methods, it is necessary to construct much thicker and heavier walls. This weight requires a larger structural framework, thereby increasing foundation costs. Sandwich panels break this cycle from the outset.
As they are factory-made, on-site delays are reduced. Even in a small building, this difference can amount to several weeks. In large-scale projects, this time saving is much more significant.
Points to consider when choosing a panel
Price differences on the market can sometimes reach 30% to 40%. This difference may be due to the density of the insulation, the thickness of the cladding or the gas technology used. Within a few years, this will manifest as condensation, rust and loss of insulation. Repairing the damage or removing and replacing the panel will cost far more than making the right choice from the outset.
Looking for the right sandwich panel solution for your project? Our engineering team at Mekpan Panel is ready to provide you with tailored technical support and precision pricing. Contact us today to request a customized quote.
Frequently Asked Questions
The information provided in this blog post is for general informational purposes only. Structural requirements, climate conditions, and building regulations vary by region and project type. To ensure the highest performance and safety for your investment, it is essential to consult with technical experts before making a final material choice.