Sandwich-panel

History and Major Development

Composite cladding systems have been in extensively used for a considerable time, specially for
the manufacture of vehicles such as trains and planes but the development of advanced sandwich
panels for cladding buildings first began in the 1930’s.
Sandwich panel construction techniques have experienced considerable development in the last 40 years.
Previously, sandwich panels were considered products suitable only for functional constructions and
industrial buildings. However, their good insulation characteristics, their versatility, quality and appealing
visual appearance, have resulted in a growing and widespread use of the panels across a huge variety of
buildings.
Modern sandwich panels can be flat, bent, curved and joined together in an almost unlimited range of
configurations and are available in a wide variety of colours, finishes, thicknesses, edge details and profiles
depending on performance requirements. They are generally fabricated off-site and are particularly useful
where a high-performance cladding is required, with good structural strength, a high level of insulation and
low weight.

Introduction
Sandwich panels (sometimes referred to as composite panels or structural
insulating panels (SIP)) consist of two layers of a rigid material bonded to
either side of a lightweight core. The three components act together as
a composite; that is, the combination of the characteristics of
the components results in better performance than would be possible if
they were acting alone.
A sandwich panel is any structure made of three layers: a low-density core and a thin skin-layer bonded to
each side. Sandwich panels are used in applications where a combination of high structural rigidity and low
weight is required.
The structural functionality of a sandwich panel is similar the classic I-
beam, where two face sheets primarily resist the in-plane and lateral
bending loads (similar to flanges of an I- beam), while the core material
mainly resists the shear loads (similar to the web of an I-beam). The idea is
to use a light/soft but thick layer for the core and strong but thin layers for
face sheets. This result in increasing the overall thickness of the panel
which often improves the structural attributes like bending stiffness, and
maintains or even reduces the weight.
The lightweight core keeps the two faces in the correct position, resists shear forces, and provides insulation,
while the two faces provide durability, weather and impact resistance, and resist in-
plane forces of tension and compression.
A sandwich panel is any structure made of three layers, the two thin face sheets which are made up of
Carbon, Glass or Kevlar (synthetic fibre). The thick core materials made up of Foam, honeycomb or balsa etc is
present between these two thin face sheets. These thre components are joined with adhesive such as liquid
resin, adhesive film, foaming adhesives etc.
A sandwich-structured composite is a special class of composite materials that is fabricated by attaching two
thin but stiff skins to a lightweight but thick core. The core material is normally low strength material, but its
higher thickness provides the sandwich composite with high bending stiffness with overall low density.
Open and closed cell structured foals like polyethersulfone, polyurethane, polyethylene or polystyrene foams,
balsa wood, syntactic foams, and honeycombs are commonly used core materials. Sometimes, the
honeycomb structure is filled with other foams for added strength. Open- and closed-cell metal foam can also
be used as core materials.
Laminates of glass or carbon fiber-reinforced thermostat or mainly thermoset polymers (unsaturated
polyesters, epoxies) are widely used as skin materials. Sheet metal is also used as skin material in some cases.
Sandwich panels are a very efficient way of providing high bending stiffness at low weight. The stiff, strong
facing skins carry the bending loads, while the core resists shear loads. The principle is the same as a
traditional ‘I’ beam
The stiff strong facing skins carry the bending loads, while the core resists shear loads.
Total deflection = bending + shear
Bending depends on the skin properties; shear depends on the core. (Bending stiffness can be enhanced by
increasing the thickness of panel). Bending stiffness is increased by making beams or panel thicker with
sandwich construction this can be achieved with very little increase in weight

Types of Sandwich Panels

There are three types of sandwich panels
 3D-printed biopolymer panels
 Structural Insulated Panels (SIP)
 Aluminum Composite Panels (ACP)

3D-printed biopolymer panels

Due to the ability of 3D printer to fabricate complex sandwich panels there has recently been a flourishing of
research in this area covering energy absorption, natural fibre, with continuous synthetic fibers, and for
vibration. The promise of this technology is for new geometric complexities in sandwich panels not possible
with other fabrication processes.

