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Sandwich 3D Panel System: Construction Practices and Experimental

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Conference Paper · August 2015

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 THE 7TH ASIA PACIFIC YOUNG RESEARCHERS AND GRADUATES SYMPOSIUM

“Innovations in Materials and Structural Engineering Practices”

Sandwich 3D Panel System: Construction Practices and

Experimental Investigations

P. Poluraju1, G.Apparao2
1
PhD Scholar, Structural Engineering Division, Department of Civil
Engineering
Indian Institute of Technology Madras, Chennai-
600036, India. rajupolup@gmail.com
2
Professor, Structural Engineering Division, Department of Civil Engineering,
Indian Institute of Technology Madras, Chennai-
600036, India. garao@iitm.ac.in

ABSTRACT

3D Precast concrete sandwich panels due to excellent performance, thermal efficiency, and speed of
construction are preferred as structural system. This paper brings out a comprehensive review of
construction procedure of 3D panels and application in prefabricated construction systems. Their
strength and behaviour depend on the constituent material properties. Axial compression strength of
3D wall panel depends on compressive strength of concrete and aspect ratio of the wall panel. The
strength of 3D panels is improved by the diagonals connecting the weld mesh placed on both faces. In
addition to the shear span of the panel, the flexural strength depends on degree of composite action.
The seismic performance of buildings using 3D panel need to be investigated. Typical joint
reinforcement needs to be provided to ensure integral action of panels with beams and columns.
Design of 3D compression members according to ACI 318.89, load bearing capacity of 3D-slabs as
per DIN and common construction procedure of 3D panel buildings has been discussed. From the
review of introduction to 3D panel construction system, clear that the 3D panels are effective in load
carrying capacity, shear capacity and flexural capacity. Under lateral loading the strength of panels are
found to be suitable for safety and eco-friendly building construction. Further, some experimental
observations under general loading are also discussed.
Keywords
3D Panel; Construction Practice; Axial Compression Strength

1. INTRODUCTION

Housing remains a big challenge for many governments, especially in the developing countries of the
world. The problem is aggravated by fast increasing population, migration of rural masses into the city
and industrial centers and demands for enhanced quality of life. It is difficult to meet this challenge
with traditional building construction systems, as it is essential to fulfill the housing demand in a short
time without sacrificing quality. Today, the Southern World seems to have largely overcome the
housing shortage, but the problem remains intractable in the developing countries because of financial
constraints and lack of appropriate technologies [Benayoune et al. 2004]. Industrialized construction
is carried out in two stages: manufacture of components in a permanent factory or in a workshop or a
temporary casting yard near the site of construction and assembly and erection of these precast

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elements at the construction sites. After assembly of components, they generally require no or only
very little finishing. Compared with monolithically cast in-situ concrete structures, precast concrete
allows for relatively simple repetitive handling, so that unskilled and semi unskilled labour can
produce high quality products [EVG].

1.1 What is 3D wire panel?

3D wire panel is a unique and effective element to easily build a strong insulated concrete building or
wall. Many of them use the panel for all elements of structures including walls, roof floors, sunshades,
lintels and stair case elements. Residential, commercial, institutional and multi-story buildings can be
constructed easily with this remarkable code-approved method [EVG]. The strength of the 3D system
is enormous and is partially attributed to the truss wires which are welded to connect each (face) side
of mesh to make the panel. The insulation in the center of the panel is suspended on the truss wires
and becomes a continuous thermal break when panels are connected [Benayoune 2003, Benayoune et
al. 2001 and Einea 1992]. The side panel mesh has 50 or 100 mm opening with 2.3 or 2.5 mm
diameter (Ф) galvanized wire having tensile strength up to 880 N/mm2. Inserted Expanded
Polystyrene (EPS) size is 50 mm and 100 mm. 3D wire mesh panels are used for numerous building
applications. 3D wire panels may also be used for floor systems, ceilings and to provide a roof
structure. 3D panel is an excellent product for building privacy walls around the home or building
structure [Benayoune 2006, Benayoune 2007, Benayoune 2008, Bush and Stine 1994, Einea et al.
1994 and Kabir 2002, PCI committee 1997 and Salmon et al. 1997]. The monolithic structure with 3D
wire panel enables it to withstand earthquakes, hurricanes and typhoons. In India today there is a
strong movement towards concrete mass housing. Figure 1. Demonstrates typical 3D panel with shear
connectors. The components of installed panel as follows (i) EPS core for insulation (ii) Wire mesh
on inside and outside (iii) Welded truss of wire cross pieces (iv) Sprayed concrete on both sides
(shotcrete) or manual concreting. These panels are 4 feet wide and can be produced in almost any
length. They can be used for the walls and roof as shown in Figure 2.

