BAU7

Background

The construction systems based in 3D panels that are manufactured all over the world, have not enough micro-concrete coverage in a large part of their frameworks. This is because the mesh is firmly fixed to the nucleus of the expanded polystyrene, which is regularly in an undulating curved form.

As seen in the images, the bars are on opposite sides, linked by the connector; one in the area good for recycling while the other is almost touching the panel, therefore one of them will always be unsuitable for recycling.

Option A. Lower Bar in the Correct Position
Option A. Lower Bar in the Correct Position
Option B. Upper bar in the Correct Position
Option B. Upper bar in the Correct Position

To solve this problem, we have created Bau7.

What is Bau7?

Bau7 is the design of a new form of panel, where, from a novel linear ripple that generates isosceles triangles, we get all the longitudinal bars of steel mesh to keep the maximum separation from the surface of the expanded polystyrene core. Thus the very design of the panel ensures optimal concrete cover around each of the longitudinal steel bars.

This new design is conducive to a panel with increased strength compared to anything seen previously.

Test Results

  • Strength: maximum load 1255 kN
  • Flexion:  maximum flexion moment 76.29 kN/m
  • Maximum cyclical horizontal load: 225 kN at a height of 3.38 m, equivalent to a seismic acceleration of 1.1 to 1.2 kg.

Advantages

  • Symmetric reinforcement meshes: uses constant step steel meshes.
  • Maximum utilization of steel:  all the components of the steel mesh are completely active, including those belonging to the mesh overlaps.
  • Larger useful section: the edge of the composite section is increased, with the same thickness of expanded polystyrene.
  • Better balance of materials: The uniformity of the composite section of reinforced concrete is increased.
  • Greater strength: the value of the ultimate flexion moment of the composite section is notably increased, by more than 55%.
  • Easier fabrication: the panel fabrication is simplified, as the steel meshes are perfectly symmetrical it is not necessary to turn one of them 180o on getting onto the panel bender machine.
  • Coupled panels: a tongue and groove joint has been added to the opposite ends of the panels to avoid the possibility of thermal bridges between panels.
  • Greater production: the speed of the cutting plate in the pantograph is significantly increased, by 78.4%, as production of the old undulating plates needed 32 changes in cutting direction, while the new SEVEN design only needs twelve.
  • Higher quality of the finished product: the precision of the welding connector has been increased, as the grippers do not bite the polystyrene core because there is more space in between. When the clamps bite parts of expanded polystyrene there are remnants of organic material that hinder the welding quality. This increases productivity of the Panel Bender machines so that manual reworks are not necessary.
BAUSATE-I

BAUSATE-i is a system designed for the restoration of the thermal surrounding of buildings. Thermal insulation is improved in order to achieve a comfortable internal temperature throughout the year. The energy savings that result can reach 50 KW-h / m2 /year, depending on the thickness of insulation chosen. It is also possible to reach the green zone in the Energy Efficiency rating (A, B, and C).

BAUSATE-i is the result of BAUPANEL® research to improve everything that exists today in terms of thermal insulation systems from the outside, commonly known in Spain as SATE (EIFS in English) systems.

Energy Efficiency

Improved savings

Thermal Insulation

We improve the competition

Resistance Infiltration

-

Resistance to Impacts

100 times more resistant

The EIFS conventional solutions have very low impact resistance (3 joules) making them very vulnerable to natural erosion, as well as accidental or non-intentional damage.

BAUSATE-i is 100 times more resistant (300 joules) as it has been developed from an expanded polystyrene plate assembled with a high-strength galvanized steel mesh; the zigzag profile of the plate allows placement of a robust layer of micro-concrete.

It is also noteworthy that the folded shape of the BAUSATE-i insulation plate, when supported on the front to be restored, puts in a series of mini channels that constitute an unventilated air chamber, providing greater resistance against infiltration.

