In the hands of fabricators and architects, lightweight sandwich panels are a versatile material. Capable of transforming a typical interior design or architectural project into a finished work of art, finding the right lightweight sandwich panel can be a make-or-break decision. At Kerfkore, we’ve helped hundreds of fabricators, architects, and interior designers find the perfect lightweight sandwich panels for their project – here are 9 questions to ask your supplier when determining which is right for you.
This question is important because it sets the tone for the entire engagement. If you know what to expect at each step along the way, there will be no surprises and fewer headaches.
A salesperson or representative from the supplier should be able to tell you about their company’s process for working with clients including how they determine which products are best, how they deliver solutions, and how they follow up on the project after it’s completed.
Find a supplier that keeps it simple and understands your timelines, budget, and project scope.
With so many lightweight core options available, it can be difficult to figure out which panel makes the most sense for you. You can begin by determining the necessary specifications required for your project. Then, find out which lightweight products the suppliers carry. Check to see which of their products align with your needed specs such as thermal conductivity, moisture resistance, strength, weight, etc.
Once you’ve aligned the panel’s specs with your project’s needs, you can begin examining the face materials available. Make sure your chosen face materials align with the end goal of your project. For example, if you plan to paint your panel, you will want to work with a smooth surface such as a hardboard or fiberboard.
It’s likely your project will be required to meet energy efficiency standards and LEED requirements. Because sandwich panels are comprised of different materials, it’s important to inquire about each material’s sustainability or fire rating. A panel’s core may be sourced sustainably but that doesn’t necessarily mean the face materials are.
If you’re interested in working with lightweight panels, then you’re probably also interested in keeping the overall weight of your project relatively low. A prospective supplier should be able to give you an estimated weight per square foot for your panel depending on the combination of materials chosen.
It’s always a good idea to see the products in action. Ask your panel supplier to provide pictures or videos of recent projects to understand what can be achieved. A panel supplier that cares about giving you the right products will be happy to share samples, examples, or even connect you to past customers.
Understanding your installation considerations is important because they could affect your material choices and possibly your budget. Think about whether you need custom framing or internal banding and whether either can be done during the manufacturing process or in your shop.
Some more specific questions related to installation to ask could be:
“How will this panel fasten to the mainframe?”
“Are there any limitations with edgebanding the panels that I should be aware of?”
“Can framing be added during the manufacturing process?”
Due to their dedication to manufacturing and providing excellent customer service, the team at Kerfkore can provide comprehensive support and troubleshooting during installation.
Maybe the most important question and one you’ll want to ask upfront. The right supplier will want to meet customer expectations and thus should be upfront and honest with an accurate estimate of time and costs.
If you know a stock solution won’t fit your needs, ask your supplier about their panel customization options. If you’re looking for lightweight sandwich panels, then you may also need a custom thickness or panel size to fit your project. At Kerfkore, we offer a variety of lightweight customizations, from the size and thickness of the panel to the framing and interior banding. We even offer in-house applications of decorative finishes, so that the panel is ready to install as soon as it arrives at your door. Any experienced supplier should be well-versed in working with customers to provide the right solution.
As we mentioned before, a supplier that wants to work with you should be more than happy to show off a few satisfied customers. If they can’t find any or are hesitant to, then it’s likely that they’re a supplier that’s providing a less than ideal product.
You can get a solid handle on whether a company is a group you’d like to work with or whether you can learn more about working with their products via social media. Take a couple of minutes to scan your prospective supplier’s LinkedIn, Facebook, Twitter, Instagram, or Tik Tok. Are they providing interesting examples of their work or educational videos?
Unlike going on a date, you don’t have to play 21 Questions to find out if you’re talking to the right lightweight sandwich panel supplier for your project. Just float these 9 questions and if their answers line up with your project – then it’s a match!
When we think of the greatest feats in architecture, we think of structures that seem to defy gravity or support an impossible amount of weight like skyscrapers or suspension bridges. In order for these structures to stand, they have to be incredibly efficient and purposeful with how their weight is distributed.
When it comes to interior architectural design, we can achieve this key principle of architecture with the unassuming but mighty sandwich panel.
A sandwich panel is a three-layer structure, with the two outside layers consisting of a thin, rigid material and the middle layer consisting of a thicker, lightweight material.
The materials used may vary depending on the sandwich panel’s purpose but ultimately this configuration should create a panel that becomes greater than the sum of its parts.
Sandwich panels can be useful in architecture because the outside layers provide durability and the inside layer keeps the panel lightweight, creating an easily customizable and adaptable panel.
Weight is taken into consideration for interior architecture because it affects:
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Typically, we assume the heavier a material is, the more durable and stronger it’ll be. Innovations in engineering, science, and design have made it so this is not always the case. Think of medieval knights wearing heavy steel armor for protection. Today’s soldiers are more prone to wear Kevlar, a synthetic fiber that is up to five times stronger than steel when comparing strength-to-weight ratios.
Portability is also affected by weight, lighter materials are easier to handle and transport, which means a safer and more adaptable work environment.
Working with lightweight materials can even reduce costs. There’s less of a need for reinforcing materials, potentially fewer costs for transportation, and lower labor installation costs.
