precast sandwich panel system
TRANSCRIPT
Slide 1by:
CSIR-Central Building Research Institute
n o
lo g
It is a special class of composite material that is
fabricated by attaching two thin but stiff skins
to a lightweight but thick core. The core
material is normally low strength material, but
its higher thickness provides the sandwich
composite with high bending stiffness with
overall low density.
reinforced laminates are widely used as skin
materials. Source: www.rcpoudel.com
thick layer
Reinforcement – Steel/ Textile/ Synthetic Continuous laying
Thickness 50 mm/ 60mm/ 75 mm even more Aerated/ Cellular/ EPS/ PU Thermal insulation efficiency
Ferrocement roofing/ foundations Helical anchored/ conventional
Steel redundant joints Shear connection for core & skin layers
Sandwich Panel System
• Transportable blocks for precast walls
• Easy in assemblage of panels
• Helical anchorage of foundation
Losch et al. (2011)
Saleem et al., (2008)
material and skin together
load carrying capacity was
Schematic View of Panel
Plan of Demo House
Ferrocement Panels for thermal conductivity tests
Cast Panel
Precast Sandwich Panel
strength layers refers to as
wythes separated by a low
strength material known as
insulation. There are three
major component parts of
• It is generally thin section and wythe thickness is
primarily depends on panel type and its final use.
• Wythe thickness is controlled by specified fire
resistance requirement or the minimum concrete
cover required for the reinforcement or durability.
• A non-composite panel usually requires a thicker
wythe than a composite panel with the same load
and span conditions.
composite panel thickness is assumed.
Wythe Thickness
Prestressed Panel
strand in 51 mm thick wythes containing 19 mm
maximum aggregate can be used.
• 13 mm diameter strand is commonly used in
wythes 76 mm thicker.
at the ends of the panel to limit splitting cracks
over the strands.
Connectors can provide a variety of functions:
• For panels that are stripped from the form in the horizontal
position, these connectors must resist the tensile forces
caused by the weight of the lower wythe plus any form
suction acting on that lower wythe.
• These connectors must also resist the tensile forces
resulting from out-of-plane wind suction and seismic forces.
• In fully and partially composite panels, wythe connectors
must resist horizontal, in-plane shear caused by flexural
bending.
ties, M-ties, cylindrical metal sleeve anchors, hairpins,
circular expanded metal, welded-wire trusses, and plastic or
fiber-composite pins.
• The connector spacing ranges from 400 mm × 400 mm to
1220 mm × 1220 mm.
shear forces between the two wythes.
• Sandwich panels are usually designed as one-
way structural elements; shear forces are
generated due to longitudinal bending in the
panels.
to the structural wythe.
Expanded
directions and consequently transfer both longitudinal and
transverse horizontal shears.
bond stresses for plain smooth bars along with allowable
steel stresses for bending, shear, and axial forces.
Cylindrical Sleeve Anchor Crown Anchor
Two Ways Shear Connectors
Bending Stress Distribution
load.
bottom wythes.
applied load.
the shear forces between the top
and bottom wythes.
to hold the top and bottom wythes
in their position.
structural wythe.
between composite and non-
handling stresses during
shipping and erection.
capacity is limited based on the
non-composite action.
Applications
Applications
CROSS-SECTION OF ECO-SANWICH PANEL
SOURCE: Banjad Pecur, I.; Stirmer, N. and Milovanovic, B., ´Durability properties of recycled aggregate
concrete´, RILEM International workshop on performance-based specification and control of concrete
durability, Zagreb, June 2014
EPS Core Panel System
consisting of self extinguishing expanded polystyrene
sheet, sandwiched between two engineered sheet of
welded wire fabric mesh, made of high strength galvanized
wire of 2.5 mm to 3 mm dia.
Requirement of EPS
Kg/cum.
30 mm thick sprayed concrete/ shotcrete of
cement & coarse sand in the ratio of 1:4 applied
under pressure. The shotcrete coat encases the
EPS Core with centrally placed steel welded wire
fabric mesh
3 mm to 4 mm dia. galvanized steel truss wire is
pierced completely through the polystyrene core
at the offset angle for superior strength and
welded to each of the outer layer sheet of steel
welded wire fabric mesh.
depending upon the application.