Figure 1. 3D Wire Panel (currently in use) Figure 2. Typical 3D wall panel

(Skeleton)

1.2 Applications
3D Panel - an alternative building system that uses prefabricated polystyrene panels with wire mesh
that becomes a structural wall when concrete or cement are concreted or manual concreted into place.
Unlike other building systems, 3D Panel is an environmentally friendly - recycled green product. 3D
Panel building system has tremendous flexibility - it can be used in place of wood or metal-framed
walls, masonry block walls or pre-cast panels. The 3D Panel building system saves construction time
while providing greater structural integrity. It has a versatile application to almost all construction
architecture, especially for RC structure, interior & exterior wall, single family & row house,
apartment, condominium [EVG]. 3D Panel is placed in position and layer of concrete or mortar are
applied to both sides. This is shown in Figure 3. The wall panel receives its strength and rigidity from
the diagonal cross wires welded to the welded-wire fabric on each side. This combination creates a
truss behavior, which provides rigidity and shear terms for full composite behaviour [Benayoune
2003, Benayoune et al. 2001 and Einea 1992].

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Figure 3. 3D Sandwich panel (Kabir et al. 2005)

1.3 Construction Procedure of 3D Panels

A brief general description of the recommended construction procedure has been discussed below.
However, as this system is so versatile. The step by step procedure of construction process of 3D
panel (Figure 4) discussed as follows.

1.3.1 Foundations
Often plans will specify that a system of metal anchors be placed in the wall footing or slab to secure
the panel bases. Lengths of straight rebar extending vertically out of the concrete are commonly used
for this purpose. The panels are usually placed so that the rebar is set between the mesh and the
polystyrene. This arrangement provides easy wall alignment. This is shown on the figure 5. When
panels are to be placed on existing slabs, holes may be drilled on-line to house lengths of rebar
dowels. Other methods of securement to slabs may also be used. Metal channels or sections of
preformed U-shaped welded wire fabric can be fastened or anchored to the slab with various fastening
systems, including pneumatic power guns. 3D structures are around 40 % [EVG] lighter in weight
than standard concrete constructions, which allow considerable savings in making foundations.

Figure 4. Construction process of 3D Panel (Beard sell Limited)

Figure 5. Foundations construction detailing (EVG)

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1.3.2 Handling of 3D Panels

Since panels weigh only 5.5 kg/m²[EVG], one of the best features of using 3D panels is that they can
easily be set in place or stacked, using only a one or two-man crew. This is shown on the figure 6.
1.3.3 Erection of 3D Panels
The first two panels are placed on-line (forming a corner) and the adjacent panels are clamped
together, preferably using a pneumatic fastener tool. After the first two panels are firmly attached, the
panel tops can be brought on-line using appropriate bracing. This is shown on the figure 7.The type of
bracing required will depend on several conditions, i.e. panel height, wind conditions, etc. The next
picture shows one type of simple bracing commonly used. All bracing should be located on the same
side of the wall, opposite the side which will receive concrete first. This is shown on the figure 8.
Strips of 50 x 50 mm of cover mesh (the so-called splice mesh) are used to reinforce panel seams.
These strips are easily attached to the panels, also using the pneumatic fastening gun. At corners,
right-angle wire mesh is added inside and outside (called the corner mesh), and tied to the panel mesh.

