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(L M ) EASIE-research - Results

The EASIE project aimed to promote the use of sandwich panel technology in the EU construction industry by addressing technical and standardization barriers. It focused on improving communication between researchers and end-users to enhance the practical application of research findings. The document outlines research results and guidelines for structural and thermal behavior, emphasizing the importance of effective design and construction practices.

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Huy Dao Ngoc
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© © All Rights Reserved
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100% found this document useful (1 vote)
65 views63 pages

(L M ) EASIE-research - Results

The EASIE project aimed to promote the use of sandwich panel technology in the EU construction industry by addressing technical and standardization barriers. It focused on improving communication between researchers and end-users to enhance the practical application of research findings. The document outlines research results and guidelines for structural and thermal behavior, emphasizing the importance of effective design and construction practices.

Uploaded by

Huy Dao Ngoc
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 63

Guide_Results couver+back_A5_Mise en page 1 08/12/11 15:40 Page1

2008 October

2011
September

The EASIE project has received financial support RESEARCH


RESEARCH
RESULTS
from the European Community’s Seventh Framework Programme

RESULTS
FP7/ NMP2-SE-2008 under grant agreement No 213302
Guide_Results_A5:Mise en page 1 30/08/11 19:10 Page 2

F
a
p

10
Guide_Results_A5:Mise en page 1 30/08/11 19:10 Page 3

Facilitate and promote


a wider use of sandwich
panel technology

The central aim of the EASIE (Ensuring Advancement in Sandwich


Construction through Innovation and Exploitation) European Project was
to facilitate and promote a wider use of sandwich panel technology across
the EU Construction industry by removing existing technical, codification
and standardization barriers.
From its inception the project has initiated a dialogue between the
research team and end-users and has developed and implemented a
research communication framework and action plan aimed at bringing
together the key results areas, at promoting the outcomes of the work
and at improving the end use and market uptake of the research results.
The reasons for the well documented failure of getting research findings
into practice are many and include the lack of appropriate information at
the point of use, the lack of links and collaboration between the research
and user communities, institutional barriers, the use of a format not
tailored to the target audience or a widespread resistance to change.
The researchers involved in the EASIE project were well aware of the fact
that in order to promote the uptake of their research findings it was
incumbent on them to learn how to better communicate with end-users,
how to simplify their findings and render them more easily accessible,
and how to demonstrate their application and usefulness.
The purpose of this booklet is to present the research findings in a
simplified, easily accessible way and to demonstrate their application to
users industry and commerce and in particular to SMEs.
Guide_Results_A5:Mise en page 1 30/08/11 19:10 Page 4

Contents
Structural behaviour
1 Resistance of panels with openings with reinforcement
6

Thermal behaviour
2 Principles of good practice
14

The thermal test methods


3 18

Design by testing package


4 22

Use of sandwich panels for stabilisation


5 of buildings and building components 40
Guide_Results_A5:Mise en page 1 30/08/11 19:10 Page 5

Design of frameless structures


6 made of sandwich panels 44

Guideline for construction good practice


7 of frameless buildings 48

New techniques to maintain


8 and repair sandwich panels systems 50

9 www.easie.eu 56

16 e-learning lectures are available


10 on www.easie.eu 58
Guide_Results_A5:Mise en page 1 30/08/11 19:10 Page 6

Structural
behaviour
Resistance of panels with
openings with reinforcement

1
Calculation models for large openings
 Types of large openings
At the moment, there are different types of panel systems for
large openings on the market. For windows, one can differen-
tiate between three different categories:
• Ribbon windows with adapter profiles
• Ribbon windows with punctual fixing
• Windows with bonded frames
The load transfer of each of these systems is very different so the
calculations model has to be adapted to each type. All the
models are based on the existing beam model of Böttcher (2005)
which is described in chapter 2.2.2 (Deliverable 1.2).

 Ribbon windows with adapter profiles


Based on the beam model of Böttcher (2005) a possibility
presents itself: to calculate the load bearing and deflection
behavior of sandwich panel
systems with ribbon windows
and adapter profiles within the
joint. The ribbon window itself
is not able to transfer the load
to the substructure, so the
whole load has to be transfer-
red to the adjacent panels.
In the figure an example of
an adapter profile with and
without the sandwich struc-
ture is shown.

6
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Beam (1) represents the com-


plete adjacent sandwich panel
in longitudinal direction with
the related torsional rigidity IT
and the bending stiffness EIL.
The cross-beams (2) represent
the behavior in cross direction
(EIQ, GQ). They have a distance
of lQ. The vertical elements (3)
represent the stiffness of the
joint kF and the horizontal
beam (4) represents the adap-
ter profile with its bending Figure 1: beam model
stiffness EIAdapter.
An assumption for this model The following failure modes are possible:
is the fact that the adapter profiles are
supported by the substructure. The adapter 1 • Wrinkling of the face in the adjacent panel
profile is loaded by half of the area load of the 2 • Shear failure of the core
window. Depending on the stiffness of adapter in the adjacent panel
profile, joint and sandwich panel the loads will 3 • Joint failure
be divided on the adapter profile and the 4 • Failure of the adapter profile – This case
adjacent sandwich panel. The panel is loaded will not be investigated here as the manu-
eccentrically which leads to additional facturer of the adapter profile is usually
stresses in the face and the core material. responsible for the load bearing capacity
These stresses have to be added to the of the profiles.
stresses caused by the bending moment.
1 • Wrinkling of the face:
The beam model brings the following results The normal stress in the adjacent panel can
for the particular beams: be determined by addition of the normal stress
due to bending and the normal stress caused
Longitudinal beam: My,L, MT, Qz,L by the eccentric load.
Cross-beam: My,Q and Qz
The following two ratios of normal stress in the
Joint elements: N face exist:
Adapter profile: My and Qz
Existing normal stress
After the determination of the stress resul- due to bending
(Independent from
tants and deflections using the beam model the window) (1)
the structural analyses for the different failure
modes can be implemented.

