System Description

Baupanel is an integrated structural system that is seismic resistant, thermally and acoustically insulated, and is based on a set of structural panels.

Each element is made of a 3D structure in high resistance steel, defined by two flat meshes robustly interconnected by multiple perpendicular bars.

The insulation plate is in the space between the steel meshes and has the specifications that are suitable for the project needs.

This system is put together on site by means of the application of two layers of micro concrete of a pre-determined thickness, either by pneumatic spraying or by pouring it into the formwork.

Baupanel complies with the Spanish Regulation for Industrial Concrete and the Spanish Technical Building Code regulations, and, moreover, possesses numerous documents that demonstrate technical suitability in Spain (Document of Technical Suitability No.558/10 issued by the Eduardo Torroja Institute of Construction Sciences), as well as in other countries.

On connecting the panels in a monolithic way, according to the layout of the walls and frameworks, and without using any type of joint, a super tri-dimensional structure of reinforced concrete is generated, which allows you to carry out any type of architectural work, from single-family homes to multi-floor buildings.

The hollow elements of the concrete, because of the volume of the insulation plate, offer a combination of very high structural capacity, under its own weight, together with a high level of thermal acoustic insulation.

The system can resist impact from projectiles, explosions, hurricanes and fire. Therefore, it also has many applications, both in civil projects as well as in industrial projects.

Thanks to these properties, Baupanel® is the ideal construction system to construct buildings that are have a high level of seismic resistance, where each element that it contains contributes to the absorption of horizontal forces.

With regard to safety in case of fire, the system is certified to provide fire resistance for more that 240 minutes, being particularly suitable as a firewall element in high risk zones.

Furthermore, the systems elements offer very low thermal transmittance, making them optimal for the construction of bioclimatic buildings. The highest ratings on the energy scale (A, B, and C) can easily be achieved.

The simplicity in construction permits an important reduction in the works’ schedule when compared with the traditional system, since the structure, front, partitions, framework, roof, lintels, struts and thermal acoustic insulation form one single element.

Due to its light weight (up to 50% lower than the traditional system), the area required for the foundation will be reduced, and therefore there will be a significant savings in labour and materials for the foundation.

Baupanel® is a versatile system that allows for more flexible and creative architecture, achieving more economical buildings, bound to an efficient and sustainable construction.

Baupanel® embodies more than thirty-five years’ experience in pre-industrialized systems, consolidated into a refined project that represents a valuable alternative in the construction industry sector. It has a nationwide presence and a continuing international expansion.

Applications

At present, Baupanel® can mainly be used in the following applications:

  • Single-family homes, semi-detached houses, terrace houses, etc.
  • High-rise buildings, 100% complete; we can construct building structures formed of structural walls and frameworks, achieving an award for use for six floors in Spain, without this being its functional operating limit. As it involves a system of reinforced concrete panels, this technology is already well-established in some countries and no height limit is set in accordance with local regulations. With Baupanel we can build buildings with the same limitations as any other traditional reinforced concrete structure; the panel scaffolding can be reinforced according to requirements. The thickness of the layer of micro concrete can also be increased according to the design of the structural calculation.
  • Front enclosures for traditional structures, without height limitations. Avoiding thermal bridges between frameworks and column passages.
  • BAU·SATE-i. The BAU·SATE-i system for the thermal upgrading of buildings is designed for cladding as a thermal insulation on the interior or exterior, with the intention of its use in buildings with enclosures made with the traditional system.
  • Expansion joints and resolution of dividing walls.
  • Refurbishment of historic buildings making them suitable for current usage.
  • Civil work
  • Containment walls
  • Curve forms
  • Ventilated fronts
  • Cladding pile walls and formation of buffer chambers
  • Cantilevers.
  • Pools.
  • Industrial nave.
  • Large scale industrialized construction with recyclable concrete formworks. New!
  • Combination with other construction systems, for example metallic structures, partitions of cardboard-gypsum, etc.
Advantages

The most notable advantages of Baupanel® are its excellent thermal insulation, its large structural resistance being made up in a tri-dimensional monolithic set, and the important reduction in execution time that may reach 50%.

Also of great importance is the increase in useful living space in the Baupanel house, compared to a traditional one. With an equivalent total built area, with Baupanel you can increase the useful living space by up to 5%, which will equal, for example, that for every 20 houses measuring 90m2 we will obtain one more house for the same cost. This is because traditional walls have a greater middle thickness than Baupanel® walls. We also need to highlight that the fronts, with our system, are the only ones that comply with the most demanding functional requirements of national and international regulations.

