Installation of roofs from sandwich panels, all the subtleties of technology

"All about the Facades of the House" welcomes you! We explore the complex world of sandwich panel roofing today. This ground-breaking technology, which provides a lightweight yet robust roof solution, has completely transformed the construction sector. Sandwich panels are composed of an insulating core, usually made of mineral wool, polyurethane, or polystyrene, sandwiched between two layers of metal or another material.

Sandwich panels’ effectiveness as insulation is one of its main benefits. The building’s insulating core lowers annual heating and cooling expenses by assisting in the maintenance of a comfortable interior temperature. This feature is especially helpful in areas with harsh weather, where it’s critical to maintain constant indoor conditions.

Sandwich panel roof installation entails a number of important steps. Initially, meticulous planning and measuring guarantee that panels are precisely cut to fit the roof structure. After that, the panels are lowered into position and firmly fixed to the supporting structure. Many builders find this method to be cost-effective because it expedites construction while also reducing the amount of labor required on-site.

Sandwich panels are also well known for their adaptability. They blend in perfectly with different architectural styles and can be installed on both sloped and flat roof designs. With a variety of colors and finishes to match any building facade, this adaptability also extends to aesthetics.

What is a sandwich panel

A three-layered building material is called a sandwich panel. The polyurethane-based two-component glue securely binds the roof panel’s components to one another. The three-level system’s upper and lower layers are composed of polymer-coated thin-leaf galvanized steel. The metal components of the "pie" have a thickness of 0.5 or 0.7 mm. Stiffeners profile the steel sheets. A heater, such as polystyrene foam, polyurethane foam, or basalt mineral wool, symbolizes the middle layer.

The benefits of roofing materials

• presentable appearance;
• durability;
• increased fire resistance;
• strength;
• resistance to deformation;
• light weight;
• simplicity of installation work;
• resistance to aggressive environments and other negative influences from the outside.

Characteristics and dimensions

Sandwich panel roofs are known for their superior thermal insulation, water resistance, and sound absorption capabilities. Sandwich-style roofing keeps heat inside and blocks out cold air from the outside.

The standard slab’s linear parameters are as follows:

• width – 1000 mm;
• length – from 2500 to 16000 mm;
• Product thickness – from 50 to 250 mm.

The primary attributes of the roofing material are its thermal conductivity, weight, fire resistance, bearing capacity, and sound insulation. The insulation type and panel thickness have a major impact on the product’s technical specifications.

An indicator of thermal insulation serves as a guide for determining panel thickness. More heat-trapping air will be retained in the center of the structure the thicker the plate.

Signs of mineral wool insulation in sandwich panels:

• sound insulation – from 30 to 43 dB;
• thermal conductivity – 0.05W/MK;
• Fire resistance limit – EI 30 to EI 180;
• combustibility group – NG;
• Density – from 120 to 140 kg/m 3;
• Specific weight – from 17.5 to 43.5 kg/m 2 .

Features of roofing plates insulated with polystyrene:

• sound insulation – from 25 to 39 dB;
• thermal conductivity – 0.042W/MK;
• Fire resistance limit – EI 15;
• combustibility group – g1;
• Density – 25 kg/m 3;
• Specific weight – from 12.2 to 17.2 kg/m 2 .

Features of sandwich panels insulated with polyurethane foam:

• sound insulation – from 30 to 35 dB;
• thermal conductivity – 0.022W/MK;
• Fire resistance limit – EI 15;
• combustibility group – G4;
• Density – 41 kg/m 3;
• Specific weight – from 9.2 to 15.5 kg/m 2 .

Heavy loads can be supported by three-level roofing systems without compromising material quality indicators. The coating can tolerate up to 150 kg of snow per square meter, with a maximum wind load of 48 kgf/m 2. Sandwich panels have a 30-year service life.

Preparation for installation

Without preparing the process beforehand, sandwich plate installation on the roof cannot be completed with quality. You must first become acquainted with the installation and design documentation. The project specifies the number of plates, the size and kind of sandwich panels, the mounting method nodes, and a map of the technology layout. the quantity of materials for waterproofing.

Prior to beginning installation, it is important to keep an eye on the locations of the crossbars, rafters, and runs, make any necessary adjustments, and measure the slope’s inclination. The required instruments and associated materials are gathered during the preparatory phase.

Necessary tools and materials

The following supplies and tools will be needed in order to cut the plates, attach materials, and seal butt joints during the installation process:

• electrician;
• stationary disk saw;
• shallow saw;
• screwdriver or electric drill;
• building level;
• long roofing screws made of carbon or stainless steel, equipped with sealing washers;
• Short screws for fixing the additional elements.

The thickness of the panel itself and the composition of the supporting structure are taken into consideration when choosing the screw length for fastening the sheets. The usual method for attaching the flooring from sandwich panels is to use 12.5 mm long-range screws.

Other components and forming pieces will be needed in addition to the three-layer slabs themselves:

• cornice bar;
• end strips and plugs;
• Skate bar.
• Endovs.

Chat under a sandwich panel

A sandwich panel’s frame can be made of a variety of materials:

• tree;
• metal;
• reinforced concrete.

A wooden support system has several benefits, including low heat conductivity, low cost, environmental purity of the material, and simplicity of assembly. The requirement for extra material processing to prevent material from igniting and from fungal and insect lesions is one of the drawbacks of the wood base.

Supporting structures made of reinforced concrete have low heat conductivity, high strength, rust resistance, and a long operational life. The heavy weight of the reinforced concrete crate is a major disadvantage.

A metal crate is a sturdy, dependable, and quickly constructed design that is not easily deformed. The high heat conductivity, need for anti-corrosion treatment, and high cost of the metal support are its drawbacks.

