(L M ) EASIE-research - Results
(L M ) EASIE-research - Results
2008 October
2011
September
RESULTS
FP7/ NMP2-SE-2008 under grant agreement No 213302
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Contents
Structural behaviour
1 Resistance of panels with openings with reinforcement
6
Thermal behaviour
2 Principles of good practice
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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).
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The factor m can be taken from diagrams (See Deliverable 1.2, parametric study, figure 2.8).
The confirmation is then:
(4)
Shear stress due to the existing shear force in the panel: (5)
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).
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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.
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.
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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)
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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
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.
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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)
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References
Böttcher, M. 2005, Berechnungs-
verfahren für Wand-Sandwichele-
mente mit Öffnungen.
IFBS-Fachinformation 5.09 Statik,
IFBS e.V, Düsseldorf (in German)
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Thermal
behaviour
Principles of good practice
2
Fabrication of sandwich panels
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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:
In addition good results have been obtained with rope seals or rubber piping made of EPDM
(ethylene propylene diene Monomer).
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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.
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.
Also for mineral wool panels, the tolerances play an important role. They have to be small enough
to assure the sealing.
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References
Galileo – Kreatives Bauen mit
Sandwich: Basis Info, chapter 4.9,
Version 2009-11-D1
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The thermal
3
test methods
Method 1:
It’s aim is :
• to calibrate the theory and the real
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Force in N
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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)
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
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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.
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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
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Design by testing Calculation By D I In blue light design by calculation (Is Mainz ) and
dark blues design by testing (DI)
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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.
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All the limit states require to verify the following set of equations:
At ULS:
At SLS:
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)
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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.
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.
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To determine all parameters of the moment-rotation relation tests and additional numerical
investigations were performed.
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.
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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.
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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.
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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.
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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
Demonstrator
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Details (examples)
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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.
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.
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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.
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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
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.
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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
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tters
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16 e-learning lectures
are available on
www.easie.eu
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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
>
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2008 October
2011
September
RESULTS
FP7/ NMP2-SE-2008 under grant agreement No 213302