Modern construction is impossible to imagine without the use of effective enclosing structures, and it is precisely sandwich-panel installation It is becoming a key stage in the construction of warehouses, hangars and commercial buildings. Video instructions are the most popular format of training today, as they allow you to visually evaluate the technology of docking elements and work with fasteners. Static images do not convey the dynamics of the process, namely, the speed and sequence of actions determine the tightness and durability of the entire building.
However, just watching the video is not enough for a quality result. You will need a deep understanding of the physical properties of the material, the rules of its transportation and the nuances of working with the material. flooring and insulation. In this article, we will analyze all stages of work, based on time-tested technologies and current standards. We will also pay attention to the typical mistakes that beginners make when trying to save on qualified personnel.
Preparation of the base and verification of the geometry of the framework
Before starting any work on the installation of panels, it is necessary to conduct a thorough acceptance of the metal frame of the building. Any deviation from the vertical or horizontal can lead to the sandwich-panel They simply do not stand in the grooves or form crevices that violate the thermal circuit. Video reviews often show ideal conditions, but in practice, builders face column and rigle skews that require immediate fixing.
Use a level or laser level to check the planes. Permissible deviations are usually strictly regulated by the design documentation and should not exceed several millimeters per linear meter. If the frame is assembled from LMK (light metal structures), check the quality of anticorrosion coating in the welded joints.
Pay special attention to the foundation or the base if the installation begins with the bottom row. The surface should be flat, dry and cleaned of construction debris. Often it is at the stage of preparation that the foundations are laid by the problem of tightness, so this stage cannot be ignored categorically.
⚠️ Warning: Never start mounting panels on a frame that has not passed the final stability test. Wind load on mounted, but not detached panels can lead to the collapse of the structure.
To compensate for irregularities, a special sealing tape or aligning gaskets are often used. Their use allows you to create a uniform press and avoid deformation of the metal when tightening the fastener. Remember that the metal has a high thermal conductivity, and any gaps will become bridges of cold.
Required tools and lifting equipment
Quality sandwich-panel installation It is not possible without a specialized tool. Unlike working with a conventional profile sheet, it requires careful attitude to the surface and an accurate dosage of effort when twisting screws. The main tool is a screwdriver with adjustable tightening force or a special drill screwdriver for working with the roof.
To lift the panels to height, vacuum grippers are used, which allow the elements to safely move up to 12 meters long without damaging the protective coating. The use of conventional slings or hooks often leads to scratches and dents, which later become foci of corrosion. Video materials demonstrate work with different types of grippers, choose those that fit the weight of your panels.
The list of mandatory instruments includes:
- 🛠️ Electric screwdrivers with spare batteries for continuous operation.
- ✂️ Metal cutting scissors (manual or electric) for cutting locks.
- 📏 Roulettes, levels, plumbing and laser levels for control of geometry.
- 🔨 Kiyankas with rubber buckets for editing panels without damaging the paint.
It is important to use only cutting tools that do not heat the metal. Bulgarians (angular grinding machines) with abrasive circles are prohibited, since the flickering sparks burn through the polymer coating and zinc layer, starting the rusting process. The use of a Bulgarian for cutting sandwich panels cancels the manufacturer's warranty for corrosion resistance.
Working at height will also require mounting belts, safety ropes and ladders that meet safety standards. The organization of workplaces should prevent the possibility of falling tools or materials.
Why can't you use a Bulgarian?
Sparks from the abrasive circle have a melting point of steel. Once on the polymer coating, they burn it through to the metal. Even microscopic damage to the zinc layer at the cutting site after a few years will lead to the appearance of a rusty spot that will creep under the coating.
Technology of installation of wall panels
Wall panels are mounted horizontally or vertically, but the most common is the horizontal scheme. It allows you to ensure better tightness of joints and simplifies the work on insulation of adjoining nodes. Before the start of work on the frame, a starting profile or a basement bar is set, which sets the level of the first row.
The installation process starts at the corner of the building. The panel is raised, positioned and attached to the frame through the wave or in specially provided places. Fastening elements must be strictly perpendicular to the surface to ensure tight fit of the washer and sealing gasket. A drawn screw deforms the metal, and an untwisted one does not provide tightness.
The vertical joints of the panels (if they are along the length of the ramp or wall) should be protected from blowing. For this purpose, low-level foam or special seals are used. Video instructions often focus on the moment of "clicking" the lock: you need to achieve a tight connection, but without excessive effort that can damage the lock.
The table below shows the basic parameters of fasteners for different types of panels:
| Type of panel | Diameter of the screw | Installation step (mm) | Type of sealer |
|---|---|---|---|
| Wall (minwata) | 6.3 mm | 500-1000 | EPDM |
| Roofing (minwata) | 6.3 mm | 500 | EPDM + steel washer |
| Wall (foam polystyrene) | 5.5 mm | 1000 | Polyurethane |
| Facade (HPL) | Hidden fasteners | Project | silicone |
During installation, it is necessary to constantly monitor the verticality and horizontality of the rows. Accumulated error of several millimeters at each junction to the top of the building can turn into tens of centimeters, making it impossible to install the final elements.
☑️ Check before mounting the panel
Features of laying roof sandwich panels
Installation of roof panels is the most important stage, as the roof takes on the main loads from precipitation and wind. The laying begins with a cornice overhang and moves upwards to the skate. It is important to provide the necessary overhang, which is usually between 150 and 300 mm depending on the roof slope and manufacturer’s recommendations.