Figure 6. Placement of 3D wall panels for Figure 7. Erection of 3D Panels

construction (EVG) (EVG)

Figure 8. Prop supported for slab construction (EVG)

1.3.4 Openings
Openings for doors and windows can be cut out both before and after panel erection. In either
condition, several different methods can be used. The recommended panel cutting method is to use a
handled variable speed reciprocating saw with a metal cutting blade (as shown figure 9 & 10) with a
minimum diameter of 100 mm. If electrical power is not available on the job site, panels can be cut by
using a pair of bolt cutters to snip the mesh wires, followed with a hand saw to cut out the
polystyrene. Once the opening is complete, a strip of suitable cover mesh is usually placed diagonally
above and below corners to prevent cracks.

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“Innovations in Materials and Structural Engineering Practices”

Figure 9. 3D Panel cutting method (EVG) Figure 10. Model building with openings
(EVG)

1.3.5 Utilities
Another great feature of this system is the way it accommodates utilities. Once panels are secured in
place, installation of utilities can begin. The gap between the polystyrene sheet and the layer of wire
mesh provides an excellent area for encasing both electrical conduit and water pipe. Gas line and
phone cable can also be run in this area. The next picture is a good example of electric conduit run
inside a panel. The cover mesh provides a very convenient place to tie pipe and boxes in place. This is
shown on the figure 11.

Figure 11. Electrical Conduits and Water Pipe line provisions (EVG)

1.3.6 Making Columns and Beams

Removal of some of the polystyrene panel may be necessary at times in order to strengthen a certain
area by filling it in solid with concrete. Truss pockets are also created in the same fashion. Additional
rebar may also be required in these cavities. Polystyrene removal can be achieved quickly by a variety
of means. One of the best methods to efficiently remove this material is to use a high-pressure water
spray. Another method involves the use of a propane torch to melt the polystyrene. A heat gun may
also be substituted for some applications.
1.3.7 Concrete
Concrete must be normal-weight concrete complying with the applicable code, and have a maximum
aggregate size of 9.5 mm [ESR-2435, 2005], a minimum slump of 51 mm, and a minimum
compressive strength of 17.2 MPa at 28 days. Aggregate must comply with ASTM C33. The concrete
must comply with Chapter 19 of the IBC. The top concrete facing of a roof of floor system can be
applied manually to the 3D panels as specified by he registered design professional. For walls and the
bottom side (soffit) of floor and roof panels, concrete can be applied either pneumatically
(mechanically applied by different techniques including shotcrete, or pressurized plastering
equipment) or manually (hand applied).
1.3.8 Shotcrete
Shotcrete, if specified by the registered design professional, must be normal-weight concrete
complying with IBC Section 1913, and must have a minimum specified compressive strength of 17.2
MPa at 28 days. Aggregate size must not exceed 9.5 mm and the aggregate must conform to Gradation
No. 1 in Table 2.1 of ACI 506R-90. This is shown on the figure 12. Concrete can be applied manually

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or mechanically by using the wet (mortar pump) or dry (gun) process of shotcreting. Concrete
thickness varies, but usually it is twice the distance between the face of the polystyrene and the cover
mesh. In many cases, plans call for 35 mm of concrete on each side of the panel. To ensure corrosion
resistance, the steel mesh must be covered by at least 15 mm in normal environment. In aggressive
environment, the concrete cover thickness has to be increased. It is not necessary to have all panel
work completed before shotcreting begins. Often the exterior walls will be shotcreted before utility
installation is complete various systems may be employed to apply concrete to the panel surface
[EVG].