7
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Normal stress due to eccentric loading (2)

The complete stress results in: (3)

The factor m can be taken from diagrams (See Deliverable 1.2, parametric study, figure 2.8).
The confirmation is then:

(4)

2 • Shear failure of the core:


Also in the core the stresses caused by the centric shear force have to be superimposed in
the core the stresses from the eccentric loading. For the eccentric load an effective width of the
panel of 25 cm (panel width 100 to 120 cm) can be taken into account for conservative results.

The following two ratios of shear stress in the core exist:

Shear stress due to the existing shear force in the panel: (5)

Shear stress due to the eccentric load: (6)

The confirmation according to the technical approval is: (7)

3 • Failure of the joint:


For the load transfer from the adapter profile to the adjacent panel the load bearing capacity of
the joint has to be proved as well.

The beam model provides the maximum load in the joint as normal force N in the joint elements. The
load bearing capacity of the joint Fj has to be determined by tests (See Deliverable 1.2, Chapter 2.2.4).

The result from the beam model is: (8)

The equation of approval is: (9)

8
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 Ribbon windows with punctual fixing


In line with the model described above, calculations can also be made for sandwich facades with
punctual fixed ribbon windows.
As the windows edges are unsupported the whole load has to be transferred to adjacent panels.

Figure 2: Test setup for a ribbon window with punctual fixing

The calculation and the analyses are the same as described before. Just the load is not applied on an
adapter profile but punctual on the crossbeams as described earlier except that the load.

Figure 3: Beam model for the calculation of a sandwich panel in neighborhood


of a punctual fixed ribbon window

Additional to the calculation of the panel, the punctual fixing has to be tested. The load bearing
capacity of this detail is very dependent on the kind of fixing, so the maximum load should be
derived from tests.

9
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 Windows with bonded frames


Sandwich facades with bonded window frames have a load bearing behavior which is somew-
hat different as in this case the whole panel is not replaced by a window (see figure 4). Parts of
the panel still participate in the load transfer.

Figure 4: Windows with bonded frames in a sandwich facade

Tests carried out within EASIE have shown that the frames clearly improve the load bearing
capacity of the panels. The tests have also shown that the frames do not carry parts of the load
by themselves but stabilise the faces in the high stressed regions around the opening. Therefore
it is necessary that the frame stabilises the face in a region of at least 5 cm around the opening.
For openings without frames the following basic rules for a centric small opening - derived from
the European Recommendations for sandwich panels - are given as the following four equations:
1 to 4:

(10)

where

(11)

10
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(12)

(13)

The load bearing capacity of single panels with small openings can be derived from these equa-
tions. The factor kF has to be adapted for the bonded frames to the factor kF,frame:

(14)
related load bearing capacity

related width of the opening

Figure 5: Load bearing capacity of panels with reinforced openings

Please note that the model proposed above is based on a limited number of tests and will
therefore have to be further verified with additional experiments.
For openings through longitudinal joints as shown in figure 6 below the load bearing capacity is
always the sum of the residual load bearing capacities of the outer panels. In case of a single
span panel the inner panels do not contribute to the load transfer.

11
Guide_Results_A5:Mise en page 1 30/08/11 19:10 Page 12

Figure 6: Geometries of large openings

The calculated load bearing capacity is very depending on the calculation model. If the panels
are supported laterally, they are able to carry much more load than laterally unsupported
panels. In figure 7 the related load bearing capacity for a system of two panels with an opening
(width of the opening 1 m, according to figure 6, left side) with different eccentricities is compa-
red for lateral supported and lateral not supported panels.

Figure 7: Load bearing capacity for a system of two panels with one opening (Width of the opening 1 m)

12
Guide_Results_A5:Mise en page 1 30/08/11 19:10 Page 13

Due to the neighboring panels and the bonding between the


window frame and the panels a lateral support can be assumed. In Further information
this case the following equation can be used: Further information on the struc-
tural behavior of sandwich panels
with openings can be found in the
following report, which can be
(15) downloaded at www.easie.eu:
Deliverable D1.2:
with Calculation Model determining
mechanical strength of sandwich
panels with openings with and
(16) without additional internal frame
structure
The equations 15 and 16 directly result from equation 10 and 11 as
sum of the load bearing capacities of the outer panels. Furthermore different papers on
this topic were published:
The result for the system tested within EASIE (See Deliverable 1.2, • Warmuth, F., Lange, J.: “Ope-
Chapter 2.4.2, Test 1 three panels with an opening with a width of nings in Sandwich Elements”,
CIB World Congress 2010.
1,9m) is shown in figure 8. For this test a good correlation between
the test result and the calculation proposal can be stated. Proceedings (www.cib2010.org/
post/files/papers/1013.pdf).
• Rädel, F., Lange, J.: “Tragfähig-
keit von Sandwichelementen mit
profilierten Deckschichten und
Öffnungen)“, Stahlbau, Vol. 80,
No. 9, 2011 (in German).
• Rädel, F., Lange, J.: “Eccentri-
related load bearing capacity

cally loaded Sandwich Ele-


ments”, EUROSTEEL 2011,
Budapest, September 2011.

References
Böttcher, M. 2005, Berechnungs-
verfahren für Wand-Sandwichele-
mente mit Öffnungen.
IFBS-Fachinformation 5.09 Statik,
IFBS e.V, Düsseldorf (in German)

eccentricity of the opening in mm Courage, W. & Toma T. 1994, Struc-


tural detailing of openings in sand-
wich panels. TNO report
Figure 8: All the models above are based on very few tests, so further 94-CON-R0729-01
investigations are necessary to verify these proposals!

13
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Thermal
behaviour
Principles of good practice

2
Fabrication of sandwich panels

 Panels with core material of closed cell structure


The geometry of the joint can greatly contribute to air and water
penetration. The key and slot joints in panelscan have a positive
influence on the tightness. In this context it is very important that
the abutting ends and surfaces of the panels fit into one ano-
ther very well. For a good insulation it is also important that the
metal faces have as little penetration into the core as possible
like it is shown in the right picture of figure 1.1. A bad solution is
to have the metal face bent into the core as it is done in the panel
to the left in figure 1.1. The problem is of particular importance
for thin panels (thicknesses up to 80 mm) where there are cases
where the metal faces almost touch each other in the joint.
Joints always form a line of higher thermal conduction as in
the panel area and the penetration of metal worsens this
[IFBS 4.03].

