In the last few decades, sandwich panels have proved to be a revolutionary solution in the construction industry.
By definition, this material is a self-supporting component that serves two concurrent purposes ' partitioning (roof or wall) and thermal insulation.

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6 reasons to choose sandwich panels

The sandwich panels vary by:

• length (2 to 18 m)
• thickness (40 to 230 mm)
• core type (EPS, mineral wool, polyurethane)
• profile (smooth, micro-profile, clearline, grooved etc.)
• protective coatings (polyester SP, SP polyester Mat Pearl, Cesar PUR 55, aluzinc), with panels also used with stainless steel cladding
• cladding colours (both external and internal)

Every panel consists of several layers: core with thermal insulation, steel claddings (external and internal) and coatings protecting from mechanical damage and corrosion.

REASON NO. 1.

"TIME IS MONEY"

For example, let's compare two popular technologies used in warehouse building construction.
In the first case the external partitions consist of double brick walls, while in the second case they consist of sandwich panels.

By selecting the first case we have to order the following works: wall construction, thermal insulation installation and, finally, external layer installation.

By selecting sandwich panels, the construction process is far less complicated and thus quicker and, most importantly, cheaper. Panels are finished components, suitable for easy installation, e.g. to a steel structure.

Considering the present situation on the construction services market, working time plays a key role in the cost optimisation process. The quicker the structure is completed, the less we spend on construction service costs, which have increased significantly in recent years. The rapid structure completion process also translates to earlier commencement of occupancy, which improves the return on investment for business projects.

REASON NO. 2.

"THREE CORES OR SOLUTIONS DEDICATED TO SPECIFIC NEEDS"

Sandwich panels are available in three basic variants. Each uses a specific panel core. Thus there are materials with cores made of polyurethane, mineral wool and EPS. Each of these solutions is intended to meet specific needs.

Polyurethane-core sandwich panels

Polyurethane is the best and most commonly used thermal insulation material on the market. After many years of market domination by older materials, such as mineral wool or EPS, today they are being replaced by better equivalents in the residential construction market, in the form of panels made of hard polyurethane foam ' Thermano.

Sandwich panels with this core are primarily distinguished by better thermal insulation properties. The lambda of 0.022 W/mK has no equal, meaning that this type of material is selected by project owners seeking to reduce the total heating costs.

Another benefit of using this type of panel is the potential to save space inside the building. Better thermal insulation of the partitions translates to lower wall thicknesses, compared to other types of panels or masonry, while maintaining the same thermal insulation parameters.

Another equally important benefit is the lower density of the material from which the core is made (40 kg/m3). This simplifies installation significantly, because no special tools or equipment are required on the project site.

Sandwich panels with a mineral wool core

The second type of panel has two advantages ' fire resistance and soundproofing efficiency. One feature of mineral wools is their behaviour in fires. Selected panels manufactured by Balex Metal are EI 240-rated, meaning that both the sealing and the fire rating of the partition is maintained for 240 minutes. This is enough time for people to leave the building safely as well as minimising the potential losses resulting from the fire.

Another important feature is to have a partition designed to prevent the transmission of excessive noise. The best panel versions feature good soundproofing capabilities, which in practice translates to a soundproofing effectiveness of up to 33 db.

Panels with an EPS core

The history of sandwich panels began with EPS (polystyrene). However, this type of core has been gradually replaced by mineral wool and, primarily, by polyurethane.

If we compare all three types of panel, EPS lies between the mineral wool and the polyurethane in terms of thermal insulation properties; however it is inferior to mineral wool in its reaction to fire.

Sandwich panels with an EPS core are, in turn, a budget solution that can be used successfully whenever there are no stringent requirements for fire resistance or thermal insulation.

Panel joints

It is also possible to join the panels. This applies to the panel types featuring polyurethane or mineral wool cores. This is possible both for panels with exposed fasteners (standard type) and concealed fasteners (type plus).

REASON NO. 3.

"HOW ABOUT... CONNECTING MULTIPLE COLOURS?"

Apart from the basic functions of industrial structures, attention is increasingly being paid to aesthetics. The look of our place of business, whether it be a warehouse, manufacturing plant, store or car showroom, often determines the level of trust in the brand. This is why adding unique character by the project owner to the project has become so important.

Balex Metal provides many interesting solutions, with a range of profiles, coating types (e.g. mat) and cladding colours (more than 30 different colours).

A range of selected designs can be connected freely, which can give spectacular results that attracts attention and highlights the type of business, whether the style is more classical or modern.

Due to the non-porous surface, sandwich panels are quick and easy to clean. Standard pressure washers are perfect for this purpose. The panel coating materials are completely resistant to water jet impact, thus regular cleaning will keep the structure looking new for many years.

REASON NO. 4.

