How to Choose the Thickness of Sandwich Panels: 50, 80, 100, 120, or 150 mm?
Sandwich panel thickness is one of the key parameters that must be determined before ordering the material. It affects the building’s thermal insulation, energy efficiency, construction cost, and future operating conditions.
The most common sandwich panel thicknesses are 50, 80, 100, 120, and 150 mm. However, there is no single thickness suitable for every project. The requirements for an unheated warehouse and a heated industrial facility can be completely different.
Let us look at how panels of different thicknesses differ and which option is better suited for a specific project.
What determines the choice of sandwich panel thickness?
Several factors should be considered at the same time:
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purpose of the building;
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whether the premises will be heated;
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climatic conditions;
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required indoor temperature;
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type of insulation;
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wall or roof structure;
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spacing between frame elements;
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project requirements;
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construction budget.
One common mistake is choosing panel thickness based only on price.
A thinner panel may indeed cost less, but in a heated building it can lead to greater heat loss and higher heating costs.
50 mm sandwich panels
Panels with a thickness of 50 mm are considered relatively thin.
They are primarily suitable for facilities where high thermal insulation is not required.
They can be considered for:
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unheated warehouses;
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temporary structures;
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retail pavilions;
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technical rooms;
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internal partitions;
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small utility buildings.
The main advantage of 50 mm panels is their relatively low cost and weight.
However, this thickness may be insufficient for a permanently heated building. The decision should be made with consideration of the insulation type and thermal engineering calculations.
80 mm sandwich panels
A thickness of 80 mm is an intermediate option between minimum cost and improved thermal insulation.
These panels can be used for:
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warehouses;
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commercial facilities;
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workshops;
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service stations;
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industrial premises;
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small administrative buildings.
If the premises are heated periodically or the thermal insulation requirements are moderate, 80 mm panels can be a practical solution.
However, it is important to remember that thermal performance depends not only on panel thickness but also on the type of insulation used.
100 mm sandwich panels
100 mm sandwich panels are among the most versatile options.
They provide good thermal insulation and are suitable for many types of commercial and industrial buildings.
100 mm panels are often used for:
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heated warehouses;
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industrial premises;
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shops;
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service centers;
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car washes;
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agricultural facilities;
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administrative buildings.
For many construction projects, 100 mm offers a reasonable balance between panel cost and thermal insulation performance.
However, the final choice should still take into account the climate, insulation type, and building operating conditions.
120 mm sandwich panels
A thickness of 120 mm is used when higher thermal insulation performance is required.
These panels can be used for:
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permanently heated industrial buildings;
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warm warehouses;
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industrial facilities;
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premises with a stable temperature regime;
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certain cold storage facilities.
The additional insulation thickness helps reduce heat loss through the building envelope.
This is especially important for buildings that are heated or cooled during most of the year.
150 mm sandwich panels
Panels with a thickness of 150 mm provide a high level of thermal insulation and are usually used for facilities with special temperature requirements.
For example:
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cold storage rooms;
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freezer rooms;
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food production facilities;
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logistics centers;
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heated industrial buildings;
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facilities with increased energy-efficiency requirements.
Using thicker panels makes sense when reducing heat loss is genuinely important for building operation.
Installing 150 mm panels on a small unheated warehouse simply because “thicker is better” is usually not economically justified.
Does a thicker panel always mean better insulation?
With the same type of insulation, increasing its thickness generally improves the thermal resistance of the structure.
Simply put, a thicker panel reduces heat transfer through walls or roofing more effectively.
However, comparing panels only by thickness is incorrect.
For example, 100 mm of one insulation material and 100 mm of another may have different thermal insulation characteristics.
Therefore, two parameters should always be considered together:
panel thickness + insulation type.
How does the insulation type affect the required thickness?
Different thermal insulation materials are used in sandwich panels.
Expanded polystyrene
A popular option due to its affordable price and low weight.
It is used in warehouses, commercial buildings, industrial facilities, and many other projects.
The required thickness is selected according to the thermal insulation needs of the building.
Mineral and basalt wool
Their main advantages include good sound insulation and suitability for projects with increased fire safety requirements.
For the same thickness, thermal performance should be compared based on the characteristics of the specific material.
PUR
Polyurethane foam has good thermal insulation properties.
Thanks to its low thermal conductivity, effective insulation can be achieved with a relatively small structural thickness.
PIR
PIR also offers high thermal insulation performance and is used in facilities where energy efficiency is important.
PUR and PIR panels are especially popular for cold storage and temperature-controlled rooms.
What thickness should be chosen for walls?
For wall sandwich panels, the following approximate guideline can be used:
50 mm — unheated and technical premises.
