PIR sandwich panels walland roofing – how to avoid installation errors?
PIR sandwich panelswalland roofing are materials that are widely used in industrial and agricultural construction, as well as in cold stores and freezers. Their popularity is due to excellent thermal insulation properties, high resistance and fire resistance. However, to enjoy their full benefits, it is crucial to carry out the installation correctly. In this article, we will discuss the most common mistakes when installing sandwich panels, ways to avoid them and appropriate installation techniques that will ensure the durability of the structure for years. You will also learn how specific panel parameters affect their performance.
The most common mistakes made when installing sandwich panels
The installation of sandwich panels, especially those with mineral wool, requires a precise approach and knowledge of specific technical requirements. Improper installation can affect the thermal insulation, acoustic parameters and tightness of the structure.
Inadequate preparation of the substrate for sandwich panels
The substrate on which the sandwich panels are installed should be perfectly even and stable. The substructure is the foundation on which the entire structure of external walls and roof coverings rests.
How to ensure proper substrate quality:
- Ensuring a flat surface: Sandwich panels, especially those with a mineral wool or rigid polyurethane foam core, require a flat surface. An uneven base can cause bending and stress in the panels, which leads to a decrease in their thermal insulation and tightness. Before installation, it is worth leveling the base thoroughly or using additional pads to level out any unevenness.
- Stabilization of the subfloor: The stability of the structure is crucial. If the subfloor is not solid enough, it can cause the slabs to shift or settle, affecting their durability and tightness. To avoid this problem, it is recommended to strengthen the subfloor by using additional supports or reinforcements, especially in areas subject to higher loads.
- Substructure treatment: Before installing sandwich panels, it is worth performing appropriate substructure treatment. This may include anti-corrosion protection of metal surfaces or the use of special washers and gaskets that will ensure better adhesion of the panels. In this way, you can avoid future problems with leaks and loss of thermal insulation properties.
Improper storage and transportation of sandwich panels
In order to ensure the durability of sandwich panels, proper storage and transport is necessary. The core of mineral wool or PIR foam is susceptible to moisture, therefore the panels should be stored in dry, airy places, protected with foil. During transport, both roof sandwich panels andwall, must be properly fixed to avoid mechanical damage to the cladding. Long-term exposure to moisture weakens the insulation of the boards, so they should be stored in covered places, protected from rain and condensation.
Using the wrong tools
To avoid damaging sandwich panels, use the right tools for their installation and cutting. Slow-speed saws are best for cutting sandwich panels with a polyurethane or mineral wool core, which minimize the risk of overheating the material. Grinders can cause overheating and damage to the core and facings, so they are not recommended. It is worth choosing tools with the right settings and precision, which allows you to avoid overheating the polyisocyanurate foam, increasing the durability and efficiency of the panels.
Problems at the design stage of sandwich panel structures
Designing sandwich panel structures requires taking into account parameters such as strength, thermal insulation and fire resistance. Design errors can reduce the efficiency of the panels and lead to structural problems.
Incorrect matching of spans and loads
Failure to match the span to the strength parameters of the panels can lead to a weakening of the structure, especially in the case of roof panels. To ensure the stability of the structure, it is crucial to match the span to the strength parameters. Here’s how to do it:
- Manufacturer’s load-bearing tables : Each panel has a maximum allowable load, therefore the manufacturer’s load-bearing tables should be checked prior to installation and spans should be adjusted to these guidelines to avoid overloading the structure.
- Considering the impact of snow and wind : Roofs are exposed to additional atmospheric loads. When designing roof coverings, it is worth anticipating the impact of snowfall and strong winds.
- Resistance to weather conditions : The selection of boards with increased resistance to temperature changes ensures their durability in changing weather conditions.
No detailed design details
To avoid problems with leaks and reduced insulation of sandwich panels, the design should take into account the installation details. The joints between the panels should be carefully sealed to avoid thermal bridges through which heat can escape. The seal ensures optimal insulation. Regularly checking the tightness of the joints allows for the quick detection and repair of potential leaks, which prevents heat loss. Each panel should be securely attached to the substructure, which increases the stability and durability of the structure.
