Roof sandwich panels: the advantages and subtleties of installation

Roof sandwich panels are actively used in the construction of the roof. They have all the basic requirements that apply to materials for construction.

Sandwich panels are in great demand in construction. They are a material that is characterized by improved performance. Prefabricated panels are adapted to negative climatic factors, therefore, they have become in demand in many regions in Russia. According to the monitoring, 86% of roofs are equipped with this material.

Roof sandwich panels are made to overlap roofs for various purposes. The name of the product comes from the English word "sandwich", which translates as "multi-layered sandwich".The name of the roof was due to the layering of its structure.

Products consist of several layers.

• Two sheets of steel, equipped with stiffeners. They are treated with anti-corrosion materials, so they are not afraid of the negative effects of the environment.
• Insulation. It is located between the sheets of steel. As this element is used mineral wool, polystyrene foam or polyurethane foam.
• The third layer in the roof panels is made of steel sheet. For wall products used OSB-plate.

Among the features include the following characteristics:

• The presence of the connecting lock. The best option is a Z-Lock connection, thanks to which the panels can be laid vertically or horizontally. The operation of such panels ensures complete tightness of the joints.
• The panels can be used as a easily reset roof - this quality allows using the material in buildings with explosive substances.
• The presence of ribs.

Sandwich panels have been manufactured for over 50 years and quickly gained popularity due to their positive qualities.

The advantages of the products are in the following positions:

• Low weight, which is about 40 kg per 1 m2, - this quality makes it possible to mount the material at industrial buildings and other structures with a large area. Fastening elements are not accompanied by auxiliary work and reinforcement.
• The panels allow to reduce construction costs, reduce the number of materials and activities that may be required during standard operations: installation of sheathing, sound insulation, and finishing.
• The high level of quality, which consists in anti-corrosion properties, good sound insulation, thermal insulation, fire safety, as well as a long service life.
• Attractive appearance. Products can be painted in any color.
• Sandwich panels are considered environmentally friendly material.
• Easy installation.The material does not require care and additional maintenance during use.

Sandwich panels have numerous advantages, thanks to which they are often used for individual construction, in arranging the roof for a cottage.

However, some drawbacks of the structures should be taken into account:

• The material does not pass air. You will need to think about the issue of forced ventilation and exhaust ventilation to cope with such a problem.
• Polyfoam and polystyrene are capable of releasing formaldehyde and styrene particles. It is possible to cope with this disadvantage by using mineral wool as a heater.

The technical characteristics of the sandwich panels contain information about the dimensions and mass of products, the level of fire resistance and noise insulation of products. Also in these parameters there is a bearing capacity and indicators of thermal resistance.

Width and weight affect product specifications. Competently selected panel sizes will help to avoid buying excess material. Consider the dimensions of the packed slats during transport.The ease of installation is influenced by the mass of products, which depends on the insulation used and the thickness of the material.

The thickness should be paid attention first, since the thicker the roofing panels are, the better the temperature inside the building will be. For regions with a calm climate, you can choose a material whose thickness ranges from 50-100 mm.

There are two types of wall panels: products with a width of 1000 mm and products with a width of 1200 mm. Roofing material has a width of 1000 mm.

The length of wall panels can vary and range from 500 mm to 13,500 mm, depending on the selected specification. For individual construction, you can choose an increased material thickness, which can reach 150 mm or 200 mm for regions with cold climatic conditions.

The weight of the structure is influenced not by the metal profile, but by the thickness and type of insulating material.

There are several types of sandwich panels, which differ in their purpose, material,type of thermal insulation material and polymer coating.

According to its purpose, according to GOST, two types are distinguished:

• wall;
• roofing.

Wall products are used in construction work for various purposes. They are also in demand for the construction of low-rise buildings and refrigerators. There are horizontal, vertical and inclined plates for the walls. Additionally, it is worth noting that the wall panels are used as external and internal partitions, they can be used to lay floors and equip the floor between floors. Often the material is used in the reconstruction of buildings.

Roof type designed for the construction of roofs.

In a separate category are modern items of item-by-element assembly. In their manufacture, a heater with a high level of efficiency is used with an auxiliary element in the form of galvanized steel with polymer processing.

According to this characteristic, the products are divided into the following types:

• mineral wool filler;
• fiberglass;
• polyurethane foam;
• Styrofoam;
• with polyisocyanurate foam - such panels are three-layer products, the insulation of which consists of a polyol with a polyisocyanate;
• combined.

The last fillers contain two elements: basalt wool and foam. Insulation is placed in layers, parallel to the skin.

