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Prof. K. Berner. Up-to-date progress in panel applications Institut for Sandwichtechnology Prof. Dr.-Ing. Klaus Berner Edinburgh, 23 th – 24 th of October.

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Presentation on theme: "Prof. K. Berner. Up-to-date progress in panel applications Institut for Sandwichtechnology Prof. Dr.-Ing. Klaus Berner Edinburgh, 23 th – 24 th of October."— Presentation transcript:

1 Prof. K. Berner

2 Up-to-date progress in panel applications Institut for Sandwichtechnology Prof. Dr.-Ing. Klaus Berner Edinburgh, 23 th – 24 th of October 2008

3 Prof. K. Berner One of the first German Approval for Sandwich- Panels 1978

4 Prof. K. Berner German Approval for Sandwich-Panels

5 Prof. K. Berner German Approval for Sandwich-Panels

6 Prof. K. Berner German Approval for Sandwich-Panels 1978

7 Prof. K. Berner Advancement in the Field of Sandwich Panels I. Advancement of the Production II. Optimization of Material and Cross Section III. Enlargement of the spectrum of use

8 Prof. K. Berner Advancement in the Field of Sandwich Panels I. Advancement of the Production II. Optimization of Material and Cross Section III. Enlargement of the spectrum of use

9 Prof. K. Berner I. Advancement of the Production Continous production line

10 Prof. K. Berner I. Advancement of the Production Damages

11 Prof. K. Berner I. Advancement of the Production Damages

12 Prof. K. Berner I. Advancement of the Production Quality Control with samples

13 Prof. K. Berner I. Advancement of the Production Research Project: qSpai Development of non destructive testing methods for sandwich panels Eureka project:Budget:34.000,- Status:completed

14 Prof. K. Berner I. Advancement of the Production Research Project: qSpai Three principle ways to investigate sandwich panels – Rays – Mechanics – Thermal methods

15 Prof. K. Berner I. Advancement of the Production Research Project: qSpai X-Ray

16 Prof. K. Berner I. Advancement of the Production Research Project: qSpai Discontiuities in the panels lead to thermal differences Passive Thermography Lock-in Thermography Pulse Thermography Thermal methods

17 Prof. K. Berner I. Advancement of the Production Research Project: qSpai Lock-in Thermography with results

18 Prof. K. Berner I. Advancement of the Production Research Project: qSpai Lock-in Thermography Advantages – it works – complete surface areas can be monitored – the technique is known Disadvantage – reflecting materials often dont absorb enough energy to show a visible effect. Therefore a matting colour has to be used. – The pictures are sometimes not very clear. Therefore somebody has to watch the screen. – It is difficult to illuminate and to observe non flat geometries

19 Prof. K. Berner I. Advancement of the Production Research Project: qSpai Mechanical Methods Macroscopic deformation – Oscillator coupled to the panel – Magnetic forces Microscopic deformation – Ultrasound methods – Microflown Measuring – Photometry – Vibrometry – Speckle Interferometry

20 Prof. K. Berner I. Advancement of the Production Research Project: qSpai Magnetic forces

21 Prof. K. Berner I. Advancement of the Production Research Project: qSpai Implementation of ….. design realising and

22 Prof. K. Berner I. Advancement of the Production Research Project: qSpai Implementation of …..

23 Prof. K. Berner Advancement in the Field of Sandwich Panels I. Advancement of the Production II. Optimization of Material and Cross Section III. Enlargement of the spectrum of use

24 Prof. K. Berner II.Optimization of Material and Cross Section PUR (PIR)-foam EPS (XPS) Mineral wool

25 Prof. K. Berner II. Optimization of Material and Cross Section Research Project: SwichCore SwichCore Development of a new fire resistant core material FH 3 - project:Budget: ,- Status:completed

26 Prof. K. Berner II. Optimization of Material and Cross Section Research Project: SwichCore Phenolic Foam Hybrid Foam Sodium Silicate Composite SiAC Developed core materials

27 Prof. K. Berner II. Optimization of Material and Cross Section Research Project: SwichCore Results of tensile-tests / Phenol

28 Prof. K. Berner II. Optimization of Material and Cross Section Research Project: SwichCore Full scale tests / Phenol

29 Prof. K. Berner II. Optimization of Material and Cross Section Research Project: SwichCore Reaction to fire & Fire resistance Single Burning Item SBI-Test nach EN Fire Resistance Test according to DIN EN

30 Prof. K. Berner II. Optimization of Material and Cross Section Research Project: SandTweak SandTweak Optimisation of geometry and core material of sandwich panels with metallic faces FH 3 - project:Budget: ,- Status:running

31 Prof. K. Berner II. Optimization of Material and Cross Section Research Project: SandTweak Cross Sections (out of German Approvals) roof panel 1978 – Laminoirs de Strasbourg 2008 – ArcelorMittal Construction

32 Prof. K. Berner II. Optimization of Material and Cross Section Research Project: SandTweak Cross Sections (out of German Approvals) wall panel 1978 – Laminoirs de Strasbourg 2008 – ArcelorMittal Construction