EPS Core Panel System
EPS Core Panel System
Source: BMTPC_Compendium_ET_Sept2018_3rdEdition
a = thickness of core; b = thickness of concrete; c = overall thickness
Panels are used for the floor and the roof system and
reinforced in the joists with concrete casting on the site.
The reinforcement of the panel is integrated during the
panel assembly by additional reinforcing bars inside the
joists as per design.
Suitable upto 8m span with the live load of up to 4 kN/sqm
EPS Core Panel System
erected beam-column with
suitable connection and
fittings (electrical and
plumbing) followed by
EPS panel as the unit building
material.
from the structure during its
lifetime.
The design of EPS Panels is based on the below
mentioned standards, codes and engineering practices.
CODES
IS: 875-1 Code of Practice for Design Load (Other than
Earthquake) Part 1-Dead Loads
Earthquake) Part 2-Imposed Loads.
IS 875-3 Code of Practice for Design Load (Other than
Earthquake) Part 3 Wind Loads.
IS 1893 Criteria for Earthquake Resistance Design of
Structures- Part 1 General Provision
IS 9012: Recommended Practices for shotcreting.
ACI 318R Building Code Requirements for Structural
Concrete
Live load • Live load as per IS:875 Part-2:
• Live load 2.0 kN/m2 (except for
corridors/balconies 4.0 kN/m2)
ceiling
Wind load • Wind load as per IS:875-Part 3
• Design wind speed (m/s) Vz = Vb x K1 x K2 x K3
• Design wind pressure (N/m2) Pz = 0.6 x Vz 2
Seismic
load
Shear V ( kN) = Ah × W
Design example of a load bearing wall panel
The building is to be
constructed using
EPS panels.
Properties Values
29.02 24.18 53.20
36 4.5
3 Wind Load - 0.76 kN/m2
4 Factored Base Shear - 286.53
5 Axial Force due to Total (Dead +Live) Load 143.33 kN
6 Modified Moments due to slenderness 4.28 kNm
Interaction Diagram(ID)
constructed by connecting three basic points with straight line.
0
200
400
600
800
1000
1200
1400
inside the ID, EPS
of the panels with chalk or
pencil lines.
centres on each side of the
panels.
500mm long.
foundations and 400mm above.
tight fit with the starter bars.
Placing of EPS Core panels
between the starter bars
bars shall be wire-tied to the
panel mesh and the panels to
each other on the overlapping
mesh.
openings.
them vertical before plastering.
around door and window openings.
Mesh reinforcement strips - tied diagonally
with wire around openings before plastering.
Bracing shall be required to hold them
vertical before plastering.
frame into the openings before plastering.
Fix and plaster these in place and then
secure the frames to the sub frame.
For heavy door/window frames, - Burn or cut
away the EPS where the fixing bolts are to
be secured to the wall and fill the space with
mortar or concrete to hold the bolts.
Construction Sequence
Construction Sequence..Contd.
Roof/Floor Panel
bending meshes positioned on all the corners.
Horizontal bending meshes shall be placed to
connect the floor/roof to the vertical panels.
The bending meshes shall be fixed throughout the
perimeter of the floor/roof, at the level of intrados.
• When the horizontal bending meshes are fixed and
checked, floor/roof panel shall be placed on these. The
lower mesh of the panel shall be fixed by steel wire to the
bending meshes.
gap of 35 mm should be left to ensure structural
continuity. The plaster applied on the walls shall be
continued from one level to another level.
Construction Sequence
Construction Sequence..Contd.
Standards.
guides should be used.
Plumbing and Electrical fittings
the panel wire mesh.
partially melt the EPS along the lines of the
conduits.
Construction Sequence
Quality Control
The following parameters have been considered to measure the performance of EPS
panels, based on the physical characteristics:
Safety - Shear, axial, bending, tension, point loads, surface loads,
impact loads, lifting & transportation loads etc.
