Wall sandwich panels are popular in the modern construction industry due to the many benefits they offer. By choosing a single panel, you can achieve the desired aesthetics, better insulation, and better structural strength.
However, before you choose these panels for your building structure, let’s explore some of the reasons why you should consider wall sandwich panels.
What are Wall Sandwich Panels?
Wall sandwich panels are a specially engineered material popular in modular building construction. These wall panels are uniquely identified by their two outer metal sheets, with a core material.
The outer metal sheets can be stainless steel, galvanized steel, or aluminum. On the other hand, the core material can be mineral wool, PIR/PUR, or EPS.
Benefits of Wall Sandwich Panel
· Excellent Thermal Insulation
The wall sandwich panel’s insulated core is made up of different materials that contribute to or help lessen heat transfer.
This process contributes to keeping your building cool during summer seasons and warm during winter season thus lowering the energy cost. Even during summer, it will help reduce the cost of using HVAC.
Remember, one of the key reasons for installing wall sandwich panels is the insulation property. We rate this insulation in terms of R-value (the material’s ability to resist heat flow).
Let’s explore different R-values of sandwich panels with varying core materials in the table below:
| Core Material for Sandwich Panel | R-value per inch | Fire Rating & Weight |
| Expanded Polystyrene (EPS)
| · 3.8 to 4.0 | · Fire rating: Poor · Weight: Very low |
| Polyisocyanurate (PIR) | · 7.0 to 7.2 | · Fire rating: Good · Weight: Low |
| Mineral wool | · 3.5 to 4.2 | · Fire rating: Excellent · Weight: High |
| Polyurethane (PUR) | · 6.0 to 6.5 | · Fire rating: Moderate · Wight: Low |
· Fast and Easy to Install
They are usually factory-made, thus making it easier to install and thus consuming less time. In fact, it is for this reason that you will find sandwich panels in many modular building constructions.
For example, with prefabricated panels, they come already cut-to-size and finished. This makes them easy to install.
Installing wall sandwich panels can take a few days instead of weeks, allowing the building to become operational faster. Additionally, it also contributes to making repairs and replacements simple and fast.
· Lightweight and Strong
Most wall sandwich panels have a perfect balance between structural strength and weight. This unique property makes sandwich panels a perfect option for many projects in the construction industry.
This property makes it easy to handle and transport, thus reducing labor and installation costs and consuming less time. Still, they can also withstand wind loads.
The lightweight implies you will not spend money investing in a heavily reinforced foundation or steel structure. This will ultimately save on construction costs.
· Fire Resistance
Different core materials offer varying fire resistance capabilities. A good example is mineral wool.
Since the sandwich panel in the core is made of mineral wool, it will act as a good fire resistance, improving building safety. In fact, you will find these panels referred to as fire-rated walls since they are virtually non-combustible.
· Excellent Sound Insulation
Wall sandwich panel helps to reduce external noise that may cause disruption, making it suitable to be used in factories, warehouses, cold rooms, and residential buildings. Let’s summarize their properties in the table below:
| Core Material for the Sandwich Panel | Sound Blocking Capability | Sound Absorption Capability |
| Mineral Wool | · High | · Excellent |
| PUR/PIR | · Ranges from moderate to low | · Low |
| EPS | · Low | · Very Low |
· Weather and Moisture Resistance
The outer part of the wall sandwich panel is made of metal, which contributes to its superior weather and moisture resistance. They protect buildings against harsh weather conditions such as rain, wind, humidity, and corrosion.
Additionally, this metal plays a major role in increasing the life span of the wall sandwich panel.
· Environmentally Friendly
They are known to reduce building carbon footprint. The insulated core minimizes heat loss or gain, thus lowering energy consumption for heating and cooling, and reducing harm to the environment.
· Low Maintenance
Wall sandwiches are known to be low maintenance since they are factory-made and finished, designed to last longer.
Its outer surface is designed to help resist harsh conditions such as moisture, corrosion, and weather damage, thus reducing the cost of frequent repairs and painting.
· Cost-effective
Since wall sandwich panels are easy to install, they reduce time spent during installation, thereby saving on labor costs.
It reduces energy efficiency, leading to lower and long-term operating costs and total project savings.
· Aesthetic Flexibility
They are usually available in different types of colors and design thus giving room for one to choose that fits his or her preference.
Whether you want a flat or corrugated design, most manufacturers, such as Lutonpanel, offer 100% custom designs.
FAQs
What material is the wall sandwich panel made of?
Wall sandwich material panels are made of different types of materials, such as metal, like aluminum, stainless steel, and galvanized steel, covering both the outer and bottom facings.
Additionally, the insulation layer is made up of polyurethane, polyisocyanurate, mineral wool, and expanded polystyrene.
How long do wall sandwich panels last?
The lifespan of a wall sandwich panel is between 20 years and 30 years plus.
Which are the most common types of wall sandwich panels?
| Features | PU/PUR Panels | PIR Panels | Rock Wool Panels | EPS Panels |
| Core material | Polyurethane foam | Polyisocyanurate foam | Mineral wool | Expanded polystyrene |
| Thermal insulation | excellent | excellent | good | moderate |
| Fire resistance | moderate | high | excellent | Low to moderate |
| Sound insulation | moderate | moderate | excellent | low |
| Structural strength | high | high | high | moderate |
| cost | Medium – high | high | high | low |
Are wall sandwich panels eco-friendly?
No.
This is usually affected by the type of material used to design the wall sandwich panel.
Are there specific industry standards for wall sandwich panels in the construction industry?
Yes.
Industry standards for wall sandwich panels used in the construction industry are EN 14509, which covers safety measures, strength, fire performance, and insulation, among others.
Buy your Wall Sandwich Panels from Lutonpanel
Lutonpanel has been fabricating wall sandwich panels for over 15 years. Our panels are custom-made with different upper and lower skin layers with a unique core material.
Our manufacturing process involves strict quality control to ensure your wall sandwich panels meet your unique thermal insulation and structural properties.
Tell us more about your project for 100% custom-made wall sandwich panels – Get a quote now.