We understand why weight is so important when it comes to architectural interior design and how a sandwich panel creates a lightweight panel that is stronger than the sum of its parts. So what are the cores of these wonder panels actually made of? Panels are typically constructed with a lightweight core material sandwiched between lightweight woods or particleboard. Here are some of the most common.
Usually produced from recycled cardboard, this core has a honeycomb pattern that makes it lightweight, high in compressive strength, and low cost. Just like how bees make the most of their resources, honeycomb cores utilize an efficient shape to yield a high strength-to-weight ratio and compressive strength.
As opposed to cellulose paper or cardboard, polycarbonate honeycomb cores consist of a type of plastic made from synthetic resin. The plastic allows the core to be an effective thermal insulator.
The most rigid and strongest of the honeycomb core materials listed here. However, aluminum also tends to be the most expensive.
Polypropylene plastic core is made from tough, versatile polypropylene plastic. It is strong, stiff, and light.
Expanded Polystyrene, also known as EPS foam, is a white foam plastic made from expanding polystyrene beads with steam and bonding the beads together under pressure. Recycled materials can be used in this process making it a sustainable and low-cost core material. It can be up to 70% lighter than wood panels and has low thermal conductivity, high resistance to water penetration, and high compressive strength.
Another foam plastic, Graphite Enhanced Polystyrene Core is produced from the same process as EPS foam but is infused with high purity graphite, giving the insulation a reflective property that significantly slows the transfer of heat and increases energy efficiency.
Extruded Polystyrene Core (XPS), on the other hand, is another type of foam plastic. While XPS begins with the same materials as its expanded cousin, XPS is fed additives and expands during cooling. Much of its properties are the same, low thermal conductivity, high resistance to water penetration, and high compressive strength.
Lightweight MDF is a composite wood product often made from tree fibers, resin, and wax compressed under high pressure and heat. It’s about 20% lighter than regular MDF but tends to be a less durable product. This product is often used in sandwich panels but can also be used on its own.
Hollow core particle board is made by placing tube extrusions during the manufacturing of solid particle board then removing them when the product is finished, which eliminates much of the weight. It can weigh up to 50% less than traditional wood paneling.
As its name implies, Balsa Wood is made from the Balsa Tree. If you’ve ever handled Balsa Wood, you know it’s low in density but surprisingly strong, making it a great material for a sandwich panel core. Balsa wood is five times lighter than traditional particleboard and fiberboard core materials. It’s also three times lighter than lite core plywood materials. Balsa Wood is a great, versatile material but is currently in low supply due to its use in wind turbines all over the world.
While all of these materials are made from different raw materials and through different processes, they are valued in sandwich panels for one particular attribute: they’re light weight. But that’s not the only reason why these materials should be considered by architects working on their next interior design project. Here are a few more benefits of lightweight materials worth mentioning.
Who doesn’t get a warm, fuzzy feeling when doing their part to protect Mother Nature? Now you can experience that same feeling when designing interior architecture. A good portion of the sandwich panel cores we just covered (Extruded Polystyrene, Expanded Polystyrene, and Cellulose Paper/Cardboard) can be made from recycled materials, making them environmentally responsible options for architects.
An indirect way that lightweight materials are more sustainable than other paneling is the cost of transportation. Trucks use less fuel to transport a load of lightweight panels than for a heavier load of solid paneling.
Also, sandwich panels and their lightweight cores can be effective as insulation which is a good way to save on energy costs.
Unlike heavier and clunkier materials, lightweight sandwich panels allow for easier design and flexibility. Anytime a lightweight panel has to be moved because of changes in design or undergo further fabrication it’s that much easier to do than it would be with a heavier panel. Depending on the project, handling of lightweight panels may be performed by fewer workers versus requiring equipment to handle heavier materials.
Speaking of design and flexibility, lightweight sandwich panels are incredibly versatile in their applications. Here are some of the most common ways they are used:
At Kerfkore, we offer two different lightweight sandwich panels. Our panels provide strong structural integrity with two thin rigid face materials paired with a lightweight core. With this construction, our lightweight panels can reduce weighty up to 80% compared to plywood, particleboard, and MDF. Not only is it easy to to attach our panels, but they can be used with high-pressure laminates, veneers, and more for a beautiful finish.
Our panels have the following face material options:
Both Worklite XPS and EPS are available in the following panel sizes:
Our Worklite XPS Foamkore panel is made of extruded polystyrene, a durable foam. This dense material makes it resistant to temperature changes and creates a solid edge that can be painted. Worklite XPS is offered offered in 1/2″-3″ thicknesses.
Our Worklite EPS Foamkore panel is made of expanded polystyrene, a lightweight foam. It is known for low thermal conductivity and water resistance. Worklite EPS is offered in 1/2″-3/4″ thicknesses.
Utilizing lightweight panels is only limited by an architect’s creativity. One of our favorite uses of our lightweight materials was on the set of one of The Fast & Furious movies. 400 sheets of our Worklite EPS Foamkore were used as temporary flooring and walls for the set. We’re still hoping Vin Diesel will autograph one.
Designing and working with lightweight panels opens up so many possibilities for architectural interior design. Most architectural projects struggle to find the right balance between light weight and durability. With lightweight sandwich panels, you can have the best of both worlds.
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