What you need to know about insulated panels for walls and roofs

The following text about sandwich panels for walls and roofs is intended for beginners. It is intended to provide an introduction to the subject and provide information on various aspects such as transport, relocation, etc. Of course, this text can not replace any training. It is therefore always essential to have specialists who are familiar with the transport, storage and assembly of sandwich panels.

If you are looking for more details, kindly visit Wiskind New Materials.

1. The basics: What are insulated panels?

Smart and insulated: Facade made from insulated panels

As the name suggests, “sandwich” panels consist of several layers – usually two thin covering sheets and in between there is a core. That, however, is the only similarity between them and a sandwich! When it comes to durability, the sandwich panels are way ahead of their edible namesake: The individual layers are firmly connected with each other, and are therefore often referred to as composite panels.
Insulated panels, composite panels, or sandwich panels, come in a wide variety of designs. In most cases, the outer shell consists of a galvanised steel sheet. The inner shell can be made of galvanised steel sheet, thin aluminium sheets, stainless steel or GRP (glass-fibre reinforced plastic). The core is mostly made of insulating material such as polyurethane (PUR), polyisocyanurate (PIR), or rock wool. The joining of the outer and inner layers helps to combine the properties of the materials used: bending or breaking of the surface is made difficult thanks to the core, in turn the stability of the surface protects the soft core from external influences.

2. Using insulated panels

Insulated panels are used in many industries, such as aerospace, automotive and construction. This text focuses on the use of insulated panels as ready-made elements for the construction industry.
Insulated panels are perfect for the building sector: You save time, cut costs and reduce weight and they can be used as wall, ceiling and roof. If the panels come straight from the factory, they are immediately ready for use. In one easy step, they can be attached to a support structure and are simultaneously stable walls or roofs with excellent insulation properties.
Because of the above named properties, today insulated panels are particularly popular for lightweight construction of halls, roofs for residential buildings, but also as insulation panels for insulating or also as sound proofing in drywall construction. Insulated panels with a fireproof core are also often used as fire protection panels.

Hall constructed from insulated panels

3. Types of insulated panels

3.1. Insulated roof panels

Roof panels have two uses: as roofing insulation and roofing. They can be recognised at a glance by their regular elevations on the sandwich element. These elevations are known as high ridges and serve to stiffen the panel. Good stability is indispensable – especially in the case of roof panels – since they must not only carry their own weight, but also have to withstand potential snow loads or wind loads. The space between the two high ridges is known as the low ridge. This is where the core thickness is measured. In order to ensure a seamless transition between two roof panels, there is an overlapping flap on one side of the panel. This lies on top of the adjoining panel.

Roof panels are available in a wide range of RAL colours.

3.2. ECO roof panels

A special type of roof panels are the ECO roof panels. They are covered on the underside aluminium foil rather than steel. As a result, they are classed as single-use products according to building regulations and do not need to be approved. In addition to this legal advantage, ECO roof panels have many more plus points. The aluminium foil reliably protects against products such as ammonia, which can have a negative effect on the environment. As a result, ECO roof panels are particularly suitable for use in agricultural buildings, such as stables and barns.

3.3. Insulated wall panels

Insulated wall panels have a lined profile for stability, instead of the high beadings on the roof panels. Since there is no overlapping flap due to the lack of a high ridge, the panels are connected with each other using a tongue and groove joint, which is more pronounced than on the roof panels. Optionally, it is also possible to use fastening screws, which are invisible from the outside, using a secret fixing system.

In detail: secret fixing

Wall panels can also be used as ceilings or floors.

3.4. Cold room panels

Cold room panels are a special form of wall panels. They are usually more insulated than normal insulated panels and have better quality of joints. This makes them ideal for the construction of refrigerated cold rooms and walk-in fridges. Cold room panels often also come in a food-safe coating.

