Sandwich panels require flat, covered storage on level supports, careful handling during loading and unloading, and protected transport to prevent surface damage and core deformation. Because thermoplastic composite panels combine a lightweight core with structural skins, the way you store and move them directly affects their performance in service. The sections below address the most common logistics questions from truck body builders, trailer manufacturers, and scaffolding companies sourcing composite panels.

How should sandwich panels be stored to prevent damage?

Store sandwich panels horizontally on flat, level supports spaced no more than 500 mm apart across the full panel length. Keep them in a covered, dry environment away from direct sunlight and standing water. Stack panels face-to-face with protective interleaving between each sheet to prevent surface abrasion, and never exceed the stack height recommended by your supplier.

The two most common storage mistakes are point-loading and unsupported overhangs. A panel stored with its ends unsupported will sag under its own weight over time, especially in warmer conditions where thermoplastic cores soften slightly. For large-format panels, Compoform panels can reach up to 13,500 mm in length, this means using full-length racking or a sufficient number of evenly spaced bearers.

Temperature matters more than many buyers expect. Thermoplastic sandwich panels are dimensionally stable across a wide service range, but prolonged exposure to temperatures above 60°C in storage (for example, inside an unventilated metal warehouse in summer) can cause minor surface distortion. Covered outdoor storage is acceptable short-term, but a temperature-controlled or at minimum shaded indoor environment is the right long-term choice.

For panels with finished surfaces such as white PET-film or black anti-skid coatings, keep the protective film in place until the panel is ready for installation. These surface finishes are durable in service, but they can be scratched during handling if the protective layer is removed prematurely.

What are the loading and unloading requirements for sandwich panels?

Load and unload sandwich panels using spreader bars or full-length lifting beams to distribute the load evenly across the panel. Never lift large panels from a single central point or from one end only, concentrated lifting forces can cause core shear or skin delamination, particularly in thinner configurations. Forklift tines should span as much of the panel width as possible and be padded to avoid surface indentation.

For panels up to around 2,950 mm wide and several meters long, a two-point lift with a spreader bar is standard practice. For very long panels approaching the 13,500 mm maximum, a three-point or four-point lift is safer and reduces the risk of panel flex during the lift cycle.

Edge protection is worth planning before the first delivery arrives. The glass-fibre skins on thermoplastic panels are impact-resistant in service, but a sharp knock to an unprotected edge during unloading can cause localised skin cracking. Foam edge guards or rubber corner protectors on the pallet are a simple precaution that prevents damage that would otherwise only become visible after installation.

How should sandwich panels be transported to avoid structural damage?

Transport sandwich panels flat on a rigid, level load bed with full-length support and secure, evenly distributed tie-down straps. Avoid transporting panels on edge unless the panel is specifically designed for vertical racking. Use load-spreading battens between the panel and any metal tie-down hardware to prevent point pressure on the skin surface.

Vibration during road transport is the main risk for long panels. A panel that overhangs the load bed at the rear will flex repeatedly over every road imperfection, and over a long journey this cyclic loading can initiate micro-cracking at the skin-to-core bond line. The rule of thumb is that no more than 10% of the panel length should overhang the load bed, and even that should be supported with a rear bolster.

Panels with anti-skid surfaces, such as those used for scaffolding boards and truck body floor applications, should be stacked with the anti-skid face protected, since the textured surface can abrade adjacent panels or load bed surfaces during transit. Interleaving with cardboard or foam sheet between panels in a stack prevents this.

For EV fleet operators and truck body builders working with electric vehicles, it is worth noting that the lightweight nature of thermoplastic sandwich panels is part of the transport efficiency argument beyond just payload. Lighter body structures extend battery range in electric trucks and vans. Every kilogram of structural dead weight reduces range per charge, making weight reduction a range argument, not just a payload argument. This is a standard procurement question from EV fleet buyers in 2026, and it applies equally to how panels are specified and how the finished vehicle body is assembled.

What are the shelf life and long-term storage considerations for composite panels?

