How to make a sandwich panel with your own hands: from corrugated sheets and OSB production

Recently, professional builders and home craftsmen have become interested in a quick method of constructing buildings using multilayer structures - sandwich panels. Naturally, the question arose: is it possible to make such a panel with your own hands?

Sandwich panel is a building structure consisting of three layers: two outer enclosing layers and one inner layer, which plays the role of a heat insulator. At first glance, this is the simplest design, so many people mistakenly believe that it can be made using a homemade method without any problems. In fact, the technical process of manufacturing a structure contains a number of nuances that can interfere with the work of a home craftsman. However, first things first. First, let's figure out what materials the sandwich panel structure is made from.

What is a sandwich panel

Sandwich panels are actively used in commercial construction.
The manufacturability of working with this material and the high speed of building assembly have an impact. This could be a warehouse, workshop, office building, etc. But in private housing construction, sandwich panels are still perceived as exotic. This is due to the inertial thinking of many developers who are accustomed to building the old fashioned way. Many manufacturers do not want to deal with small orders (a dozen or two panels), because... It is more profitable to sell sandwiches on an industrial scale.

First, let's briefly explain what a sandwich panel is.

The insulation in sandwiches can be based on polyurethane foam (PPU) or mineral wool - made from stone wool

Important: the heat insulator largely determines the scope of use of the sandwich panel. Polyurethane foam is not afraid of moisture, does not rot, does not become damp

Therefore, such sandwich panels are used in vegetable stores, refrigerators, places where wet processes are carried out - car washes, etc. Sandwich panels with a stone wool core, due to their high fire resistance, are most often used in the construction of shopping malls, i.e. in places with large crowds of people.

Another key difference between PPU sandwich panels and mineral wool sandwiches is a special tongue-and-groove lock. As a result, when joining the panels, a hermetically sealed connection is obtained and a closed thermal insulation loop is formed, which reduces heat loss in the building and simplifies installation.

Let's return to the story of Ansushkov.

Characteristics of purchased building materials

Manufacturers produce roofing and wall panels. The former are equipped with “overlapping” locks to improve the tightness of the joints, the latter – with “tenon/groove” connections and seam locks .

Standard panel dimensions:

• width – 1185 mm;
• length – 1-12 m;
• thickness – 50-300 mm.

Thickness plays a significant role when choosing thermal panels . The higher this indicator, the higher the energy-saving and strength characteristics of the material.

In regions with a temperate climate, when constructing houses and industrial buildings, sandwich panels with a thickness of 120 mm are used, in areas with harsh winters - 150 mm.

Sandwich panel garage

Another building that can be built from sandwich panels is a garage.

Approximate drawing of a garage

For the construction of a room, a screw foundation is also sufficient. But in this option it is impossible to build a viewing hole. If it is necessary, then the foundation must be strip.

Stages of garage construction:

1. They build the foundation using the chosen technology. The floor is concreted.
2. Concrete elements are covered with waterproofing materials - for example, two layers of roofing felt.
3. They make a garage frame from metal or wood, installing from the corners, checking the strength.
4. The wood is treated with antifungal agents and antiseptics.
5. Install vertical wall panels using self-tapping screws to fasten them at a distance of at least 5 cm from the edge, and, if necessary, metal plates.
6. A sealant is applied to the joints for waterproofing.
7. The seams between the panels are insulated and insulated - a base flashing and flashing are installed.
8. Doors are installed.

Installation of flashing and flashing

Hangars and warehouses are built in a similar way.

For the construction of such premises, used SIP panels are also used, if their operational characteristics are preserved.

Advantage

Special equipment is not as expensive as some people think. Such equipment pays for itself after approximately 500 units of panels are manufactured. Such equipment will operate with the participation of two people. To make a sandwich, the line takes no more than 10-12 minutes. You can use not only 5 minute glue, but also 10 minute glue. Thanks to this equipment, it is possible to produce sandwiches from boards such as Green Board GB3, as shown in the photo.

How to quickly and efficiently build a sauna from sandwich panels

When the house is built and the yard is landscaped, the question of building a bathhouse arises. Previously, not a single farmstead in Rus' could do without it. Today, shower cabins are more often preferred. But recently, interest in the original Russian pastime has been returning. After all, a bathhouse is an opportunity not only to wash, but also to relax with friends. For many, this is a whole ritual.