Figure 1.1: Experimental set-up

The next important element is the sealing tape. Current state of


the art is to use sealing tapes in every longitudinal joint of the
panels. Different kinds of sealing tapes exist on the market [IFBS

14
Guide_Results_A5:Mise en page 1 30/08/11 19:10 Page 15

4.02]. The most important difference is in the cell structure with open cells, partly open cells and
closed cells all used in modern sandwich panels.
These different structures lead to very different characteristics regarding the air permeability.
Closed cell structures are practical completely airtight as soon as they have contact to the
joint, whereas open structures need some compression. The required level of compression is
depending on the cellular material. According to [Galileo], the following table gives some guide
values:

Cellular Material Minimal compression for air tightness


PUR-foam, open cells 60 – 80 %
PUR-foam, open cells, impregnated by acrylate 50 – 60 %
PVC-foam, partly open cells 30%
PE-foam, partly open cells 15 %
PE-foam, closed cells -

In addition good results have been obtained with rope seals or rubber piping made of EPDM
(ethylene propylene diene Monomer).

Impregnated open celled PUR-foam Closed celled PE-foam


[www.iso-chemie.com] [www.iso-chemie.com]

Figure 1.2: Examples of sealing tapes

15
Guide_Results_A5:Mise en page 1 30/08/11 19:10 Page 16

According to that information it is essential for the tightness that the geometry of the joint al-
lows the required compression of the sealing joint.

Figure 1.3: Examples of longitudinal joints

If the shadow gap is closed for example before the sealing joint is compressed, it will not be
possible to get an air tight construction. In addition the effectiveness of the contact pressure
plays an important role. If the necessary compression can only be reached by high pressure, the
correct mounting equipment has to be used.

 Panels with core material of open cell structure


For panels with core material of open cell structure such as mineral wool a different sealant
solution is necessary. By these panels a sealant stripe of tight material with big flexibility shall be
placed in the longitudinal joint between the metal sheets. Here it is very important to seal the joint
between the sheets; otherwise an air stream through the open cell structure of the core is possi-
ble. The joint profile geometry shall be designed for this sealant stripe. Two examples are shown
in figure 1.4. The sealant shall be placed on the warm side. In special cases, e.g. walls with high
wind pressure, sealants in both faces as shown in figure 1.4 (on the left) can be useful.

Figure 1.4: Examples for a good sealing of mineral wool panels


[www.Ruukki.com], [www.fischerprofil.de]

Also for mineral wool panels, the tolerances play an important role. They have to be small enough
to assure the sealing.

16
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Installation of sandwich panel constructions


Sandwich panels are usually optimised for fabrication by the panel manufacturer. Due to the
fact that the joints are fabricated in an industrial process very small tolerances are possible.
So the question of tightness is mostly a question of a correct installation. For example TKS writes
in his installation recommendations: “It is not possible to correct the position of subsequent
panels by realigning the longitudinal joint. Sealing of the longitudinal joint is achieved by factory-
applied sealing strips. Tightness, however, is only ensured when the modular laying dimension
is exactly adhered to.”
For ensuring the air and water tightness of the panels an exact knowledge of the tolerable width
of the shadow gap (see fig. 1.3) is necessary. This is the only possibility for the fitter to check the
correctness of the construction and to guarantee a tight building envelope. The tolerances have
to be small enough to assure the required compression. Fabrica-
tors must give a value for the nominal shadow gap and tets must
be performed with a nominal gap of + 1mm. Further information
Further information on the ther-
Joints sealing openings mal behaviour can be found in the
following report, which can be
In addition to the rules for longitudinal joints which are important
downloaded at www.easie.eu:
for joints sealing openings as well there is another point to give
attention must be given to a further point. Because of different Deliverable D1.1:
joint geometries different sealing strips are used. An incorrect Design guidelines for good panel
installation of the seal will result in a lack of tightness especially joints and joints sealing openings
in the corners of the openings. focussing on air and water tightness

References
Galileo – Kreatives Bauen mit
Sandwich: Basis Info, chapter 4.9,
Version 2009-11-D1

IFBS 4.02, Bauphysik – Fugendich-


theit im Stahlleichtbau, IFBS e.V.,
Düsseldorf, 11/2004

IFBS 4.03, Bauphysik – Wärme-


brückenatlas der Metall-Sand-
wichbauweise, IFBS e.V.,
Figure 1.5: Example for an installed window in laboratory with longitudinal Düsseldorf, 03/2010
and horizontal sealing tapes

17
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The thermal

3
test methods

The standard EN 14509 allows to


calculate a coefficient k1 applied on the
stresses.
Alternative thermal methods are propo-
sed either to see the influence of the
temperature on the bending moments
either to compare the real deflection
with the theoretical deflection due at
Thermal test equipment the temperature.
Thermal test procedure
Darmstadt university
Two methods are defined:

 Method 1:
It’s aim is :
• to calibrate the theory and the real

βΔT = wtest /wtheory)


behaviour of the panel (coefficient

• to evaluate the thermal action on the


central support of a panel on 3 sup-
Test equipment: the supports System to apply the load ports below a thermal gradient alone

18
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Applying the load at


a thermal gradient of 60°c
Temperature in °C

Force in N

Heating time in minutes Deflection in mm

Table of results for a thermal gradient of 50°C


Test No. Material thickness span DT f measured f theoretical β
1 PUR 100 2,895 59,65 7,70 7,74 0,99
2 PUR 100 3,999 58,38 12,56 13,60 0,92
3 PUR 80 2,895 60,00 9,79 9,91 0,99
4 PUR 80 3,895 56,76 15,74 16,70 0,94
5 MW 90 2,895 59,00 8,63 8,39 1,03
6 MW 90 3,895 55,00 14,51 14,08 1,03
7 MW 120 2,895 59,40 6,16 6,27 0,98
8 MW 120 3,895 55,00 10,86 10,52 1,03

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 Method 2:
It’s aim is :
• to calibrate the design by calculation and design by testing procedure in general when a
thermal gradient is applied, find equivalent k1 factor (see EN 14509 formula A.16).
In this method, a thermal gradient is first applied, followed by an additional loading in the form
of a series of linear punctual loads.
Thus the behaviour of the panel below thermal gradient and loading is directly known.
The comparison of the results with and without thermal gradient are possible and the effect
of the thermal gradient is taken into account in a real way.
This test is an alternative way at the correction by k1 the wrinkling stress due to the tempe-
rature.
Load (kN)

Thermal test equipment


Aalto university Finland

Deflection in mm
Example of test results for a roof panel on
3 supports (In green) without thermal gradient,
loading alone ,and in blue below a thermal
gradient of 40°C + loading

20
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Design by
testing package
An information of this work was given to the relevant Euro-
pean codification technical committees.