Properties

  • Provides large savings in heating and air conditioning costs by reducing the U value of thermal transmittance in the building.
  • Mechanically protects the enclosure of the factory building.
  • Improved energy efficiency of the building, enabling it to meet sustainability criteria.
  • Eliminates thermal bridges, avoiding the risk of interstitial condensation and heat loss.
  • Reduces the thermal load of the structure.
  • Transfers dew point potential to the outside of the building structure.
  • Optimizes use of thermal inertia, limiting temperature fluctuations inside the building.
  • Contributes to the acoustic insulation of the front.
  • Renews appearance of the front and increases the value of the property.
  • Corrects cracks and fissures in the support, avoiding possible leaks and improving waterproof qualities.
  • It has low maintenance costs.
  • Increases the life of the building.
  • It can be installed in homes that are already occupied.
  • Does not reduce the usable area.
  • Supports the elimination of health hazards inside the building, such as moisture and condensation.
  • There is no need to remove the original coating.
  • It is environmentally friendly by not dispersing harmful polluting substances. As it can be recycled, it reduces waste and avoids the release of more CO2 into the atmosphere.

Description

BAUSATE-i is composed of a folded expanded polystyrene board with a steel mesh attached to it by means of 40 connectors for each m2. The plate thickness can vary between 30 and 300 mm, according to insulation requirements demanded for the building and its density belongs to Class III: 15 Kg / m3, with a thermal conductivity λ = 0.037 W / m K.

The reinforcement mesh attached to the plate is made of high strength galvanised steel rods (more than 650 MPa), 2.5 mm in diameter, in a 6.5 x 13 cm grid. All panels are supplied with a standard width of 1.125 m and a length of 4.00 m, which helps support a faster placement.

It is completed on site by applying a layer of micro concrete with a compression strength greater than 16 MPa, and an average thickness of 20 mm; this gives it its distinguishing strength.

Ministère public – C/Goya 17 – Madrid

Placement

BAUSATE-i is anchored to the front either by polypropylene dowels with nylon nails, or corrugated steel bars 6 mm in diameter. The amount of attachments required is according to a mechanical calculation applying the criteria of the CTE-DB-SE-AE, in particular Section 3.3, where wind force data are collected according to geographic location, harshness of the environment, height above sea level, and the shape and orientation of the front. Usually 5 attachments per m2 are required.

Once the panels are positioned and anchored to the front, we proceed to the application of the micro concrete layer with 12 mm strips placed on the steel mesh. Considering the depth of the fold (10 mm) and the diameter of the elements of steel mesh (2.5 mm), this layer acquires a recommended average thickness of 20 mm. It is applied with a mortar spraying machine and it is finished with a screed and plastering finish.

The finished surface can be completed as indicated in the project using acrylic paint or plaster mortar in a thin layer, or similar.

Comparative Advantages

  • High resistance to impacts

    100 times more resistant than conventional EIFS systems.

  • High resistance to flexion

    25 times more resistant to flexion than conventional EIFS systems.

  • Incorporates an air chamber

    improves infiltration resistance.

  • Safer placement

    can be secured with steel bars because of the greater thickness of the resistant layer.

  • Reduces execution times

    BAUSATE-i panels are supplied in plates up to 4.50 m2, which simultaneously incorporate the insulating element and the resistance frame, increasing the speed of placement.

  • Simplifies commissioning

    BAUSATE-i consists of only two operations: installing the plate and the subsequent application of the resistance layer, whereas conventional EIFS take at least six operations.

  • Does not spread fire

    the BAUSATE-i expanded polystyrene insulating plate is Class F, low flammability, so it does not spread flames in the case of fire.

Thermal transmission table

In the table below, there are four basic types of traditional front enclosures, with two different BAUSATE-i thicknesses (40 and 80 mm), with their corresponding thermal transmittance U values, and the improvement that is produced.

ENCLOSURE TYPE THICKNESS (cm) THERMAL TRANSMITTANCE U=(W/m2°K) THERMAL IMPROVEMENT PRODUCED
1 FOOT PERFORATED BRICK 27,8 1,501
1 FOOT P.F. + BAUSATE-i 40 34,8 0,524 > 2,9 times
1 FOOT P.F. + BAUSATE-i 80 38,8 0,335 > 4,5 times
CONCRETE BLOCK 28,8 1,461
CONCRETE BLOCK + BAUSATE-i 40 35,8 0,519 > 1,9 times
CONCRETE BLOCK + BAUSATE-i 80 39,8 0,332 > 3,4 times
THERMAL-CLAY 28,8 0,810
THERMAL-CLAY + BAUSATE-i 40 35,8 0,407 > 2 times
THERMAL-CLAY + BAUSATE-i 80 39,8 0,283 > 2,9 times
CAVITY WALL: L.H.D. + C.A. + L.H.D. 25 1,348
CAVITY WALL: L.H.D. + C.A. + L.H.D. + BAUSATE-i 40 32 0,504 > 2,7 times
CAVITY WALL: L.H.D. + C.A. + L.H.D. + BAUSATE-i 80 36 0,326 > 4,1 times