Having decided to build a bathhouse, you need to wisely choose a place, a method of heating the room, and learn about the characteristics of the soil at the site of the proposed construction. It is also necessary to decide what material the bathhouse will be built from.

Recently, a new material is increasingly being chosen - sandwich panels. It has its own advantages that ensure its popularity. The main thing is to use them correctly.

Choosing the best

Decide on the material from which you will make your own sandwich panels. You can use galvanized metal, some kind of particle board or natural wood. In any case, the sheets must be at least 6 millimeters thick.

And there are pros and cons to almost every option. For example, wood is quite easy to work with, but it also burns remarkably well. Plastic sandwich panels are good, but the raw material for their manufacture is not at all easy to obtain. Galvanized metal is expensive, but it does not rust and is not susceptible to fungi and rodents. However, special tools are needed to work with it.

Subtleties of assembling structures with your own hands

First you need to select materials for constructing the panels. They should be selected based on the degree of required thermal insulation and sound insulation of the building. It should be remembered that one-component and two-component adhesives have different shelf life.

All materials necessary for structures should be inspected before starting work. If dust or dirt is found, the materials must be cleaned. There will be no time for this directly during the assembly process.

Difficulties that may arise with glue when constructing a multi-faceted structure:

• when applied to a sheet, the glue foams strongly and needs to be compressed to give the required density and thickness;
• The glue hardens quickly and is not susceptible to solvents, which is why work should be done as quickly as possible.

To compress a sandwich panel, you must have a press with a pressure of 0.3 kilograms per square centimeter. The panel must be kept under pressure for two to four hours. If there is no press, you can use a vacuum pump, the effect of which is no more than 40 minutes. The method is as follows: the structures are covered with fabric and clamped, then the air is pumped out from under the fabric using a pump and hose. The products are placed on a smooth surface and left at rest for the next 24 hours. Without a doubt, factory equipment is much more convenient for quickly creating sandwich panels.

Hardened glue can only be removed mechanically or by heating it to 500 degrees, which cannot be done at home. Due to the required speed of work, the master will need a partner.

Compliance with safety regulations during production

Applying glue to the base for gluing insulation
As in any production process, safety precautions in the production of sandwich panels play an important and not the least role. So, all work should be carried out in a spacious, well-lit and ventilated room. All work with sandwich panels is carried out in special clothing with long sleeves, hands are protected with gloves, eyes, if necessary, with safety glasses.

How profitable is manual production of panels?

Manual production involves the following expense items:

• Glue;
• OSB-3 sheets;
• Expanded polystyrene;
• Vacuum pump for pumping air; So, using the example of 100 panels, we will need: 200 OSB-3 sheets for 500 rubles. each – 100 thousand rubles; from a consumption of 2 kg. glue (average price per kg. 150 rubles) per sheet - about 40 thousand rubles; vacuum pump - 15 thousand rubles; expanded polystyrene from a consumption of 0.5 cubic meters. m per panel - 90 thousand rubles. Compared to industrial panels, manual production allows you to save at least 100 thousand rubles, which is important in the current conditions. The cost of the slab is 1,300 rubles per square meter. In general, the price depends on the thickness of the slab.

Finished panels are tracked after production

Possible types of fastenings

The sandwich panel installation technology involves either horizontally oriented or vertical installation. It is unacceptable to combine these two methods for decorative purposes - however, this drawback is completely offset by the variety of color and texture solutions.

How to attach the cladding in this case - the sandwich panels are attached to the guide metal profile and the upper surface (ceiling); the elements also need to be connected to each other.

Partition mounting unit for vertical installation

The sealing compound is applied on both sides. The resulting structure from these manipulations eliminates cracks and perfectly protects the house from severe frosts. No special equipment or scaffolding is required, which reduces financial costs by a fairly large amount.

If the floor size exceeds six meters in height, then vertically oriented installation is complicated by the fact that the work cannot be carried out without the use of a crane and scaffolding. In addition, the upper parts of the vertical panels will tilt under their own weight, which will require additional strengthening. All this makes vertical installation in this case impractical.

