The technology of sandwich panels production appeared due to American architects Frank Lloyd Wright and Alden B.Dow, who were the first to use it in their projects. Already in , the American company Koppers Inc. started mass production of sandwich panels. The oldest sandwich panels manufacturers in Europe are the Finnish company Rannila now known under the Ruukki brand, the Irish company Kingspan, and the Italian company Cannon.
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Sandwich panels possess good aesthetic properties, excellent energy saving characteristics, as well as can quickly assembled and thus are widely used for construction of trade and office buildings, prefabricated frame buildings, including warehouse complexes, industrial objects, and agricultural structures.
Depending on their use, sandwich panels are divided into wall and roof panels. In selecting sandwich panels, the key parameters are thermal, strength and fire protection.
Roof sandwich panels have to ensure full air-tightness and necessary roof strength, that is why it is recommended to use panels with special profile of external facing in the form of ridges.
The energy saving properties of sandwich panels are determined by the type of core, air-tightness of the lock and availability of seal in it.
The sealant can be polymer-based, installed at the time of panels installation, or EPDM (ethylene-propylene-diene-monomer) installed into panels’ lock during production, which ensures better air-tightness and energy efficiency of the sandwich panel lock.
A critical sandwich panels’ energy efficiency parameter is thermal resistance (R0), which takes account of heat losses in the lock part of the structure. The minimum reduced thermal resistance (at 25°C) for quality sandwich panels of leading European manufacturers is presented in the following table:
Panel thickness, mmThermal resistance R0, m2*K/WMineral woolFoamed polyurethane40–2.060–2..13..64..85..15..66..87..17..37..68..19..3–.8–Panels with thermal resistance below the mentioned parameters, are not recommended for usage in construction of energy efficient buildings.
Usage of modern cores, such as mineral wool and PIR, enable construction of buildings with even zero energy consumption. Construction of passive buildings and warehouses with regulated gas environment requires usage of technical solutions on sealing of all abutments, as well as application of sandwich panels with increased energy efficiency, allowing to almost completely exclude energy losses. A sandwich panels building structure can be considered energy efficiency, if its air-tightness comprises less than 1.5 m3/m2hour.
Sandwich panels with integrated photovoltaic modules (solar batteries) are the most innovational energy saving solutions.
The sandwich panel core (insulation layer) ensures such characteristics as durability, thermal and sound insulation, and fire protection properties.
Various types of cores are used in sandwich panels production; mineral wool, foamed polyurethane (PU) and its modification – polyisocyanurate foam (PIR, IPN), rigid polyurethane foam (PUR), as well as foamed polystyrene (plastic foam) are the most widespread.
Panels filled with foamed plastic, possess the worst operational characteristics, therefore, as a rule, they are used for construction of temporary structures having useful life of up to 10 years and no fire protection requirements, because foamed plastic is combustible. Apart from that, foamed plastic has low sound attenuation, gives rise to mold spreading and can be eaten by rodents. The only advantage of foamed plastic sandwich panels is their low price.
Being used in sandwich panels with increased fire rating requirements (up to EI360), for instance, in fireproof partitions. The mineral wool U-value varies within the range of λ=0.038-0.044 W/mK. Depending on the necessary characteristics, mineral wool of various density is used in the sandwich panels structure: low density (less than 90 kg/m3) – for internal partitions, medium density (95-115 kg/m3) – for external walls and roof panels, or increased density (120 kg/m3 and more) – for fireproof partitions and wall panels having increased bearing capacity. The mineral wool characteristics have caused wide usage of sandwich panels with such a core in construction of warehouses for combustible materials, fire-hazardous productions, as well as buildings with increased acoustic requirements.
Sandwich panels from foamed polyurethane are convenient in installation due to their small weight (in most cases, foamed polyurethane density in panels comprises from 32 to 40 kg/m3) and possess higher energy saving characteristics (λ=0.020-0.022 W/mK) compared to mineral wool.
Foamed polyurethane does not absorb moisture and thus can be successfully used in panels for carwashes, swimming-pools, productions with increased humidity (malt houses of breweries, mushroom farms etc.), as well as objects located close to bodies of water.
Sandwich panels with foamed polyurethane core are used at objects with low fire safety requirements, as well as at cold storages (refrigerators and freezers, including with regulated gas environment). In this case, polypropylene inserts have to be used on panel fixings to prevent from cold bridging and reduce heat losses.
