SANDWICH PANEL ASSEMBLY DETAILS

Manufactured using ideal materials for thermal and acoustic insulation as well as waterproofing and using state-of-the-art technologies, polyurethane (PUR) sandwich panels offer numerous advantages to users as compared to other alternative materials. High-grade quality production is achieved through meticulous and precise control processes. However, users are also required to exercise due care in certain conditions during assembly in order to ensure the highest efficiency in using top-quality panels:

  • One of the most crucial points to pay attention before beginning panel assembly is to determine the predominant wind direction. Panel assembly should be carried out in the opposite direction of the predominant wind direction.
  • The number of screws to be used in assembly should be determined based on the wind conditions and as required by the details.
  • Special attention must be paid to avoid crushing the metal coatings on top of the panels during assembly and shoes with rubber soles should be worn if possible.
  • Panel longitudinal joints should be minimum 25 cm, sealant tape should be used in-between two metal components with joints, and the joint site should be reinforced by applying a pop rivet or puller screw.
  • Components such as fringes and corners that are exposed to wind effect should be fixed to each purlin.
  • In roofs with a low gradient, silicone should be used in joints.
  • During assembly, contact of materials such as steel purlins, concrete, or plaster etc. to panel coating should be prevented by using suitable insulating material or paint.
  • Aluminum materials should be protected against water, snow, and moisture from shipment from the production plant until the time of assembly (to avoid oxidation).
  • When removing panels to be installed on the roof, panels should be placed in a manner to distribute the load throughout the entire roof surface rather than placing them to close proximity to each other as a package. Packages should be placed on the truss rather than in the middle of purlins as much as possible.
  • In order to prevent panels from detachment from the roof due to wind especially in case of windy weather, the exposed panels and panel packages should be firmly fixed to the structure (in case the exteriors of the construction where the panels are intended to be assembled are exposed in the open, wind suction force should always be taken into consideration).
  • Two or more people should try not to stand on the same location during panel assembly works (As this load is considered as point charge and is not considered in panel load bearing tests as indicated by deflection especially in roof ridges and stream sides).
  • Panel pliers should always used during panel assembly to prevent any air transfer between two panels.
  • Panels must always be fixed to all load bearing purlins and horizontal beams.
  • Accessories of a minimum thickness of 0.50 mm should be used for the durability of the works and for aesthetic purposes.
  • As much as possible, all purchase orders for accessories should be placed following measurement on-site after completion of the panel assembly rather than ordering based on the project specifications. In case the time is of the essence, then wing length of such accessories should be kept longer.
  • At joint locations as required between the panels, the joint length should be minimum 250 mm taking into consideration the roof gradient (double-row waterproofing should be provided at joints).
  • The best mechanical way to resolve water problem in roof ridges and fronts is to fold down the edges of the panel left inside the accessory. Subsequent solutions consist of chemical solutions to improve safety and that are inevitable to be provided.
  • Especially in roof ridges and roof front, silicone or foam should never be used in-between the joints of the accessories.
  • It is an ideal solution to use self-drilling steel screw to install panels to steel construction and twisted steel screw to install panels to precast concrete construction during assembly.
  • When installing accessories, using a puller screw to join sheet to sheet and a pop rivet to join sheet to aluminum give better results than other alternative solutions.
  • Screws to be used in assembly must be reinforced by wide flange sleeve with EPDM sealing, which would both prevent water leakage into screws and expand the screw connection surface in roofs and exterior walls in wind suction position.
  • A uniform insulation must be provided in roof ridges by bringing together both panel edges as closely as possible and placing glass wool or rock wool in-between the edges.
  • Flat upper roof ridges should be designed based on the roof gradient to extend minimum 200 mm under the panel edges to prevent wind and water intake inside the building and bitumen-impregnated foam must always be used after folding down the panel edges.
  • When placing purchase orders for accessories (accessories to connect the roof panel to the exterior wall) of exterior building facades (front and back), make sure that such accessories return from the roof panel pitches as much as possible, otherwise, it would be too difficult to prevent water problem.
  • In case of assembly of panels with craft paper, it was observed that panel packages have changed form when exposed to sunlight for a long period, therefore, it is required to assemble such panels as soon as possible from the moment they are delivered on the site and finish coating (membrane layer finish) should immediately be performed (for panels changing its form due to exposure to sunlight for a long period, the panels should be dampened to gain its flexibility just a few hours prior to installation).
  • Especially, painted sheet panels coated with protective film should be protected against sunlight. As the protective thin polyethylene films on the painted sheet would stick to the panels more if exposed to sunlight for a long period of time, it would be difficult to remove them during assembly.