SANDWICH PANEL PERFORMANCE ADVANTAGES

With the development of manufacturing technologies coupled with high quality materials, sandwich panels with high load bearing capacity can be manufactured. Load bearing capacity not only depends on the density and thickness of the core filling material, but it also depends on the form of the metal surfaces and such panels are able to effortlessly carry loads that are significantly higher than their own weights. With these capabilities, sandwich panels are preferred as a cladding material in roof and exterior wall applications. Sandwich panels are the most ideal building material that can be used in essentially all buildings with steel, wooden, or reinforced concrete construction. In addition, sandwich panels allow for cost savings from construction materials thanks to increased purlin spacing with the selection of suitable sandwich panels as well as saving time in terms of total time of assembly. With the use of sandwich panels in buildings with custom production of panels available up to 18 meters in length, the assembly works as well as the number of joints in the covered surface will be reduced significantly. Sandwich panels are mounted on large exteriors and roof surfaces in a relatively short period of time thanks to improved shipment and transportation facilities. A rough estimate of assembly times of 10 minutes/m2 for exteriors and 8 minutes/m2 for roofs can be provided as reference data. Whereas sandwich panels do not restrict construction volume or building height, limit values are determined based on the supporting structure. Despite their standard components and limited availability of length options, sandwich panels offer limitless design opportunities for designers. Horizontal, vertical, or angular installation of panels or using varying color options allow for visual dynamics in exterior wall structures. In addition, potential design options for designers increase even more thanks to panels that can be used for multiple purposes in interior sections of buildings. Joint details include joints connecting panels and those connecting panels to the supporting structure. Tight joint providing insulating functions is ensured by using double tongue-and-groove joints in exterior wall panels and generally tongue-and-groove joints together with lateral joints in roof panels. The main requirement expected from joints is to provide airtightness, thermal insulation, and easy assembly. Easy assembly basically means that the components fully fit into each other easily during installation.

Recent studies have shown that panels offer 100 times better airtightness properties than even the highest quality windows. In addition, panels used in exterior walls are manufactured with hidden screws and therefore providing an aesthetic appearance without exposing any screws. With careful planning, large-scale expanding and renovations can be carried out without causing any disturbance to indoor activities in the building. Sandwich panels allow for longitudinal and transverse extensions based on the building structure. In addition, they offer economic and practical advantages for application as panels may be removed and reassembled elsewhere for reuse.

Sandwich panels redeem their cost within a short period of time. In addition to economic advantages provided during assembly, these panels offer more distinct amortization advantages with the energy efficiency provided by thermal insulation as compared to other building materials. By checking thermal conductivity values of the materials, energy efficiency provided can be easily identified in comparison with other materials. As PUR sandwich panels has a lower thermal conductivity coefficient compared to all other similar thermal insulation materials, they offer high insulation and energy efficiency. Therefore, they allow for preservation of resources. In addition, generating electricity using solar power by installing solar skylights on the panels is also possible. In addition to the reduced shipment time and costs, the lightweight design of sandwich panels allows for decrease in basic construction costs as it offers lower load transmission to the supporting system of the building, thus providing a positive effect. Moreover, they have low maintenance cost with a long-lasting use life. Durability of sandwich panels is ensured by modern finishing used in the panels that offers protection against high-level corrosion and UV lights.

Contrary to concrete and gas concrete used in building exteriors, PUR sandwich panels provide the same thermal insulation with very low thickness. Therefore, the total available space and volume within the building are measurably expanded.

Also known as condensability capacity, the contribution of the material to spreading fire or even the fire resistance of the material is defined as fire performance. A panel system consisting of a non-flammable metal surface and polyurethane is defined as B, s2, d0 (i.e., almost non-flammable) according to EN 13501 standard; however, potential fire behavior in buildings may not be evaluated simply based on the resistance to fire of the exterior coating material as various other factors play a role in fire behavior. Materials such as textile, furniture, PVC joinery, etc. present in the buildings are generally highly sensitive to fire and cause the fire to spread throughout the building. Therefore, each of fire safety parameters before and after fire plays a crucial role in taking necessary measures. Corrosion developing over time as water comes into contact with certain materials such as steel leads to various problems in terms of load bearing in addition to visual issues in buildings. Moreover, serious financial losses may occur as a result of water leakage from roof or exterior walls damaging materials such as fixtures and furniture, etc. located inside the building. Potential water leakage may be prevented by double tongue-and-groove joints system used in exterior wall panels. Roof panels are determined based on roof gradients in order to ensure waterproofing. The required waterproofing is ensured even in case of roof panels installed by a 5% gradient thanks to capped roof panels. High waterproofing is ensured by membrane panels in roof applications installed in roofs with a gradient lower than 5%. On the other hand, water vapor due to condensation affects the building, causing chemical degradation and deterioration of comfort conditions. Water vapor risk does not play a significant role in sandwich panels. This is because insulated metallic surfaces serve as a strong stabilizer in buildings.

Polyurethane (PUR) sandwich panels provide satisfactory levels of acoustic absorption in normal industrial buildings based on the requirements of the building; however, these are not adequate for other locations or offices that are too sensitive to noise whereas additional solutions such as vibration dampers can be used in such cases. In the production of polyurethane, which is the core filling material of sandwich panels, fully green systems are used, and production procedures are carried out using environmentally conscious systems. n-Pentane, a type of gas which is currently used to blow out polyurethane is not harmful to the environment. In addition, polyurethane can be reprocessed into powder to be reused as a thermal insulation material. Sandwich panels to be installed in roofs and exterior walls, which are defined as the building envelope, ensure protection of the building against external factors and thus ensuring long service life, energy efficiency as well as providing more comfortable living conditions.

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