Dimensions - Shape, size, thickness & tolerance
Durability - Surface material, degradation, moisture penetration &
corrosion
Functions - Visual assess, acoustic, pipes, conduits, fixtures,
Aesthetics - Surface material, colour, texture etc.
Connectivity - With other walls, floors, roofs, openings etc.
Handling - Transportation, lifting, settling etc.
To meet out the above requirements, various codes and manuals are available, as
per the requirement the relevant code may be referred. However, some standard
tests should be done for the basic materials i.e. cement, sand, stone aggregate,
water, reinforced cement concrete (RCC), steel bars, welding work, EPS, shotcrete
etc., either in field or in laboratory as per requirement.
Quality Assurance Measures/ Guidelines for EPS Panels
List of Equipment
equipment.
Sl.
Crusher for Utilization of waste EPS
EPS Block Making Machine
Preparation of EPS Blocks
3. Wire Straightening Machine
Wire Mesh Welding Machine
Galvanized Wire Mesh making
5. Mesh Cutting Machine Cutting machine
6. Mesh Bending Machine Bending machine
7. Shotcreting Equipment/Pump Concreting machine
Limitations
quality control issues.
deterioration of EPS panels (yellowing of panels) – lead to
degradation of insulation property of EPS.
Movement of moisture in EPS Core panel due to
improper shotcreting, presence of gap in between the
panels - may give rise to serious maintenance issues after
the construction.
panels do not ensure even thickness and depth of
concrete in the panel.
Initial cost of investment in setting up of factories for
production of EPS panels is high.
Applications
• Partition infill wall in multi storey framed buildings
• Floor / roof slabs
are erected on a conventional raft or strip foundations.
•If strip foundations are used, they should be levelled and
stepped as this makes panel positioning easier.
SANWICH PUFF PANELS
SANWICH PUFF PANELS
These panels consists of two facings of relatively thin metal
sheet profiled of high strength enclosing a core, which is
relatively thick and light with required stiffness. The facings are
of aluminium or steel.
Width -1000 mm to 1200 mm
Maximum Length -15 meter
PANELROOF PUF PANEL END
200mm .
high-strength steel wire forming a panel with a core
of expanded polystyrene (EPS).
walls and/or slabs.
to the surfaces of the panels to complete the
structure.
• Basic unit of Rapid Panel is the zig-zag truss. Steel
wire is bent into a zig-zag shape to form a
continuous chain of web members. This bent wire is
then welded to continuous chord wires at every
node to form the complete truss.
RAPID PANEL SYSTEM
consist of fire resistant grade
insulated polystyrene core, two
engineered layers of galvanized
pierced through the polystyrene
sheets of Galvanized steel mesh.
• These panels are used in the
construction of exterior and
interior load-bearing and non-load
construction.
space frame integrated with a polystyrene (EPS)
insulation core sandwiched between two layers of
engineered galvanized steel mesh that are held together
with steel trusses.
and welded to outer layer sheets of galvanized steel
mesh to form a rigid panel.
• Foundation is built using
• The panels are erected vertical
in plumb and temporarily
Rebar which is set between the
mesh and the polystyrene (for
easy wall alignment).
using fastener tool. Door &
erection.
hot air torch.
• Subsequently, doors and
windows are fixed.
panel is done.
Good thermal insulation properties.
Reliable robust mechanical performance.
Resistance to aggressive environments.
Easy repair and replacement in case of damage.
Jindal Steel and Power Limited
(JSPL) Township at Angul
Odisha. (The biggest township
System is being constructed by
Jindal Steel and Power Limited
(JSPL) Township at Angul
direct sun-light.
Due to poor workmanship.
• Crack formation/ breakage at joints in projections/
cantilevers (i.e. at Sunshade/ Chajja)
• Environmental hazard due to improper management of
constructional wastes at site.
bearing (EPS-NLB) panels.
Field Experiences....
