University Of Duhok

Architectural Department
Lecture 4
Stage: 4th
Building Technology

3D Panels System, Rastra System and Slip

Form System of Construction

Lecturer:
Ahmed Khairadeen Ali
3D Panels System of Construction
3D Panels System .1

The 3D panel is a versatile structural element designed for floors, walls, partitions, roof, stairs.

The 3D panel is a special structure consisting of an expanded polystyrene plate (usually called
core), both sides of which are fixed welded wire fabrics made of high strength wire. The welded
grid fabric connected piercing polystyrene with trusses of steel wire welded to the welded fabric at
an angle. It gives a rigidity special structure and simultaneously prevents polystyrene core shifting.

The 3d panels are produced on special equipment

automatic spot welding process, which leads to a stable
end-product quality. Accurate and reliable assembly
welding reinforcing cages 3D panels eliminates the
curvature at any length.
3D Panels System

3D panel (as Figure 1) includes welded reinforcing meshes of high strength wire, expanded
polystyrene uncoated, manufactured in the factory. And concrete is applied to the panel assembled
at the construction site, which gives the bearing capacity of the structure. 3D wire panel after
shotcrete has the following five components (as Figure 2).

1. The outer layer of shotcrete.

2. Welded reinforcing mesh of high
wire.
3. The core of expanded polystyrene
sheet
4. Diagonal wire (stainless or
galvanized wire).
5. The inner layer of shotcrete. Figure 2: 3D panel details after shotcrete:
Figure 1: Welded reinforcing mesh
Reinforcing mesh, expanded polystyrene
3D panel
core and diagonal wire, outer and inner
shotcrete layers.
3D Panels System
Welded reinforcing
mesh 3D panel details Welded reinforcing mesh
image: Reinforcing 3D panels in warehouse.
mesh, expanded
polystyrene core, and
diagonal wire

3D panel with V shape

Welded reinforcing diagonal wire.
mesh 3D panel without
expanded polystyrene
core.
3D Panels System
3D Panel Dimensions:
• Length - 2m, 3m, 6m.
• Width - 1.00m, 1.15m, 1.20m.
• Thickness 50mm (for walls), 100mm (for the
internal load-bearing walls), 120mm (for
exterior wall).
• Weight: 25kg (3 × 1.2m panel)
Reinforcing Welded Mesh of High-Wire
• Materials: low carbon grade, and galvanized
wire.
• Reinforcing mesh wire diameter: 3mm -
4.5mm.
• Mesh size of 50 × 50mm, 50 × 100mm, 100 ×
100mm. 50mm).
Diagonal wire
stainless steel or galvanized wire diameter
of 3mm- 4mm.
•Step laterally - 100 or 200mm.
•Step longitudinally - 100mm or 200mm.
•The distance between the mesh and
polystyrene - 16mm (for walls), 20mm
(for load-bearing walls).
•The number of diagonal bracing rods: 100
pieces per Sq. m.
The core of expanded polystyrene
(polystyrene foam P-25, P-35) thickness
50mm / 100mm /120mm / 150mm. (for
exterior walls 120mm, internal -
3D Panels System

Finished design also includes:

•After the establishment of reinforced 3D panel at a construction site, it will be done 2 - 3 layers
of concrete shotcrete method (using plaster station or hopper).
• Outer layer of concrete 50-60mm.
• Inner layer of concrete 50-60mm.
3D Panels System

3D wire panels has the advantages in terms of energy consumption, thermal protection, thermal
insulation, comfort, simplicity, speed and cost of construction, strength and durability.

The internal structure of 3D panels:

Expanded polystyrene is selected as the core because it is eco-friendly and durable material, supplying not
only high thermal insulation, but also a good resistance to fire, and therefore fire safety.
Increase the service life and durability - used polystyrene foam virtually inert and does not absorb moisture,
is durable and resistant to decay.
3D Panels System

3D panel application for building and warehouse, fence and wall

3D panel is very popular in the construction. Any project can be adapted to the construction
technology of 3D panels. Create complex architectural shapes (round, square, sloping, segment),
virtually any design. Rate the freedom to choose the architectural and design solutions due to the
simplicity and flexibility of the technology with reinforced insulation boards. Bay windows, curved
walls, wall fence, arches - all elements of the complex can be made without an increase in the cost of
construction and special architectural revisions.
3D Panels System

3D panels are usually applied into:

• In the construction of residential buildings, 3-5 story residential buildings;
3D panels are made into all the basic building blocks of buildings, walls,
floors, roof, stairs.
• Public buildings, clubs, entertainment facilities, sports halls, farmhouses.
• Commercial, industrial and administrative buildings.
• Individual warm pools.
• Sound-absorbing and protecting fences.
• Warehouses and vegetable store.
• Storage containers including tanks.
• Architectural complex forms.
3D Panels System
The technology of individual housing construction from 3D wire panels includes the following
steps: The first, 3D panels are delivered to the construction site. The very walls installation begins
with the installation of panels on a previously prepared monolithic slab or foundation. When all
communications are done, start shotcrete. Gunning - a process of applying pressure on the concrete
surface using any special equipment. In this step, design becomes bearing capacity. Monolithic overlap
formed by pouring concrete on the upper and lower panels. The generated surface is overwritten and
the finish. After a few days, when the hardened shotcrete, mounted floor and roof.
3D Panels System
Advantage of 3D Panels

• Low cost.
• High speed of construction.
• Strength and durability.
• The ability to combine technologies.

Buildings of polystyrene foam reinforced wire mesh 3D panels are extremely low cost
and exceptional tightness, along with a high degree of thermal insulation. These building
systems are now widely used in many countries of the world where there has been a rapid
development of the construction industry. This is the United States, Canada, Germany,
Austria, Italy, England, Ireland, Spain, Argentina, Brazil, Chile, Libya, Poland, Egypt,
Guatemala, Portugal, Pakistan, Turkey, Saudi Arabia, Nigeria, Venezuela, Mozambique,
Thailand, Indonesia, Mexico.
Rastra System of Construction
 2. Rastra System of Construction

RASTRA is the original Composite Insulating Concrete Form (ICF), first introduced in 1972 in Austria.
Since then over 9 million units have been placed in service with installations throughout Europe, Middle
East, Far East, North Africa, and the Americas, in all types of climates from the Austrian Alps to the
Saudi Arabian Desert, to the humid climate of Southeast Asia. Today, RASTRA is not only recognized as
the original but also as the best product of any ICF category.
 Rastra System of Construction

Approved by the International Code Council (ICC) under Legacy Report, RASTRA is the most
extensively tested Composite Insulated Concrete Form available today.
RASTRA is a stay-in-place Insulating Concrete Form (ICF) that is Structurally strong
Energy-efficient
Sound-absorbent
Non-combustible
Resistant to high wind, mold & pests
Made from 85% recycled materials.

RASTRA is recognized as the ultimate building solution for

economical and environmentally-friendly construction. This
stay-in-place system is made of a lightweight composite material
called THASTYRON, produced with 85% recycled expanded
polystyrene (Styrofoam) and 15% cement. RASTRA panels
achieve strength from a combination of features specifically
designed to maximize both shear and compressive strength.
 Rastra System of Construction

The actual panel by itself is not structural. Wall strength is created when steel reinforcement and concrete
are added to the interior of the panels. These interior channels form a grid or skeleton, of 6” diameter
columns designed to maximize strength, yet use a minimum amount of concrete. By using different
qualities of concrete and/or various amounts of reinforcement, in horizontal, vertical, or even diagonal
directions, the load capacity can be adapted to satisfy nearly any building requirement, including
multi-story and seismic zone applications.
Rastra System of Construction

Standard Panel, used for walls, has semicircular grooves on both length sides interconnected by a
number of tapered transverse channels. A standard panel is up to 10’ long, 15” or 30” high with a wall
thickness of 8.5”, 10”, 12” & 14”. One 10” x 120” single panel weighs 158 lbs dry, still light enough
to be handled without a crane. The 8.5” panel is intended for use in interior low load-bearing
applications only.

End Panel, used for wall ends, lintels, corners, window recesses, and even ceilings - has half the
width of the standard panel and has no transverse openings. For corners, cutouts are made in order to
create channels for the concrete to connect two adjacent walls.
 Rastra System of Construction
Building with Rastra
Once the foundation is finished, start at a corner and place or stack the RASTRA panels. The large but
lightweight panels can be handled without cranes and shaped with common woodworking tools.
 Rastra System of Construction
RASTRA panels can be stacked horizontally or vertically – reducing the need to lift the panels. Just tilt
them up, tack them with glue or clamp them for temporary support. Once you have a wall section
assembled, bring it into plumb. Windows and door openings can simply be cut out. Use the panels in
either direction how they will best fit the building plan. The cavities, which form the structural part once
concrete has been grouted, always line up. Concrete is grouted after a complete floor has been set in
place.
RASTRA panels can be finished with virtually any finish material including drywall, plaster, stucco,
siding, brick or stone veneers.
Rastra System of Construction
Pre-fab wall

In addition to offering component sales, RASTRA offers pre-assembled wall panels built to exact
specification. Construction timelines can be dramatically reduced.
Rastra System of Construction
Pre-fab wall