4
This work constitutes a background that will be used and dis-
cussed in the TC128SC11 WG5 and WG1 to build the final ver-
sion of the annex about the design by testing in the EN 14509.
The aim of the study was to develop the method and analyse the
advantages which design by testing could offer as an alterna-
tive to design by calculation, which is developed in the EN 14509.
The main outputs from the study are:
• A summary of the basic principles of design by testing
• Two thermal test methods are proposed: equivalent k1
coefficient by test, and verification of the theoretical and real
behaviour below thermal gradient
• 2 Theoretical guidelines with a formula to calculate the
strength of the material for flat and for ribbed panel
• 31 Numerical examples including PU and MW panels,
cladding and roofing, on 2 and 3 support, in pressure and
suction and with and without thermal gradient
• Three Excel sheets which allow for quick and easy hand
calculation by hand for the numerical examples
• Parametric study comparing the design by testing results
with those obtained following EN 14509. This study allows to
see through several load tables the advantages offered by
the design by testing method.

The design by testing guidelines : Deliverable 2.3


Two guidelines have been developed to justify the formula used for the design by testing
and that can be also used for the design by calculation.
• Guideline No 1 deals with flat panels without ribs (cladding panels)
• Guideline No 2 deals with ribbed panels with ribs on one face (roof panels)
Example of results that can be used both for design by testing and design by calculation (the two
first cases are already in the EN 14509 standard (see table E.10.2).
The parametra λ, for the equivalent two span panels, is determined either by calculation
(formula in cosh ECCS etc Stamm and Witte) or by testing by measurement of the action on the
central support or by forfeiture value.

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The examples: Deliverable 2.4


31 examples were carried out covering:
• cladding panels of Panelco, Thussenkrupp with PU and mineral wool core on 2 and 3 supports
with positive and negative loading
• Roofing panel of AMC Polska with PU core on 2 and 3 supports with positive and negative
loading with and without thermal gradient.

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For each example are defined: the panel tested, the tests which have been performed and their
results and the interpretation of the tests results to determine the bending and shear rigidity
(Bs and GcAc), the strength capacities. Moment in span and on central support, shear on end
and central support, reaction to support capacity on end and central support in ULS (Elastic and
elaso-plastic approach) and SLS and the load span tables.
The excel sheets: Deliverable 2.5
Three type of Excel sheets have been developed and are freely accessible on the EASIE website
(www.easie.eu):
1 • To determine the bending and shear rigidities

26
Guide_Results_A5:Mise en page 1 30/08/11 19:10 Page 27

2 • To determine the strength capacities

27
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3 • To determine the load tables

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The parametric study (Deliverable 2.2 )


Extensive parametric studies were carried out to compare the results of the design by testing
method with the design by calculation defined in the EN 14509.
The design by testing allows to have some benefit by comparison with the design by calculation
approach in terms of load/span tables.
This is due at the test done in the end use condition and by the use of the rest moment when it’s
significant.

Calculation From Is Mainz

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Guide_Results_A5:Mise en page 1 30/08/11 19:10 Page 30

Design by testing Calculation By D I In blue light design by calculation (Is Mainz ) and
dark blues design by testing (DI)

Design by testing Calculation By D I

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Calculation From Is Mainz

31
Guide_Results_A5:Mise en page 1 30/08/11 19:10 Page 32

In blue light design by calculation (Is Mainz ) and dark blues design by testing (DI)

Roof PU panel from AMC Polska, PU and MW Cladding panels from Thyssen, and Panelco have
been studied on 2 and 3 supports, in pression and suction, with and without thermal gradient.
SNPPA performed the calculations while IsMainz have verified and compared them with
EN14509.
Some key illustrative results are given in the above figure.

A draft annex for the TC128 SC11


A draft annex on the design by testing is being prepared in collaboration with the European
Committee for Standardization (CEN) TC128 SC11 based on the EASIE results.
This annex will define the general procedure of the design by testing and the principal formula
that must be used. The principles are given below:
The Principe of the design by testing is to verify that:

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All the limit states require to verify the following set of equations:
At ULS:

At SLS:

The deflection criteria:

where:
the load Sd cover :
• The bending moment in span
• The bending moment in central support
• The shear load at the end support
• The shear load on the central support
• The strength capacity on the end support in compression
• The strength capacity on the central support in compression
• The assembly capacity on the end support below a negative loading
• The assembly capacity on the central support below a negative loading
And all this criteria with and without thermal gradient and creep effect
k : statistic coefficient in function of the number of tests done (0.85 if only 1 test etc )
Rad,S : cover the corrections in link with the nominal panel (ratio between the measured value and
nominal value for fy, e, ti, fCc fCv etc)
Radj,Bs = γt x ([(t1 / t1obs) + (t2 / t2obs)] / 2) x (e / eobs)2

Radj,Ms = γt x (t2/t2obs) β x (fy2/fy2obs) α x (e / eobs) with alpha and beta following A.5.5.4 EN 14509
Radj,GcAc = Gck / Gcobs x (D / Dobs) or alternatively Gck / Gcobs x (dc / dcobs)

Radj,MF1 = γt x (t1/t1obs) β
Rad,V = fCvk / fcv,obs x (D / Dobs) or in alternative fCvk / fcv,obs x (dc / dcobs) or mk / m,obs x (D / Dobs)
γM : material safety factor function of the type of collapse (wrinkling, shear, compression )
f(Q): function is in link with the loading applied (strength of material formula)
X = 200 or 100 etc in function of the use of the panel