Observation Reason
Improper construction practices
Walling / Roofing Panels
Technology not widespread in India –
- lack of understanding and awareness
- skilled labours
Prefabricated affordable housing for rural and
urban poor
Improve in the standardisation
Thank You Waste materials
CSIR-Central Building Research Institute
n o
lo g
It is a special class of composite material that is
fabricated by attaching two thin but stiff skins
to a lightweight but thick core. The core
material is normally low strength material, but
its higher thickness provides the sandwich
composite with high bending stiffness with
overall low density.
reinforced laminates are widely used as skin
materials. Source: www.rcpoudel.com
thick layer
Reinforcement – Steel/ Textile/ Synthetic Continuous laying
Thickness 50 mm/ 60mm/ 75 mm even more Aerated/ Cellular/ EPS/ PU Thermal insulation efficiency
Ferrocement roofing/ foundations Helical anchored/ conventional
Steel redundant joints Shear connection for core & skin layers
Sandwich Panel System
• Transportable blocks for precast walls
• Easy in assemblage of panels
• Helical anchorage of foundation
Losch et al. (2011)
Saleem et al., (2008)
material and skin together
load carrying capacity was
Schematic View of Panel
Plan of Demo House
Ferrocement Panels for thermal conductivity tests
Cast Panel
Precast Sandwich Panel
strength layers refers to as
wythes separated by a low
strength material known as
insulation. There are three
major component parts of
• It is generally thin section and wythe thickness is
primarily depends on panel type and its final use.
• Wythe thickness is controlled by specified fire
resistance requirement or the minimum concrete
cover required for the reinforcement or durability.
• A non-composite panel usually requires a thicker
wythe than a composite panel with the same load
and span conditions.
composite panel thickness is assumed.
Wythe Thickness
Prestressed Panel
strand in 51 mm thick wythes containing 19 mm
maximum aggregate can be used.
• 13 mm diameter strand is commonly used in
wythes 76 mm thicker.
at the ends of the panel to limit splitting cracks
over the strands.
Connectors can provide a variety of functions:
• For panels that are stripped from the form in the horizontal
position, these connectors must resist the tensile forces
caused by the weight of the lower wythe plus any form
suction acting on that lower wythe.
• These connectors must also resist the tensile forces
resulting from out-of-plane wind suction and seismic forces.
• In fully and partially composite panels, wythe connectors
must resist horizontal, in-plane shear caused by flexural
bending.
ties, M-ties, cylindrical metal sleeve anchors, hairpins,
circular expanded metal, welded-wire trusses, and plastic or
fiber-composite pins.
• The connector spacing ranges from 400 mm × 400 mm to
1220 mm × 1220 mm.
shear forces between the two wythes.
• Sandwich panels are usually designed as one-
way structural elements; shear forces are
generated due to longitudinal bending in the
panels.
to the structural wythe.
Expanded
directions and consequently transfer both longitudinal and
transverse horizontal shears.
bond stresses for plain smooth bars along with allowable
steel stresses for bending, shear, and axial forces.
Cylindrical Sleeve Anchor Crown Anchor
Two Ways Shear Connectors
Bending Stress Distribution
load.
bottom wythes.
applied load.
the shear forces between the top
and bottom wythes.
to hold the top and bottom wythes
in their position.
structural wythe.
between composite and non-
handling stresses during
shipping and erection.
capacity is limited based on the
non-composite action.
Applications
Applications
CROSS-SECTION OF ECO-SANWICH PANEL
SOURCE: Banjad Pecur, I.; Stirmer, N. and Milovanovic, B., ´Durability properties of recycled aggregate
concrete´, RILEM International workshop on performance-based specification and control of concrete
durability, Zagreb, June 2014
EPS Core Panel System
consisting of self extinguishing expanded polystyrene
sheet, sandwiched between two engineered sheet of
welded wire fabric mesh, made of high strength galvanized
wire of 2.5 mm to 3 mm dia.
Requirement of EPS
Kg/cum.
30 mm thick sprayed concrete/ shotcrete of
cement & coarse sand in the ratio of 1:4 applied
under pressure. The shotcrete coat encases the
EPS Core with centrally placed steel welded wire
fabric mesh
3 mm to 4 mm dia. galvanized steel truss wire is
pierced completely through the polystyrene core
at the offset angle for superior strength and
welded to each of the outer layer sheet of steel
welded wire fabric mesh.
depending upon the application.