Structural Insulated Panel (SIP)

A structural insulated panel, or structural insulating panel, (SIP), is a form of sandwich panel used in
the construction industry.
SIP is a sandwich structured composite, consisting of an insulating layer of rigid core sandwiched between two
layers of structural board, used as a building material. The board can be sheet metal, plywood,
cement, magnesium oxide board (MgO) or oriented strand board (OSB), and the core can either be
expanded polystyrene foam (EPS), extruded polystyrene foam (XPS), polyisocyanurate foam, polyurethane
foam, or be composite honeycomb (HSC).
SIPs share the same structural properties as an I-beam or I-column. The rigid insulation core of the SIP acts as
a web, while the sheathing fulfills the function of the flanges. SIPs combine several components of
conventional building, such as studs and joists, insulation, vapor barrier and air barrier. They can be used for
many different applications, such as exterior wall, roof, floor and foundation systems.
The production of structural insulated panel started in 1940’s (1947), when different companies developed
and tested corrugated paperboard cores with various skin materials of plywood, tempered hardboard and
treated paperboard. The building was dismantled in 1978 and most of the panels retained their original
strength with the exception of paperboard which is unsuited to outdoor exposure. Panels consisting of
polystyrene core and paper overlaid with plywood skins were used in a building in 1967 and the panels have
performed well to the present day.
Structural Board and core material of structural insulated panel
SIP is a sandwich structured composite, consisting of an insulating layer of rigid core sandwiched between two
layers of structural board, used as a building material. The board can be sheet metal, plywood,
cement, magnesium oxide board (MgO) or oriented strand board (OSB), and the core can either be
expanded polystyrene foam (EPS), extruded polystyrene foam (XPS), polyisocyanurate foam, polyurethane
foam, or be composite honeycomb (HSC).
SIPs are most commonly made of OSB panels sandwiched around a foam core made of expanded polystyrene
(EPS), extruded polystyrene (XPS) or rigid polyurethane foam. Other materials can be used in replacement of
OSB, such as plywood, pressure-treated plywood for below-grade foundation walls, steel, aluminum, cement
board such as Hardiebacker, and even exotic materials like stainless steel, fiber-reinforced plastic, and
magnesium oxide. Some SIPs use fiber-cement or plywood sheets for the panels, and agricultural fiber, such
as wheat straw, for the core.
The third component in SIPs is the spline or connector piece between SIP panels. Dimensional lumber is
commonly used but creates thermal bridging and lowers insulation values. To maintain higher insulation
values through the spline, manufacturers use Insulated Lumber, Composite Splines, Mechanical Locks,
Overlapping OSB Panels, or other creative methods. Depending on the method selected, other advantages
such as full nailing surfaces or increased structural strength may become available.

Manufacturing Structural Insulated Panel (SIP)

SIP's are most often manufactured in a traditional factory. Processing equipment is used to regulate pressures
and heat in a uniform and consistent manner. There are two main processing methods which correspond to
the materials used for the SIP Panel core.
Manufacturing Structural Insulated Panel (SIP) with Polystyrene: When manufacturing a panel with a
polystyrene core both pressure and heat are required to ensure the bonding glue has penetrated and set
completely. Although a number of variations exist, in general, the foam core is first covered with an adhesive
and the skin is set in place. The three pieces are set into a large clamping device and pressure and heat are
applied. The three pieces must stay in the clamping device until the glue has cured.
Manufacturing Structural Insulated Panel (SIP) using polyurethane: When manufacturing a panel with a
polyurethane core pressure and heat are both generated from the expansion of the foam during the foaming
process. The skins are set in a large clamping device which functions as a mold. The skins must be held apart
from each other to allow the liquid polyurethane materials to flow into the device. Once in the device, the
foam begins to rise. The mold/press is generally configured to withstand the heat and the pressures
generated from the chemical foaming. The SIP Panel is left in the mold/press to cure slightly and when
removed will continue to cure for several days.
Until recently, both of these processes required a factory setting. However, recent advancements have
presented an alternative with SIP Panel processing equipment that allows SIP Panels to be manufactured on
the job-site. This is welcome news for builders in developing countries where the technology may be best
suited to reduce greenhouse emissions and improve sustainability in housing but are unavailable.

Benefits of Structural Insulated Panel

A well-built home using SIPs will have a tighter building envelope and the walls will have higher insulating
properties, which leads to fewer draughts and a decrease in operating costs. Also, due to the standardized
and all-in-one nature of SIPs, construction time can be less than for a frame home, as well as requiring fewer
trades’ people. The panels can be used as floor, wall, and roof, with the use of the panels as floors being of
particular benefit when used above an uninsulated space below. As a result, the total life-cycle cost of a SIP-
constructed building will, in general, be lower than for a conventional framed one—by as much as 40%.
Whether the total construction cost (materials and labor) is lower than for conventional framing appears to
depend on the circumstances, including local labor conditions and the degree to which the building design is
optimized for one or the other technology.