4. Composition of insulated panels: the exterior

The outer shell of an insulated panel consists of several different layers, which protect the panel from environmental influences such as UV radiation and from corrosion. The following diagram provides a nice overview of the outer shell structure:

Since all the individual layers fulfill certain functions, it is important to analyse the environmental factors to which the panels will be exposed, before purchasing the insulated panels. After doing so, the right materials and coatings can then be selected. Since the exterior and interior sides of the insulated panels are frequently exposed to very different conditions, the lacquers and materials which are used, vary according to the side they are on. For example, the exterior shell should always contain a UV protection layer and in damp interior spaces, such as swimming pools, good corrosion protection should be used.

4.1. Exterior materials

There are several basic materials from which the outer shell of insulated panels are made. Here is an overview of the properties of the materials:

Material Use Sheet steel Steel sheet metal is most often used in the production of insulated panels. The material impresses with its high stability. The sheet is galvanised and coated against corrosion GRP GRP (glass fibre reinforced plastic) can only be used for the underside of the panels. The material is used in rooms with high exposure to chemicals or salt to prevent corrosion. GRP is not as fracture-resistant as metal. Aluminium Sometimes, but not often, the shell of the insulated panel is made from aluminium. This material is particularly resistant to chemicals and salt and is therefore mainly used in the agriculture industry. Disadvantages include the high price and high thermal expansion, which can lead to structural problems.

Stainless steel

Very rarely the shell is made from stainless steel. The advantage of this material is that it is completely rust-free and is food safe. The price of the material is, however, very high. We produce stainless steel insulated panels on request from a quantity of 2,500 m².

Material thickness

The shell of the panels is available in different material thicknesses. Thinner material is lighter and less expensive but not so stable. In the case of thicker materials, it is possible to walk on a panel without damaging it. Typical values for the thickness of the steel sheet are 0.4mm and 0.6mm. Please contact us if you need any advice regarding thicknesses.

Galvanising

As corrosion protection, all our panels are galvanised in high-quality. Contact us if you have any questions about galvanisation.

4.2. Exterior coating

The coating offer further protection to the insulated panel and protects against corrosion and UV radiation. There are a variety of quality levels, depending on the situation the panels will be used in. The quality of the coating can be increased using one of the following two methods: through newly developed materials and coating methods or by a thicker coating. The standard coating applied to our insulated wall and roof is standard polyester with a thickness of 25 μ, exterior and interior. Most competitors offer only 15 μ. These are the coatings available:

Pre-coated products Standard thickness (μ) Minimum time before appearance of white rust (in h) Corrosion category Standard polyester 25 360 RC2 Polyester with high durability 25 360 RC3 PVDF 25 500 RC4 PVDF 35 500 RC4 PUR-PA 50/55 700 RC5 Plastisol 100/200 RC5 Plastic coated 100 500 /

In order to make it easier for you to choose the right coating, we provide you here with a small decision aid based on EN . Simply allocate your project to one of the following categories.

External environmental influences:

Category Description C1 - very low C2 - low

Surroundings with low pollution Agricultural areas

C3 - average

Urban and industrial areas, medium levels of sulfur dioxide pollution Coastal areas with low salt content – between 10 and 20 km from the sea

C4 - high Industrial areas and coasts with medium salt content, between 3 and 10 km from the sea C5 I – very high Industrial and coastal areas with high humidity and aggressive environments C5 M – very high Coastal areas with high salt levels, between 1 and 3 km from the sea

Internal environmental influences:

Category Description C1 – very low Heated buildings with clean air: e.g. offices, shops, schools and hotels C2 - low Non-heated buildings where condensation is possible: store rooms, sports halls C3 - medium Production rooms with high humidity and reasonably high air pollution: e.g. food industry, laundries, breweries, dairy industry C4 - high Chemical installations, swimming pools, shipbuilding and coastal installations C5 I – very high Buildings or areas with constant condensation and high air pollution C5 M – very high Buildings or areas with constant condensation and high air pollution

With the help of the following diagram, you can ensure you choose the right coating for both the exterior and interior shell of your insulated panels.

