WP2. Design by Calculation / Design by Testing Comparison. from the current standpoint of is-mainz K. Berner. 22/09/ Member of ECCS/CIB TG 7.

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1 WP2 Design by Calculation / Design by Testing Comparison from the current standpoint of is-mainz K. Berner Prof. Dr. Klaus Berner - Institute for Sandwich Technology, is-mainz - is-engineering, Darmstadt - Member of CEN TC 128/Sc11, WG 1,WG 5 - Chairman and independent expert of QC /EPAQ - Expert of DIBt, Berlin 1 - Member of ECCS/CIB TG 7.9

2 Check of the design procedure Comparison of the results of test A m a with the calculated values Testresults: WP2 Test series A Helsinki University d= 60 mm, one span L =4m 2

3 Comparison of the results of test A m a with the calculated values Testresults: WP2 Test series A Helsinki University d= 100 mm, tow span L 1 =L 2 =4m 3

4 Actions and safety level requirements EN 14509, chapter The safety of the product shall be verified by design procedures based on the limit state concept. Verification shall be by calculation in accordance with Annex E. For the application in practice design load or allowable span tables shall be available. Information shall be produced which gives all values necessary for the production of design load tables. For the purpose of this European Standard provision of this information shall be regarded as part of the product. 4

5 Formal Basic Principles for Design Procedurs Formal Basic Principles Comparison Design by Calculation Official required (acc ) and regulated on the base of Annex E in the valid Standard Design by calculation is accepted of most of the European Nations Design by Testing Perhaps in future on the base of a new Annex F. But, up to now, there is no official proposal, also not for a special test programme, for discussion in the WG5 and WG1 of the standard committee. 5

6 Allowable Span tables for a normal (small) Product Family Example: Roof panel (Core PUR/PIR) Panel thicknesses d = mm External face: profiled t 1 = 0,50 0,75 mm Internal face: lightly profiled face t 2 = 0,40 0,60 mm Possible face thickness combinations: t 1 /t 2 = 0,5/0,4; 0,5/0,5; 0,5/0,6 0,6/0,4; 0,6/0,5; 0,5/0,6 0,75/0,4; 0,75/0,6; 0,75/0,6 AIM: Allowable spans for all panel thicknesses and all face thickness combinations All static systems and loads (e.g. one span, two span, three span panels) Wall panel (Core PUR/PIR) Panel thickness d = mm External face: lightly profiled, geometry 1: t 1 = 0,50 0,75 mm Internal face: lightly profiled, geometry 2: t 2 = 0,40 0,60 mm Possible face thickness combinations: acc. to roof panel t 1 t 2 d AIM: acc. to roof panel t 2 t 1 d 6

7 Test Programme for Design by Calculation acc. To EN 14509, chapt. 6.2, Table4 Roof panel: Full scale tests t1/t2 = 0,5/0,4 mm Panel thickness Single span Simulated Central supp.tests Single span Longterm Test Single span Number of tests mm pos. neg download uplift (3) 9(12) (3) 1 10(13) Number of tests: 25 Additional: for each batch (here 3):Shear tests (short and longterm tests) and material properities tests for the core and face material Estimated cost for all tests in an EPAQ accepted laboratory: For wall panels: in principle the same full scale, shear and material tests: alltogether

8 CE labels for different panel types on the base of the ITT tests acc. To EN With this test programme acc. to EN all panel types of the product family (given as exampel) are captured with all panel and face thicknesses. That means e.g.: For roof panels: thickness 40, 60, 80, 100, 120, 140, 160 mm and for 9 face thickness combinations (as above mentioned): 7 x 9 = 63 panel types For wall the same: 63 panel types alltogether: 126 panel types This means consequently: Possibility to create with this test programme: 126 CE labels 8

9 Provisional Test programme for Design by Testing Proposal Roof panel: Full scale tests t1/t2 = 0,5/0,4 mm Panel Thickness Single span Two span Temp. tests mm L1 L2 L3 L1 L2 L3 L1 L2 L3 Longterm Test Single span Num ber of tests pos neg pos neg pos neg pos neg pos neg pos neg???number ? ? ? of tests : 85? Additional: for each batch (here 3):Shear tests (short and longterm tests) and material properities tests for the core and face material Costs:???? 9

10 CE labels for different panel types on the base of a provisional test programme for Design by Testing With this test programme only one thickness combination (t1/t2 = 0,5/0,4 mm) of the product family (given as example) is captured. (For each other face thickness combination the tests should be done once more) That means e.g.: For roof panels: thickness 40, 60, 80, 100, 120, 140, 160 mm and for 1 face thickness combination: 7 x 1 = 7 panel types For wall the same: 7 panel types alltogether only: 14 panel types instead of: 126 panel typs with the small test programme acc. EN This means consequently: Possibility to create with this test programme only 14 CE labels (instead of 126) 10

11 Calculation of allowable span tables Where is the problem with design by calculation? State of art is very clear: For each panel type a CE label must be, already now, available!! With the values declared in the CE mark it`s very easy to calculate allowable span tables, without any additional tests, special no expensive two span panel and temperature tests 11

12 Design by calculation Determination of safe load tables with a small sized Excel Programme Developed in is mainz within of the EASIE research project 12

13 EXCEL-Programme - 1.Step Input of the values for cross sections according to the CE-mark Reference:, Insulation: PUR, Density: 40 kg/m 3 Thickness: 101,7 mm. Facings: Steel 0,6 mm external: 0,5 mm internal (S 320; EN 10326). Coating: PVC. Mass: 13 kg/m MPa 320 MPa 320 Mpa 320 MPa 136,5 MPa 122,5 MPa 0,12 MPa 0,14 MPa 0,07 Mpa 4,00 MPa 0,10 MPa 1,5 7,0 13

14 EXCEL Programme 2. Step Input of the characteristic values of resistance (exemplary) accordingtothe CE-mark 320 MPa 320 MPa 320 Mpa 320 MPa 136,5 MPa 122,5 MPa 0,12 MPa 0,14 MPa 0,07 Mpa 4,00 MPa 0,10 MPa 1,5 7,0 14

15 Check of the safety factors dependent of the national regulations free selectable 15

16 EXCEL Programme 3.Step: Start of Programme run Determination of safe load tables with a small sized Excel Programme at the push of a button 16

17 EXCEL Programme 4. Step: load tables 17

18 Damages Damages due of too large spans (or too large loads) 18

19 Design by Calculation for big projects and special static systems and loads big project (cold store building) with sandwich panels To avoid damages also for big projects (e.g. cold stores) with high temperature gradient and multispan panels with different spans and special loading Only with Design by Calculation a static calculation for such projects is practical. 19

20 WP2 Design by Calculation / Design by Testing Comparison Thank you for your attention! EPAQ Congress Roma 20