Underestimation of the impact of weather conditions
To ensure the durability of sandwich panels, the influence of weather conditions must be taken into account. Variable temperatures cause thermal expansion – panels can shrink or expand, which can lead to deformation. Therefore, it is worth using flexible fastenings that will take into account these changes. Moisture can weaken the properties of the core, especially in panels with mineral wool, so it is necessary to protect them from water and condensation, e.g. by additional sealing. Fire resistance is another factor – panels with mineral wool are less susceptible to fire, which increases their safety in difficult conditions.
Assembly errors related to the installation of the panelswall
The installation of sandwich panels requires precision to ensure proper thermal insulation and acoustics. Proper installation prevents thermal bridges and ensures the tightness of the structure.
Maintaining the proper distance between the plates
Sandwich panels, especially those with a polyisocyanurate foam or mineral wool core, must be installed with minimal gaps to avoid deformation.
- Minimum distance between plates : Maintaining the correct distance prevents thermal stresses that can cause deformation when temperature changes.
- Vertical alignment : The boards should be installed in accordance with the manufacturer’s guidelines, which ensures the durability and stability of the structure.
- Precise assembly : Precise panel fit minimises the risk of thermal bridges, ensuring better thermal efficiency.
Contact protection against leaks
The joints between the plates must be carefully sealed to prevent leaks and heat loss.
- Contact tightness : Precise contact sealing blocks moisture from reaching the core, protecting the boards from damage.
- Proper sealing : Seals are necessary to protect against moisture and help maintain insulation.
- Checking the joints : Regular checking of the tightness of the joints is essential for maintaining the thermal properties.
Proper acoustic parameters
Well mountedwallSandwich panels with a mineral wool core provide excellent sound insulation.
- Sound insulation : Mineral wool boards effectively minimize noise, which is especially important in industrial buildings.
- Joint tightness : Prevents sound from passing through gaps, which improves acoustic comfort inside the building.
- Appropriate cladding : Claddings affect the acoustic properties of the panels, enhancing their ability to muffle sounds.
Assembly errors when installing roof panels
The installation of PIR roof panels requires care to ensure their tightness and stability. The key is to use the right fasteners and match the panels to the substructure.
Fixing boards with visible and hidden fixing
Roof sandwich panels can be installed using visible or hidden fixings, which requires the use of appropriate screws and washers.
- Bolts of the right length : Bolts must reach the substructure to ensure the stability of the panels even under heavy loads. This ensures that the structure remains solid and resistant to external factors.
- Corrosion resistance : Fasteners should be made of materials resistant to moisture, which protects them from rusting and extends the life of the entire structure.
- Hidden fixing : Installation with hidden fixing is an aesthetic solution that allows for a smooth roof surface without visible fasteners.
Cutting roofing sheets
Precise cutting of roof sandwich panels is crucial to maintaining their thermal insulation and tightness.
- Use of slow-speed saws : Slow-speed saws allow for precise cutting without overheating the material, which is particularly important for boards with a polyurethane or mineral wool core, which are sensitive to high temperatures.
- Avoiding grinders : Angle grinders can overheat and damage the core and the trapezoidal sheet, causing the sheets to lose their thermal properties and potentially become deformed.
- Maintaining tightness of joints : Accurate cutting enables precise fitting of the panels, which minimises the risk of leaks and ensures better insulation.
Application of seals
Seals and appropriate processing ensure the tightness of the structure and protection of the core against moisture.
- Core protection against moisture : Core protection prevents damage and maintains the thermal durability of the board for many years.
- Joint treatment : Ensures aesthetic finish as well as tightness of connections, which protects against heat loss.
- Application of gaskets : Gaskets are essential to protect the core from water ingress and prevent it from being damaged in harsh weather conditions.
Choosing the right sandwich panels for different applications
Sandwich panelswalland roof panels are widely used in the construction of industrial, refrigeration and storage facilities. A sandwich panel with a PIR foam or mineral wool core is characterized by a high insulation coefficient, which helps maintain appropriate thermal conditions. Panels with a wool core and EPS polystyrene provide higher fire resistance, which is useful in halls and public utility buildings. Panels with visible fastening and profiling of the facings are suitable for wall and partition walls. Structures available with a thickness of 100 mm can be used in cold rooms, and the use of an external facing improves their durability.
The installation of sandwich panels requires precision and adherence to the manufacturer’s guidelines. From proper storage, through precise cutting and assembly, to proper securing of joints – each stage is important for the final thermal efficiency and durability of the structure.