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Nowadays sandwich panel be widely used in area of clean room, cold room and commercial & industrial building. Attribute to its high structural rigidity and excellent thermal insulation. If you are consider to use sandwich panel for your facility, ready this guide.
Figure 1 Sandwich Panel Layers
Sandwich panel is a structure made of three layers: core of honeycomb or a solid filling, and a thin skin-layer bonded to each side. When combined, they form a panel sandwich and hence the name. The material used to make the sandwich panel are strong and should easily stand up to different elements. It is for this reason you can find the sandwich panel being used for various applications.
The sandwich panels are quite versatile when it comes to the applications. They are mostly used for industrial facilities, cold rooms, power plants, commercial buildings, and residential buildings. So, you can always find an application for a sandwich panel.
As suggested earlier, you will find that the sandwich panels are made of metal surfaces and a core material. For the surface materials, you will get options such as steel, stainless steel, aluminum, and aluminum foil. As such, you should have a wide range of options to consider.
The core materials on the other hand include EPS, rock wool, PU, PIR, XPS, MGO board, aluminum honeycomb, and paper honeycomb. Each of these core materials will have unique features. This means that you can pick the right sandwich panel based on your needs too.
The core materials can also determine the thickness of the sandwich panel. Sometimes you may have to get a specific panel because you want a thicker sandwich panel.
Sandwich panels are known to be quite flexible. It is because of this flexibility, you can find sandwich panels having many applications in the industry right now. Below are some of the places you can use the sandwich panels.
Commercial industry
Let us say you want to set up a warehouse or any other commercial building, sometimes you can use sandwich panels for the partitioning part. Since the panels have impressive fire resistance performance plus durability, you can always a use for them in the commercial sector too.
Figure 2 Commercial Industrial Sandwich Panel
Clean room industry
Clean rooms could use the sandwich panels too. These panels help a lot in maintaining the overall clean environment. Once the sandwich panels have been set up correctly, you can expect to end up with a great looking clean room generally.
Figure 3 Clean Room Sandwich Panel
Cold room industry
Sandwich panels can also be used in cold room industries such as the storage of food. Just make sure that you always get the right sandwich panel type. The cam-lock PU panel and good fire rate PIR sandwich panel is specially design and used for cold room.
Figure 4 Cold Room Sandwich Panel PIR Panel
Figure 5 Sandwich Panel Roofs
Since sandwich panel made of skin layer and core material. The HS code could apply for core material or apply for skin layer. In China, more recognized HS code by customs is HS, which indicating the sandwich panel as a structural part.
Sandwich panels can cost different prices based on a few things. The first one would be how the sandwich panel was made. If it is a machine-made sandwich panel, it will cost less than when it is a manual sandwich panel.
Other things that would affect the price of the sandwich panel include the price of the insulation material. Sometimes the insulation material can double the price. A good example is when you are using PIR insulation material. It would cost more than when using rock wool insulation material.
It is best to consult with Zonsteel to get an idea of what would be the best price depending on your application.
You will also have to think about the surface materials. This is because steel and aluminum do not cost the same. Make sure that you take the time to talk to experts in the sector to understand their pros and cons before buying.
Zonsteel offers free quotation based on your detailed requirement.
One of the biggest reasons someone would opt for a sandwich panel is because of insulation properties. It is why a sandwich panel can be used for various applications compared to some other types of panels.
Each time you want to place an order for a sandwich panel, one of the properties you would ask about include the insulation material.
Even though that is the most important property, you also have to consider the fire resistance too. Sometimes you might work in environments that might need proper protection against fire outbreaks. You would want to be sure that you can be protected in case there is a fire outbreak.
Yes. The sandwich panels come with the steel surface construction that makes the whole panel strong too. So, you will not have to worry that the sandwich panel would not work great in terms of providing structural performance.
Even though the material can deliver impressive structural performance, most people would use it for making walls after the structural part has been handled. In case you want to use it otherwise, just know that it will work great.
