We make a sandwich panel with our own hands: Step-by-step instructions + Video

We make a sandwich panel with our own hands: Step-by-step instructions + Video More and more craftsmen are interested in the fast method of making buildings from sandwich panels. And of course, the question immediately arises: can this panel be made by hand?

[contents] We make a sandwich panel with our own hands: Step-by-step instructions + Video

A sandwich panel is a building structure, usually consisting of three main layers, two of which are enclosing, and the third is internal, which plays the role of thermal insulation material. The sandwich panel manufacturing technology contains a number of difficulties. But more on that later, first let's figure out what building materials a sandwich panel can be made of.

Types of thermal insulation materials

Below we will consider in detail the materials that are used to make sandwich panels with our own hands.

  • Mineral wool is the most common material in the manufacture of sandwich panels. This material is non-flammable and does not cake over time; We make a sandwich panel with our own hands: Step-by-step instructions + Video
  • Polyurethane foam is used in conditions of high humidity ... Prolonged exposure to water will not lead to the development of mold and pathogenic fungi.

    This material is quite tough and additionally reinforces the structure of the sandwich panel;

  • Expanded polystyrene is rarely used, since this material has a low fire resistance. But this material also has undeniable advantages - an insignificant specific weight and an affordable cost.

Types of enclosing materials for sandwich panels

The following materials are used to make the enclosing layers of sandwich panels:

  • Galvanized steel sheet;
  • Aluminum sheet;
  • Plastic;
  • Fiberboard or wood. We make a sandwich panel with our own hands: Step-by-step instructions + Video

Of all the materials presented above, the strongest and most durable is galvanized steel. But, due to the high specific gravity of this material, sandwich panels with this shell are heavy.

How to hold the layers of sandwich panels together?

We forgot to mention that the composition of sandwich panels also includes polyurethane glue. One-component polyurethane adhesive hardens in air upon prolonged contact with moisture contained in it. Two-component polyurethane adhesive hardens due to a chemical reaction that occurs between the polyol and isocyanate components. We make a sandwich panel with our own hands: Step-by-step instructions + Video

These adhesives have specific requirements : after curing, they should not lose their original properties during the entire period of use of the sandwich panels. Many panel manufacturers claim that their products have a lifespan of at least 50 years.

Therefore, durability is the main requirement put forward by the adhesive. In addition, polyurethane glue must be harmless to human health. There should be no harmful chemical components in its base. And of course, the glue must be moisture resistant and resistant to temperature extremes.

Two-component adhesive is used for prefabricated sandwich panels in automatic mode.

And one-component glue is ideal for semi-automatic or manual production. This can explain its wide popularity.

Sandwich panel manufacturing technology

The sandwich panel manufacturing process consists of the following operations: We make a sandwich panel with our own hands: Step-by-step instructions + Video

  1. Installing the first shell sheet on a flat, clean surface;
  2. Applying polyurethane glue;
  3. Installing an insulation layer over glue;
  4. Applying polyurethane glue to the insulation layer;
  5. Installing the second sheet of the panel;
  6. Holding the entire structure under pressure until the layers are completely dry.

The complexity of the multi-layer construction of panels lies in the characteristics of the glue. Usually, when glue is applied to the sheets, it foams a lot.

And to give the desired thickness to the adhesive layer, the assembled sandwich panels are compressed under a certain pressure.

Considering the dimensions of the product, you need a special press to create the required pressure. He will provide the necessary pressure for the manufacture and installation of sandwich panels with his own hands. The panels are kept under pressure for two to five hours. We make a sandwich panel with our own hands: Step-by-step instructions + Video

In addition to foaming the glue, its curing rate is very high - if you slow down the process, the glue mass will begin to polymerize.

And the hardened adhesive layer will not react to any solvent. And it will only be possible to remove it mechanically. That is why the entire installation and manufacture of sandwich panels should be carried out quickly enough. And alone, you are unlikely to be able to assemble the panels, so find yourself a reliable and quick assistant.

Due to the pre-fabricated structures made of sandwich panels, this material is becoming more and more popular.

And you can assemble a country house in just a few weeks! But all sandwich panels have one main disadvantage - they are short-lived. Their service life is approximately 50 years.

Technological order of work

We make a sandwich panel with our own hands: Step-by-step instructions + Video Before assembling wall sandwich panels with your own hands , prepare all the necessary materials for bonding in advance. Inspect the sheets of the future shell and the insulation layer. If necessary, clean them of various debris and dirt.

Then you can start producing sandwich panels.

Place the first sheet of shell on the table. Spread the polyurethane adhesive evenly over the entire area. Apply it with a spray gun or rubber trowel.

And don't forget about the quick curing of the glue.

After applying the glue, place an insulation layer on top. And also apply a layer of glue to its surface. Cover the insulation layer with the applied polyurethane glue with the second sheathing sheet. Put the first sheet of the next panel on the already assembled structure and repeat the whole process again.Next, transfer the package of several structures to a special press machine for the production of sandwich panels, and hold them until the glue is completely hardened.

Pro Tip: You can extend the life of one-part adhesive by simply reducing the humidity and temperature in the work area.

Special equipment for the production of sandwich panels

We make a sandwich panel with our own hands: Step-by-step instructions + Video In this case, you can use a vacuum pump. The technological process will be as follows: the sandwich panels are covered with an awning fabric, the edges of which are clamped. Next, use a hose and a vacuum pump to pump out all the air from under the awning. The holding time will be reduced to 40 minutes.

After this procedure, all sandwich panels should lie on a flat dry surface for 24 hours.

Connecting sandwich panels to each other

We make a sandwich panel with our own hands: Step-by-step instructions + Video As a rule, sandwich panels are connected between themselves in a special lock. In a sandwich panel factory, the locks are molded on a press during compression.

Manual presses, unfortunately, do not have this function. But there is a way out.

It is necessary to put a wooden beam from one end of the sandwich panel between the enclosing layers, which will protrude beyond the shell. And on the opposite side, cut the insulation layer by the size of the protrusion of the wooden bar. As a result, you will get a completely high-quality castle.

We hope that our article will help you in making sandwich panels with your own hands. We wish you good luck!

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