33 Prof. K. Berner Core material (out of German Approvals) II. Optimization of Material and Cross Section Research Project: SandTweak 1978 – Laminoirs de Strasbourg 2008 – ArcelorMittal Construction Density40 kg/m 3 Tensile strength with faces 0,09 N/mm 2 Shear strength0,11 N/mm 2 Shear Modulus 2,5 N/mm 2 E-Modulus Core2,4 N/mm 2 Density39 kg/m 3 Tensile strength with faces 0,07 N/mm 2 Shear strength0,14 N/mm 2 Shear Modulus 2,8 N/mm 2 E-Modulus Core2,3 N/mm 2

34 Prof. K. Berner W vs. G C II. Optimization of Material and Cross Section Research Project: SandTweak Wrinkling stress W (Plantema) Internal forces (bending moment at internal support of a two span panel with flat faces) out of temperature

35 Prof. K. Berner Aim of optimization II. Optimization of Material and Cross Section Research Project: SandTweak Algorithm of Optimization material costsproduction costs load capacity building physics fire performance production technology ecological compatibility

36 Prof. K. Berner Optimization of core material II. Optimization of Material and Cross Section Research Project: SandTweak 1. Analyse of old test results (last four years) 2. Selection of experience areas for all mechanical values 3. Expanding the experience areas 4. Determination of new combinations for mechanical properties new core material

37 Prof. K. Berner Optimization of core material II. Optimization of Material and Cross Section Research Project: SandTweak Determination of new optimal variations of mechanical properties of core materials Searching of: Mechanical properties from certain sets: G c G c1 ; G c2 E cc E cc1 ; E cc2 E ct E ct1 ; E ct2 f cc f cc1 ; f cc2 f cv f cv1 ; f cv2 Aiming at Load factor: Criterions of failure w 100 % f Cv 100 % f Cc 100 % w 100 % OPTIMUM concerning design

38 Prof. K. Berner Optimization of core material II. Optimization of Material and Cross Section Research Project: SandTweak Identification of the optimal core material for a double-span beam Material values according to German Approval: allowable span L G C = 3.6 N/mm 2, E C = 3.7 N/mm 2, f Cv = 0,110 N/mm 2 L = 5.61 m Material values optimized: allowable span L G C = 5.5 N/mm 2, E C = 5.0 N/mm 2, f Cv = 0,085 N/mm 2 L = 7.37 m 31% longer spans without any further costs L w D = +0,50 kN/m 2 w S = -0,25 kN/m 2 FG III

39 Prof. K. Berner Advancement in the Field of Sandwich Panels I. Advancement of the Production II. Optimization of Material and Cross Section III. Enlargement of the spectrum of use

40 Prof. K. Berner III. Enlargement of the spectrum of use Openings requires additional girders

41 Prof. K. Berner III. Enlargement of the spectrum of use Frame Construction

42 Prof. K. Berner III. Enlargement of the spectrum of use Full scale tests

43 Prof. K. Berner III. Enlargement of the spectrum of use Research Project: SandFlat SandFlat Research and Development of flat roof sandwich elements FH 3 - project:Budget: ,- Status:completed

44 Prof. K. Berner III. Enlargement of the spectrum of use Research Project: SandFlat Deriving from problems in the industry a research project was established

45 Prof. K. Berner III. Enlargement of the spectrum of use Research Project: SandFlat Three important technical packages Seals of flat roof elements Fixings for flat roof elements Long-term loading of flat roof elements

46 Prof. K. Berner III. Enlargement of the spectrum of use Research Project: SandFlat Creep-tests Loads due to snow Loads due to high temperature Loads due to self-weight

47 Prof. K. Berner III. Enlargement of the spectrum of use Research Project: SandFlat Ideas for new seals Seals for longitudinal joint Seals for transverse joint

48 Prof. K. Berner III. Enlargement of the spectrum of use Research Project: SandFlat Water column test (developed by iS-mainz)

49 Prof. K. Berner III. Enlargement of the spectrum of use Research Project: SandFlat Test of air and water tightness according to DIN EN & DIN EN 12114

50 Prof. K. Berner III. Enlargement of the spectrum of use Research Project: SandFlat Pilot-project

51 Prof. K. Berner III. Enlargement of the spectrum of use Research Project: SandSet SandSet Research of sandwich elements used as load-bearing building components FHprofUnd - project:Budget: ,- Status:running

52 Prof. K. Berner III. Enlargement of the spectrum of use Research Project: SandSet Loads and Actions Vertical Loads Stiffening Beam Action

53 Prof. K. Berner III. Enlargement of the spectrum of use Research Project: SandSet Use for … Cold stores Exhibition Building Aquahouse

54 Prof. K. Berner III. Enlargement of the spectrum of use Research Project: SandSet Use for …

55 Prof. K. Berner III. Enlargement of the spectrum of use Research Project: SandSet Use for …

56 Prof. K. Berner Institut for Sandwichtechnology Prof. Dr.-Ing. Klaus Berner Edinburgh, 23 th – 24 th of October 2008 Thank you for your attention!


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