Sandwich panels for new construction: lightweight and quick to install

What are sandwich panels?

Sandwich panels are prefabricated building elements consisting of three layers:

• An outer plate (usually profiled steel, aluminum or fiber cement)
• An insulation core in the middle (often PIR, PUR, EPS or mineral wool)
• An interior plate that serves as a ceiling finish (flat steel, aluminum or drywall)

These three layers are bonded together under high pressure at the factory, resulting in a strong, lightweight and thermally efficient building material. Standard widths range between 1000-1200mm, while lengths can be customized to project specifications, sometimes up to 20 meters.

Advantages of sandwich panels in new construction

Quick installation and efficiency

The main advantage of sandwich panels is the significant time savings during the construction phase:

1. Prefabrication: The panels are fully prepared in the factory, making the construction site primarily an assembly zone.
2. Large elements: Cover a considerable area with a single operation.
3. Less labor intensive: Assembly requires less manpower than traditional roof construction.
4. More weather-dependent: On-site construction time is shorter, making the project less sensitive to weather conditions.

For average new construction projects, the total assembly time can be reduced by up to 50% compared to conventional roof structures.

Superior thermal performance

Sandwich panels offer excellent insulation values that are essential in today's energy-conscious building climate:

• High insulation values: Depending on the core thickness, R-values of up to 8 m²K/W are possible.
• Cold bridge-free: Due to the continuous insulation material, cold bridges are minimized.
• Airtightness: The seamless construction and professional joint sealing ensure minimal air leaks.
• Temperature regulation: More resistant to temperature fluctuations, keeping the indoor environment more stable.

These properties make sandwich panels particularly suitable for energy-efficient and passive building projects.

Constructive advantages

In addition to insulation, sandwich panels offer important structural benefits:

• Lightweight: 60-80% lighter than traditional roof structures, reducing the load on the support structure.
• High span: Some types can span up to 7 meters without intermediate support.
• Dimensional stability: Less sensitive to shrinkage, expansion or deformation.
• Fire resistance: Available in various fire resistance classes (up to 60 minutes with mineral wool core).

These features give architects more design freedom and can lead to savings on the supporting structure.

Types of sandwich panels for roofs

Several types of sandwich panels are available, each with specific properties:

Based on core material

PIR/PUR core:
- Excellent insulation value (0.022-0.025 W/mK)
- Light weight
- Good fire retardant properties
- Cost-effective

Mineral wool core:
- Superior fire resistance (up to fire class A1)
- Good sound absorption
- Slightly lower insulation value than PIR/PUR
- Heavier and more expensive

EPS core:
- Budget-friendly
- Good insulation value
- Limited fire resistance
- Suitable for less demanding applications

Based on profiling

Roof tile profile:
- Aesthetically similar to traditional roof tiles
- Available in a variety of colors
- Ideal for residential projects

Trapezoidal profiling:
- Industrial look
- Very strong structural properties
- Suitable for larger spans
- Fast water drainage for gently sloping roofs

Cost considerations in sandwich panels

The investment in sandwich panels pays for itself in several ways:

Initial cost vs. total cost of ownership

Although the purchase price of sandwich panels may be higher than some traditional materials, consider:

• Labor cost savings: Up to 50% fewer assembly hours
• Shorter construction time: Faster delivery means earlier commissioning
• Lower maintenance costs: Durable materials with long service life
• Energy savings: Lower heating and cooling costs over its lifetime