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Example 1 to 3 of f(Q) at ULS (with Qc) an SLS (with Qel) with the test loading corresponding
at 4 loads by span (also possible to do it with two loads by span, UEATC loading)

Example 1: panel on 2 supports

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Example 2: panel on 3 support (elastic behaviour)

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Example 3: panel on 2 supports with residual bending


momen (elastic-plastic approach )

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Example of Sd (q) for load table

37
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The design by testing procedure is as follows:

Performance of large scale tests


On small, intermediate and max span
of the panel range
On minimum, intermediate and maximum
thickness
Determination of
• Positive loading: 2 supports (A7 or A8 the bending and
EN 14509) and 3 supports (UEATC/EASIE)
shear rigidities Bs;
• Negative loading: 2 supports (A7 or A8 EN (BF1) and GcAc
14509) and 3 supports (UEATC/EASIE)
(Panel fixed on supports)
• By calculations
• Reaction to support test (A15 EN 14509) (EN 14509)
• Eventual thermal tests or use of k1 or
coefficient EN 14509 • By solving couple of
The results are the curves load-displace- deflection equations
ment and eventual action on the central where (Qd, f, Rd )
support (end supports) Known, and the rigidities
unknown
or
• Or span by span
(deflection and action
on central support
known)

And carried out the small tests on the


samples/ use CE marking results to find
;m…

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Guide_Results_A5:Mise en page 1 30/08/11 19:10 Page 39

Determination Determination Determination


of the strength of the strength of the load/
capacities at ULS capacities at SLS span tables:
(MU,Rd, VU,Rd, FU,Rd ) (ME,Rd, VE,Rd, FE,Rd ) • Combination at ULS
based of the use based of the use and SLS of self weight,
of the large scale of the large scale and outside load (wind,
snow, thermal gradient,
test results: creep) to determine
SU,Sd(qi) and SE,Sd(qi)

SU,Sd = (MU,Sd, VU,Sd, FU,Sd)


• in elastic (maximum
and SE,Sd = (ME,Sd, VE,Sd,
s • in elastic (maximum load in the linear
FE,Sd )
load inferior at the part of the curve load
load of wrinkling displacement (Qel/Qdp) • SU,Sd(qi) ≤ SU,Rd (from the
on central test results corrected)
support (Qcs)
• SE,Sd(qi) ≤ SE,Rd (from the
• in elastic-plastic (rest test results corrected)
moment on central
support after wrinkling • wEd < L/X at SLS
on central support,
collapse load used (Qc)

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Use of sandwich
panels for
stabilisation
of buildings

5
and building
components
Sandwich panels are traditionally used as covering and isola-
ting components of building, thus being secondary structural
components of the building. The panels are mounted on a sub-
structure and they transfer transverse loads, e.g. wind and
snow, to this substructure.
But sandwich panels have also stabilising effects on the subs-
tructure: Sandwich panels increase the resistance of building
components (beams and columns) against lateral torsional
buckling by torsional restraint. The high in-plane shear resis-
tance of sandwich panels can also be used for stabilising effects.
Buckling and lateral torsional buckling can be prevented by
re-straint of lateral displacement. Furthermore sandwich
panels can be used for global stabilisation of buildings against
horizontal loads. The panels transfer horizontal wind loads and
thus replace wind bracings.

Torsional restraint
Sandwich panels increase the resistance of substructures
(beams, purlins) against lateral torsional buckling by restraining
rotations and lateral displacements.
The torsional restraint is governed by the stiffness of the
connection of the sandwich panel to the substructure. Research
carried out at the University of Karlsruhe has shown that this
stiffness significantly depends on the transverse load transfer-
red by the sandwich panel.

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The torsional restraint can be taken into account for the design of beams and purlins. This is done
by a rotational spring, which prevents rotation of the beam around the longitudinal axis.

Stabilisation of a beam by torsional restraint

The stiffness of this rotational spring is a combination of the bending stiffness of the attached
panel, the stiffness of the connection and the distortional stiffness of the beam to be stabilised.
The bending stiffness of the panel and the distortional stiffness of the beam can be determined
comparatively easily. The stiffness of the connection was part of the investigations done within
the framework of workpackage 3 of the EASIE project. A mechanical model for determination
of the moment-rotation relation was developed.

Moment-rotation-relation for downward and uplift loading

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To determine all parameters of the moment-rotation relation tests and additional numerical
investigations were performed.

Test set-up for downward loading

The formulae apply for sandwich panels with facings made of steel, aluminium or GFRP and
with cores made of polyurethane, EPS or mineral wool. The influence of different kinds of
connections (fixings through lower and through upper crimp, fixings with calottes) has also been
investigated. Also the effects of long-term loads and elevated ambient temperature were
included in the developed model.

In-plane shear stiffness


When loaded by in-plane shear
forces, sandwich panels have a high
stiffness. The high in-plane shear
stiffness can be used for two different
stabilising effects. Sandwich panels
can restrain the lateral displacement
of beams and columns and prevent
flexural and lateral torsional buck-
ling. By acting as diaphragm sand-
wich panels can also be used for
global stabilisation of complete buil-
ding structures and for transferring
horizontal loads, e.g. wind loads. If
sandwich panels are used for trans-
Mechanical model of a fastening
ferring horizontal loads, they can
replace wind bracings.