5. Composition of insulated panels: the core

The extraordinary insulation properties of insulated panels are largely achieved thanks to the insulation core, which is protected by the external sheets made from steel or aluminium. The core of the insulated panels can be made from a variety of materials and in different thicknesses. Following, we provide you with a short overview of the materials and their functions.

5.1. Polyurethane (PU)

Polyurethane is a synthetic resin used developed in the s by Otto Bayer and his research group for IG Farben. We all know the material from around our households: our sponges are made from it. In the field of insulated panels, polyurethane is the most popular insulation material. But how good are the insulation properties? The following table is based on a standard-lined Eurobox type panel, and provides information on the insulation values (U-values) achieved according to the core thickness:

U Thickness of the panels (mm) 25 30 35 40 50 60 80 100 120 W/m² K 0.83 0.70 0.61 0.54 0.44 0.37 0.28 0.22 0.19 kcal/m² h °C 0.71 0.60 0.52 0.46 0.38 0.32 0.24 0.19 0.16

5.2. Polyisocyanurate (PIR)

Polyisocyanurates have even better insulation properties when compared to polyurethane. Thus, the same insulation value can be achieved with a lower core thickness. In addition, insulated panels with a PIR core have better fire-rating values than those with a PUR core, withstanding higher temperatures for longer. Due to this, insulated panels with a PIR core are somewhat more expensive than PUR core panels.

5.3. Rock wool

If you happen to have special fire protection requirements, then there’s no way around panels with a rock wool core. In contrast to polyurethane and polyisocyanurate, rock wool is not combustible. However, this advantage is tempered by the fact that rock wool panel have a slightly poorer insulation properties. Take a look at the U-values based on the example of a standard-lined Eurobox profile:

U Nenndicke des Paneels (mm) 50 60 80 100 120 150 W/m² K 0.75 0.63 0.49 0.39 0.33 0.27 kcal/m² h °C 0.65 0.54 0.42 0.34 0.28 0.23

​ 6. Transportation of insulated panels

If you decide on using insulating panels as part of your construction plans, transport is the first step after placing your order. For panels with lengths of up to 24 metres, there are some very important rules that you need to pay attention to in order to ensure that the insulated panels arrive undamaged.
Insulated panels usually come packaged. In order to not damage the panels during transportation, these packages must be placed horizontally on spacers made from plastic foam or wood. Please note that the spacers must be placed at a suitable distance apart. The support surface should of course correspond to the shape of the package. That is to say, if the package is flat, the surface it lies on should be flat. If the package is curved, the surface it lies on should also be curved. When stack packages on top of each other, stacking spacers must be used between the packages..
It should also be ensured that packages do not overhang by more than one metre and are secured in at least two cross-sections using straps no further than 3 metres apart. When attaching the straps, it is important to ensure that the do not themselves damaged the panels. The loading surface of the vehicle should, of course, be empty and weatherproof.

7. Storage of insulated panels

For logistic reasons, it is sometimes necessary to store insulated panels on a construction site or in a warehouse. Please ensure that the panels never lie directly on the floor, but always on timber or polystyrene spacers, which are wider than the panel itself. The spacers must be adapted to the shape of the panels and correspond to the product. For example: for a package which is curved, the spacers must have the same curvature. If lack of space means stacking the packages on top of each other, please ensure that spacers are used between the individual packages. The upper spacers should be placed in exactly the same position as the spacers below. The weight of the packages should also be noted when stacking. A maximum of 3 packages with a maximum height of 2.6m can be stacked.
The packs of panels should never be stored for an extended period in a damp environment, since condensation can collect on the poorly ventilated internal panels, and can corrode the metal. If short-term outdoor storage is necessary, it is important that the packages are not exposed to direct sunlight and that water runs off them. The inclination should be at least 5%. However, packets should not be stored outdoors for more than 60 days.
The best storage conditions for insulated panels are dry and dust-free rooms, which are also ventilated to some extent. From experience, we know that even under the best storage conditions, the storage period should still not exceed 6 months, as otherwise the properties oft he panels can change.