Figure 6 Sandwich Panels Ready for Shipping
Sandwich panels stand out as some of the best materials for constructing cleanrooms and other applications. This can make someone want to know more about the benefits of using sandwich panels. Here are some of them;
1. The panels are easy and fast to install
2. They offer the best thermal insulation
3. They are affordable building materials
4. You can choose different color options thus they can offer the best aesthetics
5. They have a high fire resistance rating
6. They also offer great air and water tightness
7. The sandwich panels are used for noise-free buildings
You can always discover more benefits of the sandwich panel if you continue using them for different projects.
The types of sandwich panels are mostly based on the insulation material. So, these are the common types of sandwich panels you can get in the market.
The sandwich panels can have different dimensions. Zonsteel has several options available. Below are some of them.
1. Machine made sandwich panel:width mm(effective mm), mm(effective 950mm). The length is customizable
2. Manual sandwich panel:half made by hand, half made by machine, any width and length
You can also get customized sandwich panels too. This is where you can request for specific sizes. It is understandable that not everyone would like a specific size of a sandwich panel. So, it is possible to tailor one to suit your needs.
The number of layers a sandwich panel depends on the application. However, the basic structure includes having steel plate surfaces with an insulation material in the middle. Below are a few examples of what you can get from a Zonsteel sandwich panel.
As you can see, it is the insulation material that changes a lot. You can play around with the insulation material depending on the sandwich panel application.
The overall fire rating of a sandwich panel generally determines where it can be used best. Some panels can withstand fire for longer periods compared to others. As such, you would want to know more about such fire resistance.
The EPS/PU/PIR are all B1 rated. This means that they are flame retardant. As for rockwool, it is rated A1. This means that it is inherently non-combustible. This is the highest rating you can get for different materials. It is because of this reason, rockwool can easily withstand temperatures over degrees Celsius.
Zonsteel still has a special sandwich panel designed to offer over 240 minutes of fire resistance. Thus, your room made of this panel can be protected until the fire engines arrive to fight the fire. Such panels are mostly reserved for cases where the equipment in highly sensitive.
Figure 7 Stacked Sandwich Panels
Whenever you want to pick sandwich panels, you will be exposed to different options in the market. Sometimes it can be hard to make up your mind on what makes the sandwich panel great. In case you are stuck, here are a few things you can keep in mind the next time you want to buy a sandwich panel.
There can be many other considerations. It all depends on the project you want to handle. In case you are stuck, it is always great to talk to Zonsteel support team for more help.
When other insulation materials can catch fire, rockwool is different. This material is good on overall in terms of keeping the fire down. This is because it is non-combustible.
Some insulation materials might not have flames while on fire, but they can release fumes and smokes that would affect the people possibly trapped in the room. However, rockwool material does not combust and can easily withstand temperatures of over degree Celsius.
Figure 8 Rock Wool Sandwich Panel
Now that you have bought your sandwich panels, you should consider the accessories too. These accessories are vital to ensure you can properly install the sandwich panels. Someone would ask, what are some of the accessories that you need for sandwich panel installation and use? Below are a few examples;
Zonsteel can always supply you with the right accessories you might need whenever you are looking for sandwich panels. Make sure you ask for them so that they are priced together with the sandwich panels.
The company is the world’s best sandwich panel manufacturers in china supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.
Figure 9 Sandwich Panel Accessories
When you are in the market for a sandwich panel, the chances are you are likely to come across PIR and PUR insulation panels.
PUR means polyurethane and PIR means polyisocyanurate. PUR was popular in the past when it comes to making insulation panels. However, that has changed over time with PIR replacing it slowly. This can make someone want to know more about the two and how they differ.
The way to produce PUR and PIR is different. PUR is A polymer with repeating structural units of urethane segment made by the reaction of isocyanate and polyol. And PIR is a foaming material made by isocyanate reacts with polyether through catalyst.