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Further information
Further information on the stabilising effects of
sandwich panels as well as some calculation
examples can be found in the following reports,
The in-plane shear stiffness of sandwich which are part of the deliverables of the EASIE
panels is very much higher than the stiffness project and can be downloaded at www.easie.eu:
of the fastenings. The same applies for the • Deliverable D3.3 – part 1: Stabilisation of
load-bearing capacity. So to make use of the beams by torsional restraint
potential presented by in-plane shear loaded • Deliverable D3.3 – part 2: In-plane shear resis-
panels, knowledge of stiffness and resistance tance of sandwich panels
of the fastenings is mandatory. Within the • Deliverable D3.3 – part 3: Stiffness and load
framework of workpackage 3 of the EASIE bearing capacity of shear loaded fastenings of
project a mechanical model for fastenings of sandwich panels
sandwich panels has been developed.
Furthermore different papers on this topic
Stiffness and load-bearing capacity of a were published:
fastening are influenced by different single • Misiek, Th., Käpplein, S., Dürr, M., Saal, H.:
components. In the mechanical model these “Stabilisation of purlins by sandwich panels –
components are replaced by longitudinal new regulations and recent research results”,
or rotational springs. For determination of CIB World Congress 2010. Proceedings
stiffness and load bearing capacity of the (www.cib2010.org/post/files/papers/462.pdf).
springs various tests have been performed • Käpplein, S., Misiek, Th., Ummenhofer, T.:
and evaluated. Finally a generalised calcula- “Aussteifung und Stabilisierung von Bauteilen
tion procedure for the stiffness of direct faste- und Tragwerken durch Sandwichelemente
nings of sandwich panels was developed. (Bracing and stabilisation by sandwich panels)“,
Stahlbau, Vol. 79, No. 5, pp. 336-344, 2010 (in
A calculation procedure for determination of German).
the stiffness of shear diaphragms made • Käpplein, S., Ummenhofer, T.: “Querkraftbeans-
of sandwich panels was developed in a former pruchte Verbindungen von Sandwichele-menten
research project by Baehre and Ladwein. (Shear loaded fastenings of sandwich panels)“,
Based on this model, calculation procedures Stahlbau, Vol. 80, No. 8, 2011 (in German).
for determination of the forces of fastenings, • Misiek, Th., Käpplein, S., Saal, H., Ummenho-
which are decisive for the load bearing beha- fer, T.: “Lateral torsional stabilization by sand-
viour and capacity of shear loaded sandwich wich panels”, eurosteel 2011.
panels, were developed within the EASIE • Baehre, R., Ladwein, Th.: Tragfähigkeit und
project. Transfer of horizontal loads and global Verformungsverhalten von Scheiben aus Sand-
stabilisation of buildings was considered as wichelementen und PUR-Hartschaumkern
well as stabilisation of single building compo- (Projekt 199). Studiengesellschaft Stah-
nents (beams and col-umns). lanwendung e.V., Düsseldorf 1994.

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Design of frameless
structures made
of sandwich panels

6
The common application of sandwich panels is restricted to
the function of space enclosure. The sandwich panels are
mounted on a substructure and they transfer transverse loads
as wind and snow to the substructure. As a recent develop-
ment, sandwich panels are used to design small buildings– such
as cooling chambers, climatic chambers and clean rooms –
without any load-transferring substructure. In this application
the panels are not only used as cladding element but also for
load transfer and bracing of the building.

Building made of sandwich panels but without load-bearing substructure

Axially loaded sandwich panels


In addition to the moments and transverse forces resulting from
transverse loads, the wall panels of frameless buildings trans-
fer normal forces arising from the super-imposed load from
overlying roof or ceiling panels. This raises the question of the

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load bearing behaviour and the load bearing capacity of sandwich panels subjected to axial load
or a combination of axial and transverse load.
Within the framework of workpackage 3 of the EASIE project, design methods for axially loaded
sandwich panels have been developed. The design model is based upon the existing design
model for panels subjected to transverse loads according to the EN 14509 standard. Buckling

designed according to 2nd order theory with the conventional amplification factor α. The
tests and numerical investigations have shown that panels subjected to axial loads can be

wrinkling stress determined in simple bending tests can be used as ultimate stress.
Furthermore the behaviour due to long-term loads (creeping of the core material) can be
considered by the design method. Only the creep coefficients, which are also used for the
design of panels subjected to transverse loads, have to be known. For verification long-term
tests on axially loaded sandwich panels were performed.

Buckling and long-term test on axially loaded sandwich panels

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The design method has the advantage that there is no necessarily of any additional test. To
design axially loaded sandwich panels only the parameters used for the design of panels
subjected to transverse loads have to be known (e.g. wrinkling stress and creep coefficients).
In addition to the global load-bearing behaviour the local load-bearing capacity at the areas of
load application, i.e. at the lower ends of the panel and at the connection between wall and
ceiling, where the superimposed loads from the ceiling are applied as normal force to the wall
panels, is to be considered. The load-application areas have been investigated by tests and
numerical calculations. A calculation procedure for determination of the local strength has been
developed.

Connection between wall and ceiling and lower end

Bracing of the building


If sandwich panels are used without load-transferring substructure, the panels have to
transfer horizontal wind loads to the foundation and to stabilise the building. For this purpose
the high in-plane shear stiffness and capacity of the panels is used. Both, stiffness and load
bearing capacity are very much higher than the corresponding values of the fastenings. Because
of that for design purposes the deformation of the panels can be neglected. Only the flexibility
of thefastenings has to be considered. Also for the load-bearing capacity the fastenings are
decisive. Thus, if a frameless structure is loaded by horizontal wind loads, the fastenings have
to be designed for this load.
Within the EASIE project basic principles for the design of frameless structures for the transfer
of horizontal loads have been worked out. Calculation procedures for determination of the
for-ces the fastenings have to be designed for were developed.

46
Guide_Results_A5:Mise en page 1 30/08/11 19:10 Page 47

General principle of transfer of horizontal wind loads in a frameless structure

Further information
All investigations on frameless structures, which were Furthermore the following papers dealing
done within the framework of the EASIE project, can with axially loaded sandwich panels were
be found in the following reports: published:
• Deliverable D3.3 – part 4: Design of axially loaded • Käpplein, S., Ummenhofer, T.: “Axial beans-
sandwich panels; global load bearing behaviour pruchte Sandwichelemente in rahmenlosen
Konstruktionen (Axially loaded sandwich
• Deliverable D3.3 – part 5: Design of axially loaded panels in frameless buildings)“, Stahlbau,
sandwich panels; load bearing behav-iour of load Vol. 79, No. 10, pp. 761-770, 2010 (in German).
application areas
• Käpplein, S., Ummenhofer, T.: “Classifica-
• Deliverable D3.3 – part 6: Transfer of horizontal wind tion of stability failure modes of sandwich
loads and stabilisation of frameless structures panels under compression loading: global
In addition a Design Guideline (Deliverable D3.4) for and local buckling, crippling at support line”,
the application of the design formulae was prepared. Procee-dings of SDSS, International Collo-
The Design Guideline also includes some calculation quium Stability and Ductility of Steel Struc-
examples. tures, pp. 1033-1040, 2010.
(www.labciv.eng.uerj.br/sdss2010/files/
All these documents can be downloaded at
www.easie.eu. sdss_rio_2010_11_17.pdf).