8. Lifting insulated panels

Even if insulated panelbelong to the lightweight construction elements, the length of them can mean they carry some considerable weight. For this reason, some basic instructions must be followed when lifting by hand or by crane.
When lifting a package by crane, synthetic sling belts (e.g. from nylon), with a minimum width of 10cm, must be placed in at least 2 places. The straps must have a minimum of half the length of the package. To prevent damage to the panels when they are lifted, apply strong and thin wooden or plastic spacers that exceed the width of the panels by at least 4cm.
When lifting the panels by hand, there should be two people working together. The panels should be always be carried with the horizontal edges upwards and downwards.

9. Cutting insulated panels

Sometimes it is necessary to cut down insulated panels to get them to working length on site.. For this purpose, the panels must be placed on a firm base and cut with a plunge saw, jigsaw or circular saw. It is important to make sure that the cutting surface does not become too hot during cutting. This could lead to the galvanization, and thus the corrosion protection, burning. Please do not use angle grinders or disc grinders as sparks could damage the anti-corrosion coating.

10. Fitting roof panels

​The substructure already in place, the insulated panels can now be put to good use

Insulated panels should always be fitted by experts. The following passage will provide a rough overview of the work.
The installation of roof panels will always be onto a substructure of timber, concrete or steel. When designing the substructure, it is imperative to include the calculation of the panel weight as well as the potential snow loads and wind loads in the region. From all this information, the distance between the supports (the purlins), onto which the panels are laid, can be determined. In order to get maximal drainage, the inclination of the roof must not be less than 5°. If the roof has a crossbar or roof penetrations, the roof should have a slope of at least 7°. Roof panels are therefore not suitable for flat roofs.
You’re now ready to go!

10.1. Laying the roof panels

Before starting the construction, the substructure should be carefully inspected: To avoid corrosion, no incompatible materials should come into contact with the panels. Furthermore, before installing the panels, the gutter and cover plates on the sides of the eaves should be fitted.

The roof panels are always laid opposite the main weather direction in order to keep the wind influences on the joins to a minimum. Therefore, the installation begins on the side facing away from the wind. Extra care should be taken with the first panel to ensure flush alignment. It is advisable to stretch a guideline on the eaves side from one end of the building to the other to ensure fitting parallel to the substructure.

Using a drill screw fix the first panel to the substructure through the middle bead near the eaves. Use a saddle washer with a rubber seal to prevent water getting in. The screw must be suitable for the chosen type of substructure and must have a rubber seal and must be tightened in such a way that the seal is pushed together slightly.

Before putting the second panel in place, it’s a good idea to mark the first panel to show where the beams of the substructure are.
Then lay the second panel: Place the overlap flap over the last bead of the first panel- In order to ensure a good join at the joint, tilt it slightly and place it on the substructure to for a seal that fits optimally.
Then screw on the panel in the same way as the first one, through the middle bead near the eaves. Ensure that you keep pressure on the joint until the second panel has been fixed properly.

Only when the second panel has been fixed as described can the joint between the two panels be screwed together. If the panels are fitted in a different order than that described, it could be that the joints slip away from each other. A saddle washer with rubber seal must be fitted under the screw.

Now repeat the whole process:

1. Mark where the steel beams are on the last panel.
2. Lay the next panel
3. Press the panels together at the joint
4. Fix the new panel through the middle bead.
5. Screw the joint between the two panels.

10.2. Overlapping the short joint

Sometimes it is necessary to join the insulated roof panels at the vertical joint. The following section  describes the procedure for such an overlap along this edge.
Since there is no overlap on this edge as standard, this must be created by removing the lower sheet and the foam insulation. The data sheet for each panel will help you determine the length of the cut-back required.

Preparation for overlapping the upper panel

First the lower panel is laid and then the upper panel is put in place so that it overlaps the lower one. This allows rainwater to drain away without running under the overlap flap. In addition, a self-adhesive seal should be applied to the lower panel at at least two. The final step is to fix the panels through the high beads.

10.3. Completion of the eaves area

The exposed insulation at the front of the building must be protected from the influence of weather and from animals. In this section we will describe the different possibilities.

