Foam Sandwich Panel Supplier

Foam Sandwich Panel-A Comprehensive Buying Guide by Sunnyda.

Foam Sandwich Panel is extremely lightweight with an easy handling experience making it perfect for your wall cladding, model making, signage, direct digital printing, retail display, and exhibition graphics applications.

It contains no traces of heavy metals or lead, possesses fine molecular structure, and offers the best density for durability and stability making it perfect for both your use and the environment.

The Foam Sandwich Panel is also resistant to extreme weather conditions, shows fire retardancy, and possesses great insulating properties that help it stand out amongst other panels.

Here is a complete guide related to a Foam Sandwich Panel that you must go through to get a better idea of what it is, its benefits, applications, installation, maintenance, and much more.

Let’s start now.

1.What is a Foam Sandwich Panel?
2.What are the Mechanical Features of a Foam Sandwich Panel?
3.What are the General Properties of a Foam Sandwich Panel?
4.What are the Acoustic Properties of a Foam Sandwich Panel?
5.What is the Burning Behavior Possessed by a Foam Sandwich Panel?
6.How does the Foaming Process of a Foam Sandwich Panel Work?
7.What are the Coating Options for your Foam Sandwich Panel?
8.What are the Applications of a Foam Sandwich Panel?
9.What is the Right Method of Foam Sandwich Panel Color Selection?
10.What are the Benefits of a Foam Sandwich Panel for your Applications?
11.What is the Load Capacity of a Foam Sandwich Panel?
12.Is a Foam Sandwich Panel Leak-Proof?
13.How your Foam Sandwich Panel Provides Environmental Protection?
14.What are the Storage Instructions for Foam Sandwich Panel?
15.How is a Foam Sandwich Panel Transported?
16.How to Install a Foam Sandwich Panel?
17.What are the Instructions for Attaching Small Elements With your Foam Sandwich Panel?
18.What are the Most Common Problems of Foam Sandwich Panel?
19.How to Solve the Problems of your Foam Sandwich Panel?
20.What are the Maintenance Instructions for your Foam Sandwich Panel?
21.Conclusion.

What is a Foam Sandwich Panel?

Foam Sandwich Building Panel is a structure made up of three layers; a core with low density and a thin skin layer adhered to both sides. It is used for applications requiring low weight and high structural rigidity.

The outer layers are kept thick to ensure maximum bending stiffness, good maintenance, perfect performance, and weight reduction.

Foam Sandwich Panel is good for making multiple complex shapes, low construction and maintenance cost, reduced damage risk, excellent damping behavior, and good adhering properties.

It is also good to be recycled thus playing positive roles for the environment.

What are the Mechanical Features of a Foam Sandwich Panel?

The mechanical features of a Foam Sandwich Panel are:

• 25-micron coat thickness

• Smooth surface finish

• ≤ 2 T coat adherence

• ≤ 3 T coat elasticity

• 18J impact strength

• ≥ 2,0 kg scratch resistance

What are the General Properties of a Foam Sandwich Panel?

The general properties of a Foam Sandwich Panel are:

• Profiled lining

• Unique surface design

• Large bond radii

• Freon free core construction

• Good thermo-insulation properties

• Protecting strip to prevent water or gas infiltration

What are the Acoustic Properties of a Foam Sandwich Panel?

Steel Foam Sandwich Panel provides excellent soundproofing because of its admirable acoustic properties, which are mentioned below:

• 25 Rw [dB]; the entire insulating capacity, in the audible spectrum range.

• 23 RA1 [dB]; barrier properties in low tone ranges

• 20 RA2 [dB]; barrier properties in high tone ranges

Sound Transmission Loss in an Hour

• 8,1 at 125 Hz

• 14,2 at 200 Hz

• 13,9 at 400 Hz

• 15,3 at 600 Hz

Sound Absorption Coefficient Variation

• 0,21 at 400 Hz

• 0,25 at 500 Hz

• 0,06 at 800 Hz

• 0,69 at 1000 Hz

What is the Burning Behavior Possessed by a Foam Sandwich Panel?

Foam Sandwich Panel acts as a thermo-insulator which helps it prevent fire catching incidents.

This is because it has a high amount of flame retardants and isocyanates which help in enhancing the fire dealing properties of the Foam Sandwich Panel.

How does the Foaming Process of a Foam Sandwich Panel Work?

