AAC Wall Panels vs. Sandwich Panels: A Detailed Comparison

Construction sector in India is evolving. In recent years it is remarkably shifting towards innovative building materials that improve efficiency, sustainability, and overall building performance. Advancements in technology, research & development have brought us prefabricated construction techniques. Also known as prefab construction or readymade wall. These solutions are more efficient in terms of speed, safety, savings, and sustainability. Leading them to be increasingly adopted by builders and architects. 

Two materials are quite popular when dealing with prefabricated walling solutions, both known for speed while saving time & cost. These materials are Autoclaved Aerated Concrete Wall (AAC Walls) and the Sandwich Panels. They have become highly popular in the modern construction industry and offer many advantages over traditional materials. They are a better option than traditional building materials like brick walls, RCC walls and drywalls 

But how do you know which one is a better walling material? 

Both of them are modern wall construction techniques and have decent insulation properties. But there are also some differences between them in many aspects. Continue reading to have a better understanding of the difference between AAC wall panel and sandwich panels to choose the right material for your next construction project. 

AAC Wall panel is a full height, lightweight, steel reinforced concrete panel made from materials like sand, cement, lime, water, and aluminum powder. This mixture undergoes chemical reaction and creates tiny air pockets giving these panels lightweight properties. As for these panels, they are cured in a high-pressure steam chamber aka autoclave, making them strong and durable. AAC wall panels can be used for both external and internal wall applications. These panels are best suited for today's modern designs to increase energy efficiency, fire safety, soundproofing, insulating properties, as well as increased earthquake safety. AAC Panels weigh 1/5th of a concrete panel and can easily be installed by on-site installers.

Some of the material properties of AAC Wall Panels are given in the table below:

Key Features of AAC Panels 

• Corrosion Protected Steel Reinforced: AAC wall panels guarantee endurance and resilient performance in construction projects for sustained longevity. 
• Lightweight: AAC panels are 60% lighter than concrete panels. They are lightweight but have high compressive strength. The lightweight design of AAC wall panels helps to reduce structural loads while maintaining stability and long-lasting integrity for your building. 
• Thermal Insulation: AAC Wall Panels provide Thermal insulation for up to 30% energy savings in different climates. It keeps buildings cooler in summer and warmer in winter 
• Fire Resistant: AAC Wall Panels have a unique cellular structure that offers an exceptional 4-hour fire rating. They have a melting point of over 1600 degrees Celsius, providing great fire resistance. Resist fire for 4 hours or more based on the thickness.  
• 4x Construction Speed: AAC Wall Panels reduce project time and assure fast and effective construction. Covers more area in less time leading to 4x Faster Construction than AAC blocks (1 AAC Panel ~15 AAC Blocks)  
• No Coping/Bond Beam: Even without coping or bond beams a great structural stability is obtained for wall heights up to 6m with AAC Wall Panels. This means less need for reinforcement, quicker construction, less use of materials, and cost savings on labor. 
• Green Building: AAC wall panels are GRIHA-listed with their sustainable construction approach, lightweight and fully recyclable designs. Their low embodied energy means that the building’s carbon footprint is significantly lower from the beginning. 
• AAC panels are used for both internal and external walls in homes, apartments, commercial buildings, office space, hotels, and hospitals. They are a perfect fit for high-rise buildings because of their light-weight nature. 

Key Advantages of AAC Panels

Here mentioned are key benefits of AAC wall Panels: 

Cost Saving: AAC wall panels are cost effective and save upto 15% in foundation cost.  

Easy Installation: Wall installation of AAC wall panels requires 1 Mason + 2 Helpers for 50 m²/day. Whereas AAC blocks are 35 m2/day, red clay bricks are 10 m2/day. 

Thermal Insulation: It offers excellent thermal control. These panels use approximately 30% less energy for cooling and heating the interior air space  

Fire-Resistant: AAC wall panels have excellent fire-resistant properties. Magicrete AAC Wall Panel provides a fire rating of 4 hours for Thickness of 100 mm. This makes it one of the best building materials available in the market,  

Sound Insulation: Our AAC Wall Panels provide extraordinary sound insulation to reduce noise pollution. The sound reduction index is more than 40 db. with 3-4 mm skim coat. To achieve an STC of 52 db. install gypsum board (12.5mm) with stud framing on both sides. 

