Roofing sandwich panels: types, characteristics, installation rules + review of the best manufacturers

Greetings and welcome to "All about the Roof," your one-stop shop for anything roofing-related. This article explores the world of roofing sandwich panels, including their types, traits, installation recommendations, and a thorough analysis of some of the leading producers in the sector.

Sandwich panels for roofing are novel constructions that combine structural support and insulation into a single, cohesive system. These panels are made up of an insulating core material sandwiched between two layers of metal, usually aluminum or steel. With different thermal and acoustic properties, the core material can be expanded polystyrene (EPS), polyurethane (PUR), or mineral wool.

Sandwich panels for roofing have a number of benefits, one of which is their versatility. They can be used in a variety of settings, including commercial and industrial buildings as well as residential residences. The panels are renowned for their lightweight yet sturdy construction and are available in different thicknesses to meet different insulation requirements.

Adherence to manufacturer guidelines and appropriate handling are essential during installation. Careful planning is necessary when installing roofing sandwich panels to guarantee a perfect fit and maximum performance. Usually, it entails preparing the roof’s surface, installing the panels, aligning them, and caulking joints to keep moisture out.

This article delves into the technical aspects of roofing sandwich panels and offers insights into the top manufacturers currently available in the market. We feature businesses that are renowned for their roofing solutions that are high-quality, dependable, and creative. Knowing the different kinds and features of roofing sandwich panels will help you make wise decisions, whether you’re a developer in need of durable roofing solutions or a homeowner trying to increase energy efficiency.

Types of roofing sandwich panels

Three layers make up a modern sandwich panel, with the insulation sandwiched between two sheets of profiled metal:

Think about the profile by itself:

• On the one hand, the panel has stiffeners presented in the form of special protrusions in the form of a trapezoid, usually 40 mm high.
• On the other hand, the panel has a microprofille with a depth of 1.5 mm.

Next, we will discuss the technical features of sandwich panels. As a result, today’s roofing sandwich panels range in length from 2 to 14 meters and in size from 1000 to 1120 mm, depending greatly on the equipment.

The sandwich panels themselves vary from one another.

• at the installation site: on roofing and wall, ceiling and universal;
• If possible, the load: on self -supporting or facing;
• At the place of assembly: on those that can be assembled directly on the construction site, election assembly products and those that are made in the factory and bring to the place of construction ready -made.

It should be noted that the original roofing panel structures featured two different kinds of edge joints: a standing fold or a seam with internal components. Undoubtedly, these systems had numerous drawbacks.

For instance, the outer metal sheet had a slight profiling and was flat, which caused it to bend under the weight of a snow cap and become deformed in the scorching sun. As a result of whatever microcracks that developed in the bends’ corners.

This is referred to as the metal’s "low -cyclic fatigue" officially. There is no way to move in these areas without damaging the insulation and the outer leaf.

Contemporary panels are very different from them:

• Firstly, the fastening of roofing sandwich panels is now different.
• Secondly, today the minimum slope of the roof from the sandwich panels is 5-7 degrees, and more than 12 are recommended.
• Thirdly, today all the same requirements are presented to such roofing sandels as to the usual roofing.

Sandwich panels are made with drainage, weatherproofing, and joint sealing in mind. All of this is accomplished in these panels by means of a unique lock.

In addition, a whole series produces the panels themselves, which have a range of characteristics:

Planting panels: simplicity and reliability

Elemental assembly roofing sandwich panels are simple multilayer constructions made up of an external cladding, a special hydraulic protection system, insulation, and a steel frame. Given that the panels are finally gathering right on the construction site, we can classify this as a semi-finished product.

The central component of this design is a 0.71 mm thick polymer-coated cold- or hot-rolled steel. Such a basis looks like a box, the bottom of which will function as the subcutaneous room’s ceiling.

Mineral wool or basalt fiber with a tiny tension is found inside such a box. Hydraulic protection from a unique vapor-permeable membrane sits atop the insulation.

Monopaneli: thoughtful structure

You will be curious to learn that only the inner side of the sandwich panels that make up a soft roof are currently manufactured. This pattern is known as "Monopanel."

These panels are frequently used to construct the roofs of industrial buildings, sports complexes, and trading buildings. The inside of such a panel serves as both the ceiling’s skin and a supporting structure at the same time.

It is constructed using a steel profile that has been coated in zinc and frequently has a polymer layer applied. Penosol, a unique filling polystyrene foam with a combustibility group of G1, is utilized as a heater. This group describes a weak combination in which the panel is charred rather than burning.

We outline the principal benefits of monopolies. One may:

• install on roofs with any bias, and quickly enough;
• transport by any transport;
• use in buildings of the second degree of fire resistance;
• carry out all installation work in a fairly wide range of humidity and temperature.