Dynamic and Static Load Tests

Eduardo Torroja Institute (20/06/2007) s / EOTA TR001

Distance between supports = 70 cm

Static: linear concentrated load in the centre of BAUSATE-i, reaching a maximum value of 56.32 KN, which the panel resists without damage.

Dynamic: a bag of 50 kg weight is dropped from a height of 120 cm, impacting BAUSATE-i with 600 joules of energy, which the panel resists without damage.

BAUCUSTIC
THERMO ACOUSTIC INSULATION SYSTEM

BAUCUSTIC is the panel that has been designed by BAUPANEL’s R+D+I department to be used as an element with high-capacity acoustic insulation against airborne noise. Its multilayer structure defines a sequence of 9 materials that the sound waves must venture to go through to spread from the emitting to the receiving source:

  1. Plastering
  2. Layer of micro reinforced concrete, 35 mm thick
  3. 30 mm expanded polystyrene sheet (δ = 15 kg / m3)
  4. 25 mm air chamber
  5. Sheet of rockwool in three types of thickness: 30, 40, 50, 60 mm (δ = 40 kg / m3)
  6. 25 mm air chamber
  7. 30 mm expanded polystyrene sheet (δ = 15 kg / m3)
  8. Layer of micro-reinforced concrete, 35 mm thick
  9. Plastering

BAUCUSTIC is supplied from the factory in a pre-industrialised sandwich panel incorporating layers 3 to 7 as a single component. These 5 layers have a steel mesh on the outer sheets, joined by electro-welded connectors.
It is completed on site using the same criteria used for all panels in the BAUPANEL system, i.e. the application of micro concrete layers with an average thickness of 35 mm.
A lower number of connectors (2.82 cm, 2 for each 10,000 cm2) allows that the layers do not interfere with each other, and that coupling will not occur.

Properties of the Sound-Absorbing Layer

Inside the BAUCUSTIC core is the main acoustic absorbent layer that consists of a sheet of rigid rockwool, which is offered in different thickness options, depending on the required level of airborne noise insulation.
The sound absorption in the central BAUCUSTIC layer varies between 0.6 and 0.8, according to the table on the right.

This central sheet of mineral wool is confined between two folded layers of expanded polystyrene, generating a series of air chambers and a surface of triangular section micro concrete. These work together, interfering with the path of propagation of sound waves (reflection and absorption).

Code Rockwool Thickness (mm) Coefficient of Sound
Absorption
(αW)
Declared
Thermal Resistance
(m2 K/W)
BPA-115 30 0,60 0,85
BPA-125 40 0,70 1,10
BPA-135 50 0,70 1,40
BPA-145 60 0,80 1,70

* Values declared by the rockwool manufacturer

Application

The “Acoustic” series in the BAUPANEL System provides more properties than the standard EPS core panel, due to the fact that rock wool core that meets the highest requirements in terms of sound insulation and fire safety.

Installation

The BPA panel must be installed according to the BAUPANEL System installation manual and the project’s technical documentation must be followed.

Acoustic Insulation

The walls in the BAUPANEL system, with an expanded polystyrene core and coated with a layer of plaster, have a global acoustic insulation value R (between 100 and 5000 Hz) contained between 39 and 44.5 dB (A), depending on the thickness. The interposition of the sound-absorbing layer of mineral wool in the core of the panel, partially replacing the thickness of expanded polystyrene, achieves values greater than 50 dB (A).

When BAUCUSTIC is used as a dividing wall without structural function it is very important to use elasticized separation bands, made with materials of low dynamic stiffness, for the purpose of preventing the spread of noise through the contours of the wall (noise flanks).

If BAUCUSTIC is part of the supporting structure of the building, it would not be possible to use elasticised separation bands, given the necessary continuity of the supporting components. In such cases the effect of the tie bars crossing the elasticised bands must be considered.

Overall, the estimated decline because of the solid bonding is of the order of 5 to 7% of the capacity of airborne sound insulation.