It is worth noting that foamed polyurethane belongs to combustible materials (G1 combustibility group) and is flammable (M1-M1 group), while fire rating of sandwich panels with foamed polyurethane core is EI15.
Foamed polyisocyanurate (PIR) represents a new generation of polyurethane core (λ=0.020-0.022 W/mK) with fire rating up to EI60. E-PIR type foamed polyisocyanurate core has EI15-EI30 fire rating, while X-PIR – up to EI60.
IPN is a trademark of modified foamed polyurethane (λ=0.020-0.022 W/mK) used in Kingspan sandwich panels. In this case, IPN according to its characteristics more corresponds to X-PIR type, while IPN-L is close to E-PIR. A drawback of IPN is the absence of this type of core among those recommended in the European standard DSTU EN , which complicates confirmation of quality characteristics for products with such core and does not guarantee its long life.
The range of sandwich panels represented at the Ukrainian market, provides almost endless possibilities of creation of unique architecture. Rich colour solutions, variations in installation direction, a variety of types of profiles and décor enable an architect to use sandwich panels not only as structural, but also a design element of a building. To increase the architectural expressiveness of the building, almost any ventilated facade cladding can be additionally mounted on the external facing of sandwich panels.
Sandwich panels with polymer-coated steel facing can have standard (always available by manufacturers in their warehouses) and bespoke colours. The range of possible colour shades of panels is determined according to the RAL, RR, or NCS international colour standards.
Due to the complexity of technological processes, manufacturers of steel with an organic coating in metallic colors RAL and RAL do not guarantee the compatibility of color tones in future deliveries. Therefore, in order to ensure the uniformity of the color of sandwich panels, it is recommended to order the production of raw materials of the same color for the entire intended batch of products.
When selecting the colour of a sandwich panel, it is necessary to take account of the ability of metal having various colours to heat and expand, because this largely determines the long life and aesthetic characteristics of panels. The darker the colour is, the more the external facing is heated, therefore dark colours are not recommended for use on the roof, where panels would be heated stronger by the sun and might become wavy, while the facing can peel off from the core. It is also not recommended to install dark sandwich panels on the southern façade, because there panels can get bent, thus creating waves, especially if panels are over 6 m long.
The DSTU EN standard, which describes the requirements for sandwich panels, divides the colors of the cladding into 3 groups: very light, light and dark. The value of the outer skin temperature is set based on the group to which the color belongs and is +55 °C for very light colors, +65 °C for light colors and +80 °C for dark colors.
Color groups according to the influence of thermal loads on structures made of sandwich panels.
I color group – very light colorsRAL: , , , , , , , II color group – light colorsRAL: , , , , , , , , , , , , , , , , , , , , , , , , ,The outer sheathing of sandwich panels of dark colors (III color group) may be subject to distortion due to the increased thermal load compared to light colors. Therefore, when designing houses made of sandwich panels, it is necessary to take into account the features of dark panels and prevent damage using solutions based on the following conditions:
There exist several types of profiles of sandwich panel facing: microprofile, linear, corrugated, smooth, stamped, and sinusoid. Due to technical peculiarities of production, smooth and sinusoid surfaces are possible only for panels with foamed polyurethane core. For premises where it is necessary to exclude dust accumulation or where frequent washing is planned, panels with smooth or microprofile surfaces should be used for convenience.
Sandwich panels with smooth cladding should only be installed as single-span structures after static calculations using TrayPan software. The use of sandwich panels with smooth skins in other structures can lead to the appearance of waviness on the front surface. This can be a barely noticeable effect, visible only under certain conditions, for example, with very high insolation of a wall or roof structure.
The possible appearance of waviness on a smooth cladding does not impair the load-bearing capacity of sandwich panels, but may lead to deterioration of the aesthetics of the facade.
Sandwich panels can be installed horizontally, vertically or at a slope. It is allowed to use sandwich panels even for erection of curved walls, if the curve radius comprises 30 m or more. For even accommodation of panels deformation, it is recommended to install them in one span.
A series of leading sandwich panels manufacturers offer additional possibilities for their decoration, such as application of any colour images onto the surface of panels, or installation of ventilated façades with decorative lining above sandwich panels.