80 mm — premises with moderate thermal insulation requirements.
100 mm — a versatile option for many heated commercial and industrial buildings.
120 mm — buildings with increased requirements for heat retention.
150 mm — premises with special temperature conditions and high thermal insulation requirements.
This is only a general guideline. The actual thickness should be selected according to the characteristics of the building.
What thickness should be chosen for roofing?
The roof is an important part of the building’s thermal envelope.
Warm air rises, so an inadequately insulated roof can cause significant heat loss.
When choosing the thickness of a roof sandwich panel, consider:
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purpose of the building;
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indoor temperature;
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insulation type;
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climatic conditions;
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snow loads;
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spacing between roof purlins;
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panel load-bearing capacity.
Therefore, roof panel selection should be based not only on thermal insulation but also on allowable structural loads.
Are panel thickness and strength the same thing?
No.
Increasing panel thickness may affect its characteristics, but load-bearing capacity depends on several factors at once:
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thickness of the metal sheets;
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profile shape;
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type of core material;
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quality of bonding between layers;
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span length;
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fastening method;
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direction of load.
Therefore, roof or wall panel thickness should not be selected based on the assumption that a thicker panel will automatically withstand any load.
The manufacturer’s technical specifications and the building project must be taken into account.
Should panels be chosen with extra thickness?
A small reserve in thermal performance can be useful, especially if the building will be permanently heated or cooled.
However, increasing the thickness excessively without a real need is not always rational.
For example, if calculations show that 100 mm is sufficient for a particular project, switching to 150 mm will increase the total cost of the panel package.
The right approach is to choose a thickness that provides the required performance without unnecessarily increasing construction costs.
What thickness should be chosen for a warehouse?
For an unheated warehouse without permanent heating, thinner panels are often considered.
For a warm warehouse where a comfortable or technological temperature must be maintained, more effective thermal insulation is required.
Therefore, panels for a warehouse should not be selected based only on the size of the building.
You need to know:
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whether heating will be installed;
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what temperature must be maintained in winter;
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whether air conditioning will be used in summer;
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what goods will be stored;
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whether a stable temperature must be maintained.
What thickness should be chosen for an industrial facility?
For industrial buildings, the production process must also be considered.
If people work inside and the facility is permanently heated, saving on thermal insulation may be uneconomical.
The greater the heat loss, the higher the cost of maintaining the required indoor temperature.
For such projects, medium and increased panel thicknesses are usually considered, but the exact solution depends on the project.
What thickness should be chosen for a cold storage room?
The requirements are significantly higher in this case.
The required thickness depends on:
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temperature inside the chamber;
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ambient temperature;
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type of refrigeration system;
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selected insulation;
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purpose of the chamber.
For cold storage and especially freezer rooms, thicker PUR or PIR panels are often used.
For such facilities, a separate thermal engineering calculation is recommended.
50, 80, 100, 120, or 150 mm — which should you choose?
If we simplify the choice:
50 mm — a budget solution for facilities without serious thermal insulation requirements.
80 mm — for moderately warm premises.
100 mm — a versatile thickness for many commercial and industrial buildings.
120 mm — improved thermal insulation for permanently heated premises.
150 mm — for facilities with high temperature-retention requirements.
However, this is not a complete engineering calculation. The optimal thickness depends on the specific project and the insulation used.
What information is needed for proper selection?
Before ordering, it is advisable to provide the manufacturer with:
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city or region of construction;
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purpose of the building;
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building dimensions;
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required indoor temperature;
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availability of heating or cooling;
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roof type;
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preferred insulation type;
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project requirements, if available.
This will help select a more suitable option and avoid both insufficient thermal insulation and unnecessary overpayment.
PanelCity sandwich panels
PanelCity manufactures wall and roof sandwich panels in Uzbekistan for various construction projects.
Depending on the purpose of the building, customers can select the required thickness, insulation type, panel length, and color from the RAL catalog.
PanelCity also manufactures accessories for the installation of wall and roof sandwich panels.
The company’s specialists will help select the appropriate product characteristics according to the requirements of your project.
Conclusion
The choice between 50, 80, 100, 120, and 150 mm sandwich panels depends primarily on the purpose of the building and the required level of thermal insulation.
For unheated structures, there is usually no need to use the thickest panels, while for permanently heated, cooled, or refrigerated premises, saving on insulation can lead to higher operating costs.
When choosing panels, consider not only thickness but also the type of insulation, metal thickness, roof and wall characteristics, loads, and climatic conditions.
Properly selected sandwich panels help achieve the optimal balance between construction cost, thermal insulation, and future building operating expenses.