Figure 12. Shotcreting of mortar/concrete (EVG)

1.4 Shear Strength

Shear strength of 3D panels depends on the number of diagonals (100 or 200 diagonals per sqm). If
the shear strength is not sufficient additional shear reinforcement has to be used. All 3D walls are also
considered as being shear walls, and can therefore be used for transferring horizontal loads, such as
wind and earthquake loads. Owing to additional reinforcements, all splices between walls and floor
slabs are shear resistant and ensure a flexurally rigid, loadbearing effect of the whole building. The
concrete with specified compression strength of 14.5 N/mm²doesn't refer to DIN but it is widely used.
This is shown conceptually on the figure 13. The shear truss shown below is widely used with 3D-
panels [EVG].

1.5 Loadbearing Capacity of 3D-Slabs according to DIN

In general, flexural design of 3D-slabs can be carried out like design of reinforced concrete slabs. The
basic design model according to DIN 1045 is shown in the following figure 14. The dimensions for t2
and depth of EPS are indicated in mm and the moments in kNm/m. Moments are calculated under
service load including the safety factor according to DIN (=1.75) at a concrete grade of 17.5 N/mm 2
(=B25). For other concrete grades these values have to be multiplied with f ck/17.5 N/mm2. The
distance between the lower edge of the EPS and the center of gravity of the reinforcement is assumed
to be 20 mm [EVG].

1.6 Earthquake Resistance

Forces acting horizontally on 3D buildings, such as earthquake forces, are transferred most effectively
by 3D shear walls. For dimensioning, 3D slabs and 3D walls can be considered independently of each
other. A frame-like design of 3D buildings with heavy reinforcement in the joints is not necessary.
This is shown conceptually in Figure 15. Especially in residential buildings a box-like 3D-structure is
the best option to receive high strength and meet architectural requirements at the same time.
Therefore, structural calculations of 3D constructions shall be made in accordance with the reinforced
concrete strength design principles [EVG]. In areas with a high earthquake risk it is recommended to
use strengthened boundary elements at the edge of a shear wall. These boundary elements are easy to
carry out and they only contain a small amount of reinforcement. In conjunction with 3D-panels they
serve as tension ties and form a structure with a very high resistance against earthquake forces. Unlike
frame structures boundary elements are flush with the walls and therefore, they will not affect the
architectural design. Tests have shown that 3D panels can be designed for compression and
compression with bending by using interaction curves constructed by standard strain compatibility.

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“Innovations in Materials and Structural Engineering Practices”

An interaction curve for the standard 3D panel is shown in the next picture. Slenderness effects can be
accounted for by using the moment magnification procedure described in ACI 318-89, Section
10.11.5. The proof of load-bearing safety is furnished by means of interaction diagrams (tables) by
using either the approximate method- which is on the safe side – according to DIN 1045, or the design
according to ACI 318-89.

Figure 13. Galvanized shear trusses all Figure 14.P-M Interaction Curves
dimensions are in [mm] Steel grade = for 3D panel (DIN-1045)
880 N/mm²(EVG)

Figure 15. Box-Like Structure.

2. ANALYSIS OF 3D WALL PANELS UNDER IN-PLANE LATERAL LOADING

2.1 General
In order to evaluate the seismic performance of the 3D wall panel, in-plane quasi-static cyclic
(reversed) loading test was carried out. This test is used to investigate the mechanism of behaviour of
the walls and related seismic resistance parameters such as hysteresis behaviour, energy dissipation
capacity, strength and stiffness degradation, and displacement ductility.

2.2 Methodology
In-plane cyclic loading test is carried out as per ASTM standard E2126-11, with combination of
constant vertical and cyclic horizontal load. The vertical load ratio on the wall specimen is N/Acfc
resulting for the panels of the ground floor is 2% while the corresponding value for the top floor
panels is 1%; these values of axial loads are comparable to those applied in practice, which is
approximately equal to the weight of the 3-4 storeys. Boundary conditions for all wall specimens are
fixed at base and free at top.