Aluminum composite panels (ACP)

Aluminium composite panels (ACP), made of aluminium composite material (ACM), are flat panels consisting
of two thin coil-coated aluminium sheets bonded to a non-aluminium core. ACPs are frequently used for
external cladding or facades of buildings, insulation, and signage.
ACP is mainly used for external and internal architectural cladding or partitions, false ceilings, signage,
machine coverings, container construction, etc. Applications of ACP are not limited to external building
cladding, but can also be used in any form of cladding such as partitions, false ceilings, etc. ACP is also widely
used within the signage industry as an alternative to heavier, more expensive substrates.
ACP has been used as a light-weight but very sturdy material in construction, particularly for transient
structures like trade show booths and similar temporary elements. It has recently also been adopted as a
backing material for mounting fine art photography, often with an acrylic finish. ACP material has been used
in famous structures as Spaceship Earth, VanDusen Botanical Garden, and the Leipzig branch of the German
National Library.
These structures made optimal use of ACP through its cost, durability, and efficiency. Its flexibility, low weight,
and easy forming and processing allow for innovative design with increased rigidity and durability. Where the
core material is flammable, the usage must be considered. The standard ACP core is polyethylene (PE)
or polyurethane (PU). These materials do not have good fire-resistant (FR) properties unless specially treated
and are therefore not generally suitable as a building material for dwellings; several jurisdictions have banned
their use completely.
The aluminium sheets can be coated with polyvinylidene fluoride (PVDF), fluoropolymer resins (FEVE), or
polyester paint. Aluminium can be painted in any kind of colour, and ACPs are produced in a wide range of
metallic and non-metallic colours as well as patterns that imitate other materials, such as wood or marble.
The core is commonly low-density polyethylene (PE), or a mix of low-density polyethylene and mineral
material to exhibit fire retardant properties.

Why we select Aluminum composite panel 

Multiple colors
 Available in almost 40 different colors  Satisfy Aesthetic taste
Light weight
 ACP is 2.5 pounds per square foot
Sustainable
 85% recycled aluminum material is used
Fire Resistant

Production process of Aluminum composite panel

There are many production process of aluminum composite sheet. According to the composite process of
plastic core panels and two-sided aluminum panels, it can be divided into cold composite method and thermal
composite method; it can also be divided into continuous composite method and intermittent composite
method
The production process of aluminum composite sheet is first to clean the aluminum coil. In the production of
aluminum coils, due to the needs of the process, the surface is coated with lubricants and anti-oxidants, and
some dirt will be attached during transportation, which will affect its adhesion and must be cleaned.
After cleaning and chemical treatment of the aluminum coil, a dense chemical protective film is formed on the
surface; this chemical film can improve the oxidation resistance of the aluminum coil and prolong the life of
the paint film.
 General process of cleaning Coating of required paint

The panels of the exterior aluminum composite sheet are coated with two layers of paint and primer. The
topcoat of the façade is a highly weather-resistant fluorocarbon resin coating, namely polyvinylidene fluoride
(PVDF). Its excellent UV resistance and environmental pollution keep the surface of the protected aluminum
coil beautiful.
The surface of the aluminum composite panel can have not only the color of the metal, but also the beautiful
marble pattern and color. Fluorocarbon coatings are usually applied to aluminum coils by roll coating and
then baked at elevated temperatures to dry them.
The equipment is continuously produced, first primed, then top coated, and finally coated with a surface
varnish. The total thickness of the three-layer paint is 30μm. Each layer of paint needs to be baked at 200 °C
for about 60 seconds to dry it.
After the oven is baked, it is quickly cooled by an air cooler. The interior wall paint can be made of epoxy
resin, polyester resin and acrylic resin. After the primer, topcoat, and surface varnish are coated, immediately
apply a PE protective film on the surface of the coating to avoid scratching the surface coating during
subsequent processing, transportation, and installation.
The protective film is self-adhesive and can be removed after installation. The aluminum coil coated with
fluorocarbon resin can enter the process of compounding with the plastic core material. The plastic core
material is also essentially three layers, with PE plastic in the middle and adhesive on both sides. PE sheets
and adhesives can be produced separately or by three-layer coextrusion.
Firstly, the three-layer co-extruded sheet with the structure of adhesive is produced, and then combined with
the upper and lower aluminum sheets. The aluminum composite sheet has 0.15mm thick aluminum panel on
both sides, and the core layer is 3～5mm, total thickness is 4~6mm. Finally, it is cut into 1220mm×2440mm
specifications.
Note: basically there is a three step process for production of Aluminum composite panel which are
 Cleaning of Aluminum Composite Sheet before Processing
 Fluorocarbon Coati ng Aluminum Composite Sheet
 Protecti ve Film to Protect Aluminum Composite Sheet