Lifting wall panels can be done in several ways

To prevent the problems described above, it is recommended to use horizontal cladding. In this case, the individual wall panels will lie on top of the bottom, and the fastenings will be made to the columns of the frame.

The end result will be a beautiful continuous skin. For horizontal installation there is a mandatory requirement - the horizontal pitch of the frame should not be longer than 6 meters.

Key points for installation and fastening

After installing the frame, self-tapping screws are used for further work to fasten the panels.

The fastening elements must be tightened so that they protrude from the frame by 1-2 cm. It should also be mentioned that a sealing tape must be installed on the columns of the frame, which stretches along the entire height.

If installation without special equipment is difficult due to the height of the building, then basement substructures, lifts and grabs must be used.

Self-tapping screw used for fastening cladding panels

Using a lift, you can lift the material and then lay it on the same substructures. After this, it is necessary to check the wall being treated for the absence of differences, and the canvas itself for compliance with the building level.

The first panel must be carefully leveled, since the quality of all subsequent work depends on it.

General diagram of fastening the mounting device for lifting material

Even the slightest deviation of the starting panel will lead to an increase in error with the installation of each subsequent element, as a result of which the upper part of the wall will take on at least an uneven appearance, and in the worst case, gaps will form at the joints, which is undesirable for thermal insulation.

We have already mentioned the need for attachment to the frame more than once, now it’s time to unfasten it

When performing all these manipulations, it is important to carefully ensure that the sandwich panel is not damaged.

Each subsequent panel is attached in the same way as the first, but even despite the maximum accuracy of installation of the initial plank, check everything is level after installing every third element.

Example of correct and incorrect placement of screws for fastening

In terms of observing other nuances, the question of how to install a sandwich panel comes down to organizing reliable joining seams. The panels are tightly connected in locks - each protrusion must fully fit into the corresponding groove, otherwise the structure will collapse immediately after commissioning, and sometimes even before it.

Depending on the severity of the climate, silicone sealant must be applied either only from the inside, or from the inside and outside. Glue and sealant are applied right before installing the panel.

The permissible temperature conditions for it are always indicated on the sealant.

Please note that the sealant will actually be suitable for your weather conditions.

An example of the correct junction of two wall panels

Transverse seams are sealed with mineral wool. The use of polyurethane foam is allowed. Some types of insulation lose their properties due to exposure to moisture. To prevent this nuance, the fastening points must be treated with waterproofing agents.

Having completed the installation work, you need to mask the seams. For this purpose, shaped elements are used, the installation of which begins from the base ebb. The camouflage is secured using small screws or rivets. The shaped elements are treated with sealant on the reverse side.

Recommendations for the use of panels

Sandwich panels can be fixed horizontally, which is most often practiced, or vertically. In the first case, installation begins from the foundation of the building, in the second - from the corner of the building.

Installation of wall panels

Vertical installation of the material is usually used for the installation of structures up to 6 m high. The two installation methods cannot be combined.

Vertical installation of panels

Several important requirements when working with multilayer material.

1. Unloading is done one package at a time using a crane or forklift.
2. The packs must be placed on a flat surface (stacked on top of each other is prohibited).
3. For convenience, the panels are installed near the work site.

Installation of panels to the frame or base is carried out using special self-tapping screws made from hardened steel. The fastener must have a sealing washer. The type of hardware is determined in accordance with the type of supporting structure and its thickness. It can be made of concrete, wood, brick or metal.

Self-tapping screws for sandwich panels

Before installing the panels on a metal or wooden base, you will need to pre-drill the mounting holes, but if you use self-drilling screws, this step will not be necessary. The length of fasteners depends on the thickness of the panel and varies from 85 to 235 mm. The most commonly used parts are 5.5 mm in diameter.

To fix the material to concrete, preliminary installation of holes is mandatory. And both in the panels and in the base. The products are fastened by installing dowels.

Fastening panels

Rules for fastening sandwich panels.

