Roofing From Sandwich Panels, Including The Features Of Its Design And Operation, As Well As How To Avoid Mistakes During Installation

2024 Author: Bailey Albertson | [email protected]. Last modified: 2023-12-17 12:53

Sandwich panel roofing: device features and installation rules

The rapid development of building technologies is a steady trend of our time. New materials appear, labor-intensive production processes are replaced by more economical and perfect ones, and construction times are reduced. The basis of progressive technologies is versatility, a rational minimum and a systematic approach, combined with the most demanded products. In this article, we will talk about the use of sandwich panels as a roofing material that significantly expands the possibilities of engineering and architectural solutions in the construction of private houses.

Content

• 1 Features and characteristics of sandwich panel roofing

  • 1.1 Video: Fire resistance of mineral wool sandwich panels
  • 1.2 Leading manufacturers of roof sandwich panels
  • 1.3 Video: Strength test of well-known manufacturers

• 2 Roofing from sandwich panels

  • 2.1 Video: the pros and cons of roofing panels - which ones to choose

  • 2.2 Elements of a sandwich roof

    2.2.1 Video: self-tapping screws for sandwich panels

• 3 Installation of a sandwich panel roof

  • 3.1 Video: how to cut sandwich panels
  • 3.2 Table: dimensions of transverse overlaps depending on the slope of the slopes
  • 3.3 Video: installation of roof sandwich profiles
  • 3.4 Installation features
  • 3.5 Errors when arranging a roof of sandwich panels

• 4 Rules for the operation of a roof made of sandwich plates

  • 4.1 Service life of sandwich panels
  • 4.2 Repair of sandwich roof structures
• 5 Reviews of Roof Sandwich Panels

Features and characteristics of a sandwich panel roof

One of the most important structural elements of a building is the roof, the construction cost of which can be up to 20% of the total construction budget. Of course, you can cut costs by using cheaper coatings. However, the roof of the house must be strong and reliable in order to withstand climatic and mechanical loads, as well as protect the building from negative atmospheric phenomena. Therefore, when choosing roofing materials, one should be guided not only by their price, but also by technical parameters, expediency of use and the possibility of decorative design of one or another roof configuration.

Roofing sandwich panels are cheaper than other covering materials, although in terms of performance they are much superior to traditional coatings

Today, roof sandwich panels are the optimal solution for roofs with an inclination angle of 5º. Among the variety of materials offered by manufacturers of roofing products, they are distinguished by an acceptable cost and have all the necessary performance characteristics:

• light weight. The roof will not exert much pressure on the supporting structures of the house, which means that you can save money when laying the foundation, especially when wall and roofing sandwich panels are used in complex construction;

  

  Complex use of wall and roof sandwich panels not only refines the structure and gives it a stylish modern look, but also saves on the construction of the building's supporting structures

• aesthetic appearance;
• simplicity and speed of installation;
• long service life - up to 20 years;

• environmental safety and increased fire protection;

  

  When choosing sandwich panels, you need to pay attention to their marking: products with the K0 index are the most fireproof, K3 are the most fire hazardous, and products of the K1 and K2 types have average fire resistance

• resistance to environmental influences;
• high sound and heat insulation performance;
• rich color range and the ability to manufacture any size, taking into account the wishes of the customer.

The main distinguishing features of a sandwich panel for roofing are:

1. Connecting lock. The most practical is the Z-Lock connection, which makes it possible to lay the panels horizontally and vertically. The use of roofing elements with such a lock guarantees absolute tightness of the joints, which allows you to save a lot on waterproofing and vapor barrier materials, the laying of which in this case becomes unnecessary.

   

   The connection of sandwich panels at the bottom into a Z-Lock ensures absolute tightness and does not require laying of hydro- and vapor barrier

2. Stiffening rib. In roofing sandwich panels, the ribs are made much higher, which ensures sufficient water drainage and gives the roof additional strength.