How about fire resistance properties? Well, the PIR and PUR panels will have different fire-retardant properties. This is because PIR can withstand temperatures of 300 degrees C, while PUR can withstand temperatures of 200 degrees C.
As for insulation properties, PIR is also better. It comes with low thermal conductivity coefficient thus it would be able to keep the temperatures maintained easily within the desired range. You would not have to spend so much.
Both panels are also lightweight. This makes it easier to raise and install them. They are still both highly resistant to possible mechanical damage. Also, moisture cannot easily damage these panels making them good for various applications.
Figure 10 Workers Installing Sandwich Panels
PIR and PU panels are the most common options for those who want to set up a cold room storage. The reason is because of their thermal insulation properties. As an example, a PIR panel has a thermal conductivity coefficient of λ = 0.019. This is better than what you get with EPS sandwich panels.
The panels are also quite strong against any mechanical damage. You will mostly like the way these panels fit and stay strong against possible damages.
MGO or magnesium sandwich panel is a common choice other than the rockwool or EPS sandwich panel. There are various reasons why this is the case. They are mentioned below.
Yes. Sandwich panels can be designed to be specifically good for roofing applications. It is for this reason; you can also get sandwich panel roofs. They will be designed to look like the normal roofs in the market. From a distance, you might not even know that it is a sandwich panel used as a roofing material.
Sandwich panel corrugated shape designed for water drainage convenience. Connect to the gutter system. Usually the roof end be covered by steel or aluminium profile, no insulation exposed in air.
The way you handle the sandwich panels can sometimes determine if the panels will break or remain strong over the storage period.
There are various scenarios you should look at and how best to have the sandwich panels handled. Here are some of them;
Unloading the panels with a forklift
One forklift can handle sandwich panel less than 10m, pay attention to the lifting point must be at the center of the sandwich panel bundle. And necessary to use a plywood protect the sandwich panel, place it between forklift and the bundle. The forks of the machine should be longer compared to the sandwich panel width. This helps a lot with the balance of the panels.
When sandwich panel length exceeding 10m, you are required to use 2 forklifts to work at the same time. Note that the distance between the panels center and the forklifts shall be the same.
The upper surface of the forks should be smooth and clean. This is vital to prevent any possible damages to the panel surfaces.
You should never unload too many panels at any given time.
Storage of the sandwich panels
When you move sandwich panel piece by piece and by hand. Then move it vertically not horizontally.
Storage of the sandwich panels
Now that you have unloaded the panels, next is to store them properly.
You should always place them on a smooth level and dry & rigid surface.
You can also add support packages such as wood or polystyrene. This helps a lot in keeping the sandwich panels protected from the elements on the surface.
You should also place the sandwich panels at an incline of around 5%. This is vital to allow for the drainage of water in case there is condensation or leaks in the rooms.
You should not stack too many panels on top of each other. Zonsteel would have special instructions on how many panels can be stuck onto each other.
In case you have to store the sandwich panels for several months without using them, make sure they are stored under a shelter. Advise the stack time less than two months, otherwise the appearance and quality will be effected. The shelter is important to protect the panels from the elements such as sun rays, rain, and more. Also, ensure the room also has adequate ventilation.
In case the sandwich panel stack without any shelter, then put a tarpaulin on top to protect it from raining, especially the rock wool sandwich panel.
The measures mentioned above are just but a few things you should keep in mind. You can still do a lot more when you have the right guidelines. Consult with Zonsteel support team to get more help where necessary.
Figure 11 Forklift Handle Sandwich Panel
Sandwich panels are mostly precut to suit your needs. However, there is no doubt that sometimes you may want to cut the panels. Like make a hole for switch, for light, or for equipment. When you have to cut the panels at the project site, you have to follow are a few tips to ensure that you do it right.