2.3 Monotonic Loading Test

Monotonic loading test was carried out to know the shear stiffness and strength as per ASTM standard
E564-06. Displacement increment is 0.5 mm. The schematic diagram of monotonic loading test setup
is shown Figure 16 and the actual (wall specimen) test setup shown in Figure 17. On top of the wall
specimen a loading frame made-up of ISMB 250 steel section was placed. This loading frame

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“Innovations in Materials and Structural Engineering Practices”

transfers he load applied from vertical loading jack to the wall specimen. The ISMB 250 section was
arrived based on the load dispersion angle of 450 from the point of application of the vertical load.

2.4 Cyclic Loading Test

In order to measure applied load on the wall in both positive and negative directions, two load cells
were placed on either side of the wall. The locations of LVDTs were same as explained in monotonic
loading test setup. The applied displacement increment is as per ASTM standard E2126-11. As per cl.
8.4.1 of ASTM E2126-11, the loading schedule consists of two displacement patterns. The first
displacement pattern consists of five single fully reversed cycles at displacements of 1.25%, 2.5%,
5%, 7.5% and 10% of the ultimate displacement (Δm). The ultimate displacement (Δm) is taken from
the monotonic loading test, i.e., the post peak displacement corresponding to 80% of peak load. The
actual loading setup is shown in Figure 17.

2.5 Observations

2.5.1 Monotonic Loading Test:

2.5.1.1 WP1-NR-Mo
3D wall specimen with no longitudinal reinforcement showed visible initial crack under monotonic
loading at deflection of 8.5 mm and the corresponding load value was 195.2 kN. The horizontal
flexural-shear crack appeared at the fixed end; due to increase in tensile stresses resulting from the
shear of wall and the crack length was approximately 30% of the wall length. As the lateral
displacement increased, initiation of bond failure was observed with formation of vertical cracks at
the fixed end. Once the specimen reaches its peak strength, its strength degrades very quickly for
further increment in
displacement. Testing is generally terminated when the lateral resistance of the specimen drops by
23% of peak strength. However, in this case, at the displacement of 47.97 mm (corresponding to load
value of 57.44 kN), the specimen lifted up about 20 mm and hence the testing was stopped due to
safety reasons. The observed crack pattern of the wall is shown in Figure 18. The observed envelop
curve shown in Figure 19. The peak lateral load is 251.81 kN and the corresponding deformation is
15.96. Post peak gradual decrement pattern, observed in the plot is due to successive shear failure at
the near to the fixed end.

Figure 16. Schematic Diagram of Test setup of

Figure 17. Test setup of the 3D wall
the 3D wall panel panel

2.5.1.2 WP1-WR-Mo
The test procedure and the increment of deformation for WP1-WR-Mo with longitudinal
reinforcement, 12 mm Ø @ 300 mm c/c, were same as adopted for WP1-NR-Mo. For WP1-WR-Mo
showed visible initial crack under monotonic loading at deflection of 10.5 mm and the corresponding
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“Innovations in Materials and Structural Engineering Practices”

load value was 190.36 kN. The inclined shear crack appeared at the wall portion; due to increase in
shear stresses resulting from the shear of wall. As the lateral displacement increased, initiation of
bond failure was observed with formation of vertical-horizontal cracks at the fixed end same as WP1-
NR-Mo. Once the specimen reaches its peak strength, its strength degrades gradually; due to ductility
displacement also due to additional longitudinal reinforcement, for further increment in displacement.
Testing is generally terminated when the lateral resistance of the specimen drops by 44% of peak
strength.

Figure 18. Observed Crack Pattern Figure 19.Observed Envelop Curve

(WP1-NR-Mo) (WP1-NR-Mo)

However, in this case, at the displacement of 29.13 mm (corresponding to load value of 38.75 kN), the
specimen lifted up about 15 mm and hence the testing was stopped due to safety reasons. The
observed crack pattern of the wall is shown in Figure 20. The observed envelop curve shown in Figure
21. The peak lateral load is 273 kN and the corresponding deformation is 18.43 mm. Post peak saw
gradual decrement pattern, observed in the plot is due to successive shear failure in the wall portion
and later at the near to the fixed end.