1. The fasteners must be located at a distance of more than 5 cm from the edges of the material.
2. Installation of hardware must be carried out strictly perpendicular to the outer layer of the panel.
3. An important point that largely affects the quality of installation is the correct tightening of fasteners. Self-tapping screws with a sealing washer must be tightened until they come into full contact with the base. In this case, you should avoid over-tightening, which over time can lead to depressurization of the connection. How to tighten self-tapping screws
4. Before installation, the protective film must be removed from some areas: locks, fastening points. Complete dismantling of the protective coating is carried out immediately after completion of installation work.

For installation, you will need clamps to support the panels until they are completely fixed. To cut the material, you can use saws (circular or band saws), a jigsaw, or electric metal shears. The grinder is not used in this case, since the temperature effect that occurs during the operation of this tool leads to damage to the material.

Prices for inexpensive sandwich panels

sandwich panels

Installation of sandwich panels

Before starting work, it is necessary to check the ends of the products. The insulation should not protrude. Otherwise, this defect must be eliminated. Waterproofing must be applied to the upper part of the plinth.

Installation of strips of sandwich panels

The top panel is inserted into the starting profile already secured with screws.

After this, 4 more parts of the starting profile are cut off. Its length is determined by the width of the slopes. The segments are inserted into the side starting profile at the top and bottom on both sides. Then they are secured with self-tapping screws to the top of the sandwich panel and to the window sill.

A caveat: most craftsmen specializing in these types of finishing work exclude this stage. In this case, the sandwich panel strips simply adjoin the top strip and the window sill. The gap at the joints is closed with a special agent - liquid plastic. It, in turn, hardens and acquires the same characteristics as ordinary plastic. There are also negligent workers who use conventional sealant, and after a short time the slopes lose their appearance: the joints treated with sealant darken and become dirty. Any of these two methods reduces work time and material consumption, and has its supporters and opponents. Therefore, the choice of option is a matter of taste.

Difficulties to be faced

It would seem that creating sandwich slabs is very simple, but in the process of work you may encounter nuances that can negatively affect the final result:

• At the moment of hardening, the glue foams, so the assembled sandwich requires compression and exposure to a certain pressure. But since the dimensions of the slabs are large, a special installation is required - a press. Not everyone has it. In this case, manual equipment with mechanical grips (tightening) can be used. This will create the required pressure - 0.3 kg per square meter. The panels should remain under this pressure for 2-4 hours. The height of the sandwich package cannot exceed 1.2 meters.
• High speed of glue hardening. If necessary, it is almost impossible to remove it: it is not susceptible to solvents. There is a way out: use a mechanical method. The applied mixture should be heated to 300-500 degrees, which is unrealistic at home. Therefore, the work must be carried out promptly; it is better to invite an assistant.

A short video demonstrates how to properly glue sandwich panels yourself:

Difficulties of self-production

Ensuring high-quality homemade performance is quite difficult. There is a risk that the materials will not adhere well to each other, which will lead to peeling and a significant deterioration in performance characteristics.

The main difficulties lie precisely in pressing the product:

1. Firstly, it is difficult to achieve uniform load distribution when connecting elements manually. Instead of a press, some use mechanical grippers . This method allows you to achieve the desired pressure - 0.3 kg/sq. m. The height of the “pyramid” of panels during pressing should not exceed 1.2 m.
2. Secondly, the drying speed of the glue requires the performer to act quickly and accurately. Some home craftsmen are trying to increase the polymerization period of the composition by lowering the temperature and increasing the humidity in the room .

The technology for assembling sandwich panels is quite simple; no special skills are required. But the presence of equipment will significantly improve the quality of products.

Polyvinyl chloride panels

PVC siding is the simplest and cheapest way to decorate the facade of a building. Such panels are popular for several reasons: ease of installation; low cost; Huge color options. Among the disadvantages, it is worth noting that such panels are made of plastic and any facade will look plastic even from the farthest distance.

This type of panel is installed exclusively horizontally. To work, you will need a construction knife or any other knife. In addition, you will need a hammer drill. You will also need a level to determine the angle of the panels, as well as a hammer for driving nails.

The initial stage of installing PVC panels is a preliminary inspection of the house. It is necessary to determine the location of the first row of panels. In the case of a new building, it is recommended to install the panels from the beginning of the foundation. Also, PVC panels can be installed from the initial row of the old finish.