Micro-concrete: Technical Specifications*
Maximum aggregate size (mm) 4
Density (Kg/m3) 21
Density (Kg/m3) 16/25
Adhesion (N/mm2) 0,3
Water absorption (g/dm2 min1/2) 0,8g
Water vapour permeability (μ) 15/25
Thermal conductivity (W/mK) 0,83

*Values declared by the manufacturer of expanded polystyrene

Expanded Polystyrene: Technical Specifications*
Behaviour to fire (M1) E
Thermal conductivity (W/mk) 0,039
Apparent density (Kg/m3) 15

*Values declared by the manufacturer of expanded polystyrene

Rockwool: Technical Specifications*
Reaction to fire A1
Thermal conductivity (λD) 0,035
Short term water absorption WS
Resistance to water vapour MU1

*Values declared by the manufacturer of expanded polystyrene

Electro welded Mesh: Specifications
Longitudinal reinforcement 20Ø2,5 mm
Transverse reinforcement Ø2,5 mm@65 mm
Connectors 12Ø3 mm @130mm
Galvanised Steel: Technical Specifications*
Type Wire galvanised low
carbon (hard) C9D
Longitudinal reinforcement 0,037 3 mm
Transverse reinforcement WS ≥ 50 gr/m3
Connectors MU1 ≥ 700 Mpa

*Values declared by the steel manufacturer

MICRO CONCRETE

For the manufacture of concrete, there must be quality control when receiving materials supplied in order to ensure that the requirements for its components in UNE-EN 14487-1 2008 () are met, as well as those in the Structural Concrete Instruction.

  • The aggregates shall comply with the requirements set out in the “Structural Concrete Instruction” (known as EHE in Spain) and have the CE mark.
  • The cements shall follow the “Cement Reception Instruction” (RC in Spain) in force, shall possess the CE mark and comply with specified in the UNE-EN 197-1: 2011 ().
  • The mixing water must meet the requirements set out in the “Structural Concrete Instruction”.
  • The additives will have the CE mark, will be in proportion, not exceeding 5% of the weight of cement, and shall comply as specified in the UNE-EN 934-2: 2010 + A1: 2012 () regulation.
  • Additions must meet the requirements specified in EN 206-1: 2008 () as well as those set out in the Structural Concrete Instruction.

When the concrete or, where appropriate, industrial mortar is supplied from a plant that has the officially recognized quality seal, control of receipt of component materials on site will not be required.

The concretes, both those made on site as well as those supplied to the site from a readymade concrete centre, must have a stamp or mark of quality. They will be inspected according to the criteria of the “Instruction of Structural Concrete Instruction”  for statistical control, in the number and amount established by the Project Manager, and the tests must be carried out  by an accredited external laboratory.

STORAGE

The BAUPANEL panels will be stored in horizontal piles that will be placed on wooden or expanded polystyrene (EPS) beams, directly supported on the ground.

The EPS or wooden boards or beams shall be at least two per stack and will be separated by a maximum distance of 2.80 metres. The height of each stack shall not exceed 4 m.

They may also be arranged by being supported on one of their edges.

Due to their light weight, it is recommended to protect them from the wind, since they could be blown away and hit any nearby object.

It is not advisable to let the parts be exposed to the sun for a long time.

CAUTION

Protect the skin, eyes and the respiratory tract. Keep out of the reach of children. In case that the mineral wool comes with your eyes, rinse immediately with plenty of water and seek medical attention. If swallowed, immediately seek medical attention and have container or label available to be shown.

HEALTH AND SAFETY

In accordance with the health and environmental regulations, there are no hazardous classifications associated with the BPA panel with regard to physical, health and environment considerations.

MORE INFORMATION

BAUPANEL System SL reserves the right to alter or modify the specifications of their products without prior notice, as per our policy of continuous improvement. The information contained in this data sheet is correct at the date of publication.

NOTE

The product specifications sheet covers the basic instructions for product application and does not relieve users of the responsibility to work in accordance with good construction practices, thermal and structural insulation work methods, and the Health and Safety at Work Regulations.

BAUPANEL® guarantees and is responsible for product quality. However, it is not possible to control the methods or conditions in which the product is used. All technical data are designed in accordance with national standards for the most common conditions.

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