How Foam and Tape Solutions Enable Energy‑Efficient Prefab Construction

Eef: There are several reasons. It is a very efficient and cost-saving solution as the assembly time on-site is reduced to a minimum and the panels are standardized in production, while preserving a range of aesthetic options.

They are also very strong, light, and durable. They also support sustainability. Prefab construction creates less waste and fewer nitrogen emissions. The panels are suitable for circular construction.

We have seen that prefabricated construction offers many benefits. But the materials and technologies used depend on the project’s needs. Concrete parts, wood, sandwich panels or other prefab solutions each has their specific advantages and requirements. As the prefab landscape is broad, let’s take a closer look at sandwich panel technologies. We will explain why and where they are mainly used. We will also cover the role of innovative foam and tape solutions in sandwich panel construction. 

Eef: Prefab construction benefits significantly from prefabricated elements (systems) for domestic applications (wood) and industrial applications (steel) as they combine speed, cost efficiency, and consistently high performance. Prefabricated panels allow for fast assembly, reduced on‑site labor, and reliable quality thanks to controlled manufacturing conditions.

When installed and sealed correctly, these panels provide excellent thermal insulation, high resistance to weather and environmental exposure, acoustic performance, and, depending on panel design, strong fire resistance. Another key advantage in prefab construction is maintainability: damaged panels can often be replaced or repaired without impacting the entire structure.

Repeatability and series production are crucial for manufacturers as they determine consistent quality, both during production and during assembly on-site, as well as smooth processing on the construction site and driving cost efficiency. Moreover, there is no need for complicated and expensive sealant or caulk materials on-site; the panels can be assembled directly upon arrival.

Eef: In prefab construction, the performance of the building envelope is determined not only by the panels themselves, but by the quality of joints, interfaces, and transitions. Even highly insulating panels can lose efficiency if joints become thermal bridges or air leakage points.

Foam cores dramatically increase stiffness while minimizing material use, and they help structures withstand compression, shear, and bending forces. The right sealing solutions ensure longterm airtightness and watertightness, improving energy efficiency, durability, and overall building value.

Eef: Innovative foam and tape solutions play a key role in sealing, dampening, and isolating joints in prefab panels. Since no two panel designs or production lines are identical, there is no one‑size‑fits‑all solution. Instead, materials must match both the application requirements and the manufacturing process.

In continuous production lines, materials like spooled PVC foams with Mylar®liner and Norseal® Extrusions supplied on long spools support inline application without interrupting production. This enables high throughput, consistent quality, and reliable sealing even under demanding conditions which are all essential for industrial prefab environments.

A great product for continuous but also controlled and secure application on sandwich panels has proven to be our PVC with Mylar, when they are applied in-line from large spools on the production line. The permanent Mylar®liner provides maximum strength and precision during application, but excellent, much needed low-friction features during final assembly.

But there are other factors to consider, like the environmental footprint of materials.

As unmatched bio-based polyurethane foam, Norseal AGP200 offers superior sealing performance, perfectly suitable for applications requiring water tightness yet high softness and conformability. It provides extremely low fogging and VOC (Volatile Organic Content) emissions, low odor, and flame resistance according to FMVSS 302, making it ideal for direct use in interior applications (Sulfur Free formulations) of buildings and for building envelopes that meet highest environmental standards as it is not only free of plasticizers and its polyol is largely based on bio-based materials.

Eef: In continuous production, all materials are processed simultaneously, and finished panels are cut to length without stopping the line. This requires sealing solutions that can be applied continuously, precisely, and at high speed.

In discontinuous manufacturing, flexibility is key. Solutions like Norseal BCF or FS1000 intumescent foam offer excellent conformability and sealing performance, making them ideal for complex joints or varying panel geometries. FS1000 also adds value through fire and smoke propagation prevention, which is increasingly relevant for prefab industrial and commercial buildings.

Eef: While panel insulation values are often the first metric discussed, real energy efficiency is achieved through system tightness. Foams and tapes eliminate air leaks, reduce thermal bridges, and ensure long‑term sealing performance even as buildings expand, contract, or age.

Independent of panel design or construction method, the right materials significantly improve airtightness, durability, building quality, and can reduce both production and maintenance costs over the building’s lifetime.

In case a seal is not properly closing the panel gaps, over time the lack of air tightness (leakage, thermal bridging) will have a dramatic effect on energy losses that could lead to up to double digit percentages.

Eef: Prefab construction is a growing market driven by demands for energy efficiency, speed, and cost control. Soft, conformable foams open up new design and manufacturing opportunities by compensating tolerances and ensuring consistent sealing at scale.

Focusing on these “small components” can have an outsized impact on the performance, reliability, and reputation of prefab building systems, especially when manufacturers aim to grow without sacrificing quality.

Eef: Innovative foam and tape products offer great potential for prefab construction in many ways. As the prefab landscape is very diverse and there are many different regional rules and regulations, let’s focus on some of the bigger topics of this industry where tapes can make the difference.

For example, automation will become more important in this market. Panel and raw material makers are seeking ways to improve efficiency. They may use robotics and smart solutions. Innovative tape materials can help protect surfaces with low-friction and highly durable mechanical, chemical and thermal resistant materials in robotic applications. Specialized tapes like UHMW help reduce maintenance efforts and manual work which saves costs and improves throughput.

Another important area with immense potential for innovation is fire protection. Making a structure airtight does not only benefit energy preservation but is also essential for fire safety. Innovative foam materials will benefit compartmentation and improve fire resistance. Norseal FS1000 is an excellent example for multifunctional innovative materials with ideal sealing properties against moisture and air ingress but also forms a fire-blocking char in that significantly improved fire resistance if applied between panels.

As we mentioned earlier, sustainability is definitely one of the most important areas for innovation in foams and tapes for prefab construction. Airtight building envelopes for temperature and airflow control are maybe the most common application people think of in foam and tape materials for construction. While preserving energy induces sustainability, we are constantly working towards products that have specific added value in this area. If we take our Norseal 2720 PVC, for instance, these features comprise:

• 100% biobased plasticizer  
• Low phthalate concentration  
• 57% biobased carbon content as per ASTM D8866-21 Method B (AMS)  
• Meets Nordic Swan Ecolabel, fulfilling or exceeding regulatory requirements and industry standards for environmental performance and safety

We are also working on PFAS-free* solutions so we can provide a strong portfolio of high-performance solutions for demanding construction applications that combine excellent performance with reduced environmental footprint to achieve demanding sustainability goals.  

These are just three areas where I see big innovation potential but there are many more which shows that construction and especially prefabricated construction can benefit a lot from new foam and tape developments.

Thank you, Eef, for these insights into the materials that enable new sandwich panel construction to become even more efficient. As we have seen, prefab construction offers great potential of sustainably changing the way we build in the future. As the best buildings are yet to be made, contact your tape expert and find out how your project can take the lead with innovative tape materials.

Our PFAS-free* designation means we do not intentionally add PFAS to our formulations during the manufacturing of the product. However, due to certain factors, trace amounts may be present as unintended impurities in the raw materials that we receive from our suppliers. The asterisk (*) reflects our commitment to transparency and scientific integrity, rather than making absolute claims that cannot be guaranteed or verified.