Start of installation

Next, you should install the initial frame, namely: corners, both external and internal, platbands, first strips for attaching panels. Installation begins from the corners. The gap between them and the cornice should not be more than 6.5 mm.

The most important stage, on which the future fate of the entire facade will depend, is the installation of the first strip of panels

It is important to install the first strip of fasteners as correctly as possible, since the fastening of the panel itself depends on it. If the strip was laid evenly, then the panel will be even.

General provisions

It is necessary to install trims, ebbs and trims on windows and doors. And after the completed stages, the installation of all other rows of the facade begins. The top panel is inserted into the profile and hammered in with a nail, but not completely. There should be an interval of 0.4 cm between panels, and no more than 6 mm between other components. In order to avoid vertical overlaps, it is recommended to install the panels at half the factory mark. This way the joints will not be visible from the front side.

Sequence of installation of facade panels

When installing panels, you must remember that parts of the products will need to be cut off. A construction knife is used for this. A ruler and level are also needed to more accurately measure the angle and draw a straight line on the product. Draw a line on the panel in the place where you need to cut off the piece, and carefully draw it with a knife several times. The advantage of plastic is that it is ideal for such manipulations.

You must be extremely careful, since mechanical damage is very visible on such material.

Such panels are most in demand due to their ease of installation and low cost. In addition, PVC products are installed at various building heights because they are very lightweight. Installation of such panels is simple and does not require much time.

The final step is to install the top row of panels. For the top row, only complete panels are needed. In addition, the last panel is closed with a special profile for drainage.

First of all, the foundation

See also
: Layout of a rectangular house: how to choose the best option

Yes, the roof is waiting for you ahead. As well as exterior cladding and interior trim.

For such a house you can use several types of foundation:

• shallow;
• slab;
• ribbon-columnar;
• pile-grillage.

Select the appropriate foundation option, after which the crown laying begins.

Purpose and design features

The first sandwich panels were created in 1930. Architect Lloyd Wright invented a technology for making an effective, durable and practical building material that used honeycomb core. Subsequently, the technique was improved and applied to the construction of buildings for various purposes. This material is in demand and has a wide range of applications.

High-quality sandwich panels are an effective building material. Such elements have a number of advantages compared to other types of panels. At the same time, you can make durable panels yourself using metal corrugated sheets and honeycomb insulation. The process requires adherence to technology and knowledge of the characteristics of materials

The advantages of using sandwich panels are the following properties:

• High level of rigidity and strength of the material, ensuring structural reliability and good performance;
• A simple technology for installing elements, which can be easily done with your own hands and in the absence of professional tools and knowledge;
• Reducing the thickness of the walls by approximately three times, as well as a corresponding reduction in the load and impact on the load-bearing parts of the structure, but maintaining high technical characteristics;
• Reducing the construction time of buildings and structures, ensuring the reliability and durability of objects;
• Resistance of sandwiches to mechanical, temperature and climatic factors.

High-quality and reliable sandwich panels are used in the construction of various types of buildings. Using this material, it is easy to create warehouse facilities, build a garage from sandwich panels, or build a private residential house. The versatility is due to the high technical characteristics and practicality of the material. At the same time, compliance with the technology of using panels allows for quick installation, ensuring comfortable operation of structures and avoiding the occurrence of surface defects after construction.

The design of sandwich panels is quite simple, which allows you to make the elements yourself. In this case, it is worth using high-quality materials that have high performance and necessary properties. Most often, the elements include a layer of external corrugated sheeting, then insulation is placed, and then metal sheeting is placed again. The following types of materials can be used as filler:

• Mineral basalt wool;
• Expanded polystyrene;
• Polyurethane foam.

What are the benefits of sandwich panels?

The popularity of the material among builders and consumers is easy to explain. What are the characteristics of multilayer panels?

1. Their use makes it possible to reduce construction time tenfold and save on labor costs.
2. Decent thermal insulation characteristics (a wall made of 100 mm panels has approximately the same thermal conductivity as a brick structure 64 cm thick) helps optimize heating costs.
3. The small mass of the products and the structure as a whole makes it possible to simplify the procedure for studying soils and laying out the foundation. In addition, transportation and movement of products is easier.
4. The minimum service life of the panels exceeds a quarter of a century.
5. The material is not subject to atmospheric influences.
6. Many types of panels have good fire resistance.
7. Externally, the panels look very aesthetically pleasing.