Apart from the external facing, visual perception of panels is also influenced by the fixing, which can be visible or hidden, as well as joint and framing elements, battens, special corner sandwich panels etc. Such seemingly insignificant details are decisive in the façade architecture of a series of objects. Therefore, if it is necessary to create an expressive building design, involvement of experienced specialists into project development is recommended.
The optimal choice of external facing material of sandwich panels is polymer-coated galvanized steel, ensuring long life and preservation of operational characteristics of a product.
A unique solution from Ruukki is sandwich panels with an external cladding made of Cor-Ten weathering steel, the use of which allows you to create energy-efficient and bright facade solutions that change their color over time. In addition, these sandwich panels are able to independently repair small scratches on the facing by forming a new patina.
Prior to purchasing sandwich panels, it is worth paying attention to the steel facing characteristics. Under DSTU EN , S250, S280 structural steel grades with flow limit 250-280 MPa can be used for manufacturing sandwich panels. In spite of that, to reduce the price, many producers use DX51 steel grade, which is not structural and thus not acceptable for non-bearing sandwich panels.
The same standard determines the need to use galvanized steel with zinc content not less than 190 g/m2. In this case, the zinc coating thickness from the external side shall be at least 13 microns, while the protective layer shall be at least 25 µm thick.
Under DSTU EN , the sandwich panels external facing thickness can be from 0.4 to 0.7 mm. In this case, the thicker a steel sheet is, the smoother the façade surface will look and the less glitter it will have in sunny weather. The internal facing layer is usually within 0.4 to 0.6 mm and affects the long life and bearing capacity of sandwich panels.
Depending on the use and operation conditions of panels, several types of polymer coatings are distinguished, of which the most widespread are:
In special cases, for instance, when the atmosphere inside the building is very aggressive due to influence of washing and abrasive detergents, as well as in pharmaceutical and food industries, it is recommended to use sandwich panels facing from stainless steel. Such a solution is the most expensive however the only possible one in certain cases.
Bearing capacity of a sandwich panel is an important characteristic, because in the course of operation panels are exposed to influence of snow, wind, seismic activity etc. When designing building envelopes using sandwich panels, it is necessary to take account of the requirements of DBN V.1.2-2 “Loads and Impacts”. For instance, for construction of the same building in various regions, the values of wind and snow loads can differ several times. It is also necessary to take account of the height and structural peculiarities, the specifics of the location, service loads, as well as the conditions of the building operation. For example, in addition to snow load, a roof has to withstand a person with a cleaning tool.
When wall sandwich panels are used in high-rise buildings, special attention can be paid to selection of fixings and number of fixing points.
In projects, where an explosive situation is possible, light removable structures need to be used. In such structures, sandwich panels with special types of fixings are applied, which ensure decompression of certain parts of the façade in case of internal pressure increase. This allows avoiding injuries to people, who are inside the premises and near the object, as well as damage to the building structures.
The necessary characteristics of sandwich panels are selected according to the bearing capacity tables and with the help of calculation software, therefore prior to purchasing, one should find out whether the supplier has such software.
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The sandwich panel thickness is selected based according to thermal and strength calculations and can be within 40 to 300 mm, and its width is from 1.0 to 1.2 m. The panel length can be from 2 to 13.5 m and is limited by transportation possibilities. Based on convenience of installation, 6-8 m long panels are the most widespread.
Sandwich panels can be supplied with flat or zig-zag lock. Flat locks can cause condensate and through freezing. In its turn, the mortice and tenon zig-zag lock is more air-tight and energy efficient.
It is important to consider that precise geometrical characteristics of sandwich panels substantially affect the air-tight matching of locks, as well as the timing and quality of installation. In spite of the broad range of sandwich panels brands at the Ukrainian market, only a few manufacturers can guarantee that during installation, deviation from geometrical dimensions will be within the tolerances specified in DSTU EN . This is caused by the fact that manufacturing products with precise geometrical parameters requires high-quality automated equipment, which only leading European manufacturers have.
Before buying sandwich panels, you have to make sure that the supplier has a declaration of performance of building products, which is a mandatory document in accordance with Regulation (EU) № 305, which has been in force in Ukraine since January 1, .
The main standard in Ukraine for supplying sandwich panels is DSTU EN , which regulates the main characteristics of products and contains references to auxiliary standards according to which the supplier have to test the declared parameters.