As the first phase in the technique, the foundation layer is welded onto the metal sheet. The workpiece is then tacked or screwed to the wood frame.

The wood is then screwed into the metal. The foaming process involves shaping the foam sheet first, etching it out then and finally joining the sheets together to form a Foam Sandwich Panel.

What are the Coating Options for your Foam Sandwich Panel?

Four of the most common generic coating options are: 

• Epoxies

• Polyurethane

• Polysiloxane

• Zinc-rich primer.

Epoxy Coating:

The epoxy coating hardens into a durable, stiff plastic layer with a wide range of mechanical quality once it has been completely set.

In Foam Sandwich Panel production, epoxy provides a good ground for gluing, foaming, and bonding.

Polyurethane Coating:

Corrosion, drying, abrasion, and other harmful process are all protected by this coating.

Because of its ease of installation and superior insulation, it is extensively used in refrigerated temperatures, ceilings, temporary accommodation, dorm, warehouse, workshop, and other purposes.

Polysiloxane Coating:

It is a styrofoam coat paint that comprises a silicon-based compound capable of lowering the content of an organic compound made up of carbon and hydrogen. This helps it ignite effectively in a fire.

Zinc-rich Primers Coating:

Zinc primers prevent corrosion of structural steel more quickly when in connection with it, preventing it from being damaged.

This enhancement in zinc concentration greatly enhances the corrosion resistance of the substrate in the Foam Sandwich Panel.

What are the Applications of a Foam Sandwich Panel?

The use of Styrofoam Sandwich Panels in the construction industry has increased throughout the last few years.

Thermal Barrier:

It is economical, lightweight, easy to install, hygienic, and capable of providing a worthy thermal barrier.

Fire Safety:

While it does not spark fires, but it is linked to hazardous activities that result in rapid fire spread.

Aeronautics, road vehicles, ships, and civil engineering all use the Foam Sandwich Panel.

Mechanical Application:

The Foam Sandwich Panel mechanical properties are directly influenced by the sandwich component qualities and production procedure.

It also works as a cladding material for constructing walls and roofs.

Material Application:

It is constructed using a thermo-insulating core with sheet metal skins on both sides. It works as curtain material, not a structural element.

It is commonly used as an exterior covering for single and multi-story structures.

Cost-Effective Application:

It is a durable and cost-effective product for various facilities, from factories to stadiums, malls to swimming pools.

EPS Insulated Panels are becoming increasingly popular as a product in new fields such as military buildings, agricultural buildings, prefabricated housing, worksite buildings, and silos.

It also has applications in industrial buildings and social areas due to its excellent acoustic and insulation properties.

What is the Right Method of Foam Sandwich Panel Color Selection?

If you want to get the most suitable Foam Sandwich Panel color, you always need to consider the type of metal and its ability to deal with expansion and contraction.

This thing largely affects the overall life of your unit, so it is an essential consideration.

Always remember that dark colors are more absorbent to heat, so if you want to install a Foam Sandwich Panel on a highly heat exposed area, make sure it is not of dark color.

This can lead to waviness in your product and even destruction of the core can occur. Moreover, bending in your unit may also occur which can be harmful for its construction.

What are the Benefits of a Foam Sandwich Panel for your Applications?

The major benefits of a Foam Sandwich Panel are:

Fire Retardancy:

When exposed to flames, it functions admirably. Some variants can withstand temperatures of up to and above 1000° C.

Soundproofing:

Sound insulating materials are necessary for applications that lead to heavy noise creation.

It assists in isolating the source of noise from other sections inside a facility, allowing such areas to remain quiet and pleasant for workers and passersby.

Insulation Against the Elements:

It provides excellent thermal insulation characteristics.

However, depending on the kind and thickness of the materials employed, the thermal insulation vs. thermal conductivity of the material varies.

Extremely High strength-to-weight Ratio:

It provides higher strength-to-weight ratios than solid laminates.

As a result, it can sustain equivalent loads with less structural material, potentially saving money on material purchases and shipping.

Cost-Effectiveness:

EPS Panel Sandwich is a low-cost alternative because its core materials are less expensive than other composite reinforcing materials.

Also, it is simple to maintain and its intrinsic endurance reduces its maintenance expenses.

What is the Load Capacity of a Foam Sandwich Panel?