   

   Roof sandwich panels have much higher stiffening ribs than wall ones, so they have higher strength characteristics

Video: fire resistance of mineral wool sandwich panels

In addition to the above, when purchasing roofing material in the form of profiled panels, you should decide on:

1. A type of insulation. If there are no restrictions on fire safety, then it is more advisable to purchase sandwich panels with an insulating layer of expanded polystyrene, which are cheaper, although they are not inferior to products with mineral wool filler in terms of durability, resistance to mechanical and chemical influences, and also in terms of the degree of sound insulation. With strict requirements for fire protection, you need to opt for products with insulation made of extruded polystyrene foam or mineral wool, which are more resistant to fire and have good heat and sound insulation, but have a high water absorption coefficient, which is why they require additional protection against moisture penetration from the outside and the accumulation of condensate …

   

   Sandwich panels with expanded polystyrene filler are cheaper, but easily ignite, therefore, with strict fire safety requirements, it is recommended to purchase products with mineral wool insulation

2. Panel dimensions. The standard dimensions of products are 1 m wide and up to 16 m long with a thickness of 0.04 to 0.16 m. Usually, the meter width is adhered to even with an individual order, since it is the most rational for laying. But the length and thickness of the panels is selected based on the parameters and geometry of the roof, storage and delivery conditions, as well as the financial capabilities of the developer.

3. Shade of polymer coating. It all depends on the personal preferences of the owners. The color of the panels is selected according to the RAL scale, taking into account the light reflectance, the architectural appearance of the building, its style orientation and the decorative cladding of the facade.

   

   The color of the roofing sandwich panels is selected according to the RAL scale, taking into account the coefficient of light reflection and light absorption, so that the covering exactly matches the decorative design of the entire area

4. The type of lock and the presence of an anti-capillary effect, which makes it possible to do without sealing elements when arranging the roof in almost all climatic zones.

Leading manufacturers of roof sandwich panels

The best manufacturer of roofing sandwich panels is the Kraft SPAN company (St. Petersburg), which, in addition to standard roofing and facade products, also produces energy-saving and acoustic panels. The products of other large enterprises are also in demand:

• LLC TSP-Panel;
• plant "Lissant";
• JSC "Teplant";
• GC "Vesta Park";
• companies "Stroypanel", "Metal Profile", "Technostil" and others.

Sandwich panels of all these manufacturers are certified in the GOST R system and comply with TU 5284-001-87396920-2014 and 5284-002-87396920-2014, and the fasteners comply with the requirements of GOST 1147-80. Product certification confirms its high quality, fire safety and hygiene.

Video: testing the strength of products from renowned manufacturers

Of course, the arrangement of a sandwich slab roof is associated with certain risks, and at all stages of construction. But we'll talk about this a little later. In the meantime, let's look at what this roofing sandwich consists of and how to use it correctly to get a really beautiful solid roof, and not a bunch of problems.

Sandwich panel roofing

An important point when arranging a roof is laying a roofing cake. The use of profiled panels greatly simplifies this process, since the panels themselves are complete structural products, ready for installation. They consist of:

• upper and lower layers of polymer-coated thin sheet coiled steel;
• protective transparent film;
• trapezoidal polystyrene foam inserts in the ribs:
• labyrinth lock connection, which ensures reliable tightness of the joints and, as a result, dryness of the insulation;
• a two-component polyurethane adhesive layer with high adhesion;

• mineral wool lamellas based on basalt fiber or expanded polystyrene.

  

  The use of sandwich panels in normal climatic conditions does not require the laying of additional insulating layers, so they are laid directly on the roof frame

In standard sandwich panels there are no hydro and vapor control layers. Their functions are transferred to the castle connection. Of course, this significantly reduces the cost of construction, but it is not always effective, especially in climatic zones with high humidity, severe frosts and heavy snowfalls. In such regions, it is more expedient to use sandwich systems of element-by-element assembly based on a cassette profile, laid along or across the rafters, with a depth corresponding to the thickness of the insulation, but not less than 100 mm.

In regions with high humidity, it is recommended to use sandwich panels of element assembly based on a cassette profile

To install additional thermal insulation, use Z-girders with a thickness of 2 mm. An increase in the layer of insulation, of course, will lead to an increase in the cost of the roofing structure, but it will pay off for long years of trouble-free operation of the roof.