Monopanels are also less expensive than other kinds of sandwich panels.

They now manufacture two primary varieties of monopolnels: metallic and soft coated. Hence, sandwich panels made of polymer-rolled material have a flawlessly smooth surface that prevents snow from collecting on the roof. It is dependable and long-lasting, with contemporary compositions used to seal all external joints and adjoining areas.

A sunscree is used to reduce the metallic coating on monopolines to a double standing fold after they have been coated on a machine with a unique longitudinal selection.

SIP panels: proven material

Up until recently, Russia used roofing sandwich panels, which are also classified as "sandwiches," though specialists occasionally refer to them as other materials. However, here, as in a traditional sandwich panel, a heater is positioned in between two rigid sheets.

We are discussing the use of structural thermal insulation panels in the construction of quickly constructed distant homes. Polystyrene foam and two OSB-3 chipping plates are glued together to form a monolithic structure.

These panels are also very easy to use and very strong. Thus, even though a square meter weighs no more than 15 kg, it can withstand pressure from above 11 tons in a vertical direction!

Another distinction between an SIP panel and a traditional sandwich panel is that the former does not have a vapor barrier or windproof membrane. Because it is glued to the heater in this instance, the OSB-3 plate does not warp with time.

It’s interesting to note that SIP panels with OSB lining on only one side are frequently available overseas, but there are also options with metal sheets.

In Russia, efforts are ongoing to develop a comparable material to replace OSB, such as cement-stoves, fibrilite slabs, or glass-deck sheets. However, there are some subtle differences: self-tapping screws in panels made of mineral binder are frequently corroded and poorly held, whereas OSB-3 is not susceptible to these issues.

Internal content and characteristics

So what material are these panels made of? Let’s examine their organization.

External coating: protection against atmospheric precipitation

The most common material for the internal and external cladding of these roofing sandwich panels is profiled metal sheets.

To provide the proper stiffness and drainage, the upper sheet’s profile is nearly flat with somewhat high trapezoidal protrusions. The panels’ temperature deformations are better compensated for by larger protrusions, but the cost increases accordingly:

The following are the primary forms of such panel profiling:

The polymer coating of roofing sandwich panels differs more noticeably. Furthermore, because the finish coating bears the entire operational load, the lining of sandwich panels is subject to the strictest specifications. When workers go to the roof to repair it or clean it of snow, this is both climatic and dynamic.

Nearly all three-layer sandwich panels sold in Russia have an outer steel lining made of cold-rolled steel sheet that is between 0.4 and 0.7 mm thick. The final polymer coating has a thickness ranging from 25 to 200 μm, and the zinc coating is applied hot.

When there is a need for a high degree of color consistency and a high degree of abrasion resistance, Hiarc polymers are used. His subspecies Hiarc Matt has a matte surface and a lovely color that draws the eye in and gives the roof a unique expressiveness. There are also sandwich panels made in metallic colors.

High Build is the next type of coating; it is a thicker primer with a unique pigment that is resistant to mechanical damage.

Polyester enamel, or polyester, is an additional coating. It is resistant to the mechanical effects of the atmosphere and appropriate for practically every climate zone. However, it is not a very trustworthy coating.

When sandwich panels don’t need to be more resistant to corrosion, this method is employed. However, this choice is inappropriate for the roof because the material is better suited for the interior than the exterior.

Pural is a coating made of polyurethane resin. It appears to be a thick layer with a high level of wear resistance.

Additionally, plastic is a polyvinyl chloride decorative polymer coating that has been specifically altered by a plasticizer. One of the most stable coatings, if you will.

Polyvinyl is a polymer coating that exhibits exceptional resistance to corrosion and ultraviolet radiation. It remarkably withstands molding and keeps its color and shine longer than other types of coatings.

Choosing insulation: bubbles or cotton wool?

Glass wool, polystyrene foam, polyurethane foam, and basalt mineral wool are all used as heaters for sandwich panels. Foam heaters are used for monopolines.

Depending on what kind of thermal insulation is needed, insulation can have a variety of densities. These products’ thicknesses, which typically range from 40 to 300 mm, are chosen based on precise heat engineering calculations.

These panels in the section are all arranged as follows:

View the video review to learn more about this topic:

Sandwich panels made of mineral (basalt) cotton wool have a density of 90–140 kg/m^ and a heat conductivity coefficient of 0.043 W/m^. However, of all the heater types that are used, this particular mineral wool is the most challenging.

The sandwich panel is positioned during installation with the insulating fibers oriented vertically. The insulation shrinkage is not threatened by this design, which is the most stable.

Glass panels have a 10% lower thermal conductivity and are marginally easier to work with than basalt. Over 400 degrees Celsius is the maximum temperature at which they can be used.

