Sandwich Panel and Double-Skin Roof Sheet Replacement

A sandwich panel roof does two jobs at once: it keeps the weather out and the heat down. When panels are dented, corroded or soaked through, both jobs suffer, and the building pays for it in leaks and higher cooling bills. ETCE replaces damaged sandwich panels and double-skin sheets with new insulated panels matched to your roof, then seals the joints so the new panels stay dry.

Across Saudi ArabiaUp to 15-year warrantyFree roof survey

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Zamil Plastics – Dammam

Why a damaged sandwich panel is worth replacing

The panels we install have a 0.5 mm steel sheet top and bottom with a 50 mm polyurethane (PU) core, a build-up that gives the roof both stiffness and insulation. That core only performs while it is dry and bonded to the skins. Once water gets in through a corroded top skin, a cracked fastener or an open lap, the insulation becomes saturated, loses much of its value and can start to separate from the steel.

In cooled warehouses, cold stores and air-conditioned factories across Dammam, Jubail and Riyadh, that matters twice over. Wet or delaminated panels let heat in during summer and can drip onto stock below. Patching the surface cannot repair a failed core. Swapping the affected panels restores insulation and strength to that section, and sealing the new joints stops the same failure from starting again.

Signs your sandwich panels are failing

Top skin rusted through or badly corroded at laps and fasteners
Panels that sag, feel soft or flex underfoot
Bulging or separation between the steel skin and the core
Water stains, drips or condensation on the inner skin
Hot spots inside the building under particular roof sections
Dents or crushed ribs from foot traffic or dropped equipment

How we replace sandwich panels

Panel-by-panel surveyThe engineer checks each panel's top skin, joints and inner face, and lists the panels that need replacing with photos in the written report.
Specify the replacementNew panels are supplied in the profile and thickness that match your roof, with 0.5 mm skins and a 50 mm PU core.
Planned removalDamaged panels are removed in a sequence agreed with you, so areas holding stock or equipment are protected and the building keeps running.
Install and fixNew panels are positioned, lapped with the existing ones and fixed to the structure, and the purlins are inspected while they are exposed.
Seal joints and fastenersPanel joints and fastener lines are covered with EPDM and Promax Bonding Adhesive, keeping water away from the new core.

Materials & workmanship

Sandwich panels with 0.5 mm top and bottom steel sheets and 50 mm PU insulation
Panels and double-skin sheets available to match a wide range of roof profiles and thicknesses
Joint seals in EPDM and Promax Bonding Adhesive, which holds at roof surface heat up to 120 °C

Photos from ETCE projects

Sandwich Panel Replacement - Zamil Plastics, Dammam

Sandwich Panel Replacement - ATCO Group – East & West Factory, Dammam

Sandwich Panel Replacement - Alfa Laval, Riyadh

Sandwich Panel Replacement - Guardian Industries Company Ltd., Dammam

Site photos from ETCE projects in Saudi Arabia and Bahrain. Tap to enlarge.

Frequently asked questions

Can you replace just one or two sandwich panels?

Yes. Most of our sandwich panel work is selective: we replace the panels that have failed and leave the sound ones in place. The survey report shows exactly which panels are affected.

Can a wet sandwich panel be dried out instead of replaced?

Once the PU core has been soaked or has come away from the skins, it rarely recovers its original insulation and strength, so replacement is the reliable fix for those panels. Panels with only surface corrosion on the top skin can often be treated instead.

What is the difference between double-skin sheets and sandwich panels?

Both have an outer and an inner metal sheet with insulation between them. A sandwich panel arrives as one bonded unit, while a double-skin roof is usually built up in layers on site. We replace both and match the new material to what is already on your roof.

Should the purlins be checked while panels are off?

Yes, and we do it as standard. Leaking panels often leave the purlins beneath them rusted, and replacing a corroded purlin section while the roof is already open is far simpler than coming back later.