Applications of Aluminum composite panel

The Aluminum Composite Panel is one of the most preferred construction materials when it comes to
implementing modern day architectural and interior designs. According to this evergrowing requirement,
there are now several units engaged in aluminum composite panel manufacturing. These united are linked for
manufacturing of aluminum composite panels that have many applications in different fields including
cladding, partitions, false ceilings and signages.
Cladding: Due to its high durability, and flexibility the ACP can be used for cladding in the interior as well as
external architecture. ACP can withstand rigorous wear and tear and thus modern-day construction
is cladded with the Aluminum Composite Panel; this extends the lifespan of the structure and façade. Also
since aluminum is a lightweight metal, it’s easy to handle and install thus increasing the likeability amongst
constructors.
Partitions: Most of the office structures these days intend to use the available floor space to optimum levels.
To achieve this, they make internal partitions forming split spaces. The material which is increasingly being
used for making these partitions is ACP Panels. Again owing to the ease of handling and maintenance, ACP is
one of the perfect materials for making partitions; In case if you do away with the idea of
having partitions and want to increase the space, it can be easily done; you just need to unscrew the rivets or
screws and move them to wherever you might want. ACP is also cost effective than most of the variants and
in view of all these advantages, it is widely used in the construction world.
False Ceilings: False ceilings not only enhance the beauty appeal of interior designs but also help in
temperature control. Hence, the ACP panels are ideal for this application since they are comprised of
polyethylene core that acts as a heat-proofing agent for regulating the heat. The aluminum sheet on the
outside offers durability that increases the lifespan of the material when compared to other materials which
are available for similar purposes.
Signage (commercial or public display signs): ACPs can be used to make versatile outdoor signages. As the
signages and hoardings are used for displaying outside where it has to withstand the temperature changes
and impact of harsh weather, ACP is the ideal material to cater this application.

Important features of Sandwich panels

 Hidden self tapping screws for aesthetic  Rigidity
appeal.  Reliable robust mechanical
 Fast installation and ease of handling. performance
 Crane assembly therefore no support  Thermal, fire and sound insulation.
required  Air tightness
 No thermal bridges and good thermal  Strong and durability
insulation  Low maintenance / cleaning
 Leak proof and great energy saver. requirements.
 Various designs/vivid colors  Low capital cost and low lifetime costs
 Light weight. Space Saving  Chemical and biological resistance
 Panels can be installed horizontally or  Weather resistance.
vertically  Dimensional stability.

Sandwich Panel construction

Material Property Honeycomb Advantages

Foam includes Relatively low crush strength and Excellent crush strength and
 polyvinyl chloride stiffness Increasing stress with stiffness
 polymethacrylimide increasing strain Friable Limited Constant crush strength
 polyurethane strength Fatigue Cannot be Structural integrity Exceptionally
 polystyrene formed around curvatures high strengths available
 phenolic High fatigue resistance
 polyethersulfone

Wood-based includes
 plywood Very heavy density Excellent strength-to-weight ratio
 balsa Subject to moisture degradation Excellent moisture resistance
 particleboard Flammable Self-extinguishing, low smoke
versions available
Manufacturing of Sandwich Structure
Sandwich Panel construction processing methods
 Autoclave  Vacuum bag  Press
Heat pressing: Heated Press, generally used for the production of flat
board or simple preformed panels. Ideally the panels should be
assembled ready for curing as a single shot process. This method is
suitable for metallic and prepreg (pre-impregnated) facing skins.
Alternatively prepreg facing skin materials may be pre-cured by using a
press, and subsequently bonding with a film adhesive layer
Vacuum Bag: Vacuum Bag Processing, used for curved and complex form
panels. The component should be assembled for cure as a single shot
process; the necessary consolidation is obtained using a vacuum. This can
be cured in an oven, and additional pressure can be applied if an autoclave
is used. This method is suitable for items with prepreg or metallic facing
skins. When flexible honeycomb core and film adhesives are used complex
items may be produced
Autoclave Processing: It is Mature and standardized method for
composites manufacturing. It has controlled thermal Program, high
pressure environment. There is High fiber volume fraction and low
void content hence it gives maximum strength. It has largest
autoclave size (30’ x 76’). It is expected to be 20% more fuel efficient
than Al jets with multiple other attributes
Building types that commonly feature sandwich panels include
 Temporary buildings  Shopping centers
 Storage buildings  Sports facilities
 Clean rooms  Transport buildings
 Agricultural buildings
 Industrial buildings and processing plants
Applications of Sandwich Panels
Industrial Buildings
 Roof  Partitions
 Walls  False Ceiling
Commercial Buildings
 Elevation  Partitions
 Side wall paneling

Warehouses / Godown
 Roof  Partitions
 Walls
Cold Stores / Blast Freezers
 Insulated Ceiling  Insulated Walls
Farm House
 Decorative Siding Panels
Pharmaceutical Manufacturing Units
 Clean Rooms  Return-Air Boxing
 Walk-on False Ceiling
Air Handling Units
 Insulated Panels
Poultry Farm
 Ceiling  Walls
Dairy Industry
 Ceiling  Walls
Malls / Departmental Stores
 Facades  Walls
 Partition