The exposed insulation must be either painted with a waterproof coating or covered with a flashing. The advantage of a flashing is that animals can’t get to the foam, which they would then burrow into and pull out. On request we can supply the panels for the eaves area with a drip edge.

11. Approval of self-supporting insulated panels according to EU standard

Insulated panels meet official approval. EU standard specifies the requirements for “factory-made self-supporting insulated panel elements with metal sheets on both sides”.

12. Fire protection classes and legislation on fire protection

In many of the scenarios where insulated panels are applied, fire protection plays an important role. The European standard DIN EN has been in place for a number of years. The European standard regulates fire protection classes much more closely.
Here is the corresponding EU table, which defines the fire resistance classes according to DIN EN and their assignment to the corresponding building supervisory requirements:

Building requirements

Weight-bearing elements¹
without clearance

Weight-bearing elements¹
with clearance

Non-supporting internal walls

Non-supporting external walls

Raised floors

Stand alone ceilings

Fire-retardent

R 30

REI 30

EI 30

E 30 (i→o) und
EI 30-ef (i←o)

REI 30

EI 30 (a↔b)

Fire-retardent

R 60

REI 60

EI 60

E 60 (i→o) und
E 60-ef (i←o)

EI 60 (a↔b)

Fire-resistant

R 90

REI 90

EI 90

E 90 (i→o) und
E 90-ef (i←o)

EI 90 (a↔b)

Fire-resistance
120 minutes

R 120

REI 120

-

-

Fire wall

-

REI-90M

EI 90-M

-

-

¹For reactive fire protection systems with components from coated steel, the specification IncSlow according to DIN EN -2 is additionally required.

In addition to these general tables, there is a further table in which all insulated panels are classified. If you order panels from us, we always provide the European fire protection class:

Classification of fire performance of construction materials (excluding flooring) according to DIN EN -1

Building requirements

Additional requirements

EU classification according to DIN EN -1¹²

No smoke

No flammable dripping

Construction materials, excl. linear pipe insulation

Linear pipe insulation

Non-flammable

●

●

A1

A1L

●

●

A2 - s1, d0

A2L - s1, d0

Fire-retardent

●

●

B - s1, d0 C - s1, d0

BL - s1, d0 CL - s1, d0

If you want to learn more, please visit our website Flush Sandwich Panel.

●

A2 - s2, d0

A2L - s2, d0

A2 - s3, d0

A2L - s3, d0

B - s2, d0 B - s3, d0

BL - s2, d0 BL - s3, d0

C - s2, d0

CL - s2, d0

C - s3, d0

CL - s3, d0

●

A2 - s1, d1

A2L - s1, d1

A2 - s1, d2

A2L - s1, d2

B - s1, d1 B - s1, d2

BL - s1, d1 BL - s1, d2

C - s1, d1

CL - s1, d1

C - s1, d2

CL - s1, d2

A2 - s3, d2 B - s3, d2 C - s3, d2

A2L - s3, d2 BL - s3, d2 CL - s3, d2

Normal flammability

●

D - s1, d0

DL - s1, d0

D - s2, d0 D - s3, d0

DL - s2, d0 DL - s3, d0

E

EL

D - s1, d1

DL - s1, d1

D - s2, d1

DL - s2, d1

D - s3, d1

DL - s3, d1

D - s1, d2

DL - s1, d2

D - s2, d2

DL - s2, d2

D - s2, d3

DL - s2, d3

E - d2

EL - d2

Highly-flammable

F

FL

¹ In the European testing and classifying rules, the smouldering performance of building materials is not recorded. For applications where the smouldering performance must be demonstrated, national regulations must be used.
² With the exception of classes A1 (not withstanding the use of footnote c to table 1 of DIN EN -2 and E) the fire performance of surfaces on exterior wall cladding (types) cannot be conclusively classified according to DIN EN -1.

