How to prepare and cut a sandwich panel

Agree service openings with the installers. A relocated duct may cross a joint or fixing zone. Before cutting to resolve a clash, check the remaining panel supports and the effect on fire performance and weather or air seals.

Lay the panel on a stable work station in accordance with system instructions. Support it against uncontrolled deflection and prevent the offcut from dropping. Protect the underside from dirt and scratches. A hard object left on the bench can damage the facing as the panel is moved.

Provide space for the offcut and access for the tool. Long or heavy panels may need handling equipment. Before turning a panel, prepare the space and supports. Select personal protection for sharp edges, dust and noise in accordance with the tool instructions.

Use a tool intended for sandwich panels, such as a suitable panel saw or saw with the specified blade. Select it for the thickness, core and cut geometry. Consult both panel and tool instructions. A saw capable of cutting sheet metal may still be unsuitable for the composite panel.

Do not cut coated panels with an angle grinder. Heat and hot particles can damage the sheet’s protective layers, with corrosion appearing later. Cut flashings with appropriate tools, such as sheet metal shears, and avoid abrasive discs.

Check the clear opening dimensions and space for framing. Mark supports and fasteners. An opening that crosses a joint or lies near a panel end requires particular assessment. A narrow remaining strip may behave differently from the full panel used in the design.

Support the offcut so the facing cannot peel away uncontrollably from the core. Follow the tool and system instructions for sequence and technique. For a fire-rated wall, approve the penetration protection detail before cutting the opening.

Use marking lines that can be removed without damaging the finish. Check the measurement again with the person responsible for the opening. Even a small error can prevent a watertight flashing detail. Once services are installed, it is harder to reach the cut and remove the waste.

Collect metal particles from both accessible faces and adjacent elements. Swarf left on a coating can rust and leave marks. Do not rub it into the finish. Use a non-scratching method approved for the material.

Inspect the edge, facings and core for burrs, local delamination or coating damage. Select edge protection compatible with the exposure and protective finish. An arbitrary paint or sealant may be incompatible with the panel materials.

Finish the cut with the specified flashing, seals and framing where required. They must keep water out and preserve the wall’s intended performance. Do not leave mineral wool exposed on the assumption that the service will cover it. Complete the opening as a coordinated assembly.

Before closing up, photograph the detail and check it against the drawing. Establish whether it will remain accessible for inspection. Record the location and extent of any alteration to an existing wall so future workers can locate cuts, joints and reinforcements.