However, polystyrene foam panels make the lightest sandwich. Its very small thermal conductivity of 0.0022 W/m2 is evident.

However, fenopolyazoic, its analogue, is equally qualitative. Penopolyazocyanurate has a greater fire resistance than regular polyurethane foam. Actually, this is his altered counterpart:

When discussing the primary distinction between the various types of insulation, fire safety comes first. As a result, mineral wool sandwich panels—class EI240—are more heat-resistant. However, the foamyazocyanuratum panels’ maximum fire resistance is EI60.

Another crucial point to remember is that you have the option to either totally remove or add an extra layer of insulation to the roofing panels of the element.

The reliability of the adhesive compound

Sandwich panels’ three primary components are interrelated. Additionally, they are appropriate for selecting glue responsibly, t.To., For instance, the same insulation made of basalt has a delicate surface and is fairly porous. Consequently, it is critical that the glue be able to fill the spaces between the metal and fibers and go deep into the insulation.

As you are aware, a significant amount of glue is used in its foamed form, which is followed by hardening. Simultaneously, the glue must be able to withstand temperature fluctuations, be resistant to atmospheric effects, and be moisture-resistant.

Modern polyurethane-based compounds, which typically join metal to other materials, satisfy all these requirements. Furthermore, one-component and two-component adhesive compounds are used especially for roofing sandwich panels.

Simultaneously, the adhesive layer’s service life precisely determines how long sandwich panels can last. It’s worth noting that sandwich panels featuring polyurethane insulation can occasionally be assembled without the use of glue by utilizing a specialized molding to join the constituent parts. Not that it’s better or worse, mind you.

View the final sandwich panels that have been released from production:

Important subtleties of fastening

With the aid of a unique lock in the bottom portion and a trapezoid-shaped protrusion on the top sheet, combine roofing sandwich panels. Installation technology is manufacturer-specified.

The process of attaching panels made of foamyazocyanurate looks like this:

Is fastened to mineral wool panels in this manner:

Advantages of the roof from sandwich panels

The ability to style at large steps between runs in roofing sandwich panels is very valuable for roof construction. This significantly lowers the overall cost of building the roof. Because of this, using sandwich panels first and foremost offers the financial advantage of enabling the construction of these roofs on nearly any kind of building.

Sandwich panels for roofing are also a fairly strong material that can easily withstand loads from snow and wind. However, there is no additional load placed on the foundation by the "sandwiches":

We also mention how simple and quick it is to install and remove these panels. They don’t require any extra fasteners or decorations.

Disadvantages, flaws and other annoying facts

Even with all of their benefits, sandwich panels have certain drawbacks. Here’s a fun video guide explaining the benefits and drawbacks of sandwich panels for roofing:

Features of the northern climate

Russia has an extremely harsh climate, particularly in the north. Currently, a lot of roofers are hesitant to utilize roofing sandwich panels because of the seasonal temperature variations that lead to considerable operating stress.

The second is that the "sandwiches" alter in size because they are on the roof in the direct sunlight. Although this is a normal process for metal surfaces, it needs to be considered when combining joint and seam angles to prevent the system as a whole from overheating. Additionally, these drawbacks are absent from the sandwich panels of the elemental assembly. Ultimately, the steel frame serves as the load bearer rather than the load itself, making the use of thermal insulation lighter and less expensive.

Another drawback is that the insulation unit of mineral wool is gradually destroyed and the fibers are blown out during the process of cyclic temperature changes through the so-called "freezing point of water." Consequently, the design’s inherent bearing capacity is lost.

Furthermore, mineral wool itself ages physically even though it bears the full operational load. However, there are concerns about how easily these panels can be maintained. The cost of repairs will be high because the roof will need to be disassembled along with the elemental assembly panels if the standard three-layer sandwich panel can still be replaced.

Installation errors and their consequences

Locks and installation technology provide the future roof’s tightness and accuracy of fastening. The primary issue in this instance was whether the joint was successful or not.

For this reason, producers are always trying to make these locks better. Ultimately, this determines the tightness, lack of gaps, and strength of the panel connections on the roof.

These are crucial signs for a roof. Additionally, a failed joint may turn into a cold bridge and a conductor for moisture from rain, but for the same walls, none of this matters as much:

When weather conditions, humidity, and air temperature fluctuate frequently, a poorly installed sandwich panel roof can develop leaks and cold bridges. If the foam sandwich is used as insulation, the skin is also exfoliated from it, increasing the fueling of the middle layer. If mineral wool is used as insulation, the moisture-induced connection between vertically oriented fibers is noted.

Furthermore, irregular local loads (such as an unsuccessful arrival, a heavy tree branch falling, or an improperly installed antenna) pose a particular threat.