"ALL MATERIALS FROM ONE MANUFACTURER"

Balex Metal panels are available with a full range of accessories. These include flashings (in any colour, including the panel colour) and all kinds of fasteners to allow panels to be fitted to any substrate (steel, reinforced concrete or wood). The project owner can also choose from a wide range of seals and gaskets to ensure the highest sealing of the partitions.

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When choosing sandwich panels, the best possible access by light should also be considered. This can be provided by small windows made of polyester, which are also available with dedicated flashings. Thanks to this, the result is an appealing and well-protected structure that protects against external conditions.

REASON NO. 5.

"IMAGINATION IS THE LIMIT"

Sandwich panel structures can be freely arranged. The material is easy to process, so buildings can be designed with windows and gates wherever required.

REASON NO. 6.

"VERSATILE APPLICATION"

In travelling the length and breadth of Europe, you cannot miss the hundreds of structures made using sandwich panels. Interestingly, today these are not only industrial structures. Residential projects are becoming increasingly popular, with many design offices even creating ready concepts based on such applications.

Sandwich panels are available in wall and roof versions, which are typical for the following types of structures:

Construction is one of the fastest-growing industries, and India must embrace these changes to take a leading role in manufacturing and commerce globally.

Sandwich panels form an integral part of modern pre-engineered building solutions and are fast growing in popularity due to their wide array of benefits. 

Whether you are in charge of choosing materials for commercial construction or the main business head with a plan for extensions, this blog is for you. In it, we'll discuss sandwich panels and why they should work best for your project, among many other aspects related to them.

What Are Sandwich Panels?

Sandwich panels are prefabricated building materials consisting of three layers: an insulating core sandwiched between two durable outer layers. These panels are designed to provide superior insulation, strength, and durability, making them ideal for a variety of applications.

A sandwich panel is a three-layer prefabrication used in building and construction. It normally features an insulating core sandwiched between durable outer layers. These panels are designed to provide class insulation, strength, and durability in a manner different from regular panels, hence being ideal for uses.

Common types of sandwich panels include:

• EPS (Expanded Polystyrene) Panels
• PUF (Polyurethane Foam) Panels
• Rockwool Panels
• Glasswool Panels

Each type of panel offers unique features that cater to specific construction requirements.

Key Benefits of Sandwich Panel Construction

1. Exceptional Thermal Insulation

Sandwich panels, regardless of type, provide outstanding thermal insulation. They maintain consistent indoor temperatures by minimizing heat transfer, which leads to reduced energy costs for heating and cooling.

For regions in India with extreme temperature fluctuations, the insulation properties of sandwich panels make them indispensable for commercial projects.

2. Superior Durability and Strength

Despite being lightweight, sandwich panels are remarkably strong and durable.

• EPS Panels are known for their rigidity and moisture resistance.
• PUF Panels offer excellent load-bearing capacity and thermal resistance.
• Rockwool and Glasswool Panels are fire-resistant, making them ideal for industries requiring high safety standards.

This durability ensures a long service life, even in harsh environmental conditions.

3. Cost-Effectiveness

Sandwich panels are cost-efficient compared to traditional building materials. Their lightweight nature reduces transportation and installation costs, while their prefabricated design ensures quicker assembly on-site.

For large-scale commercial projects, the time and money saved with sandwich panels can be significant.

4. Environmental Sustainability

Sandwich panels are recyclable and contribute to reducing the carbon footprint. Their insulation properties save energy, aligning construction practices with global sustainability goals.

5. Lightweight and Versatile

The lightweight nature of sandwich panels places less load on building structures. This reduces the cost of foundations and supporting frameworks while allowing for flexibility in design.

Applications of Sandwich Panels in Commercial Projects

Sandwich panels are widely used across various industries due to their versatility. Here are a few common applications:

• Warehouses and Industrial Sheds Panels like EPS and PUF ensure optimal conditions for storing goods.
• Cold Storage Facilities PUF and Rockwool panels help maintain low temperatures efficiently.
• Clean Rooms and Laboratories Glasswool panels are ideal for controlled environments requiring high precision.
• Office Buildings and Site Offices Sandwich panels create energy-efficient, comfortable workspaces.
• Fire-Safe Enclosures Rockwool panels offer fire safety, making them suitable for power plants and industrial units.

Conclusion

Sandwich panels are changing the construction landscape with their energy efficiency, durability, cost-effectiveness, and sustainability. The advantages of EPS, PUF, Rockwool, or Glasswool panels are clear.

These panels are a game-changer for India, where cost and energy savings are critical. They also support initiatives like Make in India and drive industrial growth.

Do you have a unique commercial project in mind? Let us assist you in turning your vision into reality! Explore the use of sandwich panels on our page and discover why we are one of India's leading sandwich panel suppliers.

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