Large wall segments up to 25ft (7m) can be pre-assembled

in the factory according to customer’s plans. These panels
may include window frames and some reinforcement.
Custom sections can be made quickly, as RASTRA panels
are taken from the store and glued to specification. No time
for curing is needed.
The panels can be set in place by light duty cranes, as
concrete is poured on site. Unlike prefab concrete panels,
slight adjustments in size can be made on site. Damaged
panels can be repaired instantly.
 Rastra System of Construction

Features & Benefits

• Superior thermal performance.
• Reduced room-to-room noise – enhanced privacy .
• Energy savings for the life of the home.
• Up to 700% stronger than wood frame construction .
• Non-combustible - 4-hour fire rating –
• Effective against hurricane force winds .
produces no toxins.
• Earthquake tested to magnitude level 8 .
• Low cost.
• Extended service life .
• Provides a much safer structure.
• Shorter construction cycles.
• Eliminates air leaks.
• Impervious to insects.
• 85% recycled-content.
• Does not promote mold growth
• Improved indoor comfort.
• improved indoor air quality.
• Works in harmony with HVAC units.
Slip Form System of Construction
Slip Forming or Slipform Construction System

Slip forming, continuous poured, continuously formed, or slipform construction is a construction

method in which concrete is poured into a continuously moving form. Slip forming is used for tall
structures (such as bridges, towers, buildings, and dams), as well as horizontal structures, such as
roadways.
Slip Forming or Slipform Construction System

Slip forming relies on the quick-setting properties of concrete, and requires a balance between
quick-setting capacity and workability. Concrete needs to be workable enough to be placed into
the form and consolidated (via vibration).
 Slip Forming or Slipform Construction System

The first residential houses built with Slip forming, Recent picture of the Swedish residential houses in
was erected 1950 in Västertorp, Sweden by Västertorp
AB Bygging
Slip Forming or Slipform Construction System
Vertical Slip Forming
In vertical slip forming, the concrete form may be
surrounded by a platform on which workers stand,
placing steel reinforcing rods into the concrete and
ensuring a smooth pour. Together, the concrete form
and working platform are raised by means of hydraulic
jacks. Generally, the slipform rises at a rate that
permits the concrete to harden by the time it emerges
from the bottom of the form.
Vertical Slip Forming
Horizontal Slip Forming
In horizontal slip forming for pavement and traffic
separation walls concrete is laid down, vibrated,
worked, and settled in place while the form itself
slowly moves ahead. This method was initially devised
and utilized in Interstate Highway construction
initiated by the Eisenhower administration during the
1950s.
Horizontal Slip Forming
Slip Forming or Slipform Construction System

Typical applications of the slipform system

Silpform system may be defined as a method of continuously casting or forming concrete with the
use of steel shuttering panels moving formwork 42 inches height with length depends on construction
work. steel shuttering panels will be tightly held together by clamps to bear on the slipform walers.
The yokes form part of a rigid assembly which incorporates steel formwork and steel walings.

Slipform systems employ robust hydraulic jacks, controlled from a central power unit, and fitted to
substantial steel yokes. Slipform systems are suitable for the rapid construction of reinforced molding
or forming concrete wall structures such as silo complexes, chimneys, reservoirs, medium to
high–rise housing, office buildings, hotels, hospitals, bridge piers, in-ground shafts, dam structures
and power station.
Slip Forming or Slipform Construction System

The technique was introduced

to residential and commercial
buildings already in the 1950s
in Sweden

Continuous slip formed gravity-based structure supports under

Slipform Monobox System construction in a Norwegian fjord. The visible jib cranes would
each be delivering buckets of concrete to the support cylinders
during the continuous pour of concrete creating seamless walls.
Slip Forming or Slipform Construction System

Advantages of slipform systems

The fastest method of constructing vertical structures. Resulting

Save construction time in reduced construction periods about 3 days for each floor.

Cost savings Reduced labour costs, of loan because finish work faster.

Due to continuous operation suitable most of wall layouts

especially silos, tank and extra high floor construction. Water
No construction joints retaining structures and nuclear structures benefit from these
features of Slipform construction.

The method can now be applied with benefit to a broad range of

Usable for all structure structures of varying complexity such as silos, tank, lift.
type Slipform system can be adapted to accommodate specific
requirements. Special forms can be fabricated for particular
project requirements
Slip Forming or Slipform Construction System

Requirements of Slipform System

- These sets of equipment are recommended for high rise

reinforce concrete wall with area of windows or doors less
than 50%
- These sets of equipment are recommended for high rise
reinforce concrete structures with a fixed-diameter wall
thickness more than 150 mm.
- Height more than 10 floors.

Construction of 2 coal silos via slip forming

Thank You