Insulated panels with rock wool core are available up to a fire class of up to F120. This means therefore, that they can withstand fire for up to 120 minutes. The panels consist of between 95-99% molten volcanic rock, drawn into filaments to attains a fibrous structure. Certified sandwich panels with a core made of rock wool may be installed in areas subject to fire protection requirements. They can be used both as an internal fire wall, or external wall and also as a low ceiling, as a roof and even as insulation of existing buildings.

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Last updated Aug

Why should I use metal wall panels instead of other wall cladding options?

There are certainly table stakes when considering wall cladding options. Indeed, the most attractive products need to offer low maintenance, high durability, and long service life.

Between an anticipated service life of 50-60 years, outstanding color retention, and minimal maintenance, metal wall panels deliver these criteria in spades.  But beyond the basics, metal wall panels outshine other product options in a few key areas.

Install Speed: Our entire society is in a rush these days, including owners who have chosen to invest in a new building. Installation speed affects the overall project budget and, perhaps more importantly, the speed to build or the number of days to owner occupancy. 

Many owners are intrigued by the fact that a single metal panel can cover a space 3’ wide by the entire height of their building in minutes vs. days for other products like brick and ACM panels.  

Flexibility:  Few products offer the ease of building modifications like metal panels. And building modifications aren’t as rare as you might initially think.  In some cases, the original building owners decide to repurpose the space, but in others, the building sells, and the new owners want to revamp things a bit. No pun intended, but metal panels make enhancements like adding doors or windows a breeze.

Since most panels install with screws, contractors can simply remove the fasteners and panels to complete the modifications, and often, the same panels can be re-installed. Products like precast walls, wood, and composite siding simply don’t offer the same flexibility.

Aesthetics:  From a design perspective, metal panels also offer unparalleled creativity. First metal panels are available in standard color palettes ranging from subtle to bold. Metal panels are also now available in two and three-dimensional prints and woodgrains. 

A product called Cor-ten is even available for owners that want a new building with a weathered and rusted look.:

Beyond that, custom colors to match corporate branding are also much more affordable with metal panels than other product options.  

Conversely, most other building products are limited to the earth tone color categories. And suppose the vast array of color options with metal panels doesn’t offer enough design flexibility. In that case, many metal panel styles can install vertically and horizontally, providing designers the ultimate opportunity for creative expression.

What is the difference between single skin and IMP panels?

There are two main categories of metal wall panels:  single skin and insulated metal panels, also known as IMP panels. As might be expected, single skin panels involve only one panel. 

In contrast, IMP panel systems are created by sandwiching a layer of foamed-in-place, polyisocyanurate, insulating core between a roll-formed interior and exterior panel.  For this reason, people often refer to IMP panels as sandwich panels. 

There are many similarities between the panel types. Both are commonly produced in 26 and 24 Ga. and offer similar paint systems. Further, both styles are commonly installed in one piece running the full height of the wall.

The biggest differences between the two involve cost, install speed, energy performance, and interior aesthetics.  In any cost comparison between the types, it's important to consider the difference between the product cost and installed system cost.  For example, while single skin panels will always be less expensive to purchase than IMPs, they offer no insulating properties.

Consequently, when single skin panels are used in buildings with conditioned air space, insulation must be purchased and installed separately. Conversely, IMP panels arrive at the job site with the insulating element included from the factory. This allows the panel and insulation to be installed in one seamless step.

So while IMP panels cost more to purchase, the final cost is often similar (or even less) than field assembled wall systems created with single skin panels and various styles of insulation.

It is also widely accepted that IMP panels offer increased energy performance over field assembled systems.  During the installation of field assembled systems, the insulation is often compressed which reduces the insulation properties at the point of compression. 

Additionally, the polyisocyanurate insulation used in IMP panels is made from a closed-cell structure which maintains the original r value throughout the product life.  Conversely, open-cell structured insulations (like rigid board) allow air to replace the gases over time.  As that process occurs, the r value offered diminishes.

Another discernable difference between the two styles involves interior aesthetics. When a field assembled system is used, the insulation is visible from the interior of the building. Owners often opt to then add a liner panel to the interior of the building to protect the insulation from damage, create a more finished appearance, facilitate a brighter space, and/or one that is more easily cleaned. 