Figure 20. Observed Crack Pattern Figure 21.Observed Envelop Curve

(WP1-WR-Mo) (WP1-WR-Mo)

3. CONCLUSION

This paper gives an overview of construction procedure of 3D panels and application in prefabricated
construction systems. The 3D System is a new, price-conscious and versatile construction method
based on quality-controlled 3D panels prefabricated on an industrial scale. 3D panels are erected and
assembled on site. Transport and handling is easy due to their light weight. 3D panels can be cut as
required with conventional hand tools or by standard hand-held electric saws. After plumbing, and
electrical or other utilities are installed, the entire structure is sprayed with concrete. The complete 3D
panel structure is a composite, combining the strength of the steel, the insulation of the polystyrene
core and the durability of the concrete. From the literature, it is clear that the 3D panels are effective

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“Innovations in Materials and Structural Engineering Practices”

in load carrying capacity, shear capacity and flexural capacity. The axial compressive strength of wall
panels, shear strength of wall panels in case of lateral loading application and flexural strength of slab
panels are found to be suitable for economical, safety and eco-friendly building construction. Further
these precast elements can be used as partition walls etc. The strength and mode of failure depends on
the level of axial loading, height of panel and percentage of reinforcement. Providing longitudinal
reinforcement along with mesh wire effectively enhances the in-plane bending capacity compared to
no reinforcement provided along with mesh. This has not been attempted in earlier studies. Panels that
are squat walls exhibit shear-dominant behaviour, while slender panels exhibit flexure-dominant
behaviour. The 3D wall panels tested under lateral loads showed significant post-cracking strength
and ductile behaviour, prior to collapse.

4. REFERENCES

A Brief Introduction into the EVG-3D Panel Constrcuction System (Changing Construction Methods
Worldwide)-report on 3D panel.
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Benayoune A, Abdul Aziz AS, Trikha DN, Abang Abdullah AA. Behaviour of precast reinforced
concrete sandwich panels with continuous shear truss connectors. Journal of Institute
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Benayoune A., Abdul Samad A.A., Trikha D.N., Abang Ali Akhand A.M. Precast reinforced concrete
sandwich panel as an industrialised building system. International Conference on Concrete
Engineering and Technology University Malaya 2004; 1-6.
Benayoune A, Aziz A, Samad A, Trikha DN, Abdullah Abang Ali A, Ashrabov AA. Structural
behaviour of eccentrically loaded precast sandwich panels. Journal of Construction Building
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Benayoune A, Samad AA, Abang Ali AA, Trikha DN. Response of pre-cast reinforced composite
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Benayoune A, Abdul Samad AA, Trikha DN, Abang Ali AA, Ellinna SHM. Flexural behaviour of
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Bush TD, Stine GL. Flexural behaviour of composite precast sandwich panels with continuous truss
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Einea A. Structural and thermal efficiency of precast concrete sandwich panel sysem. Ph.D. thesis,
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Einea A, Salmon DC, Tadros MK, Culp TD. A new structurally and thermally efficient precast
sandwich panel system. PCI Journal 1994;39(4):90-101.
ESR-2435, ICC-ES Evaluation Report, April 2005; 1-8.
Kabir MZ. Mechanical properties of 3D wall panels under shear and flexural loading. In: 4th
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PCI Committee on Precast Concrete Sandwich Wall Panels. State of the art of precast/prestressed
sandwich wall panels. PCI Journal 1997;42(2):92-133.
Salmon DC, Einea MK, Tadros A, Culp TD. Full scale testing of precast concrete sandwich panels.
ACI Journal 1997;94:354-62.

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