Foam Sandwich Panel comes in a variety of sizes and thicknesses and can be used in various applications.

The load capacity of a Foam Sandwich Panel is determined by the amount of foam in it. The Foam Sandwich Panel has an unusually high load capacity.

So it is best used in situations when panel strength is more important than efficiency.

The Foam Sandwich Panel is an insulated panel that is used to keep cold air out. It is built to withstand loads of at least 300 pounds on each side and up to 1,200 pounds total.

It is used in multiple applications, including buildings, workplaces, and shipping containers.

A polystyrene Foam Sandwich Panel is composed of alternating foam which has a maximum load capacity of more than triple its volume.

This makes it perfect for producing a panel nearly three times as thick as one of its competitors.

Is a Foam Sandwich Panel Leak-Proof?

Yes, a Foam Sandwich Panel is leakproof. This restricts the entry of water and moisture into it.Resistance to leakages also increases the overall life and durability of the product.

Moreover, it maintains the function and structure of the unit, by not letting water, moisture, or humidity making any disturbance in it.

Therefore, if you Install Composite Foam Core Panels once, you are guaranteed to use them for a longer time due to their special and amazing features.

How your Foam Sandwich Panel Provides Environmental Protection?

Foam Sandwich Panel provides environmental protection in many ways; two major ones are described below:

Sound Insulation:

In operations that generate a lot of noise, audio insulating materials are required.

The Foam Sandwich Panel assists in isolating the sound level from other areas of a business, making such areas quieter and more comfortable for employees and guests.

Thermal Insulation:

The energy needed for refrigerating operations is lowered when a Foam Sandwich Panel is used in the making of that structure, leading to a lowering in the overall energy expenses.

When properly integrated, it also lowers the risk of mold growth and excess humidity generated by thermal movement and condensation.

The temperature and massive capacity requirements of the building, as well as the surrounding environment and planned use, dictate the thickness of the insulator employed in the Foam Sandwich Panel.

What are the Storage Instructions for Foam Sandwich Panel?

For Less than a Week:

To store your Foam Sandwich Panel for less than a week, there are no technical requirements.

But you need to assure that there is a proper provision of supports to aid in the handling of your unit.

Moreover, always use a flat and plain surface to place your product, this will save it from various sorts of damages.

For More than a Week:

If you are storing your product for more than a week, don’t forget to place a slope with it.

This will help in draining our rainwater naturally.Moreover, make special arrangements to save it from vulcanization problems.It is essential to maintain a space between various units.

For this, you can add spacers, they will be very suitable in providing free airflow between various units placed together.

How is a Foam Sandwich Panel Transported?

Most of the time, the service providers themselves deliver the unit to the site with the help of special vehicles and drivers.

However, if you want to transport your Foam Sandwich Panel to a specific location, always keep in mind the following things:

• Always use forklift trucks for loading the unit from the manufacturer’s store.

• Make sure that the vehicle you are using for transportation is technically suitable for the job.

• The loading vehicle should be clean and there should be no obstacles on it.

• If you want to load two Foam Sandwich Panel units, using an open semi-trailer without any cover is recommended, as it will be more spacious and convenient.

• Never make the mistake of placing these above other products in the same vehicle.

• To tightly secure your product in its place, your vehicle must have ratchet straps; the count depends upon the number of units you are loading.

• The unit can protrude out of your vehicle up to 1.5m distance, so don’t forget to consider this space in your mind.

• It is recommended to hire a professional driver who can safely drive it to the desired location.

• For the product’s safety, make sure that you are not putting extra weight on the vehicle.

• To prevent your product damage, make sure that you safely and slowly drive through the bumps.

How to Install a Foam Sandwich Panel?

Follow this guide for installing your Sandwich Panel Foam:

Align:

Foam Sandwich Panel can be hung horizontally, vertically, or diagonally. The wording written on the tongue joints specifies which way the facing should be installed.

Screws or attaching plates can be used to secure the Foam Sandwich Panel. Screwing is the most frequent method of attaching a Foam Sandwich Panel straight to the building structure.

Hold in Upward Position:

The installation must be done by the structural designs. Begin the installation from the bottom and work your way up with the tongue facing upwards.

Use Proper Equipment:

To ensure safe operation must be performed using the proper equipment. The surfaces must be shielded from machining waste.