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Guideline for
construction good
practice of
frameless buildings

7 The design concept of a frameless building made of sandwich


panels is presented here together with the constructional
details of the panel connections. This is largely based on the
substantial collective experience of the EASIE partners and in
particular the panel manufacturers
Experiments and model calculations have determined the scale
of axial load bearing capacity and in-plane shear resistance.
It has been shown that sandwich panels have load bearing
capacity which is more than adequate for usual stresses. The
way in which the force is applied has been shown to be signifi-
cant. It was experimentally demonstrated with small scale tests
and practically by using a demonstrator that panel connections
according to known principles in the common use of sandwich
panels, as applied in the construction of cold rooms, machine
enclosures, etc., are generally suitable for pure sandwich
construction of small building structures. The guide provides a
structured series of design examples for the components to be
connected (roof / ceiling, wall, floor). Facing material specific
features and building climate aspects are taken into account.

Demonstrator

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Guide_Results_A5:Mise en page 1 30/08/11 19:10 Page 49

Details (examples)

49
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New techniques
to maintain and

8
repair sandwich
panels systems
Material ageing or damage or the need to improve the
performance or appearance or to extend the service life of
the building may require the repair 0f sandwich panels. This
may mean cleaning or painting of the surfaces, fixing the
joints and sealants or repairing the structural parts of the
façade and roof.

In EASIE conventional cladding systems based on thin-walled


purlins and sheetings and new systems based on additional
sandwich elements or monopanels have been studied.

Cladding changes the loads and the static behaviour and resis-
tance of the wall and roof structure consisting now ordinary
sandwich panel to which have been added additional compo-
nents and elements.

Guidelines have been produced for the design and installation


of cladding systems based on the study of conventional system
based on purlins in parallel or transverse direction to the span
and on trapezoidal sheetings and cassettes and on a new
system based on additional sandwich panels or monopanels
consisting of the external face and a core layer only.

Compared to the initial tests, panels with hat-profiles in longi-


tudinal direction and sinusoidal sheet mounted directly on the
face of the panel resulted in a high load-bearing capacity. The
Z-profiles led to a loss of the load-bearing capacity because of

50
Guide_Results_A5:Mise en page 1 30/08/11 19:10 Page 51

the local compression caused by the


edge of the profile into the face of the
sandwich panel.
The figure below shows the deflection of
the panel to the load of 12 kN ( 6 kN in
the case of panels with the transversal
Z-profile which did not reach this load
level). The deflection was proportional to
the load in all tests.

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*The deflection E (Z-profile) is given for a load of 6 kN.

A : initial test (l=4000 mm) D : hat-profile in transverse direction (l=4250 mm)


B : sinusoidal sheet without purlin (l=4250 mm) E : z-profile in transverse direction (l=4250 mm)
C : hat-profile in longitudinal direction (l=4250 mm)

In addition to the full scale tests, small tests were carried out to determine the stiffness of
the connection between face and cladding. In the tests, a piece of the sinusoidal sheet was
mounted on the sandwich-panel in the same way as in the full scale tests and loaded in its
longitudinal direction. The stiffness of the connection can be taken from the load-deflection
curve. Because of low results no test were performed for the Z-profile-connection.

52
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specimen c (N/mm)
hat-profile in longitudinal direction 5875
sinusoidal sheet without purlin 3086
hat-profile in transverse direction 540

A : ordinary sandwich panel D = 100 mm


B : ordinary sandwich panel + additional panel D = 40 mm, IR2-4.8 screws c/c 300 mm
C : ordinary sandwich panel + additional panel D = 40 mm, IR2-4.8 screws c/c 500 mm
D : ordinary sandwich panel + additional panel D = 40 mm, SL-2 screws c/c 500 mm
E : ordinary sandwich panel + additional panel D = 40 mm, SL-2 screws c/c 1000 mm
F : ordinary sandwich panel + additional monopanel D = 40 mm, IR2-4.8 screws c/c 300 mm
G : ordinary sandwich panel + additional monopanel D = 40 mm, IR2-4.8 screws c/c 500 mm
H : ordinary sandwich panel + additional monopanel D = 40 mm, IR2-4.8 screws c/c 1000 mm

Comparison of the experimental load-bearing capacity (total load) and stiffness (change of the
load to the change of the mid-span deflection) of the full-scale specimens with different
cladding elements and fastenings to the ordinary three-layer sandwich panel shows potential
benefits of the new cladding systems in term of mechanical behaviour.

53
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The experimental results relate to the span (4 m) and depth (100 + 40 mm) of the specimen. The
components of the cladding system were assembled with screws and rivets fixed between two
thin-walled components or elements. Gluing may be another promising way to fix the additio-
nal components to the external face of the wall and roof panel.
The benefits of the adhesive joints are the invisible fastenings and fluent flow of stresses without
stress concentrations between the components. The gluing in outdoor conditions requires
careful cleaning and preparation of the contact surfaces. The working temperature and humi-
dity may be limited to a narrow range and a prestressing of the joints is needed for a time
during the hardening of the adhesive. The gluing systems have to be tested to withstand service
conditions.
In the EASIE project, different techniques have been studied in order to return totally or partially
the resistance of the sandwich panel having defects in their external face. Repairs are normally
carried out outdoor which puts additional demands on the technique. In the study all panels
have been repaired in a horizontal position rather than the vertical position usual for wall panels.
Seven different damage patterns have been used to simulate the defects caused by a wrinkling
or a crash. Damage patterns A, B and C were caused by cutting and pressing in the upper layer
sheet. The width of the cut was a quarter (A), a half (B) or the whole width (C) of the panel.
Damage pattern D1 and D2 were made by pressing a steel ball into the panel and the damage
pattern E1 and E2 using a steel pyramid impacter.