Additional Benefits:  

• Space saving is possible with AAC wall panel. With the option of 75mm internal walls (rather than the standard 100mm), 2% of your floor space can be reclaimed, making it a more efficient option. 
• These monolithic panels are shock absorbing, resistant to extreme weather, and will not crack. 
• It is easy to chisel, cut & core the AAC Panel, as per requirement. 
• It is environmentally friendly and provides structural integrity to building structures and is non-toxic. 

Sandwich panels are made up of three layers:

• 2 Outer layers: Thin metal sheets (usually steel or aluminum).
• 1 Core layer: A layer of insulation material.

The middle layer contains a low-Density Core, which also helps with insulation and energy efficiency. A thin layer of skin sandwiched between a top and a bottom supports the two, remaining securely adhered to the core.

These panels contain a lightweight concrete core. They function to solidify the framework of this walling solution. The core can be made of various materials, EPS (Expanded Polystyrene) or PU (Polyurethane) / PIR (Polyisocyanurate) or Mineral Wool.

The Next Big Shift in Wall Construction

Built with advanced European technology, Magicrete AAC Wall Panels are lightweight, steel-reinforced, and engineered for high performance across strength, fire resistance, and thermal insulation. If you're still considering Sandwich Panels, here's why Magicrete is the smarter, future-ready choice:

Wondering why to use Magicrete AAC Wall Panels in your next construction project instead of Sandwich Panels?

Here’s a side-by-side comparison of Magicrete AAC panels and Sandwich panels based on important aspects:

When to Use AAC Wall Panels:

AAC Wall Panels can be used in various kinds of applications irrespective of climate and location of the project.  

Partition Walls: Offices, Mails, Educational Institutions (schools & universities), Restaurants, Housing Residential (independent homes & apartments), Defense, Industrial Infrastructure, Data Centers. You can even get size versatility, the thickness ranges between 75mm to 225mm in AAC wall panels unlike sandwich panels that have 50mm and 75 mm panels only 

External Walls: Residential, Commercial & Industrial PEB structures 

Prefabricated Structures: Residential, Hotels, Site Offices, Security Store Warehouse, Schools, Army Barracks, Low-cost Housing.   

Fire Separation Walls: Shopping malls, Hotels, Hospitals, Staircase enclosures. 

AAC wall panels are ideal when strength, insulation, and long-term durability are priorities. They are suitable for both internal and external walls. Ideal for homes and apartments due to their thermal and acoustic insulation. Suitable for offices and retail spaces requiring durability and fire resistance. Lightweight nature reduces structural load, making them apt for high rise buildings. 

When to Use Sandwich Panels:

They are often used in temporary or semi-permanent structures. If doing a project requires easy installation along with insulation with less focus on strength and durability sandwich panels may be the materials to use. 

AAC wall panels are made using a monolithic structure, which means they’re cast in a single type of material. This uniform casting gives them greater structural stability and long-term strength. On the other hand, sandwich panels are made with a combination of different materials like EPS, this leads to seasonal expansion, contraction, and cracks over time. While both AAC panels and sandwich panels offer modern solutions, for builders and architects who want strength, sustainability, and performance at the most affordable price, AAC wall panels bring more value. They support green building standards, reduce construction time, save energy, and last for a long time.

If you’re looking for a wall solution that offers stability, durability, and peace of mind, Magicrete AAC Wall Panels is the next big shift in wall construction, built with European Technology, these lightweight, steel-reinforced wall panels are designed for improved energy efficiency, better fire and earthquake resistance, and enhanced insulation.

As India’s leading AAC wall panel manufacturer, Magicrete supports the use of AAC wall panels. Contact us today if you are looking for durable, fire-resistant, soundproof and eco-friendly building material that can withstand moisture and humidity.