Prof. K. Berner

Prof. K. Berner

Up-to-date progress in panel applications

Institut for SandwichtechnologyProf. Dr.-Ing. Klaus Berner

Edinburgh, 23th – 24th of October 2008

Prof. K. Berner

One of the first German

Approval for Sandwich-

Panels1978

Prof. K. Berner

German Approval for Sandwich-Panels - 1978

Prof. K. Berner

German Approval for Sandwich-Panels - 1978

Prof. K. Berner

German Approval for Sandwich-

Panels1978

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

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

Prof. K. Berner

I. Advancement of the Production

Continous production line

Prof. K. Berner

I. Advancement of the Production

Damages

Prof. K. Berner

I. Advancement of the Production

Damages

Prof. K. Berner

I. Advancement of the Production

Quality Control with samples

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

Prof. K. Berner

I. Advancement of the Production

Research Project: qSpai

• Three principle ways to investigate sandwich panels

– Rays– Mechanics– Thermal methods

Prof. K. Berner

I. Advancement of the Production

Research Project: qSpaiX-Ray

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

Prof. K. Berner

I. Advancement of the Production

Research Project: qSpaiLock-in Thermography with results

Prof. K. Berner

I. Advancement of the Production

Research Project: qSpaiLock-in Thermography

• Advantages– it works– complete surface areas can be monitored– the technique is known

• Disadvantage– reflecting materials often don’t 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

Prof. K. Berner

I. Advancement of the Production

Research Project: qSpaiMechanical Methods

• Macroscopic deformation– Oscillator coupled to the panel– Magnetic forces

• Microscopic deformation– Ultrasound methods– Microflown

• Measuring– Photometry– Vibrometry– Speckle Interferometry

Prof. K. Berner

I. Advancement of the Production

Research Project: qSpaiMagnetic forces

CoreForceResetFaceForceResetMagnet FFF

Prof. K. Berner

I. Advancement of the Production

Research Project: qSpaiImplementation of …..

0,5 m m

Führungsstangeguide rod

Andruckfederpressure spring

M agnet

Kraftaufnehm erforce sensor

M axim ale “virtuelle” D efektgrößem axim um virtual s ize of the defect

design

realisingand

Prof. K. Berner

I. Advancement of the Production

Research Project: qSpaiImplementation of …..

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

Prof. K. Berner

II. Optimization of Material and Cross Section

•PUR (PIR)-foam

•EPS (XPS)

•Mineral wool

Prof. K. Berner

II. Optimization of Material and Cross Section

Research Project: SwichCore

SwichCore

Development of a new fire resistant core material

FH3 - project: Budget:163.000,- €

Status: completed

Prof. K. Berner

II. Optimization of Material and Cross Section

Research Project: SwichCore

Phenolic Foam

Hybrid Foam

Sodium Silicate Composite “SiAC”

Developed core materials

Prof. K. Berner

II. Optimization of Material and Cross Section

Research Project: SwichCoreResults of tensile-tests / Phenol

Prof. K. Berner

II. Optimization of Material and Cross Section

Research Project: SwichCoreFull scale tests / Phenol

Prof. K. Berner

II. Optimization of Material and Cross Section

Research Project: SwichCoreReaction to fire & Fire resistance

Single Burning Item SBI-Test nach EN 13823

Fire Resistance Test according to DIN EN 1364-1

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

FH3 - project: Budget:150.000,- €

Status: running

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

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

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

•Density 40 kg/m3

•Tensile strength with faces 0,09 N/mm2

•Shear strength 0,11 N/mm2

•Shear Modulus 2,5 N/mm2

•E-Modulus Core 2,4 N/mm2

• Density

39 kg/m3

• Tensile strength with faces

0,07 N/mm2

• Shear strength

0,14 N/mm2

• Shear Modulus

2,8 N/mm2

• E-Modulus Core

2,3 N/mm2

Prof. K. Berner

W vs. GC

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

3W C C FE G E S

S2

C C

3 B 1M

3 B2 1G A

Prof. K. Berner

Aim of optimization

II. Optimization of Material and Cross Section

Research Project: SandTweak

Algorithm

of

Optimization

material costs production costs

load capacity

building physics

fire performance

production technology

ecological compatibility

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

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:

Gc Gc1; Gc2

Ecc Ecc1; Ecc2

Ect Ect1; Ect2

fcc fcc1; fcc2

fcv fcv1; fcv2

Aiming at

Load factor:

Criterions of failure

w → 100 %

fCv → 100 %

fCc → 100 %

w → 100 %

OPTIMUM

concerning design

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

GC = 3.6 N/mm2, EC = 3.7 N/mm2, fCv = 0,110 N/mm2 L = 5.61 m

• Material values optimized:

allowable span L

GC = 5.5 N/mm2, EC = 5.0 N/mm2, fCv = 0,085 N/mm2 L = 7.37 m

31% longer spanswithout any further costs

L L

wD = +0,50 kN/m2

wS = -0,25 kN/m2 FG III

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

Prof. K. Berner

III. Enlargement of the spectrum of use

Openings requires additional girders

Prof. K. Berner

III. Enlargement of the spectrum of use

Frame Construction

Prof. K. Berner

III. Enlargement of the spectrum of use

Full scale tests

Prof. K. Berner

III. Enlargement of the spectrum of use

Research Project: SandFlat

SandFlat

Research and Development of flat roof sandwich elements

FH3 - project: Budget: 150.000,- €Status: completed

Prof. K. Berner

III. Enlargement of the spectrum of use

Research Project: SandFlatDeriving from problems in the industry a research project was established

Prof. K. Berner

III. Enlargement of the spectrum of use

Research Project: SandFlatThree important technical packages

• Seals of flat roof elements

• Fixings for flat roof elements

• Long-term loading of flat roof elements

Prof. K. Berner

III. Enlargement of the spectrum of use

Research Project: SandFlatCreep-tests

Loads due to snow

Loads due to high temperature

Loads due to self-weight

Prof. K. Berner

III. Enlargement of the spectrum of use

Research Project: SandFlatIdeas for new seals

Seals for longitudinal joint Seals for transverse joint

Prof. K. Berner

III. Enlargement of the spectrum of use

Research Project: SandFlatWater column test (developed by iS-mainz)

Prof. K. Berner

III. Enlargement of the spectrum of use

Research Project: SandFlatTest of air and water tightness according

to DIN EN 12865 & DIN EN 12114

Prof. K. Berner

III. Enlargement of the spectrum of use

Research Project: SandFlatPilot-project

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: 253.000,- €Status: running

Prof. K. Berner

III. Enlargement of the spectrum of use

Research Project: SandSetLoads and Actions

Vertical Loads

Stiffening

Beam Action

Prof. K. Berner

III. Enlargement of the spectrum of use

Research Project: SandSetUse for …

Cold stores

Exhibition Building

Aquahouse

Prof. K. Berner

III. Enlargement of the spectrum of use

Research Project: SandSetUse for …

Prof. K. Berner

III. Enlargement of the spectrum of use

Research Project: SandSetUse for …

Prof. K. Berner

Institut for SandwichtechnologyProf. Dr.-Ing. Klaus Berner

Edinburgh, 23th – 24th of October 2008

Thank you for your attention!