With an IMP system, the interior panel is installed at the same time as the exterior panel, saving precious time and additional cost.  

To learn more about insulated panels, give this information from the Metal Construction Association a read or check out products offered by our partner, Green Span Profiles. 

What is the difference between exposed and concealed fastener panels?

There are two primary methods to attach metal wall panels to the building structure:  exposed fastener and concealed fastener.  While both styles offer outstanding cost savings and flexibility over other wall cladding options such as ACM, there are some critical differences between the two attachment methods.  

As you might guess, exposed fastener panels attach with a screw that pierces the metal panel and penetrates the substructure below. Conversely, concealed fastener metal wall panels are attached to the substructure with either a series of clips or via integrated flanges. While the visibility of a fastener is one significant difference between the two styles, there are other differences.

The aesthetic look of the panels is also vastly different. Exposed fastener panels tend to have a series of major and minor ribs and often cover 36”, while concealed fastener panels often boast a flush or flat appearance. 

Due to their flush appearance, concealed fastener panels are typically provided in narrow cover widths such as 12”-16” to mitigate the phenomenon of oil canning.  This narrow cover width causes concealed fastener panels to cost more to purchase and install than their exposed fastener counterparts.  

What are my options for exposed fastener panels?

There are literally hundreds of different exposed fastener profiles. Panel profiles are defined by the shape and frequency of major and minor ribs, as shown in the image below.

While the choices can appear overwhelming at first, architectural applications gravitate to a few common profiles. As might be expected, some of the most popular panels allow for both vertical and horizontal installation.

7.2 Panel: Architects and designers looking to make a bold statement with metal wall panels often select 7.2 panels.  The 1 ½” rib height and major rib spacing just over 7” offer great dimension and shadow lines.  This panel style is used frequently as an economical and low-maintenance design element.  Mega-Rib is the name for McElroy Metal’s, 7.2 panel. 

Corrugated:  Everything old is new again, and that’s certainly the case with corrugated panels.  They were all the rage in the ’60s, but their use had tapered off significantly by the mid-’80s.  Fast forward 40 years, and they are in high demand again.

While cover widths can vary slightly based on the coil width, they typically cover around 3’ wide and are offered in heights such as ½” and ⅞.”  McElroy Metal’s corrugated products are named M-Cor and Multi-Cor. To learn more about corrugated products, check out our recent blog post.

R-Panel:  While this panel style originated in the pre-engineered building market, its use has expanded greatly.  This panel type is frequently found in warehouses, medical facilities, schools, and convention centers applications. It’s such a versatile product that it has even been used on airport blast walls.

McElroy Metal offers both R-Panel and also a proprietary version that is slightly different called Multi-Rib.  Both panels offer major ribs @ 12” on-center with major rib heights around 1 ¼”.

Looking for something different?  Check this out to learn more about other exposed fastener panel options.

What are my options for concealed fastener wall panels?

Concealed fastener panels offer an economical architectural solution compared to other systems such as insulated metal panels, prefab, and composite panels.  While each panel manufacturer’s offering may vary slightly, below are some popular options offered by McElroy Metal.  You can learn more about our concealed wall panel offering here.

Wave Panel: Currently, panel styles like our Wave panel are enjoying immense popularity.  Part of their appeal lies in the freedom for both vertical and horizontal installation. This panel style allows designers to combine both installation styles on the same project to create visual interest while still gaining the immense benefits of metal panels over other construction products.

FW Panel: FW Panel is a 1 1/2" deep flush metal panel designed for vertical and horizontal applications. FW panels also have an option to create custom reveals from 1 to 3 inches.

Visionline: Visionline F-Series is a flat plate system that is ideal for facades and rain screens. Visionline is available in McElroy's standard architectural colors with a 22 gauge steel substrate.

MSR: MSR combines strength and aesthetics in one profile to add curb appeal to almost any project while providing engineering and weathertightness characteristics demanded by architects and owners. MSR is also commonly referred to as a “Shadow Rib” panel. The photo below uses three of our different wall panels to create an attractive and cost-effective final result. You can learn more about the project by reading the case study here.