According to the material of the plating products are divided into the following types:

• Metal plating. Most manufacturers offer products made of stainless steel with various polymer coatings. Sheet metal with different types of profiling is actively used.
• GKL, plywood, DSP, DVP. Such plating is used only on one side, and for the second it is customary to leave metal sheets. The panels are suitable for internal partitions. They contain cable channels and wiring.
• PVC The top layer is made of rigid sheets of polyvinyl chloride, with insulation between the layers. PVC-cladded panels are used during the construction of partitions in the office, as well as for finishing window or door openings.
• Paper. The paper can be supplemented with polyethylene or aluminum foil. Products are used for thermal insulation of the roof, walls and foundations. Many buyers choose a paper-like casing with bitumen impregnation. The material is resistant to steam and does not allow condensation to accumulate.

There are several basic coatings:

• Polyester. It is used in any climatic conditions. The coating is recommended to be used inside structures. The thickness of this coating is 25 microns, heat resistance reaches 120 degrees. The material has a hardness, reasonable price. On sale there is a glossy and matte polymer of this type.
• Plastisol. The coating consists of PVC and plasticizers. The polymer can be used for structures that are located outside or inside the building. Often with the help of sandwich panels with a coating of plastisol roofing is equipped. The advantages of the material are in resistance to mechanical stress, corrosion and good formability.
• Polydifluoride. The thickness of the layer reaches 25 microns. It is resistant to high temperature conditions.The coating can withstand a range of -60 to 120 degrees.
• Pural The basis of this coating is polyurethane. The surface of the layer is dull silky, characterized by resistance to temperature differences, corrosion, aggressive substances and ultraviolet rays. A roof with such a coating is often used in harsh climatic conditions.

Wall panels and cladding products are equipped with different types of connections:

• Sheep-groove - this type is a tongue-and-groove joint.
• Secret mount.
• Z-Lock. The joint consists of two spikes with slopes and grooves of the corresponding shape. The double shutter is characterized by a high level of reliability and is preferred for wide panels.

For roofing the following connections are provided:

• Roof-Lock. It is able to prevent the seal from depressurizing during temperature expansions.
• Faltsevy castle. This compound is used in refrigeration equipment.
• Eccentric lock. It has a hooked form. It is built into the ends of the panels, due to which products can be pulled tight.

Variants of connection of sandwich panels are selected individually for each type of structure. The choice is based on such indicators as the length and thickness of the frame, the type of layout, the slope of the roof and the dimensions of the axles. The kit kit also depends on the type of assembly. Manufacturers offer 27 types of fastener assemblies for panels, among which there are endova, fastenings for parapets, gutters, roofing and wall panels, as well as overhangs.

Sandwich panels are easy and quick to install. To exclude problems during installation, experts advise before laying to carry out preparatory activities.

Assembly technology requires attention to several indicators:

• Minimum bias.
• The main dimensions of the roof.
• Readiness of the frame part. During installation of the products should be eliminated distortions or tilts. Each surface must be parallel or perpendicular.
• It is necessary to clarify the order of installation of the panels, as they have different sizes. First you need to make a calculation, and only then begin the installation.
• Arrangement of stops for the bottom row. You can use a bar, metal profile, corners. They are attached to the beams or base using powerful screws and anchors. Position the stops horizontally and check the correct positioning of the level.From the actions depends on the appearance of the structure and build quality.
• Arrangement of waterproofing.
• Preparation of the necessary tools for the work.

It is best to use a saw with small teeth in work - the grinder is forbidden to use. You should also take care in advance about the availability of connective material for products. For each thickness, its own connecting components are produced.

To install a sandwich, you need to prepare construction equipment. It should be borne in mind that without a crane it will be quite difficult to lift the panels. Special equipment must be selected with a grip that does not damage the surface of the plate.

Preparatory activities are a mandatory procedure, without which a high-quality installation is impossible, so preparation should be given special attention.

To independently install a sandwich panel, you will need to comply with SNiP and CPD. You should also use in your work routing and drawings.

Installation has its own nuances.It is necessary to create not a traditional fad, but an element, supplemented with an internal strap. As a result of actions between oncoming plates, which are located under the ridge, a void is formed. It should be filled with foam for installation work. The cut foam is closed with polyurethane gaskets, on which the plates are fixed.

As a result, the following elements will be created:

• gaskets forming the profile;
• riddles and ridges.

It is necessary to make sure that the distance between the rafters of the roof coincides with the width of the panels. Compliance with this rule eliminates trimming and trimming of plates and saves material costs.

Panel installation manual.

• The first step is to lay the bottom slab with its further fixing on the auxiliary beam, which supports the rafters. You can use the bottom-up stacking or horizontal rows. The choice of installation scheme depends on the type of construction. In the future, you need to attach the roof panels to the rafters - to attach to the ridge is unacceptable.
• Then you need to proceed to sealing. To seal the joints was of high quality,a sealant should be added to the lock joint. The event eliminates the formation of temperature bridges, and also guarantees high quality installation. If a silicone sealant is used, no acid should be present in it, otherwise corrosion and surface damage will occur.
• After the panels are on site, you need to remove the protective coating. You can remove the film from the entire product or clean only the area where the attachment will be made. Two grippers are required to lift and feed the plates - one gripper is not allowed, even if a short panel is used. Compliance with this rule will provide a smooth fit, which will not distort.