Replace Damaged Parts:

If the sheet metal face has a hole or there is a lack in the structure’s integrity and strength has been compromised, it must always be replaced.

Check for Company Seal:

Double-check that the factory-installed groove joint seal is in place. This guarantees the structure’s tightness.

What are the Instructions for Attaching Small Elements With your Foam Sandwich Panel?

For attaching small elements with your Foam Sandwich Panel follow these instructions:

• Ensure if the Foam Sandwich Panel is sturdy enough to bear the weight of the element being attached.

• Look for the right place of attachment and see if the attachment is sized well to fit in that place.

• Secure the attachment properly using locks and screws.

What are the Most Common Problems of Foam Sandwich Panel?

The most common problems of a Panel EPS are:

Loss of Flatness of Surface:

The loss of flatness of the surface is caused by mechanical grinding, which is done to enhance the roughness of the surface for better bonding.

Liquid glue may then be applied to the surface, filling the microcavities and micropores and forming a solid film that joins the core material and the face sheet.

Exposure to Direct Sunlight and Ground:

The protective coating will adhere to the metal surface extremely firmly. As a result, removing it afterward will be difficult.

Some soft sticks are placed beneath the package to give it a pitch, allowing rainfall to flow away.

Debonding:

Face sheets debond from the foam owing to a lack of adhesive in specific areas of the sheets’ surface, resulting in debonding.

This defect is frequently caused by hand gluing of face sheets during the manufacturing of a Foam Sandwich Panel.

Stacking Foam Sandwich Panel:

Even though it is robust, if the weight it has to hold is too much, it may suffer harm.

Durability Problem:

Varying with the type of the Foam Sandwich Panel, several forms of buckling behavior can be seen. It then has to be replaced frequently owing to manufacturing and durability issues.

Cosmetic Damage:

It is prone to aesthetic deterioration and is unable to handle considerable extra stresses which results in damage to the exterior surface.

Moisture:

Moisture can harm a Foam Sandwich Panel; therefore, it needs to be protected carefully. You’ll need to add another panel or a waterproof surface.

How to Solve the Problems of your Foam Sandwich Panel?

The best solutions to the most common Foam Sandwich Panel problems are:

Solving Lack of Flatness:

An epoxy-based coating placed to the B – face of these metallic substrates is used in place of the usual liquid glue.

There is no longer any need for hand bonding or severe mechanical face sheet grinding.

As a consequence, a continuous solid coating is formed on the metallic surface, ready to be attached to a variety of foam materials (polyurethane foams, polyester foams, phenolic foams, etc).

When a solution is applied to a metallic surface, the opposite side of the coating remains chemically reactive, allowing flammable materials to be adhered to the coating to create an insulated wall panel.

 Applying for Engineering Works:

Applying coatings and back coats simultaneously in engineering saving on the application cost.

In the case of stainless steel, you can maintain the A – face’s flawless look, but in the case of galvanized steel and cold rolled steel, you can coat the A – face while applying the epoxy-based coating as a back coat.

Longitudinal Problem Solving:

Additional longitudinal and cross beams alleviate the longitudinal problem by transferring the impact of the apertures and their position on the Foam Sandwich Panel.

Avoidance of Ground:

It should be avoided to put the Foam Sandwich Panel on the floor to lower the damage ratio.

Avoidance of Placing it Near Water:

It should be avoided to place the Foam Sandwich Panel near water to prevent corrosion problems.

Avoiding Stacking Multiple Items on Each Other:

It should be avoided to stacking multiple Foam Sandwich Panel items on each other to reduce the damage ratio.

What are the Maintenance Instructions for your Foam Sandwich Panel?

The maintenance instructions of your Foam Sandwich Panel include:

Yearly Checking:

The overall condition and functionality and other structural components must be checked yearly. Regular inspections help to increase the life of your Foam Sandwich Panel.

During yearly inspections, you must pay special attention to areas where dirt and moisture buildups are common.

Structural Fastening:

In conjunction with maintenance, structural fastenings must be examined.

Unscrewing several fastenings at multiple sites helps in better assessing their condition.

To prevent water from entering the screw head, focus on the fastener look and seal quality present under the screw head joints.

Documentation:

The maintenance work conducted on the structures must be documented.

The object of maintenance, the date, measurements taken, the person doing the work, and the tools and materials used are some major points that must be checked.

Seal Checking:

The seals must be examined to verify that the intended level of air and vapor tightness is maintained.