What types of coatings are available on metal panels?

Paint systems are another discernable difference when considering metal wall panels.  There are three main types of resins used on metal panels:  polyester, silicone-modified polyester, and polyvinylidene (also referred to as PVDF.) 

As might be expected, higher quality resins provide the greatest protection against panel chalk and fade. Conversely, coatings produced from lower quality resins are more apt to fade and chalk.  

The performance of these coatings follows a well-defined good, better, best hierarchy. As the image below illustrates, polyester paint systems represent the good, silicone-modified polyesters the better, with PVDF’s being the best. PVDF’s are also referred to as Kynar 500®.

Given their architectural focus and consequently demand for outstanding long-term performance, concealed fastener wall panels typically default to PVDF/Kynar 500® paint systems; however, you can’t assume the same for exposed fastener panels.  Some manufacturers, like McElroy Metal, offer exposed fastener panels in both SMP and PVDF/Kynar 500® paint systems. 

Yet others limit exposed fastener wall panels to the middle of the road performance SMP systems, which are more subject to the phenomenon of fade and chalk. These failures occur when the binder breaks down and no longer holds the pigment together. As the photo below illustrates, PVDF/Kynar 500® paint systems should be the preferred choice for projects with a top priority on curb appeal.  Learn more about coatings here.

Both PVDF (Kynar 500) and Silicone-Modified Polyester (SMP) panels were installed on this home in Louisiana. On day one, the colors were an identical shade of green. This photo taken eight years later tells a powerful story of the differences between the paint systems as it highlights both chalk and fade of the SMP paint system. Note that there is no visible fade or chalking on the darker (PVDF) panels.

What gauges are available for metal wall panels?

Metal wall panels range from 29 gauge on the lower end of the spectrum to 18 gauge on the higher end.  The gauge of metal panels affects everything from the distance they can span to how they perform against extreme winds and hail.  Panel gauges can also affect the visual appearance of oil canning.  Consequently, concealed fastener panels are often produced in heavier gauges to help combat oil canning.  

As a rule of thumb, post-frame projects tend to use 29 ga products while commercial projects gravitate to 26 or 24 gauge, and architectural projects routinely use 24 and 22 ga.

What is oil canning, and how does it affect metal wall panels?  

Oil canning is an inherent natural property in metal panels. While it’s an aesthetic concern and typically doesn’t affect panel performance, the distortion or waviness of panels can be troublesome to some building owners.

It’s important to understand that oil canning can affect all metal substrates, including steel, copper, zinc, and aluminum. The panel color, temperature, sunlight, season, and the angle the viewer is to the panels all play a part in the appearance of the oil canning effect.

To minimize the effects of oil canning, narrower panel widths, heavier gauges, and pan configurations are common strategies. To learn more about the causes and ways to mitigate oil canning during product selection and installation, check out our earlier blog post on oil canning.

Can a standing seam roof panel be used as a metal wall panel?

Standing seam roof panels can also be used as wall panels. You can read more about the University of Arkansas project at Champions Hall shown below by clicking here.  With that said, there is a crucial consideration before using standing seam panels in a wall application.  

It is important to consider how the standing seam panels engage with each other.  In other words, are they snapped or mechanically seamed together? While crews can install mechanically seamed standing seam panels for wall applications, it’s important to understand that they often choose to hand seam these panels instead of seaming them with the motorized seaming machines.  

Installers make this decision for a couple of reasons.  First, in some cases, the motorized machines struggle to pull themselves up a completely vertical wall, and in others, it can be challenging to disengage the device at the top of the wall. 

While hand seaming the panels completes the seaming operation, it can appear less visually appealing than panels seamed with a motorized device.

Consequently, while either panel style will work, wall panel applications often favor snap-type standing seam roof panels instead of mechanically seamed. 

Contact us to discuss your requirements of Embossed Wall Panels. Our experienced sales team can help you identify the options that best suit your needs.

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