Figure 12 Cutting Sandwich Panels
Sandwich panels can work great provided you also provide the right maintenance too. This is something people often leave out when they start using sandwich panels.
Sandwich panel maintenance can be divided into two phases. These phases are discussed below.
The installation period
If you want the panels to survive for long, they should always be installed based on the instructions as provided by the manufacturer. During this installation period, make sure that the metal chippings are removed from the surface of the sandwich panel. This is vital to keep them from scratching the surface.
The roof surfaces need regular cleaning. This is vital to remove metal objects such as saddle caps, nails, rivets, screws, and more.
The flashing elements are also known for holding dirt, metal chippings, metal dust, small screws, and more. Always inspect them and remove any foreign objects before applying a sealant to the elements.
Once you are done with the installation, it is best to clean the roof surfaces and gutters thoroughly. This ensures you remain with a clean sandwich panel.
The panels should be inspected for possible damages because you call it a wrap on the project. Sometimes if the installation is not done right, it can easily lead to damaged panels. In case a panel is damaged, you can always replace it.
Using the panels phase
This part is when you have been using the sandwich panels for a while. You still have to continue maintaining them if you hope to end up with a great looking sandwich panel.
This is the type of maintenance that can be done every six months. Check for any dirt and grime accumulation.
Check for any signs of leaks. Sometimes people do not seal their sandwich panels correctly. Apply additional sealant where you deem necessary.
Gutters can also be filled with multiple foreign objects. Such include plants, trash, sand, and dirt. In such a case, clean the gutters right to have a long-lasting sandwich panel.
Check the screws too. In case there are any lose screws, make sure they are re-tightened. This should leave you with sandwich panels fitting right and will not fall off easily.
It is possible that when constructing with sandwich panels, you might end up with some waste materials. These wastes are mostly derived from cut out pieces when you want to do a proper fitting. Sometimes they can be damaged panels too.
The damaged panels are those that cannot be used anymore due to breakage or any other reason. So, how are such panels disposed?
It will depend on your location. Some countries would have specific companies that are authorized to do such a job. This ensures that there is no pollution in the end. It will be best to consider what the local laws say about disposing of the sandwich panels.
Considering that the Zonsteel sandwich panels have to be transported to different countries, proper packaging is necessary.
Zonsteel will package the sandwich panels by protecting them with PE film. Then the packaged sandwich panels are attached to a steel pallet or a wooden pallet. In case they even have to be transported via sea, there should be enough protection for the sandwich panel to get to its destination safely.
The PE film is important to protect the surface from scratches. Once the sandwich panels are installed, the film can be removed to expose the beautiful look of the sandwich panel.
Sandwich panels can be delivered within 7 days. This is because Zonsteel processes the sandwich panels in bulk. So, in case you have any ongoing project, it should not delay much as the panels will be delivered within the correct timeline.
The product warranty is important for the peace of mind of any client. Zonsteel sandwich panel also come with a one-year warranty. Make sure that you always read the terms and conditions of the warranty so that you know where and how they apply.
Do not worry as the customer care team is always ready to help you with your warranty claims.
Sandwich panel customization is possible than what most people think. If you want a few things changed to your linking, let us know about them.
Some of the things you can customize include the paint, sandwich panel thickness, the steel surface thickness, size, and so much more.
It is understandable you might have different projects and thus the need to have a sandwich panel that suits you. The customer care team can share with you more details on what else is possible to customize.
Yes. Zonsteel can easily offer installation services at a fee. Keep in mind that the fee is different from what you pay for when buying the sandwich panels.
Installation can be done around the world. It can be through onsite installation or through a video link. Our engineers are always ready to step in and help whenever necessary. So, do not worry about getting the installation done right.
From the guide above, you should be in a position to choose a sandwich panel knowing that it would help you handle various applications. The Zonsteel customer support team is also available to help with any queries on sandwich panels you might have. In the end, you should be able to enjoy using a product that you understand. Give us a call today for more details.
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