Replacing Damaged Parts:

Damaged seals must be replaced with new ones, which may be done using appropriate mastic. When it is required and suitable, old seals are removed.

Conclusion

Foam Sandwich Panel is effective to thermally insulate your roofs or vehicles. It comes with an easy installation process and is easy to clean also.

All you need to do is to take care of its regular cleaning and maintenance to ensure maximum efficiency and performance of your Foam Sandwich Panel.

FAQs of Foam Sandwich Panel.

Which Pressure Provides the Maximum Air Permeability of a Foam Sandwich Panel?

Foam Sandwich Panel possesses perfect air permeability when the air pressure recorded is -50/+50 Pascals.

What is the Purpose of Protective Film Present on Both the Sides of a Foam Sandwich Panel?

Both the sides of a Foam Sandwich Panel are protected by a protective film which provides safety to the inside material during the assembly and transportation process.

When is the Right Time for Removing the Protective Film of a Foam Sandwich Panel?

The protective film present on both sides of a Foam Sandwich Panel must be removed within 1 month of the manufacturing date.

In the other case, 3 weeks after the product has been exposed to the sunlight, the protective film should be professionally removed.

What are some Possible Consequences of Aggressive External Environmental Factors to Consider Relevant to the Foam Sandwich Panel?

Some possible consequences of aggressive external factors to consider in the case of a Foam Sandwich Panel are discoloration, corrosion, and blooming.

What are the Possible External Factors that can Damage a Foam Sandwich Panel?

The possible external factors that can damage a Foam Sandwich Panel include water, chemicals, and moisture present in the surrounding environment.

How Do UV Radiations Affect the Quality of Lining of a Foam Sandwich Panel?

UV radiation may leave an adverse effect on the quality of lining of a Foam Sandwich Panel leading to its discoloration and loss of glossy appearance.

What are the Conditions to Consider when Choosing the UV Resistant Paint Coat for Foam Sandwich Panel?

The conditions to consider when choosing the UV resistant paint coat for a Foam Sandwich Panel include the geographical location (height about sea level), sunlight exposure, the aesthetic aspect related to the usage, and expected operational time.

How Animal Excrements are Damaging to the Paint Coating of a Foam Sandwich Panel?

The animal excrements contain a high quantity of ammonia and its toxic derivatives.

These substances are damaging to the paint coating of a Foam Sandwich Panel as they result in its corrosion and rapid deterioration.

What are the Standard Metal Coating Options Related to a Foam Sandwich Panel?

The metal coating options related to a Foam Sandwich Panel include 225g/m^2 zinc coating on both sides and 150 g/m^2 aluminum and zinc coating on both sides.

What are the Standard Organic Coat Details of a Foam Sandwich Panel?

The organic coat details of a Foam Sandwich Panel are 5 microns thick layer for the ground coat and 20 microns thick layer for the prime coat.

What is the Resistance of a Foam Sandwich Panel to Different Solvents?

Foam Sandwich Panel shows very good resistance to alcohols and aliphatic compounds, low resistance to ketones, good to very good resistance to aromatic compounds, very good mineral oils resistance, and low ammonia resistance.

What is R Parameter with Relevance to Foam Sandwich Panel for Roofs?

The R parameter with relevance to a Foam Sandwich Panel for roofs is the time used for the maintenance of load capacity by the loaded element.

This time must not exceed the high limits of the load capacity of that element and also not cross any operational safety boundaries.

Why Polyurethane is Used in the Construction of a Foam Sandwich Panel?

The purpose of using polyurethane in the construction of a Foam Sandwich Panel is to lower the consumption of energy as polyurethane has high durability due to which it can be used for a longer time ultimately leading to energy-saving goals.

What is the Recommended Size for Safe Transportation of a Foam Sandwich Panel?

The size mostly recommended for safe transportation of a Foam Sandwich Panel is a container with at least 250 cm width in case of an open semi-trailer.

If one desires to adjust two panels in the same container, then minimum width of 1200 mm is required (with relevance to closed semi-trailer).

What is the Extendable Distance Allowed for a Foam Sandwich Panel from the Rear Edge of the Vehicle?

The extendable distance allowed for a Foam Sandwich Panel from the rear edge of the vehicle is 1.5m. This must be checked at the time of loading to ensure safe and smooth transportation.