Roofing sandwich panels
The functionality of a building material is largely determined by its multilayer nature. It perfectly protects walls and roofs from low and high temperatures and precipitation, provides excellent thermal insulation and protects against noise. With low construction costs, it is possible to build an attractive and reliable structure in a short time.

Important! Sandwich panels are produced by many manufacturers. To become the owner of high-quality building materials, it is recommended to purchase products from trusted factories.

Sandwich panel house project

Kinds

Reinforced concrete structures are usually divided into the following types: monolithic, prefabricated, precast-monolithic. The first type is a very rare option. It is constructed in the case of the construction of unique buildings with certain technological requirements. The second type is relevant for the construction of low-rise buildings. It is worth noting the fact that experts consider the reinforced concrete frame for sandwich panels, as in the following photo, to be the most reliable. It is customary to equip it even in special zones with high seismic activity. But this quality causes the rather high cost of this option. Buildings with a reinforced concrete frame are called monolithic. However, experienced builders claim that using sandwich panels under these conditions is not very practical. Although, in fairness, we add that such an idea is relevant only in private construction. Nowadays, it is possible to equip such a structure in a relatively short period of time. If you are not confident in your own abilities, but want to build just such a structure, seek advice from professionals; A metal frame is relevant for the construction of high-rise buildings, as shown in the video. Although it is worth noting that in recent years there has been a tendency to actively use such a structure for the construction of personal cottages, garages and hangars. For example, a metal garage frame made of sandwich panels will provide the structure with a very long service life. You can also find such an option as a metal-wood frame: a metal pipe is placed in a wood shell. A characteristic feature of products of this kind is their light weight. Thanks to it and the use of sandwich panels, you can limit yourself to a shallow base. But a metal frame also has its disadvantages. These include low fire resistance. Of course, iron doesn't burn. But it is an excellent conductor of heat, which ensures instant spread of fire and heat throughout the area of ​​the structure. In addition, during the heating process, iron can simply melt. And with high humidity, steel can undergo corrosive processes, which will soon weaken the strength properties of the house. Although the reinforced concrete version is not without a similar drawback. Nowadays, metal frames are associated with prefabricated structures, so when choosing such a base, you need to immediately think about where to purchase sandwich panels and other relevant materials; Wooden frames are rarely used in the construction of modern buildings. But it is very suitable in the case of private construction. Fastening sandwich panels to a wood frame is carried out in a fairly short time. The fact is that wood is considered an excellent building material with excellent performance characteristics. It has excellent fire-resistant properties and low thermal conductivity

It is also important to note that such products for sandwich panels are erected in a fairly short time and without significant material expenditure.

Let's sum it up

Today, the most common frame options for sandwich-type slabs are structures made of metal, wood and reinforced concrete.

Each of them has characteristic features that must be taken into account when installing the cladding. And the video in this article will tell you about the features of installing products on a pre-constructed frame for sandwich panels.

Glue requirements

Any glue, no matter what quality it may be, is not suitable for making panels. The glue must retain its properties for at least several decades. Also, the glue must meet safety standards and cannot cause harm to the human body. The ideal solution would be to purchase glue from such well-known European manufacturers as Henkel and Kleiberit, as shown in the photo. Adhesives of such brands are used for the manufacture of panels in almost all leading factories in the world.

Production of SIP panels

Vacuum press for SIP panels

How to make a SIP panel? The OSB-3 sheet is laid on a flat work surface (special table), and glue is applied to it using a spray gun, glue, brush, roller, notched spatula or any other device. As a rule, the consumption of adhesive composition is 150-200 g. per square meter, but, in turn, it greatly depends on the method of application. The composition is kept for 8-10 minutes, after which expanded polystyrene grades C-25-35 is placed. In the process of making sandwich panels with your own hands, the speed of the actions performed plays a special role. The adhesive should not be allowed to polymerize between layers. Otherwise, the resulting structure will have a low level of strength and reliability; such a panel cannot be used in further construction. The laid sheet of expanded polystyrene is carefully leveled, and an even layer of adhesive is applied to it. The next layer, consisting of an OSB panel, is laid on top of the insulation. Next, the second slab is formed according to the above algorithm. You need to assemble at least 5 panels, and you should also take care of the need to apply pressure on them. For this purpose, the vacuum pressing technique is used. A pre-aligned stack of panels is covered with a cover made of awning fabric, glued together with a special adhesive, for example, “Cosmofen SA-12”. Having previously clamped the edges or ensured the proper level of tightness using any other method, air is pumped out from under the cover. Look at the photo above, it shows the panels lying under a vacuum press.

