Everything One Should Know About Sandwich Panels

A sandwich panel is a three-layer construction product consisting of two coloured galvanized steel sheets and core between them.

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The technology of sandwich panels production appeared due to American architects Frank Lloyd Wright and Alden B.Dow, who were the first to use it in their projects. Already in , the American company Koppers Inc. started mass production of sandwich panels. The oldest sandwich panels manufacturers in Europe are the Finnish company Rannila now known under the Ruukki brand, the Irish company Kingspan, and the Italian company Cannon.

Sandwich panels possess good aesthetic properties, excellent energy saving characteristics, as well as can quickly assembled and thus are widely used for construction of trade and office buildings, prefabricated frame buildings, including warehouse complexes, industrial objects, and agricultural structures.

Type of sandwich panels

Depending on their use, sandwich panels are divided into wall and roof panels. In selection of wall sandwich panels, the key parameters are heat engineering, strength, and fire protection characteristics, while for roof panels, bearing capacity and long life are also of relevance.

Roof sandwich panels have to ensure full air-tightness and necessary roof strength, that is why it is recommended to use panels with special profile of external facing in the form of ridges.

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Energy saving

The energy saving properties of sandwich panels are determined by the type of core, air-tightness of the lock and availability of seal in it.

A seal can be of butyl, installed at the time of panels installation, or EPDM (ethylene-propylene-diene-monomer) installed into panels’ lock during production, which ensures better air-tightness and energy efficiency of the sandwich panel lock.

A critical sandwich panels’ energy efficiency parameter is thermal resistance (R0), which takes account of heat losses in the lock part of the structure.

Panels with thermal resistance below the mentioned parameters, are not recommended for usage in construction of energy efficient buildings.

Usage of modern cores, such as mineral wool and PIR, enable construction of buildings with even zero energy consumption. Construction of passive buildings and warehouses with regulated gas environment requires usage of technical solutions on sealing of all abutments, as well as application of sandwich panels with increased energy efficiency, allowing to almost completely exclude energy losses. A sandwich panels building structure can be considered energy efficiency, if its air-tightness comprises less than 1.5 m3/m2hour.

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I am reviewing some composite theory to better understand sandwich panels so that I may compare tested results to theoretical results. I am having diffuclty obtaining the relative density of EPS. Also, in exploring the limit states of panel stiffness, face yielding, face wrinlking, core shear, core fracture, and bond failure. I am finding that the core shear values tend to control the capacity of simply supported panels. The skins are made of Fy = 33ksi 26 gage steel, 4" or 6" thick panels. I applied safety factors related to material strength per AISC specification for steel and safety factors for bond and shear stress per ICC AC4 for Sandwich Panels. I am using the panels in a building application. There is not much literature out there, so I was looking for some more background information, I believe there is a book by H. Allen out there, but I am unable to locate a copy. 'The analysis and design of sandwich panels' by Howard Allen is available from the library at the University of Queensland, but that is probably not helpful to you.

A book which I found helpful was 'Lightweight sandwich construction' by JM Davies which may be more accessible.

Assuming that EPS is expanded polystyrene, the density would vary depending on the supplier. It would be best to contact the supplier of the panels you are looking at and see what they can tell you.

I was speaking with a technical staff at ritek ( who was telling me something about the core being able to absorb load and therefore gains strength as the loading increases. I also noticed that the shear deformations can contribute quite significantly.

There was a paper published in the Australian Journal of Structural Engineering that I will post and hopefully it will help you out. All units will be metric.