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Four different types of materials were used for the reairs (types I, II, III and IV). In principle, it is
possible to repair cuts (A, B, C) by using a selected material and procedure and thereby improve
the load bearing capacity. None of the materials used in the study resulted in the returning of
the strength totally to the level of the initial wrinkling stress. The repairs of the dents (D1, D2, and
E2) resulted in no improvements with panels being worse than when using an improper repai-
ring procedure.

Further information
Further information on sandwich panels repair and retrofitting can be found on the project
website at www.easie.eu
For additional details on the repair technique developed within EASIE see the website of RBM
Europe BV.
Publications:
• P.Hassinen, T.Misiek and B.Naujoks “Cladding systems for small panels, refurbishment of
walls and roofs”, EUROSTEEL 2011, August 31st-September 2nd 2011, Budapest.
• P.Hassinen, T.Misiek and B.Naujoks “Fassadensysteme zur Sanierung von Wänden aus
Sandwichelemente “, Stahlbau 9, September 2011 (In German)

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www.easie.eu

9
Results of the 19 partners Manufacturing E-learning Information 10 e-letters
EASIE research (industries, lectures about
universities, Official on sandwich sandwich
industrial documents design and technology in
associations) application construction
from 10 different
European
countries have
been involved in
the project

56
Guide_Results_A5:Mise en page 1 30/08/11 19:10 Page 57

tters

57
Guide_Results_A5:Mise en page 1 30/08/11 19:10 Page 58

16 e-learning lectures
are available on
www.easie.eu

10  Load Bearing Behaviour. How is a sandwich


panel working
Comportamiento de los paneles bajo carga.
¿Cómo trabaja un panel sándwich? (Spanish version)
Jak działa płyta warstwowa - zachowanie pod
obciąeniem (Polish version)
Prof. Dr.-Ing. Jörg Lange - TU Darmstadt, Germany
Dipl.-Ing. Aneta Kurpiela - TU Darmstadt, Germany

 Actions and loads. Special Aspects


of Sandwich Structures
Oddziaływania i obciąenia. Specjalne aspekty dla
płyt warstwowych – Prof. dr in. Klaus Berner - iS
engineering, Niemcy (Polish version)
Prof. Dr.-Ing. Klaus Berner - IS Mainz, Germany

 Allowable span tables on the base


of the CE-mark
Tablas de carga con los datos del nuevo marcado CE
(Spanish version)
IS- Prof. Dr.-Ing. Klaus Berner - IS Mainz, Germany

58
Guide_Results_A5:Mise en page 1 30/08/11 19:10 Page 59

es
 Sustainability in Sandwich  Connections
Construction of Sandwich Panels
Sostenibilidad en la construcción Dr.-Ing. Thomas Misiek – KIT,
con paneles sándwich Karlsruhe, Germany
(Spanish version)
Dr.-Ing. Markus Kuhnhenne –
RWTH University Aachen, Germany

 Erection. Form the Factory


to the Final Building
Dr.-Ing. Dr Ralf Möller – Pöter &
 Fabricating and Designing Möller, siegen, Germany
Sandwich Panels for Fire
Produkcja i projektowanie płyt
warstwowych w kontekście
problematyki przeciwpoarowej
(Polish version)  Sandwich panels
Dr. Maciej Klosak - ArcelorMittal, and architecture
Poland Arquitectura con paneles sándwich

nika Poznańska, Poland


Dr.-Ing. Jacek Tasarek – Politech- (Spanish version)
Płyty warstwowe i architektura
(Polish version)
Mr. Cohen - Architectenbureau
CEPEZED B.V, The Netherlands
 Thermal Bridges and Air Tight-
ness of Sandwich Construction
Puentes térmicos y impermeabili-
dad en la construcción con paneles
sándwich (Spanish version)  Repair and retrofitting
Mostki termiczne oraz szczelność Mantenimiento y reparación
płyt (Polish version) (Spanish version)
Dr.-Ing. Ralf Podleschny – EPAQ, Dr. Paavo Hassinen – Aalto University,
Germany Finland

>
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Guide_Results_A5:Mise en page 1 30/08/11 19:10 Page 60

16 e-learning lectures are available on


www.easie.eu
 Repair and retrofitting of sand-  Detailing
wich panels Czyli jak prawidłowo projektować
Naprawa i modernizacja płyt wa_ne szczegóły płyt, by uniknąć
warstwowych (Polish version) przykrych niespodzinek podczas
Eric Rustemeijer, RBM, u_ytkowania. (Polish version)
The Netherlands Dr.-Ing. Ralf Möller - Pöter & Möl-
ler, Siegen, Germany

 Experimental studies on dura-


bility of sandwich panels  Thermal loads of sandwich
Durabilidad de los paneles sánd- panels
wich. Estudios experimentales
Obciąenie płyt warstwowych na
(Spanish version)
skutek rónicy temperatur(Polish
Dr. Paavo Hassinen – version)
Aalto University, Finland
DAFA - Polish Association of Roo-
fing and Cladding Makers, Poland

 Thermal and structural beha-


vior in openings and joints
 Stabilisation of steel structures
Comportamiento térmico y estruc-
tural en las juntas y oberturas de
las construcciones con paneles with sandwich panels
sándwich (Spanish version) Stabilizacja konstrukcji stalowych
Wytrzymałość otworów i połączeń z poprzez płyty warstwowe (Polish
uwzględnieniem działania tempera- version)
tury. (Polish version) Dr.-Ing. Thomas Misiek – KIT,
Dipl.-Ing. Felicitas Rädel - Karlsruhe, Germany
TU Darmstadt, Germany

60
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61
Guide_Results_A5:Mise en page 1 30/08/11 19:10 Page 62

Bui l di ng wi th Sandwi c h Pane l s: Fast, Safe and Ene rgy Savi ng


Guide_Results couver+back_A5_Mise en page 1 08/12/11 15:40 Page1

2008 October

2011
September

The EASIE project has received financial support RESEARCH


RESEARCH
RESULTS
from the European Community’s Seventh Framework Programme

RESULTS
FP7/ NMP2-SE-2008 under grant agreement No 213302

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