It is advisable to make additional laying of insulation when installing roofing sandwich panels in regions with severe winters and heavy snowfalls

Video: the pros and cons of roofing panels - which ones to choose

Sandwich roof elements

A sandwich roof is traditionally composed of two parts:

1. The bearing block is a rafter system that can be made of metal or wood. This is a frame that receives loads directly from the roof and transfers them to the walls and foundation. The rafter system determines the shape of the roof and its strength characteristics, so it is needless to say that when calculating it, you need to avoid flaws and shortcomings that will lead to a sharp reduction in the service life of the entire roofing structure.

   

   The rafter system for laying sandwich panels can be wooden or metal, but with the correct pitch of rafters and battens or purlins

2. The enclosing block, which includes the roofing cake with all its layers, as well as additional and forming parts - cornice, end and ridge strips, ventilation and drainage systems, fasteners, seals, etc.

   

   Additional elements are part of the roofing system, which give it a finished aesthetic appearance and protect the most vulnerable spots of the roof from destruction

The construction of a sandwich panel roof is challenging despite their versatility. Here you need an accurate calculation at all stages, from the choice of materials to direct installation. When purchasing sandwich panels of well-known brands, you can order a complete set of roofing elements in order to insure against inconsistencies or inconsistencies during installation, as well as to significantly facilitate and speed up roofing work.

Video: self-tapping screws for sandwich panels

Installation of a sandwich panel roof

The sandwich panel roofing system can be erected in record time with minimal labor costs. The following tools are required for installation work:

• electric drill with high speed or screwdriver;
• roofing screws with sealing washers suitable in length for the selected products;
• short self-tapping screws for fastening additional and forming roofing elements;
• corner, tape measure, plumb line, level, pliers and side cutters;

• reciprocating saw or hacksaw, plunger gun and jigsaw.

  

  When preparing for the installation of roof panels, it is necessary to check the presence and normal functioning of all the necessary tools

Video: how to cut sandwich panels

In addition, at the construction site you will need a hoist, preferably with a vacuum gripper. Sometimes, in order to save money, it is suggested to use hand or homemade grips. Such a proposal is permissible when the roof of a small and low structure is being set up, for example, a garage, but not a residential building, and even with a complex roof shape. First, lifting heavy structures to a decent height is unsafe. Is it worth the risk? And secondly, factory lifting mechanisms with a vacuum gripper have a wide angle of rotation, which makes it possible to lay the panels in any direction and thereby not only speed up installation work, but also avoid deformation of the sandwich plates.

Work order:

1. Preparatory stage. It starts with cleaning the construction site from debris and installing clean pallets for storing sandwich panels. Then the numbers of colors and shades of the delivered products are checked. They must match on all packs. This is followed by the study of the documentation (instructions) from the supplier, in which two layouts are given - the specification of products and the location of panels with diagrams for each attachment point. Only after fully understanding the instructions, you can proceed with the installation of sandwich panels.

   

   Sandwich panels at the construction site must be stored on special pallets covered with durable plastic wrap to avoid getting wet and damage to the products

2. Panel cutting. The key requirement here is maintaining the verticality of the cut. Above and below, cut lines are drawn and checked for coincidence. First, they cut on one side, and then on the other. For small volumes, grinding scissors are used, but in no case plasma cutting or a grinder.

   

   To trim panels, it is necessary to use cold cutting using a circular saw or jigsaw, and for small volumes, you can do with metal scissors, but subject to separate cutting of each metal surface

3. Lifting sandwich slabs to the roof. It is produced using a lifting device with vacuum suction cups. First, it is necessary to remove the protective film in the places where the grippers are installed. Sometimes, instead of vacuum grippers, clamps with felt or rubber gaskets are used.

   

   Instead of vacuum clamps, clamps with soft gaskets can be used to lift roof panels onto the roof

4. Laying the first panel. It is placed on supporting structures, clearly maintaining the slope of the roof. This is very important for the quality of installation work in general. A seal is preliminarily laid on the bearing supports. If necessary, align the position of the first panel and fix it with self-tapping screws according to the instructions. Only after that the slings are removed. In this case, bending and falling of the panels, as well as laying them on the closing plane, are unacceptable.