In places of cross joints (floats), it is necessary to remove the upper layer of the insulation and skin for tight connection of the lower layers of the metal. The resulting cavity is filled with a sealant or mounting foam, and then the alkali is installed. Sealing of joints This is a critical point on which the absence of leaks in the future depends.
To move on the already installed roof, it is necessary to use special ladders or running bridges. Step directly on the panel between runs is prohibited, as this will lead to the pressing of the metal and violation of the integrity of the insulation. Video footage often shows installers in soft shoes, but it is better to be safe and use load distributors.
Warning: When working on the roof in hot weather, the polymer coating becomes softer. Be careful not to scratch the surface of the sole of your shoe or tool. Also, do not leave metal trimmings or packaging on the roof - the wind can blow them around the object or damage the coating of neighboring panels.
The skating unit is mounted after the laying of all skates is completed. It is important to provide ventilation of the under-roof space, if it is provided for by the project, and reliable waterproofing. Use of the ventilator allows you to remove moisture from the insulation, prolonging the service life of the structure.
When installing roof panels in the cold season, use winter sealants and mounting foam, otherwise they will not polymerize and lose their properties.
Installation of additional elements and shaped products
Extra elements (laptops, ebbs, corners, basement slats) give the building a complete look and perform the function of protecting the junctions from moisture. Installation of these elements is made after the installation of the main panels, but before the final delivery of the object. Quality of installation shaped It directly affects the aesthetics and functionality of the facade.
Mounting of the alkalis is carried out by screws with a step of 300-500 mm or on adhesive sealant, if the design allows. It is important to observe the sequence of installation: usually first the elements of the lower tier (tide, socket), then the corner and wind, and last of all - skate and parapet.
The main types of extra elements:
- 🏗️ Base bar - protects the lower junction of the wall and foundation.
- 📐 External and internal corners – close the vertical joints of the panels at the corners of the building.
- 🌧️ The window tide diverts water from the window opening.
- 🏔️ The skating bar - closes the junction of the roof rays.
When trimming the extra-traction elements in size, use only metal scissors. Cutting areas must be treated with repair enamel in the color of the coating to prevent corrosion. Even quality. polyester or purals will not protect the exposed edge of the metal from rust without additional processing.
⚠️ Note: Do not use the sleeves as a ladder or support. Thin metal (usually 0.5 mm) is easily deformed under the weight of a person, and it will be impossible to straighten it without traces.
Properly mounted finishing elements are not only beauty, but also a guarantee of the absence of leaks in the most vulnerable areas of the building.
Typical errors and quality control
Even with detailed video instructions, inexperienced installers often make mistakes that are difficult to fix without dismantling the structures. The most common of them is a violation of the assembly sequence. For example, an attempt to mount the upper rows of panels before the final alignment of the lower leads to distortions of the entire wall.
Another common problem is the wrong choice of the length of screws. Too short fasteners will not enter the metal of the frame to a sufficient depth, and too long will pierce the panel through, violating the tightness. The length of the screw is calculated taking into account the thickness of the panel, the thickness of the metal of the frame and the height of the cap.
Quality control should be carried out at every stage:
- 🔍 Visual inspection for the absence of scratches and dents.
- 📐 Check the horizontality and verticality of the rows.
- 🔩 Check the force of tightening screws (the puck should be slightly pressed, but not pushed).
- 💧 Check the tightness of the joints (if necessary - spilling water).
Particular attention should be paid to the places adjacent to window and door openings. There are often gaps due to uneven cutting of the panels. The use of foam should be dosed: excess foam when expanding can bend the thin lining of the panel inside the room.
Timely detection of defects allows you to eliminate them at minimal cost. Ignoring minor violations of sandwich panel installation technology during construction can lead to serious problems with the thermal insulation and appearance of the building after 1-2 years of operation.
What to do if the panel is scratched?
Small scratches (up to metal) should be painted with repair enamel (aerosol or brush). Deep damage requires the installation of a patch of the same material on the sealant or replacement of the sheet if the damage is through and extensive.
Do I need to remove the protective film from the panels before installation?
It is recommended to remove the protective film immediately before installation or immediately after it, but no later than 2-3 weeks (depending on the season). Prolonged exposure of the film under ultraviolet light can lead to the fact that the adhesive is polymerized and the film will not be removed without damaging the coating. In winter, it is better to remove the film immediately so that it does not freeze.
Can I install sandwich panels in winter?
Yes, installation is possible at temperatures up to -20°C (for some types up to -30°C). However, there are limitations: you can not use mounting foam and sealants that are not designed for low temperatures. Metal is also becoming more brittle, so increased care is required when transporting and flexing elements.
Which is the best pitch for windy regions?
Under standard conditions, screws are installed through a wave in each run-through base. In windy regions or for high-altitude buildings, the fastener’s pitch can be reduced (e.g., mounting in each wave) in consultation with the designer. This increases the wind resistance of the structure.
How to cut sandwich panels in size on the object?
For cutting panels in size, only mechanical scissors are used (manual, electric, hewn). The use of disc saws or bulgars is prohibited, as the high temperature of the cut destroys the polymer coating and the zinc layer, leading to rapid corrosion. For cutting polystyrene foam, you can use a hot string or hacksaw with a small tooth.