In 8 hours of continuous operation, about 25-35 sandwich panels can be glued. It is worth noting that finished slabs must remain in a horizontal position for at least a day in order to finally acquire the expected performance characteristics.

Why should you choose SIP panels?

Composition of SIP panels
Panels are special structures made of wooden beams and two oriented strand boards (OSB) attached to it, the internal space between which is filled with polystyrene foam. The resulting layers are glued together with a one-component polyurethane-based adhesive.

The slabs are assembled in such a way that they are easily connected to each other using the tongue-and-groove system. Structures erected using this kind of panels are, first of all, distinguished by their low specific weight, thereby significantly reducing the load on the soil and the requirements for the foundation, respectively. In addition, a significant advantage of houses built using this technology is the highest level of strength and reliability. Thus, the panels are capable of withstanding a load in the vertical direction of up to 10 tons, and in the transverse direction - up to 2 tons throughout the entire service life, which exceeds 80 years. In addition, such buildings are erected in the shortest possible time, generally not exceeding 3 months.

Excellent sound and heat insulation characteristics, complete fire safety and an absolute level of environmental friendliness - all these qualities determine the success of SIP panels. In addition, SIP panels, with proper adherence to technology and the use of proven materials, can be produced independently at home, further reducing their cost.

Sandwich panel house

Construction of a house from sandwich panels can often be done by the future residents themselves, if they have at least basic construction skills.

The process consists of the following stages:

• Foundation construction. The appropriate option is chosen depending on the terrain and the nature of the soil. One of the most popular options is a foundation on screw piles. Its advantages are the ability to erect the base of a building in 1–2 days and the affordable cost of materials and labor.
• Waterproofing wooden parts using roofing felt or other similar materials.
• Installation of the lower strapping beam on which the floor is laid. When building on a screw foundation, wooden beams are placed on the tops of the piles.
• Laying the floor. The front side of SIP is treated with bitumen mastic. SIP sheets are laid out around the perimeter of the future building.

Laying floors from SIP panels

• Assembly of external walls of the first floor. First, lay the bottom trim. Then the walls themselves are assembled from sandwich sheets and a wooden frame. After the external walls are installed, the internal floors are made. At the final stage of the first stage, the top trim is laid.
• SIP sheets of interfloor ceilings are installed on top of the walls of the first floor in the same way as the floor of the first floor was made.
• The walls for the next level are built in the same way as the previous one. If the area of ​​the rooms is large, the floors between floors are reinforced with timber, preferably marked LVL.
• The roof is made from SIP panels.
• Install windows and doors.

Elements of a frame house

Since sandwich panels have a smooth, even surface, finishing the house is cheaper and takes less time. So, inside it is enough to cover the walls with wallpaper.

Preparing panels for use

When purchasing a new SIP panel, you should ask the seller for a certificate of conformity. If he doesn’t have one, it’s better to look for a suitable product elsewhere.

Before installation, prepare a layout diagram for the selected type of material. Particular attention is paid to the location of the locks.

Sandwich panel slope

The panels are inspected in order to detect damage and corrosion in time. If there are such places, the material is processed or replaced with another panel. Sheets on which chips are peeling off or looseness is noticed are not suitable for work. They work carefully with the joint elements so that depressurization of the joints does not occur later.

Since the panels are produced in the same sizes, they will have to be cut. For this, only cold methods are used: high temperatures can damage the insulating material or filler, and the service life of the structure is reduced. The inner and outer panels are not cut simultaneously, but alternately.

Depending on the material of manufacture, the following tools are used:

• polymer (plastisol, pural, etc.) - jigsaw, construction knife;
• OSB, drywall, metal - band or circular saw;
• metal - press guillotine.