   

   The roofing panels are laid in accordance with the slope of the roof, while before laying it is recommended to lay a self-adhesive sealing tape along the supporting supports

5. Installation of the remaining panels. They are laid with an overlap in accordance with the manufacturer's recommendation. To seal the transverse joints, butyl rubber sealant is applied to the upper skin of the lower panel, having previously fixed it to the frame. The upper panel is cut from the end side by the amount of overlap, removing the excess insulation and the lower steel sheathing, and then connect it to the lower panel and fix it with self-tapping screws.

   

   For better sealing of the transverse seam, a butyl rubber sealant is applied to the upper skin of the lower panel along the overlap width or a sealing tape is laid

6. Longitudinal panel connection. After laying the first and second rows, they proceed to the joint and sealing of the joints of adjacent roofing elements, again, strictly following the instructions.

   

   To ensure a reliable longitudinal connection of the panels, a silicone sealant is placed into the groove of the locks from the inside

7. Installation of additional and forming roofing elements. After the end of all work, completely remove the protective film.

Table: dimensions of transverse overlaps depending on the slope of the slopes

Roof slope		Recommended length of overlap, mm
in degrees	in percents
5-10	9-18	300
10–20	18–36	200

Video: installation of roof sandwich profiles

Installation features

1. Fasteners are screwed in strictly at an angle of 90º and placed at a distance of at least 50 mm from the edge of the plates.
2. Before installation, remove the protective film only from the bottom of the panels. During installation, the top protective film is removed only at the attachment points, keeping the rest until the work is completed.

3. The ridges of the locks should fit snugly into the recesses of the subsequent panels. For better sealing of the joints, silicone (without acid reaction) or butyl rubber sealant is applied to the lock groove.

   

   The connection of sandwich plates is made with an overlap with overlapping corrugation, using the advantages of the Z-Lock, which, when properly installed, provides structural strength and reliable protection against leaks

4. To avoid deformation of the locks and skewing of the panels, two grippers are used for lifting.
5. When cutting or drilling, you must constantly clean the connecting locks and the panel itself from dust and metal shavings.
6. Sandwich panels are laid in certain weather conditions - at temperatures from -15 to +30 ºC. Do not install during rain, snow, thick fog and gusty wind.

7. All roofing work is performed in soft shoes so as not to damage the polymer coating of the panels.

   

   Installation of roof sandwich panels should be carried out in soft shoes, on roofs with an inclination angle of at least 5 degrees, using special self-tapping screws, placed strictly vertically, and non-acidic sealant

Errors when arranging a sandwich panel roof

I must say right away that sandwich products do not forgive mistakes. With proper installation, following the instructions, using high-quality materials and components, it is quite possible to build a roof from sandwich panels on your own. But the risks at each stage of work are also quite high. Let's take a closer look at which of them you will have to face:

1. At the design stage. The most common mistake at this stage is that products are often chosen according to the principle of "liked and inexpensive", not paying attention to the strength characteristics of the panels and not linking them to the climatic loads of a particular area. In addition, errors can be made when calculating the pitch of the battens, girders and crossbars, the distribution of spatial stiffness, ensuring the proper level of ventilation, etc., which can lead to delamination of the upper and lower cladding of the panels, depressurization of the roof, wetting of insulation, leaks and destruction …

   

   Errors at the design stage inevitably lead to the destruction of the coating, requiring the replacement of sandwich profiles

2. At the stage of choosing materials. These mistakes will negate even a great project and correct installation. The wrong choice of the length of the products or the color of the external cladding with a low reflectivity in the hot season will lead to uneven changes in the width and length of the products, as a result of which cracks will appear and entail a rapid destruction of the roofing as a whole.
3. At the stage of delivery and storage. As mentioned above, before installation, you need to prepare a storage area for the material and pallets for its storage. But often they do not do this, but unload the panels directly to the ground in the hope that the plastic wrap that covers the products will serve as reliable protection. But alas, it can break, it can be spoiled by stray animals or rodents, then the packs of material will end up on bare ground, under winds, snows and the scorching sun and become completely unusable.