Thermoplastic sandwich panels do not have a defined shelf life in the way that adhesive-bonded or thermoset composite panels do. Because the skins and core are bonded through a thermal process rather than a chemical cure, there is no ongoing curing reaction that degrades over time. Panels stored correctly can remain in stock for extended periods without measurable loss of mechanical performance.

That said, long-term storage does introduce practical risks that are worth managing:

• UV exposure: Prolonged direct sunlight degrades most polymer surfaces over time. Wall panels with white PET-film finishes are tested to over 22,000 hours of UV resistance in service, but that rating assumes the panel is installed, not stored outdoors without protection for years.
• Moisture ingress at cut edges: If panels have been cut to size before storage, any unsealed edges expose the core to moisture. For PP-foam and PP-honeycomb cores, moisture absorption is low, but sealing cut edges before long-term storage is still good practice.
• Permanent deformation from improper support: As noted above, unsupported storage over long periods is the most likely cause of dimensional issues. A panel stored correctly on full-length bearers will remain flat indefinitely.

For scaffolding panels in particular, which are often held in depot stock between project deployments, regular inspection of edge sealing and surface condition is worth building into your maintenance schedule. Edge sealing protects the core from the repeated wash-downs and wet site conditions that scaffolding boards routinely face.

Who is responsible for logistics compliance when ordering custom-dimensioned panels?

When you order custom-dimensioned sandwich panels, responsibility for logistics compliance is shared between the manufacturer and the buyer, but the division of responsibility should be agreed in writing before the first delivery. The manufacturer is responsible for packaging panels appropriately for transport and providing handling instructions. The buyer is responsible for ensuring their site, equipment, and personnel are prepared to receive and store panels correctly on arrival.

For custom panels, particularly large-format sheets cut to non-standard dimensions, standard pallet configurations may not apply. Panels up to 13,500 mm long require purpose-built transport solutions, and the logistics plan should be confirmed as part of the order process, not after production is complete.

Key points to clarify with your supplier before ordering:

• What packaging and pallet configuration will be used for your specific panel dimensions?
• What are the minimum lifting equipment requirements for safe unloading at your facility?
• Are cut edges sealed before dispatch, or does your team need to seal them on arrival?
• What is the maximum stack height for your panel configuration during storage?
• Who carries liability for panels damaged in transit, and what documentation is required to support a claim?

For truck body builders and trailer manufacturers running ongoing production, these logistics details are not a one-off consideration. If your production schedule depends on a reliable supply of custom panels, the logistics process needs to be as well-defined as the panel specification itself.

How Compoform Supports Your Panel Logistics from Order to Delivery

We design and produce fully custom thermoplastic sandwich panels using a 72-meter double belt press production line, and we treat logistics as part of the product, not an afterthought. Every order is delivered on customised pallets matched to your panel dimensions, with handling instructions specific to your configuration.

Here is what working with us on logistics looks like in practice:

• Custom packaging per order: Panels are palletised to match your specific dimensions, including large-format sheets up to 13,500 mm x 2,950 mm.
• Edge sealing included where specified: For applications where cut edges will be exposed to moisture or repeated wash-downs, we seal edges before dispatch.
• Handling guidance provided upfront: We confirm lifting requirements, stack height limits, and storage conditions as part of the order process, so your team is prepared before the first delivery arrives.
• Ongoing supply continuity: For production runs, we work with you to align delivery schedules with your assembly line, reducing the need for large on-site panel stocks and the storage risks that come with them.

Beyond the logistics, we review your panel configuration against your application before production begins. If your floor panel specification, skin layup, or core density needs adjusting to suit your assembly process or end-use environment, we flag it before we manufacture, not after. That is the difference between a panel supplier and an application partner. To discuss your requirements, speak with our engineering team directly.

Related Articles

• How do OEM manufacturers specify sandwich panels across different vehicle types?
• How are sandwich panels fixed in commercial vehicle floors?
• How to calculate the true lifetime cost of your panel materials?
• What certifications should a sandwich panel carry?
• What should OEM manufacturers look for in a sandwich panel supplier?