The geometric parameters of sandwich panels are considered in the design of the frame. The supports should line up with the location of the panel junction, and the space between the crate’s runs should guarantee that the plates are fastened five centimeters from the edge.

Installation technology

Sandwich panels on the roof are lifted with the use of specialized machinery. The lifting mechanism should have lifting devices, such as soft grips or vacuum suction cups, to prevent damage to the material.

The protective film is removed before working on the plates’ lower surface. In the direction from the overhang to the ridge, roofing blocks are arranged in rows. Roofing screws are used to secure the panels to the frame. To avoid damaging the gasket, fasten parts must be screwed strictly perpendicular to the sheet and with little force.

The lower row corner, which creates an overhanging cornice, is where the sandwich panel roof installation starts. The next elements are overlapped and fixed to the crate and the previously laid blocks.

The endtop-panel end sections have Z-Lock style locks installed. The longitudinal fixation of sheets is accomplished through the utilization of locking joints. Making sure the castle crests fit snugly into the voids left by the slabs after them is crucial. Applying a silicone or butyl junky sealant to castle grooves ensures dependable sealing joints.

The roof skate is started after the roofing plates are laid. Ordering:

1. Installation of the internal plank of the skate.
2. Filling up the doses between the plates with mounting foam.
3. Installation of profile polyurethane laying.
4. Filling joints with mineral wool or other insulation.
5. Fixation on the crest of the Pokonkaya bar.
6. Installation on the top of the skate of polyurethane gasket with a self -adhesive base.
7. Installation of the ridge bar through short self -tapping screws.

The least amount of slope on a roof

The roof’s minimum slope from the sandwich panels is at least 7.0 in the case of transverse joints, window hatches, and other components that break the coating’s monolist. A drop in slope to 5 0 is permitted when the entire sheet occupies the entire flight along the length.

When designing the roof, the local climate is taken into consideration when choosing the slope. The roof’s slope can range from 0 to 5 in dry and hot terrain. In regions where heavy precipitation is typical, the roofing canvas is installed at a minimum angle of 40 degrees.

Additional supports are required when laying a roofing canvas on slopes that have a slope of more than 15 0 in order to prevent the sandwich panel from sliding downward.

Mounting with transverse joints

The technology of arranging transverse joints includes the following steps – at the panel of the subsequent row, part of the lower casing and insulation equal to the size of the overlap are cut off. The size of the overflow is determined based on the slope of the slope, for roofs with a slope of 5 to 10 0 – 30 cm, with a slope of 10 to 20 0 – 20 cm. A sealant is applied to the lower plane of the resulting protruding part of the outer casing, the panel is attached to the frame and fastened with the laid sheet of the lower row. The place of connection of the plates of the lower and upper row should be on the run of the frame. The gap between the sandwich panels should be completely filled with sealants, in order to avoid violation of tightness.

Installation errors and their consequences

The primary mistakes made when installing "sandwich" style roofing are as follows:

• inaccuracies in the design documentation;
• uneven frame;
• Cutting panels with a grinder;
• improper selection of screws;
• Twisting or non -switching of fasteners;
• neglect of seals;
• Incorrect adjustment device and falsis compounds.

Errors committed during the installation process eventually result in roofing leaks. A reduction in the flooring’s wind resistance indicators and other manufacturer-declared technical parameters is a risk associated with technology violations.

Operation and repair rules

It takes little work to maintain a flat roof made of sandwich panels. Operational measures consist only of a timely roof made of waste. It is required to assess the coating’s technical state once every six months. Repair and restoration work can be done as soon as possible if defects are found.

Damage to the polymer shell of the external sheathing is the most frequent defect. Use special enamel to repair sandwich panel roofs. The type of protective coating, color, and shade of roofing plates are taken into consideration when choosing painting materials for restoration projects.

Depressurization of butt joints is a flaw that can cause the insulation to be destroyed in addition to leaks. Sealant needs to be applied to the exposed seams.

Sandwich panel roof installation is a contemporary and effective way for homeowners to improve their properties. These panels are composed of two layers of metal or another robust material encasing an insulating core, usually made of expanded polystyrene (EPS) or polyurethane (PU). Excellent thermal insulation and structural strength are provided by this construction, which makes them suitable for a variety of climates and roof styles.

Sandwich panels’ ease of installation is one of their main benefits. Sandwich panels are easier to work with and lighter than more conventional roofing materials like tiles or shingles. This is a cost-effective option for many homeowners because it shortens installation times and lowers labor expenses. Because of the panels’ safe interlocking design, a weatherproof barrier is created without sacrificing aesthetic appeal.

Furthermore, sandwich panels’ long-term thermal efficiency results in energy savings. In the winter, the insulating core reduces heat loss, and in the summer, it helps keep interior temperatures lower. Its energy efficiency makes it an eco-friendly choice for sustainable housing solutions because it not only improves comfort but also lowers heating and cooling costs.

It’s crucial to speak with experts who have dealt with these materials before installing sandwich panels on a roof. Appropriate installation methods guarantee the roof’s longevity and best performance. Homeowners can benefit from a long-lasting, energy-efficient roof that raises the overall value and comfort of their properties for many years to come with careful planning and attention to detail.

Considering the article’s central claim: Learn the ins and outs of utilizing sandwich panels, a flexible and contemporary building method, to install roofs. This guide demystifies the process and makes it accessible to both professionals and homeowners. It covers everything from understanding the materials to providing step-by-step installation tips. Regardless of your goals for improving durability, energy efficiency, or aesthetic appeal, this article will provide you with the necessary knowledge to successfully install sandwich panel roofing on your next project.

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