EPS Core Panel System
EPS Core Panel System
Source: BMTPC_Compendium_ET_Sept2018_3rdEdition
a = thickness of core; b = thickness of concrete; c = overall thickness
Panels are used for the floor and the roof system and
reinforced in the joists with concrete casting on the site.
The reinforcement of the panel is integrated during the
panel assembly by additional reinforcing bars inside the
joists as per design.
Suitable upto 8m span with the live load of up to 4 kN/sqm
EPS Core Panel System
erected beam-column with
suitable connection and
fittings (electrical and
plumbing) followed by
EPS panel as the unit building
material.
from the structure during its
lifetime.
The design of EPS Panels is based on the below
mentioned standards, codes and engineering practices.
CODES
IS: 875-1 Code of Practice for Design Load (Other than
Earthquake) Part 1-Dead Loads
Earthquake) Part 2-Imposed Loads.
IS 875-3 Code of Practice for Design Load (Other than
Earthquake) Part 3 Wind Loads.
IS 1893 Criteria for Earthquake Resistance Design of
Structures- Part 1 General Provision
IS 9012: Recommended Practices for shotcreting.
ACI 318R Building Code Requirements for Structural
Concrete
Live load • Live load as per IS:875 Part-2:
• Live load 2.0 kN/m2 (except for
corridors/balconies 4.0 kN/m2)
ceiling
Wind load • Wind load as per IS:875-Part 3
• Design wind speed (m/s) Vz = Vb x K1 x K2 x K3
• Design wind pressure (N/m2) Pz = 0.6 x Vz 2
Seismic
load
Shear V ( kN) = Ah × W
Design example of a load bearing wall panel
The building is to be
constructed using
EPS panels.
Properties Values
29.02 24.18 53.20
36 4.5
3 Wind Load - 0.76 kN/m2
4 Factored Base Shear - 286.53
5 Axial Force due to Total (Dead +Live) Load 143.33 kN
6 Modified Moments due to slenderness 4.28 kNm
Interaction Diagram(ID)
constructed by connecting three basic points with straight line.
0
200
400
600
800
1000
1200
1400
inside the ID, EPS
of the panels with chalk or
pencil lines.
centres on each side of the
panels.
500mm long.
foundations and 400mm above.
tight fit with the starter bars.
Placing of EPS Core panels
between the starter bars
bars shall be wire-tied to the
panel mesh and the panels to
each other on the overlapping
mesh.
openings.
them vertical before plastering.
around door and window openings.
Mesh reinforcement strips - tied diagonally
with wire around openings before plastering.
Bracing shall be required to hold them
vertical before plastering.
frame into the openings before plastering.
Fix and plaster these in place and then
secure the frames to the sub frame.
For heavy door/window frames, - Burn or cut
away the EPS where the fixing bolts are to
be secured to the wall and fill the space with
mortar or concrete to hold the bolts.
Construction Sequence
Construction Sequence..Contd.
Roof/Floor Panel
bending meshes positioned on all the corners.
Horizontal bending meshes shall be placed to
connect the floor/roof to the vertical panels.
The bending meshes shall be fixed throughout the
perimeter of the floor/roof, at the level of intrados.
• When the horizontal bending meshes are fixed and
checked, floor/roof panel shall be placed on these. The
lower mesh of the panel shall be fixed by steel wire to the
bending meshes.
gap of 35 mm should be left to ensure structural
continuity. The plaster applied on the walls shall be
continued from one level to another level.
Construction Sequence
Construction Sequence..Contd.
Standards.
guides should be used.
Plumbing and Electrical fittings
the panel wire mesh.
partially melt the EPS along the lines of the
conduits.
Construction Sequence
Quality Control
The following parameters have been considered to measure the performance of EPS
panels, based on the physical characteristics:
Safety - Shear, axial, bending, tension, point loads, surface loads,
impact loads, lifting & transportation loads etc.