Sandwich fixing:

• the three self-tapping screws of the last slab should be screwed into the roof girder through the wave that the stiffeners form
• the step of runs from the end of the plate to the first screw should be at least 50 mm;
• other plates can be fixed with two screws.

Installation of panels can be carried out on different bases.

• Metal frame. Fastening to metal structures occurs with the help of self-drilling screws.To make this procedure, it will be necessary to make holes of a smaller diameter into the supporting elements — in the future, a screw will be screwed in here.
• Wood guides. To ensure fixation, fit simple screws for working on wooden surfaces.
• The base is made of concrete. Dowels are used, which should be inserted into pre-prepared holes. Then the panel is attached with anchors.

Experts recommend for work to choose screws from steel, on which there is a rubber sealing of synthetic rubber. Places in which the panels are connected are recommended to be strengthened with the help of metal interception in the form of a trapezoid.

Knowing the features of installation and observing the recommendations from experts, you can do it yourself to correctly install roofing panels. Proper installation is considered the key to long-term service of the material and the attractive appearance of the structure.

The rules of operation are periodic maintenance of the panels.

This will require:

• Remove the protective film within two weeks of installation.
• Systematically clean the drain and roof debris. In the work should use cleaning products of a mild nature. Strong contamination can be wiped with soapy water, then rinsed with plain water.

Many users encounter thermal deformations that manifest themselves in the form of transverse folds, tears or cuts in fasteners.

The causes of the deformation are as follows:

• Use of panels of dark color in regions with hot climate.
• Wrong calculations of the load during the operation of the product with hygroscopic insulation. The mass of the material increases with the accumulation of moisture, increases the load, which further leads to the collapse of the walls or roof, as well as to the deformation of the products.
• If there is no expansion joint in the project, then during the use the lock is deformed, the product geometry is distorted, and users may encounter the fact that the roof and the junction point of the deflector flow.
• Unevenly exposed panels vertically when joining lead to a distortion of the locking mechanism.
• Irregularly twisted screws will lead to the curvature of the sheets and loss of tightness.

To minimize the likelihood of deformation of products, you should follow some rules:

• choose products need a lighter shade;
• it is necessary to use a two-support mounting option;
• panels should be used, the maximum length of which does not exceed 6 m.

During the use of the roof can be faced with damage to the polymer coating. If this defect is found, you should promptly start the restoration process - painting the product. To do this, you need to choose a paint of the required shade, which is suitable for working with a polymer coating.

Based on the depth of damage, the paint is applied in one or two layers. To paint a small area, you will need a thin soft brush. If the panel is to be painted completely, spray gun is used. Before the event should be removed rust and polish the area. Deep damage is treated with a primer.

The impact of the external environment can damage not only the outer layer, but also the insulating material.

After the damage site is discovered, it is necessary to examine its boundaries in order to calculate the volume and type of repair measures. In some cases, minor defects in the surface hide significant defects in the inner layer - if such problems are found, it may be necessary to dismantle the damaged panel. However, external damage does not always spoil the structure of the material, and users carry out the usual restoration of the sheet.

The most complex and costly measures will be required for the separation of sheets. It is necessary to quickly begin to restore the starting mechanical properties of products. If panels with mineral wool insulation were purchased, they should be replaced with identical raw materials.

Sandwich panels are in great demand,therefore, there are many trademarks on the Russian market that sell this material for construction.

According to customer reviews, the following manufacturers are considered the best:

• "Lissant." The brand is known since 2008 and currently has several production lines, which are located in different cities. The manufacturer ensures that the production quality standards are respected. The panels are made only from high quality materials, the production process is carried out on Italian equipment.

• LLC "Teplant". The company is a subsidiary of the Kuibyshev Combine, which is engaged in the production of products from mineral wool. Production of sandwich panels has been going on since 2001. The products of this manufacturer is considered the best brand, which is engaged in mass deliveries of material to the construction market.
• GC "Vesta Park". The trademark contains wall and roof panels, the color range of which allows you to choose products for every taste.The manufacturer provides strict quality control, due to which the company has repeatedly been nominated in various competitions.

• LLC TD "Stimet". The manufacturer is in demand due to affordable prices and high quality products. Products are equipped with a traditional faltsevy locking compound, foam plastic or mineral wool is used as thermal insulation.
• "Technostil". The company has been operating since 2008. The manufacturer claims that it plans to take the lead in the construction market. The brand has great prospects, since all products are checked by strict quality control, and production facilities are constantly being upgraded. Buyers are attracted by affordable prices and high quality products.

The process of installation of roofing sandwich panels, see below.