Although the availability of a declaration of conformity is the only mandatory document for the sale of sandwich panels in Ukraine, the supplier may additionally provide other documents and services that allow the consumer to obtain extended information about product quality, simplify calculation & design, and reduce the cost of insurance for the facility:
According to DSTU V.2.7-169, the warranty period has to be at least 5 years. It is worth noting that leading manufacturers provide a sandwich panels guarantee for 5 years – for the integrity of the product, at least 25 years – for the effective operation of the core and up to 30 years – for the aesthetic properties of the facing.
When using sandwich panels in construction in areas of increased seismic activity, the supplier additionally have to provide a conclusion on seismic resistance.
For complete confidence in the quality of the supplied panels, it is also recommended to request separate certificates and protocols for the materials that were used in the production of a particular batch of panels: steel, core and glue.
Before buying sandwich panels, it is important to know that even the best products, when using low-quality accessories or improper installation, are unlikely to last the declared period by the manufacturer. The choice of fixings, seals, battens, and rails, like the choice of sandwich panels themselves, has to be based on qualitative characteristics of products, peculiarities of a specific type of panels, and the manufacturer’s recommendations.
In spite of the seeming ease, sandwich panels installation is a rather complicated and responsible stage, which all subsequent operational costs and building useful life depend on. Therefore it is recommended to commission sandwich panels installation to experienced specialized construction companies, which are able to confirm their experience with the relevant warranty.
When storing mineral wool sandwich panels in the open air, the core can absorb moisture, as a result the thermal performance of the products can deteriorate significantly. To prevent the joint parts of sandwich panels from getting wet, the Finnish manufacturer Ruukki offers Rain Protect technology, which protects the insulation from rain during storage and maintains the panels quality.
Inexpensive sandwich panels with the lowest requirements to quality and long life, are represented in Ukraine by a broad list of brands, from which one can distinguish AluTherm, Arsenal, Asten, Pantech, Promstan, Cualimetal, Gor Stal, Izovol, Paneltech.
The medium price segment is filled with products by Adamietz, Arcelor, Balex, Isopan, Izopanel, Joris, Metecno, Pruszynski, USP, Inteco, Thermo-bud, TPK.
Sandwich panels of the highest quality in Ukraine, meeting the DSTU EN European quality standard, are represented by only two brands – Kingspan and Ruukki.
One should remember that the sandwich panels price means not only funds initially spent for manufacturing and installation. Purchasing better quality products, the building owner not only receives excellent appearance and safety of a building, but can recover the funds spent due to reduction of costs for heating and air conditioning, as well as due to absence of problems with operation of the roof and façades throughout the whole useful life of a building.
A PU Sandwich Panel Machine is a cutting-edge manufacturing equipment that plays a crucial role in the production of polyurethane (PU) insulated panels, also known as sandwich panels.
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A PU sandwich panel machine is an advanced manufacturing equipment used to produce polyurethane (PU) insulated panels. These panels consist of a core material (usually polyurethane foam) sandwiched between two outer layers, often made of metal sheets like steel or aluminum. PU sandwich panels are known for their excellent thermal insulation properties and are widely used in building construction, cold storage, warehouses, and more.
1. Production Capacity
The production capacity of the PU Sandwich Panel Machine is a critical factor to examine. It determines the quantity of panels the machine can produce within a given timeframe. Assess your business requirements and project the volume of panels needed daily, weekly, or monthly. Choose a machine that aligns with your production goals to ensure smooth operations without compromising on quality.
2. Raw Material Compatibility
Raw material compatibility is another vital aspect to contemplate. Different machines may have specific requirements concerning the core material (PU foam) and the outer metal layers. Check if the machine can handle the thickness, width, and type of materials you intend to use. Ensuring seamless compatibility will prevent production issues and optimize the overall manufacturing process.
3. Automation and Control System
In today's digital age, automation plays a significant role in enhancing productivity and efficiency. Look for a PU Sandwich Panel Machine equipped with advanced automation and a user-friendly control system. Features like touch-screen interfaces, programmable settings, and remote monitoring capabilities empower operators to manage the machine seamlessly, reducing human errors and downtime.