LIGHTWEIGHT

The panels are remarkably easy to move during construction, transportation and installation, due to their lower weight, which facilitates their use in any situation. After being applied, the micro-concrete lightness becomes a remarkable structural rigidity. This will ensure the integrity and the response to the use for which it was intended. The weight of the panels prior to the application of micro-concrete varies according to type, from 3.5 kg / m2 up to 5 Kg / m2. This means a single operator can easily move more than 3 m2 of panel without help and with little effort.

THERMAL INSULATION

The total U-value of the thermal transmittance of a wall composed of a 4 cm thick panel of expanded polystyrene of 15 Kg / m3 density, coated on both sides with 3 cm thick micro concrete, is equal to 0.78 W / m2 ° K. If the wall is made of an 8 cm panel, the total U thermal transmittance would equal 0.49 W / m2 ° K. These results are greatly lower than the thermal transmittance values of walls in the traditional system, and this means that houses built with Baupanel have an energy savings, which normally reaches more than 30 kWh / m2 a year, both in the heating and cooling cycles.

COST SAVINGS

Baupanel® System represents a real advantage for both end users and construction companies, given that it provides better performance than traditional systems, at significantly lower cost. The concept of having an element that meets, at the same time, the function of horizontal and vertical closure with high strength and thermal and acoustic insulation has undoubtedly been successful and innovative. For this reason, economic comparisons between BAUPANEL® projects compared to other traditional systems have demonstrated significant savings.

SEISMIC RESISTANT

Laboratory tests carried out on a two floor prototype true to scale have shown that the structure resists horizontal accelerations of 1.4 g that are far superior to the effect of a devastating first category earthquake, without suffering damage of any kind. The results obtained in these tests represent the scientific confirmation of what has already been proven by nature. In fact, many buildings built with the system have successfully withstood the most severe earthquakes in many countries, without suffering any damage.

FIREPROOF

Concrete is an M0 (incombustible) material and the expanded polystyrene used for the manufacture of panels is Euroclass type E (self extinguishable, does not spread flames). In various fire resistance tests conducted on walls constructed with 12 and 15 cm panels of finished thickness, they have shown a resistance of more than 180 minutes.

HURRICANE RESISTANT

Baupanel buildings constructed in areas with a high risk of cyclones have demonstrated the ability to withstand the force of Category 5 hurricanes with winds above 155 mph.

The simple construction allows for a significant reduction in work time over the traditional system, since a single element structure is formed with fronts, partition walls, floors, roof, lintels, braces and thermal acoustic insulation.

STRENGTH

Numerous laboratory tests carried out in Spain and in countries around the world have demonstrated the increased structural strength of the BAUPANEL® system. When structures are formed with our system, the loads are distributed in a multitude of linear elements (bearing walls), and therefore the values of working tensions of these components are decreased. This greatly increases the safety factor. The supporting function is also increased because all gravitation, seismic and wind actions are transferred to the foundation with much less of their own weight than the traditional system.

QUICK INSTALLATION

Numerous experiments carried out under the most diverse conditions in different countries of the world, and with very different levels in the training of the workforce, have proved an effective reduction of work execution times when compared to traditional building systems.

Environment Impact
Energy Saving and Environmental Protection

Currently the construction sector is responsible for 40% of consumption of worldwide energy production. In addition, the sector is responsible for 25% of the waste generated in the world.

However, Baupanel® whose main element is expanded polystyrene (EPS), which is an efficient and effective thermal insulation material and which plays an important role in reducing carbon dioxide emissions into the atmosphere, is making a very positive contribution to the reduction of global warming. CFCs or HCFCs are not used as foaming agents in the production of EPS, therefore its manufacture does not cause any damage to the ozone layer.

Throughout the remaining useful life of the building, BAUPANEL® ensures a significant reduction in the need for external energy input, thus achieving lower consumption of fossil fuels. This in turn leads to lower CO2 emissions to the atmosphere.

For the purposes of the Energy Certification of Buildings, which is a requirement under the Directive 2002/91 / EC and Directive 2010/31 / EU, BAUPANEL® is a construction system that makes it possible for the building to have a maximum energy rating [class A] at an affordable price. This is due to its substantial thermal insulation, which is an added value for both developers and the building’s end users by reducing energy consumption bills for heating / cooling.

Properties of Expanded Polystyrene (EPS)

Expanded polystyrene is a biologically inert, non-toxic and stable material.

It does not contribute to the formation of methane gas or provide any other potential greenhouse gases. Furthermore, its waste does not pose any risk of contamination to groundwater.

Expanded polystyrene is 100% RECYCLABLE. During production of the BAUPANEL® panels, virtually no EPS waste is produced, because the little waste resulting from cutting the blocks is recycled directly in the same production plant.

The polystyrene used for BAUPANEL® panels is the self-extinguishing type, that is, the material does not propagate flames.

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