Dimensions - Shape, size, thickness & tolerance
Durability - Surface material, degradation, moisture penetration &
corrosion
Functions - Visual assess, acoustic, pipes, conduits, fixtures,
Aesthetics - Surface material, colour, texture etc.
Connectivity - With other walls, floors, roofs, openings etc.
Handling - Transportation, lifting, settling etc.
To meet out the above requirements, various codes and manuals are available, as
per the requirement the relevant code may be referred. However, some standard
tests should be done for the basic materials i.e. cement, sand, stone aggregate,
water, reinforced cement concrete (RCC), steel bars, welding work, EPS, shotcrete
etc., either in field or in laboratory as per requirement.
Quality Assurance Measures/ Guidelines for EPS Panels
List of Equipment
equipment.
Sl.
Crusher for Utilization of waste EPS
EPS Block Making Machine
Preparation of EPS Blocks
3. Wire Straightening Machine
Wire Mesh Welding Machine
Galvanized Wire Mesh making
5. Mesh Cutting Machine Cutting machine
6. Mesh Bending Machine Bending machine
7. Shotcreting Equipment/Pump Concreting machine
Limitations
quality control issues.
deterioration of EPS panels (yellowing of panels) – lead to
degradation of insulation property of EPS.
Movement of moisture in EPS Core panel due to
improper shotcreting, presence of gap in between the
panels - may give rise to serious maintenance issues after
the construction.
panels do not ensure even thickness and depth of
concrete in the panel.
Initial cost of investment in setting up of factories for
production of EPS panels is high.
Applications
• Partition infill wall in multi storey framed buildings
• Floor / roof slabs
are erected on a conventional raft or strip foundations.
•If strip foundations are used, they should be levelled and
stepped as this makes panel positioning easier.
SANWICH PUFF PANELS
SANWICH PUFF PANELS
These panels consists of two facings of relatively thin metal
sheet profiled of high strength enclosing a core, which is
relatively thick and light with required stiffness. The facings are
of aluminium or steel.
Width -1000 mm to 1200 mm
Maximum Length -15 meter
PANELROOF PUF PANEL END
200mm .
high-strength steel wire forming a panel with a core
of expanded polystyrene (EPS).
walls and/or slabs.
to the surfaces of the panels to complete the
structure.
• Basic unit of Rapid Panel is the zig-zag truss. Steel
wire is bent into a zig-zag shape to form a
continuous chain of web members. This bent wire is
then welded to continuous chord wires at every
node to form the complete truss.
RAPID PANEL SYSTEM
consist of fire resistant grade
insulated polystyrene core, two
engineered layers of galvanized
pierced through the polystyrene
sheets of Galvanized steel mesh.
• These panels are used in the
construction of exterior and
interior load-bearing and non-load
construction.
space frame integrated with a polystyrene (EPS)
insulation core sandwiched between two layers of
engineered galvanized steel mesh that are held together
with steel trusses.
and welded to outer layer sheets of galvanized steel
mesh to form a rigid panel.
• Foundation is built using
• The panels are erected vertical
in plumb and temporarily
Rebar which is set between the
mesh and the polystyrene (for
easy wall alignment).
using fastener tool. Door &
erection.
hot air torch.
• Subsequently, doors and
windows are fixed.
panel is done.
Good thermal insulation properties.
Reliable robust mechanical performance.
Resistance to aggressive environments.
Easy repair and replacement in case of damage.
Jindal Steel and Power Limited
(JSPL) Township at Angul
Odisha. (The biggest township
System is being constructed by
Jindal Steel and Power Limited
(JSPL) Township at Angul
direct sun-light.
Due to poor workmanship.
• Crack formation/ breakage at joints in projections/
cantilevers (i.e. at Sunshade/ Chajja)
• Environmental hazard due to improper management of
constructional wastes at site.
bearing (EPS-NLB) panels.
Field Experiences....
Observation Reason
Improper construction practices
Walling / Roofing Panels
Technology not widespread in India –
- lack of understanding and awareness
- skilled labours
Prefabricated affordable housing for rural and
urban poor
Improve in the standardisation
Thank You Waste materials