4. During installation. The main mistakes, of course, are in violation of the standards - GOST 23407-78, SNiP 12-01-2004, GOST R 12.1.019-2009, SNiP 21-01-97, SNiP 12-03-2001, in deviation from the minimum allowable parameters when assembling load-bearing structures, non-observance of working conditions and organization, as well as incompetence of installers. For example, the absence or incorrect arrangement of expansion joints will lead to deterioration of the lock connection and a violation of its tightness, which is fraught with leaks in many places of the roof. In case of violation of the seam connection of sandwich profiles or improper fastening and the choice of self-tapping screws, the destruction of the structure will not only inevitably entail leaks, but also significantly reduce the wind resistance of the roofing, which can easily be blown off the roof by a gusty wind.

   

   Failure to comply with building codes and manufacturer's recommendations will negatively affect the tightness of the roofing and cause leaks.

Sandwich panels are a modern material that, like other progressive developments, gives a great chance for long-term roof operation. But every little thing is important here - from correct calculations at the design stage to the qualifications of performers. It is enough to take everything into account, and the sandwich-slab roof will reward its owners with reliability, strength, beauty and longevity.

Rules for the operation of sandwich-board roofs

Subject to the installation conditions, the roof made of sandwich panels does not require special care. It is enough only:

• remove the protective film over the entire roof no later than two weeks after the completion of installation work;
• periodically clean the gutters and the roof from debris, using soft improvised means, and wipe the places of strong pollution with soapy water and rinse with clean water;

• at least twice a year, inspect the roof and monitor the integrity of the coating, the reliability of the fasteners (if necessary, tighten it), seal the joints, and if damage is found, timely carry out repair and restoration work.

  

  The sandwich panel roof does not require special care, but it must be kept clean and inspected in a timely manner

Service life of sandwich panels

Several factors simultaneously influence the viability of a profiled slab roof:

• product manufacturing technology;
• the quality of the raw materials used in the manufacture - filler, facing, glue;
• correct packaging, transportation, warehousing and storage.

The lining of the panels takes on all the negative manifestations of the environment - climatic loads, temperature drops, ultraviolet radiation and high humidity. Therefore, the protection of the insulation, the aesthetic appeal of the roof and the service life of the covering flooring depend on its quality.

Unfortunately, many manufacturers, in pursuit of profit, lower the cost of production by using thinner metal, which, naturally, negatively affects the quality of the product. Such a coating is short-lived and vulnerable to deformation, and dents and scratches very quickly lead to premature metal corrosion. Therefore, when choosing panels, it is very important to pay attention to the thickness of the steel used - it must be at least 0.5 mm - and the presence of a protective polyester layer.

High-quality and ready-to-install sandwich panels can only be obtained in the factory. Manual production, which is often advertised on the web, is money wasted. The price is lower, but there is no quality either, since there is no automated line, there is no possibility of using the latest developments, there is no quality control at all stages of production - from the purchase of raw materials to storage and shipment of products.

High-quality roofing sandwich panels are manufactured only in the factory with proper quality control at each stage of production

To increase the service life of sandwich structures will help:

• purchase of products from a trusted and reliable supplier;
• compliance with the terms of delivery and storage of panels;
• compliance with all standards and recommendations of the manufacturer.

Sandwich roof repair

If, during operation, damage to the polymer layer of the plates was found, it should be started as soon as possible to restore it by painting. To do this, you need to choose the appropriate paint, starting not only from the color and shade of the panels, but also from the type of protective layer.

Depending on the depth of damage, the paint is applied in one or two layers. A thin soft brush is used to finish a small area, and pneumatic spray is used to paint the entire panel. Before painting, you need to remove the rust, if it has had time to form, gently sand the damaged area by hand, apply a primer with a deep scratch, treat the surface with a rust converter and degrease with white spirit.

Reviews of sandwich roof panels

Choosing sandwich panels as a roof covering, you get an excellent opportunity not only to shorten the construction time, but also to significantly save on construction. As practice has shown, a roof made of pre-fabricated profiled products is 20-30% cheaper for developers than traditional coatings. The main thing is that the structure is correctly designed and installed. Then it will retain all its advantages for many years and will delight you with its reliability and extraordinary beauty.