4. Panel Thickness Range
The versatility of the machine in producing panels of various thicknesses is vital. Depending on your clients' requirements and project specifications, you may need to manufacture sandwich panels with different thicknesses. A machine with a wide panel thickness range allows you to cater to diverse market demands and offers more opportunities for business expansion.
5. Customization Options
Every project and client may have unique preferences and specifications. Choosing a PU Sandwich Panel Machine that offers customization options can give your business a competitive edge. Look for a machine that allows you to adjust panel dimensions, facing materials, and other specifications to meet the specific needs of your customers. The ability to offer tailored solutions can attract a broader clientele and foster long-term partnerships.
When it comes to PU Sandwich Panel Machines, there are two main types available in the market: Continuous PU Sandwich Panel Lines and Discontinuous PU Sandwich Panel Lines. Each type has its own unique characteristics and applications.
Continuous PU Sandwich Panel Lines are advanced production systems designed for high-volume manufacturing of PU insulated panels. These lines operate continuously, producing panels in a continuous flow. The process involves the automatic feeding of raw materials, continuous roll forming of the panels, and precise application of PU foam between the metal sheets. The panels are then cut to the desired lengths.
One of the significant advantages of continuous lines is their efficiency in producing large quantities of panels with consistent quality. The continuous flow allows for faster production rates, making them ideal for industries with high demand for sandwich panels. These lines are commonly used for manufacturing panels used in roofing, wall cladding, and partitioning systems.
Continuous PU Sandwich Panel Lines often feature advanced automation and control systems, ensuring precise panel dimensions and reducing the need for manual intervention. The integration of energy-efficient components in these lines contributes to cost savings and sustainability in manufacturing processes.
Discontinuous PU Sandwich Panel Lines, also known as batch-type lines, are designed for more flexible and smaller-scale production. Unlike continuous lines, these machines produce panels in batches, allowing for greater customization and versatility. The process involves loading individual panels into the machine, applying PU foam, and then curing the panels in a separate press.
The key advantage of discontinuous lines is their ability to cater to specific customer demands and project requirements. These lines are ideal for producing customized panels with varying dimensions and specifications. They are commonly used in applications where panel designs change frequently or for producing panels with unique shapes.
Discontinuous PU Sandwich Panel Lines are often preferred by manufacturers who require more adaptability in their production process. These lines offer greater control over the production of different panel types, making them suitable for niche markets and specialized projects.
PU Sandwich Panel Machines offer a wide range of advantages that make them a popular choice in the construction industry. Let's explore the key benefits of using these machines to manufacture PU insulated panels:
One of the most significant advantages of PU Sandwich Panel Machines is the excellent thermal insulation properties of the panels they produce. PU foam, which forms the core of the sandwich panels, is known for its exceptional insulating capabilities. These panels effectively trap air within the foam cells, creating a barrier against heat transfer. As a result, buildings and structures constructed with PU sandwich panels enjoy superior thermal comfort and reduced energy consumption for heating and cooling. The insulation properties make them ideal for cold storage facilities, temperature-controlled warehouses, and energy-efficient buildings.
PU sandwich panels are both lightweight and durable, making them an attractive choice for various construction applications. The combination of lightweight PU foam core and sturdy outer metal layers results in panels that are easy to handle and transport while providing excellent structural strength. The lightweight nature of these panels also reduces the overall weight of the building, which can be advantageous for certain projects, such as in cases of retrofitting or when constructing on weak foundations.
PU Sandwich Panel Machines contribute to rapid construction timelines due to the quick and efficient installation of the panels. The continuous production process in some machines enables a seamless flow of panels, leading to faster assembly on-site. Moreover, the lightweight nature of the panels facilitates swift handling and placement, reducing labor time and expenses. This advantage is particularly valuable for projects with tight deadlines or those located in areas with challenging weather conditions.
The versatility of PU sandwich panels allows them to be used in a wide range of applications across the construction industry. They are suitable for both external and internal building components, such as roofs, walls, partitions, and ceilings. Their adaptability makes them an excellent choice for various structures, including commercial buildings, industrial facilities, residential homes, and prefabricated structures.
In conclusion, choosing the right PU Sandwich Panel Machine is a critical decision that can significantly impact the success of your manufacturing business. By considering key features such as production capacity, raw material compatibility, automation, energy efficiency, panel thickness range, and customization options, you can make an informed choice that aligns with your production goals and market demands.
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