PUF Panel Wall Installation: Step-by-Step Technical Guide

Understanding Wall Panel Installation

Installing PUF wall panels might look straightforward—after all, you're essentially attaching pre-made panels to a structure. But the difference between a good installation and a great one lies in dozens of small details that affect thermal performance, weather resistance, and longevity.

Having supervised hundreds of installations, I've compiled this guide covering everything our trained teams do to achieve consistently excellent results.

Pre-Installation Requirements

Structure Verification

Before any panel goes up, verify:

• Girt alignment: Maximum deviation of 3mm over any 3-meter span
• Plumb accuracy: Columns must be within tolerance
• Level base: Starting point must be perfectly level
• Structural completion: All welding and bolting finished
• Clean surfaces: Remove rust, oil, and debris from steel

Material Inspection

• Check panels for transport damage
• Verify panel dimensions match drawings
• Confirm all accessories are on-site
• Ensure sealants are within expiry dates

Step-by-Step Installation Process

Step 1: Base Preparation

The base channel or angle sets the foundation for everything above:

• Install base channel at exact level, typically 150mm above floor
• Apply sealant tape to top of base channel
• Install thermal break material between steel and panel if required

Step 2: First Panel Installation

The first panel determines alignment for the entire wall:

• Start from one corner, working systematically
• Check plumb with spirit level
• Secure temporarily while verifying alignment
• Apply sealant to vertical joint before next panel

Step 3: Subsequent Panels

Continue with systematic installation:

• Engage tongue-and-groove or cam-lock joint fully
• Maintain consistent gap (typically 2-3mm for sealant)
• Fix panels to girts at specified intervals
• Progress upward if doing horizontal installation

Step 4: Opening Treatments

Door and window openings require careful attention:

• Frame openings before panel installation where possible
• Use appropriate flashings around all openings
• Seal all gaps with compatible sealant
• Install sub-frames for doors and windows

Step 5: Corner and Edge Finishing

• Install corner flashings with proper overlap
• Seal all exposed panel edges
• Apply top flashing at roof junction
• Install base flashing for weather protection

Critical Quality Points

Thermal Bridging Prevention

Thermal bridges are the enemy of insulation performance:

• Use thermal break strips between panels and steel structure
• Avoid direct contact between outer and inner skins via fasteners
• Ensure continuous insulation at joints
• Seal all penetrations completely

Weather Sealing

Water ingress is the most common installation failure:

• All vertical joints must have sealant backing
• Horizontal joints overlap with upper panel outside
• Flashings overlap by minimum 50mm
• Use appropriate sealants for each application

Common Installation Mistakes

Avoid these frequent errors:

• Skipping thermal breaks: Creates condensation and energy loss
• Insufficient sealant: Leads to water and air leakage
• Over-tightening fasteners: Damages panel skins
• Ignoring manufacturer spacing: Causes sagging or buckling
• Installing in rain: Traps moisture in joints
• Wrong fastener types: Leads to corrosion and failure

Special Applications

Cold Storage Walls

For cold storage applications, additional requirements include:

• Vapor barrier on warm side
• Cam-lock joints for airtightness
• Higher thickness panels (80-150mm)
• Heated door frame integration

Cleanroom Walls

For cleanroom installations:

• Flush panel surfaces
• Coved corners at wall-floor junctions
• Integration with HVAC and HEPA systems
• GMP-compliant finishes

Conclusion

Proper wall installation is both an art and a science. While this guide covers the fundamentals, complex projects benefit from experienced supervision. Whether you're working with installation contractors or considering self-installation, understanding these principles helps ensure quality results.

Need technical support for your wall installation? Contact PHOENIXX for installation guidance, contractor recommendations, or direct installation services.