To ensure an even cut, the panel is fixed and the sheet is clearly marked. The front layer is always cut first.

Attention! Grinders and other tools with high cutting speeds are not recommended. They can cause fire insulation and damage the integrity of the protective coating.

How to make sandwich panels yourself

The technology for manufacturing sandwich panels cannot be called complex. However, it has some nuances, failure to comply with which can negate all efforts. A certain difficulty in self-production lies in the lack of special equipment - a press.

Choice of insulation and outer layer

The type of cladding depends on the specific application. As a rule, self-assembled thermal panels are used in private housing construction. OSB wood boards 9 mm thick are used for work.

It is extremely difficult to make sandwich panels from corrugated sheets yourself. Here you cannot do without equipment for working with metal and a unit for pressing finished products.

When choosing thermal insulation, preference is given to polystyrene foam or polystyrene foam

It is important to correctly calculate the thickness of the insulation, based on the specifics of the building being constructed and the climatic characteristics of the region. The dimensions of the sheets are determined by the dimensions of the future structure

It is necessary to plan the arrangement of panels in such a way as to minimize labor costs for cutting and avoid waste.

Requirements for the adhesive composition

To make thermal plates you will need polyurethane glue. In mass production conditions, two types of composition are used:

• two-component - polymerization occurs upon contact of the polyol and isocyanate components; the adhesive requires preparation before use;
• one-component - hardens during interaction with air.

At home, use the latter option. The one-component composition is more practical to use and is not inferior in adhesive properties to its two-component counterpart.

The adhesive for assembling homemade panels must meet the following requirements:

• preservation of qualities throughout the entire service life;
• moisture resistance;
• environmental safety - the composition should not contain toxic components;
• resistance to temperature fluctuations – maintaining properties in conditions from -40°C to +50°C.

Assembling sandwich panels: step-by-step instructions

Before starting production, it is necessary to prepare the work area - clear the place of debris. You can carry out the assembly on a low table or build a platform on a flat floor.

Steps for assembling sandwich panels with your own hands:

1. Lay the first frame sheet and cover it with glue. The composition is distributed evenly using a rubber notched spatula or sprayer.
2. Place insulation. The work is carried out quickly enough, until the adhesive composition has dried.
3. Coat the inner layer with glue.
4. Lay the outer cladding on heat-insulating material.

Next, production continues - the following sheets are laid on the assembled panel, adhering to the described technology. A layer of paper is placed between the plates.

When working, you should adhere to the following rules:

• the time for distributing the glue is limited - no more than 10 minutes, otherwise the composition will harden and the layers will not stick together;
• the polymerization process is accompanied by foaming - at this time it is necessary to compress the workpieces, the required force is about 18 tons;
• holding time under pressure is about 3 hours;
• The cutting of edges and preparation of interlocking joints begin after the panels have completely dried - no earlier than a day later.

It is advisable to hire an assistant for the job. With two people it is easier to lay large sheets of materials and you can reduce the time for applying glue.

Creating a lock connection

In production conditions, locks are made automatically during pressing of products. Manual equipment does not have such functionality, but you can develop a locking system with your own hands. At one end of the slab you need to attach a wooden block, and at the other, cut out the heat-insulating material. The depth of the recess should correspond to the thickness of the insert.

What difficulties may you encounter and how to overcome them?

If you were unable to get a press, you can use a vacuum pump. It happens like this:

• The panels placed in the bag are covered with thick awning fabric, clamping its edges.
• Then, using a pump, air is removed from under the awning.
• The stack of panels is kept under vacuum for about 35 - 40 minutes.
• After this, the panels should rest for 24 hours on a flat horizontal surface.

Since factory sandwich panels are connected to each other into a lock, craftsmen have figured out how to organize a similar lock for their products:

• To do this, a wooden (locking) beam is placed at one end of the product between the outer panels, partially protruding beyond the panel.
• And from the other end the insulation is trimmed to the amount of the protrusion of the bar. Thus, later during installation you can use a locking connection between adjacent panels. It makes the entire structure more durable and reliable.

Making sandwich panels for building your own home is quite possible. But for this you need to have the necessary equipment and skill, otherwise homemade panels may turn out to be of poor quality, and the house will not last long.