Installing sandwich panels with future repairs in mind

For refurbishment, plan temporary protection for the interior. Removing a wall can expose machinery to rain and dust and give unauthorised people access. Limit each day’s work to an area the crew can close again. Where the installation zone crosses a route used by staff, organise an alternative route or traffic controls before starting.

Check the design dimensions against the actual support centrelines, levels and vertical alignment, then confirm the panel lengths. Vertical and horizontal layouts put joints in different places and require different support arrangements. Verify which facings are specified as well as the nominal core thickness.

Mark doors, windows, corners and proposed service penetrations on the drawing. If the last panel would leave a narrow strip, adjust the layout before cutting. Where heavy services pass through the wall, design their supports before closing it. The thin metal facing alone should not carry their weight.

On delivery, check the panel markings, dimensions and condition of the accessible surfaces. Record damage before installation so that it can be distinguished from any damage caused later. Arrange packs in installation order on ground that stays dry, clear of routes needed by site equipment.

Follow the product instructions for gripping, lifting and storage. Protect the edges and coatings. Sliding one panel over another can damage the surfaces that need to seal at the joint. When lifting panels upright, leave enough room to guide them into position without leaning them against finished cladding.

Align the starter components and first panel before fixing the next panels. Close each joint as specified for its profile. Select fasteners, washers and seals for the panel, substrate and loads. Follow the specified tightening method to avoid deforming the facing.

Schedule the plinth connection, corners and roof junction as part of the wall installation. Check that each seal is continuous before the flashing covers it. Fit the layers shown on the detail drawing so the flashing can perform its intended function. Gaps are easier to locate now than after the heating is switched on and occupants notice draughts.

At every cut opening, check the support, the seal and the closure of exposed core edges. Use cutting tools approved for the facing. Clear swarf as work proceeds before it causes local surface damage. Remove the protective film at the time and in the manner specified for the product.

Inspect the wall again after the services installers have finished. An unused hole, a poorly supported pipe or a cut flashing can compromise an otherwise sound wall. Check the proposed fixings before hanging heavy cabinets or cable trays. Planning these attachments keeps the finished surface easier to maintain.

At handover, check the wall for plumb and flatness, inspect edge closures and coatings, and compare the work with the drawings. Record repairs made after installation. Photograph junctions before equipment hides them and mark the locations of different panel types on a drawing. A repair crew can then identify the right panel and connection for a local replacement.

Give the operator the maintenance requirements and the limits on attaching further equipment. Fit impact guards where the wall is exposed to knocks. If an extension is planned, document how the new façade will join the existing section. Keep these details with the handover records for later inspections.