They have the potential to cause additional harm to the coating as well as the longitudinal joint’s depressurization. Furthermore, it is more difficult to repair such damage than it is to see it with the naked eye.

However, if you follow all installation guidelines, it is actually possible to avoid all of the listed drawbacks and points when working with sandwich panels.

Difficulties of transportation and storage

Sandwich panels for roofing have certain drawbacks, like light damage during installation and transit, so they must be handled with caution. For this reason, manufacturing companies frequently offer their own services to finish roof equipment, from design to installation.

Additionally, since a qualified team is already familiar with all the nuances of dealing with this type of roofing material, we suggest using such services. Even for the storage of the panels themselves, there are numerous suggestions.

The majority of manufacturers, incidentally, are concerned that installation regulations in our nation frequently overlook them and that roof panels occasionally get wet before reaching the roof. In this instance, the ensuing seasonal freezing and thawing processes rapidly rob the fibrous insulation of its properties.

Because of these uncertainties, the homeowners continue to favor a more traditional and well-established roofing style in which the insulation is specifically allocated for their location and is always accessible. The roof’s bearing capacity does not, at least, decrease if cotton wool is wet; problems will only arise in different ways.

This article for "All about the roof" examines roofing sandwich panels, including their different varieties, special qualities, and crucial installation instructions. We also carry out a thorough analysis of the top producers in the sector. Sandwich panels for roofing are effective and adaptable building materials with superior insulating qualities and structural integrity for contemporary architecture. Homeowners and builders can guarantee long-lasting and energy-efficient roofs for their buildings by making educated decisions based on their understanding of roof types and installation techniques.

Stages of installation: unusual technology

Let’s examine the fundamentals of installing roofing sandwich panels on a roof. Hence, buildings with a roof slope of at least 12% and no more than 12 meters utilize sandwich panels for three-layer roofing. They are positioned on 1.5-meter-step runs.

In contrast to traditional sandwich panels, Monopanels allow for any area to be created, any angle of inclination, and a step of three to four meters.

In real life, installing a roof like this looks like this:

Naturally, using a single panel on the slanted roof to eliminate transverse joints is the most practical option. Even so, it happens frequently these days when sandwich panels come together on the roof to form an overlap. In this instance, the panels are laid up from the bottom.

Install hat profiles across the rafters to fix such a roofing. In accordance with the run, the panels are installed along the rafters. Here, the regiments themselves fix the heat-lowering Insolon strip on top of the membranes to prevent the formation of cold bridges at the junction.

The Klyammers are used to attach the roofing sheets of monopols to one another, and the Klyammers are fastened together by self-wrapping screws. Install this panel using self-tapping screws, tightening it to runs of up to 4 mm:

Additionally, a soft roof made of common, traditional materials—like piece hounds, for example—can be built on top of it. Because they can be installed almost any time of year by any builder without the need for special training, monopanels are convenient in and of themselves.

Roofing panels can be installed in accordance with runs or fastened with bolts; self-tapping screws with a unique puck are an additional option. The type of spike, the heat-insulating tourniquet, and the specific screeds are the most useful connections.

The roofing design itself dictates the hat profile, which in the case of the metal tile is equal to its step.

The sandwich panels are fastened to the house’s walls with the same extra components as an ordinary roof:

However, the principal hubs of this kind of roof are:

Consequently, construct a sandwich panel roof overhang:

The following are the primary choices for setting up the roof’s drain:

With a single product that combines strength, insulation, and ease of installation, roofing sandwich panels provide a flexible solution for contemporary construction projects. These panels are composed of two metal sheets, usually aluminum or steel, bonded to a core material, which is frequently mineral wool, polyurethane, or polystyrene. Excellent thermal performance is provided by this design, which is essential for preserving building energy efficiency.

The core material should be carefully considered when selecting roofing sandwich panels. Superior insulation qualities and their lightweight design make polyurethane panels easy to handle during installation. Although polystyrene panels are less expensive, they provide good insulation but are less effective in very cold temperatures. Although mineral wool panels are heavier and might need additional structural support, they excel at acoustic insulation and fire resistance.

To guarantee optimum performance, roofing sandwich panel installation calls for careful attention to detail. The integrity of the roof may eventually be compromised by thermal bridging and water intrusion, which can be avoided by properly sealing joints and edges. To get the best results, installation instructions provided by the manufacturer should be carefully followed.

A number of producers are distinguished in the industry by the high caliber of their roofing sandwich panels. A variety of panels are available from companies like Tata Steel, Kingspan, and Metecno that are suited to various building needs and climate conditions. Their products are trusted choices for architects, builders, and property owners worldwide because of their renowned durability, thermal efficiency, and adherence to industry standards.

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